PHOTOVOLTAIC FRAME WITH LAMINATE RECEIVER

Photovoltaic (PV) frames, PV frame systems, methods of PV manufacture, articles of PV manufacture, and processes involving PVs are provided. These frames may employ a laminate receiver configured to receive a surface of a PV laminate and support that PV laminate upon installation of a PV system.

BACKGROUND

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.

DETAILED DESCRIPTION

“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).

“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.

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).

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.

FIGS. 1A-1Billustrate cross-sectional views of a frame section with laminate receiver108and adhesive flow channel107before100and after150insertion of a PV laminate101into the laminate receiver108, as may be employed, according to some embodiments. Labelled inFIGS. 1A and 1Bare triangular cross-section104, overhang width103of triangular cross-section104, overhang102of triangular cross-section104, laminate stops106, adhesive flow channel107, RTV silicone bead/adhesive111, flange end112, corner support110, lower flange153, web/wall113, lower flange109, frame cross-section114, bottom flange with upturned end115, bottom flange116, spread RTV silicon adhesive151, spread RTV silicone adhesive152, upper flange105, alignment/stacking recess162, and alignment/stacking protrusion161. The laminate receiver108is shown with an upper flange105, adhesive flow channel107, and lower flange153defining an area into which a surface of a PV laminate101may be inserted. In embodiments, the laminate channel may have a smaller upper flange than a lower flange and a wall of the receiving channel may have a triangular cross-section104. The overhang102of the triangular cross-section104may extend beyond a web/wall113of a frame and may be sized and configured to add rigidity to the laminate receiver108.

As the PV laminate101is inserted into the laminate receiver, a bead111of adhesive may be compressed and may flow around the laminate and into and through the channel107of the laminate receiver108. The spread location is shown at151and152ofFIG. 1B. After setting the adhesive the PV laminate may now be considered secure in the frame and may be secured in a PV system installation.

FIGS. 2A-2Dillustrate cross-sectional views of frame sections with laminate receiver and one or more adhesive channels, as may be employed, according to some embodiments. Labelled inFIGS. 2A-2Dare truncated upper flange205, extended upper flange260, laminate receiver208, adhesive flow channel207, flange end212, corner support210, web/wall213, bottom flange with upturned end215, and dimensions290-93. Truncated upper flanges205may be employed instead of extended upper flanges260in embodiments. By limiting the size of the upper flange, additional light may reach the PV laminate when installed. Adhesive flow channels may be present in various surfaces of the laminate receiver. For example, an inner surface of the truncated upper flange205includes such a channel, as is shown inFIG. 2A.FIGS. 2C and 2Dshow how adhesive flow channels may be present on upper and back surfaces of a laminate receiver in embodiments. Also shown inFIGS. 2C and 2Dis laminate stop206.

FIGS. 3A-3Dillustrate cross-sectional views of frame sections with a laminate receiver and one or more adhesive channels as may be employed, according to some embodiments. Labelled inFIGS. 3A-3Dare RTV silicone bead/adhesive311, upper flange305, lower flange end312, bottom flange with upturned end315, laminate receiver308, squeezed RTV silicone/adhesive351, squeezed RTV silicone/adhesive352, adhesive channels355, adhesive channels356, PV laminate301, and squeezed RTV silicone adhesive354.FIGS. 3B and 3Dshow expected location of squeezed adhesive or silicone. As can be seen here, the outward surfaces of the adhesive contours to surfaces of the laminate receiver308and the surfaces of the PV laminate301. As the adhesive is reconfigured during assembly from bead form311to its final squeezed form351,352, and354, the adhesive may flow via the channels356or355or other adhesive flow channels of embodiments. In addition to allowing for adhesive flow, the flow channels may also allow for increased surface area adhesion, thereby providing for additional grip of PV laminate held in the laminate receiver308. As can be seen at351, the adhesive may not squeeze out past the top flange305. The amount of adhesive employed may be managed so as to limit or eliminate squeeze out while at the same time proving for sufficient adhesion for anticipated loads. An advantage of managing adhesive or adhesive flow in this manner may be that adhesive does not reach the exposed surface of the PV laminate, thereby providing maximum solar exposure to PV cells of the PV laminate.

FIGS. 4A-4Hillustrate cross-sectional views of frame sections with a laminate receiver and one or more adhesive flow channels, as may be employed, according to some embodiments. Labelled in one or more ofFIGS. 4A-4Hare laminate receiver408, adhesive flow channel407, three pitches (grades) on laminate receiver lower surface471,472, and473, web/wall413, reinforced corner485, outer border alignment470, different wall thickness480, reinforced corner490, corner support410, bent end492, hooked flange end491, chamfered flange end473, upper flange bent end493, adhesive flow channel455, upper flange flapper end494, adhesive flow channel407, support connector482, and hooked flange end495. Various configurations of the upper flange end (bent, hooked, flapper, etc.) may be employed in embodiments to control adhesive/adhesive flow in and around the edge of a PV laminate. By creating a tight seal between the laminate receiver and the PV laminate, errant adhesive/adhesive flow can be minimized in some embodiments.

As can be seen inFIGS. 4F and 4G, the channels455may have different shapes and may have various locations. Here, inFIG. 4F, there are two rectangular channels located close to the back wall along the bottom flange. While inFIG. 4G, there are six semi-circular channels located on the bottom flange along most of its width. The upper flange inFIGS. 4F and 4Gshow still different figurations for flow channels withFIG. 4Fshowing a flat recess whileFIG. 4Gshows a flapper configuration with a recessed cylindrical void499.

FIGS. 5A-5Cillustrate cross-sectional views of frame sections receiving PV laminates with different edge details in a laminate receiver, as may be employed, according to some embodiments. Labelled in one or more ofFIGS. 5A-5Care laminate receiver508, PV laminate501, PV laminate end with single chamfer510, PV laminate end with double chamfer511, and PV laminate end with bullnose512. As can be seen in these figures, the flat surface of the PV laminate is in contact with the upper flange505and forms a seal577between the two components. Extra adhesive may flow out along the bottom surface of the PV laminate but may be retarded from flowing along an exposed top surface of the PV laminate by the seal577between the upper flange505and the PV laminate501.

FIGS. 6A-6Cillustrate cross-sectional views of frame sections with alignment/stacking protrusions and alignment/stacking recesses, as may be employed, according to some embodiments. The stacking protrusions and stacking recesses of embodiments may be located on outside or exposed surfaces of the frames. These protrusions and recesses may run along the length of the frames and may be continuous along the length, or may be located at intervals along the length with breaks between them. The recesses and protrusions may serve to align, self-center, or both, frames positioned atop one another. The protrusions and recesses may be located near or at outer perimeter locations of the frames. Labelled inFIGS. 6A-6Care stacking protrusions661, expected PV laminate601, first frame671, second frame672, stacking recess662, expected stacking protrusion667, chamfered/beveled stacking protrusion with grooves668, laminate receiver608, flange616, web/wall613, stacked frame6731, stacked frame6732, stacked frame6733, frame insert spacing692, direction of stacking600, and frame insert spacing691. The chamfered/beveled edges may be angled so as to provide self-centering bias when frames are stacked atop each other. In other words, a polygonal frame stacked atop another polygonal frame may find its center above each other because the angels of the protrusion661meeting the recess662causes the two frames to center between each other. The protrusions and recesses may be various shapes in embodiments. In preferred embodiments they can mimic the opposite of the shape of the recess or protrusion in the frame above or below so as to mate with the applicable recess or protrusion. Grooves or channels may also be present to enhance gripping and friction.

FIGS. 7A-7Billustrate cross-sectional views of frame sections coupled to a frame anchor clamp and further secured by a frame anchor insert as may be employed, according to some embodiments. The frame anchor clamp700of embodiments may serve to secure a PV frame and laminate to a support structure on a roof or elsewhere. The frame anchor inserts710,715, and717may serve to couple the frame and PV laminate to the anchor clamp700. The insert may have upper portions710, outside portions715, and inner portions717. These inner and upper portions may be configured to mate with and secure to a frame, while the outer portions may be configured to mate with and secure to a frame anchor clamp700.

FIG. 8illustrates labelled widths and lengths of an exemplary laminate receiver, as may be employed, according to some embodiments. As can be seen, a channel is present in the back wall of the receiver and the receiver is in the shape of a “J”. While various ratios may be employed in embodiments, the ratio of the width of the upper flange to the lower flange is identified in this example as being a factor of at least three. In other words, in some embodiments, the width of the lower flange is at least three time the width of the upper flange. In some 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.