U.S. patent application number 13/480254 was filed with the patent office on 2013-01-10 for integrated photovoltaic rooftop modules.
This patent application is currently assigned to SOLON CORPORATION. Invention is credited to Daniel S. ALCOMBRIGHT, David REGO, John W. RETHANS, Jerrod Quinton RODOWCA, Ben Michael STRINER.
Application Number | 20130008490 13/480254 |
Document ID | / |
Family ID | 47114401 |
Filed Date | 2013-01-10 |
United States Patent
Application |
20130008490 |
Kind Code |
A1 |
REGO; David ; et
al. |
January 10, 2013 |
INTEGRATED PHOTOVOLTAIC ROOFTOP MODULES
Abstract
Photovoltaic modules including a solar panel integrated with a
supporting frame, and which are configured to be installed on a
building rooftop. Modules according to the present teachings may be
at least partially pre-assembled, with a solar panel oriented at a
predetermined angle relative to the rooftop mounting surface of the
supporting frame.
Inventors: |
REGO; David; (Marana,
AZ) ; ALCOMBRIGHT; Daniel S.; (Tucson, AZ) ;
RODOWCA; Jerrod Quinton; (Tucson, AZ) ; STRINER; Ben
Michael; (Tucson, AZ) ; RETHANS; John W.; (San
Carlos, CA) |
Assignee: |
SOLON CORPORATION
Tucson
AZ
|
Family ID: |
47114401 |
Appl. No.: |
13/480254 |
Filed: |
May 24, 2012 |
Related U.S. Patent Documents
|
|
|
|
|
|
Application
Number |
Filing Date |
Patent Number |
|
|
61505463 |
Jul 7, 2011 |
|
|
|
61535593 |
Sep 16, 2011 |
|
|
|
61547589 |
Oct 14, 2011 |
|
|
|
61587454 |
Jan 17, 2012 |
|
|
|
Current U.S.
Class: |
136/251 ;
29/890.033 |
Current CPC
Class: |
F24S 25/11 20180501;
Y10T 29/49108 20150115; Y02B 10/12 20130101; H01L 31/05 20130101;
H02S 20/24 20141201; Y02B 10/20 20130101; H02S 40/36 20141201; F24S
25/16 20180501; Y02E 10/47 20130101; F24S 25/13 20180501; F24S
2025/02 20180501; Y10T 29/49355 20150115; Y02E 10/50 20130101; F24S
25/50 20180501; Y02B 10/10 20130101 |
Class at
Publication: |
136/251 ;
29/890.033 |
International
Class: |
H01L 31/048 20060101
H01L031/048; H01L 31/18 20060101 H01L031/18 |
Claims
1. A photovoltaic module, comprising: a first frame portion
defining a first plane and including: a. left and right side
members, each side member having a leading edge and a trailing
edge; and b. at least one cross member connecting the left and
right side members; a second frame portion defining a second plane
oriented at a nonzero angle relative to the first plane, the second
frame portion including left and right support members, each
support member connected to one of the side members and having an
upper surface lying substantially within the second plane; and a
photovoltaic panel supported by the frame and lying substantially
parallel to the second plane; wherein each leading edge is
configured to be connected to a leading edge of a laterally
adjacent module and a trailing edge of a longitudinally adjacent
module, and each trailing edge is configured to be connected to a
trailing edge of a laterally adjacent module and a leading edge of
a longitudinally adjacent module; and wherein the first and second
frame portions are constructed from a non-conductive, extruded
material.
2. The module of claim 1, wherein the first and second frame
portions are constructed from a wood plastic composite
material.
3. The module of claim 2, wherein the wood plastic composite
material includes a combination of reclaimed wood fibers and
thermoplastic polymer.
4. The module of claim 1, wherein the first and second frame
portions each include a plurality of frame members that are
connected together by heat welding.
5. (canceled)
6. The module of claim 1, wherein the left and right support
members are heat welded to the left and right side members,
respectively, and wherein a rear support member is heat welded to
the cross member.
7. The module of claim 1, wherein the second frame portion includes
a front cross member including a top surface lying substantially
within the second plane.
8. The module of claim 1, wherein the first and right side members
each include a leading edge connection aperture and a trailing edge
connection aperture, and wherein the connection apertures are
configured to receive a connection member for connecting the module
to an adjacent, substantially similar module.
9. (canceled)
10. A method of assembling a photovoltaic module, comprising:
forming a frame by heat welding a plurality of frame members
together to define a first plane and a second plane oriented at a
predetermined angle relative to the first plane; and attaching a
photovoltaic cell to the frame so that the cell is supported by the
frame and lies substantially parallel to the second plane; wherein
the frame members are formed from a non-conductive, extruded
material; wherein the frame includes a first frame portion defining
the first plane and including: a. left and right side members, each
side member having a leading edge and a trailing edge; and b. at
least one cross member connecting the left and right side members;
wherein the frame further includes a second frame portion defining
the second plane and including left and right support members, each
support member connected to one of the side members and having an
upper surface lying substantially within the second plane; and
wherein each leading edge is configured to be connected to a
leading edge of a laterally adjacent module and a trailing edge of
a longitudinally adjacent module, and each trailing edge is
configured to be connected to a trailing edge of a laterally
adjacent module and a leading edge of a longitudinally adjacent
module.
11. The method of claim 10, wherein the frame members are formed
from a wood plastic composite material.
12. The method of claim 10, wherein the at least one cross member
includes a front cross member and a rear cross member, and further
comprising orienting the front cross member so that its top surface
lies substantially within and helps to define the second plane.
13. The method of claim 10, wherein forming the frame consists
essentially of heat welding the frame members together.
14. The method of claim 10, further comprising attaching a rear
wind deflector to the frame, and disposing electrical connecting
wires within first and second apertures formed in the wind
deflector.
15. A method of assembling a photovoltaic module, comprising:
extruding an electrically substantially non-conductive material
into rails having a desired cross sectional profile; cutting the
rails into a plurality of frame members; attaching the frame
members to each other to form a frame; and attaching a photovoltaic
cell to the frame; wherein the frame defines a first plane and a
second plane oriented at a predetermined nonzero angle relative to
the first plane, and wherein attaching the cell to the frame
includes positioning the cell to be supported by the frame and to
lie substantially within the second plane; wherein the frame
includes a first frame portion defining the first plane and
including: a. left and right side members, each side member having
a leading edge and a trailing edge; and b. at least one cross
member connecting the left and right side members; wherein the
frame further includes a second frame portion defining the second
plane and including left and right support members, each support
member connected to one of the side members and having an upper
surface lying substantially within the second plane; and wherein
each leading edge is configured to be connected to a leading edge
of a laterally adjacent module and a trailing edge of a
longitudinally adjacent module, and each trailing edge is
configured to be connected to a trailing edge of a laterally
adjacent module and a leading edge of a longitudinally adjacent
module.
16. The method of claim 15, wherein the material is a wood plastic
composite material.
17. The method of claim 15, wherein attaching the frame members to
each other includes heat welding the frame members to each
other.
18. The method of claim 15, wherein attaching the frame members to
each other consists essentially of heat welding the frame members
to each other.
19. The method of claim 15, wherein the at least one cross member
includes a front cross member and a rear cross member.
20. (canceled)
21. The module of claim 8, wherein the connection apertures are
configured to receive a u-bolt assembly.
22. The module of claim 21, wherein the connection apertures are
configured to receive a u-bolt assembly including a u-bolt and a
connecting plate.
Description
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] The present application claims priority to the following
United States provisional patent applications: application No.
61/505,463 filed Jul. 7, 2011, application No. 61/535,593 filed
Sep. 16, 2011, application No. 61/547,589 filed Oct. 14, 2011, and
application No. 61/587,454 filed Jan. 17, 2012. These applications
are hereby incorporated by reference into the present disclosure
for all purposes.
INTRODUCTION
[0002] Solar, or photovoltaic (PV), panels have been used for
decades to create usable electrical power by harnessing the sun's
energy. PV panels are usually mounted in suitable locations for
maximum exposure to the sun. Frequently, these locations include
building rooftops, both industrial and residential. Accordingly,
various methods and devices have been developed for mounting PV
panels on the roofs of buildings.
[0003] The terms "solar panels," "photovoltaic panels," and "PV
panels," as used in this disclosure, include all types of
photovoltaic material suitable for mounting in a generally planar
orientation. For example, solar panels suitable for use with the
present teachings include those constructed from both thin-film
flexible PV material, such as material incorporating copper indium
gallium diselenide (CIGS) type semiconductors, and also panels
based on more rigid PV material such as crystalline silicon.
[0004] Solar panels are typically sold separately from the racks or
mounting structures used to install them on a building rooftop.
This situation often requires a user to acquire custom-built rack
mounting solutions with accompanying high installation costs.
One-size-fits-all rack mounting systems are available. However,
those systems tend to be complex, heavy, require multiple roof
penetrations, and employ metal construction requiring extensive
grounding. Existing systems also tend to require assembly by
skilled workers and/or the use of one or more tools. Exemplary
existing systems are described, for example, in U.S. Pat. Nos.
4,371,139, 5,228,924, 5,505,788, 5,746,839 (reissued as RE038988),
6,495,750, 6,501,013, 6,534,703, 6,570,084, 6,809,251, 6,809,253,
and 7,814,899, each of which is hereby incorporated by reference
into the present disclosure for all purposes.
[0005] Therefore, it is desirable to provide a rooftop PV mounting
system that is lightweight, easily transported, and easily
installed.
SUMMARY
[0006] The present teachings disclose improved PV modules and
assemblies of modules, including apparatus, methods of use, and
methods of manufacture. The disclosed assemblies generally include
a solar panel integrated with a supporting frame, and are
configured to be installed on a building rooftop. Modules according
to the present teachings may be at least partially pre-assembled,
with a solar panel oriented at a predetermined angle relative to
the rooftop mounting surface of the supporting frame.
BRIEF DESCRIPTION OF THE DRAWINGS
[0007] FIG. 1A is an isometric view of a photovoltaic module,
according to aspects of the present teachings.
[0008] FIG. 1B is an isometric view of a variation of the module of
FIG. 1A, in which a rear edge of a photovoltaic panel of the module
terminates to leave a gap between the panel and a rear wind
deflector of the module.
[0009] FIG. 1C is an isometric view of another variation of the
module of FIG. 1A, in which a top edge of a rear wind deflector of
the module terminates to leave a gap between the rear wind
deflector and a photovoltaic panel of the module.
[0010] FIG. 2 shows a frame portion of the module of FIG. 1.
[0011] FIG. 3 is a left side elevational view of the frame shown in
FIG. 2.
[0012] FIG. 4 is a top view of the frame shown in FIG. 2.
[0013] FIG. 5 is a semi-transparent, magnified sectional view of a
portion of the frame shown in FIG. 2.
[0014] FIG. 6 is a magnified left side elevational view of portions
of the frame shown in FIG. 2.
[0015] FIG. 7 is an isometric view showing an assembly of four
adjacent photovoltaic modules, according to aspects of the present
teachings.
[0016] FIG. 8 is a magnified view of a central portion of the
assembly of modules shown in FIG. 7, also showing a connection
member in the form of a strap that may be used to connect the
modules together.
[0017] FIG. 9 is a magnified view showing portions of two laterally
adjacent photovoltaic modules, including electrical connectors
protruding from wiring apertures in each module.
[0018] FIG. 10 shows the two laterally adjacent modules of FIG. 9,
where the electrical connectors have been pulled out of their
associated apertures, so that portions of their associated wires
are exposed.
[0019] FIG. 11 shows the two laterally adjacent modules of FIGS.
9-10, where the electrical connectors have been joined together to
form an electrical junction so that the modules are electrically
connected.
[0020] FIG. 12 shows the two laterally adjacent modules of FIGS.
9-11, where the electrical junction has been recessed within the
right-hand module.
[0021] FIG. 13 depicts a u-shaped connection member being used to
join together four photovoltaic modules, according to aspects of
the present teachings.
[0022] FIG. 14 depicts a hold-down mechanism in the form of a
z-shaped plate and associated hardware, according to aspects of the
present teachings.
[0023] FIG. 15 is an isometric view depicting another embodiment of
a photovoltaic module, according to aspects of the present
teachings.
[0024] FIG. 16 depicts the module of FIG. 15 in a collapsed
configuration.
[0025] FIG. 17 depicts a frame portion of the module of FIGS.
15-16.
[0026] FIG. 18 depicts an interconnection mechanism and the manner
in which it is configured to interconnect plural photovoltaic
modules of the type shown in FIGS. 15-17, according to aspects of
the present teachings.
[0027] FIG. 19 is an isometric view of yet another embodiment of a
photovoltaic module, according to aspects of the present
teachings.
[0028] FIG. 20 depicts a sectional view of the module of FIG.
19.
[0029] FIG. 21 is a flowchart depicting a method of installing an
assembly of photovoltaic modules on a substantially flat surface,
according to aspects of the present teachings.
[0030] FIG. 22 is a flowchart depicting another method of
installing an array of photovoltaic modules, according to aspects
of the present teachings.
[0031] FIG. 23 is a flowchart depicting yet another method of
installing an array of photovoltaic modules, according to aspects
of the present teachings.
[0032] FIG. 24 is a flowchart depicting still another method of
installing photovoltaic modules, according to aspects of the
present teachings.
[0033] FIG. 25 is a flowchart depicting a method of assembling a
photovoltaic module, according to aspects of the present
teachings.
[0034] FIG. 26 is a flowchart depicting another method of
assembling a photovoltaic module, according to aspects of the
present teachings.
DETAILED DESCRIPTION
[0035] The present teachings describe improved photovoltaic modules
and assemblies of modules, including apparatus, methods of use, and
methods of manufacture. The disclosed assemblies generally include
a solar panel integrated with a supporting frame, and are
configured to be installed on a building rooftop. Modules according
to the present teachings may be at least partially pre-assembled,
with a solar panel oriented at a predetermined angle relative to
the rooftop mounting surface of the supporting frame. Modules
according to the present teachings also may be connected together,
both mechanically and electrically, to form assemblies of
photovoltaic modules in an improved manner.
[0036] I. Modules and Assemblies of Modules
[0037] This section describes photovoltaic modules and assemblies
of multiple photovoltaic modules according to aspects of the
present teachings; see FIGS. 1A-20.
[0038] FIG. 1A is an isometric view depicting a photovoltaic
module, generally indicated at 10, according to aspects of the
present teachings. Module 10 includes a frame generally indicated
at 12, and a photovoltaic panel 14 mounted upon or otherwise
attached to the frame. As described previously, photovoltaic panel
14 is not limited to any particular type of photovoltaic material.
Nonexclusive examples of suitable materials for use in conjunction
with the present teachings include flexible, thin-film, CIGS-based
materials, and more rigid, crystalline silicon-based materials.
[0039] FIGS. 2-4 respectively depict an isometric view, a side
elevational view, and a top view of frame 12. As indicated
particularly in FIG. 3, frame 12 can be thought of as including a
first, lower frame portion generally indicated at 16, and a second,
upper frame portion generally indicated at 18. However, the
distinction between the first and second frame portions is made
only for convenience in describing frame 12 below in greater
detail. All of the various parts of frame 12, including the first
and second frame portions, will typically be joined together
securely, for example by heat welding.
[0040] Lower frame portion 16 includes left and right side members
20 and 22, a front cross member 24 connecting the left and right
side members, and a first rear cross member 26 also connecting the
left and right side members. A second rear cross member 28 and
several ballast support members 30a, 30b, 30c and 30d also may form
parts of lower frame portion 16. The bottom surface of lower frame
portion 16 defines a plane, so that when frame 12 is placed on a
substantially planar building rooftop or any other substantially
planar surface, the bottom surface of frame portion 16 will make
contact with the planar rooftop surface, providing stability to the
frame.
[0041] FIG. 5 depicts a magnified side sectional view of a portion
of frame 12, showing that front cross member 24 may be oriented at
an angle relative to the other parts of lower frame portion 16. In
this case, front cross member 24 may not help to form the bottom
surface of lower frame portion 16, but rather may have at least a
top surface 32 which is angled relative to the plane defined by the
bottom surface of lower frame portion 16. As will be described in
more detail below, front cross member 24 may be oriented in this
manner to help support photovoltaic panel 14.
[0042] In the embodiment depicted in FIGS. 1-5, upper frame portion
18 includes left and right support members 34 and 36, and rear
support members 38, 40 and 42. In the depicted embodiment, left and
right support members 34 and 36 are each connected to a respective
one of left and right side members 20 and 22, whereas rear support
members 38, 40 and 42 are each connected to rear cross member 26.
Other embodiments according to the present teachings may include a
greater or lesser number of support members, and in some cases may
include left and right support members but no rear support members,
or may include one or more rear support members but no left or
right support members.
[0043] In any case, the second or upper frame portion 18 defines a
second plane, which is oriented at a predetermined, nonzero angle
relative to the plane defined by the bottom surface of frame 12.
More specifically, each of left and right support members 34 and 36
includes an upper surface shown respectively at 44 and 46, lying
substantially within and thereby helping to define the second
plane. Similarly, each of rear support members 38, 40 and 42
includes an upper surface shown respectively at 48, 50 and 52, also
angled to lie substantially within and thereby helping to define
the second plane. These rear support members are configured to at
least partially support the photovoltaic panel disposed on top of
the frame.
[0044] As discussed previously and depicted in FIG. 5, front cross
member 24 may have a top surface 32 which is angled relative to the
plane defined by the bottom surface of lower frame portion 16. This
angle is chosen so that top surface 32 also lies within and helps
to define the second plane. Accordingly, photovoltaic panel 14 of
module 10 is supported by upper surface 32 of front cross member
24, upper surfaces 44 and 46 of the left and right support members,
and/or upper surfaces 48, 50 and 52 of the rear support members,
all of which lie within and define a common plane within which
photovoltaic panel 14 of module 10 is mounted. In other words,
photovoltaic panel 14 lies substantially within the second plane
defined by the second or upper frame portion.
[0045] While the preceding description refers to a single,
predetermined angle between the plane defined by the bottom of the
module frame and the plane defined by the top supporting surface of
the module frame (and thus between the rooftop or other supporting
surface and the photovoltaic panel), the present teachings are not
restricted to this possibility. Rather, referring to the plane
defined by the bottom of the frame as the "first plane" and the
plane defined by the top supporting surface of the frame as the
"second plane," in some cases the angle between the first plane and
the second plane may be predetermined to have a single value (as
shown in FIGS. 1-7), but in other cases (not shown) the angle
between the first plane and the second plane may be selectable
within a predetermined continuous range, and in still other cases
(also not shown) the angle between the first plane and the second
plane may be selectable within predetermined discrete values.
[0046] FIG. 6 is a magnified side elevational view depicting
portions of left side member 20 and left support member 34. As FIG.
6 depicts, the side members may include various connection
apertures configured to receive a connecting member for securely
attaching the module to an adjacent, substantially similar module.
Specifically, left side member 20 includes a leading edge 54, a
front aperture 56 disposed near the leading edge, a trailing edge
58, and a rear aperture 60 disposed near the trailing edge.
Similarly, as can be seen, for example, in FIG. 1A, right side
member 22 includes a leading edge 62, a front aperture 64 disposed
near the leading edge, a trailing edge 66, and a rear aperture 68
disposed near the trailing edge. Each leading edge is configured to
be connected to a leading edge of a laterally adjacent module and a
trailing edge of a longitudinally adjacent module, and each
trailing edge is configured to be connected to a trailing edge of a
laterally adjacent module and a leading edge of a longitudinally
adjacent module. The manner in which these edges and apertures may
be used to join two or more modules together mechanically, to form
a photovoltaic assembly, will now be described in more detail.
[0047] More specifically, the front and rear apertures of each side
member are configured to receive a connection member for securing
module 10 to an adjacent, substantially similar module. For
example, FIG. 7 depicts four adjacent modules 10a, 10b, 10c and
10d, each of which are substantially similar or identical to module
10 described previously. Accordingly, reference numbers followed by
"a," "b," "c" or "d" should be understood to represent components
of modules 10a, 10b, 10c or 10d which are substantially similar to
their counterparts in module 10.
[0048] Modules 10a, 10b, 10c and 10d are disposed adjacent to each
other. More specifically, module 10b is disposed laterally adjacent
to and longitudinally aligned with module 10a, module 10c is
disposed longitudinally adjacent to and laterally aligned with
module 10a, and module 10d is disposed laterally adjacent to and
longitudinally aligned with module 10c, and is therefore
longitudinally adjacent to and laterally aligned with module 10b.
As described in more detail below, the modules are joined together
at least at a central intersection region, generally indicated at
100.
[0049] FIG. 8 is a close-up view of intersection region 100,
showing a pair of connection members 102 in the form of
self-connecting straps that may be passed through adjacent
apertures of modules 10a, 10b, 10c and 10d. Although connection
member 102 is depicted as an adjustable strap, other types of
connection members are within the scope of the present teachings,
including other flexible and/or elastic connection members that may
be formed into closed loops, and also including more rigid,
multi-piece connection members that may be inserted through
apertures of adjacent modules and then fastened together to connect
the modules.
[0050] In FIG. 8, modules 10a, 10b, 10c and 10d are secured
together with a first connection member or strap 102 passing
through right rear aperture 68a of module 10a and left rear
aperture 60b of module 10b, which is laterally adjacent to right
rear aperture 68a of module 10a. A second connection member or
strap 102 passes through right front aperture 64c of module 10c,
which is longitudinally adjacent to right rear aperture 68a of
module 10a, and left front aperture 56d of module 10d, which is
laterally adjacent to right front aperture 64c of module 10c and
longitudinally adjacent to left rear aperture 60b of module
10b.
[0051] As depicted in FIG. 8, each strap 102 also passes through an
aperture 106 in a joining member 104 disposed on each side of
intersection region and spanning the leading and trailing edges of
the adjacent modules. The joining members are disposed adjacent to
the side members of the modules, with their apertures aligned with
the apertures of the side members. Straps 102 are then each formed
into a loop, for example by buckling their two ends together, and
tightened to connect the modules to each other securely.
[0052] In some cases, connecting members such as straps, rigid
connecting members and/or the like may be used to connect fewer
than four adjacent modules together. For example, referring again
to FIG. 7, a connecting member may pass through the trailing edge
connection aperture of the left side member of module 10a and the
leading edge connection aperture of the left side member of module
10c, and another connecting member may pass through the trailing
edge connection aperture of the right side member of module 10b and
the leading edge connection aperture of the right side member of
module 10d. In like manner, any number of laterally aligned and
longitudinally adjacent modules may be connected with connecting
members passing through the trailing edge connection apertures of
the front module, and the leading edge connection apertures of the
rear module.
[0053] Similarly, yet another connecting member may pass through
the leading edge connection apertures of the right side member of
module 10a and the left side member of module 10b, and still
another connecting member may pass through the trailing edge
connection apertures of the right side member of module 10c and the
left side member of module 10d. In like manner, any number of
longitudinally aligned and laterally adjacent modules may be
connected with a first connecting member passing through the
trailing edge connection apertures of the adjacent modules, and/or
a second connecting member passing through the leading edge
connection apertures of the adjacent modules. Furthermore, the
foregoing discussion should make it apparent that for the assembly
of four modules depicted in FIG. 7, as many as five separate
connecting members may be used to connect the adjacent modules into
a stable configuration. Greater or fewer numbers of connecting
members may be used in assemblies having different numbers of
modules.
[0054] Referring again to FIG. 8, trailing edge 66a of module 10a
is depicted as angled slightly backward (toward module 10a) from
top to bottom, and leading edge 62c of module 10c is depicted as
angled slightly forward (away from module 10c) from top to bottom.
Specifically, each leading edge defines a leading edge plane angled
at a non-perpendicular angle relative to the plane of the bottom
portions of the module frames, and each trailing edge defines a
trailing edge plane angled at 180 degrees minus the angle of the
leading edge plane relative to the first plane. Accordingly,
trailing edge 66a and leading edge 62c are configured to mate or
register together when module 10a and module 10c are placed
longitudinally adjacent to each other.
[0055] More generally, the leading edge of each side member may be
constructed with a shape complementary to a shape of the trailing
edge of each side member, so that each pair of modules will become
registered when the modules of the pair are placed longitudinally
adjacent to each other. Similarly, the lateral side portions of
left and right side members may be constructed with complementary
shapes (not shown), to facilitate positioning of laterally adjacent
modules.
[0056] As can be seen, for example, in FIG. 1A, module 10 of the
depicted embodiment also includes a rear wind deflector 70,
attached to rear cross member 26. The wind deflector depicted in
FIG. 1A is mounted substantially perpendicularly with respect to
the lower frame portion of the module and thus is disposed
substantially perpendicular to the plane of the lower frame portion
of the module. This substantially perpendicular configuration of
the wind deflector with respect to the first plane may improve
manufacturability, reduce quality related defects, and reduce cost
of assembly. In FIG. 1A, solar panel 14 extends rearward to meet
the top of wind deflector 70, without leaving any gaps between the
solar panel and the wind deflector. In other words, a rear edge of
the photovoltaic panel and a top edge of the wind deflector meet at
an acute angle in the embodiment of FIG. 1A.
[0057] In other embodiments, the rear edge of the photovoltaic
panel and the top edge of the wind deflector may not meet, but
rather a small gap may be formed between the rear edge of the panel
and the top edge of the deflector. For example, as depicted in FIG.
1B, the solar panel may be sized so that its rear edge terminates
before reaching the plane of the wind deflector. The module of FIG.
1B is otherwise substantially identical to the module of FIG. 1A,
and corresponding components are indicated with a primed reference
number. In the module depicted in FIG. 1B, however, a slightly
angled gap 75' (with no corresponding component in FIG. 1A) will be
formed between a rear edge of the photovoltaic panel and a top edge
of the wind deflector, where the gap lies in the plane of the
panel.
[0058] Similarly, as depicted in FIG. 1C, the solar panel may
extend back to meet the plane of the wind deflector, but the top
edge of the wind deflector may terminate before it meets the solar
panel. The module of FIG. 1C is otherwise substantially identical
to the modules of FIGS. 1A and 1B, and corresponding components are
indicated with a double primed reference number. In the module
depicted in FIG. 1C, however, a substantially vertical gap 75''
will be formed between the rear edge of the photovoltaic panel and
the top edge of the wind deflector. If both the wind deflector and
the solar panel terminate before reaching their line of
intersection, an angled gap will be formed between their terminal
edges. In any case, a gap between the rear edge of the photovoltaic
panel and the top edge of the wind deflector may act as a chimney
to vent hot air generated by the solar panel.
[0059] In still other embodiments, the wind deflector may be
mounted at an acute angle, with or without a gap formed between the
top of the deflector and the solar panel. Regardless of the size of
the solar panel or the orientation of the wind deflector, cut-outs
at the top of the wind deflector (not shown) also may facilitate a
chimney or venting effect.
[0060] As is also depicted, for example, in FIG. 1A and FIGS. 9-12,
wind deflector 70 includes a left wiring aperture 72 and a right
wiring aperture 74, each of which is configured to allow passage of
a wire for forming an electrical connection between module 10 and
an adjacent, substantially similar module. FIGS. 9-12 show an
electrical connection being made between two laterally adjacent
modules 10a and 10b. As described previously, modules 10a and 10b
are substantially similar or identical to module 10 described
previously. Accordingly, reference numbers followed by "a" or "b"
should be understood to represent components of modules 10a or 10b
which are substantially similar to their counterparts in module
10.
[0061] More specifically, FIG. 9 shows an electrical connector 76a
protruding from a right wiring aperture 74a of module 10a, and
another electrical connector 78b protruding from a left wiring
aperture 72b of module 10b. Connector 76a is shown as a "female"
connector and connector 78b is shown with a "male" connector, but
this choice is arbitrary and could be reversed. More generally,
many different types of electrical connectors may be used. The
configuration shown in FIG. 9, where only the electrical connectors
protrude from the wiring apertures, could represent one desirable
configuration for transporting modules 10a and 10b to a customer or
to an installation location.
[0062] FIG. 10 shows a configuration in which connectors 76a and
78b have been pulled out of their respective wiring apertures, so
that a portion of associated wires 80a and 82b have also been
pulled through the apertures. These wires would have been recessed
and stored inside modules 10a and 10b prior to being pulled through
the apertures. FIG. 11 shows a configuration in which an electrical
connection, such as a series connection or a parallel connection,
has been made between modules 10a and 10b, by joining together
connectors 76a and 78b to form an electrical junction, generally
indicated at 84. FIG. 12 shows a configuration in which connectors
76a and 78b, along with wire 82b, all have been recessed within
module 10b by passing them through wiring aperture 72b. This
represents one possible desirable configuration after modules 10a
and 10b have been installed on a surface such as a rooftop.
[0063] As can be seen, for example, in FIG. 11, wiring apertures
74a and 72b each include an upper portion 86a, 86b configured to
allow passage of a connecting wire and an electrical connector, and
a lower portion 88a, 88b configured to prevent passage of the
electrical connector. Furthermore, the lower portions of the wiring
apertures, but not the upper portions of the apertures, may be
configured to provide substantial friction to wires 80a and 82b, so
that the wires can only be moved easily when they are manually
moved upward and into the upper portions of the apertures. In other
words, the upper portion of each of the wiring apertures may be
configured to allow passage of a connecting wire substantially
without friction, and the lower portion of each of the wiring
apertures may be configured to hold the wire in place and to
prevent the wire from slipping without manual assistance.
[0064] The wiring arrangement allows quick interconnection in the
field, because either connector may be easily obtained by pulling
it up and out of its keyhole-shaped aperture. Furthermore, each of
the configurations depicted in FIGS. 9-12 may be a stable
configuration, in which connectors 76a, 78b and wires 80a, 82b are
unlikely to change positions without manual intervention.
[0065] FIG. 13 depicts intersection region 100 of modules 10a, 10b,
10c and 10d, where an alternative connection member in the form of
a u-shaped bolt (or "u-bolt") 102' is used to interconnect the
modules. U-bolt 102' is configured to span an intersection region
of two or more modules and is used in conjunction with a connecting
plate 104', which also spans the intersection region between two or
more modules. For example, as FIG. 13 depicts, u-shaped bolt 102'
is configured to fit within connecting plate 104', which spans an
intersection of first and second laterally aligned modules 10a and
10b with third and fourth modules 10c and 10d, which are
longitudinally adjacent to modules 10a and 10b.
[0066] A pair of notches including a distal notch 108' and a
proximal notch 110' is formed in each side or "leg" portion of the
u-bolt, to engage complementary apertures 106' in the connecting
plate. Thus, the leg portions of u-bolt 102' may be passed through
apertures 68a, 60b, 64c and 56d of modules 10a, 10b, 10c and 10d
respectively, and one of notches 108', 110' on each side of the
u-bolt may be engaged with apertures 106'. In some cases, a second
connecting plate 104' may be used on the other side of the
intersection region, in which case the distal connecting plate
(relative to the u-bolt) will engage outer or distal notches 108',
and the proximal connecting plate will engage inner or proximal
notches 110'.
[0067] When the u-bolt is used to interconnect exactly two
longitudinally adjacent and laterally aligned modules (not shown)
rather than four modules, such as at the left or right edges of an
assembly of modules, the connection member is configured to pass
through one of the front apertures of the first module and an
adjacent rear aperture of the second module. In that case,
relatively less of the leg portions of the u-bolt will be disposed
within the apertures of the module frame side members, and inner or
proximal notches 110' will typically engage apertures 106' of the
connecting plate. Furthermore, the u-bolt may be shaped so that its
two distal end portions are set slightly wider apart than apertures
106', so that a compressive force is needed to insert the u-bolt
into the connecting plate. Similarly, a compressive will then be
needed to remove the u-bolt from the connecting plate, resulting in
a secure connection between the u-bolt and the connecting
plate.
[0068] The frame portions of modules according to the present
teachings may be constructed at least in part from non-conductive,
extruded materials such as wood and/or wood plastic composite (WPC)
materials. A suitable material may include a combination of
reclaimed wood fibers and thermoplastic polymer. For example,
Fibrex.RTM. material manufactured by Andersen Corporation of
Bayport, Minn. may be particularly suitable. The use of WPC
materials may provide various advantages, such as lighter weight
and greater resistance to corrosion, and may avoid the necessity of
electrically grounding assemblies of the modules.
[0069] For similar reasons, module frame portions according to the
present teachings may be more generally constructed from
non-conductive, extruded materials. For example, typical plastic
materials that are used in extrusion include but are not limited
to: polyethylene (PE), polypropylene, acetal, acrylic, nylon
(polyamides), polystyrene, polyvinyl chloride (PVC), acrylonitrile
butadiene styrene (ABS) and polycarbonate. Such materials may be
extruded directly into module frame portions, coextruded in
multiple layers with additional materials (including nonconductive
materials such as wood filler), or mixed with additives to be
extruded as a compound. In any case, the extruded frame portions
may be relatively light weight and strong, and may not require
electrical grounding when assembled into one or more module
frames.
[0070] A frame may be assembled according to the present teachings,
for example, by heat welding a plurality of WPC frame members into
a frame structure configured to provide a flat base at the bottom
and an angled top mounting surface, as described previously. For
example, the frame members may include first and second side
members and a rear cross member that collectively define a first
(bottom) plane, and first and second side support members and a
rear support member that collectively define a second (mounting)
plane. In this case, the first and second side support members may
be heat welded to the first and second side members, respectively,
and the rear support member may be heat welded to the rear cross
member.
[0071] As described previously, according to the present teachings
a module frame may include a front cross member including a top
surface lying substantially within the second or mounting plane, to
facilitate mounting of a photovoltaic panel. A laminated PV sheet
may be bonded to the top of the mounting surface to create an
integrated module, for example using a suitable adhesive. A wind
deflector according to the present teachings may be constructed,
for example, from ABS plastic or some other suitable, non-corrosive
material. Extruded, non-conductive frame members also may include
other desirable mounting features. For example, the first and
second side members each may include a leading edge connection
aperture and a trailing edge connection aperture, where the
connection apertures are configured to receive a connection member
for connecting the module to an adjacent, substantially similar
module.
[0072] Should modules according to the present teachings need to be
secured to the surface of a roof or other structure, pavers or
other ballast may be disposed on a flat section of the frame
structure defined by ballast support members 30a, 30b, 30c and 30d
extending rearward from the wind deflector. For instance, ballast
pavers (not shown) may be configured to be supported by the ballast
support members of the frame and to fit securely within the spaces
between the ballast support members.
[0073] In some cases, rooftop-penetrating hold-down mounts also may
be used to attach the modules to a roof or to another surface such
as the ground. For example, FIG. 14 depicts a hold-down mechanism,
generally indicated at 150, configured to secure photovoltaic
modules to a flat surface in accordance with aspects of the present
teachings.
[0074] Hold-down mechanism 150 includes a z-shaped plate (or
"z-plate") 152 and a compression plate assembly 154. Z-plate 152
has a lower portion 156 configured to securely engage a module
frame portion such as a side member 170, for example by sliding
lower portion 156 of plate 152 along the side member from one
distal end to a desired location. Z-plate 152 also has an
intermediate portion 158 extending diagonally upward from lower
portion 156, and an upper portion 160 configured to engage
compression plate assembly 154. A fin portion 159 may be formed
between lower portion 156 and intermediate portion 158, to provide
additional strength to the z-plate to resist deformation under load
forces.
[0075] Compression plate assembly 154 includes a compression plate
162 configured to engage a flat surface, for example with
penetrating members such as screws 164 that fit through apertures
of the compression plate. The compression plate assembly also
includes a bolt housing 166 configured to receive and securely
engage a bolt 168 or other similar fastener. Bolt 168 may be passed
through a slot 170 formed in upper portion 160 of the z-plate and
then engaged with bolt housing 166, to securely attach z-plate 152
to compression plate assembly 154.
[0076] When (i) lower portion 156 of z-plate 152 is engaged with a
photovoltaic module frame member such as side member 170, (ii)
upper portion 160 of the z-plate is engaged with compression plate
assembly 154, and (iii) compression plate 162 is attached to a
rooftop or other flat surface by penetrating members 164, then
hold-down mechanism 150 effectively attaches the photovoltaic
module frame to the rooftop or other desired flat surface. With or
without the addition of additional ballast, this can help an array
of modules resist lift forces, such as Bernoulli-type forces
resulting from wind passing over the assembly.
[0077] FIGS. 15-17 are isometric views depicting another exemplary
photovoltaic module, generally indicated at 200, according to
aspects of the present teachings. FIG. 15 shows module 200 in an
un-collapsed or installed configuration (with ballast pavers 210
shown), FIG. 16 shows module 200 in a collapsed or shipping/storage
configuration, and FIG. 17 shows just a frame portion of module
200, which is generally indicated at 212. In addition to frame
portion 212, module 200 includes a photovoltaic panel 214 mounted
upon or otherwise attached to the frame. Photovoltaic panel 214 may
be constructed from any type of photovoltaic material, including
flexible, thin-film materials and more rigid, crystalline
silicon-based materials.
[0078] Frame 212 includes various support members such as side
support members 216, 218, a front support member 220, and a rear
support member 222. Each of these support members may have a
substantially u-shaped cross section. The various support members
of frame 212 may be joined together by any suitable mechanism, such
as heat welding or brazing. The various support members also may
include features that facilitate the attachment of panel 214 to
frame 212, and/or that facilitate the interconnection of plural
modules.
[0079] For example, as can be seen in FIG. 17, front support member
220 may include plural brackets 224, which are configured to
receive and secure the leading edge of panel 214. Engagement of
brackets 224 with the leading edge of panel 214 allows a secure
connection between the panel and the frame, while still providing
sufficient flexibility to allow the panel to move between an
un-collapsed configuration and a collapsed configuration.
[0080] Similarly, rear support member 222 may include plural
brackets 226, which are configured to receive and secure the bottom
edge of a rear wind deflector 228, which is attached to panel 214
at three rotatable hinges 230. Thus, when module 200 is in its
installed configuration, wind deflector 228 may be rotated into a
substantially vertical orientation and its bottom edge inserted
into brackets 226, whereas when module 200 is in its collapsed
configuration, the bottom edge of wind deflector 228 may be removed
from brackets 226 and the wind deflector may be rotated into a
substantially horizontal orientation under panel 224. Of course,
any ballast such as pavers 210 would not be present when module 200
is in a collapsed state.
[0081] FIGS. 15-17 also illustrate features of frame 212 that
facilitate the interconnection of plural modules such as module
200, and FIG. 18 is a magnified view of an intersection region that
could be formed between four substantially similar such modules.
Specifically, left side member 216 includes a leading edge region
232 that is slightly narrower than trailing edge region 234, and
similarly, right side member 218 includes a leading edge region 236
that is slightly narrower than trailing edge region 238. This
allows the leading edges of one module frame to slide into the
trailing edges of another module, as depicted in FIG. 18, which is
a magnified view of an intersection region, generally indicated at
250, of four adjacent modules.
[0082] Side frame members 216 and 218 each also include apertures
near their leading and trailing edges, as indicated at 240, 242,
244 and 246. Thus, as depicted in FIG. 18, adjacent modules may be
positioned with the leading and trailing apertures of their
respective side frame members overlapping. A connecting member 252
then may be positioned over the apertures, and a complementary
cotter pin-type fastener 254 may be passed through the apertures to
secure the adjacent modules together. Connecting member 252 may
include an extension 256 having an aperture 258 configured to
receive a penetrating member such as a screw or bolt (not shown),
which may be used to attach the connecting member (and thus the
modules) to a rooftop or other surface upon which the modules are
mounted.
[0083] FIG. 19 is an isometric view and FIG. 20 is a sectional view
of yet another embodiment of a photovoltaic module, generally
indicated at 300, according to aspects of the present teachings.
Module 300 generally includes a base portion 312 and a photovoltaic
panel 314 (not shown in FIG. 19) mounted to the base portion.
Photovoltaic panel 314 may be of any type, including the types
described previously with respect to modules 100 and 200.
[0084] Base portion 312 of module 300 may be unitarily constructed,
and may be formed from one or more non-conductive materials so that
module 300 does not require electrical grounding. For example, the
base portion may be formed from recycled rubber or the like. The
base portion may include a peripheral support portion 316 and a
central support portion 318, which together are configured to
support panel 314. A plurality of openings 320, 322 and 324 may be
formed in the base portion to reduce the weight of the base portion
and to facilitate heat transfer away from the module. Apertures 326
at the leading edge of the base portion may be used to secure
module 300 to an adjacent module and/or to a rooftop or other
surface.
[0085] II. Methods of Installation, Assembly and Manufacture
[0086] This section describes methods of installing, assembling and
manufacturing photovoltaic modules according to aspects of the
present teachings; see FIGS. 21-26.
[0087] FIG. 21 is a flowchart depicting a method, generally
indicated at 400, of installing an assembly of photovoltaic modules
on a substantially flat surface according to aspects of the present
teachings. The modules assembled according to method 400 may be of
any suitable type, including but not limited to the modules
described previously in the present teachings.
[0088] At step 402, first and second photovoltaic modules are
positioned to be laterally aligned and longitudinally adjacent to
each other. At step 404, a third module is positioned laterally
adjacent and longitudinally aligned with the first module, and a
fourth module is positioned laterally adjacent and longitudinally
aligned with the second module, to form an assembly of four
adjacent modules. In a method involving the interconnection of just
two longitudinally adjacent modules, step 404 may be omitted.
[0089] At step 406, a first leg of a u-bolt is passed through a
first aperture disposed near a trailing edge of a side member of
the first module and a second leg of the u-bolt is passed through a
second aperture disposed near a leading edge of a side member of
the second module. At step 408, which again may be omitted in a
method of interconnecting just two longitudinally adjacent modules,
the first leg of the u-bolt is passed through a third aperture
disposed near a trailing edge of a side member of the third module
and the second leg of the u-bolt is passed through a fourth
aperture disposed near a leading edge of a side member of the
fourth module.
[0090] At step 410, the u-bolt is secured to the first and second
modules by securing the first leg and the second leg to a
connecting plate that spans the leading and trailing edges of the
first and second modules, respectively. When method 400 includes
interconnecting four rather than just two adjacent modules, step
410 includes securing the u-bolt to the first, second, third and
fourth modules by securing the first leg and the second leg to a
connecting plate that spans the leading edges of the first and
third modules and the trailing edges of the second and fourth
modules.
[0091] The u-bolt and connecting plate used in method 400 may be of
the type described previously and denoted, for example, by
reference numbers 102' and 104', respectively. Accordingly,
securing the first and second legs of the u-bolt to the connecting
plate may include engaging a notch formed in each leg with
respective first and second complementary apertures formed in the
connecting plate. Furthermore, the legs of the u-bolt may be set
apart from each other by a distance that exceeds the distance
between the apertures of the connecting plate when the legs are in
an unbiased configuration, so that the legs require compression
toward each other to engage the apertures of the connecting plate.
In some cases, the u-bolt assembly may be configured so that the
required compression can be achieved manually, in which case
modules may be attached to each other by hand and without the use
of tools. In other cases, the u-bolt assembly may be configured so
that a tool is generally required to achieve the desire
compression, in which case a specialized compression tool may be
provided.
[0092] FIG. 22 is a flowchart depicting another method, generally
indicated at 450, of installing an array of photovoltaic modules
according to aspects of the present teachings. More specifically,
method 450 describes the electrical interconnection of two adjacent
modules. At step 452, first and second photovoltaic modules are
positioned on a substantially flat surface so that the modules are
longitudinally aligned with each other and laterally adjacent to
each other. Each of the modules includes a rear wind deflector
having at least one wiring aperture, and any of the previously
described modules having a rear wind deflector with wiring
apertures may be suitable for installation according to method 450.
For example, suitable modules include those having left and right
wiring apertures with a connecting wire disposed in each wiring
aperture, where the connecting wires disposed in the left and right
wiring apertures carry opposite polarity. As described above, the
wiring apertures may include upper and lower portions of different
sizes.
[0093] At step 454, a first connecting wire is moved into an upper
portion of the wiring aperture of the first module, so that first
connecting wire can move freely through the aperture. At step 456,
the first connecting wire is pulled through the wiring aperture of
the first module, thereby moving an electrical connector disposed
at a distal end of the first wire further from the wiring aperture
of the first module. At step 458, the electrical connector of the
first module is connected to an electrical connector disposed at a
distal end of a second connecting wire protruding from the wiring
aperture of the second module, to form an electrical connection
between the first and second modules.
[0094] At step 460, the first and second connecting wires are moved
through the wiring apertures to position the electrical connectors
behind one of the wind deflectors, after connecting the electrical
connectors to each other. At step 462, the first connecting wire is
moved into a lower portion of the wiring aperture(s) of the first
and/or second modules so that the first connecting wire is held in
place by friction. This prevents unwanted movements of the
connected wires after they are connected and disposed in a desired
assembled configuration.
[0095] In some installations, some of the steps above may be
omitted or altered. For example, the present teachings contemplate
that the connected wires may not necessarily be moved so that the
electrical connectors are disposed behind one of the wind
deflectors, in which case step 460 may be omitted. Similarly, in
some cases the connecting wires may be held in place by means other
than friction through the lower portion of the wiring aperture(s),
or not held in place at all, in which case step 462 may be omitted
or altered.
[0096] FIG. 23 is a flowchart depicting yet another method,
generally indicated at 500, of installing an array of photovoltaic
modules according to aspects of the present teachings. More
specifically, method 500 describes the electrical interconnection
of four adjacent modules. At step 502, first, second, third and
fourth photovoltaic modules are positioned on a substantially flat
surface so that the first and second modules are longitudinally
aligned with each other and laterally adjacent to each other, the
third module is laterally aligned and longitudinally adjacent to
the first module, and the fourth module is laterally aligned and
longitudinally adjacent to the second module. The resulting module
configuration generally resembles the physical configuration
depicted in FIG. 7.
[0097] At step 504, which is optional, a rear wind deflector of one
or more of the modules may be removed to gain access to the
connecting wires associated with that particular module.
Alternatively, if step 504 is omitted, the connecting wires may be
accessed through wiring apertures formed in the rear wind deflector
of each module, as described previously. Also as described
previously, each wiring aperture may include two aperture portions,
one of which is sized to allow passage of a wire and an associated
electrical connector substantially without friction, and the other
of which is sized to prevent passage of the electrical connector
and to hold the wire in place with friction.
[0098] At step 506, which is also optional, the wiring
configuration of at least one of the modules may be reversed, for
example by placing the right-hand connecting wire of the module in
the left-hand wiring aperture of the module, and placing the
left-hand connecting wire of the module in the right-hand wiring
aperture of the module. This step may be performed, for example, to
interconnect two longitudinally adjacent modules (such as at the
lateral edges of an array of modules), in which case the wiring
apertures of the respective modules in closest physical proximity
to each other would have the same electrical polarity in the
absence of reversing the wiring configuration of one of the
modules.
[0099] At step 508, a right-hand connecting wire of the first
module is pulled through a right-hand wiring aperture disposed in a
rear wind screen of the first module. At step 510, the right-hand
connecting wire of the first module is connected to a left-hand
connecting wire of the second module, to form an electrical
connection between the first and second modules.
[0100] At step 512, a right-hand connecting wire of the second
module is pulled through a right-hand wiring aperture disposed in
the rear wind screen of the second module. At step 514, the
right-hand connecting wire of the second module is connected to one
of the connecting wires of the third module, to form an electrical
connection between the second and third modules.
[0101] If the second module is being connected to another laterally
adjacent module, then at step 514 the right-hand wire of the second
module will typically be connected to a left-hand wire of the third
module. On the other hand, if the second module is being connected
to a longitudinally adjacent module, then at step 514 the
right-hand wire of the second module will typically be connected to
a right-hand wire of the third module, which would therefore
typically have its wiring configuration reversed so that the
right-hand wires of the second and third longitudinally adjacent
modules have opposite polarities.
[0102] At step 516, the remaining (unconnected) wire of the third
module is pulled through a wiring aperture disposed in a rear wind
deflector of the third module, and at step 518, this previously
unconnected wire of the third module is connected to a connecting
wire of the fourth module, to form an electrical connection between
the third and fourth modules. This completes the electrical
interconnection of the four modules, although additional steps may
be taken to integrate the assembly of modules into an electrical
system and/or to physically interconnect the modules.
[0103] For example, at step 520, the unconnected wires of the first
and fourth modules may be electrically connected to a junction box,
DC/AC converter, or any other device suitable for integrating power
generated by the assembled modules into a household or commercial
electrical grid. At step 522, the first, second, third and fourth
modules may be physically interconnected, for example with a u-bolt
that spans an intersection region of the modules. As described
previously, a suitable u-bolt may include leg portions that are
passed through connection apertures disposed in the frame portions
of the modules, and into a connecting plate on the opposite side of
the frame portions.
[0104] FIG. 24 is a flowchart depicting still another method,
generally indicated at 550, of installing photovoltaic modules
according to aspects of the present teachings. At step 552, two
photovoltaic modules are placed onto a substantially flat surface
such as a building rooftop or the ground. Suitable modules include,
for example, any of the various modules described above or modules
having similar characteristics or combinations of
characteristics.
[0105] At step 554, the modules are aligned laterally, so that
their respective frame side members lie approximately along the
same lines. At step 556, at least one of the modules is
repositioned longitudinally until a shaped leading edge of one of
the modules registers with a shaped trailing edge of another one of
the modules. In other words, the modules are moved toward each
other until their frames mate together, indicating that they are
positioned correctly. As described previously, the leading edge and
trailing edge of each module define complementary shapes, such as
complementary planes that are each non-perpendicular to a plane
defined by the substantially flat surface, to facilitate
registration of the module frames with each other.
[0106] Method 550 also may include various additional physical
and/or electrical interconnection steps, such as those described
previously. For instance, at step 558, the modules may be
physically connected with a connection member that spans the
leading edge of the rear module and the trailing edge of the front
module. The connection member may, for example, be a u-bolt
assembly including a u-shaped bolt and a connecting plate. In this
case, physically connecting the modules includes inserting a first
leg portion of the u-shaped bolt into a first aperture in the
leading edge, inserting a second leg portion of the u-shaped bolt
into a second aperture in the trailing edge, and engaging each leg
portion with a corresponding aperture formed in a connection plate
disposed on a side of the leading and trailing edges opposite a
direction of insertion of the leg portions into the leading and
trailing edges.
[0107] At step 560, the modules may be electrically interconnected,
for instance by pulling a first connecting wire from a wiring
aperture formed in a rear wall of a first of the modules, pulling a
second connecting wire from a wiring aperture formed in a rear wall
of a second of the modules, and connecting the wires. The wiring
apertures may be substantially keyhole-shaped apertures formed in a
rear wind deflector of each module, in which case method 550 may
include at step 562 placing at least one of the wires into a lower
portion of one of the wiring apertures to hold the wire in place
with friction, after connecting the wires. At step 564, an
electrical connection region of the wires may be repositioned
behind one of the rear walls. This step (step 564) would typically
be performed after connecting the wires at step 560 but before
moving one or more wires into the lower portion of a wiring
aperture at step 562.
[0108] FIG. 25 is a flowchart depicting a method, generally
indicated at 600, of assembling a photovoltaic module according to
aspects of the present teachings. At step 602, a photovoltaic
module frame is formed by heat welding a plurality of frame members
together to define a first plane and a second plane oriented at a
predetermined angle relative to the first plane. As described
previously, the frame members may be formed from a variety of
materials, including substantially electrically nonconductive
materials such as a wood plastic composite material, which can be
an extruded material. The frame members may be attached to each
other essentially only by heat welding, or in some cases heat
welding may be replaced or augmented by other attachment procedures
such as adhesives or attachment hardware.
[0109] The frame members include members sufficient to rest in a
stable configuration on a flat surface such as a rooftop or the
ground (i.e., the first plane) and to support a photovoltaic panel
in the second plane. For example, the frame members might include a
pair of side members, a pair of side support members, a front cross
member and a rear cross member, as described previously. At step
604, which is optional, a front cross member is oriented so that
its top surface lies substantially within and helps to define the
second plane. This orientation would typically be performed prior
to heat welding or otherwise attaching the front cross member to
any of the other frame members.
[0110] At step 606, a photovoltaic cell is attached to the frame so
that the cell lies substantially within the second plane. At step
608, which is optional, a rear wind deflector is attached to the
frame. At step 610, which is also optional, electrical connecting
wires are disposed within first and second apertures formed in the
wind deflector. Suitable photovoltaic cells, rear wind deflectors
and connecting wires include any of those described previously in
the present disclosure.
[0111] FIG. 26 is a flowchart depicting another method, generally
indicated at 650, of assembling a photovoltaic module according to
aspects of the present teachings. At step 652, an electrically
substantially nonconductive material is extruded into one or more
rails having a desired cross sectional profile. As described above,
suitable materials include wood plastic composite materials such as
those formed through a combination of reclaimed wood fibers and
thermoplastic polymer.
[0112] At step 654, the rails are cut into a plurality of frame
members sufficient to form at least a portion of a photovoltaic
module frame. For example, the rails may be cut into a front cross
member, a rear cross member, a pair of side members, and a pair of
side support members, among others. In some cases, fewer or
additional frame members may be cut, depending on the particular
frame design.
[0113] At step 656, the frame members are attached to each other to
form a photovoltaic module frame. The attachment of the frame
members to each other may include a combination of heat welding,
adhesives and/or attachment hardware, and in some cases may consist
entirely (or substantially entirely) of just heat welding. This
highlights an important advantage of using wood plastic composite
materials, which have been found to attain a strong degree of
adhesion through the use of heat welding alone. Attaching the frame
members to each other typically will include forming a frame
defining a first plane and a second plane oriented at a
predetermined angle relative to the first plane.
[0114] At step 658, a photovoltaic cell is attached to the frame,
for example through the use of adhesives and/or dedicated mounting
hardware. When the frame has been formed to define two separate
planes, attaching the photovoltaic cell to the frame will typically
include positioning the cell to lie substantially within the second
plane.
[0115] III. Additional Features and Advantages
[0116] The following, among others, are additional possible
advantages of integrated PV rooftop modules and assemblies of
modules according to aspects of the present teachings:
[0117] Installation throughput of module assemblies according to
aspects of the present teachings may be greater than eight racks
per labor hour.
[0118] Assemblies according to aspects of the present teachings may
induce a maximum pressure of 2.8 lb/ft.sup.2 on the roof without
additional ballasting.
[0119] Modules according to aspects of the present teachings may be
physically interconnected to adjacent modules to reduce the amount
of required ballast.
[0120] Assemblies according to aspects of the present teachings may
be electrically non-conductive and therefore may not require
grounding.
[0121] Assemblies according to aspects of the present teachings may
not require any specialized tools to install.
[0122] Each solar panel of modules according to aspects of the
present teachings may be fully integrating into the racking
structure, such that no assembly of an individual module may be
required.
[0123] The following numbered paragraphs further describe aspects
of the present teachings:
[0124] A. A photovoltaic assembly comprising at least a first
photovoltaic module, the module including:
[0125] a first frame portion defining a first plane and having:
[0126] a. left and right side members, each side member including a
leading edge, a front aperture disposed near the leading edge, a
trailing edge, and a rear aperture disposed near the trailing edge;
[0127] b. a front cross member connecting the left and right side
members; and [0128] c. a rear cross member connecting the left and
right side members;
[0129] a second frame portion defining a second plane oriented at a
predetermined angle relative to the first plane, the second frame
portion having left and right support members, each support member
connected to one of the side members and including an upper surface
lying substantially within the second plane; and
[0130] a photovoltaic panel supported by the upper surfaces of the
left and right support members and lying substantially within the
second plane;
[0131] wherein the front and rear apertures of each side member are
configured to receive a connection member for securing the first
module to an adjacent module.
[0132] A1. The assembly of paragraph A, further comprising a second
photovoltaic module substantially similar to the first module,
wherein the second module is disposed laterally adjacent to and
longitudinally aligned with the first module, and wherein the first
and second modules are secured together with a first connection
member passing through one of the rear apertures of the first
module and an adjacent rear aperture of the second module.
[0133] A2. The assembly of paragraph A1, wherein the first and
second modules are further secured together with a second
connection member passing through one of the front apertures of the
first module and an adjacent front aperture of the second
module.
[0134] A3. The assembly of paragraph A1, wherein the first
connection member is a self-connecting strap forming a loop that
connects the first and second modules.
[0135] A4. The assembly of paragraph A1, wherein the first
connection member is a u-shaped bolt configured to fit within a
receiving plate which spans an intersection region of the first and
second modules with third and fourth longitudinally adjacent
modules.
[0136] A5. The assembly of paragraph A, further comprising a second
photovoltaic module substantially similar to the first module,
wherein the second module is disposed longitudinally adjacent to
and laterally aligned with the first module, and wherein the first
and second modules are secured together with a connection member
passing through one of the front apertures of the first module and
an adjacent rear aperture of the second module.
[0137] A6. The assembly of paragraph A5, wherein the first
connection member is a u-shaped bolt configured to fit within a
receiving plate which spans an intersection region of the first and
second modules.
[0138] A7. The assembly of paragraph A, further comprising second,
third and fourth photovoltaic modules, all substantially similar to
the first module, wherein the second module is disposed laterally
adjacent to and longitudinally aligned with the first module, the
third module is disposed longitudinally adjacent to and laterally
aligned with the first module, and the fourth module is disposed
laterally adjacent to and longitudinally aligned with the third
module and longitudinally adjacent to and laterally aligned with
the second module; and
[0139] wherein the first, second, third and fourth modules are
secured together with a connection member passing through one of
the rear apertures of the first module, a rear aperture of the
second module which is adjacent to the rear aperture of the first
module, a front aperture of the third module which is adjacent to
the rear aperture of the first module, and a front aperture of the
fourth module which is adjacent to the front aperture of the third
module.
[0140] A8. The assembly of paragraph A, wherein the front cross
member has a top surface angled to lie substantially within the
second plane and which partially supports the photovoltaic
panel.
[0141] A9. The assembly of paragraph A, wherein the second frame
portion further includes at least one rear support member having a
top surface angled to lie substantially within the second plane and
which partially supports the photovoltaic panel.
[0142] A10. The assembly of paragraph A, wherein the leading edge
of each side member has a shape complementary to a shape of the
trailing edge of each side member.
[0143] B. A photovoltaic module, comprising:
[0144] a frame including a first portion having right and left side
members defining a first plane and a second portion defining a
second plane oriented at a predetermined angle relative to the
first plane;
[0145] a photovoltaic panel supported by the second portion of the
frame and lying substantially within the second plane;
[0146] wherein the right and left side members of the first portion
of the frame each include at least one aperture configured to
receive a connection member for securing the module to an adjacent,
substantially similar module.
[0147] B1. The photovoltaic module of paragraph B, wherein the at
least one aperture includes a front aperture disposed near a
leading edge of the associated side member, and a rear aperture
disposed near a trailing edge of the associated side member.
[0148] B2. The photovoltaic module of paragraph B, wherein the
connection member is a u-bolt configured to secure the module to an
adjacent module by passing leg portions of the u-bolt through
aligned apertures in adjacent side members of the modules from one
side of the side members, and then engaging notches disposed in the
leg portions with complementary apertures of a receiving plate
disposed on the other side of the side members.
[0149] B3. The photovoltaic module of paragraph B2, wherein the leg
portions of the u-bolt include a pair of inner notches configured
to engage the complementary apertures of the receiving plate when
the u-bolt is used to secure exactly two laterally aligned adjacent
modules, and a pair of outer notches configured to engage the
complementary apertures of the receiving plate when the u-bolt is
used to secure four adjacent modules.
[0150] B4. The photovoltaic module of paragraph B, wherein the
second portion of the frame further includes a front cross member
extending between the left and right side members and including a
top surface that lies substantially within the second plane.
[0151] C. A method of installing an assembly of photovoltaic
modules on a substantially flat surface, comprising:
[0152] positioning first and second modules to be laterally aligned
and longitudinally adjacent to each other;
[0153] passing a first leg of a u-bolt through a first aperture
disposed near a trailing edge of a side member of the first module
and passing a second leg of the u-bolt through a second aperture
disposed near a leading edge of a side member of the second module;
and
[0154] securing the u-bolt to the first and second modules by
securing the first leg and the second leg to a connecting plate
that spans the leading and trailing edges of the first and second
modules, respectively.
[0155] C1. The method of paragraph C, further comprising:
[0156] positioning a third laterally adjacent and longitudinally
aligned with the first module, and a fourth module laterally
adjacent and longitudinally aligned with the second module, to form
an assembly of four adjacent modules;
[0157] passing the first leg of the u-bolt through a third aperture
disposed near a trailing edge of a side member of the third module
and passing the second leg of the u-bolt through a fourth aperture
disposed near a leading edge of a side member of the fourth module;
and
[0158] wherein securing the u-bolt includes securing the u-bolt to
the first, second, third and fourth modules by securing the first
leg and the second leg to a connecting plate that spans the leading
edges of the first and third modules and the trailing edges of the
second and fourth modules.
[0159] C2. The method of paragraph C, wherein securing the first
and second legs to the connecting plate includes engaging a notch
formed in each leg with respective first and second complementary
apertures formed in the connecting plate.
[0160] C3. The method of paragraph C2, wherein the legs of the
u-bolt are set apart from each other by a distance that exceeds the
distance between the apertures of the connecting plate when the
legs are in an unbiased configuration, so that the legs require
compression toward each other to engage the apertures of the
connecting plate.
[0161] D. A photovoltaic module, comprising:
[0162] a first frame portion defining a first plane and having:
[0163] a. left and right side members, each side member including a
leading edge and a trailing edge; [0164] b. a front cross member
connecting the left and right side members; and [0165] c. a rear
cross member connecting the left and right side members;
[0166] a second frame portion defining a second plane oriented at a
predetermined angle relative to the first plane and having: [0167]
a. left and right support members, each support member connected to
one of the side members and including an upper surface lying
substantially within the second plane; and [0168] b. at least one
rear support member extending upward from the rear cross member and
having a top surface lying substantially within the second
plane;
[0169] a photovoltaic panel lying substantially within the second
plane and supported by the upper surfaces of the left and right
support members and by the top surface of the rear support member;
and
[0170] a rear wind deflector attached to one of the frame portions
and including left and right wiring apertures;
[0171] wherein each wiring aperture is configured to allow passage
of a wire for forming an electrical connection between the first
module and an adjacent, substantially similar module.
[0172] D1. The module of paragraph D, wherein the wiring apertures
each include an upper portion configured to allow passage of the
wire and an electrical connector, and a lower portion configured to
allow passage of the wire and to prevent passage of the electrical
connector.
[0173] D2. The module of paragraph D1, wherein the upper portion of
each of the wiring apertures is configured to allow passage of the
wire substantially without friction, and the lower portion of each
of the wiring apertures is configured to hold the wire in place and
to prevent the wire from slipping without manual assistance.
[0174] D3. The module of paragraph D, wherein the rear wind
deflector is disposed substantially perpendicular to the first
plane, and wherein a rear edge of the photovoltaic panel and a top
edge of the wind deflector meet at an acute angle.
[0175] D4. The module of paragraph D, wherein the rear wind
deflector is disposed substantially perpendicular to the first
plane, and wherein a rear edge of the photovoltaic panel terminates
before reaching a top edge of the wind deflector, to form a gap
lying substantially within the second plane, between the rear edge
of the photovoltaic panel and the top edge of the wind
deflector.
[0176] D5. The module of paragraph D, wherein the rear wind
deflector is disposed substantially perpendicular to the first
plane, and wherein a top edge of the wind deflector terminates
before reaching the second plane, to firm a substantially vertical
gap between a rear edge of the photovoltaic panel and the top edge
of the wind deflector.
[0177] D6. The module of paragraph D, wherein each of the side
members includes a first connection aperture disposed in proximity
to its leading edge and a second connection aperture disposed in
proximity to its trailing edge, and wherein the connection
apertures are configured to receive a connecting member for
securely attaching the module to an adjacent, substantially similar
module.
[0178] D7. The module of paragraph D6, wherein the connection
member is a u-bolt that spans an intersection region of the
modules.
[0179] E. A method of installing an array of photovoltaic modules,
comprising:
[0180] positioning first and second photovoltaic modules on a
substantially flat surface so that the modules are longitudinally
aligned with each other and laterally adjacent to each other,
wherein each module includes a rear wind deflector having at least
one wiring aperture;
[0181] pulling a first connecting wire through the wiring aperture
of the first module, thereby moving an electrical connector
disposed at a distal end of the first wire further from the wiring
aperture of the first module; and
[0182] connecting the electrical connector of the first module to
an electrical connector disposed at a distal end of a second
connecting wire protruding from the wiring aperture of the second
module, to form an electrical connection between the first and
second modules.
[0183] E1. The method of paragraph E, wherein the wind deflectors
of the first and second photovoltaic modules each include left and
right wiring apertures with a connecting wire disposed in each
wiring aperture, and wherein the connecting wires disposed in the
left and right wiring apertures carry opposite polarity.
[0184] E2. The method of paragraph E, further comprising moving the
first connecting wire into an upper portion of the wiring aperture
of the first module so that first connecting wire can move freely
through the aperture, prior to pulling the first connecting wire
through the aperture.
[0185] E3. The method of paragraph E2, further comprising moving
the first connecting wire into a lower portion of the wiring
aperture of the first module so that the first connecting wire is
held in place by friction, after pulling the first connecting wire
through the aperture.
[0186] E4. The method of paragraph E, further comprising moving the
first and second connecting wires through the wiring apertures and
thereby positioning the electrical connectors behind one of the
wind deflectors, after connecting the electrical connectors to each
other.
[0187] E5. The method of paragraph E4, further comprising moving at
least one of the connecting wires into a lower portion of one of
the wiring apertures, so that the connecting wires are held in
place by friction, after positioning the electrical connectors
behind one of the wind deflectors.
[0188] F. A method of installing an array of photovoltaic modules,
comprising:
[0189] positioning first, second, third and fourth photovoltaic
modules on a substantially flat surface so that the first and
second modules are longitudinally aligned with each other and
laterally adjacent to each other, the third module is laterally
aligned and longitudinally adjacent to the first module, and the
fourth module is laterally aligned and longitudinally adjacent to
the second module;
[0190] pulling a right-hand connecting wire of the first module
through a right-hand wiring aperture disposed in a rear wind
deflector of the first module;
[0191] connecting the right-hand connecting wire of the first
module to a left-hand connecting wire of the second module, to form
an electrical connection between the first and second modules;
[0192] pulling a right-hand connecting wire of the second module
through a right-hand wiring aperture disposed in the rear wind
deflector of the second module;
[0193] connecting the right-hand connecting wire of the second
module to a first connecting wire of the third module, to form an
electrical connection between the second and third modules;
[0194] pulling a second connecting wire of the third module through
a wiring aperture disposed in a rear wind deflector of the third
module; and
[0195] connecting the second connecting wire of the third module to
a connecting wire of the fourth module, to form an electrical
connection between the third and fourth modules.
[0196] F1. The method of paragraph F, further comprising physically
interconnecting the first, second, third and fourth modules with a
u-bolt that spans an intersection region of the modules.
[0197] F2. The method of paragraph F1, wherein leg portions of the
u-bolt pass through connection apertures disposed in the frame
portions of the modules, and into a connecting plate.
[0198] F3. The method of paragraph F, wherein each wiring aperture
includes two aperture portions, one of which is sized to allow
passage of a wire and an associated electrical connector
substantially without friction, and the other of which is sized to
prevent passage of the electrical connector and to hold the wire in
place with friction.
[0199] F4. The method of paragraph F, further comprising reversing
the wiring configuration of at least one of the modules, by placing
the right-hand connecting wire of the module in the left-hand
wiring aperture of the module, and placing the left-hand connecting
wire of the module in the right-hand wiring aperture of the
module.
[0200] F5. The method of paragraph F4, further comprising removing
the wind deflector of the at least one module to gain access to the
connecting wires.
[0201] G. A photovoltaic module comprising:
[0202] a first frame portion defining a first plane and including:
[0203] a. left and right side members, each side member having a
leading edge and a trailing edge; and [0204] b. at least one cross
member connecting the left and right side members;
[0205] a second frame portion defining a second plane oriented at a
predetermined angle relative to the first plane, the second frame
portion including left and right support members, each support
member connected to one of the side members and having an upper
surface lying substantially within the second plane; and
[0206] a photovoltaic panel fixedly attached to the upper surfaces
of the left and right support members and lying substantially
within the second plane;
[0207] wherein each leading edge is configured to be connected to a
leading edge of a laterally adjacent module and a trailing edge of
a longitudinally adjacent module, and each trailing edge is
configured to be connected to a trailing edge of a laterally
adjacent module and a leading edge of a longitudinally adjacent
module.
[0208] G1. The module of paragraph G, wherein each leading edge has
a shape complementary to a shape of each trailing edge.
[0209] G2. The module of paragraph G1, wherein each leading edge
defines a leading edge plane angled at a non-perpendicular angle
relative to the first plane, and each trailing edge defines a
trailing edge plane angled at 180 degrees minus the angle of the
leading edge plane relative to the first plane.
[0210] G3. The module of paragraph G, wherein each leading edge
includes a leading edge connection aperture, each trailing edge
includes a trailing edge connection aperture, and each connection
aperture is configured to receive a connection member configured to
connect together at least two adjacent side members.
[0211] G4. The module of paragraph G3, wherein the connection
member is a self-connecting strap configured to pass through
adjacent apertures of two laterally adjacent side members and form
a loop.
[0212] G5. The module of paragraph G3, wherein the connection
member is a u-bolt including leg portions configured to pass
through adjacent apertures of two longitudinally adjacent side
members and then through a connecting plate that spans an
intersection region of the longitudinally adjacent side
members.
[0213] G6. The module of paragraph G5, wherein the leg portions
each include a proximal notch and a distal notch, and wherein each
notch is configured to engage a complementary aperture in the
connecting plate.
[0214] G7. The module of paragraph G6, wherein the proximal notches
are configured to engage the connecting plate when the u-bolt
connects exactly two longitudinally adjacent modules, and the
distal notches are configured to engage the connecting plate when
the u-bolt connects two pairs of longitudinally adjacent modules,
wherein the pairs are laterally adjacent to each other.
[0215] H. A method of installing photovoltaic modules,
comprising:
[0216] placing at least two photovoltaic modules onto a
substantially flat surface;
[0217] aligning the modules laterally; and
[0218] repositioning at least one of the modules longitudinally
until a shaped leading edge of one of the modules registers with a
shaped trailing edge of another one of the modules.
[0219] H1. The method of paragraph H, wherein the leading edge and
the trailing edge define complementary planes that are each
non-perpendicular to a plane defined by the substantially flat
surface.
[0220] H2. The method of paragraph H, further comprising physically
connecting the modules with a connection member that spans the
leading edge and the trailing edge.
[0221] H3. The method of paragraph H2, wherein the connection
member is a u-bolt assembly including a u-shaped bolt and a
connecting plate, and wherein physically connecting the modules
includes: [0222] a. inserting a first leg portion of the u-shaped
bolt into a first aperture in the leading edge, and inserting a
second leg portion of the u-shaped bolt into a second aperture in
the trailing edge; and [0223] b. engaging each leg portion with a
corresponding aperture formed in a connection plate disposed on a
side of the leading and trailing edges opposite a direction of
insertion of the leg portions into the leading and trailing
edges.
[0224] H4. The method of paragraph H2, further comprising
electrically connecting the modules by pulling a first connecting
wire from a wiring aperture formed in a rear wall of a first of the
modules, pulling a second connecting wire from a wiring aperture
formed in a rear wall of a second of the modules, and connecting
the wires.
[0225] H5. The method of paragraph H4, wherein the wiring apertures
are substantially keyhole-shaped apertures formed in a rear wind
deflector of each module, and further comprising placing at least
one of the wires into a lower portion of one of the wiring
apertures to hold the wire in place with friction, after connecting
the wires.
[0226] H6. The method of paragraph H4, further comprising
repositioning an electrical connection region of the wires behind
one of the rear walls, after connecting the wires.
[0227] I. A photovoltaic module comprising:
[0228] a frame defining a first plane and a second plane oriented
at a predetermined angle relative to the first plane, the frame
including at least left and right side members; and
[0229] a photovoltaic panel fixedly attached to the frame and lying
substantially within the second plane;
[0230] wherein a leading edge of each side member has a shape which
is complementary to a shape of a trailing edge of each side member,
so that longitudinally adjacent modules are configured to register
with each other.
[0231] I1. The module of paragraph I, wherein each leading edge is
oriented at a non-perpendicular angle relative to the first plane,
and each trailing edge is oriented at a complementary angle
relative to the first plane.
[0232] I2. The module of paragraph I, wherein each leading edge
includes a leading edge connection aperture, each trailing edge
includes a trailing edge connection aperture, and each connection
aperture is configured to receive a connection member configured to
connect together at least two adjacent side members.
[0233] I3. The module of paragraph I, further comprising a u-bolt
connection member assembly configured to connect together two
longitudinally adjacent side members.
[0234] I4. The module of paragraph I, further comprising a
self-connecting strap assembly connection member configured to
connect together two laterally adjacent side members.
[0235] J. A photovoltaic module, comprising:
[0236] a frame defining a first plane and a second plane oriented
at a nonzero angle relative to the first plane; and
[0237] a photovoltaic panel supported by the frame and lying
substantially within the second plane;
[0238] wherein the frame is constructed from a non-conductive,
extruded material.
[0239] J1. The module of paragraph J, wherein the frame is
constructed from a wood plastic composite material.
[0240] J2. The module of paragraph J1, wherein the wood plastic
composite material includes a combination of reclaimed wood fibers
and thermoplastic polymer.
[0241] J3. The module of paragraph J, wherein the frame includes a
plurality of frame members that are connected together by heat
welding.
[0242] J4. The module of paragraph J3, wherein the frame includes
first and second side members and a rear cross member that
collectively define the first plane, and first and second side
support members and a rear support member that collectively define
the second plane.
[0243] J5. The module of paragraph J4, wherein the first and second
side support members are heat welded to the first and second side
members, respectively, and wherein the rear support member is heat
welded to the rear cross member.
[0244] J6. The module of paragraph J4, wherein the frame includes a
front cross member including a top surface lying substantially
within the second plane.
[0245] J7. The module of paragraph J4, wherein the first and second
side members each include a leading edge connection aperture and a
trailing edge connection aperture, and wherein the connection
apertures are configured to receive a connection member for
connecting the module to an adjacent, substantially similar
module.
[0246] K. A method of assembling a photovoltaic module,
comprising:
[0247] forming a frame by heat welding a plurality of frame members
together to define a first plane and a second plane oriented at a
predetermined angle relative to the first plane; and
[0248] attaching a photovoltaic cell to the frame so that the cell
lies substantially within the second plane.
[0249] K1. The method of paragraph K, wherein the frame members are
formed from a substantially electrically nonconductive
material.
[0250] K2. The method of paragraph K1, wherein the frame members
are formed from a wood plastic composite material.
[0251] K3. The method of paragraph K, wherein the frame members
include at least a pair of side members, a pair of side support
members, a front cross member and a rear cross member, and further
comprising orienting the front cross member so that its top surface
lies substantially within and helps to define the second plane.
[0252] K4. The method of paragraph K, wherein forming the frame
consists essentially of heat welding the frame members
together.
[0253] K5. The method of paragraph K, further comprising attaching
a rear wind deflector to the frame, and disposing electrical
connecting wires within first and second apertures formed in the
wind deflector.
[0254] L. A method of assembling a photovoltaic module,
comprising:
[0255] extruding an electrically substantially nonconductive
material into rails having a desired cross sectional profile;
[0256] cutting the rails into a plurality of frame members;
[0257] attaching the frame members to each other to form a frame;
and
[0258] attaching a photovoltaic cell to the frame.
[0259] L1. The method of paragraph L, wherein the material is a
wood plastic composite material.
[0260] L2. The method of paragraph L, wherein attaching the frame
members to each other includes heat welding the frame members to
each other.
[0261] L3. The method of paragraph L, wherein attaching the frame
members to each other consists essentially of heat welding the
frame members to each other.
[0262] L4. The method of paragraph L, wherein cutting the rails
includes cutting at least a front cross member, a rear cross
member, a pair of side members, and a pair of side support
members.
[0263] L5. The method of paragraph L4, wherein attaching the frame
members to each other includes forming a frame defining a first
plane and a second plane oriented at a predetermined angle relative
to the first plane, and wherein attaching the cell to the frame
includes positioning the cell to lie substantially within the
second plane.
[0264] Multiple examples of integrated PV rooftop modules having
various features have been described and depicted in this
disclosure. These features may be interchanged to produce other
examples of integrated PV rooftop modules according to the present
teachings. Many combinations of features are possible and are
within the scope of the present teachings.
* * * * *