APPARATUS AND METHOD FOR SOLAR PANEL WITH INTEGRATED WIRE MANAGEMENT

A photovoltaic module generates electrical power when installed on a roof. The module is constructed as a laminated sandwich having a transparent protective upper layer adhered to a photovoltaic layer. The photovoltaic layer is adhered to the top of a rigid layer, preferably formed from a fiber reinforced plastic. A wire support tray assembly is affixed to an edge of the photovoltaic module, the wire support tray assembly includes a base portion and a cover portion. The base portion has at least one base portion flange configured to lock with least one corresponding cover portion flange. The base portion has a longitudinally-extending slot configured to couple with the edge of the photovoltaic module. Preferably the wire tray assembly holds the module wiring and occludes it from view. Preferably, the cover portion is concave to shelter the wiring from inclement weather.

BACKGROUND OF THE INVENTION

1. Field of the Invention

The present invention relates to solar panels/modules for generating electrical energy, and more particularly to photovoltaic panels/modules with integrated wire management structures, preferably on-board. This application is an improvement of U.S. patent application Ser. No. 14/732,010, filed Jun. 15, 2015, the entire contents of which are incorporated herein by reference.

2. Description of the Related Art

Conventional photovoltaic modules for generating electrical power for residences and businesses are often flat and are placed on a portion of a roof that is exposed to the sun. Historically, such modules were placed on structures erected on the roof to support and protect the modules. More recently, photovoltaic modules have become available that can be mounted directly on a flat or tilted roof. See, for example, US Patent Application Publication No. 2005/0178428 A1 to Laaly et al., (the entire contents of which are incorporated herein by reference), which discloses a module that incorporates a roofing membrane into the module structure. The module is intended to be installed on a new roof or replacement roof with the membrane providing moisture protection for the underlying structure as well as providing electrical power.

See also U.S. Pat. Nos. 7,531,740 and 7,557,291 both to Flaherty, et al., the entire contents of both of which are incorporated herein by reference. These patents disclose such photovoltaic modules for roof-top installation.

A problem with above mentioned direct roof top attached crystalline silicon photovoltaic cell based solar modules is their installation tends to take a great deal of time in laying the panels out and then electrically connecting plural panels together to form the desired array. During installation, a part of or all of the wiring is left, and is often is exposed to the elements. Some solutions have been proposed in which plug-and-play type side connectors have been added to quickly plug together plural solar modules. See, for example, U.S. Pat. Nos.: 7,713,089; 7,819,114; 8,455,752; and 8,922,972; and also USPPNs 2008/0149170; 2013/0263910; and 2014/0090694; the contents of each of which are incorporated herein by reference. However, these proposed solutions still require a skilled worker to run the different required wirings from module to module, or from groups of modules to groups of modules. Thus, what is needed is a solar panel/module system that is quick and easy to install, and provided superior electrical connections.

SUMMARY OF THE INVENTION

The photovoltaic module described herein and illustrated in the attached drawings enables electricity-generating solar modules to be installed quickly and with reliable electrical connections that offer additional protection to the module cables.

In accordance with one aspect according to the present invention, a photovoltaic module has an upper transparent protective layer, and a photovoltaic layer positioned beneath the upper transparent protective layer. The photovoltaic layer includes a plurality of electrically interconnected photovoltaic cells disposed in an array. A semi-rigid substrate layer is positioned beneath the photovoltaic layer. A wire support tray assembly is affixed to an edge of the photovoltaic module; the wire support tray assembly comprising a base portion and a cover portion. The base portion has at least one base flange configured to lock with at least one corresponding cover portion flange. The base portion has a longitudinally-extending slot configured to couple with the edge of the photovoltaic module.

In accordance with another aspect according to the present invention, a photovoltaic module has a rectilinear panel having a surface with a plurality of photovoltaic cells disposed thereon in an array. A wire tray assembly is disposed along at least one edge of the photovoltaic module; the wire tray assembly including a base portion and a cover portion. The cover portion has structure configured to removably couple the cover portion to the base portion. Preferably, the wire tray assembly is made of a flexible plastic material. The cover portion preferably has a substantially concave-shaped cross section. At least one joint cover portion is configured to cover adjacent base portions disposed at a junction of said adjacent base portions.

In accordance with a further aspect according to the present invention, a photovoltaic module has a rectilinear panel having a plurality of photovoltaic cells disposed thereon in an array. All four edges of the panel are preferably tapered edges. At least one panel edge has a wiring tray assembly having (i) a base portion, and (ii) a cover portion. The cover portion is removably coupled to the base portion and has a substantially concave cross section configured to deflect water from entering the wiring tray assembly.

In accordance with yet another aspect according to the present invention, a method of assembling a photovoltaic module includes, in any order: (i) providing a rectilinear photovoltaic panel having a plurality of cells disposed thereon; (ii) coupling a wire tray base portion to an edge of the photovoltaic module; (iii) inserting photovoltaic module wiring into the wire tray base portion; and (iv) coupling a wire tray cover portion to the wire tray base portion so as to cover and protect (and occlude) the photovoltaic module wiring.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

Briefly, the present integrated wire/cable management structures for both residential and commercial photovoltaic (“PV”) modules are designed to: (i) keep module interconnection wiring, jumpers, and home run cables off roof surfaces, (ii) minimize system install time and wire tray usage, (iii) minimize installation errors in the field, (iv) enhance protection from weather and solar related degradation, and (v) assist with safely hoisting the module to the roof. The low profile (height) of the wire clips does not substantially increase wind resistance of the installed photovoltaic systems and also enhances the aesthetics thereof. As wire management clips are exposed to direct sun light, stainless steel clips are preferred to minimize the impact of UV degradation. UV-resistant polymer materials can also be used for the wire clips. “Integrated” means where all parts of the wire assembly described herein are configured to fit together into a preferably single coordinated structure, comprising base, cover, tray, joints, etc. Preferably the integrated structure is designed to be attached to the photovoltaic module, and thus disposed “on-board” the module.

PV wiring requirements for residential roof top installations should meet the National Electrical Code (“NEC”) latest revision, currently 2014 and 2017 in some jurisdictions. Many Authorities Having Jurisdiction (“AHJs”), such as state, county, and municipal governing bodies follow the NEC code. But, some local codes could be more stringent. For possible PV commercial and industrial uses, PV module interconnection requirements are typically defined by the AHJ for: AC modules; DC modules with module level power control; DC modules with string power control, i.e. with line inverters; home run cable requirements, etc.

Preferably, the PV installation should involve no cable (or any other) penetration through roof deck. Cables should run on the roof only. With the present invention, those cables will be kept up off of the roof and substantially co-planar with the PV panels. Preferably, Underground Service Entrance (“USE”)-2-rated or Underwriters Labotratory (“UL”) 4703-rated or equivalent AC/DC PV cables are used, for direct, exposed to sun irradiation applications. Cables and connectors should not be in direct contact with the roof. This is achieved in the present invention where the co-planar wiring support clips (or trays) hold the cables above the roof surface. Cable connectors are preferably interlocked, and the connector interlocking preferably is by hand-only. Disconnecting is preferably achieved with tools per NEC 2008 and 2011. Interconnection cables are preferably fixed within 300 mm from a junction box, as is provided with the clips according to the present invention. Cables should be fixed in place every 1.4 m of run-length; again, easily achieved with the clips according to the present invention, which fix the cables at approximately every 6-46 inches, preferrably about 12 inches.

The cabling/wiring that runs from the coupled-together plural PV panels to an electrical/mechanical collection device is termed the home run cabling. Home run cable should preferably be kept off roof, which is accomplished according to the present invention, and may be routed through one or more electrical conduits. The clips according to the present invention are preferably sized to accommodate one or a plurality of home run cables. Usable conduit types include Rigid Metal Conduit (“RMC”) and/or Intermediate Metal Conduit (“IMC”). UV resistant, liquid-proof liquid tight flexible plastic conduit may also be used. Cables in conduits should be water resistant. Conduit dimensions may be determined by fill-factor and cable cross section areas. Steel junction boxes or polymer junction box with knock-outs can be used for interconnecting cables and/or wires to home run cables.

As will be described in greater detail below, preferably, one or two wire clips may be located adjacent to the junction box, and/or the DC power optimizer, and/or the micro inverter, and/or packet energy transfer (PET) module, mounted on the PV module. Additional clips may be added to a module for jumpers and home run cable management. The locations of the additional clips may be on the same side of the junction box and/or adjacent to the junction box side and/or opposite to the junction box side, depending on any specific application. A number of, 0 to (but not limited to) 20, additional clips can be added to a module based on any specific application. The original and/or additional clips may be added at the factory, on the work-site, or even on the roof.

As illustrated inFIGS.1a,2,3,4, and5, of co-pending U.S. application Ser. No. 14/454,226, filed Aug. 7, 2014 (the contents of which are incorporated herein by reference), and with reference toFIGS.1aand2of the subject application, a laminated photovoltaic module100is preferably configured as a generally rectangular module, which is sized and shaped in accordance with the sizes and shapes of conventional building materials, such as a 4×8 foot module. Thus, the module100can be handled by a construction crew without requiring any special material handling equipment. Of course, the module100may be any convenient size (4×8, 4×6, 4×4, 3×3, 3×2, 2×2, 2×1, 1×1, etc.), and shape (square, round, triangular, trapezoidal, etc.) useful in the construction industry, and with either rounded corners or substantially right angle corners.

The module100is preferably assembled in a factory or other suitable environment so that the module100is complete and ready to install on a substantially flat roof (which may be horizontal or tilted), or sloped shingle roofs, such as, but not limited to, asphalt, laminated, wood, slate, concrete, or other location having adequate exposure to the sun. In one preferred embodiment, as shown inFIGS.1aand2,3, the module100has dimensions of approximately 99-101 centimeters (˜39-40 inches) by 199 centimeters (˜78 inches) and has a thickness of approximately 0.5 centimeter (0.2 inch). In another preferred embodiment, the module100has dimensions of approximately 101 centimeters (˜40 inches) by 101 centimeters (˜40 inches) and has a thickness of approximately 0.3 centimeter (⅛ inch) when installed. In fact, the thickness of the module may be the same as (or thinner than) the thickness of the laminated roofing shingle. Thus, the module100does not add significant height to a roof structure and will not block water flow on sloped roofs. In yet another embodiment, the module100has dimensions of approximately 99-101 centimeters (˜39-40 inches) by 239 centimeters (˜94 inches) and has a thickness of approximately 0.5 centimeter (0.2 inch). In a particularly preferred embodiment, the module has dimensions of 99 cm×167.5 cm×0.5 cm.

As shown inFIG.1a, the module100preferably has a transparent upper protective layer110that faces upward and is exposed to the sun. A middle layer is preferably positioned beneath the upper protective layer110. The middle layer comprises a plurality of photovoltaic cells122electrically interconnected to form a photovoltaic array. The middle layer preferably rests on a rigid lower substrate. The middle layer is preferably secured to the rigid lower layer by a lower adhesive layer. The middle layer is preferably secured to the upper protective layer110by an upper adhesive layer. The middle layer is thus encapsulated between the lower adhesive layer and the upper adhesive layer.

The upper protective layer110preferably provides impact protection as well as weather protection to the module100. The upper protective layer110advantageously comprises of a transparent flexible polymer material, such as, but not limited to Ethylene tetrafluoroethylene (ETFE), a fluorine based co-polymer, which is formed into a film layer of suitable thickness (e.g., approximately 0.005-0.015 centimeter (0.002-0.006 inch)). Thus, the photovoltaic cells122in the middle layer are exposed to direct sunlight without being exposed to moisture and other climatic conditions and without being exposed to direct impact by feet, falling objects, and debris. Tempered glass or weather resistant polymer materials having a suitable thickness may also be used as the upper protective layer110.

The rigid lower layer substrate preferably comprises fiber reinforced plastic (FRP). For example, the FRP layer advantageously comprises a polyester resin with embedded stranded glass fibers. Preferably the said FRP layer has a thickness of approximately 0.1 centimeter to 1 centimeter (0.079 inch-0.39 inch), and additionally, the said FRP lower surface can be either flat or with a defined pattern/rib. The lower layer of FRP thus provides an advantageous combination of rigidity, light weight, very low permeability, and flatness.

As shown inFIG.2, the preferred embodiment provides that the photovoltaic cells122are electrically interconnected in a series-parallel configuration in a conventional manner to provide a suitable output voltage or a desired photovoltaic module form factor. For example,FIGS.1aand2show a photovoltaic module suitable for flat roof application. Photovoltaic cells122are arranged in 6 rows of 12 cells each; however, one, two, or more cells may be omitted from at least one of the edge rows to provide room for positioning an electrical enclosure, such as, but not limited to junction box170(having a first weather-resistant electrical conductor172and a second weather-resistant electrical conductor174), module power optimizer, micro inverter, and other useful electrical control and/or power-conditioning circuitry, as discussed above. The photovoltaic module100preferably includes two module output conductors176,178(e.g.,FIG.2) that extend from the top surface of the middle layer in the area of the omitted photovoltaic cell(s). Each of the module output conductors176,178is preferably connected to a respective one of the weather-resistant electrical conductors172,174within the electrical enclosure170after the photovoltaic module100is laminated, as discussed below. In an alternative embodiment, the junction box may be mounted on the bottom surface of the solar panel, opposite the side on which the solar cells are mounted.

FIG.3is a close-up perspective view of theFIG.1aembodiment, showing plural wiring support members301,303, and305. In this embodiment, the wiring support members301,303, and305are stainless steel clips which are (preferably) permanently attached to the edges of the PV module via screw(s), rivet(s), glue(s), interference fit, hot-melt, tape(s) etc., or any combination of these. Preferably, the clips are installed on the sloped surfaces of the tapered edge99. The clips may be installed in the factory either during or after manufacture of the PV module100. Alternatively, the clips may be installed in the field, for example, with weather-proof adhesive tapes, foam tapes, two-sided tapes, hot melt, glue-gun, butyl tape, etc. The clips are sized and dimensioned so as to support one or more of (i) wire(s) and/or cable(s), (ii) conduit(s) which hold one or more wire(s) and/or (cables), and/or (iii) wiring tray(s) which hold one or more of (i) and/or (ii). As one example, plural clips305may hold a wire, or a homerun cable, or be configured to releasably (or permanently) couple with a corresponding receptacle(s) (or protrusion) in the side of a wire tray. Most preferably, each clip305is multi-modal, and can support one or more wires, and/or one or more cables, and/or one or more conduits, and be coupleable to corresponding structure on/in a wiring tray.

The clips301,303, and305are preferably disposed on at least two perpendicular edges of the PV module100. In the most preferred embodiment, the clips are disposed along a front edge150, a first side edge152, and a second side edge (not shown). Of course, clips can be provided on all four edges. As can be seen in the drawings, the clips301and303are disposed so that the clip structure does not protrude substantially beyond the outer edge of the edges150and152. As used herein, “does not protrude” encompasses insubstantial protrusions where the clip is affixed to the edges150and152, as shown in the Figures. Thus, each of clips301and303has an opening which faces outward away from an interior of the PV module100. These clips are useful for wiring one module to another, and their design keeps the wires/cables from overlying the photovoltaic cells. Clip305, on the other hand, protrudes beyond an outer edge of the edge150, and has an opening which faces inward toward an interior of the PV module100. Clips305are useful for homerun wires/cables which carry the electricity to a roof junction box (not shown) where the power is collected and directed to an inverter and electrical panel.

FIG.4shows the PV module100with wires/cables/conduits401which are held by clips301and303; and wires/cables/conduits40which are held by one or more of clip305, The wires403may comprise homerun cabling. Also shown inFIG.4is one or more electrical devices170, which may comprise electrical circuitry (discussed above), which collects power from the solar cell (may condition it), and directs it off-board via wires401. The device170may conveniently be disposed on an upper surface of the PV module100where one or more (preferably two) cells are missing from the array. Note that the clips are preferably designed so that the wires/cables may be easily inserted therein and/or removed therefrom. Note also that the device170is disposed between two rows of solar cells (running substantially horizontally in the Figure), but substantially in-line with the row of solar cells (running substantially vertically in the Figure).

FIG.5is a top plan view of theFIG.4embodiment showing a substantially square PV module100, with clips301on left and right side edges152of the module, and clips303and clips305on the front edge150thereof. Preferably, the edges152are perpendicular to the edge150.

FIG.6is a top plan view of theFIG.4embodiment showing a preferred configuration in which the electrical device170is equipped with weather resistant plugs601and603, each coupled to the device170with respective short, flexible, weather resistant cables605and607. The plugs601and603can be removably (or permanently) coupled to corresponding plugs on wires/cables401and/or403.

FIGS.7a,7b,7c, and7dare perspective views of various clips which may be used in accordance with the present invention for holding wires/cables, etc., as discussed above. The clips may be modified Heyco SunRunner clips (FIG.7a), and SunRunner 2 clips (FIG.7b), with dimensions based on cable diameters. These clips may be provided by Heyco Products, Inc., 1800 Industrial Way, Toms River, NJ 08755. Flat extensions,701and703may replace the SunRunner (FIG.7c) and SunRunner 2 (FIG.7d) clips' crimp structures, respectively. Each flat extension is preferably 1-1.5 inch long and with the same width and thickness to the SunRunner and SunRunner 2 clips. In one preferred embodiment, the flat portion is extended from the wire/cable clip portion. More preferably, a gradual bend702and704, of 3-6 mm in height is inserted between the flat portion and the wire/cable clip portion, that substantially levels (makes horizontal) the wire/cable clip portion,708and709, respectively to the top surface of the PV module.

The clips301and/or305preferably include an upper portion733which is biased in a direction substantially orthogonal to the plane of the upper surface of the PV module100. This biasing acts to keep the wiring/cabling/conduits securely held within the clip. The upper portion733preferably includes an upwardly extending tang734, which acts to guide wiring/cabling/conduits into the interior of the clip during installation. Note that the clip has an opening710which is preferably narrower than an interior thereof. In a preferred embodiment, the clip also includes an interior bias member705, which acts to compress wiring/cabling/conduits downward to the upper surface of the base portion701. This will keep the wiring/cabling/conduits securely within the clip even in difficult weather and/or installation conditions. In a further preferred embodiment, some or all of the edges of the clip are rounded or beveled to prevent damage the sheathing of the wiring/cabling/conduits.

The clips301and305may be identical (size and/or shape), or different, depending on the projected installation. For example, the clips305may be larger than the clips301, when they are used for bigger cabling, such as truck cable for AC micro-inverters. The clips may be sized differently, but have identical shapes, or have differing shapes but sized identically, again depending on installation. Preferably, at least one clip has a base portion701used to affix (permanently or removably) the clip to the lower surface of the PV module100. As discussed above, the clip may be affixed by bonding, epoxy, tape, glue, screws, rivets, or any convenient method. The s-bend702is used to level wire/cable clip portion708to the module100upper surface110, and keeps wires/cables off the roof surface. The flat base701is sufficiently attached to the PV module lower surface105. The downwardly projecting tang717may be used for ease of installation of the clip onto the PV module. The base701may include a bias which acts to keep the clip pressed to the PV module edge.

FIGS.8aand8bshow other preferred embodiments that can be used in the present invention. The clips are modified Heyco SunRunner and SunRunner 2 clips, as discussed above. The flat portions801and804are bent approximately ˜180 degrees, to extend under the wire/cable clip portions,808and809, respectively. More preferably, a bending radius of 1.2 mm to 3.0 mm,802and803, is used to clear the wire/cable clip portion on the module100upper surface. Even more preferably, a bending angle of about 5 degrees to about 10 degrees,807, is used for a flat portion811that raises the wire/cable clip portion on the top of the module100upper surface, and prevents wires/cables from touching the module upper surface.

The preferred method of installation of the module100on a composite shingle roof comprises applying a layer of Peel-And-Stick (PAS) tape to the bottom surface of the rigid lower layer130. Positions of the PAS tapes are designed for common roof shingle course width, nominally about 5⅝ inches apart (FIG.1b). Preferably, the tape layer160comprises a suitable double-stick tape, such as, for example but not limited to, a self-sealing tape having a formulation of resins, thermoplastics, curing rubbers, and non-curing rubbers. The double-stick tape has adhesive on both sides. When manufactured, the double-stick tape has a release layer on each side to prevent adhesion. One release layer is advantageously removed during the process of manufacturing the modules. The exposed adhesion side of the tape layer160is positioned on and adhered to the bottom surface of the rigid lower layer130before shipping the module100. Then, during installation of the module100, the remaining release layer is removed so that the module can be adhered to the surface of an existing roof. The surface of the existing roof is cleaned and suitably prepared to receive the module100. After installation, suitable pressure is applied to the upper layer110of the module100to permanently adhere the module to the surface of the roof. In one preferred embodiment, The PAS tape160comprises plural Butyl tape in an array of, for example, 8 rows by 4 columns of tape-squares. Tape size can be, but not limited to: 2×4 inches to 4×4 inches. Preferably, the lower edge of the butyl tape is aligned approximately with the lower edge of each shingle course for installation, but the upper edge of the butyl tape may be spaced somewhat from the top edge of the module100.

Once the PV module is installed on the roof, the wiring/cabling/conduits/trays are installed by simply pressing them into/onto the clips. The wiring/cabling/conduits/trays are then connected, pulled tight, and run to the appropriate junction box.

FIGS.9aand9bare perspective and partial cross-section views of an embodiment using cable trays instead of (or in addition to) the wiring clips. This embodiment provides improved weather protection for the wiring/cables/conduits, prevents workers from tripping over or otherwise disturbing the wires, and provides an enhanced aesthetic appearance. Of course, whole or partial wiring trays may be used in conjunction with clips301and/or305, depending on the desired installation. Preferably, the cable trays901,903, and905comprise rigid and/or semi-rigid and/or bendable UV and/or weather resistant plastic sheaths having a smooth low profile and a flat bottom cross section, as best seen inFIG.9b. In one preferred embodiment, cable trays901and903are affixed to the edge150of PV module100, to accommodate at least the homerun cabling. The tray905may be affixed to another side edge of the PV module100. Of course, cable trays may be provided on one, two, three, or all four edges of the PV module100. In another preferred embodiment, cable trays can be installed peripheral to the PV module100with PAS Butyl tape. The trays are preferably parallel to edges of the PV modules. Each PV module edge may have one, two, three, or more cable trays coupled in series or in parallel. For parallel cable tray installations, each cable tray may be coupleable (releasably or permanently) to one or two adjacent cable trays. The cable trays may be solid, perforated, meshed, or any convenient structure.

InFIG.9b, the tray903preferably comprises a quarter-circle shape having a first, straight side911, a second straight side913, and a curved side915. Preferably, a gap917is provided between a distal end of the curved side915and a side portion of the first side911. Note that a distal end of the first side911extends beyond the gap917. This is to make it easy for a workman to lay one or more wires/cables/conduits onto the extended portion of first side911, and sliding it down through the gap917, where the above-described geometry keeps the wires/cables/conduits secured in place within the cable tray903.

Preferably, the cable trays are affixed to the PV module100edges with liquid adhesives, tapes, clip, crimp, bolts, screws, rivets, etc. In the most preferred embodiment, the cable trays are affixed to the PV module edge(s) with one or more clips, legs, fixtures, etc. In another preferred embodiment, the cable trays are installed peripheral to the PV module100with PAS Butyl tape. The attachment may be permanent or releasable. Preferably, the tray can be affixed to the PV module without tools, either on the roof or adjacent thereto. Of course, the tray may be affixed to the PV modules in the factory. In a preferred embodiment, the clips301,303, and305may be constructed for use to support the wiring/cables/conduits or to couple to a corresponding receptacle (preferably a biased receptacle) in the cable tray.

Integrated wire management systems preferably protect electrical cables and connecters from UV, and harsh environmental conditions like snow, sleet, rain, animals, etc. In addition, integrated wire management enhances modules' aesthetics by covering junction boxes and the conductor wires to provide a uniform appearance of the modules and module arrays. Further features may include wire trays with covers, removable and/or hinged. Preferably, the wire tray structures described below are made of integral pieces of UV-resistant, water-proof, semi-rigid, or rigid plastic. Both integrated wire tray and cover are preferably made of plastic materials (not metal) to eliminate any grounding requirement. Trays may be made of hard plastic to provide rigidity. Covers can also be made by either elastic plastic or rigid plastic materials. Preferably, the covers are flexible enough to be removably coupled to the base. Various shapes and dimensions of integrated wire trays and covers can be employed for different applications, e.g., minimizing sun-shading on the modules, reducing accumulations of leaves and debris, enhanced wind load resistance, enhanced water and snow seals and shedding.

FIG.10ais a front view of the solar module with integrated wire management, with a wire tray cover attached. The solar module100includes a ten by six, 2-dimensional matrix array of solar cells101. At one end of the module, a top cover1001of a wire tray1002is shown.FIG.10bis similar toFIG.10a, but shows the module with the wire tray cover1002removed. A junction box1003is preferably centrally-located in the wire tray1001, and preferably contains electrical connection circuitry and wiring for connecting together outputs from the solar cells101.FIG.10cis a view of the bottom of solar module100, showing the bottom of the wire tray1002.FIG.10dis a side view of the solar module with on-board wire management, with a wire tray cover attached, with further structure to be described below.

FIG.11is a close-up cross-sectional view of theFIG.10bmodule, with cover attached. In this embodiment, the wire tray cover1002is preferably a single, integral piece of weather resistant polymer, such as but not limited to Polyvinyl Chloride, Acrylonitrile Butaduene Styrene, Polycarbonate, Polyphenylene Ether, Polyamide, etc. A wire tray base1005underlies the cover1002, and is affixed to the module100via glue, epoxy, screws, thermal bonding, etc. Preferably, the base1005is also a single, integral piece of plastic, such as but not limited to Polyvinyl Chloride, Acrylonitrile Butaduene Styrene, Polycarbonate, Polyphenylene Ether, Polyamide, etc. The base1005preferably has a horizontal surface1006(generally parallel to a top surface of the module100), and two perpendicular (vertical) portions1007aand1007b. Each of these vertical portions has an apex1007cand1007d, respectively. Preferably, each vertical portion has a clip portion1008aand1008b, respectively, generally comprising a horizontal surface, although acute angles may be provided for greater security and sealing. As shown, the wire tray cover1002has matching vertical portions1009aand1009b, with complementary apexes1009cand1009d, and complementary horizontal clip portions1010aand101b. Again, these clip portions may be generally horizontal and/or acute in angle. Note that the cover1002preferably comprises an non-symmetrical, curved shape designed with a wing1002athat slopes downward more gradually that the inner slope1002b. This shape is especially designed to channel water and debris away from the solar module100and toward the outer edges of the module and minimize shading of sun light. Such a design keeps the wires inside the tray and properly guided, enhancing speed of installation.

FIG.11also shows cable1020, a junction box1022, and adhesive attachment1024. This attachment may comprise suitable glue, silicone, epoxy, thermal bonding, screws, clips, etc., and affixes the wiring tray onto the module100. An integrated spacer1030may be provided at the edge of the wiring tray base1006to couple to adjacent solar modules100. Note that the spacer1030may include one or more voids1032for flexibility and thermal management. The integrated wing/flange structures hold wires and cables down in wire tray, and speeds module interconnection during installation.

FIG.12is a perspective view of theFIG.11embodiment, showing the cover1002, clip portions1010aand1010b, and wing portion1002a.

FIG.13is a perspective view of theFIG.11embodiment, showing the base1006, the clip portions1008aand1008b, and the spacer portion1030. A cut-out or notch portion1050may be provided in the central portion of the base1006, to accommodate space for the junction box location, to be described below. As shown, preferably the notch portion1050is only provided in the tray1006, and not the spacer1030.

Preferably, both the integrated wire tray1006and cover1002are made of plastic materials to eliminate grounding requirement. Trays are preferably made of hard plastic to provide rigidity. The covers1002may be made by either elastic plastic or rigid plastic materials. Various shapes and dimensions of integrated wire trays and covers can be employed for different applications, e.g., minimizing shading on modules, reducing accumulation of leafs and debris, enhanced wind load resistance, enhanced water and snow seal.

FIG.14ais a cross-sectional view of an embodiment where the wiring tray cover and base are one, single, integral piece, with a hinge1401on at least one side. The preferred hinge is a notch in the vertical sidewall1400. The notch may be semicircular in shape, triangular in shape, trapezoidal in shape, or any convenient shape. Of course, the hinge may comprise other structures such as a typical three-piece hinge with two side plates and a connecting pin.

FIG.14bis a cross-sectional view of an embodiment where the wiring tray cover is hinged, showing the cover closed and locked. Note the substantially vertical wall1402in the spacer1030. This vertical wall1402may be designed to provide flexibility to the horizontal portion of the space to allow flexibility what coupling the wiring tray to the solar module and allow cover section to open wide for wire and cable handling.

FIG.15ais a top plan view of an embodiment showing the module101, featuring the wire tray base1006and the cover1002at the shorter side of the module. Of course, one or more of the wiring tray assemblies may be provided on any side of the module, or plural sides of the module. In theFIG.15embodiment, decentralized junction box structures1501,1502, and1503are provided to handle the electrical connections from one sub string of solar cells, each. It should be noted that there will be a notch in the wiring tray base for each such junction box.FIG.15bis a top plan view of another embodiment showing decentralized junction box structures1501,1502,1503are positioned under the cover1002.FIGS.15cand15dare side views of the embodimentsFIGS.15aand15b, respectively. InFIG.15cshows an embodiment wherein the cover1002is more sloped, and the junction box1020is disposed outside of the cover1002. InFIG.15d, the junction box1522is disposed on the base1506, under the cover1502. The Vertical wall-wing structures1514and1515are used to couple the cover1502to the base1506, as will be described in greater detail below.

FIGS.16aand16bare side views of preferred embodiments showing the wire tray and cover. InFIG.16a, the cover1002is more semicircular, dome shaped to deflect water and debris. The cover vertical walls1601is shorter that the vertical wall1602. The base1610features vertical walls1611and1612. Base wings1614and1615are angled at a preferably obtuse angle with respect to their corresponding walls, to provide a biasing spring-like mechanism to keep the cover1002firmly affixed to the base1610. Wings1614and1615also function as cable/wire retainers to keep the cables, wires, and connectors down in the tray to ease the installation of the covers. Voids1621,1622, and1623are preferably provided to add flexibility to the wire tray mechanism during installation and use. The base wings1614and1615may each comprise a substantially vertical wall portion coupled at an obtuse angle with respect to a contact portion, which contacts an interior surface of the cover. Flanges1641,1642,1643, and1644are provided to affix the cover to the base, as will be describe below.

InFIG.16b, the cover1002is shown attached to the base1610via the flanges1641,1642,1643, and1644. Note that the base wings1614and1615are shown bent more to the horizontal than inFIG.16a, to keep tension on the flanges, to keep the cover1002secured to the base1610, keeping the flanges well engaged.

FIGS.17a,17b,17c, and17d, are side views showing the operation of preferred embodiments. InFIG.17a, an inter-row spacer1701is provided for easy coupling of one 100 to and adjacent module100. Preferably, the inter-row spacer1701is made of an elastic, polymer, or rubber material, to provide some flexibility, ease installation, and accommodate module dimension change with module temperature. As can be seen, an adjacent, next-row module100is leveraged into the spacer1701, using the ramp-like surface1702of the spacer.FIG.17cshows the completed installation of the next-row module100. Note that the cover1002preferably contacts each of the adjacent modules100.FIG.17dshows an end-row spacer1709, which has a vertical surface to cap-off the end of the module row. Note that indentation1711in the spacer1709is fitted to make a good seal with the bottom of the cover1002. The inter-row spacers provide/enable fixed spacing between module rows and hold modules on same levelled plane. Thus, the module array will appear uniform from any perspective. The top-row (or last course) of modules has a spacer that is preferably mated to the cover to provide a sealing function to the wire tray and cover that prevents debris, water, snow, insects, etc. getting under tray cover.

FIGS.18a,18b, and18care perspective views showing end cap structure, according to preferred embodiments. These end cap structures are designed to provide a weather-proof seal at the open ends of the combined wiring tray base and cover. InFIG.18a, the end cap1801preferably comprises a semicircular piece of semi-rigid plastic1802, matching the profile of the wire tray cover1002. At the flat bottom edge of the end cap1801are preferably three tensile clips1803,1804, and1805, projecting orthogonally from the flat piece1802. These tensile clips preferably match with corresponding voids at the end of the base1006, to align the end cap to the base. Substantially vertical walls1806and1807project orthogonally from the piece1802, and have corresponding flanges1808and1809. These flanges preferably couple with corresponding flanges at the end of base1006, to secure the end cap in place.FIG.18bshows the back side of the end cap, andFIG.18cshows the end cap1801mounted to the wiring tray base1006.

FIGS.19aand19bshow an alternative embodiment where the cover1002slopes more gradually to the outside of the module100. This asymmetrical wire tray cover design features a lower profile to minimize possible shading on the modules. The lower profile also reduces debris accumulation on the next up-slope modules. Similar to the embodiment ofFIGS.16aand16b, biasing wings1914and1915are provided to keep tension on the connections between flanges1941,1942,1943, and1944, to keep the cover1002secured to the base1006, and to hold the cables, wires, and connectors down in the tray base for ease of cover installation and removal. Note that the biasing wing1914is a separate structure from the vertical wall supporting the flange1942, whereas, the biasing wing1915is supported on the same substantially vertical wall as the flange1944. Of course, any combination of vertical walls, flanges, and biasing members may be adapted for any type of installation.

FIGS.20a,20b, and20care similar to theFIGS.18a,18b, and18c, but featuring the more gradually-sloped profile to match the profile of the cover ofFIG.19a. InFIG.20a, the end cap2001preferably comprises a sloped piece of semi-rigid plastic2002, matching the profile of the sloped wiring tray cover1002. At the flat bottom edge of the end cap2001a tensile clip2004, projecting orthogonally from the flat piece2002. This tensile clip preferably matches with a corresponding void at the end of the base1006, to align the end cap to the base. Substantially vertical walls2006and2007(with2006being shorter than2007) project orthogonally from the piece2002, and have corresponding flanges2008and2009. These flanges preferably couple with corresponding flanges at the end of base1006, to secure the end cap in place.FIG.20bshows the back side of the end cap, andFIG.20cshows the end cap2001mounted to the wire tray base1006. Thus, the end cap provides a uniform shape for the integrated wire tray/cover system. The end-cap protects the wire tray system from leafs, debris, insects, and snow, etc.

FIG.21is a perspective view of the base1006, showing the vertical walls2105and2107, together with their respective flanges2106and2108. The base1006is preferably made of a single, integral piece of semi-rigid plastic. Voids2109and2110may be provided to enhance the light weight of the assembly, together with substantially vertical wall2111which provides flexibility during installation. Preferably, the base may be attached to the module100with one or more adhesives such as glue, epoxy, thermal resins, etc. Also preferably, the bottom surface2112of the base may have an adhesive, such as double-sided tape, to adhere the base to one or more roof shingles. Thus, the whole base's bottom surface2112can be adhered to shingle roof to provide sufficient wind resistance to the home run wire tray system. The base may be substantially 84 mm by 74 mm to ensure that the base will fit on a single tab of a shingle. The base's height of substantially 13 mm ensures wire tray system complies with the National Electrical Code (NEC) code.

FIG.22shows an embodiment wherein a tray2200may be provided as the base piece, or as an insert into the base1006. The tray2200also protects home run cables from touching the roof surface, for safety and to comply with NEC codes. The one-piece construction features integrated wings2201and2202to ease wire/cable installation, and/or to keep the cover tensioned against the base, as discussed above.

FIG.23is a perspective view of cover2301with substantially vertical walls2302and2303, together with their respective flanges2304and2305. Preferably, the top of the cover is smooth, rounded, and symmetrical to minimize wind-resistance, prevent debris accumulation, and reduce the number of accessories required as described below.

FIGS.24a,24b,24c, and24dshow the home run tray assembling process for theFIGS.21-23embodiment. InFIG.24a, the tray2200is inserted into the base1006, with the tray flanges2401and2402engaging with respective base flange2405and2406; as depicted inFIG.24b. Next, as shown inFIG.24c, the cover2301is inserted into the tray2200, with the tray flanges2401and2402engaging with respective cover flanges2303and2304.FIG.24dshows the assembled base, tray, and cover. Preferably, the home run tray assembly can be disassembled and reassembled as needed for rework of photovoltaic systems.

FIG.25shows the home run accessories which may be provided to enhance the appearance of the module, and to further add to the wind, water, debris-repelling qualities of the module. InFIG.25, the module100has a home run wire tray2501along at least one portion (less than all) of one side of the module, and a home run wire tray2502along the entire portion of another (perpendicular) side of the module. L-joint2503and T-joint2504are provided to accommodate the wiring from the solar cells into the wiring tray2501, and to run the wires along the tray2540. L-joint2505is provided to run the wiring from tray2501to tray2502(and to route any wires coming from the solar cells adjacent thereto). An L-joint is provided at an end of the tray2502, to route the wires to a junction box and/or inverter (not shown). A transition joint2507is provided to route wires to a/the junction box. Each joint may comprise a base portion shaped generally similar to the shown covers, and having a cross-section generally similar to those shown inFIGS.24a,24b,24c, and24d, but necessarily having L-shaped, T-shaped, or transition-shaped outlines.

FIGS.26a,26b,26c,26d,26e, and26fare perspective views of the covers of the various joints discussed above. InFIG.26a, an L-joint cover2601is shown, having substantially vertical walls2602,2603,2604, and2605, together with their respective flanges2606,2607,2608, and2609. InFIG.26b, a T-joint cover2611is shown, having substantially vertical walls2612,2613,2614, and2615, together with their respective flanges2616,2617,2618, and2619. The covers are preferably smooth single pieces of integral plastic to prevent ingress of wind, water, and debris. Because of the symmetrical homerun tray cover design, only one L-joint cover and one T-joint cover design are used. Thus, part counts for installation is minimized.

FIG.26cshows a perspective view of a left-transition cover which may be used to transition a lower-profile wiring tray into a higher-profile wire tray (such as from an on-board tray carrying relatively fewer wires to a tray having more wires). InFIG.26c, the cover2601comprises a higher cover portion2602, a transition (high-to-low) cover portion2603, and a lower cover portion2604. It can be seen that the transition portion2602and the lower portion2604each have a flaring, more gradually sloped cover portion2603aand2604a, to accommodate a base portion with a wider dimension in the width dimension than that of the base affixed to the higher portion2602. Each high and low portion may include substantially vertical walls2604and2605, together with corresponding flanges2606and2607. The shape of the outline of2602and2604preferably matches the on-board tray cover and homerun tray cover for ascetically coupling between adjacent covers.FIG.26dshows the left-transition cover2601from the opposite perspective. The vertical wall2604of the lower cover portion2604can be readily seen, together with its corresponding flange2606. The high cover portion2602can be seen to comprise substantially vertical walls1610and2611together with their corresponding flanges2612and2613. Again, these flanges will engage with corresponding flanges on the respective base portions.

FIGS.26eand26fare very similar toFIGS.26cand26d, but showing a right-transition cover2620. Higher cover portion2622is adjacent transition cover portion2623which merges with lower cover portion2624. Gradual sloping portions2623aand2624aprovide a gradual slope in the width dimension. The shape of the outline of2622and2624preferably matches the on-board tray cover and homerun tray cover for ascetically coupling between the covers. Substantially vertical walls2626and2627are provided, with their respective flanges2628and2629. Substantially vertical walls2630,2631, and2632are provided, together with their corresponding flanges2633,2634, and2635.

FIGS.27aand27bshow an embodiment for home run tray-end caps2701. As with theFIGS.18a,18b, and18cembodiment, substantially vertical walls2703and2704are provided together with their corresponding flanges2705and2706. The flat piece2702preferably has an orthogonally-projecting bottom tab2714, and an orthogonally-projecting top tab2715. These tabs are configured to engage corresponding void in respective tray and cover portions. The end cap2701features holes2721,2722,2723,2724,2725, and2726at the bottom portion of the flat piece2702. These holes may be provided for moisture drainage, as well as cooling of the air within the wire trays.

FIGS.28a,28b,28c, and28dare perspective views of cover portions combining L-joints with transition portions. InFIG.28a, an L-joint with a left transition2801is shown. This comprises the L-joint2802, the left transition2803, including the flared portion2804. As with the above-described embodiments, flanges2811,2812,2813, and2814are configured to couple the joint2801to the underlying base(s). Preferably, these combined joints and transitions are made of a single piece of semi-rigid of semi-flexible plastic and/or rubber materials. InFIG.28b, an L-joint with a right transition2821is shown. This comprises the L-joint2822, the right transition2823, including the flared portion2824. As with the above-described embodiments, flanges2831,2832,2833, and2834are configured to couple the joint2821to the underlying base(s).

InFIG.28c, an L-joint with a left transition2841is shown, but with the flare going the opposite direction of the flare inFIG.28a. This comprises the L-joint2842, the left transition2843, including the flared portion2844. As with the above-described embodiments, flanges2851,2852,2853, and2854are configured to couple the joint2841to the underlying base(s). InFIG.28d, an L-joint with a right transition2861is shown, but with the flare going the opposite direction of the flare inFIG.28b. This comprises the L-joint2862, the left transition2863, including the flared portion2864. As with the above-described embodiments, flanges2871,2872,2873, and2874are configured to couple the joint2861to the underlying base(s).

FIGS.29aand29bare perspective views of cover portions combining T-joints with transition portions. InFIG.29a, a T-joint with a right transition2901is shown. This comprises the T-joint2902, the right transition2903, including the flared portion2904. As with the above-described embodiments, flanges2911,2912,2913, and2914are configured to couple the joint2901to the underlying base(s). InFIG.29b, a T-joint with a left transition2921is shown. This comprises the T-joint2922, the left transition2923, including the flared portion2924. As with the above-described embodiments, flanges2931,2932,2933, and2934are configured to couple the joint2921to the underlying base(s).

FIG.30ais a section view of a solar module embodiment with integrated wire tray showing 3 mounting holes for easy module handling.FIG.30bis a perspective view of the base3006ofFIG.30a, showing the mounting hole3001in greater detail. Integrated wire tray mounting holes3001,3002, and3002may be provided for easy module handling. By allowing the installer to use a carabiner, hook, or ring to secure the module for hoisting to the roof, it avoids the necessity to use a strapping system or laddervator method to hoist modules to the roof in a safe and code compliant method. The hole can be sized for suitable hardware mounting, such as carabiner clips, hooks, spring snap links, etc. for raising modules onto roofs. The holes may even be sized to accommodate a human finger and/or fingers and/or hand. Also, one or more indentations may be provided for allowing easy human-handling of the module(s). Additionally, the mounting holes3001,3002, and3003may also be used to secure the module/wire tray on roofs with adhesively attached polymer mounting hardware for enhanced wind resistance. This may offer a method of securing the modules on a pitched roof surface using fall-protection hardware as a temporary storage until the installer is ready to adhesively mount the module in the designated location.

Non-curing adhesives are preferably used for module installation. Two types of elastic adhesives are preferably used for module attachment on roof surfaces. One is curable with time and heat. The other is not cured. The modules preferably use non-curable thermoplastic adhesives for module attachment. The advantage of using non-cured adhesives for module attachment on roofs is that the module can be removed and replaced or re-installed as needed without altering or damaging the roofing surface and/or structure. Removal of modules can be done simply by using thermal means, such as but not limited to use a heating blanket.

A UV blockage label is shown inFIGS.31aand31b. Preferably, the modules100use one or more top, surface-mounted junction boxes3112, each preferably having waterproof conductors3114and3116for connection to the home run wiring, for example. To protect the junction box from UV light and heat from the sun, a module label3118, preferably made with Aluminum film, is placed on the top and/or sides of the junction box. The Aluminum film is preferably anodized for an enhanced emission coefficient and reflection. The enhanced emission coefficient will dissipate heat from junction box effectively, and the enhance reflection of heat from ambient. In addition, Aluminum film blocks UV rays. The Aluminum film is preferably about 0.002 to 0.005 mm thick, and is preferably attached with a weather resistant adhesive, such as an acrylic adhesive.

In the embodiment depicted inFIGS.32a,32b, and32c, module level power electronics (MPLE) can be combined with the junction box to form a single electrical enclosure on each PV module100. Junction boxes are preferably in the form of thin long enclosure3212, with the power electrical parts securely mounted/fixed inside the enclosure. Preferably, connectors can be either fixed-length, like conventional junction box connectors shown inFIGS.31aand31b, or they can comprise a one-polarity connector3214, with the other polarity being a build-in connector3216. Furthermore, the one polarity cable3214can be retractable into the enclosure3212and extendable when needed to connect to the connector3216of an adjacent PV module100. Either polarity connector can be fixed or retractable.

Preferably, the enclosure3212is substantially the same length as the module100width, to make the cable connections convenient. Additional wire trays and covers can thus be omitted, since only minimum lengths of cables are exposed to ambient wind/weather.

Various adhesion patterns for module mounting on shingles may be used. Prior adhesion patterns were, typically, 2×2, 3×3, or 4×4 arrays of uniformly-distributed strips of double stick tape. It has been found that such adhesion arrays provided less-than optimum adhesion of the modules top the roofs. Surprisingly, it has been determined that adhesion arrays that are more weighted to the outer edges of the modules act to more securely affix the modules to the roof surfaces. Adhesion patterns are designed to have module securely attached to composite shingle. Double sided thermoplastic adhesive tapes are preferable arranged for both portrait and landscape module installation orientation. Three preferable designs of the double side adhesive tape layout are described below. Adhesive tapes can be preinstalled on the module100in module factories.

InFIG.33a, the bottom surface of the module100(typically 4×8 feet) has a pattern of thirty-four adhesive portions3312distributed more toward the four edges of the module100that the inside portion thereof. Preferably, each adhesive pad is about 8 inches by 4 inches, which will thus cover approximately 42 percent of the bottom surface of the module100. Preferably, the adhesive pad coverage should comprise between about 20 percent and about 70 percent of the module back surface, more preferably between about 30 percent and about 50 percent, and most preferably between about 40 percent and about 50 percent. Note the two center adhesion pads3320, which will keep the center of the module100affixed to the roof surface, thus combating any wing foil lift which may be generated by the module100in high-wind conditions.

InFIG.33b, the bottom surface of the module100is preferably covered with ten adhesive pads3314and seven adhesive pads3316. The adhesive pads3316may be about 12 inches by 4 inches; and the adhesive pads3314may be about 12 inches by 8 inches (note that the pads3314may comprise two pads3316placed adjacent each other). Such an irregular two-dimensional array will provide about 48 percent coverage of the bottom surface of the module100, thus providing greatly enhanced sticking power. Again, one or more center adhesive pads3322may be provided.

InFIG.33c, nine to sixteen adhesive pads3318may be used. One or more center pads3224may also be provided. This configuration may result in about 44 percent coverage of the bottom surface of the module100.

To protect double sided adhesive tapes before field installation, one or more removable protective film(s)3330is preferably applied on the double side adhesive tapes' outer surface on the bottom surface of the module100, as shown inFIG.33d. Such protective film(s) preferably should have low surface tension so it can be easily removed during module installation. Preferable materials for such film(s) can be, but are not limited to, wax paper, polyester film, fluoropolymer film, etc. One or two pieces of protective film3330can be applied on each module bottom surface.

An alternative on-board tray and cover design is shown inFIGS.34a,34b,34c,34d, and34e. The cross-section view ofFIG.34ashows the module100inserted into the gap3412between the base3410and the bottom shelf piece3414. The module may be adhered to the base3410by glues, silicones, adhesives, screws, grommets, etc. The junction box3420is adhered to the base3410by adhesives, or other means described above. In the embodiment ofFIG.34a, the wire tray3422and top cover3402combine to form a rectangular cross-section, which provides a smaller footprint when viewed from above and from both orthogonal sides. The substantially rectangular cross section provides the lowest height tray and cover height.

As seen inFIGS.34a,34b,34c, and34d, the base portion3410has a substantially vertical left wall3441having a substantially horizontal wing portion3442, and one, two, or more locking flanges3443. The base portion3410also has a substantially vertical right wall3451having a substantially horizontal wing portion3452, and one, two, or more locking flanges3453. The cover portion3402has a substantially vertical left wall3461, and one, two, or more locking flanges3463; and a substantially vertical right wall3471, and one, two, or more locking flanges3473. When the cover is installed on the base, the locking flanges engage with each other to keep the cover installed, and the wing portions bias the cover upward, firmly engaging the locking flanges. Thus, the double clip structure on each side of the wire tray provides for the secure holding of the covers, and enhances the resistance to any wind uplift. This symmetrical cover design simplifies installation and reduces end cap numbers. The cover can be installed at either 0 degrees or 180 degrees, along the longitudinal axis, and the end caps can be used at either end.

As seen inFIG.34e, the tray (or base) portion has a notch or a cutout portion3480configured to fit around the junction box3420, and the integrated wings3442and3452are configured for holding the wire and connectors in place and biasing the cover upward to lock the locking flanges. Preferably, the tray (or base) portion3410is factory-installed on the module100. Preferably, the cover has tapered ends3483and3484(FIG.34c), where the cover can be removed with suitable tools, such as flat tip screw driver.

Another alternative embodiment is seen inFIGS.35a,35b,35c,35d, and35e. The cross-section view ofFIG.35ashows the module100inserted into the gap3512between the base3510and the bottom shelf piece3514. As seen inFIGS.35a,35b,35c, and35d, the base portion3510has a substantially vertical left wall3541sloping at a quarter curve into a substantially horizontal wing portion3542, and one, two, or more locking flanges3543. The base portion3510also has a substantially vertical right wall3551sloping at a quarter curve into a substantially horizontal wing portion3552, and one, two, or more locking flanges3553.

The cover portion3502has a substantially vertical left wall3561, and one, two, or more locking flanges3463; and a substantially vertical right wall3571, and one, two, or more locking flanges3573. When the cover is installed on the base, the locking flanges engage with each other to keep the cover installed, and the wing portions bias the cover upward, firmly engaging the locking flanges. Thus, the double clip structure on each side of the wire tray provides for the secure holding of the covers, and enhances the resistance to any wind uplift. This near symmetrical cover design simplifies installation and reduces end cap numbers. The end caps can be used at either end. The curved U-channel edge portion3599on the cover3502provides a tool access point to install or decouple the cover from the tray.

As seen inFIG.35e, the tray (or base) portion3502has a notch or a cutout portion3580configured to fit around the junction box3520, and the integrated wings3542and3552are configured for holding the wire and connectors in place and biasing the cover upward to lock the locking flanges. Preferably, the tray (or base) portion3510is factory-installed on the module100. TheFIGS.35a-eembodiment presents a more curved, rounded appearance that theFIGS.34a-eembodiment. This will aid in fending off wind and rain and snow and ice. Also, the more rounded wings3542and3552will provide an even stronger upward biasing force to more firmly engage the interlocking flanges.

Yet another alternative embodiment is shown inFIGS.36a,36b, and36c. The features are substantially the same as those shown inFIGS.35a,35b, and35d, respectively, and will not be further described herein. However, the cover3502includes a bent edge3602which makes removal of the cover3502easy, with just one or more fingers.

FIG.37ashows an end cap for the embodiment ofFIGS.34a-e, whileFIG.37bshows an end cap for the embodiment ofFIGS.35a-e. InFIG.37a, the end cap3722has a substantially flat end portion3723and four orthogonal projecting walls3724,3725,3726, and3727. The end portion3723preferably has a substantially rectangular profile, with radiused, curved corners at the upper edge thereof. Note that at least the projecting walls3724and3726have interlocking flanges3728and3729for interlocking-coupling with complementary interlocking flange structure on an adjacent cover. Of course, the projecting walls3725and3727may also have similar interlocking flanges. InFIG.37b, the end cap3742has a substantially flat end portion3743and four orthogonal projecting walls3744,3745,3746, and3747. The end portion3743preferably has a substantially rectangular profile, with radiused, curved corners at the upper edge thereof, but the curve has a larger radius than theFIG.37aembodiment. Note that at least the projecting walls3744and3746have interlocking flanges3748and3749for interlocking-coupling with complementary interlocking flange structure on an adjacent cover. Of course, the projecting walls3745and3747may also have similar interlocking flanges.

The present invention is disclosed herein in terms of a preferred embodiment thereof, which provides an exterior building module as defined in the appended claims. Various changes, modifications, and alterations in the teachings of the present invention may be contemplated by those skilled in the art without departing from the intended spirit and scope of the appended claims. It is intended that the present invention encompass such changes and modifications.