This invention relates to a modular solar racking system. This invention addresses the problems of installation time and inventory particularly in the system described in PCT/AU2015/000001. This invention also addresses the problems associated with accommodating building roof infrastructure [ie air conditioning infrastructure etc.], and heavy snow loads.

Background to the invention

Patent application PCT/AU2015/000001 discloses a solar panel roof mounting system. This system had difficulty in accommodating variable dimensions of solar panels and in providing support for all types of solar panels sizes.

It is an object of this invention to provide a commercial solar generator racking system that is easy to install and ameliorates the disadvantages of the prior art.

Brief description of the invention

To this end the present invention provides a modular rack array for supporting solar panels which includes

a longitudinal support rack which is securable to a roof and which has two longitudinal sides with solar panel support ledges on both sides and hold down receiving recesses located between each row of support ledges

the arrangement enabling a single solar panel to be supported by two parallel support racks and additional panels to be supported by an additional support rack with the panel hold down recesses being arranged to bear down on the upper side of the solar panel edges so that two parallel edges of said solar panel are held within the receiving recesses of said support racks.

This invention provides improvements in PCT/AU2015/000001 and can be assimilated with the teachings of that invention.

As provided in PCT/AU2015/000001 this invention provides:

· A variable modular rack array embodiment for supporting solar panels which includes specific solar panel hold down clips designed to fix both amorphous (~ 8.5 mm thick photo voltaic panels {PVP's]) and the standard framed (e.g. 60 or 72 cell PVP). • Where the variability is provided via a tubular longitudinal support system that can be extended 'ad infinitum' to suit any required roof longitudinal dimension. And...

• The lateral dimension extended via modular additions of the said longitudinal assembly.

In this invention there is provided the addition of an innovative propriety rack embodiment with the capabilities:

• Single client [PVP design] specificity;

• A slide-in slot insert system for installing PV panels and strengthening

beams, preferably with an end retaining spring moulded into the rack;

• A preferred PVP design specific fixed length modular longitudinal connective system;

• A preferred PVP design specific fixed length modular Longitudinal

strengthening beam;

· A variable vertical support system, with minimal component part number and a robust 'click-and-fix' system provided via standard thermoplastic HDPE SF moulding;

• The said support system preferably having the capability of raising the PVP array above any roof infrastructure (e.g. air conditioning [AC], units and infrastructure), therefore maximizing PVP to roof area population ratios.

• Preferably with a capability for the insertion of a strengthening beam capable of supporting lower strength PVP in landscape orientation, and for the general support of PV panels in landscape orientation for snow loads.

This invention also provides preferred improvement(s) to the variable racking system of:

• A specifically designed [to suit the preferred PVP type thickness dimension], as an optionally insertable PVP load strengthening beam [or bar], providing support to any type of PVP supported by the rack system;

• The said beam is inserted longitudinally, sandwiched between two adjacent PVP's and optionally at either end of the said installed PVP's. Detailed description of the invention

A preferred embodiment of the invention will now be described with reference to the drawings in which:

Figure 1 is an illustration of a prototype rack, designed specifically for low latitudes and minimal tool cost;

Figures 2 & 3 illustrate the back to back [BB], and front to back [FB], connective capabilities of the prototype rack.

Figure 3 a & b illustrate the rack clip design variations that accommodate and fix the assorted commercially available variable thickness PVP designs;

Figure 4 illustrates the two embodiments of the PVP load support beam;

Figure 5 illustrates the prototype rack x2 assembly with amorphous PVP panels, clips and load support beams;

Figure 6 illustrates the prototype rack x4 assembly, in BB configuration, complete with clips, load support beams and top retainer, with two 72 cell standard PVP panels;

Figure 7 illustrates the propriety rack [p-rack] design;

Figure 8 illustrates the iBeam design;

Figure 9 illustrates a non elevated BB and an FB assembly of two propriety racks and iBeam using the stud part as a fixing mechanism;

Figure 10 illustrates the assembly of the p-rack stand mechanism;

Figure 11 illustrates the array end block design, a completion part for the first and last rows of the elevated PVP array. The said block avails the installation of the stand mechanism in the said first and last array rows;

Figure 11 illustrates the assembly and exploded views of the p-rack, stand mechanism and end blocks;

Figure 13 illustrates a 4x p-rack elevated structure of all the above components [p- rack x4, iBeam x3, load support beam x3 and Stand assembly x6], including two 72 cell PV panels. Figure 1 illustrates the major design components of the prototype Truss [T] rack [fig 1 , 1-01-001-1]. The variation of the prototype to the previous patent design being in the rectangular mouldings see fig 1 , 1-01-006-1 , on either end of the T-rack. The said variations were implemented on a cost basis given the rack deployment would be limited to the very low latitudes. Figure 2 illustrates the T-rack prototype assembly options - BB and FB configurations. Figure 3 illustrates the prototype clip design variations used with the prototype T-rack. The differences in design reflective of the variation in thickness of commercially available solar Panel designs.

Figure 4 illustrates the design of the load strengthening beam, note that the said beam will need to be matched to the thickness of the users preferred PVP. Fig 4 (a) 1-03-002-1 , illustrates the slot width needed for First Solar Type Panels, and Fig 4 (b) 1-03-002-2, illustrates the slot width needed for a framed 72 cell PVP. Fig 4 (a)

1- 03-003-1 , illustrates the end tongue which sits on top of the T-rack top lip [see fig 1 1-01-002-1 , & fig 5], this component part is non structural as the major reinforcing component part of the said beam is in the close fit of the C-slot [see fig 4 (a) 1-03-

002- 1 , and fig 4 (b) 1-03-002-2. Note that the corresponding part used for the framed PVP's [see Fig 4 (b) 1-03-003-2], is vertically oriented to allow for the greater thickness of the said PVP. The holes [either circular or other designs], are placed in non structural positions and are needed to remove unnecessary polymer volume establishing a lower cost per watt [output] in relation to the overall cost of the assembly. Figure 5 illustrates a typical assembly of three First Solar PVP's [aspect

5- 001], on two T-racks [1-01-001-1], with four load strengthening beams [1-03-001- 1], and clips [1-02-001-2]. The load strengthening beams are used to strengthen the PVP's for high snow loads and for service access in situations where PVP vs Area Density need to be at a maximum. Figure 6 is a complete T-rack assembly of four T- racks [1-01-001-1], four 72 cell PVP's [aspect: 6-001], three variable pipes [aspect:

6- 002], six strengthening beams [1-03-001-1], and clips [1-02-001-1].

Figure 7 illustrates the propriety rack design [2-01-001-1] - [P-rack]. Because this design incorporates the use of fixed distance iBeams, replacing the 'infinite' longitudinal pipe in previous embodiments, to accommodate the need for company specific PVP designs, allowing the fixing clips to be replaced with C-slots [2-01-002- 1], and a single retaining clip moulded into the rack body [2-01-003-1]. This rack design incorporates vertical cylindrical clamping sections [2-01-007-1], and stud fixing mouldings [2-01-006-1], for the fixing / clamping of two P-racks [in either BB or FB orientation], and a vertical pipe stand. This capability has the advantage of elevating the P-rack superstructure above 'floor' level above any roofing infrastructure [e.g. AC units and or ducting etc], allowing a greater area for solar panel array deployment.

Figure 8 illustrates the ibeam, which consists of two parallel faces [2-02-004-1], normal to a reinforced standard I-beam section [2-02-006-1]. The I beam connects with the P-rack at the end blocks 2-01-004-1, via a vertical slide of the said parallel face [2-02-004-1], into P-rack moulded grooves [2-01-011-1]. When placed in position, the bottom of the said parallel face [2-02-005-1], mates with the P-rack stop moulding [2-01-010-01], and the P-rack retaining clip [2-01-008-1] - which deflects in the ibeam insertion process returns to its original position - locking the ibeam in position.

Figure 9 illustrates two P-racks [2-01-001-1], in BB and FB orientations, fixed via stud [2-03-001-1], which incorporates a stud pipe threaded at both ends [2-03-002- 1], and two lock nuts [2-03-003-1]. Both orientations have an ibeam [2-02-001-1], fixed in position.

Figure 10 illustrates an assembled (a) and exploded view (b) of the stand [or 'leg']. The stand includes a top cap [2-04-003-1], main pipe [2-04-002-1], base plate [2-04- 004-1], which can be fixed to the flood/roof or to a ballasted plate [not shown]. There is also a hole cut into the pipe to allow the fitment of the stud pipe [2-03-001-1], which as well as fixing P-racks, also accommodates the stand pipes in the same procedure.

Figure 11 illustrates the end block. In essence when assembling the P-rack into an elevated array, the said end block allows for the fixing/placement of a stand on the first and last row positions for each array column. The design of the block is a replication of the P-rack end block [2-01-004-1].

Figure 12 illustrates an assembled (a) and exploded view (b) of two P-racks [2-01- 001-1], three pipe stand assemblies [2-04-001-1], two end blocks [2-05-001-1], and three stud fixing devices [2-03-001-1].

Figure 13 illustrates an elevated assembly of two 72 cell solar panels [aspect: 13- 001], four P-racks [2-01-001-1], three ibeams [2-02-001-1], three load strengthening beams [1-03-001-2], and six pipe stand & stud fixing assemblies [2-04-001-1].

Lateral strength of the elevated structure is provided via standard cross bracing procedures utilizing SWR tendons fixed from below the base of the P-rack array assembly to the stand base, as per design wind requirement. The invention adds to the teaching of PCT/AU2015/000001 , being constructed as modular parts, in which the P-racking array can be assembled to form a high strength plastic support infrastructure with a high degree of integrity/reliability, and combined with the strength of steel [or equivalent], pipe stands provides a durable competitive, cost effective, time saving solution to the elevated racking industry.

Those skilled in the art will realise that this invention provides a unique material/assembly to provide an unballasted solar racking system, with optimal connectivity, installation speed and contiguous array strength, that will resist wind induced lift forces, whilst maximising commercial roof coverage ratio.

Those skilled in the art will realise that the present invention may be made in embodiments other than those described without departing from the core teachings of the invention. The modular platform may be adapted for use in a range of applications and sizes and can be shaped to fit the requirements of the desired application.