PHOTOVOLTAIC DEVICE ASSEMBLY AND METHOD

• US 20120118349A1
• Filed: 05/01/2009
• Published: 05/17/2012
• Est. Priority Date: 05/05/2008
• Status: Active Grant

• Current Assignee: Dow Global Technologies LLC (Dow, Inc.)
• Original Assignee: Dow Global Technologies, Inc. (Dow, Inc.)
• Inventors: Keenihan, James R., Langmaid, Joe A., Cleereman, Robert J., Graham, Andrew T.
• Granted Patent: US 9,147,786 B2
• Time in Patent Office: Days
• US Class Current: 136/244
• 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 kit comprising:

a. at least a plurality of photovoltaic devices in at least two rows or columns as applied to a structure, the photovoltaic device including;

i. a photovoltaic cell assembly including at least one peripheral edge, at least one photovoltaic cell inboard of the at least one peripheral edge, which the photovoltaic cell includes a photoactive portion, 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;

ii. at least one buss terminal for transferring current to or from the photovoltaic cell assembly;

iii. a body portion including lower surface portion that contacts the structure, and an upper surface portion that receives a fastener that attaches the photovoltaic device to the structure, 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;

b. at least one edge piece disposed at the end or within the at least two rows of photovoltaic devices, the at least one edge piece including at least two edge connector assemblies for connecting each respective row of photovoltaic devices.

2. The photovoltaic device kit according to claim 1, further including at least one spacer device connected between two photovoltaic devices, one photovoltaic device and one edge piece, or both.

3. The photovoltaic device kit according to claim 1, wherein the at least one edge piece includes a building connector assembly or electrical lead assembly.

4. The photovoltaic device kit according to claim 1, includes at least one integral photovoltaic connector assembly located within the at least one peripheral edge, a separate connector, or both.

5. The photovoltaic device kit according to claim 4, wherein the at least one integral photovoltaic connector assembly, the at least two edge connector assemblies, or both include a strain relief feature.

6. The photovoltaic device kit according to claim 3, wherein the at least one integral photovoltaic connector assembly, the at least two edge connector assemblies, or both, further includes an integral connector housing adapted to receive a connector element.

8. The photovoltaic device kit according to claim 1, wherein the at least one edge piece includes at least one edge connector assembly for connecting to a second edge piece.

10. The kit according to claim 1 wherein the structure is a building.

7. (canceled)

9. (canceled)

11. A photovoltaic device assembly comprising:

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

b. a plurality of second photovoltaic devices individually interconnected via the plurality of photovoltaic array connector assemblies in a second row or column, wherein both the first and second photovoltaic devices include an electrical return circuit; and

c. a first edge piece spanning between and connecting the first and second rows or columns at one end and a second edge piece spanning between and connecting the first and second rows or columns at an opposing end, wherein at least the first edge piece includes a first electrical circuit that includes at least a pass-though electrical connector or electrical lead assembly and wherein at least the second edge piece includes a second electrical circuit that includes at least an electrical return circuit interconnect.

12. The photovoltaic device assembly according to claim 11, including a second edge piece spanning between and connecting the first and second rows or columns at an opposing end, wherein at least the first edge piece includes a first electrical circuit that includes at least a pass-though electrical connector or electrical lead assembly and wherein at least the second edge piece includes a second electrical circuit that includes at least an electrical return circuit interconnect.

13. The photovoltaic device assembly according to claim 11, wherein the plurality of first photovoltaic devices and the plurality of second photovoltaic devices comprise:

a. a photovoltaic cell assembly including at least one peripheral edge, at least one photovoltaic cell inboard of the at least one peripheral edge, which the photovoltaic cell includes a photoactive portion, 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;

b. at least one buss 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 lower surface portion that contacts a structure, and an upper surface portion that receives a fastener that attaches the photovoltaic device to the structure, 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.

14. The photovoltaic device assembly according to claim 12, wherein the body portion and at least one peripheral edge at least include a unitary polymeric portion.

15. The photovoltaic device assembly according to claim 11 wherein the first edge piece and the second edge piece comprise a polymeric body that substantially envelops at least a portion of the first and second electrical circuits respectfully.

16. The photovoltaic device assembly according to claim 11 wherein the integral photovoltaic connector assembly includes a locator feature for locating one of the plurality of first photovoltaic devices and the plurality of second photovoltaic devices to another or to the first or second end piece within the respective row.

17. The photovoltaic device assembly according to claim 11 wherein the first row, second row, or both, include at least one spacer device.

18. The device assembly according to claim 11 wherein the structure is a building.

19. A method of constructing a photovoltaic device assembly on a surface of a structure, comprising the steps of:

a. providing a plurality of individual photovoltaic devices, wherein the individual photovoltaic devices include;

i. a photovoltaic cell assembly including at least one peripheral edge, at least one photovoltaic cell inboard of the at least one peripheral edge, which the photovoltaic cell includes a photoactive portion, 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;

ii. at least one buss terminal for transferring current to or from the photovoltaic cell assembly; and

iii. a body portion including lower surface portion that contacts the structure, and an upper surface portion that receives a fastener that attaches the photovoltaic device to the structure, 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;

b. providing a plurality of edge pieces;

c. attaching a first individual photovoltaic device to the surface;

d. attaching a second individual photovoltaic device to the first individual photovoltaic device.

e. attaching the second individual photovoltaic device to the surface;

f. repeat steps c-e until a first row or column is attached to the surface;

g. begin attaching a second row or column of individual photovoltaic devices immediately adjacent to in partial contact with the first row or column, using the same steps as the first row or column; and

h. attaching at least one edge piece via a connector element to at least one end of the first and second row or column.

20. The method of constructing a photovoltaic device assembly on a surface of a structure according to claim 19, including the step of providing a spacer device.

21. The method of constructing a photovoltaic device assembly on a surface of a structure according to claim 20, wherein the first row/column, second row/column, or both, include at least one spacer device in place of at least one of the individual photovoltaic devices.

22. The method of constructing a photovoltaic device assembly on a surface of a structure according to claim 19 wherein the steps c-h are repeated to create the photovoltaic device assembly with a plurality of rows/columns.

24. The method of constructing a photovoltaic device assembly on a surface of a structure according to claim 19 wherein some or all of the plurality of connector elements have the first end portion integral to the edge piece, the photovoltaic device, or both.

25. The method of claim 19 wherein the structure is a building.

26. The method of claim 19, includes providing at least one integral photovoltaic connector assembly located within the at least one peripheral edge, a separate connector, or both.

23. (canceled)