Method for quick self interconnection of photovoltaic cell arrays and panels

• US 9,865,757 B2
• Filed: 04/21/2015
• Issued: 01/09/2018
• Est. Priority Date: 04/23/2014
• Status: Active Grant

• Current Assignee: Helion Concepts, Inc.
• Original Assignee: Helion Concepts, Inc.
• Inventors: Krishnamoorthy, Sudarshan
• Primary Examiner(s): MEKHLIN, ELI S
• Application Number:
  US14/691,842
• Publication Number:
  US 20150311371A1
• Time in Patent Office: 994 Days
• CPC Class Codes: H01L 31/0201 comprising specially adapted module bus-bar structures
• CPC Class Codes: H01L 31/0504 specially adapted for series or parallel connection of solar cells in a module
• CPC Class Codes: H01R 2101/00 One pole
• CPC Class Codes: H01R 24/28 Coupling parts carrying pins, blades or analogous contacts and secured only to wire or cable
• 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: Y02E 10/50 Photovoltaic [PV] energy

Abstract

Interconnectable solar photovoltaic appliance that can be connected to each other and other derivative products in multiple series and parallel configurations to supply a specific amount of electrical power to an application requiring electrical energy. The resultant design is modular and expandable. Examples include photovoltaic appliances that are variable in size in shape so as to accommodate the spatial constraints and power requirements of their intended applications.

Claims

1. A modular solar cell assembly comprising:

a solar cell structure for receiving solar energy and converting the solar energy into electricity, the solar cell structure including first and second outputs of respective first and second polarities;

an insulating layer;

an interconnect layer; and

a backing layer;

wherein the modular solar cell assembly has a perimeter including at least a first side comprising a plurality of connectors including at least first, second and third connectors, the first and second connectors coupled electrically by the interconnect layer to the first output of the solar cell structure, and the third connector coupled electrically by the interconnect layer to the second output of the solar cell structure;

wherein the plurality of connectors are configured for repeatable connection and disconnection to one or more adjacent modular solar cell assemblies of like design without soldering thereto.

2. The modular solar cell assembly of claim 1 wherein at least one of the plurality of connectors is a male connector having a protrusion extending beyond a border of the interconnect layer, and at least one of the plurality of connectors is a female connector configured to receive a male connector of an adjacent modular solar cell assembly of like design.

3. The modular solar cell assembly of claim 1 wherein the plurality of connectors are female connectors configured to receive and mechanically and electrically couple with a male coupler to facilitate connection to an adjacent modular solar cell assembly of like design.

4. A modular solar cell system comprising at least two modular solar cell assemblies as in claim 3 and one or more male couplers for connecting together the at least two modular solar cell assemblies, wherein the plurality of the connectors of the at least two modular solar cell assemblies are configured and placed to facilitate each of:

a parallel connection between the at least two modular solar cell assemblies using two of the male couplers; and

a series connection between the at least two modular solar cell assemblies using one of the male couplers.

5. A modular solar cell system comprising at least first, second, third and fourth modular solar cell assemblies as in claim 3 and a plurality of male couplers for coupling together the at least first, second, third and fourth modular solar assemblies as follows:

the first and second modular solar cell assemblies are coupled in parallel to one another in a first stage using two of the male couplers placed along a first side of the first modular solar cell assembly and a first side of the second modular solar cell assembly;

the third and fourth modular solar cell assemblies are coupled in parallel to one another in a second stage using two of the male couplers placed along a first side of the third modular solar cell assembly and a first side of the fourth modular solar cell assembly; and

the first stage and the second stage are connected together in series using one of the male couplers placed on a second side of the first modular solar cell assembly and on a second side of the third modular solar cell assembly;

such that outputs from the system can be taken from a third side of the first modular solar cell assembly and a third side of the third modular solar cell assembly.

6. A modular solar cell assembly as in claim 3 wherein the connectors are constructed of a flexible and elastic metal for facilitating repeatable connection over a detent, a ridge or dimple of the male coupler.

7. A modular solar cell assembly as in claim 1 wherein the solar cell structure is a photovoltaic solar cell.

8. A modular solar cell assembly as in claim 1 having an outer perimeter in the shape of a polygon having at least three connectors including at least one connector coupled to the first output of the solar cell structure and at least one connector coupled to the second output of the solar cell structure on each of at least two sides thereof.

9. A modular solar cell assembly as in claim 1 having an outer perimeter in the shape of a polygon having at least three connectors including at least one connector coupled to the first output of the solar cell structure and at least one connector coupled to the second output of the solar cell structure on each of at least three sides thereof.

10. A modular solar cell assembly as in claim 9 wherein the polygon is a square or a rectangle.

11. A modular solar cell assembly as in claim 1 further comprising at least one circuit element disposed in connection to the interconnect layer including one of an LED display, a diode, a resistor and a switch.

12. A modular solar cell assembly as in claim 1 further comprising an encapsulating layer covering at least the solar cell structure and weatherproofing at least a portion of the plurality of connectors.

13. The modular solar cell assembly of claim 1, wherein the perimeter comprises a second side including at least fourth, fifth and sixth connectors, the fourth connector being coupled electrically by the interconnect layer to the first output of the solar cell structure, and the fifth and sixth connectors being coupled electrically by the interconnect layer to the second output of the solar cell structure.

14. A modular solar cell assembly comprising:

a solar cell structure for receiving solar energy and converting the solar energy into electricity and having first and second outputs of first and second polarities;

an insulating layer;

an interconnect layer; and

a backing layer;

wherein the modular solar cell assembly has a perimeter including at least a first side comprising a plurality of connectors including at least first, second and third connectors, the first and second connectors coupled electrically by the interconnect layer to the first output of the solar cell structure, and the third connector coupled electrically by the interconnect layer to the second output of the solar cell structure;

wherein the plurality of connectors facilitate selective coupling of the modular solar cell assembly in parallel or series with one or more other modular solar cell assemblies using first and second male couplers configured for insertion into the plurality of connectors.

15. The modular solar cell assembly of claim 14 wherein the modular solar cell assembly is rectangular and the perimeter includes three connectors on two opposing sides thereof.

16. The modular solar cell assembly of claim 14, wherein the perimeter comprises a second side including at least fourth, fifth and sixth connectors, the fourth connector being coupled electrically by the interconnect layer to the first output of the solar cell structure, and the fifth and sixth connectors being coupled electrically by the interconnect layer to the second output of the solar cell structure.

17. A method of constructing a solar cell array comprising connecting together at least two modular solar cell assemblies, wherein each of the at least two modular solar cell assemblies comprise:

a solar cell structure for receiving solar energy and converting the solar energy into electricity and having first and second outputs of first and second polarities;

an insulating layer;

an interconnect layer; and

a backing layer;

wherein each of the first and second modular solar cell assemblies has a perimeter including at least a first side comprising a plurality of connectors including at least first, second and third connectors, the first and second connectors coupled electrically by the interconnect layer to the first output of the solar cell structure, and the third connector coupled electrically by the interconnect layer to the second output of the solar cell structure;

wherein the plurality of connectors facilitate selective coupling of the modular solar cell assembly in parallel or series with one or more other modular solar cell assemblies using first and second male couplers configured for insertion into the plurality of connectors.

18. The method as in claim 17 wherein the first of the at least two modular solar cell assemblies has a second side with fourth, fifth and sixth connectors, the fourth connector being coupled electrically by the interconnect layer to the first output of the solar cell structure, and the fifth and sixth connectors being coupled electrically by the interconnect layer to the second output of the solar cell structure, and the step of connecting together the first and second modular solar cell assemblies is performed by using a first male coupler to couple together the fifth connector of the first modular solar cell assembly and the second connector of the second modular solar cell assembly, achieving an electrical connection of the first and second modular solar cell assemblies in series with one another.

19. The method of claim 17 wherein the step of connecting together the first and second modular solar cell assemblies is performed by using a first male coupler to couple the first connector of the first modular solar cell assembly to the first connector of the second modular solar cell assembly, and a second male coupler to couple the third connector of the first modular solar cell assembly to the third connector of the second modular solar cell assembly, achieving an electrical connection of the first and second modular solar cell assemblies in parallel with one another.

20. The method of claim 17 wherein the step of connecting is performed without applying adhesive or soldering.