mounting system

Abstract

The present application relates to a mounting system comprising: a mounting bracket; and at least one first retainer assembly comprising: a through bolt in mechanical communication with the mounting bracket; a biasing element operably coupled to the through bolt; a mounting tab operably coupled to the through bolt; and a nut operably coupled to the through bolt, wherein a portion of the mounting tab is configured to be received within a portion of a solar module supported on the mounting bracket.

Description

[0001] Divisional application information

[0002] This application is a divisional application of the invention patent application filed on May 3, 2019, with application number 201980030332.5 and invention title "Solar Module Installation System". Technical Field

[0003] This invention generally relates to a system for mounting solar modules. More specifically, this invention relates to a retainer assembly for coupling solar modules to a frame.

[0004] Related technical background

[0005] A solar mounting system is provided to support one or more photovoltaic (“PV”) module arrays and couple said arrays to a frame (e.g., multiple parallel-oriented rotatable torque tubes). The solar mounting system is designed to keep the PV modules in a fixed position relative to the torque tubes while the torque tubes rotate during solar tracking.

[0006] Solar installation systems can add significant costs to solar power systems for at least two reasons. First, the manufacture and transportation of the components themselves are expensive, partly due to their weight and size. Second, installation can be a laborious and time-consuming process, requiring skilled installers to ensure quality on-site. Therefore, there is a need for PV installation systems that are easier and more efficient to package, transport, and install. Summary of the Invention

[0007] In one aspect of the invention, a solar module mounting bracket system is provided. The solar module mounting bracket system includes: a plurality of solar modules, each including a mounting slot formed in a sidewall of the solar module; a torque tube configured to support the solar modules such that they are rotatable; a plurality of mounting brackets configured to integrate with the torque tube, and the plurality of solar modules being mounted to the plurality of mounting brackets; and at least one first retainer assembly connected to one of the plurality of mounting brackets, the first retainer assembly including a through bolt, a spring, a mounting tab, and a nut. When the solar modules are placed on the mounting brackets and supported by the torque tube, the mounting tab retainer assembly is received within the mounting slot of the solar module.

[0008] In another aspect of the invention, a second retainer assembly is connected to a second of the plurality of mounting brackets, the second retainer assembly including a snap-fit ​​element positioned on the second mounting bracket such that when the solar module is placed on the second mounting bracket, the snap-fit ​​element is received from the inside into a slot of the solar module, and wherein the snap-fit ​​element prevents the solar module from moving in the direction of the closed portion of the snap-fit ​​element.

[0009] In another aspect of the invention, the system includes a plurality of first retainer assemblies and a single second retainer assembly for a predefined section of the torque tube. The predefined section of the torque tube may be a segment of the torque tube between two ground supports.

[0010] In another aspect of the invention, the plurality of mounting brackets includes a first mounting bracket having: a bottom surface configured for integration with a first clamp assembly; a top surface configured for integration with a first retainer assembly; and a threaded U-bolt, wherein the first clamp assembly includes: a bottom surface having a radius substantially similar to the radius of the torque tube; two holes configured to receive the threaded U-bolt; and a locking tab configured to be received into one or more locking holes of the torque tube, wherein at least one first retainer assembly is mounted on the first mounting bracket.

[0011] In another aspect of the invention, the plurality of mounting brackets includes a second mounting bracket having: a top surface having four or more mounting holes configured for integration with the second retainer assembly; a bottom surface having a radius substantially similar to that of the torque tube, the bottom surface including a locking tab configured to be received into one or more locking holes of the torque tube; and two or more holes configured to receive threaded U-bolts, wherein at least one of the second retainer assemblies is mounted in the second mounting bracket.

[0012] In another aspect of the invention, the plurality of mounting brackets includes a third mounting bracket having: a top surface including four or more mounting holes configured for integration with a second retainer assembly; a bottom surface including a radius substantially similar to the radius of the torque tube, the bottom surface including a locking tab configured to be received into one or more locking holes of the torque tube; and two or more holes configured to receive threaded U-bolts, wherein the top surface includes a clamping assembly configured for integration with a bearing housing assembly, wherein at least one second retainer assembly is mounted in the third mounting bracket.

[0013] Further details, advantages, and aspects of exemplary embodiments of the present invention are described in more detail below with reference to the accompanying drawings. Attached Figure Description

[0014] This document describes embodiments of the present invention with reference to the accompanying drawings, in which:

[0015] Figure 1 This is a perspective view of a solar tracker system according to an exemplary embodiment of the present invention;

[0016] Figure 2 yes Figure 1 Exploded view of a solar tracker system;

[0017] Figure 3 yes Figure 2 An enlarged perspective view of a portion of the image depicts the first mounting bracket that is mounted to the torque tube and supports the solar module.

[0018] Figure 4 A first mounting bracket according to the present invention is depicted;

[0019] Figure 5 yes Figure 2 Enlarged perspective view of the first mounting bracket and solar module;

[0020] Figure 6 The method for securing two solar modules according to the present invention Figure 2 A perspective view of the track;

[0021] Figure 7 yes Figure 4 Exploded view of the first mounting bracket;

[0022] Figure 8 yes Figure 7 An enlarged view of a portion of the first mounting bracket;

[0023] Figure 9 It is supported by Figure 1 Perspective view of the first and second mounting brackets on the torque tube of the solar power system;

[0024] Figure 10 yes Figure 9 Exploded perspective view of the second mounting bracket;

[0025] Figure 11 It is supported by Figure 1 Illustrative views of the third mounting bracket on the torque tube of the solar power system, the bearing housing assembly, and the solar module;

[0026] Figure 12 yes Figure 2 An enlarged side view of the third mounting bracket and bearing housing assembly; and

[0027] Figure 13 yes Figure 2 Detailed exploded view of the third mounting bracket and bearing housing assembly. Detailed Implementation

[0028] According to various embodiments of the present invention, the present invention relates to a system for mounting solar modules (e.g., PV modules) onto a torque tube of a solar tracker. The system includes a plurality of solar modules, each having a mounting slot formed in a sidewall. The torque tube is configured to support the solar modules such that the solar modules can rotate and track the position of the sun. A plurality of mounting brackets are configured to integrate with the torque tube and secure the plurality of solar modules to the torque tube. The mounting brackets include retainer assemblies that are received in the slots and secure the solar modules to the track. When the solar modules are placed on the mounting brackets and supported by the torque tube, the retainer assemblies are received in the mounting slots of the solar modules. The retainer assemblies enable efficient mounting of the solar modules onto the solar tracker. These and further details of the solar power system and the retainer assemblies will be described below.

[0029] Embodiments of the solar module installation system and its installation method disclosed herein are described in detail with reference to the accompanying drawings, in which the same reference numerals designate the same or corresponding elements in each of the plurality of views. As used herein, the term "solar module" refers to any suitable solar panel or array of solar panels that converts energy from the sun into usable energy. Although generally described with reference to solar tracker systems, the invention is not limited thereto and can be used for any solar module installation.

[0030] refer to Figure 1 and 2According to the present invention, a solar tracker system 10 is described. The solar tracker system 10 typically includes an array of solar modules 12 (e.g., PV modules), a torque tube 14, and mounting brackets 100, 200, 300 for coupling the array of PV modules 12 to the torque tube 14. Each of the mounting brackets 100, 200, 300 is oriented vertically relative to the torque tube 14 and extends below each PV module 12. The torque tube 14 is rotatable about an axis to adjust the angular orientation of the PV modules 12 relative to the sun. The solar tracker system 10 includes a bearing housing assembly (BHA) 13 at one end and a rotary gear actuator 15 at the opposite end. Although not shown, the system 10 may include more than one torque tube 14 connected via a clip (not shown) to the rotary gear actuator 15 or the torque tube 14. The rotary gear actuator 15 may be located at the center of the plurality of torque tubes 14 or at one end of the connected torque tubes 14. Although described in conjunction with a rotary drive mechanism, other mechanisms for moving the PV module 12 relative to the sun are contemplated within the scope of the invention. For example, it is considered that multiple actuator systems could be used instead of the rotary gear drive 15.

[0031] Figure 2 Three first mounting brackets 100, one second mounting bracket 200, and one third mounting bracket 300 are depicted for coupling four PV modules 12 to the torque tube 14. As depicted, the second mounting bracket 200 is mounted closest to the rotary gear drive 15. The solar modules 12 are mounted between the second mounting bracket 200 and the first mounting brackets 100. Any number of solar modules 12 can then be mounted between several sets of first mounting brackets 100. Finally, at the distal end of the torque tube 14, the solar modules are mounted between the first mounting brackets 100 and the third mounting bracket 300. This third mounting bracket 300 is positioned closest to the BHA 13.

[0032] refer to Figure 3 The illustration shows an exemplary first mounting bracket 100. The first mounting bracket 100 has a generally rectangular shape. The solar module 12 may include a side rail 12a, which includes several mounting slots 12b. The mounting slots 12b of the side rail 12a are configured to receive retaining tabs 203 of the first mounting bracket 100. Figure 7 The retaining tab 203 is shown in more detail below. The mounting slot 12b may be elliptical in shape; however, other shapes, such as square or circular, may be utilized. The mounting slot 12b also provides the additional benefit of grounding through the locking devices of the mounting brackets 100, 200, 300 and the metal-to-metal contact of the side rails 12a of the solar module 12.

[0033] refer to Figure 4The illustration describes an exemplary first mounting bracket 100, which typically includes a first retainer assembly 500 disposed on the upper surface of the first mounting bracket 100. In an embodiment, the first retainer assembly 500 is a spring clip that engages with the side rail 12a of the solar module 12.

[0034] During assembly, refer to Figure 5 and 6 The first retainer assembly 500 of the first mounting bracket 100 is aligned to mate with one of the mounting slots 12b in the sidewall 12a of the solar module 12. Once the first retainer assembly 500 engages with the mounting slot 12b, the mounting tab 203 of the first retainer assembly 500 is now advantageously positioned to engage with the other solar module 12. A spring 202 of the first retainer assembly 500 prevents the bolt 201 from dislodging upon engagement with the solar module 12. The mounting tab 203 and the solar module 12 are relatively secured, thereby allowing the second solar module 12 to engage. At this stage, after installing both solar modules 12, the bolt 201 of the first retainer assembly 500 can be tightened to ensure that the solar module 12 remains securely attached to the first mounting bracket 100, as... Figure 6 As shown. The additional solar module 12 can be fastened to the next first mounting bracket 100 via the retainer assembly 500 in the manner described above.

[0035] refer to Figure 7 The diagram illustrates an exploded view of an exemplary first mounting bracket 100, which typically includes one or more retainer assemblies 500, a first clamp assembly 102, a U-bolt 106, and one or more nuts 107. A rail 101 of the first mounting bracket 100 is configured to receive the first clamp assembly 102. In an embodiment, the first clamp assembly 102 has a radius substantially the same as the radius of the torque tube 14. The first clamp assembly 102 may include locking tabs 108 configured to be received into one or more locking holes in the torque tube 14. The first clamp assembly 102 has multiple holes for receiving the U-bolt 106. The U-bolt 106 is then received through the multiple holes in the rail 101 and secured using nuts 107 to frictionally engage with the torque tube 14. Other locking devices known in the art (e.g., clamps or locking pins) may be used to secure the U-bolt 106.

[0036] In one embodiment, the first mounting bracket 100 includes one or more first retainer assemblies 500 configured to hold the solar module 12. Each first retainer assembly 500 includes a through bolt 201, a washer and spring assembly 202, a retaining tab 203, and a nut 204. The through bolt 201 is inserted through a hole in the rail 101, passing through the bottom surface of the first mounting bracket 100 such that the head of the through bolt 201 abuts against the bottom surface of the rail 101. A serrated or ribbed flange head on the through bolt 201 may be used to assist in locking the nut 204. The hole may be a slot or any other advantageous shape. The washer and spring assembly 202 and the retaining tab 203 are then applied to the protrusion of the through bolt 201, wherein the nut 204 is tightened onto the through bolt 201. The force of the spring assembly 202 causes the head of the bolt 201 to abut against the bottom surface of the rail 101. This preloading helps keep the solar module in place during installation before it is tightened into place via nut 204.

[0037] In one embodiment, the retaining tab 203 may be threaded, eliminating the need for a separate nut 204. Consideration has been given to the possibility that the retaining tab 203 may have a fan-shaped shape to assist in securing the edge of the mounting slot 12b in the solar module 12. In another embodiment, the retaining tab 203 may utilize other captive shapes.

[0038] refer to Figure 8 ,exhibit Figure 7 An exemplary washer and spring assembly 202. The washer 202b may be slotted to assist in locking the spring 202a so that it does not fall out through the hole in the top surface of the rail 101. It is considered that, for example, the washer 202b and the spring 202a may be welded or brazed together.

[0039] refer to Figure 9 This illustrates an exemplary second mounting bracket 200 mounted on the torque tube 14. The second mounting bracket 200 is positioned on the torque tube 14 and is located near the rotary gear drive 15. Figure 2 The solar tracker system 10 typically has a second mounting bracket 200 on each side of the rotary gear drive 15. The first mounting bracket 100 is positioned along the longitudinal axis of the torque tube 14 at a distance approximately equal to the width of one of the solar modules 12.

[0040] refer to Figure 10An exploded view of an exemplary second mounting bracket 200 is shown. In one embodiment, the second mounting bracket 200 has a plurality of second retainer assemblies 510 disposed on the upper surface of the second mounting bracket 200. The second retainer assemblies 510 are spaced apart from each other along the longitudinal axis of the second mounting bracket 200. In one embodiment, each of the retainer assemblies 510 includes a latching member 511 positioned on the second mounting bracket 200 such that when the solar module 12 is placed on the second mounting bracket 200, the latching member 511 is received from the inside in a slot 12b of the solar module 12. The latching member 511 prevents the solar module 12 from moving in the direction of the closed portion of the latching member 511. In another embodiment, each of the second retainer assemblies 510 further includes a clamp 512 and a through bolt 513 clamping onto the top of the solar module 12. After the clip 511 is installed from the inside of the solar module 12, the clamp 512 holds the top of the solar module side rail 12a in place and is secured in place by tightening the bolt 513. The clip 511 may be a J-shaped hook, an upward-pointing pin, a tab, or other structure for fastening the solar module side rail 12a.

[0041] The second mounting bracket 200 is configured for integration with the torque bar clamp 501. The torque bar clamp 501 is configured to provide frictional engagement with the torque tube 14. The second mounting bracket 200 includes a plurality of mounting holes configured for integration with the second retainer assembly 510 and the torque bar clamp 501.

[0042] The second mounting bracket 200 has a radius substantially the same as that of the torque tube 14 and is configured to provide frictional engagement with the torque tube 14. The second mounting bracket 200 may include locking tabs configured to be received into one or more locking holes in the torque tube 14. The second mounting bracket 200 has multiple holes for receiving U-bolts 503 and securing them with nuts 502 for frictional engagement with the torque tube 14. The torque tube 14 is clamped between the U-bolt 503 and the torque strip clamp 501. Tightening the nut 502 allows the U-bolt 503 and the torque strip clamp 501 to provide clamping force around the torque tube 14. Other locking devices known in the art (e.g., clamps or locking pins) can be used to secure the U-bolt 503.

[0043] refer to Figures 11 to 13This describes an exemplary third mounting bracket 300. The third mounting bracket 300 is configured for integration with a torque clip 301. Consideration is given that the structure of the third mounting bracket 300 may be identical to that of the second mounting bracket 200, except for the torque clip 301. The torque clip 301 may be located at the center of the third mounting bracket 300. The torque clip is configured to provide frictional engagement with the torque tube 14. The third mounting bracket 300 includes a plurality of mounting holes configured for integration with one or more second retainer assemblies 510 and the torque clip 301. Consideration is given that the plurality of mounting holes may be circular, slotted, or any other advantageous shape for mounting bolts or other retaining mechanisms.

[0044] The torque clip 301 of the third mounting bracket 300 is configured for integration with the bearing housing assembly (BHA) 13 via a connecting rod 315. The connecting rod 315 may have a tab at its end, which is received by an opening in the side of the torque clip 301 of the third mounting bracket 300. It is conceivable that the solar tracking system 10 may have the third mounting bracket 300 mounted on either side of the BHA 13.

[0045] The third mounting bracket 300 includes a radius that matches the torque tube 14 and is configured to provide frictional engagement with the torque tube 14. The third mounting bracket 300 may include a locking tab configured to be received into one or more locking holes in the torque tube 14. The third mounting bracket 300 has multiple holes for receiving a U-bolt 303 and securing it with a nut 302 for frictional engagement with the torque tube 14. The U-bolt 301 passes through a hole in the bottom surface of the third mounting bracket 300 and through a torque strip clamp 301, and is secured with a nut 302. This clamping provides frictional engagement with the torque tube 14. Other locking devices known in the art (e.g., clamps or locking pins) may be used to secure the U-bolt 503.

[0046] The third mounting bracket 300 is connected to the solar module 12 in a similar manner to the second mounting bracket 200 using the second retainer assembly 510. That is, after the snap fastener 511 is installed from the inside of the solar module 12, the clamp 512 holds the top of the solar module side rail 12a, and the solar module 12 is secured in place by tightening the bolts 513. Mounting the solar module 12 onto the third mounting bracket 300 can be the first or last installation of the solar module during assembly.

[0047] Although generally described as being used in solar tracking systems, mounting brackets 100, 200, and 300 can be used in any suitable solar module mounting system, such as fixed solar systems, to improve the installation efficiency of solar modules.

[0048] In the embodiments, the fasteners described herein may be any suitable fastening mechanism, including but not limited to adhesives, hinges, clips, ropes, straps, belts, tapes and / or fabric fasteners.

[0049] As used herein, the terms parallel and perpendicular are understood to include relative configurations that are substantially parallel and substantially perpendicular, ranging from truly parallel and truly perpendicular to approximately + or -30 degrees.

[0050] It should be understood that various modifications can be made to the embodiments disclosed herein. Therefore, the above description should not be construed as limiting, but merely as examples of various embodiments. Those skilled in the art will contemplate other modifications within the scope and spirit of the appended claims.

Claims

1. An installation system comprising: Mounting brackets are operatively coupled to the solar modules; as well as At least one first retainer assembly, comprising: A through bolt, which is mechanically connected to the mounting bracket; A biasing element operably coupled to the through bolt, the biasing element including a spring; Mounting tabs that are operatively coupled to the through bolt; A nut, operably coupled to the through bolt; and A washer including a groove defined within a portion of the washer, the groove being configured to receive a portion of the spring, wherein a portion of the mounting tab is configured to be received within the mounting groove of the solar module when the solar module is placed on the mounting bracket.

2. The installation system according to claim 1, further comprising: Second mounting bracket; and A second retainer assembly coupled to the second mounting bracket includes a latching member positioned on the second mounting bracket such that the latching member is received from the inside within a portion of the solar module, and wherein the latching member prevents the solar module from moving in the direction of the closed portion of the latching member.

3. The installation system of claim 2, further comprising a plurality of first retainer assemblies and a single second retainer assembly for a predefined section of the torque tube.

4. The mounting system according to claim 3, wherein the mounting bracket comprises: The bottom surface is configured for integration with the first clamp assembly; The top surface is configured for integration with the first retainer assembly; and Threaded U-bolts; The first clamp assembly includes: an arcuate bottom surface; two holes configured to receive the threaded U-bolt; and a locking tab, wherein at least one first retainer assembly is mounted on the mounting bracket.

5. The mounting system according to claim 3, wherein the second mounting bracket comprises: A top surface including four or more mounting holes configured for integration with the second retainer assembly; and an arcuate bottom surface including locking tabs; and Two or more holes configured to receive threaded U-bolts; The second retainer assembly is mounted on the second mounting bracket.

6. The installation system according to claim 3, further comprising a third mounting bracket, the third mounting bracket comprising: A top surface including four or more mounting holes configured for integration with the second retainer assembly; and an arcuate bottom surface including locking tabs; and Two or more holes configured to receive threaded U-bolts. The top surface includes a clamping assembly configured for integration with the bearing housing assembly; The second retainer assembly is mounted on the third mounting bracket.

7. An installation system comprising: Multiple mounting brackets; At least one first retainer assembly connected to one of the plurality of mounting brackets, the first retainer assembly including a through bolt, a spring, a mounting tab, and a nut, wherein the mounting tab is configured to be received within a mounting slot of the solar module; and The first retainer assembly further includes a washer having a groove defined within a portion of the washer, the groove being configured to receive a portion of the spring within the groove.

8. The installation system according to claim 7, further comprising: A second retainer assembly, which is connected to a second of the plurality of mounting brackets, includes a latching member positioned on the second of the plurality of mounting brackets such that when the solar module is placed on the second of the plurality of mounting brackets, the latching member is received from the inside into a slot of the solar module, wherein the latching member prevents the solar module from moving in the direction of the closed portion of the latching member.

9. The installation system of claim 8, further comprising a plurality of first retainer assemblies and a single second retainer assembly for a predefined section of the torque tube.

10. The mounting system of claim 9, wherein the plurality of mounting brackets includes a first mounting bracket, the first mounting bracket comprising: The bottom surface is configured for integration with the first clamp assembly; The top surface is configured for integration with the first retainer assembly; and Threaded U-bolts; The first clamping assembly includes: an arc-shaped bottom surface; two holes configured to receive the threaded U-bolt; and a locking tab configured to be received into one or more locking holes defined by a torque tube. The at least one first retainer assembly is mounted on the first mounting bracket.

11. The mounting system of claim 9, wherein the plurality of mounting brackets includes a second mounting bracket comprising: The top surface includes four or more mounting holes configured for integration with the second retainer assembly; And an arcuate bottom surface, the bottom surface including a locking tab configured to be received into one or more locking holes defined by a torque tube; and Two or more holes configured to receive threaded U-bolts. The at least one second retainer assembly is mounted on the second mounting bracket.

12. The mounting system of claim 9, wherein the plurality of mounting brackets includes a third mounting bracket comprising: The top surface includes four or more mounting holes configured for integration with the second retainer assembly; And an arcuate bottom surface, the bottom surface including a locking tab configured to be received into one or more locking holes defined by a torque tube; and Two or more holes configured to receive threaded U-bolts. The top surface includes a clamping assembly configured for integration with the bearing housing assembly; The second retainer assembly is mounted in the third mounting bracket.

13. The mounting system of claim 7, wherein the washer is fixedly coupled to the spring.

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