US20210324586A1

US20210324586A1 - Photovoltaic panel assemblies for structurally demanding applications

Info

Publication number: US20210324586A1
Application number: US17/365,836
Authority: US
Inventors: Joe Don Byles
Original assignee: Solar Hardscapes LLC
Current assignee: Solar Hardscapes LLC
Priority date: 2018-08-06
Filing date: 2021-07-01
Publication date: 2021-10-21
Also published as: US20200199826A1; CA3108538A1; WO2020033371A1; MX2021001427A; AU2019318770A1; EP3833818A1; US11078632B2; EP3833818A4

Abstract

A PV panel assembly includes a PV panel and a frame. The PV panel includes one or more PV cells and is operable to provide electrical power at a panel output terminal in response to operating light incident on a panel upper surface. The frame extends along the panel peripheral edge and defines a frame inside surface which, together with a lower panel surface, defines a base volume. A molded base material is located in the base volume. A light-transmissive cover material extends over the panel first surface and over at least a portion of a frame outside surface which faces away from the base volume. The PV panel assembly may be incorporated in a landscape installation and connected with other such assemblies in the installation to provide a ground mounted PV panel array which also functions as a hardscape such as a walkway or patio.

Description

CROSS-REFERENCE TO RELATED APPLICATION

This application claims the benefit, under 35 U.S.C. § 120, of U.S. patent application Ser. No. 16/803,898 filed Feb. 27, 2020 entitled “LANDSCAPE PAVERS FOR GROUND INSTALLATION OF PHOTOVOLTAIC PANELS,” which claimed the benefit of PCT International Patent Application No. PCT/US2019/045251 filed Aug. 6, 2019 and entitled “LANDSCAPE PAVERS FOR GROUND INSTALLATION OF PHOTOVOLTAIC PANELS, LANDSCAPE PAVER INSTALLATIONS, AND INSTALLATION METHODS,” which claimed the benefit, under 35 U.S.C. § 119, of U.S. Provisional Patent Application No. 62/764,495 filed Aug. 6, 2018 and entitled “APPARATUS AND METHOD OF LIGHT PERMEABLE LANDSCAPE PAVER FOR GROUND INSTALLATION OF PHOTOVOLTAIC MODULE ARRAY.” The entire content of each of these prior patent applications is incorporated herein by this reference.

TECHNICAL FIELD OF THE INVENTION

The invention relates to photovoltaic panels and photovoltaic panel systems, and, more particularly, to photovoltaic panel assemblies which may be used in structurally demanding applications such as in walkways or patio hardscapes for example. The invention includes photovoltaic panel assemblies which may be used in structurally demanding applications and to installations of such photovoltaic panel assemblies. The invention also encompasses methods for producing a photovoltaic panel assembly.

BACKGROUND OF THE INVENTION

A photovoltaic (PV) cell generates electricity in response to light striking a surface of the cell material. In particular, a PV cell may be placed in sunlight to generate electricity from the sunlight striking the cell. Individual PV cells may be arranged in groups in a sheet of material to form a PV panel capable of generating a useful amount of electricity for storage or for immediate use in electrically powered devices. PV generating capacity has grown exponentially within the past few decades and is an ever-increasing percentage of distributed energy production within the United States and around the world.
PV panel arrays are commonly installed on commercial and residential rooftops to make use of that area for power generation. For low-slope roofs (commonly defined as having no more than four inches of rise over every twelve inches of run) a PV panel array may be installed with a racking system that is ballasted with weights to hold it down. There is no need for any rooftop penetrations in these low-slope roofs because the PV panels and racking are held by the weight of the ballast rather than a mechanical attachment to the roof structure. For steep-sloped roofs (commonly defined as having over four inches of rise for every twelve inches of run) PV panel array installation requires a racking system that must be mechanically attached to the roof structure. This mechanical attachment generally requires penetrations to be drilled through the rooftop, so that the system can be bolted to the underlying building structure. The hardware of the penetration is then flashed and waterproofed to the extent possible to prevent leakage.
Both low-slope and steep-sloped roof PV panel installations present problems, both practical and aesthetic. First, any rooftop PV panel installation that requires roof penetrations presents the problem of potential leakage and expensive repairs for leakage damage within the structure and for preventing further leakage. With regard to steep-sloped shingle roofs, the roof penetration and hardware installation may break the mastic sealant which helps hold the rows of shingles in place during high wind events, and thus leave the roof prone to wind damage. While ballasted PV panel racking systems which may be installed on low-slope roofs are typically less expensive to install and may be installed relatively quickly, the ballast weight adds to the load on the roof structure and thus the roof structure must be designed to take the added load. For some buildings a ballasted PV panel racking system may only be added after the building structure is modified to properly support the added weight. Both low-slope and steep-slope roof PV panel installations must also be designed for high and variable wind conditions and dangers from seismic events, and must be tested in order to be certified to UL standards for resistance to wind and seismic events. Additionally, rooftop PV panel installations present relatively dangerous working conditions both for installation work and maintenance since the installations are necessarily at height. The danger for workers is particularly acute for steep-slope installations where a worker may easily slide off the roof and suffer a debilitating or even fatal fall. Rooftop PV panel installations also present problems when maintenance is required for the roof or the roofing material must be replaced. Such roofing repair or replacement may require the entire rooftop PV panel array to be removed and then reinstalled once the roofing repair or replacement is done.
In both low-slope and steep-slope roof installations, the PV panels provide a visual distraction to the roofing surface and the building aesthetic. This is particularly the case for steep-slope roof installations where the PV panels are clearly visible from generally every viewpoint to the building. Even in low-slope PV panel installations, some or all of at least some of the PV panels or the racking system may be visible from at least some points of view to the building and may affect the building aesthetics.
There have been a number of attempts to minimize the visual impact of the PV panel array in rooftop installations. U.S. Pat. No. 8,319,093 discloses a PV module particularly for use in rooftop installations. The PV module, which may include a number of individual PV cells, includes a color layer with pigments that cause the PV module to simulate conventional roofing. Another attempt to make a rooftop PV installation less apparent and visible is to incorporate the PV cells into a roofing material or shingle that is applied into a field of conventional roofing material. This approach is illustrated by Dow Powerhouse® shingles. However, these types of shingles do not blend in well with surrounding roofing shingles, and this may cause the installation to have a negative impact on the building aesthetics. Another drawback of incorporating PV cells into a roofing shingle is that it greatly multiplies the number of electrical connections that must be made in the PV installation, which increases both points of potential failure and installation labor. Yet another drawback of incorporating PV cells into roofing shingles is the heat build-up occasioned by having the PV cells directly on the roof deck and roofing underlayment with no means of cooling the cells. Conventional PV panel array installations rely on air flow beneath each PV panel to isolate the PV cells from the rooftop temperatures which can reach fifty to one hundred degrees hotter than the ground ambient temperature. Preventing undue heat buildup in a PV cell is important because the heat buildup can lead to a large drop in output from the PV cell.
Yet another attempt to hide PV rooftop installations has been developed by Tesla Corporation where the PV cells are incorporated into glass shingles of tiles and these PV-integrated shingles or tiles are installed together with “blank” shingles or tiles which do not incorporate PV cells. This arrangement is intended to provide a single continuous appearance across the entire roofing installation. However, this system requires a large number of electrical connections and also suffers from the heat buildup problem described above. In addition, the shingles or tiles are relatively heavy and require that the underlying structure be designed to accommodate the additional weight of the roofing material. The labor to install such a system is also more than a standard roof and the economics of the roofing material and labor may make it cost prohibitive.
All rooftop PV device installations also have the disadvantage of having to meet strict code requirements of electrical, fire, mechanical, and other regulations that are triggered when they are placed upon rooftops. If one does not want to deal with the restrictions, limitations and costs associated with mounting a PV panel array on a rooftop, one could consider a ground mounted system where the array is placed on elevating poles or other structures on adjacent ground area to the building. However, a major limitation of such elevated ground installations is that residential homes have limited area that is typically reserved for lawns, patios, sidewalks and other features demanded by residential homeowners. Commercial properties too may have limited free ground area for such elevated ground PV panel array installations. Furthermore, elevated ground PV panel arrays in a residential or commercial setting can be more aesthetically distracting than a roof mounted array.
U.S. Published Patent Application No. 2005/0199282 by Oleinick et al. and U.S. Published Patent Application No. 2018/0102730 by Brusaw et al. both disclose PV panel assemblies which may be used for paving roads, driveways, and walkways. These panel assemblies, however, have a distinctively non-traditional appearance and do not provide a cost-effective or aesthetically pleasing installation that would be readily accepted by commercial building owners or home owners. These panel assemblies leave the PV panel prone to damage from forces which may be applied in a given installation.

SUMMARY OF THE INVENTION

It is an object of the invention to provide devices and systems which overcome the above-noted problems and others associated with PV panel installations. These problems are addressed by providing PV panel assemblies which are suitable for structurally demanding applications such as in ground installations. By facilitating the installation of PV panels in structurally demanding settings such as in walkways and patio hardscapes, for example, the PV panel assemblies and installations according to the present invention allow these settings to be used for electrical power generation without interfering with the property aesthetics and without taking up property area only for such power generation.
A PV panel assembly according to one aspect of the present invention includes a PV panel and a frame, the frame being defined by a first lateral side component and a second lateral side component. The PV panel has a panel first surface and a panel second surface each bounded by a panel peripheral edge, with the panel peripheral edge defined by a first side peripheral edge and a second side peripheral edge lying opposite to each other. The PV panel includes one or more PV cells and is operable to provide electrical power at a panel output terminal in response to operating light incident on the panel first surface. The first lateral side component extends along the first side peripheral edge of the panel and defines a first lateral side inside surface. The second lateral side component extends along the second side peripheral edge of the panel and defines a second lateral side inside surface lying opposite to the first lateral side inside surface so that the two (first and second) lateral side inside surfaces together with the panel second surface, define a base volume. A molded base material is located in the base volume. This molded base material comprises a material solidified from a flowable material placed in the base volume and molded against at least a portion of the panel second surface and against at least a portion of the first and second lateral side inside surfaces. A light-transmissive cover material extends over the panel first surface.
In a PV panel assembly according to this first aspect of the invention, the molded base material provides a rigid support for the PV panel which allows the paver to be placed on the ground or a prepared sand bed. The frame made up of the first and second lateral side components provides a form for receiving the base material in the manufacture of the paver. The light-transmissive cover material extending over the panel first surface provides a tough and wear-resistant material to protect the panel first surface from footsteps and the weight of objects placed on the installed panel assembly. However, light and sunlight in particular may still penetrate through the cover material to reach the PV panel first surface and cause the panel to generate electricity. Thus a PV panel assembly according to this first aspect of the invention may be installed in a structurally demanding setting such as a landscape, and the panel output terminals connected to provide electrical generation for current use or storage in an electrical storage system such as a battery system.
As used in this disclosure and the accompanying claims, the designation “PV panel” refers to a device having one or more PV cells which produce a photovoltaic effect in response to operating light incident on a surface of the cell. “Operating light” is used herein to refer to the level of light needed for the PV cell to produce the photovoltaic effect. Such PV cells may be formed in any fashion using any photovoltaic material technology now known or developed in the future. For example, a solar cell which may be used in a PV panel in accordance with the present invention may comprise a monocrystalline, polycrystalline, or amorphous silicon cell, thin film PV cell, multi junction PV cell, or any other type of PV cell. In accordance with current manufacturing techniques, a number of PV cells which individually provide a small light collection area are typically connected together to form a PV panel which overall provides a large light collection area. However, the designation “PV panel” as used in this disclosure and accompanying claims is not limited to such multiple PV cell arrangements. Also, a PV panel as used in this disclosure will commonly include a sheet of backing material and a sheet of transparent upper surface material in the PV panel structure. These backing and upper surface materials serve to protect the PV cells, conductor traces, and other electronic elements which may be included with the PV cells.
The designation “light-transmissive” as used in this disclosure and the accompanying claims means that the material or structure is capable of transmitting operating light to the collection surface of a PV cell, that is, sufficient light to, when the light is incident on the surface of a PV cell, cause the PV cell to generate electricity. A light-transmissive material need not transmit all wavelengths equally, and may essentially block or greatly attenuate some wavelengths in the spectrum of sunlight. Regardless of any such wavelength transmissivity preference, sufficient light at a given wavelength may pass through the light-transmissive material in the thicknesses used in the structures described herein to cause a PV cell operable on that wavelength to produce the photovoltaic effect to generate electricity. Of course, implementations according to the various aspects of the invention may use highly light-transmissive materials to allow for higher levels of electricity generation from installations according to the present invention.
The present disclosure and accompanying claims may use terms such as top, bottom, side, lateral, upper, and lower in reference to a certain feature or structure. These relative positional terms are used with reference to the orientation of the example PV panel assemblies and installations shown in the drawings.
In some implementations of a PV panel assembly according to the first aspect of the invention, the first and second lateral side components each include a panel capture flange having a capture surface facing the panel first surface in an area adjacent to the panel peripheral edge. Since the molded base material is molded against the first and second lateral side components to connect the molded base material to these lateral side components, the capture flange serves to couple the PV panel to the molded base material. That is, the first and second lateral side components are fixed to the molded base material by virtue of the molding, and the PV panel is fixed relative to the two lateral side components by abutment against the capture flange. This coupling of the PV panel to the molded base material via the two lateral side components is addition to the coupling provided by molding the base material against the panel second surface.
The first and second lateral side components making may each also include a base material capture flange located at an end of the component opposite to the end having the panel capture flange. The base material capture flange is in position to help retain the molded base material in position relative to the first and second lateral side components and the PV panel.
Regardless of how the PV panel is positioned or connected to the frame prior to introduction of the material which forms the molded base material of a PV panel assembly according to the first aspect of the invention, a portion of the frame made up of the first and second lateral side components may be exposed on a bottom surface of the PV panel assembly. Where the frame is formed from an electrically conductive material, this exposed portion of the frame provides a grounding point for the PV panel assembly.
Implementations of a PV panel assembly according to the first aspect of the invention may also include reinforcing elements embedded in the molded base material to enhance the strength of the composite structure made up of the PV panel, frame (made up of the first and second lateral side components), molded base material, and cover material. Such reinforcing elements may be included in spaced apart layers of reinforcing fibers or other elements within the thickness of the molded base material and may extend substantially parallel to the panel plane defined by the PV panel first surface. Embedding features may also be included protruding from the inside surface of each of the first and second lateral side components in position to be embedded in the molded base material. The embedding features may help to retain the position of the first and second lateral side components and the PV panel coupled to the molded base material.
The cover material included in PV panel assemblies according to the first aspect of the invention may be a material molded on to the PV panel and frame. In this case, a layer of the molded cover material defines a lower cover material surface which is molded against the panel first surface and defines a cover material upper surface facing away from the panel first surface. Also in these molded cover material embodiments, a cover material inside lateral surface may be molded against an outside surface of each of the first and second lateral side components.
A PV panel assembly according to the first aspect of the invention may include at least one reduced light transmissivity layer located in the cover material between a load receiving surface and the panel first surface. Any such reduced light transmissivity layer is formed from a light-transmissive material in which is included low-light-transmissivity granular material. “Low-light-transmissivity” in this sense and as used elsewhere in this disclosure and the accompanying claims means that the granular material transmits less than approximately 50% of incident light in the operating spectrum of the given PV panel. This low-light-transmissivity granular material serves to provide an appearance to the PV panel assembly that may mimic a traditional landscape paver of concrete, stone, or other traditional paver material. The appearance may be enhanced by the color presented by the panel first surface visible through the light transmissive cover material and by granular material which exhibits a light transmissivity greater than a low-light-transmissivity material and may be included in the reduced light transmissivity layer or elsewhere in the PV panel assembly above the PV panel. In some cases, the low-light-transmissivity granular material may be suspended in the reduced light transmissivity layer below the load receiving surface. In any event the low-light-transmissivity granular material is preferably present in such a concentration that it reduces the light transmissivity of the reduced light transmissivity layer by no more than approximately 10%. That is, the concentration of low-light-transmissivity material in the reduced light transmissivity layer is preferably limited to a concentration in which the low-light-transmissivity material reduces the light transmissivity of the layer by no more than approximately 10% as compared to a case in which no low-light-transmissivity material was included in the layer. Also, the grains which make up the low-light-transmissivity granular material may be limited to a certain size ranges to produce the desired appearance while avoiding undue impact on the amount of light which may reach the PV panel.
A second aspect of the invention encompasses a PV panel installation which may employ PV panel assemblies according to the first aspect of the invention. A PV panel installation according to this second aspect of the invention includes a PV panel supporting bed and two or more PV panel assemblies as described above supported on the supporting bed. Some implementations may further include a moisture introduction arrangement in fluid communication with the PV panel supporting bed. The PV panel supporting bed in these installations may be formed as a layer of granular material such as a layer of paver sand which produces a porous and permeable layer of material above a suitable subgrade.
The moisture introduction arrangement allows water to be released into the porous and permeable layer formed by the granular material making up the PV panel supporting layer. This introduced water and the evaporation of the water serves to moderate the temperature of the PV panel supporting bed and thereby moderate the temperature the PV panel in the installation. This moderation of temperature allows the PV panel to operate more efficiently and compensates for any loss of efficiency cause by the reduction of light incident on the panel through the cover material. In particular, the moderation of temperature helps compensate for the reduction of light reaching the PV panel occasioned by any reduced light transmissivity layer in the PV panel assemblies.
In installations according to this second aspect of the invention which include the moisture introduction arrangement, the moisture introduction arrangement may include at least one conduit extending through the volume defined by the PV panel supporting bed. The conduit incorporates suitable emitters or is formed at least partially from a water-permeable material to facilitate the communication of water from the conduit to the porous and permeable layer comprising the PV panel supporting bed.
A third aspect of the present invention encompasses methods of producing a PV panel assembly having a PV panel such as that described above in connection with the first aspect of the invention. Methods according to this aspect of the invention include supporting the PV panel on a support surface in a first molding position in which the panel second surface faces upwardly away from the support surface. The methods further include defining a base volume of the PV panel assembly. This base volume comprises a volume defined by the panel second surface and a peripheral transverse surface extending along the entire length of the panel peripheral edge where the peripheral transverse surface extends transverse to a plane defined by the panel second surface. While supporting the PV panel in the first molding position, methods according to this aspect of the invention further include placing a flowable base-forming material within at least a portion of the base volume so that the flowable base-forming material is molded against at least a portion of the panel second surface and at least a portion of the peripheral transverse surface. The flowable base-forming material is then caused to solidify while molded against the panel second surface and peripheral transverse surface to thereby form a molded base material within the base volume and being molded against the portion of the panel second surface and the portion of the peripheral transverse surface. One the flowable base-forming material is solidified the PV panel is removed from the first molding position together with the molded base material. A light-transmissive cover material is then molded against substantially the entire panel first surface.
An installation as described above and in further detail below in connection with the drawings, functions to provide a PV panel array that may be identical or very similar in appearance to that of a conventional construction feature such as a landscape paver patio, walkway or drive way while simultaneously providing solar generated electricity. The sun energy moves through the atmosphere and strikes the top surface of the PV panel assemblies and travels through the light-transmissive cover materials and then into the PV panel where the electricity is generated. Where included in the installation, the moisture introduction arrangement (which may comprise low volume drip irrigation lines) provides cooling to the PV panels including any associated electronics, such as batteries and micro-inverters, through the heat absorbing capacity of the water and through the cooling occasioned by evaporation of the introduced water. The PV panel assemblies can be installed in a configuration to form areas of a patio, walkway, or drive of uniform appearance which blends in well or is even indistinguishable from adjacent areas formed from traditional, non-PV generation enabling, materials.
The PV panel installation according to the various aspects and feature of the invention has the following advantages:

- (1) No rooftop installation is required, thus avoiding drawbacks and dangers of rooftop installation as described above, such as roof modification and the unsightly appearance of the PV panel array on the roof
- (2) No conventional ground mount is required which takes up ground space and is unsightly.
- (3) The installed PV panel array may also provide a functional and aesthetically pleasing ground surface amenity such as a patio, walkway, or drive way.
- (4) The diurnal temperature swings of installations according to the invention may be typically on the order of ten degrees Fahrenheit where the ambient temperature swing might be thirty-five degrees Fahrenheit and the rooftop temperature swings might be one hundred degrees Fahrenheit. The lower temperature swing reduces stresses on the PV panels and associated electronic components.
- (5) The PV panel electrical generation performance is better that prior art installations due to the cooler operating temperatures.
- (6) Installation labor and maintenance is lower in cost and safer for on-ground locations as opposed to the elevated roof or elevated ground mount locations.

These and other aspects of the invention and advantages and features of the invention will be apparent from the following description of representative embodiments, considered along with the accompanying drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a perspective view of a PV panel assembly comprising a landscape paver embodying the principles of the invention.

FIG. 2 is a view in section taken along line 2-2 in FIG. 1.

FIG. 3 is an enlarged view of a portion of the cover material showing a reduced light transmissivity layer.

FIG. 4 is a view in section similar to FIG. 2, but showing a PV panel assembly comprising a landscape paver having an alternate frame structure.

FIG. 5 is an elevation view along a vertical plane through a PV panel installation embodying principles of the invention, the PV panel installation employing landscape pavers as shown in FIGS. 1 and 2.

FIG. 6 is a perspective view of an alternate landscape paver embodying principles of the invention.

FIG. 7 is a partially broken-away perspective view of a framed PV panel which may be used in a PV panel installation in accordance with aspects of the invention.

FIG. 8 is an elevation view along a vertical plane through a PV panel installation embodying principles of the invention, the PV panel installation employing landscape pavers as shown in FIG. 6 and framed PV panels as shown in FIG. 7.

FIG. 9 is an enlarged view of a small portion of a PV panel installation similar to that shown in FIG. 8, but showing an alternate elastomer arrangement between the pavers and PV panel.

FIG. 10 is a schematic section representation of a PV panel installation according one implementation of the present invention.

FIG. 11 is a schematic section representation of a PV panel installation according another implementation of the present invention.

DESCRIPTION OF REPRESENTATIVE EMBODIMENTS

In the following description, FIGS. 1-4 will be referenced below to describe PV panel assemblies which include an integrated PV panel and installations using such composite PV panel assemblies. FIGS. 5-9 will be referenced below to describe installations in which a PV panel is set separately from pavers to form a hardscape capable of PV power generation, and pavers which may be used in such installations. FIG. 10 will be referenced to describe another example PV panel installation in accordance with aspects of the invention in which the PV panels are set in place in the installation separately from the landscape pavers and other installation components. FIG. 11 will be referenced to describe another example PV panel installation in accordance with aspects of the invention in which a PV panel is integrated with a paver and set in place in the installation by setting the paver.
FIG. 1 shows a perspective view of a composite PV panel assembly in accordance with aspects of the present invention in which a PV panel is coupled to a base material. This particular PV panel assembly comprises a landscape paver 100. As indicated in the figure, it is not apparent at least from the illustrated perspective that paver 100 incorporates a PV panel (the PV panel being shown at 200 in FIG. 2). The outward appearance from this perspective provides the appearance of a traditional square paver with a top surface 101 (representing a load receiving surface for the paver) and in the case of this square example, four side surfaces 102 including the two such surfaces visible from this perspective. The hidden lines shown in FIG. 1 show the outline of a rigid frame 104 which is included in composite paver 100, and defined by frame elements 104 a, 104 b, 104 c, and 104 d. Rigid frame 104 is associated with a PV panel included in paver 100 and shown and described in connection with the section view of FIG. 2. As will be described below in connection with FIG. 2, frame 104 may be thought of as including two opposing lateral side components. In this particular example, the portion of frame 104 comprising frame elements 104 a and 104 b may be thought of as a first lateral side component, and the portion of frame 104 comprising frame elements 104 c and 104 d may be thought of as a second lateral side component. A defining characteristic of the first and second lateral side components is that they each extend along a respective portion of a peripheral edge of the PV panel and lie on opposite each other across the PV panel (as best illustrated in FIG. 2, but also apparent from FIG. 1). Depending upon the particular construction of the paver 100 using low-light-transmissivity granular material as discussed in detail below, the rigid frame 104 and the PV panel may not be discernable as such from the perspective shown in FIG. 1. In this example, the only indication that paver 100 incorporates a PV panel is the arrangement of two pairs of leads 106 and 108 protruding from a bottom surface of the paver not visible in this perspective.
It should be appreciated that the square shape of paver 100 is simply provided as an example and that pavers according to the present invention may be formed in any desired shape. Pavers according to the invention may provide a top surface in the shape of an elongated rectangle or other polygonal shape, or a circle, oval, or other non-polygonal shape. Also, although FIG. 1 shows that the top surface 101 and side surfaces 102 of paver 100 includes slight undulations or contours across the surfaces, each surface remains substantially planar. Various features or roughness may be molded or otherwise provided in particularly top surface 101 to provide a generally planar, nonslip surface appropriate for use as a walking surface. Also, PV panel assemblies embodying principles of the invention such as example paver 100 may have any suitable dimensions, including common traditional paver dimensions. For example, paver 100 may be approximately 24 inches by 24 inches and approximately 2 inches thick along a thickness axis T shown in FIG. 2.
The section view of FIG. 2 shows that the PV panel shown generally at 200 and frame 104 (made up of elements 104 a-d and including 104 b and 104 d visible in the section of FIG. 2) are included in paver 100 between a molded base material 202 and a cover material 203. PV panel 200 has a panel first surface 205 and a panel second surface 206. These two surfaces 205 and 206 are bounded by a peripheral edge 207. In this example implementation, peripheral edge 207 of PV panel 200 forms generally a square shape in top plan view to maximize the surface area of panel first surface 205 in paver 100. Operating light incident on panel first surface 205 produces a photovoltaic effect so that PV panel 200 is operable to provide electrical power at a panel output terminal, defined in this case by either of the two pairs of leads 106 and 108 shown in both FIGS. 1 and 2. The example PV panel 200 includes a junction box 208 located on the panel second surface 206. Junction box 208 may include electronic components associated with panel 200 and terminals for the positive and negative wires of leads 106 and the positive and negative wires of leads 108. It will be appreciated that PV panels such as panel 200 may, depending upon the PV technology employed, be formed from multiple layers of semiconductor materials together with other structures such as conductor traces, all encapsulated between one or more layers of backing material and one or more layers of glass or other transparent cover material. Since the present invention encompasses any PV technology for producing a PV panel, and since in any event the internal structure of the PV panel is not relevant to an understanding of the present invention, each PV panel shown in section in the drawings is shown without any internal detail.
FIG. 2 shows that frame elements 104 b and 104 d of rigid frame 104 in the example embodiment of FIGS. 1 and 2 each includes a frame member 210 that extends in the direction of the thickness axis T and transvers (perpendicular in this example) to a plane defined by panel first surface 205. In this example, and as is apparent from the hidden lines shown in FIG. 1, frame member 210 extends along the entire panel peripheral edge 207 and thus frame elements 104 a and 104 c also include frame member 210. The frame member 210 of each frame element 104 a-d defines a frame inside surface 211 and a frame member border surface 211 a with the latter facing the peripheral edge 207. The frame inside surface 211 along frame elements 104 a and 104 b may be thought of as a first lateral side inside surface defined by the first lateral side component (made up of frame elements 104 a-b) while the frame inside surface 211 along frame elements 104 c and 104 d may be though of as a second lateral side inside surface defined by the second lateral side component (made up of frame elements 104 c-d). The frame inside surface 211, that is the first and second lateral side inside surfaces, together with the panel second surface 206 defines a base volume while a frame outside surface 212 along each of the frame elements 104 a-d faces away from the base volume. The molded base material 202 is located in the base volume and in this example fills the entire base volume so as to define most of a bottom surface 214 of paver 100. In particular, molded base material 202 includes a base material backing surface which is molded against at least a portion of panel second surface 206 and a lateral surface which is molded against at least a portion of the frame inside surface 211. The example of FIG. 2 shows two different spaced apart layers of reinforcing material 204 included in the molded base material 202 to improve the strength characteristics of paver 100, and particularly, improve resistance to bending from a plane parallel to the plane of panel first surface 205.
Cover material 203 extends over the panel first surface 205 and preferably, but not necessarily, over at least a portion of the frame outside surface 212. In this example, cover material 203 extends over substantially all of the frame outside surface 212 to define all of the sides 102 of paver 100. Cover material 203 is comprised of a light transmissive material at least in portions extending over one or more areas of panel first surface 205 and preferably over the entire panel first surface. As will be discussed below, cover material 203 may include a material which is molded over the PV panel and frame to define a lower cover material surface molded against the panel first surface and a cover material inside lateral surface molded against the frame outside surface 212, that is, against the outside surface of the frame elements 104 a-d making up the first and second lateral side components of the PV panel assembly comprising paver 100.
In the example of FIG. 2 frame 104 includes a panel support flange 216 extending from frame inside surface 211. This panel support flange 216 defines a peripheral sealing surface 217 abutting a portion of panel second surface 206 in this case. This example frame 104 further includes a panel capture flange 218 located at a panel capture end of frame member 210. Panel capture flange 218 together with panel support flange 216 defines a panel receiving channel which captures peripheral edge 207 of PV panel 200 around the entire peripheral edge. In the example of FIG. 2 at least a portion of frame 104 is exposed on bottom surface 214 of landscape paver 100. Where the frame comprises an electrically conductive material such as aluminum, this exposed portion of frame 104 provides a ground point for the PV panel when the paver is placed in an installed position as will be described further below in connection with FIG. 5. Alternatively, the entire frame 104 may be completely encapsulated within base material 202 and cover material 203 so that the frame is isolated from the environment.
In order to produce an appearance approximating a traditional landscape paver, paver 100 includes a reduced light transmissivity layer 221 shown in FIG. 2 as a thin layer of material which includes the paver top surface 101. This reduced light transmissivity layer 221 includes a light transmissive material 301 in which is embedded or otherwise included low-light-transmissivity granular material 302 as shown in the enlarged view of FIG. 3. The low-light-transmissivity granular material may comprise grains of sand, quartz, plastics, combinations of these materials, and or other suitable low-light-transmissivity granular materials to produce the desired appearance. While the grains 302 of low-light-transmissivity granular material will block some of the incident light from passing through from paver top surface 101 to panel first surface 205, the granular material is preferably included in such a concentration so as to reduce the overall light transmissivity of the reduced light transmissivity layer by no more than approximately 10%, that is, 10% as compared to the light transmissive material 301 in layer 221 if the material included no such granular material. The low-light-transmissivity granular material positioned over one or more areas of the reduced light transmissivity layer 221 may be made up of grains having a maximum dimension between approximate 10 microns and approximately 7500 microns, and preferably between approximately 2000 microns and approximately 3000 microns.
FIG. 4 shows an alternative PV panel assembly in the form of a paver 400 including a rigid frame 401 having a different configuration as compared to frame 104 shown in FIG. 2. This alternate embodiment includes a PV panel 404, molded base material 405, and cover material 406 similar to the embodiment shown in FIG. 2. However, frame 401 includes tube structure including an outside member 408 and an inside member 409. Outside member 408 in this embodiment forms the frame outside surface 411 facing cover material 406, while inside member 409 forms the frame inside surface 412. Frame 401 also includes a base member 413 which is exposed at the paver bottom side 414. Base member 413 also includes a lip or base material capture flange 415 which projects from inside surface 412. The example frame 401 shown in FIG. 4 also includes embedding elements comprising studs 416 which may be spaced apart along the frame inside surface 412 along the length of the frame to further strengthen the composite structure.
The alternative paver construction shown in FIG. 4 also includes an access opening 418 formed in the molded base material 405 to provide access to panel junction box 420. In this alternate construction, lead pairs 421 and 422 extend through the access opening rather than being embedded in the molded base material as shown in the example of FIG. 2.
The example of FIG. 4 also shows a GPS electronic module 424 operatively connected to a battery 425 for supplying power to the GPS electronic module. In this example GPS electronic module 424 and battery 425 are contained in PV panel junction box 420 although it will be appreciated that these elements may be located in a separate junction box or placed in another location within the paver structure. A small portion of the PV panel output in this arrangement may be used to charge battery 425. Suitable electronic components for providing the desired charging may be housed within junction box 420 or elsewhere in the paver. GPS electronic module 424 may be in wired or wireless communication with appropriate receiving hardware located in paver 400 or remotely to provide spatial location of the module and therefore the composite paver 400 in which it is located. In addition to providing spatial location information, GPS electronic module 424, or a separate electronic module located in junction box 420 or elsewhere in the structure of paver 400, may include electronic components for monitoring and collecting performance data for the paver such as power output, paver temperature, and cumulative power output, for example. This performance data for paver 400 may be communicated from GPS electronic module 424 or other module to monitoring and reporting components for the PV panel assembly installation in which paver 400 is included.
The alternate PV panel assembly construction shown in FIG. 4 also includes a different configuration for the reduced light transmissivity layer as compare to that shown in FIG. 2. In the example of FIG. 4, all of cover material 406 makes up the reduced light transmissivity layer including low-light-transmissivity granular material 427. However, it should be appreciated that implementations according to the present invention are not limited to the two arrangements for the reduced light transmissivity layer shown in FIGS. 2 and 4. For example, another arrangement within the scope of the present invention includes a distinct reduced light transmissivity layer spaced apart from both the assembly top surface and from the surface of the cover material facing the PV panel. Additionally, there may be multiple reduced light transmissivity layers in the cover material over the PV panel. More generally, the reduced light transmissivity layer or layers may be formed at any location of the cover material and in any fashion to incorporate the low-light-transmissivity granular material. In any of these arrangements, the granules of low-light-transmissivity material in one or more layers above the PV panel first surface together with coloration of the PV panel first surface (and the coloration of any upwardly facing frame surfaces) allows the PV panel assembly to match or at least approximate the appearance of a traditional paver appropriate for walkways, patios, and other hardscapes.
Numerous types of materials may be used for forming the frame, such as frames 104 and 401, shown in FIGS. 2 and 4, respectively. For example, the rigid frame may be formed from aluminum or other suitable metals. These frames may also be formed from plastics. Also, because the frame may be completely encapsulated and protected within the cover material, the frame may be formed from fiber board and similar materials.
Base material such as that shown at 202 and 405 in FIGS. 2 and 4, respectively, may comprise concrete or any other suitable material which may be molded within the frame. Where concrete is used it may include lightening materials and additives to provide the desired strength and weight characteristics for the completed PV panel assembly.
The cover material which may be used in a composite PV panel assembly according to the present invention may comprise a suitable clear polymer resin, epoxy, pourable clear plastic polymer, or any clear, moldable material which provides the desired light transmissivity when the material is cured or hardened.
It should also be appreciated that any of the features shown in the two example configurations of FIGS. 2 and 4 may be used in other configurations within the scope of the present invention. For example, although reinforcing material 204 is shown only in the embodiment of FIG. 2, such material may also be included in any other embodiment including the embodiment of FIG. 4. Likewise, the studs 416 shown in the example of FIG. 4, may be included in any other embodiment, including the embodiment of FIG. 2.
The composite PV panel assemblies shown for example in FIGS. 2 and 4 may be formed in any suitable process. One preferred fabrication process includes first forming the PV panel and frame arrangement with the frame arrangement defining a peripheral transverse surface (e.g., surface 211 in FIG. 2), and supporting this arrangement inverted from the position shown in the figures so that the peripheral transverse surface (211 in FIG. 2) and panel second surface (206 in FIG. 2) form an upwardly facing receptacle for receiving base material in liquid or flowable form. Since the base material may be fairly heavy, good support may be needed for the PV panel to prevent bending in the PV panel under the load of the base material before the base material solidifies. Also, forms may be required to provide any desired features in the base material, such as the access opening 418 shown in FIG. 4.
Once the base material is placed in the above-noted upwardly opening receptacle formed by the frame and PV panel, and solidifies appropriately, the resulting intermediate structure of PV panel, frame, and base material may be placed in a suitable mold which allows the cover material to be molded on to the structure. For example, the intermediate structure may be placed PV panel side down into a mold which leaves a gap into which the cover material may be poured, injected, or otherwise placed. It is also possible to partially prefill the mold and press the intermediate structure into the partially filled mold to form the desired cover layer. Once the cover material has hardened sufficiently, the resulting structure may be removed from the mold for any further processing or assembly.
Any low-light-transmissivity granular material desired for a given implementation may be introduced into the structure in a number of ways within the scope of the present invention. For example, the granular material may be spread out across the bottom of the mold used to mold the cover material onto the intermediate structure. This process produces a reduced light transmissivity layer generally as shown in the example of FIGS. 2 and 3. Alternatively, the low-light-transmissivity granular material may be mixed uniformly with the cover material prior to being molded on to the intermediate structure to produce a reduced light transmissivity layer as shown in the example of FIG. 4. In yet other techniques, the cover material may be molded on in multiple layers, any one or more of which may contain the low-light-transmissivity granular material.
The view of FIG. 5 may be used to described a PV panel installation employing PV panel assemblies such as those shown in FIGS. 1-4. Installation 500 includes a PV panel supporting bed 501 formed on a subgrade 502. PV panel supporting bed 501 includes a layer of granular material above subgrade 502, preferably a granular material such as paver sand. A moisture introduction arrangement is in fluid communication with PV panel supporting bed 501. In this case the moisture introduction arrangement includes at least one conduit 504 extending through the volume defined by PV panel supporting bed 501. Conduit 504 may include periodic emitters or may be formed in part or in sections of a permeable material to allow water directed through the conduits 504 to escape into the granular material comprising PV panel supporting bed 501.
The example of FIG. 5 shows multiple pavers 100 set in PV panel supporting bed 501 so as to be supported by the bed of granular material. The PV panels 200 integrated in pavers 100 are shown connected in series by lead pairs 106 and 107. Each of these connections may be formed from a suitable waterproof connector 506 such as an MC-4 connector for example. Although not shown FIG. 5, it will be appreciated that these lead pairs 106 and 107 are connected to the leads of other such pavers to form an array of series connected panels which is ultimately connected by suitable means to further equipment associated with the array. In particular, panels such as panels 200 shown FIG. 5 may be connected in series to an inverter as is known in the field of PV panel arrays. However, the present invention is not limited to any particular arrangement for connecting the various PV panels of an array of pavers. For example, PV panels according to the invention may be connected in parallel with each other rather than in series. Also, any additional electrical equipment may be included in an installation such as installation 500 to enhance the performance or otherwise affect the performance of the PV panel array including optimizers and other circuitry that may be associated with each panel or groups of panels in the installation.
Regardless of how the PV panels in the composite PV panel assembly pavers are connected to equipment for extracting power from the array, the paver provides cover material 203 as a light transmissive layer above each panel so that light, especially sunlight, incident on the paver may pass through to the PV panel. The light transmissive layer also serves to protect the relatively fragile PV panel surfaces from contact and also serve as a carrier for the granular material described above which provides the desired appearance for the pavers. Meanwhile, the molded base material 202 in each paver 100 supports the respective PV panel 200 to prevent any bending forces in the panel which might damage the panel structure. Base material 202 also functions to transfer any forces applied to the light transmissive load bearing surface 101 of the PV panel assembly paver to the material making up the PV panel supporting bed 501 below. Water may be introduced into the granular material making up the PV panel supporting bed 501, and this introduced water together with the evaporation of that water helps moderate the temperature of pavers 100 and PV panels 200 incorporated in the pavers. Aside from the water which may be introduced into PV panel supporting bed 501, the thermal mass of the bed 501 and subgrade 502 in which it is formed also helps moderate temperature swings in PV panels 200 due to incident sunlight and atmospheric conditions.
FIG. 6 shows an alternative landscape paver 600 which may be used in installations in accordance with aspects of the present invention in which the PV panel is not incorporated in the pavers, but is installed separately from the pavers. Paver 600 includes a paver load receiving surface or top surface 601, a paver bottom surface (the edge of which is indicated at 602), and a paver lateral surface 603. In this case the paver lateral surface 603 comprises the four lateral sides of the rectangular box shape formed by the paver. The paver body defined between the paver load receiving surface 601, paver bottom surface 602, and paver lateral surface 603 is light transmissive so that at least some light incident on the paver load receiving surface 601 may travel through the paver body and escape from the paver body through paver bottom surface 602. Paver 600 also includes at least one reduced light transmissivity layer extending transverse to a direction from paver load receiving surface 601 to paver bottom surface 602. The reduced light transmissivity layer in paver 600 includes a light transmissive material in which is included low-light-transmissivity granular material as described above in connection with FIGS. 2 and 4.
In the example paver 600 shown in FIG. 6, the paver body includes an upper assembly 606 and a lower assembly 607. Upper assembly 606 in this example is made up of a single layer 609 comprising the reduced light transmissivity layer of the paver, and a main layer 610 of light transmissive material. Lower assembly 607 in paver 600 includes a layer 612 of light transmissive elastomer material. As will be described below in connection with an installation in which paver 600 is used, this light transmissive elastomer is placed facing and perhaps directly in contact with the upwardly facing surface of the PV panel.
While example paver 600 includes three layers of material, layers 609, 610, and 612, it will be appreciated that a light transmissive paver in accordance with the aspects of the invention may include more than three layers. Also, it is possible that a bottom elastomer layer may be omitted from the paver and instead applied in an installation as a separate layer of material. In this case a light transmissive paver may include only the reduced light transmissivity layer and one additional layer, or even a single layer of material incorporating low-light-transmissivity granular material. The various layers of material included in the upper assembly 606 of paver 600 may include any of the light transmissive materials described above in connection with the composite pavers shown in FIGS. 2 and 4. The low-light-transmissivity granular material may also comprise any of the materials described above in connection with the composite pavers.
FIG. 7 shows an example of a PV panel structure which may be used together with light transmissive pavers such as paver 600 to produce a PV panel installation in accordance with aspects of the present invention. The illustrated PV panel structure includes a PV panel 700 having a panel first surface 701 to which light may be directed to produce the desired photovoltaic effect. PV panel 700 in this example is mounted in a rigid frame 703 which extends around the entire peripheral edge of PV panel 700. Frame 703 may have a channel structure similar to that shown in FIGS. 2 and 4 for capturing the peripheral edge of PV panel 700. Frame 703 also includes a frame member which may be similar to frame member 210 shown in FIG. 2 or a tube structure having frame members similar to frame members 408 and 409 shown in FIG. 4.
FIG. 8 shows a PV panel installation 800 employing pavers 600 shown in FIG. 6 and the PV panel structure shown in FIG. 7. Installation 800 includes a PV panel supporting bed 801 of granular material formed on a subgrade 802 similar to the PV panel supporting bed 501 shown in the installation of FIG. 5. However, in installation 800 each PV panel structure including PV panel 700 and frame 703 is set directly in the PV panel supporting bed 801. That is, PV panels 700 are positioned on panel supporting bed 801 with panel first surface 701 facing upwardly and the panel second surface 702 (shown in FIG. 7) facing the granular material forming the PV panel supporting bed. Since this example includes frame 703 with each PV panel 700, the frame protrudes into the material of PV panel supporting bed 801 in position to stabilize the PV panel from lateral movement. PV panels 700 in this installation are connected in series via connectors 806 similarly to the arrangement shown in FIG. 5, although alternative installations may connect the panels differently as described above in connection with the installation shown in FIG. 5 together with additional circuitry known in the field of PV power generation.
The light transmissive paver 600 in this installation is placed with the bottom surface 602 formed by elastomer material 612 facing the upwardly facing panel first surface 701 while the panel second surface 702 is supported by the granular material making up the PV panel supporting bed 801. This support from PV panel supporting bed 801 below prevents the relatively fragile PV panel 700 from bending significantly under loads which may be placed on the top surface of the installation comprising the load receiving surfaces 601 of pavers 600.
The example installation 800 of FIG. 8 includes conduits 804 similar to those described above in connection with the insulation shown in FIG. 6. However other implementations including separately installed pavers and PV panels may omit the conduits and rely on the temperature moderating effect of subgrade 802 and PV panel supporting bed 801 to moderate the temperatures of the PV panels and thus improve the performance and reliability of the panels.
FIG. 9 shows a small portion of another installation 900 similar to that shown in FIG. 8. The view of FIG. 9 shows that installation 900 includes a framed PV panel 901 similar panel 700 and frame 703 in FIG. 8, supported on a PV panel support bed 905 corresponding to bed 801 in FIG. 8. Installation 900 further includes light transmissive pavers 906 above PV panel 901. However, installation 900 shown in FIG. 9 relies on a separate sheet 908 of light transmissive elastomer between the upwardly facing surface of PV panel 901 and the bottom surface 910 of the light transmissive pavers 906 placed over the PV panels in the installation. This is in contrast to the arrangement shown in FIG. 8 using pavers such as those shown in FIG. 6 which incorporate an elastomer layer as the bottom layer of the paver itself. Yet other implementations may include both an elastomer layer at the bottom of the pavers as in FIGS. 6 and 8, and a separate sheet of elastomer material such as sheet 908 in FIG. 9 that extends over the upwardly facing first panel surface in position to receive the light transmissive pavers.
The PV panel installation shown schematically in FIG. 10 includes two light-transmissive landscape pavers 1000 located on top of a PV panel 1001. PV panel 1001 is positioned in landscape ground 1002 set on top of a PV panel supporting bed comprising a bed of sand 1003. An optional layer of landscape fabric 1004 is located between the PV panel lower surface and the upper surface of sand bed 1003. Sand bed 1003 may contain a series of low volume drip lines 1005 similar to drip irrigation lines to emit water to sand bed 1003 in a controlled manner for cooling of PV panel 1001, and any associated electronics, such as batteries or micro-inverters 1006.
Light transmissive landscape pavers 1000 in this example embodiment include a glass container 1007 with an optical, highly light-transmissive coating 1008 on the upper surface, contained within or below the glass container 1007 upper surface 1009. Within glass container 1007 is a water clear to clear polyurethane rubber 1012 which substantially fills the glass container and extends down to the upper surface of PV panel 1001. There may be a grout fill material 1013 which is in between adjacent light-transmissive landscape pavers 1000. Sun rays 1014 pass through the atmosphere 1015 above pavers 1000, through the light transmissive landscape pavers 1000, and strike the PV panel 1001, allowing solar electric energy to be produced from an aesthetically pleasing landscape paver installation such as a walkway or patio.
The installations according to the preferred embodiments shown in FIGS. 8 and 10 locate conventional PV panels just below the ground, preferably in a sand base such that the sand material butts up to the bottom side surface of the PV panel back sheet or back glass, providing compressive support to the PV panel. The PV panels in the array may be connected together in a typical fashion of any convention multi-panel solar array. All of the necessary electrical connections can be implanted in the sand base beneath the solar modules and waterproofed with conventionally available waterproof connectors. If desired, a water permeable landscape fabric can be installed between the sand layer and the solar panel modules. Additional cooling of the panels can be attained by intermittently running low volume irrigation drip lines installed within the sand base to keep the sand base moist and provide cooling through the latent heat of evaporation as water evaporates from the sand base.
Once the base of sand, optional landscape fabric and irrigation drip tubing is established and the PV panels are laid on top and connected up, the light-transmissive landscape pavers can be laid down over the modules to form the upper patio, walkway or drive surface. The light permeable landscape pavers can be laid in any pattern and extend out past the area of the solar panel modules to create a landscape feature independent of the geometry of the solar array beneath it. In areas of landscape feature where there are no solar modules below the light permeable landscape pavers can be directly laid on a sand base with water permeable landscape fabric on it.
The light permeable landscape pavers can be designed and fit tightly so that no filling grout material is needed between the pavers or they can have an appropriate grout material filled in between the pavers.
The schematic representation of FIG. 11 shows a composite light-transmissive paver 1100 with integrally molded concrete back 1101, a PV panel 1102, and a clear resin or polymer cover material 1103 providing a top surface 1104 for the paver. Composite paver 1100 is placed on sand or the ground surface 1105 such that it can function as a landscape paver paved patio, walkway or path and an element of a functioning PV panel array.
The integrally molded composite light-transmissive landscape paver may be installed by placing the unit over a sand base like a conventional paver, connecting the leads from the PV panels embedded in the composite light-transmissive landscape pavers, and routing the connections to a string inverter and/or appropriate electrical or panel connections. The electrical inverter could also be located on the back of the PV module and embedded in the concrete on the backside of the composite unit paver.
As used herein, whether in the above description or the following claims, the terms “comprising,” “including,” “carrying,” “having,” “containing,” “involving,” and the like are to be understood to be open-ended, that is, to mean including but not limited to. Also, it should be understood that the terms “about,” “substantially,” and like terms used herein when referring to a dimension or characteristic of a component indicate that the described dimension/characteristic is not a strict boundary or parameter and does not exclude variations therefrom that are functionally similar. At a minimum, such references that include a numerical parameter would include variations that, using mathematical and industrial principles accepted in the art (e.g., rounding, measurement or other systematic errors, manufacturing tolerances, etc.), would not vary the least significant digit.
Any use of ordinal terms such as “first,” “second,” “third,” etc., in the following claims to modify a claim element does not by itself connote any priority, precedence, or order of one claim element over another, or the temporal order in which acts of a method are performed. Rather, unless specifically stated otherwise, such ordinal terms are used merely as labels to distinguish one claim element having a certain name from another element having a same name (but for use of the ordinal term).
The term “each” may be used in the following claims for convenience in describing characteristics or features of multiple elements, and any such use of the term “each” is in the inclusive sense unless specifically stated otherwise. For example, if a claim defines two or more elements as “each” having a characteristic or feature, the use of the term “each” is not intended to exclude from the claim scope a situation having a third one of the elements which does not have the defined characteristic or feature.
The above-described preferred embodiments are intended to illustrate the principles of the invention, but not to limit the scope of the invention. Various other embodiments and modifications to these preferred embodiments may be made by those skilled in the art without departing from the scope of the present invention. For example, in some instances, one or more features disclosed in connection with one embodiment can be used alone or in combination with one or more features of one or more other embodiments. More generally, the various features described herein may be used in any working combination.

Claims

1. A PV panel assembly including:

(a) a PV panel having a panel first surface and a panel second surface with the panel first surface and the panel second surface bounded by a panel peripheral edge, the PV panel being operable to provide electrical power in response to operating light incident on the panel first surface, wherein the panel peripheral edge is defined by a first side peripheral edge and a second side peripheral edge, the second side peripheral edge lying opposite to the first side peripheral edge;

(b) a first lateral side component extending along the first side peripheral edge and defining a first lateral side inside surface;

(c) a second lateral side component extending along the second side peripheral edge and defining a second lateral side inside surface which lies opposite to the first lateral side inside surface so that the first lateral side inside surface, the second lateral side inside surface, and the panel second surface together define a base volume;

(c) a molded base material located in the base volume, the molded base material comprising a material solidified from a flowable material placed in the base volume and molded against at least a portion of the panel second surface and least a portion of both the first lateral side inside surface and the second lateral side inside surface; and

(d) a cover material extending over the panel first surface, the cover material being light-transmissive at least in portions extending over one or more areas of the panel first surface.

2. The PV panel assembly of claim 1 wherein the first lateral side component extends along the entire length of the first side peripheral edge and the second lateral side component extends along the entire length of the second side peripheral edge.

3. The PV panel assembly of claim 1 wherein:

(a) the first lateral side component includes a first border part which includes a first border surface facing the first side peripheral edge; and

(b) the second lateral side component includes a second border part which includes a second border surface facing the second side peripheral edge.

4. The PV panel assembly of claim 3 wherein:

(a) the first lateral side component includes a first panel capture flange having a first side capture surface facing the panel first surface in a first area adjacent to the panel peripheral edge; and

(b) the second lateral side component includes a second panel capture flange having a second side capture surface facing the panel first surface in a second area adjacent to the panel peripheral edge.

5. The PV panel assembly of claim 4 wherein:

(a) the first lateral side component extends along a thickness axis of the PV panel assembly from a first panel capture end at which the first panel capture flange is located to a first lower end, and wherein the first lateral side component includes a base material capture flange extending transverse to the first lateral side inside surface and having a first base material capture surface against which the flowable material is molded; and

(b) the second lateral side component extends along the thickness axis of the PV panel assembly from a second panel capture end at which the second panel capture flange is located to a second lower end, and wherein the second lateral side component includes a second base material capture flange extending transverse to the second lateral side inside surface and having a second base material capture surface against which the flowable material is molded.

6. The PV panel assembly of claim 4 wherein:

(a) the first lateral side component extends along a thickness axis of the PV panel assembly from a first panel capture end at which the first panel capture flange is located to a first lower end, and further including at least one first side embedding feature protruding from the first lateral side inside surface at a location between the first lower end and the panel second surface, the at least one first side embedding feature having first side embedding surfaces against which the flowable material is molded; and

(b) the second lateral side component extends along the thickness axis of the PV panel assembly from a second panel capture end at which the second panel capture flange is located to a second lower end, and further including at least one second side embedding feature protruding from the second lateral side inside surface at a location between the second lower end and the panel second surface, the at least one second side embedding feature having second side embedding surfaces against which the flowable material is molded.

7. The PV panel assembly of claim 1 further including reinforcing elements embedded in the molded base material and extending transverse to a thickness axis of the PV panel assembly from the first lateral side component to the second lateral side component.

8. The PV panel assembly of claim 1 wherein the cover material is a layer of molded material comprising a material solidified from a flowable material molded against the panel first surface and against an outside surface of the first lateral side component and an outside surface of the second lateral side component.

9. The PV panel assembly of claim 1 further including a load receiving surface spaced apart from the panel first surface at least by the cover material and further including at least one reduced light transmissivity layer extending transverse a thickness axis of the PV panel assembly, the at least one reduced light transmissivity layer including a light-transmissive material in which is included low-light-transmissivity granular material including grains which are suspended in the reduced light transmissivity layer spaced apart from the load receiving surface.

10. The PV panel assembly of claim 9 wherein the low-light-transmissivity granular material reduces the light transmissivity of the reduced light transmissivity layer by no more than approximately 10%.

11. The PV panel assembly of claim 9 wherein the low-light-transmissivity granular material in at least some of an area of the reduced light transmissivity layer is made up of grains having a maximum dimension of between approximately 10 microns and 7500 microns.

12. A PV panel installation including:

(a) a supporting bed;

(b) two or more PV panel assemblies supported on the supporting bed; and

(c) wherein each PV panel assembly includes,

(i) a PV panel having a panel first surface and a panel second surface with the panel first surface and the panel second surface bounded by a panel peripheral edge, the PV panel being operable to provide electrical power in response to operating light incident on the panel first surface, wherein the panel peripheral edge is defined by a first side peripheral edge and a second side peripheral edge, the second side peripheral edge lying opposite to the first side peripheral edge;

(ii) a first lateral side component extending along the first side peripheral edge and defining a first lateral side inside surface;

(iii) a second lateral side component extending along the second side peripheral edge and defining a second lateral side inside surface which lies opposite to the first lateral side inside surface so that the first lateral side inside surface, the second lateral side inside surface, and the panel second surface together define a base volume;

(iv) a molded base material located in the base volume, the molded base material comprising a material solidified from a flowable material placed in the base volume and molded against at least a portion of the panel second surface and least a portion of both the first lateral side inside surface and the second lateral side inside surface; and

(v) a cover material extending over the panel first surface, the cover material being light-transmissive at least in portions extending over one or more areas of the panel first surface.

13. The PV panel installation of claim 12 wherein the first lateral side component extends along the entire length of the first side peripheral edge and the second lateral side component extends along the entire length of the second side peripheral edge.

14. The PV panel installation of claim 12 wherein in each respective PV panel assembly:

15. The PV panel installation of claim 14 wherein in each respective PV panel assembly:

16. The PV panel installation of claim 14 wherein in each respective PV panel assembly:

17. The PV panel installation of claim 13 wherein in each respective PV panel assembly:

18. The PV panel installation of claim 12 wherein each respective PV panel assembly includes a load receiving surface spaced apart from the panel first surface at least by the cover material and further including at least one reduced light transmissivity layer extending transverse to a thickness axis of the respective PV panel assembly, the at least one reduced light transmissivity layer including a light-transmissive material in which is included low-light-transmissivity granular material including grains which are suspended in the reduced light transmissivity layer spaced apart from the load receiving surface.

19. A method of producing a PV panel assembly having a PV panel which (i) includes a panel first surface and a panel second surface with the panel first surface and the panel second surface bounded by a panel peripheral edge, and which (ii) is operable to provide electrical power in response to operating light incident on the panel first surface, the method including:

(a) supporting the PV panel on a support surface in a first molding position in which the panel second surface faces upwardly away from the support surface;

(b) defining a base volume of the PV panel assembly, the base volume comprising a volume defined by the panel second surface and a peripheral transverse surface extending along the entire length of the panel peripheral edge, the peripheral transverse surface extending transverse to a plane defined by the panel second surface;

(c) while supporting the PV panel in the first molding position, placing a flowable base-forming material within at least a portion of the base volume so that the flowable base-forming material is molded against at least a portion of the panel second surface and at least a portion of the peripheral transverse surface;

(d) causing the flowable base-forming material to solidify while molded against the panel second surface and peripheral transverse surface to thereby form a molded base material within the base volume, the molded base material being molded against the portion of the panel second surface and the portion of the peripheral transverse surface;

(e) removing the PV panel from the first molding position together with the molded base material; and

(f) molding a light-transmissive cover material against substantially the entire panel first surface.

20. The method of claim 19 wherein the molded base material remains molded against the portion of the peripheral transverse surface when the PV panel is removed from the first molding position together with the molded base material.