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Sensing, interlocking solar panel system and installation method — Smash Solar, Inc. (US10536108B2)

ABSTRACT

Abstract

A preassembled solar panel module includes a solar panel configured for receiving and converting solar radiation to produce electrical power. Multiple panel rails are coupled in preassembly to a backside surface of the solar panel, including at least two panel rails disposed halfway or more along opposing longest edges of the solar panel. Multiple snap connector components are each coupled to one of the at least two rails and are each configured to couple with a complimentary snap connector component of an adjacent preassembled solar panel module or of a wind deflector accessory, or both. One or more mounting feet are each coupled at a selected location to one of the at least two panel rails and are each configured for coupling at a selected location to a roof or to other sunlight receiving surface.

Description

PRIORITY AND RELATED APPLICATIONS

This application claims priority to U.S. provisional patent application Ser. No. (USSN) 62/197,564, filed Jul. 27, 2015, which is incorporated by reference.

This application is also a continuation-in-part (CIP) of U.S. Ser. No. 14/521,245, filed Oct. 22, 2014, which is a CIP of U.S. Ser. No. 14/054,807, filed Oct. 15, 2013, which claims priority to U.S. Ser. No. 61/712,878, filed Oct. 12, 2012, which are incorporated by reference.

This application is also a CIP of U.S. Ser. No. 15/138,437, filed Apr. 26, 2016, which claims priority to U.S. Ser. No. 62/152,938, filed Apr. 26, 2015, which are each incorporated by reference.

This application is also a CIP of PCT/US2016/000019, filed Mar. 2, 2016, which claims priority to U.S. Ser. No. 62/127,287, filed Mar. 2, 2015, which are each incorporated by reference.

This application also claims priority to United States provisional patent applications serial numbers (USSN) 62/321,467, filed Apr. 12, 2016, and USSN 62/326,811, filed Apr. 24, 2016, and USSN 62/203,304, filed Aug. 10, 2015, and USSN 62/260,321, filed Nov. 26, 2015, and USSN 62/209,860, filed Aug. 25, 2015, and USSN 62/203,902, filed Aug. 11, 2015, which are each incorporated by reference.

GOVERNMENT LICENSE RIGHTS

This invention was made with government support under the SunShot Financial Assistance Award number DE-EE0006457 awarded by the Department of Energy. The government has certain rights in the invention.

BACKGROUND

Solar panels are widely used in the production of electricity with multiple panels typically connected together as panel assemblies. These solar panel assemblies are usually arranged in arrays and mounted on structural racking systems on the roofs of buildings, on the ground or other fixed structures. A fixed structure can include, but is not limited to, existing residential or commercial roof tops, horizontal surfaces or vertical surfaces, existing fences, railings, walls or open ground-mounted areas. In many jurisdictions, these mounting systems pass loading tests to ensure they can withstand static and dynamic loading anticipated during the life of the installation. These solar racking systems are often custom designed for each application and custom installed by contractors and tradespeople using specialty skills and following the approved drawings.

PV Solar modules typically are constructed using a lamination of a front sheet of glass, a layer of adhesive sealant, photovoltaic materials and conductors, another layer of adhesive and a sheet of specially designed polymer sheet, called the backsheet. These PV “glass-backsheet” modules are typically constructed with a frame to add rigidity to the “glass-backsheet” lamination and to provide a mounting point for the module.

In addition, a number of solar panel manufacturers have released new solar panels with integrated micro-inverters to simplify the electrical installation process. But a simple, low skill mechanical installation of a solar array remains unavailable on the market today.

Typical solar mounting or racking systems fail to provide the flexibility and ease of installation that many believe necessary for large scale adoption of solar power in the United States and around the world.

It is desired to have a solar module system that includes a flexible, configurable design that allows direct attachment either to the roof sheathing (plywood spanning over structural roof rafters or roof trusses that serves as a foundation for roofing materials) or to the roof rafters or roof trusses themselves. It is further desired to have a flexible, configurable solar module system that may be installed in a streamlined installation process which eliminates much if not all of the expense of custom design and installation activities. It is desired to have a solar module system that reduces work on the roof and reduces the skills and experience potentially necessary on the roof to perform a high quality solar array installation.

BRIEF DESCRIPTION OF THE DRAWINGS

FIGS. 1-3 schematically illustrate partial top perspective views of example embodiments of a preassembled solar panel module including a mounting foot and snap connector components each coupled separately to one of multiple panel rails that are coupled to a backside surface of an otherwise frameless solar panel module.

FIG. 4 schematically illustrates a side view of the solar panel module of FIGS. 1-3 .

FIG. 5 schematically illustrates a partial top perspective view of a preassembled solar panel module including a mounting foot and snap connector components coupled separately to a notched rail that is attached along one edge of the backside of an otherwise frameless preassembled solar panel module in accordance with certain embodiments.

FIG. 6A-6J schematically illustrate in multiple perspective and side views example embodiments of mounting feet including example mounting feet having defined therein a rail-receiving recess including a notched edge configured to compliment a notched rail as in the example of FIG. 5 , and including example mounting feet that include a slide-lock mechanism that permits a length of the notched rail to be received within the recess in a first position and that is slidable to a second position to secure the rail within the recess, and that is slidable back to the first position to permit the rail to be decoupled from the recess, e.g., to adjust the position of the mounting foot relative to the rail or to replace the mounting foot or the entire solar panel module to which the mounting foot is coupled, in accordance with certain embodiments.

FIGS. 7-8 schematically illustrate perspective views of the mounting foot of FIG. 6 coupled to a roof or other sunlight receiving surface location in accordance with certain embodiments.

FIGS. 9-11 schematically illustrate, respectively, side views of the mounting foot of FIGS. 6-8 (i) with the slide lock disposed in the second position in FIG. 9 , (ii) with the slide lock being disposed in the first position in FIG. 10 to permit a rail to be received into the rail-receiving recess (or to permit decoupling from a rail), and (iii) with the slide lock disposed again in the second position in FIG. 11 to secure a received rail within the recess.

FIGS. 12-13 schematically illustrate exploded perspective and side views, respectively, of the mounting foot of FIG. 6 .

FIGS. 14A-14B schematically illustrate exploded side views of mounting feet that are configured for respectively coupling either side of a solar panel module to a roof or other sunlight receiving surface location in accordance with certain embodiments.

FIG. 15 schematically illustrates an exploded perspective view of a mounting foot that is configured for coupling a preassembled solar panel module to a roof or other sunlight receiving surface location in accordance with certain embodiments, wherein the example mounting foot that is schematically illustrated in FIG. 15 is configured to couple to one of multiple panel rails that are attached to the backside of the preassembled solar panel module.

FIGS. 16A-16B schematically illustrate backside views respectively of end and interior solar panel modules each having long and short panel rails that are coupled to a backside surface of the preassembled solar panel modules, wherein each of the solar panel modules of FIGS. 16A-16B also include snap connector brackets at each corner where the long and short panel rails meet and snap connector components attached at mid-rail locations to the long panel rails in accordance with certain embodiments.

FIGS. 16C-16F schematically illustrate example embodiments of panel rail architectures, snap connector brackets and mid-rail components, corner bumpers and mounting feet that are configured for coupling to a backside surface of a solar panel to form a preassembled solar panel module in accordance with multiple example embodiments.

FIG. 17 schematically illustrates a frontside view the interior solar panel module of FIG. 16B .

FIGS. 18-20 schematically illustrate perspective, partial perspective, and side views, respectively, of the end solar panel module of FIG. 16A .

FIG. 21 schematically illustrates a preassembled solar panel module including a panel rail, a snap connector component and a mounting foot coupled to a backside surface of a solar panel to form a preassembled solar panel module in accordance with certain embodiments, wherein the snap connector component and the mounting foot are shown coupled to the panel rail at different locations for, respectively, coupling the preassembled solar panel module to an adjacent preassembled solar panel module of an installed array and for coupling the preassembled solar panel module directly to a roof or other sunlight receiving surface location.

FIG. 22A-22B schematically illustrate end and partial perspective views, respectively, of a panel rail that is configured for coupling to a backside of a preassembled solar panel module and to one or more mounting feet and one or more snap connector brackets and/or mid-rail snap connector components in accordance with certain embodiments.

FIGS. 22C-22D schematically illustrate side views of short and long panels, respectively, in accordance with the example embodiment of FIG. 22B .

FIG. 23 schematically illustrates a backside view of an opaque preassembled solar panel module that includes two long rails attached near and aligned each with one of two long edges of a rectangular solar panel and two short rails that are spaced a significant distance each from one of two short edges of the rectangular solar panel.

FIG. 24 schematically illustrates a backside view of a transparent solar panel module otherwise having similarly disposed long and short rails as in FIG. 23 .

FIG. 25 schematically illustrates a partial backside view of a preassembled solar panel module that includes a snap connector component coupled at ends of each of a short panel rail as in FIG. 22C and a long panel rail as in FIG. 22D , wherein the short and long panel rails are coupled to a backside surface of the preassembled solar panel module as in the example embodiment of FIG. 24 .

FIG. 26 schematically illustrates a top perspective view of the preassembled solar panel module of FIG. 24 .

FIG. 27 schematically illustrates a partial top perspective view of the preassembled solar panel module of FIG. 24 .

FIG. 28A schematically illustrates a top perspective view of an at least partially preassembled solar panel module including a transparent backside solar panel surface in accordance with certain embodiments that does not show snap connectors coupled at the ends of the long and short rails nor mounting feet.

FIG. 28B schematically illustrates a frontside view of the preassembled solar panel module of FIG. 28A .

FIG. 28C schematically illustrates a backside view of an at least partially preassembled solar panel module including an opaque backside solar panel surface in accordance with certain embodiments that does not show snap connector components coupled to any of the two long panel rails nor the two short panel rails, nor any mounting feet.

FIG. 28D schematically illustrates a backside view of a preassembled solar panel module including an opaque backside solar panel surface in accordance with certain embodiments that shows snap connector brackets coupled one at each corner of the solar panel module at the ends of two long rails, a pair of short rails, four mid-rail snap connector components coupled two to each of the two long rails, and two mounting feet coupled one to each of the two long rails.

FIG. 28E schematically illustrates a backside perspective view of an at least partially preassembled solar panel module including an opaque backside solar panel surface in accordance with certain embodiments that does not show snap connectors coupled to any of the two notched long rails nor the two short rails, nor any mounting feet.

FIGS. 29A-29B schematically illustrate end and side views, respectively, of a long panel rail in accordance with certain embodiments for coupling to a backside of a preassembled solar panel module and for coupling to a pair of short rails disposed as in the example embodiment of FIG. 24 .

FIGS. 29C-29E schematically illustrate end, perspective and side views, respectively, of a long panel rail that is configured in accordance with certain embodiments for coupling to a backside of a preassembled solar panel module and for coupling to a pair of short rails disposed as in the example embodiments of FIG. 24 .

FIGS. 29F-29G schematically illustrate side and partial side views, respectively, of a long panel rail in that is configured in accordance with certain embodiments for coupling to a backside of a preassembled solar panel module and for coupling to a pair of short rails disposed as in the example embodiment of FIG. 24 .

FIG. 29H schematically illustrates a partial perspective view of an at least partially preassembled solar panel module including an example embodiment of a panel rail coupled to a backside solar panel surface, wherein the panel rail shown in FIG. 29H includes an outside vertical wall that has a series of rectangular cutouts defined therein for receiving complimentary protrusions of mounting feet and/or snap connector components to prevent movement of mounting feet and/or snap connector components along the rail.

FIG. 30 schematically illustrates a preassembled solar panel module including a pair of long panel rails coupled to a backside surface and aligned with long edges of a rectangular solar panel in accordance with certain embodiments, wherein the example prea

PRIORITY AND RELATED APPLICATIONS

This application claims priority to U.S. provisional patent application Ser. No. (USSN) 62/197,564, filed Jul. 27, 2015, which is incorporated by reference.

This application is also a continuation-in-part (CIP) of U.S. Ser. No. 14/521,245, filed Oct. 22, 2014, which is a CIP of U.S. Ser. No. 14/054,807, filed Oct. 15, 2013, which claims priority to U.S. Ser. No. 61/712,878, filed Oct. 12, 2012, which are incorporated by reference.

This application is also a CIP of U.S. Ser. No. 15/138,437, filed Apr. 26, 2016, which claims priority to U.S. Ser. No. 62/152,938, filed Apr. 26, 2015, which are each incorporated by reference.

This application is also a CIP of PCT/US2016/000019, filed Mar. 2, 2016, which claims priority to U.S. Ser. No. 62/127,287, filed Mar. 2, 2015, which are each incorporated by reference.

This application also claims priority to United States provisional patent applications serial numbers (USSN) 62/321,467, filed Apr. 12, 2016, and USSN 62/326,811, filed Apr. 24, 2016, and USSN 62/203,304, filed Aug. 10, 2015, and USSN 62/260,321, filed Nov. 26, 2015, and USSN 62/209,860, filed Aug. 25, 2015, and USSN 62/203,902, filed Aug. 11, 2015, which are each incorporated by reference.

GOVERNMENT LICENSE RIGHTS

This invention was made with government support under the SunShot Financial Assistance Award number DE-EE0006457 awarded by the Department of Energy. The government has certain rights in the invention.

BACKGROUND

Solar panels are widely used in the production of electricity with multiple panels typically connected together as panel assemblies. These solar panel assemblies are usually arranged in arrays and mounted on structural racking systems on the roofs of buildings, on the ground or other fixed structures. A fixed structure can include, but is not limited to, existing residential or commercial roof tops, horizontal surfaces or vertical surfaces, existing fences, railings, walls or open ground-mounted areas. In many jurisdictions, these mounting systems pass loading tests to ensure they can withstand static and dynamic loading anticipated during the life of the installation. These solar racking systems are often custom designed for each application and custom installed by contractors and tradespeople using specialty skills and following the approved drawings.

PV Solar modules typically are constructed using a lamination of a front sheet of glass, a layer of adhesive sealant, photovoltaic materials and conductors, another layer of adhesive and a sheet of specially designed polymer sheet, called the backsheet. These PV “glass-backsheet” modules are typically constructed with a frame to add rigidity to the “glass-backsheet” lamination and to provide a mounting point for the module.

In addition, a number of solar panel manufacturers have released new solar panels with integrated micro-inverters to simplify the electrical installation process. But a simple, low skill mechanical installation of a solar array remains unavailable on the market today.

Typical solar mounting or racking systems fail to provide the flexibility and ease of installation that many believe necessary for large scale adoption of solar power in the United States and around the world.

It is desired to have a solar module system that includes a flexible, configurable design that allows direct attachment either to the roof sheathing (plywood spanning over structural roof rafters or roof trusses that serves as a foundation for roofing materials) or to the roof rafters or roof trusses themselves. It is further desired to have a flexible, configurable solar module system that may be installed in a streamlined installation process which eliminates much if not all of the expense of custom design and installation activities. It is desired to have a solar module system that reduces work on the roof and reduces the skills and experience potentially necessary on the roof to perform a high quality solar array installation.

BRIEF DESCRIPTION OF THE DRAWINGS

FIGS. 1-3 schematically illustrate partial top perspective views of example embodiments of a preassembled solar panel module including a mounting foot and snap connector components each coupled separately to one of multiple panel rails that are coupled to a backside surface of an otherwise frameless solar panel module.

FIG. 4 schematically illustrates a side view of the solar panel module of FIGS. 1-3 .

FIG. 5 schematically illustrates a partial top perspective view of a preassembled solar panel module including a mounting foot and snap connector components coupled separately to a notched rail that is attached along one edge of the backside of an otherwise frameless preassembled solar panel module in accordance with certain embodiments.

FIG. 6A-6J schematically illustrate in multiple perspective and side views example embodiments of mounting feet including example mounting feet having defined therein a rail-receiving recess including a notched edge configured to compliment a notched rail as in the example of FIG. 5 , and including example mounting feet that include a slide-lock mechanism that permits a length of the notched rail to be received within the recess in a first position and that is slidable to a second position to secure the rail within the recess, and that is slidable back to the first position to permit the rail to be decoupled from the recess, e.g., to adjust the position of the mounting foot relative to the rail or to replace the mounting foot or the entire solar panel module to which the mounting foot is coupled, in accordance with certain embodiments.

FIGS. 7-8 schematically illustrate perspective views of the mounting foot of FIG. 6 coupled to a roof or other sunlight receiving surface location in accordance with certain embodiments.

FIGS. 9-11 schematically illustrate, respectively, side views of the mounting foot of FIGS. 6-8 (i) with the slide lock disposed in the second position in FIG. 9 , (ii) with the slide lock being disposed in the first position in FIG. 10 to permit a rail to be received into the rail-receiving recess (or to permit decoupling from a rail), and (iii) with the slide lock disposed again in the second position in FIG. 11 to secure a received rail within the recess.

FIGS. 12-13 schematically illustrate exploded perspective and side views, respectively, of the mounting foot of FIG. 6 .

FIGS. 14A-14B schematically illustrate exploded side views of mounting feet that are configured for respectively coupling either side of a solar panel module to a roof or other sunlight receiving surface location in accordance with certain embodiments.

FIG. 15 schematically illustrates an exploded perspective view of a mounting foot that is configured for coupling a preassembled solar panel module to a roof or other sunlight receiving surface location in accordance with certain embodiments, wherein the example mounting foot that is schematically illustrated in FIG. 15 is configured to couple to one of multiple panel rails that are attached to the backside of the preassembled solar panel module.

FIGS. 16A-16B schematically illustrate backside views respectively of end and interior solar panel modules each having long and short panel rails that are coupled to a backside surface of the preassembled solar panel modules, wherein each of the solar panel modules of FIGS. 16A-16B also include snap connector brackets at each corner where the long and short panel rails meet and snap connector components attached at mid-rail locations to the long panel rails in accordance with certain embodiments.

FIGS. 16C-16F schematically illustrate example embodiments of panel rail architectures, snap connector brackets and mid-rail components, corner bumpers and mounting feet that are configured for coupling to a backside surface of a solar panel to form a preassembled solar panel module in accordance with multiple example embodiments.

FIG. 17 schematically illustrates a frontside view the interior solar panel module of FIG. 16B .

FIGS. 18-20 schematically illustrate perspective, partial perspective, and side views, respectively, of the end solar panel module of FIG. 16A .

FIG. 21 schematically illustrates a preassembled solar panel module including a panel rail, a snap connector component and a mounting foot coupled to a backside surface of a solar panel to form a preassembled solar panel module in accordance with certain embodiments, wherein the snap connector component and the mounting foot are shown coupled to the panel rail at different locations for, respectively, coupling the preassembled solar panel module to an adjacent preassembled solar panel module of an installed array and for coupling the preassembled solar panel module directly to a roof or other sunlight receiving surface location.

FIG. 22A-22B schematically illustrate end and partial perspective views, respectively, of a panel rail that is configured for coupling to a backside of a preassembled solar panel module and to one or more mounting feet and one or more snap connector brackets and/or mid-rail snap connector components in accordance with certain embodiments.

FIGS. 22C-22D schematically illustrate side views of short and long panels, respectively, in accordance with the example embodiment of FIG. 22B .

FIG. 23 schematically illustrates a backside view of an opaque preassembled solar panel module that includes two long rails attached near and aligned each with one of two long edges of a rectangular solar panel and two short rails that are spaced a significant distance each from one of two short edges of the rectangular solar panel.

FIG. 24 schematically illustrates a backside view of a transparent solar panel module otherwise having similarly disposed long and short rails as in FIG. 23 .

FIG. 25 schematically illustrates a partial backside view of a preassembled solar panel module that includes a snap connector component coupled at ends of each of a short panel rail as in FIG. 22C and a long panel rail as in FIG. 22D , wherein the short and long panel rails are coupled to a backside surface of the preassembled solar panel module as in the example embodiment of FIG. 24 .

FIG. 26 schematically illustrates a top perspective view of the preassembled solar panel module of FIG. 24 .

FIG. 27 schematically illustrates a partial top perspective view of the preassembled solar panel module of FIG. 24 .

FIG. 28A schematically illustrates a top perspective view of an at least partially preassembled solar panel module including a transparent backside solar panel surface in accordance with certain embodiments that does not show snap connectors coupled at the ends of the long and short rails nor mounting feet.

FIG. 28B schematically illustrates a frontside view of the preassembled solar panel module of FIG. 28A .

FIG. 28C schematically illustrates a backside view of an at least partially preassembled solar panel module including an opaque backside solar panel surface in accordance with certain embodiments that does not show snap connector components coupled to any of the two long panel rails nor the two short panel rails, nor any mounting feet.

FIG. 28D schematically illustrates a backside view of a preassembled solar panel module including an opaque backside solar panel surface in accordance with certain embodiments that shows snap connector brackets coupled one at each corner of the solar panel module at the ends of two long rails, a pair of short rails, four mid-rail snap connector components coupled two to each of the two long rails, and two mounting feet coupled one to each of the two long rails.

FIG. 28E schematically illustrates a backside perspective view of an at least partially preassembled solar panel module including an opaque backside solar panel surface in accordance with certain embodiments that does not show snap connectors coupled to any of the two notched long rails nor the two short rails, nor any mounting feet.

FIGS. 29A-29B schematically illustrate end and side views, respectively, of a long panel rail in accordance with certain embodiments for coupling to a backside of a preassembled solar panel module and for coupling to a pair of short rails disposed as in the example embodiment of FIG. 24 .

FIGS. 29C-29E schematically illustrate end, perspective and side views, respectively, of a long panel rail that is configured in accordance with certain embodiments for coupling to a backside of a preassembled solar panel module and for coupling to a pair of short rails disposed as in the example embodiments of FIG. 24 .

FIGS. 29F-29G schematically illustrate side and partial side views, respectively, of a long panel rail in that is configured in accordance with certain embodiments for coupling to a backside of a preassembled solar panel module and for coupling to a pair of short rails disposed as in the example embodiment of FIG. 24 .

FIG. 29H schematically illustrates a partial perspective view of an at least partially preassembled solar panel module including an example embodiment of a panel rail coupled to a backside solar panel surface, wherein the panel rail shown in FIG. 29H includes an outside vertical wall that has a series of rectangular cutouts defined therein for receiving complimentary protrusions of mounting feet and/or snap connector components to prevent movement of mounting feet and/or snap connector components along the rail.

FIG. 30 schematically illustrates a preassembled solar panel module including a pair of long panel rails coupled to a backside surface and aligned with long edges of a rectangular solar panel in accordance with certain embodiments, wherein the example preassembled solar panel module illustrated schematically at FIG. 30 does not include any short rails.

FIG. 31A schematically illustrates a partial side view of adjacent solar panel modules, each including a track coupled with complementary snap connectors and a mounting foot that is coupled to a roof or other sunlight receiving surface using a sheathing toggle anchor in accordance with certain embodiments.

FIG. 31B illustrates a backside view of a perimeter solar panel module including an interlocking mounting system for coupling adjacent solar panels and a wind deflector in accordance with certain embodiments.

FIG. 31C illustrates a backside view of a corner solar panel module including an interlocking mounting system for coupling adjacent solar panels with configurable mounting brackets and a pair of wind deflectors in accordance with certain embodiments.

FIG. 31D illustrates the solar panel module of FIG. 31C which couples with the pair of wind deflectors using same or similar snap connectors as are used for coupling adjacent solar panel modules in accordance with certain embodiments.

DETAILED DESCRIPTION OF THE EMBODIMENTS

A preassembled solar panel module includes a solar panel configured for receiving and converting solar radiation to produce electrical power. Multiple panel rails are coupled in preassembly to a backside surface of the solar panel, including at least two panel rails disposed a quarter length or halfway or three-quarters or more along a length of opposing longest sides of the solar panel. Multiple snap connector components are each coupled to one of the at least two rails and are each configured to couple with a complimentary snap connector component of an adjacent preassembled solar panel module or of a wind deflector accessory, or both. One or more mounting feet are each coupled at a selected location to one of the at least two panel rails and are each configured for coupling at a selected location to a roof or to other sunlight receiving surface.

An array of preassembled solar panel modules is provided that exhibits a height to gap ratio that is in a range between 0.42<H/G<15. H is a height of a preassembled solar panel module measured as a spacing of said backside surface of said preassembled solar panel module from said roof or other sunlight receiving surface, and G is a gap spacing between nearest edges of adjacent preassembled solar panel modules.

Another array of preassembled solar panel modules is provided wherein 0.42<H/G<3.

Another array of preassembled solar panel modules is provided wherein 0.42<H/G<1.5.

An array of preassembled solar panel modules is provided in certain embodiments wherein 20 mm<G<120 mm.

An array of preassembled solar panel modules is provided in certain embodiments wherein 50 mm<H<300 mm.

An array of preassembled solar panel modules is provided in certain embodiments wherein H<75 mm and G>37.5 mm.

An array of preassembled solar panel modules is provided in certain embodiments wherein H/G≈1

An array of preassembled solar panel modules is provided in certain embodiments including one or more wind deflectors coupled to sides of preassembled solar panel modules that each define a peripheral segment of the array.

An array of preassembled solar panel modules is provided in certain embodiments including one or more short panel rails coupled to the backside surface of the preassembled solar panel module disposed a quarter length or halfway or three-quarters or more along a length of opposing shortest sides of the solar panel between at least two long panel rails that are disposed at opposing longest sides of the solar panel.

An array of preassembled solar panel modules is provided in certain embodiments including two or more short panel rails coupled to the backside surface of the preassembled solar panel module disposed a quarter length or halfway or three-quarters or more along short dimension segments spaced from either shortest edge of the solar panel between at least two long panel rails that are disposed at opposing longest sides of the solar panel.

An array of preassembled solar panel modules is provided in certain embodiments including bumpers at corners of the preassembled solar panel modules that extend normally from the backside surface further than any of the panel rails.

An array of preassembled solar panel modules is provided in certain embodiments, including at least two panel rails with outer facing walls having one or more features, e.g., notches, recesses, cutouts or protrusions, or combinations thereof, for coupling with complimentary features of mounting feet or of snap connector components, or both, for preventing movement along the panel rails of the mounting feet or of the snap connector components, or both.

An array of preassembled solar panel modules is provided in certain embodiments, wherein one or more mounting feet each include a slider and at least two panel rails each include a flange that does not overlap the slider in a direction normal to the preassembled solar panel module when the slider is in an open position, thereby permitting receipt of a flange end of a panel rail within a rail receiving recess defined within each of the mounting feet. The panel rail flange does overlap the slider in the direction normal to the preassembled solar panel module when the slider is slid to a closed position from the open position for securing a mounting foot to a panel rail. One or more snap connector components may include a slider for securing one or more snap connector components to one or more panel rails.

An array of preassembled solar panel modules is provided in certain embodiments, wherein one or more toggle anchors are provided each including a rotatably-attached, elongated washer for piercing roof sheathing or other sunlight receiving surface material in a first position and rotating to a second position for securing a mounting foot of a preassembled solar panel module of the array to the sunlight receiving surface after the piercing.

An array of preassembled solar panel modules is provided in certain embodiments, including one or more frameless solar panels. The one or more frameless solar panels may be strengthened by coupling two or more panel rails to a backside surface that are configured to stiffen the solar panel.

In certain embodiments, adjacent solar panel modules of an array are secured together by coupling together complimentary snap connector components that may be coupled one to each of two adjacent preassembled solar panel modules.

A frameless, preassembled solar panel module is also provided that includes a frameless solar panel configured for receiving and converting solar radiation to produce electrical power and multiple panel rails coupled in preassembly to a backside surface of the solar panel, including at least two panel rails disposed a quarter length or more along opposing longest edges of the solar panel. Multiple flexible snap connector components are each coupled in preassembly to one of the at least two rails and are each configured to for coupling with a complimentary snap connector component of an adjacent preassembled solar panel module or of a wind deflector accessory, or both. One or more mounting feet are each coupled in preassembly at a selected location to one of the at least two panel rails and each mounting foot is configured for coupling at a selected location to a roof or to another sunlight receiving surface. In certain embodiments, one or more wind deflectors are coupled to one or more sides of the frameless, preassembled solar panel module. These one or more sides are selected in preassembly for coupling wind deflectors thereto for defining a peripheral segment of an array of multiple modules.

A frameless, preassembled solar panel module may include one or more short panel rails coupled to the backside surface of the preassembled solar panel module disposed a quarter length along opposing shortest sides of the solar panel between at least two long panel rails that are disposed at opposing longest sides.

A frameless, preassembled solar panel module may include two or more short panel rails coupled to the backside surface of the preassembled solar panel module disposed a quarter length or more along short dimension segments spaced from either shortest side of the solar panel between at least two long panel rails that are disposed at opposing longest sides.

A frameless, preassembled solar panel module may include in certain embodiments a bumper at each corner of the frameless, preassembled solar panel module that extends normally from the backside surface further than any of the panel rails.

A frameless, preassembled solar panel module may include in certain embodiments at least two panel rails that include outer facing walls with one or more features, e.g., a series of notches, recesses, cutouts or protrusions, or combinations thereof, for coupling with complimentary notches of mounting feet or of snap connector components, or both, for preventing movement along a panel rail of a mounting foot or of a snap connector component, or both.

A frameless, preassembled solar panel module may include in certain embodiments a mounting foot that includes a slider and at least two panel rails coupled to a backside surface that each include a flange that does not overlap the slider in a direction normal to the preassembled solar panel module when the slider is in an open position, thereby permitting receipt of a flange end of a panel rail within a rail receiving recess defined within the mounting foot assembly. The panel rail flange does overlap the slider in a direction normal to the preassembled solar panel module when the slider is slid to a closed position from an open position for securing a mounting foot to a flanged panel rail. One or more snap connector components may include a slider for securely coupling to a flanged panel rail.

A frameless, preassembled solar panel module may include mounting feet in certain embodiments that are configured to be coupled to a sunlight receiving surface using one or more toggle anchors that include a rotatably-attached, elongated washer for piercing roof sheathing or other sunlight receiving surface material in a first position and rotating to a second position securing the mounting foot to the surface material after the piercing. The frameless, preassembled solar panel module may be strengthened by the panel rails being configured to stiffen the solar panel. The frameless, preassembled solar panel module may be configured for coupling with one or more adjacent frameless, preassembled solar panel modules by coupling together complimentary snap connector components that are coupled one to each of two adjacent preassembled solar panel modules.

A frameless, preassembled solar panel module may include one or more snap connector components configured to provide relative alignment with adjacent modules of an array by the coupling together of complimentary snap connector components coupled one to each of the adjacent preassembled solar panel modules.

A frameless, preassembled solar panel module may include one or more snap connector components that include a locking mechanism to secure the coupling with a snap connector component of an adjacent preassembled solar panel module.

A frameless, preassembled solar panel module may include one or more mounting feet that include one or more pivoting features configured to provide relative movement between a pair of components to prevent or reduce strain or stress.

A frameless, preassembled solar panel module may include one or more mounting feet that include one or more pivoting features configured to provide relative movement of a preassembled solar panel module to prevent or reduce stress or strain from wind or snow loading or other factors by flexing about the one or more pivoting features.

A frameless, preassembled solar panel module may include two or more overlapping surfaces that are each configured to receive and convert solar radiation to generate electrical power.

In certain embodiments, the frame of a conventional solar panel is replaced on a glass-backsheet solar photovoltaic (PV) module by a set of long panel rails coupled to the bottom or backside of the module along the long edges of the module. A set of one or more short rails may be coupled along one or more short edges of the modules and/or spaced significantly from the short edges for example even at mid-rail locations between the long rails or for example a pair of short rails may be disposed ⅓ of the length of the long rails from the ends of the long rails. The rails may be configured to provide rigidity to glass-backsheet lamination in certain embodiments.

The rails may also be configured for providing a base for side snap brackets to couple to the solar PV module and/or for providing a base for corner snap brackets to couple to the module. The rails may also be configured for providing a base for mounting feet to couple to the solar PV module for securing the module to a roof or other sunlight receiving surface. The rails may also be configured to provide a structure for securing power electronics, cables and/or wires.

The coupling of a mounting foot to a panel rail can be performed in a number of ways including inserting pins from the foot into holes or slots in the rail (see, e.g., FIGS. 1-3, 5, 6F-6J, 22B, 29D-29H ). In addition to the method described to support the glass-backsheet PV module, another embodiment is provided that includes a panel rail system coupled to the bottom or backside of a solar PV module. In this embodiment, rails are coupled to the bottom or backside of the module at the long sides of the modules that are employed to provide utility for dual glass PV modules, which are modules constructed with a second sheet of transparent or translucent glass, while a solar PV module may also include a single top or frontside sheet of glass and an opaque polymer backsheet. In the dual-glass embodiment, the dual glass long rails are coupled to the glass backsheet, and may also be coupled to side snaps, long snaps, bumpers, mounting feet, power electronics or clips for holding cables or wires conducting electricity produced by the PV module, or combinations thereof.

In certain embodiments, polymer materials are employed for snaps, bumpers, brackets, mounting feet, or rail coatings, or combinations thereof, that allow the safe installation, use and operation of the pre-assembled solar panel modules without needing any equipment grounding or bonding alternative metal parts contained within the system.

Furthermore, the back coupling of the rails to the solar module serves in certain embodiments to prevent premature degradation of the solar module, which could otherwise reduce a module's power production over time, primarily but not exclusively due to the elimination of potential induced degradation, which is a condition that has afflicted many conventional framed, glass-backsheet modules.

PREASSEMBLED

FIGS. 1-5, 16A-28B and 30-31D illustrate several embodiments of fully or partially preassembled and/or installed solar panel modules. A fully preassembled solar panel module in accordance with certain embodiments includes two or more panel rails coupled to a backside surface, and two or more snap connector components and one or more mounting feet each coupled to at least one of the panel rails. Multiple solar panel modules of an array are secured to a roof or other sunlight receiving surface by coupling the one or more mounting feet to the roof or other sunlight receiving surface and by coupling together adjacent snap connector component pairs of adjacent solar panel modules. A partially preassembled solar panel module may be shipped before coupling the one or more mounting feet, which may be coupled at selected locations along the rails that are determined onsite based on locations of bands of sheathing strength and/or on specific details relating to the roof or other sunlight receiving surface upon which the solar array is being installed.

The mounting feet are designed in certain embodiments to be coupled to preassembled solar panel modules before anchoring the feet and the modules of the array to a roof or other sunlight receiving surface. A fully preassembled solar panel module includes the one or more mounting feet coupled thereto at least by the time of anchoring to the roof. During shipping, the mounting feet may or may not be coupled to a partially preassembled solar panel module.

A partially preassembled solar panel module may include two or more panel rails coupled to a backside surface. The solar panel module may be deemed to be fully preassembled when the one or more mounting feet are each coupled to one of the backside-attached panel rails. A fully or partially preassembled solar panel module may include one or more bumpers, one or more brackets, e.g., that may couple to ends of one or more panels rails or may include built-in snap connector components, and/or one or more snap connector components along one or more sides and/or at one or more of the corners for coupling together adjacent modules of a solar array. Particular configurations of side snap connectors and/or corner snap connectors may be customized specific to installation applications, e.g., residential pitched roof solar arrays may include snap-connected adjacent solar panel modules or solar farm arrays or multi-directional arrays that may include some adjacent solar panel modules that are snap-connected together and some that are not, and an array may include no snap connected adjacent solar modules in certain applications.

For residential pitch roof applications, snap connector components are included with preassembled solar panel modules in accordance with several example embodiments. For other applications, like low slope commercial or residential roof, preassembled solar panel modules may include fewer preassembled components. In such low slope applications, for example, either the side snaps, the corner snaps or the bumpers or combinations thereof may be excluded from a preassembled solar panel module in certain embodiments.

As another example, for an installation in which a customer prefers not to see brackets or snap-connector components along a perimeter edge of a solar array, the brackets or the side snaps or the corner snaps or the bumpers or combinations thereof may be optionally removed to provide a clean frameless aesthetic and an edge free from components which can catch debris or be used by insects for nesting. Wind deflectors may be provided that also serve aesthetically to block certain components from view and from damaging effects from wind or rain or other natural factors.

in some applications, like low slope commercial or residential roof, fewer than all installed components may be coupled in preassembly to the solar panel module. In a low slope application, for example, either the side snaps, the corner snaps or one or more bumpers or wind deflectors, or combinations thereof, may be excluded from a preassembled solar panel module or optionally included even module-to-module depending on the arrangement and particulars of the array and the installation surface. Any one or more of these components may be installed in a subsequent assembly step before transport to an install site or at an install site prior to mounting to a roof or other sunlight receiving surface, or even after mounting, or may be subsequently removed, or may left off one or more modules or from an entire array of preassembled solar panel modules.

A long panel rail, i.e., a panel rail that is aligned with a longest side of a solar panel, may be as long as the longest side of the solar panel, or may be much smaller, e.g., a quarter, a half or three-quarters of the length of the long side of the solar panel. When shorter panel rails are used, there may be more than one of them disposed coaxially or non-coaxially, and spaced-apart along the long side of the solar panel. For example, there may be two panels rails coupled along each long side of a preassembled solar panel module, one for coupling with a mounting foot and the other for coupling with a snap coupler component. In another example, three panel rails, each being one quarter of the length of the longest side of a solar panel module, are disposed coaxially along the longest side of a preassembled solar panel module and spaced apart by an eighth of the length of the longest side of the module.

The panels rails in a dual glass, frameless solar panel module configuration may provide some stiffening support to the module, although dual glass module already has two plane glass stiffness. In a glass-polymer backsheet module, that may or may not include a frame, the panel rails would be configured to provide enhanced stiffness in both the short and long sides of the module.

BRACKETS

In certain embodiments, one or more mounting feet, one or more panel rails, one or more snap connectors, one or more wind deflectors and/or one or more accessory components may be coupled to one or more brackets that are coupled to a backside of a preassembled solar panel module, and brackets of adjacent modules of an array may be coupled together. In certain embodiments, all of these components are coupled to underside brackets, while in other embodiments, these brackets have a more limited use, e.g., coupling just to brackets of adjacent modules or for coupling long and short panel rails together, while other embodiments include no brackets. The function of the brackets in certain embodiments may be served by one or more panel rails, e.g., for coupling with mounting feet or a mounting foot or mounting foot component may be built-in integrally with a bracket or panel rail or with the preassembled solar panel module itself.

In certain embodiments, mounting feet may couple with a track or panel rail or bracket or an aluminum extrusion running along a backside or bottom edge of a frameless PV module. In certain embodiments, brackets are coupled at backside corners of a preassembled solar panel module for coupling with one or more panel rails and/or snap connectors, while in other embodiments, snap connectors are integral with the brackets. In other embodiments brackets and snap connector components are one and the same component that may couple to a panel rail or directly to an underside or backside surface of a preassembled solar panel module. Corner brackets may be integral with or coupled to corner bumpers that protect the underside of the preassembled solar panel module during shipping, stacking, storage and/or installation. Snap connectors at the corners may be coupled to ends of long rails and/or to ends of short rails or directly to the solar panel, or combinations of these. The panel rails, brackets and/or snap connector components may be coupled to the backside of a preassembled solar panel module using adhesive. In certain embodiments, none of the panel rails, brackets and/or snap connectors is coupled to any edge of the preassembled solar panel module, which may or may not include a frame, and which may have a dual-glass (front and back) design or a single glass (front),-polymer (backside) design.

Transparency is needed for the frontside of the module in order that solar radiation may directly reach the optoelectronic components of the photovoltaic module, while transparency is optional for the backside surface, which may be alternatively opaque, translucent or even reflective. In certain embodiments, alternative optical paths may be employed for directing solar radiation to impinge upon these or other subsets of optoelectronic components such as by using mirrors or lenses for collecting and/or focusing and/or redirecting the solar radiation. For example, a mirror may be provided to redirect solar radiation to impinge upon the optoelectronic components from the backside, and more than one photovoltaic layer may be stacked within a single preassembled solar panel module for increased efficiency.

Brackets and/or snap connectors may be coupled directly to the solar panel or to long or short rails, or combinations thereof. Side snap connector components may be coupled to a panel rail using a bolted mechanism or a slide-flange mechanism in certain embodiments. Corner snap connectors may be coupled to ends of panel rails or to the underside surface of the preassembled solar panel module, or combinations thereof. Corner bumpers, corner brackets and corner snaps may be combined into a single integral component in certain embodiments, which may couple to a panel rail or may be integrally-formed with a panel rail. In certain embodiments, corner bumpers and corner snaps may be combined into a single integral corner bracket component, which may also couple to short and/or long rail ends and/or to the underside surface of a preassembled solar panel module in accordance with certain embodiments. Any of these corner bracket embodiments may couple long and short rails together end to end, or end to mid-rail location.

In certain embodiments, corner brackets may serve to couple long rails to short rails as well as to couple adjacent preassembled solar panel modules together, and to protect the underside of the preassembled module as a bumper to absorb collisions and prevent contact damage to the module. In certain embodiments, corner snaps are coupled at all four underside corners of a preassembled solar panel module, and side snaps are coupled mid-rail to each long rail and aligned with and/or coupled to one or more short rails. These side snaps may be configured to serve as a bracket for coupling panel rails to the backside of the module, or to other rails or other components in certain embodiments, while panel rails may be adhesively coupled to the backside surface of a preassembled solar panel module. In certain embodiments, one or more side snaps may couple to both a long rail and a short rail.

Certain embodiments include fewer side snaps or no side snaps, while corner snap brackets are also optional, particularly in embodiments configured as a minimalist installation, e.g., for modules of an array that are disposed along the perimeter of a solar array or in the case of alternative roofing systems in which these components are not used.

SNAP CONNECTORS

In some embodiments, snap connectors or snaps may be provided at the corners, while snap connectors or snaps that are not at the corners may be coupled to the long rails anywhere along the length of the rail. The snap connectors may be configured as a sleeve disposed around a length of a panel rail, or the snap connectors may couple to the rails using a slider to catch a panel rail flange or using a bolt and nut mechanism or peg and slot mechanism in certain embodiments.

In certain embodiments, snap connectors may be coupled to rail connectors that connect long rails to short rails on one side (facing in away from the edge of the module) and that connect long rails to snap connectors on the other side (facing out towards the edge of the module). Snap connectors or snaps can serve multiple purposes, including creating a module to module coupling location, coupling to a long panel rail, coupling to a short panel rail, or efficiently transferring mechanical load from module to snap to foot, or combinations thereof. Snap connectors in certain embodiments offer a rotational lock of the snap coupling mechanism which improves the usability and the effectiveness of the snap locking operation by installers.

In certain embodiments, mounting feet couple to brackets, e.g., as in FIGS. 31C-31D , and the brackets are coupled to the backside of the solar panel. In other embodiments, mounting feet don't couple to brackets but to panel rails, e.g., as in FIGS. 1-5, 16C-16D, 21, 28D and 31A . The panel rails are disposed close to the edges in certain embodiments so that mounting feet can be non-overlapping of the solar panel at a roof or other sunlight receiving surface location where snap toggle mounting is performed. Mounting feet can be easily adjusted to another location along a rail, e.g., that overlaps a sheathing strong point or band of sheathing strength, in preassembly or on location. Snaps, snap connectors or snap couplers can be easily adjusted to any location along a panel rail to align with complimentary snaps, snap connectors or snap couplers on an adjacent preassembled solar panel module.

FIGS. 1-3 schematically illustrate partial top perspective views of example embodiments of a preassembled solar panel module including a mounting foot and snap connector components each coupled separately to one of multiple panel rails that are coupled to a backside surface of an otherwise frameless solar panel module. The backside coupled rails allow the secure mounting of frameless solar panel modules to rigid structures without the need of a frame. Replacing a traditional solar panel module frame with rails as shown lowers cost and improves reliability of the module by removing the risk of increased module degradation due to the voltage difference between the modules and the frame, called potential induced degradation or PID.

FIG. 1 schematically illustrates a preassembled solar panel module 102 in accordance with certain embodiments that includes complimentary, e.g., male and female, corner snap couplers

104 A, 104 B, a side snap coupler 106 B, which is configured to couple with a complimentary side snap coupler of an adjacent preassembled solar panel module in an array, a corner bumper 112 and a mounting foot 108 that is shown engaging with a panel rail with notches 109 configured for interlocking with complimentary features on the mounting foot 108 .

FIG. 2 illustrates a preassembled solar panel module 202 including a side snap connector component 106 A coupled to a panel rail 210 that has a series of notches 209 for coupling with a mounting foot 208 that includes a rail clip 222 , a height adjustment mechanism 224 , a pivot adjustment handle or lever 240 , and a foot base 226 in accordance with certain embodiments.

FIG. 3 illustrates a preassembled solar panel module 302 including corner snap couplers

304 A, 304 B, and a corner bumper 312 , as well as side snap couplers 306 B that are coupled to a panel rail 310 that has a series of notches 309 for interlocking with a complimentary series of features of the snap coupler 306 B and for coupling with and interlocking with complimentary features of a mounting foot 308 in accordance with certain embodiments.

FIG. 4 schematically illustrates a side view of the solar panel module of FIGS. 1-3 . In FIG. 4 , we see the Female corner snap 404 B with a rotating lock 430 and a corner bumper 412 . This FIG. 4 shows the height H of the system or the dimension between the roof or other fixed surface and the back side of the preassembled solar panel module 402 . This low profile design is valuable as it lowers the effective wind loading on the preassembled solar module array and by extension all its components which saves weight and cost.

FIG. 4 schematically illustrates a side view of one corner of the module 302 of FIG. 3 including a corner snap coupler 404 B, a corner bumper 412 , a short side panel rail 411 . FIG. 4 also shows a foot arm 432 coupled to a foot base

CLAIMS

Claims ( 20 )

What is claimed is:

1. An array of two or more preassembled solar panel modules, each preassembled solar panel module comprising:

a solar panel configured for receiving and converting solar radiation to produce electrical power;

a plurality of panel rails coupled in preassembly to a backside surface of the solar panel, including at least two panel rails disposed halfway or more along opposing longest edges of the solar panel;

a plurality of module connector components each coupled to one of the at least two rails and to a complimentary module connector component of an adjacent preassembled solar panel module or of a wind deflector accessory, or both;

one or more mounting feet each coupled both at a selected location to one of the at least two panel rails and at a selected location to a roof or to other sunlight receiving surface upon which said array is installed, and

wherein 0.42<H/G<15, where H is a height of a preassembled solar panel module measured as a spacing of said backside surface of said preassembled solar panel module from said roof or other sunlight receiving surface, and where G is a gap spacing between nearest edges of adjacent preassembled solar panel modules, and

wherein said mounting feet each include a slider and said at least two panel rails each include a flange that does not overlap the slider in a direction normal to the preassembled solar panel module when the slider is in an open position, thereby permitting receipt of a flange end of a panel rail within a rail receiving recess defined within each of said mounting feet, wherein said flange does overlap the slider in said direction normal to the preassembled solar panel module when the slider is slid to a closed position from said open position for securing the mounting feet to the at least two panel rails.

2. The array of claim 1 , wherein 0.42<H/G<3.

3. The array of claim 1 , wherein 0.42<H/G<1.5.

4. The array of claim 1 , wherein 20 mm<G<120 mm.

5. The array of claim 1 , wherein 50 mm<H<300 mm.

6. The array of claim 1 , wherein H<75 mm and G>37.5 mm.

7. The array of claim 1 , wherein H/G≈1.

8. The array of claim 1 , comprising a plurality of wind deflectors coupled to sides of preassembled solar panel modules that each define a peripheral segment of the array.

9. The array of claim 1 , further comprising one or more short panel rails coupled to said backside surface of said preassembled solar panel module disposed halfway or more along opposing shortest edges of the solar panel between said at least two panel rails that are disposed at said opposing longest edges.

10. The array of claim 1 , further comprising two or more short panel rails coupled to said backside surface of said preassembled solar panel module disposed halfway or more along short dimension segments spaced from either shortest edge of the solar panel between said at least two panel rails that are disposed at said opposing longest edges.

11. The array of claim 1 , further comprising bumpers at corners of said preassembled solar panel modules that extend normally from said backside surface further than any of said plurality of panel rails.

12. The array of claim 1 , wherein said at least two panel rails include outer facing walls with one or more features for coupling with one or more complimentary features of said mounting feet or of said snap connector components, or both, for preventing movement along said at least two panel rails of said mounting feet or of said snap connector components, or both.

13. The array of claim 12 , wherein said one or more features comprise a series of notches or recesses or both.

14. The array of claim 1 , wherein said solar panel comprises a frameless solar panel.

15. The array of claim 1 , wherein said module connector components comprise snap connector components, and wherein adjacent solar panel modules are coupled together by coupling together complimentary snap connector components that are coupled one to each of two adjacent preassembled solar panel modules.

16. An array of two or more preassembled solar panel modules, each preassembled solar panel module comprising:

a solar panel configured for receiving and converting solar radiation to produce electrical power;

a plurality of panel rails coupled in preassembly to a backside surface of the solar panel, including at least two panel rails disposed halfway or more along opposing longest edges of the solar panel;

a plurality of module connector components each coupled to one of the at least two rails and to a complimentary module connector component of an adjacent preassembled solar panel module or of a wind deflector accessory, or both;

one or more mounting feet each coupled both at a selected location to one of the at least two panel rails and at a selected location to a roof or to other sunlight receiving surface upon which said array is installed, and

one or more toggle anchors each comprising a rotatably-attached, elongated washer for piercing roof sheathing or other sunlight receiving surface material in a first position and rotating to a second position securing the toggle anchor after said piercing, and

wherein 0.42<H/G<15, where H is a height of a preassembled solar panel module measured as a spacing of said backside surface of said preassembled solar panel module from said roof or other sunlight receiving surface, and where G is a gap spacing between nearest edges of adjacent preassembled solar panel modules.

17. The array of claim 1 , wherein said mounting feet include one or more pivoting features configured to provide relative movement between a pair of components to prevent or reduce strain or stress within the array.

18. The array of claim 1 , wherein said mounting feet each include one or more pivoting features configured to provide relative movement of a preassembled solar panel module to prevent or reduce stress or strain from wind or snow loading or other factors by flexing about the one or more pivoting features.

19. The array of claim 1 , wherein solar panel includes at least two overlapping surfaces that are configured to receive and convert solar radiation to generate electrical power.

20. The array of claim 16 , wherein said mounting feet each include a slider and said at least two panel rails each include a flange that does not overlap the slider in a direction normal to the preassembled solar panel module when the slider is in an open position, thereby permitting receipt of a flange end of a panel rail within a rail receiving recess defined within each of said mounting feet, wherein said flange does overlap the slider in said direction normal to the preassembled solar panel module when the slider is slid to a closed position from said open position for securing the mounting feet to the at least two panel rails.

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Sensing, interlocking solar panel system and installation method

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