Solar Panels and Rails with Edge Connectors

Abstract

The solar panel (1) of Figures 1A and 1B includes crystalline solar panels and thin-film solar panels, and has a frame (6, 7) on at least two opposite side edges (4, 5) for use in a tilt-fixed solar system (Figure 1A) as well as a tracking solar system (Figure 1B), and is provided with connecting portions (8, 9, 16, 26) of Figures 2, 4, 6, 8, 11, 13-15, 20, 23 as well as connecting portions (10, 11, 15, 25) cooperating with each other substantially in the form of tongues (15, 25) and grooves (8, 16, 26), wherein the connecting portions are provided with integrated mechanical locking elements (12, 28, 37) to prevent displacement or separation of the connected solar panel and rails in directions perpendicular to and parallel to the solar panel surface. Furthermore, the interlocking tongue and groove are balanced by a series of forces as shown in Figures 8 and 25 and are integrated to support each other and provide combined mechanical strength to support the solar panel, providing reduced material usage, reduced dimensions, reduced packaging materials, reduced transportation costs, reduced installation time, as well as the opportunity to limit installer error, and other benefits.

Description

[Technical field]

[0001] The invention relates to a solar panel made of solar cells on glass and a frame, and rails for fixing the solar panel on top. [Background technology]

[0002] The present invention is primarily directed to so-called c-silicon solar panels, but is generally applicable to other types of solar panels, such as thin film solar panels, bifacial solar panels, compound solar panels or other solar panels, which are comparable to c-silicon solar panels in the sense of solar cells mounted on or grown on glass and covered by another glass or otherwise.

[0003] It is known that such solar panels can be secured to the roof and / or rails of the rack structure in a variety of ways.

[0004] According to a first possibility, the solar panels are attached to the rails by clamps at the top of the frame or at the bottom of the frame. The clamps, mid clamps, end clamps or simple clamps are made of metal and are fastened to the rails through holes or slats using bolts and nuts. These prior art techniques require many parts and are tediously time-consuming for the installer to handle and fix.

[0005] According to the second possibility, the solar panels are attached to the rails directly via bolts and nuts through prefabricated holes in the lower part of the frame and through holes or slats in the rails. This method has the advantage that fewer parts are required to clamp, but prefabricated holes must be aligned to access the bolts, which is often difficult or impossible, for example when installing on the top of the roof, and requires on-site drilling, slowing down the process.

[0006] According to the third possibility, the solar panels are attached to the rails by clamps inserted from the sides of the frame. This method has the advantage of quick insertion and fastening, but requires prefabricated slats on the sides of the frame. The frame therefore has a larger size and more material is used. Up to now, only one company in the solar industry uses this method, First Solar, with clamps made by ModuRack, Inc., the partner company where the inventor works.

[0007] According to a fourth possibility, the solar panel is attached to the rail by clamping the inner edge of the frame (patent pending by the inventor no. 15081817). This method has the advantage of quick clamping and integrated grounding effect. The frame remains the same size and does not benefit from the reduction of material and height.

[0008] The disadvantage of the above types of frame clamps is, among other things, that the frame itself needs to be strong enough to support the solar panels and meet all of the industrial mechanical and safety codes and requirements. As a result, current solar panel frames require the use of a large amount of material, mainly aluminum. The frame height also limits the packaging density, leading to high packaging and shipping costs. The clamping process also limits the installation speed, leading to high labor costs, especially long project implementation times.

[0009] Solar panels have used similar frame designs without significant modification for decades since the start of significant industrial scale-up. To remedy these shortcomings, technologies have been developed that attempt to increase installation speed, such as First Solar S6 frames with so-called "speed slots."

[0010] Edge connectors, on the other hand, are known for other applications such as flooring, where so-called tongue and groove are applied to opposing sides of floor panels, which are then connected in turn. These techniques cannot be applied to solar panels due to the fact that solar panels need to be fixed in an outdoor environment due to the sunlight and there is no flat sub-floor to support them. Free floating is also not allowed in solar panel installations. Summary of the Invention

[0011] The present invention is directed to an improved solar panel of the type previously mentioned, which allows the solar panel to be coupled to the rail in an optimal manner, and which allows the solar panel to be manufactured in a smooth manner with reduced material usage, reduced frame height and faster installation, which preferably eliminates one or more of the above-mentioned drawbacks. It is understood that, being integrated with the rail via interlocking tongue and groove elements, the solar panel frame and rail form a fastening for the solar panel and rail in such a way that the frame and rail together provide mechanical strength.

[0012] Furthermore, the present invention is also directed to a solar panel such that subsequent repairs and / or replacements of the solar panel can be accomplished in an optimal manner.

[0013] To this end, the invention relates to a solar panel, consisting of solar cells and glass, provided on at least two opposite side edges with a frame provided with connections, approximately in the form of tongue and groove, which cooperate with the connections of the rails, said connection parts being provided with integrated mechanical locking elements preventing slippage and swinging of the connected solar panel perpendicular and parallel to the solar panel surface relative to the associated rail edge, thus optimizing these connections in a manner that eliminates slippage and swinging.

[0014] The present invention is also directed to a solar panel having the advantage of reduced installer error during preparation and / or installation.

[0015] In a first important preferred form embodiment, the solar panel frame and rail are interlocked to form an integral part with combined strength from the frame and rail. At the point where the solar panel frame and rail engage, they apply tension to each other and provide mechanical strength to the solar panel through the strength of the rail at most, if not all, locations along the entire length of the frame-rail connection. This is one of the most notable differences from the clamping method previously described where support is limited only to the location of the clamp.

[0016] Furthermore, the connecting portion is provided with a locking mechanism that eliminates play between the solar panel and the rail and prevents misalignment or shaking.

[0017] The locking mechanism also has an optimized design that eliminates and / or reduces installer error.

[0018] According to another contemplated feature, the joint is thus formed as one piece with the solar panel frame and the support rail of the rack system.

[0019] According to the second embodiment, the coupling locking part of the solar panel frame and rail has shapes such as snap-in (rotation direction C), slide-in (direction B) and parallel push-in (direction E) as shown in Figures 25 to 27, and the optimization mentioned above is achieved. As a result, the solar panel can be installed in these three ways, and the subsequent replacement of any one solar panel can be achieved by removing the panel or the coupling rail.

[0020] Due to the fact that the interlocking provides the lock between the solar panel frame and the rails, and the rails are made of steel, aluminum or any other with strength that meets the regulatory and mechanical requirements, a significant material saving of the frame can be guaranteed and the height can be reduced. The always perfect connection under tension provided by the locking function eliminates any slippage or swaying, even under repeated cycles of thermal expansion and wind effects.

[0021] The combination of features may or may not be combined with the previously mentioned feature that the locking means tensions the solar panel and the rail when they are joined.

[0022] This invention for solar panel frames and rails includes a tongue and groove feature. The tongue can have various shapes to match the groove. The tongue can be on either the frame side or the rail side and has a groove on the other. Some of the tongue and matching groove pairs allow all of the snap-in, push-in, and slide-in features. Some of the tongue and matching groove pairs allow only one or two features.

[0023] According to a third important preferred embodiment, the solar panel frame and the connecting rail are characterized by an upper lip of a groove that defines a contact level of the top of the rail. A locking element is formed with a downwardly inclined upper lip inside at least a portion of the groove, which portion extends beyond the lower lip of the groove.

[0024] According to a particular embodiment of the shape, the connector is configured as a rectangle, with connectors on all four edges.

[0025] According to a preferred embodiment, the solar panels are configured as rectangular and the connections are provided on the opposing long sides of the solar panels rather than on the two opposing short edges.

[0026] According to a preferred embodiment, the solar panel frame can be provided with grooves as connections and the rails are provided with tongues as connections. The advantage is that the rails can be c-purlins which are easy to manufacture and the engineering data is readily available.

[0027] According to a particular form of embodiment, the grooves of the solar panel frame are open to the inside, the advantage being that the solar panels are symmetrical and the gap between two adjacent solar panels has a minimum width.

[0028] In the most preferred embodiment, the base material used for the frame and the joints is made of the same material, a single metallic material, more specifically extruded aluminum, which is already widely used for solar panel frames.

[0029] In the most preferred embodiment, the basic material used for the rails and the connectors shall be made of the same material, a single metallic material, more specifically, roll-formed galvanized steel, which is already widely used in solar racking systems.

[0030] The fact that the present invention applies to solar panels and rails made of the above mentioned materials brings the advantage that the manufacturing processes, i.e. extrusion and roll forming, are very efficient and mature manufacturing processes, and these materials, i.e. aluminum and steel, are the most basic, widely available and currently used materials.

[0031] Both extrusion and roll formed products have a smooth, uniform surface and have the advantage that the solar panels can be manually slid along each other's surfaces into a locked position.

[0032] If the frame and rails are made of a synthetic-based material, for this use the composite can consist of a mixture of synthetic materials and even recycled materials.

[0033] The solar panels are preferably fixed to each other by interlocking rails without the use of bolts, this interlocking allows the solar panels to be replaced in the event of damage to the solar panels, however it is clear that sliding limiting pins or bolts between the solar panels and the interlocking rails are not excluded.

[0034] The present invention also relates to the manufacturing methods, namely extrusion and roll forming, both of which provide a one-pass process to complete the design profile. [Brief description of the drawings]

[0035] [Figure 1] FIG. 1 shows a cross section of a typical (prior art) solar panel (or module) having a frame that is secured to a rail by mid-clamps and end clamps. [Diagram 2] FIG. 2 shows a diagram of an assembled solar panel for a fixed-mount solar system with a frame and rail connection according to the present invention. [Diagram 3] FIG. 3 shows a schematic diagram of a solar panel assembled for a single-axis tracking solar system with interlocking frame and rail according to the present invention. [Figure 4] Figure 4A shows a schematic cross-section of a solar panel, single glazing, with a frame according to the invention, and a glass inserted into a groove, and Figure 4B shows a schematic cross-section of a solar panel, double glazing, with a frame according to the invention, and a glass inserted into a groove. [Diagram 5] Figure 5A shows a schematic cross-section of a solar panel, single glazing, with a frame according to the invention, and Figure 5B shows a schematic cross-section of a solar panel, double glazing, with a frame according to the invention, and with a glass bonded to the frame. [Figure 6] FIG. 6 shows a cross section of a solar panel frame connected to a rail by a tongue and groove according to the present invention. [Figure 7]FIG. 7 shows a cross section of a solar panel frame coupled to a rail by translational tongue and groove engagement in accordance with the present invention. [Figure 8] FIG. 8 shows a cross section of a solar panel frame connected to a rail by a tongue and groove according to the present invention. [Figure 9] FIG. 9 shows a cross section of a solar panel frame coupled to a rail by translational tongue and groove engagement in accordance with the present invention. [Figure 10] 1 depicts a cross section of a solar panel frame coupled to a rail by rotating engagement of a tongue and groove in accordance with the present invention. [Figure 11] FIG. 11 shows a cross section of a solar panel frame connected to a rail by a tongue and groove according to the present invention. [Figure 12] FIG. 12 shows a cross section of a solar panel frame coupled to a rail by rotating engagement of a tongue and groove in accordance with the present invention. [Figure 13] FIG. 13 shows a cross section of an interlocking rail according to the invention. [Figure 14] FIG. 14 shows a cross section of an interlocking rail according to the invention. [Figure 15] FIG. 15 shows a cross section of an interlocking rail according to the invention. [Figure 16] FIG. 16 shows a cross section of a solar panel frame according to the present invention. [Figure 16B] FIG. 16B illustrates a cross section of a solar panel frame according to the present invention, where one or more glasses are bonded to the frame. [Figure 17] FIG. 17 shows a cross section of a solar panel frame according to the present invention. [Figure 18] FIG. 18 shows a cross section of a solar panel frame according to the present invention. [Figure 19] FIG. 19 shows a cross section of a solar panel frame according to the present invention. [Figure 20] FIG. 20 shows a cross section of a solar panel frame according to the present invention. [Figure 20B] FIG. 20B shows a cross section of a solar panel frame according to the present invention. [Figure 21] FIG. 21 shows a cross section of a solar panel frame according to the present invention. [Figure 21B] FIG. 21B shows a cross section of a solar panel frame according to the present invention. [Figure 22] FIG. 22 shows a cross section of a solar panel frame according to the present invention. [Figure 22B] FIG. 22B shows a cross section of a solar panel frame according to the present invention. [Diagram 23] FIG. 23 shows a cross section of a solar panel connecting rail according to the present invention. [Figure 24] FIG. 24 shows a cross section of a solar panel frame coupled with a rail according to the present invention. [Diagram 25] FIG. 25 shows a detailed cross section of a solar panel frame coupled with a rail according to the present invention. [Figure 26] FIG. 26 shows a detailed cross-section of a solar panel frame that translates and interfaces with the rail and panel surface in accordance with the present invention. [Figure 27] FIG. 27 shows a detailed cross section of a solar panel frame that interfaces at an angle with a rail in accordance with the present invention. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0036] The present invention relates to a solar panel and rail system consisting of a solar panel 1 and an interlocking rail 2, such as the solar panel and rail shown in Figs.

[0037] These solar panels 1 can be of various shapes, for example rectangular or square, or any other shape. These rails 2 can be of various shapes, for example c-channel with inwardly curved edges, or any other shape.

[0038] In the most preferred embodiment, the solar panel shall be manufactured in a longitudinal shape, for example 1-4 meters in length and 0.5-2 meters in width, as shown in Figures 1-3. The thickness may also vary, but is preferably 1.0-6.0 cm, more specifically 2.5 cm.

[0039] In the most preferred embodiment, the rail shall be manufactured in a longitudinal c-channel shape, for example, 0.4 to 12 meters long, as shown in Figures 2 to 3. The height and width may also vary, but the height is preferably 4.0 to 16.0 cm, more specifically 10 cm, and the width is preferably 3.0 to 11.0 cm, more specifically 7 cm.

[0040] Each solar panel 1 has frames 6-7 with connecting grooves 8-9 on the edges of at least two opposing sides 4-5, as shown in Figures 4A and 4B, allowing two adjacent identical solar panels 1 to be connected to a rail 2 by connecting tongues 10-11, as shown in Figure 6. One or more pieces of glass may be inserted into the grooves 8' and 9' of the frames 6 and 7.

[0041] Each solar panel 1 also has frames 6-7 with connecting grooves 8-9 on the edges of at least two opposing sides 4-5, as shown in Figures 5A and 5B, allowing two adjacent identical solar panels 1 to be connected to a rail 2 by connecting tongues 10-11, as shown in Figure 6. One or more pieces of glass may be glued to the surfaces 8" and 9" of the frames 6 and 7.

[0042] According to the invention, as shown in FIG. 6, mechanical locking parts or elements 12-13 are provided which are integrated into the coupling grooves 8-9 and the coupling tongues 10-11 to prevent the coupled solar panel 1 and rail 2 from slipping and sliding apart in a direction A perpendicular to each side 4-5 of the coupled solar panel 1 and parallel to the solar panel surface 14, the coupling grooves 4-5 and the locking elements 12-13 are formed in one piece with the core 15 of the frame 6-7 of the solar panel 1, the coupling grooves 8-9 are shaped such that they can engage with each other by themselves, by fitting the rails with the coupling tongues 10-11 and / or by rotating after the coupling parts are partially engaged, so that each subsequent solar panel 1 can be inserted laterally into the previous rail and each rail can be inserted into the previous solar panel, and the coupling grooves 8-9 and preferably the coupling tongues 10-11 engage without play in all directions of the plane perpendicular to the aforementioned edges.

[0043] As shown in FIGS. 2-3, in the case of a solar panel 1 having an elongated shape, the connecting portions 8-9 and 10-11 are disposed on the long side portions 4-5, respectively.

[0044] The connections 8 - 9 , 10 - 11 can be realized in various shapes, but their basic shape is always formed by a tongue 15 and a groove 16 .

[0045] In the embodiment in the form of Figures 6-7, the frame 6 of the associated solar panel 1 is provided with an interlocking groove 16, and the associated rail is provided with an interlocking tongue 15 and groove 16, which allows the engagement of the solar panel 1 by translation in the movement direction B, and ensures that the solar panel 1 connected to the rail 2 cannot move vertically up or down relative to the solar panel surface 14 without any snap-together effect. This particular design allows for effortless engagement by translation but not by rotation.

[0046] In the embodiment in the form of Figures 8-10, the frame 6 of the associated solar panel 1 is provided with a coupling groove 16, and the associated rail is provided with a coupling tongue 15 and a locking element 12, which allow the engagement of the solar panel 1 by translation in the movement direction B, resulting in a co-interlocking effect. The tongue 15 is formed with a curve 17 and the groove 16 is formed with a slope 18 to ensure that the solar panel 1 coupled to the rail 2 cannot move vertically in the up-down direction D relative to the solar panel surface 14, and also to ensure that the solar panel 1 coupled to the rail 2 cannot move parallel in the direction A relative to the solar panel surface 14.

[0047] To allow the solar panel 1 and the rail 2 to be inserted into each other by a rotational movement, the tongue 15 of the rail 2 is preferably formed in a circular, rolled shape of more than 180°. The bottom of the element 17 of the tongue 15 sits on the lower part 18 of the groove 16. The slope of the lower part 18 of the groove 16 creates a force F1 on the bottom part 17 of the tongue 15. The surface of the locking element 12 creates a force F2 on the upper part 19 of the tongue 15. The upper part 20 of the groove 16 creates a force F3 on the tongue 15. Together with the two angles α of the blocking element 12 and the slope β of the bottom part 18 of the groove 16, we must balance the forces, including the weight W of the solar panel and the force on the solar panel caused by the wind load Fw, as follows: F2*Cos(α)=F1*Sin(β) ensures that there is no lateral movement of solar panel 1 relative to rail 2. (1 / 2)*W+F1'*Cos(β)=F2'*Sin(α)+F3'+(1 / 2)*Fw

[0048] Since Fw is randomly affected by the wind, the other forces, F1', F2' and F3' acting on the solar panel 1 need to be modified accordingly. A tongue and groove design linked with locking elements serves this purpose.

[0049] The distance L between the farthest tongue tip and the inner surface of the groove ranges from 0 mm to 8 mm, and is preferably 5 mm, to allow for tolerances caused by installer error and misalignments from other parts, such as solar panel width tolerance.

[0050] 9 shows a cross section of a solar panel frame coupled to a rail by translating and engaging a tongue and groove according to the invention. The slope of the bottom 18 of the groove 16 provides an entry guide for the tongue 15. The constant deformation of the top 19 and bottom 17 of the tongue 15 and the locking element 12 and bottom 18 of the groove 16 allows the tongue 15 to enter the groove 16. Once in position, the forces F1', F2', F3' are balanced as well as the solar panel weight W and the wind load Fw.

[0051] 10 shows a cross section of a solar panel frame coupled to a rail by rotating and engaging the tongue and groove according to the present invention. The opening 20 in the groove 16 allows the tongue 15 to be inserted without deformation, easing entry. However, when rotated downward to engage the locking element 12 in the groove 16, some deformation occurs to allow engagement and locking. This design particularly facilitates rotation for engagement.

[0052] As shown in Figs. 11-12, the solar panel 1 according to the invention can be rotated to engage when the tip 21 of the tongue 15 is inserted into the opening 20 of the groove 16. The rotation angle γ can be adjusted by adjusting the tip 21 of the tongue 15, the locking element 12, and the tip 21 of another locking element 22 added to the groove 16 of the frame 2 of the solar panel 1. The rotation angle γ is intentionally designed to be relatively large, preferably larger than 30 degrees, to ensure that both lateral movement in direction A and vertical movement in direction D are eliminated. In Fig. 11, the tongue 15 of the rail 2 can be engaged with the groove 16 of the frame 6 by sliding along direction E. Adjustments and deviations are allowed either on the tongue 15 side of the rail 2 or on the groove 16 side of the frame 6. This particular design according to the invention as shown in Figs. 11-12 makes the sliding for engagement particularly easy.

[0053] 13-15, the tongue 15 of the rail 2, according to the present invention, can have many shapes that allow the tongue 15 to be inserted and engaged into the groove 16 by lateral movement in direction B or direction B', by rotation in direction C, and by sliding in direction E. Changing the shape of the tongue 15 affects which of the directions B or B', C, and E is easier to move. It also affects the manufacturing process, such as roll forming the tongue 15 from a metal plate, such as a steel plate.

[0054] As represented in figures 16-19, the frame may have various shapes as long as the two important features according to the invention are obtained: a groove 16 for engagement with the tongue 15 of the rail 2 and a groove 23 for engagement with one or more glasses of the solar panel 2. The groove 23 engages with one glass if the solar panel is a single-glazed solar panel, or with multiple glasses if the solar panel is a double-glazed solar panel. The gap width 24 of the groove 23 can be adjusted accordingly to the thickness of the glass or glasses.

[0055] As represented in Figures 20-22, according to the invention, a tongue 25 is made in the frame 6, while a groove 26 is made in the rail 2. The frame 6 has two important features, namely the groove 24 which engages with the glass pane or panes, and the tongue 25 which engages with the groove 26 in the rail 2.

[0056] Using the tongues 25 on the side of the frame 6, the frame 6 may be engaged with the rail 2 by moving in direction B', rotating in direction C or sliding in direction E.

[0057] As represented in Figures 20B-22B, according to the invention, a tongue 25 is made in the frame 6, while a groove 26 is made in the rail 2. The frame 6 has two important features: a surface 8" that adhesively engages with the glass piece or pieces, and the tongue 25 that engages with the groove 26 in the rail 2.

[0058] Using the tongues 25 on the side of the frame 6, the frame 6 may be engaged with the rail 2 by moving in direction B', rotating in direction C or sliding in direction E.

[0059] The specific thickness T may be changed. The frame may be manufactured by extrusion of aluminum, plastic, composites, or other materials. The specific thickness T may remain the same, and thus the frame may be manufactured by roll forming of a metal sheet, such as a steel sheet or an aluminum sheet.

[0060] All the various forms of embodiments of the invention, such as the frame and rail in various designs with the tongue on either the rail side or the frame side, have the feature that the frame, whether the tongue is on the frame side or the rail side, is engaged with the glass or glasses by means of a groove or surface bonding, and with the rail by means of a tongue and groove. The engagement between the frame and the rail allows the formation of an integrated system, in which a force is created between the frame and the rail along the entire engagement or connection length with the rail, through the tongue and groove and the locking element, which not only supports the frame with the weight W of the solar panel, but also balances the wind load Fw applied to the solar panel and keeps it in balance.

[0061] This integration along the entire connection length between the frame 6 and the rail 2 is an important embodiment of this invention. The tongue and groove integration of the solar panel frame and rail, with or without locking elements and with the tongue on the frame or on the rail, allows the strength of the frame 6 and rail 2 to form an integrated system to support the solar panel 1.

[0062] This integration, according to the invention, provides the opportunity to easily install or engage the solar panel on the rails in a short time by parallel pressing and pulling, by rotation as well as by sliding, and more importantly, to reduce the material usage of the frame and / or rails, thus reducing the size of the frame height H2, which determines the thickness of the solar panel 1. The reduction in material usage, for example in the frame material, can lead to a significant reduction in the frame material usage, such as the aluminum usage, since most solar panel frames are currently made of aluminum. The reduction in the frame height can lead to a reduction in the thickness of the solar panel, thus increasing the number of solar panels in the same volume of package, reducing the packaging and transportation costs.

[0063] 23 to 27 show the most preferred embodiment of the present invention, in which parts corresponding to the previous embodiment are shown with corresponding reference numerals.

[0064] The rail 2 may preferably be made of a roll-formed metal sheet, in particular a steel sheet, and may have a thickness T1 preferably in the range of 0.3 mm to 3 mm, in particular 1 mm to 1.5 mm. The width W1 is preferably in the range of 2 cm to 20 cm, in particular 6 cm to 10 cm. The height H1 is preferably in the range of 3 cm to 30 cm, in particular 6 cm to 12 cm. The radius R1 is preferably in the range of 1 mm to 4 mm, in particular 2.5 mm to 3.5 mm. The radius R2 may be close to R1, but does not have to be the same. The radius R1 and radius R2 are preferably 2 to 3 times larger than the thickness T1. This factor of 2 to 3 is especially for roll-formed manufacturing processes.

[0065] The frame 6 may be made by extrusion of a metal material, in particular aluminum with an anodized surface. The height H2 of the frame 6 is preferably in the range of 10 mm to 60 mm, in particular 20 mm to 25 mm for solar panels of sizes comparable to existing sizes. The preferred range of the height H2 increases with increasing size of the solar panel. In general, the thickness T2 of the frame 6 may vary slightly, and is preferably in the range of 0.5 mm to 2 mm, in particular 1 mm to 1.5 mm.

[0066] The height H3 of the locking element 12 is preferably in the range of 0.5 mm to 4 mm, and particularly 2 mm. A small value of H3 allows easy engagement by movement in the direction B as in Fig. 26, while a large value of H3 allows a large locking force F2' on the frame 6 while still allowing easy engagement by subsequent rotation in the direction C as in Fig. 27.

[0067] When the frame 6 and rail 2 are engaged, forces F2', F3', F4', and F5', along with the weight W of the solar panel and the wind load Fw from the wind, are balanced as follows: F4'=F2'*Cos(δ)

[0068] The balance of forces ensures that there is no lateral movement in direction A between the frame 6 and the rail 2 . (1 / 2)*W+F5'=F2'*Sin(δ)+F3'+(1 / 2)*Fw

[0069] The balance of forces ensures that there is no up and down movement between the frame 6 and the rail 2 in the direction D. These forces also support the weight W of the solar panel and balance the wind load Fw. These forces also generate a friction force Ff between the frame 6 and the rail 2. The friction force Ff represents a combination of the friction forces generated by forces F2', F3', F4', and F5'. However, there is an option to later add a locking pin between the frame 6 and the rail 2 to further ensure that there is no unwanted sliding between the frame 6 and the rail 2 along the direction E.

[0070] In this most preferred case according to the invention, the tongue 28 of the rail 2 may be inserted and engaged in the groove 16 of the frame 6 in the direction of movement B or in the direction of rotation C. In this preferred case, the material usage is optimized, the same material is used, in particular steel for the rail and aluminum for the frame. In this case, the manufacturing procedure is also optimized, in particular the rail is manufactured by roll forming and the frame is manufactured by extrusion and anodizing. Furthermore, in this preferred case according to the invention, the installation procedure is optimized, both by translation to engagement as well as rotation to engagement, creating a snap-n-lock effect, increasing the efficiency and speed of installation by illuminating or reducing the tolerances and errors of the installer. In this most preferred case, the two opposing long edges are provided with interlocking tongues and grooves, and the two opposing short edges are not. In this case, the frames of the two opposing short edges are similar in the upper section but do not have an interlocking groove in the lower section.

[0071] The most desirable benefit that can be derived from this invention is the optimization of multiple benefits, namely, reduced material usage, reduced packaging and shipping costs due to reduced thickness of the solar panels, and increased installation speed, among other benefits.

[0072] An important feature here is that the interlocking tongues 28 and grooves 16 are provided with locking elements 12, so that the panels in a common plane exert a tension on each other in the engaged state, so that the engaged frame 6 and rail 2 are compressed together and frictionally locked. As shown, this is preferably achieved by providing the interlocking part with an elastically yieldable or bendable material, where the aluminum frame and the steel rail are at least partially deformed in the engaged state, thus creating a tension, so that the engaged frame 6 of the solar panel 1 is locked to the rail 2.

[0073] Due to the fact that contact forces F2'-F5' on the one hand and these tension forces F2'-F5' on the other hand are created, frictional forces against sliding along the direction E are created, so that the solar panel 1 is locked to the rail by compression and friction. The frictional forces can be configured by adjusting the dimensions of the connection such that no locking pins or bolts are required to prevent subsequent slippage along the rail edge.

[0074] The angle ε of the guiding surface 30 of the tongue 28 is preferably in the range of 5° to 45°, in particular 30°, and the contact angle δ of the surface 31 of the locking element 12 is preferably in the range of 5° to 45°, in particular 30°. The optimum selection of the values ​​of ε and δ depends on the elasticity of the material of the frame 6 and the rail 2, the thickness T, the pressing force in the direction B as well as the locking forces F2' to F5' and the associated friction forces.

[0075] Although the locking forces F2'-F5' are preferably transmitted by the frame 6 and rail 2 described above, the invention does not exclude other forms of locking elements or structures whereby these forces are transmitted by other compressive contacts.

[0076] It has been noted that the compression deformation is relatively small, for example a few hundredths to a few tens of millimeters, and does not affect either the glass attached to the frame or the rails that may be fixed to the rack.

[0077] Due to the fact that initially, the compression contact may not be uniform along the edge of the solar panel, this uneven distribution of compression may be subsequently healed due to wind load forces on the solar panel as well as due to repeated thermal cycling of weather or due to tracking with a single axis tracking system etc. This makes the engagement of the frame with the rail more stable and uniform.

[0078] According to a variation of the invention, as an option, tension can be supplemented by an additional pin or bolt in the integrated tongue and groove.

[0079] A further particular feature of the embodiment of Figures 25-27 is that the solar panel 1 with the frame 6 can be selectively engaged by a rotational movement in direction C as represented in Figure 27 in such a manner that maximum compressive forces F2'-F5' are generated at the couplings during engagement, preferably by partially engaging and rotating the couplings.

[0080] The advantage of this is that the solar panel 1 can be easily engaged by a rotational movement and thus without the need for the use of tools. The inventors also point out that disengagement can be achieved without tools by rotation, which is the best case in situations where the solar panel needs to be replaced later, for example in later maintenance. Engagement and disengagement without tools or excessive force and deformation ensures that the solar panel is not damaged during the installation and repair process.

[0081] According to the present invention, the locking force on the frame at one side 4 may be balanced by the locking force at the other side 5, as in Figures 4A-5B, but this is not preferred or recommended by the inventors, considering that the strain forces on the frame at one side 4 and the other side 5 may affect the connection between these two sides, including the engagement of the glass with the frame. These engagement strengths may or may not sustain the strain between these two sides 4,5.

[0082] According to the present invention, when the four sides 4-5, 4'-5' as shown in Figures 2-3 are provided with the connecting frames 6-7 as shown in Figures 4A-5B, these connections can be made in such a way that the engagement is stronger in one direction than in the other direction. For example, in the case of a longitudinal solar panel 1 as shown in Figures 2-3, the locking at the smaller sides 4'-5 can be more pronounced, less pronounced or equal to that at the longer sides 4-5. The arrangement of the solar panel can affect the engagement at the long or short sides.

[0083] These differences in engagement can be obtained by configuring the contact surface 30 of the tongue 28 and the contact surface of the locking element 12 of the groove 16 at different angles, angle δ and angle ε, as in FIG.

[0084] In a preferred form of the invention, the solar panel 1 includes a connecting tongue 28, as shown in FIG. 25, and exhibits any one or a combination of two or more of the following features:

[0085] The curvature 32 at the bottom of the tongue 28 is circular with a radius R1 and the curvature at the lower corner 33 of the groove 16 has the advantage that it forms a guide when rotating the solar panels 1 into their locking position on the rail 2 during installation and makes it easier for the solar panels 1 to engage with each other.

[0086] The angles σ and ε being the same or similar, have the advantage that the locking elements can be easily shifted relative to one another during rotational engagement or dismantling of the solar panel 1 and that the locking elements are not damaged, e.g. permanent deformation of the frame and / or rails, even when the solar panel is engaged and dismantled.

[0087] The dust chamber 34 between the tongue and groove of the engaged solar panel 1 and rail 2 as in FIG. 25 has the advantage that any inclusions that may get between the solar panels 1 during engagement cannot adversely affect good engagement.

[0088] The inclined surfaces 35 formed on the outer parts of the locking elements 12, as shown in figures 25-26, have the advantage that the surfaces 30 of the tongues 28 shift smoothly against each other, resulting in a uniform deformation of both the tongues 28 and the grooves 16.

[0089] The contact surface 36 formed by the upper part of the groove 16, as in FIG. 25, is flat and parallel to the plane defined by the solar panels 1, and in addition the lower contact surface formed by the surface 37 of the lower part of the groove 16 is in coordination with each other, which has the advantage that even if the insertion depth of the tongue 28 into the groove 16 may vary due to various causes, no mutual displacement in height between the two engaged solar panels 1 is possible, in other words no height difference occurs between adjacent solar panels.

[0090] In the embodiment of Figures 23-27 all these features are combined, but as is evident from Figures 6-22B it is clear that these features can also be provided separately or in limited combination with each other.

[0091] As is apparent from Figures 6 to 27, an important feature of the preferred embodiment of the invention is that the cooperating locking element, in other words the part which provides the mating locking and engagement effect, is located on that part of the upper lip 12 of the groove on the frame side, or on that part of the lower lip of the groove on the rail side, and vice versa wise, which extends beyond the distal edge of lip 12.

[0092] It will be apparent that the interlocking tongue and groove can be formed by extrusion, or it can also be formed by a roll forming or milling process.

[0093] According to a particular feature of the present invention, the frame 6 of the solar panel 1 is oxidized before the glass is assembled, more specifically a surface treatment process, preferably selected from the following series of processes: anodizing coating, coloring, coating, mechanical surface treatment, chemical film coating, bright anodizing coating (gloss treatment), enamel coating, plating, and no treatment. In addition, new technologies such as ion plating and sputtering have been developed. Among these aforementioned treatments, the preferred treatment is anodizing coating.

[0094] According to a particular feature of the invention, the rail 2 is treated with a zinc coating, more specifically a surface treatment process, preferably selected from the following sequence of processes: galvanizing, plating, burnishing, spraying, painting, anodizing and megni coating. Among these aforementioned treatments, the preferred treatments are galvanizing and / or megni coating. The surface treatment process may be before or after the roll forming process.

[0095] These surface treatments also provide the advantage that the aforementioned solar panel frames and rails remain protected from rust, at least over the long service life of the solar system in an outdoor environment. Using stainless steel materials, or other materials with weather retaining properties, surface treatments may not be necessary.

[0096] It should be noted that the invention is in no way limited to the form of the embodiments described by way of example and shown in the figures described above, but that such solar panels and rails can be embodied in various shapes and sizes without departing from the scope of the invention.

[0097] For example, the various features described in the presented embodiments or presented examples may be selectively combined with one another.

[0098] Furthermore, all embodiments of the connecting elements previously described can be applied to the long sides as well as to the short sides of the solar panel, or only the long sides or only the short sides can have such connecting elements from this invention.

[0099] Again, as noted, the tongue may be on the frame side or the rail side and the groove on the opposing side.

[0100] FIG. 1 represents a cross section of a typical solar panel (prior art) with a frame, the frame being fixed to a rail by a mid clamp and an end clamp (solar panel and solar module can be used interchangeably). FIG. 2 represents a diagram of a solar panel assembled for a fixed-layout solar system with a frame and rail connected according to the invention. FIG. 3 represents a schematic diagram of a solar panel assembled for a single-axis tracking solar system with a frame and rail connected according to the invention. FIG. 4A-4B represent schematic cross sections of a solar panel, single glass and double glass with a frame and glass inserted in a groove according to the invention. FIG. 5A-5B represent schematic cross sections of a solar panel, single glass and double glass with a frame and glass bonded to the frame according to the invention. FIG. 6-15 represent cross sections of several rail design embodiments with tongue according to the invention. FIG. 6-19 represent cross sections of several frame design embodiments with groove according to the invention. FIG. 16B represents a cross section of a frame with glass bonded. Other frames are similar to the cross section of FIG. 16 to FIG. 16B. Figures 20-22 show cross-sections of embodiments of tongue frame and groove rail designs, further illustrating the uniform thickness of the frame and rail. Figures 23-27 show cross-sections of the most preferred embodiment of the tongue and groove frame and rail and locking element according to the invention. The solar panel and rail can be engaged by sliding along the tongue and groove edge, by sliding perpendicular to the tongue and groove edge (Figure 26), and by rotating and snapping in (Figure 27).

Claims

1. 1. A solar panel system comprising: A solar panel (1) having an upper surface (14) and a pair of opposing side edges; A rail (2) is disposed below the solar panel (1) to fix the solar panel (1) in a predetermined position; a pair of solar panel frames (6, 7) attached to the solar panel (1) and the rail (2) to connect the solar panel (1) to the rail (2), each of the solar panel frames (6, 7) being provided with a panel receiving groove (8', 9'); Equipped with the pair of solar panel frames (6, 7) are attached to the solar panel (1) by gluing the pair of opposite side edges of the solar panel (1) onto the pair of solar panel frames (6, 7) or by inserting the pair of opposite side edges of the solar panel (1) into the panel receiving grooves (8', 9'); The rail (2) has an upwardly opening C-shaped cross section defined by a bottom portion and a pair of ribs protruding upward from both sides of the bottom portion, and rail-side connecting portions (10, 11) are integrally provided on each of the ribs. A frame-side connecting portion (8, 9) is integrally provided at a lower portion of each of the solar panel frames (6, 7), and is configured to connect the solar panel (1) to the rail (2) by attaching the solar panel frame (6, 7) to the rail (2) in cooperation with the rail-side connecting portion (10, 11), Either the frame side connecting portion (8, 9) or the rail side connecting portion (10, 11) has a connecting groove (8, 9), and the other has a connecting tongue (10, 11) that can be inserted into the connecting groove, Each of the connecting grooves (8, 9) has a groove bottom, an upper lip extending from an upper edge of the groove bottom, and a lower lip extending from a lower edge of the groove bottom, and is formed to open in a substantially horizontal direction, and is provided with a locking element (12) protruding downward at the extended end of the upper lip, the groove surfaces defining said connecting groove (8, 9) include an upper groove surface defining an upper surface of said connecting groove, a lower groove surface defining a lower surface of said connecting groove, an inner groove surface defining the groove bottom surface of said connecting groove, and an open groove surface including a surface of said locking element (12) facing said connecting groove (8, 9); When the solar panel frame (6, 7) and the rail (2) are connected, the connecting tongues (10, 11) are inserted into the connecting grooves (8, 9) and contact the upper groove surface and / or the lower groove surface and / or the inner groove surface and / or the open groove surface to form contact surfaces between the connecting tongues (10, 11) and the upper groove surface and / or the lower groove surface and / or the inner groove surface and / or the open groove surface, respectively, and the contact surfaces function as cooperative contact surfaces that limit the movement of the connecting tongues (10, 11) relative to the connecting grooves (8, 9), thereby preventing substantial separation between the solar panel frame (6, 7) and the rail (2) in a direction perpendicular to the pair of opposing side edges of the solar panel (1); A solar panel system in which, when viewed from above, the overlapping portions of the cooperating contact surfaces onto which the adhesion portions of the pair of opposing side edges of the solar panel (1) to the solar panel frame (6, 7) or the insertion portions into the panel receiving grooves (8', 9') are overlapped are parallel to the upper surface (14) of the solar panel (1).

2. 1. A solar panel system comprising: A solar panel (1) having an upper surface (14) and a pair of opposing side edges; A rail (2) is disposed below the solar panel (1) to fix the solar panel (1) in a predetermined position; a pair of solar panel frames (6, 7) attached to the solar panel (1) and the rail (2) to connect the solar panel (1) to the rail (2), each of the solar panel frames (6, 7) being provided with a panel receiving groove (8', 9'); Equipped with the pair of solar panel frames (6, 7) are attached to the solar panel (1) by gluing the pair of opposite side edges of the solar panel (1) onto the pair of solar panel frames (6, 7) or by inserting the pair of opposite side edges of the solar panel (1) into the panel receiving grooves (8', 9'); The rail (2) has an upwardly opening C-shaped cross section defined by a bottom portion and a pair of ribs protruding upward from both sides of the bottom portion, and rail-side connecting portions (10, 11) are integrally provided on each of the ribs. A frame-side connecting portion (8, 9) is integrally provided at a lower portion of each of the solar panel frames (6, 7), and is configured to connect the solar panel (1) to the rail (2) by attaching the solar panel frame (6, 7) to the rail (2) in cooperation with the rail-side connecting portion (10, 11), Either the frame side connecting portion (8, 9) or the rail side connecting portion (10, 11) has a connecting groove (8, 9), and the other has a connecting tongue (10, 11) that can be inserted into the connecting groove, Each of the connecting grooves (8, 9) has a groove bottom, an upper lip extending from an upper edge of the groove bottom, and a lower lip extending from a lower edge of the groove bottom, and is formed to open in a substantially horizontal direction, and is provided with a locking element (12) protruding downward at the extended end of the upper lip, the groove surfaces defining said connecting groove (8, 9) include an upper groove surface defining an upper surface of said connecting groove, a lower groove surface defining a lower surface of said connecting groove, an inner groove surface defining the groove bottom surface of said connecting groove, and an open groove surface including a surface of said locking element (12) facing said connecting groove (8, 9); When the solar panel frame (6, 7) and the rail (2) are connected, the connecting tongues (10, 11) are inserted into the connecting grooves (8, 9) and contact the upper groove surface and / or the lower groove surface and / or the inner groove surface and / or the open groove surface to form contact surfaces between the connecting tongues (10, 11) and the upper groove surface and / or the lower groove surface and / or the inner groove surface and / or the open groove surface, respectively, and the contact surfaces function as cooperative contact surfaces that limit the movement of the connecting tongues (10, 11) relative to the connecting grooves (8, 9), thereby preventing substantial separation between the solar panel frame (6, 7) and the rail (2) in a direction perpendicular to the pair of opposing side edges of the solar panel (1); A solar panel system, wherein the connecting grooves (8, 9) are shaped such that, when the solar panel frame (6, 7) is connected to the rail (2), a chamber is provided defined by a gap between the upper surface of the connecting tongue (10, 11) and the adjacent upper groove surface, and by a gap between the curved connecting tongue (10, 11) and a lower inner corner of the connecting groove (8, 9), which is curved at a smaller radius than the connecting tongue (10, 11), the chamber being disposed inside the connecting groove (8, 9) on the tip side of the connecting tongue (10, 11).

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