Connector device for building integrated photovoltaic device

• US 9,184,310 B2
• Filed: 08/08/2014
• Issued: 11/10/2015
• 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, Joe A., Eurich, Gerald K., Lesniak, Michael J., Mazor, Michael H., Cleereman, Robert J., Gaston, Ryan S.
• Primary Examiner(s): Abrams, Neil
• Assistant Examiner(s): CHAMBERS, TRAVIS SLOAN
• Application Number:
  US14/358,513
• Publication Number:
  US 20150072541A1
• Time in Patent Office: 459 Days
• Field of Search: 439/68, 439/345, 439/507, 439/510, 439/512
• 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 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 photovoltaic assembly comprising:

a first photovoltaic device and a second photovoltaic device adjacent to the first photovoltaic device;

a first connector housing integral to and disposed in a side portion of the first photovoltaic device;

a second connector housing integral to and disposed in a side portion of the second photovoltaic device;

at least one electrical terminal at least partially encapsulated in each of the first and second connector housings; and

,

a connector assembly including a connector element having a first end and a second end and at least one electrically conductive member having at opposing ends a first and a second electrical terminal at least partially encapsulated in the connector element, wherein the first end of the connector element is geometrically complementary with the first connector housing and the second end of the connector element is geometrically complementary with the electrical terminal of the second connector housing;

wherein connecting the first electrical terminal of the connector with the electrical terminal of the first connector housing, and connecting the second electrical terminal of the connector element with the electrical terminal of the second connector housing results in completing an electrical circuit therebetween and wherein the connector element and the first and second housings provide a rotationally adjustable location function between the first and second photovoltaic devices.

2. The photovoltaic assembly according to claim 1, further comprising a locking device that locks the connector assembly to the opposing connector housing upon installation.

3. The photovoltaic assembly according to claim 1, wherein the opposing connector housing in a photovoltaic system component includes a strain relief feature.

4. The photovoltaic assembly of claim 1 wherein the first connector housing and the second connector housing are receptacle housings and the connector is a header connector.

5. The photovoltaic assembly of claim 1 wherein the first connector housing and the second connector housing are header housings and the connector is a receptacle connector.

6. The photovoltaic assembly according to claim 1, wherein the first connector housing and the second connector housing are integrated structurally into the first photovoltaic device and the second photovoltaic device respectively.

7. The photovoltaic assembly according to claim 1, wherein the connector element includes a second electrically conductive member having at opposing ends a first and a second electrical terminal at least partially encapsulated in the connector element.

8. The photovoltaic assembly according to claim 7, wherein the connector element includes a bearing wall and a plurality of gapping segments, and when the geometrically complementary first end of the connector element is in communication with the first connector housing and when the geometrically complementary second end of the connector element is in communication with the second connector housing the bearing wall contacts the first connector housing and the second connector housing so that a gap is created for allowing rotational adjustment of the first photovoltaic device and the second photovoltaic device relative to each other.

9. The photovoltaic assembly according to claim 7, wherein the at least one electrically conductive member and the second electrically conductive member extend from a first end to a second end of the connector element.

10. The photovoltaic assembly according to claim 9, wherein the first end and the second end of the connector element and the first connector housing and the second connector housing are keyed so that the connector element can only be installed in one way.

11. A photovoltaic device connector assembly for connecting and locating a plurality of photovoltaic devices comprising:

a first receptacle connector housing at least partially connectively disposed into a side portion of a first photovoltaic device and having;

at least one first locator portion located in a peripheral wall portion and

at least one electrical terminal at least partially encapsulated in the first receptacle connector housing;

a second receptacle connector housing at least partially connectively disposed into a side portion of a second photovoltaic device having;

at least one second locator portion located in a peripheral wall portion, the second locator portion geometrically complementary with the first locator portion and

at least one electrical terminal at least partially encapsulated in the second connector receptacle housing;

wherein the first receptacle connector housing is at least partially connectively disposed on a side portion of a first photovoltaic device and the second receptacle connector housing is at least partially connectively disposed on a side portion of a second photovoltaic device; and

,

a header connector element having a first end and a second end;

at least one electrically conductive member having at opposing ends a first and a second header electrical terminals at least partially encapsulated in the header connector element, the first header electrical terminal of the connector element is geometrically complementary with the receptacle electrical terminal of the first connector housing and the second header electrical terminal of the connector element is geometrically complementary with the receptacle electrical terminal of the second connector housing;

wherein the first and second locator portions provide a rotationally adjustable location function between the first and second photovoltaic device; and

wherein the first header electrical terminal of the header connector connects with the receptacle electrical terminal of the first receptacle connector housing, and the second header electrical terminal of the header connector element connects with the receptacle electrical terminal of the second receptacle connector housing resulting in completing an electrical circuit therebetween.

12. The photovoltaic device connector assembly of claim 11 which further comprises a locking device that locks the header connector element to the first or second receptacle connector housing upon installation.

13. The photovoltaic device connector assembly of claim 11 wherein the first or second receptacle connector housing in the first or second photovoltaic device includes a strain relief feature.

14. The photovoltaic device connector assembly according to claim 11, wherein the first connector housing and the second connector housing are integrated structurally into the first photovoltaic device and the second photovoltaic device respectively.

15. The photovoltaic device connector assembly of claim 11 wherein the first receptacle connector housing is integral to an outer wall section of the first photovoltaic device and the second receptacle connector housing is integral to an outer wall section of the second photovoltaic device.

16. The photovoltaic device connector assembly of claim 15, wherein the header connector comprises a base portion including a first end portion, a second end portion, an intermediate portion, and an outer surface wherein the first end portion is integral to the outer surface.

17. The photovoltaic device connector assembly of claim 11 wherein the connector assembly includes a second electrically conductive member.

18. The photovoltaic device connector assembly according to claim 17, wherein the header connector includes a bearing wall and a plurality of gapping segments, and when the geometrically complementary first locator portion of the header connector is in communication with the first receptacle connector and when the geometrically complementary second locator portion of the header connector is in communication with the second receptacle connector the bearing wall contacts the first receptacle connector and the second receptacle connector so that a gap is created for allowing rotational adjustment of the first photovoltaic device and the second photovoltaic device relative to each other.

19. The photovoltaic device connector assembly according to claim 17, wherein the at least one electrically conductive member and the second electrically conductive member extend from a first end to a second end of the connector element.

20. The photovoltaic device connector assembly according to claim 19, wherein the first receptacle, the second receptacle, and the header connector are keyed so that the header connector can only be inserted into the first receptacle and the second receptacle in one way.