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Photovoltaic device assembly and method

  • US 10,121,911 B2
  • Filed: 07/13/2015
  • Issued: 11/06/2018
  • Est. Priority Date: 05/05/2008
  • Status: Active Grant
First Claim
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1. A method comprising the steps of:

  • a. providing a plurality of individual photovoltaic devices on a surface of a structure, wherein the individual photovoltaic devices each include;

    i. a photovoltaic cell assembly including;

    1. at least one peripheral edge, and2. at least one photovoltaic cell inboard of the at least one peripheral edge, wherein the at least one photovoltaic cell includes a photoactive portion, and a surface that allows transmission of light energy to the photoactive portion for conversion into electrical energy;

    ii. at least one bus terminal for transferring current to or from the photovoltaic cell assembly; and

    iii. a body portion including;

    1. a lower surface portion that contacts the structure, and2. an upper surface portion that receives a fastener that attaches the individual photovoltaic devices to the structure,wherein the body portion is at least partially joined to at least one edge portion of the at least one peripheral edge of the photovoltaic cell assembly along at least a portion of a bottom segment of the body portion while leaving the surface of the at least one photovoltaic cell exposed;

    b. providing a plurality of edge pieces;

    c. attaching a first individual photovoltaic device to the surface of the structure;

    d. attaching the second individual photovoltaic device to the first individual photovoltaic device;

    e. attaching the second individual photovoltaic device to the surface of the structure;

    f. repeating steps c-e until a first row or column is attached to the surface;

    g. attaching a second row or column of individual photovoltaic devices immediately adjacent to and in partial contact with the first row or column, using the same steps as the first row or column;

    h. attaching one of the plurality of edge pieces via a connector assembly to a first end of each of the first row or column and the second row or column;

    i. attaching a third row or column of individual photovoltaic devices immediately adjacent to and in partial contact with the second row or column, using the same steps as the first row or column; and

    j. attaching a second of the plurality of edge pieces via a connector assembly to a second end of each of the second row or column and the third row or column;

    wherein the at least one bus terminal extends along the first row or column through the one of the plurality of edge pieces located at the first end to the second row or column then through the second of the plurality of edge pieces to the third row or column so that the at least one bus terminal has a serpentine configuration; and

    wherein some of the plurality of edge pieces include;

    a main body portion;

    two connector assemblies that connect to two respective rows or columns so that the two respective rows or columns are electrically connected, the two connector assemblies being a separate element from the main body portion, wherein each connector assembly includes electrical connectors housed within a connector housing, and wherein the connector housing is connected to a surface of the main body portion of the edge piece; and

    electrical elements that span between the two connector assemblies, the electrical elements at least partially defining the at least one bus terminal.

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