Solar module frame with track flange

Abstract

A solar module frame is configured to define a plurality of photovoltaic cells. The solar module frame includes a first sidewall at a first side of the frame and a second sidewall at a second side of the frame. Extending from the first sidewall is a first outwardly downward flange including at least one fastening hole, and extending from the first sidewall is a first inwardly upward flange defining a photovoltaic cell socket on the first side. Extending from the second sidewall is a second outwardly downward flange including at least one fastening hole, and extending from the second sidewall is a second inwardly upward flange defining a photovoltaic cell socket on the second side.

Description

Related applications

[0001] This application claims priority to U.S. Provisional Patent Application No. 63 / 622,716, filed January 19, 2024, the contents of which are hereby incorporated by reference. Technical Field

[0002] This disclosure generally relates to embodiments of apparatus, systems, and methods for solar module frames. The solar module frame apparatus, systems, and methods disclosed herein can be configured to facilitate more efficient and effective mounting to support structures, such as torque tubes of solar trackers. Background Technology

[0003] Solar modules use photovoltaic cells to convert sunlight into energy. A solar tracking system can support multiple solar modules and rotate them at various angular orientations throughout the day to optimize the solar irradiance angle and thus optimize energy generation at the solar modules.

[0004] Conventional solar tracking systems consist of multiple components assembled and installed in the field at the location where the system will operate. Typical on-site installation of solar tracking system components relies on manual labor. For example, a typical installation involves manually installing tracks at torque tubes to support one or more solar modules, followed by additional manual labor to install the solar modules onto the installed tracks at the torque tubes. This typically requires highly tedious manual labor to place and secure the tracks to the torque tubes via numerous connection points, and then place and secure the solar modules onto the installed tracks. Furthermore, solar tracking systems are often installed in relatively remote locations, and therefore, installation incurs costs associated with transporting manual labor to these locations for potentially lengthy periods. Consequently, current typical manual labor for solar tracking system component installation can significantly increase the labor and cost considerations for solar tracking system applications. Summary of the Invention

[0005] This disclosure generally describes embodiments of apparatus, systems, and methods for solar module frames. The solar module frame apparatus, systems, and methods disclosed herein can be configured to facilitate more efficient and effective installation of solar module frames at support structures. For example, the solar module frame apparatus, systems, and methods disclosed herein can be configured to facilitate more efficient and effective installation of solar module frames at torque tubes in solar tracking systems. Specifically, embodiments may include a solar module frame configured to, for example, be directly mounted to a torque tube in a solar tracking system by including an outwardly downward flange at the solar module frame (e.g., such that the solar module frame directly contacts the torque tube or contacts the torque tube via a gasket interface assembly). The outwardly downward flange at the solar module frame may be configured to receive one or more suitable fastening members therein that directly couple the solar module frame to the torque tube via the outwardly downward flange.

[0006] Compared to previous solar module frames, the embodiments disclosed herein can, for example, reduce the number of connection points between the solar module frame and the support structure (e.g., a torque tube). As an example, the outward lower flange at the solar module frame embodiment disclosed herein can serve as a type of integrated track for coupling the solar module frame to the torque tube, and thus, the solar module frame embodiment disclosed herein can be directly attached to the torque tube via this outward lower flange, thereby eliminating the need for and installation of one or more separate track assemblies (e.g., separate track assemblies associated with each solar module frame in a previous solar tracking system) typically used in previous solar tracking systems. Furthermore, the embodiments disclosed herein can provide one or more connection interfaces tuned for autonomous (e.g., robotic) installation between the solar module frame embodiment disclosed herein and the support structure (e.g., the torque tube). For example, the embodiments disclosed herein can provide one or more connection interfaces tuned for autonomous (e.g., robotic) installation orientation (e.g., tuned for top-down robotic coupling of the solar module frame embodiment to the support structure) between the solar module frame embodiment disclosed herein and the torque tube.

[0007] One embodiment includes a solar module system. This solar module system embodiment includes a first solar module frame and a second solar module frame. The first solar module frame includes: a first sidewall located on a first side of the first solar module frame; a second sidewall located on a second opposite side of the first solar module frame; a first outward lower flange extending from the first sidewall; a first fastening hole defined at the first outward lower flange; and a first inward upper flange extending from the first sidewall and defining a first photovoltaic cell socket. The second solar module frame includes: a third sidewall located on a first side of the second solar module frame; a fourth sidewall located on a second opposite side of the second solar module frame; a second outward lower flange extending from the third sidewall; a second fastening hole defined at the second outward lower flange; and a second inward upper flange extending from the third sidewall and defining a second photovoltaic socket. The first outward lower flange of the first solar module frame and the second outward lower flange of the second solar module frame are configured to overlap each other, wherein the first fastening hole and the second fastening hole are axially aligned to receive a common fastening member at each of the first fastening hole and the second fastening hole.

[0008] In a further embodiment of this system, the first outwardly lower flange extends from the first sidewall at the bottom portion of the first sidewall, and the first inwardly upper flange extends from the first sidewall at the top portion of the first sidewall, thereby being spaced apart from the first outwardly lower flange along the length of the first sidewall. In some such embodiments, the first solar module frame further includes a third outwardly lower flange extending from the second sidewall and a third fastening hole defined at the third outwardly lower flange. In some such embodiments, the first solar module frame may further include a fourth inwardly upper flange extending from the second sidewall and defining a third photovoltaic cell socket, the third photovoltaic cell socket being axially aligned with the first photovoltaic cell socket at a common height.

[0009] In a further embodiment of this system, the system may additionally include the common fastening member, which may include blind rivets inserted into each of the first and second fastening holes and configured to fasten the first and second solar module frames to the torque tube.

[0010] In a further embodiment of this system, the first outward lower flange of the first solar module frame and the second outward lower flange of the second solar module frame overlap and contact each other, wherein the first fastening hole and the second fastening hole are axially aligned to receive the common fastening member at each of the first fastening hole and the second fastening hole.

[0011] In a further embodiment of this system, the system additionally includes a lip extending from the first sidewall of the first solar module frame in the same direction as the first outwardly downward flange. A flange receptacle space may be defined between the lip, the first outwardly downward flange, and the first sidewall, and this flange receptacle space may receive the second outwardly downward flange of the second solar module frame, wherein the second outwardly downward flange overlaps with the first outwardly downward flange. In some such embodiments, the lip extends from the first sidewall at a height position along the first sidewall, the height position being between the first outwardly downward flange and the first inwardly upward flange. In some such embodiments, the lip extends from the first sidewall by a shorter distance than the distance by which the first outwardly downward flange extends from the first sidewall. For example, the lip may extend from the first sidewall by the distance terminating before intersecting the central longitudinal axis of the first fastening hole. Moreover, for example, the lip abuts the common fastening member when the common fastening member is received at each of the first and second fastening holes.

[0012] In a further embodiment of this system, the system additionally includes at least one washer assembly that contacts at least one of the first outwardly downward flange and the second outwardly downward flange. For example, the at least one washer assembly may be a first washer assembly that contacts the first outwardly downward flange, and the system further includes a second washer assembly that contacts the second outwardly downward flange. The first washer assembly may contact the torque tube of the solar tracker on one side and contact the first outwardly downward flange on a second opposite side.

[0013] As stated herein, some embodiments of the solar module frame and system disclosed herein may include at least one lip (e.g., only one lip). This lip may be included at the solar module frame. For example, the lip may be included at the first sidewall of the solar module frame, for example at a height position along the first sidewall, said height position being between the height positions at the first sidewall of the outward lower flange and the height positions at the first sidewall of the inward upper flange. The lip may extend from the first sidewall by a distance smaller than the distance by which the outward lower flange extends from the first sidewall. The lip may be configured to extend a distance from the first sidewall and terminate at a radial position along that distance before intersecting the central longitudinal axis of the fastening hole defined at the outward lower flange. The lip may be configured to abut with the fastening member inserted into the fastening hole at the outward lower flange.

[0014] Another embodiment includes a solar module frame. This embodiment of the solar module frame includes: a first sidewall at a first side of the first solar module frame; a second sidewall at a second opposite side of the first solar module frame; a first outward lower flange extending from the first sidewall; a first fastening hole defined at the first outward lower flange; a first inward upper flange extending from the first sidewall and defining a first photovoltaic cell socket thereon; a lip extending from the first sidewall in the same direction as the first outward lower flange; a second outward lower flange extending from the second sidewall; a second fastening hole defined at the second outward lower flange; and a second inward upper flange extending from the second sidewall and defining a second photovoltaic cell socket thereon, the second photovoltaic cell socket being aligned in height with the first photovoltaic cell socket.

[0015] In a further embodiment of this solar module frame, the flange socket space (for example, such as...) Figure 3B (Location description) is defined between the lip, the first outwardly lower flange, and the first sidewall. This flange socket space is aligned in height with the second outwardly lower flange at the first sidewall and the second sidewall (e.g., as...). Figure 3B (Example illustrated). The lip may extend from the first sidewall at a height position along the first sidewall, said height position being between the first outwardly lower flange and the first inwardly upper flange. For example, the lip may extend from the first sidewall by a shorter distance than the first outwardly lower flange extends from the first sidewall. In one such example, the lip may extend from the first sidewall by the distance that terminates before intersecting the central longitudinal axis of the first fastening hole.

[0016] Details of one or more examples are set forth in the accompanying drawings and the following description. Other features, objects, and advantages will become apparent from this description, the accompanying drawings, and the claims. Attached Figure Description

[0017] The following figures illustrate specific examples of the invention and therefore do not limit the scope of the invention. The figures are intended to be used in conjunction with the explanations in the following detailed description, wherein similar reference characters denote similar elements. Examples of the invention will be described below in conjunction with the figures.

[0018] Figure 1 A schematic perspective view illustrating a solar tracker device.

[0019] Figures 2A to 2I This describes an embodiment of a solar module frame with an outwardly downward flange. Figure 2A A perspective view showing a solar module frame with an outwardly downward-facing flange, and Figure 2B Show its side view. Figures 2C to 2E The example showcases a bottom gasket assembly and a fastening member for coupling a solar module frame with an outwardly downward-facing flange to a torque tube, wherein... Figure 2C A perspective view showing the pre-installed fastening components. Figure 2D Showing its side view, and Figure 2E A side view showing the fastening components installed to couple two solar module frames to a gasket assembly and a torque tube via their respective outwardly downward flanges. Figures 2F to 2G The demonstration examples include a bottom washer assembly, a top washer assembly, and a fastening member for coupling a solar module frame with an outwardly downward-facing flange to a torque tube. Figure 2F The diagram shows a perspective view of the fastening components used to couple two solar module frames to bottom and top gasket assemblies and torque tubes via their respective outwardly downward flanges. Figure 2G Show its cross-sectional view. Figure 2H to 2I The example showcases a top washer assembly and a fastening member for coupling a solar module frame with an outwardly downward-facing flange to a torque tube, wherein... Figure 2H The perspective view shows the fastening components that couple two solar module frames to the top gasket assembly via their respective outwardly downward flanges and directly to the torque tube. Figure 2I Show its cross-sectional view.

[0020] Figures 3A to 3I This describes another embodiment of a solar module frame with an outwardly downward flange. Figures 3A to 3I The embodiment of the solar module frame shown at the site can be compared with the relevant information. Figures 2A to 2I The embodiments of the solar module frames shown and described are similar or identical, differing only in that... Figures 3A to 3I The solar module frame embodiment shown may include an additional lip, for example, at the outward lower flange. Figure 3A A perspective view showing a solar module frame with an outwardly downward flange and a lip, and Figure 3B Show its side view. Figures 3C to 3E The demonstration example shows a bottom gasket assembly and a fastening member for coupling a solar module frame with an outwardly downward flange and a lip to a torque tube. Figure 3C A perspective view showing the fastening components installed to couple two solar module frames to a gasket assembly and a torque tube via their respective outwardly downward flanges. Figure 3D The side view shows that the lip of at least one solar module frame is adjacent to a fastening member. Figure 3F to 3G The demonstration examples include a bottom washer assembly, a top washer assembly, and a fastening member for coupling a solar module frame with an outwardly downward flange and a lip to a torque tube. Figure 3FThe image shows a perspective view of the fastening components used to couple two solar module frames to the bottom and top gasket assemblies and the torque tube via their respective outwardly downward flanges. Figure 3G The cross-sectional view shows that the lip of at least one solar module frame is adjacent to the fastening member and the top gasket assembly. Figures 3H to 3I The example showcases a top washer assembly and a fastening member for coupling a solar module frame with an outwardly downward-facing flange to a torque tube, wherein... Figure 3H The diagram shows a perspective view of the fastening components installed to couple two solar module frames to the top gasket assembly via their respective outwardly downward flanges and directly to the torque tube. Figure 3I The cross-sectional view shows that the lip of at least one solar module frame is adjacent to the fastening member and the top gasket assembly. Detailed Implementation

[0021] The following detailed description is exemplary in nature and is not intended to limit the scope, applicability, or configuration of the invention in any way. Rather, the following description provides some practical illustrations of examples for carrying out the invention. Those skilled in the art will recognize that many of the stated examples have various suitable alternatives.

[0022] Figure 1 An embodiment of a solar tracker device 10 is described. The solar tracker device 10 may include multiple supports 12 spaced apart from each other and embedded in the ground. The solar tracker device 10 may include one or more torque tubes 14 extending between adjacent supports 12 and rotatably supported at each support 12. The solar tracker device 10 may further include multiple solar module frames 16 supported at the respective torque tubes 14. For example, during the day, as the position of the sun changes relative to the solar modules 16, one or more torque tubes 14 may be rotated in direction 15 to change the angle of the solar modules 16. A bearing housing assembly 17 may be configured to rotatably connect the torque tubes 14 along the span of the solar tracker device 10. The span between two adjacent supports 12 may be referred to as a compartment 18, and for example, each compartment 18 may be rotatably connected to an adjacent compartment 18 via the bearing housing assembly 17. Multiple rows of solar trackers 10 may be arranged in a north-south longitudinal orientation to form a solar array.

[0023] Each solar module frame 16 may include a frame 100, which is coupled to a torque tube 14 and a plurality of photovoltaic cells 19 defined by the frame 100. Figure 1 The examples shown illustrate several pairs of solar module frames 16 mounted laterally to the torque tube 14, but embodiments within the scope of this disclosure (e.g., Figures 2A to 2I Examples and / or Figures 3A to 3IThe embodiments shown herein may include solar module frames 16 mounted side-by-side longitudinally to torque tube 14. As will be described herein, in some examples, solar module frames 100 may be directly coupled to torque tube 14 (e.g., such that solar module frames 100 contact torque tube, for example such that an outwardly lower flange at solar module frames 100 contacts torque tube 14), and in other examples, solar module frames 100 may be indirectly coupled to torque tube 14 by directly coupling solar module frames 100 to a gasket assembly, an adjacent frame, and / or other suitable intermediate assembly and connecting that intermediate assembly to torque tube 14. As will also be described herein, in various embodiments, adjacent solar module frames 100 of adjacent solar modules 16 may be coupled together, for example, using a single fastening member.

[0024] The following disclosure describes various embodiments of solar module frames that can be used, for example, in solar tracker devices. Such embodiments disclosed herein can, for example, facilitate more labor-efficient installation of solar module frames at solar tracker devices. The following description will describe various embodiments of solar module frames for coupling one or more solar module frames to a support structure, which in the example application of the solar tracker device cited herein is a torque tube.

[0025] Figures 2A to 2I This describes an embodiment of a solar module frame 200 having an outwardly downward flange 202.

[0026] Figure 2A A perspective view of a solar module frame 200 with an outwardly facing lower flange 202 is shown. Figure 2B A side view is shown. The solar module frame 200 defines a plurality of photovoltaic cells 19 and thus forms a solar module 16 that can be mounted to the torque tube 14. The solar module frame 200 may include a first side 204 and a second opposing side 206. The illustrated embodiment of the solar module frame 200 includes an outwardly downward flange 202—outwardly downward flange 202a—at the first side 204 and an outwardly downward flange 202—outwardly downward flange 202b—at the second side 206. Figure 2BAs best viewed, an outwardly downward flange 202 may extend from a sidewall 210 of the solar module frame 200. For example, a first side 204 of the solar module frame 200 may include a first sidewall 210a, and a second side 206 of the solar module frame 200 may include a second sidewall 210b. An outwardly downward flange 202a may extend from the first sidewall 210a (e.g., extending vertically from the first sidewall 210a), and an outwardly downward flange 202b may extend from the second sidewall 210b (e.g., extending vertically from the first sidewall 210a). The illustrated embodiment shows the first sidewall 210a having an outwardly downward flange 202a extending from the first sidewall 210a at or near the bottom surface of the first sidewall 210a, and the first sidewall 210a further includes an inwardly upward flange 211a. An inwardly extending upper flange 211a may extend from the first sidewall 210a in a direction opposite to that of the outwardly extending lower flange 202a and at or near the top surface of the first sidewall 210a. Similarly, the illustrated embodiment shows a second sidewall 210b having an outwardly extending lower flange 202b extending from or near the bottom surface of the second sidewall 210b, and the second sidewall 210b further including an inwardly extending upper flange 211b. The inwardly extending upper flange 211b may extend from the second sidewall 210b in a direction opposite to that of the outwardly extending lower flange 202b and at or near the top surface of the second sidewall 210b. The inwardly extending upper flange 211a may define a first-side photovoltaic cell (e.g., photovoltaic cell stack) socket 212a, and the inwardly extending upper flange 211b may define a second-side photovoltaic cell (e.g., photovoltaic cell stack) socket 212b.

[0027] To facilitate coupling of the solar module frame 200 (e.g., directly or indirectly) to (e.g., coupling the solar module to) a torque tube, the outward lower flange 202 may include one or more flange fastening holes 208 (e.g., one fastening hole 208a at the outward lower flange 202a on the first side 204, and one fastening hole 208b at the outward lower flange 202b on the second side 206). For example, the one or more fastening holes 208 may be centered along the width of the outward lower flange 202, and the one or more fastening holes 208 may extend through the thickness of the outward lower flange 202.

[0028] The solar module frame 200 can be configured to couple to the torque tube 14. Figures 2C to 2E The illustration shows a bottom washer assembly 220 and a fastening member 230 (e.g., a blind fastening member, such as a blind rivet) for coupling a solar module frame 200 with an outwardly downward flange 202 to a torque tube 14, wherein... Figure 2C A perspective view showing the fastening member 230 pre-installed on the solar module frame 200. Figure 2D Showing its side view, and Figure 2EThe illustration shows a side view of a fastening member 230 installed to couple two solar module frames 200a, 200b to a gasket assembly 220 and a torque tube 14 via their respective mating outward lower flanges 202a, 202b. As shown in the illustrated example, the gasket assembly 220 and the fastening member 230 couple both the first solar module frame 200a and the second solar module frame 200b to the torque tube 14. The bottom gasket assembly 220 may include a bottom surface configured to sit on the torque tube 14, and this bottom surface of the bottom gasket assembly 220 may define a cross-sectional profile (e.g., semicircular) that matches the cross-sectional profile (e.g., semicircular) of the torque tube 14 on which the bottom gasket assembly 220 will be situated. For example, the outward lower flange 202a of the first solar module frame 200a and the outward lower flange 202b of the second solar module frame 200b may abut at the gasket assembly 220, for example, wherein the outward lower flange 202a of the first solar module frame 200a and the outward lower flange 202b of the second solar module frame 200b overlap each other (e.g., contact each other), as shown for the illustrated embodiment. The outward lower flange 202a of the first solar module frame 200a and the outward lower flange 202b of the second solar module frame 200b may overlap each other, wherein the fastening holes 208 at each of the outward lower flanges 202a and 202b are axially aligned to facilitate reception of the fastening member 230. Therefore, a single fastening member 230 can be configured to couple the pair of solar module frames 200a, 200b to the torque tube 14 using the mating outward lower flanges 202a, 202b at the pair of solar module frames 200a, 200b.

[0029] Figures 2F to 2G The example shows the bottom gasket assembly 220 and the top gasket assembly 225, as well as the fastening member 230 for coupling the solar module frames 200a and 200b with corresponding mating outward lower flanges 202a and 202b to the torque tube 14. Figure 2F The illustration shows a perspective view of the fastening members 230 of the mounting structure for coupling two solar module frames 200a and 200b to the bottom gasket assembly 220 and the top gasket assembly 225 and the torque tube 14 via their respective outwardly downward flanges 202a and 202b. Figure 2GA cross-sectional view is shown. The bottom washer assembly 220 may be similar to or the same as the previously described bottom washer assembly. The top washer assembly 220 and the bottom washer assembly 225 may each include a fastening hole configured to receive the fastening member 230 therein. The top washer assembly 225 may be positioned relative to the bottom washer assembly 220 on opposite sides of the mating outward lower flanges 202a, 202b. The outward lower flanges 202a of the first solar module frame 200a and 202b of the second solar module frame 200b may mat at the bottom washer assembly 220 and the top washer assembly 225, for example, wherein the outward lower flanges 202a of the first solar module frame 200a and 202b of the second solar module frame 200b overlap (e.g., contact each other), as shown for the illustrated embodiment. The top washer assembly 225 may be located at the top side (e.g., contacting the top side) of the overlapping outward lower flanges 202a, 202b, and the bottom washer assembly 220 may be located at the bottom side (e.g., contacting the bottom side) of the overlapping outward lower flanges 202a, 202b. The outward lower flanges 202a of the first solar module frame 200a and 202b of the second solar module frame 200b overlap each other, wherein the fastening holes 208 at each of the outward lower flanges 202a and 202b are axially aligned to facilitate reception of the fastening member 230 through the overlapping outward lower flanges 202a, 202b and through the top washer assembly 220 and the bottom washer assembly 225. Therefore, a single fastening member 230 can be configured to couple the pair of solar module frames 200a, 200b to the torque tube 14 using the mating outward lower flanges 202a, 202b at the pair of solar module frames 200a, 200b, as well as the top washer assembly 220 and the bottom washer assembly 225.

[0030] Figures 2H to 2I The example showcases a top washer assembly 225 and a fastening member 230 for coupling solar module frames 200a, 200b, each having outwardly downward flanges 202a, 202b, to a torque tube 14. Figure 2H The image shows a perspective view of a fastening member 230 installed to couple two solar module frames 200a and 200b to a top washer assembly 225 via their respective outwardly downward flanges 202a and 202b, and directly to a torque tube 14. Figure 2IA cross-sectional view is shown. The top washer assembly 225 may be similar to or the same as the previously described top washer assembly. The top washer assembly 225 may be positioned relative to the torque tube 14 on opposite sides of the mating outward lower flanges 202a, 202b. The outward lower flanges 202a of the first solar module frame 200a and 202b of the second solar module frame 200b may mat at the top washer assembly 225, for example, wherein the outward lower flanges 202a of the first solar module frame 200a and 202b of the second solar module frame 200b overlap each other (e.g., contact each other), as shown for the illustrated embodiment. The top washer assembly 225 may be at the top side of the overlapping outward lower flanges 202a, 202b (e.g., contacting the top side), and the torque tube 14 may be at the bottom side of the overlapping outward lower flanges 202a, 202b (e.g., contacting the bottom side). The outward lower flange 202a of the first solar module frame 200a and the outward lower flange 202b of the second solar module frame 200b overlap each other, wherein the fastening holes 208 at each of the outward lower flanges 202a and 202b are axially aligned to facilitate reception of the fastening member 230 through the overlapping outward lower flanges 202a, 202b and through the top washer assembly 225. Therefore, a single fastening member 230 can be configured to couple the pair of solar module frames 200a, 200b to the torque tube 14 using the mating outward lower flanges 202a, 202b and the top washer assembly 225, thereby directly coupling the pair of solar module frames 200a, 200b to the torque tube 14.

[0031] Figures 3A to 3I Another embodiment of a solar module frame 300 with an outwardly downward flange 202 is described, and this embodiment of the solar module frame 300 further includes at least one lip 350. Therefore, Figures 3A to 3I The embodiment of the solar module frame 300 shown here is related to... Figures 2A to 2I The embodiments of the solar module frame 200 shown and described are similar or identical, except that... Figures 3A to 3I The solar module frame 300 shown may include an additional lip 350, for example, at the outward lower flange 202.

[0032] Figure 3A A perspective view of a solar module frame 300 with an outwardly downward flange 202 and a lip 350 is shown. Figure 3B Showing its side view. The solar module frame 300 may be similar to or the same as the solar module frame 200, except that the solar module frame 300 includes at least one lip 350. Therefore, in Figures 3A to 3I Used at Figures 2A to 2IThe same reference characters are used to denote the same features. The lip 350 may be located, for example, at the outward lower flange 202. The illustrated embodiment includes at least one lip 350 on only one side of the solar module frame 300 (e.g., side 206 as shown here) (and therefore, there is no lip on the other side 204 of the frame 300, and only the outward lower flange 202a and the inward upper flange 211a are present).

[0033] For example, a lip 350 may be included at a sidewall 210 (e.g., a second sidewall 210b) of the solar module frame 300. In various instances, the lip 350 may extend from the sidewall 210 (e.g., the second sidewall 210b) of the solar module frame 300, for example, at a height position along the sidewall 210 between the height position at the sidewall 210 of the outward lower flange 202 (e.g., the second outward lower flange 202b) and the height position at the sidewall 210 of the inward upper flange 211 (e.g., the second inward upper flange 211b). The lip 350 may extend from the sidewall 210 by a smaller distance LD than the distance by which the outward lower flange 202 extends from the sidewall 210. As one such example, the lip 350 may extend from the sidewall 210 by a distance LD and terminate at a radial position along that distance LD before intersecting with the central longitudinal axis 209 of the fastening hole 208 (e.g., fastening hole 208b), which is defined at the outwardly lower flange 202 (e.g., outwardly lower flange 202b). The lip 350 may be configured to mate with a fastening member 230 inserted into the fastening hole 208 at the outwardly lower flange 202. When a top washer assembly is included (e.g., for example, ...), Figures 3F to 3I (as shown in the location), the lip 350 can be configured to mate with the fastening member 230 and the top washer assembly inserted into the fastening hole 208 at the outward lower flange 202.

[0034] Figures 3C to 3E The example demonstrates a bottom gasket assembly 220 and a fastening member 230 for coupling a solar module frame 300 having an outwardly downward flange 202 and a lip 350 to a torque tube 14, wherein... Figure 3C A perspective view showing a fastening member 230 of a gasket assembly 220 and a torque tube 14, coupled to two solar module frames 300a and 300b via their respective outwardly downward flanges 202a and 202b and at least one lip 350. Figure 3DShow its side view. As stated, each solar module frame 300 may include a lip 350 on one side (e.g., a lip 350 on side 206) but not on the opposite side (e.g., not on side 204). Thus, when two such solar module frames 300a, 300b are placed at torque tube 14 (e.g., at washer 220 at torque tube 14), one mating side (e.g., sidewall 210b) of one such solar module frame 300b may include a lip 350, while the other mating side (e.g., sidewall 210a) of the other such solar module frame 300a may lack any lip 350, resulting in a pair of mating outward lower flanges 202a, 202b of the respective solar module frames 300a, 300b and a lip 350 placed at torque tube 14 (e.g., at washer 220 at torque tube 14). As illustrated herein, the lip 350 of a solar module frame 300b may be located near the fastening member 230. Also illustrated herein, as a complement or alternative to the positioning of the lip 350 adjacent to the fastening member 230, the lip 350 contained in the solar module frame 300b (e.g., at the side wall 210b of the solar module frame 300b) may abut with the outwardly downward flange 202a of another solar module frame 300a.

[0035] Figure 3F to 3G The examples show a bottom washer assembly 220 and a top washer assembly 225, as well as a fastening member 230 for coupling solar module frames 300a, 300b having outwardly downward flanges 202a, 202b and at least one lip 350 to a torque tube 14. Figure 3F The illustration shows a perspective view of the fastening members 230 of the bottom gasket assembly 220 and the top gasket assembly 225, and the torque tube 14, installed to couple two solar module frames 300a and 300b via their respective outwardly lower flanges 200a and 200b and mating lip 350. Figure 3GA cross-sectional view is shown. As seen here, at least one lip 350 of a solar module frame 300b may be located near the fastening member 230 and the top washer assembly 225. Specifically, in this embodiment, the lip 350 may overlap with the outward lower flange 200a of another adjacent solar module frame 300a and be adjacent to the fastening member 230. This may include the lip 350 overlapping with the outward lower flange 200a of another adjacent solar module frame 300a, and this outward lower flange 200a of the other adjacent solar module frame 300a may overlap with the outward lower flange 200b of the solar module frame 300b that includes the lip 350. Therefore, when the pair of solar module frames 300a and 300b are coupled to the torque tube 14 using top and / or bottom washer assemblies 220 and 225, the stacked arrangement adjacent to the fastening member 230 may, from top to bottom, include the lip 350 of the solar module frame 300b, the outwardly lower flange 200a of the solar module frame 300a, and the outwardly lower flange 200b of the solar module frame 300b including the lip 350. When the top washer assembly 225 is included, the top washer assembly 225 may be at least at the same height as the lip 350 relative to this stacked arrangement.

[0036] Figures 3H to 3I The example shows the top gasket assembly 225 and the fastening member 230 for coupling the solar module frames 300a, 300b with outwardly downward flanges 202a, 202b and lip 350 to the torque tube 14. Figure 3H The illustration shows a perspective view of a fastening member 230 installed to couple two solar module frames 300a and 300b to a top gasket assembly 225 and directly to a torque tube 14 via their respective outwardly downward flanges 202a and 202b and lip 350. Figure 3IThe cross-sectional view shows that at least one lip 350 of a solar module frame 300b is adjacent to the fastening member 230 and the top washer assembly 225. The top washer assembly 225 may be positioned relative to the torque tube 14 on opposite sides of the mating outward lower flanges 202a, 202b, and the top washer assembly 225 may be adjacent to the lip 350. The outward lower flanges 202a of the first solar module frame 300a, 202b of the second solar module frame 300b, and the lip 350 of the second solar module frame 300b may mat at or near the top washer assembly 225, for example, wherein the lip 350 of the second solar module frame 300b, the outward lower flanges 202a and 202b of the first solar module frame 300a, and the outward lower flanges 202b of the second solar module frame 300b overlap (e.g., contact each other), as shown for the illustrated embodiment. The top washer assembly 225 may be adjacent to the lip 350 at the top side (e.g., contacting the top side) of the overlapping outward lower flanges 202a, 202b, and the torque tube 14 may be adjacent to the bottom side (e.g., contacting the bottom side) of the overlapping lip 350 and the outward lower flanges 202a, 202b. The lip 350, the outward lower flanges 202a, and the outward lower flanges 202b may overlap each other, wherein the fastening holes 208 at each of the outward lower flanges 202a and 202b are axially aligned to facilitate reception of the fastening member 230 through the overlapping outward lower flanges 202a, 202b and through the top washer assembly 225, and wherein the lip 350 terminates before intersecting the axial position of the fastening holes 208. Therefore, a single fastening member 230 can be configured to couple the pair of solar module frames 300a, 300b to the torque tube 14 using the mating lips 350 and outward lower flanges 202a, 202b at the pair of solar module frames 300a, 300b and the top washer assembly 225, so as to directly couple the pair of solar module frames 300a, 300b to the torque tube 14.

[0037] Various examples have been described. These and other examples are within the scope of the appended claims.

Claims

1. A solar module system, comprising: The first solar module frame includes: The first sidewall is located on the first side of the first solar module frame. The second sidewall is located on the second opposite side of the first solar module frame. The first outwardly downward-facing flange extends from the first sidewall. The first fastening hole is defined at the first outwardly downward flange, and A first inwardly upward-facing flange extends from the first sidewall and defines the first photovoltaic cell socket; and The second solar module frame includes: The third sidewall is located on the first side of the second solar module frame. The fourth sidewall is located on the second opposite side of the second solar module frame. The second outwardly downward-facing flange extends from the third sidewall. The second fastening hole is defined at the second outwardly downward flange, and The second inwardly upward flange extends from the third sidewall and defines the second photovoltaic socket. The first outward lower flange of the first solar module frame and the second outward lower flange of the second solar module frame are configured to overlap each other, wherein the first fastening hole and the second fastening hole are axially aligned to receive a common fastening member at each of the first fastening hole and the second fastening hole.

2. The system of claim 1, wherein the first outwardly downward flange extends from the first sidewall at the bottom portion of the first sidewall, and wherein the first inwardly upward flange extends from the first sidewall at the top portion of the first sidewall, thereby being spaced apart from the first outwardly downward flange along the length of the first sidewall.

3. The system of claim 2, wherein the first solar module frame further includes a third outwardly downward flange extending from the second sidewall and a third fastening hole is defined at the third outwardly downward flange.

4. The system of claim 3, wherein the first solar module frame further includes a fourth inwardly upward flange extending from the second sidewall and defining a third photovoltaic cell socket, the third photovoltaic cell socket being axially aligned with the first photovoltaic cell socket at a common height.

5. The system of claim 1, further comprising the common fastening member, wherein the common fastening member comprises a blind rivet inserted at each of the first fastening hole and the second fastening hole and configured to fasten the first solar module frame and the second solar module frame to the torque tube.

6. The system of claim 1, wherein the first outward lower flange of the first solar module frame and the second outward lower flange of the second solar module frame overlap and contact each other, wherein the first fastening hole and the second fastening hole are axially aligned to receive the common fastening member at each of the first fastening hole and the second fastening hole.

7. The system according to claim 1, further comprising: A lip that extends from the first sidewall of the first solar module frame in the same direction as the first outwardly downward flange.

8. The system of claim 7, wherein the flange socket space is defined between the lip, the first outward lower flange and the first sidewall, and wherein the flange socket space receives the second outward lower flange of the second solar module frame, wherein the second outward lower flange overlaps with the first outward lower flange.

9. The system of claim 8, wherein the lip extends from the first sidewall at a height position along the first sidewall, the height position being between the first outwardly lower flange and the first inwardly upper flange.

10. The system of claim 7, wherein the lip extends from the first sidewall by a smaller distance than the first outwardly downward flange extends from the first sidewall.

11. The system of claim 10, wherein the lip extends from the first sidewall a distance that terminates before intersecting the central longitudinal axis of the first fastening hole.

12. The system of claim 11, wherein when the common fastening member is received in each of the first fastening hole and the second fastening hole, the lip abuts against the common fastening member.

13. The system of claim 1, further comprising at least one washer assembly that contacts at least one of the first outwardly downward flange and the second outwardly downward flange.

14. The system of claim 13, wherein the at least one washer assembly is a first washer assembly that contacts the first outwardly lower flange, and wherein the system further includes a second washer assembly that contacts the second outwardly lower flange.

15. The system of claim 14, wherein the first washer assembly contacts the torque tube on one side and contacts the first outwardly downward flange on a second opposite side.

16. A solar module frame, comprising: The first sidewall is located on the first side of the first solar module frame; The second sidewall is located on the second opposite side of the first solar module frame; The first outwardly downward protruding flange extends from the first sidewall; The first fastening hole is defined at the first outward lower flange; A first inwardly upward flange extends from the first sidewall and defines a first photovoltaic cell socket there; A lip that extends from the first sidewall in the same direction as the first outwardly downward flange; The second outwardly downward flange extends from the second sidewall; The second fastening hole is defined at the second outwardly downward flange; and A second inwardly upward flange extends from the second sidewall and defines a second photovoltaic cell socket, which is aligned in height with the first photovoltaic cell socket.

17. The frame of claim 16, wherein the flange socket space is defined between the lip, the first outward lower flange and the first sidewall, and wherein the flange socket space is aligned in height with the second outward lower flange at the first sidewall and the second sidewall.

18. The frame of claim 17, wherein the lip extends from the first sidewall at a height position along the first sidewall, the height position being between the first outward lower flange and the first inward upper flange.

19. The frame of claim 16, wherein the lip extends from the first sidewall by a smaller distance than the first outwardly downward flange extends from the first sidewall.

20. The frame of claim 19, wherein the lip extends from the first sidewall a distance that terminates before intersecting the central longitudinal axis of the first fastening hole.

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