Integrated commercial and industrial solar solutions

Abstract

Embodiments of solutions for PV modules with integrated mounting systems are presented. Application of the systems are found primarily but not solely in commercial and industrial rooftop solar installations. The disclosed solutions allow for a very flexible use of said PV modules with integrated mounting systems in various installation situations, with a focus on demonstrating concepts that show direct applicability of mounting featured for adhesive as well as for ballasted solutions, as well as the combination of both. Support features that enable ergonomic transport and high speed, straightforward installation are highlighted. Features for alignment, for providing structural strength, specifically under snow and wind loading, as well as reliable, strong, yet accommodating interlinkage of PV modules are disclosed. The use of polymeric or fiber reinforced polymeric frames and mounting structures eliminates the need for grounding. Features are presented which a focus on not requiring tooling or hardware along with the installation.

Description

[0001] INTEGRATED COMMERCIAL AND INDUSTRIAL SOLAR SOLUTIONS

[0002] Inventors: Karl -Josef Kramer, Gianluigi Mascolo, Nathan Taylor, Jason Zerweck, Todd Esser and Sara Berg-Love

[0003] CROSS-REFERENCE TO RELATED APPLICATIONS

[0004]

[0001] This application claims priority to U.S. Provisional Application Serial No. 63 / 666,264, filed July 1st, 2024, which is hereby incorporated by reference in its entirety.

[0005] FIELD OF THE INVENTION:

[0006]

[0002] The present technology relates to photovoltaic (PV) modules and mounting systems.

[0007] BACKGROUND

[0008]

[0003] Reducing the cost of commercial and industrial (C&I) rooftop solar installation is a necessity for deploying more systems in a shorter time, which is needed in order to rapidly expand this segment of the Photovoltaic (PV) solar market.

[0009]

[0004] The use of lighter weight modules and racking systems increases the overall available market, in particular for commercial and industrial rooftops, especially to those roofs that are not strong enough to support heavy ballasted PV systems.

[0010]

[0005] Lighter panels and installation systems need to be designed to pass certification and have the necessary strength and resistance against wind, snow load and fire.

[0011]

[0006] This Invention was made with U.S. Government support under Award No. DE- SC0021791, awarded by the Department of Energy. The Government has certain rights in this invention.

[0012] Description of the invention

[0013]

[0007] The presented invention enables bringing modules onto rooftops as an all-in-one package. In addition, it enables fast installation that can be carried out by a single person.

[0014] Quick, yet secure roof installation, attachment and interlocking of modules and arrays of modules is achieved.

[0008] The presented invention discloses a novel lightweight, very strong and easy and quick to install PV module with integrated racking system. A new lightweight and strong support structure for beams supporting the module backside has been devised; a novel snow mount foot technology which supports the module in strategic locations is introduced and detailed; a strong, versatile east-west connection that allows the accommodation of uneven roof surfaces while providing strong linkage between modules for added wind uplift resistance is presented. The system has been designed to accommodate adhesive, ballasted and tethered installation on rooftops, all with the same integrated racking structure. All racking components have been demonstrated to fit within the silhouette of the system for stacking and transportation. Microinverter and DC optimizer options for factory installation as well as for safe, quick and straightforward installation on site of such units have been devised. A carry handle, ergonomically positioned on the underside of the module, is presented. A support structure along the south edge of the PV module frame is introduced, together with a means to quickly, easily and sturdily engage it. Electric cable management that is an integral part of the PV system, especially along its north edge mount support, is presented as well.

[0015] This disclosure primarily envisions firstly the use of an unframed photovoltaic solar module laminates, such as but not limited to a 60 or 72 cell photovoltaic module, made of for instance 60 or 72 multi- or monocrystalline silicon solar cells or half-cells, third cells or other combinations, with 120, 132, 144 and any number of half cells per module laminate. Such cells can be made from solar wafers of different sizes, including 156, 158, 166, 182, 210 mm on a side, or any other size. Cells can be made using passivated emitter rear contact (PERC), tunnel oxide passivated contact (TOPCon), heterojunction technology (HJT), integrated back contact (IBC) or any other technology. The same features apply to the use of other solar cell and module materials such as gallium arsenide or thin film module, for instance but not limited to thin film modules comprised of CIGS or CdTe or perovskite technology or combinations of above technologies. With suitable adaptations, the presented features can be applied to framed photovoltaic modules as well. Their use and application are envisioned and enclosed in full in this disclosure.

[0016]

[0009] In this invention, said solar module laminate is enclosed by a rectangular molded frame and glued or mechanically attached to the frame in such a way as to leave a gap around the perimeter of the laminate that enables easy water drainage from the laminate surface and thus reduces build-up of dirt along the edges of the module. The rectangular frame also serves to provide the kind of protection and structural strength that a standard aluminum frame provides.

[0017]

[0010] The number one requirement for the disclosed PV system is to achieve high strength at minimum weight. For this optimization, several concepts have been compared. Prior work has taught that the key to high strength is the proper design of the frame and especially the support beams running across the backside of the module. In a prior product, these beams were laid out in an open U shape, which is conducive to injection molding. The material of the overall can be a technopolymer based on glass filled nylon, glass filled polypropylene or others. An example brand name is Ultramid. However, other geometries of the beams, as well as other materials can be chosen. This disclosure teaches the use of support beams in the shape of I-beams, I-beams with web height that differs along the length of the beam, or with flanges that differ along the length of the beam, and I-beams in combination with other features, such as circular rods that allow for pivoting of components of the disclosed integrated PV system solution around an axis for folding and unfolding. Folded positioning is required for stacking and transportation of the PV systems. The components are unfolded during the placement and installation of the PV systems.

[0018] [OH] The mounting structure that serves to secure the module to the roof is attached during the manufacturing process of the frame to the module, preferably, but not limited to, the underside of the panel. The attachment is preferably done in such a way that the overall form factor of the panel is not or only slightly increased, especially in the two long directions of the panel. By assuring such attachment of the mounting structure to the panel it is assured that the panel, with its mounting structure attached, can be carried to its designated installation location on the roof, without the need of carrying any peripheral mounting structure components or tools, and can be carried to its location by a single person and also be installed by a single person. Even a person with limited experience or skills to install solar systems can perform the installation because of the design’s simplicity.

[0019]

[0012] Keeping the outside dimensions of the module with frame and with the racking components essentially the same as the dimensions of just module with frame assures that the shipping density can be significantly higher than for such modules that have separate racking components. Practically, the mounting components are incorporated in the silhouette and maximum dimensions of the frame of the laminate. Shipping cost can thus be significantly reduced.

[0020] [0131 Also, no packaging or wrapping material and spacers are needed and therefore there is very little material cleanup and removal effort required on the roof after the installation. This offers significant savings to installers and developers of solar projects.

[0021]

[0014] We present various concepts, including a structure allowing integrated module with installation system that can be stacked at essentially the same formfactor and density as modules, either by nesting north mount support and mount feet within the frame for shipment or by nesting feet underneath the north mount support and within the thickness confines of the frame. This embodiment includes mount feet, a rotatable attachment inside a PV module frame that allows pivoting a PV module frame and connect with mount feet of adjacent modules. In the presented invention, we focus on concepts which allow for the use either of adhesive which is applied to the underside of mount feet or of ballast weights to be placed on top of said mounting feet, instead of or in addition to said adhesive mounting to the roof, all while avoiding shading from said ballast weights. Such embodiments are enabled by having an elevating feature added along the south edge of the module frame, which keeps the south edge of the module frame sufficiently high to not suffer shading from an adjacent ballast weight, such as a paver. In this disclosure, various embodiments are presented for enabling said elevating feature, called south edge mount support while retaining the full stackability of the overall module with integrated frame and installation system.

[0022]

[0015] In addition, we teach the use of various connections to ensure solid connectivity along east-west direction, with east-west being the direction nomenclature for an array that is essentially south facing. The current disclosure demonstrates new concepts that provide significant new ideas and improvements for sound, reliable, yet flexible connection along the east-west direction.

[0023]

[0016] The mounting structures presented in here allow for flexibility with respect to the mode of installation, in accommodating for adhesive, ballasted and roof penetrated fixed connection to the roof.

[0024]

[0017] The same east-west connecting structure also allows for interconnection of adjacent solar modules, thereby increasing the tributary components of adjacent modules to resisting wind loads, which in turn qualifies the system to withstand higher wind loads. The mounting structure is shipped as integral with one module, called primary module for now, but allows for fixation of adjacent modules. Connections are established to the modules to the east and to the west, as well as to the north and to the south. The presented configurations cause the entire module array to be positively interlocked mechanically for maximum structural efficiency in withstanding environmental loads.

[0025]

[0018] In the various embodiments, we present mounting structures that are attached to the module with frame prior to installation, but with differences in the design and function of the mounting structure. These embodiments are based on a concept capable to work both with a molded frame as well as with a standard Al frame module, but from a cost point-of-view, molded frames are more readily capable of providing the disclosed features at lower cost. While the features presented herein lend themselves ideally to injection molding processes, the use of fiber reinforced plastics that are e g., pultruded and machined afterwards are also envisioned as an alternate approach to achieving the proposed structures and associated functions. The embodiments consist of at least one structure that is tucked in, preferentially below the module and, upon installation can swing or slide out or be removed and reattached to lift up at least one side of the module, for instance the north side (on an installation in the northern hemisphere). Optionally, an additional similar structure can be attached to the south side (also for the example of installation in the northern hemisphere), preferably lifting up said module to a lower extent. Such additional lifting can be advised when a ballasted design is chosen which requires pavers or other weight carriers to be placed in such a way as to not cause additional shading issues to a module’s northern neighbor or neighbors.

[0026]

[0019] Various embodiments for accomplishing said additional lifting of the second (typically southern) side, in a north-south oriented structure, are shown.

[0027]

[0020] Said embodiments enable east-west connection between adjacent modules by an integrated panel that swings or slides out to enable connection to the neighbor module.

[0028] NOMENCLATURE OF THE DRAWINGS

[0029]

[0021] The following listing describes the disclosed and marked individual features in the drawings. Features and their description is referred to in the description of the drawings.

[0030]

[0031] DESCRIPTION OF THE DRAWINGS

[0032]

[0022] The features, nature, and advantages of the disclosed subject matter may become more apparent from the detailed description set forth below when taken in conjunction with the drawings in which like reference numerals indicate like features. At times, a feature may have two reference numerals assigned to it. In general, this may indicate that the same feature is functionally in a different functional position or status, such as for instance folded in, unfolded, or in transition.

[0033]

[0023] The drawings serve to explain the inventions disclosed herein. For simplicity, it is assumed that the installation is done in the northern hemisphere, with a north-south oriented exposure geometry. That means to express that panels are tilted typically with the northern edge as high or higher than the southern edge; panel rows arranged east- west and subsequent rows arranged due north or due south. Naturally the same concepts hold as well for the southern hemisphere with arrangements adapted accordingly, and also hold for exposures that are not exactly in Due southern centered exposure. A person with skill in the art will also be able to derive usefulness to east-west type of PV system arrangements for many of the disclosed features. All arrangement geometries are considered captured as part of this invention.

[0034]

[0024] Fig. 1 A shows the underside of a PV system 10 consisting of a PV module laminate 20,40 with frame 50 and integrated mounting system. The PV laminate 20 is supported by a frame with north 80, south 90, east 110 and west 100 edge beams, as well as with inner support beams 120. A north mount support 200 is folded in for transport on the north edge 60 of the system. The folding is done by rotational motion. A south mount support 500 is also folded in on the south edge 70. The folding is done by rotational motion. Mount feet 400 are attached to the north mount support by the mount foot side engagement hook 220. The north mount support can be comprised of a plurality of segments or of one segment, or of a plurality of segments that are locked together and can be rotated as one piece. An east-west connection panel 600 (not depicted in Fig. 1A, but in Fig. IB) is snapped to one of the mount feet for transportation, then, for installation, is removed and connects adjacent PV systems at their circular recess area 240, which is gear shaped in the depicted embodiment. The gearshaped connection prevents relative rotation of east west connection panel and connected PV systems, once installed Other embodiments to prevent such relative rotation are envisioned as well. Snow mount feet 840 are attached to said inner support beams and are also folded in for transport by means of a rotational motion. A central carry handle 360 is supported by the middle two inner support beams. The PV system has its mounting features folded in for stacking and transport. Snow mount feet are an option for enhancing the robustness of the system under snow load. PV laminates typically are comprised, among other components, of a front (top) glass sheet, encapsulant above and below PV cells, PV cells with metallization strings, and a rear (bottom) layer which is typically either a polymeric backsheet which is typically white, transparent or black, or a second sheet of glass.

[0035]

[0025] Fig. IB shows the same PV system as Fig 1A, but from the top side, whereby, for illustration purposes, the PV laminate 20 is not shown. The PV system 10 has all its mounting components (mount feet, snow mount feet, rear (north) mount support and front (south) mount supports) folded in for transport.

[0036]

[0026] Fig. 1C shows a PV system similar to Fig 1 A, additionally including recess features for cable management along the north mount support.

[0037]

[0027] Fig. 2A shows the underside of a deployed PV system 10 consisting of a PV module laminate 20 with frame 50 and integrated mounting system. The PV laminate is supported by a frame with north 80, south 90, east 110 and west 100 edge beams, as well as with inner support beams 120. A north mount support 200 is unfolded for installation. Mount feet 400 are attached to said north mount support and are rotated in place for installation. The mount feet of the neighboring module 405 connect to the south mount support 500. The eastwest connection panel 600 is installed at a location close to the edge, where it is mounted at the circular gear shaped recess area 240 at the installation stage, to make solid contact to the western neighbor module. Snow mount feet 840 are attached to said inner support beams and also unfolded for installation. A central carry handle 360 is supported by the two inner support beams. The PV system has its mounting features unfolded for installation.

[0038]

[0028] Fig. 2B shows a deployed PV system 10 consisting of a PV module laminate 20, with frame 50 and integrated mounting system. The PV module laminated is omitted in the figure for illustration purposes. The PV laminate is supported by a frame with north 80, south 90, east 110 and west 100 edge beams, as well as with inner support beams 120. A north mount support 200 is unfolded for installation. Mount feet 400 are attached to said north mount support and are rotated in place for installation. The east-west connection panel 600 is installed at the circular recess area 240 close to the edge, where it is mounted at the installation stage, to make solid contact to the western neighbor module. Snow mount feet 840 are attached to said inner support beams and also unfolded for installation. A central carry handle 360 is supported by the two inner support beams. The PV system has its mounting features unfolded for installation. The PV system further contains a wind deflector 900 along its east edge. This is an optional piece for PV systems installed at the east edges of PV system arrays. It is not required for functionality at the edges of arrays. PV system arrays do not require such edge wind deflectors for functionality or for performance.

[0039]

[0029] Fig. 3 A shows an array of PV systems 10, each consisting of a PV module 20 laminate with frame 50 and integrated mounting system. The PV laminate is supported by a frame with north 80, south 90, east 110 and west 100 edge beams, as well as with inner support beams 120. A north mount support 200 is unfolded for installation. Mount feet 400 are attached to said north mount support and are rotated in place for installation. The east-west connection panel 600 is installed at a location close to the edge, where it is mounted at the installation stage, to make solid contact to the western neighbor module. For illustration purposes, one of the modules has its mount feet covered with ballast pavers 430, whereas the other modules do not. This illustrates the different attachment methods, wherein one method is to weigh down the PV array with pavers, the other to have an adhesive at the underside of the mount feet, protected by a liner which is removed at the time of installation, and wherein the mount feet are adhesively attached to the roof membrane.

[0030] Fig. 3B shows an array of PV systems 10, each consisting of a PV module laminate 20 with frame 50 and integrated mounting system. The PV laminate is supported by a frame with north 80, south 90, east 110 and west 100 edge beams, as well as with inner support beams 120. A north mount support 200 is unfolded for installation. Mount feet 400 are attached to said north mount support and are rotated in place for installation. The east-west connection panel 600 is installed at a location close to the edge, where it is mounted at the installation stage, to make solid contact to the western neighbor module. For illustration purposes, all of the modules have their mount feet covered with ballast pavers 430. This is a potential installation mode, especially on rooftops where adhesive attachment is not possible due to the roof surface. Furthermore, the PV array is equipped with wind deflectors 900 along the west edges of the array. Such wind deflectors at edges of the PV array are optional.

[0040]

[0031] Fig. 4A shows the underside of a PV system 10 which includes inner support beams 120 and west edge beam 100. Said inner support beams engage with north 80 and south 90 edge beams and have a cross-sectional profde of an I beam 175, with optional variable web height across the span. Also shown is an inner lateral beam 85. Inner support beams as well as east and west edge beams are shown with additional strengthening ribs 88.

[0041]

[0032] Fig. 4B shows an example of an I-beam 175 cross section with web 185 and with upper 190 and lower 195 flange.

[0042]

[0033] Fig. 4C shows an example of an I-beam 175 segment with variable web 185 height.

[0043]

[0034] Fig. 5 A illustrates a PV system 10 with markings for potential segmentation into

[0044] PV module frame 50 elements.

[0045]

[0035] Fig. 5B illustrates example segments of the frame 50 of a PV system 10.

[0046]

[0036] Fig. 5C illustrates an example connection between an inner support beam 120 and a north 80 or south 90 edge beam of a PV system in non-engaged position. Also shown is a receptacle 165 in north or south edge beam 80,90. In the depicted embodiment, the receptacle is essentially a socket. Said receptacles or sockets are the positions of engagement of west edge, east edge or inner support beam. For manufacturing reasons, the frame can be produced in segments. However, it is also envisioned that a frame with essentially same functions and beam components as described herein can be produced with fewer separate elements than shown in this disclosure, or even produced as one piece.

[0047] [0371 Fig- 5D illustrates an example connection between an inner support beam 120 and a north 80 or south 90 edge beam of a PV system in engaged position. As the PV system and its frame 50 are assembled, these frame segments are engaged. Additional attachment support, either adhesively in the attachment region or via a fastening bolt or screw in the attachment region, is envisioned as optional, but not shown.

[0048]

[0038] Fig. 5E illustrates a refined attachment with a smooth transition between inner support beam 120 and north 80 or south 90 edge beam.

[0049]

[0039] Fig. 6A shows a north 80, south 90, east 110 or west 100 edge beam with a distancing lip 160 for uniform adhesive distribution and distance between PV laminate and all associated beams. Such distancing lips can be distributed across the whole frame surface. In this figure, the distancing lip is depicted as spanning the full width of the beam. It can also be designed to span only a partial width of the beam.

[0050]

[0040] Fig. 6B shows a cross-section of the frame edge beam of a PV system with a PV module laminate 20 and with a gap between the underside of said PV module laminate and said frame edge beam 80,90, wherein said gap is enabled by a distancing lip 160. Also shown is a ledge at the edge of said frame edge beam 170, which serves to protect the edge of said PV laminate during stacking and shipment.

[0051]

[0041] Fig. 6C shows the schematic cross section of an edge beam 80,90,100,110 in a two-piece mold tool 155. The beam is tilted slightly for separation of the two-piece tooling. In addition, the inner walls of the I-beam structure have a finite slope that enables the release from the mold. Top side feature provides separation between modules for stacking and protects the edge of the typically glass-based PV laminate 20. Also shown is the distancing lip 160, indicating that the schematic cross-section of this part is taken in the region of the distancing lip, wherein this embodiment of the distancing lip only covers part of the beam width.

[0052]

[0042] Fig. 7A shows PV laminate with north 80 or south 90 edge frame beam that has cylindrical pivoting rods or hinges 130. Said pivoting rods allow for the rotation off north mount support 200 or south mount support 500 for the purpose of transportation and installation. Cylindrical pivoting rods are cored out, leaving a circular disk along the cylindrical rod. Said cylindrical pivoting rods are held by cylindrical rod holders 135.

[0043] Fig. 7B shows PV laminate 20 with north 80 or south 90 edge frame beam that has cylindrical pivoting rods 130. Said pivoting rods allow for the rotation off north mount support 200 or south mount support 500 for the purpose of transportation and installation. Cylindrical pivoting rods are cored out, leaving circular disks along the rod as well as lateral segments on the cylinder surface. Said cylindrical pivoting rods are held by cylindrical rod holders 135.

[0053]

[0044] Fig. 8A shows a PV system 10 with a north mount support 200, wherein said north mount support is connected to the north edge beam 80 of the frame 50 of the PV system and can rotate around said edge beam and is continuous across the span of the module width. In this embodiment, the north mount support has a gap between north edge support beam and the upper part of the north mount support as well as a gap between the lower part of the north mount support and the ground or rooftop.

[0054]

[0045] Fig. 8B shows a PV system 10 with a north mount support 200, wherein said north mount support is connected to the north edge beam 80 of the frame 50 of the PV system and can rotate around said edge beam and is continuous across the span of the module width. In this embodiment of the north mount support the gap between north edge support beam and the upper part of the north mount support as well as the gap between the lower part of the north mount support and the ground or rooftop are minimized. Also shown is a carry handle 360. The lower side of said carry handle and the upper side of said PV system should have a distance that allows for ergonomic carry of said PV system by a single person. The distance should be approximately 17-21 inches tall to enable such carrying by a very large majority of people.

[0055]

[0046] Fig. 9A shows a PV system 10 with a north mount support 200, wherein said north mount support is connected to the north edge beam 80 of the frame 50 of the PV system and can rotate around said edge beam and is segmented into an east and a west segment across the span of the module width. In this embodiment, the north mount support is split into two halves, an eastern and a western portion. The system is shown folded for transportation and stacking.

[0056]

[0047] Fig. 9B shows the same PV system as Fig. 9A, with components folded out and deployed. The underside of the PV system 10 is depicted. On the underside of the mount foot 400, a location with adhesive 410 is shown. Said adhesive can span the complete mount foot or parts of it.

[0048] Fig. 9C shows the same PV system as Fig. 9 A, with components folded out and deployed. The top side of the PV system 10 is depicted. For illustration, one PV system is weighed down using ballast pavers 430 placed on mount feet 400, whereas the other PV system does not have ballast pavers, as it is envisioned as attached adhesively.

[0057]

[0049] Fig. 10A shows a PV system in deployed state. The figure also shows the circular engagement area 240 on the north mount support 200 for the east-west connection panel 600.

[0058]

[0050] Fig. 10B shows the cross-section of a PV system with PV laminate 20, PV laminate frame 50 and north mount support 200, where north mount support has a snapping feature 225 that is engaged with a snapping feature holding position on the frame edge.

[0059]

[0051] Fig. 10C shows the cross-section of a PV system with PV laminate 20, PV laminate frame 50 and north mount support 200 at a different cross-sectional point, namely in the region of the hinge 130. The figure indicates a resting region on the frame side engagement hook 210 with a broad area for secure load transfer between PV laminate frame and north mount support. A rotation limiting plate 140 on the north edge beam 80 prevents the north mount support from rotating further than it should upon deployment.

[0060]

[0052] Fig. 10D shows a north mount support 200 with snapping features for transport and for deployment. Snapping features 225 to snap the north mount support to inner support beams 120 are indicated. The figure also shows the circular recess area for the east-west connection panel engagement 240, which, in this embodiment, is depicted as gear-shaped.

[0061]

[0053] Fig. 10E shows PV system 10 with north mount support 200 folded in and held in place by engaging with inner support beams 120 by means of a snapping feature 225. The figure also shows the circular engagement area for the east-west connection panel 240.

[0062]

[0054] Fig. 10F shows the cross-section of said snapping features 225 that hold north mount support 200 in place with respect to inner support beam 120.

[0063]

[0055] Fig. 11A shows PV system with north edge beam 80 and shows north mount support 200 with support ribs 205 and with frame side engagement hooks 210 and foot engagement hooks 220. Also shown is a mount foot 400 with cylindrical rod feature 435 that enables the foot pivoting around the lower part of the north mount support by means of engaging with the foot engagement hooks, with the center of the cylindrical rod feature of the mount foot defining the pivoting axis.

[0056] Fig. 1 IB shows a close-up of a north mount support 200 in an embodiment where the north mount support has a gap between north edge beam 80 and north mount support.

[0064]

[0057] Fig. 11C shows a close-up of a north mount support 200 in an embodiment where the north mount support has a minimized gap between north edge beam 80 and north mount support.

[0065]

[0058] Fig. 1 ID shows a close-up of north mount support 200 from Fig. 11C in an embodiment where the north mount support has a minimized gap between north edge beam 80 and north mount support, with a view from the opposing side the north mount support.

[0066]

[0059] Fig. 12A shows a cable from one of the junction boxes 300 of a PV laminate 20 being tethered along the carry handle 360 and north mount support 200 of PV system 10. The cable exists to the outside of the north mount support via a through-hole 280 near the center of the north mount support. The cable from the other polarity is not shown but may exit either through the same through-hole or through the adjacent through hole in the adjacent segment of the north mount support. The view is from the top, with the PV laminate omitted for illustration purpose. Also shown are cable holding features along the carry handle 320. The carry handle is engaged to the inner support beams 120 of the frame of the PV system. It is also suspended by lower retention features, which prevent the carry handle from pivoting out during the transport.

[0067]

[0060] Fig. 12B shows the cable routing schematic when the PV system is deployed. Cable from junction box 300 is carried alongside carry handle 360 (cable not shown in that section) and fed through a through-hole 280 to the outside of the north mount support. The north mount support has a recess 260 to route the cable towards the northeast and northwest edges of the PV system for connection to neighbor PV systems, and has cable retention regions 270 that prevent the cable from slipping out and also are capable of holding return cables from other modules or strings.

[0068]

[0061] Fig. 12C shows a carry handle 360 for a PV system 10 with a different tethering location 320 for a cable connecting to the lower junction box 300 of the PV laminate 20 (not shown). Also shown are carry handle attachment slides 370 for connection with inner support beams 120.

[0069]

[0062] Fig. 12D shows a carry handle 360 integrated in a PV system 10, with the handle linked to two inner support beams 120. A cutout in the handle allows for sufficient space for a carrier’s fingers to grab on to the handle. Extensions near the bottom of the carry handle 390 prevent the bottom part of the handle from swinging away from the PV laminate and asserting excess torque at the upper connection points.

[0070]

[0063] Fig. 13 A shows the cable 257 nested in a recess of the north mount support 260 and held in place by cable retention regions 270. Also shown is a cable connector 258 resting recess 265 that allows to store the cable connector for transport and have it ready for connection upon installation.

[0071]

[0064] Fig. 13B shows a close-up of said connector 258 resting recess 265 which includes a lip 285 for secure fastening of the electrical PV module cable for transport.

[0072]

[0065] Fig. 13C shows a close-up of the cable recess 260. Only one side of the PV system is shown. The other side contains the cable and connector of the opposite polarity opposite polarity. The cable directions can be swapped upon installation by proper design of cable lengths.

[0073]

[0066] Fig. 14A shows the installed PV system with north mount support 200, which also contains return cables 259 from other modules that are neatly held above the surface using cable retention regions 270.

[0074]

[0067] Fig. 14B shows a close-up of said cable retention region 270.

[0075]

[0068] Fig. 14C shows a cross-section of the cable retention region 270, showing a cable retention holder 285, in this embodiment with a holding lip that prevents cables 257 from slipping up and out of the retention region.

[0076]

[0069] Fig. 15A shows a deployed PV system 10 with north mount support 200 and mount feet 400, and also containing attachment panels for DC optimizers 330, as well as an attachment panel 335 for an optional access point that is used to address one of more DC optimizers in a PV array.

[0077]

[0070] Fig. 15B shows an example of a DC optimizer 325 mounted on an attachment panel 330 for a DC optimizer. The DC optimizer can be shipped pre-mounted, if required.

[0078]

[0071] Fig. 15C shows the cross section of a DC optimizer 325, mounted on an attachment panel 330, wherein the attachment panel is clipped without tools onto the north mount support 200.

[0079]

[0072] Fig. 16A shows a deployed PV system with north mount support 200 and mount feet 400, and also containing an attachment panel for microinverter 350.

[0073] Fig. 16B shows the cross section of a microinverter 345, mounted on an attachment panel 350, wherein the attachment panel is clipped without tools onto the north mount support 200.

[0080]

[0074] Fig. 17A shows alternate options for attachment panels 355 to mount DC optimizers 325 or microinverters 345 on. Said panels can be folded in for transport and DC optimizers or microinverters can be pre-installed at the factory. This figure shows the microinverter attachment panel folded in for transport.

[0081]

[0075] Fig. 17B shows the cross section of a deployed PV system 10, with an attachment panel for microinverter or DC optimizer 355 folded out in a deployed position. .

[0082]

[0076] Fig. 17C shows the underside of a deployed PV system 10 with an attachment panel for a microinverter or DC optimizer 355, with the attachment panel folded in.

[0083]

[0077] Fig. 17D shows the underside of a deployed PV system 10 with an attachment panel for a microinverter or DC optimizer 355, with the attachment panel folded out in a deployed position.

[0084]

[0078] Fig. 18A shows a mount foot 400 for a PV system. The mount foot contains cylindrical rod features 440 along one edge (southern edge) to connect with the mount foot side hinge of the north mount support. It also contains cylindrical rod features 435 along the other edge (northern edge) to connect with the engagement hooks of the south mount support of the northern neighbor module. Said cylindrical rod features are each held by cylindrical rod holders 445. It also contains hook guidance and retention features 480 to prevent hooks from the south mount support of the northern neighbor module from disengaging after engagement and deployment. It also contains ballast paver centering sidewall 465 features that prevent a placed paver from slipping sideways and off the mount foot.

[0085]

[0079] Fig. 18B shows a mount foot 400 with ballast paver 430. Ballast paver centering sidewall features 465 are also shown. In the other direction, the ballast paver is prevented from slipping by the cylindrical rod features 420.

[0086]

[0080] Fig. 18C shows a mount foot 400, connected to a north mount support 200 of a PV system in a folded-in position. Also shown is an east-west connection panel 600, snapped onto said mount foot for transport and held in place by snapping features 495.

[0087]

[0081] Fig. 19A shows a PV system with folded out north mount support 200 and with mount foot 400, wherein said mount foot is snapped into a position that is over-rotated past its installation angle, enabling removal of a liner protecting an adhesive at the underside of the foot.

[0088] [0821 Fig- 19B shows a side view of a PV system with folded out north mount support 200 and with mount foot 400, wherein said mount foot is snapped into a position that is overrotated past its installation angle, enabling removal of a liner protecting an adhesive at the underside of the foot and wherein the southern edge 425 of said mount foot is rounded essentially concentric to the pivoting axis of the mount foot for its rotation around the mount foot side hinge of the mount support, said pivoting axis defined by cylindrical rod features 435 of said mount foot, and wherein such rotation of the mount foot does not require the lifting of the north mount support. Said cylindrical rod features 435 are depicted in figure 18A.

[0089]

[0083] Fig. 19C shows the PV system with north mount support 200 and mount foot 400, including cored out mount foot side hinges 235 of north mount support and including rounded southern edge of said mount foot.

[0090]

[0084] Fig. 19D shows the underside of a deployed PV system with PV laminate 20,40, frame 50, including north edge beam 80, east edge beam 110 and inner support beam 120, north mount support 200, mount foot 400 with adhesive 410 on underside of said mount foot and deployed snow foot 840. Said adhesive can be covered with a protective liner before installation which is peeled of for installation. Adhesion of the mount foot to the roof surface provides one of the potential attachment mechanisms or the PV system.

[0091]

[0085] Fig. 20 shows a mount foot 400, attached to the south mount support 500 of a northern neighboring PV system 10 with frame edge beam 90. The remainder of the PV system that the mount foot is attached to is hidden from side for illustration purposes.

[0092]

[0086] Fig. 21 A shows the cross section of a deployed PV system 10 with north frame edge beam 80, north mount support 200 and folded out mount foot 400, wherein said mount foot is weighed down by a ballast paver 430. The figure also shows the northern neighbor PV system, with its south mount support 500 deployed and engaged with the southern neighbor PV system’s mount foot 400.

[0093]

[0087] Fig. 21B shows one embodiment of a south mount support 500 of a PV system, wherein said south mount support is a fixed integral part of the south edge beam 90 of said PV system which provides sufficient lift to establish that the southern edge 70 of the module clears the shadow generated by a ballast paver 430 placed on the connecting mount foot 400.

[0088] Fig. 21 C shows another embodiment of a south mount support 500 of a PV system, wherein said south mount support is hinged to the south edge beam 90 of said PV system and can be rotated around the hinge axis for deployment.

[0094]

[0089] Fig. 2 ID shows another embodiment of engagement between a mount foot 400 and its northern neighbor PV module. In this embodiment, a lifting bar 525 is part of the mount foot or its own component and whereas the south mount support 500 of the northern neighbor PV system is a fixed integral part of the south edge beam 90 of said PV system, but wherein the necessary lift to prevent shading from a ballast paver 430 placed on the connecting mount foot is essentially provided by the lifting bar.

[0095]

[0090] Fig. 22A shows a PV system with south edge beam 90 and a south mount support 500 with the south mount support folded in for transport and stacking.

[0096]

[0091] Fig. 22B shows a PV system with south edge beam 90 and a south mount support 500 with the south mount support rotated out in a first step during installation, to provide lifting.

[0097]

[0092] Fig. 22C shows a PV system with south edge beam 90 and a south mount support 500 with the south mount support rotated out in a first step during installation, to provide lifting and afterwards shifted sideways to lock it in place. Cylindrical rod holders 135 prevent said south mount support from rotating back in this sideways shifted position.

[0098]

[0093] Fig. 22D shows a PV system with south edge beam 90 and a south mount support 500 with the south mount support rotated out in a first step during installation, to provide lifting and afterwards shifted sideways to lock it in place. The mount support is cored out with ribs 515 for uniform and low-cost injection molding. The figure shows the workings of a locking mechanism. A locking wedge 545 prevents the south mount support from sliding sideways. Resting area on south mount support 530 (seen in Figure 26D) prevents said south mount support from over-rotating and cylindrical rod holder 135 on south edge beam prevents the south mount support from rotating back into a folded position. The PV system may contain an eastern south mount support and a western south mount support. For locking them in place, it is advantageous to have them shift for locking in a mirror symmetry, i.e., either both shifting outwards towards the module edges or both inwards towards each other. Since the south mount supports engage with feet of their southern neighbor’s PV system 405 and said feet have a fixed lateral gap, these mount feet define the lateral gap between said south mount supports. The mirror symmetry prevents said mount supports from both accidentally shifting out of position in unison.

[0099] [0941 Fig- 22E shows a PV system with south edge beam 90 and a south mount support 500 with the south mount support folded in for transport and snapped to an inner support beam 120 via a south mount support transport snapping feature 505.

[0100]

[0095] Fig. 23A shows a south mount support 500 of a PV system with frame side engagement hook 510 and mount foot side engagement hook 520.

[0101]

[0096] Fig. 23B shows the frame side engagement hook 510 of the south mount support 500 of a PV system locked into the pivoting rod / hinge 130 on the south edge beam 90. A locking wedge 545 prevents the south mount support from sliding sideways.

[0102]

[0097] Fig. 23 C shows a south mount support 500 of a PV system with a locking protrusion 535 which engages with a cylindrical pivoting rod 130 of a south frame edge beam, preventing the south mount support from shifting out.

[0103]

[0098] Fig. 23D shows a south mount support 500 of a PV system with a south frame edge beam 90, wherein the south mount support has been rotated and shifted in place, and wherein said locking protrusion 535 engages with a cored-out part of said cylindrical rod 130 of the south frame edge beam to stabilize the south mount support.

[0104]

[0099] Fig. 24A shows a PV system 10 with integrated frame 50 and racking system, including edge beams 110,90 and inner support beams 120 and a south mount supports 500, rotated and shifted in place. Said PV system is shown during installation and mating to the mount feet 400 of its southern neighbor PV system which has already been installed, southern neighbor PV system not shown. The mount foot side hinges of said south mount supports engage with the cylindrical rods of said southern neighbor PV system’s mount feet 440. In addition to mount foot side engagement hooks of south mount support 520 which engage with the mount feet of the southern neighbor module, a frame comer support 540, here in the shape of a hook, which is part of the south mount support is shown.

[0105]

[0100] Fig. 24B shows a PV system 10 from previous figure being rotated around a pivot axis defined by the cylindrical rods of the mount feet of the southern neighbor PV system 440. Figures 24A and 24B show different embodiments of the PV system.

[0106]

[0101] Fig. 25A shows a south mount support 500 with frame side engagement hooks 510 and mount foot side engagement hooks 520. To facilitate engagement with circular rod features on southern neighbor PV system’s mount foot 440, the mount foot side engagement hooks have a pointy lead-in ramp 550 in the direction of the southern neighbor PV system. Also shown is a retention facet 570 on the mount foot side engagement hooks.

[0107]

[0102] Fig. 25B shows a mount foot 400 with cylindrical rod feature 440 that the south mount support 500 of the northern neighbor PV system engages with. Said mount foot also includes a retention ramp 450. The guidance and locking feature contains a lead-in upward ramp to guide the mount foot side hook of the south mount support of the northern neighbor PV system up and in for installation. It also contains a near-vertical inside locking flank which prevents said mount foot side hook from slipping out after engaging.

[0108]

[0103] Fig. 25C shows a south mount support 500 with frame side engagement hooks 510 and mount foot side engagement hooks 520, engaged with a mount foot 400. PV laminate and frame not shown for illustration purposes. The retention facet on the mount foot side engagement hook 570 interacts with the inside locking flank of said retention ramp 450 on said mount foot, in order to prevent said mount foot side hook from slipping out after engaging. The PV system (not shown, for illustration purposes) is approximately vertical during the engagement process with its southern neighbor’s mount foot.

[0109]

[0104] Fig. 26A shows a side view of a mount foot 400 and the south mount support’s 500 mount foot side hook 520 during the engagement and sliding in. Said mount foot side hook 520 engages with the cylindrical rod 440 on the mount foot, which is held by cylindrical rod holder 445. The pointy lead-in ramp 550 of the mount foot side hook points in the direction of the southern neighbor PV system.

[0110]

[0105] Fig. 26B shows a side view of a mount foot 400 and the south mount support’s 500 mount foot side hook 520 after the engagement and showing how the inside locking flank 460 on the retention ramp 450 of the mount foot and the retention facet 570 on the mount foot side hook of the south mount support act together to prevent disengagement.

[0111]

[0106] Fig. 26C shows a side view of a mount foot 400 and the south mount support’s 500 mount foot side hook 520 after the engagement and sliding in, with said hook fully inserted and wrapped around the cylindrical rod 440 on the mount foot. It is visible that the hook sits deeper and closer to the ground than in figure 26A. The weight of the PV system resting on said south mount support facilitates dropping said hook down after engagement and prevents it from slipping out upon rotation or other motion.

[0107] Fig. 26D shows a side view of a mount foot 400 and the south mount support’s 500 mount foot side hook 520 in its installed position.

[0112]

[0108] Figure 27 shows modified engagement structures for mating south mount support 500 of one PV system with the mount foot 400 of its southern neighbor PV system.

[0113]

[0109] Fig. 27A shows a south mount support 500 with frame side engagement hooks 510 and mount foot side engagement hooks 520. To facilitate engagement with cylindrical rod features on southern neighbor PV system’s mount foot 440, the mount foot side engagement hooks have a pointy lead-in ramp 550 in the direction of the southern neighbor PV system, which help to give alignment tolerance in vertical direction for engagement, as is depicted in figures 27B, 27C, 27D and a sloped edge ramp 560 in the lateral direction, which facilitates alignment in the lateral direction for the installer.

[0114]

[0110] Fig. 27B shows a side view of a mount foot 400 and the south mount support’s 500 mount foot side hook 520 during the engagement as the PV system is being lowered onto the mount foot’s cylindrical rod for engagement 440. The mount foot has a guidance and retention feature 480 to prevent hooks from disengaging. Said guidance and retention feature 480 has a ramp with resting position 470.

[0115]

[0111] Fig. 27C shows a side view of a mount foot 400 and the south mount support’s 500 mount foot side hook 520 after the engagement and showing how the ramp with resting 470 position on the mount foot serves to rest the engaging PV system and prevent it from sliding back and away from the mount foot’s cylindrical rod 440. Said cylindrical rod 440 on the mount foot is held by cylindrical rod holder 445.

[0116]

[0112] Fig. 27D shows a side view of a mount foot 400 and the south mount support’s 500 mount foot side hook 520 during the engagement and sliding in, aided by gravity and by the ramp with resting position 470 on the mount foot, with said hook fully inserted. It is visible that the hook sits deeper and closer to the ground than in figure 27C.

[0117]

[0113] Fig. 27E shows a side view of a mount foot 400 and the south mount support’s 500 mount foot side hook 520 int its installed position.

[0118]

[0114] Fig. 28A shows a cross section of a PV system’s north edge beam 80 and a north mount support 200, with said mount support in the deployed position. An extended flat region on the frame side hook 210 of the north mount support enables a wide area contact 230 with the north edge beam and prevents local stresses during snow loading of said PV laminate 20. Visible on the edge beam are sloped angles in the inner cross section of the beam that facilitate injection molding, while the upper side of the beam is flat for engagement with the PV laminate.

[0119]

[0115] Fig. 28B shows a cross section of a PV system’s north edge beam 80 and a north mount support 200, with said mount support in the folded position.

[0120]

[0116] Fig. 28C shows a cross section of a PV system’s north edge beam 80 and a north mount support 200, with said mount support in the insertion position for factory assembly.

[0121]

[0117] Fig. 28D shows a cross section of a PV system’s south edge beam 90 and a south mount support 500, with said mount support in the deployed position. An extended flat region on the frame side hook 510 of the south mount support enables a wide area contact 530 with the south edge beam and prevents local stresses during snow loading of said PV laminate.

[0122]

[0118] Fig. 28E shows a cross section of a PV system’s south edge beam 90 and a south mount support 500, with said mount support in the folded position.

[0123]

[0119] Fig. 28F shows a cross section of a PV system’s south edge beam 90 and a south mount support 500, with said mount support in the insertion position for factory assembly.

[0124]

[0120] Fig. 29A shows an east-west connection panel 600. Also shown are gear-shaped circular protrusions 640 with teeth along the perimeter. Said circular protrusions are ideally conical to facilitate engagement with circular recesses 240 on north mount supports 200. The mated gear-shaped geometries are meant to prevent the relative rotation of neighboring connected PV systems when connected via the east-west connection panel. Other embodiments are also envisioned which achieve such prevention of relative rotation of neighboring connected PV systems. They include ratcheted east-west connection panel latches.

[0125]

[0121] Fig. 29B shows a PV system 1 10 and a PV system 2 10, which are neighbors to the east and west, respectively. Each PV system has an engagement region 240 to connect an east-west connection panel 600. Said engagement region can be in the form of a circular recess, and have an east-west connection panel latch mechanism 610. In the depicted embodiment, east-west connection panel latch mechanism 610 is fastened to the north mount support 200 by a screw 620. A barbed snap can also be used for this function. Also shown is an east-west connection panel that is to be installed. The circular recesses on the north mount supports are ideally conical to some degree, to facilitate engagement with the east- west connection panel’s circular protrusions 640.

[0122] Fig. 29C shows the same set of PV systems 10, with an east-west connection panel 600 attached between them. The view is from the north. The east-west connection panel latches 610 are open (here: horizontal). When rotated, the latch moves along the circular ramp features 630 in the engagement region 240. Here, the western neighbor panel’s western edge is higher than its easter edge, indicating a non-flat roof surface. The east-west connection panel contains sufficient adjustment capability to accommodate such differing angles between adjacent modules while still providing a tight connection.

[0126]

[0123] Fig. 29D shows the same set of PV systems 10, with an east-west connection panel 600 attached between them. The view is from the north. The east-west connection panel latches 610 are open (here: horizontal). The western neighbor panel’s western edge is lower than its easter edge, indicating a non-flat roof surface. The east-west connection panel contains sufficient adjustment capability to accommodate such differing angles between adjacent modules while still providing a tight connection.

[0127]

[0124] Fig. 30A shows an array of PV systems 10. Depicted in said PV array are said PV systems containing a PV laminate 20 with frame 50, a north mount support 200 and mount feet 400. Linking PV systems along the east-west direction is an east-west connection panel 600.

[0128]

[0125] Fig. 30B shows a PV system 1 10 and a PV system 2 10, which are neighbors to the east and west, respectively. Each PV system has an engagement region 240 to connect an east-west connection panel 600. Said engagement region can be circular, and have an east-west connection panel latch 610, which can be fastened to the north mount support 200 by a screw 620. A barbed snap can also be used for this function.

[0129]

[0126] Fig. 30C shows the same set of PV systems 10, with an east-west connection panel 600 attached between them. The east-west connection panel latches 610 are open (here: horizontal). The east-west connection panel contains circular ramp feature 630 concentric with the pivoting axis of said east-west connection panel latch.

[0130]

[0127] Fig. 30D shows the same set of PV systems 10, with an east-west connection panel 600 attached between them. The east-west connection panel latches 610 are closed and locked (here: vertical). The east-west connection panel’s circular ramp feature 630 that are concentric with the pivoting axis of said east-west connection panel latch prevent said latch from rotating back and opening.

[0128] Fig. 31 A shows an east-west connection panel 660 with an alternate connection concept. Also shown are north mount supports 200 of adjacent panels, wherein one mount support accommodates rotation of said east-west connection panel, whereas the other mount support accommodates vertical and horizontal translation. The west PV system is higher than the east PV system. The systems are close together. Circular recesses and protrusions 670 on one side of the engagement location between east-west connection panel and north mount support, and vertical and horizontal recesses and protrusions 675 on the other side of the engagement location between east-west connection panel and north mount support the establishment of a tight connection between adjacent modules through said east-west connection panel.

[0131]

[0129] Fig. 3 IB shows an east-west connection panel 660 with an alternate connection concept. Also shown are north mount supports 200 of adjacent panels, wherein one mount support accommodates rotation of said east-west connection panel, whereas the other mount support accommodates vertical and horizontal translation. The west PV system is lower than the east PV system. The systems are close together.

[0132]

[0130] Fig. 31C shows an east- west connection panel 660 with an alternate connection concept. Also shown are north mount supports 200 of adjacent panels, wherein one mount support accommodates rotation of said east-west connection panel, whereas the other mount support accommodates vertical and horizontal translation. The west PV system is higher than the east PV system. The systems are further apart.

[0133]

[0131] Fig. 3 ID shows an east-west connection panel 660 with an alternate connection concept. Also shown are north mount supports 200 of adjacent panels, wherein one mount support accommodates rotation of said east -west connection panel, whereas the other mount support accommodates vertical and horizontal translation. The west PV system is lower than the east PV system. The systems are further apart.

[0134]

[0132] Fig. 32A shows an east-west connection panel 660 with an alternate connection concept. Also shown are north mount supports 200 of adjacent panels, wherein one mount support accommodates rotation of said east-west connection panel, whereas the other mount support accommodates vertical and horizontal translation. The east-west connection panel is tightened using a ratcheting screw 680, akin to a gas cap.

[0133] Fig. 32B shows a ratcheting screw 680, akin to a gas cap, for tightening down east-west connection panels 660to north mount supports 200.

[0135]

[0134] Fig. 32C shows an alternate latching system for the attachment of an east-west connection panel 660 to north mount supports 200. The system consists of a rotating bar with central pivoting cylinder 690. The rotating bar latches to receptacle features 695 on each north mount support.

[0136]

[0135] Fig. 32D shows a rotating bar with central pivoting cylinder 690.

[0137]

[0136] Fig. 33A shows an array of PV systems 700. Depicted in said PV array are said PV systems containing a PV laminate with frame, a north mount support and mount feet. Linking PV systems along the east-west direction are east-west connection panels. Also shown are north-south running tethering cables 705 that are fed through the north and south mount supports of the PV systems. Such tethering can be done across a whole array or only along edges or other strategic regions of an array. Said tethering cables can be tied to the rooftop using cable mounts. Such tethering can be done in addition to adhesion or ballasting or in lieu of adhesion or ballasting.

[0138]

[0137] Fig. 33B shows an array of PV systems 700. Depicted in said PV array are said PV systems containing a PV laminate with frame, a north mount support and mount feet. Linking PV systems along the east-west direction are east-west connection panels. Also shown are tethering cables 705 that are fed through the north and south mount supports of the PV systems. An additional east-west running tethering cable 710 in east-west direction is also shown. It can be run above the mount feet, run through holes on the mount feet, or otherwise linked to the PV systems.

[0139]

[0138] Fig. 33C shows a through-hole 250 in a north mount support 200, through which a tethering cable 705 is fed. Also shown is a cutout 580 in the south mount support 500, to enable a straight horizontal continuation of a tethering cable.

[0140]

[0139] Fig. 33D shows arrays of PV systems 700 and tethering cables 705,710 that are installed along the edges of PV arrays.

[0141]

[0140] Fig. 33E shows a tethering cable mount 720 that can be firmly attached to a roof deck using screw holes 730 and that further contains attachment holes for tethering cables 740. Tethering cable tightening mechanisms, using ratcheting cable tighteners and crimping tools are known.

[0141] Fig. 34A shows the underside of a PV system, with PV laminate 40, with inner support beams 120 and with a north or south frame edge beam 50. Said frame edge beam also contains stacking features 930, to safely distance the PV system from a neighbor system, when stacked for transport and storage.

[0142]

[0142] Fig. 34B shows a PV system with PV laminate 20, frame edge beams 50 and with stacking features along the edge and on the comers of said frame 920.

[0143]

[0143] Fig. 35A shows the cross-sectional side view of an installed PV system with inner support beam 120, south mount support 500, north mount support 200, folded out mount foot 400 and snow mount foot 800, attached to an inner support beam 120 or an east or west edge beam 100,110. Also depicted is the installation surface 243, which can be, but is not limited to the surface of a roof deck. Said snow mount foot significantly reduces sagging of said beams under snow load. Also shown are the vertical dimension 802 of a snow mount foot and the bottom edge 804 of a snow mount foot. In this embodiment, the vertical dimension 802 is selected such that inner support beam 100 stays essentially straight when a vertical snow load pushes down on said PV system, causing the bottom edge 804 of said snow mount foot to touch the installation surface 243.

[0144]

[0144] Fig. 35B shows the cross-sectional side view of an installed PV system with west edge beam 100, south mount support 500, north mount support 200, folded out mount foot 400 and snow mount foot 800, attached to an inner support beam 120 or an east or west edge beam 100,110. Also depicted is the installation surface 243, which can be, but is not limited to the surface of a roof deck. Said snow mount foot significantly reduces sagging of said beams under snow load. Said north mount support is designed with a slightly different angle. Also shown are the vertical dimension 802 of a snow mount foot and the bottom edge 804 of a snow mount foot. In this embodiment, the vertical dimension 802 is selected such that west edge beam 100 stays essentially straight when a vertical snow load pushes down on said PV system, causing the bottom edge 804 of said snow mount foot to touch the installation surface 243. The same holds for east edge beam 110 (not depicted here).

[0145]

[0145] Fig. 35C shows the cross-sectional side view of an installed PV system with west edge beam 100, south mount support 500, north mount support 200, folded out mount foot 400 and snow mount foot 800, attached to an inner support beam 120 or a east or west edge beam. Said snow mount foot significantly reduces sagging of said beams under snow load. Said mount foot further contains a ballast paver 430. The snow mount foot height may be selected to keep the PV laminate straight as shown. The snow foot height may also be selected to be somewhat lower and thus the PV laminate is encouraged, under snow load, to form a cylindrical surface, albeit with very large radius, which can provide added stability to the system when under load.

[0146]

[0146] Fig. 35D shows the cross-sectional side view of two installed PV systems with west edge beams 100, south mount supports 500, north mount supports 200, folded out mount feet 400 and snow mount feet 800, Said mount feet further contain ballast pavers 430. Also indicated are shading angles for shade that southern PV system effects on northern neighbor PV system. The figure illustrates that south mount support 500 has a height that enables the south frame edge 70 of said PV system to be elevated substantially to reduce or avoid shading of the northern PV system from a paver 430 placed on the mount feet of the southern neighbor module. This is important for an application where the PV system is weighed down using ballast pavers. However, for a system that is mounted adhesively, a lower elevation of said south edge of PV frame may be sufficient, so that the south mount support’s main function is to provide connectivity to the mount foot of the southern neighbor module via at least one rotatable mount foot side engagement hook 520, shown in other figures, such as Figure 27.

[0147]

[0147] Fig. 36A shows the cross-sectional side view of an installed PV system with inner support beam 120, south mount support 500, north mount support 200, folded out mount foot 400 and snow mount foot 800, attached to an inner support beam 120 or an east or west edge beam 100,110. Said snow mount foot significantly reduces but not completely avoids sagging of said beams under snow load. Also depicted is the installation surface 243, which can be, but is not limited to the surface of a roof deck. Also shown are the vertical dimension 802 of a snow mount foot and the bottom edge 804 of a snow mount foot. In this embodiment, the vertical dimension 802 is selected such that west edge beam 100, and with it the PV module laminate can deflect downwards when a vertical load, such as from snow loading, is applied to said PV system, until the bottom edge 804 of said snow mount foot touches the installation surface 243. The same holds for east edge beam 110 and for inner support beam 120 (both not depicted in this cross section). This figure is shown without such an external vertical load.

[0148] Fig. 36B shows the cross-sectional side view of an installed PV system with west edge beam 100, south mount support 500, north mount support 200, folded out mount foot 400 and snow mount foot 800, attached to an inner support beam 120 or an east or west edge beam 100, 110. The PV system is depicted experiencing a downward force 806, such as from a snow load. That force acts typically on the PV laminate (depicted in other figures, such as Figure 1 A, 1C) and is then conveyed in part to the depicted support and edge beams. Also depicted is the installation surface 243, which can be, but is not limited to the surface of a roof deck. Said snow mount foot 800 significantly reduces but not completely avoids sagging of said beams under snow load. West edge, east edge and inner support beams 100 (or 110, 120, which are not shown), all bend under the downward force 806, until the bottom edge 804 of snow mount foot 800 touches installation surface 243. If all snow mount feet are designed with same vertical dimension 802, then the support beams under load have a form approaching a circular arc and the PV laminate 20 has the shape approaching that of a partial cylinder shell, which can act to partially stabilize the PV laminate. If snow mount feet supporting east and west edge beam have a taller dimension than snow mount foot or snow mount feet supporting inner support beam or inner support beams, then the PV laminate 20 may form a shape closer to a partial ellipsoidal shell under downward force, with edges higher than the center. All embodiments are meant to be covered and are achievable by suitable tailoring of the vertical dimension of individual snow mount feet.

[0148]

[0149] Fig. 37A shows the underside of a PV system with PV laminate 40 and inner support beam 120. Also shown is a snow mount foot 800, in an embodiment where said snow mount foot is engaged with said inner support beam by sliding along the lower flange of said beam. Guidance and stopping features 810 on said support beam are also shown. They prevent snow mount foot from disengaging Snow mount foot contains engagement features that establish a T-shaped guide 820. It also contains snapping and stopping features 830. While the figure shows a snow foot mounted to an inner support beam, east and west edge beams are envisioned to have the same structural features to enable snow mount foot attachment.

[0149]

[0150] Fig. 37B shows the underside of a PV system with PV laminate 40 and inner support beam 120. Also shown is a snow mount foot 800, in an embodiment where said snow mount foot is engaged with said inner support beam by sliding along the lower flange of said beam. Guidance and stopping features 810 on said support beam are also shown. The snow mount foot has been installed and is held firmly in position through a T-shaped guide 820 and snapping and stopping feature 830.

[0150] [1511 Fig- 38A shows an alternative embodiment for a snow mount foot 840. Shown here is the cross-section side view of a PV system with PV laminate 20 and support beam 120. A snow mount foot and a snow mount foot attachment plate 850 are also shown. Said snow mount foot attachment plate can alternatively also be an integral part of the support beam. The snow mount foot is folded in for transport and stacking. While the figure shows the snow mount foot attached to an inner support beam, the same structural capability is envisioned for the east and west edge beam 100,110.

[0151]

[0152] Fig. 38B shows an alternative embodiment for a snow mount foot 840. Shown here is the view from below of a PV system with PV laminate 40 and support beam 120. A snow mount foot and a snow mount foot attachment plate 850 are also shown. Said snow mount foot attachment plate can also be an integral part of the support beam. The snow mount foot is folded in for transport and stacking.

[0152]

[0153] Fig. 38C shows an alternative embodiment for a snow mount foot 840. Shown here is the cross-section side view of a PV system with PV laminate 20 and support beam 120. A snow mount foot and a snow mount foot attachment plate 850 are also shown. Said snow mount foot attachment plate can also be an integral part of the support beam. The snow mount foot is folded out to its deployed position and supports the support beam.

[0153]

[0154] Fig. 39A shows a snow mount foot 840, attached to a segment of an inner support beam 120 and held to said inner support beam by a snow mount foot attachment plate 850. The snow mount foot has circular engagement and pivoting rods 880. The snow mount foot is brought next to said attachment plate position and then the pivoting rods are slid in to matching receptacles 860 at the snow mount foot attachment plate. The snow mount foot has strengthening ribs 875 running perpendicular to the support beam to provide extra strength.

[0154]

[0155] Fig. 39B shows a snow mount foot 840 after attachment to said snow mount foot attachment plate 850. The snow mount foot is folded in. This procedure is carried out at the assembly factory prior to stacking and shipment.

[0155]

[0156] Fig. 39C shows a snow mount foot 840, attached to a segment of an inner support beam 120 and held to said inner support beam by a snow mount foot attachment plate 850. The snow mount foot has circular engagement and pivoting rods 880. The snow mount foot has been rotated from its folded position.

[0156] [1571 Fig- 39D shows a snow mount foot 840, attached to a segment of an inner support beam 120 and held to said inner support beam by a snow mount foot attachment plate 850. The snow mount foot has circular engagement and pivoting rods 880. The snow mount foot has been rotated from its folded position and subsequently pushed forward (southward) to its final installation position. Snapping flags 890 on the snow mount foot engage south of receptacles for the pivoting rods and prevent a disengagement of the snow mount foot.

[0157]

[0158] Fig. 40A shows an installed PV system 10 with PV laminate 20, frame 50, south mount support 500 and north mount support 200. Also shown is an optional east side wind deflector 900 that can be positioned at the western edge of an array of said PV systems. Said east side wind deflector is being slid into position from the north and east.

[0158]

[0159] Fig. 40B shows an installed PV system 10 with PV laminate 20, frame 50, south mount support 500 and north mount support 200. Also shown is an optional east side wind deflector 900 that can be positioned at the western edge of an array of said PV systems. Said east side wind deflector is engaged and in position. Engagement points include snapping regions along the edge support beam and a hook receptacle in the north mount support 910.

[0159]

[0160] Fig. 41A shows a PV system 10 with a north mount support 200, wherein said north mount support is connected to the north edge beam 80 of the frame 50 of the PV system and can rotate around said edge beam and is segmented into an east and a west segment across the span of the module width. In this embodiment, the north mount support is split into two halves, an eastern and a western portion. In addition, the north mount supports have gaps 950 to allow for placement of a ballast paver partially or completely underneath the PV system’s PV module laminate. The system is shown folded for transportation and stacking.

[0160]

[0161] Fig. 41B shows the same PV system 10 as Fig. 41A, with components folded out and deployed.

[0161]

[0162] Fig. 41C shows the same PV system 10 as Fig. 41A, with components folded out and deployed. The top side of the PV system is depicted. Ballast pavers 430 are placed on mount feet 400 and are placed partially underneath the PV module laminate 20.

[0162]

[0163] Fig. 42A shows an alternative embodiment for a PV system frame 50. In addition to edge beams 80,90,100,110 and inner support beams 120 running from north to south, a set of additional inner lateral beams 85 is placed to support the rear of the PV laminate (not depicted).

[0163] [1641 Fig- 42B shows a close-up of the alternative embodiment for a PV system frame 50. Inner support beams 120 and west and east edge beams 100 contain receptacles 105, 125 to enable engagement of additional inner lateral beams.

[0164]

[0165] Fig. 43A shows a PV system 10 with PV module laminate 20, frame 50 and south mount supports 500, where said south mount supports are folded out.

[0165]

[0166] Fig. 43B shows a PV system 10 with PV module laminate 40, frame 50 and south mount support 500, where said south mount support is folded out and where snow mount feet 800 / 840 are in place. In this embodiment, four snow mount feet are attached. In equivalent embodiments, snow mount feet are also attached to east and west edge beams 110,100.

[0166]

[0167] Fig. 43 C shows a PV system 10 with PV module laminate 40, frame 50 and south mount support 500, where said south mount support is folded out and where snow mount feet 800 / 840 are in place and mount feet 400 are rotated out, beyond the angle of final deployment.

[0167]

[0168] Fig. 43D shows a PV system 10 with PV module laminate 40, frame 50 and south mount support 500, where said south mount support is folded out and where snow mount feet 800 / 840 are in place and mount feet 400 are rotated out, beyond the angle of final deployment. The north mount support 200 is rotated out for installation.

[0168]

[0169] Fig. 43E shows PV systems 10 in a first installation row, each with PV module laminate 20, frame 50 and south mount support 500, where said south mount support is folded out and where snow mount feet 800 / 840 are in place and mount feet 400 are rotated out, beyond the angle of final deployment. The north mount support 200 is rotated out for installation and the PV systems are placed in position.

[0169]

[0170] Fig. 43F shows installed PV systems 10 in a first installation row, each with PV module laminate 20, frame 50 and south mount support 500, where said south mount support is folded out and where snow mount feet 400 are in place, where the north mount support 200 is in place and mount feet are rotated into their final deployed position flat on the rooftop. The east-west connection panel 600 between PV systems has been unsnapped from is transport position and has been attached to its position linking two neighbor PV systems.

[0170]

[0171] Fig. 44A shows an installed first row, a south row, of PV systems 10. It also shows a northern neighbor PV system with PV module laminate 20, frame 50 and south mount support 500, where said south mount support is folded out and where snow mount feet 800 / 840 are in place. Said south mount support has mount foot side hooks 520 which are being engaged with mount feet 405 of the southern neighbor PV system that is part of the south row.

[0171]

[0172] Fig. 44B shows an installed first row, a south row, of PV systems 10. It also shows a northern neighbor PV system with PV module laminate 20, frame 50 and south mount support 500, where said south mount support is folded out and where snow mount feet 800 / 840 are in place. Said south mount support has mount foot side hooks 520 which are being engaged with mount feet 405 of the southern neighbor PV system that is part of the south row. The mount feet 400 of said northern neighbor module are rotated out, beyond the angle of final deployment. The north mount support 200 is rotated out for installation.

[0172]

[0173] Fig. 44C shows two rows of installed PV systems 700, wherein the southern row is completely installed, whereas its northern neighbor row has the PV module laminate 20 and frame 50 supported by south 500 and north 200 mount, with mount feet 400 still turned up. For removal of adhesive liner.

[0173]

[0174] Fig. 44D shows two rows of completely installed PV systems 700, The northern row has east-west connection panels 600 attached and mount feet 400 are fully installed on the rooftop.

[0174]

[0175] Fig 45A shows an embodiment of multiple PV systems 10 stacked for transportation, in this case, arranged vertically, such as for transportation. Components depicted on the underside of the system: including the north mount support 200, mount feet 400, snow mount feet 840 and south mount support 500, are folded in, and the east-west connection panel 600 is attached to an inner lateral beam 85 for transportation. A carry handle 365 with two grip options is shown.

[0175]

[0176] Fig 45B shows an embodiment of the underside of a deployed PV system 10 consisting of a PV module laminate 40 with frame 50 and integrated mounting system, as described below. A north mount support 200 is unfolded for installation. Mount feet 400 are attached to said north mount support and are rotated in place for installation. The mount feet of the neighboring module 405 connect to the south mount support 500. The east-west connection panel 600 is installed at a location close to the edge, where it is mounted at the circular gear shaped recess area 240 at the installation stage, to make solid contact to the western neighbor module. Snow mount feet 840 are attached to said inner support beams and also unfolded for installation. A central carry handle 365 is supported by the two inner support beams.

[0176] [1771 Fig- 45C shows a deployed PV system 10 consisting of a PV module laminate 20, with frame 50 and integrated mounting system. A north mount support 200 is unfolded for installation. Mount feet 400 are attached to said north mount support and are rotated in place for installation. The east-west connection panel 600 is installed at the circular recess area 240 close to the edge, where it is mounted at the installation stage, to make solid contact to the western neighbor module. Snow mount feet 840 are attached to said inner support beams and also unfolded for installation. The PV system has its mounting features unfolded for installation.

[0177]

[0178] Fig. 46 shows the underside of a PV system 10 which includes inner support beams 120 and inner lateral beams 85. Said inner support beams engage with north 80 and south 90 edge beam. Inner support beams as well as east and west edge beams are shown with additional strengthening ribs 88. An embodiment of a carry handle 365 in shown, supported by two inner support beams. This carry handle has two grip options and strengthening ribs 366. Also depicted is a central south mount support element 502 that is rotated in place to centrally support the south edge. The disclosed embodiment envisions a single person holding up and carrying said PV system by using said carry handle 365. It is also envisioned that for a two- person carry option, two similar carry handle can be installed near to east edge beam and west edge beam, respectively, and be similarly attached and supported.

[0178]

[0179] Fig. 47A shows a northwest comer region of a PV system 10 including the laminate 20, north edge beam 80, north mount support 200, mount foot 400, east-west connection panel 600, the mount support with recess 260 for cable routing, and how each of these pieces latches together. A cable (not shown) nests in a recess of the north mount support 260 and is held in place by cable retention regions 270. The north mount support has a frame side engagement hook 210 which engages the north edge beam pivoting rods 130, and a mount foot side engagement hook 220 which engages the cylindrical engagement rods 435 on the mount foot. This figure also depicts another embodiment of an east-west connection latching system. In the comer, the east-west connection panel 600 rests in the circular shaped recess area 240 and is held in place by an east-west connection panel attachment snap 602 and on each side by two semi-circular east-west connection panel latches 605 that turn to lock the panel in place. Said attachment snap 602 snaps to an attachment snap receptacle 604 on north mount support 200. (Figure 47B). In this embodiment, said east-west connection latches are each turned towards an angle-locking edge 603 of said east-west connection panel and restrict the east-west connection panel from rotational motion.

[0179]

[0180] Fig. 47B shows a north comer of a PV system 10 including the laminate 20, north edge beam 80, north mount support 200, mount foot 400, east-west connection panel 600, the mount support cable system, and how each of these pieces latches together. A cable (not shown) nests in a recess of the north mount support 260 and is held in place by cable retention regions 270. The north mount support has a frame side engagement hook 210 which engages the north edge beam pivoting rods 130, and a mount foot side engagement hook 220 which engages the cylindrical engagement rods 435 on the mount feet. This figure also depicts another embodiment of an east-west connection latching system. The circular gear shaped recess area for the east-west connection panel 240 and the recess area 242 for the two semicircular east-west connection panel latches 605 that lock the panel in place are both visible. Also depicted is the attachment snap receptacle 604 on north mount support 200 to which the east-west connection panel attachment snap 602 of said east-west connection panel 600 attaches.

[0180]

[0181] Figure 48A shows a pivoting and sliding snow mount foot 840 attached to an inner support beam 120, and the snow mount foot engagement and pivoting rods 880 on the foot engage with built-in inner support beam receptacle hooks 865 to attach the foot. The snow mount foot also has strengthening ribs 875 running perpendicular to the inner support beam. In this figure, the snow mount foot is folded up towards a lateral support beam 85 for transportation. The mechanisms is the same for east and west edge beams 100, 110 (not shown in this Figure).

[0181]

[0182] Figure 48B shows a pivoting and sliding snow mount foot 840 that has been rotated downward, the first of two steps of engagement for installation. It is attached to an inner support beam 120, and the pivoting rods 880 on the foot engage with the inner support beam receptacle hooks 865 to attach the foot. The snow mount foot also has strengthening ribs 875 running perpendicular to the inner support beam. The cutout 866 in the inner support beam rib allows space for the pivoting rod when the foot slides.

[0183] Figure 48C shows a pivoting and sliding snow mount foot 840 that has been rotated downward and slid to the left, along the main direction of inner support beam 120, where it is locked in and able to support a load. It is attached to an inner support beam 120, and the pivoting rods 880 on the foot engage with the inner support beam receptacle hooks 865 to attach the foot. The snow mount foot also has strengthening ribs 875 running perpendicular to the inner support beam. The pivoting rod occupies the cutout in the inner support beam rib 866.

[0182]

[0184] The mechanisms depicted in Figures 48A-C are the same for east and west edge beams 100, 110 (not shown in these Figures).

[0183]

[0185] Several useful features which are described in this disclosure as part of a north- south oriented structure, are applicable to east-west installation geometries as well. It is clear to someone with reasonable knowledge of the field to be able to apply or combine features shown in one embodiment to or with features of another disclosed embodiment and to apply general useful features from a north-south arrangement to an east-west installation arrangement . Such combinations and transferred application of disclosed concepts are intended to be covered by this enclosure in their entirety.

Claims

CLAIMSWhat is claimed is:

1. A photovoltaic (PV) system, comprising:A PV laminate with a PV module frame, together comprising a PV module, said PV module frame having edge beams along north, south, east and west edges, said north and south edge beam each containing at least one pivoting rod (hinge), said PV module frame having along one edge a north mount support, attached to said pivoting rod in north edge beam, to elevate said edge of said PV module, said north mount support being rotatable around said pivoting rod of north edge beam, and folded in underneath the frame for stacking and transportation into a folded position and rotated out and unfolded for installation, said frame having along the opposing edge at least one south mount support, attached to said pivoting rod in south edge beam, to elevate said edge of said PV module, said south mount support being rotatable around said pivoting rod of south edge beam, and folded in underneath the frame for stacking and transportation into a folded position and rotated out and unfolded for installation, said north mount support further having at least one mount foot side engagement hook, said mount foot side engagement hook attaching to at least one mount foot, attached in a rotatable way, said mount foot having a cylindrical rod for north mount support attachment, said mount foot further having a cylindrical rod for northern neighbor PV system’s south mount support engagement, said south mount support having at least one mount foot side engagement hook on the side opposing the side where said PV frame south edge beam is attached, said south mount foot side engagement hook being able to engage with mount foot of a neighbor module by rotating said PV module in such a way that said south mount foot side engagement hook connects with a cylindrical rod on neighbor module’s mount foot for south mount support engagement said south mount support further having a locking feature to prevent backsliding from an installed position, said south mount support having two degrees of motion, wherein firstly, said south mount support is rotated out from a transport position tucked in within the silhouette of said PV frameinto an installation position, and wherein secondly, said south mount support sideways parallel to the edge of said PV frame into a locked position, said PV frame further comprising at least one inner support beam.

2. The PV system in claim 1, further comprising capability of attaching a plurality of snow mount feet to its frame, by means of attaching said snow mount feet to west edge beam, east edge beam and inner support beams, wherein said snow mount feet, in their installed position, are placed underneath west edge beam, east edge beam and inner support beams, respectively, and wherein the height of said snow mount feet can be chosen to be equal for each snow mount foot or different for each or some snow mount feet.

3. The PV system in claim 2, wherein each said snow mount foot is attached in a rotatable form to the respective beam, west edge beam, east edge beam and inner support beam or beams, and wherein said snow mount feet are rotated into a tucked-in position within the confines of the PV module frame for transport and wherein said snow mount feet are rotated into a position underneath said west edge, east edge and inner support beam, respectively, during installation of said PV system.

4. The PV system in claim 3, wherein said snow mount feet can further be slid in a direction parallel along their respective beams into a locked position.

5. The PV system in claim 2, wherein the height of said snow mount foot is chosen such that said snow mount feet are raised above the surface when there is no snow load and allow the PV laminate and at least an inner support beam to bend downward under snow load before said snow mount foot engages with the installation surface.

6. The PV system in claim 1, wherein said north mount support further comprises a plurality of cable retention features to elevate cabling from the installation surface.

7. The PV system in claim 6, wherein said mount support further comprises a recess in said north mount support for cable routing.

8. The PV system in claim 1, wherein said mount foot allows either adhesive connection to a surface via an adhesive layer at the bottom of said mount foot, or allow alternatively or in addition the placement of a ballast paver on top of said mount foot, and wherein said mount foot has ballast paver centering sidewall features to prevent said pavers from shifting off of said mount foot.

9. The PV system in claim 1, where said north mount support contains at least one through-hole enabling the tethering to a surface via a steel or other cable that runs essentially horizontal to the rooftop and wherein said PV system or an array of said PV systems are tied to the rooftop via a tethering cable mount.

10. The PV system in claim 1, wherein north mount support contains essentially circular shaped recess areas, each close to north mount support’s west and east edges, where an east- west connection panel can be applied.11 . The PV system in claim 10, wherein said east-west connection panel is secured by an east-west connection panel latch mechanism.

12. The PV system in claim 1, wherein said south mount support provides sufficient elevation to prevent shading of south edge of said PV system from a paver placed on southern neighbor system's mount foot, and wherein said south mount support has mount foot side engagement hooks.

13. The PV system in claim 1, wherein said south mount support does not provide substantial elevation to the south edge of PV module frame to prevent shading of south edge of said PV system from a paver placed on southern neighbor system's mount foot, and wherein said south mount support has mount foot side engagement hooks.

14. The PV system in claim 1, containing a south mount support and wherein mount foot side engagement hooks of south mount support are shaped to provide engagement lead-in guidance in lateral and vertical direction.

15. The PV system in claim 1, containing a south mount support and at least one mount foot and wherein said mount foot contains a lead-in and retention ramp for northern neighbor PV's system's south mount support's mount foot engagement hook.

16. The PV system in claim 1, further comprising a carry handle, wherein said carry handle is connected to two inner support beams.

17. The PV system in claim 1, wherein said west edge beam, east edge beam and inner support beam have cross-sections that are essentially I-beam shaped.

18. The PV system in claim 17, wherein the web height of the I-beam varies along its length.

19. The PV system in claim 1, further comprising at least one inner lateral beam.

20. The PV system in claim 1, wherein a beam (north, south, east, or west edge, inner support or inner lateral) in one direction contains a receptacle for connecting to an adjacent orthogonal beam.

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