Abstract:
A system for mounting and installing of solar photovoltaic modules is provided. The system is a lightweight, quick to install, and aerodynamic mounting system for integrating solar photovoltaic modules and solar photovoltaic arrays for low-slope rooftops. The mounting and installing of solar photovoltaic modules includes a rubber mat, a rail member positioned atop the rubber mat, a link member coupling multiple rails, a bottom link member and a top link member coupled to a rail member, a rear wind deflector coupled to a top link member, a flanking wind deflector coupled to a top link member and a rail member.

Description:
BACKGROUND OF THE INVENTION 
       [0001]    1. Field of the Invention 
         [0002]    The present invention relates generally to a system for integrating and mounting solar photovoltaic modules and arrays, and more specifically, the present invention relates to a lightweight, quick to install and aerodynamic mounting system for integrating solar photovoltaic modules and solar photovoltaic arrays for low-slope rooftops. 
         [0003]    2. Description of the Related Art 
         [0004]    Solar irradiance is the most ample source of energy on this planet, which maintains the majority of all life on earth. Being able to harness the abundant solar energy and convert it into usable electricity is one of the main contributors behind the growth of the solar photovoltaic industry. 
         [0005]    As the industry continues to grow and the technology advances, solar photovoltaic modules (“PV Modules”) become increasingly popular, and so do the means by which they are utilized. Countries all over the world encourage their populace to contribute and generate their own electricity by means of such PV modules and offer them a variety of incentives. Business owners with large low-slope rooftops are particularly attracted to this idea because it is a means by which income is created, savings are procured, and space that is otherwise unused and is in ample supply can be effectively utilized. 
         [0006]    The PV modules are typically positioned on rooftops facing either north or south depending on the location of the rooftop with respect to the equator. This direction ensures maximum exposure of the PV modules to the sun throughout the year. Similarly, the tilt angle at which a PV module is inclined directly affects the overall performance thereof throughout each day. This tilt angle is directly proportional to the latitude at which the PV modules are mounted. The correct alignment of these PV modules to the right angle and direction is crucial to their effectiveness. 
         [0007]    Therefore, solar photovoltaic mounting systems (“Mounting System”) are vital in the design aspects. It is imperative to develop a mounting system that can effectively aim each PV module at the optimal angle and direction. However, at the same time, it must be able to secure the PV modules to withstand all sorts of forces that may be experienced on an open rooftop; from wind loads and snow loads to seismic loads, among many others. Uplift forces and drag forces are the most crucial of these forces; they are highly dependent on the wind zone of the building and the height. An ideal racking system must be both lightweight and aerodynamic because many rooftops are not designed to carry additional dead loads. If a mounting system is very lightweight, it must be equally as aerodynamic in order to eliminate any compensating ballast. 
         [0008]    When PV modules are grouped together, they are referred to as solar photovoltaic arrays (hereinafter referred to as “PV Arrays”). PV arrays are crucial in the solar industry for creating efficient and effective systems. When PV modules are grouped together, they can form an interconnected grid wherein each PV module is connected to its adjacent. PV module and so on, in both directions. This arrangement is crucial because a strong interconnection can allow for system weight and features of components further away to share loading and share aerodynamic qualities. When implemented correctly, this can lead to some PV arrays with little to no extra ballasting at all, and ideally, a system that is entirely self-ballasted. The larger the PV arrays, the larger their averaging areas, and therefore the stiffer the system, the more aerodynamic it becomes, and the more self-dependent it becomes with respects to additional ballast. Determining their averaging area, whether the system is a two-by-two (whereas this would be described as two PV modules north-south and two PV modules east-west), or whether the system is three-by-three, or four-by-four, and so on, is the key to making a PV array self-ballasted. 
         [0009]    In light of the foregoing, there exists a need to provide a mounting and installation system for PV modules and PV arrays that is lightweight quick to install, and aerodynamic in nature, in addition, the mounting and installation system should be self-ballasted and should eliminate the above mentioned limitations of the prior art systems. 
       SUMMARY 
       [0010]    An object of the present invention is to provide a system for mounting and installing solar photovoltaic modules and solar photovoltaic arrays for low-slope rooftops that is lightweight, quick to install, and aerodynamic. The solar photovoltaic system includes a rail structure which provides a rigid linking platform to interconnect solar photovoltaic modules. The photovoltaic modules are secured atop a bottom and top link member by means of a module mounting clamp, which can additionally ground the solar photovoltaic modules. Forces acting on the solar photovoltaic system can be reduced by means of utilizing a rear and a flanking wind deflector. Linking wind deflector members are secured by means of self-drilling machine thread screws to additionally provide a bonding connection. Interconnecting the present invention into a solar photovoltaic array enables structural strengths and ballasting to be used supportively throughout the army where it may be required. 
         [0011]    Another object of the present invention is to provide a method for mounting and installing of solar photovoltaic modules and arrays that provides an interconnected structural grid throughout the entire solar photovoltaic array using a series of linking members. The structure of the grid is distinguished by a combination of two groupings of members running in perpendicular axis to one another. One grouping of the current embodiment is a series of rail and connector members secured to one another along an axis, traditionally, although not limited to, North-South, with a similar innumerable series of this grouping running in parallel to this axis. The second grouping of the current embodiment is a series of solar photovoltaic modules and module mounting clamps secured to one another along a second axis perpendicular to the first grouping. This interconnected structural grid of groupings form a solar photovoltaic array capable of sharing ballasting effects and structural rigidity. 
         [0012]    Another object of the present invention is to provide a method for mounting, and installing, of solar photovoltaic modules and arrays that provides reduced additional load requirements to an existing roof by means of a self-ballasting. One embodiment of the current invention is a lightweight aluminum alloy, which serves to little any additional loading on the roof than necessary. The method by which this self-ballasting technique is utilized is by means of the interconnectedness of the members throughout the solar photovoltaic array; this can allow the weight of the solar photovoltaic system to ballast itself under the proper circumstances. A self-ballasted solar photovoltaic array will not require ballasting stones anywhere throughout the array, enabling for lightweight system on rooftops that have a low load reserves. 
         [0013]    Another object of the present invention is to provide a method for mounting and installing of solar photovoltaic modules and arrays that provides averaging areas to determine the ballasting scenario and stiffness of a solar photovoltaic array. These averaging areas may be affected by, but are not limited to, the wind exposure and the position within the interconnected grid. One embodiment of this method includes; dividing the solar photovoltaic array into sections deduced from their wind exposure; similarly dividing the sections into zones deduced from the solar photovoltaic module&#39;s position within the interconnected grid; allocating respective ballasting values according to their sections and zones. 
         [0014]    Another object of the present invention is to provide a method for mounting and installing, of solar photovoltaic modules and arrays that provides an easy installation by using, a. 
         [0015]    “click-in” installation mechanism. One embodiment of this method includes; a rail member and a bottom link member. Another embodiment of this method includes; a rail member and a top link member. In one aspect, a method is disclosed for installing of the click-in technique, the method includes the steps of; obtaining a rail member and a bottom link member; orienting and positioning the rail member atop the desired snake; setting the link member atop the rail member; pressing the link member with adequate downward force into the rail member. In one aspect of the current invention, click-in method ensues subsequent to a series of audible ‘clicking’ sounds coming from the locking of the bottom link member to the rail member. 
         [0016]    Another object of the present invention is to provide a system for mounting and installing, of solar photovoltaic modules and arrays that provides a single electrical grounding connection throughout the entire solar photovoltaic array. By means of, but not limited to, bonding a combination of module mounting clamps, self-drilling machine thread screws, the “click-in” mechanism, and the interconnected structural grid of the solar photovoltaic array, the solar photovoltaic system can experience a single grounding/bonding connection. 
         [0017]    In another embodiment of the present invention, a solar photovoltaic module integration system includes a roof protection mat, a rail member positioned atop the roof protection mat, a connector member that couples multiple rail members, a bottom link member and a top link member coupled to a rail member, a rear wind deflector coupled to a top link member and a rail member, and a flanking wind deflector coupled to a top link member and a rail member. 
         [0018]    Embodiments of the present invention provide a photovoltaic array. The photovoltaic array includes a roof protection mat and a plurality of rail members that are substantially parallel and are disposed at a first predetermined distance from each other atop the roof protection mat. The photovoltaic array further includes a plurality of bottom link members, a plurality of top link members, and a plurality of link members. First bottom and top link members are removably secured atop a first rail member at a second predetermined distance from each other by way of first and second link members respectively, and second bottom and top link members are removably secured atop a second rail member at the second predetermined distance from each other by way of third and fourth link members respectively. A first photovoltaic module of a plurality of photovoltaic modules is removably secured to the first rail member by way of the first bottom and top link members, and to the second rail member by way of the second bottom and top link members. The first photovoltaic module forms a predetermined angle with respect to the first and second rail members, which is between 5 and 25 degrees. A plurality of wind deflectors and flanking wind deflectors is also provided, a wind deflectors conceals a rear portion of the first photovoltaic module and first and second flanking wind deflectors conceal first and second side portions of the first photovoltaic module, respectively. 
         [0019]    There has thus been outlined, rather broadly, some of the features of the invention in order that the detailed description thereof may be better understood, and in order that the present contribution to the art may be better appreciated. There are additional features of the invention that will be described hereinafter. 
         [0020]    In this respect, before explaining at least one embodiment of the invention in detail, it is to be understood that the invention is not limited in its application to the details of construction or to the arrangements of the components set forth in the following description or illustrated in the drawings. The invention is capable of other embodiments and of being used and carried out in various ways. Also, it is to be understood that the phraseology and terminology employed herein are for the purpose of the description and should not be construed as limiting. 
         [0021]    Other objects and advantages of the present invention will become obvious to the reader and it is intended that these objects and advantages are within the scope and spirit of the present invention. To the accomplishment of the above and related objects, this invention may be embodied in the form illustrated in the accompanying drawings, attention being called to the fact, however, that the drawings are illustrative only, and that changes may be made in the specific construction illustrated and described within the scope of this application. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0022]    Various other objects, features and attendant advantages of the present invention will become fully appreciated as the same becomes better understood when considered in conjunction with the accompanying drawings, in which reference characters designate the same or similar parts throughout the several views, and wherein: 
           [0023]      FIG. 1A  is an upper perspective view of a solar photovoltaic array, in accordance with various embodiments of the present invention; 
           [0024]      FIG. 1B  is a side view of the solar photovoltaic array of  FIG. 1A , in accordance with various embodiment of the present invention; 
           [0025]      FIG. 1C  is a top view of the solar photovoltaic array of  FIG. 1A , in accordance with various embodiment of the present invention; 
           [0026]      FIG. 2A  is a front view of a rail member, in accordance with an embodiment of the present invention; 
           [0027]      FIG. 2B  is a top view of the rail member of  FIG. 2A , in accordance with an embodiment of the present invention; 
           [0028]      FIG. 2C  is a side view of the rail member of  FIGS. 2A and 2B , in accordance with an embodiment of the present invention; 
           [0029]      FIG. 2D  is an upper perspective view of the rail member of  FIGS. 2A-C , in accordance with an embodiment of the present invention; 
           [0030]      FIG. 3  is an upper perspective view of a bottom link member, in accordance with an embodiment of the present invention; 
           [0031]      FIG. 4  is an upper perspective view of a top link member, in accordance embodiment of the present invention; 
           [0032]      FIG. 5  is an upper perspective view of a connecting member, in accordance with an embodiment of the present invention; 
           [0033]      FIG. 6A  is an upper perspective view of a rear wind deflector, in accordance with an embodiment of the present invention; 
           [0034]      FIG. 6B  is a side view of the rear wind deflector of  FIG. 6A , in accordance with an embodiment of the present invention; 
           [0035]      FIG. 7A  is an upper perspective view of a flanking wind deflector, in accordance with an embodiment of the present invention; and 
           [0036]      FIG. 7B  is an upper perspective view of a flanking wind deflector assembly, in accordance with an embodiment of the present invention. 
       
    
    
       [0037]    As used in the specification and claims, the singular forms “a”, “an” and “the” include plural references unless the context clearly dictates otherwise. For example, the term “an article” may include a plurality of articles unless the context clearly dictates otherwise. 
         [0038]    Those with ordinary skill in the art will appreciate that the elements in the Figures are illustrated for simplicity and clarity and are not necessarily drawn to scale. For example, the dimensions of some of the elements in the Figures may be exaggerated, relative to other elements, in order to improve the understanding of the present invention. 
         [0039]    There may be additional components described in the foregoing application that are not depicted on one of the described drawings. In the event such a component is described, but not depicted in a drawing, the absence of such a drawing should not be considered as an omission of such design from the specification. 
       DETAILED DESCRIPTION OF THE INVENTION 
       [0040]    As required, detailed embodiments of the present invention are disclosed herein; however, it is to be understood that the disclosed embodiments are merely exemplary of the invention, which can be embodied in various forms. Therefore, specific structural and functional details disclosed herein are not to be interpreted as limiting, but merely as a basis for the claims and as a representative basis for teaching one skilled in the art to variously employ the present invention in virtually any appropriately detailed structure. Further, the terms and phrases used herein are not intended to be limiting but rather to provide an understandable description of the invention. 
         [0041]    Turning now descriptively to the drawings, in which similar reference characters denote similar elements throughout the several views, the figures illustrate a system for mounting and installing of solar photovoltaic modules and arrays, in accordance with various embodiments of the present invention. The system for mounting and installing of solar photovoltaic modules and arrays includes a roof protection mat, a rail member positioned atop the roof protection map, a link member that couples multiple rails, a bottom link member and a top link member coupled to a rail member, a rear wind deflector coupled to a top link member and a rail member, a flanking, wind deflector coupled to a top link member and a rail member. 
       Solar Photovoltaic Array  100   
       [0042]      FIGS. 1A and 1B  illustrate an example of a section of a solar photovoltaic (PV) module array  100 , in accordance with various embodiments of the present invention. The solar PV module array  100  includes a plurality of solar PV modifies  102  that are tilted at an angle to most effectively capture solar radiation. For example, the solar PV modules  402  may be titled at an angle of 20 degrees with respect to the horizontal. It should be noted that the angles shown in  FIGS. 1A and 1B  are illustrative only, and they do not restrict the scope of the invention in any way. The solar PV modules  102  may therefore be mounted at angles other than those illustrated herein, such as, for example at any angle between 5 degrees and 25 degrees. The solar PV modules  102  are uniformly supported and secured at the angle by a bottom link member  300  and a top link member  400 . Each solar photovoltaic module  102  requires two bottom link members  300  and two top link members  400  disposed at the corners thereof, and each bottom or top link member can support and secure up to two solar photovoltaic modules  102 . These bottom and top link members  300  and  400  are then secured to an underlying plurality of rail member  200  to form columns of link members in the solar photovoltaic array  100 . Parallel columns of rail members  200  and link members  300  and  400  form the foundation and structure of the solar photovoltaic array  100 .  FIG. 1C  illustrates a top view of an example of a section of a solar photovoltaic module array  100 . The details of the rail members  200  are illustrated in the forthcoming description. 
       Rail Members  200   
       [0043]      FIGS. 2A and 2B  are front and top views of the rail member  200 , in accordance with an embodiment of the present invention.  FIG. 2C  is a side view of the rail member of  FIGS. 2A and 2B , in accordance with an embodiment of the present invention, and  FIG. 2D  is an upper perspective view of the rail member of  FIGS. 2A-C , in accordance with an embodiment of the present invention. Preferably, the rail member  200  is roll-formed from 1.0 to 3.0 millimeter thick aluminum coils. The lengths of these rail members can vary, but are preferably 1.7, 3.5 and 5.2 meters in length to optimally accommodate a series of solar photovoltaic modules  102  in each column and to be able to customize the solar photovoltaic array layouts depending on their size and capacity. Referring, now to  FIG. 2A , the rail member  200  generally forms a tray shaped channel  202  with the edges  204  folded back therefrom. The width of the rail member  200  allows for ballast of various sizes to either be mounted atop the rail securely, or fit protected within the channel. This channel additionally provides structural rigidity throughout the solar photovoltaic array  102 . The rolled edges  204  are rolled to a desired height to allow for a click-in feature to be used with the link members  300  and  400  of  FIGS. 1A and 1B . Prior to the roll-forming process, the rail member  200  is punched to create a linear elongated hole pattern  206  along the skirts functioning as a natural draining system throughout the causeway of the rail member  200 . The rail member  200  is successively punched again to generate another unique hole pattern, creating circular shaped dimples  208  along the under carriage  210  which assist to increase the friction coefficient between the rail member  200  and a roof protection mat not shown in  FIGS. 2A-2D ) of the solar photovoltaic module to reduce the probability of the system being influence by horizontal wind forces. To install, the rail member  200  is generally, although not limited to, be positioned atop a protective mat, a sacrificial EDPM or TPO roofing material. In a situation involving an above-average possibility of seismic activity, a bonding solution is provided to fasten the rail member  200  to the rooftop in order to keep the system  100  stabilized and secure. 
       Bottom Link Member  300   
       [0044]      FIG. 3  is an upper perspective view of a bottom link member  300 , in accordance with an embodiment of the present invention. The bottom link member  300  is composed of an aluminum body  302  which is generally formed and bent from sheet metal to the desired shape. This shape provides ideal distribution of loads through the body  302  and the feet  304  of the bottom link member  300  from the wind forces acting of the solar photovoltaic module  102 . The tilt angle of the bottom link member can be manufactured to, but is not limited to, angles ranging from 5 to 25 degrees to accommodate the desired incident angles to utilize the solar radiation. The bottom link member  300  is symmetrical on either side to best hold and support two solar photovoltaic modules  102 . Each side includes a notch  306 , which acts as a click-in feature when used in conjunction with the rail member  200 . This click-in feature not only acts to secure each bottom link member  300  to the rail member  200  tightly, but also ensures an electrical bonding connection between the bottom link member  300  and the rail member  200 . Additionally, the bottom link member contains a cut-out  308  at the base to enable a means of management of electrical wires throughout the solar photovoltaic array  100 . In some cases, a rubber trimming may be used on the cut-out  308  to protect and safely house the electrical wires. To facilitate the installation of the solar photovoltaic modules  102 , the top of the bottom member  300  has two flanged surfaces  310  to align and guide the solar photovoltaic module  102  into place. In order to secure the module in place, the member comprises of a cut-out  312  which is used by a clamping device (not shown) to attach and additionally ground the solar photovoltaic module to the member, 
       Top Link Member  400   
       [0045]      FIG. 4  is an upper perspective view of a top link member  400 , in accordance with an embodiment of the present invention. The top link member  400  is similar in construction to the bottom link member  300  of  FIG. 3 . The top link member  400  is also composed of an aluminum body and is generally manufactured from sheet metal. The top link member  400  is shaped similarly provides ideal distribution of loading through the body  402  and into feet  404  at the bottom of the top link member  400  due to its carefully crafted center of gravity. Additionally, each side includes click-in tabs  406 , in the same manner as the bottom link member  300 , which when used in conjunction with the rail member  200 , form a secure mechanical and electrical bonding connection. The foot of the top link member  400  also provides notch  408  to allow for ease of installation using the click-in feature. To similarly assist in cable management of the solar modules array, the member features a cut out  410  at its foot to provide a safe and simple causeway for the electrical wires, in various embodiments of the present invention, a rubber trimming may also be used on the cut-out  410  to protect and safely house the electrical wires. The center most section accommodates a pattern of holes  412  that are used for mounting micro inverters, which can be mounted to the top link member  400  of each solar photovoltaic module as opposed to the roof, off the building or inside the building. These micro inverters can be fastened using any sequence of these holes  412  illustrated in  FIG. 4 . Electrical wire management, which uses wires to connect the modules and other electrical components of the solar photovoltaic array  102  together, may also be possible by use of clips, or other fastening devices, using these holes  412 . To secure the module in place, the member comprises of a cut-out  414  which is used by a clamping device (not shown) to attach and additionally ground the solar photovoltaic module to the member, similarly as the bottom link member  300 . The top section of the member features two tabs  416  which are used at a further step in the installation to mount and position rear wind deflectors or flanking wind deflectors. 
       Connecting Member  500   
       [0046]      FIG. 5  is an upper perspective view of a connecting member  500 , in accordance with an embodiment of the present invention. This connecting member  500  is used to connect two adjacent rail members  200  in columns of a solar photovoltaic array  100 . The connecting member  500  is composed of an aluminum body and is generally formed from sheet metal. Each side consists of tabs  502  generally naming 90 degrees to cradle two rail members. The rail members are secured together using fasteners through a series of holes  504  on both sides of the connecting member  500 . Used correctly, this connecting member  500  may act as an electrical bonding path for interconnecting the solar photovoltaic array  100 . 
       Rear Wind Deflector  600   
       [0047]      FIG. 6A  is an upper perspective view of a rear wind deflector  600 , and  FIG. 6B  is a side view of the rear wind deflector of  FIG. 6A , in accordance with various embodiments of the present invention. The rear wind deflector  600  is generally used to conceal the rear portion of each solar photovoltaic module  102 , to reduce uplift and drag forces that may be acting on the solar photovoltaic array  100  from turbulent winds. The rear wind deflector  600  is formed from aluminum sheet metal, and is ideally manufactured using brake form and bending processes. The rear wind deflector  600  forms a unique shape in order to increase its aerodynamics without compromising its effectiveness at reducing uplift and drag forces on the solar photovoltaic module  102 . In the embodiment of the present invention, a large cut out  602  is introduced at the top to allow breathability and ventilation of the solar photovoltaic module  102 , while still significantly decreasing the wind forces. To increase the stiffness, two diagonal brake form lines  604  are formed into the structure of the member; in addition, two flanges are introduced at the top and bottom  606  to provide additional stiffness. For installation purposes, the design features two bends with a cut-out slit  608  at the top of the member for ease of mounting and securing onto the top link member  400 . Similarly, two tabs elongate horizontally  610  from the bottom to sit atop the rail member  200 , to be further fastened and secured to the rail member  200 . These two bends with cut-out notches  610  provide extra flexibility in the system  100  during installation to account for different module sizes and customizability of the solar photovoltaic array. Furthermore, the rear wind deflector  600  assists in interconnecting the solar photovoltaic array  100  with a large interlocking flange  612  that is used to join adjacent rear wind deflectors  600 . This acts to further increase the stiffness of the entire solar photovoltaic array  100 . 
       Flanking Wind Deflector  700   
       [0048]      FIG. 7A  is an upper perspective view of a flanking wind deflector  700 , and  FIG. 7B  is an upper perspective view of a flanking, wind deflector assembly  702 , in accordance with various embodiments of the present invention. The flanking wind deflector  700  is generally used to conceal the sides of the solar photovoltaic array  100  to reduce the effects of uplift and drag wind forces on a given rooftop. The flanking wind deflector  700  is similarly formed of sheet metal aluminum. The flanking wind deflectors  700  form an ideal angle (as shown in  FIG. 7A ) of declination ranging for 0 to 20 degrees depending on the solar photovoltaic tilt of the PV module  102 . To assist in reducing uplift and drag forces on the system  100 , and to increase natural cooling and ventilation of the solar photovoltaic modules  100 , the side of the flanking wind deflector has several ventilation slits  704 . These slits can be but are not limited to this pattern. For installation purposes, the design features a slit  706  at the top of the member for ease of mounting and securing onto the bottom link member  300 , as demonstrated in  FIG. 7B . This feature additionally forces the flanking wind deflector  700  to be properly aligned to the top link member  400 . At the rear of the flanking wind deflector  700  is a tab which elongate horizontally from the bottom  708  to sit atop the rail member  200 , to be further fastened and secured to the rail member  200 , also demonstrated in  FIG. 7B . Along with these features, 2 holes on the top of the design  710  allow the flanking rear deflector  700  to be secured to the underlying, structure, as shown in  FIG. 7B . In the same manner to the rear wind deflector  600  described in the previous description, the flanking wind deflector  700  assists in interconnecting the solar photovoltaic array  100  with a large interlocking flange (not shown) that is used to join adjacent rear wind deflectors  600 . This acts to further increase the stiffness of the entire solar photovoltaic array  100 . 
         [0049]    Thus, the present invention has been described herein with reference to a particular embodiment for a particular application. Although selected embodiments have been illustrated and described in detail, it may be understood that various substitutions and alterations are possible. Those haying ordinary skill in the art and access to the present teachings may recognize additional various substitutions and alterations are also possible without departing from the spirit and scope of the present invention.