Abstract:
A structure and support member for photovoltaic arrays is provided. The member provides a structural connection between photovoltaic modules, wind deflectors and similar hardware. The invention provides an advantage of quick and easy installation of hardware components and associated parts, and meets the demand for a single device capable of combining solar energy associated hardware into photovoltaic arrays.

Description:
CROSS REFERENCE TO RELATED APPLICATIONS 
       [0001]    This application claims priority to U.S. Provisional Patent Application No. 62/365,062, filed on Jul. 21, 2016, and U.S. Provisional Patent Application No. 62/371,924, filed Aug. 8, 2016, both of which are relied upon and incorporated herein in their entirety by reference. 
     
    
     FIELD OF INVENTION 
       [0002]    This invention generally relates to photovoltaic arrays, and more particularly to a structure and support member for photovoltaic (PV) arrays and associated hardware. 
       BACKGROUND OF THE INVENTION 
       [0003]    A photovoltaic (PV) installation typically includes a collection of photovoltaic modules combined and placed in a support structure that houses each of the photovoltaic components to form a photovoltaic array. Typically, photovoltaic arrays are placed in an outdoor location to be exposed to sunlight and wind conditions. To promote optimal collection of solar energy, PV modules are mostly installed with an angled/tilted orientation. Further, because PV modules may become damaged by extreme weather conditions, wind deflectors are routinely installed aside to prevent wind from penetrating underneath the PV array. Installing optimally oriented PV modules and associated wind deflection devices often requires a significant number of hardware components to effectively combine and secure the PV modules in a PV array. Installing a significant number of hardware components is often costly and time consuming. 
         [0004]    Given the aforementioned challenges, it is desirable to have a single hardware component that may be used for combining PV modules and associated components in PV arrays. 
       SUMMARY OF THE INVENTION 
       [0005]    Photovoltaic (PV) arrays routinely require hardware to support construction and installation. Embodiments of the present invention provide a structure and support member for use with PV arrays and wind deflectors that reduces the cost and time associated with installation of both components. 
         [0006]    In an embodiment of the present invention, a structure and support member is provided. The structure and support member features attachment components and surface areas for securing multiple PV modules, wind deflectors and/or similar hardware in a PV array. 
         [0007]    These and other objects and advantages of the invention will become apparent from the following detailed description of the preferred embodiment of the invention. Both the foregoing general description and the following detailed description are exemplary and explanatory only and are intended to provide further explanation of the invention as claimed. 
         [0008]    The accompanying drawings are included to provide a further understanding of the invention and are incorporated in and constitute part of this specification, illustrate several embodiments of the invention that together with the description serve to explain the principles of the invention. 
     
    
     
       BRIEF DESCRIPTION OF THE FIGURES 
         [0009]      FIG. 1  is a top perspective view of a structure and support member for photovoltaic arrays according to aspects of the present invention. 
           [0010]      FIG. 2  is perspective view of an assembly with a wind deflector installed on the structure and support member of  FIG. 1  in the middle of a photovoltaic array according to aspects of the present invention. 
           [0011]      FIG. 3  is a perspective view of a see-through wind deflector and the assembly of  FIG. 2 . 
           [0012]      FIG. 4  is a perspective view of a PV array assembly with a wind deflector, the structure and support member of  FIG. 1 , and a single tilt photovoltaic module according to aspects of the present invention. 
           [0013]      FIG. 5  is a perspective view of a PV array assembly with a wind deflector, the structure and support member of  FIG. 1 , and two tilted photovoltaic modules according to aspects of the present invention. 
           [0014]      FIG. 6  is a profile view of a structure and support member for PV arrays according to an aspect of the present invention. 
           [0015]      FIG. 7  is a perspective top view of the structure and support member of  FIG. 6 . 
       
    
    
     DETAILED DESCRIPTION OF THE INVENTION 
       [0016]    Embodiments of the invention will be described more fully hereinafter with reference to the accompanying drawings, in which embodiments of the invention are shown. This invention may, however, be embodied in many different forms and should not be construed as limited to the embodiments set forth herein; rather, these embodiments are provided so that this disclosure will be thorough and complete, and will fully convey the scope of the invention to those skilled in the art. 
         [0017]    In the following description, numerous specific details are set forth. However, it is to be understood that embodiments of the invention may be practiced without these specific details. In other instances, well-known methods, structures and techniques have been shown in detail in order not to obscure an understanding of this description. 
         [0018]    The present invention, as shown in  FIGS. 1-7 , is directed towards a structure and support member  100 / 300 . The structure and support member  100 / 300  is configured to provide structure and support to components, including, but not limited to photovoltaic panels, racking components, wind deflectors, ballast pans, roof anchors, and the like commonly used in solar mounting systems. In an aspect, the structure and support member  100 / 300  can be constructed from aluminum extrusion. In another aspect, the member  100 / 300  could be constructed from welded aluminum, welded steel, laid-up fiberglass, injection molded plastic or any other suitable method and material know in the art that is durable and can prevent failing from exposure to natural elements. 
         [0019]    In an aspect, as illustrated in  FIGS. 1-5 , the structure and support member  100  comprises a semi-rectangular frame formed from two side members  102  and  103  extending upward from a base  104  in a slightly angled fashion, as shown In  FIG. 1 . In an exemplary aspect, the side members  102  and  103  are oriented at an angle that corresponds to the lowest practical wind speeds as determined in wind tunnel testing with member  100 . The base  104  provides a support surface for the member  100  when installed atop roofs or similar locations due to the weight/force of associated components (e.g. PV modules). In an aspect, the structure and support member  100  is secured to a mounting surface via the base  104 . In an aspect, the structure and support member  100  can be ballasted in place with commonly available concrete blocks. In another aspect, the structure and support member  100  can be anchored to a roof using known fastening means, including, but not limited to, brackets, fasteners, bolts, and the like. The structure and support member  100  features stabilizers  104   a  and  104   b  that extend, respectively, from the left and right sides of the base  104 . In an aspect, stabilizers  104   a  and  104   b  feature intersecting members  105   a  and  105   b  that are perpendicular to the stabilizers  104   a  and  104   b . In an aspect, the intersecting members  105   a  and  105   b  can be used to attach railing components, mountings, racking components, ballast support, roof anchors, or any other similar hardware know in the art. 
         [0020]    The top portion of member  100  features two equal length, angled inward, protrusions  106  and  107 . Protrusions  106  and  107  both feature raised module interfaces  106   a  and  107   a  in their respective centers that run the length of the protrusions. The module interfaces  106   a  and  107   a  provide a surface area to which PV modules abut when combined into a PV array. The surface area helps to restrict movement of the PV modules and provide structural integrity to the overall construction of a PV array. In addition to the restriction, the surface area aids in locally stabilizing the array during installation before the modules are permanently attached. The module interfaces  106   a  and  107   a  each feature apertures  106   b  and  107   b  that are configured to receive fasteners used to secure the PV modules. The apertures  106   b ,  107   b  receive nuts or studs, or extruded features that are designed to interface with existing or future module clamps or other securing fasteners. 
         [0021]    The angled protrusions  106  and  107  interact with a center structure  108  centered in the top portion of the member  100 . In an aspect, the center structure  108  is V-shaped, forming a roof-like structure. The V-shaped center structure  108  is configured to hold wiring or cable management of hardware or trays. In other embodiments, the center structure  108  can feature any other shape suitable to enable desired orientation of PV modules, wind deflectors and/or associated components. In other embodiments, center structure  108  of the structure and support member  100  can have other shapes. 
         [0022]    The center structure  108  features arms  108   a  and  108   b  that extend above the angled protrusions  106  and  107 . In an aspect, one arm  108   b  features an angled, flat surface area  108   c  with a stud  108   d  extending from its center. In an aspect, the stud  108   d  can be a threaded stud  108   d  received by a hole (not shown) in the flat surface area  108   c . In other aspects, the stud  108   d  can be an extruded feature into which a screw or snap-on fastener or connector is inserted. In other embodiments, arm  108   a  can also feature a flat surface area with a stud extending from the surface area. In an aspect, the stud  108   d  is centered in the middle of the surface area  108   c ; however, it can be oriented in a variety of locations as deemed desirable. The surface area (e.g.  108   c ) provides a contact area to which a wind deflector  200  ( FIG. 2 ) may rest/abut while being held in place by the peg (e.g.  108   d ). The stud  108   d  is configured to mate with slot  200   a  ( FIG. 2 ), or any similar structure typically found on wind deflectors or related components, such that the mating of the stud  180   d  and slot  200   a , and in some cases another securing means, secures the wind deflector in place. In an aspect, the stud  108   d  can be threaded, with a nut bolt being used as the other securing means. In other embodiments, hitch pins, push-on fasteners, and the like can be used. 
         [0023]    In an aspect, one of the side members  103  features a first extension  109 . In an aspect, the first extension can be a rectangular flat-surface extension  109 , the flat-surface extension  109  located approximately two-thirds the length of the side member  103  from the base  104 . The rectangular flat-surface extension  109  extends from the side member  103  angled at a degree complimentary to the angled flat surface area  108   c . The rectangular flat-surface extension  109  provides a contact area to support a wind deflector  200  as it rests/abuts the extension  109 . In other embodiments, in order to provide a more versatile member  100 , the side member  102  can also be configured to match the design of side member  102  such that either side member can support/interact similar components/hardware. 
         [0024]    In an aspect, the side member  103  extending from the base  104  features a second extension  110  located approximately one-third the length from the bottom of the side member  103 . The second extension  110  intersects perpendicularly with an angled support surface  111 . In an aspect, the angled support surface  111  is approximately the same width of the side member  103 . In an aspect, the angled flat surface  111  is co-planar to the angled flat surface area  108   c . In an aspect, the location of the extension  110  with its angled support surface  111  and the flat surface area  108   c  are arranged to facilitate wind deflector stability by lowering the wind loads on the wind deflectors. The angled support surface  111  can include a peg  111   a  located at the center of the surface  111 ; however, the peg  111   a  can be oriented in a variety of locations as deemed desirable. The angled support surface  111  provides a contact area to which a wind deflector  200  ( FIG. 2 ) can rest/abut while being held in place by a peg  111   a , with the peg  111   a  mating with slot  200   b  ( FIG. 2 ), or any similar structure typically found on wind deflectors or related components, such that the mating of the peg and slot secures the wind deflector in place. 
         [0025]      FIGS. 2-3  illustrate a solar assembly  10  using a structure and support member  100  with a wind deflector  200  installed in the middle of PV array  210  according to aspects of the present invention. The PV array features three PV modules,  211 ,  212  and  213  interconnected by the structure and support member  100 , with a wind deflector  200  installed in an angled fashion. The PV modules  211 ,  212 , and  213  are supported by module interfaces  106   a  and  107   a  the angle protrusions  106  and  107  of the member  100 . As discussed above, slots  200   a ,  200   b  of the wind deflector  200  can receive pegs  108   d ,  111   a  that secure the wind deflector  200  on the structure  100 . Further, the angled, flat surface area  108   c , the rectangular flat-surface extension  109 , and the angled support surface  111  provide the support for the wind deflector  200 . 
         [0026]      FIG. 4  is a PV array assembly  20  with a member  100 , a single tilt photovoltaic module  211  and a wind deflector  200  according to aspects of the present invention. The PV module  211  in a single tilt PV array is generally oriented such that the module  211  is south facing in the northern hemisphere east and west facing to promote optimal collection of sun radiation energy. As shown, the PV module  211  is supported by a module interface  106   a  of an angled protrusion  106  of the member  100 . The wind deflector  200  is supported by the flat surface area  108   c , the extension  109 , and the angled support surface  111 . 
         [0027]      FIG. 5  is a PV array assembly with a member  100 , two tilted photovoltaic modules  211  according to aspects of the present invention. The PV modules  211  in a dual tilt PV array  210  are generally oriented such that the modules are east and west facing in the northern hemisphere to promote optimal collection of sun radiation energy. Similar as shown in  FIGS. 2-3 , the PV modules  211  are supported by the module interfaces  106   a ,  107   a  of the angles protrusions  106 ,  107  of the support member. 
         [0028]      FIGS. 6-7  illustrate another structure and support member  300  according to an aspect of the present invention. The structure and support member  300  includes many of the same components of the structure and support member  100  illustrated in  FIGS. 1-4 , including the co-planar angled flat surface area  308   c  and angled support surface  311  that is used to support a wind deflector. In addition, a securing flange  320  extends from a top located protrusion  307 . The securing flange  320  can provide support for a PV module when attached, or help retain a wind deflector. In addition, interior tabs  330  can be used to hold other accessories. 
         [0029]    Having thus described exemplary embodiments of the present invention, it should be noted by those skilled in the art that the disclosures are exemplary only and that various other alternatives, adaptations, and modifications may be made within the scope of the present invention. Accordingly, the present invention is not limited to the specific embodiments as illustrated herein, but is only limited by the following claims.