Apparatus for mounting a power conditioner to a photovoltaic module frame

An apparatus for mechanically coupling a power conditioner to a photovoltaic (PV) module frame. In one embodiment, the apparatus comprises: a bracket, adapted for mechanically coupling the power conditioner to the PV module frame, comprising at least one inner-flange tab and at least one outer-flange tab for trapping a flange of the PV module frame between them; and at least one self-locking mounting structure for locking the bracket to the PV module frame without requiring any holes in the PV module frame.

BACKGROUND OF THE INVENTION

Field of the Invention

Embodiments of the present disclosure relate generally to power conditioners and, more particularly, to an apparatus for coupling a power conditioner to a photovoltaic module frame.

Description of the Related Art

Traditional photovoltaic (PV) frame-attach systems for mounting a power conditioner to a PV module frame utilize an adapter plate in addition to a mounting member built into the power conditioner enclosure. In order to couple the power conditioner to the PV module frame, multiple bolts or fasteners are used that require a specific torque during assembly to provide a sufficient retention force. Such systems thus require additional components (e.g., nuts, bolts, brackets, tools for assembly, and the like) as well as time and effort spent drilling holes in specific locations on the PV module frame and then assembling the bracket and fasteners and attaching them to the frame.

Therefore, there is a need in the art for an apparatus for efficiently mounting a power conditioner to a PV module frame.

SUMMARY OF THE INVENTION

Embodiments of the present invention generally relate to an apparatus for apparatus for mechanically coupling a power conditioner to a photovoltaic (PV) module frame substantially as shown in and/or described in connection with at least one of the figures, as set forth more completely in the claims.

DETAILED DESCRIPTION

FIG. 1is a bottom angled perspective view of a power module assembly100in accordance with one or more embodiments of the present invention. The power module assembly comprises a PV module102coupled to a power conditioner104via frame-mounting bracket106(which may also be referred to as “bracket106”). The power conditioner104comprises a module level power electronics (MPLE) enclosure encasing power electronics that are electronically coupled to the DC output from the PV module102, for example via a cable connector192of the power conditioner104. The power electronics convert the DC power received from the PV module102to an output power (DC or AC) that may be coupled to an output via an AC cable connector194of the power conditioner104.

The PV module102comprises a frame116that surrounds the perimeter of a solar panel180and may be constructed of any rigid material, such as aluminum, rigid plastic, and the like, or any combination of such rigid materials. The PV module frame comprises a flange120running generally around the perimeter on the rear side of the frame116.

In accordance with one or more embodiments of the present invention, the frame-mounting bracket106is a flexible-plate bracket that securely couples the power conditioner104to the frame116without using any holes in the frame116and without using any secondary fasteners such as bolts, nuts, washers, and the like. The bracket106is self-locking to the frame116and can be removed from the PV module102as needed.

The bracket106comprises a plurality of mounting members for mechanically coupling and self-locking the power conditioner104to the frame116. Generally the bracket106removeably couples the power conditioner104to the frame116such that it can be manually de-coupled from the frame116without requiring any special tools. The bracket106comprises a plurality of offset tabs, including outer-flange tabs112-1and112-2(collectively referred to as outer-flange tabs112) and inner-flange tabs110-1,110-2,110-3and110-4(collectively referred to as inner-flange tabs110). The inner-flange tabs110are offset from the outer-flange tabs112; for example, as depicted inFIG. 1the inner-flange tabs110-1and110-2are straddle the horizontal edges of the outer-flange tab112-1, and the inner-flange tabs110-3and110-4straddle the horizontal edges of the outer-flange tab112-2. In other embodiments, the inner-flange tabs110and the outer-flange tabs112may be positioned differently but still remain offset from one another.

The bracket106also comprises spring clips114-1and114-2, collectively referred to as spring clips114, and a spring-action corner-locking member108. Other embodiments of the bracket106may comprise additional or fewer of one or more of the outer-flange tabs112, the inner-flange tabs110, the spring clips114, or the corner-locking member108.

The bracket106is substantially L-shaped and is formed from a single piece of stamped sheet metal. In other embodiments, the bracket106may have a different shape and/or may be formed from a different rigid material, such as a different type of metal, rigid plastic, or the like. In some embodiments, the bracket is made of aluminum, although other materials may be used in other embodiments. In one or more embodiments, the bracket106or portions of the bracket106are formed from a thermally-conductive material such that the bracket106acts as a heat-spreader to spread heat generated by the power conditioner104.

The bracket106is generally affixed to the power conditioner104using an adhesive; after the adhesive is applied, the power conditioner104is snap-fit to the bracket106via the spring clips114. The spring clips114extend perpendicular from the face to the bracket106to securely fasten the bracket106to the power conditioner104and hold the power conditioner104in place while the adhesive cures. In some embodiments, a high-performance silicone adhesive and sealant may be used to affix the bracket106to the power conditioner104, such as PV-804, although in other embodiments other types of sealants may be used. Although two spring clips114are depicted inFIG. 1, additional spring clips114may be used in other embodiments.

The inner-flange tabs110and the outer-flange tabs112are positioned along the two frame-facing edges of the bracket106(i.e., the inner-flange tabs110and the outer-flange tabs112extend outward from the bracket edges that face the frame116). The inner-flange tabs110are positioned on the inner-side of the flange120(i.e., the side of the flange120facing the solar panel180) and the outer-flange tabs112are positioned on the outer-side of the flange120(i.e., the side of the flange facing away from the solar panel180) such that the flange120is held between the inner-flange tabs110and the outer-flange tabs112. The inner-flange tabs110and the outer-flange tabs112trap the power conditioner104/bracket106in the plane of the frame116, thereby allowing the bracket106to be secured to the frame116.

In certain embodiments, such as the embodiment depicted inFIG. 1, the bracket106is mechanically self-locked to the frame116via the corner-locking member108. The corner-locking member108is substantially triangular in shape and comprises locking member flanges140-1and140-2(collectively referred to as locking member flanges140) disposed along opposite outer edges of the corner-locking member108to fit over a corner of the frame116. The corner-locking member108extends from the main body of the bracket116at a locking-member joint150. The locking-member joint150(i.e., the narrow span between the corner-locking member108and the main body of the bracket106) is sufficiently elastic to allow a spring-like motion so that the corner-locking member108opens as it is being pushed into the frame corner and then snaps down as the locking member flanges140pass over the frame edge. Generally, the locking-member joint150is a moveable joint that enables the corner-locking member108to be flexed out-of-plane with respect to the main body of the bracket106such that it snaps over the frame corner to trap the bracket106in the corner of the frame116. In other embodiments, other types of joints may be used for the locking-member joint150.

In order to mechanically couple the bracket106to the frame116, the inner-flange tabs110and the outer-flange tabs112are aligned with the flange120such that the inner-flange tabs110are disposed along the inner face of the flange120and the outer-flange tabs112are disposed along the outer face of the flange120. The corner locking member108is then pulled up—i.e., outwards from the plane of the bracket106—and slid over the edge of the frame116such that the locking member flanges140are positioned on the exterior sides of the frame116. The spring-action of the corner locking member108retracts to bring the corner locking member108substantially flush with the frame116, where the locking member flanges140are disposed along the exterior walls of the frame corner and secure the corner locking member108to the corner of the frame116. The corner locking member108may then be manually pressed downward toward the frame116to further securely fasten the bracket106to the frame116.

The frame-mounted bracket106can be removed from the frame116as needed; for example, an edge such as the tip of a screwdriver may be slide between the corner locking member108and the frame116to disengage the corner locking member108from the frame116.

In certain embodiments, the corner locking member108comprises one or more sharp edges to “bite” into the frame material. In one or more of such embodiments where the bracket106and the frame116are each made from an electrically conductive material, such biting into the frame material provides firm electrical contact for grounding purposes. For example, in some embodiments the power conditioner104may comprise a non-conductive touch-safe enclosure that's double insulated; in such embodiments, the bracket106may be grounded via the frame116and the PV module racking.

In one or more embodiments, the spring-action mechanism of the corner locking member108may provide a constant tension force pulling the bracket106and the power conditioner104into the corner position of the frame116to ensure better contact with the frame116. In some alternative embodiments, the corner locking member108may be built up in a separate assembly that is later bonded to a standard PV module mounting plate that accepts the power conditioner104.

Those of ordinary skill in the art will recognize that the bracket106described herein may be customized to fit particular power conditioners104(i.e., their MPLE enclosures), PV module frames, racks, and the like. For example, the bracket106may be elongated on one or more sides, the spring-locking corner locking member108may be expanded or shrunk for better trapping on the frame116, or the like.

FIG. 2is a top perspective view of a bracketed power conditioner assembly200in accordance with one or more embodiments of the present invention. The top perspective view depicted inFIG. 2shows the surfaces of the bracketed power conditioner assembly200that face the back side of the PV module102when the power conditioner assembly200is coupled to the PV module102.

The bracketed power conditioner assembly200comprises the bracket106coupled to the power conditioner104. The spring clips114hold the power conditioner104securely to the bracket106. As previously described, the bracket106may be affixed to the power conditioner104using an adhesive; where the power conditioner104is held in place via the spring clips114while the adhesive cures. Although two spring clips114are depicted, in other embodiments the bracket106may have fewer or more spring clips114and/or other types of fasteners for securing the power conditioner104to the bracket106.

As previously described, on a first outer edge of the bracket106, the inner-flange tabs110-1and110-2straddle the outer-flange tab112-1and are positioned such that the inner-flange tabs110-1and110-2are offset for the outer-flange tab112-1in both the vertical plane as well as the horizontal plane. Analogously, on a second outer edge of the bracket106, the inner-flange tabs110-3and110-4straddle the outer-flange tab112-2and are positioned such that the inner-flange tabs110-3and110-4are offset for the outer-flange tab112-2in both the vertical plane as well as the horizontal plane. The vertical distance between the inner-flange tabs110and the outer-flange tabs112is such that the flange120of the frame116fits between the inner-flange tabs110and the outer-flange tabs112. In other embodiments, the bracket106may have fewer or more inner-flange tabs110and/or outer-flange tabs112.

FIG. 3is a bottom angled exploded perspective view of a power module assembly100in accordance with one or more embodiments of the present invention.

As depicted inFIG. 3, the corner locking member108is flexed at the locking-member joint150such that it is positioned outwards from the plane of the bracket106and away from the frame116. The corner locking member108can then be slid over the edge of the corner of the frame116and snap-fit to the corner such that the locking member flanges140are positioned on the exterior sides of the frame corner. The spring-action of the corner locking member108then retracts to snap-fit the corner locking member108substantially flush with the frame116, where the locking member flanges140are disposed along the exterior walls of the frame corner and secure the corner locking member108to the corner of the frame116.

FIG. 4is a bottom angled perspective view of a power module assembly100in accordance with one or more other embodiments of the present invention. The power module assembly100comprises the PV module102coupled to the power conditioner104via the bracket106. As previously described, the bracket106comprises the spring clips114for securely fastening the bracket106to the power conditioner104, and the inner-flange tabs110/outer-flange tabs112for holding the frame flange120between them.

In some embodiments, such as the embodiment depicted inFIG. 4, the corner locking member108is replaced by a first side-latching trap402-1and a second side-latching trap402-2(collectively referred to as side-latching traps402). The side-latching traps402are separate components from the bracket106and are coupled to the frame116for mechanically coupling the bracket106to the frame116. The side-latching traps402may be made from any suitable rigid material, for example the side-latching traps402may be made from the same material as the frame116(such as an electrically conductive material), although alternatively they may be made from a different material. In some alternative embodiments, the bracket106may comprise both the corner locking member108as well as one or more side-latching traps402.

The side-latching traps402are sized and shaped to securely fit to the frame116. The side-latching traps402may be available in a variety of sizes to accommodate different sizes of PV module frames, thereby allowing the bracketed power conditioner assembly200to be coupled to a variety of differently-sized PV modules. The side-latching traps402are generally removably coupled to the frame116, for example the side-latching traps402may be snap-fit to the frame116in order to be replaced or serviced as needed, although in certain embodiments the side-latching traps402may be permanently coupled to the frame116or even part of the frame116itself.

The side-latching traps402are self-locking mounting structures that secure the bracket106on each of two sides that form a corner of the frame116, leaving that corner of the frame116free to couple as desired with roof mounting fixtures in some rail-less PV racking systems. In some embodiments, the side-latching traps402contain spring-like mechanisms to secure the side-latching traps402in place. The spring-like mechanisms allow some compliance to stretch out and latch when installing and provide a restoring force that always tries to pull the bracketed power conditioner assembly200into the corner of the frame116, thereby securely retaining it and, in those embodiments where the side-latching traps402are formed from an electrically conductive material, electrically grounding the bracket106to the frame116. For example, in certain embodiments such as the embodiment depicted inFIG. 4, the side-latching traps402-1and402-2comprise hooking features404-1and404-2, respectively, disposed at the interior ends of the side-latching traps402-1and402-2(i.e., the ends facing the interior of the frame116). The hooking features404-1and404-2fit into corresponding receptacles406-1and406-2, respectively, of the bracket106to secure the bracket106to the frame116.

In some other embodiments, the side-latching traps402may be modified in one or more ways, for example depending on the material and manufacturing method used to manufacture the side-latching traps402.

FIG. 5is a bottom angled perspective view of a power module assembly100in accordance with still other embodiments of the present invention. The power module assembly100comprises the PV module102coupled to the power conditioner104via the bracket106. As previously described, the bracket106comprises the spring clips114for securely fastening the bracket106to the power conditioner104, and the inner-flange tabs110/outer-flange tabs112for trapping the frame flange120between them.

In one or more embodiments, such as the embodiment depicted inFIG. 5, the corner locking member108is replaced by a corner-lock bracket fastener502, separate from the bracket106, that is attachable to and detachable from the bracket106for securing the bracket106to the frame116. The bracket fastener502is sized and shaped to fit securely over a corner of the frame116and may be made from any suitable rigid material; for example the bracket fastener502may be made from the same material as the frame116(such as an electrically conductive material), although alternatively it may be made from a different material. The bracket fastener502may be available in a variety of sizes to accommodate different sizes of PV module frames, thereby allowing the bracketed power conditioner assembly200to be coupled to a variety of differently-sized PV modules.

The bracket fastener502comprises a first frame-attach clip508-1and a second frame-attach clip508-2, collectively referred to as frame-attach clips508, for fastening the bracket fastener502to the frame116. The frame-attach clips508are substantially L-shaped and are disposed on each of two sides that form a corner of the frame116, although in other embodiments one or both of the frame-attach clips508may be differently shaped and/or positioned. In some embodiments, the frame-attached clips508may snap-fit the bracket fastener502to the frame116, although in other embodiments the bracket faster502may be permanently coupled to the frame116or even part of the frame116itself.

The bracket fastener502comprises a spring-action latch504that hooks or latches to a corresponding latch receptacle506of the bracket106. For example, as depicted inFIG. 5, the latch receptacle506is a hole in the bracket106and the spring-action latch504has a hook shape that inserts into the latch receptacle506to lock the bracket106to the frame116. In other embodiments, one or more components of the bracket fastener502may be designed or configured differently but still perform the same functions as described herein. For example, the latch504and/or the latch receptacle506may have a different shape and/or position while still mating to secure the bracket106to the frame116. As another example, the bracket fastener502may comprise a plurality of spring-action latches504that are each inserted in corresponding latch receptacles506of the bracket106while a spring mechanism tightly and securely pulls the bracket106towards the frame116.FIG. 6is a block diagram of a system600for power conversion using one or more embodiments of the present invention. This diagram only portrays one variation of the myriad of possible system configurations and devices that may utilize the present invention. The present invention can be utilized in any system for coupling a power conditioner (e.g., a DC-DC converter, a DC-AC inverter, or the liker) to a photovoltaic (PV) module.

The system600comprises a plurality of the power conditioners104-1,104-2, . . .104-N mechanically coupled to a plurality of PV modules102-1,102-2, . . .102-N in a one-to-one correspondence via corresponding brackets106-1,106-2, . . .106-N as described above. Each of the power conditioners104-1,104-2, . . .104-N is further electrically coupled to the corresponding PV module102-1,102-2, . . .102-N as shown by the dashed lines. The system600further comprises a controller606; a bus608; and a load center610.

The power conditioners104are coupled to the controller606via the bus608. The controller606is capable of communicating with the power conditioners104by wireless and/or wired communication (e.g., power line communication) for, for example, providing operative control of the power conditioners104, collecting data from the power conditioners104, and the like. In some embodiments, the controller606may be a gateway that is further coupled by wireless and/or wired techniques to a master controller via a communications network, such as the Internet.

The power conditioners104are further coupled to the load center610via the bus608. The power conditioners104convert the DC power from the PV modules102to an output power; in some embodiments the output power may be DC output power (i.e., the power conditioners104are DC-DC converters), while in other embodiments the output power may be AC output power (i.e., the power conditioners104are DC-AC converters). The power conditioners104couple the generated output power to the load center610via the bus608. The generated power may then be distributed for use, for example to one or more appliances, and/or the generated energy may be stored for later use, for example using batteries, heated water, hydro pumping, H2O-to-hydrogen conversion, or the like. In some embodiments, the power conditioners104convert the DC input power to AC power that is commercial power grid compliant and couple the AC power to the commercial power grid via the load center610.

The foregoing description of embodiments of the invention comprises a number of elements, devices, circuits and/or assemblies that perform various functions as described. These elements, devices, circuits, and/or assemblies are exemplary implementations of means for performing their respectively described functions.