Abstract:
A floating support structure for a solar panel array having flotation elements and a support structure disposed above the flotation elements for adjustably and removably mounting at least one solar collector panel. Connectors joining floatation elements form a platform for gangways and catwalks providing access for installation, repair, and maintenance, even when the solar panel array is installed on a body of water.

Description:
CROSS REFERENCE TO RELATED APPLICATIONS  
       [0001]     The present application is a continuation-in-part of U.S. Utility patent application Ser. No. 11/264,285, filed 10/31/2005 (Oct. 31, 2005), which claims the benefit of U.S. Provisional Patent Application, Ser. No. 60/623,328, filed 10/29/2004 (Oct. 29, 2004). 
     
    
     STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT  
       [0002]     Not applicable.  
       REFERENCE TO A MICROFICHE APPENDIX  
       [0003]     Not applicable.  
       TECHNICAL FIELD  
       [0004]     The present invention relates generally to photovoltaic power systems, and more particularly to support structures for solar photovoltaic collector panels, and still more particularly to a modular floating support structure for a solar panel array.  
       BACKGROUND INFORMATION AND DISCUSSION OF RELATED ART  
       [0005]     With a few exceptions, solar panel support structures are almost invariably adapted for installation of a solar panel on the ground or a rooftop. Notable exceptions include support frameworks for mounting solar panels on vehicles and boats, and more exotic uses may even call for an installation with no support framework, such as with small glue on/screw on thin solar panels for use in extreme environments.  
         [0006]     Rooftop solar arrays require the modification of the rooftop structure, can be dangerous and difficult to work on, and provide only a limited footprint. On the other hand, land is increasingly expensive and may be exploited for a number of purposes other than solar array installation. Additionally, the amount of land required for a solar array that generates a significant amount of electrical power can be considerable. Accordingly, because bodies of water comprise two thirds of the surface area of the earth, and because many large areas of water surfaces have no critical uses that cannot be provided for elsewhere, it may be desirable to dedicate large surface areas of water to the collection of solar energy and the conversion of solar energy to electricity.  
         [0007]     There is as yet no known art showing suitable flotation elements for installing and deploying a large solar array on a body of water.  
       BRIEF SUMMARY OF THE INVENTION  
       [0008]     The present invention is a floating support structure for solar collectors. The invention provides for water-mounting of an array of solar panels with no ground mounts, roof mounts, minimal materials and minimal labor in installation. In addition, the invention includes a pre-angled mounting component for tilting the array (herein after referred to as “framework”) at a desired angle for best collection of solar radiation (e.g., 20 degrees). It also provides for transverse angling of the entire array on water, which incorporates posts mounted vertical and separately.  
         [0009]     The inventive apparatus comprises a number of lightweight elongate tube elements that can be assembled at the time of manufacture. Alternatively, because the tubular elements are easily stacked and compactly stored, the assembly elements can be transported to an installation site and assembled at the site.  
         [0010]     It is therefore an object of the present invention to provide a new and improved modular floating support structure for a solar panel.  
         [0011]     It is another object of the present invention to provide a new and improved floating support structure for a solar panel array that may be connected to other like modules to form an array.  
         [0012]     A further object or feature of the present invention is a new and improved floating structure for a solar panel array that permits solar panels to be tilted for optimum solar energy collection while afloat.  
         [0013]     An even further object of the present invention is to provide a novel floating structure for a solar panel array that is lightweight and easily transported to and assembled at or near an installation site.  
         [0014]     There has thus been broadly outlined the more important features of the invention in order that the detailed description that follows may be better understood, and in order that the present contribution to the art may be better appreciated. Additional objects, advantages and novel features of the invention will be set forth in part in the description as follows, and in part will become apparent to those skilled in the art upon examination of the following. Furthermore, such objects, advantages and features may be learned by practice of the invention, or may be realized and attained by means of the instrumentalities and combinations particularly pointed out in the appended claims.  
         [0015]     Still other objects and advantages of the present invention will become readily apparent to those skilled in this art from the following detailed description, which shows and describes only the preferred embodiments of the invention, simply by way of illustration of the best mode now contemplated of carrying out the invention. As will be realized, the invention is capable of modification in various obvious respects without departing from the invention. Accordingly, the drawings and description of the preferred embodiment are to be regarded as illustrative in nature, and not as restrictive. 
     
    
     BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS  
       [0016]     The invention will be better understood and objects other than those set forth above will become apparent when consideration is given to the following detailed description thereof. Such description makes reference to the annexed drawings wherein:  
         [0017]      FIG. 1  is a perspective view of the modular floating support structure of the present invention, shown supporting two solar panels;  
         [0018]      FIG. 2i s a front view in elevation thereof;  
         [0019]      FIG. 3  is a rear view in elevation thereof;  
         [0020]      FIG. 4  is a side view in elevation thereof;  
         [0021]      FIG. 5i s a side view in elevation of a plurality of the modular floating support structures showing how such structures may be connected and deployed in a floating solar panel array;  
         [0022]      FIG. 5A  is a perspective view showing a bar with carabineers disposed at its ends as used to connect adjacent modules at their respective sides;  
         [0023]      FIG. 6  is a top view showing a plurality of the inventive modular support structures connected in an array;  
         [0024]      FIG. 7  is a side view in elevation of a second preferred embodiment of the present invention, showing an individual floatation element and a solar panel mounted thereto;  
         [0025]      FIG. 7A  is a rear view thereof;  
         [0026]      FIG. 7B  is a side view in elevation of a solar panel array mounted on a plurality of the floatation and support elements shown in  FIGS. 7 and 7 A;  
         [0027]      FIG. 8  is a top plan view thereof, the floatation elements being shown with phantom lines;  
         [0028]      FIG. 9  is a side view in elevation of the floatation element of the second preferred embodiment showing the structural components in phantom;  
         [0029]      FIG. 10  is an end view in elevation of the exterior interior portion of the end cap for the floatation element of the second preferred embodiment, shown along line  10 - 10  of  FIG. 11 ;  
         [0030]      FIG. 11  is a cross-sectional side view in elevation showing the end cap, exterior and interior tubes, and mounting apertures of the floatation element, the view taken along section line  11 - 11  of  FIG. 10 ;  
         [0031]      FIG. 12  is an end view in elevation of the interior side of the floatation element end cap viewed from line  12 - 12  of  FIG. 13 ;  
         [0032]      FIG. 13  is a cross-sectional side view in elevation of the end cap and tube elements taken along section line  13 - 13  of  FIG. 12 ;  
         [0033]      FIG. 14  is an upper left front perspective view showing a third preferred embodiment of the modular floating support structure of the present invention, shown supporting an array of solar panels;  
         [0034]      FIG. 15  is an upper left perspective of the modular floating support structure and solar panels as shown in  FIG. 14 ;  
         [0035]      FIG. 16  is a top plan view of the inventive apparatus supporting a large array of solar panels;  
         [0036]      FIG. 17A  is a cross-sectional side view in elevation of the inventive apparatus taken along section line  17 A- 17 A of  FIG. 16 ;  
         [0037]      FIG. 17B  is a cross-sectional side view in elevation of the inventive apparatus taken along section line  17 B- 17 B of  FIG. 16 ;  
         [0038]      FIG. 18  is an upper front left perspective view showing detail of the terminal end of the lateral gangway joining elements of the modular floating support structure of the present invention, taken along detail line  18  of  FIG. 14 ;  
         [0039]      FIG. 19  is an upper rear left perspective view of the other terminal end of the lateral gangway, taken along detail line  19  of  FIG. 15 ;  
         [0040]      FIG. 20  is an upper perspective view of an alternative floatation element for the inventive apparatus;  
         [0041]      FIG. 21  is an exploded view showing the floatation element of  FIG. 20 ;  
         [0042]      FIG. 22  is a cross-sectional end view in elevation taken along section line  22 - 22  of  FIG. 20 ;  
         [0043]      FIG. 23  is a cross-sectional side view in elevation showing a fourth preferred embodiment of the floatation element of the present invention; and  
         [0044]      FIG. 23  is a cross-sectional side view in elevation of a fifth preferred embodiment of the floatation element. 
     
    
     DETAILED DESCRIPTION OF THE INVENTION  
       [0045]     Referring to  FIGS. 1 through 23 , wherein like reference numerals refer to like components in the various views, there is illustrated therein a new and improved modular floating support structure for a solar panel array, the first preferred embodiment of which is generally denominated  100  herein.  
         [0046]      FIG. 1  is a perspective view of the first preferred embodiment of the modular support structure, while  FIGS. 2, 3 , and  4  are, respectively, front, back, and side elevation views of the module of  FIG. 1 . Collectively, these views show that this basic modular component of a floating array comprises first and second elongate flotation elements  110 ,  120 , preferably substantially cylindrical pontoons, each having connector tubes  130 ,  140 , and  150 ,  160 , extending longitudinally from each end of the pontoons. Preferably the connector tubes are round in cross section, and their respective distal ends include front and rear connection means, preferably connector rings,  170 ,  190 , and  180 ,  200 , respectively. The front connector rings  170 ,  190  are disposed generally perpendicular to the rear connector rings  180 ,  200 , and either the front or rear connector rings or both are provided with a hinge element that allows the rings to capture rings in an adjacent module, in the manner of a tubular carabineer. Effectively, then, one set of connector rings comprises rigid connector rings, while the complementary set of connector rings comprises carabineers that attach to the rigid connector rings. As with carabineers, it is well known to provide locking means to prevent the hinge element in the carabineer from inadvertently opening. Such structures considered obvious design choices and are contemplated within the scope of the present invention.  
         [0047]     Straddling the ends of each flotation element are angled upright supports,  210 ,  220 , and  230 ,  240 , glued, welded, bolted, or otherwise affixed at their lower ends to the connector tubes extending longitudinally from the flotation element, or to the flotation elements themselves, and which angle inwardly toward one another to join or substantially join at their respective upper ends,  250 ,  260 , and  270 ,  280 . The angled uprights are preferably fabricated from square tubing. The manufacturing means may be adapted to the anticipated installation, as welding or gluing may provide a sturdier structure with greater durability, but assembly with nuts and bolts may allow for easy transportation for assembly at an installation site.  
         [0048]     Spaced apart parallel plates  290 / 300 , and  310 / 320 , may be glued, welded, bolted, or otherwise rigidly affixed to the opposite sides of the uprights at or near the junction of the upper ends of the angled uprights to provide increased structural integrity. Additionally, the plates may be provided with holes in which to journal the ends  330 ,  340  of a rotatable panel frame mounting tube  350 . Two or more additional transverse tubes  360 ,  370 , may be disposed between, and connected to, the angled uprights, so as to make a generally rigid framework structure. Adjustment/locking means  380  may be provided to permit selective release, rotation, and re-locking of the mounting tube. A number of suitable devices can be provided, including hole and nipple assemblies, pawl and ratchet, locking collar and ring, and the like. The drawings show a pawl and ratchet assembly as an illustrative mechanism.  
         [0049]     The rotatable panel frame mounting tube can be provided with a plurality of support rails  390  on which to fasten and secure one or more solar photovoltaic panels  400 .  
         [0050]     The module framework may also be provided with side connector rings  410 ,  420 ,  430 ,  440 , disposed along each of the sides of the support structure. While only one side connector ring need be provided for each side of the support structure, and may be positioned anywhere along the length of the flotation element or connector tubes, it is preferable to have two side connector rings, one each extending outwardly from a each front and rear connector tube. Referring now to  FIG. 5A , side connector bars  450 , having hinged carabineers connector rings  460 ,  470  at each end may then be provided as means for joining the sides of adjacent support modules in a floating solar panel array  500  (see  FIGS. 5 and 6 ). As an alternative, a side connector bar may be provided for installation between the front or rear connector ring of an adjoining support structure, so that no additional rings need be provided to ensure that the spacing between floating modules is fixed.  
         [0051]      FIGS. 5 and 6  show the modules of  FIGS. 1-4  connected with the above-described connector rings and side connector bars to form a floating solar panel array  500 . The support modules are preferably spaced in accordance with ambient wave conditions of the body of water in which the installation will be deployed. Thus, the sizing and weight distribution of each module, and the spacing of modules relative to one another, can be tailored to minimize roll, pitch, yaw, heave, surge and sway under the wave conditions most likely to be encountered in the particular environment of use.  
         [0052]      FIGS. 7-13  show a second preferred embodiment  700  of the modular floating support structure for a solar panel array of the present invention. In this alternative embodiment, the floatation elements  710  comprise an outer tube  720  having an interior wall  730  and an exterior surface  740 , an inner tube  750  having an interior wall  760  and an exterior surface  770  spaced apart from the interior wall of the outer tube, and polygonal end caps  780  welded to the ends of the outer and inner tubes so as to create a watertight and airtight seal over first and second air chambers  790 ,  800 .  
         [0053]     The end caps  780  are preferably polygonal when viewed on end (see  FIG. 7 ), and are conformed on an interior surface with an inner socket  810  which tightly fits over, captures, and retains an end of the inner tube  750  when welded, and an outer socket  820  which tightly fits over, captures, and retains an end of the outer tube  720  when welded. The top side  830  of the end caps essentially comprise a mounting platform which include apertures  840 , preferably threaded, for accepting mounting bolts  850  to be employed in fastening the solar panel mounting structures.  
         [0054]     The foundation of the mounting structures includes front and back lowermost structural channel  860  preferably aluminum extrusions, which are mounted on the top side of the floatation elements with mounting bolts  850  and span transversely across the top sides of the floatation elements to join each adjacent pair into a structural foundation for one or more solar panels  870  in a solar panel array  880 .  
         [0055]     The second elements in the mounting structure include front and rear longitudinal structural channels  890 ,  900 , which are removably mounted onto the lowermost structural channels  860  in a generally perpendicular orientation. A front foot  910 , preferably bent solid bar, is removably mounted on the front longitudinal structural channel  890 . A back modified queen post truss  920 , with or without interior vertical supports, and also preferably bent solid bar, is removably mounted on the rear longitudinal structural channel  900 . The truss includes a horizontal keystone portion  930  having apertures (not shown) for passing bolts  940  to removably mount a rear foot  950 , also preferably bent sold bar. Front and rear panel rails  960 ,  970 , attached to and disposed on the underside of each of the solar panels, are attached to the front foot and rear foot, respectively.  
         [0056]      FIGS. 14-19  show a third preferred embodiment  1400  of the modular floating support structure for a solar panel array of the present invention. In this embodiment each of the floatation elements  1410  comprises a single substantially cylindrical tube or pipe  1420  covered with a welded cap  1430  at each end to form a watertight and airtight seal, as is well known in the art. The tubes are preferably fabricated from readily available PVC, HDPE, ABS, CPVC tubing material, though numerous other watertight materials would be perfectly suitable.  
         [0057]     Mounting elements are disposed along the length of the floatation elements and proximate the ends. These structures include a slightly flexible metal band  1440  having ends  1450  with bolts  1460  extending therefrom. A mounting bracket  1470  is provided for placement over the top portion  1480  of the cylindrical pipe  1420 . The mounting bracket  1470  includes a mounting post  1480  having an angled top  1490  with apertures for passing mounting bolts on which to connect panel rails  1500  disposed on the underside of solar panels  1510 . The mounting brackets further include downwardly angling shoulders  1520  each having a horizontally extending tab  1530  with apertures for passing the bolts  1460  on the ends of band  1440 . When bolts  1460  are tightened onto tabs  1530 , the band and mounting bracket form a clamp over the cylindrical floatation element. The shoulders  1520  of the mounting bracket each also include an integral or welded reinforcement bar  1540  having an aperture  1550  for passing a fastener to join a connector bar  1560  between mounting brackets. The connector bars may be structural channel, solid bars, round or rectangular tubes, or other suitably strong elongate connector.  
         [0058]     In the above-described and illustrated configuration, the floatation elements, mounting brackets, and connector bars provide a platform for mounting axially disposed gangways  1570 , which are placed over the connector bars and provide access to the panels disposed along the length of the floatation elements, even when the apparatus is floating in deep water. Referring now to  FIG. 15 , it is seen that these elements combine to form discrete modular systems  1580 ,  1590 ,  1600 ,  1610  of the floating apparatus of the present invention. The gangways maybe employed as connectors and when joined end-to-end with another gangway connect adjacent floating modules.  
         [0059]     The third preferred embodiment of the inventive floating support structure for a solar panel array also includes a catwalk  1620  disposed over a plurality of floatation elements proximate their respective ends, or between any set of mounting brackets anywhere along the length of the floatation elements where solar panels are not mounted. The catwalk is disposed over mounting bars  1630 , preferably extruded aluminum structural channel or steel channel, which extend between mounting brackets  1470 . At a first end  1640  the catwalk is firmly attached to a mounting bar. A second end  1650  includes casters  1660  having a small amount of travel in a channel  1670  attached to a mounting bar. This provides some accommodation to movements caused by surface waves on the water. Either the catwalk or any one of the gangways may be joined to a dock to provide access from land to the floating array.  
         [0060]      FIGS. 20-22  show a fourth alternative embodiment  2000  of the floatation element of the present invention. In this embodiment, the pontoon comprises doubled walled corrugated pipe having a channel or slot  2010  in each end  2020 . A cylinder of foam  2030  covered by a watertight bag  2040  is inserted into the pipe and a cap  2050  placed on the end to form a watertight seal. Mounting apparatus described in connection with the third preferred embodiment may be employed for supporting a solar panel array.  
         [0061]      FIG. 23  shows a fifth preferred embodiment of the floatation element. In this embodiment, pipe  2300  is cut along its length to provide an axial opening into which a foam insert  2310  is wedged and captured by resilient ends  2320 . Again, mounting apparatus as described in connection with the third preferred embodiment may be employed for supporting a solar panel array. Alternatively, mounting apparatus may be fastened (e.g., by bolts) directly to the upper portion  2330  of the cut pipe.  
         [0062]     As will be appreciated by those with skill in the art, a number of suitable materials may be employed for the tubing and flotation elements of the support structure of the present invention for either of the preferred embodiments, including fibre glass, ABS, HDPE, PVC, CPVC, and the like, as well as composite materials, metals and metal alloys, and so forth. The various components need not be fabricated from the same material, and some combination of plastic, composite, and/or metal may be preferable.  
         [0063]     The flotation element used in the present invention—i.e., the pontoon—is preferably sealed and may be left either with an unfilled void or it may be filled with polyethylene foam, polystyrene foam, or the like.  FIGS. 13-15  show a possible floatation element configuration suitable for use in the present invention. This includes a corrugated cylindrical pipe, a foam insert having a watertight sealed plastic cover bag, and a cap at each end.  
         [0064]     The above disclosure is sufficient to enable one of ordinary skill in the art to practice the invention, and provides the best mode of practicing the invention presently contemplated by the inventor. While there is provided herein a full and complete disclosure of the preferred embodiments of this invention, it is not desired to limit the invention to the exact construction, dimensional relationships, and operation shown and described. Various modifications, alternative constructions, changes and equivalents will readily occur to those skilled in the art and may be employed, as suitable, without departing from the true spirit and scope of the invention. Such changes might involve alternative materials, components, structural arrangements, sizes, shapes, forms, functions, operational features or the like.  
         [0065]     Therefore, the above description and illustrations should not be construed as limiting the scope of the invention, which is defined by the appended claims.