Patent Publication Number: US-2018054157-A1

Title: Systems and methods for improved installation of photovoltaic assemblies

Description:
BACKGROUND 
     Solar power has long been viewed as an important 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 residential-, industrial- and commercial-type applications in which relatively significant amounts of solar energy can be collected and utilized in supplementing or satisfying power needs. One way of implementing solar energy collection technology is by assembling an array of multiple solar modules. 
     One type of solar energy system is a solar photovoltaic system. Solar photovoltaic systems (“photovoltaic systems”) can employ solar panels made of silicon or other materials (e.g., III-V cells such as GaAs) to convert sunlight into electricity. 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.) 
     A typical conventional PV module includes a PV laminate or panel having an assembly of crystalline or amorphous semiconductor devices (“PV cells” or “solar cells”) electrically interconnected and encapsulated within a weather-proof barrier. One or more electrical conductors are housed inside the PV laminate through which the solar-generated current is conducted. 
     Regardless of an exact construction of the PV laminate, most PV applications entail placing an array of solar modules at the installation site in a location where sunlight is readily present. This is especially true for residential, commercial or industrial applications in which multiple solar modules are desirable for generating substantial amounts of energy, with the rooftop of the structure providing a convenient surface at which the solar modules can be placed. 
     In some arrangements, solar modules are placed side-by-side in an array. Each solar module can be mounted to a support structure, such as a roof, by coupling the module to a mounting structure (e.g., a rail) by way of a coupling member (e.g., a clamp, clip, anchor or mount). It can be challenging to couple modules side-by-side because the array assembler typically engages the coupling member while also ensuring that adjacent modules are positioned properly on the mounting structure. Accordingly, there remains a continuing need for improved systems and methods for mounting solar modules to a support structure with minimal installation time and/or resources. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       The following drawings illustrate by way of example and not limitation. For the sake of brevity and clarity, every feature of a given structure is not always labeled in every figure in which that structure appears. Identical reference numbers do not necessarily indicate an identical structure. Rather, the same reference number may be used to indicate a similar feature or a feature with similar functionality, as may non-identical reference numbers. The figures are not drawn to scale. 
         FIG. 1  depicts a front side of a photovoltaic (PV) module, in accordance with an embodiment of the present disclosure; 
         FIG. 2  depicts a front side of a PV assembly, in accordance with an embodiment of the present disclosure; 
         FIG. 3  depicts a side view of PV assembly, in accordance with an embodiment of the present disclosure; 
         FIG. 4  depicts a magnified view of a spacing device, in accordance with an embodiment of the present disclosure; 
         FIG. 5  depicts a magnified view of a spacing device, in accordance with an embodiment of the present disclosure; 
         FIG. 6  depicts a side view of a PV assembly, in accordance with an embodiment of the present disclosure; 
         FIG. 7  depicts a side view of a PV assembly, in accordance with an embodiment of the present disclosure; 
         FIG. 8  depicts a perspective back side view of a PV assembly, in accordance with an embodiment of the present disclosure; 
         FIG. 9  depicts a flowchart listing operations in a method for assembling a PV array, in accordance with an embodiment of the present disclosure; 
     
    
    
     DETAILED DESCRIPTION 
     The following detailed description is merely illustrative in nature and is not intended to limit the embodiments of the subject matter of the application or uses of such embodiments. As used herein, the word “exemplary” means “serving as an example, instance, or illustration.” Any implementation described herein as exemplary is not necessarily to be construed as preferred or advantageous over other implementations. Furthermore, there is no intention to be bound by any expressed or implied theory presented in the preceding technical field, background, brief summary or the following detailed description. 
     Certain terminology may be used in the following description for the purpose of reference only, and thus are not intended to be limiting. For example, terms such as “upper”, “lower”, “above”, and “below” refer to directions in the drawings to which reference is made. Terms such as “front”, “back”, “rear”, “side”, “axial”, and “lateral” describe the orientation and/or location of portions of the component within a consistent but arbitrary frame of reference which is made clear by reference to the text and the associated drawings describing the component under discussion. Such terminology may include the words specifically mentioned above, derivatives thereof, and words of similar import. Similarly, the terms “first”, “second”, and other such numerical terms referring to structures do not imply a sequence or order unless clearly indicated by the context. 
     Terminology—The following paragraphs provide definitions and/or context for terms found in this disclosure (including the appended claims): 
     This specification includes references to “one embodiment” or “an embodiment.” The appearances of the phrases “in one embodiment” or “in an embodiment” do not necessarily refer to the same embodiment. Particular features, structures, or characteristics can be combined in any suitable manner consistent with this disclosure. 
     This term “comprising” is open-ended. As used in the appended claims, this term does not foreclose additional structure or steps. 
     Various units or components may be described or claimed as “configured to” perform a task or tasks. In such contexts, “configured to” is used to connote structure by indicating that the units/components include structure that performs those task or tasks during operation. As such, the unit/component can be said to be configured to perform the task even when the specified unit/component is not currently operational (e.g., is not on/active). Reciting that a unit/circuit/component is “configured to” perform one or more tasks is expressly intended not to invoke 35 U.S.C. §112, sixth paragraph, for that unit/component. 
     As used herein, the terms “first,” “second,” etc. are used as labels for nouns that they precede, and do not imply any type of ordering (e.g., spatial, temporal, logical, etc.). For example, reference to a “first” encapsulant layer does not necessarily imply that this encapsulant layer is the first encapsulant layer in a sequence; instead the term “first” is used to differentiate this encapsulant from another encapsulant (e.g., a “second” encapsulant). 
     The terms “a” and “an” are defined as one or more unless this disclosure explicitly requires otherwise. 
     The following description refers to elements or nodes or features being “coupled” together. As used herein, unless expressly stated otherwise, “coupled” means that one element/node/feature is directly or indirectly joined to (or directly or indirectly communicates with) another element/node/feature, and not necessarily mechanically. 
     As used herein, “inhibit” is used to describe a reducing or minimizing effect. When a component or feature is described as inhibiting an action, motion, or condition it may completely prevent the result or outcome or future state completely. Additionally, “inhibit” can also refer to a reduction or lessening of the outcome, performance, and/or effect which might otherwise occur. Accordingly, when a component, element, or feature is referred to as inhibiting a result or state, it need not completely prevent or eliminate the result or state. 
     As used herein, the term “substantially” is defined as largely but not necessarily wholly what is specified (and includes what is specified; e.g., substantially 90 degrees includes 90 degrees and substantially parallel includes parallel), as understood by a person of ordinary skill in the art. In any disclosed embodiment, the terms “substantially,” “approximately,” and “about” may be substituted with “within [a percentage] of” what is specified, where the percentage includes 0.1, 1, 5, and 10 percent. 
     In the following description, numerous specific details are set forth, such as specific operations, in order to provide a thorough understanding of embodiments of the present disclosure. It will be apparent to one skilled in the art that embodiments of the present disclosure may be practiced without these specific details. In other instances, well-known techniques are not described in detail in order to not unnecessarily obscure embodiments of the present invention. The feature or features of one embodiment can be applied to other embodiments, even though not described or illustrated, unless expressly prohibited by this disclosure or the nature of the embodiments. 
     Various embodiments disclosed herein relate to mounting an array of solar modules to a support structure, such as a roof. For example, a mounting structure, such as a rail, can be attached to the roof or other support structure by way of one or more roof anchors. Solar modules can be positioned atop the rails adjacent to one another and can be coupled to the rails by way of a coupling member, such as a clamp assembly. When installing solar modules to form a PV array, an assembler may encounter various challenges. For example, the assembler may attempt to bring two adjacent rows of solar modules into alignment, while simultaneously clamping one or more solar modules to the rails. In many circumstances, it can be challenging to align adjacent rows of an array, for example if the rows do not share a common rail. Accordingly, various embodiments disclosed herein are configured to assist an assembler in constructing an array. For example, in some embodiments, a spacing device is provided to aid in alignment of rows and or columns of a photovoltaic (PV) array to enable minimal installation times and resources. 
     Improved PV assemblies for converting solar radiation to electrical energy and methods of installation thereof are disclosed herein. PV arrays comprising a plurality PV modules are also described herein. A PV assembly can comprise at least one PV module having a front side and a back side opposite the front side. A PV module can comprise a plurality of solar cells encapsulated within a PV laminate. In some embodiments, a PV module includes a frame at least partially surrounding the PV laminate. In such embodiments, frame can comprise an outer surface feature. The PV assembly can further comprise at least one spacing device positioned between adjacent PV modules. A spacing device can comprise a spacer body having a predetermined width for defining a predetermined distance or gap between adjacent PV modules. As one example, adjacent modules or rows may share a common mounting structure or rail. In various embodiments, the spacing device can comprise at least one engagement feature for engaging at least one PV module. The spacing device can also comprise an abutting feature or portion for resting against or contacting at least one PV module. 
       FIG. 1  illustrates a top-down view of a module  100  having a front side  102  that faces the sun to collect solar radiation during normal operation and a back side  104  opposite the front side  102 . The module  100  comprises a laminate  106  encapsulating a plurality of solar cells  108 . In some embodiments, the module  100  can be ‘frameless.’ However, in other embodiments, module  100  comprises a support member or frame  120  surrounding the laminate  106 , such as depicted in  FIG. 1 . The frame  120  can be formed of a metal (e.g. aluminum) material, a polymeric material, or a combination thereof. In other embodiments, a support member or frame can partially surround the laminate. In some embodiments, the frame  120  can be integrally formed or formed as a unitary body. In other embodiments, the frame  120  can be formed from an assembly of parts. 
     The solar cells  108  can face the front side  102  and be arranged into a plurality of solar cell strings  109 . The laminate  106  can include one or more encapsulating layers which surround and enclose the solar cells  108 . In various embodiments, the laminate  106  comprises a top cover  103  made of glass or another transparent material on the front side  102 . In certain embodiments, the material chosen for construction of the cover  103  can be selected for properties which minimize reflection, thereby permitting the maximum amount of sunlight to reach the solar cells  108 . The top cover  103  can provide structural rigidity to the laminate  106 . The laminate  106  can further comprise a backsheet  105  on the back side  104 . The backsheet  105  can be a weatherproof and electrically insulating layer which protects the underside of the laminate  106 . The backsheet  105  can be a polymer sheet, and it can be laminated to encapsulant layer(s) of the laminate  106 , or it can be integral with one of the layers of the encapsulant. 
       FIG. 2  illustrates a top-down view of a photovoltaic assembly  101  comprising a plurality of modules  100  (individual modules depicted as  100 ,  100 ′,  100 ″) arranged into a photovoltaic array  101 . Each module  100  has a front side  102  that faces the sun during normal operation and a laminate  106  comprising a plurality of solar cells  108 . The photovoltaic array  101  can be configured in a “portrait” orientation as depicted in  FIG. 2 . However in other embodiments, modules can be arranged in a “landscape” orientation. Six PV modules  100  are depicted in the example of  FIG. 2 , however any desirable number of modules can be provided in any desirable configuration to form a PV array. 
     The PV assembly of  FIG. 2  comprises a plurality of PV modules  100  arranged into a plurality of rows of PV array  101 . For ease of description, three PV modules  100  are arranged into a first row  112  and three PV modules  100  are arranged into a second row  114 . In one embodiment, the first and second rows  112 / 114  are adjacent such as depicted in  FIG. 2 . The first row  112  and the second row  114  are separated by a predetermined distance or gap G. The PV assembly of  FIG. 2  comprises a plurality of spacing devices  130  positioned between PV modules of adjacent rows  112 / 114  of PV array  101 . The plurality of spacing devices  130  are located in or set the gap G between adjacent rows  112 / 114 . In the exemplary embodiment depicted in  FIG. 2 , two spacing devices  130  are provided between adjacent modules in adjacent rows (e.g. two spacing devices between module  100  of row  112  and module  100 ″ of row  114 ). However, any desirable number of spacing device can be provided in any desirable arrangement. For example, one spacing device can be provided between adjacent modules. In various embodiments, one or more spacing devices can be provided between adjacent rows of a PV array, adjacent columns of a PV array, or a combination thereof. 
       FIG. 3  depicts a side view of PV assembly  101  comprising module  100  of row  112 , module  100 ″ of row  114  and spacing device  130  therebetween. The cross sectional view of module  100  in  FIG. 3  shows frame  120  surrounding the laminate  106  to define an outer edge  122  of PV module  100 . The frame  120  comprises an upper portion  126  comprising a laminate-receiving channel  124 . The upper portion  126  of frame  120  further comprises an upper surface feature, flange or lip  127  at outer edge  122 . Furthermore, the frame  120  comprises a lower base portion  128  comprising a lower surface feature, flange or lip  129  at outer edge  122  of PV module  100 . In the embodiment depicted in  FIG. 3 , the upper and lower surface features  127 / 129  of frame  120  comprise longitudinally extending ridges, however any desirable surface feature on the frame can be provided. For example, the frame can comprise flanges, lips, ridges, recesses, projections, sinusoidal cross sections, saw-tooth cross sections, substantially planar surfaces, combinations thereof, or derivatives thereof. 
     In an embodiment, the spacing device  130  comprises a spacer body  132  having a predetermined width W so as to set or define a predetermined distance or gap G between adjacent PV modules  100 / 100 ″. In some embodiments, spacing devices can comprise at least one engagement feature for engaging one or more outer surface features of a PV module so as to fixedly connect the spacing device to the PV module. For example, spacing device  130  comprises an upper arm  136  comprising an upper engagement feature  137  for engaging the upper surface feature  127  of frame  120 . The spacing device  130  further comprises a lower arm  138  comprising a lower engagement feature  139  for engaging the lower surface feature  129  of frame  120 . In some embodiments, the PV module can be frameless and a spacing device can comprise one or more engagement features for engaging any desirable feature of the PV module (e.g. the laminate  106 ). 
     In an embodiment, body  132  of spacing device  130  can comprise a compressible feature such that upon contact or engagement of the spacing device  130  with the module  100 , the spacing device is fixedly connected to the module. In one embodiment, the compressible feature can be integrally formed with the spacing device such that the spacing device is molded as a single component. In other embodiments, the compressible feature can be formed separately from the spacing device and then subsequently coupled to the spacing device. Non-limiting examples of the compressible feature include a compressible polymer material, a metallic wire, a spring tensioned structure, a sinusoidal shaped structure, a W-shaped structure, a U-shaped structure, an S-shaped structure, an X-shaped structure, a spiral structure, a coil, a spring, or a combination thereof. 
     In an embodiment, a spacing device can comprise one or more abutting portions for contacting an outer edge of a PV module so as to set or maintain a gap between modules during installation. As depicted in  FIG. 3 , spacing device  130  comprises an abutting portion  134  for contacting outer edge  122 ′ of PV module  100 ′. In the non-limiting example of  FIG. 3 , spacing device  130  comprises two engagement features  137 / 139  for engaging a first module  100  in a first row  112  of array  101  and one abutting portion  134  for contacting in a second module  100 ′ in a second row  114  of array  101 . In various embodiments, a spacing device can comprise one or more engagement features for engaging one or more PV modules of an array. Furthermore, in some embodiments, a spacing device can comprise one or more abutting features for contacting or butting against one or more PV modules of an array. 
       FIG. 4  depicts a magnified view of spacing device  130 . The spacing device  130  comprises an upper arm  136 , a lower arm  138  and a body  132  therebetween. As shown, the upper and lower engagement features  137 / 139  of the upper and lower arms  136 / 138  comprise recesses  146 / 148  sized to fit upper and lower surface features  127 / 129  of frame  120 . 
     In an embodiment, the body  132  of the spacing device is bent or curved such as depicted in  FIG. 4 . In other embodiments, the body of the spacing device can be substantially linear. The shape or structure of the body of the spacing device can be provided in any desirable structure or form. For example, the body of the spacing device can comprise a structure selected from the group of an incurvate structure, a serpentine structure, a bowed structure, a W-shaped structure, a U-shaped structure, an S-shaped structure, an X-shaped structure, a spiral structure, a coil, a spring, or a combination thereof. 
     In an embodiment, the spacing device comprises a polymeric material. For example, spacing devices can comprise materials selected from the group of: polyethylene (PE), polypropylene (PP), polystyrene (PS), polyphenylene oxide (PPO), polyvinyl chloride (PVC), polyetherether ketone (PEEK), polyamides, polycarbonates, acetal resins, acrylonitrile butadiene styrene (ABS) resins, their derivatives or combinations thereof. In one embodiment, a spacing device comprises a thermosetting polymer. In some embodiments, a spacing device comprises a thermoplastic material. Extrusion and/or injection molding manufacturing processes can be employed for production of the spacing device. 
     In one embodiment, spacing device comprises metallic elements and/or other flexible materials. For example, a spacing device can comprise a metal wire or stamped metal piece. In another embodiment, a spacing device can comprise a composite material. In yet another embodiment, the spacing device can comprise a metallic wire embedded within a polymeric and/or thermoplastic material. 
     In various embodiments, the body of the spacing device  130  forms a cavity  140  such as depicted in  FIG. 4 . In one embodiment, the spacing device can comprise one or more features within or extending into the cavity, for example to provide structural support to the spacing device or for wire or cable management. As depicted in  FIG. 4 , the spacing device  130  comprises a plurality of protrusions  142  extending into the cavity  140  which can facilitate management of cables or wires associated with the PV assembly  101 . However in other embodiments, the body  132  of the spacing device  130  can be substantially smooth or planar throughout. 
       FIG. 1-4  illustrate various embodiments of PV assemblies and spacing devices. Unless otherwise specified below, the numerical indicators used to refer to components in the  FIG. 5-8  are similar to those used to refer to components or features in  FIG. 1-4  above, except that the index has been incremented by 100. 
     The body of the spacing device can comprise any desirable structure to set, establish or maintain a predetermined distance or gap between adjacent modules of a PV array during installation. In an embodiment, the body of the spacing device comprises a structure selected from the group of a linear structure, an incurvate structure, a serpentine structure, a bowed structure, a W-shaped structure, a U-shaped structure, an S-shaped structure, an X-shaped structure, a spiral structure, a coil, a spring, or any derivative or combination thereof. 
     In various embodiments, spacing devices comprise one or more features to provide structural support, to facilitate flexibility and/or to direct wires or cables associated with the array. In one embodiment, a spacing device comprises a crosspiece extending across a void or cavity of the spacing device. As an example,  FIG. 5  depicts a spacing device  230  curved to form a cavity  240 . The spacing device  230  further comprises a crosspiece  242  extending across cavity  240 . A crosspiece can provide structural support to the spacing device, restrict flexibility of the spacing device and/or direct wires or cables associated with the array. 
       FIG. 6  depicts a side view of PV assembly  201  comprising a first module  200  of a first row, a second module  200 ″ of a second row and spacing device  230  therebetween. In an embodiment, the first row of PV array  201  is adjacent to the second row of PV array  201 . As depicted in  FIG. 6 , the spacing device  230  comprises upper and lower engagement features  237 / 239  for engaging with upper and lower surface features  227 / 229  of frame  220  of module  200 . In other embodiments not depicted, a spacing device can further comprise one or more engagement features for engaging with at least one surface feature of frame  220 ″ of module  200 ″ in addition to one or more engagement features for engaging with at least one surface feature of frame  220  of module  200 . 
     In an embodiment, spacing devices comprise one or more features to engage and/or contact the module at any desirable location. In the example depicted in  FIG. 6 , the engagement features  237 / 239  of the spacing device  230  engage outer surface features  227 / 229  located at side edge  222  of frame  200 . In other embodiments, the spacing device can comprise one or more engagement and/or abutting features to engage or contact the module at a back side of the module.  FIG. 7  depicts a side view of PV assembly  301  comprising a first module  300  of a first row, a second module  300 ″ of a second row and spacing device  330  therebetween. The spacing device  330  comprises an upper arm  336  comprising upper engagement feature  337  for engaging upper surface feature  327  of frame  320 . The spacing device  330  further comprises a lower arm  338  comprising a lower engagement feature  339  for engaging lower surface feature  329  of frame  320 . The lower arm  338  of spacing device  330  extends to the back side  304  of module  200  as depicted in  FIG. 7  and  FIG. 8 . 
       FIG. 8  depicts a perspective back side view of PV assembly  301 . The cross sectional view of module  300  in  FIG. 8  shows frame  320  surrounding laminate  306 . The lower arm  338  of spacing device  330  comprises an engagement feature  352  for engaging an outer surface feature  350  located underneath or at the back side  304  of module  300 . In an embodiment, the arms  336 / 338  can comprise any desirable number or type of engagement features and/or abutting features to set or establish a predetermined distance or gap between adjacent modules of a PV array including but not limited to a hooking feature, an L-shaped feature, a recessed feature, a projecting feature, a substantially planar feature or a combination thereof. 
     Improved methods for installing a plurality of PV modules to form PV arrays are also described herein.  FIG. 9  depicts a flowchart  400  listing operations in a method for assembling a PV array comprising a plurality of PV modules, in accordance with an embodiment of the present disclosure. Referring to operation  402  of flowchart  400 , a method for assembling a PV array comprises arranging a first set of PV modules into a first row of an array. The method further comprises providing at least one spacing device at an outer edge of a first of the PV modules in the first row at operation  404 . In various embodiments wherein the spacing device comprises one or more engagement features, operation  404  can include engaging the spacing device with the PV module. Referring to operation  406  of flowchart  400 , a method for assembling a PV array comprises arranging a second set of PV modules into a second row adjacent to the first row. In an embodiment, arranging the second set of PV modules into the second row comprises contacting a second of the PV modules in the second set with an abutting portion of the spacing device such that a width of the spacing device sets a predetermined distance or gap between PV modules of the first and second rows. 
     The above specification and examples provide a complete description of the structure and use of illustrative embodiments. Although certain embodiments have been described above with a certain degree of particularity, or with reference to one or more individual embodiments, those skilled in the art could make numerous alterations to the disclosed embodiments without departing from the scope of this invention. As such, the various illustrative embodiments of the methods and systems are not intended to be limited to the particular forms disclosed. Rather, they include all modifications and alternatives falling within the scope of the claims, and embodiments other than the one shown can include some or all of the features of the depicted embodiment. For example, elements can be omitted or combined as a unitary structure, and/or connections can be substituted. Further, where appropriate, aspects of any of the examples described above can be combined with aspects of any of the other examples described to form further examples having comparable or different properties and/or functions, and addressing the same or different problems. Similarly, it will be understood that the benefits and advantages described above can relate to one embodiment or can relate to several embodiments. For example, embodiments of the present methods and systems can be practiced and/or implemented using different structural configurations, materials, and/or control manufacturing steps. The claims are not intended to include, and should not be interpreted to include, means-plus- or step-plus-function limitations, unless such a limitation is explicitly recited in a given claim using the phrase(s) “means for” or “step for,” respectively.