IP Library › Granted Patent US 10,812,013
Granted Patent B2
US 10,812,013 · App. 16/193,983 · Granted Oct 20, 2020

Frame assemblies and photovoltaic devices including the same

Inventors: Joshua Conley (Perrysburg, OH); Benjamin DeFresart (Chandler, AZ); Peter Hruby (Scottsdale, AZ); Matthew Kuzila (Phoenix, AZ); Daniel Smith (Gilbert, AZ); Thomas Truman (Toledo, OH)
Assignee: First Solar, Inc.
H02S30/10H01L31/0488
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Quick Facts
Patent No.
US 10,812,013
App. No.
16/193,983
Granted
Oct 20, 2020
Kind
B2
Abstract

A photovoltaic device can include a module and a rail. The module can have an edge formed around a perimeter of the module. The rail can include a coupling surface at a top side of the rail, and a recessed surface offset from the coupling surface and towards a bottom side of the rail.

Claims (53)

1. A photovoltaic device comprising:

a module having an edge formed around a perimeter of the module, wherein the module comprises a semiconductor material located between a front sheet and a back sheet; and

a rail comprising a coupling surface at a top side of the rail, a recessed surface offset from the coupling surface and towards a bottom side of the rail, and a riser that extends from the coupling surface to the recessed surface, wherein:

the coupling surface extends from an interior side of the rail towards an exterior side of the rail;

the recessed surface is offset from the coupling surface by a recess distance;

the coupling surface at the top side of the rail is coupled to the back sheet of the module;

the edge of the module is offset from an exterior side of the rail towards the interior side of the rail; and

the edge of the module is offset from the riser towards the interior side of the rail.

2. The photovoltaic device of claim 1 , wherein the riser is substantially orthogonal to both the coupling surface and the recessed surface.

3. A photovoltaic device comprising:

a module having an edge formed around a perimeter of the module, wherein the module comprises a semiconductor material located between a front sheet and a back sheet; and

a rail comprising a coupling surface at a top side of the rail, a recessed surface offset from the coupling surface and towards a bottom side of the rail, and a base member having a support surface located at the bottom side of the rail, wherein:

the coupling surface extends from an interior side of the rail towards an exterior side of the rail;

the recessed surface is offset from the coupling surface by a recess distance;

the coupling surface at the top side of the rail is coupled to the back sheet of the module;

the edge of the module is offset from an exterior side of the rail towards the interior side of the rail; and

the support surface has a width that is less than a width of the recessed surface.

4. The photovoltaic device of claim 3 , wherein the base member is a body that provides a mounting surface at a height with respect to the support surface.

5. The photovoltaic device of claim 4 , wherein the height of the mounting surface of the base member is between about 75% and about 150% of the recess distance.

6. The photovoltaic device of claim 5 , wherein the width of the support surface is less than about 95% of the width of the recessed surface.

7. The photovoltaic device of claim 3 , wherein the base member and the recessed surface are flush at the exterior side of the rail.

8. The photovoltaic device of claim 3 , wherein the coupling surface is defined on a head section of the rail, and the head section comprises a bottom face positioned between the top side and the bottom side of the rail.

9. The photovoltaic device of claim 8 , wherein a base offset distance is defined between the support surface of the base member and the bottom face of the head section, and the base offset distance is greater than the recess distance.

10. The photovoltaic device of claim 9 , wherein the base offset distance is at least about 125% of the recess distance.

11. The photovoltaic device of claim 8 , comprising a support plate extending between the head section and the base member, wherein the support plate defines a height.

12. The photovoltaic device of claim 11 , wherein the height of the support plate is greater than the recess distance.

13. The photovoltaic device of claim 11 , comprising a slot formed in the support plate, wherein the slot comprises a flat bottom.

14. The photovoltaic device of claim 11 , comprising a threaded bore formed in the support plate.

15. The photovoltaic device of claim 1 , comprising a beam having a top flange and a bottom flange, and wherein the beam is coupled to the rail.

16. The photovoltaic device of claim 15 , wherein a width of the bottom flange is greater than a width of the top flange.

17. The photovoltaic device of claim 1 , wherein the coupling surface at the top side of the rail is coupled to the back sheet of the module with an adhesive.

18. A stack of photovoltaic devices comprising:

a first photovoltaic device comprising:

a module having an edge formed around a perimeter of the module, wherein the module comprises a semiconductor material located between a front sheet and a back sheet; and

a rail comprising a coupling surface at a top side of the rail, and a recessed surface offset from the coupling surface and towards a bottom side of the rail, wherein:

the coupling surface extends from an interior side of the rail towards an exterior side of the rail;

the recessed surface is offset from the coupling surface by a recess distance;

the coupling surface at the top side of the rail is coupled to the back sheet of the module; and

the edge of the module is offset from an exterior side of the rail towards the interior side of the rail; and

a second photovoltaic device comprising a second base member having a support surface located at a bottom side of a second rail, wherein:

the support surface of the second rail has a width that is less than the width of the recessed surface; and

the support surface of the second rail contacts the recessed surface.

19. The photovoltaic device of claim 16 , comprising a base member having a support surface located at the bottom side of the rail, wherein the support surface has a width that is less than a width of the recessed surface.

20. A photovoltaic device comprising:

a module having an edge formed around a perimeter of the module, wherein the module comprises a semiconductor material located between a front sheet and a back sheet;

a rail comprising a coupling surface at a top side of the rail, and a recessed surface offset from the coupling surface and towards a bottom side of the rail, and

a beam having a top flange and a bottom flange, wherein:

the coupling surface extends from an interior side of the rail towards an exterior side of the rail;

the recessed surface is offset from the coupling surface by a recess distance;

the coupling surface at the top side of the rail is coupled to the back sheet of the module;

the edge of the module is offset from an exterior side of the rail towards the interior side of the rail;

the beam is coupled to the rail; and

a width of the bottom flange is greater than a width of the top flange.

Assignments (2)
RELEASE OF SECURITY INTEREST Recorded Feb 13, 2026
From: JPMORGAN CHASE BANK, N.A.
To: FIRST SOLAR, INC.
Reel/Frame 074858/0364 →
SECURITY INTEREST Recorded Jul 10, 2023
From: FIRST SOLAR, INC.
To: JPMORGAN CHASE BANK, N.A., AS ADMINISTRATIVE AGENT
Reel/Frame 064237/0462 →
Cited By (3)
US 1,127,696 US 1,127,697 US 1,142,149