Solar module spacer
Patent Information
- Application Number
- JP2024539301
- Authority / Receiving Office
- JP · JP
- Patent Type
- Applications
- Current Assignee / Owner
- Priority Date
- 2021-12-29
- Filing Date
- 2022-12-09
- Publication Date
- 2025-12-18
Smart Images
Figure 00000000_0000_ABST
Abstract
Description
[Technical field]
[0001] The present disclosure relates to spacers for spacing adjacent stacked solar modules. Such spacers may find particular, but not exclusive, application in the transportation of solar modules. [Background technology]
[0002] A solar module for providing electrical energy from sunlight typically comprises an array of solar cells disposed between a backing layer and a front protective glass layer. A frame is typically provided that extends around a rectangular perimeter of the backing layer and the glass layer. The rectangular frame, typically formed from extruded sections, protects the solar cells and facilitates mounting the solar module to a structure such as the roof of a building.
[0003] Solar modules are typically shipped (e.g., to a site or between various distribution facilities) in containers (such as boxes) that contain several solar modules arranged in a stack. The solar modules may be stacked together vertically (i.e., each solar module extends on a generally horizontal plane) or horizontally (i.e., each solar module extends on a generally vertical plane). In either case, it is known to provide spacers between each pair of adjacent modules to prevent the solar modules from coming into potentially damaging contact during shipping.
[0004] Thus, packaging solar modules involves an operator placing several spacers around the periphery of each solar module before placing another solar module against or on top of the spacer. This can be time consuming and result in operator fatigue, so operators are prone to misaligning spacers and / or accidentally omitting spacers when packaging solar modules. This, in turn, can result in poor packaging of the solar modules and increased chances of damage during transport.
[0005] There is a need to improve at least one of the problems discussed above with respect to solar module packaging. Summary of the Invention
[0006] According to a first aspect, there is provided a spacer for spacing two adjacent stacked solar modules, the spacer comprising: a body having spaced apart opposing first and second edges, the body including an upper contact surface for contacting an upper solar module and a lower contact surface for contacting a lower solar module; An upper protrusion (e.g., a first upper protrusion) arranged to press against the frame of the upper solar module, the upper protrusion protruding upward from or adjacent to the first edge of the body to a free end; A lower protrusion (e.g., a first lower protrusion) arranged to press against a frame of a lower solar module, the lower protrusion protruding downwardly to a free end from or adjacent to the first end of the body, the lower protrusion being offset from the upper protrusion in a direction along the first end.
[0007] The offset configuration of the lower and upper protrusions avoids interference between a first lower protrusion of a similar spacer and an upper protrusion of a similar spacer when the spacer is stacked on top of a similar spacer, e.g., before the spacer is assembled with a solar module. This configuration thus facilitates stacking a spacer with multiple similar spacers, e.g., before the spacer is assembled with a solar module. The ability to stack a spacer with similar spacers provides more efficient storage of stacked spacers. It also facilitates the use of the spacers in an automated solar module stacking process. For example, the ability to stack spacers can enable the spacers to be loaded into a feeder device (e.g., a vibratory bowl feeder) to feed the spacers to a handling device (e.g., an XY handler) for automated placement of the spacers on the solar module. By facilitating placement in an automated (mechanically driven) manner, the spacers enable a packaging process with a reduced rate of misaligned or omitted spacers.
[0008] Furthermore, the configuration of the protrusions (e.g., the protrusions extend to a free end) is such that the spacer can be positioned by, for example, lowering it onto the solar module, rather than having to be pushed laterally onto the frame of the solar module. Again, this facilitates automation of the positioning of the spacer.
[0009] For the avoidance of doubt, it is not necessary for the entire upper projection (during use) to press against the frame. As can be appreciated, in embodiments (discussed further below) in which the upper projection includes a sloped inwardly facing opposing surface, only a portion (and in some cases only a very small portion) may press against the frame. In general, the role of the upper projection is to limit movement of the frame in at least one direction.
[0010] Further, and as discussed below, it should be understood that the first edge and second edge are not limited to being straight (e.g., each edge may extend around a corner to have two joined vertical portions).
[0011] The following are optional features, which can be applied alone or in any combination with any aspect.
[0012] The lower protrusion may be a first lower protrusion and the spacer may include a second lower protrusion projecting downwardly from the body to a free end. The second lower protrusion may be spaced apart from the first lower protrusion in a direction toward a second edge of the body such that a space for receiving a frame of a lower solar module is defined between the first lower protrusion and the second lower protrusion.
[0013] As should be understood, the provision of spaced apart lower and upper protrusions means that the upper solar module can be interlocked (using some spacers) with the lower solar module. This interlocking of the upper and lower solar modules by the spacers limits the relative movement between the solar modules in a plane parallel to the solar modules. This ensures that, for example, during transportation, the solar modules remain aligned with each other to form a vertically extending stack of solar modules. Without such interlocking, sudden movements (such as emergency braking by a vehicle transporting the solar modules) can result in an uneven stack of solar modules (which makes unloading / loading difficult).
[0014] Each of the first and second lower protrusions may include an inwardly facing opposing surface (for pressing against the solar module frame when received in the space therebetween). At least one of the inwardly facing opposing surfaces (e.g., each inwardly facing opposing surface) may be in the form of a guide surface configured to guide the solar module frame into the space defined between the first and second lower protrusions. The guide surface may be inclined in a downward and outward direction from the body (i.e., inclined relative to a vertical axis). The guide surface may be disposed at an angle relative to the lower contact surface.
[0015] The space defined between the first and second lower projections may be in the form of a channel (having a lower opening). The guide surface may thus be configured to guide the frame of the lower solar module into the channel. The lower contact surface may define the bottom of the channel (i.e., the upper side of the channel). The channel may be wider at the opening of the channel (in a direction extending between the first edge and the second edge) than at the base of the channel. The channel may thus taper inwardly in an upward direction.
[0016] As used herein (at least with reference to features of the spacer), the term "inwardly" is intended to mean a direction toward the center of the spacer (i.e., toward a centerline extending centrally between a first edge and a second edge of the body). Accordingly, the term "outwardly" is used to describe a direction away from the center of the spacer.
[0017] Providing a guide surface can facilitate receiving a portion of the frame of the solar module between the first and second lower protrusions. As mentioned above, the inclined surface can guide the frame into the channel defined between the lower protrusions. This can accommodate some initial misalignment between the spacer and the frame when positioning the spacer on the frame while maintaining the precision of the final positioning of the spacer on the frame. This in turn can allow for an increased tolerance in the initial positioning of the spacer, and thus allow such positioning to be performed in an automated manner (e.g., by an automated handling device).
[0018] A spacer may be configured such that when stacked with multiple similar spacers, the spacers form an organized vertical stack of spacers (i.e., the stack extends along a straight vertical path, with all of the spacers having the same orientation and stacked directly on top of each other).
[0019] The spacer may include a recess arranged to receive an upper protrusion or a first lower protrusion of a similar spacer when the spacer is stacked with (i.e., above or below) a similar spacer.
[0020] Thus, the recess may be vertically aligned (i.e. directly below / above) with the upper protrusion or the first lower protrusion of a similar spacer, i.e. when the recess is positioned to accommodate an upper protrusion of a similar spacer, the recess is vertically aligned below the upper protrusion of the spacer, and when the recess is positioned to accommodate a first lower protrusion of a similar spacer, the recess is vertically aligned above the first lower protrusion of the spacer.
[0021] The recess may have a shape complementary to that of the upper protrusion or the first lower protrusion (i.e., the protrusion that the recess is configured to accommodate). The recess may taper inwardly in a direction to receive a protrusion of a similar spacer during use. Thus, the recess may be wider at the open end of the recess (in a direction along the first edge) than at the opposite distal (closed) end of the recess. The recess may have a trapezoidal cross-sectional shape (taken in a direction along the first edge).
[0022] The upper projection and / or the first lower projection may taper inwardly from a proximal end (where the upper projection and / or the first lower projection are connected to the body) to a free (distal) end of the upper projection and / or the first lower projection. The proximal end of the upper projection and / or the first lower projection may be wider (in a direction along the first edge) than the distal end. The upper projection and / or the first lower projection may have a trapezoidal cross-sectional shape (taken in a direction along the first edge).
[0023] The tapered nature of the recess and the corresponding upper protrusion or first lower protrusion can facilitate insertion of the protrusion of a similar spacer into the recess when the spacer is stacked with the similar spacer, i.e., the tapering can allow the spacer to self-align with the similar spacer when the spacer is stacked on top of the similar spacer.
[0024] The recess may be at least partially defined by an upper protrusion or a first lower protrusion (i.e., a protrusion that the recess is not configured to accommodate) (e.g., a side of the recess may be defined by the upper protrusion or the first lower protrusion).
[0025] The spacer may include two upper protrusions and the recess may be defined between the two upper protrusions.The spacer may include two first lower protrusions and the recess may be defined between the two first lower protrusions.
[0026] The spacer may include a plurality of first lower projections (each of which may be as described above) spaced apart in a direction along the first edge of the body, and recesses (e.g., each of which may be as described above) may be defined between adjacent pairs of the first lower projections.
[0027] The spacer may include a plurality of upper protrusions (each of which is as described above) spaced apart along a first edge, and recesses (e.g., each of which is as described above) may be defined between adjacent pairs of the upper protrusions.
[0028] In other words, the spacer may comprise one or more upper protrusions and one or more first lower protrusions, and each of the one or more first lower protrusions may be offset from each of the one or more upper protrusions in a direction along the first edge.
[0029] Each pair of adjacent upper protrusions may be vertically aligned (i.e., directly above) a corresponding recess defined between the pair of first lower protrusions. Each pair of adjacent first lower protrusions may be vertically aligned (i.e., directly below) a corresponding recess defined between the pair of upper protrusions. In this manner, each upper protrusion may be offset from each first lower protrusion along the first edge.
[0030] Thus, a first edge of the body of the spacer may include a plurality of upper protrusions and a plurality of first lower protrusions arranged in an alternating pattern (e.g., forming a wavy shape) along the first edge. In this way, when the spacer is stacked on top of a similar spacer, the first lower protrusions may interlock with the upper protrusions of the similar spacer. This can provide a particularly robust connection between the two spacers when stacked.
[0031] The height of the or each first lower protrusion (eg from the lower contact surface) may be substantially the same as the height of the second lower protrusion.
[0032] The second lower projection may be elongate in a direction along (i.e., parallel to) the second edge of the body. The second lower projection may extend along most (e.g., the entire) of the body in the direction of the second edge. In this regard, the second lower projection may be in the form of a rib, lip, or flange of the body. The second lower projection may project (e.g., downwardly) from or adjacent to the second edge.
[0033] The second lower projection may be hollow. Thus, the second lower projection may include a cavity that may be open at an upper end (i.e., an open-topped cavity). The walls of the second lower projection may surround (and thus define) the cavity. The cavity may extend along a longitudinal axis of the second lower projection. The second lower projection may include a dividing wall extending transversely to the longitudinal axis (and / or in a direction between the first and second edges) that divides the cavity into separate cavity portions. The walls surrounding the cavity and / or the dividing wall may provide means for gripping the spacer by a handling device.
[0034] The or each first lower projection may be hollow. The or each first lower projection may include a cavity that may be open at an upper end (i.e. an open-topped cavity). The walls of the or each first lower projection may surround (and thus define) the cavity. Again, the walls surrounding the cavity may provide means for gripping the spacer by a handling device.
[0035] The spacer may comprise an opening for fluid flow passing from above the spacer to below the spacer. The opening may be formed to extend through each first lower protrusion and / or second lower protrusion. Thus, for example, if the first lower protrusion or the second lower protrusion, or each first lower protrusion or each second lower protrusion, comprises a cavity, the opening may be arranged to provide for fluid flow from the cavity. Thus, the opening may be formed at the lower end of the cavity (at the free end of the protrusion). If the second lower protrusion comprises a dividing wall, the opening may be provided at the lower end of each cavity portion. Each of the first lower protrusion and the second lower protrusion may comprise an opening formed in the first lower protrusion and the second lower protrusion (for example at the free end of the first lower protrusion and the second lower protrusion). The or each opening may have a diameter of 0.5 to 3 mm, for example 0.7 to 1.5 mm, for example about 1.2 mm.
[0036] The or each opening may allow water to flow through the spacer (e.g. to prevent water from collecting on or in a portion of the spacer). Alternatively or additionally, the opening may help to prevent a vacuum from forming between like spacers when stacked on top of each other. This may facilitate use of the spacers with a handling device (as it allows the handling device to more easily remove a single spacer from a stack of spacers).
[0037] The or each upper protrusion may be a first upper protrusion and the spacer may further comprise a second upper protrusion. The second upper protrusion may be spaced apart from the first upper protrusion (or at least one first upper protrusion if a plurality of first upper protrusions are provided) in a direction towards the second edge. In this way, the first upper protrusion and the second upper protrusion may define a spacing between the first upper protrusion and the second upper protrusion for receiving a frame of an upper solar module.
[0038] Each of the first and second upper projections may include an inwardly facing opposing surface (i.e., facing the other of the upper projections). At least one (e.g., both) of the inwardly facing opposing surfaces may be in the form of a guide surface configured to guide the frame of the upper module into the space between the first and second upper projections. The guide surface may be inclined in an upward and outward direction. The guide surface may be disposed at an angle relative to the upper contact surface.
[0039] The second upper protrusion may be spaced inwardly from the second edge. A spacing between the first upper protrusion and the second upper protrusion may be less than a spacing between the first lower protrusion and the second lower protrusion.
[0040] The second upper protrusion may be box-shaped (may be substantially rectangular). The height of the second upper protrusion (e.g., from the upper contact surface) may be less than the height of the first upper protrusion. The second upper protrusion may be configured such that, in use, an outer glass layer of the upper solar module is supported on the second upper protrusion.
[0041] The spacer may include a plurality of second upper protrusions (each of which may be as described above). The second upper protrusions may be spaced apart along a path that is substantially parallel to one or both of the first edge and the second edge. The provision of a plurality of second upper protrusions may distribute forces applied to the upper solar module (e.g., a glass layer of the upper solar module).
[0042] The body may be substantially planar. The body may extend horizontally. The upper contact surface and / or the lower contact surface may be planar. The upper contact surface and / or the lower contact surface may extend horizontally.
[0043] The spacer may be integrally formed (i.e., may be a single piece). The spacer may be formed by injection molding. The spacer may comprise a plastic material. The spacer may comprise high density polyethylene (HDPE) resin.
[0044] The spacer may be configured to receive between a linear portion of the frame of the upper solar module and a linear portion of the frame of the lower solar module. That is, the spacer may be configured to space two edge portions (as opposed to corner portions) of two respective solar module frames. In such an embodiment, each of the first edge and the second edge may be linear (and parallel). Similarly, the channel defined by the first lower protrusion and the second lower protrusion may extend along a linear path, and the space defined by the first upper protrusion and the second upper protrusion may extend along a linear path.
[0045] In other embodiments, the spacer may be configured to receive between a corner portion of the frame of the upper solar module and a corner portion of the frame of the lower solar module. In this regard, the spacer may be referred to as a "corner spacer." In such an embodiment, the first edge and the second edge may extend along a path that follows the shape of the corner. Thus, each of the first edge and the second edge may include a first interface portion and a second interface portion that are substantially perpendicular to each other.
[0046] In other words (and for the avoidance of doubt), the above references to a first edge or a second edge are intended to encompass edges that are non-linear (e.g., extend around a corner and may include two joined perpendicular edge portions).
[0047] Thus, in such an embodiment, the channel (defined between the first and second lower projections) may follow the corner path (i.e., have a first and second junction that are substantially perpendicular to one another). Similarly, the first and second upper projections may define a space that follows the corner path.
[0048] The first edge may be an in-use peripheral edge of the spacer (i.e., disposed around the solar module in use). Thus, the first upper and lower protrusions may be configured to press against an outer surface of the frame of the respective solar module.
[0049] The second edge may be an inner edge of the spacer during use (i.e., disposed on an inner side of the frame of the solar module during use), and the second upper and lower protrusions may thus be configured to press against an inner surface of the frame of the respective solar module.
[0050] In a second aspect, there is provided a spacer for spacing two adjacent stacked solar modules, the spacer comprising: a body having spaced apart opposing first and second edges, the body including an upper contact surface for contacting an upper solar module and a lower contact surface for contacting a lower solar module; a first lower protrusion (e.g., arranged to press against a frame of a lower solar module), the first lower protrusion protruding downward from or adjacent to a first edge of the body to a free end of the first lower protrusion; a second lower protrusion (e.g., arranged to press against a frame of a lower solar module), protruding downward from the main body to a free end of the second lower protrusion, the second lower protrusion being spaced apart from the first lower protrusion in a direction toward a second edge of the main body, such that a space for receiving the frame of the lower solar module is defined between the first lower protrusion and the second lower protrusion; Equipped with Each of the first lower protrusion and the second lower protrusion includes an inwardly facing opposing surface, at least one of the inwardly facing opposing surfaces being in the form of a guide surface configured to guide the frame of the lower solar module into a space defined between the first lower protrusion and the second lower protrusion.
[0051] The spacer may include an upper protrusion (e.g., a first upper protrusion) arranged to press against the frame of the upper solar module. The upper protrusion may protrude upward from or adjacent to the first edge of the body to a free end of the upper protrusion.
[0052] The spacer of the second aspect may be otherwise as described above in relation to the first aspect. For example, the first lower projection may be offset in a direction along the first edge from the upper projection. The spacer may alternatively or additionally comprise any of the optional features described above in relation to the second aspect.
[0053] In a third aspect, there is provided a solar module assembly, the solar module assembly comprising: A spacer as described above with respect to the first or second aspect; a lower solar module including a frame extending around a periphery of an assembly of solar cells, a portion of the frame of the lower solar module pressing against a lower contact surface (and, for example, against the first lower protrusion and / or the second lower protrusion) of the spacer; An upper solar module including a frame extending around the periphery of an assembly of solar cells, wherein a portion of the frame of the upper solar module presses against an upper contact surface (and, for example, a first upper protrusion and / or a second upper protrusion) of a spacer.
[0054] The upper and lower solar modules may be as described above with respect to the first and second aspects.
[0055] In a fourth aspect, there is provided an automated method for stacking solar modules, the method comprising: lowering the spacer according to the first and second aspects onto the lower solar module by an automated handling device such that the frame of the lower solar module presses against the lower contact surface (and e.g. the first lower protrusion and / or the second lower protrusion) of the spacer; Positioning the upper solar module on the spacer such that the frame of the upper solar module presses against the upper contact surface (and, for example, the first upper protrusion and / or the second upper protrusion) of the spacer.
[0056] The method may include aligning the spacer (eg, using an automated handling device) above a frame of the lower solar module before lowering the spacer.
[0057] The method may further include feeding the spacers to an automated handling device (eg, by an automated feeder).
[0058] Those skilled in the art will understand that, unless mutually exclusive, a feature or parameter described in connection with any one of the above embodiments may be applied to any other embodiment. Further, unless mutually exclusive, any feature or parameter described herein may be applied to any embodiment and / or may be combined with any other feature or parameter described herein. [Brief description of the drawings]
[0059] Embodiments will now be described, by way of example only, with reference to the drawings in which:
[0060] [Figure 1A] 1 is a schematic cross-sectional view illustrating a spacer according to a first embodiment for separating two adjacent solar modules. [Figure 1B] FIG. 2 is a top perspective view of the spacer according to the first embodiment. [Figure 1C] FIG. 2 is a bottom perspective view of the spacer of the first embodiment. [Figure 2A] FIG. 13 is a top perspective view of a spacer according to a second embodiment. [Figure 2B] FIG. 11 is a bottom view of the spacer of the second embodiment. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0061] Aspects and embodiments of the present disclosure will now be discussed with reference to the accompanying drawings. Further aspects and embodiments will be apparent to those skilled in the art.
[0062] 1A, 1B, and 1C illustrate a spacer 100 for spacing two adjacent stacked solar modules 101a, 101b (shown in FIG. 1A). Each solar module 101a, 101b includes a frame 102 that extends around the periphery of (and holds the edges of) a solar cell assembly 103. Although not shown, the solar cell assembly 103 includes an array of solar cells disposed between a back layer and a front glass layer. Both solar modules 101a, 101b are illustrated with their respective glass layers facing downwards.
[0063] Each frame 102 is formed of a sidewall 104 and three flanges 105, 106, 107 extending inwardly from the sidewall 104. Specifically, each frame 102 includes an upper flange 105 at the top end of the sidewall 104, a lower flange 106 at the bottom end of the sidewall 104, and an intermediate flange 107 between the upper flange 105 and the lower flange 106. An edge of the solar cell assembly 103 is received (and held) between the lower flange 106 and the intermediate flange 107.
[0064] The spacer 100 comprises a planar horizontal body 108 having spaced apart opposing first and second linear edges 110 and 109. The body 108 includes a planar upper contact surface 111 for contacting the upper solar module 101a of the two solar modules 101a, 101b, and a planar lower contact surface 112 for contacting the lower solar module 101b of the two solar modules 101a, 101b.
[0065] The spacer 100 further includes a first upper protrusion 114 protruding upward from a first edge 110 of the body 108 to a free end, and six rectangular parallelepiped-shaped second upper protrusions 115 also protruding upward from the body 108. The second upper protrusions 115 are spaced apart from the first upper protrusion 114 in a direction toward the second edge 109, and are arranged to be spaced apart along linear paths that are parallel to and located between the first edge 110 and the second edge 109 of the body 108. In this manner, a space for receiving a portion of the upper solar module 101a is defined between the first upper protrusion 114 and the second upper protrusion 115.
[0066] In particular, as shown in Fig. 1A, the lower flange 106 of the frame 102 of the upper solar module 101 is received and held in the space between the upper protrusions 114, 115 (such that the side wall 104 presses against the lower end of the first upper protrusion 114). As is also apparent from Fig. 1A, the height of each second upper protrusion 115 is the same as the thickness of the lower flange 106. As a result, the solar cell assembly 103 (particularly the protective glass layer) of the upper solar module 101a rests on the distal end surface of the second upper protrusion 115.
[0067] To facilitate reception of the lower flange 106 between the upper protrusions 114, 115, the first upper protrusion 114 includes an inwardly facing opposing surface in the form of a guide surface 116. The guide surface 116 is inclined upwardly and outwardly from the upper contact surface 111 of the body 108. When the spacer 100 is used, this means that the lower flange 106 of the upper solar module 101a can be guided into the space between the upper protrusions 114, 115 by the guide surface 116 (i.e., when the solar module 101a is lowered onto the spacer 100). Thus, the spacer 100 accommodates a certain degree of misalignment with the upper solar module 101a during engagement of the upper solar module 101a with the spacer 100.
[0068] The spacer 100 further comprises two first lower projections 118 and an elongated second lower projection 117. The second lower projection 117 projects downwardly from the second edge 109 of the body 108 to a free end and extends along the second edge 109 for the length thereof.
[0069] Both of the two first lower projections 118 are offset along the first edge 110 from the first upper projection 114. Both of the first lower projections 118 project downward from the first edge 110 of the body 108 to their respective free ends and are spaced apart from one another along the first edge 110 (the upper projection 114 is located directly above this space between the first lower projections 118). Each of the first lower projections 118 is hollow and formed of a wall surrounding an open-topped cavity 124. The second lower projection 117 is also hollow and formed of a surrounding wall defining a cavity that is divided into three cavity portions 125 by two transverse dividing walls. The walls defining the lower projections 117, 118 may be used, for example, by a handling device to grip the spacer 100 during use. The provision of cavities / void portions 124 , 125 also helps to minimize the weight and material requirements of the spacer 100 .
[0070] Each cavity 124 and cavity portion 125 includes a corresponding opening 126 formed at the bottom end of each cavity 124 and cavity portion 125 (i.e., formed at the bottom end of the corresponding lower protrusion 117, 118). These openings 126 allow for water flow out of the cavities / cavity portions 124, 125 and also prevent a vacuum from forming when the spacer 100 is stacked with like spacers (by providing a path for air to flow between the spacers 100).
[0071] The second lower projection 117 includes an inwardly facing opposing surface 119 that faces the corresponding inwardly facing opposing surfaces 120 of the two first lower projections 118. Together, these surfaces 119, 120 define a channel 121 for receiving a portion of the lower solar module 101b (as depicted in FIG. 1A ). In particular, this channel 121 receives the upper flange 105 of the frame 102 of the lower solar module 101b.
[0072] In practice (when the spacer 100 is used in a vertical stack of solar modules), the spacer 100 is placed on the frame 102 of the lower solar module 101b. To aid in this placement, the inwardly facing opposing surfaces 120, 119 of the lower projections 117, 118 are configured as guide surfaces. These opposing surfaces are therefore inclined relative to the lower contact surface 112 of the body 108. In particular, each of these inwardly facing opposing surfaces 119, 120 is inclined downwardly and outwardly, i.e., away from the center of the channel 121. As a result, the channel 121 is wider at the lower open end of the channel 121 (in the direction extending between the first edge 110 and the second edge 109) than at the bottom of the channel 121 (defined by the lower contact surface 112).
[0073] Thus, when the spacer 100 is positioned on the upper flange 105 of the lower solar module 101b, the spacer 100 is guided onto the upper flange 105 by the inclined inwardly facing (guide) surfaces 119, 120. In this manner, the inclined inwardly facing (guide) surfaces 119, 120 allow for some initial misalignment between the channel 121 and the upper flange 105. This facilitates positioning of the spacer 100 via an automated process, which may require a larger tolerance than manual positioning of the spacer 100.
[0074] Spacer 100 further includes a recess 122 defined between the two spaced apart first lower projections 118. This recess 122 is positioned directly below outer upper projection 114 and is thus arranged to receive a portion of the outer upper projection (not shown) of a similar spacer when spacer 100 is stacked on top of the similar spacer.
[0075] As should be clear from the figure, when stacked in this manner, the (lower) free ends of the lower projections 117, 118 of the spacers 100 rest on the upper contact surface of a similar spacer. All of the lower projections 117, 118 have the same height (i.e. extend the same extent from the lower contact surface 112), so that when a spacer 100 is stacked on top of a similar spacer, the bodies 108 of the two spacers 100 are substantially parallel to each other. As can be appreciated, this configuration means that when many spacers 100 are stacked on top of each other, the stack forms a vertically extending row. Thus, the stacked spacers 100 can be more easily accommodated, for example, in a feeder of a handling device.
[0076] To further assist in stacking of the spacer 100 (with other similar spacers), both the first upper projection 114 and the recess 122 are inwardly tapered (i.e., narrow) in the upward direction (i.e., each has a substantially trapezoidal shape). That is, both the first upper projection 114 and the recess 122 are wider at their lower ends (measured in a direction along the first edge 110) than at their upper ends. The recess 122 is specifically defined between two sloping side surfaces 123 of the spaced apart first lower projection 118.
[0077] As can be seen, the spacer 100 of FIGS. 1A-1C is configured to be received between straight portions (i.e., between corners) of the frames 102 of the upper and lower solar modules 101a, 101b, respectively.
[0078] 2A and 2B illustrate a spacer 100' configured to space the corners of the frames 102 of the solar modules 101a, 101b from one another. The spacer 100' includes many of the features of the spacer 100 of Figures 1A-1C, and for that reason the same reference numbers are used.
[0079] This spacer 100' differs from the previous ones in that the body 108 is shaped to accommodate the corners of two solar module frames. The body 108 is thus L-shaped and has a first spaced apart opposing edge 110 and a second spaced apart opposing edge 109, each following an L-shaped or corner-shaped path. As a result, the second lower protrusion 117 (extending along the second edge 109) and the channel 121 (defined in part by the second lower protrusion) are also L-shaped. This allows the channel 121 to accommodate the corner of the frame 102.
[0080] The spacer 100' also includes more first upper projections 114 and lower projections 118 than the spacer 100 discussed above. In particular, the spacer 100' comprises four first upper projections 114 spaced apart along the first edge 110 and five first lower projections 118 spaced apart along the first edge 110. The first upper projections 114 and the first lower projections 118 are offset from one another such that they are arranged in an alternating pattern along the first edge 110 (i.e., forming a wavy structure at the first edge 110). Each pair of the first lower projections 118 defines a tapered recess 122 between the first lower projections 118 for receiving a corresponding first upper projection of a similar spacer when the spacer is stacked on the similar spacer. In this manner, the first lower projections 118 are configured to mate with the first upper projections of a similar spacer when the spacer is stacked on the similar spacer.
[0081] The spacer 100' also includes more second upper projections 115 than the spacer 100 described above. In particular, the spacer 100' comprises two groups of second upper projections 115. Each group of second upper projections 115 is disposed on a respective leg of the L-shaped body 108 and includes five second upper projections 115 that are L-shaped and spaced apart from one another along a linear path that is parallel to (but spaced apart from) the second edge 109.
[0082] This configuration of the second upper protrusion 115 results in a space defined between the first upper protrusion 115 and the second upper protrusion 115 that is shaped to receive a corner of a solar module frame (i.e., is L-shaped).
[0083] It will be understood that the present invention is not limited to the embodiments described above, and various modifications and improvements can be made without departing from the concepts described herein. Any feature can be used separately or in combination with any other feature, except where mutually exclusive, and the present disclosure extends to and includes all combinations and subcombinations of one or more features described herein.
Claims
1. A spacer for spacing two adjacent stacked solar modules, comprising: a body having spaced apart opposing first and second edges, the body including an upper contact surface for contacting an upper solar module and a lower contact surface for contacting a lower solar module; a first upper protrusion arranged to press against a frame of the upper solar module, the first upper protrusion protruding upward from the first edge of the body or adjacent to the first edge of the body to a free end of the first upper protrusion; a first lower protrusion arranged to press against a frame of the lower solar module, the first lower protrusion protruding downward from the first edge of the body or adjacent to the first edge of the body to a free end of the first lower protrusion, the first lower protrusion being offset from the first upper protrusion in a direction along the first edge; A spacer comprising:
2. 2. The spacer of claim 1, further comprising a second lower protrusion protruding downward from the body to a free end, the second lower protrusion being spaced apart from the first lower protrusion toward the second edge of the body such that a space for receiving a frame of the lower solar module is defined between the first lower protrusion and the second lower protrusion.
3. 3. The spacer of claim 2, wherein each of the first lower protrusion and the second lower protrusion includes an inwardly facing opposing surface, and at least one of the inwardly facing opposing surfaces is in the form of a guide surface configured to guide the frame of the lower solar module into the space defined between the first lower protrusion and the second lower protrusion.
4. The spacer of claim 3 , wherein the guide surfaces are inclined downward and outward.
5. 3. The spacer of claim 2, wherein the height of the first lower projection from the lower contact surface is substantially the same as the height of the second lower projection from the lower contact surface.
6. 2. The spacer of claim 1, comprising a recess positioned to receive the first upper protrusion or the first lower protrusion of a similar spacer when the spacer is stacked with the similar spacer.
7. when the recess is positioned to receive the first upper protrusion of the similar spacer, the recess is vertically aligned below the first upper protrusion of the spacer; 7. The spacer of claim 6, wherein said recess is vertically aligned above said first lower projection of said spacer when said recess is positioned to receive said first lower projection of said similar spacer.
8. 7. A spacer according to claim 6, wherein the recess tapers inwardly in a direction to receive the protrusion of the like spacer in use.
9. The spacer of claim 6 , wherein the recess is partially defined by the first upper protrusion or the first lower protrusion.
10. The spacer of claim 1 , wherein the first upper projection and / or the first lower projection tapers inwardly from the proximal end to the free end of the first upper projection and / or the first lower projection.
11. the spacer comprises two first upper protrusions, and the recess is defined between the two first upper protrusions; or The spacer of claim 10 , wherein the spacer comprises two first lower protrusions, and the recess is defined between the two first lower protrusions.
12. 2. The spacer of claim 1, comprising a plurality of first upper protrusions spaced apart along the first edge and a plurality of first lower protrusions spaced apart along the first edge, the first upper protrusions and the first lower protrusions being arranged in an alternating pattern along the first edge.
13. 2. The spacer according to claim 1, further comprising a second upper protrusion spaced apart from the first upper protrusion toward the second edge, wherein a space for receiving a frame of the upper solar module is defined between the first upper protrusion and the second upper protrusion.
14. A second upper protrusion is provided which is spaced apart from the first upper protrusion towards the second edge, and a space for receiving a frame of the upper solar module is defined between the first upper protrusion and the second upper protrusion; The spacer of claim 2 , wherein a distance between the first upper protrusion and the second upper protrusion is smaller than a distance between the first lower protrusion and the second lower protrusion.
15. 14. A spacer according to claim 13, wherein the height of the second upper projection is less than the height of the or each first upper projection.
16. 14. The spacer of claim 13, comprising a plurality of second upper projections spaced apart along a path substantially parallel to the first edge.
17. The spacer of claim 2 , wherein at least one of the first lower projection and the second lower projection includes an open-topped cavity.
18. The spacer of claim 1 comprising openings for fluid flow passing from above the spacer to below the spacer.
19. A spacer including an opening for fluid flow passing from above the spacer to below the spacer; 18. The spacer of claim 17, wherein the opening is positioned to provide fluid flow from the open-top cavity.
20. The spacer of claim 1 which is integrally formed.
21. The spacer of claim 1 , configured to be received between a linear portion of a frame of the upper solar module and a linear portion of a frame of the lower solar module.
22. The spacer of claim 1 , configured to be received between a corner portion of a frame of the upper solar module and a corner portion of a frame of the lower solar module.
23. A spacer for spacing two adjacent stacked solar modules, comprising: a body having spaced apart opposing first and second edges, the body including an upper contact surface for contacting an upper solar module and a lower contact surface for contacting a lower solar module; a first lower protrusion projecting downwardly from or adjacent to the first edge of the body to a free end of the first lower protrusion; a second lower protrusion, which protrudes downward from the main body to a free end of the second lower protrusion, the second lower protrusion being spaced apart from the first lower protrusion in a direction toward the second edge of the main body, such that a space for receiving a frame of the lower solar module is defined between the first lower protrusion and the second lower protrusion; Equipped with a spacer, wherein each of the first lower protrusion and the second lower protrusion includes an inwardly facing opposing surface, and at least one of the inwardly facing opposing surfaces is in the form of a guide surface configured to guide the frame of the lower solar module into the space defined between the first lower protrusion and the second lower protrusion.
24. 24. The spacer of claim 23, comprising a first upper protrusion arranged to press against a frame of the upper solar module, the upper protrusion protruding upwards from or adjacent to the first edge of the body to a free end of the upper protrusion.
25. A solar module assembly, comprising: A spacer according to any one of claims 1 to 24; a lower solar module including a frame extending around a periphery of an assembly of solar cells, a portion of the frame of the lower solar module pressing against the lower contact surface of the spacer; an upper solar module including a frame extending around a periphery of an assembly of solar cells, wherein a portion of the frame of the upper solar module presses against the upper contact surface of the spacer; A solar module assembly comprising:
26. 1. An automated method for stacking solar modules, said method comprising: - lowering a spacer according to any one of claims 1 to 24 onto the lower solar module by an automated handling device so that a frame of the lower solar module presses against the lower contact surface of the spacer; positioning the upper solar module on the spacer such that a frame of the upper solar module presses against the upper contact surface of the spacer; An automated method, including: