PV Edge Blocks for Ground-Mounted Wind-Stable Arrays
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Solution Overview
Problem
Conventional Utility-Scale Photovoltaic (PV) systems face challenges with high structural racking costs, wind loading, microcracking, and corrosion, which affect module efficiency and longevity, while also requiring extensive land use and complex installation processes.
Innovation Solution
The Earth Mount Technology eliminates the need for structural racking by placing PV modules directly on the ground, using edge blocks to stabilize and orient the modules, reducing wind loading, and preventing corrosion, thus lowering costs and increasing efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If conventional structural racking systems are used to support PV modules, then module stability and orientation are improved, but system cost and complexity increase
Solution Approach 1:
The patent removes the complex structural racking system entirely, extracting only the essential function of ground contact and module support. Modules are placed directly on the ground with simple edge blocks providing stabilization, eliminating steel structures, concrete foundations, and associated corrosion protection systems.
Solution Approach 2:
The patent replaces expensive, complex structural racking with simple, inexpensive edge blocks that can be easily replaced if needed. The system uses basic materials like wood or simple composite blocks rather than expensive galvanized steel structures with multi-year corrosion warranties.
2Strength
If PV modules are elevated on structural racking, then wind loading resistance is improved, but corrosion resistance and cost are worsened
Solution Approach 1:
The patent removes the steel structural racking system that is susceptible to corrosion from DC impressed current and environmental factors. By eliminating steel components entirely, the corrosion problem is solved while maintaining adequate wind resistance through direct ground contact and simple edge block stabilization.
Solution Approach 2:
The ground itself serves as the support structure, providing natural stabilization and protection. The earth contact point acts as a natural anchor, eliminating the need for corrosion-prone steel piles and concrete foundations that require maintenance and protection systems.
3Manufacturing precision
If PV modules are mounted on structural racking, then installation orientation precision is improved, but installation time and labor cost increase
Solution Approach 1:
The patent divides the array into modular sections with simple edge blocks at boundaries. Each module or small group of modules can be independently positioned and stabilized, allowing parallel installation without waiting for complex racking assembly. The segmented approach simplifies orientation tasks while accelerating deployment.
4Stability of the object's composition
If conventional racking systems are used, then module support and stabilization are improved, but land use efficiency decreases
Solution Approach 1:
The patent removes the space-consuming steel racking structures, concrete foundations, and associated clearance zones. By placing modules directly on the ground, the system maximizes land utilization without requiring the extensive right-of-way and setback distances needed for conventional elevated racking systems.
Data Source
AI summary
Edge blocks for a PV array comprising fastener or component holes for anchoring the array bonding the array and protecting array cabling. Edge blocks provide a favorable aerodynamic shape to help deflect incoming wind, the channel rainwater and to protect edge of the array. Methods having steps of placing modules contacting native topography or a smoothed or substantially flat portion of the ground in an array and holding the array together and down are also disclosed.