Abstract:
A solar panel system and method wherein unframed solar panels are positioned on support beams above a support structure in a configuration that leaves two of the edges of the solar panels unframed. This avoids trapping of water and dirt and the like, which occurs with prior art, framed panels. A liner comprised of a compliant material may be interposed between the support beams and the two panel edges so as to protect those two edges, while leaving the remaining two edges in their original, unframed condition.

Description:
FIELD OF THE INVENTION 
       [0001]    The present invention relates generally to solar panel systems and methods and, more particularly, to a solar panel and system featuring unframed solar panels. 
       BACKGROUND OF INVENTION 
       [0002]    Prior art systems and methods for mounting photovoltaic or other types of solar panels meet are intended to hold the solar panels against wind, hail, rain and snow. In a typical prior art installation, four-sided solar panels are shipped from the manufacturer with a metal frame around the four edges of the solar panel. During the manufacturing process, the unframed solar panels may be mounted into the frames by inserting the solar panel into a channel fabricated into the frame. This insertion process must be done carefully to avoid damage to the edges of the glass and is often done by hand at significant expense. 
         [0003]    In the field installation process for a prior art system, a supporting structure may be built consisting of horizontal beams supported by vertical posts. Then, the metal frames of the framed solar panels are attached to the horizontal beams with mounting brackets and mounting hardware, e.g., bolts. (See, e.g.,  FIGS. 1-2 .) The frame around the solar panel protects the edge of the glass and supports the solar panel against the forces of created by the weight of the solar panels, by snow loads and by wind loads. However, the frames can hold water, leading to corrosion and poor reliability. They can also trap dirt along the bottom edge of the solar panel and shade part of the panel from the sunlight, reducing efficiency. 
       SUMMARY OF THE INVENTION 
       [0004]    In accordance with an embodiment of the present invention, a solar panel system is disclosed. The system comprises, in combination: a liner comprised of a compliant material positionable about two opposing edges of a four edge solar panel; two support beams configured to support the two opposing edges of the four edge solar panel, with the liner interposed between the two support beams and the two opposing edges, and with two remaining edges of the four edge solar panel in an unframed condition; and a support structure for the solar panel system that is adapted to receive thereon the two support beams. 
         [0005]    In accordance with another embodiment of the present invention, a solar panel system is disclosed. The system comprises, in combination: a four edge solar panel; a liner comprised of a compliant material positionable about two opposing edges of the four edge solar panel; two support beams configured to support the two opposing edges of the four edge solar panel, with the liner interposed between the two support beams and the two opposing edges, and with two remaining edges of the four edge solar panel in an unframed condition; wherein the two support beams each comprise a lower horizontal member, an upper horizontal member, a vertical member interposed between the lower horizontal member and the upper horizontal member, and a separator positioned on an upper surface of the upper horizontal member; a top plate coupled to the separator; and a support structure for the solar panel system that is adapted to receive thereon the two support beams. 
         [0006]    In accordance with a further embodiment of the present invention, a method for assembling a solar panel array is disclosed. The method comprises: providing a four edged solar panel; providing a support structure for the solar panel array; positioning on the support structure two support beams; interposing a liner comprised of a compliant material between two opposing edges of the four edge solar panel and the two support beams; and leaving two edges of the four edge solar panel in an unframed condition. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0007]      FIG. 1  is a top view of a framed solar panel component of a prior art system, including an inset portion of the panel shown in cross-section from an end thereof. 
           [0008]      FIG. 2  is a perspective view of a prior art solar panel system. 
           [0009]      FIG. 3  is a perspective view of base components of a solar panel system consistent with an embodiment of the present invention. 
           [0010]      FIG. 4  is a perspective view of a solar panel system consistent with an embodiment of the present invention, illustrating an exemplary placement of solar panel support beams. 
           [0011]      FIG. 5  is a perspective view of the solar panel system of  FIG. 4 , illustrating an exemplary placement of unframed solar panels on the solar panel support beams. 
           [0012]      FIG. 4A  is an end view of a solar panel support beam, consistent with an embodiment of the present invention. 
           [0013]      FIG. 5A  is an end view of a solar panel support beam, consistent with an embodiment of the present invention, illustrating exemplary coupling of unframed solar panels thereto. 
       
    
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS 
       [0014]    Referring first to  FIGS. 1-2 , an exemplary, ground-installed, prior art solar panel system  100  is illustrated. The prior art system  100  may comprise four vertical supports  102 , two horizontal supports  104 , each of which is coupled at each opposing end to a vertical support  102 , and a plurality of solar panels  106  coupled to and positioned across the horizontal supports  104 . Each solar panel  106  includes a frame  108  around an edge portion thereof. 
         [0015]    Referring now to  FIGS. 3-5A , assembly of a solar panel system  10  consistent with an embodiment of the present invention is illustrated. The system  10  utilizes at least one and preferably a plurality of solar panels  16 . Solar panels  16  are provided without framing therearound. 
         [0016]    In one embodiment, assembly of a system  10  commences with installation of vertical supports  12 , followed by the coupling thereto of horizontal supports  14  (see  FIG. 3 ). Support beams  18  may then be coupled to the horizontal supports (see  FIG. 4 ). The support beams  18  will provide support for the solar panels  16 , as herein described. 
         [0017]    Referring specifically to  FIGS. 4A and 5A , an embodiment of a support beam  18  consistent with an embodiment of the present invention is illustrated. In one embodiment, the support beam  18 , when viewed from an end thereof, may have a substantially “I” shape, comprising lower horizontal member  20 , upper horizontal member  22 , and a vertical member  24  interposed therebetween. Additionally, a separator  26  may be provided on an upper surface of the upper horizontal member  22 . 
         [0018]    Support beams  18  may be mounted to the horizontal supports  14 , in an orientation that will expose the separator  26  at a top of the structure. (Mounting may be accomplished utilizing bolts, screws, or other desired mounting means.) In another embodiment, the support beam  18  may be extruded and the separator  26  at the top of the structure may be an integral part of the extruded support beam. Support beams  18  should be spaced sufficiently far apart so that, as described below, a single solar panel  16  may be installed onto a pair of support beams  18 , with an underside of the solar panels  16  along an edge thereof being supported, on two sides thereof, by the upper horizontal member  22 . Where a plurality of solar panels  16  are to be installed, as illustrated for example in  FIGS. 4 ,  5  and  5 A, it can be seen that a single support beam  18  may provide support for edges of two neighboring solar panels  16 . 
         [0019]    Referring specifically to  FIG. 5A , so as to protect the edges of the solar panels  16  that are supported by the support beams  18 , a liner  28  may be utilized. The liner  28  is preferably formed of a compliant material, such as butyl rubber, though other materials may also be utilized. In one embodiment, the liner  28  is provided along an underside of the edge of the solar panel  16 , above the edge of the solar panel  16 , and along the outer edge itself of the solar panel  16 . 
         [0020]    The liner  28  may be a single piece, or may be multiple pieces. For example, it may be desired to provide a single piece having a substantially sideways “L” shape, so as to line the area above the upper horizontal member  22  and along the separator  26 . The portion of the liner  28  located above the solar panel  16  may be substantially flat and may be provided as a separate piece. Alternatively, an entire liner  28 , as shown in  FIG. 5A , may be provided as a one-piece, substantially “U” shaped assembly, which may be affixed to an edge of the solar panel  16  prior to the positioning thereof on the support beam  18 . 
         [0021]    After the solar panel  16 , with liner  28 , is positioned on the support beam  18 , it may be desired to securely affix the solar panel  16  in position. Referring to  FIG. 5A , in one embodiment, a top plate  30  is coupled to the separator  26 . The top plate  30  may be affixed with sheet metal screws or other coupling means. 
         [0022]    As described herein, only two opposite edges of the solar panels  16  are held by the liner  28 . It should be noted that when solar panels  16  are mounted in a static array, they are usually tilted toward the ground in the southern direction to better capture the sunlight. In a tracking array, they are typically tilted toward the east in the morning and the west in the afternoon. If the solar panel system  10  is oriented with the support beams  18  along the direction of the tilt, it can be seen that the bottom and top edges of the solar panels  16  would be unframed. Thus, there will be no structure on these edges to catch water or dirt. As a consequence, the reliability of the solar panels  16  is improved and the shadowing of the bottom edge by dirt is eliminated. 
         [0023]    The solar panel system  10  described above can be assembled by a sequence of steps in which the components are added on top of each other. First, in one embodiment, the support beams  10  and  12  are put in place. Then, the next level of support beams  18  with separators  26  may be placed on top of them. Then, the lower part of the liner  28  may be placed on top of the support beams  18 . Finally, the solar panels  16  may be placed on top of the line  28 , the second part of the liner  28  may be placed on top of the solar panels  16 , and then the top plate  30  may be placed on top of the liner  28  to hold the liner  28  and solar panels  16  in place. In this embodiment, none of these steps require inserting solar panels into a channel, require any critical tolerancing or apply any significant pressure to the solar panel during the installation process. Such an assembly is relatively quick, inexpensive and unlikely to cause the solar panels  16  to break. 
         [0024]    Although particular embodiments of the invention have been described in detail for purposes of illustration, various modifications may be made without departing from the spirit and scope of the invention. Accordingly, the invention is not to be limited, except as by the appended claims.