CN112236870A

CN112236870A - Photovoltaic module with cross rail assembly

Info

Publication number: CN112236870A
Application number: CN201980034287.0A
Authority: CN
Inventors: 李·高尔尼
Original assignee: SOLAR ENERGY Co
Current assignee: Maikesheng Solar Energy Co ltd
Priority date: 2018-03-30
Filing date: 2019-03-29
Publication date: 2021-01-15
Also published as: EP3776845A4; EP3776845A1

Abstract

One embodiment relates to a Photovoltaic (PV) module including a frame adapted to receive a perimeter of a back side of a Photovoltaic (PV) laminate. The cross rail assembly may include: an electrically conductive frame adapted to receive a perimeter of a back side of a Photovoltaic (PV) laminate; one or more electrically conductive cross rail members providing structural rigidity to the electrically conductive frame; and one or more pairs of couplers connected to the conductive frame, wherein: at least one coupler includes a ground coupler having a first keyed portion adapted to be inserted into an opening in the conductive frame and a second keyed portion adapted to mate with an end of a conductive cross-rail member of the one or more conductive cross-rail members to ground the conductive cross-rail member to the frame; or at least one coupler of at least one of the one or more pairs of couplers includes a length defining a cable slot.

Description

Photovoltaic module with cross rail assembly

Priority

This application claims priority to U.S. non-provisional application serial No. 16/370,792 filed on day 29, 3/2019, which claims priority to U.S. provisional application serial No.62/651,035 filed on day 30, 3/2018 and U.S. provisional application serial No. 62/660,835 filed on day 20, 4/2018, the entire contents of each of which are each incorporated herein by reference.

Background

Photovoltaic (PV) cells, often referred to as solar cells, are devices used to convert solar radiation into electrical energy. Generally, solar radiation impinging on the surface of a solar cell substrate and entering the substrate forms electron and hole pairs in the bulk of the substrate. The electron and hole pairs migrate to the p-type and n-type doped regions in the substrate, creating a voltage difference between the doped regions. The doped region is connected to a conductive region on the solar cell to conduct current from the cell to an external circuit. When PV cells are combined in an array such as a PV module, the electrical energy collected from all of the PV cells can be combined in series and parallel arrangements to provide a power source having a certain voltage and current.

Brief description of the drawings

The following drawings are described by way of example and not limitation. For purposes of simplicity, not every feature of a given structure will necessarily be labeled in every drawing in which the structure appears. Like reference numerals do not necessarily denote like structure. Rather, the same reference number or a different reference number may be used to indicate similar features or features with similar functionality. The figures are not drawn to scale.

Fig. 1A shows a perspective view of the bottom of a Photovoltaic (PV) module including a PV laminate mounted on a frame.

Fig. 1B shows a perspective view of a roof and mounting frame for mounting the PV module of fig. 1A.

Fig. 2A shows a perspective view of a cross rail attached to a PV module similar to the PV module of fig. 1A.

Fig. 2B shows a perspective view of the attachment point of the cross rail to the PV laminate of the PV module of fig. 2A.

Fig. 2C shows a perspective view of the attachment point of the cross rail to the bottom lip of the long member of the frame of the PV module of fig. 2A.

FIG. 2D illustrates a perspective view of a single/double wall adapter that may be used in accordance with some embodiments.

Fig. 3 illustrates a cross-sectional view of a PV module having a cross-rail assembly, wherein the cross-sectional view exposes sides of the cross-rail assembly, in accordance with various embodiments.

Fig. 4A illustrates a perspective view of a cross-rail assembly including an angle key retained to a dimpled member of a frame of a PV module, in accordance with various embodiments.

Fig. 4B illustrates a perspective view of a cross-rail assembly including T-shaped corner keys attached to sections of components of a frame of a PV module, in accordance with various embodiments.

Fig. 4C illustrates a perspective view of a cross-rail assembly including a short corner key attached to a keyway of a member of a frame of a PV module, in accordance with various embodiments.

Fig. 4D illustrates a perspective view of a cross-rail assembly attached to a splined bore in a member of a frame of a PV module, in accordance with various embodiments.

Fig. 5A-5D illustrate perspective views of PV modules having a cross-rail assembly similar to that of fig. 4A, in accordance with various embodiments.

Fig. 6 illustrates a perspective view of a PV module having a cross-rail assembly similar to that of fig. 4B, in accordance with various embodiments.

Fig. 7A-7C illustrate partial bottom views of PV modules having a cross-rail assembly similar to that of fig. 4C, in accordance with various embodiments.

Fig. 8A-8B illustrate partial cross-sectional views of PV modules having a cross-rail assembly similar to that of fig. 4D, in accordance with various embodiments.

Fig. 8C-8D show partial cross-sectional views of yet another PV module having a cross-rail assembly that is similar in some respects to the cross-rail assembly shown in fig. 8A-8B.

Fig. 9 illustrates a partial cross-sectional view of a PV module having a cross-rail assembly including couplers (e.g., spacers and fasteners adapted to attach the spacers) to frame members and cross-rail members, respectively, according to various embodiments.

Fig. 10 illustrates a partial cross-sectional view of a PV module having a cross-rail assembly that includes couplers (e.g., spacers and fasteners extending through frame members, spacers, and cross-rail members), according to various embodiments.

Fig. 11 illustrates a partial bottom view of a PV module, similar to the PV module of fig. 6, in accordance with various embodiments.

Fig. 12 illustrates an assembly process of a PV module similar to the PV module of fig. 5A-5D, according to various embodiments.

Figure 13 illustrates bottom views of six different PV assemblies with non-conductive cross-rail assemblies according to various embodiments.

Fig. 14A illustrates a plan view of a photovoltaic module 1450, in accordance with various embodiments.

Fig. 14B illustrates bottom views of four different PV assemblies with cross-rail assemblies according to various embodiments.

Figure 14C illustrates a perspective view of a bottom of another PV assembly having a cross-rail assembly, in accordance with various embodiments.

Fig. 15 illustrates a bottom view of another PV assembly having a cross-rail assembly in which only a subset of the cross-rail members are attached to the frame via ground couplers, according to various embodiments.

Detailed Description

The following detailed description is merely exemplary in nature and is not intended to limit the described embodiments or the application and uses of such embodiments. As used herein, the word "exemplary" means "serving as an example, instance, or illustration. Any embodiment described herein as exemplary is not necessarily preferred or advantageous over other embodiments. Furthermore, there is no intention to be bound by any expressed or implied theory presented in the preceding technical field, background, brief summary or the following detailed description.

References to the phrase "one embodiment" or "an embodiment" do not necessarily refer to the same embodiment. The particular features, structures, or characteristics may be combined in any suitable manner consistent with the present disclosure.

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

"about" or "approximately". As used herein, the term "about" or "approximately" with respect to a recited numerical value, including, for example, integers, fractions, and/or percentages, generally indicates that the recited numerical value encompasses a range of values (e.g., +/-5% to 10% of the recited numerical value) that one of ordinary skill in the art would consider equivalent to the recited numerical value (e.g., performs substantially the same function, functions in substantially the same way, and/or has substantially the same result).

"comprising" is an open-ended term that does not exclude other structures or steps.

"configured to" refers to a structure by indicating a device such as a unit or component, including a structure that performs one or more tasks during operation, and such a structure is configured to perform the task even if the device is not currently operating (e.g., not turned on/inactive). A device "configured to" perform one or more tasks is expressly intended to not invoke section 35u.s.c. § 112(f), the sixth section.

The terms "first," "second," and the like are used as labels for terms after them and do not imply any type of order (e.g., spatial, temporal, logical, and the like). For example, reference to a "first" IEC does not necessarily imply that the IEC is an IEC in a sequence; instead, the term "first" is used to distinguish this IEC from another IEC (e.g., "second" IEC).

"based on". As used herein, the term is used to describe one or more factors that affect the results of a determination. The term does not exclude further factors that may influence the determination result. That is, the determination may be based only on those factors or at least partially on those factors. Consider the phrase "determine a based on B. Although B may be a factor that affects the determination of a, such phrases do not exclude that the determination of a is also based on C. In other examples, a may be determined based on B alone.

"coupled" -the following description means that elements or nodes or structural features are "coupled" together. As used herein, unless expressly stated otherwise, "connected" means that one element/node/feature is directly or indirectly connected to (or directly or indirectly communicates with) another element/node/feature, and not necessarily mechanically.

"prevent" means to reduce, minimize, or effectively or virtually eliminate something, such as completely avoiding an outcome, consequence, or future state.

The terms "a" and "an" are defined as one or more unless the disclosure clearly requires otherwise.

The term "substantially", as used herein, is defined as largely but not necessarily entirely what is specified (and includes what is specified; e.g., "substantially 90 degrees" includes 90 degrees, "substantially parallel" includes parallel), as will be understood by one of ordinary skill in the art. In any disclosed embodiment, the terms "substantially", "about" and "approximately" may be substituted with "within a percentage of what is specified, wherein the percentage includes 0.1%, 1%, 5% and 10%.

As used herein, "region" may be used to describe a discrete area, volume, portion, or location of an object or material having definable characteristics, but not necessarily fixed boundaries.

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

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

Photovoltaic (PV) modules may generate Direct Current (DC) electricity based on received solar energy. A PV module may include a plurality of solar or PV cells electrically coupled to one another, allowing the PV cells to contribute to providing a combined output power to the PV module. Some PV modules include a PV laminate that encapsulates solar cells and a rectangular frame on which the perimeter of the PV laminate 105 is mounted. Fig. 1A shows a perspective view of a PV module including a frame (e.g., a metal frame) having a first side on which a perimeter of the PV laminate 105 is mounted and an opposing second side. The frame comprises a first frame member 101, a second frame member 102, a third frame member 103 and a fourth frame member 104.

PV modules may be mounted on mounting rails of a mounting frame, which in some applications may be located on a roof. Fig. 1B shows a perspective view of a mounting frame 121 located on a roof 120. The second side of the mounting frame (fig. 1A) may contact the mounting frame 121. Depending on the mounting requirements and/or application, the second side of the

long members

101 and 102 of the frame (fig. 1) may contact the mounting frame 121, or the second side of the

short members

103 and 104 of the frame (fig. 1) may contact the mounting frame 121.

Referring now to fig. 2A, some PV modules may include at least one cross rail 210. The use of one or more cross rails 210 may inhibit cell cracking in the PV module. Additionally, the use of one or more cross-rails 210 may enable the use of different sizes and materials for the frame and/or the PV laminate 205 (e.g., lighter frames, thinner PV laminates, and/or PV laminates having different layer combinations). In the example shown, the cross rail 210 extends from the first long member 201 of the frame to the second long member 202 of the frame; however, in other examples, longer and/or heavier cross rails 210 may extend from the first short member 203 of the frame to the second short member 204 of the frame.

The cross rail 210 may also comprise metal, and thus building codes may require the cross rail 210 to be grounded to the frame. In some PV modules, this continuous material path requirement can be met by running the cross-rail 210 against the inside of the frame. The continuity can be achieved using screws or rivets, i.e. they can be screwed or inserted into the frame. Fig. 2B shows an example in which rivets are inserted through the top flange of the cross rail 210 and the frame 201 (and/or through the PV laminate). Fig. 2C shows an example in which rivets are inserted through the bottom flange of the cross rail 210 and the bottom flange of the frame 201.

In some applications, the PV module may include various other components. The DC power generated by the PV modules may be converted to AC power by using a power inverter. The power inverter may be electrically coupled to the output of the PV module (the output of the PV module may include electrical connections protruding from the back sheet of the PV laminate, which may also be encapsulated by a junction box in some examples). Intermediate wiring (e.g., DC-4 connections) may be employed between the PV modules, junction box, and power inverter. The power inverter may be electrically coupled to a DC output of the PV module (e.g., a PV cable). The power inverter may be located physically separate from the PV module, requiring only intermediate wiring and/or accessories thereof to physically couple the PV module to the power inverter.

During installation of the PV modules without cross-rails, the PV modules can be placed on the mounting frame in any configuration, and the PV cables can be installed between the mounting frame (fig. 1B) and the PV laminate (fig. 1A). This facilitates installation by the installer and allows the position of the PV module on the mounting frame to be selected based on the application requirements (rather than the requirements for cabling).

In contrast, installing PV modules having one or more cross-rails can present problems. If the desired location of the PV module would result in the cross-rail forming a "double wall" with the mounting frame, the installer cannot install at the desired location (it is out of specification to run the PV cables below the "double wall" (e.g., below the mounting frame)). For this reason, the installer and/or the consumer may dislike PV modules with cross rails.

While the PV module may include short cross-rail members to allow cables to be routed between the mounting rails and the short cross-rail members even when one of the short cross-rail members is mounted above and parallel to the mounting rails of the mounting frame, the mechanical strength of this design is not necessarily compatible with certain PV laminates and/or certain PV frames. Furthermore, since the inertia of a beam is proportional to its cubic height, the mechanical strength and/or material volume used for this cross member may not be optimal. Some embodiments disclosed herein may include a cross-rail assembly that includes a cross-rail member that is taller than this short cross-rail member (e.g., as tall as a member of the frame or at least taller than the short cross-rail member under which the cable may be routed). The cross-rail assembly may include one or more portions to define one or more channels through which cables may be routed even if the cross-rail assembly is mounted above and parallel to the mounting rail. In embodiments where the cross-rail assembly includes a metal cross-rail member attached to the frame using a pair of spacers to define the channel, the metal cross-rail member may be electrically connected to the frame only through the pair of spacers.

One embodiment may include an apparatus having: a frame adapted to receive a perimeter of a back side of a Photovoltaic (PV) laminate; one or more cross-rail members that can provide structural rigidity to the frame; and one or more pairs of couplers coupleable to the frame, each coupler of the pair including a first portion adapted to define a groove and a second keyed portion inserted into a different end of a respective cross rail member of the one or more cross rail members; wherein each cross-rail member may be electrically connected to the frame only through the couplers of a respective one of the one or more pairs of couplers.

One embodiment may include an apparatus having a cross-rail assembly for use in a Photovoltaic (PV) module. In a certain example, the apparatus may include: a PV laminate having a front side, a back side, and a plurality of solar cells encapsulated between the front side and the back side; a frame, wherein a perimeter of the PV laminate is mounted to the frame. The cross-rail assembly may provide structural rigidity to the PV laminate and frame. The cross rail assembly may include a plurality of sections, and one or more of the sections may have a height that is less than the height of the remaining sections. If the cross-rail assembly is placed over the mounting rail at the installation site, an excavation may be formed by one or more portions of the cross-rail assembly and one or more corresponding areas of the mounting rail. The installer may connect the cables in series through one or more tunnels. Other embodiments may be disclosed and/or claimed.

One embodiment is an apparatus for use in a Photovoltaic (PV) assembly, the PV assembly comprising one or more mounting rails and a PV module, the PV module comprising: a frame; and a PV laminate having a front side, a back side, and a plurality of solar cells encapsulated between the front and back sides, wherein a perimeter of the PV laminate is mounted on the frame. The apparatus includes one or more cross-rail assemblies adapted to provide structural rigidity to the PV laminate and the frame, each cross-rail assembly extending from a first member of the frame to a second member of the frame, the cross-rail assemblies being grounded to the frame and having a first side facing a back side of the PV laminate and an opposite second side. At least one of the one or more cross-rail assemblies includes one or more first portions having one or more heights that are less than a height of a remainder of the at least one cross-rail assembly, wherein the one or more first portions of the at least one cross-rail assembly define one or more channels. The one or more channels comprise one or more galleries when the at least one cross-rail assembly is mounted above and parallel to the mounting rail of the one or more mounting rails. Other embodiments may be disclosed and/or claimed.

The following detailed description is merely exemplary in nature and is not intended to limit the embodiments of the subject matter of the application or the uses of such embodiments. As used herein, the word "exemplary" means "serving as an example, instance, or illustration. Any embodiment described herein as exemplary is not necessarily to be construed as preferred or advantageous over other embodiments. Furthermore, there is no intention to be bound by any expressed or implied theory presented in the preceding technical field, background, brief summary or the following detailed description.

Fig. 3 illustrates a cross-sectional view of a PV module 300 having a cross-rail assembly 310, wherein the cross-sectional view exposes the sides of the cross-rail assembly 310, in accordance with various embodiments. PV module 300 includes a PV laminate 305, a first frame member 301 (e.g., a long side frame member), a second frame member 302 (e.g., a long side frame member), a third frame member 303 (e.g., a short side frame member), and a fourth frame member (not shown). The cross rail assembly 310 includes a first portion 311 and a second portion 312. The cross-rail assembly 310 includes a first side 321 facing the PV laminate 305 and an opposing second side 322. In the first portion 311, the second side 322 may define a groove 320, e.g., a cable groove. In some embodiments, the channel 320 may include cable management features that may be used to route cables (not shown) through the channel 320 by an installer. In any embodiment, the cross rail assembly 310 may have a third portion (not shown) similar to the first portion but located on the other end of the cross rail assembly 310 to provide the channel 320 on both sides.

In the illustration, the cross rail assembly 310 is shown in contact with the back side of the PV laminate 305. In embodiments where the cross-rail assembly 310 is in contact with the PV laminate 305 (e.g., as shown at 321), an adhesive may be located between the cross-rail assembly 310 and the back side of the PV laminate 305, which may be used to limit deflection in both upward and downward loads. Additionally, in some embodiments, only the second portion 312 is in contact with the PV laminate 305. For example, to facilitate installation, the first portion 311 may define additional grooves (not shown) similar to the grooves 320 between the PV laminate and the first portion 311. In some embodiments, the additional grooves (which may eliminate the left and right hand designation for the cross-rail assembly 310 in the parts list) may be referred to as "virtual" grooves because all cables may be routed through the grooves 320.

The cross-rail assembly 310 may include any pair of any conductive cross-rail member and any ground coupler described herein. Referring briefly to fig. 5A, some conductive cross rail members 551 may span only a portion of the distance between long

side frame members

533 and 534. One connector in pair 532 of fig. 5A may span the remainder of the distance to define a cable trough. The other coupler of pair 532 may be different, for example, may not define a cable slot.

Referring again to fig. 3, in other embodiments, the cross-rail assembly 310 may include a conductive cross-rail member that spans the entire distance between the first frame member 301 and the second frame member 302. Fig. 4D shows a perspective view of the cross-rail assembly including the conductive cross-rail member 454 to span the entire distance between opposing members of the frame. In these embodiments, the conductive cross rail member 454 may penetrate an opening 471, such as a ridge opening, in the frame member. As will be explained in more detail later, the conductive cross rail member 454 may be grounded to the frame by a ground coupler or by an interface between an end of the conductive cross rail member 454 and the interior of the frame member.

Referring again to fig. 3, the second portion 312 is shown with the second side in a different plane than the second side of the frame (which exposes the third frame member 303); however, in other examples, the second side of the second portion 312 may be in the same plane as the second side of the frame. Specifically, the second portion 312 may have any height greater than the height of the first portion 311 and no greater than the height of the frame. Thus, the PV module 300 can be mounted above and parallel to the mounting rail. The PV panel 300 is compatible with a variety of PV laminate designs and/or frame designs, is lightweight, and is inexpensive to manufacture and/or install.

The shape of the channel 320 is shown as rectangular; however, in other embodiments, the groove 320 may have any shape that may be used to string cables through the groove 320 during installation. Also, in the example shown, the channel 320 is defined by the first portion 311 of the cross-rail assembly 310, the first frame member 301, and the second portion 312 of the cross-rail assembly 310. In other examples, the channel 320 may be defined only by the first portion 311 and the first frame member (as in the curved channel 820 shown in fig. 8A). In other examples, it is possible and practical to define the groove 320 only in the first portion 311 (e.g., the groove 320 need not necessarily be defined by a side of the first member 301).

In some embodiments, the first frame member 301 may be a long side frame member of a rectangular frame. In other embodiments, the first frame member 301 may be a short side frame member of a rectangular frame.

Fig. 4A shows a perspective view of a cross-rail assembly including a cross-rail 451 and a corner key 432 that is retained to a dimpled member of a frame 401 of a PV module, in accordance with various embodiments. Fig. 4B illustrates a perspective view of a cross-rail assembly including cross-rails 452 and T-keys 433 attached to various segments of the components of the frame 402 of the PV module, according to various embodiments. Fig. 4C illustrates a perspective view of a cross-rail assembly including a cross-rail 453 and a short corner key 434 attached to a keyway of a member of a frame of a PV module, according to various embodiments. Fig. 4D illustrates a perspective view of a cross-rail assembly including a cross-rail member 454 attached to a splined aperture 471 in a member of a frame of a PV module, in accordance with various embodiments.

Fig. 5A-5D illustrate a PV module 500 having a cross-rail assembly similar to that of fig. 4A, in accordance with various embodiments. Referring to fig. 5A, the PV module 500 includes a PV laminate 505, which may be similar to any of the PV laminates described herein. In this embodiment, components such as micro-inverters, junction boxes, etc. may be mounted on the back side of the PV laminate 505. PV module 500 also includes a cross-rail assembly, which may be similar to any of the cross-rail assemblies described herein. The cross-rail assembly includes a cross-rail member 551 and a coupler pair 532. Cross rail members 551 may be electrically connected to the frame by pairs 532 and/or one or more couplers in pairs 532, e.g., only by pairs 532. In fig. 5A, the cables are routed in the volume defined by the frame and cross-rail members 551 such that the cables do not interfere with contact between the cross-rail members 551 (or frame) and the mounting frame 121 (fig. 1B) and/or roof 120 (fig. 1B), and may also simplify installation/assembly/transportation.

Referring to fig. 5B, connector 552 of pair 532 (fig. 5A) is shown. The coupler 552 may include a first tab 581 and a second tab including an end 582. In a certain example, the first tab 581 and the second tab may be arranged in an L-shape. The end 582 may be formed (e.g., keyed, molded, extruded) to mate with a cavity in the end of the cross-rail member 551.

The frame member 501 includes an opening 571 that provides access to the cavity. The cavity may be defined by the inner and outer walls of the frame member 501. The first tab 581 may be located in the cavity and keyed to mate with the cavity. In a certain example, positioning the first tab 581 in the cavity may lock the first tab 581 in place at the cavity. After insertion into the opening 571, the first tab 581 can be positioned in the cavity.

Referring to fig. 5C (which is a cross-sectional view looking perpendicular to the cross-rail assembly and parallel to the frame member 501), the coupler 552 may define

channels

520 and 521. In this view, a cross-sectional view of the frame portion and a plan view of the coupler 552 are shown. In this example, the grooves 520 may be used to run cables in series during installation of the PV module 500 (fig. 5A). In contrast, in some examples, the trench 521 may be a virtual trench (which may be an artifact of the manufacture of the coupler 552, without any left/right part designation, not intended for use in stringing cables). Of course, the channel 521 may be a virtual channel for certain PV module 500 mounting configurations, or may receive cables in other PV module 500 mounting configurations depending on the application. In this example, the coupler 552 and the flange of the frame member 501 corresponding to the channel 520 define a cable management feature. Additionally, the inner side walls of the frame member 501 may also define cable management features for suspending cables strung through the channel 520.

With respect to electrical connection to the frame through pair 532 (fig. 5A, e.g., only through pair 532), fig. 5C specifically illustrates a "metal-to-metal" contact (which may also be referred to as a contact optimized for electrical grounding) between coupler 552 and the inside of frame member 501, particularly the inside of the outer wall of frame member 501. Although the exterior of the frame member 501 may be anodized to prevent corrosion (involving a relatively weak conductor layer such as an oxide on the anodized surface), the interior of the frame member 501 may not be anodized. For this or other reasons, the electrical resistivity of the surface of the outside of the frame member (e.g., hollow frame member) may be greater than the electrical resistivity of the surface of the inside of the frame member. Thus, "metal-to-metal" may refer to contact between non-anodized surfaces of metal parts. In some examples of PV modules, metal fasteners are required to pierce the anodized surface to meet grounding requirements that may not need to be followed due to contact on the inside of the frame member 501.

Fig. 5D shows a perspective view of a cross-section through the coupler 552 (e.g., a cross-sectional view that appears perpendicular to the frame member 501 and parallel to the cross-rail assembly). The end 582 of the second protrusion of coupler 552 is shown within a cavity defined by coupler 552 (in some examples, coupler 552 may be double-walled, similar to frame member 501). In this view, the opening 571 is referred to as a "key recess".

In any of the embodiments described herein, the frame members may be single-walled or double-walled (similar to frame members 501 of fig. 5B), and the cross-rail assemblies may be single-walled or double-walled. Additionally, in some embodiments of PV modules having frame members and cross-rail assemblies, the number of walls of the cross-rail assembly need not be the same as the number of walls of the frame members. Adapters may be used to attach, for example, a single wall cross rail assembly to a double wall frame member. FIG. 2D illustrates a perspective view of a single/double wall adapter that may be used in accordance with some embodiments. This feature, or any other feature of U.S. provisional application serial No.62/651,035, may be used in any embodiment of a photovoltaic module having a cross-rail assembly as described herein. In particular, any feature of the adapter may be used with any of the couplers (e.g., ground couplers) described herein to provide a coupler (e.g., a ground coupler) to attach a single-walled or double-walled cross-rail member to a double-walled or single-walled frame (respectively).

In a certain embodiment, the connection key 210 of fig. 2D is a single wall key with two connection holes 213. In one embodiment, the single-wall bond may be a single-wall aluminum bond. Other materials such as galvanized steel or carbon laminates or polymers may also be used. In addition, one connection hole, or more than two connection holes, for example, 3, 4, 5 or more connection holes, may be employed in embodiments. These attachment holes 213 may be used to secure the keys to the single wall frame portion during manufacture. In a certain example, the connection hole may alternatively be referred to as a screw hole, and a screw may be used as the connection member; however, the attachment holes may have other configurations, such as a pin hole combination, a rivet hole combination, a tox-hole combination, a tab slot/recess combination, or a flange slot/recess combination, and combinations thereof.

Also labeled in fig. 2D are open ended hollow 214, clamping end 217, long key arm 219, optional

key hollows

211, 212, 220, short key arm 218, and edge key arm 216. In some embodiments, a connecting key may have two short key arms, two long key arms, three or more key arms (e.g., when three or more frame portions are connected together), one long key arm and one short key arm, as well as various permutations of these examples. As described above, the attachment holes 213 may be threaded to receive screws, and may be sized and configured to receive other attachment members, such as pins, rods, rivets, tox attachment members, and the like. Other attachment techniques may be used, such as a flange slot/recess combination or a tab slot/recess combination.

In embodiments, the connection key may connect the cross rail assembly and the frame portion at various angles, which may include: 11.25 °, 22.5 °, 45 °, 60 °, 75 °, 90 °, 110 °, 115 °, 125 °, 135 °, and 180 °. The frame portion may be made of various materials and may include a metal having sufficient rigidity. In embodiments, the connecting keys and frame portions may be galvanized or otherwise treated to be weather resistant.

Fig. 6 illustrates a PV module 600 having a cross-rail assembly similar to that of fig. 4B, in accordance with various embodiments. PV module 600 includes a cross-rail member 651, which may be similar to cross-rail member 551 (fig. 5A-5D). The cross-rail member 651 can be electrically connected to the frame of the PV module 600 by a pair of couplers 632 (e.g., in some examples, only by a pair of couplers 632).

An exploded view of one of the couplers shows the first, second, and third tabs arranged in a T-shape. For example, the cross-rail assembly may be positioned perpendicular to the frame as shown. In a certain example, one of the projections defining the groove may have a keyed end, similar to end 582 (fig. 5B).

In this example, the frame member is segmented. One of the tabs is keyed and located in a cavity of one of the segments of the frame member. The other of the tabs is also keyed and located in the cavity of the other section of the frame member. In other words, the coupler connects the frame member segments together in addition to connecting the cross rail members to the frame. The coupler may have "metal-to-metal" contacts, similar to the "metal-to-metal" contacts described with respect to fig. 5D.

Fig. 7A-7C illustrate partial bottom views of PV modules having a cross-rail assembly similar to that of fig. 4C, in accordance with various embodiments. This coupler 732 is referred to as a "short key". Again, the cross-rail member 751 can be electrically connected to the frame by a coupler pair (e.g., only by a coupler pair in some examples). A "metal-to-metal" contact similar to the previously described "metal-to-metal" contact may be defined in the respective areas of the keyway and the short key 732.

The short key 732 may be L-shaped or T-shaped and may include a protrusion that defines a groove (referred to in this example as a through-the-room DC cable) and includes a keyed end to mate with a cross-rail keyway defined by the cross-rail member 751. The other one or more protrusions may mate with frame member keyways defined by frame member 701. Fig. 7B and 7C show cross-sectional views of the frame member 701 and the cross rail member 751, respectively. The keyway may be about half the height of the associated member (which may be the same height in this example), but may be other proportions in other examples. As shown in the cross-sectional view, in this example, the frame member 701 may be double-walled and define a keyway, and the cross rail member 751 may be an I-structure and define a keyway.

Also, as shown, the hollow defined by each keyway (to mate with the key region of coupler 732) may be larger in size than the opening in the keyway. The sidewalls of the keyway defining this opening may be cut away (only in selected portions of the keyway) during installation to provide the keying zone into the hollow. The key region can then be slid into the hollow and the remainder of the keyway (with no side walls cut away) can secure the coupler into the component.

Fig. 8A-8B illustrate partial cross-sectional views of PV modules having a cross-rail assembly similar to that of fig. 4D, in accordance with various embodiments. In this view, a cross-sectional view of the frame portion and cross rail member 851 is shown. In this example, the cross rail assembly includes a cross rail member 851 for physical contact with the frame member 801. The ends of the cross rail member 851 form a metal-to-metal contact in the hollow portion in the frame member 801. Further, the cross rail member 851 and the frame member 801 define a cable slot (e.g., through which a DC cable passes).

Referring to fig. 8B, the openings in the frame member 802 may be splines. The cross-rail member 852 cross-section comprises a twisted I-shape (as shown, wherein the opposite sides of the top and bottom of I are not parallel with the other sides of the top and bottom). This shape allows the cross rail member 852 to be rotated to be inserted into the spline shaped opening and then twisted to lock into place.

Figures 8C-8D show partial cross-sectional views of yet another PV module having a cross-rail assembly. In this example, the cross-rail member 853 does not define any grooves. However, the cross-rail member 853 still includes metal-to-metal contacts (e.g., with the lower resistivity surface of the frame member 803) and locking features to mate with the opening 871 in the frame member 803, and for these reasons rivets (due to the metal-to-metal contacts and locking features on the non-anodized regions) that are required for certain PV modules may not be needed.

Fig. 9 illustrates a partial cross-sectional view of PV modules having cross-rail assemblies that respectively include couplers 932 (e.g., spacers and fasteners adapted to attach the spacers to frame members 901 and cross-rail members 951, respectively), according to various embodiments. In this example, the fasteners can pierce the surfaces of the members 901 and 951 (e.g., the anodized surfaces of the bottom flanges) to provide continuity between the cross members 951 and the frame 901 (from the cross rail members 951, through the fasteners, spacers, another fastener, to the frame member 901).

The spacer 932 may include projections (such as prongs) to wedge fit the spacer into place for retaining the spacer 932 when the fastener is installed. In this example, the projections mate with approximately 270 degree circular formations on the inner wall of the frame member 902. In other examples, the frame member 902 need not include a circular formation, and the tabs may be longer and may engage the back of the PV laminate to wedge the spacer in place. In this example, the spacer 932 has an arithmetic helical segment shape (similar to a nautilus) in which the end of the helical segment that makes the smallest turn defines the cable management feature (and another region of the helical segment, such as the remainder of the helical segment, defines the groove). In other examples, the spacer may have any shape, such as a U-shape (with the bottom of the U facing the PV laminate), and may or may not include a protrusion that extends into the groove for cable management.

Fig. 10A-10B illustrate partial cross-sectional views of PV modules having a cross-rail assembly that includes couplers 933 (e.g., spacers and fasteners extending through frame member 902 and cross-rail member 952), in accordance with various embodiments. In this example, the head of the fastener may provide metal-to-metal contact with the inner wall of the frame member 902, and may also pierce any anodized surface on the other side of the inner wall. Fasteners may also pierce the ends of the cross rail member 952.

The outer wall of the frame member 902 may include an opening (not shown) sized to fit over the head of the fastener to mount the fastener from the outside of the PV module. The spacers may include small protrusions as shown to engage mating hollows on the ends of the cross rail member 952, which may align the spacers for installing fasteners into the predrilled holes between the mating hollows.

In this example, the springs may be coupled to the PV module as shown. In the release position, the spring may block access into the groove. The spring may be actuated to insert the cable into the groove and then the spring may spring back to the original position. The springs shown may be used as the cable management features of the channels of any of the other PV modules described herein. Other examples may not require a spring, and gravity may be sufficient to return the cable management component (e.g., the closure tab) to its original state after insertion of the cable.

Fig. 11A-11B illustrate PV modules similar to the PV module of fig. 6, according to various embodiments. As shown, the PV module may include

frame member segments

1101 and 1102 that are joined end-to-end to form, for example, the long sides of the frame, as shown in fig. 11C. The

frame segments

1101 and 1102 may be joined to the cross rail member 1152 by T-couplers 1131, shown in more detail in fig. 12B. In some, a cover may be used as shown to protect the PV laminate and fill any gaps between frame segments 1101 and 1102 (although in some embodiments, the ends of the instances of

frame segments

1101 and 1102 may be in physical contact, leaving substantially no gaps). The grooves and the couplers 1131 in the grooves may be covered by the PV laminate (e.g., to protect them from the elements).

Fig. 12A-12I illustrate an assembly process of a PV module according to various embodiments, similar to the PV module of fig. 5A-5D. The short

side frame members

1203 and 1204 may be disposed on the back of the PV laminate 1205 (or vice versa, e.g., the PV laminate 1205 may be disposed on the short side frames 1203 and 1204), as shown in fig. 12A-12B. A coupler 1231 (e.g., an L-shaped coupler in this embodiment) may be inserted into an opening 1207 defined by the interior sidewalls of the long side frame members 1201 and 1202 (by moving the coupler 1231 through the opening 1207 toward the exterior sidewalls), as shown in fig. 12C.

Then, by moving the coupler 1231 in the orthogonal direction (parallel to the length of the long side frame member 1201), the keyed protrusion of the coupler 1231 can be inserted into the hollow between the side walls, as shown in fig. 12D to 12F. This may lock coupler 1231 into place. The cross-rail member 1251 may slide over the keyed end of the other protrusion of the coupler 1231 (in some examples, this may be performed prior to inserting the coupler 1231 into the long side frame member 1201).

With the coupler 1231 in place, the assembly of long

side frame members

1201 and 1202, coupler 1231, and cross rail member 1251 may be disposed on the back of the PV laminate 1205. This may include first inserting the corner keys 1299 into the short side frame members (as shown for frame member 1204 in fig. 12G-12I), and then sliding the

long side members

1201 and 1202 over the other protrusions of the corner keys 1299. The PV modules can then be transported to the installation site where the installer can string the cables through the trench.

Fig. 13 shows bottom views of six

different PV assemblies

1351, 1352, 1353, 1354, 1355 and 1356 with non-conductive

cross-rail assemblies

1361, 1362, 1363, 1364, 1365 and 1366, respectively, according to various embodiments. The non-conductive

cross-rail assemblies

1361, 1362, 1363, 1364, 1365, and 1366 may be manufactured using any known molding, casting, and/or forming process. In some embodiments, the non-conductive

cross-rail assemblies

1361, 1362, 1363, 1364, 1365, and 1366 may comprise non-extruded members (e.g., only non-extruded members). In some embodiments, the non-conductive

cross-rail assemblies

1361, 1362, 1363, 1364, 1365, and 1366 may comprise plastic.

The non-conductive

cross-rail assemblies

1361, 1362, 1363, 1364, 1365, and 1366 may limit the bending of the PV laminate 1305 under load by reinforcing the PV laminate 1305, e.g., each may shorten the distance from two frame support features of the PV laminate 1305, e.g., may form additional load paths between the PV laminate 1305 and mounting system components, such as the mounting rails 1399. In some embodiments, the height of the non-conductive

cross-rail assemblies

1361, 1362, 1363, 1364, 1365, and 1366 may be greater than a selected value (e.g., half the distance between the back of the PV laminate 1305 and the plane of the frame bottom) to provide such reinforcement. The non-conductive

cross-rail assemblies

1361, 1362, 1363, 1364, 1365, and 1366 may be attached to the back sheet of the PV laminate 1305 using, for example, an adhesive similar to other embodiments of the cross-rail assemblies described herein.

Likewise, any of the non-conductive

cross rail assemblies

1361, 1362, 1363, 1364, 1365, and 1366 may contact a mounting system component, such as mounting rail 1399. In some embodiments, any of the non-conductive

cross-rail assemblies

1361, 1362, 1363, 1364, 1365, and 1366 may distribute contact forces from the mounting system components through a larger area of the PV laminate 1305. Other embodiments of the non-conductive cross-rail assembly may have any shape to transfer loads between the mounting system components and the PV laminate 1305 under low pressure.

Non-conductive

cross rail assemblies

1361, 1362, 1363, 1364, 1365, and 1366 may define

cable gaps

1371, 1372, 1373, 1374, 1375, and 1376 with frame 1301 (e.g., the long side members of frame 1301). In the illustrated embodiment,

cable gaps

1371, 1372, 1373, 1374, 1375, and 1376 are also defined by the back side of PV laminate 1305. In other embodiments, the conductive cross rail assembly may have any of the illustrated shapes of the non-conductive

cross rail assemblies

1361, 1362, 1363, 1364, 1365, and 1366, and additionally may include a cross section similar to cross section 311 (fig. 3), and/or may include a separate component, such as any of the conductive spacers described herein, to electrically connect the conductive cross rail assembly to the frame of the PV assembly. In these embodiments, the conductive cross rail assembly and/or the additional components may define a cable trough with the frame. Also, the conductive cross-rail assembly can make contact with a conductive mounting rail (similar to mounting rail 1399) to form an electrical path (e.g., a unique electrical path) between the frame of the PV module and the conductive mounting rail.

The shape of any cross-rail assembly according to embodiments disclosed herein may differ significantly from the "bar" shape of the cross-rail member shown in fig. 2A. For example, such a shape may or may not be defined at all by an elongated member, e.g., a cross-rail assembly similar to the non-conductive cross-rail assembly 1366 may include a shape (e.g., a circle) that is not defined by any elongated member. Also, any cross rail member may comprise a circular core and one or more elongated projections extending from the circular core (which may or may not be parallel with any member of the frame, and in the case of more than one elongated projection, may not be parallel with another of the elongated projections). Also, some shapes may have elongated members that are not parallel to any member of the frame, e.g., a cross-rail assembly similar to the non-conductive

cross-rail assemblies

1364 and 1365. Also, some shapes may include elongated projections extending from a point similar to the non-conductive cross-rail assembly 1361 (such as a double cross shape with two such points). In the non-conductive cross-rail assembly with elongated protrusions 1361, at least one elongated protrusion is not parallel (e.g., orthogonal) to another elongated protrusion.

Fig. 14A-14C include

alternative PV assemblies

1451, 1452, 1453, 1454, and 1455 having

cross-rail assemblies

1461, 1462a, 1462b, 1463, 1464A, and 1464b, respectively.

PV assemblies

1451, 1452, 1453, 1454, and 1455 and

cross-rail assemblies

1461, 1462a, 1462b, 1463, 1464a, and 1464b may provide substantial structural support for the entire frame, referring to fig. 1. In certain examples, the

cross-rail assemblies

1461, 1462a, 14622b, 1463, 1464a, and 1464b may provide structural support that allows use of partial frames, e.g., discontinuous frames and/or frames that include gaps between frame portions.

Such PV assemblies

1451, 1452, 1453, 1454, and 1455 and

cross-rail assemblies

1461, 1462a, 1462b, 1463, 1464a, and 1464b may significantly reduce costs while providing the expected comparable structural integrity, i.e., a complete frame, as compared to using the entire frame.

Fig. 14A illustrates a plan view of a photovoltaic module 1450, respectively, in accordance with various embodiments. As shown, photovoltaic module 1450 may include a partial frame 1401, a plurality of solar cells 1404, a laminate 1405, and gap portions 1402 between partial frame portions 1404. Photovoltaic assembly 1450 may represent a plan view of

PV assemblies

1451, 1452, 1453, 1454, and 1455 depicted in fig. 14B.

Fig. 14B-14E illustrate bottom views of four different PV assemblies 1451 (fig. 14B), 1452 (fig. 14C), 1453 (fig. 14D), and 1454 (fig. 4E) having

cross-rail assemblies

1461, 1462a, 1462B, 1463, 1464a, and 1464B, respectively, according to various embodiments. Referring to PV assembly 1451, cross-rail assembly 1461 may include a cross-structure that may connect partial frame 1401 (including gap 1402) between separate partial frames at the ends of partial frame 1401. Referring to PV assembly 1452,

cross-rail assemblies

1462a, 1462b may include a support portion 1462a and a central support portion 1462b, wherein the support portion may be connected to an end of partial frame 1401, and central portion 1462b may be connected to all of support portions 1462 a. Referring to PV assembly 1453, cross-rail assembly 1463 may comprise a cross-structure that may be connected at the corners of a partial frame 1401, which may include

gaps

1402, 1403. Referring to PV assembly 1454, cross-rail assemblies 1464a, 1464b may include support portions 1464a and a central support portion 1464b, wherein the support portions may be connected to end portions and corner portions of partial frame 1401, and central portion 1462b may be connected together to support portion 1462 a. Also, the partial frame 1401 may comprise gaps 1401 at the long sides of the PV assembly and/or may comprise gaps 1403 at the short sides of the PV assembly.

Referring again to fig. 14B, the

cross-rail assemblies

1461, 1462a, 1462B, 1463, 1464a, and 1464B may be manufactured using any known molding, casting, and/or forming process. In some embodiments, the

cross-rail assemblies

1461, 1462a, 1462b, 1463, 1464a, and 1464b may include non-extruded components (e.g., only non-extruded components). In some embodiments, the

cross-rail assemblies

1461, 1462a, 1462b, 1463, 1464a, and 1464b may comprise plastic. In one embodiment, the

cross-rail assemblies

1461, 1462a, 1462b, 1463, 1464a, and 1464b may limit bending of the PV laminate 1405 under load by reinforcing the PV laminate 1405, e.g., each may form a load path between the PV laminate 1405 and a mounting system component (such as the mounting rail 1399 of fig. 13). In one example, the

cross-rail assemblies

1461, 1462a, 1462b, 1463, 1464a, and 1464b may be non-conductive, e.g., may comprise a non-conductive material. In another example, the

cross-rail assemblies

1461, 1462a, 1462b, 1463, 1464a, and 1464b may be non-conductive, e.g., may comprise a non-conductive material.

Fig. 14F illustrates a perspective view of a PV assembly 1455 according to various embodiments. In one example, the cross-rail assembly may include a support portion 1465a and a central support portion 1465 b. In a certain example, support portions 1465a may be connected to end portions and corner portions of partial frame 1401 (for PV laminate 1405), and central portions 1465b may be connected together to support portions 1465a, shown for clarity.

Fig. 15 shows a bottom view of another PV assembly having an electrically conductive cross-rail assembly in which only a subset of the cross-rail members are attached to the frame via ground couplers, according to various embodiments. The frame of the PV assembly includes frame member 1501, frame member 1502, frame member 1503, and frame member 1504. The cross rail assembly includes a plurality of cross rail members. A ground coupler 1532 (which is similar to any ground coupler, keyed adapter, etc. described herein in any example) electrically connects individual ones of the cross-rail members 1510 to the frame. In this example, ground coupler 1531 attaches the cross rail member to the corners defined by frame members 1502 and 1503 (e.g., tethered to one or more frame members, such as the corners defined by the frame members), but in other examples, a ground coupler for a separate cross rail member may attach a separate cross rail member to one of frame members 1501-1504.

The other remaining cross-rail members may be electrically connected to the frame only by the individual cross-rail members 1510 and their ground couplers 1532. The other remaining cross-rail components may not have their own couplers (e.g., the other remaining cross-rail components may be "unbundled" from the frame members, but rather adhered to the PV laminate 1505, similar to the manner in which any of the non-conductive cross-rail components described above may be adhered to the PV laminate). In this example, a circular cross-rail member 1511 electrically couples the other cross-rail members to the individual cross-rail members 1510. Any of the cross-rail members (including cross-rail member 1510 and/or circular cross-rail member 1511) may be adhered to the PV laminate 1505 in a manner similar to the manner in which any of the non-conductive cross-rail members described herein may be adhered to the PV laminate.

Examples of the invention

Example 1 is a Photovoltaic (PV) module, comprising: a PV laminate having a front side, a back side, and a plurality of solar cells encapsulated between the front side and the back side; a frame, wherein a perimeter of the PV laminate is mounted on the frame; a cross-rail assembly adapted to provide structural rigidity to the PV laminate and the frame, the cross-rail assembly extending from a first member of the frame to a second member of the frame, the cross-rail assembly grounded to the frame and having a first side facing the back side of the PV laminate and an opposite second side; and a cable trough defined by an end of a member of the cross-rail assembly and a ground coupler adapted to attach the end of the member of the cross-rail assembly to one of the first and second members of the frame or a first portion of a plurality of portions of the cross-rail assembly, wherein a distance between the first side of the cross-rail assembly and the second side of the cross-rail assembly in the second portion is less than a distance between the first side of the cross-rail assembly and the second side of the cross-rail assembly in a second, different portion of the plurality of portions of the cross-rail assembly.

Example 2 includes the subject matter of example 1 or any other example herein, wherein the one of the first member or the second member of the frame includes a hollow defined by interior sidewalls of a plurality of sidewalls of the one of the first member or the second member, and wherein the ground coupler extends through an opening formed in the interior sidewalls.

Example 3 includes the subject matter of example 2 or any other example herein, wherein the ground coupler comprises a first protrusion and a second protrusion arranged in an L-shape, the first protrusion located in the hollow and the second protrusion defining the cable slot. While in some examples the first and second projections may be arranged in an L-shape, in other examples the first and second projections may be arranged along intersecting lines that form any angle (e.g., any obtuse angle, such as less than 160 degrees in some examples, or any acute angle, such as greater than 70 degrees in some examples).

Example 4 includes the subject matter of example 3 or any other example herein, wherein the second protrusion is secured to the end of the member of the cross-rail assembly.

Example 5 includes the subject matter of example 3 or any other example herein, wherein the first protrusion is keyed and wherein the hollow includes a key recess.

Example 6 includes the subject matter of example 2 or any other example herein, wherein the one of the first member or the second member of the frame is segmented into segments, wherein the hollow is defined by ends of the segments, and wherein the ground coupler includes first, second, and third tabs arranged in a T-shape, the first and second tabs being located in the hollow and the third tab defining the cable trough. While in some examples the ground couplers may be arranged in a T-shape, in other examples the angle between any two projections may be a right angle, any acute angle, any obtuse angle, etc.

Example 7 includes the subject matter of example 6 or any other example herein, wherein the first protrusion and the second protrusion are keyed, and wherein the hollow includes a plurality of openings to form with the first protrusion and the second protrusion.

Example 8 includes the subject matter of example 6 or any other example herein, wherein a third protrusion is secured to the end of the member of the cross-rail assembly.

Example 9 includes the subject matter of example 6 or any other example herein, wherein a first end portion of the third protrusion is keyed, and wherein the first end of the third protrusion is located in a keyway formed on an end of the cross-rail, and wherein a second, different portion of the third protrusion defines the cable slot.

Example 10 includes the subject matter of example 1 or any other example herein, wherein the one of the first member or the second member of the frame comprises a keyway defining an opening adapted to receive a keying tab of the ground coupler, and wherein the keying tab of the ground coupler extends through a hollow defined by the keyway.

Example 11 includes the subject matter of example 1 or any other example herein, further comprising a keyed protrusion formed on the end of the member of the cross-rail assembly, wherein the keyed protrusion is located in a hollow defined by an inner sidewall of the one of the first member or the second member and an outer sidewall of the one of the first member or the second member.

Example 12 includes the subject matter of example 11 or any other example herein, wherein the inner wall includes a spline opening having a first region, one or more projections each defining one or more second regions, and wherein the keyed projections are located only in the first region of the spline opening.

Example 13 includes the subject matter of example 1 or any other example herein, wherein the ground coupler comprises a conductive spacer and one or more conductive fasteners to form an electrical path comprising the member of the cross-rail assembly and the frame.

Example 14 includes the subject matter of example 13 or any other example herein, wherein the one or more fasteners include a first fastener and a second fastener to attach the electrically conductive spacer to the end of the member of the cross-rail assembly and the frame, respectively.

Example 15 includes the subject matter of example 13 or any other example herein, wherein the one or more fasteners include a fastener having a length longer than a length of the conductive spacer, wherein the fastener extends through an opening in the frame, an opening in the space, and an opening in an end of the member of the cross-rail assembly.

Example 16 includes the subject matter of example 1 or any other example herein, wherein the cable trough is defined by the first portion of the cross-rail assembly and one of the first member and the second member of the frame.

Example 17 includes the subject matter of example 1 or any other example herein, wherein the cable trough comprises a first cable trough, the member of the cross-rail assembly comprises a first member of the cross-rail assembly, the ground coupler comprises a first ground coupler, the plurality of portions of the cross-rail assembly comprise a first plurality of portions of the cross-rail member, and wherein the PV module further comprises: one or more second cable troughs defined by one or more second members of the cross-rail assembly and one or more second ground couplers, respectively, to connect one or more ends of the one or more second members of the cross-rail assembly to one of the first and second members of the frame, respectively, or to one or more first portions of one or more second portions of the cross-rail assembly, respectively, wherein a distance between the first side of the cross-rail assembly and the second side of the cross-rail assembly in the one or more first portions of the one or more second portions is less than a distance between the first side of the cross-rail assembly and the second side of the cross-rail assembly in one or more second different portions of the second plurality of portions of the cross-rail assembly .

Example 18 includes the subject matter of example 1 or any other example herein, wherein the first member of the frame is on a first edge of the PV module and the second member of the frame is on an opposite second edge of the PV module.

Example 19 includes the subject matter of example 18 or any other example herein, wherein the frame comprises a rectangular frame, and wherein the first member and the second member are longer than a third member and a fourth member of the rectangular frame.

Example 20 includes the subject matter of example 1 or any other example herein, wherein the cross-rail assembly is in contact with the back side of the PV laminate.

Example 21 includes the subject matter of example 20 or any other example herein, wherein the member of the cross-rail assembly is adhered to the back side of the PV laminate.

Example 22 includes the subject matter of example 1 or any other example herein, wherein the perimeter of the PV panel contacts a first side of the first member or the second member of the frame, and wherein a distance between the first side of the first member and the second member of the frame and an opposing second side of the first member and the second member of the frame is equal to the distance between the first side of the cross-rail assembly and the second side of the cross-rail assembly in a second different one of the plurality of portions of the cross-rail assembly.

Example 23 includes the subject matter of example 1 or any other example herein, wherein the second portion of the cross-rail assembly can be arranged to form a wall with a mounting rail of a mounting frame, and wherein the first portion of the cross-rail assembly and the corresponding location on the mounting rail define a cable pit.

Example 24 is an apparatus, comprising: a frame adapted to receive a perimeter of a back side of a Photovoltaic (PV) laminate; one or more cross-rail members adapted to provide structural rigidity to the frame; and one or more pairs of couplers connected to the frame, each coupler of the pair including a first portion adapted to define a groove and a second keyed portion inserted into a different end of a respective cross rail member of the one or more cross rail members; wherein each cross-rail member is electrically connected to the frame only through the coupler of a respective one of the one or more pairs of couplers.

Example 25 includes the subject matter of example 24 or any other example herein, wherein a side of the one or more cross-rail members is arranged in a same plane as a side of the frame to receive a perimeter of a back side of a Photovoltaic (PV) laminate.

Example 26 includes the subject matter of example 25 or any other example herein, wherein opposing sides of the one or more cross-rail members are disposed at the same location as opposing sides of the frame.

Example 27 includes the subject matter of example 26 or any other example herein, wherein the frame comprises four frame members, at least one of the frame members comprising a plurality of segments, and wherein an end of each of the segments defines one of a void or a protrusion to mate with the other of the void or protrusion of the coupler, wherein the count of the one or more pairs of couplers is equal to N, and wherein the count of the segments is N + 1.

Example 28 is an apparatus for a Photovoltaic (PV) assembly, the PV assembly comprising one or more mounting rails and a PV module, the PV module comprising a frame and a PV laminate having a front face, a back face, and a plurality of solar cells encapsulated between the front face and the back face, wherein a perimeter of the PV laminate is mounted on the frame, the apparatus further comprising: one or more cross-rail assemblies adapted to provide structural rigidity to the PV laminate and the frame, each cross-rail assembly extending from a first member of the frame to a second member of the frame, the cross-rail assembly grounded to the frame and having a first side facing the back side of the PV laminate and an opposite second side; wherein at least one of the one or more cross-rail assemblies comprises one or more first portions having one or more heights that are less than one or more heights of the remainder of the at least one cross-rail assembly, wherein the one or more first portions of the at least one cross-rail assembly define one or more grooves.

Example 29 includes the subject matter of example 28 or any other example herein, wherein the one or more grooves comprise one or more grooves when the at least one cross-rail assembly installer is above and parallel to a mounting rail of the one or more mounting rails.

Example 30 includes the subject matter of example 29 or any other example herein, wherein the one or more cross-rail assemblies each comprise one or more cross-rail members, wherein the one or more cross-rail assemblies further comprise one or more pairs of couplers, each coupler of the pair attached to a different end of a respective cross-rail member of the one or more cross-rail members.

Example 31 is a Photovoltaic (PV) module, comprising: a PV laminate having a front side, a back side, and a plurality of solar cells encapsulated between the front side and the back side; a frame, wherein a perimeter of the PV laminate is mounted on the frame; a non-conductive cross-rail assembly adapted to provide structural rigidity to the PV laminate and the frame, the non-conductive cross-rail assembly extending from a first member of the frame to a second member of the frame, the non-conductive cross-rail assembly having a first side adhered to a back side of the PV laminate and an opposing second side adapted to make contact with one or more mounting cross-rails; and a cable gap defined by the non-conductive cross-rail assembly, the first or second member of the frame, and the back side of the PV laminate.

Example 32 includes the subject matter of example 31 or any other example herein, wherein the cable gap is further defined by an end of an elongated member of the non-conductive cross rail assembly, wherein the elongated member is non-parallel and non-orthogonal to the first member and the second member of the frame.

Example 33 includes the subject matter of example 31 or any other example herein, wherein the non-conductive cross rail assembly comprises a circular core centered at a center of the back side of the PV laminate.

Example 34 includes the subject matter of example 31 or any other example herein, wherein the non-conductive cross rail assembly comprises one or more protrusions extending from the circular core.

Example 35 includes the subject matter of example 35 or any other example herein, wherein the non-conductive cross rail assembly comprises a first elongated protrusion that is non-parallel to a second elongated protrusion of the non-conductive cross rail assembly.

The above disclosure and examples provide a complete description of the structure and use of illustrative embodiments. Although certain embodiments have been described above with a certain degree of particularity, or with reference to one or more individual embodiments, those skilled in the art could make numerous alterations to the disclosed embodiments without departing from the scope of this invention. Thus, the various illustrative embodiments of the methods and systems are not intended to be limited to the specific forms disclosed. Rather, these embodiments include all modifications and alterations within the scope of the claims, and embodiments other than the illustrated embodiments may include some or all of the features of the described embodiments. For example, elements may be omitted or combined into a single structure, and/or connections may be substituted. Moreover, where appropriate, aspects of any of the examples described above can be combined with aspects of any of the other examples described to form further examples having equivalent or different properties and/or functions and addressing the same or different problems. Also, it is to be understood that the benefits and advantages described above may relate to one embodiment, or may relate to multiple embodiments. For example, various structural configurations, materials, and/or control production steps may be used to practice and/or implement embodiments of the methods and systems of the present invention. The claims are not intended to be, and should not be construed as, containing method or step functional language limitations unless such limitations are expressly enumerated in the given claims by the phrases "method for … …" or "step for … …," respectively.

Claims

1. An apparatus, comprising:

an electrically conductive frame adapted to receive a perimeter of a back side of a Photovoltaic (PV) laminate; one or more electrically conductive cross rail members providing structural rigidity to the electrically conductive frame; and

one or more pairs of couplers connected to the conductive frame,

wherein:

at least one coupler of at least one of the one or more pairs of couplers includes a ground coupler having a first keyed portion and a second keyed portion, the first keyed portion adapted to be inserted into an opening in the conductive frame,

the second keyed portion is adapted to mate with an end of a conductive cross-rail member of the one or more conductive cross-rail members to ground the conductive cross-rail member to the frame; or

At least one coupler of at least one of the one or more pairs of couplers includes a length defining a cable slot.

2. The apparatus of claim 1, wherein the at least one pair of couplers includes a first coupler having the length defining the cable slot and a second ground coupler having the first keyed portion and the second keyed portion.

3. The apparatus of claim 1, wherein sides of the one or more electrically conductive cross rail members are arranged in the same plane as sides of the electrically conductive frame that receive a perimeter of a back side of a Photovoltaic (PV) laminate.

4. The apparatus of claim 3, wherein opposing sides of the one or more conductive cross rail members are arranged at the same location as opposing sides of the conductive frame.

5. The apparatus of claim 4, wherein the electrically conductive frame comprises four electrically conductive frame members, at least one of the electrically conductive frame members comprising a plurality of electrically conductive segments, and wherein each of the electrically conductive segments comprises an end defining one of a void or a protrusion to mate with the other of the void or protrusion of a respective one of the couplers, wherein the count of the one or more pairs of couplers is equal to N, and wherein the count of the segments is N + 1.

6. The apparatus of claim 1, wherein the ends of the conductive cross rail member are in contact with an outside surface of the conductive frame, wherein the outside surface of the conductive frame has a greater resistivity than an inside surface of the conductive frame, and wherein the first keyed portion is in physical contact with the inside surface of the conductive frame.

7. The apparatus of claim 1, wherein the cable trough is further defined by an end of a respective one of the one or more cross-rail members and a portion of the conductive frame.

8. The apparatus of claim 1, wherein at least one of the conductive cross rail members is electrically connected to the conductive frame only through the ground coupler, or a path of highest conductivity between the at least one of the conductive cross rail members includes the ground coupler.

9. The apparatus of claim 8, wherein the one or more conductive cross-rails comprise a plurality of conductive cross-rails, and wherein the plurality of conductive cross-rail members are electrically connected to the conductive frame only through the ground coupler, or a highest conductivity path between each of the plurality of conductive cross-rail members comprises the same ground coupler.

10. The apparatus of claim 1, wherein the electrically conductive frame is double-walled and the one or more cross-rail members are single-walled.

11. A Photovoltaic (PV) module, comprising:

a PV laminate having a front side, a back side, and a plurality of solar cells encapsulated between the front side and the back side;

a frame, wherein a perimeter of the PV laminate is mounted on the frame;

a non-conductive cross-rail assembly adapted to provide structural rigidity to the PV laminate and the frame, the non-conductive cross-rail assembly extending from a first member of the frame to a second member of the frame, the non-conductive cross-rail assembly having a first side adhered to a back side of the PV laminate and an opposite second side in contact with one or more mounting rails; and

a cable gap defined by the non-conductive cross-rail assembly, the first or second member of the frame, and the back side of the PV laminate.

12. The PV module of claim 11, wherein the cable gap is further defined by ends of an elongated member of the non-conductive cross rail assembly, wherein the elongated member is non-parallel and non-orthogonal to the first and second members of the frame.

13. The PV module of claim 11, wherein the non-conductive cross-rail assembly comprises a circular core centered on a center of the back side of the PV laminate.

14. The PV module of claim 11, wherein the non-conductive cross-rail assembly comprises one or more tabs extending from the circular core.

15. The PV module of claim 11, wherein the non-conductive cross-rail assembly comprises a first elongated protrusion that is non-parallel to a second elongated protrusion of the non-conductive cross-rail assembly.

16. The PV module of claim 11, wherein the non-conductive cross-rail members, respective portions of the back side of the PV laminate, and respective portions of the frame define a volume, wherein the volume includes a micro-inverter or junction box and associated cables.

17. An elongated ground coupler having a first end, a second end, and a length between the first end and the second end, the ground coupler comprising:

a first keyed portion at the first end adapted to be inserted into an opening defined by an electrically conductive frame of a Photovoltaic (PV) module; and

a second portion at the second end adapted to mate with an end of an electrically conductive cross rail member of the PV module.

18. The ground coupler of claim 17, wherein the length segment comprises an elongated length to define a cable trough with the conductive frame and the conductive cross-rail member, wherein a first side wall of the cable trough is defined by the conductive frame of the PV module, a second side wall of the cable trough is defined by the end of the cross-rail member, and a bottom of the cable trough is defined by the length segment.

19. The ground coupler of claim 17, wherein the second portion comprises a single wall key.

20. The ground coupler of claim 17, wherein the first keyed portion is arranged to be inserted into a corner defined by a plurality of conductive frame members of the conductive frame or into a length of a conductive frame member of the conductive frame.

21. The ground coupler of claim 17, wherein the first keyed portion is arranged to be inserted into a splined opening, wherein the opening defined by the conductive frame includes the splined opening.