Photovoltaic module and module arrays

A photovoltaic (PV) module including a PV device and a frame. The PV device has a PV laminate defining a perimeter and a major plane. The frame is assembled to and encases the laminate perimeter, and includes leading, trailing, and side frame members, and an arm that forms a support face opposite the laminate. The support face is adapted for placement against a horizontal installation surface, to support and orient the laminate in a non-parallel or tilted arrangement. Upon final assembly, the laminate and the frame combine to define a unitary structure. The frame can orient the laminate at an angle in the range of 3°-7° from horizontal, and can be entirely formed of a polymeric material. Optionally, the arm incorporates integral feature(s) that facilitate interconnection with corresponding features of a second, identically formed PV module.

BACKGROUND

The present disclosure relates to solar roof tiles. More particularly, it relates to photovoltaic modules adapted for rapid installation as part of an arrayed, rooftop photovoltaic system.

Solar power has long been viewed as an important, highly viable, alternative energy source. To this end, substantial efforts and investments have been made to develop and improve upon solar energy collection technology. Of particular interest are industrial- or commercial-type applications in which relatively significant amounts of solar energy can be collected and utilized in supplementing or satisfying power needs.

Solar photovoltaic technology is generally viewed as the optimal approach for large scale solar energy collection, and can be used as a primary and/or secondary (or supplemental) energy source. In general terms, solar photovoltaic systems (or simply “photovoltaic systems”) employ solar panels made of silicon or other materials (e.g., III-V cells such as GaAs) to convert sunlight into electricity. More particularly, photovoltaic systems typically include a plurality of photovoltaic (PV) modules (or “solar tiles”) interconnected with wiring to one (or more) appropriate electrical components (e.g., switches, inverters, junction boxes, etc.). The PV module conventionally consists of a PV laminate or panel generally forming an assembly of crystalline or amorphous semiconductor devices electrically interconnected and encapsulated. One or more electrical conductors are carried by the PV laminate through which the solar-generated current is conducted.

Regardless of an exact construction of the PV laminate, most PV applications entail interconnecting an array of PV modules at the installation site in a location where sunlight is readily present. This is especially true for commercial or industrial applications in which a relatively large number of PV modules are desirable for generating substantial amounts of energy, with the rooftop of the commercial building providing a convenient surface at which the PV modules can be placed. As a point of reference, many commercial buildings have large, flat roofs that are inherently conducive to placement of a significant array of PV modules. In fact, utilizing an existing rooftop as the PV module installation site represents the most efficient use of space in that the building/rooftop structure is already in existence, and thus minimizes the need for additional, separate structures necessary for supporting the PV modules. While rooftop installation is thus highly viable, certain environment constraints must be addressed. For example, the PV laminate is generally flat or planar; thus, if simply “laid” on an otherwise flat rooftop, the PV laminate may not be positioned/oriented to collect a maximum amount of sunlight throughout the day. Instead, it is desirable to tilt the PV laminate at a slight angle relative to the rooftop (i.e., toward the southern sky for northern hemisphere installations, or toward the northern sky for southern hemisphere installations). Further, rooftop-installed PV modules are oftentimes subjected to windy conditions, a concern that is further heightened where the PV laminate is tilted relative to the rooftop as described above.

In light of the above, conventional PV module installation techniques have included physically interconnecting each individual PV module of module array directly with, or into, the existing rooftop structure. For example, some PV module configurations have included multiple frame members that are physically attached to the rooftop via bolts driven through the rooftop. While this technique may provide a more rigid mounting of the PV module to the rooftop, it is a time-consuming process, and inherently permanently damages the rooftop. Further, because holes are formed into the rooftop, the likelihood of water damage is highly prevalent. More recently, PV module configurations have been devised for commercial, flat rooftop installation sites in which the arrayed PV modules are self-maintained relative to the rooftop in a non-penetrating manner. More particularly, the PV modules are interconnected to one another via a series of separate, auxiliary components, with a combined weight of the interconnected array (and possibly additional ballast and/or wind-deflecting fairings or “wind deflectors” mounted to one or more of the PV modules at the installation site) serving to collectively offset wind-generated forces.

While the non-penetrating PV module array approach has been well-received, certain drawbacks may still exist. For example, a large number of parts are required, along with the logistical management of these parts, to facilitate non-penetrating, interconnected mounting of an array of PV modules. In this regard, the arrangement of PV modules (e.g., number, location, and type) will vary for each installation site. Thus, the number and types of requisite, auxiliary mounting components will also vary, and must be accurately ordered and delivered to the installation site with the PV modules. Thus, considerable upfront planning is necessary. Along these same lines, installation requirements for several non-penetrating PV module formats entail wind-deflecting auxiliary components (e.g., a perimeter curb) that are configured or sized as a direct function of the resultant perimeter shape or geometry of the arrayed PV modules. Once again, substantial upfront planning must be performed in order to ensure that these wind-deflecting components, as well as other installation components, are provided to the installation site in forms that are properly sized and shaped in accordance with the expected shape of the PV module array. Clearly, any errors in the upfront planning, miscommunication of the installation parameters, incorrect part list ordering, etc., can negatively impact and overtly delay the installation process. Further, where the auxiliary installation components are packaged apart from the PV modules, as is common in the industry, it is highly difficult at best for the installation personnel to quickly recognize whether ordering and/or shipping errors have occurred. Instead, these errors only become evident during the actual installation process, and typically cannot be quickly rectified. Similarly, fairly significant labor and expertise (and thus cost) is required to install non-penetrating PV modules at a commercial building's rooftop. Finally, considerable expense is necessitated by the handling and disposal of the shipping materials required in providing all of the PV modules, as well as all of the auxiliary mounting components and related equipment.

PV module-based solar energy represents an extremely promising technology for reducing the reliance of commercial or industrial businesses upon conventional, natural resource-based energy. To be competitive with traditional sources of municipal power, however, the costs associated with solar PV systems should desirably be reduced wherever possible. Thus, a need exists for a PV module and related PV module systems or arrays that are readily mounted to commercial rooftops in a non-penetrating fashion.

SUMMARY

Some aspects in accordance with principles of the present disclosure relate to a photovoltaic (PV) module including a PV device and a frame. The PV device includes a PV laminate having a perimeter and a front face defining a major plane. The frame is assembled to and encases the perimeter of the PV laminate. In this regard, the frame includes opposing, leading and trailing frame members, and opposing, first and second side frame members. Further, an arm is provided that projects from one of the frame members and forms a support face opposite the front face of the PV laminate, with the support face being adapted for placement against a separate installation surface, thereby supporting and orienting the PV laminate relative to the installation surface. With this in mind, a plane of the support face and the major plane of the PV laminate are non-parallel (e.g., the PV laminate is tilted relative to the support face). Regardless, upon final assembly (e.g., factory assembly), the PV laminate and the frame combine to define a unitary structure. In some embodiments, the frame is configured such that when the support face is placed on a flat surface, the PV laminate is oriented at a non-parallel angle relative to the flat surface, for example, at an angle in the range of 3°-7°. In other embodiments, the unitary structure feature of the PV module entails that the frame cannot be disassembled from the PV laminate without destroying at least one of the frame members. In yet other embodiments, the frame members are entirely formed of a polymeric material. In yet other embodiments, one or more of the frame members incorporates integral features that facilitate interconnection with corresponding features of a second, identically formed PV module.

Other aspects in accordance with principles of the present disclosure relate to a method of manufacturing a PV module. The method includes providing a PV device including a PV laminate having a perimeter at a front face defining a major plane. A frame is also provided including leading, trailing, and first and second side frame members. Further, the frame includes an arm projecting from one of the frame members and defining a support face. The PV laminate is mounted to the frame members such that the frame members encase the perimeter. Further, the frame members are mounted to one another. Upon final assembly (e.g., factory assembly), the PV laminate and the frame combine to define a unitary structure, with a plane of the support face and the major plane of the PV laminate being non-parallel. In some embodiments, the frame members are simultaneously mounted to one another and the PV laminate, thereby simplifying the overall manufacturing process.

Other aspects in accordance with principles of the present disclosure relate to a photovoltaic module system kit for non-penetrating installation at a substantially flat surface, such as a commercial building rooftop. The system kit has at least two PV modules each including a PV device and a frame. The PV device includes a PV laminate. The frame is assembled to and surrounds the PV laminate to define a unitary structure. Further, the frame includes an arm forming a planar support face for placement against a separate installation surface so as to tilt the PV laminate relative to the installation surface. The support face and the PV laminate are non-parallel to effectuate tilted arrangement upon non-penetrating installation to a flat rooftop. In kit form appropriate for shipping, the frame of the first PV module is nested on top of the frame of the second PV module, whereby the arm(s) carried by the frames do not impede the nested relationship.

DETAILED DESCRIPTION

One embodiment of a photovoltaic (PV) module20in accordance with principles of the present disclosure is shown inFIGS. 1A and 1B. The PV module20includes a PV device22(referenced generally) and a frame24. Details on the various components are provided below. In general terms, however, the PV device22includes a PV laminate26that is encased by the frame24. In this regard, the frame24provides one or more support faces that effectuate a tilted orientation of the PV laminate26relative to a flat installation surface (e.g., a flat rooftop). Further, in some embodiments, the frame24incorporates one or more features that facilitate mounting of the PV module20to one or more similarly constructed PV modules. Regardless, the frame24and the PV laminate26are assembled to one another to form or define a unitary structure. With this configuration, the PV module20is highly amenable to non-penetrating, commercial rooftop installations in which a minimal number of additional parts are required for effectuating mounting of multiple ones of the PV modules20as part of a PV system array. This, in turn, greatly simplifies the installation process, for example in terms of labor, parts, and upfront planning, while greatly reducing shipping and handling costs. Benefits are realized in the installation of the PV modules20to any substantially flat surface (e.g., maximum pitch of 2:12), including commercial rooftop, residential rooftop, and ground mount applications.

The PV device22, including the PV laminate26, can assume a wide variety of forms currently known or in the future developed appropriate for use as a solar photovoltaic device. In general terms, the PV laminate26consists of an array of photovoltaic cells. A glass laminate may be placed over the photovoltaic cells for environmental protection. In some embodiments, the photovoltaic cells advantageously comprise backside-contact cells, such as those of the type available from SunPower Corp., of San Jose, Calif. As a point of reference, in backside-contact cells, wirings leading to external electrical circuits are coupled on the backside of the cell (i.e., the side facing away from the sun upon installation) for increased area for solar collection. Backside-contact cells are also disclosed in U.S. Pat. Nos. 5,053,083 and 4,927,770, which are both incorporated herein by reference in their entirety. Other types of photovoltaic cells may also be used without detracting from the merits of the present disclosure. For example, the photovoltaic cells can incorporate thin film technology, such as silicon thin films, non-silicon devices (e.g., III-V cells including GaAs), etc. Thus, while not shown in the figures, in some embodiments the PV device22can include one or more components in addition to the PV laminate26, such as wiring or other electrical components.

Regardless of an exact construction, the PV laminate26can be described as defining a front face30and a perimeter32(referenced generally inFIGS. 1A and 1B). As a point of reference, additional components (where provided) of the PV device22are conventionally located at or along a back face of the PV laminate26, with the back face being hidden in the view ofFIGS. 1A and 1B.

With the above understanding of the PV device22, and in particular the PV laminate26, in mind, the frame24includes a leading frame member40, a trailing frame member42, a first side frame member44, and a second side frame member46. As described below, the frame24incorporates one or more additional features that facilitate arrangement of the PV laminate26at a desired orientation (e.g., tilted) relative to a substantially flat surface such as a rooftop. By way of further explanation,FIG. 2provides a simplified illustration of the PV module20relative to a relatively flat, horizontal surface S. Though hidden in the view ofFIG. 2, a location of the PV laminate26is generally indicated, as is a plane PPVof the PV laminate26that is otherwise established by the front face30(FIGS. 1A and 1B). With this in mind, and relative to the arrangement ofFIG. 2, the frame24supports the PV laminate26relative to the flat surface S at a slope or tilt angle θ. The tilt angle θ can otherwise be defined as an included angle formed between the PV laminate plane PPVand a plane of the flat surface S. With this in mind, the frame24is configured to support the PV laminate26at a tilt angle θ in the range of 1°-30°, in some embodiments in the range of 3°-7°, and yet other embodiments at 5°. As a point of reference, with tilted PV solar collection installations, the PV laminate26is desirably positioned so as to face or tilt southward (in northern hemisphere installations). Given this typical installation orientation, then, the leading frame member40can thus be generally referred to as a south frame member, and the trailing frame member42referred to as a north frame member. Returning toFIGS. 1A and 1B, and consistent with these directional designations, the first side frame member44can be referred to as a west frame member, whereas the second side member46can be referred to as an east frame member.

The frame members40-46can assume a variety of forms appropriate for encasing the perimeter32of the PV laminate26, as well as establishing the desired tilt angle θ (FIG. 2). In some embodiments, the frame members40-46are separately formed, and subsequently assembled to one another and the PV laminate26in a manner generating a unitary structure upon final construction.

Each of the frame members40-46can incorporate, in some embodiments, identical features that promote assembly to the PV laminate26.FIGS. 3A and 3Billustrate examples of these features relative to the first side frame member44. In particular, the first side frame member44generally includes a frame body50and a bracket assembly52. The frame body50can assume a variety of forms or shapes, and in some embodiments is akin to an I-beam in cross-section as reflected inFIG. 3A. Regardless, the bracket assembly52projects upwardly (relative to the orientation ofFIGS. 3A and 3B) from the frame body50and includes a C-shaped bracket60that defines or is defined by a lower surface62, an upper surface64, and an end surface66. The lower surface62is formed proximate the frame body50, and the upper surface64is formed opposite the lower surface62. The end surface66interconnects the lower and upper surfaces62,64, with the surfaces combining to define a channel68sized to receive the PV laminate26(FIG. 1B). More particularly, the channel68is sized to receive a corresponding edge of the PV laminate26, and an appropriate adhesive employed to permanently affix or bond the PV laminate26to the bracket60.

A spacing between the lower and upper surfaces62,64can be greater than an expected height or thickness of the PV laminate26(FIG. 1B), with the bracket assembly52further including a plurality of spaced guide features70adapted to centrally maintain the PV laminate26between the surfaces62,64in some embodiments. One of the guide features70is shown in greater detail inFIG. 3C, and includes a lower guide tab72aprojecting from the lower surface62, and an upper guide tab72bprojecting from the upper surface64. The guide tabs72a,72bcan be vertically aligned and having an increasing height or thickness in extension toward the end surface66as reflected byFIG. 3D. Thus, in a region of guide tabs72a,72b, the channel68tapers in height from an open end74to the end surface66.

By correlating the guide tabs72a,72bwith an expected thickness of the PV laminate26, the bracket assembly52is adapted to quickly receive, and desirably position, the PV laminate26relative to the bracket60for subsequent adhesive bonding as shown inFIG. 3E. As a point of reference,FIG. 3Erepresents the PV laminate26in simplified form, and the PV laminate26can have various features not specifically illustrated but accounted for by the guide features70(e.g., the PV laminate26can taper in thickness toward the perimeter edge). Regardless, the PV laminate26is maintained within the channel68, via the guide tabs72a,72b, at an off-set or spaced position relative to the surfaces62-66. This off-set provides sufficient spacing within the channel68for receiving and maintaining an adequate volume of adhesive (not shown), such as an RTV silicone adhesive, otherwise used to bond the PV laminate26to the bracket60(and in particular the surfaces62-66), with the PV laminate26being centered between the lower and upper surfaces62,64in some embodiments.

Returning toFIGS. 3B and 3C, one or more of the frame members40-46(FIG. 1A) can include additional features that promote assembly with the PV laminate26. For example, with respect to the first side frame member44, the bracket assembly52can further include one or more ramps80. The ramps80are laterally spaced from one another (e.g., aligned with respective ones of the guide features70), and provide a ramp surface82extending from the frame body50to the lower surface62of the bracket60. More particularly, the ramp surface82extends in an angular fashion downwardly and away from the lower surface62, and provides a surface for guiding the PV laminate26(FIG. 3D) into the channel68. Thus, assembly of the PV laminate26entails sliding an edge of the PV laminate along the surface82of the ramp(s)80, with the ramp surface82directing the PV laminate26into the channel68via respective ones of the lower guide tabs72a(FIG. 3C) as described above. Alternatively, a wide variety of other configurations can be employed to facilitate assembly of the frame24and the PV laminate26such that one or more of the above-described features can be omitted.

Returning toFIG. 1B, one or more or all of the frame members40-46can incorporate the I-beam shaped (or other shape) frame body50and/or bracket assembly52(FIG. 3A) described above. In addition, in some embodiments, the frame members40-46include or form connector fittings adapted to facilitate robust interconnection or assembly of the frame members40-46to one another. For example, the leading and trailing frame members40,42can include or form identically, opposing male connectors100,102(identified for the trailing frame member42inFIG. 1B), whereas each of the side frame members44,46includes or forms opposing, first and second female connectors104,106(identified for the first side frame member44inFIG. 1B). In general terms, each of the female connectors104,106are configured to receive a corresponding one of the male connectors100,102in a press fit-type relationship. Notably, the connector type (i.e., male or female) associated with each of the frame members40-46can vary (e.g., the leading frame member40can form two female connectors, or one female connector and one male connector) so long as a male/female connection pair is established at each of the frame member40-46intersections.

One embodiment of male and female connectors useful with the present disclosure is shown inFIGS. 4A and 4B, and in particular the male connector100of the trailing frame member42and the female connector104of the first side frame member44. As illustrated, the male and female connectors100,104have an identical shape, with the female connector104forming a receptacle110within which the male connector100is received. The corresponding shape associated with the connectors100,104is generally cross-like, including a first segment112and a second segment114(identified for the male connector100inFIG. 4A). The segments112,114extend in an approximately perpendicular fashion relative to one another, with the second segment114bisecting the first segment112in some embodiments. To provide enhanced support of the frame members42,44relative to an interior of the frame24(i.e., a location of the PV laminate26(FIG.1A)), the second segment114has an elongated, interior extension portion116(relative to the first segment112). Further, in some constructions, at least the second segment114tapers in width from a base end120to a free end122. Stated otherwise, a horizontal dimension of the second segment114at the base end120is greater than that at the free end122. With this tapered construction, along with a corresponding shape defined by the female connectors104or106, the male connector100is readily insertable into the receptacle110of the female connector104. As the male connector100is further forced into the receptacle110(and/or vice-versa), a tapered press fit junction is achieved whereby the male connector100is frictionally locked within the female connector104.

Returning toFIGS. 1A and 1B, the frame24can incorporate other designs to facilitate robust assembly of the frame members40-46. However, at least with embodiments in which the frame members40-46are simultaneously assembled to the PV laminate26(via an adhesive) and to one another (e.g., via the connectors100-106), the resultant assembly includes the PV laminate26and the frame24combining to define a unitary structure, with the frame members40-46completely “capturing” the PV laminate26. As used through this specification, a “unitary structure” is in reference to a robust, unchanging assembly whereby the frame24cannot be disassembled from the PV laminate26without destroying at least one of the frame members40-46. Notably, no additional components or specialized tools are required to effectuate complete, final assembly of the frame24and the PV laminate26in accordance with the above configurations. This presents significant savings in installation time as installers are not required to assemble component parts at the installation site to “complete” an individual PV module.

In addition to the frame members40-46described above, in some embodiments the frame24further includes one or more arms that facilitate desired orientation of the PV laminate26relative to an installation surface, as well as mounting of two or more PV modules20to one another. For example, in some embodiments, the frame24includes a first arm130, a second arm132, a third arm134, and a fourth arm136. The arms130-136can be formed by or otherwise associated with various ones of the frame members40-46; with the construction ofFIGS. 1A and 1B, for example, the first and third arms130,134are provided as opposing extensions of (or from) the first side frame member44, whereas the second and fourth arms132,136are provided as opposing extensions of (or from) the second side frame member46. Upon final assembly of the frame24, the first and second arms130,132project or extend longitudinally beyond (e.g., forward) the leading frame member40, whereas the third and fourth arms134,136project or extend longitudinally beyond (e.g., rearward) the trailing frame member42as shown inFIG. 1A.

The first and second arms130,132can be of an identical construction, defining mirror images upon final construction of the frame24. With this in mind,FIG. 1Billustrates the first arm130as including or defining a side wall140and a flange142. The flange142projects inwardly from the side wall140along a perimeter thereof. The flange142effectively defines an overall width of the first arm130. Further, extension of the flange142relative to the side wall140forms a mounting region144adapted to promote mounting with an arm (not shown) of a second PV module20as described below, with the mounting region144including or forming a bore146through the side wall140. Regardless, the mounting region144is located longitudinally beyond (or is spaced from) not only the first side frame member44, but also the leading frame member40. This relationship is best reflected inFIG. 5relative to the mounting region144of the second arm132relative to the leading frame member40(referenced generally).

Additional optional features of the first and second arms130,132are further described with reference toFIG. 5, and in particular with respect to the second arm132that is otherwise visible in the view ofFIG. 5. As shown, the second arm132extends outwardly and downwardly from the second side frame member46(and thus the leading frame member40that is otherwise generally referenced inFIG. 5). More particularly, forward (i.e., leftward relative to the orientation ofFIG. 5) extension of the second arm132terminates at a leading surface150. The leading surface150(along with an identical surface of the first arm130(FIG. 1B)) serves as the forward-most end of the frame24, and thus of the PV module20. As described below, this forward extension or dimension, along with the longitudinal positioning of the mounting region144, is selected to correspond with a dimension of the fourth arm136(and a mounting region formed thereby) in establishing a desired end-to-end assembly of two PV modules20. It will be understood that a similar relationship is established between the first arm130(FIG. 1B) and the third arm134(FIG. 1B) (again, as between two PV modules20positioned end-to-end).

Similarly, downward extension of the second arm132from the second side frame member46terminates at a bottom surface152. The bottom surface152(along with an identical surface of the first arm130(FIG. 1B), as well as with one or more surfaces provided by the third and fourth arms134,136as described below) serves as a bottom-most surface of the frame24and provides a support face at which the PV module20is supported relative to an installation surface. More particularly, downward extension of the first and second arms130,132is selected in accordance with selected dimensional attributes of the third and fourth arms134,136(described in greater detail below) to collectively create or define a common support face (e.g., including the bottom surface152) that in turn dictates the desired, tilted orientation of the PV laminate26on a flat installation surface as mentioned above.

Returning toFIG. 1B, the third and fourth arms134,136have an identical construction in some embodiments, forming mirror images of one another upon final construction of the frame24. With this in mind, certain features of the third arm134are illustrated inFIGS. 3A and 3B. The third arm134can be L-shaped, and includes a shoulder160and a foot162. The shoulder160can be formed with, and extends downwardly from and beyond, the first side frame member44. As illustrated, a supportive interface between the shoulder160and the first side frame member44(and in particular the frame body50) is established along a length of the first side frame member44, proximate a trailing end164thereof. In this regard, downward extension of the shoulder160(as well as positioning of the foot162as described below) is such that an interior-most face166of the shoulder160is laterally offset from an exterior-most face168of the first side frame member44. That is to say, an entirety of the portion of the third arm134extending from the first side frame member44is spatially positioned to the side of and away from the first side frame member44. For reasons made clear below, this optional arrangement promotes desired spacing between two PV modules20when arranged side-by-side. Further, the transversely offset position of the third arm134(and the fourth arm136) facilitated nested, stacked arrangement of multiple ones of the PV modules20, for example during shipping and/or storage. Along these same lines, and as best shown inFIG. 6, the interior-most face166of the shoulder160(extending beyond the first side frame member44) can form a trough170that further facilitates stacked, nested arrangements.

Returning toFIGS. 3A and 3B, the foot162extends rearwardly from the shoulder160and forms a mounting region180, a lower surface182, and an upper surface184. The mounting region180is defined at a spatial location that is longitudinally spaced from the first side frame member44(and thus longitudinally spaced from the trailing frame member42upon final construction as shown inFIG. 1A). More particularly, longitudinal extension of the foot162from the shoulder160spatially positions the mounting region180rearward of not only the first side frame member44, but also the trailing frame member42. The selected extension dimensions of the foot162(and in particular the spatial coordinates of the mounting region180) correlates with the extension dimensions associated with the first arm130(and in particular the spatial coordinates of the mounting region144(FIG. 1B)) as described above to establish desired, end-to-end spacing of two of the PV modules20when mounted to one another (it being understood that an identical relationship is established between the second and fourth arms132,136). With this in mind, the mounting region180can include a bore190extending between an interior face192and an exterior face194.

Returning toFIG. 5, the lower surface182is relatively planar along a length of the foot162, and establishes a desired orientation of the PV laminate26(referenced generally) via arrangement of the fourth arm136in extension from the second side frame member46(it being recalled that the third arm134(FIGS. 3A and 3B) has an identical construction in some embodiments). In particular, the lower surface182serves as a part of the PV module support face described above, and defines a plane PAthat is non-parallel relative to the plane PPVof the PV laminate26(as otherwise spatially maintained by the frame members40-46). Further, the plane PAof the lower surface182(as well as the identical plane defined the lower surface of the third arm134intersects the bottom surface152of the second arm132(as well as the identical bottom surface of the first arm130(FIG. 1B)). Thus, the arms130-136combine to spatially establish the desired, tilted orientation of the PV laminate26relative to a flat installation surface.

As mentioned above, the shoulder160extends from a point along a length of the corresponding side frame member44,46(e.g., the second side frame member46in the view ofFIG. 5). With this in mind, the foot162forms the upper surface184to be spaced below the second side frame member46(as well as below the trailing frame member42). Thus, the upper surface184, the shoulder160, and the second side frame member46combine to define a gap200(referenced generally inFIG. 5). The gap200provides a highly convenient, protected area along which wiring202(e.g., east-west wiring) associated with the PV device22(as well as wiring from other PV modules20assembled in an array) can be placed without the cumbersome need to route wires under each PV module as is otherwise required with conventional designs. In this regard, the wiring202can be placed on to, and safely maintained by, the upper surface184.

Usefulness of the arm configurations described above in facilitating mounting of two or more of the PV modules20to one another can be described with reference toFIG. 7. In particular,FIG. 7illustrates relevant portions of four, identically-constructed ones of the PV modules20in accordance with the present disclosure, including PV modules20a-20dmounted in an array210. The first and second PV modules20a,20bare mounted to one another in an end-to-end relationship, as are the third and fourth PV modules20c,20d. In addition, the first and third PV modules20a,20care mounted to one another in a side-by-side relationship, as are the second and fourth PV modules20b,20d.

Mounting of the first and second PV modules20a,20bincludes the first arm130aof the first PV module20amounted to the third arm134bof the second PV module20b, and the second arm132aof the first PV module20amounted to the fourth arm136bof the second PV module20b. Similar mounting relationships are established between the first arm130cof the third PV module20cand the third arm134dof the fourth PV module20d, as well as the second arm132cand the fourth arm136d. Finally, the fourth arm136bof the second PV module20bis mounted to the third arm134cof the third PV module20c.

To effectuate a more complete mounting between the respective arm pairs (e.g., the arms130a/134b), a coupling device220(referenced generally) can be provided, for example including a bolt component222and a nut component224. More particularly, upon arrangement of respective ones of the PV modules20in an end-to-end relationship (e.g., the first and second PV modules20a,20b), the mounting regions of the corresponding arm pairs (e.g., the mounting region144aof the first arm130aand the mounting region180b(referenced generally) of the third arm134b) are naturally or intuitively positioned by an installer such that the respective bores146(FIG. 1B),190(FIG. 3A) are aligned for commonly receiving the bolt222. Further, the arms130-136are configured such that the bottom surface152of the first or second arm130or132is aligned or co-planar with the lower surface182of the corresponding third or fourth arm134or136. For example, and with additional reference toFIG. 8, the bottom surface152of the second arm132cof the third PV module20cis aligned with the lower surface182of the fourth arm136dof the fourth PV module20d. Similar, aligned relationships are established at the other arm mounting interfaces, such as the arm mounting interface130a/134b,132a/136b, and130c/134d. With this construction, then, in the mounted arrayed arrangement210ofFIGS. 7 and 8, the PV laminates26a-26dare all oriented at virtually identical tilt angles; the commonly, spatially positioned surfaces152,182of the various arms130-136dictate that regardless of the number of PV modules20within the array210and regardless of the number of PV modules20mounted to an individual PV modules20(including a single, standing-alone PV module20), desired tilted orientation of the corresponding PV laminates26in consistently provided with a straightforward installation process. Along these same lines, by interconnected the PV modules20to one another, the array210can quickly be installed on a rooftop without requiring rooftop-penetrating components or any specialty tools.

The simplified array210is but one example of a PV module installation facilitated by the present disclosure. The PV module20constructions of the present disclosure allow for virtually any array installation configuration (e.g., in terms of number of PV modules20mounted to one another on a substantially flat commercial rooftop and/or overall “shape” or geometry of the resultant array). Regardless of the parameters of the desired array, the individual PV modules20are simply and quickly mounted to one another as described above, and can be placed at any location within the array. Thus, the PV module20has a universal configuration. East-west wiring (or other wiring) can be run “beneath” a line of mounted PV modules20as described above (e.g., inFIG. 5). Simplified, consistent arrangement of other wiring, such as “home run” wiring (e.g., north-south wiring or east-west wiring), is also facilitated by features of the PV modules20of the present disclosure. For example, as reflected inFIG. 9, that otherwise provides a top view of the array210, the side-by-side arranged PV modules20a,20cand20b,20ddefine a longitudinal gap230relative to the corresponding PV laminates26a-26d. More particularly, the above-described, laterally off-set position of the third and fourth arms134,136of each of the PV modules20(e.g., the fourth arm136bof the second PV module20band the third arm134dof the fourth PV module20dinFIG. 9) creates the longitudinal gap230when the PV modules20are disposed side-by-side. Wiring can be run along the longitudinal gap230, maintained away from or “above” the rooftop surface by placement on the upper surface184associated with each of the arms134,136. For both east-west and north-south wiring, the above construction eliminates the need for time-consuming and cumbersome routing of wires underneath individual PV modules. Rather, the installer can simply walk along or through the array210and place wiring as necessary without needing to lift the PV modules20and/or routing wires under the PV modules20.

As is evident from the above, the PV modules20of the present disclosure greatly simplify the rooftop installation process. Minimal on-site assembly is required in installing an array of tilted, non-penetrating PV solar tiles. An additional advantage is recognized in the context of upfront planning. Because the PV module20can effectively be installed (non-penetrating) “as is,” the upfront installation planning process essentially entails the step of ordering the number of PV modules20determined to be necessary for a particular installation site. Unlike conventional commercial rooftop PV solar tile formats, installers of PV modules20of the present disclosure are not required to estimate the number and type of auxiliary installation component parts ahead of time and hope that the correct estimate is made (and that the correct component parts are actually delivered). In fact, each PV module20can be provided to the installation site in a kit form, including the PV module20and a standard number of the coupling devices220(FIG. 7) and, an optionally, a wind deflector. With this kitted form, the installer has all components necessary to install the PV module array, regardless of the number of PV modules20to be installed and/or the actual “shape” of the desired array. While it is recognized that some installation sites may require additional components (e.g., ballast), the desired quantities of these components are more readily estimated (as compared to auxiliary installation component parts with conventional tilted, non-penetrating rooftop PV solar tiles), such that upfront planning is greatly eased with the present disclosure. Further, the PV modules20can include optional features that facilitate assembly of the common components such as wind deflectors and/or ballast.

In addition to promoting simplified, rapid installation, features of the PV modules20of the present disclosure greatly reduce packaging and shipping expenses. Returning toFIGS. 1A and 1B, in some embodiments the frame24is formed entirely of plastic or polymeric material(s). For example, the frame24, and in particular the frame members40-46and arms130-136, are molded polymeric components, such as injection molded PPO/PS (Polyphenylene Oxide co-polymer/polystyrene blend) or PET (Polyethylene Terephthalate), although other polymeric or electrically insulating material(s) are also acceptable. The resultant PV module20is lightweight (e.g., on the order of 3 lbs/ft2), and therefore relatively inexpensive to install and presents minimal rooftop loading concerns. Further, as compared to conventional PV module constructions that rely primarily upon metal framework and related installation components, the PV modules20of the present disclosure incorporating the optional non-conductive plastic frame24do not require additional grounding components (and related installation procedures). Alternatively, however, the frame24can be partially or entirely formed of metal.

Regardless of the material(s) used in forming the frame24, identically formed ones of the PV modules20can be compactly arranged for shipping to an installation site. For example,FIG. 10illustrates three of the PV modules20e-20gof the present disclosure stacked in a nested arrangement as part of a kitted system240. The frame members40e-46eof the first PV module20eabut against the corresponding frame members40f-46fof the second PV module20f(it being understood that the leading frame members40and the first side frame members44are hidden in the view ofFIG. 10); a similar arrangement is established between the frame members40f-46fof the second PV module20fand the frame members40g-46gof the third PV module20g. The laterally off-set arrangement of the corresponding third and fourth arms134,136promote this stacked assembly. For example, the third and fourth arms134e,136eof the first PV module20e“clear” the frame24fof the second PV module20fin placing the frame24eof the first PV module20eonto the frame20fof the second PV module20f. Notably, the trough170associated with each of the third and fourth arms134,136as described above with respect toFIG. 6further promotes the stacked, nested arrangement of the PV modules20e-20g. For example, the shoulder160of the fourth arm136fof the second PV module20fis slidably received within the trough170(hidden inFIG. 10) of the fourth arm134eof the first PV module20e. As a result, the PV modules20of the present disclosure can be closely stacked for high shipping density, thereby greatly minimizing shipping (and related packaging) waste and cost. Notably, this same, nested or stacked arrangement is also achieved with shipping formats including additional components such as a wind deflector250as shown inFIG. 11. More particularly, respective ones of the wind deflector250are assembled to each of the PV modules20e-20gso as to extend between the corresponding trailing frame member42and third/fourth arms134/136(e.g., the wind deflector250eis assembled to the trialing frame member42eand the third/fourth arms134e/136eof the first PV module20e) in a manner that does not impeded the desired, stacked arrangement in a kitted system.

The PV modules of the present disclosure provide a marked improvement over previous designs. The frame allows for simple, rapid, non-penetrating installation of a PV module array to a flat commercial rooftop, with the corresponding PV laminate desirably being arranged at a tilted orientation. Further, the unitary construction of the frame and PV device (and in particular the PV laminate) greatly reduces ordering, shipping, and handling steps and expenses in a manner not previously considered possible. In sum, the PV modules of the present disclosure address most, if not all, of the drawbacks associated with conventional non-penetrating, tilted PV solar tile installations, thereby enhancing market viability of this environmentally imperative energy technology.

Although the present disclosure has been described with reference to preferred embodiments, workers skilled in the art will recognize that changes can be made in form and detail without departing from the spirit and scope of the present disclosure. For example, while the frame has been described as including four of the arms, in other embodiments, a lesser or greater number can be provided. Along these same lines, while the various arms have been described as being formed as part of certain frame members (e.g., the side frame members), in other embodiments, one or more of the arms can project from (or be formed as part of) other(s) of the frame members.