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

• Current Assignee: Dow Global Technologies LLC (Dow, Inc.)
• Original Assignee: Dow Global Technologies LLC (Dow, Inc.)
• Inventors: Keenihan, James R., Langmaid, Joseph A., Cleereman, Robert J., Graham, Andrew T.
• Primary Examiner(s): Pillay, Devina
• Application Number:
  US14/797,857
• Publication Number:
  US 20150318427A1
• Time in Patent Office: 1,212 Days
• CPC Class Codes: H01L 31/02008 for solar cells or solar cell modules
• CPC Class Codes: H01L 31/02013 comprising output lead wires elements
• CPC Class Codes: H01L 31/048 Encapsulation of modules
• CPC Class Codes: H01L 31/05 Electrical interconnection means between PV cells inside the PV module, e.g. series connection of PV cells electrodes H01L31/0224; electrical interconnection of thin film solar cells formed on a common substrate H01L31/046; particular structures for electrical interconnecting of adjacent thin film solar cells in the module H01L31/0465; electrical interconnection means specially adapted for electrically connecting two or more PV modules H02S40/36
• CPC Class Codes: H01L 31/0508 the interconnection means having a particular shape
• CPC Class Codes: H01L 31/18 Processes or apparatus specially adapted for the manufacture or treatment of these devices or of parts thereof
• CPC Class Codes: H01R 12/79 connecting to rigid printed circuits or like structures
• CPC Class Codes: H01R 13/055 co-operating with sockets having a rectangular transverse section
• CPC Class Codes: H01R 13/113 co-operating with pins or blades having a rectangular transverse section
• CPC Class Codes: H01R 13/639 Additional means for holding or locking coupling parts together, after engagement, e.g. separate keylock, retainer strap
• CPC Class Codes: H01R 13/7032 making use of a separate bridging element directly cooperating with the terminals
• CPC Class Codes: H01R 31/00 Coupling parts supported only by co-operation with counterpart
• CPC Class Codes: H02S 20/23 specially adapted for roof structures
• CPC Class Codes: H02S 20/25 Roof tile elements
• CPC Class Codes: H02S 40/34 comprising specially adapted electrical connection means to be structurally associated with the PV module, e.g. junction boxes
• CPC Class Codes: H02S 40/36 characterised by special electrical interconnection means between two or more PV modules, e.g. electrical module-to-module connection
• CPC Class Codes: Y02A 30/60 Planning or developing urban green infrastructure
• CPC Class Codes: Y02B 10/10 Photovoltaic [PV]
• CPC Class Codes: Y02E 10/50 Photovoltaic [PV] energy
• CPC Class Codes: Y10T 29/49117 Conductor or circuit manufacturing
• CPC Class Codes: Y10T 29/49355 : Solar energy device making
• CPC Class Codes: Y10T 29/49826 : Assembling or joining

Abstract

The present invention is premised upon a connector device and method that can more easily electrically connect a plurality of PV arrays and/or locate these arrays upon a building or structure. It also can optionally provide some additional components (e.g. a bypass diode and/or an indicator means) and can enhance the serviceability of the array.

Claims

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, and

2. 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, and

2. 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.

2. The method according to claim 1, wherein some or all of the connector assemblies have a first end portion that is integral to the plurality of edge pieces, the plurality of photovoltaics devices, or both.

3. The method of claim 1, wherein the structure is a building.

4. The method of claim 1, includes a step of providing at least one connector assembly located integrally within the at least one peripheral edge, as a separate connector, or both.

5. The method of claim 1, wherein the method includes a step of connecting a pass-through electrical connector or electrical lead assembly to the first row or column opposite the edge piece connected to the end of the first row or column.

6. The method of claim 1, wherein the plurality of edge pieces include a starter edge piece, an end edge piece, and edge pieces that include two or more edge connector assemblies that connect two rows or columns of photovoltaic devices together.

7. The method of claim 1, wherein the connector housing of each connector assembly is inserted into the main body portion of the edge piece.

8. The method according to claim 1, including the step of providing a spacer device between two of the individual photovoltaic devices.

9. The method according to claim 8, wherein the first row or column, second row or column, or both, include at least one spacer device in place of at least one of the individual photovoltaic devices.

10. The method according to claim 1, wherein the steps c-h are repeated to create a photovoltaic device assembly with a plurality of rows or columns.

11. The method of claim 10, wherein the method includes a step of connecting the plurality of edge pieces to the plurality of rows or columns.

12. The method of claim 11, wherein the method includes a step of connecting a pass-through electrical connector or electrical lead assembly to the first row or column opposite the edge piece connected to the first end of the first row or column.

13. The method of claim 10, wherein the at least one bus terminal is two bus terminals and method includes a step of connecting the two bus terminals together by connecting a starter piece to an end of the first row or column opposite the edge piece connected to the first end of the first row or column.

14. The method of claim 13, wherein the method includes a step of connecting an end piece to an end of a last row or column and the end piece includes a pass-through electrical connector.

15. The method of claim 1, wherein the method includes a step of attaching a fourth row or column of individual photovoltaic devices immediately adjacent to in partial contact with the third row or column, using the same steps as the first row or column.

16. The method of claim 15, wherein the method includes a step of attaching a third of the plurality of edge pieces via a connector assembly at a first end of the third row or column and the fourth row or column opposite the second edge piece connected to the second row or column and the third row or column.

17. The method of claim 1, wherein the main body portion of some of the plurality of edge pieces includes an inner surface portion that is solid or has geometric features.

18. The method of claim 17, wherein the geometric features are ribs.

19. The method of claim 18, wherein the method includes a step of press-fitting the electrical elements spanning between the two connector assemblies into cuts in the ribs.

20. The method of claim 1, wherein the method includes a step of inserting the two connector assemblies into a housing that is integral to the main body portion of the edge pieces.

21. The method of claim 20, wherein the housing integral to the edge piece is a receptacle housing that receives the two connector assemblies and connects the two connector assemblies to the electrical elements that span between the two connector assemblies.