Photovoltaic module with a horizontal rail assembly

Abstract

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

Description

[0001] Priority

[0002] This application claims priority to U.S. Non - Provisional Application Serial No. 16 / 370,792, filed on March 29, 2019, which claims priority to U.S. Provisional Application Serial No. 62 / 651,035, filed on March 30, 2018, and U.S. Provisional Application Serial No. 62 / 660,835, filed on April 20, 2018. The entire contents of each of the above - mentioned U.S. applications are hereby incorporated herein by reference, respectively. Background Art

[0003] Photovoltaic (PV) cells (often referred to as solar cells) are devices used to convert solar radiation into electrical energy. Generally, solar radiation that irradiates on the surface of a solar cell substrate and enters the substrate forms electron - hole pairs in the substrate body. The electron - hole pairs migrate to the p - type doped region and n - type doped region in the substrate, thereby forming a voltage difference between the doped regions. The doped regions are connected to the conductive regions on the solar cell to conduct the current from the cell to an external circuit. When PV cells are combined in an array such as a PV module, the electrical energy collected from all the PV cells can be combined in series and parallel arrangements to provide a power source with a certain voltage and current.

[0004] Brief Description of the Drawings

[0005] The following drawings are illustrative by way of example and not limitation. For the sake of brevity, not every feature of a given structure is necessarily labeled in every drawing in which the structure appears. The same reference numeral does not necessarily denote the same structure. Instead, the same reference numeral or different reference numerals may be used to denote similar features or features with similar functions. The drawings are not drawn to scale.

[0006] Figure 1A A perspective view of the bottom of a photovoltaic (PV) module is shown, which PV module includes a PV laminate mounted on a frame.

[0007] Figure 1B A perspective view showing a roof and mounting frame for mounting Figure 1A the PV module is shown.

[0008] Figure 2A A perspective view showing a transverse rail attached to a PV module similar to Figure 1A the PV module is shown.

[0009] Figure 2B A perspective view showing the attachment point of the transverse rail to Figure 2A the PV laminate of the PV module is shown.

[0010] Figure 2C A perspective view showing the attachment point of the transverse rail to Figure 2APerspective view of the attachment point of the bottom lip of the long member of the frame of the PV module.

[0011] Figure 2D Perspective view of a single-wall / double-wall adapter that can be employed according to some embodiments.

[0012] Figure 3 Cross-sectional view of a PV module having a cross rail assembly according to various embodiments, wherein the cross-sectional view reveals the side of the cross rail assembly.

[0013] Figure 4A Perspective view of a cross rail assembly including a corner key according to various embodiments, the corner key holding a recessed member of the frame of the PV module.

[0014] Figure 4B Perspective view of a cross rail assembly including a T-shaped corner key according to various embodiments, the T-shaped corner key being attached to respective segments of a member of the frame of the PV module.

[0015] Figure 4C Perspective view of a cross rail assembly including a short corner key according to various embodiments, the short corner key being attached to a keyway of a member of the frame of the PV module.

[0016] Figure 4D Perspective view of a cross rail assembly according to various embodiments, the cross rail assembly being attached to a spline hole in a member of the frame of the PV module.

[0017] Figures 5A to 5D Perspective view of a PV module having a cross rail assembly according to various embodiments, the cross rail assembly being similar to Figure 4A the cross rail assembly.

[0018] Figure 6 Perspective view of a PV module having a cross rail assembly according to various embodiments, the cross rail assembly being similar to Figure 4B the cross rail assembly.

[0019] Figures 7A to 7C Partial bottom view of a PV module having a cross rail assembly according to various embodiments, the cross rail assembly being similar to Figure 4C the cross rail assembly.

[0020] Figures 8A to 8B Partial cross-sectional view of a PV module having a cross rail assembly according to various embodiments, the cross rail assembly being similar to Figure 4D the cross rail assembly.

[0021] Figures 8C to 8D Partial cross-sectional view of yet another PV module having a cross rail assembly, the cross rail assembly being similar in some respects to Figures 8A to 8BCross rail assembly shown.

[0022] Figure 9 A partial cross-sectional view of a PV module having a cross-rail assembly including couplers (eg, spacers and fasteners adapted to attach the spacers) to frame members and cross-rail members, respectively, according to various embodiments is shown.

[0023] 10 illustrates a partial cross-sectional view of a PV module having a cross-rail assembly including couplers (eg, spacers and fasteners extending through frame members, spacers, and cross-rail members) according to various embodiments.

[0024] Figure 11 A partial bottom view of a PV module according to various embodiments is shown, the PV module being similar to Figure 6 of PV modules.

[0025] Figure 12 The assembly process of a PV module according to various embodiments is shown. The PV module is similar to Figures 5A to 5D of PV modules.

[0026] Figure 13 Shown are bottom views of six different PV assemblies having non-conductive cross rail assemblies according to various embodiments.

[0027] Figure 14A A plan view of a photovoltaic assembly 1450 is shown according to various embodiments.

[0028] Figure 14B Bottom views of four different PV assemblies having cross-rail assemblies according to various embodiments are shown.

[0029] Figure 14C Shown is a perspective view of the bottom of another PV assembly having a cross-rail assembly according to various embodiments.

[0030] Figure 15 A bottom view of another PV assembly having a cross-rail assembly according to various embodiments is shown, wherein only a subset of cross-rail members are attached to the frame via ground couplers. DETAILED DESCRIPTION

[0031] The following detailed description is merely exemplary in nature and is not intended to limit the embodiments or the application and use of such embodiments. As used herein, the word "exemplary" means "used as an example, instance or illustration". Any embodiment described herein as exemplary is not necessarily preferred or advantageous over other embodiments. In addition, it is not intended to be bound by any express or implied theory presented in the aforementioned technical field, background technology, summary of the invention or the following detailed description.

[0032] The mention of the phrase "an embodiment" or "some embodiments" does not necessarily refer to the same embodiment. Specific features, structures, or characteristics may be combined in any suitable manner consistent with the present disclosure.

[0033] Terms. The following paragraphs provide definitions and / or contexts of terms that exist in the present disclosure (including the appended claims):

[0034] "About" or "approximately". As used herein, for recited numerical values, including, for example, integers, fractions, and / or percentages, the term "about" or "approximately" generally means that the recited numerical value encompasses a range of values (e.g., + / - 5% to 10% of the recited numerical value) that a person of ordinary skill in the art would consider equivalent to the recited numerical value (e.g., performing substantially the same function, operating in substantially the same manner, and / or having substantially the same result).

[0035] "Comprising" is an open - ended term that does not exclude other structures or steps.

[0036] "Configured to" represents a structure by indicating a device such as a unit or a component, including a structure that performs one or more tasks during operation, and such a structure is configured to perform the task even when the device is not currently operating (e.g., not turned on / activated). A device "configured to" perform one or more tasks is expressly not intended to invoke 35 U.S.C. § 112, paragraph 6.

[0037] Terms such as "first", "second", etc. are used as labels for the nouns that follow and do not imply any type of order (e.g., spatial, temporal, and logical, etc.). For example, the mention of "a first" IEC does not necessarily imply that the IEC is the IEC in a certain sequence; rather, the term "first" is used to distinguish that IEC from another IEC (e.g., "a second" IEC).

[0038] "Based on". As used herein, this term is used to describe one or more factors that affect the determination result. This term does not exclude additional factors that may affect the determination result. That is, the determination result may be based only on those factors or at least partially on those factors. Consider the phrase "determine A based on B". Although B may be a factor that affects the determination result of A, such a phrase does not exclude the determination result of A also being based on C. In other instances, A may be determined only based on B.

[0039] "Coupled" - The following description refers to elements or nodes or structural features being "coupled" together. As used herein, unless otherwise expressly specified, "connected" means that one element / node / feature is directly or indirectly connected to another element / node / feature (or directly or indirectly in communication therewith), and is not necessarily a mechanical connection.

[0040] "Prevent" means to reduce, decrease, minimize, or effectively or practically eliminate something, such as completely avoiding a result, consequence, or future state.

[0041] Unless otherwise explicitly required by this disclosure, the terms "a" and "an" are defined as one or more.

[0042] As used herein, the term "substantially" is defined as largely but not necessarily completely what is specified (and includes what is specified; for example, "substantially 90 degrees" includes 90 degrees, "substantially parallel" includes parallel), as would be understood by one of ordinary skill in the art. In any disclosed embodiment, the terms "substantially", "about", and "approximately" may be replaced by "within a certain percentage of what is specified", where the percentage includes 0.1%, 1%, 5%, and 10%.

[0043] As used herein, "region" may be used to describe a discrete region, volume, portion, or location of an object or material having definable characteristics but not necessarily fixed boundaries.

[0044] In addition, certain terms may be used in the following description only for purposes of reference, and thus are not intended to be limiting. For example, terms such as "upper", "lower", "above", and "below" refer to the directions provided for reference in the drawings. Terms such as "front", "back", "rear", "side", "outer", and "inner" describe the orientation and / or position of certain parts of a component within a consistent but arbitrary reference system, which can be clearly understood by referring to the text describing the component in question and the associated drawings. Such terms may include the words specifically mentioned above, their derivatives, and words of similar meaning.

[0045] In the following description, numerous specific details are given, such as specific operations, in order to provide a thorough understanding of embodiments of the present disclosure. It will be apparent to those skilled in the art that embodiments of the present disclosure may be practiced without these specific details. In other instances, well-known techniques have not been described in detail to avoid unnecessarily obscuring embodiments of the present disclosure.

[0046] A photovoltaic (PV) module can generate direct current (DC) electricity based on the received solar energy. The PV module can include a plurality of solar or PV cells that are electrically coupled to each other, thereby allowing the PV cells to contribute to providing a combined output power for the PV module. Some PV modules include a PV laminate that encapsulates the solar cells and a rectangular frame that mounts around the periphery of the PV laminate 105. Figure 1AA perspective view of a PV module is shown including a frame (e.g., a metal frame) having a first side and an opposing second side of the perimeter on which a PV laminate 105 is mounted. The frame includes a first frame member 101, a second frame member 102, a third frame member 103, and a fourth frame member 104.

[0047] The PV modules may be mounted on mounting rails of a mounting frame, which in some applications may be located on a roof. Figure 1B A perspective view of a mounting frame 121 located on a roof 120 is shown. The mounting frame ( Figure 1A ) may contact the mounting frame 121. Depending on the installation requirements and / or application, the second sides of the long members 101 and 102 of the frame (FIG. 1) may contact the mounting frame 121, or the second sides of the short members 103 and 104 of the frame (FIG. 1) may contact the mounting frame 121.

[0048] Reference now Figure 2A , some PV modules may include at least one cross rail 210. The use of one or more cross rails 210 may inhibit cell cracking in the PV module. In addition, the use of one or more cross rails 210 may enable the use of different sizes and materials for the frame and / or PV laminate 205 (e.g., a lighter frame, a thinner PV laminate, and / or a PV laminate with a different layer combination). In the example shown, the cross rail 210 extends from the first long member 201 of the frame to the second long member 202 of the frame; however, in other examples, a longer and / or heavier cross rail 210 may extend from the first short member 203 of the frame to the second short member 204 of the frame.

[0049] The cross rail 210 may also include metal, so building codes may require that the cross rail 210 be grounded to the frame. In some PV modules, this continuous material path requirement can be met by running the cross rail 210 close to the inside of the frame. Screws or rivets can be used to achieve continuity, that is, they can be screwed or inserted into the frame. Figure 2B An example is shown where rivets are inserted through the top flange of the cross rail 210 and the frame 201 (and / or through the PV laminate). Figure 2C An example is shown where a rivet is inserted through a bottom flange of the cross rail 210 and a bottom flange of the frame 201.

[0050] In some applications, a PV module may include various other components. The DC power generated by the PV module can be converted to AC power by using a power inverter. The power inverter can be electrically coupled to the output of the PV module (the output of the PV module may include electrical connectors protruding from the backsheet of the PV laminate, which in some examples may also be encapsulated by a junction box). Intermediate wiring (e.g., DC-4 connectors) can be employed between the PV module, the junction box, and the power inverter. The power inverter can be electrically coupled to the DC output of the PV module (e.g., a PV cable). The power inverter can be located at a physically separate location from the PV module, and only intermediate wiring and / or its accessories are required to physically couple the PV module to the power inverter.

[0051] During the installation of a PV module without cross rails, the PV module can be placed on the mounting frame in any configuration, and the PV cable can be installed between the mounting frame ( Figure 1B ) and the PV laminate ( Figure 1A ). This makes it easier for installers to perform the installation and allows the position of the PV module on the mounting frame to be selected based on application requirements (rather than cable laying requirements).

[0052] In contrast, problems may arise when installing a PV module with one or more cross rails. If the desired position of the PV module results in the cross rails forming a "double wall" with the mounting frame, the installer cannot install at that desired position (it is against the code to lay the PV cable below the "double wall" (e.g., below the mounting frame)). For this reason, installers and / or consumers may dislike PV modules with cross rails.

[0053] Although a PV module may include short cross rail members to allow the cable to be routed between the mounting rail and the short cross rail member even when one of the short cross rail members is installed above and parallel to the mounting rail of the mounting frame, the mechanical strength of this design may not be compatible with some PV laminates and / or some PV frames. Additionally, since the inertia of a beam is proportional to the cube of its height, the mechanical strength and / or material volume used for this lateral member may not be optimal. Some embodiments disclosed herein may include a cross rail assembly that includes a cross rail member having a height greater than that of this short cross rail member (e.g., as tall as the members of the frame or at least taller than the short cross rail member under which the cable can be routed). This cross rail assembly may include one or more portions to define one or more grooves through which the cable can be routed even when the cross rail assembly is installed above and parallel to the mounting rail. In embodiments where the cross rail assembly includes a metal cross rail member attached to the frame using a pair of spacers to define the groove, the metal cross rail member may be electrically connected to the frame only through the pair of spacers.

[0054] An embodiment may include a device having: a frame adapted to receive a perimeter of a back side of a photovoltaic (PV) laminate; one or more cross rail members that may provide structural stiffness to the frame; and one or more pairs of couplers that may be coupled to the frame, each coupler in the pair including a first portion adapted to define a groove and a second keying portion inserted into a respective different end of one or more of the cross rail members; wherein each cross rail member may be electrically connected to the frame only through a coupler in a respective one of the one or more pairs of couplers.

[0055] An embodiment may include a device having a cross rail assembly for use in a photovoltaic (PV) module. In one example, the device may include: a PV laminate having a front side, a back side, and a plurality of solar cells encapsulated between the front side and the back side; and a frame to which a perimeter of the PV laminate is mounted. The cross rail assembly may provide structural stiffness to the PV laminate and the frame. The cross rail assembly may include a plurality of portions, and a height of one or more of the portions may be less than a height of the remaining portions. If the cross rail assembly is placed above a mounting rail at an installation site, a trench may be formed by one or more portions of the cross rail assembly and one or more corresponding regions of the mounting rail. An installer may string a cable through one or more of the trenches. Other embodiments may be disclosed and / or claimed.

[0056] An embodiment is a device for use in a photovoltaic (PV) assembly, the PV assembly including one or more mounting rails and a PV module including: a frame; and a PV laminate having a front side, a back side, and a plurality of solar cells encapsulated between the front side and the back side, wherein a perimeter of the PV laminate is mounted to the frame. The device includes one or more cross rail assemblies adapted to provide structural stiffness to the PV laminate and the frame, each cross rail assembly extending from a first member of the frame to a second member of the frame, the cross rail assemblies being grounded to the frame and having a first side facing a back side of the PV laminate and an opposite second side. At least one of the one or more cross rail assemblies includes one or more first portions having a height less than a height of the remaining portions of the at least one cross rail assembly, wherein the one or more first portions of the at least one cross rail assembly define one or more grooves. When the at least one cross rail assembly is mounted above and parallel to a mounting rail of the one or more mounting rails, the one or more grooves include one or more trenches. Other embodiments may be disclosed and / or claimed.

[0057] The following detailed description is merely exemplary in nature and is not intended to limit the embodiments of the subject matter of the present application or the use of such embodiments. As used herein, the word "exemplary" means "used as an example, instance, or illustration". Any embodiment described herein as exemplary is not necessarily understood to be preferred or advantageous over other embodiments. In addition, it is not intended to be bound by any express or implied theory presented in the aforementioned technical field, background technology, invention content, or the following detailed description.

[0058] Figure 3 A cross-sectional view of a PV module 300 having a cross-rail assembly 310 is shown, wherein the cross-sectional view exposes a side of the cross-rail assembly 310 according to various embodiments. The PV module 300 includes a PV laminate 305, a first frame member 301 (e.g., a long side frame member), a second frame member 302 (e.g., a long side frame member), a third frame member 303 (e.g., a short side frame member), and a fourth frame member (not shown). The cross-rail assembly 310 includes a first portion 311 and a second portion 312. The cross-rail assembly 310 includes a first side 321 facing the PV laminate 305 and an opposing second side 322. In the first portion 311, the second side 322 may define a groove 320, such as a cable groove. In some embodiments, the groove 320 may include a cable management feature that can be used by an installer to run cables (not shown) through the groove 320. In any embodiments, cross rail assembly 310 may have a third portion (not shown) that is similar to the first portion but located on the other end of cross rail assembly 310 to provide grooves 320 on both sides.

[0059] In the illustration, the cross rail assembly 310 is shown in contact with the back side of the PV laminate 305. In embodiments where the cross rail assembly 310 is in contact with the PV laminate 305 (e.g., as shown at 321), an adhesive may be located between the cross rail assembly 310 and the back side of the PV laminate 305, which adhesive may be used to limit deflection in both upward and downward loads. Additionally, in some embodiments, only the second portion 312 is in contact with the PV laminate 305. For example, to facilitate installation, the first portion 311 may define an additional groove (not shown) similar to the groove 320 between the PV laminate and the first portion 311. In some embodiments, the additional groove (which may eliminate the left-hand and right-hand designations for the cross rail assembly 310 in the parts list) may be referred to as a "virtual" groove because all cables may be routed through the groove 320.

[0060] Cross rail assembly 310 may include any pair of any conductive cross rail members and any ground couplers described herein. Figure 5A, Some conductive cross-rail members 551 may span only a portion of the distance between the long-side frame members 533 and 534. Figure 5A One coupler in the pair 532 may span the remainder of the distance to define a cable trough. The other coupler in the pair 532 may be different, for example, may not define a cable trough.

[0061] Referring again to Figure 3 , In other embodiments, the cross-rail assembly 310 may include conductive cross-rail members that span the entire distance between the first frame member 301 and the second frame member 302. Figure 4D A perspective view of a cross-rail assembly including a conductive cross-rail member 454 that spans the entire distance between opposite members of a frame is shown. In these embodiments, the conductive cross-rail member 454 may penetrate an opening 471 in the frame member, such as a ridge opening. As will be explained in more detail later, the conductive cross-rail member 454 may be grounded to the frame through a ground coupler or through an interface between an end of the conductive cross-rail member 454 and the interior of the frame member.

[0062] Referring again to Figure 3 , The second portion 312 is shown with its second side in a plane different from the second side of the frame (which exposes the third frame member 303); however, in other examples, the second side of the second portion 312 may be in the same plane as the second side of the frame. Specifically, the second portion 312 may have a height greater than that of the first portion 311 and no greater than the height of the frame. Thus, the PV module 300 may be mounted above and parallel to the mounting rail. The PV panel 300 may be compatible with various PV laminate designs and / or frame designs, lightweight, and have low manufacturing and / or installation costs.

[0063] The shape of the channel 320 is shown as rectangular; however, in other embodiments, the groove 320 may have any shape that can be used to string cables through the groove 320 during installation. Also, in the example shown, the channel 320 is defined by the first portion 311 of the cross-rail assembly 310, the first frame member 301, and the second portion 312 of the cross-rail assembly 310. In other examples, the groove 320 may be defined only by the first portion 311 and the first frame member (as in the curved groove 820 shown in Figure 8A . In other examples, it is possible and practical to define the groove 320 only in the first portion 311 (e.g., the groove 320 does not necessarily have to be defined by the side of the first member 301).

[0064] In some embodiments, the first frame member 301 may be a long-side frame member of a rectangular frame. In other embodiments, the first frame member 301 may be a short-side frame member of a rectangular frame.

[0065] Figure 4A A perspective view of a cross rail assembly including a cross rail 451 and a corner key 432 is shown, the corner key holding a recessed member to the frame 401 of the PV module. Figure 4B A perspective view of a cross rail assembly including a cross rail 452 and a T-shaped corner key 433 is shown, the T-shaped corner key being attached to segments of a member of the frame 402 of the PV module. Figure 4C A perspective view of a cross rail assembly including a cross rail 453 and a short corner key 434 is shown, the short corner key being attached to a keyway of a member of the frame of the PV module. Figure 4D A perspective view of a cross rail assembly including a cross rail member 454 is shown, the cross rail member being attached to a spline hole 471 in a member of the frame of the PV module.

[0066] Figures 5A to 5D A PV module 500 having a cross rail assembly is shown according to various embodiments, the cross rail assembly being similar to Figure 4A the cross rail assembly. See Figure 5A , the PV module 500 includes a PV laminate 505, which may be similar to any PV laminate described herein. In this embodiment, components such as micro-inverters, junction boxes, etc. may be mounted on the back surface of the PV laminate 505. The PV module 500 also includes a cross rail assembly, which may be similar to any cross rail assembly described herein. The cross rail assembly includes a cross rail member 551 and a pair of couplers 532. The cross rail member 551 may be electrically connected to the frame through the pair 532 and / or one or more couplers in the pair 532, for example, only electrically connected to the frame through the pair 532. In Figure 5A , cables are routed within the volume defined by the frame and the cross rail member 551 such that the cables do not interfere with the contact between the cross rail member 551 (or the frame) and the mounting frame 121 ( Figure 1B ) and / or the roof 120 ( Figure 1B ), and may also simplify installation / assembly / transportation.

[0067] See Figure 5B , a coupler 552 of the pair 532 ( Figure 5A ) is shown. The coupler 552 may include a first protrusion 581 and a second protrusion, the second protrusion including an end 582. In one example, the first protrusion 581 and the second protrusion may be arranged in an L-shape. The end 582 may be formed (e.g., keyed, molded, extruded) to mate with a cavity in the end of the cross rail member 551.

[0068] The frame member 501 includes an opening 571 that provides access to a cavity. The cavity may be defined by an inner wall and an outer wall of the frame member 501. A first protrusion 581 may be located within the cavity and keyed to mate with the cavity. In some examples, positioning the first protrusion 581 within the cavity may lock the first protrusion 581 in place at the cavity. After insertion into the opening 571, the first protrusion 581 may be positioned within the cavity.

[0069] See Figure 5C (which is a cross-sectional view that appears perpendicular to the cross rail assembly and parallel to the frame member 501), the coupler 552 may define grooves 520 and 521. In this view, a cross-sectional view of the frame portion and a plan view of the coupler 552 are shown. In this example, the groove 520 may be used to string cables during the installation of the PV module 500 ( Figure 5A ). In contrast, in some examples, the groove 521 may be a virtual groove (which may be an artifact of manufacturing the coupler 552, without any left / right component designation and not intended for stringing cables). Of course, the groove 521 may be a virtual groove for certain PV module 500 installation configurations, or may accommodate cables in other PV module 500 installation configurations depending on the application. In this example, the coupler 552 and the flange of the frame member 501 corresponding to the groove 520 define a cable management feature. Additionally, the inner sidewall of the frame member 501 may also define a cable management feature for suspending the cables strung through the groove 520.

[0070] Regarding the electrical connection to the frame through 532 ( Figure 5A , for example, only through 532), Figure 5C Specifically shown is the "metal-to-metal" contact (also referred to as contact optimized for electrical grounding) between the coupler 552 and the inner side (specifically, the inner side of the outer wall of the frame member 501) of the frame member 501. Although the exterior of the frame member 501 may be anodized to prevent corrosion (involving a relatively weak conductor layer, such as the oxide on the anodized surface), the inner side of the frame member 501 may not be anodized. For this or other reasons, the resistivity of the surface of the outer side of the frame member (e.g., a hollow frame member) may be greater than the resistivity of the surface of the inner side of the frame member. Thus, "metal-to-metal" may refer to the contact between the non-anodized surfaces of metal components. In some examples of PV modules, metal fasteners are required to pierce the anodized surface to meet the grounding requirements, which may not need to be complied with due to the contact on the inner side of the frame member 501.

[0071] Figure 5DA perspective view showing a cross-section through the coupler 552 (e.g., a cross-sectional view that appears perpendicular to the frame member 501 and parallel to the cross rail assembly) is shown. The end 582 of the second protrusion of the coupler 552 is shown within the cavity defined by the coupler 552 (in some examples, the coupler 552 may be double-walled, similar to the frame member 501). In this view, the opening 571 is referred to as a "key recess".

[0072] In any of the embodiments described herein, the frame member may be single-walled or double-walled (similar to Figure 5B the frame member 501), and the cross rail assembly may be single-walled or double-walled. Additionally, in some embodiments of a PV module having a frame member and a cross rail assembly, the number of walls of the cross rail assembly need not be the same as the number of walls of the frame member. An adapter may be used to attach, for example, a single-walled cross rail assembly to a double-walled frame member. Figure 2D A perspective view of a single-wall / double-wall adapter that may be employed according to some embodiments is shown. This feature or any other feature of U.S. Provisional Application Serial No. 62 / 651,035 may be used in any embodiment of a photovoltaic module having a cross rail assembly as described herein. Specifically, any feature of this adapter may be used with any of the couplers (e.g., a ground coupler) described herein to provide a coupler (e.g., a ground coupler) for attaching a single-walled or double-walled cross rail member (respectively) to a double-walled or single-walled frame.

[0073] In a certain embodiment, Figure 2D this connection key 221 is a single-wall key having two connection holes 213. In one embodiment, the single-wall key may be a single-wall aluminum key. Other materials may also be used, such as galvanized steel or carbon laminate or polymer.

[0074] Additionally, one connection hole, or more than two connection holes, such as 3, 4, 5, or more connection holes, may be employed in an embodiment. These connection holes 213 may be used during manufacturing to secure the key to the single-wall frame portion. In one example, the connection holes may alternatively be referred to as screw holes, and screws may be used as the connecting members; however, the connection holes may have other configurations, such as a pin hole combination, a needle hole combination, a rivet hole combination, a tox-hole combination, a tab slot / recess combination, or a flange slot / recess combination, and combinations thereof.

[0075] In Figure 2DAlso marked therein are the open-end hollow portion 214, the clamping end 217, the long key arm 219, the optional key hollow portions 211, 212, 220, the short key arm 218, and the edge key arm 216. In some embodiments, the connecting key may have two short key arms, two long key arms, three or more key arms (e.g., when connecting three or more frame portions together), one long key arm and one short key arm, and various permutations of these examples. As described above, the connecting hole 213 may be threaded to receive a screw, and its size and configuration may be for receiving other connecting members, such as pins, rods, rivets, tox connectors, etc. Other connection techniques may be used, such as flange groove / recess combinations or tab groove / recess combinations.

[0076] In an embodiment, the connecting key may connect the cross rail assembly and the frame portion at various angles, and the angles may include: 11.25°, 22.5°, 45°, 60°, 75°, 90°, 110°, 115°, 125°, 135°, and 180°. The frame portion may be made of various materials and may include a metal having sufficient stiffness. In an embodiment, the connecting key and the frame portion may be galvanized or otherwise treated to resist weathering.

[0077] Figure 6 A PV module 600 with a cross rail assembly according to various embodiments is shown, and the cross rail assembly is similar to Figure 4B the cross rail assembly. The PV module 600 includes a cross rail member 651, which may be similar to the cross rail member 551 ( Figures 5A to 5D ). The cross rail member 651 may be electrically connected to the frame of the PV module 600 through a coupler pair 632 (e.g., in some examples, only through the coupler pair 632).

[0078] An exploded view of one of the couplers shows a first protrusion, a second protrusion, and a third protrusion arranged in a T-shape. For example, the cross rail assembly may be positioned perpendicular to the frame as shown. In a certain example, one of the protrusions defining the groove may have a keyed end, similar to the end 582 ( Figure 5B ).

[0079] In this example, the frame member is segmented. One of the protrusions is keyed and located in the cavity of one segment of the frame member. The other of the protrusions is also keyed and located in the cavity of another segment of the frame member. In other words, in addition to connecting the cross rail member to the frame, the coupler also connects the frame member segments together. The coupler may have a "metal-to-metal" contact, similar to the "metal-to-metal" contact described with respect to Figure 5D .

[0080] Figures 7A to 7CShows a partial bottom view of a PV module having a transverse rail assembly according to various embodiments, the transverse rail assembly being similar to Figure 4C The coupler 732 is referred to as a "short key". Again, the transverse rail member 751 can be electrically connected to the frame by a coupler pair (e.g., in some instances only by a coupler pair). "Metal-to-metal" contacts similar to those previously described can be defined within the corresponding regions of the keyway and the short key 732.

[0081] The short key 732 can be L-shaped or T-shaped and can include a protrusion that defines a groove (referred to in this instance as a DC cable passing through the room) and includes a keying end to mate with the transverse rail keyway defined by the transverse rail member 751. One or more other protrusions can mate with the frame member keyway defined by the frame member 701. Figure 7B and 7C Show cross-sectional views of the frame member 701 and the transverse rail member 751, respectively. The keyway can be approximately half the height of the associated member (the same height in this instance), but can be other ratios in other instances. As shown in the cross-sectional view, in this instance, the frame member 701 can be double-walled and define a keyway, and the transverse rail member 751 can be an I-structure and define a keyway.

[0082] Moreover, as shown, the size of the hollow portion (to match the key area of the coupler 732) defined by each keyway can be larger than the opening in the keyway. The sidewalls of the keyway that define this opening can be cut away (only in selected portions of the keyway) during installation to set the keying area into the hollow portion. The keying area can then be slid into the hollow portion, and the remaining portion of the keyway (where the sidewalls have not been cut away) can secure the coupler to the member.

[0083] Figures 8A to 8B Shows a partial cross-sectional view of a PV module having a transverse rail assembly according to various embodiments, the transverse rail assembly being similar to Figure 4D In this view, a cross-sectional view of the frame portion and the transverse rail member 851 is shown. In this instance, the transverse rail assembly includes a transverse rail member 851 to make physical contact with the frame member 801. The ends of the transverse rail member 851 form metal-to-metal contacts within the hollow portions in the frame member 801. Moreover, the transverse rail member 851 and the frame member 801 define a cable trough (e.g., through which a DC cable passes).

[0084] See Figure 8B, The opening in the frame member 802 can be a spline. The cross-section of the horizontal rail member 852 includes a twisted I-shape (as shown, where the opposite sides of the top and bottom of the I are not parallel to the other sides of the top and bottom). This shape allows the horizontal rail member 852 to be rotated to insert it into the spline-shaped opening and then twisted to lock it in place.

[0085] Figures 8C to 8D A partial cross-sectional view of another PV module with a horizontal rail assembly is shown. In this example, the horizontal rail member 853 does not define any grooves. However, the horizontal rail member 853 still includes metal-to-metal contact (e.g., with a surface of lower resistivity of the frame member 803) and locking features to cooperate with the opening 871 in the frame member 803, and for these reasons, the rivets required for some PV modules may not be needed (due to the metal-to-metal contact and locking features on the non-anodized areas).

[0086] Figure 9 A partial cross-sectional view of a PV module with a horizontal rail assembly according to various embodiments is shown, which respectively includes a coupler 932 (e.g., a spacer and fasteners adapted to attach the spacer to the frame member 901 and the horizontal rail member 951, respectively). In this example, the fasteners can pierce the surfaces of the members 901 and 951 (e.g., the anodized surface of the bottom flange) to provide continuity between the cross member 951 and the frame 901 (from the horizontal rail member 951, through the fasteners, spacer, another fastener, to the frame member 901).

[0087] The spacer 932 can include protrusions (such as pins) to wedge-fit the spacer in place for holding the spacer 932 when installing the fasteners. In this example, the protrusions cooperate with a circular formation of approximately 270 degrees on the inner wall of the frame member 902. In other examples, the frame member 902 does not have to include a circular formation, and the protrusions can be longer and can engage the back of the PV laminate to wedge the spacer into place. In this example, the spacer 932 has an arithmetic spiral segment shape (similar to a nautilus), where one end of the smallest turn of the spiral segment defines a cable management feature (and another area of the spiral segment such as the rest of the spiral segment defines a groove). In other examples, the spacer can have any shape, such as a U-shape (the bottom of the U facing the PV laminate), and can or may not include protrusions extending into the groove for cable management.

[0088] Figures 10A to 10BA partial cross-sectional view of a PV module with a horizontal rail assembly according to various embodiments is shown. The horizontal rail assembly includes a coupler 933 (e.g., a spacer and a fastener extending through the frame member 902 and the horizontal rail member 952). In this example, the head of the fastener can provide metal-to-metal contact with the inner wall of the frame member 902 and can also pierce any anodized surface on the other side of the inner wall. The fastener can also pierce the end of the horizontal rail member 952.

[0089] The outer wall of the frame member 902 can include an opening (not shown) sized to fit the head of the fastener for mounting the fastener from the outside of the PV module. The spacer can include small protrusions as shown to engage mating hollow portions on the end of the horizontal rail member 952, which can align the spacer for mounting the fastener into pre-drilled holes between the mating hollow portions.

[0090] In this example, as shown, a spring can be coupled to the PV module. In the released position, the spring may block the passage into the groove. The spring can be actuated to insert a cable into the groove, and then the spring can snap back to its original position. The spring shown can be used as a cable management feature for the grooves of any other PV module described herein. Other examples may not require a spring, and gravity may be sufficient to return a cable management component (e.g., a closing tab) to its initial state after inserting the cable.

[0091] Figure 11 of (a) to Figure 11 of (b) shows a PV module similar to Figure 6 the PV module according to various embodiments. As shown, the PV module can include frame member segments 1101 and 1102 that are end-to-end joined to form, for example, a long side of the frame, as Figure 11 shown in (c). The frame segments 1101 and 1102 can be joined to the horizontal rail member 1152 by a T-shaped coupler 1131, which is shown in more detail in Figure 12 (d2). In some, a cover can be used as shown to protect the PV laminate and fill any gap between the frame segments 1101 and 1102 (although in some embodiments, the ends of the frame segments 1101 and 1102 instances can physically contact with substantially no gap left). The groove and the coupler 1131 in the groove can be covered by the PV laminate (e.g., to protect them from elements).

[0092] Figure 12 of (d1) to Figure 12 of (k) shows the assembly process of a PV module according to various embodiments, which is similar to Figures 5A to 5DPV module. The short side frame members 1203 and 1204 can be arranged on the back surface of the PV laminate 1205 (and vice versa, for example, the PV laminate 1205 can be arranged on the short side frames 1203 and 1204), as Figure 12 shown in (d1) to Figure 12 shown in (d2). The coupler 1231 (for example, an L-shaped coupler in this embodiment) can be inserted into the opening 1207 defined by the inner side walls of the long side frame members 1201 and 1202 (by moving the coupler 1231 through the opening 1207 towards the outer side wall), as Figure 12 shown in (e).

[0093] Then, by moving the coupler 1231 in an orthogonal direction (parallel to the length segment of the long side frame member 1201), the keyed protrusion of the coupler 1231 can be inserted into the hollow portion between the side walls, as Figure 12 shown in (f) to Figure 12 shown in (h). This can lock the coupler 1231 in place. The cross rail member 1251 can slide over the keyed end of another protrusion of the coupler 1231 (in some instances, this can be performed before inserting the coupler 1231 into the long side frame member 1201).

[0094] With the coupler 1231 in place, the assembly of the long side frame members 1201 and 1202, the coupler 1231, and the cross rail member 1251 can be arranged on the back surface of the PV laminate 1205. This can include first inserting the corner key 1299 into the short side frame member (as Figure 12 shown in (i) to Figure 12 shown for the frame member 1204 in (k)), and then sliding the long side members 1201 and 1202 over the other protrusions of the corner key 1299. Then the PV module can be transported to the installation site, where installers can string cables through the grooves.

[0095] Figure 13A bottom view of six different PV modules 1351, 1352, 1353, 1354, 1355, and 1356 according to various embodiments is shown, each of the six PV modules having non-conductive cross rail assemblies 1361, 1362, 1363, 1364, 1365, and 1366. The non-conductive cross rail assemblies 1361, 1362, 1363, 1364, 1365, and 1366 can be manufactured using any known molding, casting, and / or forming process. In some embodiments, the non-conductive cross rail assemblies 1361, 1362, 1363, 1364, 1365, and 1366 can include non-extruded components (e.g., only non-extruded components). In some embodiments, the non-conductive cross rail assemblies 1361, 1362, 1363, 1364, 1365, and 1366 can include plastic.

[0096] The non-conductive cross rail assemblies 1361, 1362, 1363, 1364, 1365, and 1366 can limit the bending of the PV laminate 1305 under load by reinforcing the PV laminate 1305. For example, each can shorten the distance from two frame support parts of the PV laminate 1305. For example, an additional load path can be formed between the PV laminate 1305 and a mounting system component such as a mounting rail 1399. In some embodiments, the height of the non-conductive cross rail assemblies 1361, 1362, 1363, 1364, 1365, and 1366 can be greater than a selected value (e.g., half the distance between the back of the PV laminate 1305 and the plane of the bottom of the frame) to provide such reinforcement. The non-conductive cross rail assemblies 1361, 1362, 1363, 1364, 1365, and 1366 can be attached to the backsheet of the PV laminate 1305 using an adhesive similar to that described for other embodiments of the cross rail assemblies herein.

[0097] Similarly, any non-conductive cross rail assembly 1361, 1362, 1363, 1364, 1365, and 1366 can contact a mounting system component such as a mounting rail 1399. In some embodiments, any non-conductive cross rail assembly 1361, 1362, 1363, 1364, 1365, and 1366 can distribute the contact force from the mounting system component over a larger area of the PV laminate 1305. Other embodiments of the non-conductive cross rail assembly can have any shape to transfer the load between the mounting system component and the PV laminate 1305 under a downward force.

[0098] Non-conductive cross rail assemblies 1361, 1362, 1363, 1364, 1365, and 1366 may define cable gaps 1371, 1372, 1373, 1374, 1375, and 1376 with a frame 1301 (e.g., a long side member of the frame 1301). In the illustrated embodiment, the cable gaps 1371, 1372, 1373, 1374, 1375, and 1376 are also defined by the back side of the PV laminate 1305. In other embodiments, the conductive cross rail assembly may have any of the illustrated shapes of the non-conductive cross rail assemblies 1361, 1362, 1363, 1364, 1365, and 1366, and may additionally include a cross section similar to cross section 311( Figure 3 ), and / or may include separate components (such as any of the conductive spacers described herein) to electrically connect the conductive cross rail assembly to the frame of the PV assembly. In these embodiments, the conductive cross rail assembly and / or the additional components may define a cable trough with the frame. Moreover, the conductive cross rail assembly may be in contact with a conductive mounting rail (similar to mounting rail 1399) to form an electrical path (e.g., the only electrical path) between the frame of the PV module and the conductive mounting rail.

[0099] The shape of any cross rail assembly according to the embodiments disclosed herein may be significantly different from the "bar" shape of the cross rail member shown Figure 2A . For example, such a shape may be defined by or may not be entirely defined by an elongate member. For example, a cross rail assembly similar to non-conductive cross rail assembly 1366 may include a shape that is not defined by any elongate member (e.g., circular). Moreover, any cross rail member may include a circular core and one or more elongate protrusions extending from the circular core (which may or may not be parallel to any member of the frame, and in the case of more than one elongate protrusion, may not be parallel to another of the elongate protrusions). Moreover, some shapes may have an elongate member that is not parallel to any member of the frame, such as cross rail assemblies similar to non-conductive cross rail assemblies 1364 and 1365. Moreover, some shapes may include elongate protrusions extending from a point similar to non-conductive cross rail assembly 1361 (such as a double cross shape having two such points). In non-conductive cross rail assembly 1361 having elongate protrusions, at least one elongate protrusion is not parallel (e.g., orthogonal) to another elongate protrusion.

[0100] Figures 14A to 14COptionally include PV modules 1451, 1452, 1453, 1454, and 1455 each having horizontal rail assemblies 1461, 1462a, 1462b, 1463, 1464a, and 1464b. The PV modules 1451, 1452, 1453, 1454, and 1455 and the horizontal rail assemblies 1461, 1462a, 1462b, 1463, 1464a, and 1464b can provide substantial structural support for the entire frame, refer to FIG. 1. In one example, the horizontal rail assemblies 1461, 1462a, 14622b, 1463, 1464a, and 1464b can provide structural support that allows the use of partial frames, for example, discontinuous frames and / or frames including gaps between frame portions. Compared with using an entire frame, such PV modules 1451, 1452, 1453, 1454, and 1455 and horizontal rail assemblies 1461, 1462a, 1462b, 1463, 1464a, and 1464b can significantly reduce costs while providing comparable structural integrity, i.e., a complete frame.

[0101] Figure 14A Plan views of a photovoltaic module 1450 according to various embodiments are shown respectively. As shown, the photovoltaic module 1450 can include a partial frame 1401, a plurality of solar cells 1404, a laminate 1405, and a gap portion 1402 between partial frame portions 1401. The photovoltaic module 1450 can represent Figure 14B a plan view of the PV modules 1451, 1452, 1453, 1454, and 1455 described in

[0102] Figure 14BThe bottom views of four different PV modules 1451, 1452, 1453, and 1454 having cross rail assemblies 1461, 1462a, 1462b, 1463, 1464a, and 1464b respectively according to various embodiments are shown. Referring to PV module 1451, cross rail assembly 1461 may include a cross structure that can connect partial frame 1401 (including gap 1402) between separate partial frames at the ends of partial frame 1401. Referring to PV module 1452, cross rail assemblies 1462a, 1462b may include support portions 1462a and a central support portion 1462b, where the support portions may be connected to the ends of partial frame 1401, and the central portion 1462b may be connected to all support portions 1462a. Referring to PV module 1453, cross rail assembly 1463 may include a cross structure that can be connected at the corners of partial frame 1401, where the partial frame may include gaps 1402, 1403. Referring to PV module 1454, cross rail assemblies 1464a, 1464b may include support portions 1464a and a central support portion 1464b, where the support portions may be connected to the end portions and corner portions of partial frame 1401, and the central portion 1464b may be connected together to support portions 1464a. Moreover, partial frame 1401 may include gap 1402 at the long sides of the PV module and / or may include gap 1403 at the short sides of the PV module.

[0103] Referring again to Figure 14B , cross rail assemblies 1461, 1462a, 1462b, 1463, 1464a, and 1464b can be manufactured using any known molding, casting, and / or forming processes. In some embodiments, cross rail assemblies 1461, 1462a, 1462b, 1463, 1464a, and 1464b may include non-extruded components (e.g., only non-extruded components). In some embodiments, cross rail assemblies 1461, 1462a, 1462b, 1463, 1464a, and 1464b may include plastics. In one embodiment, cross rail assemblies 1461, 1462a, 1462b, 1463, 1464a, and 1464b can limit the bending of PV laminate 1405 under load by reinforcing PV laminate 1405, e.g., each can form a load path between PV laminate 1405 and mounting system components such as Figure 13 mounting rail 1399). In one instance, cross rail assemblies 1461, 1462a, 1462b, 1463, 1464a, and 1464b can be non-conductive, e.g., may include non-conductive materials. In another instance, cross rail assemblies 1461, 1462a, 1462b, 1463, 1464a, and 1464b can be non-conductive, e.g., may include non-conductive materials.

[0104] Figure 14C A perspective view of a PV module 1454 in accordance with various embodiments is shown. In one example, the cross rail assembly may include a support portion 1464a and a central support portion 1464b. In one example, the support portion 1464a may be connected to the end portions and corner portions of a portion of the frame 1401 (for the PV laminate 1405), and the central portion 1464b may be connected to the support portion 1464a together, shown for clarity.

[0105] Figure 15 A bottom view of another PV module having a conductive cross rail assembly in accordance with various embodiments is shown, where only a subgroup of the cross rail members are attached to the frame via a ground coupler. The frame of the PV module includes frame members 1501, 1502, 1503, and 1504. The cross rail assembly includes a plurality of cross rail members. A ground coupler 1532 (similar to any ground coupler, bonding adapter, etc. described herein in any example) electrically connects a single cross rail member 1510 among the cross rail members to the frame. In this example, the ground coupler 1532 attaches the cross rail member to the corner defined by frame members 1502 and 1503 (e.g., tethered to one or more frame members, such as the corner defined by the frame members), but in other examples, the ground coupler for a single cross rail member may attach the single cross rail member to one of the frame members 1501 - 1504.

[0106] The other remaining cross rail members may be electrically connected to the frame only through the single cross rail member 1510 and its ground coupler 1532. The other remaining cross rail members may not have their own couplers (e.g., the other remaining cross rail components may be “untied” relative to the frame members, but instead adhered to the PV laminate 1505, similar to the way any non - conductive cross rail components described above may be adhered to the PV laminate). In this example, a circular cross rail member 1511 electrically couples the other cross rail members to the single cross rail member 1510. Any cross rail member (including cross rail member 1510 and / or circular cross rail member 1511) may be adhered to the PV laminate 1505, similar to the way any non - conductive cross rail member described herein may be adhered to the PV laminate.

[0107] Example

[0108] Example 1 is a photovoltaic (PV) module, the PV module comprising: a PV laminate having a front face, a back face, and a plurality of solar cells encapsulated between the front face and the back face; a frame, wherein the perimeter of the PV laminate is mounted on the frame; a cross rail assembly adapted to provide structural rigidity to the PV laminate and the frame, the cross rail assembly extending from a first member of the frame to a second member of the frame, the cross rail assembly being grounded to the frame and having a first side facing the back face of the PV laminate and an opposite second side; and a cable trough defined by an end of a member of the cross rail assembly and a ground coupler adapted to attach the end of the member of the cross rail assembly to one of the first member and the second member of the frame, or a first portion of a plurality of portions of the cross rail assembly, wherein a distance between the first side of the cross rail assembly and the second side of the cross rail assembly in a second portion is less than a distance between the first side of the cross rail assembly and the second side of the cross rail assembly in a second different portion of the plurality of portions of the cross rail assembly.

[0109] Example 2 includes the subject matter according to Example 1 or any other example herein, wherein one of the first member or the second member of the frame includes a hollow portion defined by an inner side wall of a plurality of side walls of one of the first member or the second member, and wherein the ground coupler extends through an opening formed in the inner side wall.

[0110] Example 3 includes the subject matter according to Example 2 or any other example herein, wherein the ground coupler includes a first protrusion and a second protrusion arranged in an L shape, the first protrusion being located in the hollow portion and the second protrusion defining the cable trough. Although in some examples the first protrusion and the second protrusion may be arranged in an L shape, in other examples, the first protrusion and the second protrusion may be arranged along an intersection line forming any angle (e.g., any obtuse angle, e.g., less than 160 degrees in some examples, or any acute angle, e.g., greater than 70 degrees in some examples).

[0111] Example 4 includes the subject matter according to Example 3 or any other example herein, wherein the second protrusion is fastened to the end of the member of the cross rail assembly.

[0112] Example 5 includes the subject matter according to Example 3 or any other example herein, wherein the first protrusion is keyed and wherein the hollow portion includes a key recess.

[0113] Example 6 includes the subject matter according to Example 2 or any other example herein, wherein one of the first member or the second member of the frame is segmented into segments, wherein the hollow portion is defined by the ends of the segments, and wherein the ground coupler includes a first protrusion, a second protrusion, and a third protrusion arranged in a T-shape, the first protrusion and the second protrusion being located in the hollow portion and the third protrusion defining the cable trough. Although in some examples the ground coupler may be arranged in a T-shape, in other examples, the angle between any two protrusions may be a right angle, any acute angle, any obtuse angle, etc.

[0114] Example 7 includes the subject matter according to Example 6 or any other example herein, wherein the first protrusion and the second protrusion are keyed, and wherein the hollow portion includes a plurality of openings to form together with the first protrusion and the second protrusion.

[0115] Example 8 includes the subject matter according to Example 6 or any other example herein, wherein the third protrusion is fastened to the end of the member of the cross rail assembly.

[0116] Example 9 includes the subject matter according to Example 6 or any other example herein, wherein a first end portion of the third protrusion is keyed, and wherein the first end of the third protrusion is located in a keyway formed on the end of the cross rail, and wherein a second different portion of the third protrusion defines the cable trough.

[0117] Example 10 includes the subject matter according to Example 1 or any other example herein, wherein one of the first member or the second member of the frame includes a keyway that defines an opening adapted to receive a keyed protrusion of the ground coupler, and wherein the keyed protrusion of the ground coupler extends through the hollow portion defined by the keyway.

[0118] Example 11 includes the subject matter according to Example 1 or any other example herein, further including a keyed protrusion formed on the end of the member of the cross rail assembly, wherein the keyed protrusion is located in a hollow portion defined by an inner sidewall and an outer sidewall of one of the first member or the second member.

[0119] Example 12 includes the subject matter according to Example 11 or any other example herein, wherein the inner wall includes a splined opening having a first region, one or more protrusions respectively defining one or more second regions, and wherein the keyed protrusion is only located in the first region of the splined opening.

[0120] Example 13 includes the subject matter according to Example 1 or any other example herein, wherein the ground coupler includes a conductive spacer and one or more conductive fasteners to form an electrical path between the member of the cross rail assembly and the frame including the same.

[0121] Example 14 includes the subject matter according to Example 13 or any other example herein, wherein the one or more fasteners include a first fastener and a second fastener to attach the conductive spacer to the end of the member of the cross rail assembly and the frame, respectively.

[0122] Example 15 includes the subject matter according to Example 13 or any other example herein, wherein the one or more fasteners include fasteners having a length longer than the length of the conductive spacer, and the fasteners extend through openings in the frame, openings in the space, and openings in the ends of the members of the cross rail assembly.

[0123] Example 16 includes the subject matter according to Example 1 or any other example herein, wherein the cable trough is defined by the first part of the cross rail assembly and one of the first member and the second member of the frame.

[0124] Example 17 includes the subject matter according to Example 1 or any other example herein, wherein the cable trough includes a first cable trough, the member of the cross rail assembly includes a first member of the cross rail assembly, the ground coupler includes a first ground coupler, the plurality of parts of the cross rail assembly includes a first plurality of parts of the cross rail member, and wherein the PV module further includes: one or more second cable troughs, the one or more second cable troughs are defined by one or more second members of the cross rail assembly and one or more second ground couplers, respectively, to connect one or more end portions of the one or more second members of the cross rail assembly to one of the first member and the second member of the frame, or to one or more first parts of one or more second plurality of parts of the cross rail assembly, respectively, wherein a distance between the first side and the second side of the cross rail assembly in the one or more first parts of the one or more second plurality of parts is less than a distance between the first side and the second side of the cross rail assembly in one or more second different parts of the second plurality of parts of the cross rail assembly.

[0125] Example 18 includes the subject matter according to Example 1 or any other example herein, wherein the first member of the frame is on a first edge of the PV module and the second member of the frame is on an opposite second edge of the PV module.

[0126] Example 19 includes the subject matter according to Example 18 or any other example herein, wherein the frame includes a rectangular frame and wherein the first and second members are longer than the third and fourth members of the rectangular frame.

[0127] Example 20 includes the subject matter according to Example 1 or any other example herein, wherein the cross rail assembly contacts the back side of the PV laminate.

[0128] Example 21 includes the subject matter according to Example 20 or any other example herein, wherein the members of the cross rail assembly are adhered to the back side of the PV laminate.

[0129] Example 22 includes the subject matter according to Example 1 or any other example herein, wherein the perimeter of the PV panel contacts a first side of the first or second member of the frame and wherein the distance between the first side of the first and second members of the frame and an opposite second side of the first and second members of the frame is equal to the distance between the first side and the second side of the cross rail assembly in a second different part of the plurality of parts of the cross rail assembly.

[0130] Example 23 includes the subject matter according to Example 1 or any other example herein, wherein the second part of the cross rail assembly can be arranged to form a wall with a mounting rail of a mounting frame and wherein corresponding positions on the first part of the cross rail assembly and the mounting rail define a cable trench.

[0131] Example 24 is a device that includes: a frame adapted to receive a perimeter of a back side of a photovoltaic (PV) laminate; one or more cross rail members adapted to provide structural rigidity to the frame; and one or more pairs of couplers connected to the frame, each coupler in the pair including a first part adapted to define a groove and a second keying part inserted into different ends of a corresponding one of the one or more cross rail members; wherein each cross rail member is electrically connected to the frame only by the coupler in a corresponding one of the one or more pairs of couplers.

[0132] Example 25 includes the subject matter according to Example 24 or any other example herein, wherein sides of the one or more transverse rail members are arranged in the same plane as sides of the frame to receive a perimeter of a back side of a photovoltaic (PV) laminate.

[0133] Example 26 includes the subject matter according to Example 25 or any other example herein, wherein opposite sides of the one or more transverse rail members are arranged in the same positions as opposite sides of the frame.

[0134] Example 27 includes the subject matter according to Example 26 or any other example herein, wherein the frame includes four frame members, at least one of the frame members includes a plurality of segments, and wherein an end of each of the segments defines one of a hollow portion or a protrusion to mate with the other of the hollow portion or the protrusion of the coupler, wherein a count of the one or more pairs of couplers is equal to N, and wherein a count of the segments is N + 1.

[0135] Example 28 is an apparatus for a photovoltaic (PV) module, the PV module including one or more mounting rails and a PV module including a frame and a PV laminate having a front side, a back side, and a plurality of solar cells encapsulated between the front side and the back side, wherein a perimeter of the PV laminate is mounted on the frame, the apparatus further including: one or more transverse rail assemblies adapted to provide structural rigidity to the PV laminate and the frame, each transverse rail assembly extending from a first member of the frame to a second member of the frame, the transverse rail assembly being grounded to the frame and having a first side facing the back side of the PV laminate and an opposite second side; wherein at least one of the one or more transverse rail assemblies includes one or more first portions having one or more heights less than one or more heights of the remaining portion of the at least one transverse rail assembly, and wherein the one or more first portions of the at least one transverse rail assembly define one or more grooves.

[0136] Example 29 includes the subject matter according to Example 28 or any other example herein, wherein the one or more grooves include one or more channels when the at least one transverse rail assembly is mounted above and parallel to a mounting rail of the one or more mounting rails.

[0137] Example 30 includes the subject matter according to Example 29 or any other example herein, wherein each of the one or more cross rail assemblies includes one or more cross rail members, and wherein the one or more cross rail assemblies further include one or more pairs of couplers, each coupler in the pair being attached to a different end of a corresponding cross rail member of the one or more cross rail members.

[0138] Example 31 is a photovoltaic (PV) module, the PV module including: a PV laminate having a front face, a back face, and a plurality of solar cells encapsulated between the front face and the back face; a frame, wherein a perimeter of the PV laminate is mounted on the frame; a non-conductive cross rail assembly adapted to provide structural stiffness to the PV laminate and the frame, the non-conductive cross rail assembly extending from a first member of the frame to a second member of the frame, the non-conductive cross rail assembly having a first side adhered to the back face of the PV laminate and an opposite second side adapted to contact one or more mounting cross rails; and a cable clearance defined by the non-conductive cross rail assembly, the first member or the second member of the frame, and the back face of the PV laminate.

[0139] Example 32 includes the subject matter according to Example 31 or any other example herein, wherein the cable clearance is further defined by an end of an elongate member of the non-conductive cross rail assembly, the elongate member being non-parallel and non-orthogonal to the first member and the second member of the frame.

[0140] Example 33 includes the subject matter according to Example 31 or any other example herein, wherein the non-conductive cross rail assembly includes a circular core centered on the center of the back face of the PV laminate.

[0141] Example 34 includes the subject matter according to Example 31 or any other example herein, wherein the non-conductive cross rail assembly includes one or more protrusions extending from the circular core.

[0142] Example 35 includes the subject matter according to Example 35 or any other example herein, wherein the non-conductive cross rail assembly includes a first elongate protrusion non-parallel to a second elongate protrusion of the non-conductive cross rail assembly.

[0143] The foregoing disclosure and examples provide a complete description of the structure and use of illustrative embodiments. Although certain embodiments have been described above with a degree of particularity or with reference to one or more individual embodiments, those skilled in the art can make various changes to the embodiments of the present disclosure without departing from the scope of the invention. Accordingly, the various illustrative embodiments of the methods and systems are not intended to be limited to the specific forms of the present disclosure. Instead, these embodiments include all modifications and alternatives within the scope of the claims, and embodiments different from the illustrated embodiments may include some or all of the features of the illustrated embodiments. For example, an element may be omitted or combined into a single structure, and / or connections may be replaced. Additionally, where appropriate, aspects of any of the above examples may be combined with aspects of any of the other examples described above to form additional examples having equivalent or different properties and / or functions and solving the same or different problems. Similarly, it should be understood that the above benefits and advantages may relate to one embodiment or may relate to multiple embodiments. For example, different structural configurations, materials, and / or control production steps may be used to practice and / or implement embodiments of the methods and systems of the present invention. The claims are not intended to include, nor should they be construed as including, method or step function language limitations, unless such limitations are expressly recited in a given claim using the phrases "means for... method" or "step for...".

Claims

1. An apparatus, comprising: a conductive part frame including a plurality of discontinuous frame members, the conductive part frame being configured to receive a perimeter of a back side of a photovoltaic (PV) laminate, wherein the conductive part frame is positioned along a partial perimeter of the PV laminate, and wherein the frame members include gaps between individual frame members; one or more conductive cross rail members providing structural rigidity to the conductive part frame, wherein the conductive cross rail members are positioned non - collinearly with the frame members; and one or more pairs of couplers connected to the conductive part frame, wherein: at least one coupler of at least one pair of the one or more pairs of couplers includes a grounding coupler having a first bonding portion and a second bonding portion, the first bonding portion being adapted to be inserted into an opening in the conductive part frame, the second bonding portion being adapted to cooperate with an end of a conductive cross rail member of the one or more conductive cross rail members to ground the conductive cross rail member to the frame; or at least one coupler of at least one pair of the one or more pairs of couplers includes a length segment defining a cable trough.

2. The apparatus according to claim 1, wherein the at least one pair of couplers includes a first coupler and a second grounding coupler, the first coupler having the length segment defining the cable trough, and the second grounding coupler having the first bonding portion and the second bonding portion.

3. The apparatus according to claim 1, wherein a side surface of the one or more conductive cross rail members is arranged in a same plane as a side surface of the perimeter of the conductive part frame that receives the back side of the PV laminate.

4. The apparatus according to claim 3, wherein opposite side surfaces of the one or more conductive cross rail members are arranged in the same position as opposite side surfaces of the conductive part frame.

5. The apparatus according to claim 4, wherein the conductive part frame includes four conductive frame members, at least one of the conductive frame members including a plurality of conductive segments, and wherein each of the conductive segments includes an end defining one of a hollow portion or a protrusion to cooperate with the other of the hollow portion or the protrusion of a corresponding one of the couplers, wherein the count of the one or more pairs of couplers is equal to N, and wherein the count of the segments is N + 1.

6. The apparatus according to claim 1, wherein an end of the conductive cross rail member contacts an outer surface of the conductive part frame, the outer surface of the conductive part frame having a greater resistivity compared to an inner surface of the conductive part frame, and wherein the first bonding portion physically contacts the inner surface of the conductive part frame.

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

8. The device according to claim 1, wherein at least one of the conductive cross rail members is electrically connected to the conductive partial frame only through the grounding coupler, or the path with the highest conductivity between at least one of the conductive cross rail members includes the grounding coupler.

9. The device according to claim 8, wherein the one or more conductive cross rails include a plurality of conductive cross rails, and wherein the plurality of conductive cross rail members are electrically connected to the conductive partial frame only through the grounding coupler, or the path with the highest conductivity between each of the plurality of conductive cross rail members includes the same grounding coupler.

10. The device according to claim 1, wherein the conductive partial frame is double-walled and the one or more cross rail members are single-walled.

11. A photovoltaic (PV) module, comprising: a PV laminate having a front face, a back face, and a plurality of solar cells encapsulated between the front face and the back face; a conductive partial frame including a plurality of discontinuous frame members, wherein the perimeter of the PV laminate is mounted on the frame, wherein the conductive partial frame is positioned along a partial perimeter of the photovoltaic laminate, and wherein the frame members include gaps between individual frame members; a non-conductive cross rail assembly adapted to provide structural rigidity to the PV laminate and the frame, the non-conductive cross rail assembly extending from a first member of the frame to a second member of the frame, the non-conductive cross rail assembly having a first side adhered to the back face of the PV laminate and an opposite second side in contact with one or more mounting rails, wherein the non-conductive cross rail assembly is positioned so as not to be collinear with the frame members; and a cable gap defined by the non-conductive cross rail assembly, the first member or the second member of the frame, and the back face of the PV laminate.

12. The photovoltaic (PV) module according to claim 11, wherein the cable gap is further defined by an end of an elongate member of the non-conductive cross rail assembly, wherein the elongate member is not parallel and not orthogonal to the first member and the second member of the frame.

13. The photovoltaic (PV) module according to claim 11, wherein the non-conductive cross rail assembly includes a circular core centered on the center of the back face of the PV laminate.

14. The photovoltaic (PV) module according to claim 13, wherein the non-conductive cross rail assembly includes one or more protrusions extending from the circular core.

15. The photovoltaic (PV) module according to claim 11, wherein the non-conductive cross rail assembly includes a first elongate protrusion that is not parallel to a second elongate protrusion of the non-conductive cross rail assembly.

16. The photovoltaic (PV) module according to claim 11, wherein the non-conductive cross rail assembly, the corresponding portions of the back side of the PV laminate, and the corresponding portions of the frame define a volume, and wherein the volume includes a micro-inverter or a junction box and associated cables.

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