Photovoltaic (PV) cells, commonly known as solar cells, are devices for conversion of solar radiation into electrical energy. Generally, solar radiation impinging on the surface of, and entering into, the substrate of a solar cell creates electron and hole pairs in the bulk of the substrate. The electron and hole pairs migrate to p-doped and n-doped regions in the substrate, thereby creating a voltage differential between the doped regions. The doped regions are connected to the conductive regions on the solar cell to direct an electrical current from the cell to an external circuit. When PV cells are combined in an array, such as a PV module, the electrical energy collected from all of the PV cells can be combined in series and parallel arrangements to provide power with a certain voltage and current.
PV modules, which may comprise PV laminates and related electronics, are often supported by a frame assembly of one or more numerous components. These frame assemblies can be secured to PV modules, can serve to hold PV modules in place, and can serve to hold PV modules in relative position to each other. The frame assemblies can be secured to supports, which themselves hold the frame assemblies and PV modules of PV systems in place. The frame assemblies can also couple with underlying buildings, foundations, or other support structures of a PV system or portions of a PV system.
The following detailed description is merely illustrative in nature and is not intended to limit the embodiments of the subject matter of the application or uses of such embodiments. As used herein, the word “exemplary” means “serving as an example, instance, or illustration.” Any implementation described herein as exemplary is not necessarily to be construed as preferred or advantageous over other implementations. Furthermore, there is no intention to be bound by any expressed or implied theory presented in the preceding technical field, background, brief summary or the following detailed description.
This specification includes references to “one embodiment” or “an embodiment.” The appearances of the phrases “in one embodiment” or “in an embodiment” do not necessarily refer to the same embodiment. Particular features, structures, or characteristics may be combined in any suitable manner consistent with this disclosure.
Terminology. The following paragraphs provide definitions and/or context for terms found in this disclosure (including the appended claims):
“Comprising.” This term is open-ended. As used in the appended claims, this term does not foreclose additional structure or steps.
“Configured To.” Various units or components may be described or claimed as “configured to” perform a task or tasks. In such contexts, “configured to” is used to connote structure by indicating that the units/components include structure that performs those task or tasks during operation. As such, the unit/component can be said to be configured to perform the task even when the specified unit/component is not currently operational (e.g., is not on/active). Reciting that a unit/circuit/component is “configured to” perform one or more tasks is expressly intended not to invoke 35 U.S.C. § 112(f) for that unit/component.
“First,” “Second,” etc. As used herein, these terms are used as labels for nouns that they precede, and do not imply any type of ordering (e.g., spatial, temporal, logical, etc.). For example, reference to a “first” frame member does not necessarily imply that this frame member is the first frame member in a sequence; instead the term “first” is used to differentiate this frame member from another frame member (e.g., a “second” frame member).
“Based On.” As used herein, this term is used to describe one or more factors that affect a determination. This term does not foreclose additional factors that may affect a determination. That is, a determination may be solely based on those factors or based, at least in part, on those factors. Consider the phrase “determine A based on B.” While B may be a factor that affects the determination of A, such a phrase does not foreclose the determination of A from also being based on C. In other instances, A may be determined based solely on B.
“Coupled”—The following description refers to elements or nodes or features being “coupled” together. As used herein, unless expressly stated otherwise, “coupled” means that one element/node/feature is directly or indirectly joined to (or directly or indirectly communicates with) another element/node/feature, and not necessarily mechanically.
“Inhibit”—As used herein, inhibit is used to describe a reducing or minimizing effect. When a component or feature is described as inhibiting an action, motion, or condition it may completely prevent the result or outcome or future state completely. Additionally, “inhibit” can also refer to a reduction or lessening of the outcome, performance, and/or effect which might otherwise occur. Accordingly, when a component, element, or feature is referred to as inhibiting a result or state, it need not completely prevent or eliminate the result or state.
In addition, certain terminology may also be used in the following description for the purpose of reference only, and thus are not intended to be limiting. For example, terms such as “upper”, “lower”, “above”, and “below” refer to directions in the drawings to which reference is made. Terms such as “front”, “back”, “rear”, “side”, “outboard”, and “inboard” describe the orientation and/or location of portions of the component within a consistent but arbitrary frame of reference which is made clear by reference to the text and the associated drawings describing the component under discussion. Such terminology may include the words specifically mentioned above, derivatives thereof, and words of similar import.
The terminology used herein is for the purpose of describing particular embodiments only and is not intended to be limiting of the invention. As used herein, the singular forms “a,” “an” and “the” are intended to include plural forms as well, unless the context clearly indicates otherwise.
As used herein, the terms “about” or “approximately” in reference to a recited numeric value, including for example, whole numbers, fractions, and/or percentages, generally indicates that the recited numeric value encompasses a range of numerical values (e.g., +/−5% to 10% of the recited value) that one of ordinary skill in the art would consider equivalent to the recited value (e.g., performing substantially the same function, acting in substantially the same way, and/or having substantially the same result). As used herein, the terms “about” or “approximately” in reference to a recited non-numeric parameter generally indicates that the recited non-numeric parameter encompasses a range of parameters that one of ordinary skill in the art would consider equivalent to the recited parameter (e.g., performing substantially the same function, acting in substantially the same way, and/or having substantially the same result).
Recitation of ranges of values herein are merely intended to serve as a shorthand method of referring individually to each separate value falling within the range, unless otherwise indicated herein, and each separate value is incorporated into the specification as if it were individually recited herein.
In the following description, numerous specific details are set forth, such as specific operations, in order to provide a thorough understanding of embodiments of the present disclosure. It will be apparent to one skilled in the art that embodiments of the present disclosure may be practiced without these specific details. In other instances, well-known techniques are not described in detail in order to not unnecessarily obscure embodiments of the present disclosure.
Embodiments may comprise photovoltaic (PV) frames, PV frame systems, methods of PV manufacture, articles of PV manufacture, and processes involving PVs. The frames may employ a PV laminate receiver configured to receive one or more surface of a PV laminate and support that PV laminate upon installation of a PV system. The laminate receivers may employ adhesive channels. These one or more channels may manage flow and/or seating of adhesive in the laminate receiver when a surface of a PV laminate is inserted into or is within a laminate receiver. In embodiments, the frames may employ stacking recesses and stacking protrusions along their length. The protrusions and recesses may be positioned and sized to allow for stacking of frames and, sometimes, self-centering stacking of frames in some embodiments. The frames and systems including these frames may comprise various materials including metal, metal alloys, ceramics, polymers, and combinations thereof.
In embodiments, laminate receivers may have an upper flange and a lower flange as well as one or more channels for adhesive flow. Laminate receivers may comprise one or more laminate stops configured to align a laminate within the laminate receiver. A bead or multiple beads of adhesive, such as room temperature vulcanizing (RTV) silicone or other suitable adhesive, may be placed on or around a surface of the laminate receiver or the PV laminate or both, and the laminate and the laminate receiver may be brought together with the adhesive filling some or all gaps in between the two mating components. The laminate receiver may include one or more channels in which the adhesive may flow during assembly and/or until curing is complete. The laminate receiver may also include an alignment stop or stops that may be configured and serve to orient a portion of a laminate within the laminate receiver. These stops may be positioned, for example, at a back wall of a laminate receiver and may serve to prevent an edge of a laminate from fully contacting the back wall of the laminate receiver. The resulting space between the back wall and the edge of the laminate may serve as a flow channel for adhesive. Flow channels may also be formed on other areas of the laminate receiver, such as on an upper flange or a lower flange or both.
In embodiments, the flow channel may serve to create a passage in the back or side of the laminate receiver to allow RTV silicone or other RTV material or other adhesive to flow and wrap around the PV laminate more evenly. This may be suitable to provide that a sufficient amount of adhesive is present to resist uplift and downforce, loads from top clamps, and other loads. In embodiments, additional adhesive may be placed along a bottom flange of the laminate receiver as well.
In embodiments, flanges of a laminate receiver may be configured with additional features to manage adhesive flow in and around edges of a photovoltaic laminate being held in a laminate receiver. These features may also provide for reducing edge loading or pinpoint loading on PV laminate positioned in a laminate receiver. This reduced loading may serve to reduce PV laminate breakage. The configuration of the features may include grooves, dimples, coves, channels, protrusions, hooks, and flaps, among others.
The frame systems, which can comprise the frames, may comprise various materials including metal, metal alloys, ceramic, polymers and combinations thereof. Thus, these frames and the other sections of the frame systems and components of embodiments may comprise various materials including metal, metal alloys, ceramic, polymers and combinations thereof.
In embodiments, the upper flange or other upper surface of a laminate receiver may be sized to be only a portion of the size of a corresponding lower flange of the laminate receiver. For example, an upper flange may be nonexistent or may have a width of 1, 2, 3, 4 or 5 mm or more or less, while a lower flange of a laminate receiver may have a width of 1, 2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, 15, 16, 17, 18, 19, 20 mm or more or less. The width of the upper flange or other upper surface of a laminate receiver may be set depending upon an expected snow load, wind load, or other load that may place a normal force or rotational moment or other load on a PV laminate supported by a laminate receiver of a frame. Likewise, the width of the lower flange or other lower surface of a laminate receiver may be set depending upon an expected snow load, wind load, or other load that may place a normal force or rotational moment or other load on a PV laminate supported by a laminate receiver of a frame. In other words, a distributed load across a face of a laminate may cause rotational forces near or at the ends of a laminate that act to urge the laminate edges out of a laminate receiver of a supporting frame. Likewise, a distributed load across a face of a laminate may cause rotational forces near or at the middle, ends, or both of a laminate that act to urge the laminate edges out of a laminate receiver of a supporting frame. The width of the upper flange or other upper surface of a laminate receiver, the lower flange or other lower surface of a laminate receiver, or both, may be set depending on the expected strength of such forces, or based on other factors, or both. Minimizing the size of the upper flange can serve to provide greater exposed surface area for PV laminates in the laminate receiver and supported by the frame.
In some embodiments, the lower flange of the frame may be sloped and have one or more slopes or pitches along its width. This slope may serve to reduce edge loading concentrations on a PV laminate and thereby inhibit breakage of the PV laminate. In some embodiments, the laminate receiver may sit atop or otherwise be connected to a single wall frame section while in other embodiments, double wall, triple wall or other multiple wall configurations may be employed. The laminate receiver may be cantilevered over an exposed outer wall or may be aligned with one or more outer walls. The laminate receiver may have a triangular cross-section and may be connected to a portion of the wall. This connection may serve to transfer torque or other forces from the laminate receiver to a wall or other portion of a frame.
In embodiments, the frames may be configured with one or more beveled surfaces or chamfered surfaces to provide for alignment during stacking. This stacking may occur during transport or other pre-assembly steps. Stacking protrusions and recesses of a frame may serve to self-center frames stacked atop one another or otherwise placed together. Alignment surfaces may be grooved, and the grooves may provide friction as well as tactile signals beneficial while stacking the frames. This self-centering feature may be created by beveled edges or other surfaces on different portions of the frame where these beveled or biased surfaces urge mating frame sections to self-center when mated. For example, a left-side bevel may be at −45° and a right-side bevel may be +45°. These mirrored angels may then guide a mating piece towards a center location or other target mating location.
Frame inserts may be employed and may be coupled to insert spacings along exposed surfaces of the frame sections. The frame inserts may be configured to integrate with frame clamps, which can serve to secure the frames to sub-frame assemblies or a support structure.
Embodiments may include a photovoltaic (PV) laminate double-wall support frame comprising two upright walls spaced apart from each other and each wall having a length; an upper connector connecting upper sections of the two upright walls to each other along the length of the walls; and a PV laminate receiver positioned above the upper connector, the laminate receiver having a top flange, a first PV laminate stop, and adhesive flow channel, the flow channel formed in an exposed inner surface of the laminate receiver, the top flange having a perimeter edge a majority of which does not extend beyond both upright walls. In embodiments, the support frame may have a wall that extends below the upper connector and connects to one of the two upright walls. In embodiments, the laminate receiver may have sides that form a triangle when the laminate receiver is viewed in cross-section and/or the exposed inner surface may be an upright side of the laminate receiver. In embodiments, a lower connector may be employed with the lower connector connecting lower sections of the two upright walls to each other along the length of the walls. Moreover, the lower connector may have a flange, the flange extending beyond an outer surface of an upright wall, the flange may have a lower perimeter surface, the lower perimeter surface having a chamfer along a length of the lower perimeter surface. Still further in embodiments, the two upright walls may have different heights, and/or the perimeter edge of the laminate receiver may not extend beyond either upright wall.
In embodiments, a top flange of the laminate receiver may have a plurality of exposed groves along a top surface of the top flange, the grooves oriented lengthwise along the top flange. And in embodiments, a top flange may have a triangular cross section.
In embodiments, a support frame may comprise a second PV laminate stop. Moreover, a first PV laminate stop and a second PV laminate stop may be positioned opposite each other and may be positioned on one or more accessible internal surface of the laminate receiver. The PV laminate receiver may also have a beveled top surface.
Embodiments may also comprise a photovoltaic (PV) laminate frame system comprising a PV laminate having a plurality of external edges and a plurality of PV cells; adhesive; and a plurality PV frame sections, wherein at least one of the frames of the plurality comprises: a PV laminate receiver, the PV laminate receiver having an upper surface, a lower surface spaced apart from upper surface, a connecting surface connecting the upper surface to the lower surface, and a laminate stop. In embodiments, a portion of the PV laminate may be positioned within laminate receiver. In embodiments, the laminate stop may inhibit movement of the PV laminate towards at least one internal surface of the laminate receiver. In embodiments, a width of the upper surface along the upper surface length may be no more than approximately one-third of the width of the lower surface along a majority of the lower surface length. In embodiments, adhesive may be a room temperature vulcanizing (RTV) material. In embodiments, at least a laminate receiver of one of the frames of the plurality may also comprise a flow channel for the adhesive, the flow channel positioned away from an external edge of the PV laminate when the PV laminate is seated in the laminate receiver.
In embodiments, each of the frame sections of the plurality of frame sections may comprise a double-wall channel and a chamfered edge along an external surface of the double-wall channel.
In embodiments, an upper surface of the laminate receiver may have a grooved exposed surface, the grooved exposed surface having a triangular cross-section along at least a portion of its length.
Embodiments may include a photovoltaic (PV) laminate frame system comprising a first PV laminate having a peripheral surface and a plurality of PV cells; a room temperature vulcanizing silicone; and an elongated PV frame section comprising: a PV laminate receiver, the receiver having an upper surface, a lower surface spaced apart from the upper surface, a connecting surface connecting the upper surface to the lower surface, a flow channel exposed to permit flow of the silicone in the channel, and a laminate stop, the laminate stop integral with the PV laminate receiver. In embodiments, a portion of the PV laminate may be positioned within the laminate receiver, wherein the laminate stop may inhibit movement of the PV laminate towards at least one internal surface of the laminate receiver. In embodiments, a width of the upper surface along the upper surface length may be no more than one-half of the width of the lower surface along a majority of the lower surface length, and at least facing surfaces of the lower surface and the upper surface may not be parallel.
In embodiments, the elongated PV frame section may comprise a metal alloy, metal, ceramic, polymer and combinations thereof. In embodiments, the flow channel may be positioned away from the peripheral surface of the first PV laminate when the PV laminate is seated in the laminate receiver. In embodiments, the frame section may comprise a double-wall channel and a chamfered edge along an external surface of the double-wall channel and/or the upper surface of the laminate receiver may have a grooved exposed surface, the grooved exposed surface having a triangular cross-section along at least a portion of its length.
In embodiments, a clamping or securement force exerted by the frame onto the PV laminate may be adjusted through changes in the upper flange, the lower flange, the amount of RTV silicone or other adhesive, as well as other adjustments in the designs and systems taught herein. Design criteria may consider reduction in clamping force on the PV laminate through one or more of these design adjustments as well as a potential uplift failure resulting from adhesive pullout if the adhesive coverage changes or is designed away.
Embodiments may provide compatibility with a variety of frame anchor clamp geometries and may provide suitable surface area for the clamp to sit on and may include: (1) allowing frame anchor clamp laminate receiver to be used between adjacent laminates with an adapter, (2) allowing use of an adapter to locally increase the surface area of flanges of the laminate receiver, (3) increasing surface area of PV laminate interface to extending beyond an outer web wall, and/or (4) adjusting the size of the laminate receiver to suit or maximize power/efficiency requirements.
Preferred embodiments may provide for PV laminate penetration depth of approximately 4 mm or more into the laminate receiver. A 4 mm or more penetration depth of the laminate receiver may accommodate a web/wall thickness of approximately 1.5 mm in embodiments.
As described above, a built-in stacking feature(s) may be provided and may serve to reduce or eliminate supplemental plastic corner pieces. In embodiments, the stacking angle may be a function of the largest volume of material to be removed without impacting the functionality of the frame clamp or making the frame section un-extrudable.
As the PV laminate 101 is inserted into the laminate receiver, a bead 111 of adhesive may be compressed and may flow around the laminate and into and through the channel 107 of the laminate receiver 108. The spread location is shown at 151 and 152 of
As can be seen in
Although specific embodiments have been described above, these embodiments are not intended to limit the scope of the present disclosure, even where only a single embodiment is described with respect to a particular feature. Examples of features provided in the disclosure are intended to be illustrative rather than restrictive unless stated otherwise. The above description is intended to cover such alternatives, modifications, and equivalents as would be apparent to a person skilled in the art having the benefit of this disclosure.
The scope of the present disclosure includes any feature or combination of features disclosed herein (either explicitly or implicitly), or any generalization thereof, regardless of whether it mitigates any or all of the problems addressed herein. Accordingly, new claims may be formulated during prosecution of this application (or an application claiming priority thereto) to any such combination of features. In particular, with reference to the appended claims, features from dependent claims may be combined with those of the independent claims and features from respective independent claims may be combined in any appropriate manner and not merely in the specific combinations enumerated in the appended claims.
This application incorporates by reference, in its entirety, U.S. provisional application 62/939,880, which is entitled Photovoltaic Frame with Laminate Receiver and was filed on Nov. 25, 2019. This application also claims priority to the '880 application:
Number | Date | Country | |
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62939880 | Nov 2019 | US |