Obviousness — US Patent 11411529

Obviousness Analysis under 35 U.S.C. § 103 for US11411529

This analysis identifies combinations of prior art references that would render the claims of US patent 11411529 obvious to a person having ordinary skill in the art (PHOSITA). The motivation to combine these references is also explained.

The patent US11411529 relates generally to self-powered solar tracker apparatuses. Key features include aligning the center of mass with the center of rotation to reduce motor load, a modular torque tube design (often weld-free and swage-fitted), a self-contained energy system (solar panel, DC-DC converter, battery, boost converter, capacitor, and microcontroller) to operate without external power, and adjustable support structures (e.g., spherical bearings) to accommodate construction tolerances.

Prior Art References from the Patent Document:

The patent US11411529 itself cross-references the following prior art, which serves as a starting point for this analysis:

U.S. application Ser. No. 14/101,273, filed Dec. 9, 2013.
U.S. Provisional Application No. 61/735,537, filed Dec. 10, 2012.
U.S. patent application Ser. No. 16/128,022, filed Sep. 11, 2018.
U.S. patent application Ser. No. 14/972,036, filed Dec. 16, 2015, now U.S. Pat. No. 10,075,125.
U.S. Provisional Application No. 62/095,670, filed Dec. 22, 2014.

For this analysis, U.S. Pat. No. 10,075,125 is particularly relevant as it is an earlier granted patent from the same patent family. The other applications also represent highly relevant prior art, either as earlier filings from the same lineage or as directly cited related art.

A PHOSITA in this field would possess knowledge of mechanical engineering, solar energy systems, electrical power management, and control systems relevant to solar tracking.

Obviousness Combinations for Inferred Independent Claims:

Claim 1: Self-Powered Tracker Apparatus with Center of Mass Alignment

Combination: U.S. Pat. No. 10,075,125 (or any of the earlier related applications such as US 14/972,036 or US 16/128,022) in view of general knowledge of self-powered control systems.

Reasoning:
U.S. Pat. No. 10,075,125 (or its parent applications) likely discloses the core mechanical structure of a solar tracker, including the adjustable hanger assembly, clam shell clamp, continuous torque tube, solar modules, and a motor-driven tracking mechanism, as these are fundamental to solar trackers and are explicitly mentioned as existing in the background of US11411529. The concept of aligning the center of mass with the center of rotation to reduce motor load is a well-known engineering principle for minimizing power consumption and stress on drive mechanisms. A PHOSITA would understand that reducing the load on a motor directly translates to lower energy consumption.

The remaining elements of Claim 1, specifically the self-powered energy system (solar panel <300W, DC-DC converter, battery, boost converter, capacitor for stable voltage, and a microcontroller for management, operating at <15 Watt-hours/day), represent a conventional approach to providing localized power for low-power remote systems. Self-powered control systems using small solar panels, batteries, and charge controllers (which include DC-DC conversion, boost conversion, and microcontroller management) were well-known at the time of the earliest priority date of US11411529 (December 22, 2014, via US 62/095,670). For example, remote weather stations, agricultural sensors, and even smaller lighting systems frequently employ such architectures.

A PHOSITA would have been motivated to combine these elements to address the known problem of providing power to remote solar trackers without the expense and logistical challenges of running external power lines. The motivation would be to create a truly independent, self-sufficient solar tracker system, thereby reducing installation costs, simplifying deployment, and improving system reliability by eliminating external grid dependencies. The specific power consumption limits (less than 300 Watts for the solar panel and less than 15 Watt-hours per day for operation) would be parameters a PHOSITA would optimize based on the power requirements of the motor and control system, given the available solar energy and battery technology.

Claim 2: Pier-Supported Tracker Apparatus with Offset Drive and Notched Torque Tube

Combination: U.S. Pat. No. 10,075,125 (or related applications) in view of conventional mechanical fastening techniques and tolerance compensation mechanisms.

Reasoning:
U.S. Pat. No. 10,075,125 (or its underlying applications) is highly likely to disclose a pier-supported solar tracker with a drive assembly, a torque tube, and clamps for supporting solar modules. These are core components described in both the background and summary of US11411529 and are typically found in such systems.

The specific features of Claim 2 that might be considered inventive are:

A drive mount capable of compensating for construction tolerances in at least three axes.
An offset clamp device coupled to a cylindrical bearing device and a clamp housing member in the drive.
Notches spatially disposed along the torque tube for clamp mating to prevent movement.
A clamp with a support region for a solar module.

Compensating for construction tolerances in multiple axes is a common engineering problem, especially in large-scale installations like solar farms where ground irregularities and manufacturing variances are expected. Drive mounts with adjustable features (e.g., slotted holes, shims, spherical or universal joints) to accommodate such tolerances were well-known in mechanical design. The use of a cylindrical bearing device within the drive assembly is a standard way to facilitate rotation while providing support. An "offset clamp device" integrated into the drive device is a design choice to manage torque application and alignment, a common consideration in mechanical power transmission.

The use of notches on a shaft or tube in combination with a mating feature on a clamp (e.g., a pin or protrusion) to prevent relative movement (slipping or twisting) is a fundamental mechanical fastening technique. This is commonly employed where a secure, non-rotational connection between a shaft and a component is required. For example, splines, keyways, or even simple pins through holes serve similar functions. Applying this to a solar tracker's torque tube and module clamps would be an obvious choice for a PHOSITA seeking to ensure the rigid attachment of solar modules and prevent slippage, especially under wind loads.

A PHOSITA would be motivated to combine these known elements to improve the robustness, ease of installation, and reliability of the solar tracker system. Specifically, addressing construction tolerances reduces installation time and cost, while securely fastening clamps to the torque tube via notches ensures the structural integrity and precise tracking of the solar modules.

Claim 3: Alternative Tracker Apparatus with Offset Crank and Continuous Torque Tube

Combination: U.S. Pat. No. 10,075,125 (or related applications) in view of conventional crank and shaft coupling mechanisms.

Reasoning:
This claim describes a drive device with a crank configured in an offset manner to a frame assembly, which is coupled to solar modules, and a continuous torque tube. It further specifies a first crank and a second crank coupled to respective torque tubes via swage fittings, all connected to a second pier with a drive mount.

U.S. Pat. No. 10,075,125 (or its parent applications) is highly likely to disclose a solar tracker with a continuous torque tube, solar modules on a frame, a drive device, and support piers, as these are the core elements.

The "offset crank" configuration is a mechanical design choice often used to achieve specific motion profiles, leverage, or to position components clear of other structures. Cranks are fundamental mechanical linkages for converting rotational motion to oscillatory motion or vice versa. The concept of coupling a drive device to a torque tube via one or more cranks to impart rotational motion is well-established in mechanical engineering.

Swage fittings are a known method for creating strong, permanent, and often weld-free connections between tubes or shafts, particularly where axial and torsional loads are expected. Their use to couple cranks to torque tubes would be an obvious selection for a PHOSITA seeking a reliable and efficient connection method that avoids the complexities and potential weaknesses of welding, especially for field assembly.

A PHOSITA would be motivated to combine these features to optimize the mechanical advantage and movement of the torque tube, or to achieve a specific packaging or alignment requirement. The use of swage fittings specifically addresses the practical considerations of manufacturing and assembly, aiming for robust and cost-effective connections.

Claim 4: Solar Tracker Apparatus with Upright Spherical Bearing Hanger

Combination: U.S. Pat. No. 10,075,125 (or related applications) in view of known bearing types and their applications in load-bearing and alignment-compensating structures, combined with standard practices for electrical grounding and mechanical damping.

Reasoning:
This claim builds on the basic solar tracker structure (clamp housing member, pier, torque tube, solar modules) and introduces specific hanger features: an upright clamp housing member with a spherical bearing in the upper region, a clam shell clamp suspended from the spherical bearing, and the torque tube supported by it in an offset position. It also emphasizes weld-free assembly via swage devices, elastomeric dampers for harmonic waveform prevention, locking dampers for high-wind stow, an underground controller box, linear actuation, electrical grounding via the spherical bearing, and independent driving of tracker rows.

U.S. Pat. No. 10,075,125 (or related applications) is expected to disclose the fundamental pier-mounted torque tube solar tracker with solar modules and a drive.

The use of a spherical bearing device in a hanger assembly for a rotating shaft (like a torque tube) is a well-known engineering solution for accommodating angular misalignment, construction tolerances, and allowing limited multi-axial movement while supporting a load. PHOSITAs would recognize the benefits of spherical bearings in such applications to simplify installation and reduce stress on the structure due to imperfections or dynamic loads. Suspending a clam shell clamp from such a bearing to hold a torque tube is a straightforward application of this bearing type. The offset positioning of the torque tube from the center of rotation is a design choice that could be motivated by various factors, such as optimizing torque application or balancing the structure.

Weld-free assembly via swage devices for torque tubes is explicitly mentioned and claimed in Claim 5 of US11411529, and is also described as beneficial for cost, installation time, and manufacturability in the patent. As discussed for Claim 3, swage fittings are a known and obvious alternative to welding for strong tube connections.

Elastomeric dampers are commonly used in mechanical systems to absorb vibrations and prevent resonant frequencies or harmonic waveforms, particularly in structures subjected to dynamic forces like wind (as in large solar panel arrays). A PHOSITA would readily understand the benefit of incorporating such dampers to improve structural integrity and longevity. Similarly, locking dampers or rigid structures to fix solar panels in a stow position during high winds is a standard safety and damage prevention measure for tracker systems.

Underground controller boxes are a common practice for protecting sensitive electronics in outdoor environments from weather, vandalism, and extreme temperatures. Linear actuation for torque tubes is a known alternative to rotary drives, often used with rack-and-pinion or lead screw mechanisms.

Finally, the function of a spherical bearing device in allowing for accommodation of construction tolerance, tracker movement, and acting as a bonding path of least resistance for taking an electrical current to ground would be evident to a PHOSITA. Electrical grounding for safety is a universal requirement for outdoor electrical installations. Using structural components as part of the grounding path, provided they offer sufficient conductivity and low resistance, is a known technique.

The motivation for a PHOSITA to combine these elements would be to create a more robust, easily installable, durable, and safe solar tracker system. Each element addresses a known problem or offers an established advantage in mechanical and electrical engineering contexts.

Claim 5: Tracker Apparatus with Multiple Weld-Free Torque Tubes

Combination: U.S. Pat. No. 10,075,125 (or related applications) in view of conventional modular construction techniques and mechanical fastening systems (specifically swaging and U-bolts).

Reasoning:
This claim focuses on the modular construction of the torque tube from multiple cylindrical steel sections, specifically highlighting weld-free swage-fitted connections and the use of U-bolt devices with notches. The claim specifies torque tube lengths greater than 80 meters.

U.S. Pat. No. 10,075,125 (or its underlying applications) is likely to describe a continuous torque tube for supporting solar modules, which would imply the need for coupling multiple sections for long arrays.

Modular construction of long structures from shorter, connectable sections is a standard practice in engineering to facilitate transport, handling, and assembly on site. For solar trackers, especially for lengths exceeding common manufacturing or shipping limits (e.g., 80 meters as claimed), a modular approach is essential.

As discussed for Claim 3, swage-fitting as a weld-free connection method for tubes is a well-known mechanical technique providing strong axial and torsional connections. A PHOSITA would be motivated to use swage fittings to create a continuous torque tube without welding, given the benefits in cost, installation time, and consistency of connection (as explicitly stated in US11411529).

The use of notches on the torque tube in conjunction with U-bolt devices to prevent relative movement (slipping) is a standard and obvious mechanical fastening technique, similar to that discussed for Claim 2. U-bolts are commonly used to secure pipes or shafts to supports or other components, and a notch provides a positive stop to resist axial or rotational displacement. The combination of these ensures a secure attachment of structural components to the torque tube.

The specification of steel for the torque tubes is a default material choice for structural components in such applications due to its strength and cost-effectiveness.

A PHOSITA would be motivated to combine these elements to enable the construction of very long solar tracker rows (e.g., greater than 80 meters, up to 200 meters as disclosed in US11411529) using modular, easily assembled, and robust components, thereby improving scalability and reducing installation complexity.

Claim 6: Tracker Apparatus with Multi-Directional Clamp Holding Member

Combination: U.S. Pat. No. 10,075,125 (or related applications) in view of known adjustable mounting brackets and mechanisms for accommodating spatial variations.

Reasoning:
This claim describes a pier member with a clamp holding member attached to its upper region, where the clamp holding member is capable of moving in at least six distinct directions (first, second, third, fourth, fifth, and sixth, representing linear adjustments along three orthogonal axes and their opposites).

U.S. Pat. No. 10,075,125 (or its underlying applications) is expected to disclose pier members and clamp holding members as part of a solar tracker's support structure.

The ability of a clamp holding member to move in multiple directions (e.g., three translational degrees of freedom, and potentially rotational) is a direct engineering solution to the problem of construction tolerances, particularly for pier installations where precise alignment cannot be guaranteed due to uneven terrain or installation inaccuracies. Adjustable mounting brackets and mechanisms allowing for such multi-directional positioning are common in various industries, including construction, manufacturing, and even photography equipment (e.g., tripod heads). These adjustments are typically achieved through combinations of slotted holes, shims, eccentric cams, or multi-axis slides.

A PHOSITA would be motivated to incorporate such a multi-directionally adjustable clamp holding member to simplify the installation process, reduce the need for extremely precise (and costly) pier placement, and allow for field adjustments to ensure proper alignment of the torque tube and solar panels. This directly addresses the practical challenges of deploying large-scale solar tracker systems on varied terrain.

Claim 7: Solar Tracker Apparatus with Suspended Clam Shell and Twist-Free Drive

Combination: U.S. Pat. No. 10,075,125 (or related applications) in view of known bearing designs (spherical/cylindrical), load distribution principles, and torque management techniques for rotating shafts.

Reasoning:
This claim focuses on an upright clamp housing member with a spherical (or cylindrical/fixed) bearing from which a clam shell clamp housing member is suspended, supporting a torque tube in an offset position. A key aspect is a drive device coupled to the second end of the torque tube, configured to be substantially free from twisting action under load.

U.S. Pat. No. 10,075,125 (or its underlying applications) is highly likely to describe a solar tracker with a torque tube, support piers, a drive mechanism, and clamps.

The use of a spherical bearing (or cylindrical/fixed bearing) to suspend a clam shell clamp and support a torque tube in an upright clamp housing member is an application of known bearing technology to allow for rotation and accommodate misalignment, as discussed for Claim 4. The suspension aspect ensures that the weight of the torque tube and modules is borne by the hanger assembly, facilitating the drive mechanism's primary role in rotation rather than load-bearing. The "offset position from a center region of rotation" can be a deliberate design choice to optimize torque transfer or balance the system, a concept understood by a PHOSITA.

The most distinctive feature here is configuring the drive device and torque tube to be substantially free from a twisting action while under a load. This is a well-known engineering goal in designing rotating shaft systems. To achieve "substantially free from twisting," a PHOSITA would consider several approaches:

High torsional stiffness: Using a torque tube made of a material with high shear modulus and/or a large diameter-to-wall-thickness ratio. The patent itself mentions HSS steel pipes with 1-10 inch diameter, which are designed for high torsional strength.
Distributed support: Providing adequate support along the length of the torque tube (e.g., through multiple piers and hanger assemblies) to limit overall twist.
Drive system design: The drive itself could be designed to apply torque with minimal induced bending or localized twisting moments. The crank system described in Claim 3 could contribute to this by providing a balanced application of force.
Minimizing external twisting loads: While the system experiences loads from rotation and wind, the design aims to manage these to prevent excessive twisting.

A PHOSITA would be motivated to ensure the torque tube remains substantially free from twisting to maintain the precise alignment of the solar modules, which is critical for efficient solar tracking. Twisting would lead to misalignment of panels along the row, reducing energy capture and potentially damaging the structure. This is a fundamental design consideration in any long, rotating shaft system.

The combination of a well-supported, centrally-loaded torque tube via a suspension system (using a spherical bearing) and a drive designed to minimize twisting under load represents an obvious application of standard mechanical engineering principles to optimize the performance and longevity of a solar tracker.