U.S. patent application number 14/055694 was filed with the patent office on 2014-04-17 for photovoltaic laminate segments and segmented photovoltaic modules.
This patent application is currently assigned to SUNPOWER CORPORATION. The applicant listed for this patent is SUNPOWER CORPORATION. Invention is credited to Carl LENOX.
Application Number | 20140102505 14/055694 |
Document ID | / |
Family ID | 44787232 |
Filed Date | 2014-04-17 |
United States Patent
Application |
20140102505 |
Kind Code |
A1 |
LENOX; Carl |
April 17, 2014 |
PHOTOVOLTAIC LAMINATE SEGMENTS AND SEGMENTED PHOTOVOLTAIC
MODULES
Abstract
One embodiment of the invention relates to a segmented
photovoltaic (PV) module which is manufactured from laminate
segments. The segmented PV module includes rectangular-shaped
laminate segments formed from rectangular-shaped PV laminates and
further includes non-rectangular-shaped laminate segments formed
from rectangular-shaped and approximately-triangular-shaped PV
laminates. The laminate segments are mechanically joined and
electrically interconnected to form the segmented module. Another
embodiment relates to a method of manufacturing a large-area
segmented photovoltaic module from laminate segments of various
shapes. Other embodiments relate to processes for providing a
photovoltaic array for installation at a site. Other embodiments
and features are also disclosed.
Inventors: |
LENOX; Carl; (Oakland,
CA) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
SUNPOWER CORPORATION |
San Jose |
CA |
US |
|
|
Assignee: |
SUNPOWER CORPORATION
San Jose
CA
|
Family ID: |
44787232 |
Appl. No.: |
14/055694 |
Filed: |
October 16, 2013 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
12763067 |
Apr 19, 2010 |
8572836 |
|
|
14055694 |
|
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Current U.S.
Class: |
136/244 ;
136/251 |
Current CPC
Class: |
Y02P 80/25 20151101;
H02S 20/23 20141201; H02S 40/36 20141201; Y02B 10/12 20130101; H01L
31/02013 20130101; Y10T 29/49117 20150115; Y02E 10/50 20130101;
H01L 31/05 20130101; Y02B 10/10 20130101; Y10T 29/49993 20150115;
H01L 31/02 20130101; Y10T 29/49002 20150115; Y10T 29/49826
20150115; Y02P 80/20 20151101; H01L 31/0504 20130101 |
Class at
Publication: |
136/244 ;
136/251 |
International
Class: |
H01L 31/05 20060101
H01L031/05; H01L 31/042 20060101 H01L031/042; H01L 31/048 20060101
H01L031/048 |
Goverment Interests
STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT
[0002] This invention was made with Government support under
Contract No. DEFC36-07GO17043 awarded by the United States
Department of Energy. The Government has certain rights in this
invention.
Claims
1. A segmented photovoltaic module comprising: rectangular-shaped
laminate segments formed from rectangular-shaped photovoltaic
laminates; non-rectangular-shaped laminate segments formed from
rectangular-shaped and approximately-triangular-shaped photovoltaic
laminates; mechanical joints between laminate segments; and
electrical interconnections between the laminate segments.
2. The segmented photovoltaic module of claim 1, further
comprising: stiffening ribs to provide mechanical support between
the laminate segments.
3. The segmented photovoltaic module of claim 1, further
comprising: elastomer to protect the electrical interconnections
between the laminate segments.
4. The segmented photovoltaic module of claim 1, further
comprising: a DC-to-AC micro-inverter integrated with the module so
that the module is configured to output AC power.
5-21. (canceled)
22. The segmented photovoltaic module of claim 1, further
comprising: a DC-to-DC power converter integrated with the module
so that the module is configured to output conditioned DC
power.
23. The segmented photovoltaic module of claim 1, wherein the
electrical interconnections between the laminate segments comprise
metal tabs that are soldered together.
24. The segmented photovoltaic module of claim 1, wherein the
approximately-triangular-shaped laminate segments each comprises an
arrangement of rectangular-shaped photovoltaic laminates within a
triangular outline.
25. The segmented photovoltaic module of claim 1, wherein the
approximately-triangular-shaped laminate segments each comprises an
arrangement of rows of rectangular-shaped photovoltaic laminates in
which a next row has one less rectangular-shaped photovoltaic
laminate than a previous row.
26. The segmented photovoltaic module of claim 1 further
comprising: an opening surrounded by the laminate segments.
27. The segmented photovoltaic module of claim 26, wherein the
opening is rectangular in shape and has a perimeter formed by edges
of four rectangular-shaped laminate segments.
28. The segmented photovoltaic module of claim 1, wherein the
laminate segments fit within a predetermined build envelope.
29. The segmented photovoltaic module of claim 28, wherein the
predetermined build envelope includes a diagonal edge.
30. The segmented photovoltaic module of claim 28, further
comprising: a carrier frame to support the laminate segments.
31. A photovoltaic module comprising: a plurality of laminate
segments arranged in an array, each laminate segment comprising a
laminate with a plurality of solar cells therein; electrical
interconnections between the laminate segments; and mechanical
joints between the laminate segments, wherein the mechanical joints
at least partially enclose the electrical interconnections.
32. The photovoltaic module of claim 31, further comprising: an
encapsulant material surrounding the electrical interconnections to
electrically insulate the electrical interconnections.
33. The photovoltaic module of claim 32, wherein the encapsulant
material is located in the mechanical joints and provides
environmental protection for the electrical interconnections.
34. The photovoltaic module of claim 32, wherein the encapsulant
material is elastomeric.
35. The photovoltaic module of claim 31, wherein the electrical
interconnections comprise metal tabs from adjacent laminate
segments that are soldered together.
36. The photovoltaic module of claim 31, wherein the mechanical
joints comprise back-side channels and caps at ends of the
back-side channels.
37. A set of segmented photovoltaic modules for creating a
photovoltaic array in custom-shaped envelope, the set comprising a
first segmented photovoltaic module of a first shape and a second
segmented photovoltaic module of a second shape.
Description
CROSS-REFERENCE TO RELATED APPLICATION(S)
[0001] The present patent application is a divisional application
of U.S. patent application Ser. No. 12/763,067, filed Apr. 19,
2010, the disclosure of which is hereby incorporated by reference
in its entirety.
BACKGROUND OF THE INVENTION
[0003] 1. Field of the Invention
[0004] The present invention relates generally to photovoltaic
modules and processes for manufacturing and installing photovoltaic
modules.
[0005] 2. Description of the Background Art
[0006] Photovoltaic (PV) cells, also referred to as "solar cells,"
are well known devices for converting solar radiation to electrical
energy. Photovoltaic cells may be packaged together in a
photovoltaic module. The PV module may include a plurality of
interconnected photovoltaic cells in a laminate, and an external
junction box attached to the laminate, including leads and
connectors which allow modules to be interconnected
electrically.
[0007] PV modules are typically installed on a support structure at
the installation site. The PV modules are typically then
electrically interconnected with the leads from one module to the
next in series, or to a common bus in parallel, or a combination of
series and parallel connections.
SUMMARY
[0008] One embodiment of the invention relates to a segmented
photovoltaic (PV) module which is manufactured from laminate
segments. The segmented PV module includes rectangular-shaped
laminate segments formed from rectangular-shaped PV laminates and
further includes non-rectangular-shaped laminate segments formed
from rectangular-shaped and approximately-triangular-shaped PV
laminates. The laminate segments are mechanically joined and
electrically interconnected to form the segmented module.
[0009] Another embodiment relates to a method of manufacturing a
large-area segmented photovoltaic module from laminate segments of
various shapes. The method is performed at a manufacturing
facility. A plurality of the laminate segments of various shapes
are mechanically joined to fill a predetermined envelope for the
segmented photovoltaic module. Electrical interconnections are made
between the plurality of laminate segments, and a protective cover
is formed over the electrical interconnections. A junction box is
integrated with the module for connecting to the segmented
photovoltaic module.
[0010] Another embodiment relates to a process for providing a
photovoltaic array for installation at a site. Survey data of the
site at which the photovoltaic array is to be installed is
received. A determination is made of a customized envelope which
defines a selected area of the site. A corresponding set of
laminate segments which are designed to be arranged to cover the
selected area, and includes non-rectangular-shaped laminate
segments, is determined.
[0011] Another embodiment pertains to another process for providing
a photovoltaic array for installation at a site. Survey data of the
site at which the photovoltaic array is to be installed is
received. A determination is made of a customized envelope which
defines a selected area of the site. In this process, a custom set
of pre-fabricated segmented modules which are designed to be
arranged to cover the selected area, and includes
non-rectangular-shaped segmented modules, is determined.
[0012] These and other embodiments and features of the present
invention will be readily apparent to persons of ordinary skill in
the art upon reading the entirety of this disclosure, which
includes the accompanying drawings and claims.
BRIEF DESCRIPTION OF THE DRAWINGS
[0013] FIG. 1 is a perspective view of the front-side of a
segmented large-area PV module in accordance with an embodiment of
the invention.
[0014] FIG. 2 is a perspective view of the back-side of the
segmented large-area PV module of FIG. 1 in accordance with an
embodiment of the invention.
[0015] FIG. 3 is a close-up perspective view of the front-side of
one end of a joint between two laminate segments of the segmented
large-area PV module of FIG. 1 in accordance with an embodiment of
the invention.
[0016] FIG. 4 is a cross-sectional view of a joint between two
laminate segments of the segmented large-area PV module of FIG. 1
in accordance with an embodiment of the invention.
[0017] FIG. 5 is a photographic image showing a rigid polymeric
frame created to support a plurality of laminate segments forming a
prototype of a larger segmented PV module in accordance with an
embodiment of the invention.
[0018] FIG. 6 is a flow chart of a process for creating and
installing a segmented large-area PV module in accordance with an
embodiment of the invention.
[0019] FIG. 7 depicts an example site survey to capture an as-built
roof area.
[0020] FIGS. 8A and 8B depict the formation of an example segmented
large-area module for the as-built roof area in accordance with an
embodiment of the invention.
[0021] FIG. 9 depicts the segmented large-area module mounted on a
carrier frame in accordance with an embodiment of the
invention.
[0022] FIG. 10A illustrates the pre-assembled segmented large-area
module on the carrier frame arriving on site in accordance with an
embodiment of the invention.
[0023] FIG. 10B illustrates the lifting of the carrier frame onto
the roof in accordance with an embodiment of the invention.
[0024] FIG. 10C illustrates the segmented large-area module as
installed on the roof area in accordance with an embodiment of the
invention.
[0025] FIG. 11 is a schematic diagram depicting two example smaller
laminate segments in accordance with an embodiment of the
invention.
[0026] FIG. 12 depicts a "fractal" set of ten different segmented
PV modules in accordance with an embodiment of the invention.
[0027] FIG. 13A depicts the surface coverage on a section of a roof
using an arrangement of conventional rectangular PV modules.
[0028] FIG. 13B depicts the surface coverage on the same section of
the roof using a first arrangement of segmented PV modules in
accordance with an embodiment of the invention.
[0029] FIG. 13C depicts the surface coverage on the same section of
the roof using a second arrangement of segmented PV modules in
accordance with an embodiment of the invention.
[0030] FIG. 14 is a flow chart of a process for creating and
installing a customized set of pre-fabricated segment modules in
accordance with an embodiment of the invention.
DETAILED DESCRIPTION
[0031] In the present disclosure, numerous specific details are
provided, such as examples of apparatus, components, and methods,
to provide a thorough understanding of embodiments of the
invention. Persons of ordinary skill in the art will recognize,
however, that the invention can be practiced without one or more of
the specific details. In other instances, well-known details are
not shown or described to avoid obscuring aspects of the
invention.
[0032] Segmented Large-Area Photovoltaic Module
[0033] FIG. 1 is a perspective view of the front-side of a
segmented large-area PV module 100 in accordance with an embodiment
of the invention. In this view, the segmented large-area PV module
100 is shown, including the front-side (light-receiving side) 102
of the rectangular laminate segments and the front-side material or
pieces 104 of the joints therebetween. Each laminate segment may
include a laminate with a plurality of solar cells therein. The
joints interconnect the adjacent segments, both mechanically and
electrically.
[0034] In this embodiment, the segmented large-area PV module 100
comprises multiple rectangular laminate segments 102 which are
joined into a single very large module. Such a very large module
may be used on a tracker, for example. In other embodiments, the
laminate segments may be of various shapes, rectangular and
non-rectangular, and may be interconnected to fill various shapes
of envelopes.
[0035] FIG. 2 is a perspective view of the back-side of the
segmented large-area PV module of FIG. 1 in accordance with an
embodiment of the invention. In this view, the back-side 202 of the
rectangular laminate segments and the back-side channels 204 of the
joints are shown. Also shown in FIG. 3 are caps (flat end parts)
206 at the ends of the joints.
[0036] FIG. 3 is a close-up perspective view of the front-side of
one end of a joint between two laminate segments of the segmented
large-area PV module of FIG. 1 in accordance with an embodiment of
the invention. This perspective shows the front-side 102 of the two
adjacent laminate segments, the front-side material or piece 104 of
the joint between them, and an end cap 206 of that joint.
[0037] FIG. 4 is a cross-sectional view of a joint between two
laminate segments of the segmented large-area PV module of FIG. 1
in accordance with an embodiment of the invention. Shown in FIG. 4
are two PV laminates (laminate segments) 402, each laminate 402
including a plurality of solar cells and electrical connections
between the solar cells. Bypass diodes may also be embedded within
the PV laminates. The specific configuration for the electrical
connections and bypass diodes within a PV laminate 402 depends on
the specific implementation used.
[0038] As further shown, each PV laminate 402 includes at least one
exit tab 408. Typically, exit tabs 408 are included on two opposing
sides for each laminate 402. The exit tab 408 comprises a
non-insulated conductive portion (typically, a metal) which extends
out of the PV laminate. In one embodiment, each PV laminate 402
includes two exit tabs 408. Each exit tab 408 is electrically
connected within the PV laminate 402 to at least one of the solar
cells. For example, the exit tab 408 may be electrically connected
to a solar cell in a corner position within the PV laminate
402.
[0039] An optional electrical junction box or other stiffening
structure (stiffener) 412 is also shown in FIG. 4. As shown, the
stiffening structure 412 may be located on one side of the PV
laminates 402 and may partially enclose the exit tabbing 408.
[0040] In accordance with an embodiment of the invention, a solder
connection or solder joint 410 may be formed during the
manufacturing process in a factory to electrically connect in a
permanent manner the exit tabbing 408 from the two PV laminates
402. After forming the solder connection 410, an encapsulant
(potting) material 406 may be introduced to electrically-insulate
and environmentally-protect the exit tabbing 408 and solder
connection 410. The encapsulant material 406 is preferably
elastomeric so as to be resistant to cracking.
[0041] In accordance with an embodiment of the invention, the
laminate segments may be combined or joined together, both
mechanically and electrically, during the manufacturing process so
as to create larger segmented modules. For instance, FIG. 5 shows a
rigid polymeric perimeter frame 501 which was used in a small-scale
prototype to provide support for elastomeric potted joints between
the nine rectangular laminate segments in a three-by-three array.
The nine rectangular laminate segments were arranged in the nine
array spaces 502. In this case, the segmented module is formed by
the three-by-three arrangement of joined segments. Of course, other
shapes and sizes of segmented modules may be created.
[0042] FIG. 6 is a flow chart of a process 600 for creating and
installing a segmented large-area PV module in accordance with an
embodiment of the invention. This process 600 shows an exemplary
process that efficiently generates a customized set of laminate
segments which is used form the segmented large-area PV module that
is installed.
[0043] As seen in FIG. 6, survey data is received 602. The survey
data may be received electronically (for example, via a network
connection) from a site survey that accurately captures geometric
angles and dimensions of the area on which the PV modules are to be
installed. The location and dimensions of obstructions may also be
included in the survey data. Tools which may be used to perform the
site survey include high-definition surveying (HDS) systems,
differential global positioning system (DGPS), satellite imagery or
aerial photography, and laser templating tools. For example, FIG. 7
depicts a site surveyor 702 capturing survey data for an as-built
roof area 704 including an obstruction 706.
[0044] The survey data is then processed to determine 604 a
customized geometric envelope for the installation of a solar
array. The customized geometric envelope is designed such that it
may be filled using an arrangement of laminate segments to build
one or more segmented modules. For example, FIG. 8A depicts a
particular geometric envelope 802 which may be determined for the
as-built roof area 804 shown in FIG. 7. In this example, the area
of the envelope 802 includes an opening 804 which is designed to
fit around the obstruction 706 in the roof area 704. In addition,
other documentation and calculations may be generated, such as
permit submittals, energy simulations, and so forth.
[0045] An appropriate set of segmented modules is then provided
606. The set may include laminate segments of various shapes that
may be arranged to fill the geometric envelope determined from the
survey data. For example, as shown in FIG. 8B, the geometric
envelope 802 of FIG. 8A may be filled with a single segmented
module comprised of eight square-shaped laminate segments 812 and
two triangular-shaped laminate segments 814. More generally,
multiple segmented large-area modules may be created from sets of
laminate segments, each large-area module being created within a
predetermined build envelope.
[0046] The laminate segments (for example, 812 and 814) of the set
may be advantageously joined/interconnected at a manufacturing
facility to form 607 the segmented large-area module(s) 816. The
segmented large-area module(s) 816 is (are) then transported to the
installation site. This embodiment is described in further detail
below in relation to FIGS. 9, 10A, 10B and 10C.
[0047] The segmented modules are then transported 608 to the
installation site. If the set has been previously joined 607 into
one or more large-area module(s), then each large-area module may
be mounted on a carrier frame prior to transport. An example of a
carrier frame 900 with a large-area module 816 mounted thereon is
illustrated in FIG. 9.
[0048] The laminate segments are then installed 610 at the
installation site. If the set has been previously joined 607 into
one or more large-area module(s), then one or more pre-assembled
large-area module(s) may arrive on site on a carrier frame as
transported by a truck 1002, for example. FIG. 10A illustrates the
pre-assembled segmented large-area module on the carrier frame
arriving on site in accordance with an embodiment of the invention.
FIG. 10B shows the large-area module being lifted onto the roof
installation site 1004 by way of a crane 1006 lifting the carrier
frame. FIG. 10C depicts the large-area module 806 after
installation. The carrier frame 900 may be placed back on the truck
1002 for return. Other array panels or modules may be installed
similarly. Alternatively, smaller segmented modules may be manually
lifted onto the roof for installation.
[0049] In another embodiment, the segmented module(s) may have
sufficient rigidity such that a carrier frame would not be needed.
In that case, the segmented module(s) may be lifted into place
directly and secured to the roof (or other installation site).
[0050] In a further embodiment, mounting pins or attachments may be
placed on a roof (or other site), and the segmented module(s) may
be lifted into place and secured to them.
[0051] "Fractal" Set of Smaller Segmented Photovoltaic Modules
[0052] FIG. 11 is a schematic diagram depicting two example smaller
laminate segments in accordance with an embodiment of the
invention. Each of these smaller laminate segments may have fewer
solar cells 1102 than a typical conventional solar module. A
typical conventional solar module is made from a rectangular
laminate which may have seventy-two solar cells, for example. Each
module segment may include conductive exit tabs 1104 on two of its
sides for electrically interconnecting the segment with neighboring
segments. The exit tabs 1104 are interconnected electrically with a
string of solar cells 1102 in that segment.
[0053] The first example module segment 1110 is made from a
square-shaped mini-laminate which includes sixteen solar cells. The
second example module segment 1120 is made from an approximately
triangular-shaped (actually, a square with a corner cut off)
mini-laminate which includes ten solar cells. Of course, other
shapes and sizes of laminate segments may be created, and they may
include various numbers of solar cells.
[0054] FIG. 12 depicts a flexible ("fractal") set of ten segmented
PV modules 1202 formed from the square and triangular laminate
segments of FIG. 11 in accordance with an embodiment of the
invention. Each of these ten segmented PV modules has a different
shape from the others. In accordance with an embodiment of the
invention, each of these segmented PV modules may include a
junction box 1204 (for example, on the back-side of the module) for
connecting the modules in series, which may incorporate a series DC
power converter. In an alternate embodiment, each segmented
[0055] PV module may include a micro-inverter or parallel DC power
converter 1206 such that the module outputs AC or DC power to a
common bus for a photovoltaic array.
[0056] As described further below, these different shapes may be
combined in a flexible manner so as to create PV arrays filling
custom-shaped envelopes. The electrical interconnections between
the laminate segments may be formed, for example, by soldering the
exit tabbing, as appropriate, to form the desired string or strings
of solar cells. Exit tabbing at the ends of a string of solar cells
may be interconnected to the junction box 1204.
[0057] The first segmented PV module 1202-A comprises an 8-by-8
square module of solar cells. It is formed by mechanically joining
and electrically interconnecting four of the square PV segments
1110.
[0058] The second segmented PV module 1202-B comprises a
triangle-like module of 36 solar cells. It is formed by
mechanically joining and electrically interconnecting one square PV
segment 1110 with two of the triangular PV segments 1120.
[0059] The third segmented PV module 1202-C comprises a
corner-shaped module of 48 solar cells. It is formed by
mechanically joining and electrically interconnecting three square
PV segments 1110.
[0060] The fourth segmented PV module 1202-D comprises another
corner-shaped module of 48 solar cells. It is also formed by
mechanically joining and electrically interconnecting three square
PV segments 1110.
[0061] The fifth segmented PV module 1202-E comprises a module of
26 solar cells. It is formed by mechanically joining and
electrically interconnecting one square PV segment 1110 with one
triangular PV segment 1120.
[0062] The sixth segmented PV module 1202-F comprises another
module of 26 solar cells. It is also formed by mechanically joining
and electrically interconnecting one square PV segment 1110 with
one triangular PV segment 1120.
[0063] The seventh segmented PV module 1202-G comprises a
rectangular module of 32 solar cells. It is formed by mechanically
joining and electrically interconnecting two square PV segments
1110.
[0064] The eighth PV module 1202-H comprises a module of 42 solar
cells. It is formed by mechanically joining and electrically
interconnecting two square PV segments 1110 with one triangular PV
segment 1120.
[0065] The ninth segmented PV module 1202-I comprises another
module of 42 solar cells. It is also formed by mechanically joining
and electrically interconnecting two square PV segments 1110 with
one triangular PV segment 1120.
[0066] The tenth segmented PV module 1202-J comprises another
module of 58 solar cells. It is also formed by mechanically joining
and electrically interconnecting three square PV segments 1110 with
one triangular PV segment 1120.
[0067] FIG. 13A depicts the surface coverage on a section of an
example roof area using an arrangement 1300 of conventional
rectangular PV modules. In this example, the conventional
rectangular PV modules have 72 solar cells each. The arrangement of
the conventional rectangular modules covers the area 1302 depicted
and leaves the remainder 1304 of the roof area uncovered. In this
case, the conventional modules covering the area 1302 have a
capacity to generate 6.4 kilowatts of solar energy.
[0068] FIG. 13B depicts the surface coverage on the same section of
the roof using a first arrangement 1310 of segmented PV modules
1202 in accordance with an embodiment of the invention. In this
example, a varied set of segmented PV modules 1202 of the types (A
through J) shown in FIG. 12 are arranged to cover the irregular
area 1312 depicted and leave the remainder 1314 of the roof area
uncovered. In this case, the segmented PV modules 1202 covering the
area 1312 have a capacity to generate 8.1 kilowatts of solar
energy, which is substantially greater than the capacity of the
conventional PV modules in FIG. 13A.
[0069] FIG. 13C depicts the surface coverage on the same section of
the roof using a second arrangement 1320 of segmented PV modules
1202 in accordance with an embodiment of the invention. In this
example, a different set of segmented PV modules 1202 of the types
(A through J) shown in FIG. 12 are arranged to cover the area 1322
depicted and leave the remainder 1324 of the roof area uncovered.
In this case, the segmented PV modules 1202 covering the area 1322
have a capacity to generate 8.0 kilowatts of solar energy, which is
substantially greater than the capacity of the conventional PV
modules in FIG. 13A.
[0070] FIG. 14 is a flow chart of a process 1400 for creating and
installing a customized set of pre-fabricated segment modules in
accordance with an embodiment of the invention. This process 1400
may advantageously utilize the "fractal" set of segmented PV
modules 1202 discussed above in relation to FIG. 12.
[0071] Survey data of the installation site may be received 1402
and a customized geometric envelope for installation of a PV array
may be determined 1404 from the survey data These steps 1402 and
1404 are similar to steps 602 and 604 of FIG. 6. However, in this
case, the various shapes in the fractal set of segmented modules
allow the geometric envelope to be very flexible in terms of its
shape. Examples of such flexible geometric envelopes (1312 and
1322) are shown in FIGS. 13B and 13C, as described above.
[0072] The geometric envelope is determined 1404 such that it may
be filled using a custom set of pre-fabricated segmented modules of
various shapes. For example, a first custom set comprising various
of the segmented modules 1202 shown in FIG. 12 may be arranged to
fill the geometric envelope 1312 shown in FIG. 13B, while a second
(different) custom set comprising various of the segmented modules
1202 shown in FIG. 12 may be arranged to fill the geometric
envelope 1314 shown in FIG. 13C. The custom set so determined is
provided 1406 and transported 1408 to the installation site. The
custom set may then be installed 1410 at the site to form the PV
array within the customized geometric envelope.
[0073] In an alternate process, an inventory of segmented modules
of various shapes may be kept on a truck and brought to an
installation site. A determination may be made at the installation
site as to the segmented modules to be installed and the array
layout. The installer may then retrieve those modules from the
inventory on the truck and install them according to the array
layout.
[0074] While specific embodiments of the present invention have
been provided, it is to be understood that these embodiments are
for illustration purposes and not limiting. Many additional
embodiments will be apparent to persons of ordinary skill in the
art reading this disclosure.
* * * * *