WO2018022655A1 - Traitements de bord de modules pv pour interconnexions de module à module - Google Patents

Traitements de bord de modules pv pour interconnexions de module à module Download PDF

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Publication number
WO2018022655A1
WO2018022655A1 PCT/US2017/043788 US2017043788W WO2018022655A1 WO 2018022655 A1 WO2018022655 A1 WO 2018022655A1 US 2017043788 W US2017043788 W US 2017043788W WO 2018022655 A1 WO2018022655 A1 WO 2018022655A1
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WO
WIPO (PCT)
Prior art keywords
module
support structure
laminated support
modules
backside
Prior art date
Application number
PCT/US2017/043788
Other languages
English (en)
Inventor
Dominico Julian
Todd A. Pelman
Robert Baikie
Thomas P. Hunt
Garrison J. Buchanan
Leo F. Casey
Scott W. ALDOUS
Philipp H. Schmaelzle
William J. Shields
Raphael J. Feldman
Justin S. Hyde
Duncan W. Harwood
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X Development Llc
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 X Development Llc filed Critical X Development Llc
Publication of WO2018022655A1 publication Critical patent/WO2018022655A1/fr

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Classifications

    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01L—SEMICONDUCTOR DEVICES NOT COVERED BY CLASS H10
    • H01L31/00—Semiconductor devices sensitive to infrared radiation, light, electromagnetic radiation of shorter wavelength or corpuscular radiation and specially adapted either for the conversion of the energy of such radiation into electrical energy or for the control of electrical energy by such radiation; Processes or apparatus specially adapted for the manufacture or treatment thereof or of parts thereof; Details thereof
    • H01L31/04—Semiconductor devices sensitive to infrared radiation, light, electromagnetic radiation of shorter wavelength or corpuscular radiation and specially adapted either for the conversion of the energy of such radiation into electrical energy or for the control of electrical energy by such radiation; Processes or apparatus specially adapted for the manufacture or treatment thereof or of parts thereof; Details thereof adapted as photovoltaic [PV] conversion devices
    • H01L31/042—PV modules or arrays of single PV cells
    • H01L31/05—Electrical interconnection means between PV cells inside the PV module, e.g. series connection of PV cells
    • H01L31/0504—Electrical interconnection means between PV cells inside the PV module, e.g. series connection of PV cells specially adapted for series or parallel connection of solar cells in a module
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01L—SEMICONDUCTOR DEVICES NOT COVERED BY CLASS H10
    • H01L31/00—Semiconductor devices sensitive to infrared radiation, light, electromagnetic radiation of shorter wavelength or corpuscular radiation and specially adapted either for the conversion of the energy of such radiation into electrical energy or for the control of electrical energy by such radiation; Processes or apparatus specially adapted for the manufacture or treatment thereof or of parts thereof; Details thereof
    • H01L31/04—Semiconductor devices sensitive to infrared radiation, light, electromagnetic radiation of shorter wavelength or corpuscular radiation and specially adapted either for the conversion of the energy of such radiation into electrical energy or for the control of electrical energy by such radiation; Processes or apparatus specially adapted for the manufacture or treatment thereof or of parts thereof; Details thereof adapted as photovoltaic [PV] conversion devices
    • H01L31/042—PV modules or arrays of single PV cells
    • H01L31/048—Encapsulation of modules
    • H—ELECTRICITY
    • H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
    • H02S—GENERATION OF ELECTRIC POWER BY CONVERSION OF INFRARED RADIATION, VISIBLE LIGHT OR ULTRAVIOLET LIGHT, e.g. USING PHOTOVOLTAIC [PV] MODULES
    • H02S20/00—Supporting structures for PV modules
    • H—ELECTRICITY
    • H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
    • H02S—GENERATION OF ELECTRIC POWER BY CONVERSION OF INFRARED RADIATION, VISIBLE LIGHT OR ULTRAVIOLET LIGHT, e.g. USING PHOTOVOLTAIC [PV] MODULES
    • H02S30/00—Structural details of PV modules other than those related to light conversion
    • H02S30/20—Collapsible or foldable PV modules
    • H—ELECTRICITY
    • H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
    • H02S—GENERATION OF ELECTRIC POWER BY CONVERSION OF INFRARED RADIATION, VISIBLE LIGHT OR ULTRAVIOLET LIGHT, e.g. USING PHOTOVOLTAIC [PV] MODULES
    • H02S40/00—Components or accessories in combination with PV modules, not provided for in groups H02S10/00 - H02S30/00
    • H02S40/30—Electrical components
    • H02S40/38—Energy storage means, e.g. batteries, structurally associated with PV modules
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
    • Y02E—REDUCTION OF GREENHOUSE GAS [GHG] EMISSIONS, RELATED TO ENERGY GENERATION, TRANSMISSION OR DISTRIBUTION
    • Y02E10/00—Energy generation through renewable energy sources
    • Y02E10/50—Photovoltaic [PV] energy
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
    • Y02E—REDUCTION OF GREENHOUSE GAS [GHG] EMISSIONS, RELATED TO ENERGY GENERATION, TRANSMISSION OR DISTRIBUTION
    • Y02E70/00—Other energy conversion or management systems reducing GHG emissions
    • Y02E70/30—Systems combining energy storage with energy generation of non-fossil origin
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
    • Y02P—CLIMATE CHANGE MITIGATION TECHNOLOGIES IN THE PRODUCTION OR PROCESSING OF GOODS
    • Y02P90/00—Enabling technologies with a potential contribution to greenhouse gas [GHG] emissions mitigation
    • Y02P90/50—Energy storage in industry with an added climate change mitigation effect

Definitions

  • This disclosure relates generally to solar power generation, and in particular but not exclusively, relates to floating solar power generation.
  • FIG. 1 is a block diagram illustrating components of a floating photovoltaic (“PV”) power generation system, in accordance with an embodiment of the disclosure.
  • FIG. 2 illustrates details of a mooring assembly and edge protection members of the floating PV power generation system, in accordance with an embodiment of the disclosure.
  • FIG. 3 is a functional block illustration of a PV module, in accordance with an embodiment of the disclosure.
  • FIG. 4A is a backside illustration of a floating PV module, in accordance with an embodiment of the disclosure.
  • FIG. 4B is profile illustration of a floating PV module, in accordance with an embodiment of the disclosure.
  • FIG. 5 is a plan view illustration of edge treatments for interconnections between PV modules, in accordance with an embodiment of the disclosure.
  • FIG. 6A is an exploded perspective view illustration of edge treatments for interconnections between PV modules, in accordance with an embodiment of the disclosure.
  • FIG. 6B is a side view illustration of edge treatments for interconnections between PV modules, in accordance with an embodiment of the disclosure.
  • FIGs. 7A and 7B illustrate different views of a slide zipper implementation of a continuous connector for module-to-module interconnections, in accordance with an embodiment of the disclosure.
  • FIG. 7C is a cross-sectional illustration of another slide zipper implementation of a continuous connector for module-to-module interconnections, in accordance with an embodiment of the disclosure.
  • FIG. 7D is a cross-sectional illustration of yet another slide zipper implementation of a continuous connector for module-to-module interconnections, in accordance with another embodiment of the disclosure.
  • FIGs. 8 illustrates a toothed zipper implementation of a continuous connector for module-to-module interconnections, in accordance with an embodiment of the disclosure.
  • FIG. 9A is a perspective illustration
  • FIG. 9B is a side view illustration, of a hot melt flap implementation of a continuous connector for module-to- module interconnections, in accordance with an embodiment of the disclosure.
  • FIG. 10 is a side view illustration of drainage features integrated into flexible flaps of an edge connection strip, in accordance with an embodiment of the disclosure.
  • FIG. 11 is a cross-sectional illustration of a demonstrative material stack of a laminated support structure of a PV module, in accordance with an embodiment of the disclosure.
  • PV photovoltaic
  • Embodiments of systems and apparatuses for photovoltaic (“PV") module edge treatments that facilitate module-to-module interconnections of PV modules into contiguous PV arrays are described herein.
  • numerous specific details are set forth to provide a thorough understanding of the embodiments.
  • One skilled in the relevant art will recognize, however, that the techniques described herein can be practiced without one or more of the specific details, or with other methods, components, materials, etc.
  • well-known structures, materials, or operations are not shown or described in detail to avoid obscuring certain aspects.
  • FIG. 1 is a block diagram illustrating components of a floating PV power generation system 100, in accordance with an embodiment of the disclosure.
  • the illustrated embodiment of PV power generation system 100 includes a PV array 105, edge protection members 110, a mooring assembly, a waterproof enclosure 120, an electrical interconnect assembly 125, a shore substation 130, and a shore power cable 135.
  • the illustrated embodiment of PV array 105 includes PV modules 140.
  • the illustrated embodiment of the mooring assembly includes mooring legs 145 and tensioning frame 150.
  • the illustrated embodiment of waterproof enclosure 120 houses a power combiner 155, a controller 160, a monitoring system 165, and communication adapters 170 and 175.
  • the illustrated embodiment of shore substation 130 includes a power converter 180, a controller 185, a monitoring system 190, and a communication adapter 195.
  • PV power generation system 100 is a solar power generation system that floats on waterbodies, such as reservoirs, lakes, or even protected coastal waters, though reservoirs may be the most suitable locations for a variety of reasons. For instance, reservoirs are typically shallow protected waterbodies. Floating solar power generation can compare favorably to land-based solar power generation systems because the surface of reservoirs often represents unused or underused space. In contrast, land-based solar power generation systems often compete with agricultural uses. Inherent attributes of a water based deployment can be leveraged for effective cooling that increases operational efficiency, extends expected service lifespans, and otherwise increases a return on investment ("ROI") for a commercial- scale power generation system. Additionally, floating solar power systems, such as PV power generation system 100, reduces water evaporation, which is an important benefit for many reservoirs.
  • ROI return on investment
  • PV power generation system 100 is moored in a waterbody 101 and coupled to deliver solar power to shore substation 130 disposed on a shore of waterbody 101.
  • Shore substation 130 may be coupled to deliver the solar power to a power grid or directly coupled to a local community or nearby facility (e.g., factory).
  • PV array 105 includes a number of PV modules 140 mechanically bound together to form a contiguous block or array of PV modules 140. While PV power generation system 100 can be deployed with a variable number of PV modules 140, which may each have a variety of different sizes, in one embodiment, each PV module 140 is 100 m long by 2 m wide and outputs 20 kW.
  • 50 PV modules 140 are connected to form a square contiguous PV array 105 having an overall power generation of 1 MW.
  • PV arrays 105 having larger or smaller individual PV modules 140 and/or having a greater or smaller number of connected PV modules 140 may be implemented.
  • FIG .1 illustrates just eight PV modules 140 included within PV array 105 for simplicity of illustration.
  • Each PV module 140 includes solar cells connected in series and/or parallel in one or more solar cell strings to generate solar power.
  • the solar cells are embedded within a laminated structure forming a sort of floating solar mat, which is compliant to folding or bending in response to wave action on a surface of waterbody 101.
  • each PV module 140 is formed from a series of smaller (e.g., 2m by lm) rigid PV panels (e.g., rigid glass solar panels) physically linked end-to-end. These rigid PV panels may be floated in sections on a rafting frame that includes one or more of the rigid PV panels.
  • Each rafting frame section may be flexibly linked end-to-end to another rafting frame section to form a longer column (or row), as represented by PV modules 140 in FIG. 1.
  • the periodic flexible connection points between each rafting section provides compliancy to wave action.
  • PV modules 140 use buoyancy to float on or near the surface of waterbody 101, extensive (and often expensive) support housings and infrastructure that typify land based solar power systems may not be necessary. By floating PV modules 140 on or near the surface of waterbody 101, PV modules 140 intimately contact the water for inherent heat dissipation and thermal cooling.
  • PV array 105 is held in place by the mooring assembly, which includes mooring legs 145 and tensioning frame 150.
  • Tensioning frame 150 maintains tension on PV array 105 to ensure the individual PV modules 140 do not tangle or otherwise experience compression that could damage PV modules 140.
  • Tensioning frame 150 is tethered to mooring legs 145 so that the overall PV array 105 maintains a desired location within waterbody 101.
  • Mooring legs 145 may be anchored to a bottom of the waterbody using various types of anchors (e.g., gravity anchor, embedment anchor, etc.). Each mooring leg 145 may include an anchor, rode, and a buoy.
  • the illustrated embodiment of PV power generation system 100 further includes edge protection members 110 that extend around multiple sides (e.g., all sides in the embodiment of FIG. 1) of PV array 105 to protect PV modules 140 from floating debris in waterbody 101.
  • edge protection members 110 are disposed between tensioning frame 150 and PV array 105 and also serve as a mechanical intermediary between tensioning frame 150 and PV array 105.
  • Edge protection members 110 protect the PV array 105 for external forces.
  • edge protection members 110 may serve as a wind block to prevent wind from getting under the edges of PV array 105 and lifting PV array 105 off the surface of the waterbody in high wind conditions.
  • Edge protection members 110 may also serve as a barrier against waves and current that could otherwise submerge, or partially submerge, PV array 105.
  • PV modules 140 are electrically coupled to the functional units housed within waterproof enclosure 120 via electrical interconnect assembly 125.
  • electrical interconnection assembly 125 is a waterproof wiring harness having individual power leads of variable length that match the variable distances between waterproof enclosure 120 and the connection points on PV modules 140.
  • a single wiring harness allows for a quick and organized deployment in the field.
  • the connection points on PV modules 140 may include pigtail connections or socket connections mounted to a junction box integrated into one end of PV modules 140.
  • Waterproof enclosure 120 houses power combiner 155, controller 160, monitoring system 165, and communication adapters 170 and 175. Waterproof enclosure 120 is placed in the waterbody and provides environmental protection to these internal components and in particular provides thermal heat dissipation to the surrounding water for the power electronics of power combiner 155.
  • waterproof enclosure is a metal enclosure (e.g., aluminum) that dissipates heat via convection to the surrounding water.
  • Power combiner 155 operates to combine the solar power generated by PV modules 140 to which it is connected.
  • Power combiner 155 may be implemented as a DC-to-DC power converter or DC-to-AC power inverter that steps up the voltage output from PV modules 140 for transport to shore substation 130 over shore power cable 135.
  • Monitoring system 165 and controller 160 are included within waterproof enclosure 120 to monitor electrical interconnect assembly 125 and shore power cable 135 for upstream and/or downstream fault conditions and other operational signals (e.g., power up or power down signals).
  • Monitoring system 165 may include an impedance monitor, voltage meter, or current meter that monitor the various conductors of electrical interconnect assembly 125 and shore power cable 135.
  • Monitoring system 190 and controller 185 within shore substation 130 may also perform similar monitoring and control functions over shore power cable 135.
  • Communication adapters 170, 175, and 195 provide data communications between shore substation 130 and PV modules 140.
  • shore substation 130 communicates with the components in waterproof enclosure 120 using optical communication protocols over an optical fiber bundled with shore power cable 135 while the components of waterproof enclosure 120 communicate with PV modules 140 using power line communication protocols over electrical interconnect assembly 125.
  • shore substation 130 includes power converter 180 that serves to step up the voltage of the power received over shore power cable 135 to a grid-level voltage. Power converter 180 also isolates the grid from any fault in PV power generation system 100.
  • Controller 160 choreographs the operation of the other functional elements within waterproof enclosure 120 while controller 185 choreographs the operation of the other functional elements within shore substation 130. Controllers 160 and 185 may be implemented as hardware logic (e.g., application specific integrated circuit, field programmable gate array, etc.), software or firmware instructions executing on a microcontroller, or a combination of both.
  • FIG. 2 illustrates details of a mooring assembly and edge protection members of a floating PV power generation system 200, in accordance with an embodiment of the disclosure.
  • PV power generation system 200 is one possible implementation of PV power generation system 100; however, certain components (e.g., waterproof enclosure, electrical interconnect assembly, shore power cable, shore substation, etc.) have been omitted from FIG. 2 so as not to clutter the drawing.
  • the illustrated embodiment of the mooring assembly includes a tensioning frame 205 and mooring legs 210.
  • the illustrated embodiment of tensioning frame 205 includes main lines 215, adjustable tensioning tethers 220, and boom ties 225.
  • the illustrated embodiment of the edge protection members includes floating boom sections 230 and boom-to-array connectors 235.
  • Tensioning frame 205 serves as a connection between mooring legs 210 and PV array 201. Tensioning frame 205 maintains tension on the PV modules of PV array 201 to prevent them from experiencing compression buckling or twisting that damages the PV modules. In the illustrated embodiment, tensioning frame 205 physically connects to floating boom sections 230 while boom-to-array connectors 235 translate the tensile force to PV array 201. In other embodiments, tensioning frame 205 may couple directly to PV array 201. In one embodiment, floating boom sections 230 are disposed along the outside perimeter of main lines 215 (not illustrated).
  • Mainlines 215 are support lines extending between mooring legs 210. Mainlines 215 form an arc between their connecting mooring legs 210, which maintains tension on boom ties 225.
  • Boom ties 225 extend between the mainlines 215 and floating boom sections 230 and serve to apply tensile forces around all sides of PV array 201. In the illustrated embodiment, boom ties 225 exerted a tensile force onto the outer sides of floating boom sections 230, which in turn translate the tensile force to PV array 201 via boom-to-array connectors 235. In other embodiments, boom ties 225 may connect directly to the PV modules by passing through or over floating boom sections 230.
  • Tensioning frame 205 may be formed as a rope rigging. For example, tensioning frame 205 may be fabricated of a low weight, stretch resistant, UV stable line. In one embodiment, tensioning frame 205 is a sheathed polymer line.
  • Adjustable tensioning tethers 220 provide a mechanism for adjusting the tension on tensioning frame 205 by adjusting their lengths.
  • each adjustable tensioning tether 220 may be implemented as a pulley assembly (e.g., block and tackle) with a lock, replaceable tethers of variable lengths, cinch-tight straps, or otherwise.
  • Adjustable tensioning tethers 220 allow the system to be deployed and interconnected while tensioning frame 205 is relaxed, then subsequently pulled taut to a desired tensile force to ensure PV array 201 is appropriately held in place. If tensioning frame 205 stretches after the initial deployment or a wind or wave storm, adjustable tensioning tethers 420 can readily be retightened as needed.
  • FIG. 3 is an illustration of a photovoltaic (“PV”) module 300, in accordance with an embodiment of the disclosure.
  • PV module 300 is one possible implementation of PV modules 140 illustrated in FIG. 1.
  • the illustrated embodiment of PV module 300 includes laminated support structure 305, solar cell strings 310 including solar cells 315, distributed circuitry 320, a junction box 325, power lines 330, signal lines 335, side edge treatments 340, end edge treatments 345, and output ports 350.
  • Solar cell strings 310 each includes a plurality of solar cells 315 electrically connected in series to generate solar power and a current in response to light incident upon a frontside of PV module 300.
  • PV module 300 may include any number of solar cell strings 310 each having any number of solar cells 315.
  • PV module 300 is well-suited for generating kilowatts of power and may be coupled with additional instances of PV module 300 for generating megawatts of power.
  • each solar cell 315 may be designed to output 10A @ IV
  • each solar cell string 310 may include between 50 and 1000 series connected solar cells 315 to generate 10A @ 1000V on output ports 350.
  • PV module 300 may be referred to as a "macro" module to indicate that the design of PV module 300 is well-suited for integrating large numbers (e.g., 100's or 1000's) of solar cells 315 into a single contiguous module or form factor for commercial scale power generation.
  • large numbers e.g., 100's or 1000's
  • the designs disclosed herein are also applicable to sub-kilowatt power generation applications.
  • PV module 300 encases solar cell strings
  • Laminated support structure 305 is fabricated as a multi-layer laminated structure that is durable, environmentally benign/inert, and relatively low cost when compared to conventional commercial grade solar power generating systems that include rigid housings and bulky support structures.
  • Laminated support structure 305 is a mat-like protective encasement that surrounds solar cell strings 310 and is compliant to rolling or folding. By embedding solar cell strings 310 in a laminated structure and floating them on a waterbody, expensive frames and mechanical support infrastructures can be avoided thereby facilitating simplified storage and quick deployment in a variety of environmental conditions.
  • PV module 300 may be deployed in horizontal, inclined, or vertical orientations.
  • PV module 300 can be temporarily deployed for short-term power generation (e.g., portable deployments, deployments in the event of unexpected power grid failure, deployments in the event of natural disasters, etc.), seasonal power generation, or long-term/quasi-permanent deployments (e.g., multi-year or multi-decade). PV module 300 can be tailored for deployment over land or water bodies (e.g., water reservoirs as discussed herein).
  • short-term power generation e.g., portable deployments, deployments in the event of unexpected power grid failure, deployments in the event of natural disasters, etc.
  • seasonal power generation e.g., or long-term/quasi-permanent deployments (e.g., multi-year or multi-decade).
  • PV module 300 can be tailored for deployment over land or water bodies (e.g., water reservoirs as discussed herein).
  • solar cells 315 are fabricated of monocrystalline silicon; however, in other embodiments, solar cells 315 may be implemented using polycrystalline silicon, thin film technologies, other semiconductor materials (e.g., gallium arsenide), or other solar cell technologies.
  • the illustrated embodiment of each solar cell string 310 includes a plurality of solar cells 315 coupled in series.
  • solar cell strings 310 may also include a group of parallel coupled solar cells 315 that are coupled in series with other parallel coupled solar cells 315.
  • the physical layout of these series coupled solar cells 315 may assume a variety of different patterns and routes.
  • a given solar cell string 310 may follow a straight path, a zigzag or serpentine path, a curved path, a spiral path, or trace out any number of a geometric patterns (e.g., concentric rectangles, etc.).
  • junction box 325 includes the centralized circuitry for managing operations of solar cell strings 310, collecting the solar power or current generated by solar cell strings 310, and outputting the solar power via output ports.
  • junction box 325 is a single enclosure that includes both power electronics, communication electronics, sensors, and control logic for PV module 300.
  • junction box 325 is a hermetically sealed enclosure that dissipates heat to its surrounding environment.
  • junction box 325 may represent multiple interconnected physical enclosures. Junction box 325 may be integrated into laminated support structure 305, mounted on a frontside, backside, or both sides of laminated support structure 305.
  • junction box 325 is disposed proximate to one end of PV module 300, though it may also be mounted along a side edge or other interior location.
  • PV module 300 also includes distributed circuitry 320 integrated within laminated support structure 305 and disposed throughout PV module 300.
  • Distributed circuitry 320 is coupled to solar cell strings 310 to selectively route current generated by solar cells 315 under the influence and control of a controller within junction box 325.
  • Distributed circuitry 320 may be coupled in various shunting paths across different portions of the various solar cell strings 310 to bypass failing sections of solar cells 315, to discharge and shutdown one or more solar cell strings 310 (or portions thereof), to respond to a failure or short circuit condition sensed within PV module 300, or otherwise.
  • distributed circuitry 320 includes switches, transistors, or fuses disposed in line with solar cells 315, which can be selectively activated/deactivated (e.g., energized, blown, etc) to open circuit or short circuit sections of solar cell strings 310.
  • Signal lines 335 are routed within laminated support structure 305 to interconnect distributed circuitry 320 to junction box 325.
  • Signal lines 335 may be parallel or serial datapaths, and may include one or more addressing lines, command lines, and/or sensing lines.
  • FIG. 3 illustrates signal lines 335 as distinct physical lines, in other embodiments, power line communications or even wireless communications may be used in place of signal lines 335.
  • Distributed circuitry 320 also serves to increase yield rates for PV modules 300.
  • PV module 300 may include 100's or even 1000's of solar cells 315. If every solar cell 315 is required to function in order to obtain a functioning PV module 300, the yield rate of PV modules 300 could be unviable for mass production.
  • distributed circuitry 320 includes inline fuses and switches dispersed throughout solar cell strings 310 to actively shunt or otherwise isolate non-functioning solar cells 315, or sections of solar cells 315, from the remaining functioning solar cells 315. By sensing and actively isolating non-functioning solar cells 315 from functioning solar cells 315, yield rates for PV modules 300 can be substantially increased.
  • PV module 300 includes edge treatments for physically interconnecting and mounting one or more PV modules 300 in a variety of environments to form a contiguous PV array.
  • the illustrated embodiment of PV module 300 includes side edge treatments 340 disposed along side edges of PV module 300 and end edge treatments 345 disposed along the shorter end edges of PV module 300.
  • side edge treatments 340 may be disposed along the shorter end edges while end edge treatments 345 may be disposed along the longer side edges.
  • Side edge treatments 340 represent edge connection strips and optional drainage features that facilitate mechanically connecting PV module 300 to other PV modules 300 to form a large PV array when deployed in the field.
  • Example edge connection strips may include a toothed zipper, a slide zipper, a hot melt flap, or otherwise.
  • Side edge treatments 340 may further include various drainage features such as contours (e.g., scallops or notches) or through holes to prevent pooling of rain or water and facilitate water drainage at the edges of a given PV module 300 even if positioned as an interior module of a large contiguous array of PV modules 300.
  • side edge treatments 340 facilitate quick deployment of large contiguous solar power systems of variable size and power ratings.
  • End edge treatments 345 facilitate mechanical mounting or holding of PV module 300 taut when unfolded or unrolled.
  • end edge treatments 345 may include loops, periodic grommet holes, clips, or other mounting locations for attaching various types of mounting tethers or tensioning systems to PV module 300 in a fully deployed orientation (e.g., unfolded, unrolled) while resisting environmental forces (e.g., wind, waves, etc.).
  • side edge treatments 340 and end edge treatments 345 facilitate variable size deployments, that can be mechanically and electrically interconnected into a contiguous system and which can be mounted in a variety of orientations (vertical, horizontal, inclined) and environments (e.g., land or water).
  • PV module 400 represents a demonstrative floating implementation of PV modules 300 illustrated in FIG. 3.
  • the illustrated embodiment of the backside (or underside) of PV module 400 includes laminated support structure 305, junction box 325, side edge treatments 340, end edge treatments 345, floatation pads 405, floatation pads 410, a cutout 415, and backside electrode 420 having sections 420A-C.
  • floatation pads 405 are disposed in a pattern beneath solar cell strings 310 to provide buoyancy to solar cell strings 310, distributed circuitry 320, and the bulk of laminated support structure 305.
  • FIG. 4A illustrates floatation pads 405 disposed in a periodic pattern that covers less than the entirety of the underside of laminated support structure 305. Partial coverage with uniform deployment ensures even floatation support while also allowing direct and substantially uniform exposure of water to the backside of laminated support structure 305 for even cooling.
  • Floatation pads 405 can assume a variety of different shapes, cross-sections, and patterns and may be fabricated from a variety of low density materials such as polystyrene foam, hollow high-density polyethylene (“HDPE”), inflatable bladders, etc.
  • low density materials such as polystyrene foam, hollow high-density polyethylene (“HDPE”), inflatable bladders, etc.
  • floatation pads 410 are disposed on the backside of laminated support structure adjacent to cutout 415.
  • Floatation pads 410 provide increased buoyancy localized around junction box 325 to carry its additional weight.
  • Floatation pads 410 may be fabricated of the same or different buoyant material as floatation pads 405.
  • Both floatation pads 405 and floatation pads 410 may be fixed to the underside of PV module 400 via mechanical fasteners (e.g., rivets, snaps, etc.), environmentally friendly adhesive, spot melting to form a bond, or otherwise.
  • junction box 325 is disposed in and/or over cutout 415 to expose at least a portion of a backside of junction box 325 to the water below.
  • Cutout 415 is a hole through laminated support structure 305 that provides good thermal contact between the water and junction box 325 for efficient cooling.
  • FIGs. 4A and 4B illustrate cutout 415 as disposed in an interior portion of laminated support structure 305 proximate to one end, in other embodiments, cutout 415 may be disposed directly along an edge or end of PV module 400.
  • PV module 400 also includes backside electrode 420 disposed along the backside of laminated support structure 305.
  • Backside electrode 420 is externally exposed to provide direct electrical contact with the external environment. In the case of the floating PV module 400, this means backside electrode 420 provides electrical contact to the water body over which PV module 400 is floating.
  • backside electrode 420 is coupled to junction box 325.
  • an impedance sensor is coupled to backside electrode 420 to monitor the impedance between backside electrode 420 and one or more internal connection points. If a low resistance or short circuit condition is identified, then it can be assumed that laminated support structure 305 has been breached by the water. In other words, backside electrode 420 is used to monitor for insulation failure or conduction to the water.
  • backside electrode 420 includes three sections 420A, 420B, and 420C that run along the side edges and up the middle for most, if not all, of the length of PV module 400.
  • Sections 420A and 420C that run along the perimeter edges also serve as a perimeter safety guard structure.
  • sections 420A and 420C operate to bend the electric field around the edges of PV module 400 to terminate back on sections 420A and C of backside electrode 420.
  • this guarding function contains current to the immediate vicinity around the edges of PV module 400 and serves as a low impedance electric field termination preventing the electric field from extending out from the module where it could have environmental or safety impacts.
  • Backside electrode 420 may be fabricated from a variety of conductive materials.
  • backside electrode 420 is a conductive metal tape.
  • backside electrode 420 is riveted through laminated support structure 305 to the frontside using metallic, or otherwise conductive rivets, to provide electrical insulation fault detection or conductivity to the frontside of laminated support structure 305.
  • conductive fasteners may be used to electrically connect backside electrode 420 to the frontside of laminated support structure 305.
  • resistive/impedance elements may be coupled in series or parallel with the conductive fasteners to control the resistance/impedance of the back-to-front interconnection.
  • FIG. 5 is a plan view illustrating details of side and end edge treatments of
  • each PV module 500 represents a possible implementation of PV modules 140, 300, or 400 discussed above.
  • the illustrated embodiment of each PV module 500 includes a laminated support structure 505 in which solar cells are encased, side edge treatments, end edge treatments, and a junction box 510.
  • the illustrated embodiments of side edge treatments include edge connection strips 515 each having a flexible flap 520 and a continuous connector 525.
  • the side edge treatments further include drainage features 530 and mechanical fasteners 535 disposed through elongated slots 540.
  • the illustrated embodiment of the end edge treatments include end connectors 545 and wiring clips 550.
  • Edge connection strips 515 extend along side edges of laminated support structure 505 for mechanically connecting a given PV module 500 to an adjacent PV module 500.
  • a continuous connector 525 is disposed along an edge of each edge connection strip 515 to provide a uniform connection along that side edge of PV module 500.
  • Edge connection strips 515 enable an array of PV modules 500 to be physically joined in the field and sequentially built up into a contiguous array of PV modules of a variable and selectable size.
  • Each edge connection strip 515 includes flexible flap 520 interposed between continuous connector 525 and laminated support structure 505.
  • Flexible flap 520 can provide a number of benefits.
  • Flexible flap 520 is fabricated of a material that is flexible (e.g., nylon mesh, plastic, etc.) and provides a measure of additional flex between adjacent laminated support structures 505 to provide an enhanced flex location between adjacent PV modules 500 that more easily flexes in response to environmental influences (e.g., waves, wind, debris, wildlife, etc.).
  • flexible flap 520 is formed of a material that is more flexible than laminated support structure 505, which can reduce stresses on each PV module 500 while deployed. Additionally, the additional flexibility provided by flexible flap 520 can ease deployment for field technicians.
  • the flexible nature of flexible flap 520 is integral to the operation of drainage features 530 (discussed in greater detail below).
  • FIGs. 6A and 6B are illustrations of different views of edge treatments including edge connection strip 515.
  • FIG. 6A is an exploded perspective illustration while FIG. 6B is a side illustration of the same.
  • flexible flap 520 has a first side that is secured to a side edge of laminated support structure 505.
  • Continuous connector 525 is disposed along a second opposite side of flexible flap 520.
  • edge connection strip 515 is secured to laminated support structure 505 via mechanical fasteners 535 that extend through holes 551 on flexible flap 520 and elongated slots 540 on laminated support structure 505.
  • Elongated slots 540 are elongated to ease alignment (e.g., provide "play") between edge connection strip 515 and laminated support structure 505 during assembly.
  • Mechanical fasteners 535 may be implemented using a variety of different fasteners including rivets, nuts and bolts, staples, crimp connectors, or otherwise.
  • Holes 551 and elongated slots 540 are periodically disposed between adjacent drainage features 530. These periodic mounting locations straddle drainage features 530 to allow flexible flap 520 to relax or sag proximate to the drainage features 515.
  • drainage features 530 are scallops notched into the side edge of laminated support structure 505. The scallops (notches) provide a path for water (e.g., rainwater) that accumulates proximate to edge connection strip 515 on the frontside of PV module 500 to drain through to the backside.
  • drainage features 530 may assume a variety of other shapes or contours (e.g., elliptical, rectangular, triangular, irregular, etc.) notched into the edge of laminated support structure 505.
  • drainage features 530 may be disposed adjacent or near to the side edge of laminated support structure 505 as a hole of various shapes, but not disposed directly on the side edge as illustrated.
  • FIGs. 6A and 6B illustrate a floating solar embodiment of PV module 500 that includes floatation pads 555 periodically disposed under laminated support structure 505.
  • floatation pads 555 are secured to laminated support structure 505 using the same mechanical fasteners 535 that secures edge connection strip 515 to laminated support structure 505.
  • floatation pads 555 may assume a variety of different shapes and sizes.
  • floatation pads 555 are replaced with a single floating mat layer with cutouts that allow water to reach the backside of laminated support structure 505 for thermal cooling.
  • floatation may be integrated into laminated support structure 505 itself.
  • PV module 500 further includes a backside electrode 560 attached to the backside of laminated support structure 505 also using the same mechanical fasteners 535.
  • backside electrode 560 is electrically conductive and exposed to the backside environment (e.g., waterbody) to provide an electrical ground to the backside environment.
  • mechanical fasteners 535 are fabricated of an electrically conductive material (e.g., metal) to electrically connect the backside of PV module 500 to its frontside.
  • resistive/impedance elements may be introduced into, or adjacent to, mechanical fasteners 535 to control the resistance/impedance of the back-to-front electrical interconnection.
  • edge connection strip 515 may include one or more conductive interface points that electrically interconnect backside electrodes 560 of interconnected PV modules 500.
  • mechanical fastener 535 is a metallic rivet with metallic washers 565 disposed at either end with laminated support structure 505, floatation pads 555, edge connection strip 515, and backside electrode 560 sandwiched there between.
  • Metallic washers 565 provide a larger surfaces area to prevent tearing and pull-through of mechanical fasteners 535 through elongated slots 540.
  • PV module 500 in FIG 6A further depicts example end edge treatments including end connectors 545 and wiring clips 550.
  • End connectors 545 provide end connection locations for holding PV module 500 in place and may be attached to a tensioning frame (e.g., tensioning frame 205) and/or edge protection member (e.g., floating boom section 230).
  • tensioning frame e.g., tensioning frame 205
  • edge protection member e.g., floating boom section 230
  • end connectors 545 are periodically spaced holes with grommets.
  • end connectors 545 may be implemented with snaps, clips, buckles, or otherwise.
  • Wiring clip 550 is disposed along the end edge of PV module 500 to route electrical cables (e.g., electrical interconnect assembly 125) along that edge.
  • Wiring clips 550 may be disposed along any edge of PV module 500 where cable organization is desired.
  • FIG. 6A illustrates a mechanical fastening of edge connection strip 515 to laminated support structure 505
  • flexible flap 520 may be integral to, or laminated into, the material stack (or edges thereof) that forms laminated support structure 505.
  • FIGs. 7-9 illustrate demonstrative implementations of continuous connector 525.
  • FIGs. 7A and 7B illustrate different views of slide zippers 700 and 701, in accordance with an embodiment of the disclosure.
  • the illustrated embodiments of slide zippers 700 and 701 each include two linear interlocking teeth 705 and 710 that extend along a length of a given PV module 500 and are mounted to a side of a corresponding flexible flap 520.
  • Linear interlocking teeth 705 and 710 of slide zipper 700 are shaped to interlock with corresponding teeth 710 and 705 of slide zipper 701.
  • slider zipper 700 disposed along a right side of a PV module 500 has downward facing teeth 705 and 710 while slider zipper 701 disposed along a left side of a given PV module 500 has upper ward facing teeth 705 and 710.
  • Slide zipper 700 and 701 interlock with the application of sufficient pressure.
  • a sliding/rolling pressure tool may be used to apply the requisite pressure during deployment.
  • FIGs. 7A and 7B illustrate slide zippers 700 and 701 as each including two linear interlocking teeth, in other embodiments, slide zippers 700 and 701 may be implemented with a single interlocking tooth or several interlocking teeth.
  • slide zippers 700 and 701 may also be slid longitudinally along a sliding axis (normal to the page in FIG. 7B) to establish the connection.
  • slide zippers 700 and 701 substantially do not constrain motion in at least one degree of freedom (e.g., along the sliding axis).
  • FIG. 7C is a cross-sectional illustration of a slide zipper 702, in accordance with another embodiment of the disclosure.
  • Slide zipper 702 is yet another possible implementation of continuous connector 525.
  • the illustrated embodiment of slider zipper 702 includes a clasping end 715 that slides over a bulbous end 720.
  • Clasping end 715 and bulbous end 720 may also be considered as a single linear, interlocking tooth configuration.
  • Clasping end 715 is c-shaped, and in one embodiment, sufficiently flexible that the application of a requisite compressive force will cause it to slide over and lock onto bulbous end 720.
  • clasping end 715 may also sufficiently stiff that it will hold onto bulbous end 720 and resist typical environmental force when deployed in the field without breaking its connection.
  • clasping end 715 may also be engaged over bulbous end 720 by sliding clasping end 715 over bulbous end 720 starting at one end and advancing forward while the entire PV module 500 is floated into position. In this end sliding embodiment, clasping end 715 need not be flexible.
  • FIG. 7C illustrates an embodiment of continuous connector 525 where one side of PV module 500 includes a clasping end 715 while the other side includes a bulbous end 720 for establishing module-to-module interconnections.
  • FIG. 7D is a cross-sectional illustration of a slide zipper 703, in accordance with another embodiment of the disclosure.
  • Slide zipper 703 is yet another possible implementation of continuous connector 525.
  • the illustrated embodiment of slider zipper 703 includes a dual sided clasp 730 that slides over bulbous ends 740.
  • dual sided clasp 730 is a center removeable component that can be separated from both PV modules. Similar to clasping end 715, dual sided clasp 730 is sufficiently flexible that the application of a requisite compressive force will cause it to slide over and lock onto each bulbous end 740. Of course, dual sided clasp 730 is also sufficiently stiff that it will hold onto bulbous ends 740 and resist typical environmental forces when deployed in the field without breaking its connection.
  • dual sided clasp 730 may be rigid.
  • the mechanical connection between adjacent PV modules may also be established by sliding dual sided clasp 730 axially over bulbous ends 740.
  • Dual sided clap 730 may be fabricated of various materials such as plastic, metal, composites, or otherwise.
  • FIG. 8 illustrates a toothed zipper implementation of continuous connector 525, in accordance with another embodiment of the disclosure.
  • the illustrated embodiments of toothed zippers 800 and 801 each include teeth 805 that repeat along a length of a given PV module 500. Teeth 805 are shaped to interlock with corresponding teeth 805 on an adjacent PV module 500. A zipper sled 810 is used to joint and interlock the teeth 805 during deployment.
  • flexible flaps 520 may be implemented as nylon meshes to which toothed zippers 800 and 801 are sewed. Toothed zippers 800 and 801 may also represent coil zippers where teeth 805 are individual loops of a spiral element.
  • FIGs. 7 and 8 illustrate non-permanent connection embodiments that can be disconnected for repairs/replacement in the field by a technician without cutting edge connection strip 515 or flexible flaps 520.
  • FIG. 9 illustrates a hot melt flap implementation of continuous connector 525, in accordance with another embodiment of the disclosure.
  • the illustrated embodiments of hot melt flaps 900 and 901 each include a plastic flap 905 that integrates with flexible flap 520.
  • Hot melt flaps 900 and 901 are aligned next to each other and fused together with the application of heat.
  • a hot shoe tool may be used to apply the requisite heat.
  • Hot melt flaps 900 and 901 represent a semi-permanent bond that must be cut or reheated to separate. If cut, hot melt flaps 900 and 901 can still be refused again by applying an additional bonding flap for thermal fusing.
  • hot melt flaps 900 are fabricated as plastic sheets.
  • FIG. 10 is a side view illustration of drainage features 1000 integrated into flexible flaps 1005 of edge connection strips 1010, in accordance with an embodiment of the disclosure.
  • Edge connection strips 1010 are similar to edge connection strips 515 except for the integration of drainage features 1000 into flexible flaps 1005 as opposed to the side edges of laminated support structure 505.
  • drainage features 1000 are one way valves periodically disposed along the length (into the page in FIG. 10) of flexible flap 1005. Drainage features 1000 operate to perform the same function as drainage features 530 to drain away excess water that accumulates on the frontside of the PV module while block water from seeping up from the underside.
  • the one way valves may be simple flaps disposed on the backside of flexible flaps 1005, spring loaded values, or otherwise.
  • FIG. 11 is a cross-sectional illustration of a demonstrative material stack 1100 for implementing laminated support structure 305, in accordance with an embodiment of the disclosure.
  • Material stack 1100 is also well suited for deployment in an aqueous environment, such as a water reservoir.
  • the illustrated embodiment of material stack 1100 includes a substrate layer 1105, a water block layer 1110, a backside encapsulant layer 1115, a frontside encapsulant layer 1125, a stiffener layer 1130, an ultraviolet (“UV”) blocking layer 1135, and a superstate layer 1140.
  • UV ultraviolet
  • Frontside encapsulant layer 1125 and backside encapsulant layer 1115 sandwich around solar cells 315 which are electrically interconnected front to back and back to front by electrodes 1120. Both frontside and backside encapsulant layers 1125 and 1115 conform to and otherwise mold around solar cells 315.
  • frontside and backside encapsulant layers 1125 and 1115 are formed of ethylene-vinyl acetate (EVA) each approximately 0.9 mm thick.
  • EVA ethylene-vinyl acetate
  • frontside and backside encapsulant layers 1125 and 1115 are fabricated from layers of polyolefin.
  • heat and pressure are used to encapsulate solar cells 315 between the frontside and backside encapsulant layers. For example, even pressure may be applied using a vacuum tool, which also serves to eliminate deleterious moisture and air pockets.
  • Substrate layer 1105 provides physical environmental protection to the backside of solar cells 315.
  • substrate layer 1105 protects against damage occurring from physical impacts, animal influence, and other forms of physical intrusions from the backside.
  • substrate 1105 is fabricated of polyethylene terephthalate (PET) approximately 0.27 mm thick.
  • PET polyethylene terephthalate
  • substrate layer 1105 is pigmented black in color.
  • Water block layer 1110 is an optional waterproofing layer that can extend the lifespan of solar cells 315 when the PV module is deployed as a floating module.
  • Water block layer 1110 may be fabricated as a metal foil layer, such as aluminum foil, an oxide layer, such as silicon dioxide, or otherwise.
  • Stiffener layer 1130 is a layer that adds stiffness to the PV module to reduce the incidence of fracture of solar cells 315 when the PV module is rolled and further provides mechanical protection. Stiffener layer 1130 operates to limit the bend radius. In the illustrated embodiment, stiffener layer 1130 is disposed across the top side of solar cells 315. Stiffener layer 1130 may be fabricated of a polymer material having the desired stiffness, such as a 0.27 mm thick layer of clear PPE.
  • UV blocking layer 1135 is also an adhesive that is disposed between superstate layer 1140 and stiffener layer 1130 to bond the two layers together.
  • UV blocking layer 1135 includes UV filtering characteristics to block or otherwise reduce the amount of harmful UV light that penetrates to the lower layers. UV light can age or otherwise damage the underlying material layers thereby shorting the deployed lifespan of the PV module.
  • UV blocking layer 1105 is a 0.2 mm thick layer of UV blocking EVA encapsulant.
  • Superstate layer 1140 provides physical environmental protection to the frontside of solar cells 315.
  • superstate layer 1140 protects against damage occurring from physical impacts, animal influence, and other forms of physical intrusions from the frontside.
  • superstate layer 1140 is fabricated of a polymer material.
  • superstate layer 1140 is a 0.2 mm thick layer of a fluoropolymer such as ethylene tetrafluoroethylene (ETFE).
  • ETFE ethylene tetrafluoroethylene

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  • Condensed Matter Physics & Semiconductors (AREA)
  • Electromagnetism (AREA)
  • General Physics & Mathematics (AREA)
  • Engineering & Computer Science (AREA)
  • Computer Hardware Design (AREA)
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  • Life Sciences & Earth Sciences (AREA)
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  • Photovoltaic Devices (AREA)

Abstract

L'invention concerne un module photovoltaïque (« PV ») pour la génération de puissance solaire qui inclut une structure de support stratifiée qui peut être enroulée ou pliée, une pluralité de cellules solaires encastrées dans la structure de support stratifiée, et des bandelettes de connexion de bords. Les cellules solaires sont interconnectées pour générer de la puissance solaire en réponse à la lumière incidente sur une face avant de la structure de support stratifiée. Les bandelettes de connexion de bords s'étendent le long des bords de la structure de support stratifiée pour la connexion mécanique du module PV à d'autres modules PV. Les bandelettes de connexion de bords incluent chacune un connecteur continu qui assure une connexion uniforme le long d'un bord respectif parmi les bords latéraux du module PV.
PCT/US2017/043788 2016-07-28 2017-07-25 Traitements de bord de modules pv pour interconnexions de module à module WO2018022655A1 (fr)

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