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Tesla patent reveals Solar module aimed at faster, more attractive installations

(Credit: Tesla)

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Tesla Solar may have taken a step back from the limelight in recent years due to the electric car maker’s efforts to ramp the Model 3 sedan, but recent signs from the company indicate that it is now ready to start aggressively pushing its Energy business. Apart from high-profile projects such as the 50% expansion of the Hornsdale Power Reserve, Tesla also appears to be working on notable improvements to its residential solar system installation processes. 

One such improvement was outlined in a recent patent application titled Method and apparatus for mounting photovoltaic modules. The patent describes a novel mounting system for photovoltaic modules that make them easier to install, maintain, and even remove if necessary. Tesla notes that its patent allows solar panel installations to be more aesthetically pleasing than traditional PV setups as well. 

In its discussion, Tesla explained that solar panel installations are usually hit by a number of challenges, particularly in terms of alignment, grounding, wiring, rafter connections, and several other factors related to the mounting of the PV system itself. With this in mind, Tesla stated that there is a clear need for a PV module mounting system that is simple, cost-effective, and widely adaptable. 

A side elevation cross-sectional view of a first embodiment of an interlocking photovoltaic module mounting system, illustrating two adjacent interlocked photovoltaic module frames. (Credit: US Patent Office)

To address these challenges, Tesla has come up with an invention that utilizes an interlocking photovoltaic module mounting system. This design provides a “one piece, integrated photovoltaic module frame portion that is directly mountable to a support structure and interlocks with separate adjoining photovoltaic module frame portions.” 

“A preferred embodiment of the invention includes an interlocking mechanism comprising at least one C-shaped channel portion on the outside surface of the PV module frame member with the opening oriented parallel to the plane of the substantially flat top solar cell covering, and which interlocks with an identical adjoining C-shaped channel portion of an adjoining PV module frame member through the use of a separate male coupling member which is inserted into the C-shaped portions of the two adjoining modules. The adjacent C-shaped channel portions do not overlap each other. The male coupling member may also serve as a means for providing electric ground continuity between PV modules,” Tesla wrote. 

Such a system would offer a variety of benefits for Tesla and homeowners. Among these benefits include potentially faster installation processes, easier maintenance, and even simpler removal, to name a few. Utilizing the design outlined in Tesla’s patent, the electric car maker further explained that solar installations would look better, since the mounting systems provide no gaps between modules. Such a system will likely not make regular solar panel installations as attractive as, say, a Tesla Solar Roof installation, but it does allow for a very sleek overall look. 

“The inventive system thus provides an interlocking, self-grounding, and self-aligning framing structure for each module, which provides three-dimensional adjustability, allows simple connection to the rafters, minimizes penetrations in the roof, allows access to wiring interconnects without removing modules, does not require expensive strut hardware, utilizes a non-overlapping, interlocking mechanism which allows for all PV modules in an array to rest in the same plane instead of having consecutive modules at slightly different angles due to the overlapping nature of an interleaved connection, and which in some embodiments allows removal of single PV modules from the middle of the array. 

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“The inventive system also provides an attractive appearance by having a low profile, with no gaps between modules, and no visible hold-downs or hardware, plus optional cosmetic flashings for screening visible edges of the array and optional cosmetic caps for covering the small gaps that may occur, or in one embodiment, for bridging between two adjacent PV modules to cover the wiring. Additional benefits are further described herein,” Tesla noted. 

Promoting solar installations to homeowners is a key component of Tesla Energy’s business. And to gain an advantage in the residential solar market, Tesla would need to ensure that its PV installations are worthy of its premium brand while being cost-effective overall. Tesla’s electric cars are a cut above the rest of the market and thus, the expectations for its energy business are high. With such ideas as presented in this recently published patent application, it would appear that Tesla is actively exploring ways to improve its residential solar initiatives, even down to their mounting system. 

Read the full discussion on Tesla’s innovative PV mounting solution patent here.

Simon is an experienced automotive reporter with a passion for electric cars and clean energy. Fascinated by the world envisioned by Elon Musk, he hopes to make it to Mars (at least as a tourist) someday. For stories or tips--or even to just say a simple hello--send a message to his email, simon@teslarati.com or his handle on X, @ResidentSponge.

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Elon Musk says Tesla Cybercab future is ‘obvious to anyone with eyes and a brain’

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Elon Musk said the Tesla Cybercab will perform “a majority of all passenger miles” where it is allowed to operate and that point is “obvious to anyone with eyes and a brain.”

Musk used the point to double down on the company’s decision to ax the cult-favorite Cybertruck, as its production space will be removed and transitioned into additional Cybercab lines. The move has catalyzed a polarizing conversation on whether its right or wrong.

Whatever side you are on — it’s happening.

Regardless, Musk seems to be getting to the point that he is done talking about the choice. At some point, you have to think that this was truly a difficult decision for him and the company as well, and this is not something he took lightly. In fact, he’s probably a little bit disappointed with it, too.

But the point remains that the Cybertruck is gone. Musk’s focus is purely on developing an autonomous platform that the world will utilize for transportation, and he’s telling you that anyone “with eyes and a brain” can see it:

Tesla is betting that all of its passengers in the future will be okay with not owning their own personal cars and will be fine with ride-hailing for the rest of their lives. Every dinner, every errand, every trip to the airport and transportation thereafter, will all be operated by ride-sharing, and in Tesla’s perfect world, it will happen in a Cybercab.

As of now, Cybercab is only active in Austin, but it has been spotted all over the country with a driver behind the wheel in those prototypes. In Austin, the car has no steering wheel or pedals for people to control the vehicle.

The Cybertruck dilemma is one that has truly come across the entire Tesla community and while it seems to be a great idea to keep it because people love it, the business side of things is steering Musk and Tesla in another direction.

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Tesla slims Cybertruck offerings to only its most expensive trim

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Credit: u/dregonzz/Reddit

Tesla has slimmed its Cybertruck offerings to offer only its most expensive trim: the Cyberbeast.

After announcing that the Cybertruck would no longer be produced and the company would wind down manufacturing sometime in the middle of 2027, Tesla started to eliminate some of the configurations offered to customers.

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Now, only one remains: the $109,990 Cyberbeast. This is truly what seems like Tesla’s last effort to deter any remaining orders from coming in: eliminate the cheap trims and leave only the high-dollar vehicle within the lineup of Cybertruck options.

Those who want to take advantage of this last-ditch opportunity to own Tesla’s symbolic pickup have to pay to play.

Tesla says the reason for the wind down is truly because of Cybercab and its importance to the future.

Despite cries for Tesla to continue production of the pickup, Musk says it is too difficult to ramp a high-volume line instead of ending the truck altogether. He also says Cybercab is what will take passengers around for the “majority of all miles in any jurisdiction where it is not prohibited by law.”

Tesla is going all in on autonomy, and that’s never been a secret. But the commitment to a two-door, two-seat Cybercab truly limits people from having options for labor or hobbies. It also limits people from having their entire family in a single car.

Parents with even a single child will be required to take multiple vehicles if Cybercab is truly the only option Tesla plans to have.

Elon Musk keeps justifying Tesla Cybertruck’s cancelation, but it’s confusing

Tesla has stated the Robovan will also be in production eventually, but it still does not seem like the most ideal vehicle to own. It seems like it is geared more toward commercial uses, but Tesla might have something in the pipeline for families.

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Tesla exec hints at a wild fix for Robotaxi’s biggest weather problem

Tesla VP Lars Moravy says focused lasers could keep robotaxi cameras clear instead of wipers.

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Tesla Cybercab in a rainy Austin, Texas rendering

Tesla may one day use lasers instead of wiper blades to keep its robotaxi cameras clear. Lars Moravy, Tesla’s Vice President of Vehicle Engineering, floated the idea in a new episode of Jay Leno’s Garage released Monday, where he and design chief Franz von Holzhausen walked Leno through the Model Y L.

“If you fire them in a focused area, you can clean the sheet of water and create a barrier,” Moravy said. “When you think about autonomy, it might be a good solution to only clean the area where the camera is.” He added that clearing an entire windshield would take too many lasers to be practical.

The comment brings back one of Tesla’s stranger patents. The company filed for “Pulsed Laser Cleaning of Debris Accumulated on Glass Articles in Vehicles and Photovoltaic Assemblies” in May 2019, and the U.S. Patent Office granted it in September 2021. An updated divisional version was granted on March 31, 2026. The system detects debris on the glass, identifies what it is, and pulses the laser at a calibrated rate so the beam never penetrates deeper than the glass itself. The filing names windshields, side windows, camera lenses and solar panels as possible targets.

Lasers were once rumored for the Cybertruck, which appeared at its November 2019 unveiling with no wipers at all. Tesla eventually settled on a single oversized blade, and Elon Musk admitted the wiper was the part of the truck that troubled him the most. That production line is now scheduled to shut down around mid 2027 to make room for more Cybercab output.

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What has changed since then is who is in the vehicle. A privately owned car has a driver who can notice a smeared windshield and do something about it. A Cybercab heading to its next pickup has nobody on board to check. Tesla has been chipping away at that problem with conventional hardware. Model Y Robotaxis in Austin were spotted with washers on their side repeater cameras in January, and a lens cleaning patent granted in May describes a fluid and wiper assembly for vehicle cameras and Optimus’ eyes. A laser would remove the fluid and the blades, both of which need regular replacement across a fleet.

The same episode gave Leno his first ride on Full Self-Driving (Supervised). The Model Y L pulled over on its own when an ambulance approached with its sirens on. “We got it on self-driving mode! I’m not touching anything,” Leno said. Moravy and von Holzhausen also explained that owners remain responsible while using FSD (Supervised), while Tesla takes responsibility for Robotaxi rides because it acts as the operator. Tesla launched the Model Y L in the U.S. in July at $61,990.

Moravy gave no timeline, and he described the laser setup as something Tesla is considering rather than a confirmed feature. The fleet it would serve keeps getting bigger, though. Tesla launched unsupervised Robotaxi service in San Antonio on Monday, its eighth city, and expanded its Austin service area to roughly 443 square miles on the same day. Several of those markets, including Houston, Miami and Tampa, see heavy seasonal rain.

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