BACKGROUND OF THE INVENTION

The present invention relates to a method and apparatus for module attachment to a support structure and, more particularly, to boltless module attachment.

Solar panels or modules are mounted to support structures designed to hold the panel in place in an orientation facing the sun or about 20° from horizontal. Current module attachment typically utilizes 4 manually inserted bolts per module. A typical solar field may have about 20 to 680,000 solar panels. Therefore, many thousands of bolts, even millions in some cases, must be used to install a solar field.

The bolts are difficult to position. One person holds the panel in place while another person inserts a bolt from the back of the panel, leading to awkward ergonomics for the installer team. Maintaining alignment during this assembly process is time consuming and difficult due to the height of the work, the weight of the modules, and the angle of installation. In cold weather, the bolt placement and assembly are even more difficult due to the need to wear gloves. Many bolts are lost in this process and assembly requires a lot of time. Missing bolts may result in module damage after system commissioning.

Moreover, the bolts require initial torquing as well as recurring torquing over the 20+ year life of the system. The bolts may need to be retorqued each year or after each major weather event, leading to additional installation and maintenance expense. It is impossible to determine whether the bolts have been properly torqued after assembly without untightening and retorqueing. Moreover, inspectors are required to visually mark each connector as it is torqued or may mark connectors without assurance that torquing has been properly performed.

The bolts are secured with nuts and specialized washers that often feature ribs to provide electrical grounding between the module frame and the support structure. When nuts are missing or under-torqued, additional grounding screws, wires, cables, or straps must be added to assure electrical ground continuity between the solar module frame and support structure. Otherwise, the solar array may not be properly grounded, leading to potential safety and performance risks.

As can be seen, there is a need for an optimized and lower cost system, method, and apparatus for attaching a module to an underlying support structure without the use of bolts.

The present invention provides a new panel attachment system and method therefor using interlocking flanges and/or interlocking stud and slot components. The “perfect alignment and rapid torquing” (PART™) system eliminates the need for bolts when attaching solar panels to support structures, which speeds assembly even with gloves. The inventive panel frame may comprise a slot. The support structure may comprise a stud. The installer may position the panel slot(s) over the stud(s) and drop the panel into the slot. Alternatively, the panel frame and support structure may have interlocking flanges. No bolts and no torquing are required.

The invention provides lower costs, faster installation, and may reduce defects introduced using traditional installation methods.

SUMMARY OF THE INVENTION

In one aspect of the present invention, a boltless module mounting system, comprising at least one module frame having a module therein; at least one support structure having support rails; and plurality of boltless mounting components operative to attach the at least one module frame to the support rails.

In another aspect of the present invention, a boltless module mounting system is provided, comprising at least one module comprising posts and at least one support structure comprising support rails with receiving slots having a receiving hole and two or more slide slots, wherein said posts are operative to interlock with said receiving slots.

In another aspect of the present invention, a method of installing a boltless module is provided. The method comprises providing a boltless module frame with a module therein, said boltless module frame further comprising a plurality of boltless connectors, providing a support structure with a plurality of boltless connectors, aligning the plurality of boltless connectors, lowering said boltless module frame onto said support structure, and sliding said boltless module frame such that the plurality of boltless connectors interlock.

These and other features, aspects and advantages of the present invention will become better understood with reference to the following drawings, description, and claims.

