WO2010019752A2 - Photovoltaic panel having one or more ancillary electrodes - Google Patents

Photovoltaic panel having one or more ancillary electrodes Download PDF

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Publication number
WO2010019752A2
WO2010019752A2 PCT/US2009/053666 US2009053666W WO2010019752A2 WO 2010019752 A2 WO2010019752 A2 WO 2010019752A2 US 2009053666 W US2009053666 W US 2009053666W WO 2010019752 A2 WO2010019752 A2 WO 2010019752A2
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WO
WIPO (PCT)
Prior art keywords
ancillary
panel
electrode
photovoltaic
electrically connected
Prior art date
Application number
PCT/US2009/053666
Other languages
French (fr)
Other versions
WO2010019752A3 (en
Inventor
James William Ashmead
Michael Robert Mc Quade
Original Assignee
E. I. Du Pont De Nemours And Company
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 E. I. Du Pont De Nemours And Company filed Critical E. I. Du Pont De Nemours And Company
Publication of WO2010019752A2 publication Critical patent/WO2010019752A2/en
Publication of WO2010019752A3 publication Critical patent/WO2010019752A3/en

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Classifications

    • HELECTRICITY
    • H01ELECTRIC ELEMENTS
    • H01LSEMICONDUCTOR DEVICES NOT COVERED BY CLASS H10
    • H01L31/00Semiconductor 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
    • H01L31/04Semiconductor 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
    • H01L31/042PV modules or arrays of single PV cells
    • H01L31/05Electrical interconnection means between PV cells inside the PV module, e.g. series connection of PV cells
    • HELECTRICITY
    • H02GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
    • H02SGENERATION OF ELECTRIC POWER BY CONVERSION OF INFRARED RADIATION, VISIBLE LIGHT OR ULTRAVIOLET LIGHT, e.g. USING PHOTOVOLTAIC [PV] MODULES
    • H02S20/00Supporting structures for PV modules
    • H02S20/20Supporting structures directly fixed to an immovable object
    • H02S20/22Supporting structures directly fixed to an immovable object specially adapted for buildings
    • H02S20/23Supporting structures directly fixed to an immovable object specially adapted for buildings specially adapted for roof structures
    • YGENERAL 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
    • Y02TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
    • Y02BCLIMATE CHANGE MITIGATION TECHNOLOGIES RELATED TO BUILDINGS, e.g. HOUSING, HOUSE APPLIANCES OR RELATED END-USER APPLICATIONS
    • Y02B10/00Integration of renewable energy sources in buildings
    • Y02B10/10Photovoltaic [PV]
    • YGENERAL 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
    • Y02TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
    • Y02EREDUCTION OF GREENHOUSE GAS [GHG] EMISSIONS, RELATED TO ENERGY GENERATION, TRANSMISSION OR DISTRIBUTION
    • Y02E10/00Energy generation through renewable energy sources
    • Y02E10/50Photovoltaic [PV] energy

Definitions

  • This invention relates to a photovoltaic panel having a first and a second primary electrode and one or more ancillary electrodes, each ancillary electrode being associated with a primary electrode .
  • Description of the Art The potential of solar energy as a clean, renewable energy source is well documented. However, a substantial impediment to more widespread use of solar energy is the significant initial cost of installation of an array of photovoltaic panels.
  • the panels In order to minimize installation costs it is desirable to arrange the panels on a support structure, such as a roof of a private residence or commercial building, in a regularly shaped array of one or more linear row(s) of adjacent panels.
  • a regularly shaped (typically rectangular, including square) matrix-like array in which each panel in each row or column is electrically connected with adjacent panel (s) facilitates the installation of the array, thus minimizing costs.
  • formation of a regularly shaped panel array may be precluded by a roof area having an irregular shape, the presence of multiple elevations across the breadth of the roof (e.g., dormers), and/or the existence of various penetrations or obstructions through the roof (e.g., vent pipes, chimneys) .
  • the process of installing a photovoltaic array may also present unique challenges with respect to optimizing various practical aspects of the array. For example: it may be desired to minimize the length of interconnecting wiring so as to reduce the amount of electrical cable used; it may be desirable for aesthetic purposes to hide the interconnecting wiring; or it may be desirable to eliminate or minimize the use of electrical junction or combiner boxes .
  • a photovoltaic panel having structural features which permit panels to be electrically connected into arrays configured to mitigate such obstacles and installation challenges, thus minimizing installation cost and maximizing available collection area.
  • Such interconnection features should also permit electrical connection between panels (even when arranged in regular arrays) that most efficiently accommodate factors that would otherwise diminish collection efficiency.
  • photovoltaic panel with structural features which facilitate diagnosis and/or trouble-shooting of problems with individual panel (s) or the array in which the panel (s) is (are) disposed.
  • the present invention generally relates to a photovoltaic panel that includes a photovoltaic module having a plurality of electrically interconnected photovoltaic cells terminating in a first connection tab of a first polarity and a second connection tab of a second polarity.
  • the module may include a suitable support frame, if desired.
  • the present invention is directed to a panel that includes one or more ancillary electrodes each electrically connected to a connection tab.
  • Each ancillary electrode is configured to exhibit an ampacity determined with respect to a predetermined ampacity threshold.
  • the predetermined ampacity threshold is defined in accordance with the fabrication technology of the photo-conversion material used to make the photovoltaic cells present in the module. For crystalline photovoltaic cells the predetermined ampacity threshold is on the order of about 0.1 amperes, while for thin film photovoltaic cells the predetermined ampacity threshold is on the order of about 0.001 amperes. Based upon its exhibited ampacity each ancillary electrode is operative to perform either a voltage test function or a power transmission function.
  • both a primary electrode and the ancillary electrode (s) connected thereto are directly connectible to and simultaneously capable of transmitting power to a primary or an ancillary electrode on another panel.
  • a photovoltaic panel includes a single ancillary electrode that is electrically connected to a selected one of the connection tabs. If the ancillary electrode is configured to exhibit an ampacity above the predetermined threshold the ancillary electrode is operative to carry power when connected to an electrical destination. Alternatively, if the ancillary electrode is configured to exhibit an ampacity substantially at or below the predetermined threshold the ancillary electrode is able to operate only as a voltage test terminal for the panel. If configured as a voltage test terminal for the panel the ancillary electrode is preferably accessible from the radiation collection surface of the panel.
  • a photovoltaic panel in another embodiment of this aspect of the present invention includes both a first and a second ancillary electrode.
  • each ancillary electrode is electrically connected to a respective one of the connection tabs and each ancillary electrode is configured to exhibit an ampacity above the predetermined threshold, whereby each ancillary electrode is operative to carry power when connected to an electrical destination.
  • the ancillary electrodes facilitate electrical series interconnections between panels in an array.
  • both ancillary electrodes may be electrically connected to the same connection tab.
  • one ancillary electrode may be configured to exhibit an ampacity above the predetermined threshold, whereby that ancillary electrode is operative to carry power when connected to an electrical destination, while the other ancillary electrode may be configured to exhibit an ampacity substantially at or below the predetermined threshold, whereby that ancillary electrode is able to operate as a voltage test terminal for the panel.
  • both ancillary electrodes that are electrically connected to the same connection tab may exhibit an ampacity such that both ancillary electrodes are operative to carry power when connected to an electrical destination. In this latter instance (two ancillary power transmission electrodes connected to the same connection tab) facilitate electrical parallel interconnections between strings of panels.
  • a panel may include an arrangement in which three ancillary electrodes are disposed on the panel.
  • a pair of ancillary electrodes each exhibiting an ampacity above the predetermined threshold i.e., power transmission electrodes
  • a third ancillary electrode having an ampacity substantially at or below the predetermined threshold i.e., a voltage test electrode
  • one (or more) additional ancillary electrodes may be deployed on the panel.
  • the present invention is directed to a photovoltaic array comprising at least a first and a second photovoltaic panel each having at least one ancillary electrode in accordance with the present invention and to methods for forming such a photovoltaic array.
  • Use of panels in accordance with the present invention facilitates the configuration of an array in ways that overcome the various obstacles to the formation of a regularly shaped rectangular array or that neutralize factors that minimize the solar collection efficiency of the array.
  • a single ancillary power transmission electrodes on one or both of the panels may be used to electrically connect a connection tab on the first of the panels to a connection tab on the other of the panels in either an series or a parallel configuration.
  • each of the physically spaced panels carry a pair of ancillary power electrodes and each electrode in the pair is electrically connected to a respective one of the connection tabs
  • an electrical series interconnection between panels in an array may be implemented.
  • both of the ancillary power transmission electrodes on each panel are electrically connected to the same connection tab electrical parallel interconnections (daisy chain fashion) between strings of panels are facilitated.
  • the ancillary power transmission electrode on one (or both) of the panel (s) may be used to electrically connect the connection tab on that panel to any one of various other electrical destinations.
  • the ancillary power transmission electrode (s) on the panel (s) are utilized to electrically connect a connection tab on a panel to an electrical destination. In this usage, however, it is necessary to provide an insulating member for isolating the primary electrodes on the first and second panels from each other.
  • the use of panels in accordance with the present invention also enables installers to overcome the various challenges to array optimization.
  • Having a panel with three or more power transmission ancillary electrodes connected to the same selected one of the connection tabs allows for flexibility in interconnecting in either a single point parallel interconnection among strings of panels, a daisy chain parallel interconnection among strings of panels, or a series connection between panels. It should be recognized that regulatory authorities limit the number of parallel interconnections before an over- current limiting device is required.
  • the present invention is a kit containing at least one photovoltaic panel in accordance with the present invention and at least one cable useful to connect an ancillary electrode on that panel to an electrical destination.
  • Figure 1 is a side elevation view entirely in section of a stylized representation of a photovoltaic panel having ancillary electrodes in accordance with the present invention, and additionally including at least one additional test contact;
  • Figure IA is a side elevation view entirely in section illustrating the electrical interconnection between two overlapped panels
  • Figures 2A and 2B are enlargements of the circled portion of the photovoltaic panel of Figure 1 illustrating respective exemplary mounting arrangements on the panel for the ancillary electrodes;
  • Figures 3A and 3B are diagrammatic illustrations of the utilization of photovoltaic panels in accordance with the present invention to overcome two commonly encountered obstacles associated with the formation of an array of photovoltaic panels on a support structure, in which:
  • Figure 3A illustrates a situation in an array which presents the need to connect electrically an electrode on one photovoltaic panel to a physically spaced destination, such as an electrode of an opposite polarity on another photovoltaic panel or to another destination; and
  • Figure 3B illustrates a situation in which adjacent photovoltaic panels are physically overlapped with each other, but in which the primary electrodes on the respective overlapped panels are electrically isolated so that an electrode of a given polarity on each photovoltaic panel may be electrically connected to a physically spaced destination;
  • FIGS. 3C through 3E are diagrammatic illustrations of the utilization of photovoltaic panels in accordance with the present invention configured in ways that overcome various practical challenges associated with the formation of an array of photovoltaic panels on a support structure, in which:
  • Figure 3C illustrates a so-called "daisy chained" parallel connection scheme in which each of the parallel string connections is distributed throughout the array;
  • Figure 3D illustrates a "single point" parallel connection scheme in which all of the parallel strings are joined at a single location in the array
  • Figure 3E illustrates a hybrid scheme utilizing both daisy chained and single point connection schemes
  • Figures 4A and 4B are elevation views entirely in section which illustrate a connection arrangement in which an electrode of a first polarity on one photovoltaic panel may be electrically connected to a physically spaced destination in accordance with the present invention
  • Figures 5A and 5B are elevation views similar to Figures 4A, 4B, illustrating an alternative connection arrangement in accordance with the present invention by which an electrode on one photovoltaic panel in an array is electrically connected to a physically spaced destination
  • Figure 6A is a side elevation view entirely in section showing the introduction of an insulating member over a primary electrode on one photovoltaic panel
  • Figure 6B is a side elevation view similar to Figure IA illustrating the electrically isolated primary electrodes on two physically overlapped panels.
  • Figure IA is a side elevation view entirely in section of a stylized representation of a photovoltaic panel generally indicated by the reference character 10.
  • the photovoltaic panel 10 includes three ancillary electrodes: viz., a pair of power transmission electrodes 50, 52 (also seen in Figures 2A, 2B) ; and a voltage test electrode 68 (shown in more detail in Figure IB) .
  • a panel may be configured to deploy only a single ancillary power transmission electrode 50 or 52, as the case may be, (regardless of whether a voltage test electrode 68 is also deployed) .
  • a panel may be configured to deploy one or more additional ancillary power transmission electrode (s) (beyond the pair of electrodes 50, 52 illustrated) .
  • both a primary electrode and the ancillary electrode (s) connected thereto are directly connectible to and simultaneously capable of transmitting power to a primary or an ancillary electrode on another panel .
  • the photovoltaic panel 10 is a four- sided member, typically rectangular (including square) when viewed in plan, having opposed pairs of horizontal side edges and respectively adjacent vertical side edges.
  • Each panel 10 comprises a photovoltaic module 12, itself containing a plurality of electrically interconnected photovoltaic cells.
  • the module 12 is usually engaged by a support frame generally indicated by the reference character 14.
  • the photovoltaic module 12 is a laminated structure that includes a photovoltaic layer 12P in which the photovoltaic cells are encapsulated. Two representative photovoltaic cells 12C are schematically indicated in the drawings.
  • the photovoltaic layer 12P is usually sandwiched between a lower support sheet 12S and a transparent covering sheet 12T.
  • the outer surface of the support sheet 12S defines the lower surface 12L of the module 12.
  • the outer surface of the transparent covering sheet 12T defines a generally planar radiation collection surface 12R for the module.
  • Each photovoltaic cell 12C is operative to generate an electric current in response to incident radiation falling upon the radiation collection surface 12R.
  • Photovoltaic cells 12C within the module 12 are typically connected with each other by metallizations, indicated diagrammatically by the reference character 12M.
  • the series collection of photovoltaic cells within the module terminates in connection tabs, generally indicated by the reference character 12E, disposed on surfaces of the module.
  • the connection tabs 12E are used to electrically connect the photovoltaic cells 12C within the module to a point on the exterior of the module 12.
  • One connection tab 12E P has a positive electrical polarity while the other connection tab 12E N has a negative electrical polarity.
  • the photovoltaic layer 12P and the photovoltaic cells 12C contained therewithin may be fabricated using either crystalline or thin film forms of photo-conversion material.
  • the fabrication technology of the photo- conversion material influences the ampacity thresholds between voltage test function and power transmission function, as will be discussed.
  • the support frame 14 comprises at least one, but preferably two, opposed pairs of frame bar members that lie on the perimeter of the photovoltaic module 12.
  • the frame bars may be connected to each other at their ends to entirely circumscribe the module, if desired.
  • Sectional views illustrating the functional and operation features of one opposed pair of frame bars 22 and 24 are shown in the drawings. It should be understood that the frame 14 may alternatively be implemented using a modularized frame structure in which a plurality of standardized frame pieces are interconnected into the desired peripheral form.
  • Each frame bar 22, 24 has a pair of grasping fingers 22A, 22B and 24A, 24B projecting from the main body portion of the respective bar. Each pair of grasping fingers respectively edge-wise grips the photovoltaic module 12 over an extended portion of the length of the module.
  • a flexible seal member may be provided between the fingers and the surfaces of the module, if desired.
  • the first finger 22A, 24A of each respective frame bar 22, 24 overlies a portion of the upper radiation collection surface 12R.
  • the second finger 22B, 24B of each frame bar 22, 24 engages the lower surface 12L.
  • the interior margins of the first fingers 22A, 24A may be inclined (as indicated at 221 and 241 in Figure IA) to minimize the area of the photovoltaic layer 12P shaded by those fingers.
  • the pairs of grasping fingers 22A, 22B and 24A, 24B on each respective frame bar 22, 24 prevent the module 12 from leaving the frame 14 in an upward or downward direction (as viewed in Figure IA) .
  • the module 12 is relatively free to move in directions parallel to the plane of the radiation collection surface 12R, as in response to differential thermal expansion between the frame and the module .
  • each frame bar 22, 24 has a keying flange 28, 30 respectively extending laterally therefrom.
  • the keying flange 28 has a planar mating surface 28A and an exterior surface 28B thereon. Similar mating and exterior surfaces 3OA, 3OB respectively are disposed on the flange 30.
  • the mating surface 28A of the flange 28 is vertically offset from the lower surface 22B of the frame bar 22 by a distance 28T.
  • a first and a second primary electrode 34, 36 respectively, are mounted on the panel 10 for the purpose of electrically connecting the photovoltaic cells 12C within the module 12 of one panel to the cells in another adjacent panel.
  • the primary electrodes 34, 36 are disposed at any convenient position on the respective mating surfaces 28A, 3OA of each keying flange 28, 30. It should be understood, however, that these primary electrodes 34, 36 may be mounted on or depend from any convenient location on the panel 10. For example, primary electrodes may be mounted on or depend from only one of the frame bars 22 or 24 or may be mounted on or depend from the module 12 itself.
  • the first primary electrode 34 is illustrated as a disc-like member that is embedded into the material of the mating surface
  • the second primary electrode 36 is also a substantially disc-like member having an enlarged annular shoulder 36S.
  • the electrode 36 is urged toward the mating surface 30A of the flange 30 by the action of a biasing spring 42.
  • the spring 42 is received in a counterbore 30C provided in the flange 30.
  • the primary electrode 36 is retained in the counterbore 30C by the abutting interaction of the shoulder 36S on the electrode against a shoulder 30S formed in the flange 30 by the counterbore 30C.
  • the mouth of the counterbore 30C is threaded, as at 30T, for a purpose to be described.
  • the first primary electrode 34 and the second primary electrode 36 each have a respective electrical polarity, determined by the electrical polarity of the connection tab 12E of the module 12 to which the respective electrode is connected.
  • the primary electrode 34 is illustrated to have negative electrical polarity due to its connection to the negative connection tab 12E N .
  • the primary electrode 34 has positive electrical polarity due to its connection to the positive connection tab 12E P .
  • Each primary electrode 34, 36 is connected in any convenient manner to its respective connection tab 12E N , 12E P .
  • the connection between the electrode 34 and the negative tab 12E N is schematically illustrated by a conductor 34C that extends through a passage 22C provided in the frame bar 22 for this purpose.
  • the connection between the electrode 36 and the positive tab 12E P is schematically illustrated by a conductor 36C that extends through a passage 24C in the frame bar 24.
  • relevant safety standards e.g., Underwriters' Laboratory Standards UL-1703 or UL-486A
  • the panel 10 includes one or more ancillary electrodes each electrically connected to a connection tab.
  • Each ancillary electrode is configured to exhibit an ampacity determined with respect to a predetermined ampacity threshold.
  • Ampacity is the property of an ancillary electrode that defines its current carrying capacity.
  • the ampacity of an ancillary electrode is determined by the nature of the material used to form the electrode, its thickness, its cross-sectional area and surface properties. The fabrication technology of the photo-conversion material in the module mandates the ampacity thresholds that differentiate ancillary voltage test electrodes from ancillary power transmission electrodes.
  • each ancillary electrode deployed in accordance with the present invention is operative to perform either a voltage test function or a power transmission function. It is understood that any power transmission ancillary electrode has adequate ampacity to enable it to function as a voltage test electrode.
  • the panel 10 includes a first ancillary electrode 50 and a second ancillary electrode 52.
  • each ancillary electrode 50, 52 (and each primary electrode, 34, 36 for that matter) exhibits an ampacity permitting the electrode to provide a power transmission function.
  • each ancillary electrode 50, 52 is electrically connected to a respective one of the connection tabs from the photovoltaic cells.
  • the ancillary electrode 50 is electrically connected to the connection tab 12E N , as by a conductor 50C schematically illustrated in the Figures.
  • the ancillary electrode 52 is electrically connected to the other connection tab 12E P , as by a conductor 50C also schematically illustrated in the Figures.
  • connection tabs electrically connected to a respective one of the connection tabs
  • connection tabs or like language denoting the connection of an ancillary electrode to a connection tab
  • a connection between an ancillary electrode 50, 52 and its respective connection tab 12E N , 12E P may be effected by connecting the ancillary electrode directly (via a suitable conductor) to the particular tab, directly (via a suitable conductor) to primary electrode associated with the tab, or through a suitable conductor to any conductor extending between a tab and its associated primary electrode.
  • both ancillary electrodes 50, 52 may be electrically connected to the same connection tab, if desired.
  • FIGs 2A and 2B are enlargements of the circled portion of the photovoltaic panel 10 of Figure IA illustrating various suggested structural forms for the ancillary electrodes 50, 52 and exemplary arrangements for mounting the ancillary electrodes on the frame of the panel 10.
  • Each ancillary electrode 50, 52 has an ampacity that is greater than the predetermined threshold determined in accordance with the fabrication technology of the photo- conversion material used for the cells 12C in the module.
  • the predetermined ampacity threshold of the ancillary electrodes 50, 52 is above about 0.1 amperes
  • the predetermined ampacity threshold of the ancillary electrodes 50, 52 is above about 0.001 amperes.
  • each ancillary electrode 50, 52 is secured at the bottom of a threaded bore 50B, 52B formed in the respective frame bars 22, 24.
  • Each ancillary electrode 50, 52 is substantially plate-like in form and has a central threaded opening 50A, 52A provided therein.
  • the electrical connection between an ancillary electrode 50, 52 and its respective connection tab 12E N , 12E P is schematically illustrated in the Figures by respective conductors 5OC, 52C connected to the conductors 34C, 36C extending between a connection tab and its associated primary electrode.
  • Each conductor 5OC, 52C is diagrammatically shown to extend through a passage 22P, 24P provided through the respective frame bar 22, 24.
  • a groove 5OG, 52G formed in the bottom of each threaded bore 5OB, 52B receives a respective O-ring seal 5OS, 52S.
  • a deformable polymeric seal may be integrated into the frame bar in place of the discrete O- ring.
  • the ancillary electrode 50, 52 and its respective conductor 5OC, 52C are each stamped as a rigid integral piece that is contoured to fit within its respective passage 22P, 24P in the frame bar.
  • Each of the bores 5OB, 52B is closed by a respective insulating cover 60, 62.
  • Each cover 60, 62 has a central driver slot 60S, 62S on its exterior surface and an annular bead 6OB, 62B formed on its interior surface.
  • each cover 60, 62 has peripheral threads 6OT, 62T thereon.
  • Each cover 60, 62 is secured by the engagement of peripheral threads 6OT, 62T with the threads disposed near the mouth of the respective bore 50B, 52B.
  • the annular bead 6OB on the cover's interior surface is brought to bear into sealing engagement against the O-ring seal 50S, 52S in the bottom of the bore.
  • the engaged disposition of a cover 60 within the bore 52B is illustrated on the right hand side of Figure 2A.
  • FIG 2B illustrates an alternative exemplary arrangement for mounting the ancillary electrodes 50, 52 on the panel 10.
  • each ancillary electrode 50, 52 is embedded within and substantially surrounded by the material of a frame bar 22, 24.
  • the ancillary electrode 50 is similar to the structure shown in Figure 2A.
  • the ancillary electrode 52 is implemented using an alternative configuration.
  • the ancillary electrode 52 includes a post 52P that projects from the face of the electrode 52.
  • the post 52P may have spring arms thereon.
  • Each frame bar 22, 24 has a threaded protuberance, or boss, 22E, 24E that overlies the ancillary electrode 50, 52.
  • the groove 5OG, 52G is formed in the face of the boss 22E, 24E to receive the respective 0-ring seal 5OS, 52S.
  • An access bore 22V, 24V extends through the boss 22E, 24E into communication with the respective ancillary electrode.
  • the bore 22V registers with the opening 5OA in the electrode 5OA.
  • the post 52P extends centrally and axially through the bore 24V.
  • Each access bore 22V, 24V is closed by a respective removable insulating cap 64, 66.
  • Each cap 64 has interior threads 641 that may be threaded onto the exterior threads of each boss 22E, 24E.
  • Each cap has exterior threads 64E, 66E for a purpose to be discussed.
  • the engaged disposition of the cap 66 with the boss 24E on the frame bar 24 is illustrated on the right hand side of Figure 2B.
  • the annular bead 64B, 66B on the cap's interior surface bears against the O-ring seal 5OS, 52S to seal the access bore 22V, 24V.
  • both ancillary electrodes may be mounted to the same frame bar or disposed in a convenient location on the module 12 (whether or not a frame 14 is included with the panel) .
  • the panel 10 is also shown to include another ancillary electrode 68 that has an ampacity less than the threshold, whereby the ancillary electrode 68 may function as a voltage test terminal for the panel.
  • An ancillary electrode 68 available as a voltage test terminal facilitates array maintenance and system commissioning in that it provides an accessible point where test equipment may be connected to monitor electrical conditions of the module.
  • the accessible test arrangement 68 includes a test point contact 68T that is mounted at the base of a threaded counterbore 68B formed in the finger 22A of the frame bar 22.
  • the test contact 68T is electrically connected to one of the connection tabs (e.g., the connection tab 12E N ) by a conductor 68W and, thus, to the electrode 34.
  • the conductor 68W passes through a duct 22D formed in the frame bar 22.
  • connection tabs electrically connected to a respective one of the connection tabs
  • a connection between test contact 68T and a connection tab 12E N , 12E P may be effected by connecting the test contact 68T directly (via a suitable conductor) to the particular tab, directly (via a suitable conductor) to primary electrode associated with the tab, or through a suitable conductor to any conductor extending between a tab and its associated primary electrode.
  • the surface of the contact 68T presented to the counterbore 68B may be provided with a threaded recess 68R to receive a probe of a test instrument.
  • the counterbore 68B is closed by a weather-tight cap 68C.
  • the ancillary electrode 68 may be disposed on the photovoltaic module 12 itself. This arrangement is also illustrated in Figure IB. In this case the bore 68B' extends through the transparent layer 12T. An insulating sleeve 68S' having the test point contact 68T' at its lower end is inserted into the bore 68B. The test point contact 68T' is connected electrically to the metallization 12M between cells 12P by the conductor 68W . The water-tight cap 68C closes the bore 68B' .
  • a panel may include one (or more) additional ancillary electrode (s) suitable for use as voltage test terminal (s), regardless of whether additional ancillary electrodes suitable as power transmission electrodes is (are) deployed. Any additional voltage test terminal (s) (if deployed) may be electrically connected either of the connection tabs, as convenient.
  • the frame bars 22, 24 are fabricated from a suitable electrically non-conductive material having sufficient voltage-insulation properties, such as a glass-reinforced polyester resin.
  • a suitable electrically non-conductive material is the injection- moldable or extrudable glass-fiber reinforced polyethylene terephthalate (PET) resin with appropriate fire-retardant properties sold by E.I. du Pont de Nemours and Company under the trademark RYNITE ® .
  • PET polyethylene terephthalate
  • Any convenient manufacturing technique may be used.
  • a frame bar may be extruded as an integral member and thereafter machined to form the various passages, bores, counterbores, recesses, and/or protuberances above described.
  • the covers or caps are fabricated from the same or other electrically insulating materials.
  • the frame bars may be manufactured from a conductive material, so long as suitable electrical insulation material is provided to surround the electrically conductive tabs, electrodes, contacts and current-carrying conductors.
  • a photovoltaic array usually comprises one or more linear rows of adjacent panels arranged in matrix fashion.
  • the panels are mounted either directly to a support structure (e.g., a roof) or through suitable framework members affixed to the support structure .
  • Figure IB illustrates a straightforward electrical series interconnection between two similarly configured, physically adjacent panels 10, 10 1 .
  • Each panel 10, 10 1 is configured as described in connection with Figures IA and 2A.
  • the negative polarity connection tab 12E N on the panel 10 is connected to the positive polarity connection tab 12E P on the panel 10 1 through abutting contact between the respective primary electrodes 34 and 36 of these panels.
  • the panels 10, 10 1 are arranged in complimentary confrontational relationship such that the mating surface 28A on the first keying flange 28 of a first panel 10 physically overlaps and abuts with the mating surface 3OA of a second keying flange 30 of the second, adjacent, panel 10 1 .
  • This mechanically keyed relationship between the panels juxtaposes the negative primary electrode 34 on the flange 30 of the panel 10 with the positive primary electrode 36 on the flange 30 of the panel 10 1 .
  • the negative primary electrode 34 (on the panel 10) is disposed in electrically conductive contact with the positive primary electrode 36 (on the panel 10 1 ) .
  • the spring 42 acts to urge the primary electrode 36 toward the primary electrode 34 to dispose these primary electrodes in electrical contact, thereby to connect the connection tab on the panel 10 to the connection tab on the panel 10' .
  • the flanges 28, 30 may be mechanically secured in the described overlapped relationship in any suitable manner. Sealed integrity against the ingress of water between the electrodes 34, 36 on the abutting mating surfaces 28A, 30A is maintained by the gasket 38.
  • obstructions may be present which prevent physically overlapping the keying flanges of the panels, thus precluding the possibility of electrical interconnection using the primary electrodes in the manner illustrated in Figure IB.
  • FIG. 3A illustrates a typical situation in which two panels 10 A , 10 B in accordance with the present invention are physically separated due to any of the various reasons discussed earlier. Despite such separation it may nevertheless be desirable for electrical considerations that either :
  • connection tab of one polarity on the panel 10 A be connected to the electrical destination defined by the connection tab of the opposite polarity on the panel 10 B (i.e., an electrical series connection between panels) ; or,
  • connection tab of one polarity on the panel 10 A be connected to the electrical destination defined by the connection tab of the same polarity on the panel 10 B (i.e., an electrical parallel connection between panels) .
  • one or both of these two physically separated panels 10 A and/or 10 B be electrically connected to another physically spaced electrical destination, such as another panel, an inverter, a combiner box, a DC disconnect switch, a battery charger, a fuse, a blocking diode, or a ground fault current interrupter.
  • another physically spaced electrical destination such as another panel, an inverter, a combiner box, a DC disconnect switch, a battery charger, a fuse, a blocking diode, or a ground fault current interrupter.
  • Configuring an array including one or more panels each having one or more ancillary electrodes 50 and/or 52 in accordance with the present invention facilitates the electrical interconnection of the panel (s) to all of these physically spaced electrical destinations.
  • one of the panels 10 A or 10 B includes at least one ancillary power transmission electrode connected to one of the connection tabs on the panel, that panel may be interconnected in series or parallel with the other panel.
  • the ancillary power transmission electrode on one of the panels e.g., the first panel 10 A
  • the connection tab of the opposite polarity on the second panel 10 B as by making any convenient electrical connection using the primary electrode connected to the appropriate connection tab on the second panel
  • the ancillary power transmission electrode on the first panel 10 A is connected to the connection tab of the same polarity on the second panel 10 B (as by making any convenient electrical connection using the primary electrode connected to that appropriate connection tab on the second panel) .
  • the ancillary electrode on that panel is connected to that destination.
  • both of the panels 10 A or 10 B include an ancillary power transmission electrode
  • the series or parallel interconnections may be effected by connecting the ancillary electrode on the first panel to the ancillary electrode on the second panel (assuming that each ancillary electrode is connected to the appropriate tab on its panel.)
  • the connection of a panel 10 A or 10 B to one of the other physically spaced electrical destinations the ancillary electrode on that panel is connected to that destination.
  • the array is configured using panels that include a pair of ancillary electrodes 50 and 52, each connected to a respective connection tab on the panel as shown and described in connection with Figures IA, IB, 2A, 2B.
  • the series or parallel interconnections between panels and to the other spaced destinations are effected using the appropriate combination of ancillary power transmission electrodes .
  • connection may be physically realized using a unitary cable or interconnected segmented cables.
  • panels 10 A and 10 B are each configured as shown in Figures IA, IB, 2A, 2B.
  • Figures 4A, 4B and 5A, 5B examples of various possible arrangements for connecting the ancillary electrodes to these physically spaced electrical destinations are illustrated in Figures 4A, 4B and 5A, 5B.
  • FIGS 4A and 4B taken together, show an arrangement for connecting ancillary electrodes configured as shown in Figure 2A to a physically spaced electrical destination using a pair of joinable cable segments 7OA, 7OB.
  • Each of the panels 10 A , 10 B is shown supported on a suitable support member V A , V B .
  • Each cable segment 7OA, 7OB comprises a predetermined length of electrical conductor surrounded by an insulating jacket.
  • An enlarged insulating plug head 72A, 72B is disposed at the first end of each respective cable segment 7OA, 7OB.
  • a threaded conductive post 78A, 78B projects from each respective insulating plug head.
  • the face of each plug has a ring 8OA, 8OB formed thereon.
  • the bare electrical conductor may be left exposed at the second, distal, end of each segment 7OA, 7OB.
  • a complimentary connector 76A, 76B is disposed at the distal end of each respective cable segment.
  • the complimentary connectors 76A, 76B may take any of a variety of forms. For example, a crimp-on terminal, a ring-style, a spade right-angle terminal, a hook terminal or a so-called "MC connector” may be used.
  • An "MC connector” is a connection device manufactured and sold by Multi-Contact USA, Santa Rosa, California, a wholly-owned subsidiary of Multi-Contact AG, Basel Switzerland.
  • each of the posts 78A, 78B is threaded into the central opening 52A, 5OA of the respective ancillary electrodes 52, 50.
  • the O-ring 52S, 5OS for that electrode is compressed against the ring 8OA, 8OB formed in the face of the plug head, thus providing a water-tight seal .
  • the cable segments 7OA, 7OB are connected to each other using the complimentary connectors 76A, 76B.
  • the cable segments 7OA, 7OB are connected to each other using the complimentary connectors 76A, 76B.
  • the cable segments may be connected.
  • the complimentary connectors 76A, 76B instead of a unitary cable with same handed threads at both ends, tightening of one end of the cable does not cause the other to loosen.
  • each of the panels 10 A , 10 B may be connected to a separate electrical destination (i.e., not to each other) .
  • the desired electrical destination would be outfitted with a suitable connector complimentary to the connector disposed at the end of the cable segment 7OA, 7OB.
  • FIGs 5A and 5B illustrate an alternative scheme for the instance when the panels have the ancillary electrode arrangement as shown in Figure 2B.
  • This connection arrangement utilizes a unitary cable 84 terminated at each end with a connecter 85, 86 that is complimentary to the configuration of the ancillary electrode used in each of the panels 10 A , 10 B .
  • the complimentary connecters 85, 86 may be similar to the MC connectors described earlier.
  • Each connector 85, 86 includes a cap 85C, 86C having threads 85T, 86T that provide the insertion force to join and to retain the connectors to the electrodes.
  • Each cap cap 85C, 86C is rotatable with respect to the cable 84 to avoid the loosening of one end of the cable while the other end is threaded.
  • the interior of each cap 85C, 86C has rings 85B, 86B that abut the seals 5OS.
  • Configuring an array that includes one or more panels each having one or more ancillary electrodes 50 and/or 52 solves another commonly encountered situation illustrated in Figure 3B.
  • the physical circumstances of the array are such that two panels 10 c , 10 D having primary electrodes arranged as shown in Figure 1 are able to be physically overlapped and joined with each other such that a primary electrode of a first polarity on the first panel is juxtaposed with the primary electrode of the second polarity on the second panel (in the manner depicted and discussed in connection with Figure IA) .
  • Such connections may also be implemented so long as one (or both) of the panels 10 c , 10 D have one or more ancillary electrodes in accordance with the present invention .
  • Figures 6A and 6B illustrate how these connections may be effected.
  • an insulating cap 60 or 62
  • a cover 64 or 66
  • an insulating cap 60 or 62
  • a cover 64 or 66
  • ancillary electrodes on a panel 10 c , 10 D as seen in Figures 2A, 2B
  • the cap 60 or cover 64 As seen in Figure 6A, before the panel 10 D is overlapped onto the panel 10 c the cap 60 or cover 64, as the case may be, is positioned over the threaded mouth of the counterbore 3OT.
  • the cap 60 or cover 64 is secured into the flange of the panel, using the external threads 6OE, 64E on the cap or cover.
  • the primary electrode 36 As the cap 60 or cover 64 is threaded into the panel, the primary electrode 36 is depressed into the flange 30.
  • Figure 6B is a side elevation view similar to Figure IA illustrating the electrically isolated primary electrodes on two physically overlapped panels. The presence of the cap 60 or cover 64 electrically isolates the electrodes 34, 36 from each other.
  • Each of the panels 10 c , 10 D may be connected to a physically spaced destination using any of the cables in the manner discussed in connection with Figures 3A, 4A, 4B, 5A, 5B.
  • a photovoltaic array often presents unique challenges with respect to optimizing various practical aspects of the array. For example: it may be desired to minimize the length of interconnecting wiring so as to reduce the amount of electrical cable used; it may be desirable for aesthetic purposes to hide the interconnecting wiring; or it may be desirable to eliminate or minimize the use of electrical junction or combiner boxes.
  • each of Figures 3C through 3E shows a panel (e.g., panels 10 ⁇ 1 , 10 E”2 , 10 E"3 and 10 E”4 , as the case may be) each disposed at the end of a panel string diagrammatically indicated by the reference characters S 1 , S 2 , S 3 and S 4 .
  • the scenarios are intended to depict the panels 10 ⁇ 1 , 10 E"2 , 10 E"3 and 10 E"4 as being physically spaced from each other by significant distances when viewed in terms of cable length (although the solutions presented are operative even if panels are closely adjacent to each other) .
  • a remote destination R is also shown as being spaced closest to one of the panels. The destination R can take the form of any of the electrical destinations listed earlier .
  • Each panel may carry some predetermined number of ancillary power electrodes A 1 , A 2 , A 3 , ... A N , as the case may be.
  • ancillary power electrodes A 1 , A 2 , A 3 , ... A N are illustrated. However, this is not meant to imply that the given panel can not carry additional ancillary power electrodes. To the contrary, owing to various other manufacturing and logistical costs is believed that each panel in an array would be identically configured.
  • FIG. 3C illustrates a so-called “daisy chain” parallel connection which, in the circumstance there illustrated, allows strings S 1 , S 2 and S 3 to be connected in parallel while the panel IC ⁇ "1 is simultaneously connected to the destination R proximal thereto. It should be appreciated from the following that for any parallel connection scheme it is required that a minimum of two ancillary electrodes be connected to a connection tab of a given polarity per panel.
  • Figure 3D illustrates a so-called "single-point" interconnection scheme which would eliminate the excessive wire run H, at the cost of using a third ancillary electrode A 3 on the panel.
  • Figure 3E illustrates a hybrid connection scheme in which both a "daisy chain" and a "single point" are employed.
  • any of the interconnections discussed in connection with Figures 3C through 3E may be implemented using any combination of cable arrangements discussed in connection with Figures 4A, 4B, 5A, 5B.
  • Figures 3C through 3E make clear that the addition of an appropriate number of ancillary power electrodes necessary to effect parallel interconnections provides a high level of installation flexibility and allows for a broad range of optimization strategies with their associated tradeoffs.
  • Each use of a daisy chain or a parallel interconnection scheme eliminates the need for a junction or combiner box. The judicious implementation of a single-point scheme minimizes wire cost and may contribute to array aesthetics.
  • the present invention may be implemented in kit form.
  • kit form one or more panels in accordance with any embodiment of the present invention are packaged together with suitably segmented or unitary cable (s) whereby arrays having any of the various interconnection schemes discussed herein may be implemented.
  • s suitably segmented or unitary cable

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Abstract

A photovoltaic panel includes a primary electrode also to each connection tab. One or more ancillary electrodes is(are) also electrically connected to a tab. Each ancillary electrode is configured to exhibit an ampacity determined with respect to a predetermined ampacity threshold. The predetermined ampacity threshold is defined in accordance with the fabrication technology of the photo-conversion material used to make the photovoltaic cells present in the module. Both a primary electrode and any ancillary electrode(s) connected thereto are directly connectible to and simultaneously capable of transmitting power to a primary or an ancillary electrode on another panel.

Description

T I TLE
PHOTOVOLTAIC PANEL HAVING ONE OR MORE ANCILLARY ELECTRODES
CLAIM OF PRIORITY
This application claims priority from each of the following United States Provisional Applications, hereby incorporated by reference: (1) Photovoltaic Panels Having Laterally
Extending Keying Structures Thereon, Application S.N. 61/088,412 filed 13 August 2008 (CL-4337);
(2) Photovoltaic Panel Having One or More Ancillary Electrodes Thereon, Application S.N. 61/174,146 filed 30 April 2009 (CL-4570) ;
(3) Photovoltaic Array Using Panels Having One or More Ancillary Electrodes Thereon, Application S.N. 61/174,164 filed 30 April 2009 (CL-4638);
(4) Method for Installing A Photovoltaic Array Incorporating Photovoltaic Panels Having One Or More
Ancillary Electrodes Thereon, Application S.N. 61/174,175 filed 30 April 2009 (CL-4664); and
(5) Kit For Forming A Photovoltaic Array Using Panels Having One or More Ancillary Electrodes Thereon, Application S.N. 61/174,181 filed 30 April 2009 (CL-4663) .
BACKGROUND OF THE INVENTION
Field of the Invention This invention relates to a photovoltaic panel having a first and a second primary electrode and one or more ancillary electrodes, each ancillary electrode being associated with a primary electrode . Description of the Art The potential of solar energy as a clean, renewable energy source is well documented. However, a substantial impediment to more widespread use of solar energy is the significant initial cost of installation of an array of photovoltaic panels.
In order to minimize installation costs it is desirable to arrange the panels on a support structure, such as a roof of a private residence or commercial building, in a regularly shaped array of one or more linear row(s) of adjacent panels. A regularly shaped (typically rectangular, including square) matrix-like array in which each panel in each row or column is electrically connected with adjacent panel (s) facilitates the installation of the array, thus minimizing costs. However, there are obstacles which make the interconnection of panels into a regularly shaped rectangular array difficult. For example, formation of a regularly shaped panel array may be precluded by a roof area having an irregular shape, the presence of multiple elevations across the breadth of the roof (e.g., dormers), and/or the existence of various penetrations or obstructions through the roof (e.g., vent pipes, chimneys) .
The process of installing a photovoltaic array may also present unique challenges with respect to optimizing various practical aspects of the array. For example: it may be desired to minimize the length of interconnecting wiring so as to reduce the amount of electrical cable used; it may be desirable for aesthetic purposes to hide the interconnecting wiring; or it may be desirable to eliminate or minimize the use of electrical junction or combiner boxes .
Even when it is convenient to interconnect panels into a regular array, other factors may be present that minimize the efficiency of solar collection by the array. Examples of such other factors are the orientation of the structure with respect to the sun and/or shadows from neighboring buildings or vegetation that shade portions of the array.
In view of the foregoing it is believed to be advantageous to provide a photovoltaic panel having structural features which permit panels to be electrically connected into arrays configured to mitigate such obstacles and installation challenges, thus minimizing installation cost and maximizing available collection area. Such interconnection features should also permit electrical connection between panels (even when arranged in regular arrays) that most efficiently accommodate factors that would otherwise diminish collection efficiency. It is also believed to be advantageous to provide a photovoltaic panel that deploys that minimum number of repetitive panel features which allows maximum installation flexibility while avoiding unnecessary manufacturing costs.
It is also believed to be advantageous to provide a photovoltaic panel with structural features which facilitate diagnosis and/or trouble-shooting of problems with individual panel (s) or the array in which the panel (s) is (are) disposed.
SUMMARY OF THE INVENTION
The present invention generally relates to a photovoltaic panel that includes a photovoltaic module having a plurality of electrically interconnected photovoltaic cells terminating in a first connection tab of a first polarity and a second connection tab of a second polarity. The module may include a suitable support frame, if desired.
In one aspect the present invention is directed to a panel that includes one or more ancillary electrodes each electrically connected to a connection tab. Each ancillary electrode is configured to exhibit an ampacity determined with respect to a predetermined ampacity threshold. The predetermined ampacity threshold is defined in accordance with the fabrication technology of the photo-conversion material used to make the photovoltaic cells present in the module. For crystalline photovoltaic cells the predetermined ampacity threshold is on the order of about 0.1 amperes, while for thin film photovoltaic cells the predetermined ampacity threshold is on the order of about 0.001 amperes. Based upon its exhibited ampacity each ancillary electrode is operative to perform either a voltage test function or a power transmission function. In all embodiments of the invention both a primary electrode and the ancillary electrode (s) connected thereto are directly connectible to and simultaneously capable of transmitting power to a primary or an ancillary electrode on another panel. In one embodiment of this aspect of the present invention a photovoltaic panel includes a single ancillary electrode that is electrically connected to a selected one of the connection tabs. If the ancillary electrode is configured to exhibit an ampacity above the predetermined threshold the ancillary electrode is operative to carry power when connected to an electrical destination. Alternatively, if the ancillary electrode is configured to exhibit an ampacity substantially at or below the predetermined threshold the ancillary electrode is able to operate only as a voltage test terminal for the panel. If configured as a voltage test terminal for the panel the ancillary electrode is preferably accessible from the radiation collection surface of the panel.
In another embodiment of this aspect of the present invention a photovoltaic panel includes both a first and a second ancillary electrode. In one preferred instance each ancillary electrode is electrically connected to a respective one of the connection tabs and each ancillary electrode is configured to exhibit an ampacity above the predetermined threshold, whereby each ancillary electrode is operative to carry power when connected to an electrical destination. In this instance the ancillary electrodes facilitate electrical series interconnections between panels in an array. In an alternative instance both ancillary electrodes may be electrically connected to the same connection tab. In such an instance one ancillary electrode may be configured to exhibit an ampacity above the predetermined threshold, whereby that ancillary electrode is operative to carry power when connected to an electrical destination, while the other ancillary electrode may be configured to exhibit an ampacity substantially at or below the predetermined threshold, whereby that ancillary electrode is able to operate as a voltage test terminal for the panel. Alternatively, both ancillary electrodes that are electrically connected to the same connection tab may exhibit an ampacity such that both ancillary electrodes are operative to carry power when connected to an electrical destination. In this latter instance (two ancillary power transmission electrodes connected to the same connection tab) facilitate electrical parallel interconnections between strings of panels.
In yet another embodiment of this aspect of the present invention a panel may include an arrangement in which three ancillary electrodes are disposed on the panel. In this arrangement a pair of ancillary electrodes each exhibiting an ampacity above the predetermined threshold (i.e., power transmission electrodes) are connected either to a respective connection tab of the panel or to the same selected one of the connection tabs. In addition, a third ancillary electrode having an ampacity substantially at or below the predetermined threshold (i.e., a voltage test electrode) is connected to one of the connection tabs.
It lies within the contemplation of the invention that one (or more) additional ancillary electrodes (useful for either a power transmission or voltage test function) may be deployed on the panel.
-o-O-o-
In other aspects the present invention is directed to a photovoltaic array comprising at least a first and a second photovoltaic panel each having at least one ancillary electrode in accordance with the present invention and to methods for forming such a photovoltaic array. Use of panels in accordance with the present invention facilitates the configuration of an array in ways that overcome the various obstacles to the formation of a regularly shaped rectangular array or that neutralize factors that minimize the solar collection efficiency of the array.
For example, in one arrangement where the first and the second panels of the array are physically spaced apart from each other, a single ancillary power transmission electrodes on one or both of the panels may be used to electrically connect a connection tab on the first of the panels to a connection tab on the other of the panels in either an series or a parallel configuration.
In the instance where each of the physically spaced panels carry a pair of ancillary power electrodes and each electrode in the pair is electrically connected to a respective one of the connection tabs, an electrical series interconnection between panels in an array may be implemented. When both of the ancillary power transmission electrodes on each panel are electrically connected to the same connection tab electrical parallel interconnections (daisy chain fashion) between strings of panels are facilitated. Alternatively, the ancillary power transmission electrode on one (or both) of the panel (s) may be used to electrically connect the connection tab on that panel to any one of various other electrical destinations. If the first and the second panels of the array are arranged such that the primary electrodes on the panels are physically joined to each other with the primary electrode of the first polarity on the first panel juxtaposed with the primary electrode of the second polarity of the second panel, the ancillary power transmission electrode (s) on the panel (s) are utilized to electrically connect a connection tab on a panel to an electrical destination. In this usage, however, it is necessary to provide an insulating member for isolating the primary electrodes on the first and second panels from each other.
Regardless of whether the panels are physically spaced or juxtaposed, the use of panels in accordance with the present invention also enables installers to overcome the various challenges to array optimization. Having a panel with three or more power transmission ancillary electrodes connected to the same selected one of the connection tabs allows for flexibility in interconnecting in either a single point parallel interconnection among strings of panels, a daisy chain parallel interconnection among strings of panels, or a series connection between panels. It should be recognized that regulatory authorities limit the number of parallel interconnections before an over- current limiting device is required.
-o-O-o-
In still another aspect the present invention is a kit containing at least one photovoltaic panel in accordance with the present invention and at least one cable useful to connect an ancillary electrode on that panel to an electrical destination.
BRIEF DESCRIPTION OF THE DRAWINGS The invention will be more fully understood from the following detailed description taken in connection with the accompanying drawings, which form a part of this application and in which:
Figure 1 is a side elevation view entirely in section of a stylized representation of a photovoltaic panel having ancillary electrodes in accordance with the present invention, and additionally including at least one additional test contact;
Figure IA is a side elevation view entirely in section illustrating the electrical interconnection between two overlapped panels;
Figures 2A and 2B are enlargements of the circled portion of the photovoltaic panel of Figure 1 illustrating respective exemplary mounting arrangements on the panel for the ancillary electrodes; Figures 3A and 3B are diagrammatic illustrations of the utilization of photovoltaic panels in accordance with the present invention to overcome two commonly encountered obstacles associated with the formation of an array of photovoltaic panels on a support structure, in which: Figure 3A illustrates a situation in an array which presents the need to connect electrically an electrode on one photovoltaic panel to a physically spaced destination, such as an electrode of an opposite polarity on another photovoltaic panel or to another destination; and
Figure 3B illustrates a situation in which adjacent photovoltaic panels are physically overlapped with each other, but in which the primary electrodes on the respective overlapped panels are electrically isolated so that an electrode of a given polarity on each photovoltaic panel may be electrically connected to a physically spaced destination;
Figures 3C through 3E are diagrammatic illustrations of the utilization of photovoltaic panels in accordance with the present invention configured in ways that overcome various practical challenges associated with the formation of an array of photovoltaic panels on a support structure, in which:
Figure 3C illustrates a so-called "daisy chained" parallel connection scheme in which each of the parallel string connections is distributed throughout the array;
Figure 3D illustrates a "single point" parallel connection scheme in which all of the parallel strings are joined at a single location in the array; and
Figure 3E illustrates a hybrid scheme utilizing both daisy chained and single point connection schemes; Figures 4A and 4B are elevation views entirely in section which illustrate a connection arrangement in which an electrode of a first polarity on one photovoltaic panel may be electrically connected to a physically spaced destination in accordance with the present invention; Figures 5A and 5B are elevation views similar to Figures 4A, 4B, illustrating an alternative connection arrangement in accordance with the present invention by which an electrode on one photovoltaic panel in an array is electrically connected to a physically spaced destination; Figure 6A is a side elevation view entirely in section showing the introduction of an insulating member over a primary electrode on one photovoltaic panel; and
Figure 6B is a side elevation view similar to Figure IA illustrating the electrically isolated primary electrodes on two physically overlapped panels.
DETAILED DESCRIPTION OF THE INVENTION
Throughout the following detailed description similar reference numerals refer to similar elements in all figures of the drawings. It should be understood that although all of the functional and operational elements of the present invention are depicted in the drawings various details of the physical structure of these functional and operational elements may be stylized in form, with some portions physically relocated, enlarged and/or exaggerated, all for convenience of illustration and ease of understanding.
Figure IA is a side elevation view entirely in section of a stylized representation of a photovoltaic panel generally indicated by the reference character 10. In the embodiment depicted in Figure IA the photovoltaic panel 10 includes three ancillary electrodes: viz., a pair of power transmission electrodes 50, 52 (also seen in Figures 2A, 2B) ; and a voltage test electrode 68 (shown in more detail in Figure IB) .
In general, however, it should be understood that it lies within the contemplation of the present invention that a panel may be configured to deploy only a single ancillary power transmission electrode 50 or 52, as the case may be, (regardless of whether a voltage test electrode 68 is also deployed) . On the other hand, it should also be understood that a panel may be configured to deploy one or more additional ancillary power transmission electrode (s) (beyond the pair of electrodes 50, 52 illustrated) . In all embodiments of the invention both a primary electrode and the ancillary electrode (s) connected thereto are directly connectible to and simultaneously capable of transmitting power to a primary or an ancillary electrode on another panel .
In the usual case the photovoltaic panel 10 is a four- sided member, typically rectangular (including square) when viewed in plan, having opposed pairs of horizontal side edges and respectively adjacent vertical side edges. Each panel 10 comprises a photovoltaic module 12, itself containing a plurality of electrically interconnected photovoltaic cells. The module 12 is usually engaged by a support frame generally indicated by the reference character 14.
The photovoltaic module 12 is a laminated structure that includes a photovoltaic layer 12P in which the photovoltaic cells are encapsulated. Two representative photovoltaic cells 12C are schematically indicated in the drawings. The photovoltaic layer 12P is usually sandwiched between a lower support sheet 12S and a transparent covering sheet 12T. The outer surface of the support sheet 12S defines the lower surface 12L of the module 12. The outer surface of the transparent covering sheet 12T defines a generally planar radiation collection surface 12R for the module. Each photovoltaic cell 12C is operative to generate an electric current in response to incident radiation falling upon the radiation collection surface 12R.
Photovoltaic cells 12C within the module 12 are typically connected with each other by metallizations, indicated diagrammatically by the reference character 12M. The series collection of photovoltaic cells within the module terminates in connection tabs, generally indicated by the reference character 12E, disposed on surfaces of the module. The connection tabs 12E are used to electrically connect the photovoltaic cells 12C within the module to a point on the exterior of the module 12. One connection tab 12EP has a positive electrical polarity while the other connection tab 12EN has a negative electrical polarity.
The photovoltaic layer 12P and the photovoltaic cells 12C contained therewithin may be fabricated using either crystalline or thin film forms of photo-conversion material. The fabrication technology of the photo- conversion material influences the ampacity thresholds between voltage test function and power transmission function, as will be discussed. In the implementation shown in the Figures the support frame 14 comprises at least one, but preferably two, opposed pairs of frame bar members that lie on the perimeter of the photovoltaic module 12. The frame bars may be connected to each other at their ends to entirely circumscribe the module, if desired. Sectional views illustrating the functional and operation features of one opposed pair of frame bars 22 and 24 are shown in the drawings. It should be understood that the frame 14 may alternatively be implemented using a modularized frame structure in which a plurality of standardized frame pieces are interconnected into the desired peripheral form.
Each frame bar 22, 24 has a pair of grasping fingers 22A, 22B and 24A, 24B projecting from the main body portion of the respective bar. Each pair of grasping fingers respectively edge-wise grips the photovoltaic module 12 over an extended portion of the length of the module. A flexible seal member may be provided between the fingers and the surfaces of the module, if desired.
The first finger 22A, 24A of each respective frame bar 22, 24 overlies a portion of the upper radiation collection surface 12R. The second finger 22B, 24B of each frame bar 22, 24 engages the lower surface 12L. The interior margins of the first fingers 22A, 24A may be inclined (as indicated at 221 and 241 in Figure IA) to minimize the area of the photovoltaic layer 12P shaded by those fingers. The pairs of grasping fingers 22A, 22B and 24A, 24B on each respective frame bar 22, 24 prevent the module 12 from leaving the frame 14 in an upward or downward direction (as viewed in Figure IA) . However, the module 12 is relatively free to move in directions parallel to the plane of the radiation collection surface 12R, as in response to differential thermal expansion between the frame and the module .
In the embodiment illustrated each frame bar 22, 24 has a keying flange 28, 30 respectively extending laterally therefrom. The keying flange 28 has a planar mating surface 28A and an exterior surface 28B thereon. Similar mating and exterior surfaces 3OA, 3OB respectively are disposed on the flange 30. The mating surface 28A of the flange 28 is vertically offset from the lower surface 22B of the frame bar 22 by a distance 28T. A first and a second primary electrode 34, 36 respectively, are mounted on the panel 10 for the purpose of electrically connecting the photovoltaic cells 12C within the module 12 of one panel to the cells in another adjacent panel. In the structure illustrated the primary electrodes 34, 36 are disposed at any convenient position on the respective mating surfaces 28A, 3OA of each keying flange 28, 30. It should be understood, however, that these primary electrodes 34, 36 may be mounted on or depend from any convenient location on the panel 10. For example, primary electrodes may be mounted on or depend from only one of the frame bars 22 or 24 or may be mounted on or depend from the module 12 itself.
In the arrangement shown in Figure IA the first primary electrode 34 is illustrated as a disc-like member that is embedded into the material of the mating surface
28A of the flange 28. A gasket 38 surrounds the electrode 34 on the mating surface 28A of the flange 28. The second primary electrode 36 is also a substantially disc-like member having an enlarged annular shoulder 36S. The electrode 36 is urged toward the mating surface 30A of the flange 30 by the action of a biasing spring 42. The spring 42 is received in a counterbore 30C provided in the flange 30. The primary electrode 36 is retained in the counterbore 30C by the abutting interaction of the shoulder 36S on the electrode against a shoulder 30S formed in the flange 30 by the counterbore 30C. The mouth of the counterbore 30C is threaded, as at 30T, for a purpose to be described.
The first primary electrode 34 and the second primary electrode 36 each have a respective electrical polarity, determined by the electrical polarity of the connection tab 12E of the module 12 to which the respective electrode is connected. Thus, in the drawings, the primary electrode 34 is illustrated to have negative electrical polarity due to its connection to the negative connection tab 12EN. Similarly, the primary electrode 34 has positive electrical polarity due to its connection to the positive connection tab 12EP.
Each primary electrode 34, 36 is connected in any convenient manner to its respective connection tab 12EN, 12EP. In Figures IA and IB the connection between the electrode 34 and the negative tab 12EN is schematically illustrated by a conductor 34C that extends through a passage 22C provided in the frame bar 22 for this purpose. Similarly, the connection between the electrode 36 and the positive tab 12EP is schematically illustrated by a conductor 36C that extends through a passage 24C in the frame bar 24. It should be understood that various protective structures are required by relevant safety standards (e.g., Underwriters' Laboratory Standards UL-1703 or UL-486A) for considerations of personal safety.
However, it should be understood that these protective structures have been omitted from the drawings for clarity of illustration.
In accordance with the present invention the panel 10 includes one or more ancillary electrodes each electrically connected to a connection tab. Each ancillary electrode is configured to exhibit an ampacity determined with respect to a predetermined ampacity threshold. Ampacity is the property of an ancillary electrode that defines its current carrying capacity. The ampacity of an ancillary electrode is determined by the nature of the material used to form the electrode, its thickness, its cross-sectional area and surface properties. The fabrication technology of the photo-conversion material in the module mandates the ampacity thresholds that differentiate ancillary voltage test electrodes from ancillary power transmission electrodes. For a photovoltaic panel of specified power output (voltage multiplied by current) panels constructed of crystalline silicon will generally optimize the power equation by having a higher current and lower voltage. Panels constructed of a thin film material will generally optimize the power equation with a lower current and higher voltage. As a result, for crystalline photovoltaic cells the predetermined ampacity threshold is on the order of about 0.1 amperes, while for thin film photovoltaic cells the predetermined ampacity threshold is on the order of about 0.001 amperes. Based upon its exhibited ampacity each ancillary electrode deployed in accordance with the present invention is operative to perform either a voltage test function or a power transmission function. It is understood that any power transmission ancillary electrode has adequate ampacity to enable it to function as a voltage test electrode.
As noted earlier, in the embodiment of the present invention shown in Figures IA and IB the panel 10 includes a first ancillary electrode 50 and a second ancillary electrode 52. For reasons that will be developed it is preferred that each ancillary electrode 50, 52 (and each primary electrode, 34, 36 for that matter) exhibits an ampacity permitting the electrode to provide a power transmission function.
In the preferred instance illustrated each ancillary electrode 50, 52 is electrically connected to a respective one of the connection tabs from the photovoltaic cells. The ancillary electrode 50 is electrically connected to the connection tab 12EN, as by a conductor 50C schematically illustrated in the Figures. Similarly, the ancillary electrode 52 is electrically connected to the other connection tab 12EP, as by a conductor 50C also schematically illustrated in the Figures. The term "electrically connected to a respective one of the connection tabs" (or like language denoting the connection of an ancillary electrode to a connection tab) means that a connection between an ancillary electrode 50, 52 and its respective connection tab 12EN, 12EP may be effected by connecting the ancillary electrode directly (via a suitable conductor) to the particular tab, directly (via a suitable conductor) to primary electrode associated with the tab, or through a suitable conductor to any conductor extending between a tab and its associated primary electrode. It should be understood that both ancillary electrodes 50, 52 may be electrically connected to the same connection tab, if desired. Figures 2A and 2B are enlargements of the circled portion of the photovoltaic panel 10 of Figure IA illustrating various suggested structural forms for the ancillary electrodes 50, 52 and exemplary arrangements for mounting the ancillary electrodes on the frame of the panel 10. Each ancillary electrode 50, 52 has an ampacity that is greater than the predetermined threshold determined in accordance with the fabrication technology of the photo- conversion material used for the cells 12C in the module. Thus, for crystalline photovoltaic cells the predetermined ampacity threshold of the ancillary electrodes 50, 52 is above about 0.1 amperes, while for thin film photovoltaic cells the predetermined ampacity threshold of the ancillary electrodes 50, 52 is above about 0.001 amperes.
In the stylized schematic arrangement shown in Figure 2A each ancillary electrode 50, 52 is secured at the bottom of a threaded bore 50B, 52B formed in the respective frame bars 22, 24. Each ancillary electrode 50, 52 is substantially plate-like in form and has a central threaded opening 50A, 52A provided therein. The electrical connection between an ancillary electrode 50, 52 and its respective connection tab 12EN, 12EP is schematically illustrated in the Figures by respective conductors 5OC, 52C connected to the conductors 34C, 36C extending between a connection tab and its associated primary electrode. Each conductor 5OC, 52C is diagrammatically shown to extend through a passage 22P, 24P provided through the respective frame bar 22, 24. A groove 5OG, 52G formed in the bottom of each threaded bore 5OB, 52B receives a respective O-ring seal 5OS, 52S. Alternatively, a deformable polymeric seal may be integrated into the frame bar in place of the discrete O- ring. In practice, the ancillary electrode 50, 52 and its respective conductor 5OC, 52C are each stamped as a rigid integral piece that is contoured to fit within its respective passage 22P, 24P in the frame bar. Each of the bores 5OB, 52B is closed by a respective insulating cover 60, 62. Each cover 60, 62 has a central driver slot 60S, 62S on its exterior surface and an annular bead 6OB, 62B formed on its interior surface. The edge of each cover 60, 62 has peripheral threads 6OT, 62T thereon. Each cover 60, 62 is secured by the engagement of peripheral threads 6OT, 62T with the threads disposed near the mouth of the respective bore 50B, 52B. When each cover 60 is securely threaded into its respective associated bore 50B, 52B, the annular bead 6OB on the cover's interior surface is brought to bear into sealing engagement against the O-ring seal 50S, 52S in the bottom of the bore. The engaged disposition of a cover 60 within the bore 52B is illustrated on the right hand side of Figure 2A.
Figure 2B illustrates an alternative exemplary arrangement for mounting the ancillary electrodes 50, 52 on the panel 10. In this stylized schematic arrangement each ancillary electrode 50, 52 is embedded within and substantially surrounded by the material of a frame bar 22, 24. The ancillary electrode 50 is similar to the structure shown in Figure 2A. However, the ancillary electrode 52 is implemented using an alternative configuration. In the embodiment illustrated the ancillary electrode 52 includes a post 52P that projects from the face of the electrode 52. The post 52P may have spring arms thereon.
Each frame bar 22, 24 has a threaded protuberance, or boss, 22E, 24E that overlies the ancillary electrode 50, 52. The groove 5OG, 52G is formed in the face of the boss 22E, 24E to receive the respective 0-ring seal 5OS, 52S. An access bore 22V, 24V extends through the boss 22E, 24E into communication with the respective ancillary electrode. The bore 22V registers with the opening 5OA in the electrode 5OA. The post 52P extends centrally and axially through the bore 24V.
Each access bore 22V, 24V is closed by a respective removable insulating cap 64, 66. Each cap 64 has interior threads 641 that may be threaded onto the exterior threads of each boss 22E, 24E. Each cap has exterior threads 64E, 66E for a purpose to be discussed. The engaged disposition of the cap 66 with the boss 24E on the frame bar 24 is illustrated on the right hand side of Figure 2B. When the cap 64, 66 is threaded onto its boss the annular bead 64B, 66B on the cap's interior surface bears against the O-ring seal 5OS, 52S to seal the access bore 22V, 24V.
It should be understood that the structure of the ancillary electrodes and the mounting dispositions as shown in Figures 2A, 2B are merely exemplary. Other structural arrangements of the ancillary electrodes and other mounting dispositions at any convenient position on the panel 10 may be utilized and remain within the contemplation of the invention. Thus, for example, both ancillary electrodes may be mounted to the same frame bar or disposed in a convenient location on the module 12 (whether or not a frame 14 is included with the panel) .
The embodiment of the present invention shown in Figures IA and IB the panel 10 is also shown to include another ancillary electrode 68 that has an ampacity less than the threshold, whereby the ancillary electrode 68 may function as a voltage test terminal for the panel. An ancillary electrode 68 available as a voltage test terminal facilitates array maintenance and system commissioning in that it provides an accessible point where test equipment may be connected to monitor electrical conditions of the module. As is perhaps best illustrated in Figure IB the accessible test arrangement 68 includes a test point contact 68T that is mounted at the base of a threaded counterbore 68B formed in the finger 22A of the frame bar 22. The test contact 68T is electrically connected to one of the connection tabs (e.g., the connection tab 12EN) by a conductor 68W and, thus, to the electrode 34. The conductor 68W passes through a duct 22D formed in the frame bar 22. Once again, the term "electrically connected to a respective one of the connection tabs" (or like language) means that a connection between test contact 68T and a connection tab 12EN, 12EP (as the case may be) may be effected by connecting the test contact 68T directly (via a suitable conductor) to the particular tab, directly (via a suitable conductor) to primary electrode associated with the tab, or through a suitable conductor to any conductor extending between a tab and its associated primary electrode. The surface of the contact 68T presented to the counterbore 68B may be provided with a threaded recess 68R to receive a probe of a test instrument. The counterbore 68B is closed by a weather-tight cap 68C.
In the event that the frame is omitted the ancillary electrode 68 may be disposed on the photovoltaic module 12 itself. This arrangement is also illustrated in Figure IB. In this case the bore 68B' extends through the transparent layer 12T. An insulating sleeve 68S' having the test point contact 68T' at its lower end is inserted into the bore 68B. The test point contact 68T' is connected electrically to the metallization 12M between cells 12P by the conductor 68W . The water-tight cap 68C closes the bore 68B' . It is noted that in accordance with the present invention a panel may include one (or more) additional ancillary electrode (s) suitable for use as voltage test terminal (s), regardless of whether additional ancillary electrodes suitable as power transmission electrodes is (are) deployed. Any additional voltage test terminal (s) (if deployed) may be electrically connected either of the connection tabs, as convenient.
In the preferred case the frame bars 22, 24 are fabricated from a suitable electrically non-conductive material having sufficient voltage-insulation properties, such as a glass-reinforced polyester resin. One suitable electrically non-conductive material is the injection- moldable or extrudable glass-fiber reinforced polyethylene terephthalate (PET) resin with appropriate fire-retardant properties sold by E.I. du Pont de Nemours and Company under the trademark RYNITE®. Any convenient manufacturing technique may be used. For example, a frame bar may be extruded as an integral member and thereafter machined to form the various passages, bores, counterbores, recesses, and/or protuberances above described. The covers or caps are fabricated from the same or other electrically insulating materials. Alternatively, it should be appreciated that the frame bars may be manufactured from a conductive material, so long as suitable electrical insulation material is provided to surround the electrically conductive tabs, electrodes, contacts and current-carrying conductors.
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As noted earlier, a photovoltaic array usually comprises one or more linear rows of adjacent panels arranged in matrix fashion. The panels are mounted either directly to a support structure (e.g., a roof) or through suitable framework members affixed to the support structure .
Figure IB illustrates a straightforward electrical series interconnection between two similarly configured, physically adjacent panels 10, 101. Each panel 10, 101 is configured as described in connection with Figures IA and 2A. In such a series interconnection the negative polarity connection tab 12EN on the panel 10 is connected to the positive polarity connection tab 12EP on the panel 101 through abutting contact between the respective primary electrodes 34 and 36 of these panels.
The panels 10, 101 are arranged in complimentary confrontational relationship such that the mating surface 28A on the first keying flange 28 of a first panel 10 physically overlaps and abuts with the mating surface 3OA of a second keying flange 30 of the second, adjacent, panel 101. This mechanically keyed relationship between the panels juxtaposes the negative primary electrode 34 on the flange 30 of the panel 10 with the positive primary electrode 36 on the flange 30 of the panel 101.
Mechanically keying the panels in this manner insures that the negative primary electrode 34 (on the panel 10) is disposed in electrically conductive contact with the positive primary electrode 36 (on the panel 101) . With the mating surfaces on the flanges in overlapped relationship the spring 42 acts to urge the primary electrode 36 toward the primary electrode 34 to dispose these primary electrodes in electrical contact, thereby to connect the connection tab on the panel 10 to the connection tab on the panel 10' . The flanges 28, 30 may be mechanically secured in the described overlapped relationship in any suitable manner. Sealed integrity against the ingress of water between the electrodes 34, 36 on the abutting mating surfaces 28A, 30A is maintained by the gasket 38. -o- O -o-
In practice, obstructions may be present which prevent physically overlapping the keying flanges of the panels, thus precluding the possibility of electrical interconnection using the primary electrodes in the manner illustrated in Figure IB.
Figure 3A illustrates a typical situation in which two panels 10A, 10B in accordance with the present invention are physically separated due to any of the various reasons discussed earlier. Despite such separation it may nevertheless be desirable for electrical considerations that either :
(1) a connection tab of one polarity on the panel 10A be connected to the electrical destination defined by the connection tab of the opposite polarity on the panel 10B (i.e., an electrical series connection between panels) ; or,
(2) a connection tab of one polarity on the panel 10A be connected to the electrical destination defined by the connection tab of the same polarity on the panel 10B (i.e., an electrical parallel connection between panels) .
Alternatively or in addition, there may be an instance in which it is desirable that one or both of these two physically separated panels 10A and/or 10B be electrically connected to another physically spaced electrical destination, such as another panel, an inverter, a combiner box, a DC disconnect switch, a battery charger, a fuse, a blocking diode, or a ground fault current interrupter. (Each panel is likely connected to a different one of these electrical destinations.)
Configuring an array including one or more panels each having one or more ancillary electrodes 50 and/or 52 in accordance with the present invention facilitates the electrical interconnection of the panel (s) to all of these physically spaced electrical destinations.
As examples, as long as one of the panels 10A or 10B includes at least one ancillary power transmission electrode connected to one of the connection tabs on the panel, that panel may be interconnected in series or parallel with the other panel. To effect a series interconnection between the panels 10A or 10B the ancillary power transmission electrode on one of the panels (e.g., the first panel 10A) is connected to the connection tab of the opposite polarity on the second panel 10B (as by making any convenient electrical connection using the primary electrode connected to the appropriate connection tab on the second panel) . To effect a parallel interconnection between the panels 10A or 10B the ancillary power transmission electrode on the first panel 10A is connected to the connection tab of the same polarity on the second panel 10B (as by making any convenient electrical connection using the primary electrode connected to that appropriate connection tab on the second panel) . To connect the panel 10A or 10B to one of the other physically spaced electrical destinations the ancillary electrode on that panel is connected to that destination.
In the event that both of the panels 10A or 10B include an ancillary power transmission electrode the series or parallel interconnections may be effected by connecting the ancillary electrode on the first panel to the ancillary electrode on the second panel (assuming that each ancillary electrode is connected to the appropriate tab on its panel.) The connection of a panel 10A or 10B to one of the other physically spaced electrical destinations the ancillary electrode on that panel is connected to that destination.
In the preferred instance the array is configured using panels that include a pair of ancillary electrodes 50 and 52, each connected to a respective connection tab on the panel as shown and described in connection with Figures IA, IB, 2A, 2B. The series or parallel interconnections between panels and to the other spaced destinations are effected using the appropriate combination of ancillary power transmission electrodes .
Any of these connections may be physically realized using a unitary cable or interconnected segmented cables.
It is assumed for this discussion that panels 10A and 10B are each configured as shown in Figures IA, IB, 2A, 2B. In such a case examples of various possible arrangements for connecting the ancillary electrodes to these physically spaced electrical destinations are illustrated in Figures 4A, 4B and 5A, 5B.
Figures 4A and 4B, taken together, show an arrangement for connecting ancillary electrodes configured as shown in Figure 2A to a physically spaced electrical destination using a pair of joinable cable segments 7OA, 7OB. Each of the panels 10A, 10B is shown supported on a suitable support member VA, VB. Each cable segment 7OA, 7OB comprises a predetermined length of electrical conductor surrounded by an insulating jacket. An enlarged insulating plug head 72A, 72B is disposed at the first end of each respective cable segment 7OA, 7OB. A threaded conductive post 78A, 78B projects from each respective insulating plug head. The face of each plug has a ring 8OA, 8OB formed thereon. The bare electrical conductor may be left exposed at the second, distal, end of each segment 7OA, 7OB. However, in many instances it is more preferable that a complimentary connector 76A, 76B is disposed at the distal end of each respective cable segment. The complimentary connectors 76A, 76B may take any of a variety of forms. For example, a crimp-on terminal, a ring-style, a spade right-angle terminal, a hook terminal or a so-called "MC connector" may be used. An "MC connector" is a connection device manufactured and sold by Multi-Contact USA, Santa Rosa, California, a wholly-owned subsidiary of Multi-Contact AG, Basel Switzerland. With the insulating covers 60, 62 (Figure 2A) removed from the ancillary electrodes 50, 52 on the panels 10B, 10A, each of the posts 78A, 78B is threaded into the central opening 52A, 5OA of the respective ancillary electrodes 52, 50. When each post 78A, 78B is fully threaded into its associated electrode 52, 50 the O-ring 52S, 5OS for that electrode is compressed against the ring 8OA, 8OB formed in the face of the plug head, thus providing a water-tight seal . Once the ancillary electrodes are engaged to their conductive posts, the connection of each of the panels 10A, 10B to a desired electrical destination may be completed by using the complimentary connectors 76A, 76B.
For example, if it is desired to connect the panels 10A, 10B in electrical series, the cable segments 7OA, 7OB are connected to each other using the complimentary connectors 76A, 76B. By first joining a separate cable segment 7OA, 7OB (as the case may be) to each respective ancillary electrode 52A, 52B, and thereafter joining the cable segments together, the cable segments may be connected. By joining cable segments using the complimentary connectors 76A, 76B, instead of a unitary cable with same handed threads at both ends, tightening of one end of the cable does not cause the other to loosen. Of course, it lies within the contemplation of the invention that each of the panels 10A, 10B may be connected to a separate electrical destination (i.e., not to each other) . In such a case the desired electrical destination would be outfitted with a suitable connector complimentary to the connector disposed at the end of the cable segment 7OA, 7OB.
Figures 5A and 5B illustrate an alternative scheme for the instance when the panels have the ancillary electrode arrangement as shown in Figure 2B. This connection arrangement utilizes a unitary cable 84 terminated at each end with a connecter 85, 86 that is complimentary to the configuration of the ancillary electrode used in each of the panels 10A, 10B. The complimentary connecters 85, 86 may be similar to the MC connectors described earlier. Each connector 85, 86 includes a cap 85C, 86C having threads 85T, 86T that provide the insertion force to join and to retain the connectors to the electrodes. Each cap cap 85C, 86C is rotatable with respect to the cable 84 to avoid the loosening of one end of the cable while the other end is threaded. The interior of each cap 85C, 86C has rings 85B, 86B that abut the seals 5OS.
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Configuring an array that includes one or more panels each having one or more ancillary electrodes 50 and/or 52 solves another commonly encountered situation illustrated in Figure 3B. In this case the physical circumstances of the array are such that two panels 10c, 10D having primary electrodes arranged as shown in Figure 1 are able to be physically overlapped and joined with each other such that a primary electrode of a first polarity on the first panel is juxtaposed with the primary electrode of the second polarity on the second panel (in the manner depicted and discussed in connection with Figure IA) . However, for various reasons (such as, shading, maximum series voltage) it is desired to connect one (or both) of these panels 10c, 10D with a distant physical destination. Such connections may also be implemented so long as one (or both) of the panels 10c, 10D have one or more ancillary electrodes in accordance with the present invention .
Figures 6A and 6B illustrate how these connections may be effected.
As discussed in connection with Figure IA when the flanges of adjacent panels are physically overlapped the electrodes 34, 36 of the panels are joined in electrically conductive contact with each other. To permit each of the panels to be electrically connected with a different physically spaced destination it is necessary that the electrically conductive contact between the primary electrodes 34, 36 of the overlapped panels be defeated. Thus, the primary electrodes, although physically juxtaposed and joined in overlapped relationship, are nevertheless electrically isolated.
In accordance with the present invention, an insulating cap 60 (or 62) or a cover 64 (or 66) used to protect the ancillary electrodes on a panel 10c, 10D (as seen in Figures 2A, 2B) may be used to accomplish this electrical isolation.
As seen in Figure 6A, before the panel 10D is overlapped onto the panel 10c the cap 60 or cover 64, as the case may be, is positioned over the threaded mouth of the counterbore 3OT. The cap 60 or cover 64 is secured into the flange of the panel, using the external threads 6OE, 64E on the cap or cover. As the cap 60 or cover 64 is threaded into the panel, the primary electrode 36 is depressed into the flange 30.
Figure 6B is a side elevation view similar to Figure IA illustrating the electrically isolated primary electrodes on two physically overlapped panels. The presence of the cap 60 or cover 64 electrically isolates the electrodes 34, 36 from each other.
Each of the panels 10c, 10D may be connected to a physically spaced destination using any of the cables in the manner discussed in connection with Figures 3A, 4A, 4B, 5A, 5B.
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As noted earlier, the installation of a photovoltaic array often presents unique challenges with respect to optimizing various practical aspects of the array. For example: it may be desired to minimize the length of interconnecting wiring so as to reduce the amount of electrical cable used; it may be desirable for aesthetic purposes to hide the interconnecting wiring; or it may be desirable to eliminate or minimize the use of electrical junction or combiner boxes.
To demonstrate how the inclusion of multiple ancillary power electrodes on a panel can facilitate the optimization of various practical aspects of array installation Figures 3C through 3E depict a number of commonly encountered interconnection scenarios.
In general each of Figures 3C through 3E shows a panel (e.g., panels 10^1 , 10E"2, 10E"3 and 10E"4, as the case may be) each disposed at the end of a panel string diagrammatically indicated by the reference characters S1, S2, S3 and S4. The scenarios are intended to depict the panels 10^1 , 10E"2, 10E"3 and 10E"4 as being physically spaced from each other by significant distances when viewed in terms of cable length (although the solutions presented are operative even if panels are closely adjacent to each other) . A remote destination R is also shown as being spaced closest to one of the panels. The destination R can take the form of any of the electrical destinations listed earlier .
Each panel may carry some predetermined number of ancillary power electrodes A1, A2, A3, ... AN, as the case may be. For clarity of illustration in each of Figures 3C through 3E only those ancillary power electrodes that is (are) used on a given panel to effect the interconnection being described is (are) illustrated. However, this is not meant to imply that the given panel can not carry additional ancillary power electrodes. To the contrary, owing to various other manufacturing and logistical costs is believed that each panel in an array would be identically configured. The generic reference character "T" is used in Figures 3C through 3E to denote that the ancillary power electrode (s) on each of the panels in a drawing is (are) connected to the connection tab of the same electrical polarity, i.e., either the positive tab 12EP or the negative tab 12EN on a panel. Figure 3C illustrates a so-called "daisy chain" parallel connection which, in the circumstance there illustrated, allows strings S1, S2 and S3 to be connected in parallel while the panel IC^"1 is simultaneously connected to the destination R proximal thereto. It should be appreciated from the following that for any parallel connection scheme it is required that a minimum of two ancillary electrodes be connected to a connection tab of a given polarity per panel.
While a "daisy chain" connection scheme may be optimal for allowing three (or more) strings to be connected in parallel with panels having a minimum number of ancillary power electrodes per panel, such a scheme may not be optimal from a cost standpoint when viewed from the overall array topology. Consider a situation in which the destination R is closer to the panel 10E"2 than to the panel IC^"1. This relationship among the panels and the destination R is illustrated in Figure 3D. From a topological standpoint a direct wire run from an ancillary electrode on the panel 10E~2 to the destination R is most efficient in this circumstance .
While it is possible to use the daisy chain scheme as shown in Figure 3C to complete the required interconnections among panels and between the panel 10E~2 and the destination R with panels each having only the minimum number of ancillary electrodes, the wire run between panels IC^"1 and 10E~3 (indicated in Figure 3D by the reference character "H") in such an installation would be excessive, adding to the cost. Moreover, even though it is possible to effect a direct interconnection between the panel IC^"1 and the destination R, the wire run in such an instance may be impossible to conceal, thus adding further wire cost and simultaneously detracting from the aesthetics of the array.
In the instance shown in Figure 3D a so-called "single-point" interconnection scheme may be more effective. Figure 3D illustrates a "single point" parallel interconnection scheme which would eliminate the excessive wire run H, at the cost of using a third ancillary electrode A3 on the panel. Figure 3E illustrates a hybrid connection scheme in which both a "daisy chain" and a "single point" are employed.
Any of the interconnections discussed in connection with Figures 3C through 3E may be implemented using any combination of cable arrangements discussed in connection with Figures 4A, 4B, 5A, 5B. Figures 3C through 3E make clear that the addition of an appropriate number of ancillary power electrodes necessary to effect parallel interconnections provides a high level of installation flexibility and allows for a broad range of optimization strategies with their associated tradeoffs. Each use of a daisy chain or a parallel interconnection scheme eliminates the need for a junction or combiner box. The judicious implementation of a single-point scheme minimizes wire cost and may contribute to array aesthetics.
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In another aspect the present invention may be implemented in kit form. In such a kit form one or more panels in accordance with any embodiment of the present invention are packaged together with suitably segmented or unitary cable (s) whereby arrays having any of the various interconnection schemes discussed herein may be implemented. -o- O -o-
Those skilled in the art, having the benefit of the teachings of the present invention as hereinabove set forth may effect numerous modifications thereto. Such modifications are to be construed as lying within the contemplation of the present invention as defined by the appended claims.

Claims

WHAT IS CLAIMED IS:
1. A photovoltaic panel comprising: a photovoltaic module including a plurality of electrically interconnected photovoltaic cells terminating in a first connection tab of a first polarity and a second connection tab of a second polarity; a first primary electrode and a second primary electrode, each primary electrode being electrically connected to a respective one of the connection tabs; and an ancillary electrode electrically connected to one of the connection tabs, both the primary electrode and the ancillary electrode connected thereto are directly connectible to and simultaneously capable of transmitting power to a primary or an ancillary electrode on another panel.
2. The photovoltaic panel of claim 1 further comprising: a frame engaging the photovoltaic module, the ancillary electrode being mounted to the frame.
3. The photovoltaic panel of claim 1 wherein the ancillary electrode has an ampacity less than or substantially equal to a predetermined threshold whereby that ancillary electrode is operative as a voltage test terminal for the panel.
4. The photovoltaic panel of claim 1 wherein the ancillary electrode has an ampacity greater than a predetermined threshold whereby that ancillary electrode is operative to carry power when it is connected to an electrical destination.
5. The photovoltaic panel of claim 3 wherein the photovoltaic cells are fabricated from crystalline silicon, and wherein the ancillary electrode has an ampacity less than or substantially equal to about 0.1 amperes whereby the ancillary electrode is operative as a voltage test terminal for the panel.
6. The photovoltaic panel of claim 5 wherein the module has a radiation collection surface thereon, the ancillary electrode being accessible from the radiation collection surface for the module.
7. The photovoltaic panel of claim 5 wherein the module has a radiation collection surface thereon, the panel further comprising a frame engaging the photovoltaic module, a surface of the frame being adjacent to the radiation collection surface of the module, the frame having an access opening formed into the surface of the frame adjacent to the radiation collection surface, the ancillary electrode being disposed within the access opening in the frame.
8. The photovoltaic panel of claim 7 further comprising: an insulating member comprising an insert sized for receipt within the access opening in the frame.
9. The photovoltaic panel of claim 3 wherein the photovoltaic cells are fabricated from a thin film photovoltaic conversion material, and wherein the ancillary electrode has an ampacity less than or substantially equal to about 0.001 amperes whereby the ancillary electrode is operative as a voltage test terminal for the panel.
10. The photovoltaic panel of claim 9 wherein the module has a radiation collection surface thereon, the ancillary electrode being accessible from the radiation collection surface for the module.
11. The photovoltaic panel of claim 9 wherein the module has a radiation collection surface thereon, the panel further comprising a frame engaging the photovoltaic module, a surface of the frame being adjacent to the radiation collection surface of the module, the frame having an access opening formed into the surface of the frame adjacent to the radiation collection surface, the ancillary electrode being disposed within the access opening in the frame.
12. The photovoltaic panel of claim 11 further comprising: an insulating member comprising an insert sized for receipt within the access opening in the frame.
13. The photovoltaic panel of claim 4 wherein the photovoltaic cells are fabricated from crystalline silicon, and wherein the ancillary electrode has an ampacity greater than about 0.1 amperes whereby the ancillary electrode is operative to carry power when connected to an electrical destination .
14. The photovoltaic panel of claim 13 further comprising: an insulating member disposed over the ancillary electrode.
15. The photovoltaic panel of claim 4 wherein the photovoltaic cells are fabricated from a thin film photovoltaic conversion material, and wherein the ancillary electrode has an ampacity greater than about 0.001 amperes whereby the ancillary electrode is operative to carry power when connected to an electrical destination .
16. The photovoltaic panel of claim 15 further comprising: an insulating member disposed over the ancillary electrode .
17. A photovoltaic panel comprising: a photovoltaic module including a plurality of electrically interconnected photovoltaic cells terminating in a first connection tab of a first polarity and a second connection tab of a second polarity; a first primary electrode and a second primary electrode, each primary electrode being electrically connected to a respective one of the connection tabs; and a first and a second ancillary electrode, each ancillary electrode being electrically connected to a connection tab, a primary electrode and each ancillary electrode connected thereto are directly connectible to and simultaneously capable of transmitting power to a primary or an ancillary electrode on another panel.
18. The photovoltaic panel of claim 17 wherein the first ancillary electrode has an ampacity less than or substantially equal to a predetermined threshold whereby that ancillary electrode is operative as a voltage test terminal for the panel.
19. The photovoltaic panel of claim 18 wherein the second ancillary electrode has an ampacity greater than the predetermined threshold whereby that ancillary electrode is operative to carry power when it is connected to an electrical destination.
20. The photovoltaic panel of claim 17 wherein the first ancillary electrode has an ampacity greater than a predetermined threshold whereby that ancillary electrode is operative to carry power when it is connected to an electrical destination.
21. The photovoltaic panel of claim 20 wherein the second ancillary electrode also has an ampacity greater than the predetermined threshold whereby that ancillary electrode is also operative to carry power when it is connected to an electrical destination.
22. The photovoltaic panel of claim 17 further comprising: a frame engaging the photovoltaic module, each of the first and second ancillary electrodes being mounted to the frame.
23. A photovoltaic panel comprising: a photovoltaic module including a plurality of electrically interconnected photovoltaic cells terminating in a first connection tab of a first polarity and a second connection tab of a second polarity; a first primary electrode and a second primary electrode, each primary electrode being electrically connected to a respective one of the connection tabs; and a first and a second ancillary electrode, each ancillary electrode being electrically connected to a respective one of the connection tabs.
24. The photovoltaic panel of claim 23 further comprising: a frame engaging the photovoltaic module, each of the first and second ancillary electrodes being mounted to the frame.
25. The photovoltaic panel of claims 23 or 24 wherein the photovoltaic cells are fabricated from crystalline silicon, and wherein the first and the second ancillary electrode each has an ampacity greater than about 0.1 amperes whereby each ancillary electrode is operative to carry power when it is connected to an electrical destination.
26. The photovoltaic panel of claim 25 further comprising: an insulating member disposed over each of the first and the second ancillary electrodes.
27. The photovoltaic panel of claims 23 or 24 wherein the photovoltaic cells are fabricated from thin film photovoltaic conversion material, and wherein the first and the second ancillary electrode each has an ampacity greater than about 0.001 amperes whereby each ancillary electrode is operative to carry power when it is connected to an electrical destination.
28. The photovoltaic panel of claim 27 further comprising: an insulating member disposed over each of the first and the second ancillary electrodes.
29. The photovoltaic panel of claim 25 further comprising: at least a third ancillary electrode, the third ancillary electrode being electrically connected to a selected one of the connection tabs, the third ancillary electrode having an ampacity less than or substantially equal to about 0.1 amperes whereby the third ancillary electrode is operative as a voltage test terminal for the panel.
30. The photovoltaic panel of claim 29 wherein the module has a radiation collection surface thereon, the third ancillary electrode being accessible from the radiation collection surface for the module.
31. The photovoltaic panel of claim 29 wherein the module has a radiation collection surface thereon, the panel further comprising a frame engaging the photovoltaic module, a surface of the frame being adjacent to the radiation collection surface of the module, the frame having an access opening formed into the surface of the frame adjacent to the radiation collection surface, the third ancillary electrode being disposed within the access opening in the frame.
32. The photovoltaic panel of claim 31 further comprising: an insulating member comprising an insert sized for receipt within the access opening in the frame.
33. The photovoltaic panel of claim 25 further comprising: at least a third ancillary electrode, the third ancillary electrode being electrically connected to a selected one of the connection tabs, the third ancillary electrode having an ampacity greater than about 0.1 amperes whereby the third ancillary electrode is operative to carry power when connected to an electrical destination.
34. The photovoltaic panel of claim 33 further comprising: an insulating member disposed over the third ancillary electrode .
35. The photovoltaic panel of claim 27 further comprising: at least a third ancillary electrode, the third ancillary electrode being electrically connected to a selected one of the connection tabs, the third ancillary electrode having an ampacity less than or substantially equal to about 0.001 amperes whereby the third ancillary electrode is operative as a voltage test terminal for the panel.
36. The photovoltaic panel of claim 35 wherein the module has a radiation collection surface thereon, the third ancillary electrode being accessible from the radiation collection surface for the module.
37. The photovoltaic panel of claim 35 wherein the module has a radiation collection surface thereon, the panel further comprising a frame engaging the photovoltaic module, a surface of the frame being adjacent to the radiation collection surface of the module, the frame having an access opening formed into the surface of the frame adjacent to the radiation collection surface, the third ancillary electrode being disposed within the access opening in the frame.
38. The photovoltaic panel of claim 37 further comprising: an insulating member comprising an insert sized for receipt within the access opening in the frame.
39. The photovoltaic panel of claim 27 further comprising: at least a third ancillary electrode, the third ancillary electrode being electrically connected to a selected one of the connection tabs, the third ancillary electrode having an ampacity greater than about 0.001 amperes whereby the third ancillary electrode is operative to carry power when connected to an electrical destination.
40. The photovoltaic panel of claim 39 further comprising: an insulating member disposed over the third ancillary electrode.
41. The photovoltaic panel of claims 23 or 24 wherein the photovoltaic cells are fabricated from crystalline silicon, and wherein at least one of the ancillary electrodes has an ampacity greater than about 0.1 amperes whereby that ancillary electrode is operative to carry power when it is connected to an electrical destination.
42. The photovoltaic panel of claim 41 further comprising: an insulating member disposed over the ancillary electrode having the ampacity greater than about 0.1 amperes .
43. The photovoltaic panel of claim 41 further comprising: at least a third ancillary electrode, the third ancillary electrode being electrically connected to a selected one of the connection tabs, the third ancillary electrode having an ampacity greater than about 0.1 amperes whereby the third ancillary electrode is operative to carry power when connected to an electrical destination.
44. The photovoltaic panel of claims 23 or 24 wherein the photovoltaic cells are fabricated from thin film photovoltaic conversion material, and wherein at least one of the ancillary electrodes has an ampacity greater than about 0.001 amperes whereby that ancillary electrode is operative to carry power when it is connected to an electrical destination.
45. The photovoltaic panel of claim 44 further comprising: an insulating member disposed over each of the first and the second ancillary electrodes.
46. The photovoltaic panel of claim 44 further comprising: at least a third ancillary electrode, the third ancillary electrode being electrically connected to a selected one of the connection tabs, the third ancillary electrode having an ampacity greater than about 0.001 amperes whereby the third ancillary electrode is operative to carry power when connected to an electrical destination.
47. The photovoltaic panel of claims 23 or 24 wherein the photovoltaic cells are fabricated from crystalline silicon, and wherein at least one of the ancillary electrodes has an ampacity less than or substantially equal to about 0.1 amperes whereby that ancillary electrode is operative as a voltage test terminal for the panel.
48. The photovoltaic panel of claim 47 further comprising: at least a third ancillary electrode, the third ancillary electrode being electrically connected to a selected one of the connection tabs, the third ancillary electrode having an ampacity greater than about 0.1 amperes whereby the third ancillary electrode is operative to carry power when connected to an electrical destination.
49. The photovoltaic panel of claims 23 or 24 wherein the photovoltaic cells are fabricated from fabricated from thin film photovoltaic conversion material, and wherein at least one of the ancillary electrodes has an ampacity less than or substantially equal to about 0.001 amperes whereby that ancillary electrode is operative as a voltage test terminal for the panel.
50. The photovoltaic panel of claim 49 further comprising: at least a third ancillary electrode, the third ancillary electrode being electrically connected to a selected one of the connection tabs, the third ancillary electrode having an ampacity greater than about 0.001 amperes whereby the third ancillary electrode is operative to carry power when connected to an electrical destination.
51. The photovoltaic panel of claims 23 or 24 wherein the photovoltaic cells are fabricated from crystalline silicon, further comprising: at least a third and a fourth ancillary electrode, each of the third and fourth ancillary electrodes being electrically connected to a respective one of the connection tabs, each of the third and fourth ancillary electrodes having an ampacity greater than about 0.1 amperes whereby each of the third and fourth ancillary electrodes is operative to carry power when connected to an electrical destination.
52. The photovoltaic panel of claim 51 further comprising: an insulating member disposed over each of the third and fourth ancillary electrodes.
53. The photovoltaic panel of claims 23 or 24 wherein the photovoltaic cells are fabricated from crystalline silicon, and further comprising: at least a third and a fourth ancillary electrode, each of the third and fourth ancillary electrodes being electrically connected to a respective one of the connection tabs, each of the third and fourth ancillary electrodes having an ampacity greater than about 0.001 amperes whereby each of the third and fourth ancillary electrodes is operative to carry power when connected to an electrical destination .
54. The photovoltaic panel of claim 53 further comprising: an insulating member disposed over each of the third and fourth ancillary electrodes.
55. A photovoltaic panel comprising: a photovoltaic module including a plurality of electrically interconnected photovoltaic cells terminating in a first connection tab of a first polarity and a second connection tab of a second polarity, and a first primary electrode and a second primary electrode, each primary electrode being electrically connected to a respective one of the connection tabs; and further comprising: a first and a second ancillary electrode, both ancillary electrodes being electrically connected to the same connection tab.
56. The photovoltaic panel of claim 55 further comprising: a frame engaging the photovoltaic module, each of the first and second ancillary electrodes being mounted to the frame.
57. The photovoltaic panel of claims 55 or 56 wherein the photovoltaic cells are fabricated from crystalline silicon, and wherein the first and the second ancillary electrode each has an ampacity greater than about 0.1 amperes whereby each ancillary electrode is operative to carry power when it is connected to an electrical destination.
58. The photovoltaic panel of claim 57 further comprising: an insulating member disposed over each of the first and the second ancillary electrodes.
59. The photovoltaic panel of claims 55 or 56 wherein the photovoltaic cells are fabricated from thin film photovoltaic conversion material, and wherein the first and the second ancillary electrode each has an ampacity greater than about 0.001 amperes whereby each ancillary electrode is operative to carry power when it is connected to an electrical destination.
60. The photovoltaic panel of claim 59 further comprising: an insulating member disposed over each of the first and the second ancillary electrodes.
61. The photovoltaic panel of claim 57 further comprising: at least a third ancillary electrode, the third ancillary electrode being electrically connected to a selected one of the connection tabs, the third ancillary electrode having an ampacity less than or substantially equal to about 0.1 amperes whereby the third ancillary electrode is operative as a voltage test terminal for the panel.
62. The photovoltaic panel of claim 57 further comprising: at least a third ancillary electrode, the third ancillary electrode being electrically connected to a selected one of the connection tabs, the third ancillary electrode having an ampacity greater than about 0.1 amperes whereby the third ancillary electrode is operative to carry power when connected to an electrical destination.
63. The photovoltaic panel of claim 59 further comprising: at least a third ancillary electrode, the third ancillary electrode being electrically connected to a selected one of the connection tabs, the third ancillary electrode having an ampacity less than or substantially equal to about 0.001 amperes whereby the third ancillary electrode is operative as a voltage test terminal for the panel.
64. The photovoltaic panel of claim 59 further comprising: at least a third ancillary electrode, the third ancillary electrode being electrically connected to a selected one of the connection tabs, the third ancillary electrode having an ampacity greater than about 0.001 amperes whereby the third ancillary electrode is operative to carry power when connected to an electrical destination.
65. The photovoltaic panel of claims 55 or 56 wherein the photovoltaic cells are fabricated from crystalline silicon, and wherein at least one of the ancillary electrodes has an ampacity greater than about 0.1 amperes whereby that ancillary electrode is operative to carry power when it is connected to an electrical destination.
66. The photovoltaic panel of claim 65 further comprising: an insulating member disposed over the ancillary electrode having the ampacity greater than about 0.1 amperes .
67. The photovoltaic panel of claim 65 further comprising: at least a third ancillary electrode, the third ancillary electrode being electrically connected to a selected one of the connection tabs, the third ancillary electrode having an ampacity greater than about 0.1 amperes whereby the third ancillary electrode is operative to carry power when connected to an electrical destination.
68. The photovoltaic panel of claims wherein the photovoltaic cells are fabricated from thin film photovoltaic conversion material, and wherein at least one of the ancillary electrodes has an ampacity greater than about 0.001 amperes whereby that ancillary electrode is operative to carry power when it is connected to an electrical destination.
69. The photovoltaic panel of claim 68 further comprising: an insulating member disposed over each of the first and the second ancillary electrodes.
70. The photovoltaic panel of claim 68 further comprising: at least a third ancillary electrode, the third ancillary electrode being electrically connected to a selected one of the connection tabs, the third ancillary electrode having an ampacity greater than about 0.001 amperes whereby the third ancillary electrode is operative to carry power when connected to an electrical destination.
71. The photovoltaic panel of claims 55 or 56 wherein the photovoltaic cells are fabricated from crystalline silicon, and wherein at least one of the ancillary electrodes has an ampacity less than or substantially equal to about 0.1 amperes whereby that ancillary electrode is operative as a voltage test terminal for the panel.
72. The photovoltaic panel of claim 71 further comprising: at least a third ancillary electrode, the third ancillary electrode being electrically connected to a selected one of the connection tabs, the third ancillary electrode having an ampacity greater than about 0.1 amperes whereby the third ancillary electrode is operative to carry power when connected to an electrical destination.
73. The photovoltaic panel of claims 55 or 56 wherein the photovoltaic cells are fabricated from thin film photovoltaic conversion material, and wherein at least one of the ancillary electrodes has an ampacity less than or substantially equal to about 0.001 amperes whereby that ancillary electrode is operative as a voltage test terminal for the panel.
74. The photovoltaic panel of claim 73 further comprising: at least a third ancillary electrode, the third ancillary electrode being electrically connected to a selected one of the connection tabs, the third ancillary electrode having an ampacity greater than about 0.001 amperes whereby the third ancillary electrode is operative to carry power when connected to an electrical destination.
75. The photovoltaic panel of claims 55 or 56 wherein the photovoltaic cells are fabricated from crystalline silicon, and further comprising: at least a third and a fourth ancillary electrode, each of the third and fourth ancillary electrodes being electrically connected to a respective one of the connection tabs, each of the third and fourth ancillary electrodes having an ampacity greater than about 0.1 amperes whereby each of the third and fourth ancillary electrodes is operative to carry power when connected to an electrical destination .
76. The photovoltaic panel of claim 75 further comprising: an insulating member disposed over each of the third and fourth ancillary electrodes.
77. The photovoltaic panel of claims 55 or 56 wherein the photovoltaic cells are fabricated from crystalline silicon, and further comprising: at least a third and a fourth ancillary electrode, each of the third and fourth ancillary electrodes being electrically connected to a respective one of the connection tabs, each of the third and fourth ancillary electrodes having an ampacity greater than about 0.001 amperes whereby each of the third and fourth ancillary electrodes is operative to carry power when connected to an electrical destination .
78. The photovoltaic panel of claim 77 further comprising: an insulating member disposed over each of the third and fourth ancillary electrodes.
79. A photovoltaic array comprising: a first and a second photovoltaic panel, the first and the second panels being physically spaced apart from each other, each of the first and second panels comprising: a photovoltaic module including a plurality of electrically interconnected photovoltaic cells terminating in a first connection tab of a first polarity and a second connection tab of a second polarity; and a first primary electrode and a second primary electrode, each primary electrode being electrically connected to a respective one of the connection tabs; wherein the first panel further comprises an ancillary electrode electrically connected to the first connection tab of the first panel, the ancillary electrode on the first panel having an ampacity greater than a predetermined threshold whereby that ancillary electrode is operative to carry power when it is connected to an electrical destination, and the ancillary electrode on the first panel is electrically connected to a one of the connection tabs on the second panel, both the primary electrode and the ancillary electrode connected thereto are directly connectible to and simultaneously capable of transmitting power to a primary or an ancillary electrode on another panel.
80. The photovoltaic array of claim 79 wherein the ancillary electrode of the first panel is electrically connected to the second connection tab of the second panel, whereby the first and the second panels are electrically connected in series.
81. The photovoltaic array of claim 79 wherein the second panel further comprises an ancillary electrode electrically connected to the second connection tab of the second panel, the ancillary electrode on the second panel having an ampacity greater than a predetermined threshold whereby that ancillary electrode is operative to carry power when it is connected to an electrical destination, and the ancillary electrode of the first panel is electrically connected to the ancillary electrode of the second panel, whereby the first and the second panels are electrically connected in series.
82. The photovoltaic array of claim 79 wherein the ancillary electrode on the first panel is electrically connected to the first connection tab of the second panel, whereby the first and the second panels are electrically connected in parallel.
83. The photovoltaic array of claim 79 wherein the second panel further comprises an ancillary electrode electrically connected to the first connection tab of the second panel, the ancillary electrode on the second panel having an ampacity greater than a predetermined threshold whereby that ancillary electrode is operative to carry power when it is connected to an electrical destination, and the ancillary electrode of the first panel is electrically connected to the ancillary electrode of the second panel, whereby the first and the second panels are electrically connected in parallel.
84. The photovoltaic array of claim 79 wherein the first panel further comprises a second ancillary electrode electrically connected to the second connection tab of the first panel, the second ancillary electrode on the first panel having an ampacity greater than a predetermined threshold whereby that second ancillary electrode is operative to carry power when it is connected to an electrical destination, and wherein the second panel further comprises a first and a second ancillary electrode, each of the first and second ancillary electrodes on the second panel being respectively connected to the first and the second connection tabs on the second panel, the first and the second ancillary electrodes on the second panel each having an ampacity greater than a predetermined threshold whereby that ancillary electrode is operative to carry power when it is connected to an electrical destination, and wherein the first ancillary electrode of the first panel is electrically connected to the second ancillary electrode of the second panel, whereby the first and the second panels are electrically connected in series.
85. The photovoltaic array of claim 79 wherein the first panel further comprises a second ancillary electrode electrically connected to the second connection tab of the first panel, the second ancillary electrode on the first panel having an ampacity greater than a predetermined threshold whereby that second ancillary electrode is operative to carry power when it is connected to an electrical destination, and wherein the second panel further comprises a first and a second ancillary electrode, each of the first and second ancillary electrodes on the second panel being respectively connected to the first and the second connection tabs on the second panel, the first and the second ancillary electrodes on the second panel each having an ampacity greater than a predetermined threshold whereby that ancillary electrode is operative to carry power when it is connected to an electrical destination, and wherein the first ancillary electrode of the first panel is electrically connected to the first ancillary electrode of the second panel, whereby the first and the second panels are electrically connected in parallel.
86. A photovoltaic array comprising: a first and a second photovoltaic panel, each panel comprising: a photovoltaic module including a plurality of electrically interconnected photovoltaic cells terminating in a first connection tab of a first polarity and a second connection tab of a second polarity; and a first primary electrode and a second primary electrode, each primary electrode being electrically connected to a respective one of the connection tabs; the first and the second panels are physically joined with each other with a primary electrode of a first polarity on the first panel being juxtaposed with the primary electrode of the second polarity on the second panel; wherein the first panel further comprises: an ancillary electrode electrically connected to the one of the connection tabs of the first panel, the ancillary electrode on the first panel having an ampacity greater than a predetermined threshold whereby that ancillary electrode is operative to carry power when it is connected to an electrical destination, and wherein the array further comprises: an insulating member disposed between the juxtaposed primary electrode of a first polarity on the first panel and the primary electrode of the second polarity on the second panel thereby electrically isolating the primary electrodes on the first and second panels from each other; the ancillary electrode of the first panel being electrically connected to an electrical destination other than a connection tab on the second panel.
87. The photovoltaic array of claim 86 wherein the second panel further comprises: an ancillary electrode electrically connected to the one of the connection tabs of the second panel, the ancillary electrode on the second panel having an ampacity greater than a predetermined threshold whereby that ancillary electrode is operative to carry power when it is connected to an electrical destination, and wherein the array further comprises: the ancillary electrode of the second panel being electrically connected to an electrical destination other than a connection tab on the first panel.
88. The photovoltaic array of claim 87 wherein the insulating member is sized for receipt over the ancillary electrode on either the first or the second panel .
89. The photovoltaic array of claim 86 wherein the insulating member is sized for receipt over the ancillary electrode on the first panel
90. A photovoltaic array comprising: a first and a second photovoltaic panel, the first and the second panels being physically spaced apart from each other, each panel comprising: a photovoltaic module including a plurality of electrically interconnected photovoltaic cells terminating in a first connection tab of a first polarity and a second connection tab of a second polarity, a first primary electrode and a second primary electrode, each primary electrode being electrically connected to a respective one of the connection tabs; each panel having a first and a second ancillary electrode, each ancillary electrode being electrically connected to a respective one of the connection tabs on that panel, each ancillary electrode having an ampacity greater than a predetermined threshold whereby the ancillary electrodes are operative to carry power when it is connected to an electrical destination; and wherein the first ancillary electrode of the first panel is electrically connected to the second ancillary electrode of the second panel, whereby the first and the second panels are electrically connected in series .
91. A photovoltaic array comprising: a first and a second photovoltaic panel, the first and the second panels being physically spaced apart from each other, each panel comprising: a photovoltaic module including a plurality of electrically interconnected photovoltaic cells terminating in a first connection tab of a first polarity and a second connection tab of a second polarity, a first primary electrode and a second primary electrode, each primary electrode being electrically connected to a respective one of the connection tabs; each panel having a first and a second ancillary electrode, each ancillary electrode being electrically connected to a respective one of the connection tabs on that panel, each ancillary electrode having an ampacity greater than a predetermined threshold whereby the ancillary electrodes are operative to carry power when it is connected to an electrical destination; and wherein the first ancillary electrode of the first panel is electrically connected to the first ancillary electrode of the second panel, whereby the first and the second panels are electrically connected in parallel .
92. A photovoltaic array comprising: a first and a second photovoltaic panel, each panel comprising: a photovoltaic module including a plurality of electrically interconnected photovoltaic cells terminating in a first connection tab of a first polarity and a second connection tab of a second polarity, a first primary electrode and a second primary electrode, each primary electrode being electrically connected to a respective one of the connection tabs; each panel having a first and a second ancillary electrode, each ancillary electrode being electrically connected to a respective one of the connection tabs on that panel, each ancillary electrode having an ampacity greater than a predetermined threshold whereby the ancillary electrodes are operative to carry power when it is connected to an electrical destination; the first and the second panels are physically joined with each other with a primary electrode of a first polarity on the first panel being juxtaposed with the primary electrode of the second polarity on the second panel, wherein the array further comprises: an insulating member disposed between the juxtaposed primary electrode of a first polarity on the first panel and the primary electrode of the second polarity on the second panel thereby electrically isolating the primary electrodes on the first and second panels from each other; at least one of the ancillary electrodes of the first panel is electrically connected to an electrical destination other than an ancillary electrode of the second panel .
93. A photovoltaic array of claim 92 wherein at least one of the ancillary electrodes of the second panel is electrically connected to an electrical destination other than ancillary electrode of the first panel.
94. The photovoltaic array of claim 92 wherein the insulating member is sized for receipt over one of the ancillary electrodes on the first or second panel.
95. A photovoltaic kit comprising: at least one photovoltaic panel, the panel itself comprising: a photovoltaic module including a plurality of electrically interconnected photovoltaic cells terminating in a first connection tab of a first polarity and a second connection tab of a second polarity; a first primary electrode and a second primary electrode, each primary electrode being electrically connected to a respective one of the connection tabs; and an ancillary electrode electrically connected to one of the connection tabs,
both the primary electrode and the ancillary electrode connected thereto are directly connectible to and simultaneously capable of transmitting power to a primary or an ancillary electrode on another panel; and at least one cable useful to connect the ancillary electrode to an electrical destination.
96. A photovoltaic kit comprising: at least one photovoltaic panel, the panel itself comprising: a photovoltaic module including a plurality of electrically interconnected photovoltaic cells terminating in a first connection tab of a first polarity and a second connection tab of a second polarity, and a first primary electrode and a second primary electrode, each primary electrode being electrically connected to a respective one of the connection tabs; and a first and a second ancillary electrode, each ancillary electrode being electrically connected to a connection tab; and at least one cable useful to connect the ancillary electrode to an electrical destination.
97. The photovoltaic panel of claim 96 wherein further comprising: a frame engaging the photovoltaic module, each of the first and second ancillary electrodes being mounted to the frame.
98. A photovoltaic kit comprising: at least one photovoltaic panel, the panel itself comprising: a photovoltaic module including a plurality of electrically interconnected photovoltaic cells terminating in a first connection tab of a first polarity and a second connection tab of a second polarity, and a first primary electrode and a second primary electrode, each primary electrode being electrically connected to a respective one of the connection tabs; and a first and a second ancillary electrode, each ancillary electrode being electrically connected to a respective one of the connection tabs; and at least one cable useful to connect the ancillary electrode to an electrical destination.
99. The kit of claim 98 wherein the photovoltaic panel further comprises: a frame engaging the photovoltaic module, each of the first and second ancillary electrodes being mounted to the frame.
100. A photovoltaic kit comprising: at least one photovoltaic panel, the panel itself comprising: a photovoltaic module including a plurality of electrically interconnected photovoltaic cells terminating in a first connection tab of a first polarity and a second connection tab of a second polarity, and a first primary electrode and a second primary electrode, each primary electrode being electrically connected to a respective one of the connection tabs; and a first and a second ancillary electrode, both ancillary electrodes being electrically connected to the same connection tab; and at least one cable useful to connect the ancillary electrode to an electrical destination.
101. The kit of claim 100 wherein the photovoltaic panel further comprises: a frame engaging the photovoltaic module, each of the first and second ancillary electrodes being mounted to the frame.
102. A method for forming a photovoltaic array comprising at least a first and a second photovoltaic panel, each panel itself comprising: a photovoltaic module including a plurality of electrically interconnected photovoltaic cells terminating in a first connection tab of a first polarity and a second connection tab of a second polarity; and a first primary electrode and a second primary electrode, each primary electrode being electrically connected to a respective one of the connection tabs; the first panel further comprising an ancillary electrode electrically connected to the first connection tab of the first panel, the ancillary electrode on the first panel having an ampacity greater than a predetermined threshold whereby that ancillary electrode is operative to carry power when it is connected to an electrical destination, the method comprising the steps of: a) disposing the first and the second photovoltaic panels on a support member in physically spaced apart relationship with each other; and b) electrically connecting the ancillary electrode of the first panel to a connection tab of the second panel.
103. The method of claim 102 wherein the ancillary electrode of the first panel is electrically connected to the second connection tab of the second panel, whereby the first and the second panels are electrically connected in series.
104. The method of claim 102 wherein the second panel further comprises an ancillary electrode electrically connected to the second connection tab of the second panel, the ancillary electrode on the second panel having an ampacity greater than a predetermined threshold whereby that ancillary electrode is operative to carry power when it is connected to an electrical destination, and wherein the ancillary electrode of the first panel is electrically connected to the ancillary electrode of the second panel, whereby the first and the second panels are electrically connected in series .
105. The method of claim 104 wherein the ancillary electrode on the first panel is electrically connected to the first connection tab of the second panel, whereby the first and the second panels are electrically connected in parallel.
106. The method of claim 102 wherein the second panel further comprises an ancillary electrode electrically connected to the first connection tab of the second panel, the ancillary electrode on the second panel having an ampacity greater than a predetermined threshold whereby that ancillary electrode is operative to carry power when it is connected to an electrical destination, and wherein the ancillary electrode of the first panel is electrically connected to the ancillary electrode of the second panel, whereby the first and the second panels are electrically connected in parallel .
107. The method of claim 102 wherein the first panel further comprises a second ancillary electrode electrically connected to the second connection tab of the first panel, the second ancillary electrode on the first panel having an ampacity greater than a predetermined threshold whereby that second ancillary electrode is operative to carry power when it is connected to an electrical destination, and wherein the second panel further comprises a first and a second ancillary electrode, each of the first and second ancillary electrodes on the second panel being respectively connected to the first and the second connection tabs on the second panel, the first and the second ancillary electrodes on the second panel each having an ampacity greater than a predetermined threshold whereby that ancillary electrode is operative to carry power when it is connected to an electrical destination, and
wherein the first ancillary electrode of the first panel is electrically connected to the second ancillary electrode of the second panel, whereby the first and the second panels are electrically connected in series .
108. The method of claim 102 wherein the first panel further comprises a second ancillary electrode electrically connected to the second connection tab of the first panel, the second ancillary electrode on the first panel having an ampacity greater than a predetermined threshold whereby that second ancillary electrode is operative to carry power when it is connected to an electrical destination, and wherein the second panel further comprises a first and a second ancillary electrode, each of the first and second ancillary electrodes on the second panel being respectively connected to the first and the second connection tabs on the second panel, the first and the second ancillary electrodes on the second panel each having an ampacity greater than a predetermined threshold whereby that ancillary electrode is operative to carry power when it is connected to an electrical destination, and wherein the first ancillary electrode of the first panel is electrically connected to the first ancillary electrode of the second panel, whereby the first and the second panels are electrically connected in parallel .
109. A method for mounting a photovoltaic array comprising at least a first and a second photovoltaic panel, each panel itself comprising: a photovoltaic module including a plurality of electrically interconnected photovoltaic cells terminating in a first connection tab of a first polarity and a second connection tab of a second polarity; and a first primary electrode and a second primary electrode, each primary electrode being electrically connected to a respective one of the connection tabs; the first panel further comprising an ancillary electrode electrically connected to the one of the connection tabs of the first panel, the ancillary electrode on the first panel having an ampacity greater than a predetermined threshold whereby that ancillary electrode is operative to carry power when it is connected to an electrical destination, the method comprising the steps of: a) disposing the first and the second photovoltaic panel on a support member in physical contact with each other such that the primary electrode of a first polarity on the first panel is juxtaposed with the primary electrode of the second polarity on the second panel, b) placing an insulating member to electrically isolate the primary electrodes on the first and second panels from each other; and c) electrically connecting the first ancillary electrode of the first panel to an electrical destination other than the second ancillary electrode of the second panel.
110. The method of claim 109 wherein the ancillary electrode on the first panel has an insulating member disposed thereover, the method further comprising the steps of: prior to step b) , removing the insulating member disposed over the ancillary electrode and using the removed insulating member for disposition between the primary electrodes on the first and second panels.
PCT/US2009/053666 2008-08-13 2009-08-13 Photovoltaic panel having one or more ancillary electrodes WO2010019752A2 (en)

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