Patent Description:
PV modules, which may comprise PV laminates and related electronics, are often supported by a frame assembly of one or more numerous components. These frame assemblies can be secured to PV modules, can serve to hold PV modules in place, and can serve to hold PV modules in relative position to each other. The frame assemblies can be secured to supports, which themselves hold the frame assemblies and PV modules of PV systems in place. The frame assemblies can also couple with underlying buildings, foundations, or other support structures of a PV system or portions of a PV system.

<CIT> discloses a photovoltaic laminate frame system according to the preamble of claim <NUM>.

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.

This specification includes references to "one embodiment" or "an embodiment. " The appearances of the phrases "in one embodiment" or "in an embodiment" do not necessarily refer to the same embodiment. Particular features, structures, or characteristics may be combined in any suitable manner consistent with this disclosure.

Terminology. The following paragraphs provide definitions and/or context for terms found in this disclosure (including the appended claims):.

In addition, certain terminology may also be used in the following description for the purpose of reference only, and thus are not intended to be limiting. For example, terms such as "upper", "lower", "above", and "below" refer to directions in the drawings to which reference is made. Terms such as "front", "back", "rear", "side", "outboard", and "inboard" describe the orientation and/or location of portions of the component within a consistent but arbitrary frame of reference which is made clear by reference to the text and the associated drawings describing the component under discussion. Such terminology may include the words specifically mentioned above, derivatives thereof, and words of similar import.

As used herein, the singular forms "a," "an" and "the" are intended to include plural forms as well, unless the context clearly indicates otherwise.

As used herein, the terms "about" or "approximately" in reference to a recited numeric value, including for example, whole numbers, fractions, and/or percentages, generally indicates that the recited numeric value encompasses a range of numerical values (e.g., +/- <NUM> % to <NUM>% of the recited value) that one of ordinary skill in the art would consider equivalent to the recited value (e.g., performing substantially the same function, acting in substantially the same way, and/or having substantially the same result). As used herein, the terms "about" or "approximately" in reference to a recited non-numeric parameter generally indicates that the recited non-numeric parameter encompasses a range of parameters that one of ordinary skill in the art would consider equivalent to the recited parameter (e.g., performing substantially the same function, acting in substantially the same way, and/or having substantially the same result).

In the following description, numerous specific details are set forth, such as specific operations, in order to provide a thorough understanding of embodiments of the present disclosure. It will be apparent to one skilled in the art that embodiments of the present disclosure may be practiced without these specific details. In other instances, well-known techniques are not described in detail in order to not unnecessarily obscure embodiments of the present disclosure.

The invention is directed towards a PV frame system. Examples, not part of the present invention, may comprise photovoltaic (PV) frames, methods of PV manufacture, articles of PV manufacture, and processes involving PVs. The frames employ a PV laminate receiver configured to receive one or more surface of a PV laminate and support that PV laminate upon installation of a PV system. The laminate receivers employ adhesive channels. These one or more channels may manage flow and/or seating of adhesive in the laminate receiver when a surface of a PV laminate is inserted into or is within a laminate receiver. In embodiments, the frames may employ stacking recesses and stacking protrusions along their length. The protrusions and recesses may be positioned and sized to allow for stacking of frames and, sometimes, self-centering stacking of frames in some embodiments. The frames and systems including these frames may comprise various materials including metal, metal alloys, ceramics, polymers, and combinations thereof.

The laminate receivers have an upper flange and a lower flange as well as one or more channels for adhesive flow. Laminate receivers comprise one or more laminate stops configured to align a laminate within the laminate receiver. A bead or multiple beads of adhesive, which is room temperature vulcanizing (RTV) silicone, are placed on or around a surface of the laminate receiver or the PV laminate or both, and the laminate and the laminate receiver may be brought together with the adhesive filling some or all gaps in between the two mating components. The laminate receiver includes one or more channels in which the adhesive may flow during assembly and/or until curing is complete. The laminate receiver also includes an alignment stop or stops that may be configured and serve to orient a portion of a laminate within the laminate receiver. These stops may be positioned, for example, at a back wall of a laminate receiver and may serve to prevent an edge of a laminate from fully contacting the back wall of the laminate receiver. The resulting space between the back wall and the edge of the laminate may serve as a flow channel for adhesive. Flow channels may also be formed on other areas of the laminate receiver, such as on an upper flange or a lower flange or both.

In embodiments, the flow channel may serve to create a passage in the back or side of the laminate receiver to allow RTV silicone or other RTV material or other adhesive to flow and wrap around the PV laminate more evenly. This may be suitable to provide that a sufficient amount of adhesive is present to resist uplift and downforce, loads from top clamps, and other loads. In embodiments, additional adhesive may be placed along a bottom flange of the laminate receiver as well.

In embodiments, flanges of a laminate receiver may be configured with additional features to manage adhesive flow in and around edges of a photovoltaic laminate being held in a laminate receiver. These features may also provide for reducing edge loading or pinpoint loading on PV laminate positioned in a laminate receiver. This reduced loading may serve to reduce PV laminate breakage. The configuration of the features may include grooves, dimples, coves, channels, protrusions, hooks, and flaps, among others.

The frame systems, which comprise the frames, may comprise various materials including metal, metal alloys, ceramic, polymers and combinations thereof. Thus, these frames and the other sections of the frame systems and components of embodiments may comprise various materials including metal, metal alloys, ceramic, polymers and combinations thereof.

The upper flange or other upper surface of a laminate receiver is sized to be only a portion of the size of a corresponding lower flange of the laminate receiver. For example, an upper flange may be nonexistent or may have a width of <NUM>, <NUM>, <NUM>, <NUM> or <NUM> or more or less, while a lower flange of a laminate receiver may have a width of <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM> or more or less. The width of the upper flange or other upper surface of a laminate receiver may be set depending upon an expected snow load, wind load, or other load that may place a normal force or rotational moment or other load on a PV laminate supported by a laminate receiver of a frame. Likewise, the width of the lower flange or other lower surface of a laminate receiver may be set depending upon an expected snow load, wind load, or other load that may place a normal force or rotational moment or other load on a PV laminate supported by a laminate receiver of a frame. In other words, a distributed load across a face of a laminate may cause rotational forces near or at the ends of a laminate that act to urge the laminate edges out of a laminate receiver of a supporting frame. Likewise, a distributed load across a face of a laminate may cause rotational forces near or at the middle, ends, or both of a laminate that act to urge the laminate edges out of a laminate receiver of a supporting frame. The width of the upper flange or other upper surface of a laminate receiver, the lower flange or other lower surface of a laminate receiver, or both, may be set depending on the expected strength of such forces, or based on other factors, or both. Minimizing the size of the upper flange can serve to provide greater exposed surface area for PV laminates in the laminate receiver and supported by the frame.

In some embodiments, the lower flange of the frame may be sloped and have one or more slopes or pitches along its width. This slope may serve to reduce edge loading concentrations on a PV laminate and thereby inhibit breakage of the PV laminate. In some embodiments, the laminate receiver may sit atop or otherwise be connected to a single wall frame section while in other embodiments, double wall, triple wall or other multiple wall configurations may be employed. The laminate receiver may be cantilevered over an exposed outer wall or may be aligned with one or more outer walls. The laminate receiver may have a triangular cross-section and may be connected to a portion of the wall. This connection may serve to transfer torque or other forces from the laminate receiver to a wall or other portion of a frame.

In embodiments, the frames may be configured with one or more beveled surfaces or chamfered surfaces to provide for alignment during stacking. This stacking may occur during transport or other pre-assembly steps. Stacking protrusions and recesses of a frame may serve to self-center frames stacked atop one another or otherwise placed together. Alignment surfaces may be grooved, and the grooves may provide friction as well as tactile signals beneficial while stacking the frames. This self-centering feature may be created by beveled edges or other surfaces on different portions of the frame where these beveled or biased surfaces urge mating frame sections to self-center when mated. For example, a left-side bevel may be at - <NUM> ° and a right-side bevel may be + <NUM>°. These mirrored angels may then guide a mating piece towards a center location or other target mating location.

Frame inserts may be employed and may be coupled to insert spacings along exposed surfaces of the frame sections. The frame inserts may be configured to integrate with frame clamps, which can serve to secure the frames to sub-frame assemblies or a support structure.

Embodiments may include a photovoltaic (PV) laminate double-wall support frame comprising two upright walls spaced apart from each other and each wall having a length; an upper connector connecting upper sections of the two upright walls to each other along the length of the walls; and a PV laminate receiver positioned above the upper connector, the laminate receiver having a top flange, a first PV laminate stop, and adhesive flow channel, the flow channel formed in an exposed inner surface of the laminate receiver, the top flange having a perimeter edge a majority of which does not extend beyond both upright walls. In embodiments, the support frame may have a wall that extends below the upper connector and connects to one of the two upright walls. In embodiments, the laminate receiver may have sides that form a triangle when the laminate receiver is viewed in cross-section and/or the exposed inner surface may be an upright side of the laminate receiver. In embodiments, a lower connector may be employed with the lower connector connecting lower sections of the two upright walls to each other along the length of the walls. Moreover, the lower connector may have a flange, the flange extending beyond an outer surface of an upright wall, the flange may have a lower perimeter surface, the lower perimeter surface having a chamfer along a length of the lower perimeter surface. Still further in embodiments, the two upright walls may have different heights, and/or the perimeter edge of the laminate receiver may not extend beyond either upright wall.

In embodiments, a top flange of the laminate receiver may have a plurality of exposed groves along a top surface of the top flange, the grooves oriented lengthwise along the top flange. And in embodiments, a top flange may have a triangular cross section.

In embodiments, a support frame may comprise a second PV laminate stop. Moreover, a first PV laminate stop and a second PV laminate stop may be positioned opposite each other and may be positioned on one or more accessible internal surface of the laminate receiver. The PV laminate receiver may also have a beveled top surface.

Examples, not part of the present invention, may also comprise a photovoltaic (PV) laminate frame system comprising a PV laminate having a plurality of external edges and a plurality of PV cells; adhesive; and a plurality PV frame sections, wherein at least one of the frames of the plurality comprises: a PV laminate receiver, the PV laminate receiver having an upper surface, a lower surface spaced apart from upper surface, a connecting surface connecting the upper surface to the lower surface, and a laminate stop. In embodiments, a portion of the PV laminate may be positioned within laminate receiver. In embodiments, the laminate stop may inhibit movement of the PV laminate towards at least one internal surface of the laminate receiver. In embodiments, a width of the upper surface along the upper surface length may be no more than approximately one-third of the width of the lower surface along a majority of the lower surface length. In embodiments, adhesive may be a room temperature vulcanizing (RTV) material. In embodiments, at least a laminate receiver of one of the frames of the plurality may also comprise a flow channel for the adhesive, the flow channel positioned away from an external edge of the PV laminate when the PV laminate is seated in the laminate receiver.

In embodiments, each of the frame sections of the plurality of frame sections may comprise a double-wall channel and a chamfered edge along an external surface of the double-wall channel.

In embodiments, an upper surface of the laminate receiver may have a grooved exposed surface, the grooved exposed surface having a triangular cross-section along at least a portion of its length.

The invention includes a photovoltaic (PV) laminate frame system comprising a first PV laminate having a peripheral surface and a plurality of PV cells; a room temperature vulcanizing silicone; and an elongated PV frame section comprising: a PV laminate receiver, the receiver having an upper surface, a lower surface spaced apart from the upper surface, a connecting surface connecting the upper surface to the lower surface, a flow channel exposed to permit flow of the silicone in the channel, and a laminate stop, the laminate stop integral with the PV laminate receiver. A portion of the PV laminate is positioned within the laminate receiver, wherein the laminate stop inhibits movement of the PV laminate towards at least one internal surface of the laminate receiver. A width of the upper surface along the upper surface length may be no more than one-half of the width of the lower surface along a majority of the lower surface length, and at least facing surfaces of the lower surface and the upper surface may not be parallel.

In embodiments, the elongated PV frame section may comprise a metal alloy, metal, ceramic, polymer and combinations thereof. In embodiments, the flow channel may be positioned away from the peripheral surface of the first PV laminate when the PV laminate is seated in the laminate receiver. In embodiments, the frame section may comprise a double-wall channel and a chamfered edge along an external surface of the double-wall channel and/or the upper surface of the laminate receiver may have a grooved exposed surface, the grooved exposed surface having a triangular cross-section along at least a portion of its length.

In embodiments, a clamping or securement force exerted by the frame onto the PV laminate may be adjusted through changes in the upper flange, the lower flange, the amount of RTV silicone or other adhesive, as well as other adjustments in the designs and systems taught herein. Design criteria may consider reduction in clamping force on the PV laminate through one or more of these design adjustments as well as a potential uplift failure resulting from adhesive pullout if the adhesive coverage changes or is designed away.

Embodiments may provide compatibility with a variety of frame anchor clamp geometries and may provide suitable surface area for the clamp to sit on and may include: (<NUM>) allowing frame anchor clamp laminate receiver to be used between adjacent laminates with an adapter, (<NUM>) allowing use of an adapter to locally increase the surface area of flanges of the laminate receiver, (<NUM>) increasing surface area of PV laminate interface to extending beyond an outer web wall, and/or (<NUM>) adjusting the size of the laminate receiver to suit or maximize power/efficiency requirements.

Preferred embodiments may provide for PV laminate penetration depth of approximately <NUM> or more into the laminate receiver. A <NUM> or more penetration depth of the laminate receiver may accommodate a web/wall thickness of approximately <NUM> in embodiments.

As described above, a built-in stacking feature(s) may be provided and may serve to reduce or eliminate supplemental plastic corner pieces. In embodiments, the stacking angle may be a function of the largest volume of material to be removed without impacting the functionality of the frame clamp or making the frame section un-extrudable.

<FIG> illustrate cross-sectional views of a frame section with laminate receiver <NUM> and adhesive flow channel <NUM> before <NUM> and after <NUM> insertion of a PV laminate <NUM> into the laminate receiver <NUM>, as may be employed, according to some embodiments. Labelled in <FIG> are triangular cross-section <NUM>, overhang width <NUM> of triangular cross-section <NUM>, overhang <NUM> of triangular cross-section <NUM>, laminate stops <NUM>, adhesive flow channel <NUM>, RTV silicone bead / adhesive <NUM>, flange end <NUM>, corner support <NUM>, lower flange <NUM>, web/wall <NUM>, lower flange <NUM>, frame cross-section <NUM>, bottom flange with upturned end <NUM>, bottom flange <NUM>, spread RTV silicon adhesive <NUM>, spread RTV silicone adhesive <NUM>, upper flange <NUM>, alignment/stacking recess <NUM>, and alignment/stacking protrusion <NUM>. The laminate receiver <NUM> is shown with an upper flange <NUM>, adhesive flow channel <NUM>, and lower flange <NUM> defining an area into which a surface of a PV laminate <NUM> may be inserted. The laminate channel has a smaller upper flange than a lower flange and a wall of the receiving channel may have a triangular cross-section <NUM>. The overhang <NUM> of the triangular cross-section <NUM> may extend beyond a web/wall <NUM> of a frame and may be sized and configured to add rigidity to the laminate receiver <NUM>.

As the PV laminate <NUM> is inserted into the laminate receiver, a bead <NUM> of adhesive may be compressed and may flow around the laminate and into and through the channel <NUM> of the laminate receiver <NUM>. The spread location is shown at <NUM> and <NUM> of <FIG>. After setting the adhesive the PV laminate may now be considered secure in the frame and may be secured in a PV system installation.

<FIG> illustrate cross-sectional views of frame sections with laminate receiver and one or more adhesive channels, as may be employed, according to some embodiments. Labelled in <FIG> are truncated upper flange <NUM>, extended upper flange <NUM>, laminate receiver <NUM>, adhesive flow channel <NUM>, flange end <NUM>, corner support <NUM>, web/wall <NUM>, bottom flange with upturned end <NUM>, and dimensions <NUM>-<NUM>. Truncated upper flanges <NUM> may be employed instead of extended upper flanges <NUM> in embodiments. By limiting the size of the upper flange, additional light may reach the PV laminate when installed. Adhesive flow channels may be present in various surfaces of the laminate receiver. For example, an inner surface of the truncated upper flange <NUM> includes such a channel, as is shown in <FIG>. <FIG> show how adhesive flow channels may be present on upper and back surfaces of a laminate receiver in embodiments. Also shown in <FIG> is laminate stop <NUM>.

<FIG> illustrate cross-sectional views of frame sections with a laminate receiver and one or more adhesive channels as may be employed, according to some embodiments. Labelled in <FIG> are RTV silicone bead/adhesive <NUM>, upper flange <NUM>, lower flange end <NUM>, bottom flange with upturned end <NUM>, laminate receiver <NUM>, squeezed RTV silicone / adhesive <NUM>, squeezed RTV silicone / adhesive <NUM>, adhesive channels <NUM>, adhesive channels <NUM>, PV laminate <NUM>, and squeezed RTV silicone adhesive <NUM>. <FIG> and <FIG> show expected location of squeezed adhesive or silicone. As can be seen here, the outward surfaces of the adhesive contours to surfaces of the laminate receiver <NUM> and the surfaces of the PV laminate <NUM>. As the adhesive is reconfigured during assembly from bead form <NUM> to its final squeezed form <NUM>, <NUM>, and <NUM>, the adhesive may flow via the channels <NUM> or <NUM> or other adhesive flow channels of embodiments. In addition to allowing for adhesive flow, the flow channels may also allow for increased surface area adhesion, thereby providing for additional grip of PV laminate held in the laminate receiver <NUM>. As can be seen at <NUM>, the adhesive may not squeeze out past the top flange <NUM>. The amount of adhesive employed may be managed so as to limit or eliminate squeeze out while at the same time proving for sufficient adhesion for anticipated loads. An advantage of managing adhesive or adhesive flow in this manner may be that adhesive does not reach the exposed surface of the PV laminate, thereby providing maximum solar exposure to PV cells of the PV laminate.

<FIG> illustrate cross-sectional views of frame sections with a laminate receiver and one or more adhesive flow channels, as may be employed, according to some embodiments. Labelled in one or more of <FIG> are laminate receiver <NUM>, adhesive flow channel <NUM>, three pitches (grades) on laminate receiver lower surface <NUM>, <NUM>, and <NUM>, web/wall <NUM>, reinforced corner <NUM>, outer border alignment <NUM>, different wall thickness <NUM>, reinforced corner <NUM>, corner support <NUM>, bent end <NUM>, hooked flange end <NUM>, chamfered flange end <NUM>, upper flange bent end <NUM>, adhesive flow channel <NUM>, upper flange flapper end <NUM>, adhesive flow channel407, support connector <NUM>, and hooked flange end <NUM>. Various configurations of the upper flange end (bent, hooked, flapper, etc.) may be employed in embodiments to control adhesive/adhesive flow in and around the edge of a PV laminate. By creating a tight seal between the laminate receiver and the PV laminate, errant adhesive/adhesive flow can be minimized in some embodiments.

As can be seen in <FIG> and <FIG>, the channels <NUM> may have different shapes and may have various locations. Here, in <FIG>, there are two rectangular channels located close to the back wall along the bottom flange. While in <FIG>, there are six semi-circular channels located on the bottom flange along most of its width. The upper flange in <FIG> and <FIG> show still different figurations for flow channels with <FIG> showing a flat recess while <FIG> shows a flapper configuration with a recessed cylindrical void <NUM>.

<FIG> illustrate cross-sectional views of frame sections receiving PV laminates with different edge details in a laminate receiver, as may be employed, according to some embodiments. Labelled in one or more of <FIG> are laminate receiver <NUM>, PV laminate <NUM>, PV laminate end with single chamfer <NUM>, PV laminate end with double chamfer <NUM>, and PV laminate end with bullnose <NUM>. As can be seen in these figures, the flat surface of the PV laminate is in contact with the upper flange <NUM> and forms a seal <NUM> between the two components. Extra adhesive may flow out along the bottom surface of the PV laminate but may be retarded from flowing along an exposed top surface of the PV laminate by the seal <NUM> between the upper flange <NUM> and the PV laminate <NUM>.

<FIG> illustrate cross-sectional views of frame sections with alignment/stacking protrusions and alignment/stacking recesses, as may be employed, according to some embodiments. The stacking protrusions and stacking recesses of embodiments may be located on outside or exposed surfaces of the frames. These protrusions and recesses may run along the length of the frames and may be continuous along the length, or may be located at intervals along the length with breaks between them. The recesses and protrusions may serve to align, self-center, or both, frames positioned atop one another. The protrusions and recesses may be located near or at outer perimeter locations of the frames. Labelled in <FIG> are stacking protrusions <NUM>, expected PV laminate <NUM>, first frame <NUM>, second frame <NUM>, stacking recess <NUM>, expected stacking protrusion <NUM>, chamfered/beveled stacking protrusion with grooves <NUM>, laminate receiver <NUM>, flange <NUM>, web/wall <NUM>, stacked frame <NUM>, stacked frame <NUM>, stacked frame <NUM>, frame insert spacing <NUM>, direction of stacking <NUM>, and frame insert spacing <NUM>. The chamfered / beveled edges may be angled so as to provide self-centering bias when frames are stacked atop each other. In other words, a polygonal frame stacked atop another polygonal frame may find its center above each other because the angels of the protrusion <NUM> meeting the recess <NUM> causes the two frames to center between each other. The protrusions and recesses may be various shapes in embodiments. In preferred embodiments they can mimic the opposite of the shape of the recess or protrusion in the frame above or below so as to mate with the applicable recess or protrusion. Grooves or channels may also be present to enhance gripping and friction.

<FIG> illustrate cross-sectional views of frame sections coupled to a frame anchor clamp and further secured by a frame anchor insert as may be employed, according to some embodiments. The frame anchor clamp <NUM> of embodiments may serve to secure a PV frame and laminate to a support structure on a roof or elsewhere. The frame anchor inserts <NUM>, <NUM>, and <NUM> may serve to couple the frame and PV laminate to the anchor clamp <NUM>. The insert may have upper portions <NUM>, outside portions <NUM>, and inner portions <NUM>. These inner and upper portions may be configured to mate with and secure to a frame, while the outer portions may be configured to mate with and secure to a frame anchor clamp <NUM>.

Claim 1:
A photovoltaic laminate frame system comprising: a first PV laminate (<NUM>, <NUM>, <NUM>, <NUM>) having a peripheral surface and a plurality of PV cells; a room temperature vulcanizing silicone; and an elongated PV frame section comprising: a PV laminate receiver (<NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>), the PV laminate receiver (<NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>) having an upper surface having a length and a width, a lower surface having a length and a width, the lower surface spaced apart from the upper surface, a connecting surface connecting the upper surface to the lower surface, a first flow channel (<NUM>, <NUM>, <NUM>) exposed to permit flow of the room temperature vulcanizing silicone in the PV laminate receiver (<NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>), and a laminate stop (<NUM>, <NUM>), the laminate stop (<NUM>, <NUM>) integral with the PV laminate receiver (<NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>), wherein a portion of the first PV laminate (<NUM>, <NUM>, <NUM>, <NUM>) is positioned within the PV laminate receiver (<NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>), wherein the laminate stop (<NUM>, <NUM>) inhibits movement of the PV laminate (<NUM>, <NUM>, <NUM>, <NUM>) towards at least one internal surface of the PV laminate receiver (<NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>), wherein the photovoltaic laminate frame system is characterized in that a width of the upper surface along the upper surface length is no more than one-half of the width of the lower surface along a majority of the lower surface length, and wherein at least facing surfaces of the lower surface and the upper surface are not parallel.