Photovoltaic Module and Interlocked Stack of Photovoltaic Modules

• US 20100212722A1
• Filed: 02/24/2009
• Published: 08/26/2010
• Est. Priority Date: 02/24/2009
• Status: Active Grant

• Current Assignee: Maxeon Solar Pte Limited
• Original Assignee: Sunpower Corporation (Totalenergies Se)
• Inventors: WARES, Brian S.
• Granted Patent: US 8,258,395 B2
• Time in Patent Office: Days
• US Class Current: 136/251
• CPC Class Codes: F24S 2025/013 Stackable support elements
• CPC Class Codes: F24S 25/20 Peripheral frames for modules
• CPC Class Codes: H01L 31/02 Details
• CPC Class Codes: H02S 20/23 specially adapted for roof structures
• CPC Class Codes: Y02B 10/10 Photovoltaic [PV]
• CPC Class Codes: Y02E 10/47 Mountings or tracking
• CPC Class Codes: Y02E 10/50 Photovoltaic [PV] energy

Abstract

One embodiment relates to an arrangement of photovoltaic modules configured for transportation. The arrangement includes a plurality of photovoltaic modules, each photovoltaic module including a frame having at least a top member and a bottom member. A plurality of alignment features are included on the top member of each frame, and a plurality of alignment features are included on the bottom member of each frame. Adjacent photovoltaic modules are interlocked by the alignment features on the top member of a lower module fitting together with the alignment features on the bottom member of an upper module. Other embodiments, features and aspects are also disclosed.

Claims

1. An arrangement of photovoltaic modules configured for transportation, the arrangement comprising:

a plurality of photovoltaic modules,

each said photovoltaic module including a frame having at least a top member and a bottom member;

a plurality of alignment features on the top member of each frame; and

a plurality of alignment features on the bottom member of each frame,

wherein adjacent photovoltaic modules are interlocked by the alignment features on the top member of a lower module fitting together with the alignment features on the bottom member of an upper module.

2. The arrangement of photovoltaic modules configured for transportation according to claim 1, wherein the alignment features on the top member comprise male alignment features, and the alignment features on the bottom member comprise female alignment features into which fit the male alignment features of another frame.

3. The arrangement of photovoltaic modules configured for transportation according to claim 2, wherein the male alignment features on the top member are self-clinching such that the male alignment features securely attach to the top member upon being pressed into holes in the top member.

4. The arrangement of photovoltaic modules configured for transportation according to claim 2, wherein the male alignment features on the top member are screwed into screw holes in the top member.

5. The arrangement of photovoltaic modules configured for transportation according to claim 2, wherein the male alignment features on the top member are extruded features which are integral with the top member of the frame.

6. The arrangement of photovoltaic modules configured for transportation according to claim 2, wherein at least one of the female alignment features comprises a drain hole in the bottom member of the frame.

7. The arrangement of photovoltaic modules configured for transportation according to claim 1, wherein the alignment features on the top member comprise outer corners, each outer corner formed by a top surface and a side surface, and corresponding alignment features on the bottom member comprise inner corners, each inner corner formed by a lip and a bottom surface.

8. The arrangement of photovoltaic modules configured for transportation according to claim 1, further comprising a pallet to which the interlocked plurality of photovoltaic modules is strapped.

9. The arrangement of photovoltaic modules configured for transportation according to claim 1, wherein the photovoltaic modules are stacked directly on top of each other without substantial space in between the adjacent photovoltaic modules.

10. The arrangement of photovoltaic modules configured for transportation according to claim 1, wherein each frame supports a plurality of silicon wafers covered on top by a glass layer and with a polymer layer underneath.

11. The arrangement of photovoltaic modules configured for transportation according to claim 10, wherein the alignment features on the top member are secured to the top member without passing through a plane of the glass layer.

12. The arrangement of photovoltaic modules configured for transportation according to claim 1, wherein the alignment features on the top member comprise female alignment features, and the alignment features on the bottom member comprise male alignment features which fit into the female alignment features of another frame.

13. A photovoltaic module comprising:

an array of solar cells; and

a frame for supporting the array of solar cells, the frame including a top member and a bottom member connected by a side member;

a plurality of alignment features on the top member; and

a plurality of alignment features on the bottom member which are configured to couple with the alignment features on the top member of another module.

14. The photovoltaic module according to claim 13, wherein the alignment features on the top member comprise male alignment features, and the alignment features on the bottom member comprise female alignment features at positions coaxial to the male alignment features on the top member.

15. The photovoltaic module according to claim 14, wherein the male alignment features are self-clinching such that the male alignment features securely attach to the top member upon being pressed into holes in the top member.

16. The photovoltaic module according to claim 14, wherein the male alignment features are screwed into screw holes in the top member.

17. The photovoltaic module according to claim 14, wherein the male alignment features are extruded features which are integral with the top member of the frame.

18. The photovoltaic module according to claim 14, wherein at least one of the female alignment features comprises a drain hole in the bottom member of the frame.

19. The photovoltaic module according to claim 14, wherein the array of solar cells comprises a plurality of silicon wafers covered on top by a glass layer and with a polymer layer underneath, and further wherein the male alignment features are secured to the top member without passing through a plane of the glass layer.

20. The photovoltaic module according to claim 13, wherein the alignment features on the top member comprise outer corners, each outer corner formed by a top surface and a side surface, and corresponding alignment features on the bottom member comprise inner corners, each inner corner formed by a lip and a bottom surface.

21. The photovoltaic module according to claim 13, wherein the alignment features on the top member comprise female alignment features, and the alignment features on the bottom member comprise male alignment features which fit into the female alignment features of another frame.