Photovoltaic device assembly and method

• US 9,147,786 B2
• Filed: 05/01/2009
• Issued: 09/29/2015
• 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:
  US12/989,743
• Publication Number:
  US 20120118349A1
• Time in Patent Office: 2,342 Days
• Field of Search: 136/244
• US Class Current: 1/1
• 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 photovoltaic device assembly comprising:

a. a plurality of photovoltaic devices arranged in at least two rows or columns and including;

i. a plurality of first photovoltaic devices individually interconnected via a plurality of photovoltaic array connector assemblies in a first row or a first column,

wherein the plurality of first photovoltaic devices include a first electrical return line;

ii. a plurality of last photovoltaic devices individually interconnected via a plurality of photovoltaic array connector assemblies in a last row or a last column,

wherein the plurality of last photovoltaic devices include a last electrical return line;

b. a plurality of edge pieces including;

i. an end edge piece including;

1. a connector assembly that connects to a first end or a second end of the plurality of last photovoltaic devices and

2. a pass-through electrical connector or an electrical lead assembly,

wherein an end electrical circuit extends between the connector assembly and the pass-through electrical connector or the electrical lead assembly;

ii. a starter edge piece including;

1. a single edge connector assembly connected to a first end or a second end of the plurality of first photovoltaic devices and including a starter electrical circuit connecting the first electric return line to the plurality of first photovoltaic devices that are individually interconnected so that energy is directed between the plurality of first photovoltaic devices and the first electrical return line; and

iii. one or more edge pieces each including two or more edge electrical circuits spanning between and connecting two of the at least two rows or columns at a first end, a second end or both ends; and

wherein the one or more edge pieces are located between the end edge piece and the starter edge piece;

wherein the plurality of first photovoltaic devices and the plurality of last photovoltaic devices comprise;

A. a photovoltaic cell assembly including

i. at least one peripheral edge and

ii. 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 includes a surface that allows transmission of light energy to the photoactive portion for conversion into electrical energy;

B. at least one bus terminal for transferring current to or from the photovoltaic cell assembly via at least one integral photovoltaic connector assembly located within the at least one peripheral edge; and

C. a body portion including;

i. a lower surface portion that contacts a structure, and

ii. an upper surface portion that receives a fastener that attaches the plurality of first photovoltaic devices and the plurality of last photovoltaic devices to the structure.

2. The photovoltaic device assembly according to claim 1,

wherein the body portion is at least partially joined to at least one edge portion 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.

3. The photovoltaic device assembly according to claim 2, wherein the body portion and the at least one peripheral edge at least include a unitary polymeric portion.

4. The photovoltaic device assembly according to claim 1, wherein the starter edge piece and the end edge piece comprise a polymeric body that substantially envelops at least a portion of the starter and end electrical circuits respectfully.

5. The photovoltaic device assembly according to claim 2, wherein the plurality of integral photovoltaic connector assemblies each include a locator feature for locating one of the plurality of photovoltaic devices to another photovoltaic device or to one of the plurality of edge pieces.

6. The photovoltaic device assembly according to claim 1, wherein at least one of the at least two rows or columns, include at least one spacer device located between two of the plurality of photovoltaic devices arranged in the at least two rows or columns.

7. The device assembly according to claim 2 wherein the structure is a building.

8. The photovoltaic device assembly of claim 1, wherein the plurality of photovoltaic array connector assemblies in the at least two rows or columns are a separate piece from each of the plurality of photovoltaic devices in each of the at least two rows or columns.

9. The photovoltaic device assembly of claim 1, wherein the starter electrical circuit, edge electrical circuit, and the end electrical circuit are integrally connected to the starter end piece, the one or more edge pieces, and the end edge piece respectively and are partially encapsulated or fully encapsulated in the starter end piece, the one or more edge pieces, and the end edge piece respectively.

10. The photovoltaic device assembly of claim 1, wherein the starter electrical circuit in the starter edge piece extends within an interior surface of the starter edge piece from the single edge connector assembly and back to the single edge connector assembly.

11. The photovoltaic device assembly of claim 1, wherein the end electrical circuit in the end edge piece extends within an interior surface of the end edge piece between the connector assembly and the pass-through electrical connector or the electrical lead assembly.

12. The photovoltaic device assembly of claim 1, wherein the starter edge piece, the end edge piece, and the one or more edge pieces are all separate pieces.

13. The photovoltaic device assembly of claim 1, wherein the one or more edge pieces comprise:

a main body portion which physically connects two or more rows or columns of photovoltaic devices;

the one or more edge pieces electrically connect two or more rows or columns to an electrical return circuit in a row or column of one of the at least two rows or columns.