Solar module carrier

The present disclosure is directed to a carrier device. A device may include a handle and at least one attachment device coupled to the handle. The at least one attachment device may be configured to couple to a solar module, wherein each attachment device includes at least one of a channel for receiving a portion of a frame of the solar module and a clamp for securing the solar module.

TECHNICAL FIELD

This disclosure relates generally to carrier devices and, more specifically, to carrier devices for carrying at least one solar module.

BRIEF SUMMARY

In one specific embodiment, a device includes a handle and at least one attachment device coupled to the handle. The at least one attachment device may include a channel configured for receiving a portion of a frame of a solar module. Further, in one embodiment, each attachment device may include an anti-slip device configured to limit movement of the solar module engaged with the attachment device. In addition, each attachment device may include an engagement device configured to be displaced by the portion of the frame upon the frame being positioned within the channel. The engagement device may be configured to provide a feedback (e.g., audible and/or tactical) upon the frame being engaged with the attachment device.

In another specific embodiment, a device includes a handle and at least one attachment device coupled to the handle and configured to couple to a solar module. Each attachment device includes a channel for receiving a frame of the solar module. Each attachment device may also include an anti-slip device proximate the channel and configured to limit movement of the frame positioned in the channel in a first direction, a second, opposite direction, or both. Moreover, the device may include a harness having at least one strap configured for securing the harness to a user. The harness may also include a latching device configured for attaching to at least one of the handle and the at least one attachment device. The harness may further include a wind force abatement device, which allows the module to align itself in such a way to reduce the force of the wind acting on the user via the harness.

According to another embodiment, a system includes a solar module and a carrier device configured to removably couple to the solar module. The carrier device may include a handle and at least one attachment device coupled to the handle and configured to couple to the solar module. Each attachment device may include at least one of a channel for receiving at least a portion of the solar module and a clamp for securing the solar module.

Other aspects, as well as features and advantages of various aspects, of the present disclosure will become apparent to those of skill in the art through consideration of the ensuing description, the accompanying drawings and the appended claims.

DETAILED DESCRIPTION

Referring in general to the accompanying drawings, various embodiments of the present disclosure are illustrated to show the structure for a carrier device. Common elements of the illustrated embodiments are designated with like numerals. It should be understood that the figures presented are not meant to be illustrative of actual views of any particular portion of the actual device structure, but are merely schematic representations which are employed to more clearly and fully depict embodiments of the disclosure.

The following provides a more detailed description of the present disclosure and various representative embodiments thereof. In this description, functions may be shown in block diagram form in order not to obscure the present disclosure in unnecessary detail. Additionally, block definitions and partitioning of logic between various blocks is exemplary of a specific implementation. It will be readily apparent to one of ordinary skill in the art that the present disclosure may be practiced by numerous other partitioning solutions. For the most part, details concerning timing considerations and the like have been omitted where such details are not necessary to obtain a complete understanding of the present disclosure and are within the abilities of persons of ordinary skill in the relevant art.

Solar photovoltaic (PV) cells use light energy (photons) from the sun to generate electricity through a photovoltaic effect. A PV solar module includes PV cells mounted behind glass and typically includes a frame at least partially surrounding the edges of the cells and glass. A PV system, which may include a plurality of solar modules and various other electrical components, may be used to generate and supply electricity in utility, commercial and residential applications. The soft-costs of installing a PV system (i.e., costs excluding the cost of the modules, inverters, and other equipment) can be more than half of the entire installation cost (e.g., more than 65% of the total cost of the installation). A large portion of the soft-costs is labor costs, including the cost of injury and accidents and workman's compensation insurance. Solar modules may also be of the type that converts energy from the sun into heat that is captured in a fluid running through collectors mounted behind glass. The heated fluid may then be used, for example, to heat water for use in a home, a pool, or a business. A solar hot water module typically includes a frame at least partially surrounding the edges of the glass and collectors. The labor required in a solar hot water installation is also a significant portion of the cost of a solar hot water system.

Solar installation companies are seeking ways to reduce labor costs. One aspect of installation labor is moving solar modules (e.g., lifting and carrying many modules from a truck to the mounting site). Moving solar modules is a physically tiring process and may require physically strong personnel. For example, a typical residential solar PV installation has around 18 solar modules and, typically, each solar module is approximately 1×1.6 meters in dimensions and approximately 42 pounds in weight. Solar modules are typically carried up a ladder and attached to a roof of a house, which is typically 5 to 8 meters tall. This can put significant strain on a person, who must simultaneously support the awkward shaped and heavy solar module during transportation, especially while ascending a ladder. Further, solar modules may have a sharp edge that is, for example, 1.5-2.5 mm thick and can cut into a hand of the person carrying the solar module. A solar module is often hefted over a person's shoulder and may contact the back of the person carrying the solar module. Accidents may occur as a consequence of fatigue or loss of balance. The Occupational Safety and Health Administration (“OSHA”) requires maintaining three points of contact when climbing a ladder. This presents a challenge when personnel must climb a ladder while carrying a module. Some installation companies today may not be in compliance with the OSHA requirements. Further, pulley systems and/or dedicated solar module lifters require significant time to set-up and add significant cost to the installation process and, thus, are not practical for residential installations.

Various embodiments of the disclosure include a device configured to attach to a solar module and provide an ergonomic, comfortable, and safe means for carrying the solar module. The device may include one or more attachment devices, wherein each attachment device may include a channel for receiving a portion of a frame of a solar module. The device may be attached near the center of an edge of a solar module so that the weight of the solar module is balanced.

FIGS. 1A-1Fare various illustrations depicting a carrier device100including a handle101and attachment devices105. Each attachment device105may include a housing106and may be coupled to and extend away from handle101. It is noted that handle101may be sized to provide a user with a comfortable and adequate means for lifting a module coupled thereto. Stated another way, a circumference and a width of handle101may be sized to provide a sufficient area for transmitting a load to a user's hand to minimize pain, discomfort, and/or fatigue to the user. In one example, a width W of handle101may be at least 3 inches and a diameter D may be substantially 1.25 inches.

Further, housing106may comprise any suitable material. As one example, housing106may comprise plastic. According to one embodiment, each attachment device105may comprise a hook-shape and include a channel103configured to receive a portion of a frame of a solar module. It is noted that although carrier device100is depicted as having two attachment devices105, the present disclosure is not so limited. Rather, carrier device100may include one or more attachment devices105.

FIG. 2illustrates a carrier device100coupled to a solar module102. More specifically, carrier device100is coupled to a portion of a frame104of solar module102.FIG. 3is another illustration depicting a cut-out portion of attachment device105coupled to frame104.FIG. 4is a zoomed-in illustration of a cut-out portion of attachment device105and frame104. As depicted inFIGS. 3 and 4, a portion of frame104may be received in a channel103(see e.g.,FIG. 4) of attachment device105.FIG. 7is another illustration of carrier device100coupled to solar module102.

It is understood that the carrier device100may include any number of attachment devices105enabling the carrier to couple to more than one module. For example, the carrier device100may include four attachment devices105such that it can couple to two separate modules. It is further understood that the handle101may enable multiple users to bear the load together or may be of a form that enables convenient coupling to a machine such as a crane, forklift, rope/cable pulley system, or storage rack. In general, handle101may be any suitable interface between the carrier device100and a separate means of lifting and/or supporting the device. For example, handle101may be a simple eye-hole for accepting a hook or a rope or it may be a threaded hole for accepting a variety of attachments or interfaces.

While the vertical offset between the bottom of channel103and the center of the handle101is short (e.g., as shown inFIGS. 1A and 2) compared to the height of the module (e.g., approximately 4″ from the bottom of channel103to the center of the handle101, as shown), the vertical offset may be longer as depicted in a carrier device100′ shown inFIGS. 10 and 11, for example. As an example, the length may be comparable to the typical length of a human arm from palm to shoulder (e.g., 24 inches). This may enable the user to maintain a relatively straight arm when lifting and carrying the module, making the weight of the module easier to bear.

With reference toFIGS. 10 and 11, carrier device100′ includes an arm brace, channel103′, and a handle101′. In one embodiment, an arm brace109, which is attached to carrier device100′, rests against the inside of the user's arm. This brace may help counteract the torque created by the horizontal offset and longer vertical offset, making it easier to carry for the user. The added lifting comfort of this longer vertical offset embodiment becomes even more important when carrier device100is enabled to couple to more than one module because the weight becomes more challenging for the user.

According to one embodiment, attachment device105may include an engagement device107(see e.g.,FIGS. 1E, 1F, and 4). In one example, engagement device107may comprise a positive-engagement device, which may include, for example, a spring-loaded member. Engagement device107may be configured to be displaced by frame104upon frame being positioned within channel103. Further, upon attachment (e.g., full engagement) of engagement device107to frame104, an audible and/or tactical feedback may be provided (e.g., to a user). The feedback may indicate to the user that the load of module102may be borne by carrier device100without disengaging. Engagement device107may also be configured to prevent carrier device100from detaching from solar module102if the user lets go of carrier device100(e.g., when module102is lowered to the ground). According to a specific embodiment, engagement device107may include a spring, such as, for example only, a metal torsion spring, to create friction against module frame104. The spring may comprise any suitable material. In one example, the spring may include a molded plastic spring.

Attachment device105may further include an anti-slip device108(see e.g.,FIGS. 1F and 4), which may be configured to limit, and possibly prevent, movement of module frame104in channel103. More specifically, anti-slip device108may limit, and possibly prevent, movement of module frame104in a first direction (indicated by arrow110; seeFIG. 3), and/or a second, opposite direction (indicated by arrow112; seeFIG. 3). This is particularly important if carrier device100is not balanced, for example, if carrier device100is not attached near the middle of an edge of frame104of module102, or if module102is bumped while carrying. Anti-slip device108may create friction between carrier device100and an edge of frame104. According to one embodiment, anti-slip device108may comprise a piece of rubber, foam, gel, and/or other high-friction material. In one example, the high friction material may deform under the weight of the module, increasing the friction.

According to one embodiment, anti-slip device108may comprise one or more sharp edges configured to contact, and possibly penetrate (e.g., “bite into”), at least a portion of an edge of module frame104. With reference toFIGS. 17 and 18, a penetration of one or more sharp edges160into module frame104is caused by the lifting force (i.e., in a direction noted by arrow164) and may create a deformation162in an edge of module frame104. Deformation162may create an interference laterally along the edge of module frame104and one or more of sharp edges160. The weight of the module may help maintain the position of the one or more sharp edges in a deformation even as a relative angle β between the lifting direction of handle101and the top frame of the module changes from substantially 90 degrees to more or less as shown inFIGS. 17 and 18. For example, angle β may decrease to substantially 60 degrees as a user lifts because carrier device100was not attached near the middle of the module frame.

Without the anti-slip device, the module frame may have a tendency to slip in the channel in the approximate direction as indicated by arrow167inFIG. 18. The interference between one or more sharp edges160and deformation162in module frame104may prevent frame104from sliding in channel103. A minimum angle before slippage may be determined by the weight of the module, the depth of the cut, the strength of the material of module frame104, one or more sharp edges160, and the angle of the cutting surface of one or more sharp edges160. One more sharp edges160may be made of a material that is stronger than a material of module frame104. Solar module frames are typically aluminum, so the one or more sharp edges160may comprise, for example, stainless steel. This difference in hardness (i.e., between module frame104and one or more sharp edges160) may minimize the deformation of one or more sharp edges160over time, which could lead to reduced effectiveness. In one example, anti-slip device108may include one or more threaded rods117aligned so that the axis of the one or more rods is parallel to the edge of module frame104(seeFIGS. 5A and 5B). In this non-limiting example, the threads119may be made of a material that is stronger than the material of module frame104and the “landing” width of the thread tip(s) in contact with the edge of module frame104is, for example only, ⅛ the thread pitch. Solar module frames are typically aluminum, so the rod may comprise, for example, stainless steel. This difference in hardness (i.e., between the module frame and the rod) may minimizes the deformation of the threads over time.

As noted above, housing106may comprise any suitable material, such as, for example only, plastic. In this example, the plastic supporting the threads tips on the far-side from the frame edge yields when first loaded (i.e., after being manufactured), but as the threads penetrate into the plastic, more plastic area is loaded, until equilibrium is reached at a stress level below yield, given that adequate total pin area is provided. Penetration of the threads into the plastic is beneficial in that it prevents the threaded pin from sliding unrestrained relative to the plastic.

The amount that the one or more sharp edges160or rod threads119penetrate (“bite”) into the module frame edge is not significant to the function or aesthetics of the module. For example, they typically penetrate (e.g., “bite”) in less than 0.1 mm and the penetrations (e.g., “bites”) are on the underside of the module102and so will typically not be seen once module102is installed in a system.

According to another embodiment, anti-slip device108may comprise a clamp configured to secure module102to carrier device100by pinching the module frame. For example, anti-slip device108may include an over-center cam configured to clamp the edge of the module frame (e.g., in response to a lifting force).FIGS. 12A and 12Billustrate one non-limiting example of a clamp140including a handle141, a frame142, and a cam144, which all pivot together about a base146. Base146includes a channel148that supports a solar module frame by outboard tabs150. Base146may also include a spring152, which when loaded, flexes laterally to pinch the solar module frame. A load to spring152may be delivered via a square post link, which in turn is connected to cam144. Thus, rotation of the assembly (i.e., handle141, frame,142, and cam144) in a first direction may clamp the solar module frame. Rotation in second, opposite direction may unclamp the solar frame. Rotation in the first direction may be induced by a vertical lifting action of handle141causing the assembly (i.e., handle101, frame,142, and cam144) to rotate and clamp the module.

FIG. 6depicts a portion of an attachment device105including a handle receiving portion114(i.e., a portion of attachment device105configured to couple to a portion of handle101). According to one embodiment, a center115of handle receiving portion114may be offset (e.g., horizontally) from the plane113of channel103(as indicated by line113). More specifically, with reference toFIG. 6, center115may be aligned in a lifting direction to the vertical angle of channel103. This alignment may reduce rocking of the edge of module frame104in channel103(e.g., when carrier device100is lifted and a user leans forward, which can create a feeling of insecurity for the user). In one example, this alignment is past the line of loading between the center115of handle receiving portion114and the center of gravity (“CG”) of solar module102(e.g., by ¼ inch). The resulting angle Θ (i.e., for the example handle geometry shown inFIG. 6) between the plane113of channel103, and the “handle plane” (i.e., the plane intersecting the anti-slip device threads' contact point(s) and a center of handle receiving portion114) is, for example only, approximately 2.2 degrees. In this specific example, the torque about the center of mass of solar module102is 42 lbf×(0.25 in)=10.5 lbf-in, which exceeds the resisting torque of engagement device (i.e., two torsion springs in this example), which has a torque of 2×7 lbf×0.45 in=6.3 lbf-in. This may force an edge of module frame104to the same angle in channel103that may occur when carrier device100is lifted and the user leans forward.

In another embodiment illustrated inFIGS. 13 and 14, carrier device100may include one or more wheels111configured to ride along a rail of a ladder129supporting part of the weight of module102. Carrier device100may further include one or more guides125that may maintain the position of wheels111centered on top of the ladder rails as carrier device100slides along ladder129. In one example, when combined with a rope and pulley system, this embodiment may provide a low cost means of hoisting a module to a roof without a user needing to be on a ladder. One end of rope may attach to handle101. The pulley may be mounted at the top of the ladder. The user may pull the other end of the rope to slide the module up the ladder.

With reference toFIGS. 8 and 15, in another embodiment, carrier device100may include a securing apparatus (also referred to herein as a “harness”)120configured to couple to at least one of handle101and attachment device(s)105. More specifically, harness120may include a latching mechanism for removably coupling to handle101, one or more attachment devices105, or both. In one embodiment, harness120may be permanently attached to handle101, one or more attachment devices105, or both. Harness120may be any suitable harness configured to couple to a user in a manner to free the user's arms and hands and move solar module102(e.g., climb a ladder or do other tasks). Thus, harness120can enable the user to maintain three points of contact (e.g., with a ladder). For example, harness120may include one or more straps122and may be worn like a backpack.

During one contemplated use, a user may lift handle101and module102over his/her shoulder and releases it onto the latching mechanism of harness120. Module102is consequently securely attached to the user's back and will not slip off. To remove the module, the user may reach over her/his shoulder or head, and grab and lift handle101to release handle101and module102from harness120. In one embodiment, harness120may include a waist belt124instead of, or in addition to, shoulder straps122.

With reference toFIGS. 15 and 16, during another contemplated use, a first user climbs a ladder with harness120and at least one module102secured to his/her back. When the first user reaches the top of the ladder a second user may grab handle101of carrier device100and lift module102off of the first user and on to a roof. In one embodiment, harness120includes a track121that guides the removal of module102by a second user. Track121may protect a head of the first user from getting hit by the bottom of module102as the second user pulls module102toward him/her. Track may include a lip123that may catch a bottom edge of module102and prevents it from sliding off of track121. The second user may then lift the weight of module102completely off of lip123. Track121may further include a means of resting on the ladder. This has the benefit of transferring the weight of module102as it is being slid along track121and resting in lip123onto the ladder so that the first user does not need to bear the full weight.

In one embodiment, as illustrated inFIG. 9, carrier device100may include a harness120′ and handle101. In one embodiment, one or both shoulder straps122′ of harness120′ may be ridged and may not be complete loops. Carrier device100may be lifted directly onto a user's shoulders or a user may squat under shoulder straps122′ and then stand to lift module102. This may eliminate the need for a reliable latch between handle101and shoulder straps122′. It may also eliminate the physical challenge of lifting a module over a user's shoulder, allowing the user to lift with his/her legs rather than his/her arms.

In one embodiment, harness120/120′ may include one or more surfaces131(seeFIG. 15) that extend downward below a bottom of module frame104. This may provide a surface for the bottom frame to rest against so that it does not rest instead on the back of the user's legs or buttocks.

If a user is climbing a ladder with carrier device100and harness120on his/her back, wind may catch the large surface area of module102and cause a force that could cause a user to lose his balance or grasp of the ladder. A wind vector coming from the side sees a small module surface area and therefore will have little impact on the user. A wind vector that has a large force component perpendicular to the outer face of module102may tend to push the user into the ladder, which may be uncomfortable for the user, but may not be dangerous. However, a wind vector that has a large component perpendicular to the underside of module102(i.e., the side of the module facing the user) can tend to push the module and user away from the ladder potentially creating a dangerous condition in which, for example, the ladder pulls away from the roof eve, or the user loses his/her grip on the ladder. In other embodiments, the present disclosure includes a wind force abatement device configured to allow module102to align itself at least partially parallel to the wind direction so as to reduce the force of the wind acting on the user via module102and harness120.

With reference toFIGS. 19 and 20, in one example, a wind force abatement device180may include a hinge aligned axially with module frame104and/or handle101. Any wind force vector component (e.g., as indicated by arrow185) that may be substantially perpendicular to the underside of module102(i.e., the side of the module facing the user) that overcomes the downward torque caused by weight of module102, may rotate the module about the hinge. Eventually, as module102(and attachment device(s)) rotates about the hinge, the wind vector component perpendicular to the underside of the module102may be reduced. Module102may stop rotating when equilibrium is reached. When the wind stops, module102may rotate back down to being flush with the user's back. Wind force abatement device thus reduces the wind forces acting on the user. Wind force abatement device180may be a hinge (e.g., a door or cabinet hinge) or a flexible member (e.g., nylon webbing material, rubber, or flexible plastic). In another example, the hinge is created by a strap of nylon webbing material that is looped around handle101and secured (e.g., by Velcro) to itself or to harness120.

In addition to module carriers configured for attaching to a frame of a solar module, various embodiments of the present disclosure are related to module carriers configured for attaching to one or more frameless modules (i.e., a module that does not have a frame around an outer edge of the module). As will be understood, frameless modules may include solar cells sandwiched between two pieces of glass. One example frameless modules is a glass-glass module, which includes glass on a top side of the module and glass on an underside of the module, in addition to (or in place of) a typical polymer backsheet.

According to one embodiment, a carrier device may be configured to secure a module by “pinching” the module. Stated another way, for example, a carrier device may create opposing forces on opposite surfaces of a module (e.g., a top major axis surface and bottom major axis surface). In one embodiment, the carrier device may include a compliant material, such as rubber, configured to contact one or surfaces of the module (e.g., to further increase friction).

FIGS. 21A and 21Bdepict a carrier device200, according to one embodiment of the present disclosure.FIG. 21Ais a side view (major-axis view) of carrier device200, andFIG. 21Bis end view (minor-axis view) of carrier device200. Carrier device200, which may also be referred to herein as a “clamp,” may include a handle201and a plurality of arms205. Carrier device200may further include a fastening device209, such as a bolt, a screw, or the like. Each arm205of carrier device200may include a compliant material204for contacting one or more surfaces of a module202. As a non-limiting example, compliant material204may comprise rubber.

In one example, each arm205may be configured to rotate about handle201. More specifically, one or more arms205may be rotated to enable module202to be positioned between arms205. Further, one or more arms205may be rotated to “pinch” module202(i.e., between two or more arms205). As will be appreciated, each arm205may be configured to apply a pressure against a surface of module202. More specifically, for example, arm205A may be configured to apply pressure in a first direction (i.e., as indicated by arrow206A), and arm205B may be configured to apply pressure in a second, opposite direction (i.e., as indicated by arrow206B).

Fastening device209may be configured for securing a position of arms205relative to one another to maintain an adequate amount of pressure one each surface of module202. Collectively, arms205, and possibly fastening device209, may be referred to herein as an “attachment device.”

Another carrier device300is illustrated inFIGS. 22A and 22B.FIG. 22Ais a side view (major-axis view) of another carrier device300, andFIG. 22Bis end view (minor-axis view) of carrier device300. Carrier device300includes a handle301and an arm303for being secured to module202(e.g., a frameless module). Arm303may extend from one surface (e.g., a first minor surface) of module202to an opposite surface (e.g., a second, opposite minor surface) of module202. Further, the module carrier may include one or more channels307configured to capture at least a portion of an end of module202. Further, module carrier300may include one or more tabs305for securing module202within channels307. Module carrier300may be configured to provide a lifting force to carry the weight of a solar module.

As will be understood by a person having ordinary skill in the art, a frameless module may be susceptible to damage, especially at the corners. Another embodiment includes a carrier device that may provide protection to a module. With reference toFIGS. 23A and 23, a carrier device400, according to an embodiment of the present disclosure, is illustrated.FIG. 23Ais a side view (major-axis view) of carrier device400, andFIG. 23Bis end view (minor-axis view) of carrier device400. Carrier device400includes handle401, one or more arms403, and one or more covers405. Each cover405may be configured to at least partially cover a corner of module202(e.g., to provide protection for the corner) positioned in a channel407. It is noted that carrier device400may include a plurality of handles401, which may enable one or more individuals to carry a solar module.

Embodiments of the present disclosure include a relatively low-cost device that may relieve stress, strain, and safety risks associated with carrying solar modules. Further, embodiments of the present disclosure may reduce the labor costs associated with moving solar modules. Further, the embodiments described herein may enable a user to carry a module up a ladder while maintaining three points of contact, as recommend by OSHA.

Although the foregoing description contains many specifics, these should not be construed as limiting the scope of the disclosure or of any of the appended claims, but merely as providing information pertinent to some specific embodiments that may fall within the scopes of the disclosure and the appended claims. Features from different embodiments may be employed in combination. In addition, other embodiments may also be devised which lie within the scopes of the disclosure and the appended claims. The scope of the disclosure is, therefore, indicated and limited only by the appended claims and their legal equivalents. All additions, deletions and modifications to the disclosure, as disclosed herein, that fall within the meaning and scopes of the claims are to be embraced by the claims.