Photovoltaic device and method

• US 8,938,920 B2
• Filed: 05/01/2009
• Issued: 01/27/2015
• Est. Priority Date: 05/05/2008
• Status: Expired due to Fees

• Current Assignee: Dow Global Technologies, Inc. (Dow, Inc.)
• Original Assignee: Dow Global Technologies LLC (Dow, Inc.)
• Inventors: Cleereman, Robert J., Lesniak, Michael J., Keenihan, James R., Langmaid, Joe A., Gaston, Ryan, Eurich, Gerald K., Boven, Michelle L.
• Primary Examiner(s): Glessner, Brian
• Assistant Examiner(s): Agudelo, Paola
• Application Number:
  US12/989,745
• Publication Number:
  US 20110100436A1
• Time in Patent Office: 2,097 Days
• Field of Search: 521/733, 136/251
• US Class Current: 52/173.3
• 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 an improved photovoltaic device (“PVD”) and method of use, more particularly to an improved photovoltaic device with an integral locator and electrical terminal mechanism for transferring current to or from the improved photovoltaic device and the use as a system.

Claims

1. A photovoltaic device comprising:

a photovoltaic cell assembly including one or more photovoltaic cells, one or more protective layers and at least some electrical circuitry wherein the photovoltaic cell assembly has an upper surface portion, a lower surface portion and a sidewall portion therebetween forming at least one peripheral edge, and the upper surface portion allows transmission of light energy to the one or more photovoltaic cells for conversion into electrical energy;

a body portion comprising a polymeric framing material having a main body portion including a lower surface portion that contacts a building structure, and an upper surface portion that receives a fastener that attaches the photovoltaic device to the building structure, at least two side body portions and a locator;

wherein the body portion is join by overmolding to the photovoltaic cell assembly to enclose at least three sides of the peripheral edge of the photovoltaic cell assembly while leaving the upper surface portion of the photovoltaic cell assembly exposed, and further wherein the locator is adapted to locate the photovoltaic device relative to another photovoltaic device during installation of the photovoltaic device directly to the building structure and the locater is disposed on a peripheral edge of the body portion and includes;

a) at least one electrical terminal, and provides

b) rotational adjustment between the photovoltaic device and another photovoltaic device;

wherein the locator protrudes from the peripheral edge of the body portion such that a small gap is maintained between adjacent photovoltaic devices attached to the building structure.

2. The photovoltaic device of claim 1, wherein the locator is included in a separate connector, an embedded connector, or a photovoltaic device connector assembly.

3. The photovoltaic device according to claim 1 which further comprises one or more separate connectors for connecting the photovoltaic device to other photovoltaic devices wherein the one or more separate connectors provide electrical connection between photovoltaic devices.

4. A photovoltaic device comprising

a photovoltaic cell assembly including one or more photovoltaic cells, one or more protective layers and at least some electrical circuitry wherein the photovoltaic cell assembly has an upper surface portion, a lower surface portion and a sidewall portion therebetween forming at least one peripheral edge, and the upper surface portion allows transmission of light energy to the one or more photovoltaic cells for conversion into electrical energy;

a body portion comprising a polymeric framing material having a main body portion including a lower surface portion that contacts a building structure, and an upper surface portion that receives a fastener that attaches the photovoltaic device to the building structure, at least two side body portions and a locator;

wherein the body portion is join by overmolding to the photovoltaic cell assembly to enclose at least three sides of the peripheral edge of the photovoltaic cell assembly while leaving the upper surface portion of the photovoltaic cell assembly exposed, and further wherein the locator is adapted to locate the photovoltaic device relative to another photovoltaic device during installation of the photovoltaic device directly to the building structure and the locater is disposed on a peripheral edge of the body portion and includes;

a) at least one electrical terminal, and provides

b) rotational adjustment between the photovoltaic device and another photovoltaic device;

wherein the at least one peripheral edge contains a female connector housing; and

the locator is pant, of a separate component comprising a connector assembly having a bearing wall shaped to complement and is connected to the female connector housing and protrudes from the peripheral edge of the body portion in a direction of the another photovoltaic device.

5. The photovoltaic device of claim 4, wherein the photovoltaic device is flexible and conforms to variability in contour in the building structure.

6. A method of installing a photovoltaic system on a building structure, comprising the steps of:

a) providing a first photovoltaic device and a second photovoltaic device according to claim 4;

b) attaching the first photovoltaic device directly to a roof deck, an exterior wall or an awning of the building structure or a protective sheath of a roof deck, an exterior wall or an awning of the building structure by affixing a fastener through the main body portion of the first photovoltaic device;

c) locating and aligning the second photovoltaic device adjacent to the first photovoltaic device by rotation of the second photovoltaic device about the protruding locator while in contact with the building structure and attaching the second photovoltaic device to the building structure by affixing a fastener through the main body portion of the second photovoltaic device; and

d) connecting at least one integrally formed electrical terminal of the first photovoltaic device to at least one integrally formed electrical terminal of the second photovoltaic device.

7. The method according to claim 6, further including the step of placing a fastener through a hole in the at least one integrally formed electrical terminal of the first photovoltaic device and through a hole in the at least one integrally formed electrical terminal of the second photovoltaic device to accomplish an electrical connection.

8. The method according to claim 7, wherein the fastener is a screw.

9. The method according of claim 6, including a photovoltaic device connector assembly to accomplish an electrical connection.

10. The method according to claim 6 wherein the step d is performed utilizing a separate connector wherein the connector provides electrical connection between the first photovoltaic device and the second photovoltaic device.

11. The photovoltaic device of claim 4, wherein an edge of the polymeric framing material seal and protect an active portion against the environment without the use of additional adhesives.

12. The photovoltaic device of claim 4, wherein there are at least two locators disposed on opposing sides of the photovoltaic device.

13. The photovoltaic to device according to claim 12 wherein the locators are integral to the body portion.

14. The photovoltaic device of claim 4, including a return circuit comprising a buss wire and two return terminals connected to the buss wire.

15. The photovoltaic device according to claim 4 wherein the body portion is molded about the photovoltaic cell assembly.

16. The photovoltaic device according to claim 4 wherein a bus terminal and a return terminal are collocated in the locator.

17. A photovoltaic device comprising a photovoltaic cell assembly including one or more photovoltaic cells, one or more protective layers and at least some electrical circuitry wherein the photovoltaic cell assembly has an upper surface portion, a lower surface portion and a sidewall portion therebetween forming at least one peripheral edge, and the upper surface portion allows transmission of light energy to the one or more photovoltaic cells for conversion into electrical energy;

a body portion comprising a polymeric framing material having a main body portion including a lower surface portion that contacts a building structure, and an upper surface portion that receives a fastener that attaches the photovoltaic device to the building structure, at least two side body portions and a locator;

wherein the body portion is join by overmolding to the photovoltaic cell assembly to enclose at least three sides of the peripheral edge of the photovoltaic cell assembly while leaving the upper surface portion of the photovoltaic cell assembly exposed, and further wherein the locator is adapted to locate the photovoltaic device relative to another photovoltaic device during installation of the phtovoltaic device directly to the building structure and the locater is disposed on a peripheral edge of the body portion and includes;

a) at least one electrical terminal, and provides

b) rotational adjustment between the photovoltaic device and another photovoltaic device;

wherein the locator is part of an embedded connector integral to the at least one peripheral edge of the photovoltaic device assembly and protrudes from the peripheral edge in a direction of the another device and comprises a bearing wail shaped to complement and connect to a female connector housing of the another photovoltaic device assembly.