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US-12620924-B2 - Support structures and mounting systems for solar panels

US12620924B2US 12620924 B2US12620924 B2US 12620924B2US-12620924-B2

Abstract

A solar panel support structure includes a first shelf for supporting a first frame section of a first solar panel module, the first shelf defining a first plane, and a second shelf for supporting a second frame section of a second solar panel module, the second shelf defining a second plane. A dividing structure is provided between the first and second shelves and extends above the first and second planes. A first shelf upturn may be provided at an end of the first shelf away from the dividing structure and extending above the first plane. A second shelf upturn may be provided at an end of the second shelf away from the dividing structure and extending above the second plane. The support structure includes one or more first movable lock tabs for engaging first and second bottom flange portions of the frame sections.

Inventors

  • John C. Patton
  • Eric Hafter
  • Tyler Hudson

Assignees

  • Origami Solar, Inc.

Dates

Publication Date
20260505
Application Date
20230818

Claims (20)

  1. 1 . A solar panel support structure comprising: a first shelf for supporting a first frame section of a first solar panel module, the first shelf defining a first plane; a second shelf for supporting a second frame section of a second solar panel module, the second shelf defining a second plane; a dividing structure provided between the first and second shelves and extending above the first and second planes; and one or more spring tabs provided in the dividing structure for engaging i) a first bottom flange portion of the first frame section, ii) a second bottom flange portion of the second frame section, or both (i) and (ii).
  2. 2 . The structure of claim 1 and further comprising one or more second spring tabs provided in the dividing structure for engaging iii) the first bottom flange portion of the first frame section, iv) the second bottom flange portion of the second frame section, or both (iii) and (iv).
  3. 3 . The structure of claim 1 wherein the one or more spring tabs comprises a lock tab, tapered tab, door tab, folded tab, fold-down tab, or any combination thereof.
  4. 4 . The structure of claim 1 wherein at least one of the spring tabs comprises a spring axis that is substantially parallel to the first plane when the spring tab engages the first bottom flange portion, or the second plane when the spring tab engages the second bottom flange portion.
  5. 5 . The structure of claim 1 wherein the one or more spring tabs bend when engaged by iii) the first bottom flange portion of the first frame section, iv) the second bottom flange portion of the second frame section, or both (iii) and (iv), and the one or more spring tabs springs back into position after the first or second bottom flange portion passes an edge of the of the one or more spring tabs to securely attach the first or second frame section of the solar panel module to the solar panel support structure.
  6. 6 . The structure of claim 1 wherein the one or more spring tabs bend downward when engaged by iii) the first bottom flange portion of the first frame section, iv) the second bottom flange portion of the second frame section, or both (iii) and (iv), and the one or more spring tabs springs back into position after the first or second bottom flange portion passes a bottom edge of the one or more spring tabs and engages an outer flange extension of the first or second bottom flange portion to securely attach the first or second frame section of the solar panel module to the solar panel support structure.
  7. 7 . The structure of claim 1 wherein the dividing structure comprises a first retaining fold.
  8. 8 . The structure of claim 1 wherein a first retaining fold is provided at an angle relative to the first plane such that a portion of the first retaining fold is positioned over an outer flange extension of a first bottom flange portion of the first frame section.
  9. 9 . The structure of claim 7 wherein the dividing structure further comprises a second retaining fold.
  10. 10 . The structure of claim 9 wherein the second retaining fold is provided at an angle relative to the second plane such that a portion of the second retaining fold is positioned over an outer flange extension of a second bottom flange portion of the second frame section.
  11. 11 . The structure of claim 7 wherein said first retaining fold comprises a fixed first position retainer fold.
  12. 12 . The structure of claim 9 wherein said second retaining fold comprises a fixed second position retainer fold.
  13. 13 . The structure of claim 1 and further comprising: a first shelf upturn provided at an end of the first shelf away from the dividing structure and extending above the first plane; and a second shelf upturn provided at an end of the second shelf away from the dividing structure and extending above the second plane.
  14. 14 . The structure of claim 13 wherein the first shelf upturn is folded at an angle relative to the first plane such that a portion of the first shelf upturn is positioned over an inner flange extension of the first bottom flange portion.
  15. 15 . The support structure of claim 13 wherein the second shelf upturn is folded at an angle relative to the second plane such that a portion of the second shelf upturn is positioned over an inner flange extension of the second bottom flange portion.
  16. 16 . The structure of claim 13 and further comprising one or more second spring tabs in iii) the first shelf upturn, iv) the second shelf upturn, or both (iii) and (iv).
  17. 17 . The structure of claim 16 wherein the one or more second spring tabs comprise a lock tab, tapered tab, door tab, folded tab, fold-down tab, or any combination thereof.
  18. 18 . The structure of claim 16 wherein the one or more second spring tabs comprise one or more lock tabs.
  19. 19 . The structure of claim 18 wherein the one or more second spring tabs engage with a first inner flange extension of the first bottom flange portion or a second inner flange extension of the second bottom flange portion.
  20. 20 . The structure of claim 18 wherein the one or more second spring tabs bend when engaged by iii) the first bottom flange portion of the first frame section, iv) the second bottom flange portion of the second frame section, or both and (iv), and the one or more second spring tabs springs back into position after the first or second bottom flange portion passes an edge of the one or more second spring tabs to securely attach the first or second frame section of the solar panel module to the solar panel support structure.

Description

This application is the US National Phase of PCT International Application No. PCT/US2023/030540 filed Aug. 18, 2023, which claims priority to and the benefit of U.S. Provisional Patent Application No. 63/399,711 filed Aug. 21, 2022, each application and any priority case are hereby incorporated by reference herein in its entirety. TECHNICAL FIELD The present disclosure relates to various embodiments for support structures and mounting systems for panels such as solar panels. BACKGROUND Photovoltaic solar panels for residential and commercial use are relatively large and heavy. For example, a typical rectangular solar panel may weigh about 20-30 kg, have a width of about 1 meter, a length of about 1.6 to 2.5 meters, and a thickness of about 3 to 5 cm. A photovoltaic solar panel may typically be a multilayer laminated structure (sometimes referred to as a PV laminate) and may include photovoltaic cells encapsulated between a top glass and a protective back-sheet. A solar panel can further include appropriate wiring and junctions so that solar-generated electricity (typically DC) may be transmitted to a desired load, grid, or energy storage unit. While having some physical toughness, significant additional strength to the panel may be provided by including it in a frame. A frame may allow for easy attaching of a photovoltaic solar panel to a rack. A framed PV laminate is sometimes referred to as a PV module. Over the years, the cost of solar panels has decreased perhaps due to a decrease in the material and manufacturing costs and even an increased efficiency of the solar cells. However, in order to further expand the use of renewable solar energy, there is a continuing desire to further reduce costs and simplify the manufacture of frames. SUMMARY The present application includes a variety of aspects, which may be selected in different combinations based upon the particular application or needs to be addressed. In various embodiments, the application may include solar panel support structure that includes a first shelf for supporting a first frame section of a first solar panel module, the first shelf defining a first plane, and a second shelf for supporting a second frame section of a second solar panel module, the second shelf defining a second plane. A dividing structure is provided between the first and second shelves and extends above the first and second planes. A first shelf upturn may be provided at an end of the first shelf away from the dividing structure and extending above the first plane. A second shelf upturn may be provided at an end of the second shelf away from the dividing structure and extending above the second plane. The support structure includes one or more first movable lock tabs provided in i) the dividing structure, ii) the first shelf upturn, or both (i) and (ii), for engaging a first bottom flange portion of the first frame section. The support structure also includes one or more second movable lock tabs provided in i) the dividing structure, ii) the second shelf upturn, or both (i) and (ii), for engaging a second bottom flange portion of the second frame section. Some embodiments of the present application may provide support structures and mounting systems that have one or more of the following advantages: improved strength, improved bending, improved twisting, improved durability, reduced material costs, reduced manufacturing costs, reduced assembly costs, higher manufacturing yield, reduced manufacturing tact time, reduced installation costs, simplified installation, reduced installation time, higher installation yield, or some other advantage. Naturally, further objects, goals and embodiments of the application are disclosed throughout other areas of the specification, claims, and drawings. BRIEF DESCRIPTION OF DRAWINGS FIG. 1A is a plan view of a non-limiting example of a framed panel structure according to some embodiments. FIG. 1B is a cross-sectional view of a non-limiting example of a framed panel structure along cutline B-B of FIG. 1A according to some embodiments. FIG. 1C is the cross-sectional view from FIG. 1B showing a non-limiting example of just the frame according to some embodiments. FIG. 2A is a plan view of a non-limiting example of a frame precursor structure and a panel prior to assembling a framed panel structure according to some embodiments. FIG. 2B is a cross-sectional view of a non-limiting example of a frame precursor structure and a panel along cutline B-B of FIG. 2A according to some embodiments. FIG. 2C is the cross-sectional view from FIG. 2B showing a non-limiting example of just the frame precursor structure according to some embodiments. FIG. 2D is a side view with slight elevation of a non-limiting example of a frame precursor structure according to some embodiments. FIG. 2E is a plan view of a non-limiting example of a frame precursor structure and a panel at an intermediate stage of assembly according to some embodiments. FIG. 3 is a plan view