Solutions for photovoltaic modules with integrated mounting systems
Embodiments of solutions for PV modules with integrated mounting systems are presented. Application of the systems are found primarily but not solely in commercial and industrial rooftop solar installations. The disclosed solutions allow for a very flexible use of said PV modules with integrated mounting systems in various installation situations, with a focus on demonstrating concepts that show direct applicability of mounting featured for adhesive as well as for ballasted solutions, as well as the combination of both. Support features that enable ergonomic transport and installation are highlighted. Features for alignment, for providing structural strength as well as reliable, strong, yet accommodating interlinkage of PV modules are disclosed. The use of polymeric or fiber reinforced polymeric frames and mounting structures eliminates the need for grounding. Features are presented which a focus on not requiring tooling or hardware along with the installation.
1 . A photovoltaic (PV) system, comprising:
a PV laminate with a frame, together comprising a PV module;
the frame having a frame mount along one frame edge to elevate the frame edge of the PV module;
the frame mount being rotatable and folded in underneath the frame for stacking and transportation into a folded position and rotated out and unfolded for installation;
the frame mount further having mount feet attached in a rotatable way;
the mount feet having an engagement bar;
wherein the mount feet are compatible with an adhesive mounting to a roof by having an adhesive layer attached to the side of the mount feet that is to mate with the roof top and wherein the adhesive layer is protected by a release liner that is removed prior to installation;
wherein the mount feet are also compatible with ballasted mounting to a roof by providing space and at least partial confinement for at least one paver to be placed on top of at least one of the mount feet;
wherein the frame further comprises at least one elevating bar, located along the frame edge opposite of the frame edge containing the frame mount,
wherein the frame edge opposite of the frame edge containing the frame mount is lifted up by the at least one elevating bar to an extent that prevents shading along the opposite frame edge from a paver placed on at least one of the mount feet;
wherein the elevating bar is attached to the frame along a frame edge opposite to the frame edge which has the frame mount attached to it;
wherein the elevating bar comprises at least one connecting hook configured to engage with an engagement bar which is part of one of the mount feet of a neighbor PV module;
wherein the elevating bar is attached to the frame in a rotatable and foldable way;
wherein the elevating bar is rotated and folded to be within the confines of the frame for stacking and transportation; and
wherein the elevating bar is rotated and folded out into a position essentially vertical to the plane of the roof for installation.
2 . The PV system of claim 1 , wherein the mount feet are arranged for stacking and transportation in an orientation which is pivoted by 180 degrees from the orientation of the frame mount in its folded position.
3 . The PV system of claim 1 , wherein the frame mount comprises on one side a hinged east-west connection panel, wherein the frame mount further comprises a transportation location for the east-west connection panel where the east-west connection panel is folded in for transport, the east-west connection panel comprising a serrated feature along one side of the east-west connection panel which is to mate with the neighbor PV module;
the frame mount further comprising an east-west connection recipient location on the side opposed to the side comprising the east-west connection panel, the east-west connection recipient location being the location where the east-west connection panel of a neighbor PV module is mated to the PV system;
the east-west connection recipient location comprising a matching serrated feature to be mated to the serrated feature of east-west connection panel of its neighbor module;
the east-west connection recipient location further comprising locking pin receptacle locations;
the east-west connection panel further comprising a locking receptacle;
the frame mount further comprising a rotatable locking latch comprising locking pins and a locking latch snap fixture and a transport location for the locking latch, wherein the locking latch is rotated and folded into a storage position flush with the frame mount for transportation,
wherein further the east-west connection panel is rotated and folded into a storage position flush with the frame mount (for transportation and wherein the east-west connection panel is rotated out for installation to a mating position for connection to its neighbor PV module, and wherein the rotatable locking latch is rotated and folded onto the east-west connection recipient location, enclosing the east-west connection panel for a tight connection by engaging the east-west connection panel using the locking latch and locking receptacle location on east-west connection panel and by engaging with the underlying east-west connection recipient location using the locking pins and locking pin receptacle locations, and wherein the serrated features on east-west connection panel and east-west connection recipient location provide angle adjustment to accommodate uneven roof surfaces.
4 . The PV system of claim 1 , wherein the frame and mounting structures are comprised of at least one of: a polymer and a fiber reinforced polymer material.
5 . The PV system in claim 1 , further comprising at least one rotatable snow mount which is rotated into a folded position to be within the confines of the PV module for stacking and transportation and being rotated out into an engaged position for installation.
6 . The PV system in claim 5 , wherein the snow mount is also a handle for carrying the PV system, wherein the handle is placed in a central position with respect to east and west edge of the frame, and wherein the handle is placed in a position wherein an installer, when carrying the PV system with the north frame edge up, can readily reach the handle with their hands.
7 . The PV system in claim 1 , wherein the frame mount comprises on one side a hinged east-west connection panel, wherein the frame mount further comprises a transportation location for the east-west connection panel where the the east-west connection panel comprising a serrated feature along one side of the east-west connection panel which is configured to mate with the neighbor PV module, said frame mount further comprising an east-west connection recipient location on the side opposed to the side comprising the east-west connection panel, the east-west connection recipient location being the location where the east-west connection panel of a neighbor PV module is mated to the PV system, the east-west connection recipient location comprising a matching serrated feature to be mated to the serrated feature of east-west connection panel of its neighbor PV module, the frame mount further comprising an east-west connection screw and a transport location for the east-west connection screw, wherein the east-west connection panel is rotated and folded into a storage position flush with the frame mount for transportation, and wherein the east-west connection panel is rotated out for installation to a mating position for connection to its neighbor PV module, and wherein the east-west connection screw is attached to the east-west connection recipient location for a tight connection, and wherein the serrated features on east-west connection panel and east-west connection recipient location provide angle adjustment to accommodate uneven roof surfaces.
8 . The PV system in claim 1 , further comprising a set of distancing lips which are part of the rim of the southern edge of the frame of the PV module, wherein the distancing lips have a height taller than the surface of the PV laminate, wherein the remainder of the rim of the southern edge of the frame of the PV module is lower than the surface of the PV laminate, and wherein this arrangement allows for improved draining of water via the southern edge of the PV module.
9 . The PV system in claim 1 , wherein at least one of the rotatable mount feet has a pivoting point recessed partially into the mount feet, and wherein the frame mount has a recess to allow for the mount feet to be rotated into a folded position within the confines of the frame of the PV module for stacking and transportation, and wherein the partially recessed pivoting point of the mount feet allows for the mount feet to be placed partially underneath the PV module during installation and thus allows for tighter module spacing, and wherein the recess in the frame mount allows for a paver to be placed on the recessed mount feet, such that the paver is partially underneath the PV module.
10 . The PV system in claim 1 , further comprising North side wind deflectors configured to be snapped on to connecting points along the frame edge of the PV modules, and wherein the mount feet have lips that define the wind deflectors in their position.
11 . The PV system in claim 1 further comprising:
wheel receptacles with attached wheels, wherein the wheels are mounted on the side opposing the side where said frame mount is attached,
the wheels configured to allow an installer to roll the PV module along the surface of a stack of PV modules;
the wheels configured to allow an installer to roll the PV module along the surface of a roof;
the wheels also configured to guide the PV modules connecting hooks into the engagement bar of mount feet of the neighbor module.
12 . A photovoltaic (PV) system, comprising:
a PV laminate with a frame, together forming a PV module, the frame having a frame mount along one frame edge to elevate the frame edge of the PV module;
the frame mount is configured to be rotatable and folded in underneath the frame for stacking and transportation into a folded position and rotated out and unfolded for installation;
the frame mount further comprising mount feet attached in a rotatable way;
the mount feet comprising an engagement bar;
the frame further comprising connecting hooks on the side opposing the side where the frame mount is attached;
the connecting hooks able to engage with mount feet of a neighbor module by rotating the PV modules around such that the connecting hooks connect with an engagement bar which is part of the neighbor PV modules mount feet;
wherein the mount feet are compatible with an adhesive mounting to a roof by having an adhesive layer attached to the side of the mount feet that is to mate with the roof top and wherein the adhesive layer is protected by a release liner that is removed prior to installation;
wherein the mount feet are also compatible with ballasted mounting to a roof by providing space and at least partial confinement for at least one paver to be placed on top of at least one of the mount feet;
wherein each mount foot further comprises an elevating bar and the frame edge opposite of the frame edge containing the frame mount is lifted up by the at least one elevating bar to an extent that prevents shading along the opposite frame edge from a paver placed on at least one of the mount feet;
wherein the elevating bar is rotatable around a hinge which is part of the mount foot, and wherein for transport and stacking this elevating bar is rotated into a position flush with the mount foot, and the mount foot with attached elevating bar is rotated and folded into the confines of the frame for transportation,
wherein frame mount, mount foot, and elevating bar are all rotated and unfolded into place for installation, with the mount foot being rotated around its hinge with the frame mount and with the elevating bar being rotated around its hinge with the mount foot; and
wherein the rotatable elevating bar serves to enable lifting the edge of another neighbor PV module, and wherein the elevating bar comprises an opening in the elevating bar which is able to engage the connecting hooks of the another neighbor PV module.
13 . The PV system of claim 12 , wherein the elevating bar further comprises a support and guidance ledge configured to support the weight of the PV module and guide the connecting hooks towards the opening in the elevating bar for engagement.
14 . The PV system of claim 12 , wherein the mount feet are arranged for stacking and transportation in an orientation which is pivoted by 180 degrees from the orientation of the frame mount in its folded position.
15 . The PV system in claim 12 , further comprising at least one rotatable snow mount which is rotated into a folded position to be within the confines of the PV module for stacking and transportation and being rotated out into an engaged position for installation, wherein the snow mount is also a handle for carrying the PV system, wherein the handle is placed in a central position with respect to east and west edge of the frame, and wherein the handle is placed in a position wherein an installer, when carrying the PV system with the north frame edge up, can readily reach the handle with their hands.
16 . A photovoltaic system, comprising:
a PV laminate with a frame, together forming a PV module, the frame having a frame mount along one frame edge to elevate the frame edge of the PV module;
the frame mount being rotatable and folded in underneath the frame for stacking and transportation into a folded position and rotated out and unfolded for installation;
the frame mount further having mount feet (attached in a rotatable way;
the mount feet having an engagement bar;
wherein the mount feet are compatible with an adhesive mounting to a roof by having an adhesive layer attached to the side of the mount feet that is to mate with the roof top, and wherein the adhesive layer is protected by a release liner that is removed prior to installation;
wherein the mount feet are also compatible with ballasted mounting to a roof by providing space and at least partial confinement for at least one paver to be placed on top of at least one of the mount feet:
wherein the frame further comprises an elevating bar, located along the frame edge opposite of the frame edge containing the frame mount;
wherein the frame edge opposite of the frame edge containing the frame mount is lifted up by the elevating bar to an extent that prevents shading along the opposite frame edge from a paver placed on at least one of the mount feet;
wherein each elevating bar comprises at least one connecting hook configured to engage with an engagement bar which is part of each mount foot of a neighbor PV module, and wherein the elevating bar is a fixed part of the frame edge which is opposite to the frame edge to which the frame mount is attached to; and
wherein the connecting hooks are configured to engage with mount feet of a neighbor PV module by rotating the PV modules around such that the connecting hooks connect with an engagement bar which is part of the neighbor PV modules mount feet.
17 . The PV system of claim 16 , wherein the mount feet are arranged for stacking and transportation in an orientation which is pivoted by 180 degrees from the orientation of the frame mount in its folded position.
18 . The PV system in claim 16 , further comprising at least one rotatable snow mount which is rotated into a folded position to be within the confines of the PV module for stacking and transportation and being rotated out into an engaged position for installation, wherein the snow mount is also a handle for carrying the PV system, wherein the handle is placed in a central position with respect to east and west edge of the frame, and wherein the handle is placed in a position wherein an installer, when carrying the PV system with the north frame edge up, can readily reach the handle with their hands.
19 . The PV system in claim 16 , further comprising a set of distancing lips which are part of the rim of the southern edge of the frame of the PV module, wherein the distancing lips have a height taller than the surface of the PV laminate, wherein the remainder of the rim of the southern edge of the frame of the PV module is lower than the surface of the PV laminate, and wherein this arrangement allows for improved draining of water via the southern edge of the PV module.
20 . The PV system in claim 16 , further comprising North side wind deflectors configured to be snapped on to connecting points along the frame edge of the PV modules, and wherein the mount feet have lips that define the wind deflectors in their position.