Integrated frames for photovoltaic modules

Abstract

An integrated frame includes: (a) an integrated portion that forms a cantilever connection with a material stack, (b) a cover that is connected to the integrated portion and extends from the integrated portion, and (c) a pair of extensions that are connected to the cover and extend from the cover, wherein the cover extends over and protects a connector that is connected to and extends from the material stack.

Description

Technical Field

[0001] The present teachings generally relate to frames for providing support for connectors of photovoltaic laminates, and more particularly to frames for controlling the geometry of and protecting the connectors. Background Art

[0002] Photovoltaic modules include an active portion that captures sunlight and converts it into electricity. The active portion may be part of a composite of several materials. A connector extends from the active portion so that an electrical connection, a mechanical connection, or both can be made. During the manufacturing process, the connector may become misaligned, moved, bent, damaged, or a combination thereof due to contact with one or more components of the manufacturing process, rendering the active portion unusable. The connector may form a cantilever connection with the active portion so that the connector may be damaged during removal and / or transportation of the active portion from the machine.

[0003] Typically, photovoltaic arrays are placed in an elevated position (such as the roof of a house or building) or in racks and frames that lift the photovoltaic array so that the photovoltaic array is exposed to sunlight. In order to get them to the roof or elevated position, each of these photovoltaic modules is moved to the roof or elevated position, and then moved along the roof or elevated position and into the appropriate position, which may cause one or more of the connectors to become damaged, bent or unable to perform its connection function. Each photovoltaic module is then directly and / or indirectly fastened to the elevated position by connecting structures such as racks and frames, so that a photovoltaic array is formed. Each photovoltaic module of the photovoltaic array includes an active portion, and the active portions of two or more photovoltaic modules can be placed in close proximity to each other, so that a photovoltaic array is formed by connecting each of the photovoltaic modules together.

[0004] In the case where the photovoltaic module provides a roof function (i.e., building integrated photovoltaics (BIPV)), the photovoltaic module may include an active portion and a support portion, and the active portion of one photovoltaic module may completely and / or partially cover the support portion of an adjacent photovoltaic module to replace the structure of the frame and rack. In the case of building integrated photovoltaic elements, the support portion may provide a roof function or a structural function for subsequent photovoltaic modules. The support structure of the roof may not have consistent flatness or strength due to manufacturing variations and / or the age of the roof, and the shape of the roof may change over time due to movement and / or aging of the foundation and / or roof structure. At some point in the life of the photovoltaic array, a homeowner, maintenance personnel, installer, or a combination thereof may need to walk through the photovoltaic array. When the individual walks through the photovoltaic array, each individual photovoltaic module may bend and flex due to changes in the strength and / or flatness of the support structure, which may cause the photovoltaic module, the connector, or both to bend enough to damage the photovoltaic module, the connector, or both. This weight and strength variation may cause the connector connecting the photovoltaic module to bend, crack, misalign, or a combination thereof, so that the connector is unable to perform the mechanical and / or electrical connection to be formed. A photovoltaic module having a connector that resists damage from manufacturing movement, installation movement, or installed movement would be attractive.A photovoltaic module in which the cantilever connection of the connector is supported so that the geometry of the connector is maintained would be attractive.

[0005] Examples of some photovoltaic modules can be found in U.S. Pat. Nos. 5,437,735, 8,631,614, U.S. Patent Application Publications Nos. 2008 / 0271773, 2010 / 0180523; and International Patent Application No. WO2011 / 019886; and Chinese Patent Nos. CN202839678U and CN202332933U, all of which are incorporated herein by reference in their entirety for all purposes. It would be attractive to have a device that supports one or more edges of a photovoltaic module and, in particular, a connector extending from the edge. It would be attractive to have a device that helps align the connector with the photovoltaic laminate, maintains the geometry of the connector relative to the photovoltaic module, or both. What is needed is a device that withstands the cantilever strength of the connector. What is needed is a device that helps seal the edge of the photovoltaic laminate close to the connector so that the edge, the area around the connector, or both are substantially impermeable to fluids. What is needed is a reusable device that helps compress and form a seal around all or a portion of a connector connected to and extending from a photovoltaic laminate. Summary of the invention

[0006] The present teachings provide a device for supporting one or both of the connectors for photovoltaic laminates. The device can be connected to the photovoltaic laminate close to the connector and provide support to the connector so that the connector generally maintains its position during its service life. The device can provide lateral support, longitudinal support, or support in any direction therebetween. The device can help align the connector during formation. The device can form a mating connection with another device (i.e., a retainer) so that a sealed connection is formed between the device, the connector and the photovoltaic laminate, the connector is aligned with the photovoltaic laminate, or both.

[0007] The present teachings satisfy one or more of the present needs by providing an integrated frame comprising: (a) an integrated portion that forms a cantilever connection with a material stack, (b) a cover that is connected to the integrated portion and extends from the integrated portion, and (c) a pair of extensions that are connected to the cover and extend from the cover, wherein the cover extends over and protects a connector that is connected to and extends from the material stack.

[0008] The present invention teaches a photovoltaic module comprising: (a) a photovoltaic laminate comprising: (i) one or more connectors connected to and extending from the photovoltaic laminate, and (ii) one or more integrated frames in communication with each of the one or more connectors; and wherein each of the one or more integrated frames is connected to the photovoltaic laminate in a position proximate to the one or more connectors so that the one or more integrated frames provide support to the one or more connectors during a manufacturing process, during use, during installation, or a combination thereof.

[0009] The present invention teaches a method comprising: (a) aligning one or more integrated frames in a laminate frame; (b) aligning one or more connectors with each of the one or more integrated frames; (c) providing one or more layers of a laminate over the laminate frame and a portion of the integrated frame, a portion of the one or more connectors, or both; (d) applying pressure to the one or more layers of the laminate, the portion of the integrated frame, and the laminate frame; and (e) heating the one or more layers of the laminate, the portion of the integrated frame, and the laminate frame.

[0010] The teachings herein surprisingly solve one or more of these problems by providing a photovoltaic module having a connector that resists damage caused by manufacturing movement, installation movement, or installed movement. The present teachings provide a photovoltaic module in which the cantilever connection of the connector is supported so that the geometry of the connector is maintained. The present teachings provide a device that supports one or more edges of the photovoltaic module and, in particular, the connector extending from the edge. The present teachings provide a device that helps align the connector with the photovoltaic laminate, maintain the geometry of the connector relative to the photovoltaic module, or both. The present teachings provide a device that withstands the cantilever strength of the connector. The present teachings provide a device that helps seal the edge of the photovoltaic laminate close to the connector so that the edge, the area around the connector, or both are substantially impermeable to fluids. The present teachings provide a reusable device that helps compress and form a seal around all or a portion of the connector, which is connected to and extends from the photovoltaic laminate. BRIEF DESCRIPTION OF THE DRAWINGS

[0011] Figure 1 illustrates a perspective view of a photovoltaic module;

[0012] Figure 2 Picture shows Figure 1 A close-up view of the integrated framework;

[0013] Figure 3 illustrates an exploded view of a photovoltaic module;

[0014] Figure 4 illustrates an exploded view of a lamination assembly and a photovoltaic laminate;

[0015] Figure 4A illustrates a close up view of a retainer and an integrated frame holding a connector in a laminate frame;

[0016] Figure 4B The retainer and integrated frame are shown with the laminate frame removed;

[0017] Figure 5 It is a perspective view of the integrated framework;

[0018] Figure 6 It is a view of one end of the integrated framework;

[0019] Fig. 7A is a side view of the integrated frame;

[0020] Figure 7B is a side view of the integrated frame;

[0021] Fig. 8A Picture shows Fig. 7A An upward perspective view of the integrated frame;

[0022] Figure 8B Picture shows Figure 7B An upward perspective view of the integrated frame;

[0023] Figure 8C The diagram shows a Figure 8B A perspective view of the bottom side of the integrated frame;

[0024] Fig. 9 A perspective view of the rear side of the retainer is illustrated;

[0025] Fig.10 A perspective view showing the front side of the holder is shown.

[0026] Fig.11 A perspective view of an integrated framework is illustrated;

[0027] Fig.12 A close up view of the alignment area of ​​the integrated frame is illustrated;

[0028] Fig.13 is a top view of the laminated assembly;

[0029] Fig.14 is a perspective view of the laminated frame;

[0030] Fig.15 is a perspective view of the front portion of the retainer;

[0031] Fig.16 is a perspective view of the rear portion of the retainer;

[0032] Fig.17 is a plan view of the laminate assembly with the retainer removed; and

[0033] Fig.18 A perspective view of a laminate frame is shown. DETAILED DESCRIPTION

[0034] The explanations and illustrations presented herein are intended to familiarize other technical personnel in the art with this teaching, its principles, and its practical application. A person skilled in the art can adjust and apply this teaching in various forms of this teaching, so that it can be best suited to the requirements of a particular purpose. Therefore, the specific embodiments of the teachings of the present invention are not intended to be exhaustive or limit this teaching as described. Therefore, the scope of this teaching should not be determined with reference to the above description, but should actually be determined with reference to the full scope of the equivalents authorized by such claims together with the attached claims. The disclosures of all articles and references (including patent applications and public cases) are incorporated by reference for all purposes. As will be understood from the following claims, other combinations are also possible, and they are also incorporated by reference in this specification.

[0035] The multiple photovoltaic modules taught herein are combined together to form a photovoltaic array. The photovoltaic array collects sunlight and converts sunlight into electricity. In general, each of the photovoltaic modules can be placed individually in a structure that accommodates all or part of all photovoltaic modules that form the photovoltaic array. The photovoltaic modules taught herein can be used with a housing that contains all individual photovoltaic modules that make up the photovoltaic array. Preferably, the photovoltaic array taught herein does not contain a separate structure that accommodates all photovoltaic modules that make up the photovoltaic array (also referred to as a solar cell array). More preferably, each individual photovoltaic module can be directly connected to the structure (i.e., building integrated photovoltaics (BIPV)), and each of the individual photovoltaic modules is electrically connected together to form a photovoltaic array. Most preferably, each individual photovoltaic module can include a base plate, interconnect wiring, and a photovoltaic laminate. Each base plate can include a support portion, an effective portion, and an overlapping portion. The effective portion (i.e., the support portion and the photovoltaic laminate) can overlap with all or part (e.g., an overlapping portion) of one or more adjacent photovoltaic modules, thereby forming a "double overlap" so that each photovoltaic module can be protected and connected to the connection surface and / or the combined photovoltaic module can form a shingled structure for diverting fluid from the roof of the structure. Each of the photovoltaic modules may have a portion that may be indirectly and / or directly connected to the connection surface. The base plate may be directly connected to the connection surface, and the photovoltaic laminate may be connected to the support portion of the base plate (i.e., the photovoltaic laminate may be indirectly connected to the connection surface). Preferably, the overlapping portion of each of the photovoltaic modules may be directly connected to the connection surface, and the active portion may be directly connected to the overlapping portion or directly connected to the connection surface by a fastener extending through the overlapping portion, extending around the overlapping portion, extending through a fastener support portion in the overlapping portion, or a combination thereof. More preferably, each of the photovoltaic modules may include a base plate and a photovoltaic laminate, and the base plate is connected to the connection surface by one or more fasteners extending through the fastener support portion, and preferably a plurality of fasteners extending through the fastener support portion.

[0036] The fastener support portion may be located in the effective portion, the overlapping portion, the support portion or a combination thereof. Preferably, the fastener support portion may be located in the overlapping portion. The fastener support portion may be a through hole extending through the overlapping portion, so that the fastener can pass through a weak area, a removable portion, a punching, a lower hardness area or a combination thereof where the fastener support portion is placed. Preferably, the fastener support portion may be a zone in which the base plate is reinforced so that the fastener can extend through and connect the photovoltaic module, the base plate or both to one or more connection surfaces, and when the base plate, the overlapping portion or both undergo movement, the fastener does not damage the photovoltaic laminate. Multiple fastener support portions may extend across the width of the base plate. The fastener support portion may be located in the base plate so that the photovoltaic laminate, the connector or both are prevented from moving, damaging, bending or a combination thereof. The one or more fastener support portions and preferably multiple fastener support portions may be located in the support portion, the overlapping portion or both of the base plate. The one or more fastener support portions may be positioned close to one or more alternative fastener support portions. The one or more alternative fastener supports can be used to provide an alternative connection location in the event that the fastener support is aligned with a crack, a recess, a seam, is not available for forming a connection, or a combination thereof. The one or more alternative fastener supports can be positioned proximate to and spaced apart from the fastener support. Preferably, a plurality of fastener supports are positioned proximate to the support portion within the overlapping portion of the base plate so that the photovoltaic module is connected to the connection surface.

[0037] The connection surface can be used to provide support for one or more photovoltaic modules so as to form a photovoltaic array. The connection surface can be a supporting structure, such as a housing for accommodating one or more of the photovoltaic modules. Preferably, the connection surface can be a roof. The roof can be made of any material having sufficient strength to support the weight of a plurality of photovoltaic modules. The roof can be made of any material that allows the plurality of photovoltaic modules to be directly connected to the roof. The roof can be composed of a plurality of boards made of: wood, plywood, structural plywood, decorative plywood, veneer plywood, commercial plywood, utility plywood, marine plywood, medium density fiberboard (MDF), oriented strand board (OSB), Sundela, hardboard, insulation board, the like or a combination thereof. Alternatively, the connection surface can be a series of structural components that do not form a continuous roof surface, such as in the case of a slat-type roof structure. A plurality of photovoltaic modules can be connected to the connection surface so that the photovoltaic modules are adjacent to each other. Preferably, the photovoltaic modules can partially overlap each other. For example, the active portion and / or support portion of one photovoltaic module may overlap the overlapping portion of one or more adjacent photovoltaic modules in a manner similar to how roof shingles are applied to a roof. Preferably, the support portion of the base plate of one photovoltaic module may extend at least partially over the overlapping portion of an adjacent base plate. Each of the base plates may include one or more fastener supports that may connect the base plate to the connection surface.

[0038] Each of the multiple photovoltaic modules and preferably base plates can be connected to the connection surface by having sufficient strength to withstand environmental conditions and forming any fasteners for fastening connection. The multiple base plates can be connected to the connection surface by means of mechanical fasteners, adhesives, interlocking connections with adjacent photovoltaic modules or their combination. Fasteners can be screws, nails, bolts, staples or their combination. Adhesives can be based on epoxy resins, based on silicones, based on acrylic acid, based on urethane, based on polyamide, based on polyolefins, based on polyesters, cross-linked adhesives, thermoplastic adhesives, pressure-sensitive adhesives, hot melt adhesives, block copolymers, segmented copolymers, single-component adhesives, multi-component adhesives, natural adhesives, synthetic adhesives, or their combination. If adhesives are used, it is preferred to use adhesives so that the pv laminate is removed from the base plate without damaging the base plate, the pv laminate or the two. Although it is not preferred, adhesives and mechanical fasteners can be used to connect the pv laminate to the base plate, the photovoltaic module is connected to the connection surface, or these two situations. The adhesive discussed herein can connect the integrated frame to the pv laminate. Fasteners can connect the base plate, the base plate with photovoltaic laminate or the two to the connection structure.

[0039] The base plate can be used to provide a roof function. The base plate can be used to connect a photovoltaic laminate (hereinafter referred to as a pv laminate) to a connection surface (e.g., a roof). The base plate can be used to allow the expansion and contraction of the pv laminate relative to the decoupling of the base plate, or vice versa. The base plate can be used to allow the removal, replacement, repair or combination of the pv laminate without removing the entire pv module from the connection surface. The base plate can be used to protect all or part of the pv laminate. The base plate can connect the pv laminate to the connection surface. The base plate can protect one or more connectors. The base plate can include one or more features to help form a connection with one or more connection devices, one or more pv laminates, or both. The base plate can be connected to the pv laminate to form an effective part.

[0040] The active portion can be used to generate electricity when the pv laminate is connected to the base portion. The active portion can be a portion of the pv laminate that is not covered by one or more adjacent photovoltaic modules. The active portion can be a combination of the support portion of the base plate and the pv laminate.

[0041] The support portion can be used to provide support for the PV laminate. The support portion can support the PV laminate during transportation. The support portion can be used to support the PV laminate when the load is applied to the PV laminate when the PV laminate is connected to the connection surface. For example, when the photovoltaic module is connected to the roof and a person walks through the photovoltaic array, the support portion can resist the bending of the PV laminate so that the PV laminate will not be damaged. The support portion can be used to provide support for one or more adjacent photovoltaic modules. The support portion of the first photovoltaic module can be used to overlap with one or more connectors of one or more second adjacent photovoltaic modules so that one or more connectors of the one or more second adjacent photovoltaic modules are protected. The support portion of the first photovoltaic module can protect one or more connectors connected to two adjacent second photovoltaic modules and extending between the two adjacent second photovoltaic modules. The support portion can provide longitudinal support, lateral support or both, so that the PV laminate is generally not deflected (that is, enough to crack, break or damage). The support portion can work in combination with all or part of the integrated frame. For example, the integrated frame can extend around all or part of the periphery of the support portion. In another example, the integrated frame may form a connection with the PV laminate and contact a portion of the support portion when the integrated frame extends toward the overlapping portion. The PV laminate may not have a fixed connection with the support portion. The support portion may not provide any sealing function to the PV laminate. The PV laminate and the support portion may not have a sealed connection. The support portion may include a connector channel or a portion of a connector channel.

[0042] The one or more connector channels can be used to receive one or more connectors of the pv laminate. The one or more connector channels can be used to protect the pv laminate connector from contact, lateral force, longitudinal force, impact, bending or a combination thereof. The one or more connector channels can help form a connection between a connector (e.g., connecting two adjacent photovoltaic modules) and a connector of the pv laminate. The one or more connector channels can receive all or part of an integrated frame, a connector or both. The integrated frame may have a portion extending into the connector channel. The integrated frame may be completely located within the connector channel. The one or more connector channels can help electrically connect two adjacent pv laminate connectors. Preferably, the one or more connector channels may be recesses that receive a connector of the pv laminate, all or part of an integrated frame or both. The one or more connector channels may be substantially inclined so that the connector channels help form a connection between a connector and a connector of the pv laminate. The one or more connector channels may be located on opposite edges of the base plate, in opposite edge regions, on opposite sides or a combination thereof. The one or more connector channels can receive all connectors of the pv laminate. The one or more connector channels may be angled downward so that the connector and the pv laminate are on the same plane. The one or more connector channels may be angled such that the integrated frame may be flush with a surface (eg, an overlapped portion) of the chassis when connected to the connector.

[0043] The one or more and preferably multiple pv laminates can be configured in any way so that each of the multiple photovoltaic modules can be electrically connected. The pv laminate may include a protective cover (e.g., a glass cover) and a pv unit (e.g., a circuit). Each of the individual photovoltaic modules can be electrically connected to an adjacent photovoltaic module through one or more connectors. The one or more connectors can be a portion of a band, a positive bus bar, a negative bus bar, a wire, an integrated flash sheet, or a combination thereof. One or more connectors can extend between two adjacent photovoltaic modules and form an electrical connection. The one or more connectors can be discrete parts that connect two adjacent pv laminates, extend from a pv laminate, or both. The connector can be a separate part, a discrete part, or both that connects two or more adjacent photovoltaic modules, an integrated flash sheet, or a combination of the two. The connector can extend from the effective portion of the photovoltaic module, as part of the photovoltaic module, or both. The connector can be an integral part of the pv laminate. The connector can be connected to the photovoltaic laminate "pv laminate" in the laminate assembly.

[0044] Photovoltaic laminates can be connected to the base plate, the support portion of the base plate, or both, and form an active portion. The pv laminate can be made of any material so that when sunlight is directed on the active portion, the sunlight is converted into electricity. The pv laminate can be made of one or more photovoltaic cells with a photoactive portion. Preferably, the pv laminate can be made of a plurality of photovoltaic cells. Photovoltaic cells can be made of any material that helps convert sunlight into electricity. Photovoltaic cells can be any type and material known in the art. Some non-limiting examples of materials from which photovoltaic cells can be made include crystalline silicon, amorphous silicon, cadmium telluride (CdTe), gallium arsenide (GaAs), copper chalcogenide-based cells (e.g., copper gallium selenide, copper indium gallium selenide, copper indium selenide, copper indium gallium sulfide, copper indium sulfide, copper indium gallium selenide sulfide, etc. (i.e., commonly known as CIGSS)), amorphous silicon cells, crystalline silicon cells, thin film III-V cells, thin film II-VI cells, IB-IIIA-chalcogenides (e.g., IB-IIIA-selenides, IB-IIIA-sulfides, or IB-IIIA-selenide sulfides), organic photovoltaic elements, nanoparticle photovoltaic elements, dye-sensitized photovoltaic cells, and / or combinations of the described materials. In one specific example, copper indium gallium selenide can be represented by the formula CuIn(1-x)GaxSe(2-y)Sy, where x is 0 to 1 and y is 0 to 2. For copper chalcogenide type cells, the teachings herein contemplate the possible use of additional electroactive layers in CIGSS-based photovoltaic cells, such as one or more of an emitter (buffer) layer, a conductive layer (e.g., a transparent conductor layer), or the like. Other materials and / or combinations are contemplated herein, particularly those disclosed in paragraph 0054 of U.S. Patent Application Publication No. 2012 / 0118349, the contents of which are incorporated herein by reference with respect to materials for the active portion. Photovoltaic cells of photovoltaic laminates may be arranged in parallel, in series, in hybrid series-parallel, and / or may be provided in independent circuits. Photovoltaic laminates may be a combination of layers and may form a pv laminate assembly.

[0045] The pv laminate assembly may include one or more of the following components: a forward protective layer, a rear protective layer, a reinforcement, a photovoltaic cell, a peripheral moisture-sensitive edge seal, one or more internal protective layers, dielectric materials that may be needed to manage the penetration of electrical components outside the laminate, attached connectors and wiring boxes, connector support structures including junction boxes, integrated low-profile connectors, encapsulants, moisture-proof backsheets that may optionally include metallized sublayers, or combinations thereof. An example of a pv laminate may include a glass or polymer moisture-proof material top layer, an encapsulant, an electrical assembly including a battery, a bypass diode, and a bus, a rear encapsulant, an aluminum-based multilayer backsheet, another encapsulant, a rear protective layer, an additional layer around the connector area including the connector support structure, an encapsulant, a dielectric layer, a connector sealing material (e.g., an adhesive or another adhesive sealant with a moisture-proof barrier), a low-profile connector attached to the battery using a bus terminal, another encapsulant layer, and another dielectric layer. The rear protective layer can help protect the laminate from any protrusion or wear from the support structure of the base plate. The PV laminate assembly may not have an encapsulation layer, a rear protective layer, or both. One or more of the layers discussed herein may be a combination of layers. For example, the forward protective layer may be a combination of multiple glass layers combined together. As another example, the reinforcement may be multiple layers bonded together. The layers of the PV laminate assembly may be laminated together. The layers of the PV laminate may be sealed at the edges. Preferably, the PV laminate has a peripheral sealed edge that is resistant to fluid penetration. As discussed herein, each individual layer may include an adhesive so that one or more layers are bonded together to form a layer, and each layer may include an adhesive above and / or below another layer so that one or more adjacent layers are bonded together. Other components and layers of photovoltaic modules that can be used with the reinforcements taught herein are contemplated herein, particularly paragraphs 0048-0053 of U.S. Patent Application Publication No. 2012 / 0118349 and paragraphs 0027-0038 and 2011 / 0220183 of U.S. Patent Application Publication No. 2018 Figure 2 A and 2B, both publications are expressly incorporated herein by reference for components, layers and / or materials that are effective portions of components, layers and / or materials that can be used in conjunction with the reinforcements and photovoltaic modules discussed herein. One or more of the layers of the pv laminate may be a circuit. The circuit may be sealed within the pv laminate.

[0046] The circuit of the photovoltaic laminate may be one or more conductive elements (i.e., busbars), one or more bands (i.e., extending from the unit to the unit of the pv laminate), or both. The circuit may extend from unit to unit, photovoltaic module to photovoltaic module, unit to photovoltaic module, effective part to effective part, or a combination thereof. The circuit may be integrated into one or more photovoltaic cells, connected to one or more photovoltaic cells, electrically connected to one or more photovoltaic cells, or a combination thereof. The circuit may be integrated into one or more layers of the photovoltaic laminate and / or around one or more layers of the photovoltaic laminate. The circuit may extend through the photovoltaic laminate, partially extending outside the photovoltaic laminate so that an electrical connection may be formed, having a portion positioned adjacent to the photovoltaic laminate, or a combination thereof. The photovoltaic laminate may be connected to the support portion of the base plate to form an adjacent portion. The pv laminate may include one or more connectors extending outside the pv laminate as part of the circuit. The one or more connectors may have a portion sealed in the pv laminate and a portion extending out of the pv laminate.

[0047] The one or more pv laminate connectors can be used to provide electrical ports for electrical entry, egress or both through each of the pv laminates. The one or more pv laminate connectors can be partially located in the pv laminate and partially extend out of the pv laminate. For example, the pv laminate connector can have a head end portion outside the pv laminate and two or more terminals extending into the pv laminate. Each of the pv laminate connectors can include an encapsulation layer (e.g., DNP), a polyolefin encapsulant, an adhesive (e.g., ADCO), a head end, a terminal, a dielectric layer, a protective layer, a head end body, a plastic cover, or a combination thereof. All layers of the pv laminate can be self-contained and remain in the pv laminate connector during manufacture. One or more of the layers can flow during manufacture so that the material flows and contacts with adjacent layers and helps form a connection (e.g., an integrated frame) with adjacent layers. Preferably, the pv laminate connector and the integrated frame are not directly connected together. The pv laminate, the connector or both can be connected to the integrated frame. The integrated frame can help connect the connector to the pv laminate. While the connector is connected to the pv laminate, the integrated frame and connector can be placed between the retainer and the laminate frame.

[0048] The one or more integrated frames can be used to protect one or more edges of the connector, the pv laminate, or both. The one or more integrated frames can be used to align the connector in the manufacturing assembly (e.g., a laminate assembly and / or a laminate frame). The integrated frame can be used to prevent damage to the conductive element, wire, bus, terminal, or a combination thereof during manufacture, transportation, and installation due to the environment (e.g., wind, water, debris), maintenance of the photovoltaic array, or a combination thereof. The integrated frame can be used to prevent the movement of the connector during the formation of the pv laminate, during the attachment of the pv laminate to the base plate, during the transportation of the pv laminate, during the transportation of the photovoltaic module, or a combination thereof. The integrated frame can form a cantilever connection with the pv laminate. The integrated frame can be connected to the pv laminate and extend above the connector. The integrated frame can have an anchoring end and a free end. The integrated frame can be connected to the pv laminate and contact the connector channel so that the connector is located below the integrated frame and protected between the base plate (e.g., the connector channel) and the integrated frame. Two integrated frames can be connected to the pv laminate. A single integrated frame may extend over all connectors of a pv laminate. A single integrated frame may be connected to a pv laminate. An integrated frame may be positioned close to each connector. Multiple integrated frames may be part of each photovoltaic module. Each pv laminate connector may be covered by a discrete integrated frame. For example, if a pv laminate includes two connectors, each connector may include an integrated frame. An integrated frame may extend around the periphery of a pv laminate. An integrated frame may extend along one or more sides, one or more edges, or both of the pv laminate. An integrated frame may be connected to one or more sides and / or one or more edges of a pv laminate. An integrated frame may be a plurality of discrete parts connected to a pv laminate and protecting connectors. An integrated frame may include a cover that extends partially and / or completely over a connector.

[0049] The cover can be used to extend over all or part of the connector. The cover can be used to prevent the connector from moving away from the base plate. The cover can be used to protect the connector from direct contact with environmental conditions (e.g., hail, rain, flying debris). The cover can extend beyond one end of the connector and help form a connection with an adjacent connection mechanism (i.e., a connector extending between two adjacent pv laminates). Each integrated frame preferably includes at least one cover, and the cover is a portion extending over all or part of the connector extending from the pv laminate. The cover can form a flat surface for a portion of an adjacent photovoltaic module to rest, contact, overlap, or a combination thereof. The cover can provide support for people walking on the photovoltaic module. The cover can be a part that extends in the air above the connector, extends above the connector and is supported on one or more sides, or both. The cover can prevent people from walking directly on the connector. The cover can extend from the edge of the pv laminate. The cover can be connected to or as part of the integrated part.

[0050] The one or more integrated parts can be used to form a connection with a pv laminate. The one or more integrated parts can form a cantilever connection with a pv laminate. The integrated parts can form a connection and support an integrated frame so that the cover extends from the pv laminate. The one or more integrated parts can be integrated into the pv laminate, connected to the pv laminate, or both. Preferably, the integrated part is connected to the outer surface of the pv laminate. More preferably, the integrated part is connected to the glass layer on the outside of the pv laminate. The integrated part can extend between the layers of the pv laminate. The one or more integrated parts can cover a portion of the pv laminate. The integrated part and the cover can be two discrete parts. Preferably, the integrated part and the cover are an integral piece, and the integrated part extends over the pv laminate to form a connection and the cover extends over the connector. The one or more integrated parts can overlap with the pv laminate and produce a connection with the pv laminate. The integrated part can form a connection with the pv laminate by an adhesive, an encapsulant, or both. The connection area of ​​the integrated part can form a fixed connection with the pv laminate. The integrated part can form a connection with the PV laminate, and the connection is strong enough so that the integrated frame will not be removed from the PV laminate. The integrated part can form a connection with the PV laminate, and the connection is strong enough so that when measured using the removal test as discussed herein, the PV laminate withstands about 0.55 MPa (80 psi) or greater, about 1.1 MPa (160 psi) or greater, about 2.2 MPa (320 psi) or greater force. The removal test method will be placed in the shelf supporting the PV laminate by the PV laminate comprising the integrated frame connected. Weight is applied to the PV laminate to prevent the PV laminate from rotating or moving away from the shelf, and then the actuator applies force to the terminal farthest from the edge of the laminate of the integrated frame. The actuator includes a 3 / 8'' diameter hemispherical tip and the actuator is connected to a load cell. The actuator moves downward at a rate of 1 inch / minute until the bond between the integrated frame and the PV laminate breaks. The peak load of the load gauge is recorded to determine the maximum force. The integrated portion can be connected to the pv laminate using one or more fasteners discussed herein and can be used to connect other components of the pv laminate, laminate frames, assemblies, or combinations thereof together.

[0051] Fasteners can be used to create connections without damaging the PV laminate, hindering the electricity generation of the PV laminate, reducing the exposed surface area of ​​the PV laminate, or a combination thereof. Fasteners can be mechanical connectors that connect the integrated frame to the PV laminate. The mechanical connection can be heat bonding, pressure bonding, heat riveting, heat bonding lamination, melting, or a combination thereof. The mechanical connection can be a mechanical fastener, a screw, a bolt, a rivet, a nail, a threaded fastener, or a combination thereof. Preferably, the fastener is an adhesive. The adhesive can be an epoxy, a hot melt, a strip, a pressure-sensitive adhesive (e.g., a strip), based on epoxy, based on silicone, based on acrylic acid, based on urethane, based on polyamide, based on polyolefin, based on polyester, a cross-linked adhesive, a thermoplastic adhesive, a block copolymer, a segmented copolymer, a single-component adhesive, a two-component adhesive, a multi-component adhesive, a natural adhesive, a synthetic adhesive, or a combination thereof. Preferably, the adhesive is an adhesive based on polyolefins. The adhesive can be used to bond two dissimilar materials together. For example, an adhesive can bond plastic to glass. The adhesive may be softened and / or flowed to contact the integrated frame with the material of the pv laminate so that a fixed connection is formed therebetween. The one or more adhesives may help increase the strength of the mechanical fasteners, mechanical connection, or both so that the integrated frame is connected to the pv laminate through the integrated portion. The one or more fasteners may form a connection between the integrated portion and the pv laminate in the connection area.

[0052] The connection area can be used to receive one or more fasteners and produce a connection. The connection area can be used to connect the integrated frame to the pv laminate in one piece. The connection area can have an area as an integrated part such as a part and / or the same size as it. The connection area can include one or more recesses for receiving an adhesive. The connection area can have features for helping to strengthen the connection, the features including an increased surface area (e.g., grooves, depressions, recesses, channels) when compared to a connection area that does not include features (e.g., smooth) that increase the surface area. The connection recess can include one or more grooves that allow the adhesive, encapsulant, material of the pv laminate, material of the integrated frame, or a combination thereof to flow and produce a fixed connection between the pv laminate and the integrated frame. The connection area can be a portion of the integrated part that does not include any parts (e.g., step extensions and / or extensions) extending from the side and / or edge. For example, the connection area is generally planar and does not include any part extending from it toward the pv laminate to form a fixed connection. The connection area can be generally planar. The connection area may terminate in one or more protrusions, one or more stepped extensions, one or more extensions, or a combination thereof. The connection area may include one or more recesses that receive an adhesive, a bonding agent, or both.

[0053] The one or more recesses can be used to hold adhesive, bonding agent or both in the connection area. The one or more recesses can act as a recess, a holding area, a reservoir or a combination thereof. The one or more recesses can be used to create a depth so that a pool of adhesive, bonding agent or both is created. The one or more recesses can have one or more columns extending around the periphery. The one or more recesses can have an open space so that excess adhesive, bonding agent or both can flow out of the recess during the formation of the connection. The one or more recesses can have a constant depth within its area. The depth of the recess can vary. For example, the deepest part of the recess can be in the center, and the depth can gradually decrease as the recess extends toward the edge. In another example, the deepest part can be on the edge, and the depth can decrease as the recess extends toward the center. Preferably, the depth of the recess is substantially constant. The one or more recesses can be a single large recess. The one or more recesses can be multiple recesses separated by one or more features (e.g., internal columns) that prevent the movement of the adhesive, bonding agent or both in the connection area. The one or more recesses can be formed on the cover. The one or more recesses may be formed on the bottom wall of the cover. The one or more recesses may terminate at a protrusion, close to a channel in the protrusion, or both. The one or more recesses may have posts on three sides and a protrusion on a fourth side. The one or more recesses may be formed by one or more posts contacting an adjacent surface and forming a gap between the connection area of ​​the integrated frame and the adjacent surface.

[0054] The one or more posts can be used to create one or more recesses. The one or more posts can be used to partially and / or completely create an enclosed space forming one or more recesses. The one or more posts can extend along one or more sides, two or more sides, or even three or more sides. The one or more posts can extend along the full length of one side. The one or more posts can extend intermittently along one side. The one or more posts can be located in the corner of the connection area. The one or more posts can be generally "L" shaped, forming a right angle, extending on two sides, or a combination thereof. One or more spaces can be located between the one or more posts. The one or more posts can have a height of about 0.1 mm or more, about 0.5 mm or more, about 1 mm or more, or even about 1.5 mm or more. The one or more posts can have a height of about 3 cm or less, about 2 cm or less, or even about 1 cm or less (i.e., the height measured from the wall of the connection area to the post position where the post contacts the adjacent surface). The one or more posts can include one or more openings. The openings in the posts can be spaces between adjacent posts, through holes in the posts, or both. The openings can be portions of the posts with a lower height. For example, if the height of the post is about 1 mm, then the opening may have a height of about 0.5 mm or less. The opening may allow the adhesive and / or bonding agent to leave the recess in a predetermined area. The opening may be located at the bottom of the post (e.g., near the component to be adhered to), the top of the post (i.e., near the cover), or a position between the top and the bottom of the post. The one or more posts may be located in a corner, a central location, or both. The one or more posts may be connected. The one or more posts may be discrete from each other. The one or more posts may be positioned proximate to the one or more step extensions.

[0055] The one or more step extensions (hereinafter referred to as steps), one or more extensions, or both can be used to support the integrated frame on, above, or both of the connectors. The one or more steps, one or more extensions, or both can be used to provide support for the cover, the integrated portion, or both. The one or more steps, one or more extensions, or both can extend from the edge, the edge area, or both, and provide support to the integrated frame so that a substantially constant gap is generated between the integrated frame and the base plate. The one or more extensions, one or more steps, or both can form a connector recess through the integrated frame so that the connection can extend through the connector recess. The one or more steps, one or more extensions, or both can provide support for the cover, the integrated portion, or both. The one or more steps, one or more extensions, or both can maintain the connector recess through which the connector extends, so that when force is applied to the photovoltaic module, the connector recess protects the pv laminate connector. The one or more steps, one or more extensions, or both can be substantially the same size and shape, and provide substantially the same amount of support to the integrated frame. The one or more steps, one or more extensions, or both can have a portion extending from each side and / or edge of the integrated frame. The one or more steps, one or more extensions, or both may extend from opposite sides and / or edges, a single side and / or edge, multiple sides and / or edges, or a combination thereof. The one or more steps, one or more extensions, or both may extend toward the base plate to contact the base plate, contact the pv laminate, or a combination thereof. The one or more extensions may support a cover, an integrated portion, or both. The one or more steps may be shorter than the one or more extensions. The one or more steps may gradually change length to form a shape complementary to the pv laminate and its associated components, the base plate, or both. The one or more steps may contact the pv laminate so that only the connector recess (and the portion forming the connector recess) extends above the pv laminate. The one or more steps may extend away from the integrated portion at an angle so that a portion of the step (e.g., a vertical portion (i.e., a protruding portion)) contacts the edge of the pv laminate and helps form a connection, prevents the integrated frame from moving longitudinally above the pv laminate, or both. The one or more steps may produce a stop and contact with a portion of the base plate to support the integrated frame. The one or more steps may create a stop and include a connection surface for connecting the integrated frame to the pv laminate. The one or more steps may be located close to the protruding portion, include the protruding portion, or both.

[0056] The one or more protrusions can be used to create a stop. The one or more protrusions can separate the cover and the integrated part. The one or more protrusions can be used to help align the integrated frame with the pv laminate, the base plate or both. The one or more protrusions can be used to create contact between the integrated frame and the base plate. Preferably, in the installed position, the one or more protrusions contact the pv laminate and position the integrated frame relative to the pv laminate. The one or more protrusions can form a bridge between the step extension and the extension. The one or more protrusions can be an intermediate step between the step extension and the extension. The one or more protrusions can be a vertical portion and / or wall of the step. The one or more protrusions can raise all or part of the integrated part above the base plate so that the connector recess is generated below the integrated frame. The one or more protrusions can include one or more channels for receiving and retaining an adhesive, a bonding agent or both.

[0057] The one or more channels can be used to hold adhesive, binder or both. The one or more channels can be cavities, through holes, recesses, orifices or both. The one or more channels can be used to prevent adhesive, binder or both from flowing out of the connection area along the protrusion. The one or more channels can allow adhesive or another material to flow into the recess of the integrated frame. The one or more channels can be concave features, depressions or both in the protrusion. The one or more channels can be concave features of the protrusion extending inwardly away from the connection area. The one or more channels can extend inwardly so that other protrusions are positioned forwardly of the channel relative to the connection area. The one or more channels can be recesses in the protrusion. The one or more channels can allow adhesive, binder or both to extend between the adjacent surface and the one or more protrusions so that the adhesive, binder or both are held close to the connection area. The one or more channels can be generally "U" shaped. The one or more integrated frames can include channels on each side of the connector recess.

[0058] The one or more connector recesses can be used to create a space for a connector. The one or more connector recesses can be used to create a protected position for a connector. The one or more connector recesses can be used to help form a connection between two or more connectors. The one or more connector recesses can generally surround the connector, as a space through which the connector extends so that the connector is surrounded by an integrated frame, or both. The one or more connector recesses can be formed by extending around two or more sides, three or more sides, or even four or more sides of the connector by an integrated frame. The connector recess may include an open end for receiving the connector. The connector recess may extend below a cover, a portion of an integrated portion, or both. The connector recess may extend between two or more opposing steps, extensions, or both. The connector recess may be a through hole, a removal of material, or both. The wall of the integrated frame that forms the connector recess may prevent the connector from moving laterally, moving longitudinally, bending, bending of the terminals of the connector, disconnection of the connection between the two connectors, or a combination thereof. The wall extending around the connector recess may contact all or part of the connector so that the connector is aligned relative to the pv laminate, the connector is positioned in the lamination frame, in the laminator, or a combination thereof. The connector recess may be configured such that the connector may be mounted within the connector recess in only a single configuration.The connector recess may comprise one or more alignment recesses and preferably comprises a plurality of alignment recesses.

[0059] The walls defining the one or more alignment recesses can be used to align one or more terminals, one or more terminal covers, one or more alignment portions of a connector, or a combination thereof. The walls extending around the one or more alignment recesses can be used to protect one or more terminals. The walls forming the one or more alignment recesses can align one or more terminals to one or more connectors. The walls forming the one or more alignment recesses can clamp one or more and preferably multiple terminals between the integrated frame and the pv laminate, the base plate, or both. The one or more alignment recesses can be used to receive the protrusions of the connector, the alignment portions of the connector, or both. The one or more alignment recesses can be used to prevent the connection from moving relative to the integrated frame. The one or more alignment recesses can prevent lateral movement, longitudinal movement, or both of the connector. The one or more alignment recesses can align the connector laterally, longitudinally, or both relative to the integrated frame, the pv laminate, or both. The one or more alignment recesses can be used in combination with one or more alignment cavities.

[0060] The walls forming the one or more alignment cavities can be used to prevent the movement of the connector relative to the integrated frame. The walls defining the shape of the one or more alignment cavities can be used to align the connector within the laminate frame, the integrated frame, or both. The walls defining the shape of the one or more alignment cavities can be used to allow the connector to be placed in the integrated frame only in a single configuration. Each of the one or more alignment cavities can have different shapes and sizes. For example, one alignment cavity can be substantially rectangular, and one alignment cavity can include a shape with an arcuate segment. The alignment cavity can be a mirror image. The alignment cavity can be formed in a step extension, an extension, or both. The alignment cavity can be formed in a step, an extension, or a wall between the cover and / or the integrated part and the bottom plate, the pv laminate, or both. The alignment cavity can accommodate the ear of the connector, the protrusion of the connector, or both. The wall forming the alignment cavity can extend around one or more sides, one or more ends, or both of the connector, the ear of the connector, or both. The alignment cavity can be a material removal, a recess formed in the material and / or the wall, or both. The alignment cavity can be substantially "C" shaped. The alignment cavity may extend around the distal and proximal ends of the ear of the connector so that the alignment cavity prevents movement distally or proximally relative to the end of the integrated frame. The alignment cavity may only allow the connector to be installed vertically within the integrated frame. The alignment cavity of the integrated frame may hold the connector in a specific position so that one or more retainers may extend around all or a portion of the connector, all or a portion of the integrated frame, or both. The integrated frame may be made of the same material as the base plate. The integrated frame base plate or both may be made of a polymeric composition.

[0061] The polymeric composition can be any polymeric composition that is flowable, has high electrical insulation properties, fluid impermeability, high flexibility, low creep, low modulus, flame retardant, or a combination thereof. Some polymeric compositions that can be used with the photovoltaic modules taught herein are elastomers, thermoplastics, thermosetting polymers, or a combination thereof. The polymeric composition can include filled or unfilled moldable plastics, polyolefins, acrylonitrile butadiene styrene (SAN), hydrogenated styrene butadiene rubber, polyesteramides, polysulfones, acetals, acrylic acid, polyvinyl chloride, nylon, polyethylene terephthalate, polycarbonate, thermoplastic and thermosetting polyurethanes, polyethylene, polystyrene, synthetic rubber and natural rubber, epoxides, polystyrene, thermoplastic elastomers (TPO, TPE, TPR), polyamides, silicones, vinyl resins, or any combination thereof. The polymeric composition can be free of fillers, fibers, reinforcing materials, or a combination thereof. The polymeric composition may include fillers, such as colorants; flame retardant (FR) or flame resistant (IR) materials; reinforcing materials, such as glass or mineral fibers; surface modifiers; or combinations thereof. The polymeric composition may also include antioxidants, mold release agents, foaming agents, and other common plastic additives. Examples of suitable polymeric compositions are found in U.S. Patent Application Publication No. 2011 / 0100438, which is expressly incorporated herein by reference for the contents of the polymeric composition.

[0062] The one or more retainers can be used to align the integrated frame, the PV laminate connector, or both within the laminate frame, a piece of manufacturing equipment, or both. The one or more retainers can be used to help seal one end of the connector that is connected to the PV laminate. The one or more retainers can be used to produce a homogeneous seal around one end of the PV laminate connector. The one or more retainers can evenly distribute pressure around one end of the PV laminate connector, the edge of the PV laminate, or both. The one or more retainers can be removed once the seal is produced. The one or more retainers can extend over a portion of the PV laminate connector and a portion of the PV laminate so that the retainer helps form a seal around a portion of the connector when the PV laminate is formed. The one or more retainers can be reused to produce more seals. The one or more retainers can be integrated into the connector, the integrated frame, or both. The one or more retainers can be made of any compressible material. The material of the retainer can have elastic properties. The material can be elastically deformable. The material may include rubber, elastomer, plastic, cross-linked elastomer, thermoplastic elastomer, silicone rubber, block copolymer, acrylonitrile butadiene styrene, segmented copolymer, based on polyurethane, based on polyester, based on polyolefin, based on polyamide, natural rubber, synthetic rubber, metal, aluminum, or a combination thereof. Preferably, the retainer does not contain metal. The retainer may be substantially square, rectangular, oval, circular, as a frame, with a periphery, or a combination thereof. The retainer may have a shape complementary to the alignment area of ​​the pv laminate connector, integrated frame, laminated frame, laminated boundary, laminated frame, or a combination thereof. For example, the retainer may have a portion of a supplementary step extension, an extension, a protrusion, or a combination thereof, so that when the retainer contacts the connector, the integrated frame, or both, the cover and / or the integrated portion are substantially parallel to the top side of the retainer (i.e., the side of the retainer that is positioned opposite to the integrated frame, the connector, or both). The retainer may be a periphery extending around one or more through holes and / or one or more windows. In other words, one or more through holes and / or windows may extend through the retainer.

[0063] The one or more windows can be used to hold all or part of the connector, the integrated frame, or both. The one or more windows can extend above, around, near, or a combination of the connector, the integrated frame, or both. Preferably, the window includes at least a portion as a through hole. The window can include a portion (i.e., a connector window) that is reduced in thickness relative to the main portion of the window. For example, the window can include a periphery having a through hole extending through the center of the retainer, and the connector window can be located between the periphery and the through hole. The thickness of the connector window can be about one-quarter thickness or less, one-half thickness or less, three-quarter thickness or less of the thickest part of the retainer, the periphery of the retainer, or both. The window can be used to receive a connector and form a boundary around the connector. The window can receive a connector and include a connector window extending above the terminal area of ​​the connector. The window can form a temporary connection with the connector, the integrated frame, or both, so that the retainer is retained on the connector, the integrated frame, or both. The window can allow the retainer to be plastically deformed so that the connector can be inserted into the window, and then the retainer can be retracted to hold all or part of the connector. The window can include a recess with a portion of the connector, the integrated frame, or both. The one or more windows may include one or more steps. The one or more windows may have a shape complementary to a connector, an integrated frame, a laminated frame, an alignment zone of a laminated frame, a laminated boundary, or a combination thereof. The peripheral portion of the retainer extending around the window, the connector window, or both may include one or more complementary portions. The peripheral portion of the retainer extending completely around the connector, the integrated frame, or both and / or partially around the connector, the integrated frame, or both may be a laminated frame contact portion, a laminate contact portion, a bridge, or a combination thereof.

[0064] The one or more laminate frame contact portions can be used to produce a seal with the laminate frame, contact a portion of the laminate frame, or both. The one or more laminate frame contact portions can prevent the material of the PV laminate, the connector, or both from extending out of the window, beyond the retainer, or both. The one or more laminate frame contact portions can be used to evenly distribute force, pressure, or both during the manufacturing process, the lamination process, or both. The one or more laminate frame contact portions can contact the laminate frame and produce two substantially parallel surfaces. For example, one side of the retainer can be substantially parallel to one side of the laminate frame, and the integrated frame can be substantially parallel to the second side of the laminate frame. The one or more laminate frame contact portions can contact the outer periphery of the laminate frame. The retainer can include two laminate frame contact portions, and the laminate frame contact portion can be located on the opposite sides of the window, the connector window, or both. The retainer can include multiple laminate frame contact portions. The laminate frame contact portion can help position the retainer so that the sealing edge can be formed in the PV laminate relative to the PV laminate connector. The laminate frame contact portion may not contact the PV laminate. The laminate frame contact portion may only contact the laminate frame. The one or more laminate frame contact portions may be located between the laminate contact portion and the bridge. The laminate frame contact portion may be separated from both the bridge and the laminate contact portion by one or more steps.

[0065] The one or more laminate contact portions can be used to produce a seal with a laminate frame, a pv laminate, a laminate boundary or a combination thereof. The one or more laminate contact portions can be used to bridge the gap between the laminate boundary and the pv laminate. The one or more laminate contact portions can be used to extend over both the pv laminate and the laminate boundary so that a portion of the pv laminate close to the laminate boundary is sealed, and pressure is equally distributed on the edge of the pv laminate, or both situations. The laminate contact portion can extend over a pv laminate, a laminate frame, a laminate boundary, an integrated frame, a pv laminate connector or a combination thereof. For example, an integrated frame can contact a laminate boundary and a laminate boundary can contact a pv laminate comprising a pv laminate connector, and the laminate contact portion can extend over all three so that a seal is formed between the two contact areas. The one or more laminate contact portions can have a uniform thickness across the length and / or width of the laminate contact portion. The laminate contact portion may be generally tapered as the laminate contact portion extends away from the laminate frame contact portion, toward the edge of the pv laminate, the edge of the laminate frame, or a combination thereof. The laminate contact portion may be generally "U" shaped. The laminate frame contact portion may include one or more steps. The laminate frame contact portion may have one or more portions that are mirrored with the shape of the integrated frame, the contact position of the laminate assembly, or both. The laminate contact portion may include a connector window. The laminate contact portion may contact a connector, a terminal of a connector, a part of a pv laminate that includes a terminal, or a combination thereof. The laminate contact portion may extend on both sides of a connector, a window, a connector window, or a combination thereof. The laminate contact portion may be located at one opposite end of the retainer as a bridge.

[0066] The bridge can be used to produce a single part. The bridge can be used to eliminate multiple free ends. The bridge can be used to connect the ends together. The bridge can be used to create a gripping position for adding and / or removing a retainer without the user contacting the laminate frame, the pv laminate, or both. The bridge can be the thickest part of the retainer. The thickness of the bridge can generally match the thickness of the pv laminate, the laminate frame, and the corresponding portion of the retainer extending above the pv laminate and / or the laminate frame. The bridge can be suspended on the laminate frame so that the seal is formed all the way to the edge of the pv laminate. The bridge can extend around the window. The bridge can be generally "U" shaped. The bridge can extend on both sides of the window, the connector window, or both. The bridge can connect the sides of the retainer together to form an integral part. The bridge can extend into the alignment area in the laminate frame. The bridge can rise relative to the laminate frame contact portion, the laminate contact portion, or both. One or more steps can separate the bridge from the laminate frame contact portion, the laminate contact portion, or both.

[0067] The one or more steps may produce a plurality of different planes on the retainer. The bridge, the laminate frame contact portion, the laminate contact portion, or a combination thereof may each be located on a different plane (i.e., a plane formed by the step). The step may extend a portion of the retainer above the laminate frame, into the laminate frame, parallel to the laminate frame, or a combination thereof. The step may extend a portion of the retainer in a plane substantially parallel to the plane of the laminate frame. The step may extend into the laminate frame, around a portion of the laminate frame, or in an alignment zone of the two. The step may produce one or more protrusions so that the retainer has a shape complementary to the laminate frame. The one or more steps may increase the thickness of the retainer from top to bottom, from bottom to top, from edge to edge, or a combination thereof as the retainer moves from the center of the retainer to the edge (e.g., the thickness may increase radially outward). The retainer may include a tapered surface.

[0068] The tapered surface may extend from the window toward the laminated frame, the pv laminate, or both as the retainer extends away from the window. The tapered surface may be a thickness reduction as the tapered surface extends from the window to the edge. The tapered surface may be a reduction in thickness so that the pressure on the tapered surface is reduced relative to other areas of the retainer with a greater thickness. The tapered surface may maintain a constant thickness of the laminated assembly (for example, the tapered surface may be positioned relative to the thicker part of the laminated assembly). The tapered surface may be aligned with the integrated portion of the integrated frame. The tapered surface may be tapered at the position where the connector extends into the pv laminate. The tapered surface may be substantially flat on one surface. The tapered surface may include a connector window for receiving or accommodating a portion of a connector, a pv laminate, or both. The tapered surface may have a substantially flat surface on one side and a wavy surface opposite to the flat surface. The tapered surface may include one or more locator slots. Preferably, the tapered surface is located below the locator slot.

[0069] The locator slot can be used to align the retainer on the laminate frame, around the connector, or both. The locator slot can be used to prevent the retainer from moving relative to the laminate frame once the retainer is connected to the laminate frame. The locator slot can protrude outward from the retainer. The locator slot can be a recess. The locator slot can extend into the laminate frame. The locator slot can receive a portion of the laminate frame. The locator slot can be any shape that helps align the retainer to the laminate frame. The locator slot can be circular, square, rectangular, oval, octagonal, pentagonal, diamond, star, or a combination thereof. The locator slot can be located on the bridge, the laminate frame contact portion, the laminate contact portion, or a combination thereof. The locator slot can have a shape complementary to the embossing on the laminate frame. The retainer can include one or more locator slots. Preferably, the retainer includes a plurality of locator slots. More preferably, the retainer includes two locator slots, and the locator slots are on opposite sides of the connector. The locator slot may extend all the way through the retainer (i.e., be a through hole). Preferably, the locator slot is a recess in the retainer. The retainer may be a one-piece part. The bridge, step, tapered surface, laminate frame contact portion, laminate contact portion, or a combination thereof may create a one-piece part so that the retainer can be added and removed from the laminate frame of the laminate assembly.

[0070] The laminated assembly can be used to connect the connector to the PV laminate. The laminated assembly can include a laminated frame, a main part, an alignment area, a laminated boundary, an embossing, or a combination thereof. The laminated frame can be the main part of the laminated assembly. The laminated frame can be used to produce a PV laminate. The laminated frame can be used to compress one or more layers of the PV laminate together so as to produce the PV laminate. The laminated frame can position the layers of the PV laminate. The laminated frame can help produce one or more sealing edges around the PV laminate. The laminated frame can produce a seal around the connector. The laminated frame can include one or more holes and preferably includes a plurality of holes. The hole can be in any position so that the hole is used to remove or discharge the PV laminate from the laminated assembly (e.g., separate the laminated frame and the laminated assembly). The hole can be sufficiently large so that a pin, air, fluid, mechanical device or a combination thereof can push the PV laminate out of the laminated assembly. The one or more holes can be located in the main part of the laminated frame, the alignment area, the laminated boundary or a combination thereof. The laminate frame may include one or more alignment regions that aid in aligning the connector, retainer, integrated frame, or a combination thereof to the laminate frame and / or the PV laminate.

[0071] The one or more alignment zones can be used to align the connector, the integrated frame, or both to the pv laminate, the laminate frame, or both. The one or more alignment zones can be used to constrain the geometry of the connector, the integrated frame, or both so that the connector, the integrated frame, or both can be installed only in a predetermined position. The alignment zone can be a concave portion that receives all or part of the integrated frame, the connector, or both. The alignment zone can include a protrusion extending through a portion of the connector, the integrated frame, or both and / or extending around it so that the laminate frame, the pv laminate, or both are aligned relative to the connector, the integrated frame, or both. The laminate frame may not contain an alignment zone. The laminate frame may include multiple alignment zones. The alignment zone can be positioned along the edge of the laminate frame. The alignment zones can each receive all or part of one or more integrated frames, one or more connectors, or both. Each alignment recess can hold a connector. The alignment recess can extend to the edge of the laminate frame. The alignment recess can prevent lateral movement, longitudinal movement, rotational movement, or a combination thereof of the connector, the integrated frame, or both. The alignment recess can work in conjunction with one or more embossing.

[0072] The one or more embossings may be used to retain the retainer. The one or more embossings may prevent the retainer from moving relative to the lamination frame. The one or more embossings may be located anywhere on the lamination frame, and the embossings help align another component relative to the lamination frame. The one or more embossings may be located in an alignment zone. The one or more embossings may ensure proper placement of the retainer over the connector, the pv laminate, or both. The one or more embossings may be complementary to the locator slot. The one or more embossings may protrude outwardly, as a recess, or both. The one or more embossings may be any shape that a locator slot may have. The lamination frame may include one or more embossings. Preferably, the lamination frame includes a plurality of embossings. More preferably, the lamination frame includes the same number of embossings as the locator slots. The one or more embossings may help align the lamination boundaries on the lamination frame.

[0073] The one or more lamination boundaries can be used to position one or more and preferably multiple pv laminate layers within the lamination frame. The lamination boundary can be used to align one or more laminate layers of the pv laminate with one or more connectors. Each lamination frame can include a single lamination boundary extending around the periphery of the lamination frame. The lamination boundary can include one or more and preferably multiple discrete parts. The multiple discrete parts can be all connected, contacted, or both. Preferably, the parts of the lamination boundary are not connected together, but are in contact, very close, or both. The multiple discrete parts can be connected to the lamination frame and have edges that contact one or more adjacent lamination boundaries. The lamination boundary can be spaced apart so that the integrated frame, the connector, or both can extend through the lamination boundary, leave the lamination frame, or both. The lamination boundary can produce a space of substantially the same size as the pv laminate, so that the individual layers of the pv laminate are aligned relative to each other. The lamination boundary can be connected to the lamination frame by any fastener discussed herein. Preferably, the lamination boundary is connected to the lamination frame in a detachable manner. More preferably, the lamination boundary is connected to the lamination frame by screws. The lamination boundary may be a unitary part of the lamination frame. The lamination boundary may be generated when removing material from the lamination frame. The lamination boundary may be material that has not been removed during the formation of the lamination frame. The lamination frame may help support one or more bus bars during the assembly of the layer into the lamination frame, during compression, during the flow of one or more of the layers, or a combination thereof. The one or more lamination boundaries may produce barriers that prevent the flow of the lamination material during formation and subsequently prevent the bus bars from flowing with the lamination material. The lamination frame may be reusable. The lamination boundary may not contain the step of removing the lamination frame. The lamination boundaries may be interconnected and unitary relative to each other. The lamination boundaries may all be the same thickness, width, or both. The lamination boundaries may extend substantially the same length, width, or corresponding size as the portion of the lamination frame in which they are located. Preferably, the lamination boundary (i.e., the top lamination boundary) extending along the top of the lamination frame (i.e., the portion of the lamination frame that accommodates the connector) has a width greater than the width of the other lamination boundaries. The top lamination has a width of about 1.5 times or more, about 2 times or more, about 2.5 times or more, or even about 3 times the width of one of the other lamination borders and preferably all other lamination borders. The width of the lamination border may be substantially equal to the length of the connector. The width of the top lamination border may be greater than the length of the connector.

[0074] One or more adhesives can be used to bond the integrated frame to adjacent components (e.g., photovoltaic modules, base plates, support portions, overlapping portions). The one or more adhesives can be used to provide additional adhesion to predetermined areas (e.g., connection areas). The one or more adhesives can be solid materials and / or semi-solid materials attached to the connection area. The one or more adhesives can be substantially the same size as the connection area. The one or more adhesives can have a height less than or equal to the column. The one or more adhesives can be square, rectangular, triangular, or a combination thereof. The one or more adhesives can be liquefied (e.g., become molten) during lamination, connection of the integrated frame to the photovoltaic module, or both. The one or more adhesives can be made of a polymer. The one or more adhesives can be made of the same material as one of the layers of the active portion. The one or more adhesives can be an encapsulant. The one or more adhesives can be made of ethylene copolymers, polyethylene, ethylene vinyl acetate (EVA), silane-modified polyethylene and copolymers, polyvinyl butyral (PVB), polyurethane, butyl rubber, acrylic polymers and copolymers, epoxy resins, ionomers, or mixtures thereof.

[0075] Figure 1 A perspective view of a photovoltaic module 2 is illustrated. The photovoltaic module 2 includes a base plate 6 having an overlap portion 10 and an active portion 4. The overlap portion 6 includes a molded handle 40 for carrying the photovoltaic module 2, and a connection recess 42 for forming a connection with an adjacent photovoltaic module 2. A plurality of fastener positions 50 are positioned adjacent to the connection recess 42. The opposing edges of the base plate 6 include a connector channel 16 for receiving a connector 82 of a photovoltaic laminate 80. The connector 82 is covered by an integrated frame 20, which protects the connector 82 from damage and, in particular, from bending. The photovoltaic module 2 includes an active portion 4, which includes a photovoltaic laminate 80. A plurality of locking features 14 connect the photovoltaic laminate 80 to the support portion 8 of the base plate 6.

[0076] Figure 2 Pictured Figure 1 1 is a close up view of an exemplary integrated frame 20. The integrated frame 20 is positioned in the connector channel 16 and connected to the photovoltaic laminate 80 using an overlapping joint and an adhesive. The photovoltaic laminate is connected to the base plate 6 by the locking feature 14. The base plate 6 includes a connection recess 42 that extends through the base plate 6 to form a connection with an adjacent photovoltaic module. The fastener location 50 is located proximate to the connection recess 42 for connecting the base plate 6 to a roof member (not shown).

[0077] Figure 3An exploded view of a photovoltaic module 2 is shown. The photovoltaic module 2 includes a base plate 6. The photovoltaic module 80 includes a pair of opposing connectors 82, each of which is covered by an integrated frame 20 so that the connectors 82 are protected. A plurality of locking features 14 connect the photovoltaic laminate 80 to the base plate 6.

[0078] Figure 4 The exploded view of lamination frame 90 and associated assembly is illustrated.Lamination frame 90 includes two alignment areas 92, which are recesses for receiving connector 82 so that connector 82 is aligned in lamination frame 90.Lamination boundary 94 is connected to lamination frame 90 for producing steps.During assembly, integrated frame 20 is placed in alignment area 92 and between two parts of lamination boundary 94.Connector 82 is then placed in integrated frame 20, and retainer 60 is placed above connector 82 and integrated frame 20.Lamination parts constituting the main part of photovoltaic laminate 80 are placed in lamination frame 90.The main part of lamination frame 90 includes multiple holes 91, which help remove pv laminate 80 from lamination assembly.Assembly is compressed and photovoltaic laminate 80 is connected to connector 82 and integrated frame 20.

[0079] Figure 4A A top view of a lamination assembly is illustrated that includes a retainer 60 that communicates with a lamination frame 90 and a photovoltaic laminate 80. The retainer 60 includes a window 62 that receives and holds the integrated frame 20 and the connector 82 in place so that a seal is formed around the connector 82 during the lamination process. The retainer 60 has a lamination frame contact portion 64 that extends over and contacts the lamination frame 90 so that a uniform seal is formed around the connector 82 during the lamination process. The retainer 60 includes a laminate contact portion 66 that extends over a portion of the photovoltaic laminate 80 so that a seal is formed around the connector 82 during the lamination process.

[0080] Figure 4B A top view of an integrated frame 20 integrally connected to a photovoltaic laminate 80 at a connection region 25 is illustrated. A retainer 60 extends around a portion of the integrated frame 20 and includes a window 62 such that a portion of the integrated frame 20 extends through the retainer 60. The retainer 60 includes a laminate frame contact portion 64 that contacts a laminate frame (not shown) during the assembly process. The retainer 60 forms a temporary connection with a connector (not shown) and the photovoltaic laminate 80 such that the retainer 60 is removable after the lamination process, before the photovoltaic laminate 80 is installed, or both.

[0081] Figure 5A close-up view of an exemplary integrated frame 20 is shown. The integrated frame 20 includes a cover 22 and an integrated portion 24. The cover 22 extends over a connector (not shown), and the integrated portion 24 connects the integrated frame 20 to a photovoltaic laminate (not shown). An extension 26 protrudes from the cover 22 toward a base plate (not shown). The bottom of the integrated portion 24 has a stepped extension 28 that forms a connection with the photovoltaic laminate (not shown) and the base plate (not shown).

[0082] Figure 6 A front view of an exemplary integrated frame 20 is shown. The integrated frame 20 has an integrated portion 24 that extends over and is connected to a photovoltaic laminate (not shown). A pair of opposed extensions 26 extend from a cover (not shown) to form a connector recess 32 for receiving a connector (not shown).

[0083] Fig. 7A A side view of an exemplary integrated frame 20 is shown. The integrated frame 20 includes a cover 22 connected to an integrated portion 24. The cover 22 extends over a connector (not shown) and has a pair of opposed extensions 26 that protect the sides of the connector. The integrated portion 24 has a stepped extension 28 to allow a fixed connection between the integrated portion 24 and the photovoltaic laminate 80 (not shown).

[0084] Figure 7B A side view of an exemplary integrated frame 20 is shown. The integrated frame 20 includes a cover connected to an integrated portion 24. The integrated portion 24 includes a post 38 extending from the integrated portion 24 and forming a recess 27 in a connection area (not shown) so that the adhesive and / or bonding agent is retained in the connection area. The cover 22 is connected to a pair of opposed extensions 26 that protect the connector (not shown). The integrated portion 24 has a stepped extension 28 to form a fixed connection between the integrated portion 24 and the photovoltaic laminate (not shown).

[0085] Fig. 8A Picture shows Fig. 7A2 is a bottom perspective view of an exemplary integrated frame 20. As shown, the integrated portion 24 has a connection area 25 and a step extension 28. The connection area 25 forms a primary connection with a photovoltaic laminate 80 (not shown), and some adhesive may extend to the vertical portion, the horizontal portion, or both of the step extension 28 and form a secondary connection. The step extension 28 includes a connector recess 32 extending toward the end of the cover 22 of the integrated frame 20. The protrusion 30 creates a stop that aligns the integrated frame 20 with the photovoltaic laminate (not shown). The protrusion 30 separates the integrated portion 24 from the cover 22. The cover 22 includes a pair of opposed extensions 26 that are located on both sides of the connector recess 32 when the connector recess 32 extends adjacent to the cover 22, so that the connector extends completely and / or partially into the connection recess 32 and below the cover 22. The extension 26 includes an alignment cavity 36 to align the integrated frame 20 and the connector (not shown) relative to each other. The connector recess 32 includes a pair of alignment recesses 34 that receive a portion of a connector extending from the photovoltaic laminate so that the connector (not shown), the photovoltaic laminate (not shown), and the integrated frame 20 are all aligned.

[0086] Figure 8B Pictured Figure 7B 2 is a bottom perspective view of an integrated frame 20. The integrated portion 24 has a connection area 25 and a stepped extension 28. The connection area 25 includes a recess 27, which is a recess and is at least partially constrained by a post 38 and a protrusion 30 so that an adhesive or bonding agent (not shown) is retained within the connection area 25. The stepped extension 28 includes a connector recess 32 extending toward the end of the cover 22 of the integrated frame 20. The protrusion 30 creates a stop that aligns the integrated frame 20 with a photovoltaic laminate (not shown). The protrusion 30 separates the integrated portion 24 from the cover 22, and the protrusion 30 includes a channel 31 for retaining the adhesive and / or bonding agent close to the connection area 25. The cover 22 includes a pair of opposed extensions 26, which are located on both sides of the connector recess 32 when the connector recess 32 extends adjacent to the cover 22, so that the connector extends completely and / or partially into the connection recess 32 and below the cover 22. The extension 26 includes an alignment cavity 36 to align the integrated frame 20 and the connector (not shown) relative to each other. The connector recess 32 includes a pair of alignment recesses 34 that receive a portion of the connector extending from the photovoltaic laminate to align the connector (not shown), the photovoltaic laminate (not shown) and the integrated frame 20.

[0087] Figure 8C Pictured Figure 7B20. The integrated frame 20 includes an integrated portion 24. The integrated portion 24 has a recess 27 that includes a plurality of posts 38 along the periphery of the recess 27 that form the recess 27. The recess 27 as shown includes an adhesive 39 that fits within the recess 27 and helps form a connection. When the adhesive 39 liquefies, some of the adhesive 39 extends into the channel 31 in the protruding portion 30, which helps with bonding.

[0088] Fig. 9 One side of a holder 60 contacting a connector (not shown) is shown. The holder 60 includes a periphery extending around a window 62. The periphery includes a bridge 70 connected to a laminate contact portion 66 via a pair of opposing laminate frame contact portions 64. The laminate frame contact portions 64 are each connected to a laminate contact portion 66, which includes a connector window 68 for receiving a connector (not shown).

[0089] Fig.10 The side of the retainer 60 facing away from the connector (not shown) is shown. The retainer 60 receives the connector (not shown) in the window 62 and is smooth and flat as shown so that uniform pressure is applied to all parts of the retainer 60 to form a uniform seal around the connector (not shown).

[0090] Fig.11 An example of an exemplary integrated frame 20 is illustrated having a pair of connector recesses 32 on opposing sides of the integrated frame 20. The integrated frame 20 is a unitary portion of a laminate frame.

[0091] Fig.12 A close-up view of one connection recess 32 of an exemplary integrated frame 20 is shown. The connection recess 32 has a cover 22 extending over the connection recess 32, and a pair of extensions 26 extending along each side of the connection recess 32. Each of the extensions 26 includes an alignment cavity 36 for receiving ears of a connector (not shown) so that the connector is aligned within the integrated frame 20. One end of the connection recess 32 includes a pair of alignment recesses 34 that receive corresponding features of the connector so that the connector is aligned within the connection recess 32. The integrated frame 20 also includes an integrated portion 24 that connects to a photovoltaic laminate (not shown), and a stepped extension 28 that tapers downward to form a connection with the photovoltaic laminate (not shown).

[0092] Fig.13A top view of a portion of a laminate assembly 58 is illustrated. The laminate assembly 58 includes a retainer 60 having a laminate frame contact portion 64 covering a portion of a laminate frame 90. The retainer 60 includes a window 62 that receives and exposes a connector 82 and a portion of the integrated frame 20. The retainer 60 tapers as the retainer extends over the PV laminate 80 and contacts the PV laminate at the laminate contact portion 66. The laminate contact portion 64 is larger than the connector 82 and slightly smaller than the retainer 60.

[0093] Fig.14 An alignment area 92 is shown in a lamination frame 92. The alignment area 92 includes embossing 96 that aligns a retainer (not shown) with the alignment area 92. The alignment area 92 includes holes 91 that aid in removing a connector (not shown) from the lamination assembly.

[0094] Fig.15 There are shown perspective views of the top and sides of the retainer 60. The top side of the retainer 60 includes a tapered surface 74 that tapers toward a lamination frame (not shown). The retainer 60 also includes a window 62 extending through the retainer.

[0095] Fig.16 A perspective view of the rear portion of the retainer 60 is shown. The retainer 60 includes a window 62 with a locator slot 72 on opposite sides of the window 62. A connector window 68 extends from the bottom of the window 62 and accommodates a connector (not shown). A bridge 70 extends around the top portion of the retainer 60 and extends into an alignment area (not shown) of a laminate frame (not shown). The bridge 70 extends outward relative to the laminate frame contact portion 64 (i.e., there is a step between the bridge 70 and the laminate frame contact portion 64). The locator slot 72 is located in the laminate frame contact portion 64 proximate to the bridge 70. A step 67 is located between and separates the laminate frame contact portion 64 and the laminate contact portion 66, and the laminate contact portion 66 and the bridge 70.

[0096] Fig.17 The lamination assembly 58 is shown with the retainer removed. The lamination assembly 58 includes the connector 82 and the retainer 20 located within the alignment area 92. The alignment area 92 of the lamination frame 90 aligns the pv laminate 80 with the connector 82 and helps connect the connector 82 to the lamination frame 90.

[0097] Fig.18A perspective view of a lamination frame 90 is shown. The lamination frame 90 includes a pair of alignment zones 92 at the ends of the lamination frame 90. An integral lamination border 94 extends around the peripheral edge of the lamination frame 90 to form a recess for receiving a pv laminate layer so that the layer and connector can be formed together. The lamination border 94A (top lamination border) adjacent to the top of the lamination frame 94 has a width that is almost three times the width of the lamination borders 94B on the other three edges.

[0098] Any numerical value described herein includes all values ​​with one unit as increment from the lower value to the upper limit value, provided that there is an interval of at least 2 units between any lower value and any higher value. As an example, if the value (e.g., temperature, pressure, time, etc.) of the amount or process variable of the stated component is (e.g.) from 1 to 90, preferably from 20 to 80, more preferably from 30 to 70, then it is desired to clearly list values ​​such as 15 to 85, 22 to 68, 43 to 51, 30 to 32 in this specification. For a value less than one, one unit is considered to be 0.0001, 0.001, 0.01 or 0.1, as the case may be. These are only examples of specific intent, and all possible combinations of numerical values ​​between the lowest and highest values ​​listed are considered to be clearly stated in this application in a similar manner.

[0099] Unless otherwise stated, all ranges include both endpoints and all values ​​between the endpoints. "About" or "approximately" used in conjunction with a range applies to both end values ​​of the range. Thus, "about 20 to 30" is intended to cover "about 20 to about 30", including at least the specified endpoints.

[0100] The disclosures of all articles and references (including patent applications and publications) are incorporated by reference for all purposes. The term "consisting essentially of ... " used to describe a combination should include the identified elements, ingredients, components or steps, as well as such other elements, ingredients, components or steps that do not substantially affect the basic and novel features of the combination. The use of the term "comprising" or "including" used herein to describe a combination of elements, ingredients, components or steps also encompasses embodiments that are essentially composed of the elements, ingredients, components or steps. By using the term "may" in this article, any described attribute intended to "may" be included is optional.

[0101] Multiple elements, ingredients, components or steps can be provided by a single integrated element, composition, assembly or step. Alternatively, a single integrated element, composition, assembly or step can be divided into independent multiple elements, compositions, assemblies or steps. The disclosure of "one" or "an" for describing an element, composition, assembly or step is not intended to exclude additional elements, compositions, assemblies or steps.

[0102] It should be understood that the above description is intended to be illustrative rather than restrictive. After reading the above description, many embodiments and many applications (in addition to the examples) provided will be apparent to those skilled in the art. Therefore, the scope of this teaching should not be determined with reference to the above description, but should in fact be determined with reference to the appended claims together with the full scope of equivalents authorized by such claims. The disclosures of all articles and references (including patent applications and publications) are incorporated by reference for all purposes. The omission of any aspect of the subject matter disclosed herein in the appended claims is not a disclaimer of such subject matter, nor should it be regarded as an indication that the inventor does not consider such subject matter as part of the disclosed inventive subject matter.

Claims

1. A photovoltaic module, comprising: a. A photovoltaic laminate comprising: i. one or more connectors having a portion partially located within the photovoltaic laminate and another portion extending from the photovoltaic laminate, the portion sealed within the photovoltaic laminate being formed with the layers of the photovoltaic laminate, the seal being created using one or more retainers extending around all or a portion of the one or more connectors; as well as ii. one or more integrated frames communicating with each of the one or more connectors, the integrated frames comprising a cover connected to an integrated portion and the cover extending over the connector, each of the integrated frames comprising an integrated portion integrated into the photovoltaic laminate connecting the integrated frame to the photovoltaic laminate and the cover, the integrated portion extending from the photovoltaic laminate; and wherein each of the one or more integrated frames is connected to the photovoltaic laminate in a position proximate to the one or more connectors such that the one or more integrated frames align the one or more connectors with the laminate frame, each of the integrated frames forming a cantilever connection with the photovoltaic laminate and extending over a corresponding one of the one or more connectors, the connector being covered by the integrated frame, Each of the one or more retainers includes a window for receiving at least a portion of one of the one or more connectors therein and a laminate contact portion extending over a portion of the photovoltaic laminate for forming the seal; The integrated frame and the connector are placed between a retainer and a lamination frame, the lamination frame includes a pair of alignment areas at the ends of the lamination frame, the alignment areas are recesses for receiving the connectors, and an integral lamination boundary extends around the peripheral edge of the lamination frame to form a recess for receiving the photovoltaic laminate layer, so that the photovoltaic laminate layer and the connector can be formed together. 2 . The photovoltaic module of claim 1 , wherein an extension extends from each edge of the cover toward the bottom panel of the photovoltaic laminate such that a side of each of the one or more connectors is protected by the extension.

3. The photovoltaic module of claim 1, wherein the integrated portion comprises a stepped extension that mirrors the shape of the photovoltaic laminate so that a secure connection is formed.

4. The photovoltaic module of claim 1, wherein the integrated portion includes a protruding portion to align the integrated portion and the photovoltaic laminate relative to each other, and the protruding portion includes one or more channels.

5. The photovoltaic module of claim 2, wherein connector recesses are formed between the extensions, and each of the extensions includes an alignment cavity that prevents longitudinal movement of the one or more connectors relative to each of the integrated frames. 6 . The photovoltaic module of claim 5 , wherein the connector recess comprises one or more alignment recesses extending from the cover to the integrated portion.

7. A photovoltaic module according to any of the preceding claims, wherein the one or more integrated frames include a connection area having a recess for receiving a bonding agent, an adhesive, or both, and the recess is formed by one or more posts extending at least partially along one or more sides of the connection area.

8. A method of making a photovoltaic laminate for inclusion in a photovoltaic module, comprising: a. Aligning one or more integrated frames in the laminated frame; b. aligning one or more connectors with each of the one or more integrated frames via one or more connector recesses of the integrated frame; c. providing one or more layers of a laminate over the laminate frame and a portion of the integrated frame, a portion of the one or more connectors, or both; d. applying pressure to the one or more layers of the photovoltaic laminate, the portion of the integrated frame and the laminate frame; as well as e. heating the one or more layers of the photovoltaic laminate, the portion of the integrated frame and the laminate frame; wherein a retainer is applied over the one or more layers of the photovoltaic laminate prior to applying heat, pressure, or both to the one or more layers of the photovoltaic laminate; and wherein the retainer includes a window to receive the integrated frame and the connector, and the retainer includes a laminate contact portion that extends over a portion of the integrated frame so that when pressure, heat, or both are applied, the laminate frame evenly distributes the heat, the pressure, or both at the contact points to form a seal around one or more connectors extending from the photovoltaic laminate; The integrated frame comprises an integrated part and a cover, the integrated part having a connection area forming a fixed connection with the photovoltaic laminate, the connection area terminating in one or more protrusions, one or more step extensions, one or more extensions, or a combination thereof, and one or more protrusions forming a bridge between the step extension and the extension.

9. The method of claim 8, wherein the retainer is removed and the method comprises the step of reusing the retainer.

10. The method of claim 8, wherein the method comprises the step of placing one or more adhesives in the connection areas of the integrated frame.

11. The method of claim 9, wherein the method comprises the step of placing one or more adhesives in the connection areas of the integrated frame.

12. A method according to any one of claims 8 to 11, wherein the method includes the step of aligning a pair of locator slots in the retainer with embossing extending from the lamination frame so that the retainer and lamination frame are aligned relative to each other.

13. A method according to any one of claims 8 to 11, wherein the retainer includes one or more steps, and the one or more steps are formed between the bridge and the laminate frame contact portion, between the laminate frame contact portion and the laminate contact portion, or both, and the laminate contact portion has a tapered surface.

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