WO2010014941A1 - Modules solaires, boîtes de jonction de module solaire, et procédé de montage de boîte de jonction sur des modules solaires - Google Patents

Modules solaires, boîtes de jonction de module solaire, et procédé de montage de boîte de jonction sur des modules solaires Download PDF

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Publication number
WO2010014941A1
WO2010014941A1 PCT/US2009/052471 US2009052471W WO2010014941A1 WO 2010014941 A1 WO2010014941 A1 WO 2010014941A1 US 2009052471 W US2009052471 W US 2009052471W WO 2010014941 A1 WO2010014941 A1 WO 2010014941A1
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WO
WIPO (PCT)
Prior art keywords
solar module
recited
conductor
junction box
module
Prior art date
Application number
PCT/US2009/052471
Other languages
English (en)
Inventor
Thomas Tamayo
Geoff Green
Stephen Coughlin
Robert Weiss
Fred Ratel
Original Assignee
Daystar Technologies, Inc.
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Daystar Technologies, Inc. filed Critical Daystar Technologies, Inc.
Publication of WO2010014941A1 publication Critical patent/WO2010014941A1/fr

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Classifications

    • H—ELECTRICITY
    • H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
    • H02S—GENERATION OF ELECTRIC POWER BY CONVERSION OF INFRARED RADIATION, VISIBLE LIGHT OR ULTRAVIOLET LIGHT, e.g. USING PHOTOVOLTAIC [PV] MODULES
    • H02S40/00—Components or accessories in combination with PV modules, not provided for in groups H02S10/00 - H02S30/00
    • H02S40/30—Electrical components
    • H02S40/34—Electrical components comprising specially adapted electrical connection means to be structurally associated with the PV module, e.g. junction boxes
    • 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
    • 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
    • H01L31/0488—Double glass encapsulation, e.g. photovoltaic cells arranged between front and rear glass sheets
    • 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
    • Y02E10/50—Photovoltaic [PV] energy

Definitions

  • the present invention generally relates to photovoltaic modules, photovoltaic module junction boxes, and methods of mounting photovoltaic module junction boxes. More particularly, the present invention relates to photovoltaic modules having edge- mounted external conductors and junction boxes that mount to an edge of a photovoltaic module.
  • junction box also known as a "terminal box”
  • solar module which may also be referred to in the art as a "solar panel.”
  • mounting the terminal box on the back of the module typically requires drilling holes into the substrate to allow access to the electrical contacts of the bus bar in the module.
  • drilling holes into the substrate is feasible in processes that 1) deposit the photovoltaic (“PV”) material at low temperatures, or 2) deposit the PV material onto the top cover glass (“superstrate”)
  • drilling holes into the substrate for PV module manufacturing processes that use higher temperature deposition processes presents the following challenges:
  • junction boxes, solar module assemblies, and methods of mounting junction boxes according to aspects of the present invention alleviate some if not all of these disadvantages of the prior art.
  • aspects of the present invention reduce or eliminate the need to drill holes into the active area of the solar module, thus avoiding these and other disadvantages of the prior art.
  • aspects of the invention provide a high-reliability and low-cost devices, systems, and methods for interconnecting and operating solar modules.
  • One aspect of the invention is a solar module comprising or including a front side, a back side, an edge, a layer of photovoltaic material between the front side and the back side, and a carrier electrically coupled to the layer of photovoltaic material; and an exit conductor electrically coupled to the carrier and directed out of the edge of the module.
  • the edge as disclosed herein, may be a lateral surface of the module, for example, a surface substantially perpendicular to at least one of the front side and the back side of the module.
  • the exit conductor may be positioned between the front side and the backside of the module and may comprise a thin strip of conductive material, such as, copper strip or coated copper strip.
  • the solar module may typically include a thin-film photovoltaic material, for example, a CIS, a CIGS, or a CIGSS photovoltaic material.
  • an edge-mounted solar module junction box comprising or including a housing having a first end and a second end opposite the first end, the second end adapted to receive a conductor; a cavity in the housing adapted to receive a cable terminal end in electrical contact with the conductor; and a projection from the first end of the housing positioned to cover at least a portion of an edge of a solar module when the junction box housing is mounted to a back side of the solar module.
  • the junction box may further comprise a lip on the projection positioned to cover at least a portion of a front side of the solar module, opposite the back side.
  • the housing may include an open top having a removable cover, for example, a cover having a projection positioned to project into the housing.
  • the projection on the cover into the housing may be conductive or non-conductive, but in one aspect may be a metallic spring clip.
  • junction box and cable assembly comprising the junction box recited above, a terminal mounted in the junction box, and a cable having a first end mounted to the second end of the housing and in electrical contact with the terminal and a second end having a connector.
  • a further aspect of the invention is a solar module assembly comprising a solar module and at least one junction box and cable assembly as recited above mounted to an edge of the solar module.
  • a further aspect of the invention is a solar module array having a plurality of solar module assemblies as recited above.
  • Another aspect of the invention is method of mounting a junction box to a solar module having an exit conductor, the method comprising or including: mounting a junction box housing having an open top, an at least partially open bottom, and a cable terminal end to a back side of the solar module wherein the solar module exit conductor and cable terminal end are exposed in the open top of the housing; mounting a cover having a projection on to the open top of the housing; and deflecting one of the solar module exit conductor and the cable terminal end with the cover projection to electrically engage the solar module exit conductor and the cable terminal end.
  • mounting the junction box may comprise positioning the open bottom of the junction box over the solar module exit conductor and sliding the junction box wherein the cable terminal end approaches the solar module exit conductor, or wherein the cable terminal end contacts the solar module exit conductor.
  • the cover may include a projection, for example, a cover terminal, such as, a spring clip, wherein deflecting and contacting the solar module exit conductor or the cable terminal is practiced using the spring clip.
  • the method may further include securing the solar module exit conductor and the cable terminal end with the metallic spring clip, for example, between opposing arms of the spring clip.
  • another aspect of the invention is a method of providing an external electrical contact to a solar module, the method comprising or including: providing a substrate having photovoltaic material and a conductive layer in electrical contact with the photovoltaic material; exposing a portion of the conductive layer adjacent a perimeter of the substrate; mounting a conductor, for example, an exit conductor, to the exposed portion of the conductive layer wherein a first end of the conductor is mounted to the exposed portion of the conductive layer and a second end of the conductor, opposite the first end, projects from the perimeter of the substrate; and mounting a cover glass over the substrate to provide a solar module with the conductor projecting from the perimeter of the substrate.
  • a conductor for example, an exit conductor
  • the second end of the conductor may project substantially perpendicularly from the perimeter of the substrate.
  • the perimeter of the substrate may be a longitudinal perimeter or a latitudinal perimeter, and mounting the conductor is practiced wherein the second end of the conductor projects from one of the longitudinal perimeter or the latitudinal perimeter.
  • the conductor, or exit conductor comprises an elongated strip of conductive material, such as, copper strip or coated copper strip.
  • the method may further include, prior to mounting the cover glass, mounting a seal about the perimeter of the substrate.
  • the method may also include laminating the solar module and mounting one of the junction boxes described above to the laminated solar module so that the module conductor is in electrical contact with the cable terminal end of the junction box.
  • FIGURE 1 is a top perspective view of a solar module assembly according to one aspect of the invention.
  • FIGURE 2 is a bottom perspective view of the solar module assembly shown in FIGURE 1.
  • FIGURE 3 is an exploded perspective view of the solar module assembly shown in FIGURE 1.
  • FIGURE 4 is a perspective view of a portion of the module shown in FIGURE 2 with the junction box removed as identified by Detail 4 in FIGURE 2 according to one aspect of the invention.
  • FIGURE 5 is a cross-sectional side elevation view of the detail of the portion of the module shown in FIGURE 4 as viewed along lines 5-5 in FIGURE 4.
  • FIGURE 6 is a detailed perspective view of a portion of the module with a junction box shown in FIGURE 2 as identified by Detail 4 in FIGURE 2 according to one aspect of the invention.
  • FIGURE 7 is a top plan view of the junction box shown in FIGURE 6.
  • FIGURE 8 is a right side elevation view of the junction box shown in FIGURE 6, the left side elevation being a mirror image thereof.
  • FIGURE 9 is a bottom plan view of the junction box shown in FIGURE 6.
  • FIGURE 10 is a front elevation view of the junction box shown in FIGURE 6.
  • FIGURE 11 is a rear elevation view of the junction box shown in FIGURE 6.
  • FIGURE 12 is at top plan view of the junction box shown in FIGURE 6 with the cover removed according to one aspect of the invention.
  • FIGURE 13 is a cross-sectional view of the junction box show in FIGURE 6 as viewed along section lines 13-13.
  • FIGURE 14 is an exploded perspective view of the junction box shown in FIGURE 6 according to one aspect of the invention.
  • FIGURE 15 is a bottom view of the cover of the junction box shown in FIGURE 14.
  • FIGURE 16 is a cross-sectional view of the cover shown in FIGURE 15 as viewed along section lines 16-16 in FIGURE 15.
  • FIGURE 17 is side elevation view of the spring clip shown in FIGURE 15 according to one aspect of the invention.
  • FIGURE 18 is a bottom view of the spring clip shown in FIGURE 17.
  • FIGURE 19 is side elevation view of the conductor and cable terminal assembly shown in FIGURE 14 according to one aspect of the invention.
  • FIGURE 20 is a top view of the cable terminal end shown in FIGURE 19.
  • FIGURE 21 is a side elevation view of the cable terminal end shown in FIGURE 19.
  • FIGURES 22 through 33 are schematic illustrations of a step-by-step procedure for mounting a junction box to a photovoltaic module according to aspects of the invention.
  • FIGURE 34 is a top plan view of a photovoltaic module array according to an aspect of the invention, including the photovoltaic module assembly shown in FIGURES 1 and 2 and having junction boxes as shown in FIGURE 6.
  • FIGURE 35 is a perspective view of a solar module with a junction box according to another aspect of the invention.
  • FIGURE 36 is a cross sectional view of the solar module and junction box shown in FIGURE 35 as viewed along section lines 35-35.
  • FIGURE 37 a top plan view of a solar module junction box assembly according to another aspect of the invention.
  • FIGURE 38 is a cross sectional view of the solar module junction box assembly shown in FIGURE 37 as viewed along section lines 38-38.
  • FIGURE 39 left side elevation view of solar module junction box assembly shown in FIGURE 37.
  • FIGURE 1 is a top perspective view of a solar module assembly 10 according to one aspect of the invention
  • FIGURE 2 is a bottom perspective view of solar module assembly 10 shown in FIGURE 1.
  • FIGURE 3 is an exploded perspective view of the solar module assembly 10 shown in FIGURE 1.
  • module assembly 10 includes a solar module 12 and at least one, but typically, two, junction box assemblies 14.
  • Junction box assemblies 14 may comprise one or more of the junction boxes 16 described below with respect to FIGURE 6 through 21, according to aspects of the invention.
  • junction box assemblies 14 include a junction box 16 and a cable 18 having a cable connector 20 or an exposed conductor (not shown).
  • junction box assembly 14 may be mounted to module 12 along a latitudinal edge or perimeter 17 or a longitudinal edge or perimeter 19 of module 12, for example, in approximately the center of the span of the edge 17 and/or 19 with cable 18 directed substantially toward the middle of module 12.
  • junction box assembly 14 may be mounted substantially anywhere on module 12 and effect the desired invention.
  • junction box assembly 14 may be mounted to a corner 21 of module 12, for example, adjacent a corner 21 or straddling a corner 21.
  • junction box assembly 14 may be mounted to a corner where the corner of module 12 may be beveled or trimmed to provide a surface or edge upon which junction box assembly 14 may mount.
  • FIGURE 2 illustrates one aspect of the invention with cable 18 directed toward substantially the middle of module 12
  • cable 18 may exit junction box 16 whereby cable 18 is directed away from the center of module 12, for example, substantially perpendicular to edge 17 or 19; or along an edge or perimeter 17 or 19 of module 12, for example, substantially parallel to edge 17 or 19; or even substantially perpendicular to module 12, that is, directed upward or downward, as the application may require.
  • a plurality of cables 18, for example, two or more cables 18, may emanate from junction box 16.
  • junction box 16 may be positioned electrically in series with other like or similar junction boxes, or positioned electrically in parallel with like or similar junction boxes.
  • solar module 12 includes two opposite sides: a front, or “sunny side,” 22, which is typically exposed to solar radiation, and a back, or “dark side,” 24 opposite the front side, which is typically not exposed to solar radiation.
  • solar module 12 may typically include a plurality of materials, for example, a plurality of layers of materials.
  • solar module 12 may include a top cover or "superstrate" 31, an encapsulant layer 32, one or more edge seal patches 33, one or more internal PV cell electrical connections 34, one or more external PV cell electrical connections 35, one or more latitudinal edge or side seals 36, one or more longitudinal edge or side seals 37, and a substrate 38.
  • substrate 38 includes at least some photovoltaic (PV) material 40 mounted on a base substrate 41, for example, a glass or non-metallic base substrate.
  • the base substrate 41 may be a soda lime glass.
  • base substrate 41 may be provided with a conductive coating or carrier 43 (see FIGURE 5), for example, a metallic coating, such as, a molybdenum coating.
  • the conductive coating functions as the carrier or collector of the electric current produced in PV material 40.
  • the dimensions of base substrate 41 may vary depending upon the size of module 12.
  • the base substrate 41 may have a thickness between about 1 millimeter (mm) to about 5 mm, for example, about 3.2 mm; a width between about .25 meters (m) to about 1 m, for example, about 0.6 m; and a length of between about 0.5 m and about 1.5 m, for example, about 1.2 m.
  • a photovoltaic material 40 may comprise any material that, when exposed to solar radiation, generates a flow of electric current within the material.
  • PV material 40 may be any PV material, in one aspect, PV material 40 comprises a thin- film PV material, for example, a copper- indium-selenide (CIS) PV material or a copper-indium-gallium selenium and/or sulfur (CIGS or CIGSS) PV material, or a cadmium-tellurium (Cd-Te) PV material, among other conventional PV materials.
  • substrate 38 may typically include a conducting material 43, for example, a layer or path comprising a conducting metal, for example, a molybdenum coating, or conducting oxide, for example, a transparent conducting oxide.
  • At least some PV material 40 may be removed from one or more edges of the substrate 38 to provide at least one edge of the substrate having as surface 42 that is devoid of PV material and where the base substrate 41 may be exposed, that is, is "edge deleted,” as is known in the art.
  • the width of surface 42, or the width of the "edge delete,” may vary in aspects of the invention, but may typically be about 0.125 to about 1 inch in width, for example, about 0.5 inches in width.
  • the edge-deleted surface 42 may extend at least partially along a latitudinal edge 17 or a longitudinal edge 19. As shown in FIGURE 3, edge-deleted surface 42 may also extend substantially completely across an edge 17 or 19. Accordingly, the "active area" of substrate 38 may comprise the area of substrate 38 excluding the "edge deletions" 42.
  • the latitudinal side seals 36 and the longitudinal side seals 37 may typically be mounted to substrate 38 to, for example, typically to seal the interior of module 12 from the ingress of moisture.
  • seals 36 and 37 are mounted to the edges of substrate 38, for example, outside the active area of the substrate 38, for example, seals 36 and 37 may be mounted along the edge deleted areas 42 of substrate 38.
  • the edges of the seals may be substantially collinear or "flush with" the edges of substrate 38.
  • Seals 36 and 37 may typically comprise an elastomeric material, for example, a thermoplastic butyl, among other elastomers.
  • longitudinal seal 37 may have a thickness between about .25 to about 2 mm, and typically have a thickness of about 0.74 mm; a width of between about 5 mm to about 20 mm, for example, about 10 mm; and a length of between about 0.5 m to about 2 m, for example, about 1.2 m.
  • latitudinal seal 36 may have a thickness between about .25 to about 2 mm, and typically about 0.74 mm; a width of between about 5 mm to about 20 mm, for example, about 10 mm; and a length of between about 0.3 m to about 2 m, for example, about 0.6 m.
  • the one or more external electrical connections 35 provide an external electrical interface with the active area of substrate 38 of solar module 12.
  • Exit conductor 35 may also be referred to in the art as an "exit tab.”
  • external connection or exit conductor 35 provides an electrical interface between the PV material 40 of substrate 38 and the external load, for example, via internal connection 34 and/or conductive layer 43 (again, see FIGURE 5).
  • the conductive layer 43 for example, the molybdenum layer, may be exposed to permit contact with external conductor 35 and/or internal connection 34.
  • the PV material 40 may be removed from the substrate 38 to expose conductive layer 43.
  • this exposure of conductive layer 43 by removal of PV material 40 is sometimes referred to as "mo Iy clear" in the art.
  • the width of this exposure of conductive layer 43, or the mo Iy clear may be between about 2 and about 10 mm, for example, about 6 mm.
  • the external electrical connection 35 may typically comprise a length of conductive material, for example, a thin strip of metallic material that electrically engages the PV material 40.
  • external electrical connection 35 may be attached to the active area of substrate 38 by means of a fastener or an adhesive, for example, a conductive adhesive, such as, an acrylic adhesive, among other conventional means of electrically engaging external connection 35 with substrate 38.
  • external connection 35 may comprise a copper conductor or a coated copper conductor, for example, a copper conductor coated with a silver-tin plating, or its equivalent.
  • the dimensions of external connections 35 may vary depending upon the size of module 12.
  • External connection 35 may have a thickness of between about 0.2 to about 2 mm, for example, about 0.08 mm; a width of between about 6 to about 25 mm, for example, about 12.
  • an edge seal patch 33 may be applied to prevent moisture ingress, for example, ingress about the internal or external connections 34, 35, respectively.
  • Edge seal patch 33 may comprise a material similar to edge seals 36 and
  • the one or more internal connections 34 may be mounted along the longitudinal edge of substrate 38 and/or, typically, the latitudinal edge of the substrate 38. According to aspects of the invention, internal connection 34 may provide an electrical interface between the PV material 40 of substrate 38 and external connection 35, for example, via conductive coating 43. According to aspects of the invention, internal connections 34 may typically electrically engage the active area of substrate 38, for example, internal connections 34 may be mounted to the active area of substrate 38, for instance, via a "mo Iy clear" of conductive coating 43. In one aspect, internal connections 34 may be mounted flush with the edge of the active area of substrate 38.
  • Internal connection 34 may comprise any suitable conducive material, for example, a strip of metallic material that electrically engages the PV material 40 of substrate 38 via conductive layer 43.
  • internal connection 34 may comprise buss bar tape, for example, a tin(Sn)-plated copper or its equivalent, for instance, tin-plated copper foil adhesive tape marketed under the model number 1345 by 3M.
  • Internal electrical connection 34 may be attached to the active area of substrate 38 by means of a fastener or an adhesive, for example, a conductive adhesive, such as, an acrylic adhesive, among other conventional means of electrically engaging external connection 34 with substrate
  • internal connections 34 may vary depending upon the size of module 12.
  • Internal connection 34 may have a thickness of between about 0.05 mm to about 0.15 mm, for example, about 0.10 mm; a width of between about 4 mm to about 8 mm, for example, about 6.4 mm; and a length of between about 400 mm and about 800 mm, for example, about 560 mm.
  • edge seals 36, 37 and the connections 34, 35 may be mounted individually to substrate 38 or pre-assembled prior to mounting to substrate 38.
  • longitudinal edge seal 37, latitudinal edge seal 36, and external electrical connection 35 may be preassembled and then mounted, for example, with an adhesive, to substrate 38.
  • external electrical connection 35 may be mounted to substrate 38 and then a preassembled unit comprising a latitudinal edge seal 36 and an internal electrical connection 34 may be mounted to the external connection 35, for example, with an adhesive.
  • the solar module encapsulation layer 32 may be mounted to substrate 38, for example, over PV material 40.
  • Encapsulation layer 32 provides a structure that bonds the superstrate 31 to the substrate 38 and secures PV material 40 in solar module 12.
  • Encapsulation layer 32 may comprise any conventional encapsulating material and may be mounted to substrate 38 by conventional means.
  • encapsulation layer 32 may comprise an ethylene vinyl acetate (EVA), or its equivalent, and may be mounted to substrate 38 by means of an adhesive.
  • EVA ethylene vinyl acetate
  • Cover glass or superstrate 31 may typically be mounted over encapsulation layer 32.
  • Superstrate 31 may comprise any material that transmits solar radiation to illuminate PV material 40.
  • superstate 31 may comprise a glass, for instance, a low iron glass.
  • the dimensions of superstrate 31 may vary depending upon the size of module 12.
  • Superstrate 31 may have a thickness between about 1 mm and about 5 mm, for example, about 3.2 mm; a width between about 0.25 m and about 1 m, for example, about 0.6 m; and a length between about 0.5 m and about 1.5 m, for example, about 1.2 m.
  • Substrate 38, seals 36 and 37, encapsulation layer 32, and superstrate 31 may typically be laminated together according to the conventional practice in the PV industry. After lamination, one or more junction box assemblies 14 may be mounted to solar module 12, for example, as described below with respect FIGURES 22 through 33, according to aspects of the invention, though other methods may be used.
  • FIGURE 4 is a perspective view of a portion of the solar module 12 shown in FIGURE 2 as identified by Detail 4 in FIGURE 2 with the junction box 14 removed according to one aspect of the invention.
  • FIGURE 5 is a cross-sectional side elevation view of the portion of the module shown in FIGURE 4 as viewed along lines 5-5 in FIGURE 4.
  • FIGURE 5 illustrates the relative size and positioning of the components identified in FIGURES 1-3. The features of FIGURE 5 are not shown to scale, but are sized and depicted to best illustrate aspects of the invention.
  • module 12 includes a substrate 38 having a base substrate 41, for example, glass; a conductive coating 43, for example, molybdenum, on base substrate 41; and a layer of PV material 40, for example, CIGS material, mounted on top of conductive coating 43.
  • FIGURE 5 also illustrates a typical edge delete 42 in which PV material 40 is removed to expose substrate 38.
  • FIGURE 5 also illustrates a typical area 44 where conductive layer 43 is exposed, for example, a "moly clear,” and to which electrical connections can be made to extract the electric current generated in PV material 40.
  • external connector, or exit conductor, 35 is mounted to coating 43, for example, by means of an adhesive, to conduct current from PV material 40 through coating 43 and through exit conductor 35 to an external load.
  • internal conductor 34 for example, a 3M 1345 foil tape, may be applied to coating 43 and overlap exit conductor 35 to enhance current flow from PV material 40 to exit conductor 35, for example, via coating 43 and via internal conductor 34.
  • a PV module 12 having at least one exit conductor 35 that is electrically coupled to PV material 40 and is directed out of edge 13 of PV module 12. That is, contrary to prior art PV modules, which typically are provided with external conductors that exit the module from the back or rear of the module, aspects of the present invention provide an external conductor or exit conductor 35 that exits the module from an edge 13 of the module 12. Among other things, this edge-exiting conductor 35 facilitates the fabrication and handling of thin film PV cell modules and the electrical interconnection to adjacent PV modules.
  • FIGURES 6 through 21 illustrate various aspects of junction box assembly 14 and junction box 16 shown in FIGURES 1 through 3.
  • FIGURE 6 is a detailed view of a portion of the module with a junction box shown in FIGURE 2 as identified by Detail 4 in FIGURE 2 according to one aspect of the invention.
  • junction box assembly 14 includes a junction box 16, a cable 18, and a cable connector 20.
  • junction box 16 may be mounted to the back or "dark" side 24 of solar module 12 and extend at least partially over the edge of solar module 12.
  • aspects of the invention may include a junction box 16 having a projection that extends to cover at least a portion of an edge of solar module 12.
  • a projection from junction box 16 may extend substantially completely over the edge of solar module 12, for example, including extending and covering at least a portion of the front or "sunny" side 22 of module 12.
  • Cable 18 may be any conventional cable typically used in the solar energy art. Cable 18 may be about 10 centimeters (cm) to about 30 cm in length, for example, about 20 cm in length. The end of the cable 18 may be supplied with either a male or a female connection 20 to a stripped bare wire, for example, a 5 mm stripped bare wire. However, cable 18 may comprise any termination that is compatible with conventional cable connections. For example, cable 18 may be any solar connector cable suitable for compliance with TUV, IEC, and/or UL specifications according to aspects of the invention.
  • cable 18 may be a 125-flex SOLAR FRNC cable provided by LEONI Studer AG, of Daniken, Switzerland, or its equivalent.
  • Other cables 18 that may be used include: Huber+Suhner AG RADOX SMART, Huber+Suhner AG RADOX SolarLink, Huber+Suhner AG RADOX Single Core, LAPP OLFLEX SOLAR XL multi Black, Multi-Contact FLEX-SOL, Multi-Contact FLEX-SOL, and their equivalents.
  • cable connector 20 may be any conventional male or female cable connector typically used in the art.
  • cable connector 20 may be a Y-SoB or a Y-Sol4 connector provided by Yamaichi Electronics of Kunststoff, Germany, or their equivalents.
  • Other cable connectors 20 that may be used include: Multi-Contact MC-4, Multi-Contact MC-3, Lumberg Connect LC4, Lumberg Connect LC3, and Tyco Electronics SolarLok Series, and their equivalents.
  • FIGURE 7 is a top plan view of junction box 16 shown in FIGURE 6.
  • FIGURE 8 is a right side elevation view of junction box 16 shown in FIGURE 6, the left side elevation being a mirror image thereof, and
  • FIGURE 9 is a bottom plan view of junction box 16 shown in FIGURE 6.
  • FIGURE 10 is a front elevation view of junction box 16 shown in FIGURE 6, and
  • FIGURE 11 is a rear elevation view of junction box 16 shown in FIGURE 6.
  • FIGURE 12 is at top plan view of junction box 16 shown in FIGURE 6, with the cover removed according to one aspect of the invention and
  • FIGURE 13 is a cross-sectional view of junction box 16 as shown in FIGURE 6 as viewed along section lines 13-13 in FIGURE 6.
  • junction box 16 includes a housing 50 adapted to receive an end of cable 18.
  • Housing 50 may assume any appropriate geometric shape, for example, any type of parallelepiped suitably modified to facilitate manufacture, handling, and/or assembly, for example, appropriate rounded corners and/or chamfered edges, as is conventionally practiced in the art.
  • housing 50 may be generally square or generally rectangular, triangular, or polygonal, but may also be round or oval in shape while providing the desired function described herein.
  • the sides of housing 50 may be substantially perpendicular or non-perpendicular to each other or may be tapered in the vertical or horizontal direction as needed to facilitate manufacture, handling, and/or assembly.
  • housing 50 may taper at an angle between about 1 degree to about 15 degrees, for example, between about 2 degrees and about 7 degrees.
  • housing 50 may be generally rectangular in shape, having at least one direction of elongation, and may have a taper in the direction of elongation.
  • first end 52 that is somewhat wider than a second end 54 opposite the first end 52.
  • second end 54 is adapted to receive conductor 18, for example, housing 50 may include a rib 55 shaped to receive conductor 18.
  • Housing 50 may include one or more vent holes 53, for example, as shown in FIGURES 7 and 9, one or more circular vent holes provided to permit the release of process fluids, for example, gases, during mounting to solar module 12.
  • vent holes 53 may be provided to allow escape of off-gases from adhesives or potting materials during the process of mounting junction box 16 to solar module 12, as will be discussed more fully below.
  • Housing 50 may be made from any suitable material; however, due to the nature of the use of housing 50, housing 50 may typically be made for a non-conductive material, for example, any one or more of the plastics or resins encountered in the design and fabrication of conventional electrical components. Housing 50 may typically comprise a plastic, for example, a plastic that meets UL 94-5 VA specification, for example, Valox 310 SEO or a polyphenylene oxide, or their equivalent. In one aspect, housing 50 may be made from a polyamide, for example, a Zytel FR50 BK505 polyamide provided by DuPont, or its equivalent, though other polyamides may be used.
  • Housing 50 may have a width of between about 5 mm to about 100 mm, for instance, between about 40 mm and about 70 mm, and specifically between about 50 mm and about 60 mm.
  • the length of housing 50 may vary from between about 25 mm to about 250 mm, for instance, between about 40 mm and about 100 mm, and specifically between about 70 mm and about 80 mm.
  • the height of housing 50 may vary from about 3 mm to about 100 mm, for instance, between about 10 mm and about 25 mm, and specifically between about 10 mm and about 20 mm.
  • the wall thickness of housing 50 may between about 1 mm and about 12 mm, for instance, between about 3 mm and about 7 mm, and specifically between about 4 mm and about 6 mm.
  • the mass of housing 50 may be between about 10 grams and about 30, for example, at least about 15 grams. While these dimensions and masses describe exemplary embodiments, it is understood that each of these may vary according to the selection of the material used for housing 50 and other factors that necessitate compliance with United States and European Union electrical specifications for solar modules. Thus, while another device may be of different dimensions, it is understood that the function of a housing may be the same as the present invention.
  • the solar junction box 16 including the housing 50 dimensions, module 12 thicknesses, and exit conductor 35 lengths provide an electrical path length of at least about 6 mm.
  • housing 50 of junction box 16 is adapted to mount to, engage with, at least partially cover, or substantially completely cover at least a portion of an "edge" 13 of solar module 12.
  • edge 13 comprises the lateral surface of module 12 having front side 22 and back side 24, that is, a surface substantially perpendicular to at least one of front side 22 and back side 24.
  • edge 13 of module 12 which is at least partially covered by housing 50 comprises at least one exit conductor 35, for example, an exit conductor 35 projecting from edge 13.
  • housing 50 of junction box 16 includes at least one projection 56 from first end 52.
  • Projection 56 is positioned to cover or extend over at least a portion of edge 13, for example, to cover and/or protect exit conductor 35.
  • projection 56 may be positioned to contact edge 13, however, in other aspects, due to the presence of an interposing material, for example, an adhesive or a potting material, projection 56 may not actually contact edge 13, but may cover at least a portion of edge 13, where only the interposing material actually contacts edge 13.
  • Housing 50 may typically include a surface 51 , for example, a bottom surface, that abuts rear side 24 of module 12 (again, for example, via an interposing material such as an adhesive) and projection 56 may comprise a surface 57 that may be substantially perpendicular to surface 51 of housing 50.
  • junction box 16 may include one or more recesses or channels 61, for example, along surface 57 of projection 56, to permit room for an interposing material, for example, an adhesive or potting material.
  • projection 56 from housing 50 may also include a lip 58 projecting or extending from projection 56.
  • lip 58 may project from projection 56 and extend over at least a portion of front side 22 of module 12.
  • lip 58 may contact front side 22, however, typically, an interposing material, as discussed above, may be present between lip 58 and front side 22 where only the interposing material actually contacts front side 22 and not lip 58.
  • Lip 58 may include a surface 59 that may be substantially perpendicular to surface 57 of projection 56. It is also envisioned that some aspects of the invention may not have lip 58 on projection 56, but may only have a projection 56 extending over at least a portion of edge 13.
  • housing 50 typically includes a recess or cavity 60, for example, a cavity having an open bottom positioned to abut solar module 12, for example, abutting the back side 24 of solar module 12.
  • Cavity 60 may be adapted to receive one or more electrical contacts or other electrical components, for example, one or more diodes (not shown), according to aspects of the invention.
  • One or more diodes may be provided in housing 50 to limit the flow of electrons within housing 50.
  • cavity 60 may contain one or more electrical contacts or poles 62, for example, electrical contact 62 may typically be electrically coupled do cable 18, among other electrical conduits.
  • cavity 60 in housing 50 may be adapted to receive a terminal in electrical contact with a conductor, such as, with cable 18.
  • Electrical contact 62 may be positioned and adapted to electrically contact one or more complementary electrical contacts on solar module 12, for example, to place solar module 12 in electrical contact with cable 18.
  • electrical contact 62 may be positioned and adapted to electrically contact exit conductor 35 of solar module 12.
  • structure 62 may simply be any conductive or non-conductive projection from the underside of cover 66, for example, a rib, a post, a gusset, or a bar, and the like.
  • electrical contact or projection 62 may enhance or facilitate the method of mounting housing 50 to a PV module, for example, to ensure proper electrical continuity or contact between electrical contacts.
  • junction box 16 may also be adapted to facilitate handling and positioning by automated means, for example, by means of a robotic arm end.
  • Housing 50 of junction box 16 may include one or more recesses or projections (not shown) to facilitate grasping by a robotic arm end, for example, housing 50 may include recesses on opposite sides having a self-centering geometry, for example, beveled sides, for an end effecter used in an automated assembly process.
  • FIGURE 14 is an exploded perspective view of junction box 16 shown in FIGURE 6 through 13 according to one aspect of the invention.
  • housing 50 may be a complete, one-piece, integral housing, for example, having no removable sections and no removable cover, in other aspects of the invention housing 50 may comprise two or more components that, when assembled, form housing 50.
  • junction box assembly 16 may include a housing 50 adapted to receive a cable 18, and housing 50 may comprise a base 64 and a cover assembly 66.
  • Cover assembly 66 may be removable and be adapted to engage and disengage base 64 to permit ready access to cavity 60, for example, for assembly, maintenance, and/or repair.
  • cable 18 may include a cable terminal 88, for example, a cable terminal end 88 adapted to engage exit conductor 35 and electrical contact 62 in cavity 60 of base 64.
  • FIGURE 15 is a bottom view of cover assembly 66 of the junction box 16 shown in FIGURE 14.
  • FIGURE 16 is a cross-sectional view of cover assembly 66 shown in FIGURE 15 as viewed along section lines 16-16 in FIGURE 15.
  • cover assembly 66 includes a cover 72 and may include contact 62, as discussed above.
  • Cover 72 may be adapted to releasable engage base 64, for example, cover 72 may include one or more deflectable tabs 74 positioned and adapted to removably engage one or more complementary recesses or notches in base 64.
  • Electrical contact 62 may comprise one or more metallic contacts, for example, one or more resilient metallic spring clips, as will be discussed below.
  • cover assembly 66 may include a sealing device 67, for example, an elastomeric o-ring.
  • FIGURE 17 is side elevation view of a spring clip 76 that may be used for the electrical contact 62 shown in FIGURES 14, 15, and 16 according to one aspect of the invention.
  • FIGURE 18 is a bottom view of spring clip 76 shown in FIGURE 17. Though many different types of electrical contacts 62 may be used according to aspects of the invention, the spring clip 76 shown in FIGURES 17 and 18 may be particularly advantageous according to aspects of the invention.
  • spring clip 76 comprises a thin metal plate 78 bent and shaped into the form shown.
  • Plate 78 may be made from any conductive material, but is typically metallic, for example, steel, stainless steel, copper or tin-plated copper plate. Plate 78 may typically be cut from plate, for example, stamped or laser cut from plate, and then formed into the shape shown.
  • plate 78 may be fashioned to form two or more arms 80 fashioned to be biased into contact at a nip 82, for example, two opposing arms 80.
  • arms 80 may be elastically biased to retain an electrical contact, for example, to retain exit conductor 35 engaged with terminal end 88, as shown in FIGURE 13, for instance, by squeezing exit conductor 35 and terminal end 88 between arms 80 at nip 82.
  • Plate 78 may also be fashioned with projections 84, for example, projections adapted to be received by one or more corresponding recesses in cover 72.
  • Plate 78 may have a thickness from between about 0.1 mm to about 1.0 mm, but is typically between about 0.3 mm to about 0.6 mm, for instance, about 0.4 mm.
  • FIGURE 19 is side elevation view of a cable end assembly 86 shown in FIGURE 14.
  • Cable end assembly 86 may typically include conductor 18 and a cable terminal end 88 that can be used with junction box 16 according to one aspect of the invention.
  • Cable end assembly 86 may be installed into junction box 16 to provide electrical communication between an electrical contact, for example, spring clip 76, and a conductor, for example, cable 18, to output electric power from a solar module, for example, from module 12.
  • Cable 18 may be any one of the commercially available cables listed above, for example, a 125-flex SOLAR FRNC cable provided by LEONI Studer AG. As shown in FIGURE 19, cable 18 may be modified to enhance engagement with housing 50.
  • the insulation of cable 18 may be deformed, for instance, modified with one or more annular recesses or ribs 90, to promote engagement with the junction box and to provide at least some relief of cable strain.
  • housing 50 may be molded over cable 18 whereby the over- molding provides a positive interference and positive seal to prevent disengagement of cable 18 and leakage into housing 50.
  • the modification of cable 18 may be used when the insulation of cable 18 is cross-linked or not cross-linked; however, when the insulation is not cross-linked, no modification may be necessary. As is conventional practice, at least some of the insulation at the end of cable 18 may be removed and the internal conductor exposed to accept cable terminal 88.
  • a cable strain relief mechanism (not shown) may also be provided, for example, mounted to housing 50 and cable 18, as is conventional.
  • This strain relief mechanism may comprise an over-molded rubber gland, an internal crimp ring, or some combination of both that relieves at least some stress in the cable attachment, and is also of a suitable material to comply with the necessary specifications for product reliability in the United States and the European Union.
  • cable 18 may be mounted to housing 50 at substantially a right angle to exit conductor 35, for example, to reduce strain on cable 18 and shorten cable length.
  • cable 18 may be attached at substantially parallel to exit conductor 35.
  • housing 50 may also include one or more cable holders or retainers (not shown, but disclosed in the parent provisional applications, which are included by reference herein.)
  • the cable holder may comprise one or more retainers or flexible clips having a recess adapted to receive and releasably retain cable 18 on housing 50.
  • FIGURE 20 is a top view of cable terminal end 88 shown in FIGURE 19 and FIGURE 21 is side elevation view of cable terminal end 88 shown in FIGURE 19.
  • cable terminal end 88 may typically have a first end 92 formed to engage cable 18, for example, having projections that can be crimped to cable 18, and a second end 94, opposite the first end 92, adapted to electrically contact an electrical contact, for example, spring clip 76.
  • FIGURES 22 through 33 are schematic illustrations of a step-by-step procedure for mounting a junction box assembly, for example, junction box assembly 14, to a photovoltaic module according to aspects of the invention.
  • the method can be practiced with a PV module having an external conductor or exit conductor projecting from an edge of the module, for example, module 12 having exit conductor 35 shown in FIGURES 4 and 5.
  • the mounting method may be practiced for a module having an external conductor or exit conductor projecting from any part of the module, for example, from a front side of the module, a rear side of the module, from a latitudinal edge, form a longitudinal edge, or from a corner, for example, wherein junction box assembly 14 straddles a corner of a module.
  • a module having an external conductor or exit conductor projecting from any part of the module for example, from a front side of the module, a rear side of the module, from a latitudinal edge, form a longitudinal edge, or from a corner, for example, wherein junction box assembly 14 straddles a corner of a module.
  • the method may be initiated by positioning an external conductor or exit conductor 135, which may be similar to exit conductor 35 discussed above, upon a surface 124 of PV module 112, only a representative portion of which is shown in FIGURE 22.
  • Module 112 may be similar to module 12 discussed above and surface 124 may be the front or rear side of module 112, though, typically, surface 124 may be the rear or "dark" side of module 112.
  • exit conductor 35 may project from surface 124 of PV module 112, for example, substantially perpendicularly project from surface 124, though in other aspects, exit conductor 35 may be substantially flush with surface 124.
  • the axis of exit conductor 35 may make an angle from 30 degrees to 120 degrees with the surface 124, though in other aspects, exit conductor 35 may make an angle of between 75 to 105 degrees with surface 124.
  • exit conductor 135 may be positioned anywhere on module 12, in one aspect of the invention, exit conductor 135 may be positioned adjacent an edge 113 of module 112, for example, an "edge” as discussed above with respect to edge 13. According to aspects of the invention, "adjacent" to edge 113 may mean within 6 inches of edge 113, or even within 3 inches of edge 113. For instance, exit conductor 135 may exit edge 113 of module 112, for example, from between layers of the module 112, as illustrated in FIGURE 5, and traverse at least a portion of surface 124, as shown in FIGURE 22, before projecting from surface 124.
  • Adhesive 125 may then be applied to surface 124 as shown in FIGURE 23.
  • Adhesive 125 may be applied manually to surface 124, for example, by a mechanic, but preferably, adhesive 135 may be applied by automated means, for example, by means of robotic actuator 127 having a suitable arm end tool for applying adhesive 125, as shown in FIGURE 24.
  • Adhesive 125 may be any suitable adhesive for mounting a junction box housing to surface 124, for example, a silicone adhesive, for instance, a hot-melt silicone adhesive provide by Dow Corning under the product name HM-2500, or its equivalent, or an adhesive pad having an adhesive on both sides, that is, a double-sided adhesive pad.
  • the adhesive 125 may also comprise a potting compound, for example, a high viscosity potting compound.
  • a high viscosity potting compound may be applied to surface 124 where housing 150 contacts surface 124, to prevent a low viscosity potting compound from flowing through to the outside of the housing 150.
  • adhesive 125 may comprise compliant rubber foam, for example, a rubber foam with sufficient adhesive strength that can fill any voids along the interface between housing 150 and surface 124. When rubber foam is used, a high viscosity potting compound may be omitted.
  • adhesive 125 may typically be applied as a bead in the shape of the approximate outline of the junction box housing, as will be described more clearly below.
  • the adhesive 125 may also be applied to edge 113 as shown, and to the opposite surface (not shown), opposite surface 124, for example, the front side of module 112, in particular, when the junction box includes an projection and lip as shown in FIGURE 13.
  • the method includes mounting a junction box housing 150 having an open top, an at least partially open bottom, and a cable end terminal 188 to a back side or surface 124 of a solar module 112 wherein the solar module exit conductor 135 and a cable terminal are exposed in the open top of housing 150.
  • a junction box 116 may be positioned over exit conductor 135 and adhesive 125.
  • Junction box 116 may be similar to junction box 16, discussed above, and may have a cable 118 and a cable end terminal 188 (see FIGURE 26). Cable 118 and cable end terminal 188 may be similar to cable 18 and cable end terminal 88 shown in FIGURES 19-21.
  • junction box 116 may comprise a housing 150, having a projection 156 and the projection having a lip 158, for example, similar to housing 50 shown in FIGURES 7-9.
  • housing 150 includes an open bottom and open top, for example, housing 150 may be similar to housing 50 having removable cover 66, as shown in FIGURE 14, to expose the inside of junction box 116, and through which exit conductor 135 may be viewed during this assembly method.
  • the bottom of housing 150 may be closed or substantially closed having only an opening or slit for receiving exit conductor 135.
  • housing 150 of junction box 116 is lowered onto surface 124, for example, manually or by automated robotic means, and contacts the surface 124 as shown in FIGURE 26.
  • FIGURE 26 is a top plan view of the housing 150 and surface 124 shown in FIGURE 25.
  • housing 150 may be lowered directly onto the bead of adhesive 125.
  • housing 150 may be lowered onto surface 124 whereby housing 150 is positioned off set from the bead of adhesive 125, for example, as shown in FIGURE 26.
  • housing 150 may be lowered onto surface 124 whereby at least a portion of housing 150 overhangs or extends beyond edge 113 of module 112, as shown in FIGURE 26.
  • exit conductor 135 may penetrate the open bottom of housing 150 and project from surface 124 with little or no contact with housing 150 or components in housing 150.
  • exit conductor 135 may be "threaded" through the open bottom of housing 150 and any internal components or structures to minimize or prevent damage or deflection to exit conductor 135. Accordingly, as shown most clearly in FIGURE 28 below, exit conductor 135 may typically project vertically from the open top of housing 150 after housing 150 is mounted to surface 124.
  • exit conductor 135 positioned on surface 124 and the relative position of cable terminal end 188 in housing 150.
  • exit conductor 135 and cable terminal end 188 do not make contact when housing 150 is lowered onto surface 124, in another aspect, exit conductor 135 and cable terminal end 188 may come into electrical contact when housing 150 is lowered onto surface 124 of module 112.
  • housing 150 of junction box housing 150 may be translated or "slid," as indicated by arrow 210, from a first position shown in FIGURE 26 to a second position shown in FIGURE 27 into engagement with module 112.
  • FIGURE 28 is a cross-sectional view of the assembly shown in FIGURE 27 as viewed along section lines 28-28 in FIGURE 27.
  • mounting the junction box 116 comprises positioning the open bottom of the junction box housing 150 over the solar module exit conductor 135 and sliding the junction box housing 150 whereby the cable terminal end 188 approaches or contacts the solar module exit conductor 135.
  • terminal end 188 and exit conductor 135 may be secured by conventional means, for example, with conductive tape, epoxy, a screw, a crimp, solder, spot weld, spring contact, or other securing or bonding means.
  • housing 150 may be tapered as shown in FIGURES 26 and 27, that is, narrowing in width from one end to the opposite end. As shown in FIGURES 26 and 27, this tapering of housing 150 minimizes or prevents the undesirable displacement or "smearing" of adhesive 125 as the housing is translated in the direction of arrow 210. That is, due to the tapering of housing 150, the base of housing 150 substantially only contacts the bead of adhesive 125 after substantially completing its translation from the first position shown in FIGURE 26 to the second position shown in FIGURE 27.
  • housing 150 of junction box 114 may assume a broad range of geometric shapes according to aspects of the invention, the tapered shape of housing 150 shown in Figures 26 and 27 (and housing 50 shown in FIGURES 7-9) facilitates assembly of housing 150 onto surface 124.
  • housing 150 engages adhesive 125 and PV module 112 to secure housing 150 to module 112.
  • adhesive 125 may be positioned between the bottom of housing 150 and the surface 124 of module 112 and between projection 156 and lip 158 and module 112.
  • housing 150 may not include a lip 158.
  • cable terminal end 188 may approach exit conductor 135, for example, in one aspect, as shown in FIGURE 27, with translation of the housing 150 terminal end 188 may approach or come into contact with, that is, electrical contact with, exit conductor 135.
  • exit conductor 1335 The contact between terminal end 188 and exit conductor 135 will be apparent with the further discussion below.
  • FIGURE 29 is a perspective view of the assembly shown in FIGURES 27 and 28 with a respective potting material delivery system 129, for example, an automated robotic arm end.
  • the potting material may be introduced manually or by an automated means, for example, by means of the automated robotic arm end 129 shown in FIGURE 29.
  • the potting material 215 may be any conventional potting material, for example, a two-component (for example, having a 1 : 1 ratio), platinum-cure silicone, or its equivalent.
  • one or more vent holes 136 in housing 150 may permit a more even distribution of potting material 215 by minimizing or eliminating trapped air pockets and back pressure from cavities within housing 150 while potting material 215 is introduced and, possibly, while off-gases are released from the introduction and hardening of potting material 215.
  • the introduction of potting material 215 may be omitted without detracting from aspects of the present invention.
  • a cover 166 may be positioned on the open top of housing 150 to complete the installation of junction box 116 on PV module 12.
  • cover 166 having at least one projection 162 may be placed on the open top of housing 150.
  • Cover 166 may be similar to cover 66 shown and described with respect to FIGURE 14-16 above, and projection 162 may be similar to projection 62 shown in FIGURES 14-16, for example, spring clip 76 shown in FIGURES 17 and 18.
  • projection 162 may be any conductive or non-conductive projection from the underside of cover 162, for example, a rib, a post, a gusset, or a bar and the like.
  • the method includes mounting cover 166 having a projection 162 on to the open top of the housing 150.
  • cover 166 may be positioned on the open top of housing 150 by first transferring or translating cover 166 is a lateral direction, for example, as indicated by arrow 230 in FIGURE 30.
  • the lateral movement of cover 166 may be accompanied by contact of projection 162 with upwardly extending exit conductor 135 located in housing 150.
  • projection 162 may typically deflect exit conductor 135.
  • FIGURE 31 is a cross sectional view of housing 150 and cover 166 shown in FIGURE 30 after translation of cover 166, but prior to engagement of cover 166 with housing 150.
  • the deflection of exit conductor 135 may bring exit conductor 135 into contact with cable terminal end 188, for example, into electrical contact.
  • the deflection of exit conductor 135 upon contact with projection 162 may enhance or secure the contact or engagement of edit conductor 135 with cable terminal end 188.
  • exit conductor 135 may typically be bent over cable terminal end 188, for example, folding at least a portion of exit conductor 135 over cable terminal end 188.
  • aspects of the invention further include the step of deflecting either the solar module exit conductor 135, the cable terminal end 188, or both with the cover projection 162 to electrically engage the solar module exit conductor 135 and the cable terminal end 188.
  • cover 166 When cover 166 is positioned over housing 150, as shown in FIGURE 31, cover 166 may typically moved into engagement with housing 150, as indicated by arrow 240 in FIGURE 31, for example, whereby tabs 134, for example, “snap tabs,” engage corresponding recesses or notches in housing 150, for instance, “snap into place.”
  • cover 166 may be mounted to housing 150 by one or more male/female interlocking barbs that allow one or more points of interlocking; mechanical fasteners, such as, screws or rivets; or joining means, such as, an adhesive or welding, for example, ultrasonic welding. This engagement of cover 166 with housing 150 is shown in FIGURE 32.
  • FIGURE 32 is a cross sectional view of housing 150 and cover 166 shown in FIGURES 30 and 31 after cover 166 is substantially completely engaged with housing 150.
  • projection 62 may further deflect exit conductor 135 into engagement with cable terminal end 188.
  • projection 162 may comprise an electrical contact, for example, a cover terminal.
  • mounting cover 166 on to the open top of housing 150 and deflecting exit conductor 135 with cover projection 162 may be practiced substantially simultaneously.
  • the cover terminal may be a spring clip, for example, spring clip 76 shown in FIGURES 17 and 18, which not only contacts and deflects exit conductor 135 into engagement with cable terminal end 188, but also enhances the engagement of exit conductor 135 with cable terminal end 188.
  • projection 162 may include elastically-biased arms 180 which receive and compress exit conductor 135 and cable terminal end 188 together, for example, to provide a more secure electrical contact between exit conductor 135 and cable terminal end 188. It will be apparent to those of skill in the art that projection 162 may comprise various structures and provide the desired deflection and contact between exit conductor 135 and cable terminal end 188.
  • projection 162 may comprise various forms of clips or spring clips and may provide the desired deflection and engagement between exit conductor 135 and cable terminal end 188.
  • projection 162 may contact and deflect cable terminal end 188 into engagement with exit conductor 135.
  • FIGURE 33 is a perspective view of the assembled junction box assembly 114 mounted on PV module 122, for example, on an edge 113 and surface 124 of module 112 according to aspects of the invention.
  • FIGURE 34 is a top plan view of a photovoltaic module array 250 according to an aspect of the invention, including a plurality of photovoltaic modules 12 and 112 shown in FIGURES 1, 2, and 33 and each PV module assembly having one or more junction box assemblies 14 and 114 as shown in FIGURES 6 and 33.
  • the array 250 of modules 12, 112 is electrically configured between a positive pole 260 and the negative pole 270 of array 250, as is conventional.
  • array 250 may include one or more diodes adapted to provide an electrical path if shading on the front, or sunny, side of the solar modules 12, 122 presents problems for the electrical performance.
  • FIGURE 34 include a detailed view of one of the plurality of interconnections between two junction box assemblies 14, 114 having junction boxes 16, 116.
  • This detailed view illustrates one of the relative configurations of connections of junction box assemblies 14, 114.
  • two junction box assemblies 14, 114 are positioned on edges 13, 113 of adjacent modules 12, 112 whereby respective cables 18, 118 are interconnected with appropriate connectors 20, 120.
  • mating connectors 20, 120 are typically respective male and female connectors to ensure appropriate engagement.
  • FIGURE 35 is a top plan view of a portion of a solar module 212 with a junction box assembly 214 according to another aspect of the invention.
  • FIGURE 36 is a cross sectional view of the portion of the solar module 212 and the junction box assembly 214 shown in FIGURE 35 as viewed along section lines 36-36.
  • Junction box assembly 214 includes a junction box 216, a cable 218, and a cable connector or bare conductor (not shown). Cable 218 may be any conventional cable referred to above.
  • junction box 216 may be mounted to the back or "dark" side 224 of solar module 212 and extends at least partially over the edge of solar module 212. As discussed above, junction box 216 may typically have a projection 256 that extends to cover at least a portion of an edge of solar module 212. However, in the aspect of the invention shown in FIGURES 35 and 36, solar module 216 includes a superstrate 231, for example, a glass superstrate, that is mounted offset to substrate 238.
  • the superstrate 231 and substrate 238 of module 212 shown in FIGURES 35 and 36 do not provide a well-fined "edge,” but are off-set a given distance 240, as shown in FIGURE 36.
  • This offset 240 may vary from about 0.5 to 6 inches, but is typically about 2 inches.
  • This offset 240 is typical of a type of module used in roof-mounted solar modules, for example, those solar modules mounted in solar array assemblies on a roof of a building or home. These roof-mounted modules may be referred to as "roof tiles" in the art.
  • a junction box is provided that is adapted to mount to an off-set or roof-mounted solar module.
  • module 212 typically includes an exit conductor 235 in electrical contact with PV material (not shown) in module 212 and emanating from between substrate 238 and superstrate 231 of module 212.
  • exit conductor 235 may be substantially identical to the structure, material, and function of exit conductors 35 and 135 discussed above.
  • exit conductor 235 may be adapted to engage junction box 216 having spring clip 262 in a cover 266 as discussed above
  • housing 216 may include a projection 256 that extends to cover at least a portion of an edge of substrate 238, for example, to cover and/or protect exit conductor 235, that is, in a fashion similar to that discussed above with respect to other aspects of the invention.
  • projection 256 on housing 216 may extend and approach the surface of superstrate 231 , for example, at least partially contact superstrate 231.
  • housing 216 may be mounted module 212 in a manner similar to the process shown in FIGURES 22 through 33.
  • housing 216 may be secured to substrate 238 and/or superstrate 231 by means of an adhesive or potting material 225 as shown in FIGURE 36.
  • a junction box 216 is provided that is uniquely adapted to mount to and electrically engage a solar module 212 having an offset construction, for example, similar to the construction of roof- mounted modules. Aspects of the invention are marketed under the name "Building Integration Photovoltaic” module or "BIPV” module by the applicant.
  • FIGURE 37 a top plan view of a solar module junction box assembly 314 according to another aspect of the invention.
  • FIGURE 38 is a cross sectional view of the solar module junction box assembly 314 shown in FIGURE 37 as viewed along section lines 38-38 and FIGURE 39 left side elevation view of solar module junction box assembly 314 shown in FIGURE 37.
  • Junction box assembly 314 includes a junction box 316, a cable 318, and a cable connector or bare conductor (not shown). Cable 318 may be any conventional cable referred to above.
  • junction box 316 may be mounted to the back or "dark" side of a solar module 312 (shown in phantom in FIGURE 38) and extends at least partially over the edge of solar module 312.
  • solar module 316 includes a superstrate 331 (shown in phantom), for example, a glass superstrate, and a substrate 338(shown in phantom).
  • module 312 typically includes an exit conductor 335 in electrical contact with PV material (not shown) in module 312 and emanating from between substrate 338 and superstrate 331 of module 312.
  • the structure, material, and function of exit conductor 335 may be substantially identical to the structure, material, and function of exit conductors 35 and 135 discussed above.
  • projection 356 of junction box 316 may typically extend to cover at least a portion of an edge of solar module 312, for example, to cover and/or protect exit conductor 335, that is, in a fashion similar to that discussed above with respect to other aspects of the invention.
  • junction box housing 316 is provided with at least one terminal end 388.
  • Terminal end 388 is typically electrically coupled to cable 318 by conventional means, for example, similar to the mounting of terminal end 88 shown in FIGURE 19.
  • at least a portion of terminal end 388 may be biased into contact with housing 316.
  • terminal end 388 may be biased into contact with the inside wall 317 of housing 316 whereby exit conductor 335 may be at least partially retained between the terminal end 388 and inside wall 317.
  • the biasing of terminal end 338 against inside wall 317 of housing 316 may be provided by a spring retaining force of terminal end 338, for example, by the elastic properties of terminal end 388.
  • terminal end 338 may be fashioned and mounted into housing 316 whereby the shape and elasticity of terminal end 388 biases terminal end 388 into contact with inside wall 317 to at least partially retain exit conductor 335 in housing 316.
  • junction box assembly 314 shown in FIGURES 37-39 may be provided with a means for deflecting terminal end 388 to at least partially overcome the biasing force of terminal end 388.
  • housing 316 may include at least one side through hole 390 or at least one top through hole 392 to permit access to the inside of housing 316.
  • hole 390 or 392 may be provided to permit access by a tool, as indicated by arrows, 391 and 393, respectively, to deflect at least a portion of terminal end 388 and at least partially overcome the biasing force.
  • exit conductor 325 may be introduced between terminal end 388 and inside wall 317 and/or removed from between terminal end 388 and inside wall 317.
  • exit conductor 325 When exit conductor 325 is positioned between terminal end 388 and wall 317 or removed there from, the deflection force provide by tool 391 or 393 can be removed. Accordingly, the biasing force of terminal end 388 can at least partially retain exit conductor 325 between end terminal 388 and wall 317.
  • an adhesive or potting material as discussed above, may be introduced through holes 390 and/or 392 to further retain exit conduit 325 in electrical contact with end terminal 388 and conductor 318 in housing 316.
  • housing 316 may be mounted to module 312 in a manner similar to the process shown in FIGURES 22 through 33.
  • housing 316 may be secured to substrate 338 and/or superstrate 331 by means of an adhesive or potting material.
  • a junction box 316 is provided that is uniquely adapted to mount to and electrically engage a solar module 312 without requiring a removable cover on junction box 316.
  • a junction box 316 may be provided without the need for a multipart housing, for example, as described above for other aspects of the invention.
  • the solar modules and junction boxes disclosed herein provide the further advantage of decreased costs to the solar integrators. Once a solar module has been assembled, the system integrators arrange the modules into large arrays 250 using mounting frames and additional electrical connection components. These additional components, known as "balance of system,” can be reduced in complexity, because the side- or edge-mounted modules 12, 112, 212, 312 can be connected without running additional lengths of electrical connections, for example, as shown in FIGURES 1 and 2.
  • aspects of the present invention recognize and address this concern, for example, by providing appropriate edge sealing.
  • the methods and junction boxes of the present invention address and overcome these concerns, for example, by providing a junction box housing having a projection and lip shaped to cover or wrap around the edge of the module.
  • These aspects of the invention can be used in conjunction with adhesives, potting materials, and sealant, among other materials, to minimize moisture and contaminant ingress to ensure an environmentally robust solar module and junction box.

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  • Physics & Mathematics (AREA)
  • Condensed Matter Physics & Semiconductors (AREA)
  • Electromagnetism (AREA)
  • General Physics & Mathematics (AREA)
  • Engineering & Computer Science (AREA)
  • Computer Hardware Design (AREA)
  • Microelectronics & Electronic Packaging (AREA)
  • Power Engineering (AREA)
  • Photovoltaic Devices (AREA)

Abstract

L'invention concerne des modules solaires (12, 112, 212, 312), des boîtes de jonction de module solaire (16, 116, 216, 216), et des procédés pour monter des boîtes de jonction sur des modules solaires qui facilitent la fabrication et renforcent la performance de l'ensemble de conversion d'énergie photovoltaïque. Les modules solaires (12, 112, 212, 312) sont munis de conducteurs extérieurs (35, 135, 235, 335) sortant du bord du module solaire. Des boîtes de jonction (16, 116, 216, 216) sont prévues qui sont conçues pour être montées sur les bords (13, 113) de modules solaires et venir en prise avec les conducteurs (35, 135, 235, 335) sortant du bord du module. Des procédés de montage des boîtes de jonction sont fournis qui facilitent le montage des boîtes de jonction sur des modules solaires (12, 112, 212, 312) ayant des conducteurs sortant du bord.
PCT/US2009/052471 2008-07-31 2009-07-31 Modules solaires, boîtes de jonction de module solaire, et procédé de montage de boîte de jonction sur des modules solaires WO2010014941A1 (fr)

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US8519708P 2008-07-31 2008-07-31
US61/085,197 2008-07-31
US8671008P 2008-08-06 2008-08-06
US61/086,710 2008-08-06
US21915409P 2009-06-22 2009-06-22
US61/219,154 2009-06-22

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Cited By (12)

* Cited by examiner, † Cited by third party
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WO2012055808A3 (fr) * 2010-10-25 2012-07-19 Saint-Gobain Glass France Module solaire équipé d'un élément de raccordement
CN102683456A (zh) * 2012-05-30 2012-09-19 南昌大学 一种智能光伏接线盒系统
EP2674983A1 (fr) * 2012-06-11 2013-12-18 Carl Freudenberg KG Connecteurs pour modules photovoltaïques
US8633406B2 (en) 2010-06-30 2014-01-21 First Solar, Inc. Moisture resistant cord plate for a photovoltaic module
WO2014132166A1 (fr) * 2013-02-28 2014-09-04 Tyco Electronics (Shanghai) Co. Ltd. Boîtier de connexion et appareil photovoltaïque solaire
US20140305493A1 (en) * 2013-04-12 2014-10-16 Apollo Precision (Kunming) Yuanhong Limited Flexible module connectors of flexible photovoltaic modules
CN104362972A (zh) * 2014-11-15 2015-02-18 信息产业部电子第四十研究所华成高新技术公司 带电缆保护结构的分体式光伏接线盒
JP2016067170A (ja) * 2014-09-25 2016-04-28 株式会社カネカ 太陽電池モジュール及び太陽電池モジュールの設置方法
WO2016196707A1 (fr) * 2015-06-03 2016-12-08 Tyco Electronics Corporation Boîte de jonction solaire pour panneau solaire
US9866168B2 (en) 2013-04-12 2018-01-09 Beijing Apollo Ding Rong Solar Technology Co., Ltd. Flexible photovoltaic modules having junction box supporting flaps
US10425035B2 (en) 2017-09-15 2019-09-24 Miasolé Hi-Tech Corp. Module connector for flexible photovoltaic module
EP3959754A4 (fr) * 2019-05-29 2023-01-18 SolarWindow Technologies, Inc. Dispositifs de production d'électricité de type serre à revêtement transparent homogène, et interconnexions électriques internes et externes

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WO2008052144A2 (fr) * 2006-10-25 2008-05-02 Jeremy Scholz Ensemble de branchement électrique pour montage en bordure
DE202008006120U1 (de) * 2008-05-03 2008-07-24 Lumberg Connect Gmbh Anschlussdose zur Anordnung auf einem Modul

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US4283106A (en) * 1980-02-01 1981-08-11 Amp Incorporated Symmetrical connector for solar panel arrays
WO2008052144A2 (fr) * 2006-10-25 2008-05-02 Jeremy Scholz Ensemble de branchement électrique pour montage en bordure
DE202008006120U1 (de) * 2008-05-03 2008-07-24 Lumberg Connect Gmbh Anschlussdose zur Anordnung auf einem Modul

Cited By (19)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US8633406B2 (en) 2010-06-30 2014-01-21 First Solar, Inc. Moisture resistant cord plate for a photovoltaic module
CN103155157A (zh) * 2010-10-25 2013-06-12 法国圣戈班玻璃厂 具有连接元件的太阳能模块
WO2012055808A3 (fr) * 2010-10-25 2012-07-19 Saint-Gobain Glass France Module solaire équipé d'un élément de raccordement
CN102683456A (zh) * 2012-05-30 2012-09-19 南昌大学 一种智能光伏接线盒系统
EP2674983A1 (fr) * 2012-06-11 2013-12-18 Carl Freudenberg KG Connecteurs pour modules photovoltaïques
WO2014132166A1 (fr) * 2013-02-28 2014-09-04 Tyco Electronics (Shanghai) Co. Ltd. Boîtier de connexion et appareil photovoltaïque solaire
US9735728B2 (en) * 2013-04-12 2017-08-15 Beijing Apollo Ding Rong Solar Technology Co., Ltd. Flexible module connectors of flexible photovoltaic modules
US20140305493A1 (en) * 2013-04-12 2014-10-16 Apollo Precision (Kunming) Yuanhong Limited Flexible module connectors of flexible photovoltaic modules
US9866168B2 (en) 2013-04-12 2018-01-09 Beijing Apollo Ding Rong Solar Technology Co., Ltd. Flexible photovoltaic modules having junction box supporting flaps
JP2016067170A (ja) * 2014-09-25 2016-04-28 株式会社カネカ 太陽電池モジュール及び太陽電池モジュールの設置方法
CN104362972A (zh) * 2014-11-15 2015-02-18 信息产业部电子第四十研究所华成高新技术公司 带电缆保护结构的分体式光伏接线盒
WO2016196707A1 (fr) * 2015-06-03 2016-12-08 Tyco Electronics Corporation Boîte de jonction solaire pour panneau solaire
CN107690706A (zh) * 2015-06-03 2018-02-13 泰连公司 用于太阳能板的太阳能接线盒
US9985580B2 (en) 2015-06-03 2018-05-29 Te Connectivity Corporation Solar junction box for solar panel
JP2018518138A (ja) * 2015-06-03 2018-07-05 ティーイー・コネクティビティ・コーポレイションＴＥ Ｃｏｎｎｅｃｔｉｖｉｔｙ Ｃｏｒｐｏｒａｔｉｏｎ ソーラーパネル用のソーラー接続箱
CN107690706B (zh) * 2015-06-03 2019-11-12 泰连公司 用于太阳能板的太阳能接线盒
US10425035B2 (en) 2017-09-15 2019-09-24 Miasolé Hi-Tech Corp. Module connector for flexible photovoltaic module
EP3959754A4 (fr) * 2019-05-29 2023-01-18 SolarWindow Technologies, Inc. Dispositifs de production d'électricité de type serre à revêtement transparent homogène, et interconnexions électriques internes et externes
EP3959813A4 (fr) * 2019-05-29 2023-04-26 SolarWindow Technologies, Inc. Système de dispositif de transfert de boîte de jonction de module électrique (e-jbtd) ayant des connexions internes et externes d'énergie électrique

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