Array including frameless solar modules

A solar array is mounted on a surface of a structure, the surface being generally planar. The solar array comprises a solar module and a support that supports the solar module a distance above the surface. The support defines a channel to receive the solar module. A locking mechanism engages the support to secure the solar module to the support, wherein the solar module extends between the support and the locking mechanism and into the channel such that the solar module is allowed to move relative to the support in a first plane generally parallel to the surface when the solar module is secured to the support. The locking mechanism and the support inhibit movement of the solar module in a second plane generally perpendicular to the surface when the solar module is secured to the support.

FIELD

This disclosure generally relates to solar arrays and, more specifically, to a solar array including frameless solar modules.

BACKGROUND

Solar modules convert solar energy into other forms of useful energy (e.g., electricity or thermal energy). Such modules are typically positioned above an underlying structure surface on a frame or rack. The solar modules are often connected and arranged to form an array. However, the solar modules and/or the structure surface may move relative to each other, which causes stress in the solar modules. In addition, the solar modules may experience loads and environmental forces such as wind, snow, ice, and precipitation.

BRIEF DESCRIPTION

In one aspect, a solar array is mounted on a surface of a structure, the surface being generally planar. The solar array comprises a solar module and a support that supports the solar module a distance above the surface. The support defines a channel to receive the solar module. A locking mechanism engages the support to secure the solar module to the support, wherein the solar module extends between the support and the locking mechanism and into the channel such that the solar module is allowed to move relative to the support in a first plane generally parallel to the surface when the solar module is secured to the support. The locking mechanism and the support inhibit movement of the solar module in a second plane generally perpendicular to the surface when the solar module is secured to the support.

In another aspect, a method of assembling frameless solar modules, the method comprising attaching a first set of clips to a first laminate, securing the first set of clips on the first laminate in a position, attaching a second set of clips on the second laminate, and stacking the second laminate on the first laminate such that the first set of clips engage the second set of clips. The first set of clips and the second set of clips align when the second laminate is stacked on the first laminate.

In still another aspect, a solar array for mounting on a surface of a structure comprises solar modules and supports to support the solar modules above the surface. Each support includes a keyway. Keys secure the solar modules to the supports and each key extends into the keyway and engages the respective support. Each key has an unlocked position in which the key is inserted into the keyway and a locked position in which the key extends into the keyway and secure the solar modules to the respective support.

In yet another aspect, a solar array is positioned on a surface of a structure and comprises a solar module and a pylon that supports the solar module a distance above the surface. The support defines a wire receiver to secure wires to the support, the wire receiver including at least one slot and a cleat extending across the at least one slot.

In another aspect, a solar array is mounted on a surface of a structure and comprises a solar module including a laminate and is substantially frameless. Clips are attached to the laminate and a support supports the solar module a distance above the surface. The support defines a channel configured to receive the clips, and a locking mechanism is engageable with the support to secure the solar module to the support. The clips extend between the support and the locking mechanism and into the channel.

In still another aspect, an assembly of solar modules comprises a first solar module including a first set of clips and a second solar module including a second set of clips. The first set of clips engages the set of clips, the first set of clips and the second set of clips facilitating assembly, shipping and installation of the solar modules.

DETAILED DESCRIPTION

The term photovoltaic may be abbreviated as “PV”. As used herein, the term “PV laminate” refers to any laminate that may be used to generate electricity from solar rays. The term “PV module” or “module assembly” refers to a PV laminate. The PV module may include mounting structure such as a frame and/or discrete mounting elements. The term “PV array” refers to a group of PV modules assembled as part of the same electricity generation system.

Embodiments described below include photovoltaic (PV) modules and mounting systems for the PV modules. For example, some embodiments include PV modules coupled together into a contiguous and interlocked ballasted array. The PV modules may be mounted to a surface (such as a roof) such that the modules are free to move in a plane parallel to the surface. As a result, the surface and/or the PV modules may expand or contract independently of the other. The PV modules may be supported on the surface by a support system. The support system for the PV modules translates with the roof's expansion and allows the PV modules to move independently within a controlled capture mechanism of the support system. The PV modules may be installed manually without the use of tools and without the need for electrical bonding between modules. Some embodiments of the described system include a built-in wire management device, ballast retention mechanism, and/or wind deflectors.

Referring initially toFIGS. 1A, 1B, and1C, a PV array100of one embodiment includes modules1mounted on supports on a surface of a structure. The structure may be, for example, a building having a fat roof or any other structure suitable for mounting solar modules. In other embodiments, the PV array may be installed on any surface. For example, in some embodiments, the PV array may be installed on the ground.

In this embodiment, the PV array is a 2×2 array. In other words, the PV array includes four modules1arranged in two rows and two columns. In other embodiments, the PV array may include any number of PV modules in any arrangement.

The module1includes a laminate2and support structures or clips3,4supporting the laminate. In some embodiments, the clips3,4attach the module1to pylons12,13and/or to the surface of a structure.

The laminate2includes a top surface, a bottom surface, and edges extending between the top surface and the bottom surface. The laminate2has a width and a length. In this embodiment, the laminate2is rectangular shaped. In other embodiments, the laminate2may have any suitable shape.

The laminate2also has a laminate structure that may include several layers. The layers may include, for example, glass layers, non-reflective layers, electrical connection layers, n-type silicon layers, p-type silicon layers, and/or backing layers. One or more layers may also include solar cells (not shown). In other embodiments, the solar laminate may have more or fewer, including one, layers, may have different layers, and/or may have different types of layers. In other embodiments, the laminate may be any structure that generates electricity from solar rays.

In one embodiment, for example, the laminate2includes photovoltaic material such as solar cells, and electrical interconnect conductors. The solar cells and electrical interconnect conductors may be positioned between materials including glass sheets, adhesives such as ethylene-vinyl acetate, and protectant films such as polyvinyl fluoride film. The laminate may also include external electrical terminals, wiring pigtails, and connectors to enable the module to be electrically connected to other modules and to power conversion devices. The laminate may also include electrical power conversion devices, such as micro-inverters or DC power maximizers, which may be attached to or embedded in the laminate.

FIGS. 1A-Cshow the modules1are supported above the surface at 6 points along the edges of the modules1by pylons or supports12,13, and then locked in position by keys10,11. In this embodiment, the pylons12,13, keys10,11, and clips3,4are made of molded plastic. In other embodiments, the pylons12,13, keys10,11, and clips3,4may be made of any materials that enable the pylons12,13, keys10,11, and clips3,4to function as described. In some embodiments, the pylons12,13, keys10,11, and clips3,4may be made of different materials.

As shown inFIG. 5A, the module1is frameless. In other words, the edges of the module1are free of fully enclosing structures and have only discrete mounting structures attached to the laminate. Being frameless has multiple advantages such as: i) reducing the weight and cost of the module1; ii) increasing unobstructed surface area available for solar collection; iii) allowing water, snow, and other contaminants to be more easily shed from the module surface without a frame to obstruct flow at the edges. As a result, the frameless module1has increased energy generation in comparison to at least some solar modules including fully enclosing frames. In alternative embodiments, the module1may include any frame components that enable the solar module to function as described.

Referring back toFIG. 1B, the pylons12,13support the modules1and resist forces acting on the modules1. For example, the pylons counteract downward forces from wind and snow and the gravitational forces on the modules1. In addition, the pylons12,13and the keys10,11resist environmental upward forces acting on the modules, such upward forces from wind. The multi-point support of the corner pylons or supports12and side pylons or supports13decreases the overall amount of support material required for the modules1and allow the modules1to be frameless. In this embodiment, the pylons12,13support the modules1at six points to create a 6-point loading dynamic. While the embodiment shown illustrated includes 6 point support of the modules1, it is also possible to have a 4 point support. For example, the side pylons13may be omitted in some embodiments. The 4 point support configuration would reduce the support material when the structural loading on the modules1is reduced, or the module assembles1are internally reinforced for the larger unsupported span. One method of achieving this internal reinforcement for the module assembly would be through the use of a glass-on-glass laminate. In other embodiments, the modules1may be supported in any manner that enables the modules1to operate as described.

In addition, in this embodiment, the support systems, including the pylons12,13and keys10,11, can be made from electrically insulating material, such as a polymer, and any electrically conductive components of the array can be isolated. Accordingly, there is no need for module-to-module electrical bonding within the array as might otherwise be required by electrical codes when conductive metal frames and support systems are employed. Also, the array is not required to be grounded, and the electrically insulating materials reduce potential induced degradation which can affect the lifetime and performance of PV modules.

The perimeter of the array can be fitted with optional wind deflectors5,6. In some embodiments, ballast7can be installed on the wind deflectors5,6. In addition, the ballast7can be installed on the pylons12,13throughout the array as shown inFIG. 1C. The pylons12,13, and the wind deflectors5,6allow the ballast7to be distributed throughout the array and positioned in positions where additional ballast may be required.

In reference toFIGS. 2A and 2B, a corner pylon assembly includes the corner pylon12, the corner clip3, and the corner key10. The side pylon assembly includes the side pylon13, the side clip4, and the side key11. Both the corner key10and the side key11include a lock pin14which engages with the bottom side of the top of the pylons12,13to lock the keys10,11in place.

As shown inFIGS. 3A-C&18A-C, the corner key10is configured to engage the keyway18. During assembly, the corner key10is positioned such that the lock pin14aligns with the keyway18and the corner key is inserted into the keyway. The lock pin14forces the corner key10to align such that a visible top9of the key10extends over the corner of the module1, as shown inFIG. 3B, when the corner key is positioned in the keyway. The visible top9extending over the module1indicates to the installer that the key10is not in the locked position. The corner key10may be locked into position by turning the corner key10an eighth turn in either direction. In the locked position, the corner key10captures the corner clip3and secures the module1to the corner pylon12as shown inFIG. 3C.

As shown inFIGS. 4A-C, the side key11is configured to engage the keyway18. During assembly, the side key11is positioned such that the lock pin14aligns with the keyway18and the side key is inserted into the keyway. The lock pin14forces the side key11to align such that a visible top of the side key extends over module1, as shown inFIG. 4B, when the side key11is positioned in the keyway18. The visible top9extending over the module1indicates to the installer that the key11is not in the locked position. The side key11may be locked into position by turning the side key11a quarter turn in either direction. In the locked position, the side key11captures the side clip4and secures the module1to the side pylon13as shown inFIG. 4C.

The keys10,11may be turned without the use of tools, in other words by hand. The hand turned, tool-less locking mechanism reduces the time and equipment required to install the PV modules. The distinctive visual indication of an unlocked, rotated key partially covering the active area of the PV modules, as shown inFIGS. 3B & 4B, increases installation reliability and decreases inspection time.

In alternative embodiments, the keys10,11are secured to the pylons12,13in any manner that enables the array to operate as described. For example, the keys10,11may be secured to the pylons12,13by an interference lock fit along the top of the pylons12,13without insertion of the keys10,11into a shaft.

As shown inFIG. 5A, the module1includes the photovoltaic laminate2, four corner clips3, and two side clips4. The number of side clips4could be more or less in other embodiments. The number of side clips4may be determined at least in part based on factors such as the size and shape of the photovoltaic laminate2, and the structural loads applied to the laminate2. In this embodiment, the clips3,4are attached to the photovoltaic laminate2with a structural adhesive or tape. In other embodiments, the photovoltaic laminate2may be at least partially mounted using mechanical means. The clips3,4may be captured by the pylons12,13. In particular, in the illustrated embodiment, the corner clips3are positioned in capture features17(shown inFIG. 6b) of the corner pylons12. The side clips4are positioned in capture features21(shown inFIG. 7a) of the side pylons13. The capture features17,21limit the lateral motion of the clips3,4relative to the pylons12,13. When the keys10,11are in the locked position, the module1is fully assembled and the clips3,4are captured in the pylon assembly. When the clips3,4are captured within the pylons12,13, the capture features17,21provide sufficient clearance between the keys10,11and bearing blocks16,23to allow for lateral translation of the clips3,4relative to the pylons12,13. The lateral movement of the clips3,4can reduce wearing due to shifting of support structures on the surface. For example, the clips3,4may inhibit the pylons12,13rubbing on roofing material.

The clips3,4are also configured to facilitate stacking the modules1. For example,FIG. 5Bshows three modules1stacked on top of each other. The clips3,4lock into each other as shown inFIG. 9CandFIG. 10Cand make the stacked modules1resistant to separation from lateral loads, for example during shipment. The clips3,4are an integral hardware component of the module1. For example, the clips3,4allow stacking of the modules1during shipping and installation. In addition, the clips3,4support and stabilize the module1during operation. The stacked modules1provide high shipping density and small footprint when removed from the surface. Accordingly, the clips3,4reduce the use of disposable packaging and shipping components and reduce the materials and time required for shipping, installation, and movement of the modules1. In addition, the clips3,4serve multiple functions and reduce cost, waste and part count.

FIG. 6Ashows a perspective view of the corner pylon12. The keyway18is located along the center of the pylon12and extends through the top of the pylon12towards the base. The keyway18at least partially receives the corner key10and allows the lock pin14and shaft of the corner key10to pass through the keyway18to the bottom side of the top of the pylon12where a locking mechanism is located, as shown inFIGS. 18A-C. In some embodiments, the locking mechanism as shown inFIGS. 19A-Bincludes two symmetrical circular locking ramps44molded into the pylon12for the pins14to ride across as the key10is rotated. The ramps44cause the clamping force between the key10and the pylon12to increase as the key10is rotated toward the locked position, which causes an increase in the force required to rotate the key10. When the key10is rotated into the locked position, the pins14settle into the lock groove45, thus relieving a portion or all of the clamp force on the pins14. The advantage to this design is that a clamp force is not required to keep the key10in the locked position, since unlocking the key10requires an abrupt transition of the pins14to the highest point at the end of the lock ramp44with a correspondingly high breakout rotational force. The gradients of the locking ramp44, the length of the key10, and the depth and shape of the lock groove45can be adapted to provide i) low-force locking of the key, ii) suitable as-locked tension on the key, or elimination of key tension when locked, and iii) manageable unlocking forces which prevent inadvertent unlocking of the array. Moreover, as shown inFIG. 3C, the visible top9of the key10is aligned with the module sides when the key10is in the locked position due to the rotational angle of the lock pins14relative to the visible top9of the key10and the rotational angle of the lock groove45relative to the keyways18.

Furthermore, in one embodiment the height of the channel in the pylon12allows the module1to be spaced from at least one of the key10and the pylon12when the module1is secured between the key10and the pylon12. In particular, the locking of the key10to the pylon12creates a cavity between the pylon12and the key10in which the clips3of the module1are free to slide. Moreover, the key10is locked in position by a compression force between the key10and the pylon12and the compression force does not act on the module1.

The dimensions of the pylons12, keys10, pins14, locking ramps44, and locking grooves45are designed to provide the necessary low locking force, low to zero locked force, and higher unlocking forces consistent with normal structural design criteria, material properties and manufacturing tolerances. In addition, this design is resistant to malfunction due to creep which sometimes occurs in polymeric material under load. Moreover, the key10may hold the module1to the pylon12even when stress is removed from the key

The corner clip3of the module1is captured by the back stop15and the bearing block16as shown inFIG. 6B. The clip3can move laterally within the slip channel17formed by the back stop15and the bearing block16. The bearing block16translates the downward forces from the module1to the pylon12. The back stop15controls the minimum gap between adjacent modules1allowing for pressure equalization above and below the array during wind events. The pylon12includes a ballast channel19where ballast can be placed and leaned against the side of the pylon12as shown inFIG. 8A. As shown inFIG. 7A, the pylon12may also include drainage slots or drains38that allow water on the roof surface to flow through the pylon12and minimize ponding of water on the roof. In this embodiment, the pylon includes 4 drainage slots38.

Wire receivers20are located on the sides of the pylon12as shown inFIG. 6Cand are used to secure the photovoltaic electrical wires8(shown inFIGS. 13B and 13C) above the roof. In the illustrated embodiment, the wire receivers20are planar with the sides of the pylon12. Details of how the wires8are inserted and held in the wire receivers20are shown inFIGS. 13A and 13B. In some embodiments, the wire receivers20include slots46,49,50separated by fingers47and at least one catch or cleat48. In this embodiment, the slots include a wire insert slot46, wire transition slots49, and a wire capture slot50. The wire insert slot46and the wire capture slot50extend horizontally, i.e., parallel to the mounting surface. In this embodiment, the wire insert slot46is above the wire capture slot50. The wire transition slots49extend vertically and connect the wire insert slot46and the wire capture slot50. The cleat48extends across the capture slot50, between the fingers47, and generally divides the capture slot50into two portions.

During assembly, the wire is inserted in the wire insert slot46and moved through the wire transition slots49into the wire capture slot50. Fingers47(FIG. 13C) extend horizontally along the wire insert slot46and the wire capture slot50. The two fingers47guide the wire and secure the wire in the wire capture slot50. In this embodiment, the fingers47and the cleat48are substantially planar and in the same plane generally as the side of the pylon12. In other embodiments, the wire receivers20may include any fingers47and/or cleat48that enable the wire receiver20to function as described. For example, in some embodiments, at least one of the fingers47and the cleat48may extend at an angle.

Also during assembly, the wire8is inserted in the slots46,49,50and positioned at least partially around the cleat48such that the cleat resists movement of the wire and suspends the wire about the support surface. For example, a friction force is produced between the cleat48and the wire8to resist movement of the wire. In some embodiments, the wire receivers20are integrally formed on the pylon12such that the pylons12can be stacked. For example, in some embodiments, the pylon12is formed from plastic, such as polymer, in a mold and the wire receiver20is formed by the mold. In other embodiments, the pylon12includes any wire receivers20that enable the pylon12to function as described.

The wire receiver20may secure any wires8to the pylon12. For example, in this embodiment, each wire receiver20holds up to three wires8. However, the wire receiver20is scaleable and may hold any number of the wires8.

As shown inFIGS. 14A, 14B, and 15, the wind deflector slots43may be used to capture the lock tab42of the wind deflectors5,6. The wind deflectors5,6may be secured in the wind deflector slots43when the modules1are connected to the pylons12,13by the corner key10. The wind deflectors5,6are secured to the pylons12,13by the keys10such that the wind deflectors5,6are allowed to move relative to the mounting surface similar to the modules1. As a result, movement of the entire array100, including the modules1and components such as the wind deflectors5,6is decoupled from movement of the mounting surface.

FIGS. 7A-Cshow the side pylon13. The keyway18is located along the center of the pylon13and extends through the top of the part towards the base. The keyway18at least partially receives the side key11and allows the lock pin14and shaft of the side key11to pass through the keyway18to the bottom side of the top of the pylon13where the locking ramps44and locking grooves45are located. The side key11locks in place in the locking groove in the same manner as the corner key10as illustrated inFIGS. 19A and 19B.

The side clip4of the module1is captured by the back stop22, the bearing block23and the saddle24. The clip4can move laterally within the slip channel21formed by the back stop22, the bearing block23and the saddle24. The bearing block23transmits downward forces from the module1to the pylon13. The back stop22controls the minimum gap between adjacent modules1allowing for pressure equalization above and below the array during wind events.

The pylon13includes a ballast channel19where ballast can be placed and leaned against the side of the pylon13as shown inFIG. 8A. Similar to pylon12, the pylon13also includes drainage slots38(shown in FIG.7B) along a base of the pylon, wire receivers20(shown inFIG. 7C) located on the sides of the pylon13, and wind deflector slots43(shown inFIG. 7C) to capture the lock tab42of the wind deflectors5,6.

By standing the ballast7on an edge and against the side of the pylons12as shown inFIG. 8A, the overall footprint of the ballast7on the roof is reduced. Specifically, the ballast7is positioned on the pylon12in a direction perpendicular to the surface. For example, in this embodiment, the ballast7is substantially vertical. The ballast channel19distributes the load around the entire pylon12reducing the point load on the structure supporting the array. For example, for a structure such as a roof, distribution of the load may reduce point loading on components such as foam insulation and allow the roof warranty to be maintained. The reduced footprint along with the drainage slots38help reduce water ponding on the roof to inhibit roof leaks. In addition, the reduced ponding helps keep the ballast block7dry which reduces freeze-thaw stresses that can degrade the concrete of the ballast blocks7. The placement of the ballast block7also simplifies installation. For example, the ballast blocks7may installed and/or removed from the pylons12,13with one hand.FIG. 8Bshows another embodiment of the pylon12with a wider ballast channel19that can accept four ballast blocks7. The ballast7may also be installed on the side pylons13in a similar manner to reduce point load and ponding.

An embodiment of the corner clip3is shown in the perspective view inFIG. 9Aand a side view inFIG. 9B. The corner clip3fits against the corner of the laminate2such that the laminate2slips into a laminate acceptance cavity28of the clip3. Both the acceptance cavity28and the adhesive platform27may have a layer of adhesive to secure the corner clip3to the laminate2.

An embodiment of the side clip4is shown in perspective view inFIG. 10Aand side view inFIG. 10B. The side clip4fits against any side of the laminate2. The laminate2edge slips into a laminate acceptance cavity35. Adhesive may be applied into the laminate acceptance cavity35and on an adhesive pad29to physically attach the side clip4to the laminate2. In other embodiments, the clips3,4may be secured to the laminate2by adhesive, tape, fasteners, and any other suitable attachment.

The corner clip3and the side clip4serve multiple functions. For example, the clips3,4facilitate assembly of the modules1, shipment of the modules1, and assembly of the modules1to form the array. As described below, the clips3,4engage and auto-align during assembly to facilitate attaching the clips3,4to the modules1in the correct position. In addition, the clips3,4engage and lock together to facilitate stacking the module1in a suitable assembly of modules1such as for shipping and handling the modules1. Moreover, the clips3,4are support structure attached to the laminate2and allow the modules1to be secured to the pylons12,13. The clips3,4are integrated into the modules1and eliminate the necessity of using at least some separate components during assembly, shipment, and installation.

Each corner clip3is configured to engage corner clips3stacked on top of the corner clip3. Specifically, in this embodiment, each corner clip3has a corner clip groove25that wraps around the outside of the clip and captures a corner clip tongue26of the clip above when the modules1are stacked together for shipping as shown inFIG. 9C. Once the clips3are fully engaged, the clips3lock together resisting lateral motion which simplifies packaging and reduces shipping costs. In other embodiments, the clips3may include any engagement features that enable the clips to function as described. In further embodiments, the clips may be locked together using pins and/or fasteners.

Also, each side clip4is configured to engage side clips4stacked on top of the side clip4. Specifically, in this embodiment, each side clip4has two grooves32on either side of a clip saddle30. A side clip tongue33engages with the groove32around the saddle30of the lower clip when the modules1are stacked together for shipping as shown inFIG. 10C. Once the clips4are fully engaged the clips4lock together resisting lateral motion which simplifies packaging and reduces shipping costs. In other embodiments, the clips4may include any engagement features that enable the clips to function as described. In further embodiments, the clips4may be locked together using pins and/or fasteners.

As shown inFIG. 10B, each side clip4includes a vertical support31. The vertical support31extends in a vertical direction and is spaced from an outer face of the side clip4. The vertical support31contacts an adjacent module1when the modules1are stacked, and can ensure adhesive contact between the laminate and the adhesive platform until the adhesive is cured. The vertical support31provides support, and reduces torsion forces and motion. This is advantageous because torsional forces due to stacking can rotate the adhesive platform away from the laminate so they are no longer parallel and in contact. This means that the adhesive or tape might not otherwise engage and fix the clip to the laminate.

The locking of the clips3,4to each other facilitates aligning the clips3,4to the laminate2during assembly. The first set of clips3,4may be positioned on the laminate using a jig or in any other suitable manner. Once the first set of clips3,4are fixed in the correct position on the first module of a new stack, the next and successive sets of clips3,4can be securely aligned with the first set even before the adhesive is cured. Thus, a stack of panels can be assembled rapidly with assured alignment throughout the stack. In some embodiments, the first set of clips3,4may be mounted on a manufacturing jig instead of using the first module as the jig, such that all modules in the stack are aligned to the clips on the jig before the adhesive is cured. Therefore, the clips3,4reduce cost by reducing the need for expensive equipment that would otherwise be needed to hold the position of the side clips4with respect to the laminate2for the duration of the adhesive curing time for every module.

In another embodiment, a fixture on a pallet may be provided to accept and lock the clips in place for the first module. For example there may be a pallet corner fixture block and a pallet side fixture block. These would be similar to the clips described herein but allow for being attached or fastened to the pallet.

A top view of the array is shown inFIG. 11Awith section lines showing the cross sectional views depicted in the following figures.FIG. 11Bshows the cross sectional view of the array along section line A-A. Section line A-A extends through the center of the pylon13and along the center of the back stop15and the keyway18with the ballast blocks7removed.FIG. 11Bshows how the shaft of the key10fits in the keyway18.FIG. 11Cshows the cross sectional view of the array along section line B-B. Section line B-B extends through the bearing blocks16and the corner keys and the corner pylon12.FIG. 11Cshows how a bottom of the adhesive platform27rests on a top of the bearing block16. In addition,FIG. 11Cshows the location of the locking pin14on the shaft of the corner key10just under the bottom side of the top section of the pylon13.FIG. 11Dshows the cross sectional view of the array along section line C-C. Section line C-C extends through the center of the pylon12and is parallel with the sides of the pylon's12ballast channels19.

As shown inFIG. 13A, a wire receiver20is formed along the sides of the pylons12,13and acts as an integrated wire management device. During installation, an unbroken wire8is bent and then slid into the insert slot46as shown inFIG. 13A. Then the wire8is pushed down through the transition slots49and fixed in the capture slot50as shown inFIG. 13B. Accordingly, the wire8is captured in the wire receiver20. Several wires8can be placed in one wire receiver20. The wire receiver20reduces the need for independent wire clips or zip ties and decreases time and cost to install the modules1.

FIG. 14Ais an exploded view of the wind deflector6assembly, andFIG. 14Bis an assembled view of the wind deflector6assembly. The wind deflectors5,6have bearing block notches40that fit around the bearing blocks16of the corner pylon. This captures the deflector5,6in the same manner the corner clip3of the module1is captured. The deflector5,6is captured in the slip channel17by the bearing block16and the back stop15of the corner pylon12. The captured deflector5,6has freedom of movement in at least two directions parallel to the roof plane. The wind deflector6is also captured in the side pylon slip channel21by the bearing block23and the back stop22of the side pylon13and through the saddle notch39in the wind deflector6. This mechanism also allows for freedom of movement in at least two directions parallel to the roof plane. Once the keys10,11are installed, the top of the wind deflector6is locked into the array.

While the wind deflector6illustrated inFIGS. 14A and 14Bis configured for use on a relatively long side of the module1, the deflector5for the short side of the module1is installed in a similar manner. The wind deflector5does not have a side pylon13to support the wind deflector5mid span and does not have the saddle notch39of the deflector6. For the wind deflector5the corner keys10are used to lock the top of the deflector5into the array. The bottom of the deflectors are held in place by the wind deflector lock tab42that gets inserted into the wind deflector slot43of the pylons12,13as shown inFIG. 15. The combination of the lock tab and the installed corner keys completes the capture of the wind deflector5. In addition, the wind deflector5,6may accept ballast7. Specifically, the ballast7can be installed as needed into the ballast channels41of the wind deflectors5,6. In addition, the wind deflectors5,6are supported above the surface and extend along the perimeter of the array. Accordingly, the ballast7in the wind deflectors5,6is positioned around the perimeter of the array to resist loading on the perimeter of the array. Moreover, the wind deflectors5,6are spaced from the surface such that fluid may flow along the surface without being inhibited by the wind deflectors5,6. In addition, the wind deflectors5,6are positioned substantially perpendicular to the surface to inhibit collection of fluid on the wind deflectors5,6.

The freedom of movement of the corner clips3in the slip channel17of the corner pylons12is shown inFIGS. 16A, 16B, &16C which are top views of the corner pylon assembly with the corner key10removed.FIG. 16Ashows the corner clip3with the module1positioned against the back stop15. As shown inFIG. 16B, the clip3may move in a first slip direction46such that the corner clip3is spaced from the back stop15and positioned against the bearing block16. As shown inFIG. 16C, the clip3may move in a second slip direction47such that the corner clip3is spaced from the back stop15and positioned against the bearing block16. The module1is in an extended position inFIG. 16C. In the extended position, the corner clip3is positioned the greatest distance from the back stop15in the first slip direction46and the second slip direction47. The first slip direction46is perpendicular to the second slip direction47. Allowing the module1to have freedom of movement in both directions but at least in one direction decreases stresses on the module assembly and on the structure surface leading to a more reliable system with less damage to the structure surface and the module1. In other embodiments, the corner clip3may move in any direction that enables the module1to function as described.

The allowed freedom of movement of the side clips4in the slip channel21of the side pylons13is shown inFIGS. 17A, 17B, &17C which are top views of the side pylon assembly with the side key hidden.FIG. 17Ashows the corner clip3with the module1positioned against the back stop22. As shown inFIG. 17B, the clip3may move in the first slip direction46such that the corner clip3is spaced from the back stop22and positioned against the bearing block23. As shown inFIG. 17C, the clip4may move in a second slip direction47such that the corner clip3is spaced from the back stop22and positioned against the saddle24. The module1is in an extended position inFIG. 17C. In other embodiments, the side clip4may move in any direction that enables the module1to function as described.

The freedom of movement of each module assembly in any direction is greater than the thermal expansion/contraction of the underlying surface and/or of the module1. Moreover, each module1moves independently of other modules1. Accordingly, each module1can individually relieve stresses due to thermal expansion/contraction. The described embodiments differ from at least some known systems where module assemblies are coupled together rigidly such that the module assemblies expand and contract together and the entire system must account for the total expansion/contraction of the surface in relation to the system at the periphery of the array, and between the modules in the array. In contrast, the described embodiments allow the modules1to have individual freedom of movement, which reduces stress in the system and reduces the amount of expansion/contraction that must be taken into account at the periphery of the array as well independently relieving the stress on individual modules. Accordingly, each module1may be free to move an amount that is much less that the amount the entire system would have to move to account for expansion/contraction of the entire system and/or the surface.

In addition, each module1in the array is spaced from other modules1by the pylons3,4. In particular, the pylons3,4include a spacer to keep modules at a minimum distance from each other to allow for pressure equalization. As a result, air may move between the modules1and the forces on the modules1are reduced.

In some embodiments, material may be removed from each of the components in order to save weight or cost, or for example to provide other benefits such as promoting drainage or ventilation.

With reference toFIG. 1C, during operation, the pylons12,13support the modules1, ballast7, and the wind deflectors5,6a distance above the surface and couple the modules1, ballast7, and the wind deflectors5,6together. The pylons12,13including the locked keys10,11capture the modules1and the wind deflectors. In addition, the pylons allow for the modules1to move in at least one direction parallel to the surface to reduce forces that can develop from thermal expansion of the surface and/or the modules1. The wind deflectors5,6can be installed on the perimeter of the array as needed. The wind deflectors5,6can accept ballast7to increase the stability of the array and the ability of the array to withstand wind forces. In particular, the wind deflectors5,6facilitate the array resisting loads at the perimeter of the array. The electrical wires8are secured in wire receivers20on the pylons12,13.

Referring back toFIGS. 1C, 6A, and 7C, a method of installing the array on a surface of a structure includes assembling at least four modules1and connecting the modules1together. First, a first set of pylons12,13are installed for the first module1. Second, the ballast7is installed for the pylons12,13supporting the first module assembly. Third, the module assembly's1corner and side clips3,4are positioned in the slip channels17,21. Then a second set of pylons12,13are installed for the second module1and the ballast7are installed on the pylons12,13. The second module1is positioned in the slip channels17,21. The two modules are electrically wired together and the wire8is securely mounted off the surface by inserting it into one or more of the available wire receivers20. The side key11for the side pylon13is then installed into the pylon13between the modules1and locked into place. This process is repeated until an adjacent row (or column) is installed and four modules1are coupled to the corner pylons12. The key10is installed into the corner pylon12and locked into place to secure the module assemblies to the corner pylon12. In other embodiments, any number of module assemblies may be secured to the pylons12,13that enable the array to operate as described. Once a pylon12,13is full, the pylon12,13is locked down by its corresponding key10,11. Once the array is complete, the wind deflectors5,6are installed along the perimeter of the array as necessary. They are placed down onto the pylons12,13such that their bearing block notches40and saddle notches39are wrapped around the bearing blocks16,23of the pylons12,13. In addition, the wind deflector lock tabs42are inserted into the deflector slots43on the pylons. Then the keys10,11are installed on the pylons12,13along the perimeter of the array. Finally, any required ballast7are installed onto the wind deflectors5,6. The electrical wires8can extend from the array at any point by cutting through the deflector5,6and installing proper conduit with fittings or bushing as identified by code. The array is now complete. In other embodiments, the array may be assembled in any manner and any sequence that enables the array to operate as described.

FIG. 12is a perspective view of nested pylons. Specifically, the shape of the pylons12,13allow the pylons to be nested within each other facilitate shipping and storage of the pylons12,13. Each pylon12,13defines a cavity that is configured to receive other pylons12,13.

In some embodiments, the modules1and/or the array100may be assembled manually without the use of tools. For example, the keys10,11allow the modules1to be secured to the pylons12,13without the use of tools. In addition, the clips3,4engage each other and the pylons12,13to facilitate assembly. Moreover, components such as the ballast7and the wind deflectors5,6may be positioned and installed by hand. Accordingly, embodiments of the array100and the modules1reduce the time and cost required to assemble solar modules and arrays.

In addition, in the illustrated embodiment, the solar array100is substantially planar and the laminates1are substantially parallel to the mounting surface. As a result, the array100facilitates cleaning. For example, a robotic cleaner may be used to clean the array and would experience less obstacles because the array is planar. In addition, the configuration of the modules1allows for water, snow, and other fluids to drain from the array100. For example, the modules1are frameless and the clips3,4are positioned to allow water flow along edges of the module and inhibit water collecting along the edges. In addition, the pylons12,13include drainage slots38to facilitate drainage of fluid. In other embodiments, at least some of the modules1may be positioned at angles.

Embodiments of the methods and systems described achieve superior results compared to prior methods and systems. For example, the systems and methods described simplify the installation of solar modules on structures. More specifically, the embodiments reduce the labor, tools, and materials required for layout and assembly of the solar modules. In addition, the embodiments described include keys and clips that provide freedom of movement for the modules and reduce stresses on the modules. Also, the solar modules distribute loads and reduce point loading on the structure surface.