US20160285415A1 - Electrical interconnects for photovoltaic modules and methods thereof - Google Patents
Electrical interconnects for photovoltaic modules and methods thereof Download PDFInfo
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- US20160285415A1 US20160285415A1 US15/085,864 US201615085864A US2016285415A1 US 20160285415 A1 US20160285415 A1 US 20160285415A1 US 201615085864 A US201615085864 A US 201615085864A US 2016285415 A1 US2016285415 A1 US 2016285415A1
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- photovoltaic module
- interconnection
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Classifications
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- H—ELECTRICITY
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- H02S40/00—Components or accessories in combination with PV modules, not provided for in groups H02S10/00 - H02S30/00
- H02S40/30—Electrical components
- H02S40/36—Electrical components characterised by special electrical interconnection means between two or more PV modules, e.g. electrical module-to-module connection
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- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01L—SEMICONDUCTOR DEVICES NOT COVERED BY CLASS H10
- H01L31/00—Semiconductor devices sensitive to infrared radiation, light, electromagnetic radiation of shorter wavelength or corpuscular radiation and specially adapted either for the conversion of the energy of such radiation into electrical energy or for the control of electrical energy by such radiation; Processes or apparatus specially adapted for the manufacture or treatment thereof or of parts thereof; Details thereof
- H01L31/02—Details
- H01L31/02002—Arrangements for conducting electric current to or from the device in operations
- H01L31/02005—Arrangements for conducting electric current to or from the device in operations for device characterised by at least one potential jump barrier or surface barrier
- H01L31/02008—Arrangements for conducting electric current to or from the device in operations for device characterised by at least one potential jump barrier or surface barrier for solar cells or solar cell modules
- H01L31/0201—Arrangements for conducting electric current to or from the device in operations for device characterised by at least one potential jump barrier or surface barrier for solar cells or solar cell modules comprising specially adapted module bus-bar structures
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- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01L—SEMICONDUCTOR DEVICES NOT COVERED BY CLASS H10
- H01L31/00—Semiconductor devices sensitive to infrared radiation, light, electromagnetic radiation of shorter wavelength or corpuscular radiation and specially adapted either for the conversion of the energy of such radiation into electrical energy or for the control of electrical energy by such radiation; Processes or apparatus specially adapted for the manufacture or treatment thereof or of parts thereof; Details thereof
- H01L31/02—Details
- H01L31/02002—Arrangements for conducting electric current to or from the device in operations
- H01L31/02005—Arrangements for conducting electric current to or from the device in operations for device characterised by at least one potential jump barrier or surface barrier
- H01L31/02008—Arrangements for conducting electric current to or from the device in operations for device characterised by at least one potential jump barrier or surface barrier for solar cells or solar cell modules
- H01L31/02013—Arrangements for conducting electric current to or from the device in operations for device characterised by at least one potential jump barrier or surface barrier for solar cells or solar cell modules comprising output lead wires elements
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- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01L—SEMICONDUCTOR DEVICES NOT COVERED BY CLASS H10
- H01L31/00—Semiconductor devices sensitive to infrared radiation, light, electromagnetic radiation of shorter wavelength or corpuscular radiation and specially adapted either for the conversion of the energy of such radiation into electrical energy or for the control of electrical energy by such radiation; Processes or apparatus specially adapted for the manufacture or treatment thereof or of parts thereof; Details thereof
- H01L31/04—Semiconductor devices sensitive to infrared radiation, light, electromagnetic radiation of shorter wavelength or corpuscular radiation and specially adapted either for the conversion of the energy of such radiation into electrical energy or for the control of electrical energy by such radiation; Processes or apparatus specially adapted for the manufacture or treatment thereof or of parts thereof; Details thereof adapted as photovoltaic [PV] conversion devices
- H01L31/042—PV modules or arrays of single PV cells
- H01L31/048—Encapsulation of modules
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- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01L—SEMICONDUCTOR DEVICES NOT COVERED BY CLASS H10
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- H01L31/04—Semiconductor devices sensitive to infrared radiation, light, electromagnetic radiation of shorter wavelength or corpuscular radiation and specially adapted either for the conversion of the energy of such radiation into electrical energy or for the control of electrical energy by such radiation; Processes or apparatus specially adapted for the manufacture or treatment thereof or of parts thereof; Details thereof adapted as photovoltaic [PV] conversion devices
- H01L31/042—PV modules or arrays of single PV cells
- H01L31/048—Encapsulation of modules
- H01L31/0488—Double glass encapsulation, e.g. photovoltaic cells arranged between front and rear glass sheets
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- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01L—SEMICONDUCTOR DEVICES NOT COVERED BY CLASS H10
- H01L31/00—Semiconductor devices sensitive to infrared radiation, light, electromagnetic radiation of shorter wavelength or corpuscular radiation and specially adapted either for the conversion of the energy of such radiation into electrical energy or for the control of electrical energy by such radiation; Processes or apparatus specially adapted for the manufacture or treatment thereof or of parts thereof; Details thereof
- H01L31/04—Semiconductor devices sensitive to infrared radiation, light, electromagnetic radiation of shorter wavelength or corpuscular radiation and specially adapted either for the conversion of the energy of such radiation into electrical energy or for the control of electrical energy by such radiation; Processes or apparatus specially adapted for the manufacture or treatment thereof or of parts thereof; Details thereof adapted as photovoltaic [PV] conversion devices
- H01L31/042—PV modules or arrays of single PV cells
- H01L31/05—Electrical interconnection means between PV cells inside the PV module, e.g. series connection of PV cells
- H01L31/0504—Electrical interconnection means between PV cells inside the PV module, e.g. series connection of PV cells specially adapted for series or parallel connection of solar cells in a module
- H01L31/0508—Electrical interconnection means between PV cells inside the PV module, e.g. series connection of PV cells specially adapted for series or parallel connection of solar cells in a module the interconnection means having a particular shape
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- H01L31/1876—Particular processes or apparatus for batch treatment of the devices
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- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
- Y02E—REDUCTION OF GREENHOUSE GAS [GHG] EMISSIONS, RELATED TO ENERGY GENERATION, TRANSMISSION OR DISTRIBUTION
- Y02E10/00—Energy generation through renewable energy sources
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- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
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- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
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Definitions
- the present invention is directed to interconnects for photovoltaic modules. More particularly, the invention provides electrical interconnects between conductive tabs for photovoltaic modules and methods thereof. Merely by way of example, the invention has been applied to the interconnection of photovoltaic modules with interconnection protectors. But it would be recognized that the invention has a much broader range of applicability.
- PV module A traditional photovoltaic module (“PV module”) often is equipped in the factory with two wires and expensive electrical connectors.
- these expensive electrical connectors might include push-to-connect connectors such as MC-4 compatible connectors.
- These conventional wires and connectors are then used at the installation site to interconnect PV modules into strings of modules or into larger photovoltaic arrays.
- the photovoltaic strings and modules are typically mounted in areas where they are exposed to extremes of heat and cold, are subject to thermal cycling, and are subject to hazardous weather conditions such as high winds, rain, sleet, and/or snow. Consequently, the electrical connectors interconnecting the PV modules must be weatherproof for decades, tolerant of thermal cycling, and/or allow for rapid assembly.
- PV modules need to be weatherproof after final installation at the installation site, the requirements for weatherproofing often are not as stringent between fabrication of the PV module in the factory and installation of the PV module at the installation site.
- specialized and/or automated interconnection tooling may be used for large installations.
- improved interconnections between PV modules in a large photovoltaic array can, for example, provide a significant reduction in material, labor, and/or construction costs.
- improved interconnections increases the packing density of PV modules reducing the cost of shipping PV modules to the installation site.
- the present invention is directed to interconnects for photovoltaic modules. More particularly, the invention provides electrical interconnects between conductive tabs for photovoltaic modules and methods thereof. Merely by way of example, the invention has been applied to the interconnection of photovoltaic modules with interconnection protectors. But it would be recognized that the invention has a much broader range of applicability.
- a system for interconnecting photovoltaic modules includes a first photovoltaic module and a second photovoltaic module.
- the first photovoltaic module includes a first bus bar and a first interconnect tab connected to the first bus bar.
- the second photovoltaic module includes a second bus bar and a second interconnect tab connected to the second bus bar.
- the system for interconnecting photovoltaic modules additionally includes a module interconnector configured to interconnect the first photovoltaic module and the second photovoltaic module.
- the module interconnector includes an interconnection component and an interconnection protector.
- the system for interconnecting photovoltaic modules includes a first connection component connecting the interconnection component to the first interconnect tab of the first photovoltaic module and a second connection component connecting the interconnection component to the second interconnect tab of the second photovoltaic module.
- the interconnection protector substantially encloses the interconnection component, the first connection component, and the second connection component.
- a method for installing photovoltaic modules includes providing a first photovoltaic module that includes a first bus bar, providing a second photovoltaic module that includes a second bus bar, attaching a first interconnect tab to the first bus bar, and attaching a second interconnect tab to the second bus bar.
- the method for installing photovoltaic modules further includes interconnecting the first photovoltaic module and the second photovoltaic module by connecting the first interconnect tab to an interconnection component with a first connection component and by connecting the second interconnect tab to the interconnection component with a second connection component.
- the method for installing photovoltaic modules additionally includes enclosing substantially the interconnection component, the first connection component, and the second connection component by an interconnection protector.
- the method for installing photovoltaic modules additionally includes packing, for shipping, at least the first photovoltaic module and the second photovoltaic module, the first photovoltaic module and the second photovoltaic module being interconnected to each other, shipping, to an installation site, at least the packed first photovoltaic module and second photovoltaic module, the first photovoltaic module and the second photovoltaic module being interconnected to each other, and installing, at the installation site, at least the first photovoltaic module and the second photovoltaic module.
- a method for installing photovoltaic modules includes providing a first photovoltaic module that includes a first bus bar and a first interconnect tab connected to the first bus bar and providing a second photovoltaic module that includes a second bus bar and a second interconnect tab connected to the second bus bar.
- the method for installing photovoltaic modules further includes coating the first interconnect tab at least partially with a first protective film and coating the second interconnect tab at least partially with a second protective film.
- the method for installing photovoltaic modules additionally includes packing, for shipping, at least the first photovoltaic module and the second photovoltaic module, shipping, to an installation site, at least the packed first photovoltaic module and second photovoltaic module, and installing, at the installation site, at least the first photovoltaic module and the second photovoltaic module.
- the method for installing photovoltaic modules additionally includes interconnecting, at the installation site, the installed first photovoltaic module and the installed second photovoltaic module by connecting the first interconnect tab to an interconnection component with a first connection component and by connecting the second interconnect tab to the interconnection component with a second connection component.
- the method for installing photovoltaic modules additionally includes enclosing substantially the interconnection component, the first connection component, and the second connection component with an interconnection protector.
- FIG. 1 is a simplified diagram showing a planar view of a photovoltaic module interconnection system according to one embodiment of the present invention.
- FIG. 2 is a simplified diagram showing a side view of the photovoltaic module interconnection system according to one embodiment of the present invention.
- FIG. 3 is a simplified diagram showing a planar view of a photovoltaic module as part of the photovoltaic module interconnection system according to one embodiment of the present invention.
- FIG. 4 is a simplified diagram showing a side view of a photovoltaic module as part of the photovoltaic module interconnection system according to another embodiment of the present invention.
- FIG. 5 is a simplified diagram showing a side view of a photovoltaic module as part of the photovoltaic module interconnection system according to yet another embodiment of the present invention
- FIG. 6 is a simplified diagram showing a side view of a photovoltaic module as part of the photovoltaic module interconnection system according to yet another embodiment of the present invention.
- FIG. 7 is a simplified diagram showing a method for installing photovoltaic modules using the photovoltaic module interconnection system according to one embodiment of the present invention.
- FIG. 8 is a simplified diagram showing a method for installing photovoltaic modules using the photovoltaic module interconnection system according to another embodiment of the present invention.
- the present invention is directed to interconnects for photovoltaic modules. More particularly, the invention provides electrical interconnects between conductive tabs for photovoltaic modules and methods thereof. Merely by way of example, the invention has been applied to the interconnection of photovoltaic modules with interconnection protectors. But it would be recognized that the invention has a much broader range of applicability.
- FIG. 1 is a simplified diagram showing a planar view of a photovoltaic module interconnection system according to one embodiment of the present invention.
- the photovoltaic interconnection system 100 includes a plurality of PV modules 51 .
- the PV modules 51 are interconnected to neighboring PV modules 51 using an interconnection system.
- each of the plurality of PV modules 51 includes a plurality of bus bars 52 and/or a plurality of interconnect tabs 53 .
- a first PV module 51 and a second PV module 51 are interconnected using a module interconnector 57 .
- FIG. 2 is a simplified diagram showing a side view of the photovoltaic module interconnection system 100 according to one embodiment of the present invention. This diagram is merely an example, which should not unduly limit the scope of the claims. One of ordinary skill in the art would recognize many variations, alternatives, and modifications.
- FIG. 3 is a simplified diagram showing a planar view of a photovoltaic module 51 as part of the photovoltaic module interconnection system 100 according to one embodiment of the present invention.
- the PV module 51 includes a plurality of bus bars 32 .
- the plurality of bus bars 32 are the plurality of bus bars 52 .
- each PV module 51 includes two bus bars 32 coupled to the positive and negative ends of the array of photovoltaic cells included in the PV module 51 .
- the PV module includes a plurality of interconnect tabs 33 that extend beyond the edge of the PV module 51 and protrude from a side of the PV module 51 .
- the plurality of interconnect tabs 33 are the plurality of interconnect tabs 53 .
- the each of the plurality of interconnect tabs 33 is an extension of the respective bus bar 32 .
- each of the plurality of interconnect tabs 33 is an additional conductor.
- the plurality of interconnect tabs 33 are not rated to be weatherproof as assembled in the factory, but are potted (e.g., cemented) in a weatherproof package at the installation site.
- each of the plurality of interconnect tabs 33 is coated at least partially with an electrically protective film.
- FIG. 4 is a simplified diagram showing a side view of a photovoltaic module 51 as part of the photovoltaic module interconnection system 100 according to another embodiment of the present invention.
- the PV module 51 includes a photovoltaic panel 12 that includes active and conductive layers.
- the photovoltaic panel 12 includes any material such as silicon, cadmium telluride, CIGS, organics, and/or other photovoltaic active materials.
- the photovoltaic module 51 includes a plurality of interconnect tabs 13 .
- the plurality of interconnect tabs 13 are the plurality of interconnect tabs 33 and/or the plurality of interconnect tabs 53 .
- each of the plurality of interconnect tabs 13 is an extension of a respective bus bar connected to the photovoltaic panel 12 .
- each of the plurality of interconnect tabs 13 is a separate conductor from the respective bus bar.
- each of the plurality of interconnect tabs 13 is coated at least partially with an electrically protective film.
- the PV module 51 includes a first encapsulating material 15 protecting a front panel surface and a back panel surface of the photovoltaic panel 12 from the environment.
- the first encapsulating material 15 includes glass, foil, polymer, and/or a laminate of multiple materials.
- the front panel surface is designed to face a light source (e.g., the sun) in order to generate power.
- the PV module 51 includes a second encapsulating material 14 around a plurality of edge surfaces of the photovoltaic panel 12 for protecting the photovoltaic panel 12 from the environment.
- the second encapsulating material 14 includes a polymer and/or other mixture of materials selected to minimize the damage to the photovoltaic panel 12 .
- the second encapsulating material 14 is placed above or below and/or on the sides of each of the plurality of interconnect tabs 13 .
- the first encapsulating material 15 and/or the second encapsulating material 14 substantially encloses the photovoltaic panel 12 by, for example, covering all the surfaces of the photovoltaic panel 12 except for the locations where the interconnect tabs 13 are located.
- the first encapsulating material 15 and/or the second encapsulating material 14 protects the photovoltaic panel 12 from ambient conditions outside of the PV module 51 , such as moisture, abrasion, debris, and/or oxygen.
- FIG. 5 is a simplified diagram showing a side view of a photovoltaic module 51 as part of the photovoltaic module interconnection system 100 according to yet another embodiment of the present invention.
- the PV module 51 includes a plurality of bus bars 42 .
- the plurality of bus bars 42 are the plurality of bus bars 52 .
- each PV module 51 includes two bus bars 42 coupled to the positive and negative ends of the array of photovoltaic cells included in the PV module 51 .
- the PV module 51 includes an interconnect tab 43 and an interconnect tab 44 .
- the interconnect tab 43 and the interconnect tab 44 are the plurality of interconnect tabs 53 .
- the interconnect tab 43 and/or the interconnect tab 44 protrudes from the PV module 51 parallel to the bus bars 42 .
- the interconnect tab 43 and/or the interconnect tab 44 protrudes from the PV module 51 at some angle relative to the respective bus bar 42 .
- interconnect tab 43 and/or interconnect tab 44 is an extension of the respective bus bar 42 .
- the interconnect tab 43 and/or the interconnect tab 44 is coated at least partially with an electrically protective film.
- FIG. 6 is a simplified diagram showing a side view of a photovoltaic module 51 as part of the photovoltaic module interconnection system 100 according to yet another embodiment of the present invention.
- the PV module 51 includes a photovoltaic panel 22 that includes active and conductive layers.
- the photovoltaic panel 22 includes any material such as silicon, cadmium telluride, CIGS, organics, and/or other photovoltaic active materials.
- the photovoltaic module 51 includes a plurality of interconnect tabs 27 .
- the plurality of interconnect tabs 27 are the plurality of interconnect tabs 53 .
- each of the plurality of interconnect tabs 27 are connected to a respective bus bar 26 connected to the photovoltaic panel 12 .
- each of the plurality of interconnect tabs 27 is composed of conductive tape and/or thin metal. In another embodiment, each of the plurality of interconnect tabs 27 protrudes from the side of the PV module 51 . In yet another embodiment, each of the plurality of interconnect tabs 27 extends around the first encapsulating material 25 to a front module surface or a back module surface of the PV module 51 . For example, the front module surface is designed to face a light source (e.g., the sun) in order to generate power. In yet another embodiment, the PV module 51 provides physical support for each of the plurality of interconnect tabs 27 for subsequent interconnection of multiple PV modules 51 . In yet another embodiment, each of the plurality of interconnect tabs 27 is coated at least partially with an electrically protective film.
- the PV module 51 includes a first encapsulating material 25 protecting a front panel surface and a back panel surface of the photovoltaic panel 22 from the environment.
- the first encapsulating material 25 includes glass, foil, polymer, and/or a laminate of multiple materials.
- the front panel surface is designed to face a light source (e.g., the sun) in order to generate power.
- the first encapsulating material 25 is the first encapsulating material 15 .
- the PV module 51 includes a second encapsulating material 24 around a plurality of edge surfaces of the photovoltaic panel 22 for protecting the photovoltaic panel 212 from the environment.
- the second encapsulating material 24 includes a polymer and/or other mixture of materials selected to minimize the damage to the photovoltaic panel 22 .
- the second encapsulating material 24 is placed above or below and/or on the sides of each of the plurality of interconnect tabs 23 .
- the second encapsulating material 24 is the second encapsulating material 14 .
- the first encapsulating material 25 and/or the second encapsulating material 24 substantially encloses the photovoltaic panel 22 by, for example, covering all the surfaces of the photovoltaic panel 22 except for the locations where the interconnect tabs 23 are located.
- the first encapsulating material 25 and/or the second encapsulating material 24 protects the photovoltaic panel 22 from ambient conditions outside of the PV module 51 , such as moisture, abrasion, debris, and/or oxygen.
- interconnection between a first PV module 51 and a second PV module is provided by the module interconnector 57 .
- the module interconnector 57 includes an interconnection component 56 and an interconnection protector 54 .
- electrical interconnection between the first PV module 51 and the second PV module 51 is provided by the interconnection component 56 coupled through a first connection 55 (e.g., a first connection component) to a first interconnect tab 53 on the first PV module 51 and coupled through a second connection 55 (e.g., a second connection component) to a second interconnect tab 53 on the second PV module 51 .
- first connection 55 and/or the second connection 55 are crimped, soldered, welded, and/or ultrasonically welded.
- first connection 55 and the second connection 55 are completed in the factory and/or completed at the installation site.
- the interconnection component 56 is made of the same type of metal as the first interconnect tab 53 and the second interconnect tab 53 to reduce the potential for corrosion.
- the first connection 55 and the second connection 55 are applied directly between the first interconnect tab 53 and the second interconnect tab 53 without intervening interconnection component 56 .
- interconnection protector 54 environmental protection for the electrical interconnection is provided by interconnection protector 54 .
- the interconnection protector 54 also provides environmental protection for the interface of the interconnect tabs 53 and the PV modules 51 .
- the interconnection protector 54 substantially encloses the interconnection component 56 , the first connection 55 , and the second connection 55 , but, for example, provides access points for the first interconnect tab 53 and the second interconnect tab 54 .
- the interconnection component 56 , the first connection 55 , and the second connection 55 are potted (e.g., cemented) in place inside the interconnection protector 54 using one or more potting materials.
- the one or more potting materials fill a volume inside the interconnection protector 54 that is not occupied by the interconnection component 56 , the first connection 55 , and the second connection 55 .
- the one or more potting materials include a liquid encapsulant.
- the one or more potting materials include room temperature vulcanizing silicone and/or epoxy.
- the interconnection protector 54 provides physical strain relief for the interconnection component 56 , the first connection 55 , the second connection 55 , the first interconnect tab 53 , and/or the second interconnect tab 53 .
- the interconnection protector 54 and the interconnection component 56 provide strain relief to reduce strain during thermal expansion of the PV modules 51 and/or the system that holds the PV modules 51 in place.
- interconnection component 56 includes a thin sheet of metal with accordion folds (e.g., accordion bends) to allow lengthening and shortening, potted in soft polymer inside the interconnection protector 54 .
- the interconnection component 56 includes a flexible cable with slack to allow for expansion and contraction.
- the interconnection protector 54 also provides sufficient safety to prevent accidental contact to electrical conductors (e.g., the interconnection component 56 ) at up to several thousand volts.
- electrical conductors e.g., the interconnection component 56
- the interconnect tabs 53 are provided with an electrically protective film to prevent electrical shock that is subsequently removed or pierced during assembly of connections 55 .
- connections 55 , the interconnection component 56 , and the interconnection protector 54 are installed on a group of modules 51 in a factory, for shipping a partially pre-assembled set of PV modules 51 to the installation site.
- the module interconnector 57 allows a 180 degree bend to permit front-to-front and/or back-to-back folding of PV modules 51 in a shipping container.
- the folded PV modules 51 can subsequently be rapidly and/or automatically unfolded at the installation site.
- the interconnection protector 54 is composed of harder polymer on the outside for environmental protection, and softer polymer on the inside to allow for thermal expansion.
- the interconnection protector 54 is filled with liquid and/or grease.
- the softer material inside the interconnection protector 54 is filled and/or cured in the factory and/or at the installation site.
- the interconnection protector 54 allows the interconnection of the PV module 51 with a wiring harness at the end of a string of PV modules 51 .
- the interconnection protector 54 extends on a front module surface (e.g., the light side) of the PV module 51 but does not block the module active area from being exposed to sunlight.
- the interconnection protector 54 extends around the back module surface (e.g., the dark side) of the PV module 51 for added mechanical strength and/or environmental protection.
- the interconnection protector 54 provides a surface and/or a mating component for physically mounting the PV module 51 to a racking system with sufficient strength to resist forces such as gravity and wind loading.
- the interconnection protector 54 provides a semi-permanent interconnection.
- the interconnection component 56 may be needed to cut the interconnection component 56 and re-join the cut interconnection component 56 with another interconnection component 56 using solder, welding, ultrasonic welding and/or crimping.
- the interconnection component 56 is provided with extra length to simplify the process of cutting and re-joining.
- the semi-permanent connection provided by the module interconnector 57 results in overall cost savings in a large photovoltaic installation.
- replacing a module at the installation site is rare, so the cost savings by eliminating push-to-connect connectors is more than adequate to make up for the extra effort required to cut and re-join the interconnection component 56 .
- PV modules 51 can be packed closely together for volume-efficient shipping to the installation site. For example, shipping two 6-mm-thick typical modules, with 12 mm thick connectors, needs a minimum width of 24 mm in a packing container. In another example, shipping two 6-mm-thick modules, with improved interconnections, needs a minimum width of 12 mm in a packing container, double the packing density of a typical module. In yet another example, pre-assembled sets of folded PV modules 51 , as described herein, are provided for faster installation at the installation site.
- FIG. 7 is a simplified diagram showing a method for installing photovoltaic modules 51 using the photovoltaic module interconnection system 100 according to one embodiment of the present invention.
- the method 710 includes a process 700 for providing PV modules; a process 701 for attaching interconnection tabs to PV modules; a process 702 for interconnecting PV modules; a process 703 for attaching interconnection protectors; a process 704 for packing interconnected PV modules for shipping; and a process 705 for installing PV modules at the installation site.
- the method 710 of installing PV modules 51 using the photovoltaic module interconnection system 100 can be performed using variations among the processes 700 - 705 as would be recognized by one of ordinary skill in the art.
- PV modules 51 according to one or more embodiments of the present invention are provided.
- PV modules 51 with the plurality of bus bars 52 are provided.
- the PV modules 51 include encapsulating materials (e.g., the first encapsulating material 15 or 25 and/or the second encapsulating material 14 or 24 ).
- each of the plurality of interconnection tabs 53 are attached to the PV modules 51 .
- each of the plurality of interconnection tabs are an extension of the respective bus bar 52 .
- each of the plurality of interconnection tabs 53 are a separate conductor connected to the end of the respective bus bar 52 .
- each of the plurality of interconnection tabs 53 are attached either parallel to or at some other angle to the respective bus 52 .
- each of the plurality of interconnect tabs 53 is coated at least partially with an electrically protective film.
- the PV modules 51 are interconnected.
- a first interconnection tab 53 from a first PV module 51 is electrically connected to a second interconnection tab 53 from a second PV module 51 using a interconnection component 56 using connections 55 .
- the first interconnection tab 53 from the first PV module 51 is electrically connected to the second interconnection tab 53 from the second PV module 51 without intervening interconnection component 56 .
- the interconnection protector 54 is attached at each interconnection point.
- the interconnection protector 54 is attached over the interconnection component 56 and/or the connections 55 .
- the interconnection protector 54 is potted in place.
- the interconnection component 56 , the first connection 55 , and the second connection 55 are potted in place inside the interconnection protector 54 using one or more potting materials.
- the one or more potting materials are injected into a volume inside the interconnection protector 54 that is not occupied by the interconnection component 56 , the first connection 55 , and the second connection 55 .
- the one or more potting materials include a liquid encapsulant.
- the one or more potting materials subsequently cure to form a weatherproof layer.
- the one or more potting materials include room temperature vulcanizing silicone and/or epoxy.
- the interconnected PV modules 51 are packed for shipping.
- the PV modules 51 are folded front-to-front and/or back-to-back at each interconnection point.
- the PV modules are packed in a shipping container.
- the PV modules 51 are installed at the installation site.
- the interconnected PV modules 51 are unpacked from the shipping container.
- the interconnected PV modules 51 are unfolded.
- the interconnected PV modules 51 are mounted to a rail and/or some other type of mounting system at their final installation location.
- FIG. 7 is merely an example, which should not unduly limit the scope of the claims.
- a process for shipping, to an installation site, at least the interconnected and packed first photovoltaic module 51 and second photovoltaic module 51 occurs between the process 704 for packing interconnected PV modules for shipping and the process 705 for installing PV modules at the installation site.
- a process for unpacking the interconnected and packed first photovoltaic module 51 and second photovoltaic module 51 occurs between the process 704 for packing interconnected PV modules for shipping and the process 705 for installing PV modules at the installation site.
- FIG. 8 is a simplified diagram showing a method for installing photovoltaic modules 51 using the photovoltaic module interconnection system 100 according to another embodiment of the present invention.
- the method 810 includes a process 800 for providing PV modules; a process 801 for installing PV modules; a process 802 for interconnecting PV modules; and a process 803 for attaching interconnection protectors.
- the method 810 of installing PV modules 51 using the photovoltaic module interconnection system 100 can be performed using variations among the processes 800 - 803 as would be recognized by one of ordinary skill in the art.
- PV modules 51 with the plurality of interconnection tabs 53 are provided.
- PV modules 51 with the plurality of bus bars 52 are provided.
- the PV modules 51 include encapsulating materials (e.g., the first encapsulating material 15 or 25 and/or the second encapsulating material 14 or 24 ).
- the plurality of interconnection tabs 53 are attached to the PV modules 51 .
- each of the plurality of interconnection tabs are an extension of the respective bus bar 52 .
- each of the plurality of interconnection tabs 53 are a separate conductor connected to the end of the respective bus bar 52 .
- each of the plurality of interconnection tabs 53 are attached either parallel to or at some other angle to the respective bus 52 .
- each of the plurality of interconnect tabs 53 is coated at least partially with an electrically protective film.
- the electrically protective film prevents electrical shock during handling of the PV modules 51 .
- the PV modules 51 are installed at the installation site.
- the interconnected PV modules 51 are unpacked from shipping containers.
- the interconnected PV modules 51 are mounted to a rail and/or some other type of mounting system at their final installation location.
- the PV modules 51 are interconnected.
- a first interconnection tab 53 from a first PV module 51 is electrically connected to a second interconnection tab 53 from a second PV module 51 using an interconnection component 56 and connections 55 .
- the first interconnection tab 53 from the first PV module 51 is electrically connected to the second interconnection tab 53 from the second PV module 51 without the intervening interconnection component 56 .
- the electrically protective film on the first interconnection tab 53 and the electrically protective film on the second interconnection tab 53 is pierced and/or removed.
- the interconnection protector 54 is attached at each interconnection point.
- the interconnection protector 54 is attached over the interconnection component 56 and/or the connections 55 .
- the interconnection protector 54 is potted in place.
- the interconnection component 56 , the first connection 55 , and the second connection 55 are potted in place inside the interconnection protector 54 using one or more potting materials.
- the one or more potting materials are injected to a volume inside the interconnection protector 54 that is not occupied by the interconnection component 56 , the first connection 55 , and the second connection 55 .
- the one or more potting materials include a liquid encapsulant.
- the one or more potting materials subsequently cure to form a weatherproof layer.
- the one or more potting materials include room temperature vulcanizing silicone and/or epoxy.
- FIG. 8 is merely an example, which should not unduly limit the scope of the claims.
- a process for packing, for shipping, at least the first photovoltaic module 51 and second photovoltaic module 51 occurs between the process 800 for providing PV modules and the process 801 for installing PV modules.
- a process for shipping, to an installation site, at least the first photovoltaic module 51 and second photovoltaic module 51 occurs between the process 800 for providing PV modules and the process 801 for installing PV modules.
- a process for unpacking the packed first photovoltaic module 51 and second photovoltaic module 51 occurs between the process 800 for providing PV modules and the process 801 for installing PV modules.
- a system for interconnecting photovoltaic modules includes a first photovoltaic module and a second photovoltaic module.
- the first photovoltaic module includes a first bus bar and a first interconnect tab connected to the first bus bar.
- the second photovoltaic module includes a second bus bar and a second interconnect tab connected to the second bus bar.
- the system for interconnecting photovoltaic modules additionally includes a module interconnector configured to interconnect the first photovoltaic module and the second photovoltaic module.
- the module interconnector includes an interconnection component and an interconnection protector.
- the system for interconnecting photovoltaic modules includes a first connection component connecting the interconnection component to the first interconnect tab of the first photovoltaic module and a second connection component connecting the interconnection component to the second interconnect tab of the second photovoltaic module.
- the interconnection protector substantially encloses the interconnection component, the first connection component, and the second connection component.
- the system for interconnecting photovoltaic modules is implemented according to at least FIG. 1 , FIG. 2 , FIG. 3 , FIG. 4 , FIG. 5 , and/or FIG. 6 .
- the first photovoltaic module includes one selected from a group consisting of silicon, cadmium telluride, CIGS, and organics.
- the first photovoltaic module further includes an array of photovoltaic cells, the array of photovoltaic cells includes a positive end and a negative end and the first bus bar is coupled to either the positive end or the negative end.
- the first interconnect tab protrudes from a side of the first photovoltaic module.
- the first interconnect tab is an extension of the first bus bar.
- the first interconnect tab is a separate conductor from the first bus bar.
- the first interconnect tab protrudes from the side of the first photovoltaic module in parallel with the first bus bar. In yet another example, the first interconnect tab protrudes from the side of the first photovoltaic module at an angle to the first bus bar. In yet another example, the first interconnect tab is coated at least partially by a protective film.
- the first photovoltaic module further includes a photovoltaic panel including a front panel surface, a back panel surface, and a plurality of edge surfaces. And the first photovoltaic module further includes a first encapsulating material for protecting the front panel surface of the photovoltaic panel and the back panel surface of the photovoltaic panel and a second encapsulating material for protecting the plurality of edge surfaces of the photovoltaic panel. Additionally, the first encapsulating material and the second encapsulating material substantially enclose the photovoltaic panel. In yet another example, the second encapsulating material is placed above, below, and to the sides of the first interconnect tab.
- the first photovoltaic module further includes a front module surface and a back module surface and the first interconnect tab extends around the first encapsulating material to the front module surface or the back module surface of the first photovoltaic module.
- the interconnection component is potted inside the protector using a polymer.
- the interconnection component includes a flexible cable.
- the interconnection component includes a thin sheet of metal including accordion folds.
- the first connection is formed by at least one selected from a group consisting of crimping, soldering, welding, and ultrasonic welding.
- the first connection component, the second connection component, and the interconnection component include the same metal.
- the interconnection protector provides electrical and environmental protection to the interconnection component, the first connection component, and the second connection component.
- a method for installing photovoltaic modules includes providing a first photovoltaic module that includes a first bus bar, providing a second photovoltaic module that includes a second bus bar, attaching a first interconnect tab to the first bus bar, and attaching a second interconnect tab to the second bus bar.
- the method for installing photovoltaic modules further includes interconnecting the first photovoltaic module and the second photovoltaic module by connecting the first interconnect tab to an interconnection component with a first connection component and by connecting the second interconnect tab to the interconnection component with a second connection component.
- the method for installing photovoltaic modules additionally includes enclosing substantially the interconnection component, the first connection component, and the second connection component by an interconnection protector.
- the method for installing photovoltaic modules additionally includes packing, for shipping, at least the first photovoltaic module and the second photovoltaic module, the first photovoltaic module and the second photovoltaic module being interconnected to each other, shipping, to an installation site, at least the packed first photovoltaic module and second photovoltaic module, the first photovoltaic module and the second photovoltaic module being interconnected to each other, and installing, at the installation site, at least the first photovoltaic module and the second photovoltaic module.
- the method is implemented according to at least FIG. 7 .
- the first photovoltaic module includes one selected from a group consisting of silicon, cadmium telluride, CIGS, and organics.
- the process for packing, for shipping, at least the first photovoltaic module and the second photovoltaic module includes stacking the first photovoltaic module and the second photovoltaic module either front-to-back or back-to-front by folding the interconnection component and the interconnection protector.
- a method for installing photovoltaic modules includes providing a first photovoltaic module that includes a first bus bar and a first interconnect tab connected to the first bus bar and providing a second photovoltaic module that includes a second bus bar and a second interconnect tab connected to the second bus bar.
- the method for installing photovoltaic modules further includes coating the first interconnect tab at least partially with a first protective film and coating the second interconnect tab at least partially with a second protective film.
- the method for installing photovoltaic modules additionally includes packing, for shipping, at least the first photovoltaic module and the second photovoltaic module, shipping, to an installation site, at least the packed first photovoltaic module and second photovoltaic module, and installing, at the installation site, at least the first photovoltaic module and the second photovoltaic module.
- the method for installing photovoltaic modules additionally includes interconnecting, at the installation site, the installed first photovoltaic module and the installed second photovoltaic module by connecting the first interconnect tab to an interconnection component with a first connection component and by connecting the second interconnect tab to the interconnection component with a second connection component.
- the method for installing photovoltaic modules additionally includes enclosing substantially the interconnection component, the first connection component, and the second connection component with an interconnection protector. For example, the method is implemented according to at least FIG. 8 .
- the first photovoltaic module includes one selected from a group consisting of silicon, cadmium telluride, CIGS, and organics.
- the process for interconnecting, at the installation site, the installed first photovoltaic module and the installed second photovoltaic module includes piercing the first protective film and piercing the second protective film.
- the process for interconnecting, at the installation site, the installed first photovoltaic module and the installed second photovoltaic module removing the first protective film and removing the second protective film.
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Abstract
System and method for interconnecting photovoltaic modules. The system includes a first photovoltaic module and a second photovoltaic module. The first photovoltaic module includes a first bus bar and a first interconnect tab connected to the first bus bar. The second photovoltaic module includes a second bus bar and a second interconnect tab connected to the second bus bar. The system for interconnecting photovoltaic modules additionally includes a module interconnector configured to interconnect the first and the second photovoltaic modules. The module interconnector includes an interconnection component and an interconnection protector. Additionally, the system for interconnecting photovoltaic modules includes a first connection component connecting the interconnection component to the first interconnect tab of the first photovoltaic module and a second connection component connecting the interconnection component to the second interconnect tab of the second photovoltaic module.
Description
- This application claims priority to U.S. Provisional Application No. 61/370,369, filed Aug. 3, 2010, commonly assigned and incorporated by reference herein for all purposes.
- The present invention is directed to interconnects for photovoltaic modules. More particularly, the invention provides electrical interconnects between conductive tabs for photovoltaic modules and methods thereof. Merely by way of example, the invention has been applied to the interconnection of photovoltaic modules with interconnection protectors. But it would be recognized that the invention has a much broader range of applicability.
- A traditional photovoltaic module (“PV module) often is equipped in the factory with two wires and expensive electrical connectors. For example, these expensive electrical connectors might include push-to-connect connectors such as MC-4 compatible connectors. These conventional wires and connectors are then used at the installation site to interconnect PV modules into strings of modules or into larger photovoltaic arrays. The photovoltaic strings and modules are typically mounted in areas where they are exposed to extremes of heat and cold, are subject to thermal cycling, and are subject to hazardous weather conditions such as high winds, rain, sleet, and/or snow. Consequently, the electrical connectors interconnecting the PV modules must be weatherproof for decades, tolerant of thermal cycling, and/or allow for rapid assembly.
- To minimize the total cost of a photovoltaic installation, it is often desirable to reduce both the cost of the PV module and the labor required for installation. Although the PV modules need to be weatherproof after final installation at the installation site, the requirements for weatherproofing often are not as stringent between fabrication of the PV module in the factory and installation of the PV module at the installation site. In addition, for large installations, specialized and/or automated interconnection tooling may be used. Thus, improved interconnections between PV modules in a large photovoltaic array can, for example, provide a significant reduction in material, labor, and/or construction costs. In another example, improved interconnections increases the packing density of PV modules reducing the cost of shipping PV modules to the installation site.
- Hence, it is highly desirable to improve techniques for interconnecting PV modules so to optimize the hardware and/or the process for electrically interconnecting the PV modules to reduce the total cost of the photovoltaic installation.
- The present invention is directed to interconnects for photovoltaic modules. More particularly, the invention provides electrical interconnects between conductive tabs for photovoltaic modules and methods thereof. Merely by way of example, the invention has been applied to the interconnection of photovoltaic modules with interconnection protectors. But it would be recognized that the invention has a much broader range of applicability.
- According to one embodiment, a system for interconnecting photovoltaic modules includes a first photovoltaic module and a second photovoltaic module. The first photovoltaic module includes a first bus bar and a first interconnect tab connected to the first bus bar. The second photovoltaic module includes a second bus bar and a second interconnect tab connected to the second bus bar. The system for interconnecting photovoltaic modules additionally includes a module interconnector configured to interconnect the first photovoltaic module and the second photovoltaic module. The module interconnector includes an interconnection component and an interconnection protector. Additionally, the system for interconnecting photovoltaic modules includes a first connection component connecting the interconnection component to the first interconnect tab of the first photovoltaic module and a second connection component connecting the interconnection component to the second interconnect tab of the second photovoltaic module. The interconnection protector substantially encloses the interconnection component, the first connection component, and the second connection component.
- According to another embodiment, a method for installing photovoltaic modules includes providing a first photovoltaic module that includes a first bus bar, providing a second photovoltaic module that includes a second bus bar, attaching a first interconnect tab to the first bus bar, and attaching a second interconnect tab to the second bus bar. The method for installing photovoltaic modules further includes interconnecting the first photovoltaic module and the second photovoltaic module by connecting the first interconnect tab to an interconnection component with a first connection component and by connecting the second interconnect tab to the interconnection component with a second connection component. The method for installing photovoltaic modules additionally includes enclosing substantially the interconnection component, the first connection component, and the second connection component by an interconnection protector. The method for installing photovoltaic modules additionally includes packing, for shipping, at least the first photovoltaic module and the second photovoltaic module, the first photovoltaic module and the second photovoltaic module being interconnected to each other, shipping, to an installation site, at least the packed first photovoltaic module and second photovoltaic module, the first photovoltaic module and the second photovoltaic module being interconnected to each other, and installing, at the installation site, at least the first photovoltaic module and the second photovoltaic module.
- According to yet another embodiment, a method for installing photovoltaic modules includes providing a first photovoltaic module that includes a first bus bar and a first interconnect tab connected to the first bus bar and providing a second photovoltaic module that includes a second bus bar and a second interconnect tab connected to the second bus bar. The method for installing photovoltaic modules further includes coating the first interconnect tab at least partially with a first protective film and coating the second interconnect tab at least partially with a second protective film. The method for installing photovoltaic modules additionally includes packing, for shipping, at least the first photovoltaic module and the second photovoltaic module, shipping, to an installation site, at least the packed first photovoltaic module and second photovoltaic module, and installing, at the installation site, at least the first photovoltaic module and the second photovoltaic module. The method for installing photovoltaic modules additionally includes interconnecting, at the installation site, the installed first photovoltaic module and the installed second photovoltaic module by connecting the first interconnect tab to an interconnection component with a first connection component and by connecting the second interconnect tab to the interconnection component with a second connection component. The method for installing photovoltaic modules additionally includes enclosing substantially the interconnection component, the first connection component, and the second connection component with an interconnection protector.
- Depending upon the embodiment, one or more of these benefits may be achieved. These benefits and various additional objects, features, and advantages of the present invention can be fully appreciated with reference to the detailed description and accompanying drawings that follow.
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FIG. 1 is a simplified diagram showing a planar view of a photovoltaic module interconnection system according to one embodiment of the present invention. -
FIG. 2 is a simplified diagram showing a side view of the photovoltaic module interconnection system according to one embodiment of the present invention. -
FIG. 3 is a simplified diagram showing a planar view of a photovoltaic module as part of the photovoltaic module interconnection system according to one embodiment of the present invention. -
FIG. 4 is a simplified diagram showing a side view of a photovoltaic module as part of the photovoltaic module interconnection system according to another embodiment of the present invention. -
FIG. 5 is a simplified diagram showing a side view of a photovoltaic module as part of the photovoltaic module interconnection system according to yet another embodiment of the present invention -
FIG. 6 is a simplified diagram showing a side view of a photovoltaic module as part of the photovoltaic module interconnection system according to yet another embodiment of the present invention. -
FIG. 7 is a simplified diagram showing a method for installing photovoltaic modules using the photovoltaic module interconnection system according to one embodiment of the present invention. -
FIG. 8 is a simplified diagram showing a method for installing photovoltaic modules using the photovoltaic module interconnection system according to another embodiment of the present invention. - The present invention is directed to interconnects for photovoltaic modules. More particularly, the invention provides electrical interconnects between conductive tabs for photovoltaic modules and methods thereof. Merely by way of example, the invention has been applied to the interconnection of photovoltaic modules with interconnection protectors. But it would be recognized that the invention has a much broader range of applicability.
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FIG. 1 is a simplified diagram showing a planar view of a photovoltaic module interconnection system according to one embodiment of the present invention. This diagram is merely an example, which should not unduly limit the scope of the claims. One of ordinary skill in the art would recognize many variations, alternatives, and modifications. InFIG. 1 , thephotovoltaic interconnection system 100 includes a plurality ofPV modules 51. In one example, thePV modules 51 are interconnected to neighboringPV modules 51 using an interconnection system. In another example, each of the plurality ofPV modules 51 includes a plurality ofbus bars 52 and/or a plurality ofinterconnect tabs 53. In yet another example, afirst PV module 51 and asecond PV module 51 are interconnected using amodule interconnector 57. -
FIG. 2 is a simplified diagram showing a side view of the photovoltaicmodule interconnection system 100 according to one embodiment of the present invention. This diagram is merely an example, which should not unduly limit the scope of the claims. One of ordinary skill in the art would recognize many variations, alternatives, and modifications. -
FIG. 3 is a simplified diagram showing a planar view of aphotovoltaic module 51 as part of the photovoltaicmodule interconnection system 100 according to one embodiment of the present invention. This diagram is merely an example, which should not unduly limit the scope of the claims. One of ordinary skill in the art would recognize many variations, alternatives, and modifications. InFIG. 3 , thePV module 51 includes a plurality of bus bars 32. In one example, the plurality ofbus bars 32 are the plurality of bus bars 52. In another example, eachPV module 51 includes twobus bars 32 coupled to the positive and negative ends of the array of photovoltaic cells included in thePV module 51. - In some embodiments, the PV module includes a plurality of
interconnect tabs 33 that extend beyond the edge of thePV module 51 and protrude from a side of thePV module 51. In other embodiments, the plurality ofinterconnect tabs 33 are the plurality ofinterconnect tabs 53. In yet another embodiment, the each of the plurality ofinterconnect tabs 33 is an extension of therespective bus bar 32. In yet another embodiment, each of the plurality ofinterconnect tabs 33 is an additional conductor. In yet another embodiment, the plurality ofinterconnect tabs 33 are not rated to be weatherproof as assembled in the factory, but are potted (e.g., cemented) in a weatherproof package at the installation site. In yet another embodiment, each of the plurality ofinterconnect tabs 33 is coated at least partially with an electrically protective film. -
FIG. 4 is a simplified diagram showing a side view of aphotovoltaic module 51 as part of the photovoltaicmodule interconnection system 100 according to another embodiment of the present invention. This diagram is merely an example, which should not unduly limit the scope of the claims. One of ordinary skill in the art would recognize many variations, alternatives, and modifications. As shown inFIG. 4 , thePV module 51 includes aphotovoltaic panel 12 that includes active and conductive layers. For example, thephotovoltaic panel 12 includes any material such as silicon, cadmium telluride, CIGS, organics, and/or other photovoltaic active materials. In another example, thephotovoltaic module 51 includes a plurality ofinterconnect tabs 13. In yet another example, the plurality ofinterconnect tabs 13 are the plurality ofinterconnect tabs 33 and/or the plurality ofinterconnect tabs 53. In yet another example, each of the plurality ofinterconnect tabs 13 is an extension of a respective bus bar connected to thephotovoltaic panel 12. In yet another example, each of the plurality ofinterconnect tabs 13 is a separate conductor from the respective bus bar. In yet another example, each of the plurality ofinterconnect tabs 13 is coated at least partially with an electrically protective film. - In one embodiment, the
PV module 51 includes afirst encapsulating material 15 protecting a front panel surface and a back panel surface of thephotovoltaic panel 12 from the environment. For example, thefirst encapsulating material 15 includes glass, foil, polymer, and/or a laminate of multiple materials. In another example, the front panel surface is designed to face a light source (e.g., the sun) in order to generate power. In another embodiment, thePV module 51 includes asecond encapsulating material 14 around a plurality of edge surfaces of thephotovoltaic panel 12 for protecting thephotovoltaic panel 12 from the environment. In one example, thesecond encapsulating material 14 includes a polymer and/or other mixture of materials selected to minimize the damage to thephotovoltaic panel 12. In yet another example, thesecond encapsulating material 14 is placed above or below and/or on the sides of each of the plurality ofinterconnect tabs 13. In yet another embodiment, thefirst encapsulating material 15 and/or thesecond encapsulating material 14 substantially encloses thephotovoltaic panel 12 by, for example, covering all the surfaces of thephotovoltaic panel 12 except for the locations where theinterconnect tabs 13 are located. In yet another embodiment, thefirst encapsulating material 15 and/or thesecond encapsulating material 14 protects thephotovoltaic panel 12 from ambient conditions outside of thePV module 51, such as moisture, abrasion, debris, and/or oxygen. -
FIG. 5 is a simplified diagram showing a side view of aphotovoltaic module 51 as part of the photovoltaicmodule interconnection system 100 according to yet another embodiment of the present invention. This diagram is merely an example, which should not unduly limit the scope of the claims. One of ordinary skill in the art would recognize many variations, alternatives, and modifications. As shown inFIG. 5 , thePV module 51 includes a plurality of bus bars 42. In one example, the plurality ofbus bars 42 are the plurality of bus bars 52. In another example, eachPV module 51 includes twobus bars 42 coupled to the positive and negative ends of the array of photovoltaic cells included in thePV module 51. In yet another example, thePV module 51 includes aninterconnect tab 43 and aninterconnect tab 44. In one embodiment, theinterconnect tab 43 and theinterconnect tab 44 are the plurality ofinterconnect tabs 53. In another embodiment, theinterconnect tab 43 and/or theinterconnect tab 44 protrudes from thePV module 51 parallel to the bus bars 42. In yet another embodiment, theinterconnect tab 43 and/or theinterconnect tab 44 protrudes from thePV module 51 at some angle relative to therespective bus bar 42. In yet another embodiment,interconnect tab 43 and/orinterconnect tab 44 is an extension of therespective bus bar 42. In yet another example, theinterconnect tab 43 and/or theinterconnect tab 44 is coated at least partially with an electrically protective film. -
FIG. 6 is a simplified diagram showing a side view of aphotovoltaic module 51 as part of the photovoltaicmodule interconnection system 100 according to yet another embodiment of the present invention. This diagram is merely an example, which should not unduly limit the scope of the claims. One of ordinary skill in the art would recognize many variations, alternatives, and modifications. As shown inFIG. 6 , thePV module 51 includes aphotovoltaic panel 22 that includes active and conductive layers. For example, thephotovoltaic panel 22 includes any material such as silicon, cadmium telluride, CIGS, organics, and/or other photovoltaic active materials. In another example, thephotovoltaic module 51 includes a plurality ofinterconnect tabs 27. In yet another example, the plurality ofinterconnect tabs 27 are the plurality ofinterconnect tabs 53. In yet another example, each of the plurality ofinterconnect tabs 27 are connected to arespective bus bar 26 connected to thephotovoltaic panel 12. - In one embodiment, each of the plurality of
interconnect tabs 27 is composed of conductive tape and/or thin metal. In another embodiment, each of the plurality ofinterconnect tabs 27 protrudes from the side of thePV module 51. In yet another embodiment, each of the plurality ofinterconnect tabs 27 extends around thefirst encapsulating material 25 to a front module surface or a back module surface of thePV module 51. For example, the front module surface is designed to face a light source (e.g., the sun) in order to generate power. In yet another embodiment, thePV module 51 provides physical support for each of the plurality ofinterconnect tabs 27 for subsequent interconnection ofmultiple PV modules 51. In yet another embodiment, each of the plurality ofinterconnect tabs 27 is coated at least partially with an electrically protective film. - In yet another embodiment, the
PV module 51 includes afirst encapsulating material 25 protecting a front panel surface and a back panel surface of thephotovoltaic panel 22 from the environment. For example, thefirst encapsulating material 25 includes glass, foil, polymer, and/or a laminate of multiple materials. In another example, the front panel surface is designed to face a light source (e.g., the sun) in order to generate power. In yet another example, thefirst encapsulating material 25 is thefirst encapsulating material 15. In yet another embodiment, thePV module 51 includes asecond encapsulating material 24 around a plurality of edge surfaces of thephotovoltaic panel 22 for protecting the photovoltaic panel 212 from the environment. In one example, thesecond encapsulating material 24 includes a polymer and/or other mixture of materials selected to minimize the damage to thephotovoltaic panel 22. In yet another example, thesecond encapsulating material 24 is placed above or below and/or on the sides of each of the plurality of interconnect tabs 23. In yet another example, thesecond encapsulating material 24 is thesecond encapsulating material 14. In yet another embodiment, thefirst encapsulating material 25 and/or thesecond encapsulating material 24 substantially encloses thephotovoltaic panel 22 by, for example, covering all the surfaces of thephotovoltaic panel 22 except for the locations where the interconnect tabs 23 are located. In yet another embodiment, thefirst encapsulating material 25 and/or thesecond encapsulating material 24 protects thephotovoltaic panel 22 from ambient conditions outside of thePV module 51, such as moisture, abrasion, debris, and/or oxygen. - Returning to
FIGS. 1 and 2 , in another embodiment, interconnection between afirst PV module 51 and a second PV module is provided by themodule interconnector 57. In one example, themodule interconnector 57 includes aninterconnection component 56 and aninterconnection protector 54. In yet another embodiment, electrical interconnection between thefirst PV module 51 and thesecond PV module 51 is provided by theinterconnection component 56 coupled through a first connection 55 (e.g., a first connection component) to afirst interconnect tab 53 on thefirst PV module 51 and coupled through a second connection 55 (e.g., a second connection component) to asecond interconnect tab 53 on thesecond PV module 51. For example, thefirst connection 55 and/or thesecond connection 55 are crimped, soldered, welded, and/or ultrasonically welded. In another example, thefirst connection 55 and thesecond connection 55 are completed in the factory and/or completed at the installation site. In yet another example, theinterconnection component 56 is made of the same type of metal as thefirst interconnect tab 53 and thesecond interconnect tab 53 to reduce the potential for corrosion. In yet another embodiment, thefirst connection 55 and thesecond connection 55 are applied directly between thefirst interconnect tab 53 and thesecond interconnect tab 53 without interveninginterconnection component 56. - As shown in
FIGS. 1 and 2 , environmental protection for the electrical interconnection is provided byinterconnection protector 54. For example, theinterconnection protector 54 also provides environmental protection for the interface of theinterconnect tabs 53 and thePV modules 51. In another example, theinterconnection protector 54 substantially encloses theinterconnection component 56, thefirst connection 55, and thesecond connection 55, but, for example, provides access points for thefirst interconnect tab 53 and thesecond interconnect tab 54. In yet another example, theinterconnection component 56, thefirst connection 55, and thesecond connection 55 are potted (e.g., cemented) in place inside theinterconnection protector 54 using one or more potting materials. In yet another example, the one or more potting materials fill a volume inside theinterconnection protector 54 that is not occupied by theinterconnection component 56, thefirst connection 55, and thesecond connection 55. In yet another example, the one or more potting materials include a liquid encapsulant. In yet another example, the one or more potting materials include room temperature vulcanizing silicone and/or epoxy. In yet another example, theinterconnection protector 54 provides physical strain relief for theinterconnection component 56, thefirst connection 55, thesecond connection 55, thefirst interconnect tab 53, and/or thesecond interconnect tab 53. - According to another embodiment, the
interconnection protector 54 and theinterconnection component 56 provide strain relief to reduce strain during thermal expansion of thePV modules 51 and/or the system that holds thePV modules 51 in place. For example,interconnection component 56 includes a thin sheet of metal with accordion folds (e.g., accordion bends) to allow lengthening and shortening, potted in soft polymer inside theinterconnection protector 54. In another example, theinterconnection component 56 includes a flexible cable with slack to allow for expansion and contraction. - According to yet another embodiment, the
interconnection protector 54 also provides sufficient safety to prevent accidental contact to electrical conductors (e.g., the interconnection component 56) at up to several thousand volts. For example, theinterconnect tabs 53 are provided with an electrically protective film to prevent electrical shock that is subsequently removed or pierced during assembly ofconnections 55. - According to yet another embodiment, the
connections 55, theinterconnection component 56, and theinterconnection protector 54 are installed on a group ofmodules 51 in a factory, for shipping a partially pre-assembled set ofPV modules 51 to the installation site. For example, themodule interconnector 57 allows a 180 degree bend to permit front-to-front and/or back-to-back folding ofPV modules 51 in a shipping container. In another example, the foldedPV modules 51 can subsequently be rapidly and/or automatically unfolded at the installation site. - According to yet another embodiment, the
interconnection protector 54 is composed of harder polymer on the outside for environmental protection, and softer polymer on the inside to allow for thermal expansion. For example, theinterconnection protector 54 is filled with liquid and/or grease. In another example, the softer material inside theinterconnection protector 54 is filled and/or cured in the factory and/or at the installation site. - According to yet another embodiment, the
interconnection protector 54 allows the interconnection of thePV module 51 with a wiring harness at the end of a string ofPV modules 51. - According to yet another embodiment, the
interconnection protector 54 extends on a front module surface (e.g., the light side) of thePV module 51 but does not block the module active area from being exposed to sunlight. For example, theinterconnection protector 54 extends around the back module surface (e.g., the dark side) of thePV module 51 for added mechanical strength and/or environmental protection. In another example, theinterconnection protector 54 provides a surface and/or a mating component for physically mounting thePV module 51 to a racking system with sufficient strength to resist forces such as gravity and wind loading. - In yet another embodiment, the
interconnection protector 54 provides a semi-permanent interconnection. In one example, to replace thePV module 51 at the installation site, it may be needed to cut theinterconnection component 56 and re-join thecut interconnection component 56 with anotherinterconnection component 56 using solder, welding, ultrasonic welding and/or crimping. In yet another example, theinterconnection component 56 is provided with extra length to simplify the process of cutting and re-joining. In one embodiment, the semi-permanent connection provided by themodule interconnector 57 results in overall cost savings in a large photovoltaic installation. In another embodiment, replacing a module at the installation site is rare, so the cost savings by eliminating push-to-connect connectors is more than adequate to make up for the extra effort required to cut and re-join theinterconnection component 56. - According to yet another embodiment, without bulky connectors,
PV modules 51 can be packed closely together for volume-efficient shipping to the installation site. For example, shipping two 6-mm-thick typical modules, with 12 mm thick connectors, needs a minimum width of 24 mm in a packing container. In another example, shipping two 6-mm-thick modules, with improved interconnections, needs a minimum width of 12 mm in a packing container, double the packing density of a typical module. In yet another example, pre-assembled sets of foldedPV modules 51, as described herein, are provided for faster installation at the installation site. -
FIG. 7 is a simplified diagram showing a method for installingphotovoltaic modules 51 using the photovoltaicmodule interconnection system 100 according to one embodiment of the present invention. This diagram is merely an example, which should not unduly limit the scope of the claims. One of ordinary skill in the art would recognize many variations, alternatives, and modifications. As shown inFIG. 7 , themethod 710 includes aprocess 700 for providing PV modules; aprocess 701 for attaching interconnection tabs to PV modules; aprocess 702 for interconnecting PV modules; aprocess 703 for attaching interconnection protectors; aprocess 704 for packing interconnected PV modules for shipping; and aprocess 705 for installing PV modules at the installation site. According to certain embodiments, themethod 710 of installingPV modules 51 using the photovoltaicmodule interconnection system 100 can be performed using variations among the processes 700-705 as would be recognized by one of ordinary skill in the art. - At the
process 700,PV modules 51 according to one or more embodiments of the present invention are provided. For example,PV modules 51 with the plurality ofbus bars 52 are provided. In another example, thePV modules 51 include encapsulating materials (e.g., thefirst encapsulating material second encapsulating material 14 or 24). - At the
process 701, the plurality ofinterconnection tabs 53 are attached to thePV modules 51. In one example, each of the plurality of interconnection tabs are an extension of therespective bus bar 52. In another example, each of the plurality ofinterconnection tabs 53 are a separate conductor connected to the end of therespective bus bar 52. In yet another example, each of the plurality ofinterconnection tabs 53 are attached either parallel to or at some other angle to therespective bus 52. In yet another example, each of the plurality ofinterconnect tabs 53 is coated at least partially with an electrically protective film. - At the
process 702, thePV modules 51 are interconnected. In one example, afirst interconnection tab 53 from afirst PV module 51 is electrically connected to asecond interconnection tab 53 from asecond PV module 51 using ainterconnection component 56 usingconnections 55. In another example, thefirst interconnection tab 53 from thefirst PV module 51 is electrically connected to thesecond interconnection tab 53 from thesecond PV module 51 without interveninginterconnection component 56. - At the
process 703, theinterconnection protector 54 is attached at each interconnection point. For example, theinterconnection protector 54 is attached over theinterconnection component 56 and/or theconnections 55. In another example, theinterconnection protector 54 is potted in place. In yet another example, theinterconnection component 56, thefirst connection 55, and thesecond connection 55 are potted in place inside theinterconnection protector 54 using one or more potting materials. In yet another example, the one or more potting materials are injected into a volume inside theinterconnection protector 54 that is not occupied by theinterconnection component 56, thefirst connection 55, and thesecond connection 55. In yet another example, the one or more potting materials include a liquid encapsulant. In yet another example, the one or more potting materials subsequently cure to form a weatherproof layer. In yet another example, the one or more potting materials include room temperature vulcanizing silicone and/or epoxy. - At the
process 704, theinterconnected PV modules 51 are packed for shipping. In one example, thePV modules 51 are folded front-to-front and/or back-to-back at each interconnection point. In another example, the PV modules are packed in a shipping container. - At the
process 705, thePV modules 51 are installed at the installation site. In one example theinterconnected PV modules 51 are unpacked from the shipping container. In another example, theinterconnected PV modules 51 are unfolded. In yet another example, theinterconnected PV modules 51 are mounted to a rail and/or some other type of mounting system at their final installation location. - As discussed above and further emphasized here,
FIG. 7 is merely an example, which should not unduly limit the scope of the claims. One of ordinary skill in the art would recognize many variations, alternatives, and modifications. For example, a process for shipping, to an installation site, at least the interconnected and packed firstphotovoltaic module 51 and secondphotovoltaic module 51 occurs between theprocess 704 for packing interconnected PV modules for shipping and theprocess 705 for installing PV modules at the installation site. In another example, a process for unpacking the interconnected and packed firstphotovoltaic module 51 and secondphotovoltaic module 51 occurs between theprocess 704 for packing interconnected PV modules for shipping and theprocess 705 for installing PV modules at the installation site. -
FIG. 8 is a simplified diagram showing a method for installingphotovoltaic modules 51 using the photovoltaicmodule interconnection system 100 according to another embodiment of the present invention. This diagram is merely an example, which should not unduly limit the scope of the claims. One of ordinary skill in the art would recognize many variations, alternatives, and modifications. As shown inFIG. 8 , themethod 810 includes aprocess 800 for providing PV modules; aprocess 801 for installing PV modules; aprocess 802 for interconnecting PV modules; and aprocess 803 for attaching interconnection protectors. According to certain embodiments, themethod 810 of installingPV modules 51 using the photovoltaicmodule interconnection system 100 can be performed using variations among the processes 800-803 as would be recognized by one of ordinary skill in the art. - At the
process 800,PV modules 51 with the plurality ofinterconnection tabs 53 according to one or more embodiments of the present invention are provided. For example,PV modules 51 with the plurality ofbus bars 52 are provided. In another example, thePV modules 51 include encapsulating materials (e.g., thefirst encapsulating material second encapsulating material 14 or 24). In yet another example, the plurality ofinterconnection tabs 53 are attached to thePV modules 51. In yet another example, each of the plurality of interconnection tabs are an extension of therespective bus bar 52. In yet another example, each of the plurality ofinterconnection tabs 53 are a separate conductor connected to the end of therespective bus bar 52. In yet another example, each of the plurality ofinterconnection tabs 53 are attached either parallel to or at some other angle to therespective bus 52. In yet another example, each of the plurality ofinterconnect tabs 53 is coated at least partially with an electrically protective film. In yet another example, the electrically protective film prevents electrical shock during handling of thePV modules 51. - At the
process 801, thePV modules 51 are installed at the installation site. In one example theinterconnected PV modules 51 are unpacked from shipping containers. In another example, theinterconnected PV modules 51 are mounted to a rail and/or some other type of mounting system at their final installation location. - At the
process 802, thePV modules 51 are interconnected. In one example, afirst interconnection tab 53 from afirst PV module 51 is electrically connected to asecond interconnection tab 53 from asecond PV module 51 using aninterconnection component 56 andconnections 55. In another example, thefirst interconnection tab 53 from thefirst PV module 51 is electrically connected to thesecond interconnection tab 53 from thesecond PV module 51 without the interveninginterconnection component 56. In yet another example, the electrically protective film on thefirst interconnection tab 53 and the electrically protective film on thesecond interconnection tab 53 is pierced and/or removed. - At the
process 803, theinterconnection protector 54 is attached at each interconnection point. For example, theinterconnection protector 54 is attached over theinterconnection component 56 and/or theconnections 55. In another example, theinterconnection protector 54 is potted in place. In yet another example, theinterconnection component 56, thefirst connection 55, and thesecond connection 55 are potted in place inside theinterconnection protector 54 using one or more potting materials. In yet another example, the one or more potting materials are injected to a volume inside theinterconnection protector 54 that is not occupied by theinterconnection component 56, thefirst connection 55, and thesecond connection 55. In yet another example, the one or more potting materials include a liquid encapsulant. In yet another example, the one or more potting materials subsequently cure to form a weatherproof layer. In yet another example, the one or more potting materials include room temperature vulcanizing silicone and/or epoxy. - As discussed above and further emphasized here,
FIG. 8 is merely an example, which should not unduly limit the scope of the claims. One of ordinary skill in the art would recognize many variations, alternatives, and modifications. For example, a process for packing, for shipping, at least the firstphotovoltaic module 51 and secondphotovoltaic module 51 occurs between theprocess 800 for providing PV modules and theprocess 801 for installing PV modules. In another example, a process for shipping, to an installation site, at least the firstphotovoltaic module 51 and secondphotovoltaic module 51 occurs between theprocess 800 for providing PV modules and theprocess 801 for installing PV modules. In yet another example, a process for unpacking the packed firstphotovoltaic module 51 and secondphotovoltaic module 51 occurs between theprocess 800 for providing PV modules and theprocess 801 for installing PV modules. - According to at least one embodiment, a system for interconnecting photovoltaic modules includes a first photovoltaic module and a second photovoltaic module. The first photovoltaic module includes a first bus bar and a first interconnect tab connected to the first bus bar. The second photovoltaic module includes a second bus bar and a second interconnect tab connected to the second bus bar. The system for interconnecting photovoltaic modules additionally includes a module interconnector configured to interconnect the first photovoltaic module and the second photovoltaic module. The module interconnector includes an interconnection component and an interconnection protector. Additionally, the system for interconnecting photovoltaic modules includes a first connection component connecting the interconnection component to the first interconnect tab of the first photovoltaic module and a second connection component connecting the interconnection component to the second interconnect tab of the second photovoltaic module. The interconnection protector substantially encloses the interconnection component, the first connection component, and the second connection component. For example, the system for interconnecting photovoltaic modules is implemented according to at least
FIG. 1 ,FIG. 2 ,FIG. 3 ,FIG. 4 ,FIG. 5 , and/orFIG. 6 . - In another example, the first photovoltaic module includes one selected from a group consisting of silicon, cadmium telluride, CIGS, and organics. In yet another example, the first photovoltaic module further includes an array of photovoltaic cells, the array of photovoltaic cells includes a positive end and a negative end and the first bus bar is coupled to either the positive end or the negative end. In yet another example, the first interconnect tab protrudes from a side of the first photovoltaic module. In yet another example, the first interconnect tab is an extension of the first bus bar. In yet another example, the first interconnect tab is a separate conductor from the first bus bar. In yet another example, the first interconnect tab protrudes from the side of the first photovoltaic module in parallel with the first bus bar. In yet another example, the first interconnect tab protrudes from the side of the first photovoltaic module at an angle to the first bus bar. In yet another example, the first interconnect tab is coated at least partially by a protective film.
- In yet another example, the first photovoltaic module further includes a photovoltaic panel including a front panel surface, a back panel surface, and a plurality of edge surfaces. And the first photovoltaic module further includes a first encapsulating material for protecting the front panel surface of the photovoltaic panel and the back panel surface of the photovoltaic panel and a second encapsulating material for protecting the plurality of edge surfaces of the photovoltaic panel. Additionally, the first encapsulating material and the second encapsulating material substantially enclose the photovoltaic panel. In yet another example, the second encapsulating material is placed above, below, and to the sides of the first interconnect tab. In yet another example, the first photovoltaic module further includes a front module surface and a back module surface and the first interconnect tab extends around the first encapsulating material to the front module surface or the back module surface of the first photovoltaic module. In yet another example, the interconnection component is potted inside the protector using a polymer. In yet another example, the interconnection component includes a flexible cable. In yet another example, the interconnection component includes a thin sheet of metal including accordion folds. In yet another example, the first connection is formed by at least one selected from a group consisting of crimping, soldering, welding, and ultrasonic welding. In yet another example, the first connection component, the second connection component, and the interconnection component include the same metal. In yet another example, the interconnection protector provides electrical and environmental protection to the interconnection component, the first connection component, and the second connection component.
- According to another embodiment, a method for installing photovoltaic modules includes providing a first photovoltaic module that includes a first bus bar, providing a second photovoltaic module that includes a second bus bar, attaching a first interconnect tab to the first bus bar, and attaching a second interconnect tab to the second bus bar. The method for installing photovoltaic modules further includes interconnecting the first photovoltaic module and the second photovoltaic module by connecting the first interconnect tab to an interconnection component with a first connection component and by connecting the second interconnect tab to the interconnection component with a second connection component. The method for installing photovoltaic modules additionally includes enclosing substantially the interconnection component, the first connection component, and the second connection component by an interconnection protector. The method for installing photovoltaic modules additionally includes packing, for shipping, at least the first photovoltaic module and the second photovoltaic module, the first photovoltaic module and the second photovoltaic module being interconnected to each other, shipping, to an installation site, at least the packed first photovoltaic module and second photovoltaic module, the first photovoltaic module and the second photovoltaic module being interconnected to each other, and installing, at the installation site, at least the first photovoltaic module and the second photovoltaic module. For example, the method is implemented according to at least
FIG. 7 . - In another example, the first photovoltaic module includes one selected from a group consisting of silicon, cadmium telluride, CIGS, and organics. In yet another example, the process for packing, for shipping, at least the first photovoltaic module and the second photovoltaic module includes stacking the first photovoltaic module and the second photovoltaic module either front-to-back or back-to-front by folding the interconnection component and the interconnection protector.
- According to yet another embodiment, a method for installing photovoltaic modules includes providing a first photovoltaic module that includes a first bus bar and a first interconnect tab connected to the first bus bar and providing a second photovoltaic module that includes a second bus bar and a second interconnect tab connected to the second bus bar. The method for installing photovoltaic modules further includes coating the first interconnect tab at least partially with a first protective film and coating the second interconnect tab at least partially with a second protective film. The method for installing photovoltaic modules additionally includes packing, for shipping, at least the first photovoltaic module and the second photovoltaic module, shipping, to an installation site, at least the packed first photovoltaic module and second photovoltaic module, and installing, at the installation site, at least the first photovoltaic module and the second photovoltaic module. The method for installing photovoltaic modules additionally includes interconnecting, at the installation site, the installed first photovoltaic module and the installed second photovoltaic module by connecting the first interconnect tab to an interconnection component with a first connection component and by connecting the second interconnect tab to the interconnection component with a second connection component. The method for installing photovoltaic modules additionally includes enclosing substantially the interconnection component, the first connection component, and the second connection component with an interconnection protector. For example, the method is implemented according to at least
FIG. 8 . - In another example, the first photovoltaic module includes one selected from a group consisting of silicon, cadmium telluride, CIGS, and organics. In yet another example, the process for interconnecting, at the installation site, the installed first photovoltaic module and the installed second photovoltaic module includes piercing the first protective film and piercing the second protective film. In yet another example, the process for interconnecting, at the installation site, the installed first photovoltaic module and the installed second photovoltaic module removing the first protective film and removing the second protective film.
- Although specific embodiments of the present invention have been described, it will be understood by those of skill in the art that there are other embodiments that are equivalent to the described embodiments. For example, various embodiments and/or examples of the present invention can be combined. Accordingly, it is to be understood that the invention is not to be limited by the specific illustrated embodiments, but only by the scope of the appended claims.
Claims (25)
1. A system for interconnecting photovoltaic modules, comprising:
a first photovoltaic module including a first bus bar and a first interconnect tab connected to the first bus bar;
a second photovoltaic module including a second bus bar and a second interconnect tab connected to the second bus bar;
a module interconnector configured to interconnect the first photovoltaic module and the second photovoltaic module, the module interconnector including an interconnection component and an interconnection protector;
a first connection component connecting the interconnection component to the first interconnect tab of the first photovoltaic module; and
a second connection component connecting the interconnection component to the second interconnect tab of the second photovoltaic module;
wherein the interconnection protector substantially encloses the interconnection component, the first connection component, and the second connection component.
2. The system of claim 1 wherein the first photovoltaic module includes one selected from a group consisting of silicon, cadmium telluride, CIGS, and organics.
3. The system of claim 1 wherein:
the first photovoltaic module further includes an array of photovoltaic cells, the array of photovoltaic cells including a positive end and a negative end; and
the first bus bar is coupled to either the positive end or the negative end.
4. The system of claim 1 wherein the first interconnect tab protrudes from a side of the first photovoltaic module.
5. The system of claim 4 wherein the first interconnect tab is an extension of the first bus bar.
6. The system of claim 4 wherein the first interconnect tab is a separate conductor from the first bus bar.
7. The system of claim 4 wherein the first interconnect tab protrudes from the side of the first photovoltaic module in parallel with the first bus bar.
8. The system of claim 4 wherein the first interconnect tab protrudes from the side of the first photovoltaic module at an angle to the first bus bar.
9. The system of claim 1 wherein the first interconnect tab is coated at least partially by a protective film.
10. The system of claim 1 wherein the first photovoltaic module further includes:
a photovoltaic panel including a front panel surface, a back panel surface, and a plurality of edge surfaces;
a first encapsulating material for protecting the front panel surface of the photovoltaic panel and the back panel surface of the photovoltaic panel; and
a second encapsulating material for protecting the plurality of edge surfaces of the photovoltaic panel;
wherein the first encapsulating material and the second encapsulating material substantially enclose the photovoltaic panel.
11. The system of claim 10 wherein the second encapsulating material is placed above, below, and to the sides of the first interconnect tab.
12. The system of claim 10 wherein:
the first photovoltaic module further includes a front module surface and a back module surface; and
the first interconnect tab extends around the first encapsulating material to the front module surface or the back module surface of the first photovoltaic module.
13. The system of claim 1 wherein the interconnection component is potted inside the protector using a polymer.
14. The system of claim 1 wherein the interconnection component includes a flexible cable.
15. The system of claim 1 wherein the interconnection component includes a thin sheet of metal including accordion folds.
16. The system of claim 1 wherein the first connection is formed by at least one selected from a group consisting of crimping, soldering, welding, and ultrasonic welding.
17. The system of claim 1 wherein the first connection component, the second connection component, and the interconnection component include the same metal.
18. The system of claim 1 wherein the interconnection protector provides electrical and environmental protection to the interconnection component, the first connection component, and the second connection component.
19. A method for installing photovoltaic modules, comprising:
providing a first photovoltaic module including a first bus bar;
providing a second photovoltaic module including a second bus bar;
attaching a first interconnect tab to the first bus bar;
attaching a second interconnect tab to the second bus bar;
interconnecting the first photovoltaic module and the second photovoltaic module by connecting the first interconnect tab to an interconnection component with a first connection component and by connecting the second interconnect tab to the interconnection component with a second connection component;
enclosing substantially the interconnection component, the first connection component, and the second connection component by an interconnection protector;
packing, for shipping, at least the first photovoltaic module and the second photovoltaic module, the first photovoltaic module and the second photovoltaic module being interconnected to each other;
shipping, to an installation site, at least the packed first photovoltaic module and second photovoltaic module, the first photovoltaic module and the second photovoltaic module being interconnected to each other; and
installing, at the installation site, at least the first photovoltaic module and the second photovoltaic module.
20. The method of claim 19 wherein the first photovoltaic module includes one selected from a group consisting of silicon, cadmium telluride, CIGS, and organics.
21. The method of claim 19 wherein the process for packing, for shipping, at least the first photovoltaic module and the second photovoltaic module includes stacking the first photovoltaic module and the second photovoltaic module either front-to-back or back-to-front by folding the interconnection component and the interconnection protector.
22. A method for installing photovoltaic modules, comprising:
providing a first photovoltaic module including a first bus bar and a first interconnect tab connected to the first bus bar;
providing a second photovoltaic module including a second bus bar and a second interconnect tab connected to the second bus bar;
coating the first interconnect tab at least partially with a first protective film;
coating the second interconnect tab at least partially with a second protective film;
packing, for shipping, at least the first photovoltaic module and the second photovoltaic module;
shipping, to an installation site, at least the packed first photovoltaic module and second photovoltaic module; and
installing, at the installation site, at least the first photovoltaic module and the second photovoltaic module;
interconnecting, at the installation site, the installed first photovoltaic module and the installed second photovoltaic module by connecting the first interconnect tab to an interconnection component with a first connection component and by connecting the second interconnect tab to the interconnection component with a second connection component; and
enclosing substantially the interconnection component, the first connection component, and the second connection component with an interconnection protector.
23. The method of claim 22 wherein the first photovoltaic module includes one selected from a group consisting of silicon, cadmium telluride, CIGS, and organics.
24. The method of claim 22 wherein the process for interconnecting, at the installation site, the installed first photovoltaic module and the installed second photovoltaic module includes piercing the first protective film and piercing the second protective film.
25. The method of claim 22 wherein the process for interconnecting, at the installation site, the installed first photovoltaic module and the installed second photovoltaic module removing the first protective film and removing the second protective film.
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US11159120B2 (en) | 2018-03-23 | 2021-10-26 | Nextracker Inc. | Multiple actuator system for solar tracker |
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US11387771B2 (en) | 2018-06-07 | 2022-07-12 | Nextracker Llc | Helical actuator system for solar tracker |
US11050383B2 (en) | 2019-05-21 | 2021-06-29 | Nextracker Inc | Radial cam helix with 0 degree stow for solar tracker |
US11705859B2 (en) | 2019-05-21 | 2023-07-18 | Nextracker Llc | Radial cam helix with 0 degree stow for solar tracker |
Also Published As
Publication number | Publication date |
---|---|
US9343592B2 (en) | 2016-05-17 |
WO2012018751A1 (en) | 2012-02-09 |
US20120034799A1 (en) | 2012-02-09 |
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