A frame member for a laminate structure

Abstract

A frame member for supporting a laminate structure comprising one or more solar cells. The frame member comprises forward and rearward walls that are spaced apart to define a recess there between for receipt of an edge of the laminate structure. The recess comprises an opening for insertion of the edge of the laminate structure into the recess towards an end wall opposite to the opening. A first spacing protrusion, that is integrally formed with the end wall, protrudes from the end wall into the recess to space the edge of the laminate structure from the end wall so as to form an end cavity between the edge of the laminate structure and the end wall when the edge of the laminate structure is inserted into the recess.

Description

[0001] A FRAME MEMBER FOR A LAMINATE STRUCTURE

[0002] FIELD OF THE DISCLOSURE

[0003] The present disclosure relates to a frame member for a laminate structure comprising one or more solar cells, and a solar module including such a frame member.

[0004] BACKGROUND

[0005] A typical solar module for providing electrical energy from sunlight comprises a laminate structure including an array of solar cells, each comprising a photovoltaic element, or substrate. In most arrangements the solar cells are sandwiched between a front glass layer (that faces the sun in use) and a rear layer to form the laminate structure. The rear layer may be a glass layer or may be an opaque or translucent backing layer.

[0006] The laminate structure is typically provided in a frame that extends about a periphery of the laminate structure to form the solar module. This protects the edges of the laminate structure and assists in mounting the solar module to a structure (such as rails installed on the roof of a building). To secure frame members of the frame to the edges of the laminate structure, a sealant is typically provided between the frame members and the edges of laminate structure.

[0007] The sealant is typically introduced into a recess of each frame member prior to insertion of an edge of a laminate structure into the recess. This process can, however, lead to inconsistency in the positioning of the laminate structure within a frame. This is because the sealant (at least prior to curing) allows movement of the laminate structure relative to the frame, and such movement can result in a laminate structure that is not correctly centred within a frame.

[0008] SUMMARY

[0009] In general, the present disclosure provides a frame member for supporting a laminate structure comprising one or more solar cells. The frame member comprises forward and rearward walls that are spaced apart to define a recess therebetween for receipt of an edge of the laminate structure. The recess comprises an opening for insertion of the edge of the laminate structure into the recess towards an end wall opposite to the opening.

[0010] The terms “front” and “forward” are used herein to refer to a direction that is typically towards a light source (e.g. the sun) in use and orthogonal to a front surface of the laminate structure. The terms “rear” and “rearwardly” are intended to refer to a direction that is opposite to the front / forward direction. The term “laterally inwardly” refers to a direction that is both substantially orthogonal to the edge of the laminate structure and in a direction towards the opposite edge of the laminate structure. Optional features will now be set out. These are applicable singly or in any combination with any aspect of the disclosure.

[0011] A first spacing protrusion may protrude from the end wall into the recess to space the edge of the laminate structure from the end wall so as to form an end cavity between the edge of the laminate structure and the end wall when the edge of the laminate structure is inserted into the recess.

[0012] The edge of the laminate structure (when inserted in the recess) may contact (e.g. bear against) the first spacing protrusion to provide a rigid engagement between the frame member and the laminate structure. This may prevent relative movement (i.e. in a direction into / out of the recess) between the laminate structure and the frame member. By restricting movement of the laminate structure relative to the frame member, the laminate structure is less likely to be incorrectly positioned in assembly (i.e. there is less possibility for movement of the laminate structure away from the desired alignment).

[0013] Where the laminate structure is surrounded by a frame of several (e.g. four) frame members), correctly positioning the laminate structure can ensure that it a sufficient portion of the laminate structure is received in every frame member (to ensure suitable connection between the laminate structure and each frame member). As may be appreciated, an off-centre laminate structure may be inserted too far into one frame member to the detriment of the connection between the laminate structure and a frame member on an opposite side.

[0014] Moreover, the provision of an end cavity (by spacing the laminate structure edge away from the end wall) may provide a space into which sealant (such as silicone) is able to flow (and remain) when the edge of the laminate structure is inserted into the recess. This may ensure that a volume of sealant remains between the edge of the laminate structure and the end wall so as to provide adhesion between the end wall and the edge of the laminate structure.

[0015] The first spacing protrusion may be integrally formed with the end wall. Such an arrangement may simplify assembly. For example, an integrally formed protrusion may avoid the need for the provision of a separate component inserted into the recess in order to space the laminate structure from the end wall. The provision of a separate component would increase assembly complexity, assembly time, and the likelihood of errors occurring during assembly (for example, inadvertent omission of such a component).

[0016] For the avoidance of doubt, the term “integrally formed” as used herein is intended to mean that two portions (in the above case, the end wall and the protrusion) form a unitary piece. The protrusion may, for example, be formed of the same material as the end wall. The frame member may comprise a second spacing protrusion. The second spacing protrusion may protrude rearwardly from the forward wall into the recess to space a front surface of the laminate structure, when received in the recess, from the forward wall so as to form a forward cavity between the laminate structure (i.e. the front surface of the laminate structure) and the forward wall.

[0017] For the avoidance of doubt, in some examples the second spacing protrusion may be present in the absence of the first spacing protrusion. That is, some examples may include a second spacing protrusion, but not a first spacing protrusion.

[0018] The provision of a rearwardly extending second spacing protrusion may aid in alignment of the laminate structure in a forward / backward direction when received in the recess (i.e. by providing rigid contact between the frame member and the front surface of the laminate structure). Likewise, the formation of a forward cavity may provide a space for sealant to flow into and remain, so as to provide adhesion between the forward wall and the front surface of the laminate structure. That is, the forward cavity may be configured (sized and shaped) so as to be suitable for location of sealant to secure the forward wall to the laminate structure.

[0019] The second spacing protrusion may be located at the opening to the recess. The second spacing protrusion may be configured to restrict (or prevent) sealant from flowing out of the recess between the front surface of the laminate structure and the forward wall of the frame member. Such leakage could be detrimental to the efficiency and / or appearance of a solar module formed when the frame member is used with a laminate structure. Such prevention of leakage can also be beneficial in that it may allow the frame member and laminate structure to be handled while the sealant has not yet properly cured without risk of leakage.

[0020] The second spacing protrusion may comprise an enlarged distal end. The enlarged distal end may be provided by a lip that projects towards the end wall at a distal end of the second spacing protrusion (i.e. that is distal from the forward wall). The distal end of the second spacing protrusion may be planar. Provision of an enlarged distal end (and providing a planar end surface) may increase the contact area between the second spacing protrusion and the laminate structure when received in the recess. This may improve sealing between the second spacing protrusion and the laminate structure, so as to reduce or prevent leakage of sealant between the second spacing protrusion and the front surface of the laminate structure.

[0021] The second spacing protrusion may comprise a leading portion, which may define a front boundary of the opening to the recess. The leading portion may be sloped. The leading portion may be curved (e.g. may be radiused) and may be convex. This may aid with insertion of a laminate structure into the recess. The frame member may comprise a baffle protruding into the forward cavity from the forward wall for controlling the flow of sealant, in use, along the forward cavity towards the opening. The baffle may extend only partway across the forward cavity towards the laminate structure (i.e. towards the front surface of the laminate structure).

[0022] The baffle may protrude from the forward wall at a location that is intermediate the end wall and the opening. The baffle may be closer to the opening than the end wall.

[0023] The baffle may be configured to restrict (but not completely prevent) the flow of sealant in a direction towards the opening by narrowing a portion of the forward cavity. In effect, the baffle may divide the forward cavity into first and second sub-cavities that are connected by a channel that is narrower than the first and second sub-cavities (the channel formed between a tip of the baffle and the front surface of the laminate structure when the laminate structure is received in the recess).

[0024] During installation (as the edge of the laminate structure is inserted into the recess), sealant can flow from the first sub-cavity to the second sub-cavity via the channel. As the channel is narrow relative to the first and second sub-cavities, flow of the sealant to the second sub-cavity can be restricted. This may aid in reducing leakage of sealant from the recess (between the second spacing protrusion and the front surface of the laminate structure).

[0025] The channel may have a width of between 0.5 mm and 2.0 mm, e.g. about 1 mm. The width of the channel may be taken as the distance (in the forward / backward direction) between the distal end of the second spacing protrusion and the tip of the baffle. This may be reflective of the distance between the tip of the baffle and the front surface of the laminate structure when the laminate structure is received in the recess.

[0026] A first surface of the baffle, facing towards the opening, may be curved (e.g. may be convex). A second surface of the baffle, facing towards the end wall, may be substantially planar. The curved first surface of the baffle may aid in guiding sealant (which can be viscoelastic) into the second sub-cavity (i.e. once it has flowed beyond the second surface). The substantially planar second surface may provide some resistance to flow, to help ensure that the first sub-cavity is substantially filled before sealant flows to the second sub-cavity.

[0027] A third spacing protrusion may protrude from the rearward wall into the recess to space a rear surface of the laminate structure, when received in the recess, from the rearward wall so as to form a rearward cavity between the laminate structure and the rearward wall.

[0028] For the avoidance of doubt, in some examples the third spacing protrusion may be present in the absence of the first and / or second spacing protrusions. That is, in some examples, only the third spacing protrusion may be provided, or the third spacing protrusion may be provided with only one of the first and second protrusions.

[0029] The provision of a forwardly extending third spacing protrusion may aid in alignment of the laminate structure in a forward / backward direction when received in the recess (i.e. by providing rigid contact between the frame member and the rear surface of the laminate structure). Likewise, the formation of a rearward cavity may provide a space for sealant to flow into and remain, so as to provide adhesion between the rearward wall and the rear surface of the laminate structure. That is, the rearward cavity may be configured (sized and shaped) so as to be suitable for location of sealant to secure the rearward wall to the laminate structure.

[0030] As discussed above, provision of any one (or all of) the first, second and third spacing protrusions may assist in alignment of the laminate structure relative to the frame member. Accurate alignment of the laminate structure may ensure that other parts of the solar module are sufficiently connected. This can be useful, for example, to ensure that there is electrical contact between different parts of a frame of the solar module to allow for grounding.

[0031] As an example, provision of one of (or both of) the second and third spacing protrusions may assist in forward / backward alignment of the laminate structure. In some solar modules, support bars are positioned between the rear surface of the laminate structure and a foot of the frame member that is spaced rearwardly from the rear wall (this foot is discussed further below). If there is misalignment of the laminate structure in the forward / backward direction, such that the space between the foot and the laminate structure is larger than the height of the support bar, then there may be inadequate electrical contact between the support bar and the frame member. In some cases, for example, grounding clips may be provided between the support bar and the foot to penetrate through any oxide layer on the foot, and insufficient contact can mean that the grounding clips are unable to provide such penetration. Inadequate electrical contact can be problematic for grounding of the various parts of the solar module. Accordingly, the first, second and / or third protrusions may aid in ensuring acceptable grounding of a frame of the solar module (by way of improved alignment of the laminate structure).

[0032] The third spacing protrusion may be located at the opening to the recess. The third spacing protrusion may restrict (or prevent) sealant from flowing out of the recess between the rear surface of the laminate structure and the rearward wall of the frame member.

[0033] The third spacing protrusion may comprise a leading portion, which may define a rear boundary of the opening to the recess. The leading portion of the third spacing protrusion may be sloped. In this respect, the leading portion of the third spacing protrusion may be configured to function as a ramp surface to guide the laminate structure into the recess. This may help to prevent damage to the laminate structure as it is inserted into the recess. By providing the sloped surface on the third spacing protrusion, as opposed to the second spacing protrusion, may allow the second spacing protrusion to have a greater contact area with the front surface of the laminate structure. As explained above, such contact can reduce leakage between the front surface of the laminate structure and the second spacing protrusion, which could be detrimental to performance of the laminate structure and its appearance.

[0034] While, the sloped surface of the third spacing protrusion may mean reduced contact area between the third spacing protrusion and the rear surface of the laminate structure, it is noted that leakage of sealant at this location can present less of an issue. This is because, typically, most sunlight (and often all sunlight) will enter the laminate structure through the front surface of the laminate structure rather than the back surface, so leakage of sealant onto the back surface can be less detrimental to efficiency than if it were to be on the front surface. Moreover, the back surface of the laminate structure is often not visible once the solar module is installed, so leakage onto the back surface can be of less concern with respect to the appearance of the solar module.

[0035] The rearward cavity may have a depth that is greater than 0.4 mm. The depth of the rearward cavity may be defined, for example, by the distance (in the forward / backward direction) between the forwardmost point of the third spacing protrusion and the rearward wall (i.e. a rearmost point of a recessfacing surface of the rearward wall). This may be representative of the distance, in use, between the rear surface of the laminate structure and the rearward wall (i.e. when the laminate structure is received in the recess).

[0036] The first spacing protrusion may be spaced between the forward and rearward walls to divide the end cavity into first and second cavity portions. By forming first and second cavity portions, sealant received in the end cavity may be better distributed across the edge of the laminate structure when received in the recess. For example, such an arrangement may ensure that both forward and rearward regions of the edge of the laminate structure are in contact with sealant so as to provide more uniform adhesion between the frame member and the laminate structure.

[0037] The first spacing protrusion may be tapered in a direction of extension of the first spacing protrusion from the end wall. That is, the first spacing protrusion may be narrower at a distal end (i.e. tip) that is distal from the end wall, than at a proximal end that is proximal to the end wall.

[0038] A tip of the first spacing protrusion may be truncated. In other words, the first spacing protrusion may have a trapezoidal cross-sectional shape.

[0039] A height of the first spacing protrusion from the end wall may be at least 0.5 mm, or at least e.g. 0.8 mm, or at least e.g. 1.0 mm. In general, the height of the first spacing protrusion may be determined based on the tolerances of the frame member and the laminate structure, with the aim being to ensure that the laminate structure is prevented from coming into contact with the end wall. As may be appreciated, a suitable first spacing protrusion height may thus be dependent on the various materials used, the design of the frame member and the design of the laminate structure.

[0040] A width of the first spacing protrusion, taken in a direction between the forward and rearward walls, is less than 4 mm, or e.g. less than 3 mm, or e.g. less than 2 mm, or e.g. less than 1 mm. The width of the first spacing protrusion may, for example, be determined based on the material of the frame member. Softer material may, for example, require the first spacing protrusion to be wider.

[0041] The frame member may comprise a reinforcement portion provided by a region of increased thickness at a connection between the forward wall and the end wall. This may increase the strength of the connection between the forward wall and the end wall (i.e. may increase the resistance of the frame to movement of the forward wall relative to the end wall).

[0042] The frame member may comprise more than one first spacing protrusion. That is, a plurality of first spacing protrusions (e.g. two) may protrude from the end wall into the recess, each for spacing an edge of the laminate structure from the end wall. Each first spacing protrusion may be as described above (e.g. may be tapered and / or truncated).

[0043] The forward wall may be a forwardmost wall of the frame member. The forward wall may be a flange. The forward wall may extend from the end wall. The forward wall may extend from the end wall to a free-end at the opening to the recess.

[0044] The rearward wall may be a flange. The rearward wall may extend from the end wall. The end wall (which may be considered a web) may connect the forward wall and the rearward wall. The forward, rearward, and end walls may be integrally formed. Together, the forward, rearward, and end walls may (together) form a U-shaped profile. For the avoidance of doubt, the term profile (as used herein with reference to the frame member) refers to a cross-sectional shape of the frame member taken in a plane that is perpendicular to the length of the frame member (i.e. the length being in a direction along the edge of the laminate structure).

[0045] In some examples, the frame member may comprise a mounting portion (for mounting to rails of a structure). The mounting portion may be rearward of the rearward wall. The mounting portion may comprise a foot for mounting to a rail, and may comprise an intermediate structure connecting the foot to the rearward wall. The foot may extend (e.g. inwardly towards a centreline of the laminate structure) beyond the rearward wall.

[0046] The frame member may be elongate (i.e. in a direction along the edge of the laminate structure when received in the recess). The frame member may be formed as a unitary piece. The frame member may be formable by extrusion. The cross-sectional shape of the frame member may be substantially uniform for substantially the entire length of the frame member. The frame member may be formed of a metal, such as aluminium.

[0047] The present disclosure may provide a solar module comprising: a laminate structure comprising one or more (e.g. an array of) solar cells. The solar module may comprise the frame member as described above. A first edge of the laminate structure may be received in the recess of the frame member so as to contact (e.g. bear against) the first spacing member.

[0048] The solar module may comprise two frame members, each as described above. Each of a pair of opposite edges of the laminate structure may be received in the recess of a respective frame member so as to contact the first spacing protrusion of the respective frame member. In this way, the laminate structure may be better positioned along an axis extending between the frame members.

[0049] The solar module may comprise a support bar (or reinforcement strut) extending between the frame members (i.e. from one frame member to the other). In an embodiment, the support bar (or reinforcement strut) may be as described in WO2018220593A1. The support bar may comprise an upper surface for supporting the laminate structure (e.g. may be in contact with the rear surface of the laminate structure). The support bar may comprise a lower surface supported on the respective feet of the frame members. The support bar may comprise grounding clips configured to penetrate into the feet of the frame members (e.g. to penetrate through any oxide layers on the feet of the frame members). As discussed further above, improved alignment provided by e.g. the second and third spacing protrusions may ensure suitable electrical contact between the support bar and the frame members.

[0050] The two frame member may represent a first pair of frame members, and the solar module may comprise a second pair of frame members, and each of a pair of opposite edges of the laminate structure may be received in the recess of a respective frame member (of the second pair of frame members) so as to contact the first spacing protrusion of the respective frame member.

[0051] Accordingly, the solar module may comprise four frame members (each being as described above), and each of the four frame members may be positioned such that a respective edge of the laminate structure is received in the frame member.

[0052] In any of the above example, the or each frame member may extend for substantially the entire length of the edge of the laminate structure.

[0053] For the avoidance of doubt, the term “laminate structure” defines a structure for generating electrical power from sunlight. The laminate structure includes at least one solar cell. The at least one solar cell may be configured to absorb sunlight and generate electrical current. The laminate structure may comprise a plurality of such solar cells, which may be retained between front and rear layers to form the laminate structure.

[0054] The present disclosure may also provide a method of manufacturing the frame member (as described above), the method comprising extruding the end wall and the first spacing protrusion of the frame member together as at least part of a unitary piece.

[0055] The present disclosure may also provide a method of manufacturing a solar module, the method comprising manufacturing a frame member as described above, and inserting a laminate structure into the recess of the frame member such that an edge of the laminate structure contacts the first spacing protrusion of the frame member.

[0056] The method of manufacturing a solar module may comprise providing a sealant in the recess of the frame member prior to inserting the laminate structure into the recess. The sealant may be applied, and the laminate structure may be inserted, such that sealant flows at least into an end cavity between the laminate structure and the end wall of the frame member.

[0057] The preceding summary is provided for purposes of summarising some examples to provide a basic understanding of aspects of the subject matter described herein. Accordingly, the above-described features should not be construed to narrow the scope or spirit of the subject matter described herein in any way. Moreover, the above and / or proceeding examples may be combined in any suitable combination to provide further examples, except where such a combination is clearly impermissible or expressly avoided. Other features, aspects, and advantages of the subject matter described herein will become apparent from the following text and the accompanying drawings.

[0058] BRIEF DESCRIPTION OF THE DRAWINGS

[0059] Aspects, features, and advantages of the present disclosure will now be described by way of example only, with reference to the appended drawings in which like numerals denote like elements.

[0060] Figures 1 a and 1 b are schematic plan views of a solar module including a plurality of solar cells, wherein Fig. 1 a is a front view and Fig. 1 b is a back view;

[0061] Figure 2a is a section view of a frame member of a frame the solar module;

[0062] Figure 2b is a section view of part of the solar module including the frame member of Figure 2a;

[0063] Figures 3 to 7 are section views showing variations of the frame member of Figures 2a and 2b; and Figure 8 is a flowchart depicting a method of manufacturing a solar module.

[0064] DETAILED DESCRIPTION

[0065] Aspects and embodiments of the present disclosure will now be discussed with reference to the accompanying figures. Further aspects and embodiments will be apparent to those skilled in the art.

[0066] Figs. 1 a and 1b show a solar module 10, which comprises a rectangular laminate structure 11 (e.g., a laminate structure / panel) and a frame 12 formed of four frame members 13. Each of the frame members 13 extends along a respective outer edge (not visible) of the laminate structure 11.

[0067] The laminate structure 11 includes a grid-like array of solar cells 18 that are sandwiched between a transparent glass front plate 14 and a back plate 15 of the laminate structure 11. As should be appreciated, the front plate 14 defines a forward-facing front surface 30 of the laminate structure 11 , and the back plate 15 defines a rearward-facing rear surface 31 of the laminate structure 11.

[0068] The laminate structure 11 includes electrical circuitry (e.g., an electrical assembly) to enable electrical power to be extracted from the solar cells 18. The electrical circuitry includes a pair of electrical connectors 16 (as shown in Figure 1b) which couple the laminate structure 11 to an external circuit (e.g., two adjacent laminate structures that are not shown). The external connector 16 is connected, at one end, to a junction box 17 which is arranged on the back side of the laminate structure 11 (e.g., mounted to the back plate 15). Of course, more than one junction box 17 may be provided. At least one further connector provides an electrical connection between the junction box 17 and the solar cells 18 which are arranged within the laminate structure 11 (e.g., an internal connector).

[0069] Figure 2a provides a section view of a frame member 13 of the frame 12 with the laminate structure 11 omitted (e.g. pre-assembly). Figure 2b illustrates the same frame member 13, but with the laminate structure 11 present (albeit illustrated schematically).

[0070] The frame member 13 comprises forward 19 and rearward 20 walls in the form of flanges that are spaced apart to define a recess 21 therebetween (see Figure 2a) for receipt of an edge 22 of the laminate structure 11 (as shown in Figure 2b). The recess 21 includes an opening 23 for insertion of the edge 22 of the laminate structure 11 into the recess 21 towards an end wall 24 opposite to the opening 23. The end wall 24 is in the form of a web connecting the forward 19 and rearward 20 walls. In this way, the forward 19, rearward 20, and end 24 walls together form a U-shaped profile (albeit on its side, as normally oriented in use and as illustrated).

[0071] The frame member 13 further includes a first spacing protrusion 25 that protrudes from the end wall 24 into the recess 21 . The height of the first spacing protrusion 25 (in a direction between the end wall 24 and the opening 23) is about 3 mm, and the width of the first spacing protrusion 25 (in a direction between the forward 19 and rearward 20 walls) is about 1 mm.

[0072] As is apparent from Figure 2b, when the laminate structure 11 is fully received in the recess 21 , the first spacing protrusion 25 spaces the edge 22 of the laminate structure 11 from the end wall 24 so as to form an end cavity 26 between the edge 22 of the laminate structure 11 and the end wall 24. In particular, the first spacing protrusion 25 extends towards the opening 23 and is positioned intermediate the forward 19 and rearward 20 walls so as to divide the end cavity 26 into first 27 and second 28 cavity portions.

[0073] Although not shown, when fully assembled, the frame member 13 is adhered to the laminate structure 11 by the provision of sealant between the laminate structure 11 and the frame member 13. In particular, sealant may be provided within the recess 21 prior to insertion of the laminate structure 11 , and insertion of the laminate structure 11 may cause the sealant to flow around the edge 22 of the laminate structure 11. The end cavity 26 (in particular, the first 27 and second 28 cavity portions) provides a space for sealant to remain when the laminate structure 11 has been inserted 11 , and thus ensures suitable adhesion between the edge 22 of the laminate structure 11 and the end wall 24 of the frame member 13 (once the sealant cures).

[0074] As should be appreciated from the figures, the first spacing protrusion 25 is integrally formed with the end wall 24 (i.e. so as to form a unitary piece). Indeed, the entire frame member 13 as illustrated in the figures is formed as a unitary piece via an extrusion process. Thus, although not apparent from the figures, it should be appreciated that the frame member 13 has a cross-sectional shape that is substantially uniform for substantially the entire length of the frame member 13.

[0075] A distal end 45 (i.e. tip) of the first spacing protrusion 25 is rounded, which may reduce the possibility of damage to the edge 22 of the laminate structure 11 .

[0076] The frame member 13 further includes a second spacing protrusion 29, which protrudes rearwardly (towards the rearward wall 20) from the forward wall 19 and into the recess 21. When the laminate structure 11 is received in the recess 21 , this second spacing protrusion 29 spaces a front surface 30 of the laminate structure 11 from the forward wall 19 so as to form a forward cavity 32 between the laminate structure 11 and the forward wall 19. In a similar manner as described above with respect to the end cavity 26, the forward cavity 28 provides a space for sealant to locate once the laminate structure 11 has been inserted into the recess 21. In this way, suitable adhesion can be provided between the forward wall 19 and the front surface of the laminate structure 11 .

[0077] The second spacing protrusion 29 is located at the opening 23 to the recess 21 . In this way, the second spacing protrusion 29 acts as a barrier to sealant flowing out of the forward cavity 28 and onto regions of the front surface 30 of the laminate structure 11 that are exposed externally of the frame member 13. This could otherwise be detrimental to the efficiency of the laminate structure 11 , as leaked sealant could block light entering the laminate structure 11 .

[0078] A lip 42 protrudes from the distal end 43 of the second spacing protrusion 29. In particular, the lip 42 extends from the distal end 43 towards the end wall 24. This provides the second spacing protrusion 29 with a hook-like profile.

[0079] A baffle 33 protrudes into the forward cavity 32 from the forward wall 19. The baffle 33 is configured to control the flow of sealant, in use, along the forward cavity 32 towards the opening 23. In particular, the baffle 33 extends only partway across the forward cavity 32 towards the front surface 30 of the laminate structure 11 (such that the baffle 33 is shorter than the second spacing protrusion 29). Moreover, the baffle 33 protrudes from the forward wall 19 at a location that is intermediate the end wall 24 and the opening 23 (although the baffle 33 is closer to the opening 23 than the end wall 24).

[0080] In this way, the baffle 33 divides the forward cavity 32 into first 34 and second 35 sub-cavities. The sub-cavities 34, 35 are fluidly connected by a channel 36, which is formed between a tip 37 of the baffle 33 and the front surface 30 of the laminate structure 11. During installation (as the edge 22 of the laminate structure 11 is inserted into the recess 21), sealant can flow from the first sub-cavity 34 to the second sub-cavity 35 via the channel 36. As the channel 36 is narrow relative to the first 34 and second 35 sub-cavities, flow of the sealant to the second sub-cavity 35 can be restricted. This may aid in reducing leakage of sealant from the recess 21 (between the second spacing protrusion 29 and the front surface 30 of the laminate structure 11 ).

[0081] To further aid in the control of sealant flow (as already described above), a first surface 38 of the baffle 33, facing towards the opening 23, is curved (convex). An opposite, second surface 39 of the baffle 33 (facing towards the end wall 24) is substantially planar.

[0082] A third spacing protrusion 40 protrudes from the rearward wall 20 into the recess 21 to space a rear surface 31 of the laminate structure 11 from the rearward wall 20 so as to form a rearward cavity 41 between the laminate structure 11 and the rearward wall 20. As with the forward 32 and end 26 cavities, the rearward cavity 41 provides a space for sealant to ensure that there is adhesion between the rear surface 31 of the laminate structure 11 and the rearward wall 20. The third spacing protrusion 40 is located at the opening 23 to the recess 21 (opposite the second spacing protrusion 29), so as to provide a barrier to sealant flowing from the rearward cavity 41.

[0083] A leading portion 44 of the third spacing protrusion 40 is sloped so as to provide a ramp surface to guide the laminate structure 11 into the recess 21 during assembly. To help ensure a suitable quantity of sealant is able to locate so as to be in contact with the rear surface 31 of the laminate structure 11 , the rearward cavity 41 has a depth D of about 0.4 mm (but could be deeper than this).

[0084] The frame member 13 further comprises a reinforcement portion 46 provided by a region of increased thickness at a connection between the forward wall 19 and the end wall 24. The reinforcement portion 46 increases the rigidity of the frame member 13 so as to reduce bending between the forward wall 19 and the end wall 24.

[0085] A mounting portion 47 of the frame member 13 extends rearwardly from the rearward wall 20. The mounting portion 47 is for mounting the frame member 13 (and thus the solar module 10) to a structure, such as a rail. The mounting portion 47 includes a foot 48, in the form of a flange, and an intermediate structure formed of spaced parallel webs 49, which extend between and connect the foot 48 to the rearward wall 20. Together, the foot 48, webs 49 and rearward wall 20 form a hollow box-shaped profile, so as to define a rectangular internal space 50.

[0086] Figures 3 to 7 illustrate variations of the frame member 13 described above. For clarity, only major features of these variations are labelled in the drawings. It should be appreciated that these variations are the same as the frame member 13 described above except for the differences discussed below.

[0087] The frame member 13a of Figure 3 differs from that previously described in that the first spacing protrusion 25 is tapered (i.e. narrows in a direction away from the end wall 24), and is positioned closer to the forward wall 19. The reinforcement portion 46 also differs in shape and is more pointed than that disclosed above. Unlike that previously described, this frame member 13a does not include a baffle.

[0088] The frame member 13b of Figure 4 comprises two first spacing protrusions 25, which are spaced apart from one another in a direction extending between the forward 19 and rearward 20 walls. Both of these two first spacing protrusions 25 have a tapered form.

[0089] The frame member 13c of Figure 5 includes a single first spacing protrusion 25 that is wider than those previously described (about 5 mm in the illustrated embodiment, but could be wider or narrower than this). The first spacing protrusion 25 is tapered, like previously described, but is also truncated so that a distal end 45 of the first spacing protrusion 25 is substantially planar. In other words, the first spacing protrusion 25 has a trapezoidal profile.

[0090] The frame member 13d of Figure 6 is the same as that of Figure 5, except that the frame member 13d include a baffle 33, but does not include a reinforcement portion 46. The frame member 13e of Figure 7 is the same as that of Figure 5, except that the reinforcement portion 46 is less pronounced (instead being provided by a radiused inner corner between the forward wall 19 and the end wall 24).

[0091] Figure 8 depicts a method 51 of forming a solar module, such as that described above. The method 51 comprises a step 52 of forming a frame member 13 (such as any one of the frame members 13 described above) by way of an extrusion process. At step 53, sealant is supplied into the recess 21 of the frame member 13. At step 54, the frame member 13 is mounted to a laminate structure 11 by receipt of the laminate structure 11 in the recess 21 of the frame member 13. As already described above, this will cause sealant to flow into cavities between the walls 19, 20, 24 of the frame member 13 and the laminate structure 11 . At step 55, the sealant is cured so as to adhere the frame member 13 to the laminate structure 11 .

[0092] It is to be understood that the present disclosure is not limited by specific construction details or process steps set forth in the following description and accompanying drawings. Rather, it will be apparent to those skilled in the art having the benefit of the present disclosure that the systems, apparatuses and / or methods described herein could be embodied differently and / or be practiced or carried out in various alternative ways.

[0093] Unless otherwise defined herein, scientific and technical terms used in connection with the presently disclosed inventive concept(s) shall have the meanings that are commonly understood by those of ordinary skill in the art, and known techniques and procedures may be performed according to conventional methods well known in the art and as described in various general and more specific references that may be cited and discussed in the present specification.

[0094] All examples implementing the present disclosure can be made and executed without undue experimentation in light of the present disclosure. While particular examples have been described, it will be apparent to those of skill in the art that variations may be applied to the systems, apparatus, and / or methods and in the steps or in the sequence of steps of the methods described herein without departing from the concept, spirit, and scope of the inventive concept(s). All such similar substitutions and modifications apparent to those skilled in the art are deemed to be within the spirit, scope, and concept of the inventive concept(s) as defined by the appended claims.

[0095] The use of the term "a” or "an” in the claims and / or the specification may mean “one,” as well as “one or more,” “at least one,” and “one or more than one.” As such, the terms “a,” “an,” and “the,” as well as all singular terms, include plural referents unless the context clearly indicates otherwise. Likewise, plural terms shall include the singular unless otherwise required by context.

[0096] The use of the term “or” in the present disclosure (including the claims) is used to mean an inclusive “and / or” unless explicitly indicated to refer to alternatives only or unless the alternatives are mutually exclusive. For example, a condition “A or B” is satisfied by any of the following: A is true (or present), and B is false (or not present), A is false (or not present), and B is true (or present), and both A and B are true (or present).

[0097] As used in this specification and claim(s), the words "comprising, "having,” “including,” or “containing” (and any forms thereof, such as “comprise” and “comprises,” “have” and “has,” “includes” and “include,” or “contains” and “contain,” respectively) are inclusive or open-ended and do not exclude additional, unrecited elements or method steps.

[0098] Unless otherwise explicitly stated as incompatible, or the physics or otherwise of the embodiments, examples, or claims prevent such a combination, the features of examples disclosed herein, and of the claims, may be integrated together in any suitable arrangement, especially ones where there is a beneficial effect in doing so. This is not limited to only any specified benefit, and instead may arise from an “ex post facto” benefit. This is to say that the combination of features is not limited by the described forms, particularly the form (e.g., numbering) of example(s), embodiment(s), or dependency of claim(s). Moreover, this also applies to the phrase “in one embodiment,” “according to an embodiment,” and the like, which are merely a stylistic form of wording and are not to be construed as limiting the following features to a separate embodiment to all other instances of the same or similar wording. This is to say, a reference to ‘an,’ ‘one,1or ‘some’ embodiment(s) may be a reference to any one or more, and / or all embodiments, or combination(s) thereof, disclosed. Also, similarly, the reference to “the” embodiment may not be limited to the immediately preceding embodiment. Further, all references to one or more embodiments or examples are to be construed as non-limiting to the claims.

Claims

CLAIMS1. A frame member for supporting a laminate structure comprising one or more solar cells, the frame member comprising forward and rearward walls that are spaced apart to define a recess therebetween for receipt of an edge of the laminate structure, the recess comprising an opening for insertion of the edge of the laminate structure into the recess towards an end wall opposite to the opening; wherein a first spacing protrusion, that is integrally formed with the end wall, protrudes from the end wall into the recess to space the edge of the laminate structure from the end wall so as to form an end cavity between the edge of the laminate structure and the end wall when the edge of the laminate structure is inserted into the recess.

2. The frame member according to claim 1 , comprising a second spacing protrusion protruding rearwardly from the forward wall into the recess to space a front surface of the laminate structure, when received in the recess, from the forward wall so as to form a forward cavity between the laminate structure and the forward wall.

3. The frame member according to claim 2, wherein the second spacing protrusion is located at the opening to the recess.

4. The frame member according to claim 2 or 3, comprising a baffle protruding into the forward cavity from the forward wall for controlling the flow of sealant, in use, along the forward cavity towards the opening.

5. The frame member according to claim 4, wherein the baffle extends only partway across the forward cavity towards the laminate structure.

6. The frame member according to claim 4 or 5, wherein the baffle protrudes from the forward wall at a location that is intermediate the end wall and the opening.

7. The frame member according to claim 6, wherein the baffle is closer to the opening than the end wall.

8. The frame member according to any one of claims 4 to 7, wherein a first surface of the baffle, facing towards the opening, is curved.

9. The frame member according to any one of claims 4 to 8, wherein a second surface of the baffle, facing towards the end wall, is substantially planar.

10. The frame member according to any one of the preceding claims, comprising a third spacing protrusion protruding from the rearward wall into the recess to space a rear surface of the laminatestructure, when received in the recess, from the rearward wall so as to form a rearward cavity between the laminate structure and the rearward wall.

11. The frame member according to claim 10, wherein the third spacing protrusion is located at the opening to the recess.

12. The frame member according to claim 10 or 11 , wherein the rearward cavity has a depth that is greater than 0.4 mm.

13. The frame member according to any one of the preceding claims, wherein the first spacing protrusion is spaced between the forward and rearward walls to divide the end cavity into first and second cavity portions.

14. The frame member according to any one of the preceding claims, wherein the first spacing protrusion is tapered in a direction of extension of the first spacing protrusion from the end wall.

15. The frame member according to claim 14, wherein a tip of the first spacing protrusion is truncated.

16. The frame member according to any one of the preceding claims, wherein a height of the first spacing protrusion from the end wall is at least 0.5 mm.

17. The frame member according to any one of the preceding claims, wherein a width of the first spacing protrusion, taken in a direction between the forward and rearward walls, is less than 6 mm.

18. The frame member according to any one of the preceding claims, comprising a reinforcement portion provided by a region of increased thickness at a connection between the forward wall and the end wall.

19. The frame member according to any one of the preceding claims, that is formed as a unitary piece.

20. The frame member according to any one of the preceding claims, that is formable by extrusion.21 . A solar module comprising: a laminate structure comprising one or more solar cells; and the frame member according to any one of the preceding claims, wherein a first edge of the laminate structure is received in the recess of the frame member so as to contact the first spacing protrusion.

22. The solar module according to claim 21 , comprising two frame members, each according to any one of claims 1 to 20, and wherein each of a pair of opposite edges of the laminate structure arereceived in the recess of a respective frame member so as to contact the first spacing protrusion of the respective frame member.

23. A method of manufacturing the frame member according to anyone of claims 1 to 20, comprising extruding the end wall and the first spacing protrusion together as at least part of a unitary piece.

24. A method of manufacturing a solar module, the method comprising manufacturing a frame member according to claim 23, and inserting a laminate structure into the recess of the frame member such that an edge of the laminate structure contacts the first spacing protrusion of the frame member.

25. The method of manufacturing a solar module according to claim 24, comprising providing a sealant in the recess of the frame member prior to inserting the laminate structure into the recess.

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