Photovoltaic sheathing element with a flexible connector assembly

• US 9,391,223 B2
• Filed: 03/22/2012
• Issued: 07/12/2016
• Est. Priority Date: 03/22/2011
• Status: Expired due to Fees

• Current Assignee: Dow Global Technologies LLC (Dow, Inc.)
• Original Assignee: Dow Global Technologies LLC (Dow, Inc.)
• Inventors: Langmaid, Joseph A, Keenihan, James R, Mills, Michael E, Lopez, Leonardo C
• Primary Examiner(s): Mershon, Jayne
• Application Number:
  US14/004,444
• Publication Number:
  US 20140000709A1
• Time in Patent Office: 1,573 Days
• Field of Search: 136/244, 136/256
• US Class Current: 1/1
• 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 31/18 Processes or apparatus specially adapted for the manufacture or treatment of these devices or of parts thereof
• CPC Class Codes: H02S 20/25 Roof tile elements
• 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: Y02B 10/10 Photovoltaic [PV]
• CPC Class Codes: Y02E 10/50 Photovoltaic [PV] energy
• CPC Class Codes: Y10T 29/49355 Solar energy device making

Abstract

The present invention is premised upon an assembly including at least a photovoltaic sheathing element capable of being affixed on a building structure, the sheathing element including at least: a photovoltaic cell assembly, a body portion attached to one or more portions of the photovoltaic cell assembly; at least a first and a second connector assembly disposed on opposing sides of the sheathing element and capable of directly or indirectly electrically connecting the photovoltaic cell assembly to at least two adjoining devices that are affixed to the building structure and wherein at least one of the connector assemblies includes a flexible portion; one or more connector pockets disposed in the body portion the pockets capable of receiving at least a portion of the connector assembly.

Claims

1. An assembly comprising:

a photovoltaic sheathing element capable of being affixed on a building structure, the sheathing element including at least;

a photovoltaic cell assembly,

a body portion attached to one or more portions of the photovoltaic cell assembly;

at least a first connector assembly and a second connector assembly disposed on opposing sides of the photovoltaic sheathing element and capable of directly or indirectly electrically connecting the photovoltaic cell assembly to at least two adjoining devices that are affixed to the building structure and wherein at least one of the first connector assembly and the second connector assembly includes;

a first connector portion, a second connector portion, and a flexible portion extending between and connecting the first connector portion to the second connector portion;

one or more connector pockets are disposed in the body portion within a distance from an outer edge of the body portion where the one or more connector pockets are capable of receiving at least a portion of the first connector assembly or the second connector assembly; and

wherein the first connector portion is located in the one or more connector pockets and connected to the photovoltaic cell assembly, the second connector portion is capable of moving so that the second connector portion extends into a connector in one of the at least two adjoining devices, and the flexible portion allows the second connector portion to move relative to the first connector portion.

2. The assembly according to claim 1, including a cover plate that as assembled protects one or more portions of the one or more connector pockets, one or more portions of the connector assembly, or both.

3. The assembly according to claim 1, including a sealing material disposed in the one or more connector pockets capable of protecting one or more portions of the first connector assembly, the second connector assembly, or both.

4. The assembly according to claim 2, wherein the cover plate positions and maintains location of one or more portions of the first connector assembly, the second connector assembly, or both.

5. The assembly according to claim 1, wherein the first connector assembly, the second connector assembly, or both are mechanically connected to the photovoltaic cell assembly.

6. The assembly according to claim 1, wherein the first connector assembly, the second connector assembly, or both are bonded to the photovoltaic cell assembly.

7. The assembly according to claim 1, wherein:

the first connector assembly and the second connector assembly are a separate component;

wherein the photovoltaic sheathing element includes a connector mating component electrically connected to the photovoltaic cell assembly;

wherein the flexible portion is capable of bending such that the second connector portion can move at least a distance equal to an interface length of either the first connector assembly or the second connector assembly.

8. The assembly according to claim 1, wherein disposed within the one or more connector pockets is a bridging portion;

the bridging portion including one or more of;

a first feature capable of locating the first connector assembly or the second connector assembly, securing the first connector assembly or the second connector assembly, or both;

a second feature capable of locating a cover plate, securing the cover plate, or both;

a structural portion that connects the photovoltaic cell assembly to the body portion of the assembly.

9. The assembly according to claim 1, wherein the one or more connector pockets disposed in the body portion are at least partially co-extensive with the outer edge of the body portion and include an open end that extends through the outer edge of the body portion.

10. The assembly according to claim 9, wherein at least one of the one or more connector pockets include a strip at the open end that forms a bridge and the first connector assembly, the second connector assembly, or both fit under the strip to extend out of the open end.

11. The assembly according to claim 9, wherein the body portion includes a top side, a bottom side, and the outer edge extending between and connecting the top side and the bottom side.

12. The assembly of claim 11, wherein the first connector assembly extends out of the body portion at least a distance equal to an interface length so that the first connector housing engages with the one or more adjoining array devices.

13. The assembly of claim 1, wherein the flexible portion is a locally flexible joints.

14. The assembly of claim 1, wherein the one or more connector pockets extend completely through the body portion from an upper surface to a lower surface of the body portion, are a depression in one or both of the upper surface and the lower surface, of a combination of either.

15. An photovoltaic sheathing element kit capable of being affixed on a building structure comprising:

a photovoltaic sheathing element, the sheathing element including at least;

a photovoltaic cell assembly,

a body portion attached to one or more portions of the photovoltaic cell assembly;

at least a first connector assembly and a second connector assembly capable of directly or indirectly electrically connecting the photovoltaic cell assembly to one or more adjoining array devices that is affixed to the building structure and wherein at least one of the first connector assembly and the second connector assembly includes;

a first connector portion, a second connector portion, and a flexible portion extending between and connecting the first connector portion to the second connector portion;

one or more connector pockets disposed in the body portion within a distance from an outer edge of the body portion where the one or more connector pockets are capable of receiving the flexible portion of the first connector assembly or the second connector assembly; and

wherein the first connector portion is located in the one or more connector pockets and connected to the photovoltaic cell assembly, the second connector portion is capable of moving so that the second connector portion extends into a connector in an adjoining array device, and the flexible portion allows the second connector portion to move relative to the first connector portion.

16. The kit according to claim 15, further comprising a cover plate that as assembled protects one or more portions of the one or more connector pockets and a sealing material capable of being disposed in or about the one or more portions of the one or more connector pockets.