Semirigid photovoltaic module assembly and structural support therefor

• US 4,611,090 A
• Filed: 12/28/1984
• Issued: 09/09/1986
• Est. Priority Date: 12/28/1984
• Status: Expired due to Fees

• Current Assignee: Standard Oil Company (BP PLC)
• Original Assignee: Standard Oil Company (BP PLC)
• Inventors: Hartman, Robert A., Cull, Ronald C., Koch, Paul E., Dilts, David A., Catella, Gary C.
• Primary Examiner(s): Weisstuch, Aaron
• Application Number:
  US06/687,098
• Time in Patent Office: 620 Days
• Field of Search: 136/244, 136/245, 136/251, 136/258 AM, 136/259, 40/152, 40/154, 40/156, 40/157
• US Class Current: 136/251
• CPC Class Codes: F24S 25/12 using posts in combination with upper profiles
• CPC Class Codes: F24S 25/20 Peripheral frames for modules
• CPC Class Codes: H01L 31/048 Encapsulation of modules
• CPC Class Codes: H02S 20/00 Supporting structures for PV modules
• CPC Class Codes: Y02E 10/47 Mountings or tracking
• CPC Class Codes: Y02E 10/50 Photovoltaic [PV] energy

Abstract

A semirigid support member is provided for deploying flexible photovoltaic modules in a manner that imparts a degree of rigidity and permanence to the deployment. The semirigid support members provide lightweight economical means for lending structural support to flexible photovoltaic modules. The support members may be interconnected and additionally connected to a permanent base foundation.

Claims

1. A semirigid photovoltaic module assembly comprising:

(a) a flexible photovoltaic module;

(b) a semirigid support member having a frame adapted to be in contact with the perimeter of the flexible photovoltaic module, an inwardly facing flange extending upward from the frame which overlaps a portion of the module perimeter said flexible photovoltaic module being gripped by said flange, a skirt depending downward from the frame, and rib stiffeners integral to the frame and extending inward and adapted to contact the flexible photovoltaic module; and

(c) means for attaching the photovoltaic module to the support member.

2. The semirigid photovoltaic module assembly in accordance with claim 1 wherein said flexible photovoltaic module comprises an amorphous silicon photovoltaic module.

3. The semirigid photovoltaic module assembly in accordance with claim 2 wherein said amorphous silicon photovoltaic module comprises a p-i-n structure.

4. Ihe semirigid photovoltaic module assembly in accordance with Claim 1 wherein the semirigid support member comprises an electrically insulating material.

5. The semirigid photovoltaic module assembly in accordance with claim 1 wherein said semirigid support member comprises a fiber reinforced plastic resin.

6. The semirigid photovoltaic module assembly in accordance with claim 1 wherein said semirigid support member comprises a polycarbonate.

7. The semirigid photovoltaic module assembly in accordance with claim 1 wherein said skirt has spaced, thick-walled portions.

8. The semirigid photovoltaic module assembly in accordance with claim 1 wherein said spaced, thick-walled portions of said skirt have openings therethrough.

9. The semirigid photovoltaic module assembly in accordance with claim 1 wherein said rib stiffeners are interconnected.

10. The semirigid photovoltaic module assembly in accordance with claim 1 wherein said support member additionally includes means for accepting an electrical junction box.

11. The semirigid photovoltaic module assembly in accordance with claim 1 wherein said support member additionally includes means for accepting a snap-in electrical junction box.

12. The semirigid photovoltaic module assembly in accordance with claim 1 wherein said inward-facing flange is discontinuous around the frame.

13. The semirigid photovoltaic module assembly in accordance with claim 1 wherein a plurality of flange portions are disposed in opposing configurations around the frame.

14. The semirigid photovoltaic module assembly in accordance with claim 1 wherein said means for attaching the photovoltaic module to the support member comprises an adhesive material disposed between said module and said support member.

15. The semirigid photovoltaic module assembly in accordance with claim 14 wherein said adhesive material is an epoxy resin.

16. The semirigid photovoltaic module assembly in accordance with claim 14 wherein said adhesive material is a silicone.

17. The semirigid photovoltaic module assembly in accordance with claim 1 wherein a gasket is disposed around the periphery of said photovoltaic module.

18. The semirigid photovoltaic module assembly in accordance with claim 17 wherein said gasket material is selected from the group consisting of ethylene propylene dienes, silicones, polyurethanes, and plasticized vinyls.

19. The semirigid photovoltaic module assembly in accordance with claim 18 wherein said gasket material is ethylene propylene diene.

20. The semirigid photovoltaic module assembly in accordance with claim 1 wherein a faceplate is disposed between said flexible photovoltaic module and said semirigid support member.

21. The semirigid photovoltaic module assembly in accordance with claim 20 wherein said faceplate is integral to said semirigid support member.

22. The semirigid photovoltaic module assembly in accordance with claim 20 wherein said faceplate is made from a material selected from the group consisting of polyesters, polyvinyl chloride, polycarbonates, steel, aluminum, and carbon-loaded ABS polymers.

23. The semirigid photovoltaic module assembly in accordance with claim 22 wherein said faceplate material is polyvinyl chloride.

24. A semirigid array of flexible photovoltaic modules, which semirigid array comprises:

(a) individual flexible photovoltaic modules and individual semirigid support members for said modules, each individual support member having a frame adapted to be in contact with the perimeter of a photovoltaic module, an inwardly facing flange extending upward from the frame and which overlaps a portion of the module perimeter, a said flexible photovoltaic module being gripped by said flange, a skirt depending downward from the frame, rib stiffeners integral to the frame and extending inward and adapted to contact the photovoltaic module, and means for attaching the photovoltaic module to the support member to form a photovoltaic assembly;

(b) means for fixedly attaching individual semirigid support members to adjacent semirigid support members to form an array; and

(c) means for securing at least one semirigid support member to a base so that the array of flexible photovoltaic modules may be displayed in the desired configuration.

25. The semirigid array in accordance with claim 24 wherein said individual flexible photovoltaic modules comprise amorphous silicon photovoltaic modules.

26. The semirigid array in accordance with claim 24 wherein said semirigid support members comprise an electrically insulating material.

27. The semirigid support in accordance with claim 24 wherein said semirigid support members comprise a polycarbonate.

28. The semirigid array in accordance with claim 24 wherein said skirt has spaced, thick-walled portions.

29. The semirigid array in accordance with claim 28 wherein said spaced, thick-walled portions of said skirt have openings therethrough.

30. The semirigid array in accordance with claim 24 wherein said rib stiffeners are interconnected.

31. The semirigid array in accordance with claim 24 wherein said semirigid support members additionally include means for accepting an electrical junction box.

32. The semirigid array in accordance with claim 24 wherein said inwardly facing flange is discontinuous around the frame.

33. The semirigid array in accordance with claim 24 wherein means for attaching the photovoltaic module to the support member comprises an adhesive material disposed-between said module and said support.

34. The semirigid array in accordance with claim 33 wherein said adhesive material is an epoxy resin.

35. The semirigid array in accordance with claim 24 wherein said means for attaching individual semirigid support modules to adjacent semirigid support modules comprises bolts.

36. The semirigid array in accordance with claim 24 wherein said semirigid support additionally includes at least one stabililizer bar disposed across each photovoltaic assembly and attached thereto.

37. The semirigid array in accordance with claim 24 wherein said means for securing at least one semirigid support member to a base comprises a post attached to said semirigid support member and adapted to be fixedly attached to a permanent base.

38. A semirigid array of flexible photovoltaic modules, which array comprises:

(a) individual flexible photovoltaic modules and individual semirigid support members for said modules, each individual support member having a frame adapted to be in contact with the perimeter of a photovoltaic module, an inwardly facing flange extending upward from the frame which overlaps a portion of the module perimeter, a said flexible photovoltaic module being gripped by said flange, a skirt depending downward from the frame, rib stiffeners integral to the frame and extending inward and adapted to contact the photovoltaic module, and means for attaching the photovoltaic module to the support member to form a photovoltaic assembly;

(b) means fixedly attaching individual semirigid support members to a common torque bar; and

(c) means for securing said common torque bar to a base.