Photovoltaic device and method

• US 9,196,756 B2
• Filed: 01/23/2015
• Issued: 11/24/2015
• 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: Cleereman, Robert, 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:
  US14/604,204
• Publication Number:
  US 20150129032A1
• Time in Patent Office: 305 Days
• Field of Search: 521/733
• 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 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;

at least one peripheral edge,

at least one photovoltaic cell inboard of the at least one peripheral edge,

a photoactive portion, and

at least one bus terminal for transferring current to or from the photovoltaic cell assembly,

wherein the at least one photovoltaic cell includes a surface that allows transmission of light energy to the photoactive portion for conversion into electrical energy;

a body portion including;

at least one peripheral edge,

a bottom segment,

a lower surface portion that contacts a building structure,

a return circuit that extends through the body portion;

an upper surface portion that receives a fastener that attaches the photovoltaic device to the building structure; and

at least one locator including;

at least one electric terminal or

1) a protrusion from one of the at least one peripheral edges of the body portion,

2) a recess in one of the at least one peripheral edges of the body onion or

3) a separate component that is configured to extend from and/or into one of the at least one peripheral edges,

wherein the locator allows for rotational adjustment between the photovoltaic device and another photovoltaic device during installation of the photovoltaic device on the building structure;

wherein the body portion is at least partially joined to at least one of the at least one peripheral edges of the photovoltaic cell assembly along at least a portion of the bottom segment of the body portion while leaving the surface of the at least one photovoltaic cell exposed.

2. The photovoltaic device of claim 1, wherein the locator includes the at least one electrical terminal.

3. The photovoltaic device of claim 1, wherein the photovoltaic device is flexible and conforms to an irregular contour in the building structure.

4. The photovoltaic device of claim 1, wherein the upper surface portion includes a fixation area.

5. The photovoltaic device of claim 1, wherein the body portion is comprised essentially of a polymeric framing material and wherein the at least one peripheral edge is a frame including the polymeric framing material and the frame extends on at least 3 sides of the photovoltaic cell assembly.

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

a) providing a first photovoltaic device including at least one locator that includes at least one integrally formed electrical terminal located in an inactive portion of the first photovoltaic device;

b) providing a second photovoltaic device including at least one locator that includes at least one integrally formed electrical terminal located in an inactive portion of the second photovoltaic device;

c) attaching the first photovoltaic device directly to the building structure by affixing a fastener through the inactive portion of the first photovoltaic device;

d) attaching the second photovoltaic device directly to the building structure by affixing a fastener through the inactive portion of the second photovoltaic device;

e) connecting the at least one integrally formed electrical terminal of the first photovoltaic device to the at least one integrally formed electrical terminal of the second photovoltaic device; and

f) rotationally adjusting the first photovoltaic device relative to the second photovoltaic device about the at least one locater of the first photovoltaic device and the second photovoltaic device while the first photovoltaic device and the second photovoltaic device are connected.

7. The method according to claim 6, wherein steps c, d, and e can occur in any order.

8. 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 connect the first photovoltaic device to the second photovoltaic device.

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

10. The method according of claim 6, including a photovoltaic device connector assembly to to connect the first photovoltaic device to the second photovoltaic device.