Connector device for building integrated photovoltaic device

• US 8,740,642 B2
• Filed: 05/01/2009
• Issued: 06/03/2014
• Est. Priority Date: 05/05/2008
• Status: Expired due to Fees

• Current Assignee: Dow Global Technologies LLC (Dow, Inc.)
• Original Assignee: Dow Global Technologies LLC (Dow, Inc.)
• Inventors: Keenihan, James R., Langmaid, Joseph A., Eurich, Gerald K., Lesniak, Michael J., Mazor, Michael H., Cleereman, Robert J., Gaston, Ryan S.
• Primary Examiner(s): Ta, Tho D
• Assistant Examiner(s): CHAMBERS, TRAVIS SLOAN
• Application Number:
  US12/989,742
• Publication Number:
  US 20110183540A1
• Time in Patent Office: 1,859 Days
• Field of Search: 439/345, 439/507, 439/510, 439/512
• US Class Current: 439/510
• 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 devices or photovoltaic system components and/or locate these devices/components upon a building structure. It also may optionally provide some additional sub-components (e.g. at least one bypass diode and/or an indicator means) and may enhance the serviceability of the device.

Claims

1. A method of locating and electrically connecting a plurality of photovoltaic system components together comprising the steps of:

a. providing a first photovoltaic system component with a first connector housing located on a side portion of the component, the connector housing including at least one first electrical connector terminal and at least one first locator feature;

b. providing at least a second photovoltaic system component with a second connector housing located on a side portion of the component, the second connector housing including at least one second electrical connector terminal and at least one second locator feature;

c. providing a connector that comprises i) a base portion including a first end portion, ii) a second portion, an intermediate portion and an outer surface;

a locater portion located on the outer surface of the intermediate portion, the locator portion including a bearing wall that projects away from the outer surface and is shaped to generally complement an opposing connector housing in the photovoltaic device; and

iii) at least one electrically conductive member that is substantially surround by the base portion and that spans between the first and second end portions and includes connective terminals at opposing ends that are shaped to interlock with an opposing terminal in the opposing connector housing;

so that the bearing wall at least partially contacts an opposing surface in the connector housing;

d. joining one end of the connector to the first connector housing;

e. joining the opposing end of the connector to the second connector housing;

f. rotationally locating the first and the second photovoltaic components to each other via the bearing wall of the connector; and

g. repeating steps c-f for each of the plurality of photovoltaic system components.

2. A method of locating and electrically connecting a plurality of photovoltaic system components together comprising the steps of:

a. providing a first photovoltaic system component with a first receptacle connector housing located on a side portion of the component, the receptacle connector housing including at least one first electrical connector terminal and at least one first locator feature;

providing at least a second photovoltaic system component with a second receptacle connector housing located on a side portion of the component, the second receptacle connector housing including at least one second electrical connector terminal and at least one second locator feature, wherein the first receptacle connector housing is at least partially connectively disposed on a side portion of the first photovoltaic system component and the second receptacle connector housing is at least partially connectively disposed on a side portion of the second photovoltaic system component, further wherein the first and second locator features provide a rotationally adjustable location function between the first and second photovoltaic system components; and

b. providing a header connector that comprises i) a base portion including a first end portion, ii) a second portion, an intermediate portion and an outer surface;

a locater portion located on the outer surface of the intermediate portion, the locator portion including a bearing wall that projects away from the outer surface and is shaped to generally complement an opposing connector housing in the photovoltaic device; and

iii) at least one electrically conductive member that is substantially surrounded by the base portion and that spans between the first and second end portions and includes connective terminals at opposing ends that are shaped to interlock with an opposing terminal in the opposing connector housing, so that the bearing wall at least partially contacts an opposing surface in the connector housing;

c. rotationally locating the first and the second photovoltaic system components to each other via the first and second locater portions;

d. joining the header connector to the first and the second receptacle connector housing; and

e. repeating steps c-d for each of the plurality of photovoltaic system components.