ABSTRACT
Abstract
A rack assembly is provided for mounting solar modules over an underlying body. The rack assembly may include a plurality of rail structures that are arrangeable over the underlying body to form an overall perimeter for the rack assembly. One or more retention structures may be provided with the plurality of rail structures, where each retention structure is configured to support one or more solar modules at a given height above the underlying body. At least some of the plurality of rail structures are adapted to enable individual rail structures o be sealed over the underlying body so as to constrain air flow underneath the solar modules. Additionally, at least one of (i) one or more of the rail structures, or (ii) the one or more retention structures are adjustable so as to adapt the rack assembly to accommodate solar modules of varying forms or dimensions.
Description
PRIORITY APPLICATIONS
This application is a Continuation of U.S. patent application Ser. No. 12/949,551, filed Nov. 18, 2010; which is a Continuation of U.S. patent application Ser. No. 11/332,000, filed Jan. 13, 2006, now U.S. Pat. No. 7,856,769, issued Dec. 28, 2010; which is a Continuation-in-part of U.S. patent application Ser. No. 10/855,254, filed May 26, 2004; which claims benefit of priority to:
i) U.S. Provisional Patent Application No. 60/544,753, filed Feb. 13, 2004, and ii) U.S. Provisional Patent Application No. 60/643,619, filed Jan. 15, 2005;
all of the aforementioned priority applications being hereby incorporated by reference in their respective entirety for all purposes.
The U.S. Government has a paid-up license in this invention and the right in limited circumstances to require the patent owner to license others on reasonable terms as provided for by the terms of contract No. NDC-5-55022-01 and contract No. NDO-3-33457-02, both awarded by the Department of Energy.
TECHNICAL FIELD
The disclosed embodiments relate generally to the field of solar modules. In particular, the disclosed embodiments relate to a mechanism for mounting solar modules to a surface or sub-structure.
BACKGROUND
Modules for converting solar energy into useful forms of energy such as heat and electricity have been around for decades. Because of the suns low energy intensity and the low conversion efficiency of some solar modules, a large array of solar modules is often required to service the end-use of the energy. Arrays from several dozen to several thousand square feet are common. Moreover, the variety of surfaces on which the modules may be mounted requires a wide range of flexibility and adaptability in the mounting hardware that will be used to structurally anchor the modules to the surface.
High energy prices and the desire to âbuild greenâ have led to increases in the use of solar photovoltaic (PV) modules to provide electricity and solar thermal modules to provide heating services for homes and other building structures. As a parallel development, architects and building owners have stressed the need for solar systems that are aesthetically or functionally integrated into the building façade for improved aesthetics.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a block diagram of components that combine to form a rack assembly for supporting a solar module, under an embodiment of the invention.
FIG. 2A illustrates an installed rack assembly that supports a set of solar modules over an underlying body, according to one or more embodiments of the invention.
FIG. 2B illustrates another installed rack assembly that supports a set of solar modules over an underlying body, on which one or more vents are provided, according to one or more embodiments of the invention
FIG. 3A is a side view of a free rail structure, according to an embodiment of the invention.
FIG. 3B is a side view of a shared rail structure, according to an embodiment of the invention.
FIG. 4A and FIG. 4B are isometric views of a free rail structure and a shared rail structure, respectively, as provided in an installed rack assembly, according to one or more embodiments of the invention.
FIG. 5A and FIG. 5B are side cross-sectional views of a free rail structure and a shared rail structure respectively, as mounted to a common strut runner, according to one or more embodiments of the invention.
FIG. 6A and FIG. 6B illustrate an upper rail and a lower rail of a free rail structure, according to one or more embodiments of the invention.
FIG. 7A and FIG. 7B illustrate an upper rail and a lower rail of a shared rail structure, according to one or more embodiments of the invention.
FIG. 8A is an isometric cross-sectional view of a rack assembly at a first corner of the overall perimeter, from a perspective of a free rail structures 220 , under an embodiment of the invention.
FIG. 8B is an isometric cross-sectional view of the rack assembly at a first corner of the overall perimeter, from a perspective of one of the shared rail structure, according to an embodiment of the invention
FIG. 9A is top isometric view of a thermal solar panel for use with a rack assembly, under an embodiment of the invention.
FIG. 9B is an isometric view of the thermal solar panel shown in FIG. 9A , under an embodiment of the invention.
FIG. 9C is a cross-sectional isometric view of the thermal panel shown in FIGS. 9A and 9B , under an embodiment of the invention.
FIG. 9D illustrates a shim plate for use with a thermal solar panel such as shown and described, under an embodiment of the invention.
FIG. 9E illustrates a frame of a thermal panel such as shown and described, with a set of apertures for receiving a fastener inserted through the shim plate, under an embodiment of the invention.
FIG. 10A illustrates an implementation in which a rack assembly is provided over a series of vents as part of a heat exchange system, according to an embodiment of the invention.
FIG. 10B illustrates an underside of a rack assembly, as implemented in FIG. 10A , under an embodiment of the invention.
FIG. 11A shows a configuration in which a plurality of vents are aligned and provided under one row of a rack assembly on which a solar module array is installed, according to an embodiment of the invention.
FIG. 11B shows the formation of an alternative configuration in which a multi-directional channel is formed below a rack assembly, according to an embodiment of the invention.
DETAILED DESCRIPTION
According to an embodiment, a rack assembly is provided for use in mounting solar modules to form a solar array, in which components that comprise the rack assembly form at least a partial perimeter seal to the underlying body. Among other benefits, the perimeter seal enables enable the capture of heat generated from use of the solar modules for various purposes. These purposes may include increasing efficiency of photovoltaic cells and heating air. Additionally, the perimeter seal can provide other uses, such as a cosmetic skirt that further improves aesthetics by hiding the gap between the array and underlying body. The perimeter seal can be formed such that it diverts any precipitation running down the underlying body from penetrating the underside of the array. Moreover, any mounting penetrations made under the array is protected, and the rack assembly with the partial or complete perimeter seal enables a simple covering to be provided under the array if the underlying body needs to be weatherproofed (i.e. the roof of a house).
Although the deployment of a rack assembly with a sealed or partially restricted perimeter yields aesthetic and weather proofing benefits, it also restricts the flow of air underneath the array. In traditional installations of solar photovoltaic modules, this restriction of airflow is an undesirable effect and may lead to increased module temperatures and lower conversion efficiencies.
In one embodiment, a rack assembly or mounting system is arranged such that the combination of a seamless front surface and perimeter sealing yields air channels underneath the array of solar modules. The creation of these air channels allows for the heat generated by the solar modules to be captured and removed to increase their conversion efficiency and create a useable energy stream. The system may also employ solar thermal modules that act to further boost the air temperature, leaving the array for use in cold climates or other instances in which higher air stream temperatures are required.
According to an embodiment, a rack assembly is provided for mounting solar modules over an underlying body. The rack assembly may include a plurality of rail structures that are arrangeable over the underlying body to form an overall perimeter for the rack assembly. One or more retention structures may be provided with the plurality of rail structures, where each retention structure is configured to support one or more solar modules at a given height above the underlying body. At least some of the plurality of rail structures are adapted to enable individual rail structures to be sealed over the underlying body so as to constrain air flow underneath the solar modules. Additionally, at least one of (i) one or more of the rail structures, or (ii) the one or more retention structures are adjustable so as to adapt the rack assembly to accommodate solar modules of varying forms, dimensions or installation height or spacing requirements.
According to an embodiment, the rack assembly may include coupling structures that enable the rack assembly to be sealed over the underlying body. In an embodiment, the coupling structures are in the form of a flashing component, or a combination of flashing components. According to one embodiment, the combination of flashing components include a first or lower flashing component that enable a seal to be formed with the underlying body, and a counter flashing component that overlays where the lower flashing component joins the rack assembly.
In an embodiment, the retention structures are in the form of an extended member and an underlying or lower shelf. The retention structure enables retention of a solar module when a compressive force is applied to the extended member.
According to another embodiment, a rack assembly is provided for mounting solar modules over an underlying body. The rack assembly may be installed over an underlying body and include a plurality of rail structures that are arranged to form an overall perimeter. One or more retention structures may be provided with the plurality of rail structures to support one or more solar modules mounted therein at a given height over the underlying body. At least some of the plurality of rail structures are sealed over the underlying body so that at least a portion of the overall perimeter is closed. A channel may be formed at least in part by the at least some of the portion of the overall perimeter that is sealed over the underlying body and occupies at least a portion of the given height separating the one or more solar modules from the underlying structure.
Under another embodiment, a solar energy transfer system is provided over an underlying body. The system includes a plurality of solar modules that receive solar energy and convert the solar energy into electricity or heat. The plurality of solar modules may be of a given size that is within a range of possible sizes that can be handled by the rack assembly. A rack assembly supports the plurality of solar modules a given height over an underlying body. The rack assembly may be sealed across at least a portion of its perimeter to the underlying body to define, at least in part, one or more channels underneath the plurality of solar modules that constrains air flow. Additionally, the rack assembly is cooperatively positioned with an air driver to enable the air driver to direct air through the one or more channels so that the air is heated by heat from one or more of the plurality of solar modules.
As an example, FIG. 10A and FIG. 10B illustrate a rack assembly that is cooperatively engaged with an air driver, which may be provided through use of a vent. In particular, a vent may be provided underneath the rack assembly and be coupled to, for example, a fan for drawing air. Alternatively, the vent may blow air from one location to another underneath a rack assembly such as described by one or more embodiments.
Under another embodiment, a rack assembly includes a plurality of rail structures and a plurality of retention structures. The plurality of retention structures may be provided by the plurality of rail structures. In an embodiment, one or more of the plurality of retention structures are adjustable between adjacent rail structures in order to (i) loosely grasp and hold a given solar module to enable manual adjustment of the positioning and securement of the given solar module, (ii) mechanically secure and hold the given solar module in an installed position a given height over the underlying body.
Overview
FIG. 1 is a simplified illustration of a rack assembly for supporting solar modules, under one or more embodiments of the invention. As shown, a rack assembly 10 includes a plurality of rail structures 12 that provide support for individual solar modules 14 . When installed, the rail structures 12 support the individual solar modules 14 a given height h above an underlying body 15 . The underlying body 15 may correspond to any surface, platform or structure on which solar modules 14 are mounted. For example, underlying body 15 may correspond to a rooftop of a commercial or residential building. The solar modules 14 may correspond to photovoltaic solar cells that convert solar energy into electricity, or alternatively, solar heating modules which directly generate heat using solar energy.
According to one or more embodiments, the <figure-callout id="12" label="rail structures" filenames="US08745936-20140610-D00000.png,US
PRIORITY APPLICATIONS
This application is a Continuation of U.S. patent application Ser. No. 12/949,551, filed Nov. 18, 2010; which is a Continuation of U.S. patent application Ser. No. 11/332,000, filed Jan. 13, 2006, now U.S. Pat. No. 7,856,769, issued Dec. 28, 2010; which is a Continuation-in-part of U.S. patent application Ser. No. 10/855,254, filed May 26, 2004; which claims benefit of priority to:
i) U.S. Provisional Patent Application No. 60/544,753, filed Feb. 13, 2004, and ii) U.S. Provisional Patent Application No. 60/643,619, filed Jan. 15, 2005;
all of the aforementioned priority applications being hereby incorporated by reference in their respective entirety for all purposes.
The U.S. Government has a paid-up license in this invention and the right in limited circumstances to require the patent owner to license others on reasonable terms as provided for by the terms of contract No. NDC-5-55022-01 and contract No. NDO-3-33457-02, both awarded by the Department of Energy.
TECHNICAL FIELD
The disclosed embodiments relate generally to the field of solar modules. In particular, the disclosed embodiments relate to a mechanism for mounting solar modules to a surface or sub-structure.
BACKGROUND
Modules for converting solar energy into useful forms of energy such as heat and electricity have been around for decades. Because of the suns low energy intensity and the low conversion efficiency of some solar modules, a large array of solar modules is often required to service the end-use of the energy. Arrays from several dozen to several thousand square feet are common. Moreover, the variety of surfaces on which the modules may be mounted requires a wide range of flexibility and adaptability in the mounting hardware that will be used to structurally anchor the modules to the surface.
High energy prices and the desire to âbuild greenâ have led to increases in the use of solar photovoltaic (PV) modules to provide electricity and solar thermal modules to provide heating services for homes and other building structures. As a parallel development, architects and building owners have stressed the need for solar systems that are aesthetically or functionally integrated into the building façade for improved aesthetics.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a block diagram of components that combine to form a rack assembly for supporting a solar module, under an embodiment of the invention.
FIG. 2A illustrates an installed rack assembly that supports a set of solar modules over an underlying body, according to one or more embodiments of the invention.
FIG. 2B illustrates another installed rack assembly that supports a set of solar modules over an underlying body, on which one or more vents are provided, according to one or more embodiments of the invention
FIG. 3A is a side view of a free rail structure, according to an embodiment of the invention.
FIG. 3B is a side view of a shared rail structure, according to an embodiment of the invention.
FIG. 4A and FIG. 4B are isometric views of a free rail structure and a shared rail structure, respectively, as provided in an installed rack assembly, according to one or more embodiments of the invention.
FIG. 5A and FIG. 5B are side cross-sectional views of a free rail structure and a shared rail structure respectively, as mounted to a common strut runner, according to one or more embodiments of the invention.
FIG. 6A and FIG. 6B illustrate an upper rail and a lower rail of a free rail structure, according to one or more embodiments of the invention.
FIG. 7A and FIG. 7B illustrate an upper rail and a lower rail of a shared rail structure, according to one or more embodiments of the invention.
FIG. 8A is an isometric cross-sectional view of a rack assembly at a first corner of the overall perimeter, from a perspective of a free rail structures 220 , under an embodiment of the invention.
FIG. 8B is an isometric cross-sectional view of the rack assembly at a first corner of the overall perimeter, from a perspective of one of the shared rail structure, according to an embodiment of the invention
FIG. 9A is top isometric view of a thermal solar panel for use with a rack assembly, under an embodiment of the invention.
FIG. 9B is an isometric view of the thermal solar panel shown in FIG. 9A , under an embodiment of the invention.
FIG. 9C is a cross-sectional isometric view of the thermal panel shown in FIGS. 9A and 9B , under an embodiment of the invention.
FIG. 9D illustrates a shim plate for use with a thermal solar panel such as shown and described, under an embodiment of the invention.
FIG. 9E illustrates a frame of a thermal panel such as shown and described, with a set of apertures for receiving a fastener inserted through the shim plate, under an embodiment of the invention.
FIG. 10A illustrates an implementation in which a rack assembly is provided over a series of vents as part of a heat exchange system, according to an embodiment of the invention.
FIG. 10B illustrates an underside of a rack assembly, as implemented in FIG. 10A , under an embodiment of the invention.
FIG. 11A shows a configuration in which a plurality of vents are aligned and provided under one row of a rack assembly on which a solar module array is installed, according to an embodiment of the invention.
FIG. 11B shows the formation of an alternative configuration in which a multi-directional channel is formed below a rack assembly, according to an embodiment of the invention.
DETAILED DESCRIPTION
According to an embodiment, a rack assembly is provided for use in mounting solar modules to form a solar array, in which components that comprise the rack assembly form at least a partial perimeter seal to the underlying body. Among other benefits, the perimeter seal enables enable the capture of heat generated from use of the solar modules for various purposes. These purposes may include increasing efficiency of photovoltaic cells and heating air. Additionally, the perimeter seal can provide other uses, such as a cosmetic skirt that further improves aesthetics by hiding the gap between the array and underlying body. The perimeter seal can be formed such that it diverts any precipitation running down the underlying body from penetrating the underside of the array. Moreover, any mounting penetrations made under the array is protected, and the rack assembly with the partial or complete perimeter seal enables a simple covering to be provided under the array if the underlying body needs to be weatherproofed (i.e. the roof of a house).
Although the deployment of a rack assembly with a sealed or partially restricted perimeter yields aesthetic and weather proofing benefits, it also restricts the flow of air underneath the array. In traditional installations of solar photovoltaic modules, this restriction of airflow is an undesirable effect and may lead to increased module temperatures and lower conversion efficiencies.
In one embodiment, a rack assembly or mounting system is arranged such that the combination of a seamless front surface and perimeter sealing yields air channels underneath the array of solar modules. The creation of these air channels allows for the heat generated by the solar modules to be captured and removed to increase their conversion efficiency and create a useable energy stream. The system may also employ solar thermal modules that act to further boost the air temperature, leaving the array for use in cold climates or other instances in which higher air stream temperatures are required.
According to an embodiment, a rack assembly is provided for mounting solar modules over an underlying body. The rack assembly may include a plurality of rail structures that are arrangeable over the underlying body to form an overall perimeter for the rack assembly. One or more retention structures may be provided with the plurality of rail structures, where each retention structure is configured to support one or more solar modules at a given height above the underlying body. At least some of the plurality of rail structures are adapted to enable individual rail structures to be sealed over the underlying body so as to constrain air flow underneath the solar modules. Additionally, at least one of (i) one or more of the rail structures, or (ii) the one or more retention structures are adjustable so as to adapt the rack assembly to accommodate solar modules of varying forms, dimensions or installation height or spacing requirements.
According to an embodiment, the rack assembly may include coupling structures that enable the rack assembly to be sealed over the underlying body. In an embodiment, the coupling structures are in the form of a flashing component, or a combination of flashing components. According to one embodiment, the combination of flashing components include a first or lower flashing component that enable a seal to be formed with the underlying body, and a counter flashing component that overlays where the lower flashing component joins the rack assembly.
In an embodiment, the retention structures are in the form of an extended member and an underlying or lower shelf. The retention structure enables retention of a solar module when a compressive force is applied to the extended member.
According to another embodiment, a rack assembly is provided for mounting solar modules over an underlying body. The rack assembly may be installed over an underlying body and include a plurality of rail structures that are arranged to form an overall perimeter. One or more retention structures may be provided with the plurality of rail structures to support one or more solar modules mounted therein at a given height over the underlying body. At least some of the plurality of rail structures are sealed over the underlying body so that at least a portion of the overall perimeter is closed. A channel may be formed at least in part by the at least some of the portion of the overall perimeter that is sealed over the underlying body and occupies at least a portion of the given height separating the one or more solar modules from the underlying structure.
Under another embodiment, a solar energy transfer system is provided over an underlying body. The system includes a plurality of solar modules that receive solar energy and convert the solar energy into electricity or heat. The plurality of solar modules may be of a given size that is within a range of possible sizes that can be handled by the rack assembly. A rack assembly supports the plurality of solar modules a given height over an underlying body. The rack assembly may be sealed across at least a portion of its perimeter to the underlying body to define, at least in part, one or more channels underneath the plurality of solar modules that constrains air flow. Additionally, the rack assembly is cooperatively positioned with an air driver to enable the air driver to direct air through the one or more channels so that the air is heated by heat from one or more of the plurality of solar modules.
As an example, FIG. 10A and FIG. 10B illustrate a rack assembly that is cooperatively engaged with an air driver, which may be provided through use of a vent. In particular, a vent may be provided underneath the rack assembly and be coupled to, for example, a fan for drawing air. Alternatively, the vent may blow air from one location to another underneath a rack assembly such as described by one or more embodiments.
Under another embodiment, a rack assembly includes a plurality of rail structures and a plurality of retention structures. The plurality of retention structures may be provided by the plurality of rail structures. In an embodiment, one or more of the plurality of retention structures are adjustable between adjacent rail structures in order to (i) loosely grasp and hold a given solar module to enable manual adjustment of the positioning and securement of the given solar module, (ii) mechanically secure and hold the given solar module in an installed position a given height over the underlying body.
Overview
FIG. 1 is a simplified illustration of a rack assembly for supporting solar modules, under one or more embodiments of the invention. As shown, a rack assembly 10 includes a plurality of rail structures 12 that provide support for individual solar modules 14 . When installed, the rail structures 12 support the individual solar modules 14 a given height h above an underlying body 15 . The underlying body 15 may correspond to any surface, platform or structure on which solar modules 14 are mounted. For example, underlying body 15 may correspond to a rooftop of a commercial or residential building. The solar modules 14 may correspond to photovoltaic solar cells that convert solar energy into electricity, or alternatively, solar heating modules which directly generate heat using solar energy.
According to one or more embodiments, the rail structures 12 are adjustable pair-wise, or in other combinations, in order to hold in place solar modules 14 of various dimensions and sizes. In one embodiment, the solar modules 14 are supported by a combination of retention structures 16 . Each retention structure 16 may be provided with a corresponding one of the rail structures 12 . In one embodiment, each retention structure 16 is a structural feature of the corresponding rail structure 12 . For example, each rail structure 12 may comprise of multiple interconnected segments, and the retention structure(s) may be one of the interconnected elements. Alternatively, the retention structures 16 may be integrated or unitarily formed with the individual rail structures 12 . Each retention structure 16 supports individual solar modules 14 by grasping edge segments. In one embodiment, the retention structures 16 and/or rail structures 12 are adjustable to grasp and support solar modules 14 of varying thicknesses and forms.
As shown by FIG. 1 , an embodiment provides that rail structures 12 are mounted indirectly to the underlying body 15 through use of a set of strut runners 18 . Each strut runner 18 mounts to the underlying body 15 and to multiple rail structures 12 , thus providing lateral support to maintaining the rail structures 12 upright, while at the same time providing a buffer between the individual rail structures 12 and the underlying body 15 . The rail structures 12 may mount to the strut runners 18 , and the strut runners may mount to the underlying body 15 .
According to an embodiment, the rack assembly 10 forms a portion of a solar heat exchange system that uses heat generated from the solar modules 14 for any one of various useful purposes. The heat exchange may be enabled by the formation of one or more channels 20 between an underside of solar modules 14 and the underlying body 15 . An individual channel 20 may be defined in part by one or more of the rail structures 12 , as well as the underlying body and possibly the underside of the solar modules 14 . The individual channel 20 may occupy at least a portion of the thickness defined by the height h. The solar heat exchange system may further include other components, such as thermal panels 910 ( FIG. 9A ), as well as air directors that draw air into the channel 20 , and/or push the air through the channel. When installed as part of a solar heat exchange system, the rack assembly 10 may be positioned to supply heated air to such air directors, and to be proximate to the environment that is to receive or use the heated air. For example, the rack assembly 10 may be installed on the rooftop of a dwelling, and also direct heated air into a vent or air circulation system of the dwelling as part of its ability to heat air in the channel 20 .
Useful purposes for generating heat from the solar modules 14 may include, for example, any one or more of the following: (i) cooling the individual solar modules 14 (when photovoltaic) so as to make them more efficient, (ii) pulling air from the environment underneath the solar modules 14 for purpose of heating the air for another closed environment or system (e.g. for a house), and (iii) circulating air from the closed environment or system underneath the solar modules 14 to heat that air and use it for heat.
Installed Rack Assembly
FIG. 2A illustrates an installed rack assembly 110 that supports a set of solar modules 114 over an underlying body 115 . The rack assembly 110 may be structured and adapted to include features such as described with one or more embodiments of the invention. The underlying body 115 may correspond to, for example, a rooftop or roof structure of a building or dwelling. In general, the underlying body 115 may correspond to any area, surface or platform that can receive sunlight and be connected to a building, place or location that can use the solar energy.
Embodiments of the invention contemplate that different types of solar modules 114 may be employed in various implementations and context. For example, as shown by FIG. 2A , the solar modules 114 include photovoltaic modules 124 and thermal modules 125 . Under one embodiment, the perimeter may include one or more sealed lengths 132 and an open length 134 from which air from the environment is drawn. As will be described, channels (not shown in FIG. 2A ) may be provided between the rack assembly 110 and underlying body 115 for purpose of constraining airflow. Air drivers (not show in FIG. 2A ) may drive (e.g. push or pull) air within the formed channels. The solar modules 114 generate heat, either through design or as an inherent by-product. According to one or more embodiments, this heat warms the air as it is drawn from the environment and pulled through the channels formed underneath the solar modules 114 .
Numerous alternatives and variations are contemplated. For example, all of the perimeter of the rack assembly 110 may be sealed, and air may drawn from within a dwelling on which the rack assembly 110 is provided. This air may be pushed through channels, then back into the dwelling when warmed. Alternatively, some or all of the open length 134 may be sealed, or conversely, portions of the sealed lengths 132 may be opened or perforated as part of an underlying channel system.
FIG. 2A illustrates one implementation in which heated air is directed into a duct 140 within a structure of the underlying body 115 . For example, warm air may heat a dwelling on which the rack assembly 110 is installed, and the duct 140 enables the heated air to flow into the circulation system of the dwelling.
As mentioned, the solar modules 114 may be formed by a combination of the photovoltaic modules 124 and the thermal modules 125 . The photovoltaic modules 124 can generate some residual heat when receiving solar energy and converting the solar energy into electrical current. In contrast, the thermal modules 125 may directly convert the solar energy into heat at a higher efficiency. The use and number of thermal modules 125 may depend on the use of the heated airflow, as well as the environment where the rack assembly 110 is installed. For example, when the purpose of heating air in the channels is to supply warm air to a dwelling of the underlying body 115 , the thermal modules 125 have more use in colder environments, while warm environments may require only use of photovoltaic modules 124 . Even in cold environments, thermal modules 125 may be used to convert solar energy into hot air due to the high operating efficiency achieved by their designs, and additional components may be used to drive the hot air into the dwelling.
FIG. 2B illustrates a variation similar to an embodiment such as shown in FIG. 2A , in that multiple ventilation outlets 150 may be employed for directing heated air from under the rack assembly. As such, the ventilation outlets are located underneath the thermal modules 125 . As shown with FIG. 2A , the open length 134 of the perimeter is provided on one side, and the series of vents 150 are provided lengthwise on the other side of the perimeter formed by the rack assembly 110 . For example, the vents 150 may guide the directed heated air inward into the structure of the underlying body 115 .
Rail Structure
According to one or more embodiments, one of the overall primary structural elements of the overall rack assembly is a rail structure. Rail structures are elements that provide primary support to the solar modules, thus, for example, enabling the solar modules to be oriented to receive solar energy, while at the same time being securely fixed to resist wind and other forces. Under one embodiment, two types of rail structures may be provided. A free rail structure 220 supports solar modules 114 on one lateral side (left-right in the paper), so as to form a portion of the overall perimeter of the rack assembly 110 ( FIG. 1 ) on its other side. Such a rail structure is shown and described with FIG. 3A . In contrast, a shared rail structure 240 ( FIG. 3B ) provides interior support, and supports solar modules on both a left side or a right side, so that it is shared by more than one solar module. Such a rail structure is shown and described by FIG. 3B . As will be described, each rail structure
220 , 240 is adjustable to support solar modules 114 of varying sizes. Furthermore, embodiments provide that the rail structures
220 , 240 may be configured to loosely grasp solar modules 114 , before being adjusted to clamp down onto the solar modules. Among other benefits, this feature of the free and shared rail structures
220 , 240 enables all of the solar modules to be placed in position before the individual rail structures
220 , 240 are clamped down to affix the solar modules 114 as a set in the installed position. As will be described, one or more embodiments provide that the rail structures
220 , 240 and associated features and structural elements may be used to implement a rack assembly, such as described with FIG. 1 , FIG. 2A , FIG. 2B and elsewhere described in this application.
According to one or more embodiment, such as shown by FIG. 3A and FIG. 3B , each rail structure
220 , 240 has an interleaved assembly structure that can be (i) adjusted to loosely grip or retain individual solar modules 114 , and (ii) compressed to clamp down on solar modules 114 and hold them in a fixed position. With reference to FIG. 3A , the free rail structure 220 supports a corresponding solar module 114 on one side, while forming a perimeter support of an overall rack assembly. Under one embodiment, the free rail structure 220 is a multi-piece element that can grasp and support an individual solar module from its edge section. Each solar module 114 has its own frame 235 on which an individual solar panel 214 (photovoltaic laminate or thermal glazing and absorber assembly) is supported in planar fashion. According to one embodiment, free rail structure 220 is adjustable to accommodate and grasp frames having any thickness t within a range T.
The interleaved construction of the free rail structure 220 includes a lower rail 226 and an upper rail 228 . The upper rail 228 may be moved inward within the confines of lower rail 226 , enabling an overall height of the free rail structure 220 to be contracted. Under one implementation, the inward movement of the upper rail 228 may be affected by a compression mechanism. In an embodiment, the compression mechanism, is in the form of a compression bolt 225 , which enters a top surface 227 of upper rail 228 via a hole or slot. The bolt 225 may be tightened within the opening by threading into fastener 237 located on the lower rail 226 , so as to cause the upper rail to move inward into the lower rail 226 . A washer 223 may buffer the bolt 225 when it is compressed. The bolt 225 may be of sufficient length to extend through a floor 229 of the upper rail 228 and into an interior of the lower rail 226 . However, under one embodiment, the length of the bolt 225 is not so long as to cause the bolt 225 to extend through a floor 227 of the lower rail 226 . The range of T may be dependent on one or more of the size of the compression bolt 225 , and the amount that the upper rail 228 can be pushed into the lower rail 226 .
In order to hold individual solar modules 114 captive, each free and shared rail structure
220 , 240 may include one or more retention structures
245 , 265 . The retention structures may grasp on to an edge section of the frame 235 for an individual solar module 114 . In an embodiment, the retention structure 245 is in the form of a lower shelf 244 and an upper extension 243 . When the bolt 225 is clamped down, the upper rail 228 is moved inward into the confines of the lower rail 226 , causing the upper extension to press the frame 235 of the solar module 114 against the lower shelf 244 . An overall movement of the upper rail 228 is shown by A. The resulting force affixes that edge section of the solar module 114 with the rail structure 220 . The solar module 114 may be installed when the free and shared rail structures
220 , 240 are secured to the underlying body. As will be described, the securement of the solar modules 114 to the underlying body may include one or more strut runners 450 (see FIG. 4A and FIG. 4B ), which may be used to interconnect the free rail structure 220 and the shared rail structure 240 to the to the underlying body, as well as to each other. However, use of strut runners is a design implementation, as alternatives are contemplated. For example, as an alternative or addition, each of the rail structures
220 , 240 may be secured directly to the underlying structure.
According to an embodiment, some or all of that free rail structure 220 is sealed over the underlying body on which the rack assembly 110 is mounted. In particular, one embodiment provides that free rail structure 220 is sufficiently sealed to confine the flow of air within a channel or other boundary defined by the rail structure. In one embodiment, free rail structure 220 is used with one or more flashing features or components, which may be combined with other sealants or materials in order to effectuate a seal of the <
CLAIMS
Claims ( 19 )
What is claimed is:
1. A rack assembly for mounting solar modules over an underlying body, the rack assembly comprising:
a plurality of rail structures that are arrangeable over the underlying body to form an overall perimeter for the rack assembly, the plurality of rail structures including multiple pairs of interleaved rail structures, each pair of interleaved rail structures including a lower rail structure and an upper rail structure, the upper rail structure having a rail segment protruding downward therefrom, the rail segment having a protruding height, the lower rail structure having a receiving segment extending upward therefrom to receive the rail segment therein, the receiving segment having a depth, the protruding height of the rail segment is greater than the depth of the receiving segment;
one or more retention structures provided with one or more of the upper rail structures, wherein the retention structures are configured to support one or more solar modules at a given elevation above the underlying body; and
wherein at least some of the plurality of rail structures are adapted to enable individual rail structures in the plurality of rail structures to be sealed over the underlying body so as to constrain air flow underneath the one or more solar modules; and
wherein each retention structure of the plurality of rail structures is adjustable to adapt to a thickness of a corresponding solar module that is being supported by that retention structure.
2. The rack assembly of claim 1 , further comprising one or more coupling structures, wherein each of the one or more coupling structures enables at least a portion of one of the plurality of rail structures to be sealed over the underlying body.
3. The rack assembly of claim 1 , further comprising a combination of coupling structures provided on or with individual rail structure to enable those rail structures to be sealed over the underlying body.
4. The rack assembly of claim 3 , wherein the combination of coupling structures includes an underlying flashing component that extends from each of the individual rail structure into or against the underlying body.
5. The rack assembly of claim 4 , wherein the combination of coupling structures includes an overlaying flashing component that extends from each of the individual rail structures over the underlying flashing component.
6. The rack assembly of claim 1 , further comprising a compression mechanism that is manipulated to compress the retention structures in order to cause the retention structures to grip a corresponding solar module and to provide the corresponding solar module in a fixed position.
7. The rack assembly of claim 1 , further comprising a plurality of solar modules, wherein one or more of the plurality of solar modules corresponds to a thermal panel for directly converting solar energy to heat.
8. The rack assembly of claim 7 , wherein each thermal panel includes a translucent material, an absorption layer, and a frame for containing at least the translucent material.
9. The rack assembly of claim 8 , wherein an effective thickness of at least one thermal panel is adjustable.
10. The rack assembly of claim 8 , wherein at least one thermal panel includes a shim plate that is adjustably mountable to the frame to adjust an overall thickness of that thermal panel.
11. A rack assembly for mounting solar modules over an underlying body, wherein the rack assembly is installed over an underlying body and comprises:
a plurality of rail structures that are arranged to form an overall perimeter for the rack assembly, at least some of the plurality of rail structures are sealed over the underlying body so that at least a portion of the overall perimeter is sealed over the underlying body, each of the plurality of rail structures including:
one or more retention structures to support one or more solar modules mounted thereon at a given elevation over the underlying body,
an upper rail structure having a rail segment protruding downward therefrom, and
a lower rail structure having a receiving segment extending upward therefrom to receive the rail segment therein, the rail segment having a height that is greater than a depth of the receiving segment to allow the retention structures to be adjustable so as to adapt the rack assembly to accommodate solar modules of varying forms or dimensions, and
a channel that guides air flow is formed at least in part by the at least some of the portion of the overall perimeter that is sealed over the underlying body and occupies at least a portion of the given elevation separating the one or more solar modules from the underlying structure.
12. The rack assembly of claim 11 , wherein an opening of the channel is oriented to be provided by a remaining portion of the overall perimeter that is open to permit the exchange of air with an environment of the rack assembly.
13. The rack assembly of claim 12 , wherein the overall perimeter is rectangular, and wherein the portion of the overall perimeter is sealed with the underlying body includes a majority of three lengths of the rectangle, and wherein the remaining portion of the overall perimeter that is open to permit the exchange of air with the environment corresponds to at least a portion of the remaining length of the rectangle.
14. The rack assembly of claim 11 , further comprising one or more sealing features provided with the plurality of rail structures, wherein the one or more sealing features enable the individual rail structure to be sealed over the underlying body to guide airflow so as to form at least a portion of the channel.
15. The rack assembly of claim 14 , wherein the one or more sealing features is an underlying flashing component that extends into or against the underlying body.
16. The rack assembly of claim 14 , wherein the one or more sealing features is an overlaying flashing component that extends over the underlying flashing component.
17. The rack assembly of claim 11 , further comprising a compression mechanism that is manipulated to compress the retention structures in order to cause the retention structures to grip a corresponding solar module and to provide the corresponding solar module in a fixed position.
18. The rack assembly of claim 11 , wherein the rack assembly is cooperatively positioned with an air driver to enable the air driver to direct air through the one or more channels so that the air is heated by heat from a solar module.
19. The rack assembly of claim 18 , wherein one or more of the plurality of rail structures include an interior surface from which one or more corresponding retention structures are provided, and wherein each of the one or more rail structures is provided a shim plate on an exterior surface that forms the portion of the overall perimeter so as to support that rail structure when compressed by the compression mechanism.
US13/566,935
2004-02-13
2012-08-03
Rack assembly for mounting solar modules
Expired - Lifetime
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US8745936B2
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2012-08-03
Rack assembly for mounting solar modules
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US54475304P
2004-02-13
2004-02-13
US10/855,254
US8344239B2
( en )
2004-02-13
2004-05-26
Mechanism for mounting solar modules
US64361905P
2005-01-13
2005-01-13
US11/332,000
US7856769B2
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2004-02-13
2006-01-13
Rack assembly for mounting solar modules
US12/949,551
US8256170B2
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2010-11-18
Rack assembly for mounting solar modules
US13/566,935
US8745936B2
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2004-02-13
2012-08-03
Rack assembly for mounting solar modules
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Rack assembly for mounting solar modules
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Rack assembly for mounting solar modules
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Rack assembly for mounting solar modules
US13/566,935
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Rack assembly for mounting solar modules
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Rack assembly for mounting solar modules
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2010-11-18
Rack assembly for mounting solar modules
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