A PACKAGING FACILITY FOR PHOTOVOLTAIC MODULES AND A METHOD
FOR PACKAGING PHOTOVOLTAIC MODULES
FIELD OF THE INVENTION
The present invention relates in general to a packaging facility for photovoltaic
modules and to a method for packaging photovoltaic modules and in particular,
to a special technique for packaging photovoltaic modules, involving application
of molded corners for supporting the weight of the modules, whereby the
resultant package has higher capacity to incorporate photovoltaic modules, apart
from being more compact, environment friendly, economic handy and easily
disposable.
BACKGROUND OF THE INVENTION
Traditionally, flat plate photovoltaic modules comprise interconnected cells. The
interconnected cells are laminated between EVA sheets which, in turn, are
sandwiched between glass and Tedlar back sheet, in case of crystalline silicon
photovoltaic modules. Similarly, thin film photovoltaic modules have
interconnected cells sandwiched between glass plates, with PVB or EVA as the
lamination sheet. Since modules have glass and plastics as the construction
material, they are fragile in nature and require special packaging and care during
shipment.
Accordingly, the packaging facility is required to be equipped to adequately
protect the modules against any damage and simultaneously, it has to be light
weight, easy to handle in terms of packing and unpacking, economical and
environment friendly. Further, it is of immense importance, that each packaging
facility must be able to incorporate a substantial number of photovoltaic modules,
preserving the characteristics and the performance of the modules.
The traditional packaging facilities for photovoltaic modules fundamentally
comprises, photovoltaic modules packed inside a cardboard box, which has
styrofoam padding. The box is usually made of semi-kraft paper and has a gsm
of 1650 gms. The boxes have corner inserts, having a gsm of 4200 gms. Each
box contains two photovoltaic modules.

However, the traditional packaging facilities for photovoltaic modules are not able
to ensure incorporation of a substantial number of photovoltaic modules,
preserving the characteristics and the performance of the modules. Such
packages are also not able to ensure, simultaneously being light weight, easy to
handle in terms of packing and unpacking, economical and environment friendly.
Accordingly, there was a long felt need to develop a packaging facility for
photovoltaic modules adapted to incorporate a substantial number of
photovoltaic modules, preserving the characteristics and the performance of the
modules and simultaneously ensuring being light weight, easy to handle in
terms of packing and unpacking, easily disposable, economical and environment
friendly.
The present disclosure meets the aforesaid long felt need by providing a
packaging facility for photovoltaic modules which has all the attributes, as
enumerated above.
All through out the specification, the words "packaging ", "packages",
"photovoltaic" and "modules ", are to be interpreted in the broadest sense of
the respective terms and restriction/limitation, if any, referred to in the
specification, is solely by way of example and understanding the present
invention and not by way of any sort of limitation/restriction.
OBJECTS OF THE INVENTION
It is a principal object of the present invention to provide a packaging facility for
photovoltaic modules which is adapted to protect the modules against any
damage.
It is a further object of the present invention to provide a packaging facility for
photovoltaic modules, which is adapted to incorporate a substantial number of
photovoltaic modules, preserving the characteristics and the performance of the
modules.
It is yet another object of the present invention to provide a packaging facility for
photovoltaic modules, which is light weight and easy to handle in terms of
packing and. unpacking.

It is yet another object of the present invention to provide a packaging facility for
photovoltaic modules, which is economical and environment friendly.
It is another object of the present invention to provide a packaging facility for
photovoltaic modules, which is easily disposable.
It is a further object of the present invention to provide a method for packaging
photovoltaic modules, which ensures incorporating a substantial number of
photovoltaic modules, preserving the characteristics and the performance of the
modules and simultaneously ensures that the resultant package is light weight,
easy to handle in terms of packing and unpacking, easily disposable,
economical and environment friendly .
How the foregoing objects are achieved and the other aspects of the present invention will be clear from the following description which is purely by way of understanding and not by way of any sort of limitation.
SUMMARY OF THE INVENTION
Accordingly the present invention provides a packaging facility for photovoltaic
modules including a top cover, molded corner stacks for supporting the weight of
plurality of photovoltaic modules to be stacked one over the other, a platform
having means projecting out of it for holding said modules in place compactly,
means for enveloping said modules from all sides compactly and means for
stretch wrapping the final pack whereby a substantial number of photovoltaic
modules are incorporated, preserving the characteristics and the performance of
the modules and other traits of being light weight, easy to handle in terms of
packing and unpacking, economical, environment friendly and easily disposable
are also ensured.
In accordance with preferred embodiments of the packaging facility of the
present invention:
-said top cover is made of plywood.
-said plywood is approximately 12mm thick.
-each corner of said facility, has rubber pads which damp the vibration.

-said platform comprises a wooden pallet having holes drilled in the corners and
mild steel rods project out of the holes to form one composite unit, which holds
the stacked modules in place.
-said steel rods are of approximately 6 mm diameter.
-said means for enveloping said modules from all sides comprises approximately
25 mm thick corrugated sheets.
-said means for stretch wrapping comprises approximately 80 micron thick
polythene sheets.
-said facility has at least four numbers molded corners, preferably of ABS for
each module.
The present invention also provides a method for packaging photovoltaic
modules including providing a top cover, providing molded corners preferably of
ABS for each photovoltaic module, each corner having means for damping
vibration, supporting the weight of the modules on said corners by stacking
plurality of modules one over the other, providing a platform of wood pallet
having mild steel rods of suitable diameter, projecting out of it as holding means
for holding the plurality of modules in place, enveloping the modules with means
such as corrugated sheets and finally stretch wrapping the pack with polythene
sheets.
BRIEF DESCRIPTION OF THE ACCOMPANYING DRAWINGS
The nature and scope of the present invention will be better understood from the
accompanying drawings, which are by way of illustration of some preferred
embodiments and not by way of any sort of limitation. In the accompanying
drawings:
Figure 1 illustrates a conventional package of stacked modules, involving two
pallets.
Figure 2 illustrates a conventional package of stacked modules, involving one
pallet.
Figure 3 illustrates another conventional package of photovoltaic modules.
Figure 4 illustrates another conventional package of photovoltaic modules having
two numbers of modules.

Figure 5 illustrates a further conventional package of photovoltaic modules. Figure 6 illustrates an exploded view of a preferred embodiment of the packaging facility for photovoltaic modules, in accordance with the present invention. Figure 7 illustrates a wooden pallet with M.S. rods, applied in the packaging facility in accordance with the present invention.
Figures 8(a) to 8(d) illustrates isometric front view, isometric top view, isometric bottom view and another isometric bottom view respectively, of the corner stack applied in the packaging facility in accordance with the present invention. Figure 9 illustrates a wooden pallet applied in the packaging facility in accordance with the present invention, incorporating photovoltaic modules. BRIEF DESCRIPTION OF THE INVENTION
The following describes some preferred embodiments of the present invention, which are purely for the sake of understanding the performance of the invention, and not by way of any sort of limitation.
As stated before, the packing facilities for photovoltaic modules known in the art, involved application of cardboard boxes. Fundamentally such packing facilities comprise, photovoltaic modules packed inside a cardboard box, which has styrofoam padding. The box is usually made of semi-kraft paper and has a gsm of 1650 gms. The boxes have corner inserts, having a gsm of 4200 gms. Each box contains two photovoltaic modules.
The packing facilities known in the art have been illustrated in the accompanying Figures 1 to 5. Figure 1 illustrates stacking of modules having two pallets while Figure 2 illustrates stacking of modules having one pallet. Figure 3 illustrates six corrugated boxes put on wooden pallet and then strapped. Figure 4 illustrates, packing of two numbers of modules. Figure 5 illustrates two modules packed in one corrugated box with EP foam, partition sheet and four small pieces of edge board.
The packaging facilities for photovoltaic modules known in the art were not adapted to incorporate a substantial number of photovoltaic modules, preserving the characteristics and the performance of the modules. Furthermore, such packaging facilities were not adapted to simultaneously ensure the other traits of

being light. weight, easy to handle in terms of packing and unpacking, economical, environment friendly and easily disposable.
The packaging facility in accordance with the present invention has been designed so as to possess all the attributes as stated in the preceding paragraph, simultaneously. This packaging facility dispenses with the cardboard boxes. A preferred embodiment of the packaging facility in accordance with the present invention has been illustrated in the accompanying Figure 6. As shown in Figure 6 the packaging includes a wooden top cover (1), solar modules with corner stack (2), 25mm thick corrugated sheet of four sides (3) for enveloping the modules from all sides, 6mm thick M.S. rods (4) projecting out from the wooden pallet (6) providing the platform for the package and 80 micron thick polythene sheets for wrapping (5). The different views of corner stack applied in the packaging facility in accordance with the present invention have been illustrated in Figures 8(a) to 8(d).
The new packaging preferably has four numbers molded corners, preferably of ABS for each module. The weight of the modules is supported on these at least four corners. Each corner has rubber pads which damp the vibration. Plurality of modules, say twelve numbers are stacked one over the other and the top module is covered with approximately 12 mm thick plywood. The four corners of pallet have holes drilled in them. Holding means such as four numbers mild steel rods of 6 mm diameter project out of such holes, having threads on both ends, and form one composite unit, which snugly holds the stacked modules in place. This has been very vividly illustrated in the accompanying Figure 7. 25 mm corrugated boards on the sides envelop the modules. The entire packing is stretch wrapped. Figure 9 illustrates a wooden pallet having photovoltaic modules, stacked on it in accordance with the present invention.
The method for packaging in accordance with the present invention basically includes providing preferably four molded corners of ABS, for each photovoltaic module, each corner having means for damping vibration, supporting the weight of the modules on said corners by stacking plurality of modules one over the other, providing a platform of wood pallet having M.S. rods projecting ogt of it as

holding means for holding the plurality of modules in place, enveloping the modules with means such as corrugated sheets and finally stretch wrapping the pack with polythene sheets.
The packaging facility for photovoltaic modules and the method for packaging photovoltaic modules in accordance with the present invention, all unequivocally achieve the following technical advancements and economic significance, hitherto not achieved or conceived.
a) Incorporates a substantial number of photovoltaic modules, preserving the characteristics and the performance of the modules.
b) The resultant package is light weight, easy to handle in terms of packing and unpacking,
c) The resultant package is economical, environment friendly, more compact, less voluminous and easily-disposable.
d) The resultant package dispenses extensive use of hazardous cardboard boxes.
The present invention has been described with reference to some drawings and preferred embodiments, purely for the sake of understanding and not by way of any limitation and the present invention includes all legitimate developments within the scope of what has been described hereinbefore and claimed in the appended claims.

WE CLAIM
1. A packaging facility for photovoltaic modules including a top cover, molded
corner stacks for supporting the weight of plurality of photovoltaic modules to be
stacked one over the other, a platform having means projecting out of it for
holding said modules in place compactly, means for enveloping said modules
from all sides compactly and means for stretch wrapping the final pack whereby
a substantial number of photovoltaic modules are incorporated, preserving the characteristics and the performance of the modules and other traits of being light weight, easy to handle in terms of packing and unpacking, economical, environment friendly and easily disposable are also ensured.
2. The packaging facility for photovoltaic modules as claimed in claim 1 wherein said top cover is made of plywood.
3. The packaging facility for photovoltaic modules as claimed in claim 2 wherein said plywood is approximately 12mm thick.
4. The packaging facility for photovoltaic modules as claimed in any preceding claim wherein each corner of said facility, has rubber pads which damp the vibration.
5. The packaging facility for photovoltaic modules as claimed in any preceding claim wherein said platform comprises a wooden pallet having holes drilled in the corners and mild steel rods project out of the holes to form one composite unit, which holds the stacked modules in place.
6. The packaging facility for photovoltaic modules as claimed in claim 5 wherein said steel rods are of approximately 6 mm diameter.
7. The packaging facility for photovoltaic modules as claimed in any preceding claim wherein said means for enveloping said modules from all sides comprises approximately 25 mm thick corrugated sheets.
8. The packaging facility for photovoltaic modules as claimed in any preceding claim wherein said means for stretch wrapping comprises approximately 80 micron thick polythene sheets.

9. The packaging facility for photovoltaic modules as claimed in any preceding
claim wherein said facility has at least four numbers molded corners, preferably
of ABS for each module.
10. A method for packaging photovoltaic modules including proving a top cover,
providing molded corners, preferably of ABS for each photovoltaic module, each
corner having means for damping vibration, supporting the weight of the modules
on said corners by stacking plurality of modules one over the other, providing a
platform of wood pallet having mild steel rods of suitable diameter, projecting out
of it as holding means for holding the plurality of modules in place, enveloping
the modules with means such as corrugated sheets and finally stretch wrapping
the pack with polythene sheets.