US20110198304A1 - Rack Assembly for Solar Energy Collecting Module - Google Patents
Rack Assembly for Solar Energy Collecting Module Download PDFInfo
- Publication number
- US20110198304A1 US20110198304A1 US12/367,977 US36797709A US2011198304A1 US 20110198304 A1 US20110198304 A1 US 20110198304A1 US 36797709 A US36797709 A US 36797709A US 2011198304 A1 US2011198304 A1 US 2011198304A1
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- US
- United States
- Prior art keywords
- leg
- assembly
- wind deflector
- solar collecting
- frames
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
- Abandoned
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- 239000010935 stainless steel Substances 0.000 claims 1
- 238000000034 method Methods 0.000 abstract description 17
- 230000000712 assembly Effects 0.000 description 9
- 238000000429 assembly Methods 0.000 description 9
- 238000009434 installation Methods 0.000 description 8
- 239000000853 adhesive Substances 0.000 description 6
- 230000001070 adhesive effect Effects 0.000 description 6
- 238000010276 construction Methods 0.000 description 6
- 230000005611 electricity Effects 0.000 description 6
- 238000004519 manufacturing process Methods 0.000 description 6
- 238000004080 punching Methods 0.000 description 4
- 238000005452 bending Methods 0.000 description 3
- 229910001335 Galvanized steel Inorganic materials 0.000 description 2
- 238000003491 array Methods 0.000 description 2
- 230000000295 complement effect Effects 0.000 description 2
- 238000001125 extrusion Methods 0.000 description 2
- 239000008397 galvanized steel Substances 0.000 description 2
- 239000000463 material Substances 0.000 description 2
- 230000007246 mechanism Effects 0.000 description 2
- 229910000831 Steel Inorganic materials 0.000 description 1
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Images
Classifications
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- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F24—HEATING; RANGES; VENTILATING
- F24S—SOLAR HEAT COLLECTORS; SOLAR HEAT SYSTEMS
- F24S25/00—Arrangement of stationary mountings or supports for solar heat collector modules
- F24S25/10—Arrangement of stationary mountings or supports for solar heat collector modules extending in directions away from a supporting surface
- F24S25/13—Profile arrangements, e.g. trusses
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- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F24—HEATING; RANGES; VENTILATING
- F24S—SOLAR HEAT COLLECTORS; SOLAR HEAT SYSTEMS
- F24S25/00—Arrangement of stationary mountings or supports for solar heat collector modules
- F24S25/10—Arrangement of stationary mountings or supports for solar heat collector modules extending in directions away from a supporting surface
- F24S25/16—Arrangement of interconnected standing structures; Standing structures having separate supporting portions for adjacent modules
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- H—ELECTRICITY
- H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
- H02S—GENERATION OF ELECTRIC POWER BY CONVERSION OF INFRARED RADIATION, VISIBLE LIGHT OR ULTRAVIOLET LIGHT, e.g. USING PHOTOVOLTAIC [PV] MODULES
- H02S20/00—Supporting structures for PV modules
- H02S20/20—Supporting structures directly fixed to an immovable object
- H02S20/22—Supporting structures directly fixed to an immovable object specially adapted for buildings
- H02S20/23—Supporting structures directly fixed to an immovable object specially adapted for buildings specially adapted for roof structures
- H02S20/24—Supporting structures directly fixed to an immovable object specially adapted for buildings specially adapted for roof structures specially adapted for flat roofs
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- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F24—HEATING; RANGES; VENTILATING
- F24S—SOLAR HEAT COLLECTORS; SOLAR HEAT SYSTEMS
- F24S40/00—Safety or protection arrangements of solar heat collectors; Preventing malfunction of solar heat collectors
- F24S40/80—Accommodating differential expansion of solar collector elements
- F24S40/85—Arrangements for protecting solar collectors against adverse weather conditions
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- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
- Y02B—CLIMATE CHANGE MITIGATION TECHNOLOGIES RELATED TO BUILDINGS, e.g. HOUSING, HOUSE APPLIANCES OR RELATED END-USER APPLICATIONS
- Y02B10/00—Integration of renewable energy sources in buildings
- Y02B10/10—Photovoltaic [PV]
-
- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
- Y02E—REDUCTION OF GREENHOUSE GAS [GHG] EMISSIONS, RELATED TO ENERGY GENERATION, TRANSMISSION OR DISTRIBUTION
- Y02E10/00—Energy generation through renewable energy sources
- Y02E10/40—Solar thermal energy, e.g. solar towers
- Y02E10/47—Mountings or tracking
-
- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
- Y02E—REDUCTION OF GREENHOUSE GAS [GHG] EMISSIONS, RELATED TO ENERGY GENERATION, TRANSMISSION OR DISTRIBUTION
- Y02E10/00—Energy generation through renewable energy sources
- Y02E10/50—Photovoltaic [PV] energy
-
- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
- Y10T29/00—Metal working
- Y10T29/49—Method of mechanical manufacture
- Y10T29/49826—Assembling or joining
Definitions
- FIG. 10 is a perspective view illustrating a junction between the laminate, the stiffening rib, and the rack assembly in accordance with the alternative embodiment of the invention.
Abstract
Description
- This application claims priority under 35 U.S.C. §119(c) to U.S. Provisional Patent Application Ser. No. 61/049,567, filed on May 1, 2008, which is hereby incorporated by reference in its entirety.
- Embodiments of the present invention relate to a rack assembly for mounting solar energy collecting modules and an associated method for constructing a rack assembly.
- Pholovoltaies (PV) is the field of technology and research related to the application of solar cells for energy by converting sunlight directly into electricity. Due to the growing demand for clean sources of energy, the manufacture of solar cells and PV arrays has expanded dramatically in recent years. These mechanisms may be may be ground-mounted or built into the roof or walls of a building, financial incentives, such as preferential feed-in tariffs for solar-generated electricity, and net metering, have supported solar PV installations in many countries.
- A variety of solar energy collecting modules currently exist. One such module is a PV panel which converts solar energy into electricity. Another module is a solar thermal collector which harnesses solar energy for heal. The modules can have different geometries, but are commonly made with a generally flat construction. PV panels are often electrically connected in multiples as solar photovoltaic arrays to convert energy from the sun into electricity. In operation, photons from sunlight knock electrons into a higher state of energy, creating electricity. Solar cells produce direct current electricity from light, which can be used for such tasks as powering equipment or recharging a battery. Cells require protection from the environment and are packaged usually behind a glass sheet. When more power is required than a single cell can deliver, cells are electrically connected together to form PV modules, or solar panels.
- Multiple issues have prevented the growth of solar energy from becoming even more explosive. The most pervasive of these issues may be installation and material costs. However, due to economies of scale, solar panels become less expensive as people use and buy more and as manufacturers increase production to meet demand. Thus, the cost and price is expected to drop in the years to come.
- Solar energy collecting modules are currently used in a variety of settings, including commercial, residential, and industrial environments. These modules are typically mounted on a structure secured to a support surface, such as a rooftop. Different considerations affect the design and construction of the mounting structures for the modules. These factors include ease of manufacture and installation, minimization of related costs, and resistance to environmental factors such as wind forces.
- Various problems have hindered the use and development of existing mounting structures. For example, because of lift forces created by wind gusts, existing mounting structures have often generated inadequate frictional forces to maintain satisfactory contact with the underlying support surface. Despite efforts made to reduce mounting structure surface area to create a mounting structure that minimizes lilt forces created by the wind, it has often been viewed as necessary to secure the mounting structures to the rooftop or other base supporting surface. This attachment process often proves to be harmful and destructive to the underlying supporting surface. For example, the installer may be required to penetrate the roof shingles, roofing paper, and sheathing. This penetration makes the roofless weather resistant and thus may result in damage to the building itself.
- Additionally, materials for the mounting structures are often expensive and manufacturing and installation have been complicated, thus adding to the expense of the mounting structure. An increase to the cost of the system negatively impacts the financial advantage that consumers expect from a solar energy solution.
- Generally, solving any one of the aforementioned problems has magnified the other existing problems and no suitable solution has been found for a secure mounting structure having a reasonable cost.
- Accordingly, a practical solution is needed that provides a secure mounting rack assembly with a novel construction for mounting solar energy collecting modules. Additionally, a solution is needed for providing an efficient and inexpensive method of constructing the novel rack assemblies.
- In a first aspect, an embodiment comprises a rack assembly for supporting a solar energy collecting module on a support surface. The rack assembly comprises a plurality of upright frames and a transverse element connected to the plurality of frames. Each frame comprises a first base leg extending substantially parallel to the support surface in a first direction and a second leg extending from the first leg at an angle relative to the first leg. The second leg supports the solar energy collecting module at an angle relative to the support surface. A transverse member is connected to the first leg of each of the plurality of frames and extends substantially parallel to the support surface in a second direction substantially perpendicular to the first direction. The plurality of upright frames is constructed by roll forming at least one leg of the upright frame from sheet metal.
- In a further aspect, an embodiment comprises a rack assembly for supporting a solar energy collecting module on a support surface. The rack assembly comprises a plurality of upright triangular frames. Each triangular frame comprises a first leg extending substantially parallel to the support surface in a first direction and a second leg extending from the first leg at a first angle relative to the first leg. The second leg supports the solar energy collecting module at an angle relative to the support surface. Each frame additionally includes a third leg extending from the first leg at a second angle relative to the first leg, the third leg supporting a wind deflector plate at an angle relative to the support surface, the third leg connected with the second leg to form the triangular frame. Each frame further includes a transverse member connected to the first leg of each of the plurality of frames and extending substantially parallel to the support surface in a second direction.
- In another aspect, an embodiment comprises a method for constructing a rack assembly for supporting a solar energy collecting module on a support surface. The method comprises roll forming a first and second section of channel from sheet metal. The first and second sections of channel are connected to form an upright frame. A transverse element is attached to the upright frame. The upright frame comprises a first leg formed from the first section of channel and extending substantially parallel to the support surface. The upright frame also comprises a second leg formed from the second section of channel and extending from the first leg at an angle relative to the first leg.
- In an additional aspect, an embodiment comprises a method for on-site construction of a rack assembly for supporting a solar energy collecting module on a support surface. The method comprises providing for a roll forming machine and a coil of sheet metal adjacent an installation location, using the roll forming machine to form a plurality of channels from the coil of sheet metal, and constructing an upright frame from the channels. The frame comprises a horizontally extending leg, a first upwardly angled leg, and a second upwardly angled leg. A transverse element is connected to a plurality of upright frames.
- Other objects, features, and characteristics of the present embodiments will become apparent upon consideration of the following description and the appended claims.
- In the drawings, like reference characters generally refer to the same pans throughout the different views. In the following description, various embodiments of the present invention are described with reference to the following drawings, in which:
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FIG. 1 is a front perspective view of a rack assembly according to a first embodiment. -
FIG. 2 is a rear perspective view of a rack assembly according to the first embodiment. -
FIG. 3 is a side view of a rack assembly in accordance with an additional embodiment of the invention. -
FIG. 4 is a perspective view of a clip for use with multiple embodiments of the invention. -
FIG. 5 is a perspective view of a rack assembly according to a further embodiment of the invention. -
FIG. 6 is a top plan schematic view of a rack assembly array in accordance with an additional embodiment of the invention. -
FIG. 7 is a perspective view illustrating an alternative rack assembly embodiment. -
FIG. 8 is a perspective view illustrating a pop-rivet attachment of a stiffening rib to a frame in accordance with the alternative embodiment of the invention. -
FIG. 9 is a perspective view illustrating laminates attached to the stiffening ribs in accordance with the alternative embodiment of the invention. -
FIG. 10 is a perspective view illustrating a junction between the laminate, the stiffening rib, and the rack assembly in accordance with the alternative embodiment of the invention. -
FIG. 1 illustrates a first embodiment of arack assembly 100. Therack assembly 100 may include a plurality offrames 104. Eachframe 104 may include abase leg 112 and one or moreadditional legs clips 106 andpanels 122 havingflanges 108. Atransverse member 110 may extend the length of therack assembly 100 andfriction pads 130 may be affixed to the base of therack assembly 100. - In the illustrated embodiment, two solar
energy collecting modules 102 are mounted on threeframes 104. The solarenergy collecting modules 102 are of the kind that is generally flat, such as photovoltaic modules. The solarenergy collecting modules 102 are mounted on therack assembly 100 at a predetermined angle and are secured byclips 106 andflange portions 108 ofpanels 122. Thetransverse member 110 extends the length of therack assembly 100 and is secured to theframes 104 on thebase leg 112 of each of theframes 104. Thetransverse member 110 may serve as a ballast tray for adding additional weight to therack assembly 100. - The
rack assembly 100 may be mounted on relatively leveled and mildly sloping surfaces, such as for example on the roof of a building. Thefriction pads 130 affixed to the bottom of theframes 104 may provide additional support for retaining therack assembly 100 on a support surface. Thefriction pads 130 may be made of rubber and may be affixed in a variety of configurations using one of a variety of techniques. In the illustrated embodiment, onefriction pad 130 is juxtaposed adjacent each end of thebase leg 112 of theframe 104. However, it should be understand that onefriction pad 130 or a larger number offriction pads 130 may be affixed in alternative configurations. -
FIG. 2 illustrates therack assembly 100 as shown inFIG. 1 from a rear perspective view. As can be seen more clearly, twopanels 122 extend the width of therack assembly 100. Thepanels 122 are dimensioned to serve as wind deflectors to eliminate uplift forces. Eachpanel 122 spans the distance between twoframes 104, which corresponds approximately to the width of each solarenergy collecting module 102. - Longer panels that span the lull width of the
rack assembly 100 may also be used. Thepanels 122 may be secured to theframes 104 using any appropriate fastening method, such as adhesive, screws, bolts, or pop rivets. As set forth above, with respect toFIG. 1 , thepanels 122 includeflange portion 108 which serves to retain the lop edges of each solarenergy collecting module 102. -
FIG. 3 is a side view of arack assembly 300. Theframe 304 shown in this embodiment has a triangular shape. Theframe 304 includes abase leg 312 and twoangled legs leg legs pre-selected angles - Other frame geometries may also be used, frames may have less than three legs or more than three legs. Frames may have closed geometries, such as a triangle or square, or open geometries, such as an open angle formed by two legs.
- Using a triangle frame embodiment as illustrated in
FIG. 3 , thebase leg 312 rests on a support surface. One or morefrictional pads 330 may be affixed to a portion of thebase leg 312 that contacts the support surface. In the embodiment ofFIG. 3 , the firstangled leg 314 supports the solarenergy collecting module 302, and the secondangled leg 316 supports apanel 322. - The
incline angle 324 of firstangled leg 314 may be predetermined in order to maximize the interception of solar energy. Similarly, theincline angle 328 between the first 314 and second 316 angled legs may be predetermined to utilize the wind deflecting properties of thepanels 322 and to control the amount of uplift generated by wind passing over therack assembly 300. The incline angles 324, 326, and 328 of the firstangled leg 314 and the secondangled leg 316 may be adjusted by varying the lengths of the first and secondangled legs transverse members 310 may be connected to thebase leg 312 of theframe 304. Thetransverse member 310 may be used as a ballast tray. -
FIG. 4 illustrates aclip 406 used to secure the bottom edge of solarenergy collecting modules 402. The height of theclip 406 may be selected to approximately equal the height of the solarenergy collecting module 402 such that the solarenergy collecting module 402 can be firmly and securely inserted into theclip 406. Theclip 406 may be manufactured separately from theframe 404 of therack assembly 400 and secured onto theframe 404 using fasteners such as screws, bolts, or pop rivets. Theclip 406 may alternatively be made by punching out and bending a piece of theframe 404. Alab 452 maybe used to separate and longitudinally align adjacent solarenergy collecting modules 402. -
FIG. 5 illustrates an additional embodiment of arack assembly 500 in which seventeen frames 504 support sixteen solarenergy collecting modules 502. The embodiments shown inFIGS. 1-5 are exemplary only and rack assemblies with different numbers of frames may be constructed to hold different numbers of solar energy collecting modules depending on need. Longer rack assemblies may require multiple pieces oftransverse member 510 in order to connect all the frames. -
FIG. 6 is a lop plan schematic view of arack assembly array 600. As shown inFIG. 6 ,rack assemblies 610 are combined to form arack assembly array 600. Although shown with threerack assemblies 610, a rack assembly array may include more or fewer rack assemblies. Additionally, the rack assemblies do not need to be of the same size. Rows ofrack assemblies 610 may be connected to adjacent rows with sections of galvanizedsteel strut 602. Thesteel strut 602 ties the sections ofrack assemblies 610 together to spread force loads and may additionally be used as mounting points to which electrical conduit runs can be affixed. -
FIG. 7 is a perspective view illustrating an alternative rack assembly embodiment. Arack assembly 700 includes aframe 704 for use with a solar energy collecting module in the form of an unframed PV laminate. Theframe 704 may have a triangular configuration including abase member 712 connected withangled members more stiffening ribs 740 may be provided and may be connected toangled members 714 ofmultiple frames 704, the connection may be facilitated through the use of pop-rivets or other fasteners. Therack assembly 700 may also include one or more transverse members (1110,FIG. 11 ), which may serve as ballast trays. - In order to mount PV laminates, an adhesive or other fastening means may be applied to affix the PV laminates to the
stiffening ribs 740. In addition to supporting the PV laminates, the stiffeningribs 740 may function as a bonded grounding path for theassembly 700. - Similarly to the embodiments described above with respect to
FIGS. 1-5 , therack assembly 700 may be constructed from galvanized sheet metal members assembled with pop-rivets or other fasteners. -
FIG. 8 is a perspective view illustrating a pop-rivet attachment 842 of astiffening rib 840 to a frame 804 in accordance with the alternative embodiment ofFIG. 7 . More specifically, the stiffeningrib 840 is attached by the pop-rivet attachment 842 toangled arm 814 of the frame 804. In the illustrated embodiment, aflange 808 may provide additional stability. -
FIG. 9 is a perspective view illustrating PV laminates 950 attached to a plurality of stiffeningribs 940 in accordance with an embodiment of the invention. Such attachment is preferably accomplished through the use of an adhesive, but may alternatively be accomplished through other fastening mechanisms.Flange portions 908 ofpanels 922 may operate to encase edges of the PV laminates 950. In the illustrated embodiment, twoPV laminates 950 are mounted on three stiffeningribs 940. However, it should be understood that in alternative embodiments, any suitable number of stiffeningribs 940 may be implemented for attachment to the PV laminates 950. -
FIG. 10 is a perspective view illustrating a junction betweenPV laminates 1050, astiffening rib 1040, and arack assembly 1004 in accordance with the embodiment of the invention illustrated inFIGS. 7-9 .FIG. 10 additionally illustrates a pop-rivet connector 1042 securing thestiffening rib 1040 to therack assembly 1004. Additionally,panels 1022 may includeflanges 1008 that cover an edge of thestiffening rib 1040 and further encase an edge of the PV laminates 1050. -
FIG. 11 is a side view illustrating an additional embodiment of the invention. In this embodiment, one or moretransverse ribs 1140 are attached toangled arm 1114 by pop-rivet attachment 1142. One ormore stiffening ribs 1144 are separately attached to aPV laminate 1150, preferably using adhesive 1146. The shapes of thetransverse ribs 1140 and stiffeningribs 1144 are complementary, such that thePV laminate 1150 may be attached to therack assembly 1100 by inserting thestiffening ribs 1144 into thetransverse ribs 1140. The two complementary ribs may be secured together using locking labs, adhesive, fasteners, such as pop-rivets or screws, or other appropriate means. In this manner, therack assembly 1100 may be assembled at the job site, and thestiffening ribs 1144 may be adhered to thePV laminate 1150 at another location in a controlled environment in order to minimize temperature or moisture concerns. The assembly ofPV laminate 1150 and stiffeningribs 1144 may then be transported to the job site and snapped onto thetransverse ribs 1140 previously mounted to therack assembly 1100. - The rack assembly according to the described embodiments has a relatively simple construction, which may be easily manufactured. Referring to
FIG. 1 , theframes 104 ofrack assembly 100 may be constructed using channel pieces fabricated from a roll forming process. Roll forming is a continuous bending operation in which a long strip of is passed through consecutive sets of rolls, or stands, each performing only an incremental part of a bend, until a desired cross-sectional profile is obtained. A variety of cross-sectional profiles can be produced using varied roll tools. Roll formed sections are generally lighter and stronger than extrusions of a similar shapes, as they have been work hardened in a cold state. Other advantages of roll forming include the fact that that roll formed parts can be made having a finish or already painted, furthermore, in comparison to extrusion processes, labor for roll forming is greatly reduced. - Roll forming lines can be set up with multiple configurations to punch and cut off parts in a continuous operation, for cutting a part to length, the lines can be set up to use a pre-cut die where a single blank runs through the roll mill, or a post-cut die where the profile is cutoff after the roll forming process, features may be added in a hole, notch, embossment, or shear form by punching in a roll forming line. These part features can be done in a pre-punch application before roll forming starts, in a mid-line punching application during roll forming, or a post punching application after roll forming is completed. Some roll forming lines incorporate only one of the above punch or cutoff applications, others incorporate some or all of the applications in one line.
- A roll forming process for forming the channel pieces used in the frames of disclosed embodiments may include feeding sheet metal from a coil through a plurality of roll pass combinations in a roll pass machine. The sheet metal may be galvanized steel. Galvalume or any other appropriate sheet metal. In accordance with the embodiments displayed in
FIGS. 1-10 , the resulting channel pieces may have a substantially U-shape with a flat bottom wall and a pair of opposed upstanding side walls. The roll pass machine may include flying punches to form cut-outs and sheering devices to cut the channel into pieces of predetermine lengths. Once formed, the channel pieces are connected together using fasteners to form frames. Three channel pieces of different lengths may be fastened together into a triangular shape having a base leg and two angled legs. - Another manufacturing embodiment includes forming each of the frames from a single channel piece. Instead of roll forming each leg as a separate piece of channel, the roll pass machine may be used to form a single channel long enough to form a full frame. Notches may be formed in the sidewalls of the channel to facilitate bending the single channel piece into the frame shape. The roll pass machine may use one or more flying punches to cut the notches during the roll forming process, or, as set forth above, the notches may be cut independently before or after the channel is formed. The notched piece of channel can then be folded into a frame and fastened together using fasteners.
- Following the formation of frames, a transverse member (such as
member 110 shown inFIG. 1 ) is fastened to a predetermined number of frames to form a rack assembly. A single transverse member may be used to span the full width of the rack assembly or multiple transverse members may be used to span the full width. The transverse element may also be formed using a roll forming process. - Referring to
FIG. 4 ,clip 406 may be formal from cut or stamped sheet metal patterns. A first bend is used to form the lop of the clip and a second bend is used to form the bottom of the clip that is fastened to the frame. A clip may also be made during the roll forming process of the channels. A flying punch may form a cutout portion in a channel which may then be bent to form the clip. - Referring to
FIGS. 1 and 2 ,panel 122 may be formed from cut or stamped sheet metal patterns. A first bend may be used to form theflange portion 108. The panel may be secured to therack assembly 104 after the solarenergy collecting module 102 is placed on the assembly and into theclips 106 so that theflange portion 108 retains the top edge of the solarenergy collecting module 102. - Furthermore, with respect to the embodiment of
FIGS. 7-11 . PV laminates 750 are attached to the stiffeningribs 740 by means of an adhesive. Adhesion of the sheetmetal stiffening ribs 740 to the backside of the laminate 740 is preferably accomplished in a controlled environment in order to minimize temperature or moisture concerns. Attachment of the stiffeningribs 740 to thetriangular base structures 704 is preferably accomplished by implementing a pneumatic pop-rivet gun. This can be accomplished al the job site. - The case of manufacture allows for construction of a rack assembly on-site at an installation location. A portable roll forming machine may be brought to an installation location where the channels for the frame and transverse members may be fabricated. The channels may then be fastened together to form the frames and the transverse member fastened to the frames to form a rack array, for a rooftop installation, the channels and transverse member may be formed on the ground and then lifted up to the roof where the frames and rack array are formed. A conveyor bell may be used to lift the rack array elements to the roof.
- Having described certain embodiments of the invention, it will be apparent to those of ordinary skill in the art that other embodiments incorporating the concepts disclosed herein may be used without departing from the spirit and scope of the invention. The described embodiments are to be considered in all respects as only illustrative and not restrictive.
Claims (22)
Priority Applications (2)
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US12/367,977 US20110198304A1 (en) | 2008-05-01 | 2009-02-09 | Rack Assembly for Solar Energy Collecting Module |
US12/853,838 US8272176B2 (en) | 2008-05-01 | 2010-08-10 | Methods of assembling solar energy collecting modules |
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US4956708P | 2008-05-01 | 2008-05-01 | |
US12/367,977 US20110198304A1 (en) | 2008-05-01 | 2009-02-09 | Rack Assembly for Solar Energy Collecting Module |
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US12/853,838 Continuation US8272176B2 (en) | 2008-05-01 | 2010-08-10 | Methods of assembling solar energy collecting modules |
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US20110198304A1 true US20110198304A1 (en) | 2011-08-18 |
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US12/853,838 Active 2029-06-12 US8272176B2 (en) | 2008-05-01 | 2010-08-10 | Methods of assembling solar energy collecting modules |
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US20120125408A1 (en) * | 2010-07-30 | 2012-05-24 | Rene Reyes | Solar panel racking assembly and system |
US20120186632A1 (en) * | 2011-01-25 | 2012-07-26 | Computer Components Corporation | Mounting Assembly for Supporting a Solar Panel, and Method of Employing Same |
US20120198682A1 (en) * | 2011-02-08 | 2012-08-09 | Chevron Usa Inc. | Edge conveyor belt solar string assembly device |
US20120198696A1 (en) * | 2011-02-08 | 2012-08-09 | Chevron Usa Inc. | Solar string assembly process |
US20120199180A1 (en) * | 2011-02-07 | 2012-08-09 | Loey Abdle Salam | Solar panel assemblies |
CN103746642A (en) * | 2013-12-31 | 2014-04-23 | 广东保威新能源有限公司 | Reinforced photovoltaic support system |
US8991114B2 (en) | 2009-07-02 | 2015-03-31 | Zep Solar, Llc | Pivot-fit connection apparatus, system, and method for photovoltaic modules |
US9093583B2 (en) | 2012-09-19 | 2015-07-28 | Opterra Energy Services, Inc. | Folding solar canopy assembly |
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