SYSTEM AND METHOD OF MOUNTING A REMOVABLE AND ADJUSTABLE PHOTOVOLTAIC BALLAST FRAME DEVICE

Abstract

A photovoltaic (PV) module mounting system comprises a plurality of PV modules, support brackets disposed under the modules and a ballast frame disposed under and attached to the support brackets. The ballast frame is supported on conventional building rooftops and attached thereto by conventional methods. The support bracket consists of front and rear supports, which can be adjusted to alter the desired tilt angles of the overlying PV modules. The ballast frames can be adjusted to varying widths and lengths. The system is effective in reducing the net effect of wind uplift force when modules are mounted on building rooftops. Additionally, the system provides the advantage of ease of use with less components and minimal roofing penetrations.

Description

RELATED APPLICATIONS

This application claims priority under 35 U.S.C. § 119(e) to provisional application Ser. No. 60/996,486, filed Nov. 20, 2007, the contents of which are incorporated by reference.

FIELD OF INVENTION

The present invention is directed generally to an apparatus and methods for use in a removable or adjustable mounting or assembling photovoltaic (PV) ballast frame system for use on flat surfaces.

BACKGROUND OF INVENTION

Prior art PV module ballast frame structures typically has the disadvantage of having many parts and multiple penetrations to a roofing structure upon which it is installed. Accordingly, light weight components, minimal penetration, ease of installation and reduced labor costs are major concerns of customers in the PV module ballast frame market. Specifically, the number of penetrating roofing attachments can decrease the effectiveness of expensive roofing surfaces. As a result, there is an increasing need to develop PV mounting frame systems that eliminate or reduce roofing penetration. There is an additional necessity to develop a PV mounting system, whereas to ensure that the installed system is less susceptible environmental stresses such as wind-loading.

SUMMARY OF INVENTION

The present invention in one embodiment provides a method and apparatus for mounting solar modules and other flat objects onto a relatively flat surface. Among the advantages to this embodiment includes that it has relatively few components and easy assembly. Further, parts can be configured to accommodate a plurality of sizes of flat objects. The present invention can comprise a bracket for maintaining flat objects, e.g. PV solar panels, at a plurality of angles, a ballast frame, which has the ability to be secured to a flat surface and bolt and nut hardware for attaching the bracket to the flat object and ballast frame. Additionally, embodiments of the present invention provide for minimal or zero penetrations of the flat surface upon which the system is being mounted. The minimal or zero penetrations of the flat surface, i.e., rooftop can be achieved by any fastening technique, including methods such as use of nuts, washers and bolts or adhesives. Alternatively, the present invention can be installed without the use of any fastening devices, wherein weighted objects attached to the ballast frame are used instead.

The photovoltaic ballast frame system incorporates horizontal and vertical members, at least one bracket and hardware components to attach the bracket to at least one member of the ballast frame. The ballast frame system allows for movement of the members to alter the configuration of a particular frame or collection of frames. Specifically, multiple frames can be attached to each other, as well as multiple brackets. Additionally, the ballast frame system can be constructed to accommodate varying sized or type of weighted objects. Also, the ballast frame system can incorporate grounding means between the plurality of components.

The method for constructing the photovoltaic ballast frame system includes constructing a ballast frame system, constructing at least one bracket, attaching the ballast frame to at least one bracket and attaching the ballast frame to a roofing surface. Additionally, the method includes grounding one or more components of the ballast frame system. Further, the method can include attaching a weighted object to the constructed ballast frame.

BRIEF DESCRIPTION OF DRAWINGS

The present invention will be understood and appreciated more fully from the following detailed description, taken in conjunction with the drawings in which:

FIG. 1 is a depiction of a two bay ballast frame;

FIG. 2 is a depiction of a single bay ballast frame;

FIG. 3 is a depiction of a support bracket used to support a PV module;

FIG. 4 is an embodiment of hardware used to attach the support bracket to the ballast frame and flat surface: e.g., a hex bolt, a washer or flange nut;

FIG. 5 is an inverted PV module fastened to a support bracket with a plurality of hardware components;

FIG. 6 is a PV module fastened to a double bay ballast frame;

FIG. 7 is a depiction of the fastening hardware components being used to affix the support bracket to the double bay ballast frame in FIG. 6;

FIG. 8 is a second PV module and support brackets fastened to a double bay ballast frame;

FIG. 9 is one PV module and support brackets mounted to a double bay ballast frame and a second PV module and support brackets mounted to the front end of the double bay ballast frame in the rear and a single bay ballast frame in the front;

FIG. 10 is two attached columns of PV modules and support brackets mounted to single bay ballast frames;

FIG. 11 is an exploded view of the connection of two columns of PV modules mounted to single bay ballast frames;

FIG. 12 is an alternative view of the PV module being connected to two connected ballast modules by a plurality of support brackets;

FIG. 13 is an alternative configuration of a non-extended single bay ballast frame design;

FIG. 14 is an exploded view of the connection of a plurality of non-extended single bay ballast frames; and

FIG. 15 is a 2 by 2 array comprising four modules and six single ballast frames.

DETAILED DESCRIPTION OF EXEMPLARY EMBODIMENTS OF THE INVENTION

Embodiments consistent with the present invention utilize varying configurations of ballast frames to support PV modules for personal or residential energy needs. In particular, these ballast frames can be constructed to accommodate varying sizes of PV modules as well as more than one frame can be configured to attach to each other. Typically, the ballast frames are installed on roofing structures. Accordingly, weighted objects, e.g., concrete blocks, can be placed in ballast frames to combat natural lift forces, which can be created by wind.

FIG. 1 is an exemplary non-limiting embodiment of double bay ballast frame 10. The double bay ballast frame 10 consists of horizontal members 1-4 and vertical connection members 5 and 6. Extensions 100a-d extend vertical connection members 5 and 6 for the purpose of connecting a plurality of ballast frame members. Extensions 100a and 100b are created by altering the position of horizontal members 1 and 2 within vertical members 5 and 6. A single bay ballast frame is created by horizontal members 1 and 2 and an end of 5 and 6. Similarly, another single bay ballast frame is created by horizontal members 3 and 4 and the opposite end of vertical members 5 and 6. Middle portions 101a and 101b are shown between the two single bay ballast frames.

Typically, solar panels are positioned to face a southern direction. Therefore, it should be appreciated that “vertical” connection members 5 and 6 are generally oriented in a north/south direction; whereas “horizontal” members 1 and 2 are generally positioned in an east/west direction. Generally, the “vertical” member extends perpendicularly from the “horizontal” member. Further, the ballast frame can be oriented such that it lies flat or at an angle. See FIG. 6.

The adjustable nature of the present invention can be demonstrated by FIG. 2, which is an embodiment of a single bay ballast frame 20. In this embodiment, a single row is created by horizontal members 7 and 8, wherein weighted objects can be placed. Horizontal members 7 and 8 are connected with short vertical members 9 and 10. Extension members 102a-102d are created within vertical members 9 and 10 by altering the position of horizontal members 7 and 8. An alternative embodiment of a single bay ballast frame is provided in FIG. 13.

Referring to FIG. 3, a schematic embodiment of a support bracket 30 used to support PV module on a flat surface is shown. A portion of support bracket 30 would be attached to a PV module and the other end would attach to a ballast frame as shown in FIG. 1 or 2. The bracket 30 comprises a horizontal chamber 14, a front support 16 and a rear support 15, which can both be made of folded metal, e.g., aluminum. In an alternative embodiment, front and rear supports 16 and 15 respectively, can also consist of a singular angled, e.g., a cylindrical post. Support members 15 and 16 can be attached to horizontal chamber 14 in a variety of manners including welds or mechanical means such as rivets, adhesive, bolts or other fasteners. If the support members are welded to the horizontal chamber, welds are executed at end 104 of rear support 15 and 103a and 103b for front support 16.

FIG. 4 is a non-limiting embodiment of 3 fastening elements, which are used to attach the support bracket 30 to either a PV module or a ballast frame, e.g., FIGS. 1 and 2. These elements consist of a bolt or screw 11, a washer 12 and a nut 13. As previously stated, these elements can be used to attach support members 15 and 16 to horizontal channel 14, or in any other place in the system where fastening is desired.

Referring to FIG. 5, an inverted view is shown of a PV module 19 being attached to two support brackets 17 and 18. In this embodiment, bolt 11, washer 12 and nut 13 are used to fasten brackets 17 and 18 to PV module 19.

As previously stated, a PV module can be attached to a plurality of constructed ballast frames. FIG. 6, for example, is an embodiment of a PV module 19 being attached to a double bay ballast frame 10, utilizing support brackets 106a and 106b attached. As previously described, double bay ballast frame can be comprised of two single bay ballast frames. Also, this embodiment demonstrates the double bay ballast frame attached to a roofing structure 200. The ballast frame 200 can be attached to roofing structure 200 in any desired manner, including mechanical means, adhesives etc. As shown, roofing surface 200 is a relatively flat surface; however, it should be appreciated that the present invention can be utilized in conjunction with any surface upon which the present invention can be attached.

In an effort to further depict the attachment of support bracket 106b to double bay ballast frame 10 in FIG. 6, an exploded view of such attachment is provided in FIG. 7. In this embodiment, horizontal chamber 24 is attached to rear support 25 by use of fastening elements bolt 11, washer 12 and nut 13. Support member 106b is also attached to horizontal member 2.

As previously discussed multiple PV modules can be attached to a ballast frame. Accordingly, FIG. 8 is an embodiment of an additional PV module being attached to a double bay ballast frame. PV modules 31 and 33 attached to double bay ballast frame 10. Similar to previous embodiments, support brackets 32a, 32b are attached to horizontal member 4. Support bracket 34 is attached to horizontal members 2 and 3.

Multiple PV module columns can be created by attachment of additional ballast frames to PV modules attached to other ballast frames. As shown in FIG. 9, an embodiment of PV module 41 attached to double bay ballast frame 10. Also, in this embodiment an additional PV module 42 is attached to via support brackets 45 and 46 to the front of double bay ballast frame 10 and the rear of single bay ballast frame 20. Support members 45 and 46 are attached to horizontal member 8. Additionally, a third PV module could be attached to horizontal member 7 of single bay ballast frame 20. Thus, an extended column of alternating PV modules and ballast frames can be attached to each other.

Embodiments of the present invention provides for multiple configurations or arrays of PV modules. FIG. 10 is an embodiment of alternating single bay ballast frames 51 and 54 connected to PV modules 47 and 50 respectively. In this embodiment, ballast frames 52 and 53 are attached to single bay ballast frames (and the attached PV modules 48 and 49 respectively). This configuration shows a 2 by 2 array. FIG. 11 is an exploded view of the connection of single bay ballast frames 53 and 54. As shown in previous non-limiting embodiments, the connection of ballast frames is made by use of bolt 11, washer 12 and nut 13.

Embodiments of the present invention provide for multiple configurations of PV module arrays, i.e., 1×2, 2×2 etc. arrays. FIG. 12 is an embodiment of a 1 by 2 array of PV modules 62a and 62b. In this embodiment, support brackets 63a-d are attached to ballast frames 641a-d.

Embodiments of the present invention also allow for a plurality configurations of ballast frames. For example, FIG. 13 is an alternative ballast frame design for single bay ballast frames 65a-d. In this embodiment, extensions are not affixed to vertical members 108a-d, as shown in FIG. 2. An exploded view of the connection of ballast frames 65c and 65d is shown in FIG. 14. The frames are attached by bolt 11, washer 12 and nut 13. A grounding washer 67 is also shown between the ballast frames 65c and 65d. Grounding washer 67, which can be used in any embodiment of the present invention, allows for grounding of one single bay ballast frames 65c and 65d. Grounding washers can also be used for grounding a PV module to the support bracket or from the support bracket to the ballast frame. Grounding washers provide the advantage of minimizing the number of grounding wires, which would otherwise be necessary for each module and frame member. Integration of grounding washers provides a continuous ground path throughout a PV array.

FIG. 15 is a 2 by 2 module array consisting of four PV modules 69a-d and six single bay ballast frames 70a-f. In this embodiment, a plurality of ballast blocks 71 are shown, which provides weight to counterbalance the lift force of wind when the present invention is situated on a flat surface such as a rooftop. An example of ballast blocks are concrete blocks.

While the foregoing describes various embodiments of the present invention, those of ordinary skill in the relevant arts will recognize the many variations, alterations, modifications, substitutions and the like as are readily possible, especially in light of this description, the accompanying drawings and claims drawn thereto. In any case, because the scope of the present invention may be much broader than a particular embodiment, the foregoing detailed description should not be construed as a limitation of the scope of the present invention, which is limited only by the claims appended hereto.

Claims

1. A system for removably and adjustably mounting a photovoltaic module or flat panel on an object, comprising:

a bracket wherein the bracket can be positioned in a plurality of angles;

a ballast frame, wherein the ballast frame consist of a plurality of longitudinal and latitudinal members and further wherein a plurality of brackets can be attached; and

a hardware system, wherein the bracket can be connected to at least one of the flat object or to the ballast frame.

2. A system for removably and adjustably mounting a photovoltaic module or flat panel on an object according to claim 1, wherein a weighted object can be attached to the ballast frame.

3. A system for removably and adjustably mounting a photovoltaic module or flat panel on an object according to claim 1, wherein the hardware system comprises at least one of a bolt, nut or washer.

4. A system for removably and adjustably mounting a photovoltaic module or flat panel on an object according to claim 1, wherein at least a portion of the bracket is mounted to a flat object.

5. A system for removably and adjustably mounting a photovoltaic module or flat panel on an object according to claim 3, wherein the flat object is grounded to at least one of the tilt bracket or the ballast frame.

6. A system for removably and adjustably mounting a photovoltaic module or flat panel on an object according to claim 1, wherein the weighted object comprises at least one concrete block.

7. A system for removably and adjustably mounting a photovoltaic module or flat panel on an object according to claim 1, wherein the members are arranged in a plurality configurations.

8. A system for removably and adjustably mounting a photovoltaic module or flat panel on an object according to claim 1, wherein the members comprises at least one of a longitudinal or latitudinal member.

9. A system for removably and adjustably mounting a photovoltaic module or flat panel on an object according to claim 1, wherein the bracket comprises a channel and further wherein the channel is made of aluminum or other material such as steel, wood or plastic.

10. A system for removably and adjustably mounting a photovoltaic module or flat panel on an object according to claim 1, wherein a metallic substance is affixed to the channel by at least one of welding, a rivet, an adhesive or a bolt.

11. A system for removably and adjustably mounting a photovoltaic module or flat panel on an object according to claim 7, wherein a metallic substance is affixed to at least one end of the channel by at least one of welding, a rivet, an adhesive or a bolt.

12. A system for removably and adjustably mounting a photovoltaic module or flat panel on an object according to claim 1, wherein the ballast frame comprises holes in which the bracket can be attached.

13. A system for removably and adjustably mounting a photovoltaic module or flat panel on an object according to claim 8, wherein the longitudinal and latitudinal members are assembled into a rectangular configuration.

14. A system for removably and adjustably mounting a photovoltaic module or flat panel on an object according to claim 13, wherein the members are configured to support a plurality of sizes of weighted objects.

15. A system for removably and adjustably mounting a photovoltaic module or flat panel on an object according to claim 13, wherein the rectangular configuration is dimensioned to house a plurality of concrete blocks.

16. A method of installing a photovoltaic module or flat panel on an object comprising the steps of:

constructing a ballast frame;

attaching a ballast frame to a plurality of brackets;

attaching the ballast frame affixed to the brackets to a surface.

17. The method of installing a photovoltaic module or flat panel on an object according to claim 16, wherein at least one weighted object is inserted into the ballast frame to weight the photovoltaic system to the flat surface.

18. The method of installing a photovoltaic module or flat panel on an object according to claim 16, wherein the brackets are attached to the ballast frame by at least one of a hex bolt, a washer or a flange nut.

19. The method of installing a photovoltaic module or flat panel on an object according to claim 16, wherein the ballast frame affixed to the flat surface is attached by at least one of a hex bolt, a washer or a flange nut.

20. The method of installing a photovoltaic module or flat panel on an object according to claim 16, wherein a grounding washer is inserted between more than one constructed ballast frames.