Pre-configured, deployable solar energy package

Abstract

Generally, this disclosure describes a system and method comprising a set of photovoltaic panels, each comprising two or more electrically coupled photovoltaic panels. Each photovoltaic panel has a physical connection to at least one other photovoltaic panel in the set, and each photovoltaic panel in the set has a mechanical interface configured to interact with a mounting structure. The system further includes a dispenser having guides configured to align one or more physical connections of the photovoltaic panels in the set with receiving hardware of the mounting structure. The dispenser is configured to house the set of photovoltaic panels and to sequentially distribute each photovoltaic panel onto the mounting structure as the dispenser moves along the length of the mounting structure.

Description

Technical Field

[0001] Cross - Reference to Related Applications This application claims priority to U.S. Provisional Application No. 63 / 494,135, filed on April 4, 2023. The entire content of this prior application is incorporated herein by reference.

Background Art

[0002] Solar cell arrays typically include strings of panels wired in series. Conventionally, each panel weighs about 20 kg to 50 kg and must be individually installed on a mounting rack. Installers have to lift the panels onto the rack and fasten them to the rack and then electrically connect them in series to the next panel.

Summary of the Invention

Means for Solving the Problems

[0003] This disclosure includes systems, methods, and apparatuses for fabricating, storing, transporting, and deploying pre - configured solar energy systems. The system can include a set of photovoltaic panels, and the set of photovoltaic panels includes two or more electrically coupled photovoltaic panels. Each photovoltaic panel has a physical connection to at least one other photovoltaic panel within the set of photovoltaic panels, and each photovoltaic panel within the set of photovoltaic panels has a mechanical interface configured to interact with a mounting structure. The physical connection between each pair of photovoltaic panels is configured to allow rotational movement of the pair of photovoltaic panels. The system further includes a dispenser having guides configured to align one or more physical connections of the photovoltaic panels within the set of photovoltaic panels with receiving hardware of the mounting structure. The dispenser is configured to house the set of photovoltaic panels and sequentially distribute each photovoltaic panel onto the mounting structure as the dispenser moves along the length of the mounting structure.

[0004] The implementation can optionally include one or more of the following characteristics:

[0005] In some examples, the mechanical interface includes a first portion of an auto-engaging fastener, the first portion of which is configured to engage with a corresponding second portion of the auto-engaging fastener associated with the receiving hardware of the mounting structure. In some examples, the auto-engaging fastener is at least one of Velcro, push rivets, or keyhole fasteners.

[0006] In some examples, the dispenser includes a hinged wall, which is configured to open to allow the deployment of a set of solar panels. In some examples, the hinged wall hinges away from the other walls of the dispenser and engages with one or more rails on the mounting surface.

[0007] In some examples, the set of solar panels is configured to achieve an expanded configuration after deployment.

[0008] In some examples, the physical connection for each solar panel in a set of solar panels is a disposable hinge. In some examples, the set of solar panels is stored in a folded configuration within a dispenser, and the folded configuration includes multiple folds at the hinge connection, with each fold alternately in opposite directions.

[0009] In some examples, the dispenser includes a ride mechanism configured to engage with one or more rails of the mounting structure.

[0010] In some examples, the physical connection between pairs of solar panels is configured to position the pairs of solar panels above the apex of a structure, with each solar panel on the opposite side of the apex of the structure.

[0011] In some examples, the dispenser is configured to house the solar panels in a vertical configuration.

[0012] The disclosed system configuration is advantageous because, for example, it significantly reduces the time, complexity, and effort required to deploy a string of solar panels. Instead of lifting, securing, and wiring each solar panel individually, workers simply lift a pre-configured package onto the mounting system, secure the first panel, and then slide the package along the mounting system. This sliding motion automatically distributes and secures the remaining solar panels, which are already electrically connected. Additionally, this configuration offers the opportunity for fully autonomous installation, thereby reducing the need for human intervention. This is advantageous because it reduces the likelihood of injury to people working on lifted solar rack structures, which are often located in extremely remote areas with harsh climatic conditions. This configuration also allows for more efficient and safer transport of multiple solar panels by housing them in a vertical "accordion" configuration, reducing the likelihood of damage during transport and allowing for the transport of more solar panels than might be possible if the solar panels were not configured in the disclosed vertical configuration. For example, in this configuration, solar panels do not support the weight of other solar panels, thereby reducing the force applied to each solar panel. The proposed configuration is also advantageous because the container / dispenser includes hinged walls. The hinged walls facilitate the unloading of solar panels and reduce the likelihood of damage to the solar panels during installation, as they allow the solar panels to slide and be positioned in place on the mounting structure (e.g., a solar panel rack structure). Furthermore, the container / dispenser includes guides, which allow the entire container / dispenser to engage with rails on the mounting structure and move safely along the rails, thereby facilitating the sequential distribution and installation of solar panels as the container / dispenser moves along the rails on the mounting structure. In this case as well, the likelihood of damage to the solar panels is reduced because the solar panels remain inside the container / dispenser until the container / dispenser reaches the installation position for each solar panel.Therefore, the solar panels are kept protected by the container / dispenser until they reach their installation location.

[0013] Details of these and other aspects and embodiments of the Disclosure are described in the accompanying drawings and the following description. Other features, purposes, and advantages of the Disclosure will become apparent from the description and drawings, as well as the claims. [Brief explanation of the drawing]

[0014] [Figure 1] This is a side view of a pre-configured solar energy system. [Figure 2] This is a side view of an exemplary pre-configured solar energy system deployed in an onboard system. [Figure 3] This is a top view of an exemplary pre-configured solar energy system deployed in an onboard system. [Figure 4] Figures 4A-C are cross-sectional views of exemplary hinges for a pre-configured solar energy system. [Figure 5] A flowchart illustrating an exemplary process for deploying a pre-configured solar energy system. [Modes for carrying out the invention]

[0015] This disclosure describes a pre-configured solar energy system that can be easily deployed in less time and with less effort. Outline, the system includes a dispenser that stores a solar cell string or array, or a group of panels, during transport, then aligns them with a mounting structure, and deploys them onto the mounting structure. Each panel can engage with the mounting structure via an automatic engaging fastener, such as a keyhole fastener or push rivet, as it is sequentially deployed from the dispenser. The engaged panels can then act as mechanical levers for the solar cell string as the dispensing system moves along the mounting structure.

[0016] Referring to Figure 1, a side view of a pre-configured solar energy system 100 is shown. The system 100 includes a dispenser 102 and a set of photovoltaic panels 106. As will be discussed in more detail below, the dispenser is configured to house, store, transport, and deploy the set of photovoltaic panels 106 and is sometimes referred to as a container for the photovoltaic panels 106.

[0017] The dispenser 102 includes one or more guides 104 on its bottom surface. The bottom surface of the dispenser 102 is a surface configured to support the edge of the solar panel 106 and is located between the vertical walls of the dispenser 102. The guides 104 are shaped to align and support the dispenser 102 when it is positioned on (in contact with) the mounting structure. In some implementations, the guides 104 include a low-friction surface, such as high-density polyethylene (HDPE) material, which allows the dispenser 102 to slide along the mounting system. The guides 104 may include slots, ridges, hooks, or other suitable components positioned to align the dispenser 102 with the mounting system. In some implementations, the guides 104 may include rollers, bearings, or other ride mechanisms that act as a roller conveyor for the dispenser 102. In some implementations, the guide 104 may include an electric roller conveyor, which allows the dispenser to travel along the mounting system and deploy the solar panels without requiring external force. The roller conveyor is sometimes referred to as a ride mechanism.

[0018] The dispenser 102 may include a hinged wall 104. The hinged wall 104 can be lowered and engaged with the mounting system to align the dispenser 102 with the solar panel 106. In some configurations, the hinged wall 104 includes guides and / or dunnages on its inner surface, which position the solar panel 106 during deployment and protect it during shipping. In some configurations, when deploying the solar panel 106, the system 100 is lifted onto the mounting system (for example, by a forklift), and then the hinged wall 104 is lowered, the first panel of the solar panel 106 is lowered, and engages with the mounting system. In some configurations, the hinged wall 104 is motorized and lowers automatically in response to a deployment command. An automatically descending hinged wall 104 can lower the first solar panel 106 and position it to be secured to the mounting system. In some implementations, the hinged wall is connected to a pulley system or hydraulic component that, when the hinged wall is unlocked, allows the hinged wall to slowly descend and contact the rack system.

[0019] In some implementations, the dispenser 102 is a disposable system and is made from renewable or easily disposable materials such as cardboard, particleboard, plastic, or other materials. In some implementations, the dispenser 102 is returnable and / or reusable. In these implementations, an empty dispenser 102 can be returned to the solar panel manufacturer / wholesaler after deployment. The manufacturer / wholesaler can then reload the dispenser 102 with additional solar panels 106 and reship the dispenser 102.

[0020] Each solar panel 106 can be physically and electrically connected to adjacent panels in the string by electrical connectors 110 and hinge connectors 108. In addition, each solar panel 106 may include one or more mechanical interfaces 112.

[0021] The hinge connection 108 can provide a mechanical structure that enables the folding of the solar cell string, which in turn allows for the transmission of tensile load from panel to panel. In this way, once the first photovoltaic panel 106 is mounted on the mounting system, the first panel can "pull out" the remaining panels from the dispenser. In some implementations, the hinge connection 108 is a temporary or disposable part. For example, the hinge connection 108 may be installed for storage and used during deployment, while the hinge connection 108 allows the photovoltaic panel 106 to slide out after deployment. Figures 4A to 4C show cross-sections of an exemplary hinge 400. The hinge 400 may be, for example, polyvinyl chloride (PVC), plastic, or other rubber, and includes a slot 402 for gripping the photovoltaic module. In some implementations, the hinge connection 108 includes additional padding or protection for the photovoltaic panel.

[0022] The electrical connection part 110 can include one or more wires, cables, plugs, or other connectors that electrically connect each photovoltaic panel 106. The photovoltaic panels 106 are electrically connected before being stored in the dispenser 102, reducing the amount of connection parts that need to be formed during installation or deployment. In some implementation forms, each electrical connection part 110 is a ribbon cable including two conductors, that is, a positive terminal and a negative terminal associated with the previous photovoltaic panel 106. In some implementation forms, the electrical connection part 110 includes an electrically grounded ground connection part and a positive connection part. The photovoltaic panels 106 can be connected in series, in parallel, or in a combination of series and parallel connections. For example, one dispenser 102 can store the serially connected photovoltaic panels 106 as a single string. In another example, 20 photovoltaic panels 106 can be connected in two parallel strings each consisting of 10 panels. Additionally, more panels or fewer panels can be connected. For example, the dispenser 102 can store 4 photovoltaic panels, or 50 photovoltaic panels, or (for example, according to the amount of power generated) other numbers of panels. In some implementation forms, the panels in a single dispenser can generate at least 1 megawatt of power (or another amount of power). The electrical connection part 110 can be terminated with an electrical connector 114, and the electrical connector 114 can be configured to be connected to a power system associated with the mounting system or the entire power generation system where the system 100 is deployed. The electrical connector 114 can be, for example, an Amphenol connector or other multi-pin connectors that function to form an electrical connection between the photovoltaic panel 106 and a downstream electrical device such as an inverter or an energy storage system.

[0023] The mechanical interface 112 is located on each photovoltaic panel 106 and is configured to interact with a receiving portion on the mounting system. Each photovoltaic panel 106 can include one, two, four, or five or more mechanical interfaces 112. In some implementations, the mechanical interface 112 is a push rivet, keyhole fastener, Velcro, spring latch, or other fastener that can engage the photovoltaic panel 106 and secure the photovoltaic panel 106. The mechanical interface 112 has a limited range of motion when the photovoltaic panel 106 is coupled to the mounting system until subsequent panels are secured, after which it can be positioned to be firmly fastened to the mounting system.

[0024] In some implementations, the dispenser 102 includes a towing hook 116, and the towing hook 116 can be used to pull or push the dispenser 102 along the mounting system during the deployment operation. In some implementations, the towing hook 116 can be folded or crushed within the dispenser 102 to enable more compact shipping.

[0025] FIG. 1 is shown by way of example, and it should be noted that some elements have been removed or modified for clarity. For example, the dispenser 102 may include a cover, but the cover is not shown. Additionally, the system 100 is not drawn to a particular scale, and the sizes and dimensions of FIG. 1 are illustrative only. In some implementations, additional protection or padding is installed within the dispenser 102 along with the photovoltaic panels 106. Further, although shown vertically aligned, in some implementations, the photovoltaic panels 106 can be stacked horizontally or arranged in other configurations (e.g., angled or in a cross pattern).

[0026] Figure 2 is a side view of an exemplary pre-configured solar energy system deployed on a mounting structure (e.g., a solar rack system). In the illustrated example, a hinged wall 104 is lowered and engages with the mounting structure 202. The mounting structure 202 can be aluminum, steel, or other rack systems designed to position the solar panels during operation. In some implementations, the mounting structure 202 is configured to tilt, for example, to perform solar tracking. In some implementations, the mounting structure 202 is positioned at a fixed angle so that the mounted solar panels face a preferred direction (e.g., south in the Northern Hemisphere).

[0027] Guide 104 engages with the mounting structure 202, allowing the dispenser 102 to slide or roll along the mounting structure 202 in the indicated direction. Mechanical interface 112A is indicated to be fixed or partially fixed to the mounting structure 202. As the dispenser 102 travels along the mounting structure 202, the mechanical interface 112A remains fixed to the mounting structure, thereby allowing each photovoltaic panel 106 to be successively pulled out from the dispenser 102. In the illustrated example, each photovoltaic panel 106 slides down onto the mounting structure 202 along the hinged wall 104, and the mechanical interface of the photovoltaic panel 106 engages with the mounting structure 202, allowing the photovoltaic panel 106 to be fixed to the mounting structure 202.

[0028] In this way, by transferring the panels to the mounting structure 202 using the dispenser 102, the entire string of solar power generation panels can be automatically unfolded and sequentially fixed to the mounting structure 202.

[0029] Figure 3 is a top view of an exemplary pre-configured solar energy system deployed on a mounting structure 202. In the illustrated example, the mounting structure 202 includes a mechanical receiving section 302, which is a key slot for a pin-type mechanical interface on the photovoltaic panel 106 to engage with. The mounting structure 202 is shown to have two rails, but it may have three or more rails. In some implementations, the mounting structure 202 includes a single central rail configured to tilt to adjust the angle of the mounted photovoltaic panel 106. In some implementations, the hinge connection 108 can be removed (e.g., slid out or pulled out) after the photovoltaic panel 106 is fixed to the mounting structure 202 and adjacent panels are similarly fixed. In some implementations, the hinge connection 108 remains permanently in place.

[0030] As described above, when the solar power generation panel 106 is pulled along the mounting structure, the mechanical interface falls into the larger portion of the mechanical receiving portion 302 and then slides into the smaller portion of the mechanical receiving portion 302. This secures the solar power generation panel 106 to the mounting structure and prevents the solar power generation panel 106 from slipping as the dispenser continues to move along the mounting structure 202.

[0031] Figure 5 is a flowchart illustrating an exemplary process 500 for deploying a pre-configured solar energy system. Process 500 can be carried out using the system 100 described above with respect to Figure 1, or other similar systems.

[0032] In 502, the dispenser is positioned on the mounting structure. The mounting structure can be a rack, or a brace, or other preferred configuration configured to receive and hold the solar panels in place. Once positioned on the mounting structure, the dispenser may include guides to align and, while maintaining alignment, roll or slide along the mounting structure. The guides may include rollers, a low-friction self-lubricating material (e.g., HDPE), or other preferred materials in some mounting configurations.

[0033] In 504, the first photovoltaic panel (e.g., a solar cell panel) is deployed, removed, or partially removed from the dispenser, and the mechanical interface on the panel engages with the mounting structure. This "attaches" the strings of the photovoltaic panel to the mounting structure, preventing movement as the dispenser moves.

[0034] In 506, the dispenser is translated along the mounting structure, and the solar panels are deployed sequentially. As each solar panel is deployed, the solar panel can be automatically engaged with, attached to, or secured to the mounting structure. In some implementations, the dispenser is translated along the mounting structure using lines and tow hooks. For example, a Bobcat, tractor, or other utility vehicle can connect a cable to the dispenser and pull the dispenser along the mounting structure (for example, by towing or using a winch). In some implementations, the dispenser is self-propelled. For example, the dispenser guide may include powered rollers that drive the dispenser along the mounting structure. In another example, the dispenser may include a cable winch, which can be fixed to a remote anchor point, and the cable winch can be used to pull the dispenser along the mounting structure. This process can continue until deployment is complete (508).

[0035] Once deployment is complete, in 510, the dispenser can be removed from the mounting structure, and then the fixed panels can be electrically connected to the solar energy system. In some implementations, this involves connecting a single "plug" or "connector" into downstream electronic equipment such as an energy storage system (e.g., battery, flywheel system, etc.) or an inverter system. In some implementations, this connection is made automatically. For example, the mechanical interface between each photovoltaic panel and the mounting structure can also serve as the electrical interface. Thus, an electrical connection can be established when the panel engages with the mounting structure.

[0036] In 512, optionally, a removable hinge is detached from the string of solar panels. For example, if the hinge is a removable rubber hinge, it can be pulled out from each individual panel. In some implementations, the hinge can be configured to automatically disengage when the panel string is spread apart. For example, if the relative angle between two panels exceeds 160 degrees, the hinge may break or detach and fall to the ground for easy disposal.

[0037] While this disclosure has described several embodiments and generally relevant methods, modifications and substitutions of these implementations will be obvious to those skilled in the art. Therefore, the above description of exemplary embodiments does not define or limit this disclosure. Other changes, substitutions, and modifications are possible without departing from the spirit and scope of this disclosure.

[0038] The above description is provided in the context of one or more specific implementations. Various modifications, changes, and substitutions of the disclosed implementations can be made without departing from the scope of this disclosure. Accordingly, this disclosure is not intended to be limited to the implementations described or illustrated, and the broadest scope should be given according to the principles and features disclosed herein. [Explanation of symbols]

[0039] 100 Solar Energy Systems 102 Dispenser 104 Guide, hinged wall 106 Solar power panels 108 Hinge connection 110 Electrical connection 112, 112A Mechanical Interface 114 Electrical connector 116 Towing hook 202 Mounting Structure 302 Mechanical receiving section, mechanical interface 400 Hinge 402 slots 500 processes

Claims

1. It is a solar energy system, A set of solar panels comprising two or more electrically coupled solar panels, Each solar panel has a physical connection to at least one other solar panel in the set of solar panels. Each solar panel in the set of solar panels has a mechanical interface configured to interact with the mounting structure. The physical connection between pairs of solar panels is configured to allow rotational movement of the pairs of solar panels, and the set of solar panels is configured A solar energy system comprising: a dispenser having a guide configured to align one or more of the physical connections of the solar panels in the set of solar panels with receiving hardware of the mounting structure, wherein the dispenser is configured to house the set of solar panels and to sequentially distribute each solar panel onto the mounting structure as the dispenser moves along the length of the mounting structure.

2. The solar energy system according to claim 1, wherein the mechanical interface comprises a first portion of an auto-engaging fastener, the first portion of the auto-engaging fastener configured to engage with a corresponding second portion of the auto-engaging fastener associated with the receiving hardware of the mounting structure.

3. The solar energy system according to claim 2, wherein the automatic engaging fastener is at least one of Velcro, a push rivet, or a keyhole fastener.

4. The solar energy system according to claim 1, wherein the dispenser comprises a hinged wall, the hinged wall being configured to open to allow the deployment of the set of photovoltaic panels.

5. The solar energy system according to claim 4, wherein the hinged wall is configured to hinge away from other walls of the dispenser and engage with one or more rails of the mounting structure.

6. The solar energy system according to claim 1, wherein the set of photovoltaic panels is configured to achieve a spread-out configuration after deployment.

7. The solar energy system according to claim 1, wherein the physical connection portion of each solar panel in the set of solar panels is a disposable hinge.

8. The solar energy system according to claim 7, wherein the dispenser is configured to house the set of solar panels in a folded configuration, and the set of solar panels in the folded configuration has a plurality of folds at the hinge connection, and the plurality of folds are folded alternately in opposite directions.

9. The solar energy system according to claim 1, wherein the dispenser comprises a ride mechanism configured to engage with one or more rails of the mounting structure.

10. The solar energy system according to claim 1, wherein the physical connection between the pair of photovoltaic panels is configured to position the pair of photovoltaic panels above the apex of a structure, and each of the photovoltaic panels is located opposite the apex of the structure.

11. The solar energy system according to claim 1, wherein the dispenser is configured to house the solar power generation panels in a vertical configuration.

12. A method for deploying solar energy systems, A step of positioning a dispenser on a mounting structure, wherein the dispenser includes a guide configured to align the physical connection portion of one or more solar panels in a set of solar panels with the receiving hardware of the mounting structure, The steps include engaging the first mechanical interface of the first solar panel in the set of solar panels with the receiving hardware of the mounting structure, A method comprising the step of translating the dispenser along the mounting structure, wherein the dispenser is configured to house the set of photovoltaic panels and to sequentially distribute each photovoltaic panel onto the mounting structure as the dispenser moves along the length of the mounting structure.

13. The method according to claim 12, wherein each solar panel in the set of solar panels has a physical connection to at least one other solar panel in the set of solar panels, each solar panel in the set of solar panels has a mechanical interface configured to interact with a mounting structure, and the physical connection between the pair of solar panels is configured to allow rotational motion of the pair of solar panels.

14. The method according to claim 12, wherein the mechanical interface comprises a first portion of an auto-engaging fastener, the first portion of the auto-engaging fastener being configured to engage with a corresponding second portion of the auto-engaging fastener associated with the receiving hardware of the mounting structure.

15. The method according to claim 14, wherein the automatic engaging fastener is at least one of Velcro, a push rivet, or a keyhole fastener.

16. The method according to claim 12, comprising the step of opening a hinged wall of the dispenser, wherein the hinged wall is configured to open to allow the deployment of the set of solar panels.

17. The method according to claim 16, wherein the hinged wall is configured to hinge away from other walls of the dispenser and engage with one or more rails of the mounting structure.

18. The method according to claim 12, wherein the set of solar panels is configured to achieve an unfolded configuration after deployment.

19. The method according to claim 12, wherein the physical connection portion of each solar panel in the set of solar panels is a disposable hinge.

20. The method according to claim 19, wherein the dispenser is configured to store the set of solar panels in a folded configuration, and the set of solar panels in the folded configuration has a plurality of folds at the hinge connection, and the plurality of folds are folded alternately in opposite directions.

21. The method according to claim 12, wherein the dispenser comprises a ride mechanism configured to engage with one or more rails of the mounting structure.

22. The method according to claim 12, wherein the physical connection between the pair of photovoltaic panels is configured to position the pair of photovoltaic panels above the apex of a structure, and each of the photovoltaic panels is located opposite the apex of the structure.

23. The method according to claim 12, wherein the dispenser is configured to house the solar power generation panel in a vertical configuration.

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