Photovoltaic module and interlocked stack of photovoltaic modules

• US 8,258,395 B2
• Filed: 02/24/2009
• Issued: 09/04/2012
• 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.
• Primary Examiner(s): Michener, Jennifer
• Assistant Examiner(s): Danicic, Christopher
• Application Number:
  US12/392,076
• Publication Number:
  US 20100212722A1
• Time in Patent Office: 1,288 Days
• Field of Search: None
• 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, 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, wherein the top member is disposed over a portion of a top surface and a perpendicular side surface of a glass layer of the photovoltaic module;

a plurality of male alignment features disposed over the top member and protruding from the top member of each frame perpendicular to a main longitudinal axis of the glass, wherein the male alignment features securely attach to the top member upon being pressed into holes in the top member; and

a plurality of female alignment features on the bottom member of each frame comprising a hole in the bottom member of the frame,

wherein adjacent photovoltaic modules are configured to be unterlocked by the male alignment features protruding from the top member of a lower module fitting together with the female alignment features on the bottom member of an upper module.

2. The arrangement of photovoltaic modules according to claim 1, wherein at least one of the female alignment features comprises a drain hole in the bottom member of the frame.

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

4. The arrangement of photovoltaic modules 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.

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

6. The arrangement of photovoltaic modules according to claim 5, wherein the male alignment features on the top member are secured to the top member without passing through a plane of the glass layer.

7. 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, wherein the top member is disposed over a portion of a top surface and a perpendicular side surface of a layer covering the array of solar cells;

a plurality of male alignment features disposed over the top member and protruding from the top member perpendicular to a main longitudinal axis of the glass, wherein the male alignment features are one selected from the group consisting of self-clinching male alignment features that securely attach to the top member upon being pressed into holes in the top member and male alignment features that securely attach to the top member upon being screwed into screw holes in the top member; and

a plurality of female alignment features on the bottom member comprising holes in the bottom member of the frame which are configured to interlock with the male alignment features protruding from the top member of another module.

8. The photovoltaic module according to claim 7, wherein at least one of the female alignment features comprises a drain hole in the bottom member of the frame.

9. The photovoltaic module according to claim 7, 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.

10. An arrangement of photovoltaic modules, 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, wherein the top member is disposed over a portion of a top surface and a perpendicular side surface of a glass layer of the photovoltaic module;

a plurality of male alignment features disposed over the top member and protruding from the top member of each frame perpendicular to a main longitudinal axis of the glass, wherein the male alignment features are securely attached to the top member upon being screwed into screw holes in the top member; and

a plurality of female alignment features on the bottom member of each frame comprising a hole in the bottom member of the frame,

wherein adjacent photovoltaic modules are configured to be interlocked by the male alignment features protruding from the top member of a lower module fitting together with the female alignment features on the bottom member of an upper module.

11. The arrangement of photovoltaic modules according to claim 10, wherein at least one of the female alignment features comprises a drain hole in the bottom member of the frame.

12. The arrangement of photovoltaic modules according to claim 10, further comprising a pallet to which the interlocked plurality of photovoltaic modules is strapped.

13. The arrangement of photovoltaic modules according to claim 10, wherein the photovoltaic modules are stacked directly on top of each other without substantial space in between the adjacent photovoltaic modules.

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

15. The arrangement of photovoltaic modules according to claim 14, wherein the male alignment features on the top member are secured to the top member without passing through a plane of the glass layer.