AU2020101139A4

AU2020101139A4 - Solar Panel Frame Assembly

Info

Publication number: AU2020101139A4
Application number: AU2020101139A
Authority: AU
Inventors: Ryan Groom; Daryn Stocks
Original assignee: Stocks Blocks Pty Ltd
Current assignee: Stocks Blocks Pty Ltd
Priority date: 2019-06-26
Filing date: 2020-06-25
Publication date: 2020-07-30
Anticipated expiration: 2028-06-25

Abstract

A frame assembly for supporting a solar panel comprises a pair of side walls. Each side wall comprises a bottom member, an inclined top member and a pair of end members connecting the top and bottom members. The pair of side walls are connected in a spaced-apart, parallel relationship by way of (a) at least one connecting member having respective ends that are removably coupled to opposing faces of each wall; and (b) at least one ballast support member having respective ends that are each removably coupled to opposing faces of the bottom members. An upper face of each side wall is adapted to receive a corresponding side edge of the solar panel and wherein an upper face of the at least one ballast support member is adapted to receive a ballast material. 100 113b/150 113a/150 112a 102b 102a 113d/150 106 113c 112b 108a 114113e 113f/150 112c 110 104 .f A 108b Fig. 1

Description

113b/150

113a/150 112a

102b

102a 113d/150 106

113c

112b 108a

114113e 113f/150 112c 110

104 .f

A 108b

Fig. 1

Solar Panel Frame Assembly

Field of Invention

This invention relates to solar panels and more particularly to support structures for solar panels. In particular it relates to support structures for solar photovoltaic panels but is not limited to use with such panels.

Background

Fixed solar photovoltaic panels need to be angled to the horizontal so as to 'face' the sun during daylight hours. Typically panels are aligned to face toward the equator (North in the Southern hemisphere and South in the northern hemisphere) and at an angle to the horizontal approximating the latitude. The desired alignment and angle to the horizontal may depend on load/ generating requirements. For example if more load is required in the morning the panels may be aligned more toward the sunrise (Eastwards in the Southern hemisphere) and at an angle greater than the latitudes, so that the panels are perpendicular to the sun light earlier than otherwise.

Current methods for supporting solar panels involve space frame type structures, whether mounted on a roof or on the ground. For large scale installations typically one or more panels are mounted on a space frame type support structures. The panels need to be prevented from moving when subject to strong winds. Each support structure is typically located by providing a number of concrete footings into which parts of the support structure are located or subsequently attached to and the structure is then assembled from components on site. This is time consuming and requires on site assembly and adjustment.

Embodiments of the present invention aim to provide a frame assembly that is quick to deploy, rapidly scalable and which may be placed upon relatively smooth ground and secured with ballast, so avoiding the need for concrete footings or reducing the time for on-site assembly.

Summary of the Invention

In one broad form the invention provides a frame assembly for supporting a solar panel, comprising: a pair of side walls, each side wall comprising a bottom member, an inclined top member and a pair of end members connecting the top and bottom members; the pair of side walls being connected in a spaced-apart, parallel relationship by way of: at least one connecting member having respective ends that are removably coupled to opposing faces of each wall; and at least one ballast support member having respective ends that are each removably coupled to opposing faces of the bottom members; and wherein, when so connected, an upper face of each side wall is adapted to receive a corresponding side edge of the solar panel and wherein an upper face of the at least one ballast support member is adapted to receive a ballast material.

In the embodiment the frame assembly further comprises an upright brace that extends between the upper top and bottom members and is disposed approximately halfway between the respective end members.

In the embodiment the frame assembly further comprises an additional side wall that connects to a first one of the pair of side walls in a spaced apart, parallel relationship by way of at least one connecting member and at least one ballast support member and wherein, when so connected, an upper face of the first side wall and additional side wall are adapted to receive corresponding side edges of a second solar panel.

In an embodiment each of the side walls have an identical configuration.

In an embodiment the upper face of each side wall comprises an upwardly projecting T-shaped projection that operates to form mirrored U-shaped mounting channels on the upper face configured to slidably receive corresponding edges of the solar panel.

In an embodiment a side face of each base member comprises a first pair of spaced apart projections having an end in which is disposed a longitudinal channel that steps inwardly into the projection to create an internal void and wherein an opposite side face of each base member comprises a corresponding first pair of projections on the other face and wherein a first ballast support member comprises a first pair of spaced apart T-shaped projections extending from each side that are adapted to locate within the channel/voids of corresponding projections on opposing faces of the bottom members for connecting thereto. The projections on the opposition side face of each base member may be offset to the corresponding projections on the other face and wherein the first ballast support member comprises a second adjacent pair of spaced apart T-shaped projections on each side that are located adjacent the first pair of T-shaped projections, thereby allowing either edge of the first ballast support member to connect to either face of the corresponding frame side wall.

In an embodiment the spaced apart projections on either face of the base member are located between one end of the base member and the upright brace.

In an embodiment the frame assembly further comprises a second pair of spaced apart projections on either face of the base member located on the other side of the upright member for receiving a second ballast support member in the same manner as for the first ballast support member.

In an embodiment the second ballast support member has an identical configuration to the first ballast support member.

In an embodiment a side face of each top member comprises an open-ended channel having retaining flanges extending inwardly from either end of the channel and wherein the open-ended channel is configured to slidingly receive an end plate disposed at an end of the connecting member for removable coupling thereto.

In an embodiment the connecting member comprises a rod and wherein the end plate has a longitudinal plane that is orthogonal to a longitudinal plane of the rod.

In an embodiment the side walls and ballast support member(s) are formed of high density recycled plastic.

In an embodiment the ballast comprises one or more of sand, soil, rock, earth or other solid material.

Brief Description of the Drawings

Features and advantages of the present invention will become apparent from the following description of embodiments thereof, by way of example only, with reference to the accompanying drawings, in which:

Figure 1 is an isometric view of a frame assembly in accordance with an embodiment of the invention;

Figure 2 is an alternative isometric view of the frame assembly of figure 1;

Figure 3 is a side view of the frame assembly of figure 1;

Figure 4 is a plan view of the frame assembly of figure 1;

Figure 5 is a front view of the frame assembly of figure 1;

Figure 6a is a close-up view of a section A of figure 1;

Figure 6b is a close-up view of a section B of figure 4;

Figure 7 is an isometric view of the frame assembly of figure 1 with a solar panel installed;

Figure 8 is an isometric view of an expanded frame assembly according to an embodiment of the invention; and

Figure 9 is an isometric view of the frame assembly of figure 8 with multiple solar panels installed.

Detailed Description of Preferred and other Embodiments

Referring to figures 1 to 7 there is shown a solar panel frame assembly 100 for supporting a solar panel, in accordance with a first embodiment of the invention. The assembly 100 is designed to support a generally rectangular solar photovoltaic panel 200 (figure 7) and is designed to be placed directly upon a generally level ground surface.

The assembly 100 includes a pair of identical side walls 102a, 102b that, according to the illustrated embodiment, are formed from molded high-density recycled plastic material. As will become evident from subsequent paragraphs (and with additional reference to figures 8 and 9), when connected in series, the side walls 102 operate as partitions allowing multiple solar panels 200 to be mounted in series (i.e. in a row), in a cost-effective, scalable and efficient manner.

Each side wall 102a, 102b comprises a bottom member 104, an inclined top member 106 and a pair of end members 108a, 108b that connect the top and bottom members 104, 106. An upright brace member 110 may also be provided for increasing the strength of the side wall. The brace member 110 is disposed approximately halfway between the respective end members 108a, 108b.

For assembly, the pair of side walls 102a, 102b are connected in a spaced-apart, parallel relationship (as shown in the figures) by way of at least one connecting member 112 and at least one ballast support member 114. When so connected, an upper face 120 of each side wall 102a, 102b is adapted to receive a corresponding side edge of a solar panel and an upper face of each ballast support member 114 is adapted to receive a ballast material.

In more detail, and with particular reference to figure 5, each side wall upper face 120 comprises an upwardly projecting T-shaped projection 122 that operates to form mirrored U-shaped mounting channels 124 on either edge of the upper face which receive corresponding edges of the solar panel rest (as shown in figure 7). As shown in the figures, an upper of the channel is open so as to slidably receive corresponding edges of the solar panel, while a bottom end of the channel is closed to retain the solar panel once fully inserted into the channel. The channels may be sized for particular solar panels or alternatively may be a 'generic' size, being taller than most panels on the market.

It will be understood that two or more panels may be located end on end by the assembly. Minor variations in length of different models of panel are not critical. Longer panels may extend slightly beyond the open upper end of the channels 124. Shorter panels will end before the open ends.

For removably coupling to a first ballast support member 114, and with particular reference to figures 6a and 6b, the base member 104 of each side wall 102 comprises a first pair of spaced apart projections 130a, 130b disposed between the first end member 108a and upright member 110. Each projection 130 has an end in which is disposed a longitudinal channel 132 that steps inwardly into the corresponding projection to create an internal void 134. An opposite side face of each side wall comprises corresponding projections 130c, 130d. According to the illustrated embodiment, the projections 130c, 130d are either inwardly or outwardly offset with respect to the projections on the other face (i.e. are more closely spaced or further spaced apart) for ease of manufacturing and reduced material cost. In this instance, projections 130a, 130b are more closely spaced than projections 130c, 130d.

The ballast support members 114 take the form of rectangular plates 114 that are also molded from high density recycled plastic. Both side edges of each plate 114 are provided with a first pair of spaced apart T-shaped projections 142a, 142b that are adapted to locate within the voids 134 of corresponding projections 130a, 130b of the side wall 102 for removable coupling thereto. A second pair of spaced apart T-shaped projections 142c, 142d disposed adjacent projections 142a, 142b for being received in the projections 130c, 130d on the other face of the side wall 102. This allows a single plate 114 to be used irrespective of which side wall face it is to couple to. This is best shown in the close-up view of figure 6b.

Returning to figure 1, the frame assembly 100 is adapted to receive two ballast support members 114 and accordingly each side wall 102 comprises another set of spaced apart projections 136a, 136d on either face between the other end member 108b and upright brace 110 for connecting to a second ballast support member 114.

According to the illustrated embodiment, the pair of side walls 102a, 102b are additionally connected by way of three connecting members 112 in the form of rods 112 formed from extruded aluminium. In this regard, each side wall comprises three open-ended channels 150 projecting from one face thereof. The channels 150 extend outwardly from the top member 106 at the point of connection with each of the ends 108a, 108a and upright brace 110. According to the illustrated embodiment, each channel 150 is partitioned into four separate portions that having deformable retaining flanges extending inwardly from either end. Each channel is mirrored on the opposite face of each wall 102. According to the illustrated embodiment, the open-ended channels are configured to slidingly receive an end plate 113 disposed at an end of the connecting rod 112 for removable coupling thereto. The deformable flanges operate to snap lock the connecting rod plates in place once fully inserted into the channel. As shown in the figures, the end plates 113 are coupled to each rod end have a longitudinal plane that is orthogonally disposed to the longitudinal plane of the rod. More particularly plates 113a and 113b of rod 112a are slid upwardly into position within a u-shaped channel disposed in end member 108a; plates 113c and 113d of rod 112b are slid upwardly into position within a u-shaped channel disposed in the upright brace member 110; and plates 113e and 113f of rod 112c are slid at the same incline as the top member 102b within a u-shaped channel disposed therein.

The connecting rods 112 may also advantageously provide points to tie off electrical wires and the like with suitable fasteners. It will be understood that a fewer or greater number of connecting rods/members than shown in the illustrated embodiment may be used, depending on the desired implementation.

With additional reference to figure 8, an additional side wall 102c is added to a modified frame assembly 100' for carrying an additional solar panel (see figure 9). The additional side wall 102c connects to side wall 102b of the figure 1 assembly in the same spaced apart, parallel relationship and using the same connecting rod and ballast plate arrangement. It will be understood that multiple further side walls 102 can be connected in the same fashion to connect any desired number of solar panels in series.

It will be understood that frame walls 102 may be manufactured in different versions with the top members inclined at different angles (with respect to the bottom member), for example at 15, 25 and 35 degrees.

Multiple apertures may be disposed in the side walls (not shown) for reducing the weight and amount of material required for molding. The apertures may be of any shape or configuration and may also be used for routing cables.

When installing the frame assembly 100 the walls 102 are designed to be placed directly upon a flattened surface, prior to installation of solar panels themselves. A suitable ballast material is then placed on top of the ballast support members 114. The ballast is preferably a solid material and may comprise local sand, soil, rock, earth or other solid material. Thus, it is not necessary to transport any ballast material to the installation location.

Once the assembly 100 has been secured in position and appropriately ballasted, the solar panels 200 are then mounted on the side walls 102. It will be understood that assembly can be readily expanded over time by simply adding partitions (i.e. extra walls 102). Wiring may optionally be installed into the arrays of mountings before or after mounting of the panels.

It will be understood that the solar panels 200 may couple to the upper face of the side wall using any suitable coupling/fastening arrangement and need not be slidably received as per the illustrated embodiments. For example, the panels 200 may be lifted above the assembly and lowered directly onto upper face support surfaces. Any suitable fastening means may be used to secure the panels 200 to the assembly. Alternatively, the lower end of the upper face may be provided with one or more stop members, such as an upstanding wall against whish the lower edge of a panel 200 may bear.

Unless the context clearly requires otherwise, throughout the description and any claims the words "comprise", "comprising", and the like are to be construed in an inclusive sense as opposed to an exclusive or exhaustive sense; that is to say, in the sense of "including, but not limited to".

The features of the invention described or mentioned in this document may be combined in any combination of features where features are not mutually exclusive.

In the foregoing description of certain embodiments, specific terminology has been resorted to for the sake of clarity. However, the disclosure is not intended to be limited to the specific terms so selected, and it is to be understood that each specific term includes other technical equivalents which operate in a similar manner to accomplish a similar technical purpose. Terms such as "upper" and "lower", "above" and "below" and the like are used as words of convenience to provide reference points and are not to be construed as limiting terms.

It will be apparent to those skilled in the art that many obvious modifications and variations may be made to the embodiments described herein without departing from the spirit or scope of the invention.

Claims

1. A frame assembly for supporting a solar panel, comprising:

a pair of side walls, each side wall comprising a bottom member, an inclined top member and a pair of end members connecting the top and bottom members;

the pair of side walls being connected in a spaced-apart, parallel relationship by way of:

at least one connecting member having respective ends that are removably coupled to opposing faces of each wall; and

at least one ballast support member having respective ends that are each removably coupled to opposing faces of the bottom members; and

wherein, when so connected, an upper face of each side wall is adapted to receive a corresponding side edge of the solar panel and wherein an upper face of the at least one ballast support member is adapted to receive a ballast material.

2. A frame assembly in accordance with claim 1, further comprising an upright brace that extends between the upper top and bottom members and is disposed approximately halfway between the respective end members.

3. A frame assembly in accordance with claim 1 or claim 2, further comprising an additional side wall that connects to a first one of the pair of side walls in a spaced apart, parallel relationship by way of at least one connecting member and at least one ballast support member and wherein, when so connected, an upper face of the first side wall and additional side wall are adapted to receive corresponding side edges of a second solar panel.

4. A frame assembly in accordance with any one of the preceding claims, wherein each of the side walls have an identical configuration.

5. A frame assembly in accordance with claim 4, wherein the upper face of each side wall comprises an upwardly projecting T-shaped projection that operates to form mirrored U-shaped mounting channels on the upper face configured to slidably receive corresponding edges of the solar panel.

6. A frame assembly in accordance with claim 4 or 5, wherein a side face of each base member comprises a first pair of spaced apart projections having an end in which is disposed a longitudinal channel that steps inwardly into the projection to create an internal void and wherein an opposite side face of each base member comprises a corresponding first pair of projections on the other face and wherein a first ballast support member comprises a first pair of spaced apart T-shaped projections extending from each side that are adapted to locate within the channel/voids of corresponding projections on opposing faces of the bottom members for connecting thereto.

7. A frame assembly in accordance with claim 6, wherein the projections on the opposition side face of each base member are offset to the corresponding projections on the other face and wherein the first ballast support member comprises a second adjacent pair of spaced apart T-shaped projections on each side that are located adjacent the first pair of T-shaped projections, thereby allowing either edge of the first ballast support member to connect to either face of the corresponding frame side wall.

8. A frame assembly in accordance with claim 6 or 7 when dependent on claim 2, wherein the spaced apart projections on either face of the base member are located between one end of the base member and the upright brace.

9. A frame assembly in accordance with claim 8, further comprising a second pair of spaced apart projections on either face of the base member located on the other side of the upright member for receiving a second ballast support member in the same manner as for the first ballast support member.

10. A frame assembly in accordance with claim 9, when the second ballast support member has an identical configuration to the first ballast support member.

11. A frame assembly in accordance with any one of the preceding claims, wherein a side face of each top member comprises an open-ended channel having retaining flanges extending inwardly from either end of the channel and wherein the open-ended channel is configured to slidingly receive an end plate disposed at an end of the connecting member for removable coupling thereto.

12. A frame assembly in accordance with claim 11, wherein the connecting member comprises a rod and wherein the end plate has a longitudinal plane that is orthogonal to a longitudinal plane of the rod.

13. A frame assembly in accordance with any one of the preceding claims, wherein the side walls and ballast support member(s) are formed of high-density recycled plastic.

14. A frame assembly in accordance with any one of the preceding claims, wherein the ballast comprises one or more of sand, soil, rock, earth or other solid material.

2020101139

113b/150

112a 113a/150

102b

102a 113d/150 106

113c

112b 108a

113e 113f/150 114 112c 110

104 114 A 108b

Fig. 1

Fig. 2 114

104 110 102a

Fig. 3

102a

114 2020101139

B

114

Fig. 4 120/ 120/ 122 122 124 124 124 124 116

116

114

Fig. 5

A 2020101139

134

132 130a

104

130b

Fig. 6a

130c B

142a 2020101139

142c

130a

114

142b

130b 142d

130d

Fig. 6b

Fig. 7

100’ 2020101139

102c

102b

102a

Fig. 8

Fig. 9