FIELD

[0001] The present teachings generally relate to a base plate that provides improved protection from stepping loads and more preferably reduces loads across interconnect elements within a photovoltaic laminate.

BACKGROUND

[0002] Typically, photovoltaic arrays are placed in an elevated location such as a roof top of a home or a building or in a rack and frame that elevates the photovoltaic array so that the photovoltaic array is exposed to sunlight. The roofs on homes and/or buildings generally are formed by adding a plurality of pieces of panels together so that a generally contiguous surface is formed, which are supported by one or more trusses. Photovoltaic modules may be secured to the plurality of pieces of panels directly and/or indirectly via a connection structure such as a rack and frame. Each photovoltaic module of the photovoltaic array may include only an active portion and the active portions of two or more photovoltaic modules may be placed in close proximity with one another so that a photovoltaic array is formed over and/or on the connection structure. However, in cases where the photovoltaic modules provide roofing functions, the photovoltaic modules may include both an active portion and an inactive portion and the active portion of one photovoltaic module may fully and/or partially cover the inactive portion of an adjacent photovoltaic module to replace the framing and racking structure. Further, the active portion and the inactive portion are one integrally formed piece with the photovoltaic active portion (i.e., pv laminate) located within the active portion so that in order to remove the photovoltaic active portion the entire photovoltaic module would be removed and replaced if necessary. In cases of building integrated photovoltaics, the active portion may provide roofing functions or structural functions for subsequent photovoltaic modules. These building integrated photovoltaics have a low profile and are directly connected to a support structure such that any load applied to the building integrated photovoltaics presses on all layers of the photovoltaics. These building integrated photovoltaics from time to time will be subject to weight being applied to the photovoltaic such as an installer, maintenance person, or owner walking across the photovoltaic array or snow collecting on the photovoltaic array. When the photovoltaics are rigid or include brittle laminates of photovoltaic cells, cracking may occur when these loads are applied to the photovoltaic which may impair the photovoltaics ability to create electricity. More recently, the photovoltaic module has a base plate and a photovoltaic laminate that are two separate pieces. The base plate supports the photovoltaic laminate and the base plate provides roofing functions. [0003] Examples of some photovoltaic modules may be found in U.S. Patent Nos. 5,437,735 8,601 ,754; and 8,631 ,614; U.S. Patent Application Publication No. 2008/0271773; 2008/0302030; 2010/0180523; and International Patent Application Nos. WO2016/077041 and WO2016/060924 all of which are incorporated by reference herein for all purposes.

[0004] It would be attractive to have a base plate that supports a photovoltaic laminate and prevents the photovoltaic laminate from bending when a load is applied to the photovoltaic laminate. It would be attractive to have a base plate with a support portion that receives interconnect elements so that the interconnect elements are recessed relative to the photovoltaic laminate. What is needed is a base plate that includes one or more transverse recesses that receive the interconnect elements so that the interconnect elements extend in a plane below the photovoltaic laminate. It would be attractive to have a base plate that accommodates electrical circuitry or elements of a laminate (e.g., wires, diodes) that are located upon a rear surface of the laminate so that loads (e.g., stepping loads) are evenly distributed and the laminate is not cracked. It would be attractive to include a structure that prevents or eliminates micro-cracking of a crystalline silicon laminate or a brittle laminate when loads are applied to the laminate. What is needed is a base plate that includes transverse recesses that extend in a transverse direction and one or more recesses that extend in a longitudinal direction.

SUMMARY

[0005] The present teachings meet one or more of the present needs by providing: A photovoltaic module comprising: (a) base plate including: (i) an overlap portion adapted to receive all or a portion of one or more adjacent photovoltaic components and (ii) a support portion adapted to receive a photovoltaic laminate, the support portion having a support structure that includes: (1) a plurality of channels that extends in a longitudinal direction and (2) one or more channels that extends in a transverse direction at an angle relative to the plurality of channels that extend in the longitudinal direction.

[0006] The present teachings provide a photovoltaic array including a plurality of photovoltaic modules aligned in two or more rows or columns and one or more adjacent photovoltaic components that connect the two or more rows or columns.

[0007] The teachings herein surprisingly solve one or more of these problems by providing a base plate that supports a photovoltaic laminate and prevents the photovoltaic laminate from bending when a load is applied to the photovoltaic laminate. The present teachings provide a base plate with a support portion that receives interconnect elements so that the interconnect elements are recessed relative to the photovoltaic laminate. The present teachings provide a base plate that includes one or more transverse recesses that receive the interconnect elements so that the interconnect elements extend in a plane below the photovoltaic laminate. The present teachings provide a base plate that accommodates electrical circuitry or elements of a laminate (e.g., wires, diodes) that are located upon a rear surface of the laminate so that loads (e.g., stepping loads) are evenly distributed and the laminate is not cracked. The present teachings provide a structure that prevents or eliminates micro-cracking or a crystalline silicon laminate or a brittle laminate when loads are applied to the laminate. The present teachings provide a base plate that includes one or more transverse recesses that extend in a transverse direction and one or more recesses that extend in a longitudinal direction.

BRIEF DESCRIPTION OF THE DRAWINGS

[0008] FIG. 1 is a top view of a base plate;

[0009] FIG. 1 A illustrates a cross-sectional view of the base plate of FIG. 1 ;

[0010] FIG. 1 B illustrates a cross-sectional view of the base plate;

[0011] FIG. 2 illustrates a plurality of photovoltaic cells connected by interconnect elements;

[0012] FIG. 3 illustrates a top view of a base plate with transverse recesses that run perpendicular to fluid transfer surfaces;

[0013] FIG. 4 is an exploded view of a base plate and photovoltaic laminate;

[0014] FIG. 5 illustrates a photovoltaic laminate and electrical circuitry; and

[0015] FIG. 6 illustrates a photovoltaic array.

DETAILED DESCRIPTION

[0016] The explanations and illustrations presented herein are intended to acquaint others skilled in the art with the teachings, its principles, and its practical application. Those skilled in the art may adapt and apply the teachings in its numerous forms, as may be best suited to the requirements of a particular use. Accordingly, the specific embodiments of the present teachings as set forth are not intended as being exhaustive or limiting of the teachings. The scope of the teachings should, therefore, be determined not with reference to the above description, but should instead be determined with reference to the appended claims, along with the full scope of equivalents to which such claims are entitled. The disclosures of all articles and references, including patent applications and publications, are incorporated by reference for all purposes. Other combinations are also possible as will be gleaned from the following claims, which are also hereby incorporated by reference into this written description.

[0017] A plurality of photovoltaic modules, a plurality adjacent photovoltaic components, or both of the teachings herein are combined together to form a photovoltaic array. The photovoltaic array collects sunlight and converts the sunlight to electricity. Generally, each of the photovoltaic modules may be individually placed in a structure that houses all of the photovoltaic modules forming all or a portion of a photovoltaic array. The photovoltaic modules of the teachings herein may be used with a housing that contains all of the individual photovoltaic modules and make up a photovoltaic array. Preferably, the photovoltaic array taught herein is free of a separate structure that houses all of the photovoltaic modules that make up a photovoltaic array (also referred to as a solar array). More preferably, each individual photovoltaic module may be connected directly to a structure (i.e., is a building integrated photovoltaic (BIPV)) and each of the individual photovoltaic modules is electrically connected together so that a photovoltaic array is formed. The plurality of photovoltaic modules may be connected to the structure in rows or columns. The rows or columns may be connected together by integrated flashing pieces. The integrated flashing pieces may connect two or more rows or columns of photovoltaic modules together electrically, physically, or both. Most preferably, each individual photovoltaic module may include a base plate, interconnection elements (e.g., wiring), and a photovoltaic laminate. Each base plate may include a support portion (sometimes referred to as an active portion when the photovoltaic laminate is added), and an overlap portion (sometimes referred to as an inactive portion when the photovoltaic laminate is added). The support portion may overlap all or a portion of one or more adjacent photovoltaic components (e.g., the inactive portion or the overlap portion of a photovoltaic module or a portion of an integrated flashing piece) forming a "double overlap" so that each photovoltaic module may be protected and connected to a connection surface and/or so that the combined photovoltaic modules may form a shingle structure for diverting fluids from the roof of the structure. The overlap portion may be overlapped by one or more adjacent photovoltaic components. For example, the overlap portion may be overlapped by a portion of a photovoltaic module and a portion of an integrated flashing piece. The adjacent photovoltaic components as discussed herein may be an integrated flashing piece, a photovoltaic module, a through roof connector, an interface piece between the standard roofing shingles and the photovoltaic array, or a combination thereof. Each of the photovoltaic modules and adjacent photovoltaic components may have a portion that may be indirectly and/or directly connected to a connection surface. The base plate may directly connect to a connection surface and the photovoltaic laminate may be connected to a support portion of the base plate (i.e., the photovoltaic laminate may be indirectly connected to the connection surface). Preferably, the inactive portion of each of the photovoltaic modules may be directly connected to a connection surface, and the support portion may be connected directly to the overlap portion or directly to the connection surface by a fastener that extends through the overlap portion, around the overlap portion, through a fastener support in the overlap portion, or a combination thereof. More preferably, each of the photovoltaic modules may include a base plate and a photovoltaic laminate, and the base plate is connected to a connection surface by one or more fasteners that extend through fastener locations and preferably a plurality of fasteners that extend through fastener locations.

[0018] The fastener locations may be located within the support portion, the overlap portion, the active portion, or a combination thereof. Preferably, the fastener locations may be located within the overlap portion. The fastener locations may be a through hole that extends through the overlap portion, a weakened area so that a fastener may be placed through the fastener support, a removable portion, a punch out, an area of lower hardness, or a combination thereof. Preferably, the fastener locations may be a region where the base plate is reinforced so that fasteners may extend through and connect the photovoltaic module, the base plate, or both to the one or more connection surfaces and the fasteners do not damage the photovoltaic laminate when the base plate, the overlap portion, or both is subjected to movement. A plurality of fastener locations may extend across the width of the base plate. The base plate may have two or more, four or more, six or more, eight or more, or even ten or more fastener locations. Preferably, a fastener (e.g., nail or screw) extends through each of the fastener locations to directly connect the base plate to a connection surface.

[0019] The connection surface may function to provide support to one or more photovoltaic modules so that a photovoltaic array is formed. The connection surface may be a support structure such as a housing for containing one or more of the photovoltaic modules. Preferably, the connection surface may be a roof. The roof may be comprised of a plurality of panels made of wood, plywood, structural plywood, decorative plywood, overlaid plywood, commercial plywood, utility plywood, marine plywood, medium density fiberboard (MDF), oriented strand board (OSB), Sundela, hardboard, insulation board, the like, or a combination thereof. The plurality of photovoltaic modules may be connected to the connection surface so that the photovoltaic modules are adjacent to one another. For example, an edge of one photovoltaic module may be located substantially proximate to an edge of an adjoining photovoltaic module. Preferably, the photovoltaic modules may partially overlap each other. For example, the active portion (also referred to as a support portion) of one photovoltaic module may overlap an overlap portion of one or more adjacent photovoltaic modules in a similar fashion to how roofing shingles are applied to a roof. Preferably, a support portion of a base plate of one photovoltaic module may extend at least partially over an overlap portion of an adjacent base plate. Each of the base plates may include one or more fastener supports that may connect the base plate to a connection surface.

[0020] The plurality of base plates may be connected to a connection surface with a mechanical fastener, an adhesive, an interlocking connection with an adjacent photovoltaic module, or a combination thereof. The fasteners may be a screw, nail, bolt, staple, rivet, or a combination thereof. The adhesive may be any adhesive with sufficient strength to connect the photovoltaic module to the connection surface. The adhesive may be epoxy based, silicone based, acrylic based, a urethane based, a polyamide based, a one part adhesive, a multi-part adhesive, a natural adhesive, a synthetic adhesive, or a combination thereof. The fastener may be a combination of a mechanical fastener and an adhesive fastener. Preferably, if an adhesive fastener is used, the connection formed by the adhesive may be broken without damaging the pv laminate, the base plate, or preferably both. The fasteners may connect the base plate to the roof so that the base plate may perform roofing functions.

[0021] The base plate may function to connect a photovoltaic laminate (hereinafter pv laminate) to a connection surface (e.g., a roof). The base plate may function to allow for decoupled expansion and contraction of the pv laminate relative to the base plate or vice versa. The base plate may function to allow for removal, replacement, repair, or a combination thereof of the pv laminate without removal of the entire pv module from the connection surface. The base plate may function to protect all or a portion of the pv laminate. The base plate may connect the pv laminate to a connection surface. The base plate may protect one or more connectors and or wiring. The base plate may retain roofing functions, fire retardant properties, or both when the pv laminate is removed from the base plate. Preferably, the base plate may retain adequate fire retardant properties. The base plate may include one or more features to assist in forming a connection with one or more connection devices. The base plate may include one or more devices that receive a portion of a fastener, assist in forming a connection, or both. The base plate may include one or more support portions that support a pv laminate and prevent localized movement of the pv laminate so that the pv laminate is prevented from being damaged.

[0022] The base plate may include a support portion (i.e., active portion when a photovoltaic laminate is present), an overlap portion, or both. The support portion may receive a photovoltaic laminate. The support portion may form a base for a photovoltaic laminate and associated terminals. The support portion may function to support the pv laminate when a load is applied to the pv laminate when the pv laminate is connected to a connection surface. For example, when the photovoltaic module is connected to a roof and a person walks across the photovoltaic array the support portion may resist bending of the pv laminate so that the pv laminate is not damaged. The support portion may function to provide support for one or more adjacent photovoltaic modules. The support portion of a first photovoltaic module may function to overlap one or more connectors of one or more second adjacent photovoltaic modules so that the one or more connectors of the one or more second adjacent photovoltaic modules are protected. The support portion of a first photovoltaic module may protect one or more connectors that are connected to and extend between two adjacent second photovoltaic modules. The support portion may protect the laminate from penetration by foreign objects from the backside. The support portion may provide longitudinal support, lateral support, or both so that the pv laminate, photovoltaic cells, or both do not substantially deflect (i.e., enough to crack, break, or be damaged). The support portion and the pv laminate may be connected. Preferably, the support portion and the pv laminate may be movable relative to each other when the pv laminate is connected to the support portion. The pv laminate may be free of a fixed connection with the support portion. For example, during thermal expansion the pv laminate may expand relative to the support portion of the base plate. The support portion may not provide any sealing functions to the pv laminate. The pv laminate and the support portion may be free of a sealed connection. The support portion may resist deflection and provide support to the pv laminate during loading. The support portion may function to remove fluids and/or debris away from the pv laminate. The support portion may extend under a photovoltaic laminate. The support portion may receive a portion of a photovoltaic laminate. The support portion may receive interconnect elements of the photovoltaic laminate. The support portion may prevent bending, folding, localized bending (e.g., bending in a small area such as an area that is 5 cm ² or less), or a combination thereof. Preferably, the support portion includes a support structure (e.g., support ribs) that supports a photovoltaic laminate when the photovoltaic laminate is placed upon on the base plate. The support portion may include one or more support ribs spaced apart from one or more channels (e.g., channels that extend in a longitudinal direction (i.e., fluid transfer surfaces)).

[0023] The one or more channels may function to remove water from the photovoltaic modules and the photovoltaic array. The one or more channels may function to receive a portion of a photovoltaic laminate so that even support is applied across the photovoltaic laminate. For example, if one or more parts of electrical circuitry (e.g., interconnect elements, diodes, capacitors, resistors) extend in a plane below a main plane of the photovoltaic laminate, the channels receive the one or more parts of the electrical circuitry so that the portion of the photovoltaic laminate in the main plane is supported and the interconnect elements are not stressed by the support. In another example, a main body portion of the photovoltaic laminate may lay upon support ribs and diodes and/or interconnect elements may extend below the main body portion (i.e., from a lower surface) into one or more of the channels. The one or more channels may function to prevent loads or stepping loads from being transferred to parts of the electrical circuitry. The one or more channels may maintain the laminate in a planar position (e.g., bending is prevented) while loads and/or stepping loads are applied to the laminate so that micro-cracking is prevented within the laminate (i.e., the photovoltaic cells within the laminate). The channels may prevent forces from being applied to the electrical circuitry so that the electrical circuitry and/or laminate is not stressed when a load is applied to the photovoltaic module. The one or more channels may function to allow the photovoltaic laminate to extend in two or more planes and for even support to be applied across the photovoltaic laminate. The one or more channels may allow any fluids that travel under the pv laminate to escape from under the pv laminate. The one or more channels may prevent a buildup of fluids under the pv laminate. The one or more channels may create a distance between fluids and the pv laminate so that the pv laminate does not sit in fluids. The channels may be spaced about 1 mm or more, about 2 mm or more, about 3 mm or more, or even about 4 mm or more from the pv laminate. The one or more channels may have a width of about 1 mm or more, about 2 mm or more, about 3 mm or more, or about 5 mm or more. The one or more channels may have a width of about 5 cm or less, about 4 cm or less, or about 3 cm or less. The one or more channels may function to allow fluids to be moved by gravity from the photovoltaic modules. The channels may be a plurality of fluid transfer surfaces. The channels may be aligned in a direction of a slope of a connection surface (i.e., longitudinal channels). The channels may extend in a direction transverse (i.e., transverse channels) to the slope of the connection surface. The support portion may have channels that extend substantially in the longitudinal direction (e.g., in a direction of slope of a roof or the length of the base plate) and substantially the transverse direction (e.g., transverse to the slope of a roof or transverse to the length of the base plate). When both the transverse channels and longitudinal channels are present the channels extend at an angle relative to each other. The transverse channels and the longitudinal channels may extend at an angle relative to each other. The angle may be about 45 degrees or more, about 60 degrees or more, about 75 degrees or more, or about 90 degrees. The angle may be about 135 degrees or less, about 115 degrees or less, or about 105 degrees or less. The channels may be aligned with a length of the photovoltaic module. The plurality of channels may alternate with a plurality of support ribs so that the support ribs elevate the pv laminate above the channels. The channels may run substantially parallel to support ribs. The channels may alternate with the support ribs. The channels may run substantially perpendicular to the support ribs. The transverse channels may extend through the support ribs, the longitudinal channels, or both. The transverse channels may be complementary in shape to the shape of the interconnect elements. The transverse channels may be sufficient deep so that the interconnect elements fit within the channel but allow for fluids and debris to extend under the interconnect elements. The transverse channels may be tapered to fit and support the interconnect elements. The transverse channels may mirror the shape and location of the interconnect elements. The transverse channels may assist in preventing movement of the pv laminate relative to the base plate. The transverse channels may be free of contact with the interconnect elements. The interconnect elements may not carry any load and all of the load may be carried on the pv laminate. The transverse channels may extend at a similar angle relative to the support ribs as the transverse channels extend to the longitudinal channels.

[0024] The support ribs may function to create one or more and preferably a plurality of lines of contact between the pv laminate and the base plate. The support ribs may elevate the pv laminate above the support portion and preferably above the channels. The support ribs may be fixedly connected to the pv laminate. The support ribs may be an integral part of the pv laminate. The support ribs may be a reinforcement rib. Preferably, the support ribs may be part of the base plate. The support ribs may be located on the support portion of the base plate. The support ribs may extend above a surface of the support portion so that a pv laminate is located above the base plate. The support ribs may prevent deflection of the pv laminate. The support ribs may be sufficiently tall so that fluids are not trapped between the pv laminate and the support portion (i.e., within the channels). The support ribs may be sufficiently spaced apart so that fluid may be removed from under the pv laminate by the fluid transfer surfaces. The spacing between the support ribs may vary along a height of the support rib. The spacing between the support ribs may decrease as the support ribs approach the pv laminate. For example, the support rib may be "T" shaped or "Y" shaped and as the support rib extends from a lower surface the support rib may expand outward to support the pv laminate. A width of each support rib may be constant along a length, height, or both of each support rib. The width may vary along a length, width, or both of each support rib. The support ribs may be about 5 mm or more apart, about 7 mm or more apart, about 10 mm or more apart, or even about 15 mm or more apart. The support ribs may be about 10 cm or less apart, about 5 cm or less apart, or about 3 cm or less apart. The support ribs may be evenly spaced apart. The spacing between the support ribs may vary across the width of the base plate. For example, the spacing may be larger at the edges than in the middle. A width of each support rib may be constant along a length of each support rib. The width may vary along a length of each support rib. The width of some support ribs may be greater than a width of other support ribs. For example, one support rib may be 2 cm in width and another support rib may be 3 cm in width. The support ribs may have a sufficient width so that the support ribs provide support to the pv laminate. The support ribs may have a width of about 3 mm or more, about 5 mm or more, about 10 mm or more, or even about 15 mm or more wide. The support ribs may have a width of about 30 cm or less, about 20 cm or less, or about 15 cm or less. The width of the support ribs may be about 2 times or more, 3 times or more, or even 4 times or more the width of the channels. A ratio of the width of the support ribs and the width of the channels may be about 1 :4 or less, about 1 :3 or less, about 1 :2 or less or preferably about 1 : 1. A ratio of the width of the support ribs to the width of the channels may be about 5: 1 or less, about 4: 1 or less, about 3: 1 or less, about 2: 1 or less, or about 1 : 1. Preferably, the width of the support ribs and the channels are substantially the same. The support ribs may be short enough that deflection of the pv laminate during a load may cause the pv laminate to contact the fluid transfer surfaces so that further deflection is prevented. The height of the support ribs may vary across the length and/or width of the support portion. For example, the support ribs may be formed at an angle so that the pv laminate has a slope. The support ribs may be all of a uniform height. The support ribs may have a height of about 1 mm or more, about 2 mm or more, or even about 3 mm or more. The support ribs may have a height of about 10 cm or less, about 5 cm or less or about 1 cm or less. The support ribs may provide support to the pv laminate when a load is applied that is substantially orthogonal to the pv laminate. The support ribs may be equally spaced apart along a length, width, or both of the pv laminate. The support ribs may run the length, width, or both of the pv laminate, the support portion, the base plate, or a combination thereof. The support ribs may be substantially parallel to each other, a slope of a connection surface, a flow direction of fluid, a flow direction of debris, or a combination thereof. The support ribs may have a complementary shape to a shape of the bottom of the pv laminate so that the support ribs assist in retaining the pv laminate on the base plate, above the base plate, or both. The support ribs may extend substantially to the edges of the base plate. The support ribs may not be located on the edges of the base plate and one or more lips may be located on the edges of the base plate. The support structure when including a pv laminate may form an support portion of the photovoltaic laminate.

[0025] The active portion may function to generate electricity when a pv laminate is connected to the base portion. The active portion may be a portion of the pv laminate that is not covered by one or more adjacent photovoltaic modules. The active portion may be a combination of a support portion of the base plate and a pv laminate. The pv laminate may be connected to the support portion by one or more locking features.

[0026] The one or more locking features may function to form a connection with one or more terminals, one or more pv laminates, or both. The one or more locking features may replace a fastener. The one or more locking features may be a lip that extends around a peripheral edge of a pv laminate and holds the pv laminate on the support portion. The one or more locking features may be connected to the base plate with a faster that extends partially over the pv laminate. The one or more locking features may be an integral part of the base plate. The one or more locking features may be discrete from the base plate and connected to the base plate. Preferably, there are a plurality of locking features that may be generally "L" shaped and may be fastened to the base plate to connect the photovoltaic laminate to the base plate. The one or more locking features may connect to a terminal of the pv laminate. The one or more locking features may be flexible so that the locking features move when the pv laminate is being installed, during thermal expansion of the base plate, during thermal expansion of the pv laminate, or a combination thereof. The locking features may be located on a top edge, bottom edge, either side edges, or a combination thereof to hold the pv laminate in place. The one or more locking features may work in conjunction with one or more connectors to lock the pv laminate to the base plate. The one or more locking features may assist a connector in forming and maintaining a fixed connection with a terminal of a pv laminate.

[0027] One or more connectors may extend between and connect two adjacent photovoltaic laminates. The one or more connectors may extend partially over a first photovoltaic laminate (and first photovoltaic module) and a second photovoltaic laminate (and second photovoltaic module). The one or more connectors may be straight. The one or more connectors may be "U" shaped. The one or more connectors may connector two terminals together. The one or more connectors may fit partially within a connector channel of a first base plate and partially within a connector channel of a second base plate.

[0028] The one or more connector channels may function to receive the one or more terminals of the pv laminate. The one or more connector channels may function to receive a connector that connect a first pv laminate to a second pv laminate. The one or more connector channels may function to protect the pv laminate terminals from contact, a lateral force, a longitudinal force, an impact, or a combination thereof. The one or more connector channels may assist in forming a connection between a connector (e.g., that connects two adjacent photovoltaic modules) and terminals of a pv laminate. The one or more connector channels may assist in electrically connecting two adjacent pv laminate terminals. The one or more connector channels may be a recess that receives the terminals of the pv laminate. The one or more connector channels may be generally sloped so that the connector channels assist in forming a connection between a connector and a terminal of two adjacent pv laminates. The one or more connector channels may be located on opposite edges, in opposing edge regions, on opposite sides, or a combination thereof of the base plate. The one or more connector channels may receive all of the terminals of the pv laminate. The one or more connector channels may angle downward so that the termianl and the pv laminate are on the same plane. The connector channels may include weep ports, edge channels, or both to remove fluids from the connector channels.

[0029] The one or more edge channels may function to remove fluid from the edges of the base plate. The one or more edge channels may function to allow for movement of the pv laminates within the base plate, for addition of a pv laminate into the base plate, removal of the pv laminate from the base plate, or a combination thereof while the base plate is connected to a connection surface. The one or more edge channels may create a gap between the positioning feature and the pv laminate. The one or more edge channels may function to allow for expansion and/or contraction of the base plate without contacting the pv laminate, independent of the pv laminate, or both. The edge channels may decouple the edges of the pv laminate from the base plate. The edge channels may create a gap for fluids to exit the base plate. The edge channels may extend the length, width, or both of the pv laminate. The edge channels may be located below the pv laminate. The edge channels may extend parallel to the one or more positioning features.

[0030] The one or more positioning features may function to create a side wall of connector channel. The one or more positioning features may function to protect a side of the connector channel, a side of a pv laminate, or both. The one or more positioning features may extend a sufficient amount above the connector, the terminals of the pv laminate, or both so that the connectors, terminals, or both are protected from a force, an orthogonal force, or both (e.g., a person stepping on the connectors or hail). The one or more positioning features may extend 1 mm or more, 2 mm or more, or even about 3 mm or more above the pv laminate. The one or more positioning features may extend along one or more edges and/or sides, 2 or more edges and/or sides, 3 or more edges and/or sides, may extend around a periphery of the support portion, or a combination thereof. The one or more positioning features may extend above the pv laminate without extending over the pv laminate. The positioning features may guide a connector so that the connector forms an electrical connection, a mechanical connection, or both with two adjacent pv laminate connectors. The positioning features may protect a connector spanning between two adjacent pv laminates, photovoltaic modules, or both. The positioning features may create a stop when the connector is inserted in the connector channels so that the connector is prevented from being pushed into the connectors of the pv laminate and damaging the pv laminate connectors. The one or more positioning features may be located on outside edges of the connector channels, the photovoltaic module, or both. The one or more positioning features may include one or more drain ports, one or more locators, or both.

[0031] The one or more drain ports may function to allow fluid to exit the drain channel, the edge channel, the connector channel, or a combination thereof. The one or more drain ports may be a gap, hole, slot, or a combination thereof through the positioning feature. The one or more drain ports may be located at any location along the length and/or width of the base plate. The one or more drain ports may be a single drain port in a central region of the positioning features. The drain channel, the edge channel, the connector channel, or a combination thereof may slope towards the drain port. The one or more positioning features may be located proximate to one or more handles, connection recesses, recess locks, fastener supports, connector guides, or a combination thereof.

[0032] The one or more connection recesses may function to connect two or more adjacent photovoltaic modules, two or more adjacent base plates, or both together. The one or more connection recesses may prevent movement of two or more base plates, two or more photovoltaic modules, or both relative to each other. The one or more connection recesses may function to receive a portion of an adjacent photovoltaic module, base plate, or both. Preferably, the connection recess receives a connection hook of an adjacent base plate and connects the two base plates together. Each base plate may include one or more connection hooks that extend from an underside of the base plate. The connection hooks may extend from the underside of one base plate through an upper surface and connection recess of an adjacent base plate and then hook into contact with the underside of the base plate forming a connection. The one or more connection recesses may extend along a width of the base plate. The one or more connection recesses may extend transverse to the slope of the roof. The one or more connection recesses may be located in the overlap portion, the support portion, or both. The one or more connection recesses may be spaced apart along the base plate so that the connection recesses may receive a portion of two or more adjacent base plates. The one or more connection recesses may be located along edges, in edge regions, in a central region, or a combination thereof of the base plate. Preferably the connection recesses are evenly spaced out across the base plate, the photovoltaic module, or both. The base plate may include two or more, three or more, four or more, or even five or more connection recesses, connection hooks, or both. The one or more connection recesses may be a plurality of connection recesses that each receives a portion of an adjacent base portion, an adjacent photovoltaic module, or both. The one or more connection recesses may be a through hole that extends through the base plate. The connection recesses may be a recess in the base plate that does not extend through the base plate. The one or more connection recesses may be located proximate to the connectors of the pv laminate, the connector channels, or both so that once a connection is formed the connection recesses assists in preventing movement of two adjacent connects relative to each other. The one or more connection recesses may be any shape that may receive a portion of an adjacent base plate so that the base plates are locked relative to each other, movement relative to each other is prevented, or both. The one or more connection recesses may be round, square, rectangular, oval, octagonal, triangular, a rhombus, or a combination thereof. The one or more connection recesses may include one or more connection ribs that create a border around the connection recesses.

[0033] The one or more connection ribs may function to support an adjacent photovoltaic module above the connection recess. The one or more connection ribs may function to prevent fluid from entering into the connection recess. The one or more connection ribs may be an elevated surface that extends from the base plate proximate to the connection recesses. The connection ribs may be a plurality of ribs that extend around a connection recess. The connection ribs may be a single connection rib that extends about a periphery of the connection recess. The connection ribs may assist in placing two adjacent photovoltaic modules in tension when the connection hook extends through the connection recess. For example, when a connection hook extends through the connection recess and contacts a recess lock a surface of the base plate may contact the connection rib so that the connection hook and the recess lock are always in contact. The one or more connection recesses may include a recess lock that prevents orthogonal movement, vertical movement, or both of two or more base plates, two or more photovoltaic modules, or both relative to each other.

[0034] The one or more handles may function to provide a carrying location for the base plate, the photovoltaic module, or both. The one or more handles may function to provide a location to lift the base plate, the photovoltaic module, or both. The one or more handles may be a through hole through the base plate. The one or more handles may be a through hole through the support portion, the overlap portion, or both of the base plate. The one or more handles may assist in forming a connection between two or more adjacent photovoltaic modules, base plates, or both. The one or more handles may align with another structure of one or more adjacent photovoltaic modules. The one or more handles may be located within the overlap portion and be opposite the photovoltaic laminates.

[0035] The photovoltaic laminate may be connected to a base plate, a support portion of the base plate, or both and form an active portion. The photovoltaic module includes an active portion and an inactive portion. The support portion and the active portion may be the same region of the base plate. The active portion may be any portion of the photovoltaic module that produces electricity when the active portion is in contact with sunlight. The one or more and preferably the plurality of pv laminates may be configured in any manner so that each of the plurality of photovoltaic modules may be electrically connected. The pv laminates may include a protective cover (e.g., a glass cover or a barrier plastic cover) and at least one pv cell. Each of the individual photovoltaic laminates (i.e., the pv laminates in the photovoltaic modules) may be electrically connected to an adjacent photovoltaic laminate of a photovoltaic module by one or more connectors and terminals. The one or more terminals may comprise an interconnect element, ribbon, a positive buss bar, a negative buss bar, a wire, a part of an integrated flashing piece, or a combination thereof. A connector may extend between two adjacent photovoltaic module terminals and form an electrical connection. The terminals may be an integral part of a pv laminate. The pv laminate may be made of any material so that when sunlight is directed on the active portion the sunlight is converted into electricity. The pv laminate may be made of one or more photovoltaic cells having a photoactive portion. Preferably, the pv laminate may be made of a plurality of photovoltaic cells. More preferably, the pv laminate includes a plurality of photovoltaic cells that are connected together by interconnect elements. The photovoltaic cells may be made of any material that assists in converting sunlight into electricity. The photovoltaic cells may be of any type and material known in the art. Some non-limiting examples of materials that the photovoltaic cells may be made of include crystalline silicon, mono-crystalline silicon cells, poly-crystalline or multi- crystalline silicon cells, thin film silicon cells, bifacial silicon cells, amorphous silicon, cadmium telluride (CdTe), gallium arsenide (GaAs), copper chalcogenide type cells (e.g. copper gallium selenides, copper indium gallium selenides (CIGS), copper indium selenides, copper indium gallium sulfides, copper indium sulfides (CIS), copper indium gallium selenide sulfides, etc. (i.e., known generally as CIGSS)) , thin-film lll-V cells, thin-film ll-VI cells, IB-IIIA-chalcogenide (e.g., IB-IIIA-selenides, IB-IIIA-sulfides, or IB-IIIA-selenide sulfides), organic photovoltaics, nanoparticle photovoltaics, dye sensitized photovoltaic cells, and/or combinations of the described materials. Preferably, the laminate is made of crystalline silicon. In one specific example, the copper indium gallium selenides may be represented by the formula Culn(1- x)GaxSe(2-y)Sy where x is 0 to 1 and y is 0 to 2. For copper chalcogenide type cells, additional electroactive layers such as one or more of emitter (buffer) layers, conductive layers (e.g. transparent conductive layers) or the like maybe used in CIGSS based photovoltaic cells are contemplated by the teachings herein. The photovoltaic cells of the photovoltaic laminate may be arranged in parallel, series, mixed series-parallel, and/or may be provided in independent circuits. The photovoltaic laminate may be a combination of layers and may form an assembly.

[0036] The pv laminate assembly may include one or more of the following components: a forward protective layer, a rearward protective layer, a reinforcement, a photovoltaic cell, a peripheral moisture sensitive edge seal, one or more internal protecting layers, dielectric materials as may be needed to manage the penetration of electrical components outside the laminate, attached connectors and wiring boxes, connector support structures including junction boxes, integrated low profile connectors, encapsulants, moisture resistant back sheets that may optionally include metallized sub layers, or a combination thereof. One example of a pv laminate may include a top layer of glass or a polymeric moisture barrier, an encapsulant layer, an electrical assembly comprising cells, bypass diodes and busses, a rear encapsulant layer, an aluminum based multi-layer back sheet, another encapsulant layer, a rearward protective layer, additional layers around the connector area including a connector support structure, an encapsulant, a dielectric layer, a connector sealant material such as an adhesive with a moisture barrier or another adhesive sealant or potting material, the low profile connector attached to the cells with bus terminals, another layer of encapsulant, and another dielectric layer. The rearward protective layer may help protect the laminate from any protrusions or abrasion from the support structure of the base plate. The pv laminate assembly may be free of an encapsulant layer, a rearward protective layer, or both. One or more of the layers discussed herein may be a combination of layers. For example, a forward protective layer may be a combination of multiple glass layers combined together. As another example, the reinforcement may be a plurality of layers bonded together. The layers of pv laminate assembly may be laminated together. The layers of the pv laminate may be sealed at the edges. Preferably, the pv laminate has a peripheral sealed edge that is resistant to fluid penetration. As discussed herein, each individual layer may include an adhesive so that one or more layers are bonded together forming a layer, each layer may include an adhesive over and/or under another layer so that the one or more adjacent layers are bonded together. Other components and layers of the photovoltaic module are contemplated herein that may be used with the reinforcement taught herein especially those components, layers, and/or materials disclosed. One or more of the layers of the pv laminate may be electrical circuitry. The electrical circuitry may be sealed within the pv laminate.

[0037] The electrical circuitry of the photovoltaic laminate may be one or more buss bars, one or more ribbons, one or more interconnect elements, one or more diodes, capacitors, resistors, or a combination thereof. The electrical circuitry of one pv laminate may function to receive sunlight and to convert the sunlight into power. The electrical circuitry of one pv laminate may be one or more photovoltaic cells that are connected together by one or more interconnect elements. Preferably, the electrical circuitry of each pv laminate is a plurality of photovoltaic cells and a plurality of interconnect elements that connect each of the photovoltaic cells. The electrical circuitry may extend from cell to cell, photovoltaic module to photovoltaic module, cell to a photovoltaic module, active portion to active portion, or a combination thereof. Some of the electrical circuitry may extend on an upper surface of a laminate, a lower surface of a laminate, or both. For example, interconnect elements may extend from an upper surface of one photovoltaic cell to a lower surface of an adjacent photovoltaic cell and one or more diodes may be in communication with one or more of the interconnect elements. Preferably, when diodes, capacitors, resistors, or a combination thereof are present they are located on the lower surface or internal within the photovoltaic laminate. The diodes, capacitors, resistors, or a combination thereof may prevent electricity from flowing in two directions (i.e., may keep electricity flowing in a first direction only). The diodes, capacitors, resistors, or a combination thereof may be on a lower surface electrical circuit elements, photovoltaic cells, laminate, or a combination thereof. The diodes, capacitors, resistors, or a combination thereof may have a thickness that is greater than a thickness of the pv laminate. The diodes, capacitors, resistors, or a combination thereof may extend above or below a main plane of the pv laminate. The diodes, capacitors, resistors, or a combination thereof may be connected to the interconnect elements and extend from the interconnect elements. The electrical circuitry may be integrated into the one or more photovoltaic cells, connect the one or more photovoltaic cells, be electrically connected to the one or more photovoltaic cells, or a combination thereof. The electrical circuitry may be integrated into and/or around one or more layers of the photovoltaic laminate. The electrical circuitry may extend through the photovoltaic laminate, extend partially outside of the photovoltaic laminate so that an electrical connection may be formed, have a portion that is located adjacent to the photovoltaic laminate, or a combination thereof. The photovoltaic laminate may be connected to a support portion of a base plate forming an adjacent portion. The pv laminate may include one or more terminals that are part of the electrical circuity and extend outside of the pv laminate. The one or more terminals may have a portion that is sealed within the pv laminate and connects to one or more interconnect elements and a portion that extends out of the pv laminate.

[0038] The one or more interconnect elements may extend along an upper surface of a photovoltaic cell, a lower surface of a photovoltaic cell, between two or more photovoltaic cells, or a combination thereof. The interconnect elements may function to connect a string of photovoltaic cells together. The interconnect elements may be a ribbon, a wire mesh, or a combination thereof. The interconnect elements may be overlapped with an encapsulant, adhesive, solder, weld, a protective layer, a coating, or a combination thereof. The interconnect elements may be sandwiched between the photovoltaic cells and an outer layer of the photovoltaic laminate. The interconnect elements may be located solely within the pv laminate. The interconnect elements may only connect two or more photovoltaic cells together. The interconnect element may connect to a larger bus or a larger wire that provides the power to a central location such as a terminal. The interconnect elements may connect a photovoltaic cell to a bus. The interconnect elements may extend above an upper surface of the photovoltaic cells, or below a lower surface of the photovoltaic cells. The interconnect elements may create a raised surface within the photovoltaic laminate so that the photovoltaic laminate when placed on a planar surface does not lie flat. The interconnect elements may fit within one or more transverse channels so that the main portion of the pv laminate lies flat and the interconnect elements extend in a plane below the main portion. The interconnect elements may be metallic. The interconnect elements may be made of silver, gold, copper, aluminum, iron, steel, or a combination thereof. The interconnect elements may be disposed on the cells by screen printing, gluing, welding, soldering, or a combination thereof. The interconnect elements may be connected to one or more of the cells discussed herein.

[0039] Figure 1 is a top view of a base plate 6 of a photovoltaic module. The base plate 6 includes handles 40, fastener locations 50, and connection recesses 42 located within an overlap portion 10. A connection channel 16 extends from the overlap portion 10 to a support portion 8, which is also an active portion 4 when a laminate (not shown) is installed. The connection channel 16 terminates at a drain port 30 at the edge of the base plate 6 so that fluids are removed from the base plate 6. The support portion 8 includes a support structure 90 including a plurality of channels 7, that extend in a longitudinal direction, located in an alternating fashion between a plurality of support ribs 9, and a plurality of channels 52 that extend in a transverse direction. The support ribs 9 support a laminate (not shown) and are a factor of two times or more wider than the channels 7 that extend in the longitudinal direction. Sides of the support portion 8 include positioning features 15 and edge channels 32 that allow fluid to exit the base plate 6. An end of the support portion 8 incudes locking features 14 to lock a laminate (not shown) on the support portion 8. [0040] Figure 1A is a cross-sectional view of Figure 1 along lines 1A-1A. The support portion 8 includes a support structure 90 including channels 7 extending in the longitudinal direction that located between support ribs 9. The channels 7 extending in the longitudinal have a width WT and are fluid transfer surfaces. The support ribs 9 have a width WR. The width WR is about four times larger than the width WT.

[0041] Figure 1 B is a cross-sectional view of a support portion 8 a support structure 90 that includes channels 7 extending in the longitudinal direction and support ribs 9. The channels 7 have a width W _T and the support ribs 9 have a width W _R . The width W _R is substantially equal the width W _T .

[0042] Figure 2 illustrates a plurality of interconnected cells 82. Each photovoltaic laminate 80 (not shown) includes photovoltaic cells 82. Each of the photovoltaic cells 82 are connected together by interconnect elements 84. As shown interconnect elements 84 extend from the top of one photovoltaic cell 82 to a bottom of an adjacent photovoltaic cell 82.

[0043] Figure 3 illustrates a base plate 6. The base plate 6 includes a support portion 8 that includes a support structure 90 including channels 7 and support ribs 9, which both extend in a longitudinal direction 120 from a bottom to a top of the base plate 6. The support structure 90 has channels 52, which extend in a transverse direction 122 and extend at an angle (a) relative to the channels 7 and support ribs 9 that extend in the longitudinal direction 120.

[0044] Figure 4 is an exploded view of a photovoltaic module 2. The photovoltaic module includes a photovoltaic laminate 80 with terminals 86 on opposing edges. The photovoltaic laminate 80 during installation rests upon a support portion 8. The support portion 8 includes a plurality of channels 7 and support ribs 9 that are alternating and extend in a longitudinal direction. The support portion 8 also includes a plurality of channels 53 that extend in the transverse direction.

[0045] Figure 5 is a top view of a photovoltaic laminate 80. The photovoltaic laminate 80 includes a plurality of photovoltaic cells 82 that are connected together by electrical circuitry 60. The electrical circuitry 60 is also connected to terminals 86 which are covered by an integrated frame 88. The electrical circuitry 60 includes interconnect elements 84 and diodes 62 that are connected to the interconnect elements 60 when connect the plurality of photovoltaic cells 82 together. Figure 6 illustrates a photovoltaic array 1. The photovoltaic array 1 includes a plurality of photovoltaic modules and a plurality of integrated flashing pieces, but for illustrative purposes the only photovoltaic module being discussed is the photovoltaic module 2 that is labeled. The photovoltaic module 2 is partially covered from above by two adjacent photovoltaic components 130. One of the adjacent photovoltaic components 130 is a photovoltaic module that partially covers the photovoltaic module 2 while a second adjacent photovoltaic module 130, which is an integrated flashing piece 132 partially covers a remaining portion of the photovoltaic module 2 so that all that is exposed is the active portion 4 including the photovoltaic laminate 80. The integrated flashing piece 132 also has a portion that extends alongside the photovoltaic module 2 so that the integrated flashing piece 132 spans two rows. Additionally, the photovoltaic module 2 is located next to an adjacent photovoltaic component 130 and partially covers two adjacent photovoltaic components 130. The photovoltaic module 2 has adjacent photovoltaic components 130 on all sides.

[0046] Any numerical values recited herein include all values from the lower value to the upper value in increments of one unit provided that there is a separation of at least 2 units between any lower value and any higher value. As an example, if it is stated that the amount of a component or a value of a process variable such as, for example, temperature, pressure, time and the like is, for example, from 1 to 90, preferably from 20 to 80, more preferably from 30 to 70, it is intended that values such as 15 to 85, 22 to 68, 43 to 51 , 30 to 32 etc. are expressly enumerated in this specification. For values which are less than one, one unit is considered to be 0.0001 , 0.001 , 0.01 or 0.1 as appropriate. These are only examples of what is specifically intended and all possible combinations of numerical values between the lowest value and the highest value enumerated are to be considered to be expressly stated in this application in a similar manner.

[0047] Unless otherwise stated, all ranges include both endpoints and all numbers between the endpoints. The use of "about" or "approximately" in connection with a range applies to both ends of the range. Thus, "about 20 to 30" is intended to cover "about 20 to about 30", inclusive of at least the specified endpoints.

[0048] The disclosures of all articles and references, including patent applications and publications, are incorporated by reference for all purposes. The term "consisting essentially of" to describe a combination shall include the elements, ingredients, components or steps identified, and such other elements ingredients, components or steps that do not materially affect the basic and novel characteristics of the combination. The use of the terms "comprising" or "including" to describe combinations of elements, ingredients, components or steps herein also contemplates embodiments that consist essentially of the elements, ingredients, components or steps. By use of the term "may" herein, it is intended that any described attributes that "may" be included are optional.

[0049] Plural elements, ingredients, components or steps can be provided by a single integrated element, ingredient, component or step. Alternatively, a single integrated element, ingredient, component or step might be divided into separate plural elements, ingredients, components or steps. The disclosure of "a" or "one" to describe an element, ingredient, component or step is not intended to foreclose additional elements, ingredients, components or steps.

[0050] It is understood that the above description is intended to be illustrative and not restrictive. Many embodiments as well as many applications besides the examples provided will be apparent to those of skill in the art upon reading the above description. The scope of the teachings should, therefore, be determined not with reference to the above description, but should instead be determined with reference to the appended claims, along with the full scope of equivalents to which such claims are entitled. The disclosures of all articles and references, including patent applications and publications, are incorporated by reference for all purposes. The omission in the following claims of any aspect of subject matter that is disclosed herein is not a disclaimer of such subject matter, nor should it be regarded that the inventors did not consider such subject matter to be part of the disclosed inventive subject matter.

[0051] 1 Photovoltaic array

[0052] 2 Photovoltaic Module

[0053] 4 Active portion

[0054] 6 Base Plate

[0055] 7 longitudinal Channel (Fluid transfer surface)

[0056] 8 Support portion

[0057] 9 Support ribs

[0058] 10 Overlap portion

[0059] 14 Locking feature

[0060] 5 Positioning Feature

[0061] 16 Connector channel

[0062] 30 Drain port

[0063] 32 Edge channel

[0064] 34 Drain Channel

[0065] 40 Molded in handles

[0066] 42 Connection recess

[0067] 50 Fastener Locations

[0068] 52 Transverse channel

[0069] 60 Electrical circuitry

[0070] 62 Diode

[0071] 80 Photovoltaic laminate

[0072] 82 Photovoltaic Cells

[0073] 84 Interconnect elements

[0074] 86 Terminal

[0075] 88 Integrated frame

[0076] 90 Support structure

[0077] 100 Surface structure

[0078] 120 Longitudinal direction [0079] 122 Transverse direction

[0080] 130 Adjacent photovoltaic component

[0081] 132 Integrated flashing piece.