WO2014107680A1 - Novel solar module support structure and methods relating thereto - Google Patents

Abstract

A solar module mounting apparatus is described. The solar module mounting apparatus includes: (i) a single support sheet including one or more connecting regions such that a force applied to the single support sheet is distributed throughout the single support sheet and to one or more of the connecting regions; (ii) a module fastener designed to secure a solar module on the single support sheet; and (iii) one or more support fasteners for fastening one or more of the connecting regions of the single support sheet to a supporting surface, such that when the solar module is secured on the single support sheet that is fastened to the supporting surface, a force acting upon the solar module is distributed through the single support sheet to the supporting surface.

Description

NOVEL SOLAR MODULE SUPPORT STRUCTURE AND METHODS RELATING THERETO

RELATED APPLICATION

[0001] The application claims priority from U.S. Provisional Application having Serial No.

61/749,350, filed on January 6, 2013, which is incorporated herein by reference for all purposes. FIELD OF THE INVENTION

[0002] The present invention relates to novel solar module support structures and methods relating thereto. More particularly, the present invention relates to novel solar module support structures and methods of mounting thereof that may employ a single support sheet with one or more connecting regions or a support structure with one or more recessed regions wherein the connecting regions and recessed regions provide support.

BACKGROUND

[0003] Solar photovoltaic (hereinafter known as "PV") modules are becoming increasingly popular for harnessing renewable energy. A common solar PV module design currently on the market uses a glass cover and metal frame, such as aluminum, to protect the underlying solar cells during transportation, installation and operation. More recently, non-glass solar modules, (i.e., that do not require a glass cover) that employ thin films are being used. Unfortunately, the current non-glass solar module designs are expensive and difficult to mount on supporting surfaces such as rooftops.

SUMMARY OF THE INVENTION

[0004] In view of the foregoing, one aspect of the present teachings provides a solar module mounting apparatus. The solar module mounting apparatus includes: (i) a single support sheet including one or more connecting regions such that a force applied to the single support sheet is distributed throughout the single support sheet and to one or more of the connecting regions; (ii) a module fastener designed to secure a solar module on the single support sheet; and (iii) one or more support fasteners for fastening one or more of the connecting regions of the single support sheet to a supporting surface, such that when the solar module is secured on the single support sheet that is fastened to the supporting surface, a force acting upon the solar module is distributed through the single support sheet to the supporting surface.

[0005] In one embodiment of the present arrangements, the single support sheet is a contiguous sheet. However, in another embodiment of the present arrangements, the single support sheet has defined therein apertures and/or cutouts. In one implementation of the present teachings, the single support sheet includes one or more recessed regions, each of which includes a protruding portion flanked between two sloping portions. In this embodiment one or more junction boxes may be positioned in the recessed region of the support structure. Similarly, one or more inverters may be positioned in the recessed region of the support structure. [0006] In accordance with one embodiment of the present arrangements, a first connecting region is disposed at a first edge of the single support sheet and a second connecting region is disposed at a second edge of the single support sheet, and wherein the first edge and second edge are opposite to each other.

[0007] In certain embodiments of the present arrangements, the single support sheet includes one or more edges having a sloping region that slopes away from a substantially flat region of the single support sheet and slopes towards the supporting surface, such that the sloping surface prevents wind from entering a space between the supporting surface and the single support sheet.

[0008] In some embodiments of the present teachings, the supporting surface includes one or more trusses, and wherein one or more of the connection regions of the single support sheet is aligned with one or more of the trusses such that when the single support sheet is position adjacent to the supporting surface, one or more of the support fasteners connects one or more of the connecting regions to one or more of the trusses.

[0009] The single support sheet may be made from at least one material chosen from a group comprising aluminum, steel, stainless steel, plastic, copper, glass reinforced plastic, and fiberglass. The fiberglass may be made from non-woven continuous glass fibers impregnated and/or laminated with at least one material chosen from a group comprising polypropylene, polyethylene, polyester, polyvinylchloride, acrylic and polycarbonate.

[0010] In certain embodiments of the present arrangements, the single support sheet is of a

sufficient thickness to impart a desirable amount of load bearing properties to support the solar module. By way of example, single support sheet has a thickness that is between about 0.010 inches and about 0.200 inches. One or more of the support fasteners may include adhesive and/or mechanical fasteners. One or more of the support fasteners may made from at least one material chosen from a group comprising butyl, silicone, polyurethane, polysulfide and elastomeric sealants.

[0011] Similar to one or more of the support fasteners, in certain embodiments of the present arrangements, the module fastener includes adhesive and/or mechanical fastener. In this embodiment, the module fastener may adhere a substantial portion of the solar module to the single support sheet.

[0012] In some embodiments of the present arrangements, the supporting surface includes any one of roof, wall, ground, and a structure coupled to the single support sheet and the supporting surface. In these embodiments, one or more of the support fasteners may pass through one or more of the connecting regions and through the supporting surface. However, in other implementations of this embodiment, one or more of the support fasteners are secured on the supporting surface and a portion of one or more of the support fasteners passes through one or more of the connecting regions.

[0013] One or more of the connecting regions may further include a hinge thereby allowing the single support sheet to pivot around the hinge to be in an operational configuration or in an accessible configuration, wherein in the operation configuration, the single support sheet is adjacent to the supporting surface and capable of having solar radiation impinging thereon, and in the accessible configuration, the single support sheet is positioned away and at a certain angle from the supporting surface such that certain components of the solar mounting apparatus are accessible.

[0014] In other embodiments of the present arrangements, the solar module mounting apparatus further includes two or more single support sheets, wherein one or more of the support fasteners fastens a second connecting region of a first one of the two or more single support sheets to a first connecting region of a second one of the two or more single support sheets such that the first and second ones of the two or more single sheets are coupled, and wherein a second connecting region of the first one of the two or more single support sheets is coupled to the supporting surface by one or more of the support fasteners and a second connecting region of the second one of the two or more single support sheets is coupled to the supporting surface and/or a first connecting region of a third one of the two or more single support sheets by one or more of the support fasteners.

[0015] The solar mounting apparatus of the present teachings may further include one or more inverters and/or one or more junction boxes that are positioned between the supporting surface and the single support sheet.

[0016] In another aspect, the present teachings provide a solar module mounting apparatus. The solar module mounting apparatus includes: (i) a support structure including one or more substantially flat regions and one or more recessed regions, each of which includes a protruding portions flanked between two sloping portions that slope away from one or more of the substantially flat regions; (ii) a module fastener designed to secure a solar module on the support structure; and (iii) one or more support fasteners for fastening the support structure to a supporting surface, such that when the solar module is secured on the supporting surface, the protruding portion contacts the supporting surface and a force applied to the support structure is distributed through the protruding portion to the supporting surface.

[0017] In certain embodiments of the present arrangements, the protruding portion of one or more of the recessed regions has a width between about 1 inch and about 15 inches. The sloping portions of one or more of the recessed regions may slope with respect to a substantially flat region or with respect to the protruding portion at an angle that ranges from about 25 degrees to about 90 degrees. A depth of the protruding portion, measured from the substantially flat region, is between about ½ inch and about 6 inches.

[0018] In certain embodiments of the present arrangements, the solar module mounting

apparatus further includes one or more connecting regions, such that a force applied to the support structure is distributed through one or more of the connecting regions and the protruding portion of the recessed regions to the support surface.

[0019] In yet another embodiment of the present arrangements, the support structure further includes one or more connecting regions that, in a mounted state of the solar module mounting apparatus, couple the support structure and the supporting surface, and wherein the one or more of the connecting regions are disposed in a same or substantially same plane as a substantially flat region of the support structure or in a same or substantially same plane as the protruding portion.

[0020] In yet another aspect, the present teachings provide a method of mounting a solar

module. The method of mounting the solar module includes: (i) obtaining a single support sheet including one or more connecting regions such that a force applied to the single support sheet is distributed throughout the single support sheet and to one or more of the connecting regions; (ii) securing the single support sheet on a supporting surface using one or more support fasteners to form a secured support structure subassembly, such that when the solar module is secured on the single support sheet that is fastened to the supporting surface, the force acting upon the solar module is distributed throughout the single support sheet and/or one or more of the connecting regions to the supporting surface; and (iii) mounting the solar module on the secured support structure subassembly using one or more module fasteners to form a mounted solar module assembly.

[0021] In certain embodiments of the present teachings, securing includes passing one or more of the support fasteners through one or more of the connecting regions and through the supporting surface or securing one or more of the support fasteners on the supporting surface such that a portion of one or more of the support fasteners passes through one or more of the connecting regions.

[0022] In yet another aspect, the present teachings provide another method of mounting a solar module. The method of mounting the solar module includes: (i) obtaining a single support sheet including one or more connecting regions such that a force applied to the single support sheet is distributed throughout the single support sheet and/or one or more of the connecting regions to one or more of the connecting regions; (ii) securing the single support sheet to a solar module using one or more module fasteners to form a module support structure subassembly; and (iii) mounting the module support structure subassembly on a supporting surface using one or more support fasteners, such that when the module support structure subassembly is fastened to the supporting surface, a force acting upon the solar module is distributed through the single support sheet to the supporting surface.

[0023] In yet another aspect, the present teachings provide a yet another method of mounting a solar module. The method of mounting the solar module includes: (i) obtaining a support structure including one or more recessed regions, each of which includes a protruding portion flanked between two sloping portions; (ii) securing the support structure on a supporting surface using one or more support fasteners to form a secured support structure subassembly, such that when the solar module is secured on the support structure, the support structure provides the solar module with rigid back support and affixes the solar module to the supporting surface; and (iii) mounting the solar module on the secured support structures subassembly using one or more module fasteners.

[0024] In yet another aspect, the present teachings provide a yet another method of mounting a solar module. The method of mounting the solar module includes: (i) obtaining a support structure including one or more recessed regions, each of which includes a protruding portion flanked between two sloping portions; (ii) securing the support structure to a solar module using one or more module fasteners to form a module support structures subassembly; and (iii) mounting the module support structure subassembly on a supporting surface using one or more support fasteners, such that when the solar module is secured on the module support structure subassembly, the support structure provides the solar module with rigid back support and affixes the solar module to the supporting surface.

BRIEF DESCRIPTION OF THE DRAWINGS

[0025] Figure 1 shows an exploded side-sectional view of a solar module mounting system, according to one embodiment of the present arrangements and that mounts a solar module to a supporting surface.

[0026] Figures 2 shows a perspective view of a support structure, according to one embodiment of the present arrangements and that is shown in Figure 1.

[0027] Figure 3 a shows an exploded side- sectional view of solar module mounting system of Figure 3a and that mounts a solar module to a supporting surface using a substantially flat connecting region.

[0028] Figure 3b shows an exploded side- sectional view of solar module mounting system of Figure 3a and that includes an inverter or a junction box between the solar module mounting system and the supporting surface in accordance with one embodiment of the present arrangements.

[0029] Figure 4a shows an exploded side- sectional view of a solar module mounting system, according to a yet another embodiment of the present arrangements and that includes a support structure including a protruding portion flanked between two sloping portions.

[0030] Figure 4b shows that the support structure of Figure 4A includes substantially flat connecting regions to mount the solar module to the supporting surface in accordance with one embodiment of the present arrangements.

[0031] Figure 4c shows that an inverter or a junction box, in accordance with one embodiment of the present arrangements, is positioned between the support structure and the supporting surface of Figure 4a or between the solar module and the support structure of Figure 4a.

[0032] Figure 5a shows an exploded side- sectional view of a solar module mounting system, according to a yet another embodiment of the present arrangements and that include a support structure with two protruding portions and one or more connecting regions disposed in substantially the same plane as the protruding portions.

[0033] Figure 5b shows that the support structure of Figure 5A, in accordance with one embodiment of the present arrangements and that includes substantially flat connecting regions to mount the solar module to the supporting surface.

[0034] Figure 5c shows that one or more inverters and/or one or more junction boxes, in

accordance with one embodiment of the present arrangements, are positioned between the support structure and the supporting surface of Figure 5a or between the solar module and the support structure of Figure 5 a.

[0035] Figure 5d shows a uniform force or load acting on the span of a solar module of Figure 5b and that is transfered to a supporting surface.

[0036] Figure 5e shows a top view of the support structure shown in Figure 5d and that includes one or more areas having adhesive applied thereon according to one embodiment of the present teachings.

[0037] Figure 5f shows a perspective view of the support structure shown in Figure 5e.

[0038] Figure 6a shows an integrated structure of multiple solar modules, according to one embodiment of the present teachings and that is connected to a single support structure.

[0039] Figure 6b shows a perspective view of the integrated structure of multiple solar modules shown in Figure 6a and that includes support fasteners, which may ultimately mount to a supporting surface.

[0040] Figure 7a shows another integrated structure of multiple support structures, according to another embodiment of the present teachings, arranged adjacent to each other and each of which supports multiple solar modules thereon.

[0041] Figure 7b shows a side- sectional view of an assembled solar module mounting system, according to one embodiment of the present arrangement and that incorporates the integrated structure of multiple support structures of Figure 7a. [0042] Figure 7c shows the assembled solar module mounting system of Figure 7b, according to another embodiment of the present teachings and that includes one or more hinges along an edge of solar module support structure for providing access to the underlying support surface for maintenance and angling the exposed solar cells (disposed on the support structure) for harnessing optimum solar energy.

[0043] Figure 8 shows a method of mounting, according to one embodiment of the present teachings, a solar module to a supporting surface.

[0044] Figure 9 shows another method of mounting, according to another embodiment of the present teachings, a solar module to a supporting surface.

[0045] Figure 10 shows another method of mounting, according to another embodiment of the present teachings, a solar module to a supporting surface.

[0046] Figure 11 shows another method of mounting, according to another embodiment of the present teachings, a solar module to a supporting surface.

DETAILED DESCRIPTION OF THE DRAWINGS

[0047] In the following description, numerous specific details are set forth in order to provide a thorough understanding of the present invention. It will be apparent, however, to one skilled in the art that the present invention may be practiced without limitation to some or all of these specific details. In other instances, well-known process steps have not been described in detail in order to not unnecessarily obscure the invention.

[0048] The present teachings provide novel solar module mounting system designs and methods of assembling thereof. The solar module designs of the present teachings use a support structure that transfer loads from one or more solar modules to an underlying supporting surface that may be part of a building structure where the solar module is installed.

[0049] Figure 1 shows an assembled solar module system 100, according to one embodiment of the present arrangements, for mounting a solar module 112 to a supporting surface 110.

Assembled solar module system 100 includes a support structure 102 and one or more connecting regions 104. In this embodiment, a module fastener 106 fastens solar module 112 to support structure 102. Support structure 102, among other things, provides structural support for solar module 112 such that when a force is applied to solar module 112, the force is distributed throughout support structure 102 and to one or more of connecting regions 104. One or more support fasteners 108 fasten one or more connecting regions 104 of support structure 102 to support surface 110. In this manner, a force acting on solar module 112 is distributed through support structure 102 and transferred to supporting surface 110.

[0050] Figure 2 shows a support structure 200, according to one embodiment of the present arrangements and that may be used in assembled solar module system 100 shown in Figure 1. Support structure 200 is a single support sheet including one or more connecting regions 204a and 204b. In this embodiment, a first connecting region 204a is disposed on a first edge of single support sheet 202 and a second connecting region 204b is disposed on a second edge of single support sheet 202. The first edge and second edge of support sheet 202 are opposite each other and disposed in a same or substantially same plane. This allows support structure 200 to be secured to a supporting surface on two opposite edges. In other embodiments, however, single support sheet 202 may include one or more connecting regions in other arrangements, for example, a connecting region on all four edges of single support sheet 202. Connecting regions may be thought of as any region that couples a solar module to a supporting surface, which may be part of building structure. However, as shown in the embodiment of Figure 2, connecting region may include a vertical portion that intersects with a horizontal portion. In an assembled configuration of the solar module, a bottom surface of the horizontal portion contacts the supporting surface. Furthermore, as discussed below these two surfaces may be coupled in a number of different ways.

[0051] Single support sheet 202 may be made of any material capable of supporting a solar module. In one embodiment of the present teachings, single support sheet is made from at least one material chosen from a group comprising aluminum, steel, stainless steel, copper, plastic, glass reinforced plastic and fiber glass. The fiberglass may be made from non-woven continuous glass fibers impregnated or laminated with at least one material chosen from a group comprising polypropylene, polyethylene, polyvinylchloride, acrylic and polycarbonate.

[0052] In one embodiment of the present arrangements, single support sheet 202 of support structures 200 is a contiguous sheet. However, in another embodiment of the present arrangements, single support sheet may have one or more apertures defined therein. One or more apertures may be located anywhere on single support sheet 202 and may be of any size. One or more apertures may be used to reduce the weight of support structure 200 while continuing to provide structural support to a solar module.

[0053] Similarly, support structure 200 may have any thickness capable of providing structural support to a solar module and distributing a force acting on the solar module to a supporting surface (provided below). In one embodiment of the present teachings, single support layer 202 and connecting regions 204a and 204b have a uniform thickness between about 0.010 in and about 0.200 inches. In certain embodiments of the present arrangement, however, single support layer 202 has non-uniform thickness. By way of example, certain portions of single sheet layer 202 may be thicker relative to other portions to support a greater load. As another example, support structure 200 may have one or more connecting regions 204 that are thicker than the remaining portions of the support structure. [0054] Solar modules come in varying dimensions. However, a desired size of the solar module may be dictated by the space available on a supporting surface (e.g., rooftop of a building) to mount the solar module or the energy output needed from the solar module. Therefore, support structure 200 may be manufactured to any dimension capable of supporting one or more solar modules regardless of its dimensions. In one preferred embodiment support structure 200 has a width (denoted as "w" in Figure 2) of about 12 inches in to about 50 inches and a length (denoted as "/" in Figure 2) of about 12 inches to about 90 inches. Preferably, support structure is larger than a solar module so the outside edges of the solar module are parallel with or within the boundaries of support structure 200. In other embodiments of the present arrangement, however, a solar module may extend beyond the boundaries of support structure 200.

[0055] In addition to the length and width of support structures 200, the vertical portion of

support structure 200 may also have a height (denoted as "h" in Figure 2) that is between about 0.5 inches and about 6.0 inches from the horizontal portion of connecting region 204a or 204b. As will be described in further detail below, the space between a supporting surface and the support structure may be used to house various components used in connection with a solar module system.

[0056] In one embodiment of the present teachings, single support sheet 202 of support structure 200 may include one or more edges having a sloping region that slopes away from a

substantially flat surface of single support sheet 202 and (in an assembled state of the supporting structure) slopes towards a supporting surface. When the support sheet is assembled on a supporting surface, one or more of the sloping edges may prevent wind from flowing into the space between the supporting surface and support structure 200, and thereby reducing forces acting to detach support structure 200 from a supporting surface.

[0057] Figure 3a shows an assembled solar module system 300, according to another

embodiment of the present arrangements and that includes a support structure 302 for mounting a solar module 312 to a supporting surface 310. In this embodiment, one or more module fasteners 306 fasten solar module 312 to support structure 302. Furthermore, one or more support fasteners 344 secured support structure 302 to a supporting surface 310. In this arrangement, one or more support fasteners 344, which are attached or coupled to supporting surface 310, pass through one or more connecting regions 342 of single support sheet 302. In one arrangement of the present teachings, one or more support fasteners 344 may be installed on supporting surface 310, without first installing single support sheet 302 to provide greater flexibility during installation. By way of example, support fasteners may be secured to supporting surface 310 prior to mounting single support sheet 302. Under this installation approach, a single support sheet having a solar module thereon is easily secured to supporting surface 310 using the preinstalled support fasteners 344. As another example, the present teachings approach of using support fasteners offers the flexibility of using commercially available support fasteners. As yet another example, connecting regions 342 of support structure 302 may be modified to receive any commercially available support fastener.

[0058] It is important to note that the arrangement between connecting region 342 and single support sheet 302 may be configured differently. By way of example, in Figure 3a, connecting region 342 is in the same plane as single support sheet 302. One or more support fasteners 344 attaches connecting region 342 of single support sheet 302 to supporting surface 310. In this configuration, the connecting region 342 does not contact supporting surface 310 as connecting region 342 extends in the same plane as single support sheet 302. In other embodiments, connection region 342 and single support sheet 302 are not parallel. By way of example, Figure 1 shows an embodiment where connecting region 104 is in another plane, but parallel to single support sheet 102. In this arrangement, one or more support fasteners 108 attaches connecting region 104 directly to an adjacent supporting surface 110. Moreover, the connecting regions (e.g. , connecting regions 104) contact the supporting surface (e.g. , supporting surface 1 10). As a result, depending on the type of support fasteners used, contact regions (of the support structure) may or may not contact the supporting surface.

[0059] One or more support fasteners 344 may be any means for securing single support sheet 302 to support surface 310. Similarly, one or more module fasteners 306 may be any means of securing solar module 306 to single support sheet 302. In one embodiment of the present teachings, one or more module fasteners 306 or one or more support fasteners 344 include any one of mechanical fasteners or at least one adhesive chosen form a group comprising butyl, silicone, polyurethane, polysulfide and elastomeric -based sealants. Support structure 310 may be any structures capable of supporting solar module and its associated mounting system described herein. In one embodiment of the present teachings, support structure 310 may be a structure chosen from a group comprising roof, wall, ground, and support stand or a structure coupled to roof, wall or ground.

[0060] Assembled solar module system 300 may include one or more junction boxes or inverters that receive electrical wires from one or more solar modules. The junction box may serve to receive the positive and negative conductors from the module as well as to house the protective by-pass diodes that reduce hot-spot damage. The inverter may convert the voltage from direct current to alternating current. In either case, it is preferable to have one or both of these components in close proximity to one or more solar modules 312. To this end, Figure 3b shows an inverter or a junction box 314 disposed in a space (formed by the height of the support fastener 344) between single support structure 302 and supporting surface 310. One or more apertures (not shown to simplify illustration) may be defined inside single support sheet 302 to convey any wires or cables from one or more solar modules 312 through support structure 302 to one or more underlying junction boxes 314 or inverters 316. Moreover, placement of one or more inverters or junction boxes 314 on the bottom surface of single support sheet 302 protects them from exposure to harsh environmental elements during use.

[0061] The embodiments described above provide structural support for a solar module using a single support sheet with one or more connection regions. There may be instances, where additional structural support features are desired to withstand harsh or inclement weather conditions. Therefore, the present arrangements described below provide additional support to a solar module.

[0062] Figure 4a shows a solar module mounting apparatus incorporated into an assembled solar module system 400, according to one embodiment of the present arrangements. The solar mounting module apparatus includes a support structure 402 and support fasteners 408. Support structure 402 includes a protruding region 428. With the exception of support structure 402, assembled solar module system 400 is substantially similar to assembled solar module system 100 in Figure 1. In other words, module 412, module fastener 406, connecting regions 404, support fastener 408 and supporting surface 410 are substantially similar to their counterparts, i.e., module 112, module fastener 106, connecting regions 104, support fastener 108 and supporting surface 110 in Figure 1. In this embodiment of the present arrangements, as explained below, protruding portion 428 contacts supporting surface 410 to provide additional structural support for solar module 410 as it is secured on supporting surface 410.

[0063] As shown in Figure 4a, support structure 402 includes two substantially flat regions 420 and 422 separated by recessed region 430. Recessed region 430 includes a protruding portion 428 flanked between two sloping portions 424 and 426 that slope away from substantially flat regions 420 and 422 and towards protruding portion 428. Using one or more module fasteners 406, solar module 412 may be secured to substantially flat regions 420 and 422 of support structure 402. In this configuration, any force applied to solar module 412 is transferred to support structure 402 and ultimately to supporting surface 410 to protect solar module 412 from damage or failure.

[0064] In an assembled state of solar module 412 on supporting surface 410, protruding region 428 contacts an underlying portion of supporting surface 410. Furthermore, support fasteners 408, which pass through connecting regions 404 secure support structure 402 to supporting surface 410. In this configuration, a force acting upon solar module 412 is transferred to support structure 402 and distributed throughout support structure 402. Those regions of the support structure 402 that contact supporting surface 410 transfer the force from support structure 402 to supporting surface 410. As a result, an external force applied to solar module 412 is transferred through protruding region 428 and connecting regions 404 to supporting surface 410.

[0065] In certain instances, it is not necessary to have any portion of the connecting regions contact the supporting surface 410. To this end, Figure 4b shows connecting regions 442 that may be used in conjunction with support fasteners 444. Connecting regions 442 and support fasteners 444 are substantially similar to their counterparts, i.e. , connecting regions 342 and support fasteners 344 in Figure 3a.

[0066] In certain other embodiments of the present arrangements, support structure 402 does not have one or more connecting regions 404 or 442 to connect to supporting surface 410. In other words, in these embodiments connecting regions are all together absent. Instead, protruding portion 428 connects directly to supporting 410 using one or more support fasteners 408. In this configuration, any force applied to support structure 402 is distributed through protruding portion 428 to supporting surface 410. Adhesives, which my serve as support fasteners, are preferably applied to the protruding portion to affix the support structure 402 to supporting surface 410

[0067] Protruding portion 428 may be any width sufficient to transfer a load from support

structure 402 to supporting surface 410. In one embodiment of the present arrangements, the width of protruding portion 428 may be between about linch and about 15 inches. Sloping portions 424 and 426, which couple substantially flat regions 420 and 422 to protruding portion 428, slope from flat regions 420 and 422 and protruding portion 428 at an angle that is between about 25 degrees and about 90 degrees.

[0068] Figure 4c shows that an inverter 414 or junction box 416 may be disposed within or adjacent to recessed region 430. Except for support structure 402, the mounting apparatus used in Figure 4c is the same as or substantially similar to the mounting apparatus used in Figure 3b. The location of inverter 414 and junction box 416, as illustrated in Figure 4c, are one embodiment of the present teachings. However, the location of inverter 414 and junction box 416 may change. By way of example, in another embodiment of the present teachings, junction box 416 is disposed inside recessed region 430 and inverter 414 is disposed inside a space created between support structure 402 and supporting surface 410. In addition, solar module mounting apparatus (incorporated inside assembly solar module system 400) may include multiple inverters 414 or junction boxes 416 in various locations. Regardless of the location, one or more inverters 414 or junction boxes 416 are positioned in close proximity to the solar cells of solar module 412.

[0069] To improve the structural support of a solar module support system, the present teachings offer certain support structure designs, in which points of contact between a support structure and a supporting surface are increased. In one embodiment of the present arrangements, the number of protruding portions contacting a supporting surface may be increased. For example, Figures 5a through 5f illustrate a support structure 502 according to another embodiment of the present teachings. In this embodiment, support structure 502 includes two recessed regions 530 and 532. Such recesses are created between support structure 502 and solar module 512. First recessed region 530 is created when two sloping portions 524 and 526 flank a protruding portion 528. Sloping portions 524 and 526 slope away from substantially flat regions 520 and 522 and slope towards protruding portion 528. Second recessed region 532 is created when a different set of two sloping portions 534 and 536 flank another protruding portion 538. In an assembled state, when support structure 502 is connected with a solar module 512 using one or more module fasteners 506, a force acting on solar module 512 is distributed throughout support structure 502 including protruding portions 528 and 538 and directed to an underlying supporting surface 510.

[0070] Figure 5a shows a solar module mounting apparatus incorporated into an assembled solar module system 500, according to one embodiment of the present arrangements. The solar mounting module apparatus includes a support structure 502 and support fasteners 508. As explained above, support structure 502 includes protruding portions 528 and 538. With the exception of support structure 502, assembled solar module system 500 is substantially similar to assembled solar module system 100 in Figure 1. In other words, module 512, module fastener 506, connecting regions 504, support fastener 508 and supporting surface 510 are substantially similar to their counterparts, i.e., module 112, module fastener 106, connecting regions 104, support fastener 108 and supporting surface 110 in Figure 1.

[0071] Figure 5b shows a solar module mounting apparatus incorporated inside a solar module mounting system 500, according to another embodiment of the present arrangement. The solar module mounting apparatus of Figure 5b is the same as or substantially similar to that of Figure 5a, except that connecting regions 544 of Figure 5b is different from connecting region 504 of Figure 5a. As explained above, it is not necessary to have any portion of the connecting regions contact the supporting surface 510. To this end, Figure 5b shows connecting regions 542 that may be used in conjunction with support fasteners 544. Connecting regions 542 and support fasteners 544 are substantially similar to their counterparts, i.e., connecting regions 342 and support fasteners 344 in Figure 3a.

[0072] Figure 5c shows an assembled solar module system 500, according to one embodiment of the present arrangement and that includes one or more inverters 514 or one or more junction boxes 516. Similar to one or more inverters 414 or junction boxes 416 of Figure 4c, one or more inverters 514 or junction boxes 516 may be positioned in recess regions 530 and 532. Similarly, one or more inverters 514 or junction boxes 516 may be positioned in a space between support structure 502 and supporting surface 510.

[0073] Figure 5d, which is substantially similar to Figure 5c, shows forces acting on a solar module mounting apparatus, which is incorporated, according to one embodiment of the present arrangement, inside an assembled solar module mounting system 500. According to this figure, a uniform load (shown using the downward pointing arrows) applied to a top surface of solar module 512 is transferred to support structure 502 and is distributed through one or more connecting regions 544 and protruding portions 528 and 538 to supporting surface 510. An equal and opposite reaction force (shown using the upward pointing arrows) of supporting surface acts at one or more support fasteners 544 and protruding portions 528 and 538 to support structure 502 and the load thereon. In other words, an equal and opposite reaction force applied by the supporting surface against support structure 502 ensures that solar module 512 is well supported. The embodiment described in Figure 5d is substantially similar to the embodiments shown in Figures 5a, 5b and 5c, and the transfer of load described in connection with 5d is similar when using other embodiments such as the embodiments described in Figure 5a, 5b, and 5c.

[0074] Those skilled in the art will know that, in addition to the force or load depicted in Figure 5d, other types of load may be applied to solar module 512 (i.e., concentrated load, varying load and multiple loads). Regardless of load type, the transfer of force from solar module 512 to supporting surface 510 may be the same.

[0075] Figures 5e and 5f show, according to one embodiment of the present teachings, the

application of one or more module fasteners to a support structure. One or more module fasteners 506 secure a solar module to support structure 502, which may be substantially the same as support structure 502 in Figures 5a-d. In this embodiment, one or more module fasteners 506 are an adhesive that may be applied along substantially flat areas 520, 522 and 540 on support structure 502. Adhesive 506 may be applied along the length of substantially flat surfaces 520, 522, and 540, and in a single line moving across the width of substantially flat surfaces 520, 522, and 540. The present teachings recognize that such application of fasteners (e.g. , adhesives) are not limited to support structure 502, rather their application may also extend to other support structures described herein.

[0076] As previously discussed, in one embodiment of the present teachings, an adhesive may also be used as a support fastener to secure support structure to a supporting surface. As discussed above, in one embodiment of the present arrangements, an adhesive may be used to secure one or more connecting regions of a support structure and a supporting surface. However, in another embodiment of the present arrangements, an adhesive may also be applied to a bottom surface of protruding portions 528 and 538. In an assembled state, the adhesive secures protruding portions 528 and 538 of a support structure 502 to a supporting surface. This embodiment may be advantageous for locations where wind passes through recessed regions and creates an upward force between support structure 502 and a supporting surface. Multiple points of adhesion disperses the force between the supporting surface and support structure 502.

[0077] The support structure described in Figure 5 may be manufactured to any size or

dimension and may be dependent on design requirements such as the location of the installation and the number of solar modules installed. As such Figure 6a shows, according to one embodiment of the present teachings, a solar module support subassembly 600 with multiple solar module panels 612, each containing multiple solar cells, connected to a single support structure 602. In this manner, multiple solar module panels may be installed simultaneously. This configuration may be advantageous as it results in faster installation time and requires fewer support structures.

[0078] Figure 6b shows that solar module support subassembly 600 shown in Figure 6a may be connected to one or more support fasteners. Similar to one or more support fasteners 544 of Figure 5b, one or more support fasteners 644 of Figure 6 may be used to fasten support structure 602 to a supporting surface. The present teachings recognize that the support fasteners used in Figure 6b are not limited to any specific types, and may well include other type of support fasteners described herein or fasteners that are well-known to those skilled in the art.

[0079] Figure 7a shows multiple solar module support subassembly 700, according to one embodiment of the present teachings and that includes multiple support structures 702, 702' and 702", each of which includes one or more solar modules 712. In the configuration, some of the connecting regions associated with each of the multiple support structures 702, 702' and 702" may overlap with other connecting regions of an adjacent support structure. This embodiment may be advantageous, as it requires fewer support fasteners to mount multiple support structures to a supporting surface. One or more support fasteners between adjacent support structures would secure adjacent support structures to each other and to a supporting surface. The present teachings recognize that such arrangement also reduces the footprint of the assembled solar module.

[0080] In one embodiment of the present arrangement, multiple support structures 702, 702' and 702" are arranged adjacent to one another and along a length of each support structure. As illustrated in Figures 7a and 7b, one or more support fasteners fastens a second connecting region 704b of first support structure 702 to first connecting region 704'a of second support structure 702'. Similarly, second connecting region 704'b of second support structure 702' may be fastened, using one or more support fasteners, to first connection region 704 "b of a third support structure 702". In an assembled state, one or more fasteners secure support structures 702, 702' and 702" to each other and, preferably at the same time, to a supporting surface. [0081] Figure 7b shows a partially assembled solar module system 700, according to one embodiment of the present arrangement, showing one or more support fasteners aligned with one or more trusses that may be part of or associated with a supporting surface. These trusses may be disposed at a distance that may vary depending on a variety of factors. By way of example, the supporting surface to which they are attached may require different distances between trusses to accommodate different loads or accommodate a particular building profile. In addition, local, regional or national building codes or trade customs may suggest or require trusses to be at a designated distance from each other. Regardless of the distance between trusses support structure 702 may be fabricated to any width to ensure that one or more support fasteners are aligned with one or more trusses.

[0082] To this end, Figure 7b shows an assembled solar module system 750, according to one embodiment of the present teachings and that includes support structures 702 and 702' . System 750 also includes one or more module fasteners 706, one or more solar modules 712, one or more support fasteners 744 and supporting surface 710 are the same as or substantially similar to their counterparts, i.e. , one or more module fasteners 506, solar module 512, one or more support fasteners 544 and supporting surface 510 assembled solar module system 500' of Figure 5b. According to this figure, placement of support fasteners 744 are aligned with the position of trusses 746. In this configuration, a load acting upon a solar module 712 is transferred through support structures 702 and 702' and through one or more support fasteners 708, to one or more trusses 746 of supporting surface 710. In addition to securing support structures 702 and 702' to supporting surface, one or more support fasteners 744 also secures support structures 702 and 702' to each other. Second connecting region 704b of support structure 702 overlaps first connecting region 704' a of support structure 702' and are secured together by one or more support fasteners 744. In this manner one or more support fasteners secures support structures 702 and 702' to each other and to supporting surface 710.

[0083] Figure 7c show an assembled solar module system 755, according to another embodiment of the present teachings. In this figure, connecting region 704 of support structure 702 operates in conjunction with a hinge 732. As a result, a support structure 702 may pivot around hinge 732 to provide advantages. By way of example, solar module support structure may pivot away from supporting surface 710 to allow access to an underside of the support structure where inverters and/or junction boxes may be positioned.

[0084] As another example, support structure may pivot to allow an incident angle of sunlight, as it impinges upon the solar cells, to harness an optimum amount of energy. By way of example, during the course of a day or at different times of a year, the solar modules, disposed above their respective support structures, may pivot at different angles. [0085] The present arrangement also offers novel methods of mounting inventive solar module mounting system (e.g., 100 of Figure 1 and 200 of Figure 2). Figure 8 shows a method 800, according to one embodiment of the present teachings, for a method of mounting a solar module. Method 800 preferably begins with a step 802, which includes obtaining a single support sheet (e.g., single support sheet 102 of Figure 1 , 202 of Figure 2) including one or more connecting regions (e.g., one or more connecting regions 204a and 204b of Figure 2) such that a force applied to the single support sheet is distributed throughout the single support sheet and to one or more of the connecting regions. As previously mentioned, single support sheet is capable of supporting one or more solar modules.

[0086] Next a step 804 includes securing the single support sheet on a supporting surface using one or more support fasteners (e.g., support fastener 108 of Figure 1) to form a secured support structure subassembly, such that when the solar module is secured on the single support sheet that is fastened to the supporting surface, the force acting upon the solar module is distributed throughout the single support sheet and one or more of the connecting regions and transferred to the supporting surface. Securing may include passing one or more of the support fasteners through one or more of the connecting regions and through the supporting surface or securing one or more of the support fasteners on the supporting surface such that a portion of one or more of the support fasteners passes through one or more of the connecting regions

[0087] Then a step 806 is carried out. Step 806 includes mounting the solar module on the

secured support structure subassembly using one or more module fasteners to form a mounted solar module assembly.

[0088] Figure 9 shows a method 900, according to another embodiment of the present teachings, for a method of mounting a solar module. Method 900 preferably begins with a step 902, which includes obtaining a single support sheet (e.g., single support sheet 102 of Figure 1 , 202 of Figure 2) including one or more connecting regions (e.g., one or more connecting regions 204a and 204b of Figure 2) such that a force applied to the single support sheet is distributed throughout the single support sheet and to one or more of the connecting regions.

[0089] In step 904, a single support sheet is applied to a solar module using one or more module fasteners to form a module support structure subassembly. Finally, a step 906 includes mounting the module support structure subassembly on a supporting surface using one or more support fasteners, such that when the module support structure subassembly is fastened to the supporting surface, a force acting upon the solar module is distributed through the single support sheet to the supporting surface.

[0090] In other embodiments a support structure, including one or more recessed regions, is used to support and mount a solar module to a supporting surface. The present arrangement offers novel methods of mounting a solar module mounting system (e.g., 400 of Figure 4) using a support structure including one or more recessed regions. Figure 10 shows a method 1000, according to one embodiment of the present teachings, for a method of mounting a solar module.

Method 1000 preferably begins with a step 1002, which includes obtaining a support structure including one or more recessed regions, each of which includes a protruding portion flanked between two sloping portions.

[0091] Next, a step 1004 includes securing the support structure on a supporting surface using one or more support fasteners to form a secured support structure subassembly, such that when the solar module is secured on the support structure, the support structure provides the solar module with rigid back support and affixes the solar module to the supporting surface. Finally, a step 1006 includes mounting the solar module on the secured support structures subassembly using one or more module fasteners

[0092] Figure 1 1 shows a method 1 100, according to one embodiment of the present

arrangement, for a method of mounting a solar module. Method 1100 preferably begins with a step 1 102, which includes obtaining a support structure including one or more recessed regions, each of which includes a protruding portion flanked between two sloping portions.

[0093] Next, a step 1 104 includes securing the support structure to a solar module using one or more module fasteners to form a module support structures subassembly; and

[0094] Then a step 1 106 is carried out. Step 1 106 includes mounting the module support

structure subassembly on a supporting surface using one or more support fasteners, such that when the solar module is secured on the module support structure subassembly, the support structure provides the solar module with rigid back support and affixes the solar module to the supporting surface.

[0095] Although illustrative embodiments of this invention have been shown and described, other modifications, changes, and substitutions are intended. By way of example, the present invention discloses heat bonding a foam layer and at least one skin layer without using any adhesive, other conventional layers in the solar module may be similarly bonded. Accordingly, it is appropriate that the appended claims be construed broadly and in a manner consistent with the scope of the disclosure, as set forth in the following claims.

Claims

CLAIMS What is claimed is:

1. A solar module mounting apparatus, comprising:

a single support sheet including one or more connecting regions such that a force applied to said single support sheet is distributed throughout said single support sheet and to one or more of said connecting regions;

a module fastener designed to secure a solar module on said single support sheet; and one or more support fasteners for fastening one or more of said connecting regions of said single support sheet to a supporting surface, such that when said solar module is secured on said single support sheet that is fastened to said supporting surface, a force acting upon said solar module is distributed through said single support sheet to said supporting surface.

2. The solar module mounting apparatus of claim 1, wherein said single support sheet is a contiguous sheet.

3. The solar module mounting apparatus of claim 1, wherein said single support sheet includes one or more recessed regions, each of which includes a protruding portion flanked between two sloping portions.

4. The solar module mounting apparatus of claim 3, further comprising one or more junction boxes that are positioned in said recessed region of said support structure.

5. The solar module mounting apparatus of claim 3, further comprising one or more inverters that are positioned in said recessed region of said support structure.

6. The solar module mounting apparatus of claim 1 , wherein a first connecting region is disposed at a first edge of said single support sheet, and a second connecting region is disposed at a second edge of said single support sheet, and wherein said first edge and second edge are opposite to each other.

7. The solar module mounting apparatus of claim 1, wherein said single support sheet includes one or more edges having a sloping region that slopes away from away from a substantially flat region of said single support sheet and slopes towards said supporting surface, such that said sloping surface prevents wind from entering a space between said supporting surface and said single support sheet.

8. The solar module mounting apparatus of claim 1, wherein said supporting surface includes one or more trusses, and wherein one or more of said connection regions of said single support sheet is aligned with one or more of said trusses such that when said single support sheet is position adjacent to said supporting surface, one or more of said support fasteners connects one or more of said connecting regions to one or more of said trusses.

9. The solar module mounting apparatus of claim 1, wherein said single support sheet has defined therein apertures and/or cutouts.

10. The solar module mounting apparatus of claim 1, wherein said single support sheet is made from at least one material chosen from a group comprising aluminum, steel, stainless steel, copper, plastic, glass reinforced plastic, and fiber glass.

11. The solar module of claim 10, wherein said fiber glass is made from non-woven continuous glass fibers impregnated and/or laminated with at least one material chosen from a group comprising polypropylene, polyester, polyethylene, polyvinylchloride, acrylic and polycarbonate.

12. The solar module mounting apparatus of claim 1, wherein said single support sheet has a thickness that is between about 0.010 in and about 0.200 in.

13. The solar module mounting apparatus of claim 1, wherein one or more of said support fasteners includes adhesive and/or mechanical fasteners.

14. The solar module mounting apparatus of claim 13, wherein said adhesive is made from at least one material chosen from a group comprising butyl, silicone, polyurethane, polysulfide and elastomeric sealants.

15. The solar module mounting apparatus of claim 1, wherein said module fastener includes adhesive and/or mechanical fastener.

16. The solar module mounting apparatus of claim 1, wherein said module fastener adheres a substantial portion of said solar module to said single support sheet.

17. The solar module mounting apparatus of claim 1, wherein multiple solar modules are fastened to said single supporting sheet using said mounting fasteners.

18. The solar module mounting apparatus of claim 1, wherein said supporting surface includes any one of roof, wall, ground, and a structure coupled to said single support sheet and said supporting surface.

19. The solar module mounting apparatus of claim 1, wherein one or more of said support fasteners passes through one or more of said connecting regions and through said supporting surface.

20. The solar module mounting apparatus of claim 1, wherein one or more of said support fasteners are secured on said supporting surface and a portion of one or more of said support fasteners pass through one or more of said connecting regions.

21. The solar module mounting apparatus of claim 1, wherein one or more of said connecting regions further comprise a hinge thereby allowing said single support sheet to pivot around said hinge to be in an operational configuration or in an accessible configuration, wherein in said operation configuration, said single support sheet is adjacent to said supporting surface and capable of having solar radiation impinging thereon, and in said accessible configuration, said single support sheet is positioned away and at a certain angle from said supporting surface such that certain components of said solar mounting apparatus are accessible.

22. The solar module mounting apparatus of claim 1, further comprising two or more single support sheets, wherein one or more of said support fasteners fastens a second connecting region of a first one of said two or more single support sheets to a first connecting region of a second one of said two or more single support sheets such that said first and second ones of said two or more single sheets are coupled, and wherein a second connecting region of said first one of said two or more single support sheets is coupled to said supporting surface by one or more of said support fasteners and a second connecting region of said second one of said two or more single support sheets is coupled to said supporting surface and/or a first connecting region of a third one of said two or more single support sheets by one or more of said support fasteners.

23. The solar module mounting apparatus of claim 1, further comprising one or more inverters and/or one or more junction boxes that are positioned between said supporting surface and said single support sheet.

24. A solar module mounting apparatus, comprising:

a support structure including one or more substantially flat regions and one or more recessed regions, each of which includes a protruding portion flanked between two sloping portions that slope away from one or more of said substantially flat regions;

a module fastener designed to secure a solar module on said support structure;

one or more support fasteners for fastening said support structure to a supporting surface, such that when said solar module is secured on said supporting surface, said protruding portion contacts said supporting surface and a force applied to said support structure is distributed through said protruding portion to said supporting surface.

25. The solar module mounting apparatus of claim 24, wherein said protruding portion of one or more of said recessed regions has a width between about 1 inch and about 15 inches.

26. The solar module mounting apparatus of claim 24, wherein said sloping portions of one or more of said recessed regions slope with respect to a substantially flat region or said protruding portion at an angle from about 25 degree to about 90 degrees.

27. The solar module apparatus of claim 24, wherein a depth of said protruding portion of one or more of said recessed regions, from said substantially flat region, is between about ½ inch and about 6 inches.

28. The solar module mounting apparatus of claim 24, further comprising one or more connecting regions, such that a force applied to said support structure is distributed through one or more of said connecting regions and said protruding portion of said recessed regions to said support surface.

29. The solar module mounting apparatus of claim 24, wherein said support structure further comprises one or more connecting regions that, in a mounted state of said solar module mounting apparatus, couple said support structure and said supporting surface, and wherein said one or more of said connecting regions are disposed in a same or substantially same plane as a substantially flat region of said support structure or in a same or substantially same plane as said protruding portion.

30. A method of mounting a solar module, said method comprising:

obtaining a single support sheet including one or more connecting regions such that a force applied to said single support sheet is distributed throughout said single support sheet and to one or more of said connecting regions;

securing said single support sheet on a supporting surface using one or more support fasteners to form a secured support structure subassembly, such that when said solar module is secured on said single support sheet that is fastened to said supporting surface, said force acting upon said solar module is distributed throughout said single support sheet and/or one or more of said connecting regions to said supporting surface; and

mounting said solar module on said secured support structure subassembly using one or more module fasteners to form a mounted solar module assembly.

31. The method of mounting a solar module of claim 30, wherein said securing includes passing one or more of said support fasteners through one or more of said connecting regions and through said supporting surface or securing one or more of said support fasteners on said supporting surface such that a portion of one or more of said support fasteners passes through one or more of said connecting regions.

32. A method of mounting a solar module, said method comprising:

obtaining a single support sheet comprising one or more connecting regions such that a force applied to said single support sheet is distributed throughout said single support sheet and to one or more of said connecting regions;

securing said single support sheet to a solar module using one or more module fasteners to form a module support structure subassembly; and

mounting said module support structure subassembly on a supporting surface using one or more support fasteners, such that when said module support structure subassembly is fastened to said supporting surface, a force acting upon said solar module is distributed through said single support sheet and/or one or more connecting regions to said supporting surface.

33. A method of mounting a solar module, said method comprising:

obtaining a support structure including one or more recessed regions, each of which includes a protruding portion flanked between two sloping portions; securing said support structure on a supporting surface using one or more support fasteners to form a secured support structure subassembly, such that when said solar module is secured on said support structure, said support structure provides said solar module with rigid back support and affixes said solar module to said supporting surface; and

mounting said solar module on said secured support structures subassembly using one or more module fasteners.

34. A method of mounting a solar module, said method comprising:

obtaining a support structure including one or more recessed regions, each of which includes a protruding portion flanked between two sloping portions;

securing said support structure to a solar module using one or more module fasteners to form a module support structures subassembly; and

mounting said module support structure subassembly on a supporting surface using one or more support fasteners, such that when said solar module is secured on said module support structure subassembly, said support structure provides said solar module with rigid back support and affixes said solar module to said supporting surface.