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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. 

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“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. 

“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.

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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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Tesla teases new market entrance with confusing and cryptic message

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(Credit: Tesla)

Tesla teased its entrance into a new market with a confusing and what appeared to be cryptic message on the social media platform X.

The company has been teasing its entrance into several markets, including Africa, which would be a first, and South America, where it only operates in Chile.

In September, Tesla started creating active job postings for the Colombian market, hinting it would expand its presence in South America and launch in a new country for the first time in two years.

Tesla job postings seem to show next surprise market entry

The jobs were related to various roles, including Associate Sales Manager, Advisors in Sales and Delivery, and Service Technicians. These are all roles that would indicate Tesla is planning to launch a wide-scale effort to sell, manage, and repair vehicles in the market.

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Last night, Tesla posted its latest hint, a cryptic video that seems to show the outline of Colombia, teasing its closer than ever to market entry:

This would be the next expansion into a continent where it does not have much of a presence for Tesla. Currently, there are only two Supercharger locations on the entire continent, and they’re both in Chile.

Tesla will obviously need to expand upon this crucial part of the ownership experience to enable a more confident consumer base in South America as a whole. However, it is not impossible, as many other EV charging infrastructures are available, and home charging is always a suitable option for those who have access to it.

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Surprisingly, Tesla seems to be more concerned about these middle-market countries as opposed to the larger markets in South America, but that could be by design.

If Tesla were to launch in Brazil initially, it may not be able to handle the uptick in demand, and infrastructure expansion could be more difficult. Brazil may be on its list in the upcoming years, but not as of right now.

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Tesla expands crucial Supercharging feature for easier access

It is a useful tool, especially during hours of congestion. However, it has not been super effective for those who drive non-Tesla EVs, as other OEMs use UI platforms like Google’s Android Auto or Apple’s iOS.

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tesla supercharger
Credit: Tesla

Tesla has expanded a crucial Supercharging feature that helps owners identify stall availability at nearby locations.

Tesla said on Tuesday night that its “Live Availability” feature, which shows EV owners how many stalls are available at a Supercharger station, to Google Maps, a third-party app:

Already offering it in its own vehicles, the Live Availability feature that Teslas have is a helpful feature that helps you choose an appropriate station with plugs that are immediately available.

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A number on an icon where the Supercharger is located lets EV drivers know how many stalls are available.

It is a useful tool, especially during hours of congestion. However, it has not been super effective for those who drive non-Tesla EVs, as other OEMs use UI platforms like Google’s Android Auto or Apple’s iOS.

Essentially, when those drivers needed to charge at a Supercharger that enables non-Tesla EVs to plug in, there was a bit more of a gamble. There was no guarantee that a plug would be available, and with no way to see how many are open, it was a risk.

Tesla adding this feature allows people to have a more convenient and easier-to-use experience if they are in a non-Tesla EV. With the already expansive Supercharger Network being available to so many EV owners, there is more congestion than ever.

This new feature makes the entire experience better for all owners, especially as there is more transparency regarding the availability of plugs at Supercharger stalls.

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It will be interesting to see if Tesla is able to expand on this new move, as Apple Maps compatibility is an obvious goal of the company’s in the future, we could imagine. In fact, this is one of the first times an Android Auto feature is available to those owners before it became an option for iOS users.

Apple owners tend to get priority with new features within the Tesla App itself.

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Elon Musk’s Boring Co goes extra hard in Nashville with first rock-crushing TBM

The Boring Company’s machine for the project is now in final testing.

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Credit: The Boring Company/X

The Boring Company is gearing up to tackle one of its toughest projects yet, a new tunnel system beneath Nashville’s notoriously tough limestone terrain. Unlike the soft-soil conditions of Las Vegas and Austin, the Music City Loop will require a “hard-rock” boring machine capable of drilling through dense, erosion-resistant bedrock. 

The Boring Company’s machine for the project is now in final testing.

A boring hard-rock tunneling machine

The Boring Company revealed on X that its new hard-rock TBM can generate up to 4 million pounds of grip force and 1.5 million pounds of maximum thrust load. It also features a 15-filter dust removal system designed to keep operations clean and efficient during excavation even in places where hard rock is present.

Previous Boring Co. projects, including its Loop tunnels in Las Vegas, Austin, and Bastrop, were dug primarily through soft soils. Nashville’s geology, however, poses a different challenge. Boring Company CEO and President Steve Davis mentioned this challenge during the project’s announcement in late July.

“It’s a tough place to tunnel, Nashville. If we were optimizing for the easiest places to tunnel, it would not be here. You have extremely hard rock, like way harder than it should be. It’s an engineering problem that’s fairly easy and straightforward to solve,” Davis said.

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Nashville’s limestone terrain

Experts have stated that the city’s subsurface conditions make it one of the more complex tunneling environments in the U.S. The Outer Nashville Basin is composed of cherty Mississippian-age limestone, a strong yet soluble rock that can dissolve over time, creating underground voids and caves, as noted in a report from The Tennessean.

Jakob Walter, the founder and principal engineer of Haushepherd, shared his thoughts on these challenges. “Limestone is generally a stable sedimentary bedrock material with strength parameters that are favorable for tunneling. Limestone is however fairly soluble when compared to other rack materials, and can dissolve over long periods of time when exposed to water. 

“Unexpected encounters with these features while tunneling can result in significant construction delays and potential instability of the excavation. In urban locations, structures at the ground surface should also be constantly monitored with robotic total stations or similar surveying equipment to identify any early signs of movement or distress,” he said.

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