U.S. patent application number 16/573639 was filed with the patent office on 2020-01-09 for module connector for flexible photovoltalc module.
The applicant listed for this patent is Miasole Hi-Tech Corp.. Invention is credited to Nicholai Busch, Jason Stephen Corneille, John Huang, Richard Weinberg.
Application Number | 20200014329 16/573639 |
Document ID | / |
Family ID | 65720783 |
Filed Date | 2020-01-09 |
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United States Patent
Application |
20200014329 |
Kind Code |
A1 |
Corneille; Jason Stephen ;
et al. |
January 9, 2020 |
MODULE CONNECTOR FOR FLEXIBLE PHOTOVOLTAlC MODULE
Abstract
Disclosed are module connectors for flexible photovoltaic
modules. A module connector may include a clamp and an insert
configured to be inserted into the clamp. The insert may have an
insert body, an electrical lead and an electrical connector. The
clamp may have a body portion with a recess configured to receive
the insert body, a first clamping portion configured to clamp a
second portion of the electrical connector to connect it to the
body portion, and a second clamping portion with a first clamping
surface configured to contact a first sheet of the module and a
second clamping surface configured to contact a second sheet of the
module. The second clamping portion may be configured to connect
the clamp to the module such that the clamp overlaps and extends
around a part of the first sheet, a part of the module's exterior
edge surface, and a part of the second sheet.
Inventors: |
Corneille; Jason Stephen;
(Boulder Creek, CA) ; Busch; Nicholai; (Mountain
View, CA) ; Weinberg; Richard; (Cupertino, CA)
; Huang; John; (San Jose, CA) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
Miasole Hi-Tech Corp. |
Santa Clara |
CA |
US |
|
|
Family ID: |
65720783 |
Appl. No.: |
16/573639 |
Filed: |
September 17, 2019 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
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15705910 |
Sep 15, 2017 |
10425035 |
|
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16573639 |
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Current U.S.
Class: |
1/1 |
Current CPC
Class: |
H02S 30/10 20141201;
H02S 40/34 20141201; H01L 31/02008 20130101; H01L 31/02002
20130101; H01L 31/02013 20130101; H02S 40/36 20141201 |
International
Class: |
H02S 40/34 20060101
H02S040/34; H02S 30/10 20060101 H02S030/10; H02S 40/36 20060101
H02S040/36; H01L 31/02 20060101 H01L031/02 |
Claims
1. A module connector for a flexible photovoltaic module, the
module connector comprising: an insert that is configured to be
inserted into a clamp and that includes: an insert body, a first
electrical lead with a first portion that extends into and is
sealed inside the insert body, and a second portion outside the
insert body that extends away from the insert body in a first
direction, and a first cable with a first portion that extends into
and is sealed inside the insert body, and a second portion outside
the insert body that extends away from the insert body in a second
direction, wherein the first electrical lead and the first cable
are electrically coupled to each other inside the insert body; and
the clamp that includes: a body portion that has a recess
configured to receive the insert body, a first clamping portion
that is configured to clamp the second portion of the first cable
to connect the first cable to the body portion, and a second
clamping portion that has a first surface and a second surface,
wherein: the second clamping portion is configured to be connected
with the body portion such that when connected to the body portion,
the first surface and the second surface face each other and are
offset from each other.
2. The module connector of claim 1, wherein the second clamping
portion is further configured such that when the second clamping
portion is connected with the body portion, the first surface and
the second surface are parallel to each other.
3. The module connector of claim 1, wherein the second clamping
portion is further configured to be connected to the body portion
by an attachment means that extends through the body portion.
4. The module connector of claim 1, wherein: the first surface is
located on the body portion, the clamp further comprises a flap
that is connected to the body portion and that is configured to be
moveable with respect to the body portion, and the second surface
is located on the flap.
5. The module connector of claim 1, wherein the second clamping
portion is further configured to connect the clamp to a flexible
photovoltaic module such that the clamp overlaps and extends around
a part of a first sheet, a part of an exterior edge surface, and a
part of a second sheet of the flexible photovoltaic module.
6. The module connector of claim 1, wherein the body portion, the
flap, and the flexible connector are a unitary body.
7. The module connector of claim 1, wherein: the first clamping
portion includes a clamping member configured to be moveable
between an open position and a closed position, in the open
position, the first clamping portion is configured such that the
first cable is insertable into the first clamping portion, and in
the closed position, the clamping member is configured to contact
the first cable, to connect to the body portion, and to connect the
first cable to the body portion.
8. The module connector of claim 1, wherein the first clamping
portion includes a crimping portion that is configured to crimp the
first cable.
9. The module connector of claim 1, wherein: the insert further
includes: a second electrical lead with a first portion that
extends into and is sealed inside the insert body, and a second
portion outside the insert body that extends away from the insert
body in the first direction, and a second cable with a first
portion that extends into and is sealed inside the insert body, and
a second portion outside the insert body that extends away from the
insert body in the second direction, wherein the second electrical
lead and the second cable are electrically coupled to each other
inside the insert body; and the clamp further includes a third
clamping portion that is configured to clamp the second portion of
the second cable to connect the second cable to the body
portion.
10. The module connector of claim 9, wherein: the insert is
positioned within the recess of the body portion of the clamp, the
first clamping portion is clamping the second portion of the first
cable such that the first cable is connected to the body portion,
and the third clamping portion is clamping the second portion of
the second cable such that the second cable is connected to the
body portion.
11. The module connector of claim 1, wherein the first direction is
orthogonal to the second direction.
12. The module connector of claim 1, wherein the first direction is
parallel to the second direction.
13. The module connector of claim 1, wherein the first surface of
the second clamping portion has a first part and a second part that
are offset from and coplanar with each other.
14. The module connector of claim 1, wherein: the insert body
includes a first planar exterior surface and a second planar
exterior surface, the first planar exterior surface is at an angle
of between about 140 degrees to about 180 degrees from the first
direction, and the second planar exterior surface is at an angle of
between about 140 degrees to about 180 degrees from the first
direction.
15. The module connector of claim 1, wherein a height of the insert
body is between about 6 millimeters and about 16 millimeters.
16. An apparatus comprising: a module connector for a flexible
photovoltaic module, the flexible photovoltaic module having a
first sheet, a second sheet, one or more flexible photovoltaic
cells positioned in a sealed space between the first sheet and the
second sheet, and a seal region that spans between a first section
of the first sheet and a second section of the second sheet and
that forms a part of an exterior edge surface of the flexible
photovoltaic module and, wherein the module connector includes: an
insert that is configured to be inserted into a clamp and that
includes: an insert body, an electrical lead with a first portion
that extends into and is sealed inside the insert body, and a
second portion outside the insert body that extends away from the
insert body in a first direction, a cable with a first portion that
extends into and is sealed inside the insert body, and a second
portion outside the insert body that extends away from the insert
body in a second direction, wherein the electrical lead and the
cable are electrically coupled to each other inside the insert
body, and a first section of a first clamping portion, wherein the
first clamping portion includes the first section and a second
section, and wherein the first clamping portion is configured to
clamp the second portion of the cable to connect the cable to the
body portion; and the clamp that includes: a body portion that has
a recess configured to receive the insert body, the second section
of the first clamping portion, and a second clamping portion that
has a first clamping surface configured to contact the first sheet
and a second clamping surface configured to contact the second
sheet, and that is configured to connect the clamp to the flexible
photovoltaic module such that the clamp overlaps and extends around
a part of the first sheet, a part of the exterior edge surface, and
a part of the second sheet.
17. The module connector of claim 16, wherein: the insert body
includes a first planar exterior surface and a second planar
exterior surface, the first planar exterior surface is at an angle
of between about 140 degrees to about 180 degrees from the first
direction, and the second planar exterior surface is at an angle of
between about 140 degrees to about 180 degrees from the first
direction.
18. An apparatus comprising: a module connector for a flexible
photovoltaic module, the module connector being a monolithic unit
and including: a first body portion that is flexibly attached to a
second body portion, and a recess in the first body portion,
wherein: the recess is configured to receive an insert of the
flexible photovoltaic module and to secure the insert to the module
connector, and the module connector is configured to be positioned
on the flexible photovoltaic module such that it simultaneously
contacts a top side of the flexible photovoltaic module, a bottom
side of the flexible photovoltaic module, and wraps around an edge
of the flexible photovoltaic module.
19. The apparatus of claim 18, further comprising the flexible
photovoltaic module, wherein: the insert is positioned in the
recess and secured by the module connector, and the module
connector is positioned on the flexible photovoltaic module such
that it simultaneously contacts the top side of the flexible
photovoltaic module, the bottom side of the flexible photovoltaic
module, and wraps around the edge of the flexible photovoltaic
module.
20. The module connector of claim 18, wherein: the insert body
includes a first planar exterior surface and a second planar
exterior surface, the first planar exterior surface is at an angle
of between about 140 degrees to about 180 degrees from the first
direction, and the second planar exterior surface is at an angle of
between about 140 degrees to about 180 degrees from the first
direction.
Description
INCORPORATION BY REFERENCE
[0001] An Application Data Sheet is filed concurrently with this
specification as part of the present application. Each application
that the present application claims benefit of or priority to as
identified in the concurrently filed Application Data Sheet is
incorporated by reference herein in its entirety and for all
purposes.
BACKGROUND
[0002] Photovoltaic technology is being rapidly adopted to generate
electricity from solar energy, both for local use and for supplying
power to electrical grids. Photovoltaic systems may be implemented
on structures, such as buildings and houses. In addition, light
weight photovoltaic modules are now being adopted for
transportation applications such as trucks, cars, boats, etc.
Photovoltaic cells are the basic units of such systems. One or more
photovoltaic cells are typically arranged into a photovoltaic
module, which may be then used to form a photovoltaic array.
SUMMARY
[0003] In one embodiment, an apparatus may be provided. The
apparatus may include a module connector for a flexible
photovoltaic module, the flexible photovoltaic module may have a
first sheet, a second sheet, one or more flexible photovoltaic
cells positioned in a sealed space between the first sheet and the
second sheet, and a seal region that spans between a first section
of the first sheet and a second section of the second sheet and
that forms a part of an exterior edge surface of the flexible
photovoltaic module and. The module connector may include an insert
that is configured to be inserted into a clamp and that includes an
insert body, an electrical lead with a first portion that extends
into and is sealed inside the insert body, and a second portion
outside the insert body that extends away from the insert body in a
first direction, and a cable with a first portion that extends into
and is sealed inside the insert body, and a second portion outside
the insert body that extends away from the insert body in a second
direction. The electrical lead and the cable may be electrically
coupled to each other inside the insert body. The clamp may include
a body portion that has a recess configured to receive the insert
body, a first clamping portion that is configured to clamp the
second portion of the cable to connect the cable to the body
portion, and a second clamping portion that has a first clamping
surface configured to contact the first sheet and a second clamping
surface configured to contact the second sheet, and that is
configured to connect the clamp to the flexible photovoltaic module
such that the clamp overlaps and extends around a part of the first
sheet, a part of the exterior edge surface, and a part of the
second sheet.
[0004] In some embodiments, the insert may further include a second
electrical lead with a first portion that extends into and is
sealed inside the insert body, and a second portion outside the
insert body that extends away from the insert body in the first
direction, and a second cable with a first portion that extends
into and is sealed inside the insert body, and a second portion
outside the insert body that extends away from the insert body in
the second direction. The second electrical lead and the second
cable may be electrically coupled to each other inside the insert
body. The claim may further include a third clamping portion that
is configured to clamp the second portion of the second cable to
connect the second cable to the body portion.
[0005] In some embodiments, the apparatus may further include the
flexible photovoltaic module. The second portion of the electrical
lead may extend through the seal region and into the sealed space,
and the electrical lead may be electrically connected to at least
one of the flexible photovoltaic cells.
[0006] In some such embodiments, the insert may be positioned
within the recess of the body portion of the clamp, the first
clamping portion may be clamping the second portion of the cable
such that the cable is connected to the body portion, the first
surface may be contacting the first sheet, the second surface may
be contacting the second sheet, the clamp may overlap and extends
around the part of the first sheet, the part of the exterior edge
surface, and the part of the second sheet, and the clamp may be
connected to the flexible photovoltaic module.
[0007] In some further such embodiments, the clamp may be connected
to the flexible photovoltaic module by an attachment means that
extends through at least the body portion, the first sheet, the
seal region, and the second clamping portion.
[0008] In some embodiments, the second clamping portion of the
clamp may be configured to be moveable such that the first surface
and the second surface face each other and are offset from each
other.
[0009] In some embodiments, the first surface may be located on the
body portion, the clamp may further include a flap that is
connected to the body portion and that is configured to be moveable
with respect to the body portion, and the second surface may be
located on the flap.
[0010] In some such embodiments, the clamp further includes a
flexible connector that may flexibly connect the flap to the body
portion.
[0011] In some further such embodiments, the body portion, the
flap, and the flexible connector may be a unitary body.
[0012] In some embodiments, the first clamping surface and the
second clamping surface may be planar surfaces.
[0013] In some embodiments, the first direction may be orthogonal
to the second direction.
[0014] In some embodiments, the first direction may be parallel to
the second direction.
[0015] In some embodiments, the insert body may include a first
planar exterior surface and a second planar exterior surface, the
first planar exterior surface may be at an angle of between about
140 to about 180 degrees from the first direction, and the second
planar exterior surface may be at an angle of between about 140 to
about 180 degrees from the first direction.
[0016] In one embodiment, a flexible photovoltaic module may be
provided. The flexible photovoltaic module may include a first
sheet, a second sheet, one or more flexible photovoltaic cells
positioned in a sealed space between the first sheet and the second
sheet, a seal region that spans between a first section of the
first sheet and a second section of the second sheet and that forms
a part of an exterior edge surface of the flexible photovoltaic
module, a module connector having an insert body, a first
electrical lead having a first portion and a second portion, a
first cable having a first portion and a second portion, and a
clamp having a body portion with a recess configured to receive the
insert body, a first clamping portion, and a second clamping
portion. The insert body may be configured to be inserted into the
clamp, the first portion of the first electrical lead may extend
into and be sealed inside the insert body, the second portion of
the first electrical lead may be outside the insert body, may
extend away from the insert body in a first direction, may extend
through the seal region and into the sealed space, and may be
electrically connected to at least one of the flexible photovoltaic
cells. The first portion of the first cable may extend into and may
be sealed inside the insert body, may be outside the insert body,
may extend away from the insert body in a second direction, and may
be electrically coupled to the electrical lead inside the insert
body. The first clamping portion may be configured to clamp the
second portion of the first cable to connect the first cable to the
body portion, and the second clamping portion may have a first
surface configured to contact the first sheet, a second surface
configured to contact the second sheet, and may be configured to
connect the clamp to the flexible photovoltaic module such that the
clamp overlaps and extends around a part of first sheet, a part of
the exterior edge surface, and a part of the second sheet.
[0017] In some embodiments, the insert may be positioned within the
recess of the body portion of the clamp, the first clamping portion
may be clamping the second portion of the first cable such that the
first cable is connected to the body portion, the first surface may
be contacting the first sheet, the second surface may be contacting
the second sheet, the clamp may overlap and extend around the part
of first sheet, the part of the exterior edge surface, and the part
of the second sheet, and the clamp may be connected to the flexible
photovoltaic module.
[0018] In some such embodiments, the clamp may be connected to the
flexible photovoltaic module by an attachment means that extends
through the body portion, the first sheet, the seal region, and the
second clamping portion.
[0019] In some embodiments, the apparatus may further include a
second electrical lead with a first portion that extends into and
is sealed inside the insert body, and a second portion outside the
insert body that extends away from the insert body in the first
direction, and a second cable with a first portion that extends
into and is sealed inside the insert body, and a second portion
outside the insert body that extends away from the insert body in
the second direction. The second electrical lead and the second
cable may be electrically coupled to each other inside the insert
body, and the clamp may further include a third clamping portion
that may be configured to clamp the second portion of the second
cable to connect the second cable to the body portion.
[0020] In some such embodiments, the insert may be positioned
within the recess of the body portion of the clamp, the first
clamping portion may be clamping the second portion of the first
cable such that the first cable is connected to the body portion,
the third clamping portion may be clamping the second portion of
the second cable such that the second cable is connected to the
body portion, the first surface may be contacting the first sheet,
the second surface may be contacting the second sheet, the clamp
may overlap and extend around the part of first sheet, the part of
the exterior edge surface, and the part of the second sheet, and
the clamp may be connected to the flexible photovoltaic module.
[0021] In some further such embodiments, the first direction may be
orthogonal to the second direction.
[0022] In some other further such embodiments, the first direction
may be parallel to the second direction.
[0023] In one embodiment, a module connector for a flexible
photovoltaic module may be provided. The module connector may
include an insert that may be configured to be inserted into a
clamp and that may include an insert body, a first electrical lead
with a first portion that extends into and is sealed inside the
insert body, and a second portion outside the insert body that
extends away from the insert body in a first direction, and a first
cable with a first portion that extends into and is sealed inside
the insert body, and a second portion outside the insert body that
extends away from the insert body in a second direction. The first
electrical lead and the first cable may be electrically coupled to
each other inside the insert body. The module connector may also
include a clamp that includes a body portion that has a recess
configured to receive the insert body, a first clamping portion
that is configured to clamp the second portion of the first cable
to connect the first cable to the body portion, and a second
clamping portion that has a first surface and a second surface. The
second clamping portion may be configured to be moveable such that
the first surface and the second surface face each other and are
offset from each other.
[0024] In some embodiments, the second clamping portion may be
further configured to be moveable such that the first surface and
the second surface are parallel to each other.
[0025] In some embodiments, the first surface may be located on the
body portion, the clamp may further include a flap that is
connected to the body portion and that is configured to be moveable
with respect to the body portion, and the second surface may be
located on the flap.
[0026] In some such embodiments, the clamp may further include a
flexible connector that flexibly connects the flap to the body
portion.
[0027] In some further such embodiments, the body portion, the
flap, and the flexible connector may be a unitary body.
[0028] In some embodiments, the first clamping portion may include
a clamping member configured to be moveable between an open
position and a closed position, in the open position, the first
clamping portion may be configured such that the first cable is
insertable into the first clamping portion, and in the closed
position, the clamping member may be configured to contact the
first cable, to connect to the body portion, and to connect the
first cable to the body portion.
[0029] In some embodiments, the first clamping portion may include
a crimping portion that is configured to crimp the first cable.
[0030] In some embodiments, the insert may further include a second
electrical lead with a first portion that extends into and is
sealed inside the insert body, and a second portion outside the
insert body that extends away from the insert body in the first
direction, and a second cable with a first portion that extends
into and is sealed inside the insert body, and a second portion
outside the insert body that extends away from the insert body in
the second direction, the second electrical lead and the second
cable may be electrically coupled to each other inside the insert
body. The clamp may also further includes a third clamping portion
that is configured to clamp the second portion of the second cable
to connect the second cable to the body portion.
[0031] In some such embodiments, the insert may be positioned
within the recess of the body portion of the clamp, the first
clamping portion may be clamping the second portion of the first
cable such that the first cable is connected to the body portion,
and the third clamping portion may be clamping the second portion
of the second cable such that the second cable is connected to the
body portion.
[0032] In some embodiments, the first direction may be orthogonal
to the second direction.
[0033] In some embodiments, the first direction may be parallel to
the second direction.
[0034] In some embodiments, the first surface of the second
clamping portion may have a first part and a second part that are
offset from and coplanar with each other.
[0035] In some embodiments, the insert body may include a first
planar exterior surface and a second planar exterior surface, the
first planar exterior surface may be at an angle of between about
140 degrees to about 180 degrees from the first direction, and the
second planar exterior surface may be at an angle of between about
140 degrees to about 180 degrees from the first direction.
[0036] In one embodiment, an apparatus may be provided. The
apparatus may include a module connector for a flexible
photovoltaic module. The flexible photovoltaic module may have a
first sheet, a second sheet, one or more flexible photovoltaic
cells positioned in a sealed space between the first sheet and the
second sheet, and a seal region that spans between a first section
of the first sheet and a second section of the second sheet and
that forms a part of an exterior edge surface of the flexible
photovoltaic module and. The module connector may include an insert
that is configured to be inserted into a clamp and that includes an
insert body, an electrical lead with a first portion that extends
into and is sealed inside the insert body, and a second portion
outside the insert body that extends away from the insert body in a
first direction, a cable with a first portion that extends into and
is sealed inside the insert body, and a second portion outside the
insert body that extends away from the insert body in a second
direction. The electrical lead and the cable may be electrically
coupled to each other inside the insert body, and a first section
of a first clamping portion; the first clamping portion may include
the first section and a second section; and the first clamping
portion may be configured to clamp the second portion of the cable
to connect the cable to the body portion. The clamp may include a
body portion that has a recess configured to receive the insert
body, the second section of the first clamping portion, and a
second clamping portion that has a first clamping surface
configured to contact the first sheet and a second clamping surface
configured to contact the second sheet, and that is configured to
connect the clamp to the flexible photovoltaic module such that the
clamp overlaps and extends around a part of the first sheet, a part
of the exterior edge surface, and a part of the second sheet.
[0037] In one embodiment, an apparatus may be provided. The
apparatus may include a module connector for a flexible
photovoltaic module, the module connector being a monolithic unit
and including a first body portion that is flexibly attached to a
second body portion, and a recess in the first body portion. The
recess may be configured to receive an insert of the flexible
photovoltaic module and to secure the insert to the module
connector, and the module connector may be configured to be
positioned on the flexible photovoltaic module such that it
simultaneously contacts a top side of the flexible photovoltaic
module, a bottom side of the flexible photovoltaic module, and
wraps around an edge of the flexible photovoltaic module.
[0038] In some embodiments, the apparatus may further include the
flexible photovoltaic module. The insert may be positioned in the
recess and secured by the module connector, and the module
connector may be positioned on the flexible photovoltaic module
such that it simultaneously contacts the top side of the flexible
photovoltaic module, the bottom side of the flexible photovoltaic
module, and wraps around the edge of the flexible photovoltaic
module.
BRIEF DESCRIPTION OF THE DRAWINGS
[0039] FIG. 1 depicts an isometric view of an example flexible
photovoltaic module.
[0040] FIG. 2 depicts a cross-sectional detail view of the example
flexible photovoltaic module of FIG. 1.
[0041] FIG. 3 depicts a side view of an insert of a module
connector.
[0042] FIG. 4 depicts an isometric exploded view of a module
connector that includes the insert of FIG. 1 and a clamp.
[0043] FIG. 5 depicts an isometric view of the module connector of
FIG. 4 with the insert inserted into the clamp.
[0044] FIG. 6 depicts another isometric view of the module
connector of FIG. 4.
[0045] FIG. 7 depicts yet another isometric view of the module
connector of FIG. 4.
[0046] FIG. 8 depicts a side view of the clamp of FIG. 4.
[0047] FIG. 9 depicts the insert and clamp of the module connector
of FIG. 7 along with two electrical leads.
[0048] FIGS. 10A-10D depict an example clamping sequence of the
module of FIG. 1 and the module connector of FIG. 4.
[0049] FIG. 11 depicts a partial cross-sectional detail view of the
insert, the clamp, and the module along the line B-B in FIG.
10D.
[0050] FIG. 12 depicts a partial cross-sectional detail view of the
insert and the clamp along the line C-C in FIG. 10D.
[0051] FIG. 13 depicts an isometric view of a second example module
connector.
[0052] FIG. 14 depicts an exploded isometric view of the second
example module connector of FIG. 13.
[0053] FIG. 15 depicts an isometric view of a third example module
connector.
[0054] FIG. 16 depicts an exploded isometric view of the third
example module connector of FIG. 15.
DETAILED DESCRIPTION
[0055] Flexible photovoltaic modules (referred to herein as
"modules") are made from flexible components including flexible
sealing sheets and flexible photovoltaic cells. Use of these
flexible components allows these modules to bend during handling
and installation. These modules may be installed on surfaces that
are not perfectly flat and may have some vertical surface
variations. For example, flexible modules may be installed on
commercial building rooftops. Such rooftops are substantially
horizontal but may have topographical variations such as surface
bumps and even small vertical steps.
[0056] During installation of a photovoltaic array, a flexible
photovoltaic module is electrically connected to other modules and
other electrical components of the photovoltaic array, such as
return lines, inverters, and the like. To form these connections, a
flexible photovoltaic module may have one or more electrical
connectors that are accessed during installation to connect with
components external to the module, such as electrical connectors of
adjacent modules. A module's electrical connectors include
electrically conductive elements, such as a metallic wire. As it is
accessible during installation, a metallic wire may be provided in
an electrically insulated casing as a cable. An electrical
connector may also include, or may be configured to make electrical
connections to, standard MC4 photovoltaic connectors or other types
of external photovoltaic connectors. For example, a module may have
a cable connected to a photovoltaic connector that is electrically
connected to the photovoltaic cells such that electricity generated
by the cells can be transported to the cable, the photovoltaic
connector and to an external electrical connection, such as another
module.
[0057] The one or more electrical connectors of a flexible
photovoltaic module may be electrically connected to the
photovoltaic cells that are sealed inside the module and to return
lines provided within the module that typically extend along or
across the module. The one or more electrical connectors may be
electrically connected to the photovoltaic cells by electrical
leads. An electrical lead may have a portion that extends into the
sealed space of the module, which may include extending through an
edge seal of the module. Electrical leads may be in the form of
thin but sufficiently conductive metal strips, which are sometimes
referred to as bus bars because of their flat aspect ratios (i.e.,
their heights being substantially smaller (e.g., less than 10%)
than their widths). In some of the embodiments disclosed herein,
the height of an electrical lead may be 0.1 millimeters or 0.125
millimeters, while the width may be 12 mm.
[0058] An electrical lead may be positioned within a module during
manufacturing such that one portion of an electrical lead is
located within a sealed space of the module with another portion
extending through and outside the sealed space so that it may
electrically connect with an electrical connector. During the
installation and use of the module, physical stresses may be
exerted on an electrical lead, or on an electrical connector that
is connected to that electrical lead that may adversely affect the
module, including the electrical leads and the seal of the module
where the electrical leads are located. Accordingly, as discussed
below some embodiments of the present disclosure include a module
connector that is configured to reduce such physical stresses and
their adverse effects.
[0059] Additionally, during the manufacture or installation of some
traditional flexible photovoltaic modules, the attachment of
electrical connectors to the module requires potting or adhesives
to achieve and safe and reliable connections. Some typical
connections between an electrical connector and a module may
require multiple process steps after manufacturing the module
thereby increasing time, materials, cost, as well as increasing
potential areas for failure or problems. For example, electrical
components may need to be soldered together, which presents a
potential risk of failure of the soldered connection, as well as
additional time and materials. Some traditional junction boxes may
also require potting and priming, which again introduces potential
failure areas as well as requires additional time and materials.
Also, having a module connector adhered to a module before
installation of that module at a location may make the installation
of that module more challenging and time consuming. As discussed
below, some embodiments of the present disclosure include a module
connector that avoids these problems with traditional module
connectors.
[0060] FIG. 1 depicts an isometric view of an example flexible
photovoltaic module and FIG. 2 depicts a cross-sectional detail
view of the example flexible photovoltaic module of FIG. 1. The
example flexible photovoltaic module 100 (referred to herein as
"module 100") includes a first sheet 102, a second sheet 104, and
five flexible photovoltaic cells 106. The first sheet 102 is a
flexible sheet that may be considered a top, light-facing sheet and
the second sheet 104 is also a flexible sheet that may be
considered a bottom sheet (these sheets are identified in FIG. 2).
The module also includes a sealed space 108, identified in dark
shading, between the first sheet 102 and the second sheet 104. This
sealed space 108 may be considered a plenum that is bounded, at
least in part, by the first sheet 102, the second sheet 104, and an
edge seal 110. The edge seal 110 may extend along one or more edges
of, and may span between, the first sheet 102 and the second sheet
104; it may also form a portion of the exterior surface of the
module 100.
[0061] In FIG. 1, the five flexible photovoltaic cells 106 are seen
within the sealed space 108 and electrically connected to each
other as represented by a dotted line between each cell. It is to
be understood that these flexible photovoltaic cells 106 may be
interconnected by various ways known in the art, and also may be
physically overlapping. The edge seal 110 is represented by dashed
lines for illustration purposes and is seen extending along at
least a part of three edges of the first sheet 102 and the second
sheet 104. For purposes of illustration only, the edge seal 110 is
depicted such that it is offset from the first and second sheets
102 and 104; however, it is understood that the edge seal 110 may
also form a portion of the exterior surface of the module 100 as
well as define a boundary of the sealed space 108. The edge seal
110 may also include a seal region 110A, depicted with light
shading, that may occupy a larger surface area than other regions
of the edge seal 110.
[0062] FIG. 2 is a partial section view of the module 100 of FIG. 1
that is taken along section line A-A. Here, the first sheet 102 and
the second sheet 104 can be seen vertically offset from each other,
the sealed space 108 is located between the first and second sheets
102 and 104, and a part of one of the flexible photovoltaic cells
106 is shown within the sealed space 108. As seen in FIG. 2, the
seal region 110A spans a first section of the first sheet 102 and a
second section of the second sheet 104 and forms a part of an
exterior edge surface 112 of the module 100. Here, the first sheet
102 and the second sheet 102 are substantially the same size (e.g.,
same length and width) and are substantially aligned with each
other. Substantially here means within +/-5%.
[0063] The flexible photovoltaic cells 106 may be any appropriate
solar cells that can be flexed without damage. Examples of flexible
photovoltaic cells include copper indium gallium selenide (CIGS)
cells, cadmium-telluride (Cd--e) cells, amorphous silicon (a-Si)
cells, micro-crystalline silicon (Si) cells, crystalline silicon
(c-Si) cells, gallium arsenide (GaAs) multi-junction cells, light
adsorbing dye cells, organic polymer cells, and other types of
photovoltaic cells. A photovoltaic cell typically has a
photovoltaic layer that generates a voltage when exposed to light.
The photovoltaic layer may be positioned adjacent to a back
conductive layer, which, in certain embodiments, is a thin flexible
layer of a metal such as molybdenum (Mo), niobium (Nb), copper
(Cu), silver (Ag), and combinations and alloys thereof. The
photovoltaic cell may also include a flexible conductive substrate,
such as stainless steel foil, titanium foil, copper foil, aluminum
foil, or beryllium foil. Another example includes a conductive
oxide or metallic deposition over a polymer film, such as
polyimide. In certain embodiments, a substrate has a thickness of
between about 50 microns and 1,270 microns (e.g., about 254
microns), with other thicknesses also in the scope of the
embodiments described herein. The photovoltaic cell may also
include a top flexible conductive layer. This layer can include one
or more transparent conductive oxides (TCO), such as zinc oxide,
aluminum-doped zinc oxide (AZO), indium tin oxide (ITO), and
gallium doped zinc oxide. A typical thickness of a top conductive
layer is between about 100 nanometers and 1,000 nanometers or, more
specifically, about 200 nanometers and 800 nanometers. As stated
above, the flexible photovoltaic cells 106 may be interconnected,
for example, by one or more wire networks (not depicted) which may
extend over a front side of one cell as well as over a back side of
another adjacent cell to interconnect these two cells in series. A
photovoltaic module may include any number of flexible photovoltaic
cells 106 in any appropriate arrangement.
[0064] The first and second sheets 102 and 104 may be sealing
sheets that may include flexible materials, such as polyethylene,
polyethylene terephthalate (PET), polypropylene, polybutylene,
polybutylene terephthalate (PBT), PPO, polyphenylene sulfide (PPS)
polystyrene, PC, ethylene-vinyl acetate (EVA), fluoropolymers
(e.g., polyvinyl fluoride (PVF), polyvinylidene fluoride (PVDF),
ethylene-terafluoethylene (ETFE), fluorinated ethylene-propylene
(FEP), perfluoroalkoxy (PFA) and polychlorotrifluoroethane
(PCTFE)), acrylics (e.g., poly(methyl methacrylate)), silicones
(e.g., silicone polyesters), and/or PVC, as well as multilayer
laminates and co-extrusions of these materials. A typical thickness
of a sealing sheet is between about 125 microns and 2,540 microns
or, more specifically, between about 254 microns and 1,270 microns,
though other thicknesses may be used as well. In certain
embodiments, a flexible sealing sheet includes a metallized layer
to improve its water permeability characteristics. For example, a
metal foil may be positioned in between two insulating layers to
form a composite flexible sealing sheet.
[0065] In certain embodiments, the first sheet 102 may be made from
material that is different than a material of the second sheet 104,
and the first and second sheets 102 and 104 may be of different
thicknesses from each other. In some embodiments, these sheets may
have a thickness less than 2,032 microns or, more specifically,
less than 1,016 microns or even less than 508 microns.
[0066] In certain embodiments, the module 100 may have an
encapsulant layer positioned in between the first sheet 102 and the
flexible photovoltaic cells 106, as well as another encapsulant
layer between the second sheet 104 and the flexible photovoltaic
cells 106. Examples of encapsulant layer materials include
non-olefin thermoplastic polymers or TPO, such as polyethylene
(e.g., a linear low density polyethylene), polypropylene,
polybutylene, PET, PBT, polystyrene, polycarbonates,
fluoropolymers, acrylics, ionomers, silicones, and combinations
thereof.
[0067] As noted above, the module 100 may include the edge seal 110
(including the seal region 110A) that surrounds and seals the
flexible photovoltaic cells 106 together with the first sheet 102
and the second sheet 104, as well as with other components. The
edge seal 110 may prevent moisture from penetrating towards the
flexible photovoltaic cells 106. The edge seal 110 may be made from
certain organic or inorganic materials that have low inherent water
vapor transmission rates. In certain embodiments, the edge seal 110
is configured to absorb moisture from inside the module in addition
to protecting the module 100 from moisture ingression. For example,
a butyl-rubber containing moisture getter or desiccant may be added
to the edge seal 110. In certain embodiments, a portion of the edge
seal 110 that contacts electrical components (e.g., bus bars,
diodes, return lines) of module 100 is made from a thermally
resistant polymeric material; this portion of the edge seal 110 may
be the seal region 110A. The edge seal 110 may also secure first
sheet 102 with respect to second sheet 104. In certain embodiments,
the edge seal 110 determines at least some of the boundaries of the
sealed space 108.
[0068] In some embodiments, the module 100 may be manufactured
using one or more lamination procedures in which aspects of the
module 100 may be heated and pressed. For example, the pressing may
be performed by an inflatable bladder, and such lamination may heat
the encapsulant and edge seal such that the sealed space 108 is
formed in the module 100.
[0069] A module connector of a flexible photovoltaic module
described herein may have multiple parts that are configured to be
assembled together and attached to the module. For instance, the
module connector may include an insert and a clamp; the insert may
have an electrical lead electrically connected to a photovoltaic
cell of the module and an electrical cable, and the insert may be
configured to be inserted into the clamp; the clamp may be
configured to clamp the cable to a body portion of the clamp and to
connect the clamp body to the module.
[0070] In some embodiments, the electrical leads of the module may
be positioned within the module 100 during the manufacturing of the
module 100 such that at least the edge seal 110 creates a seal
around portions of the electrical leads. For instance, the module
100 of FIG. 1 includes a first electrical lead 114 and a second
electrical lead 116 that are electrically connected to at least one
of the flexible photovoltaic cells 106 of the module 100, as
represented by the dotted line (not labeled). The first and second
electrical leads 114 and 116 are electrically connected, either
directly or indirectly (e.g., via a bus bar or return line), to the
flexible photovoltaic cells 106. For instance, the second
electrical lead 116 is electrically connected to one flexible
photovoltaic cell 106A while the second electrical lead 114 is
electrically connected to a bus bar 118 that is electrically
connected to another flexible photovoltaic cell 106E.
[0071] Each electrical lead may have a section located within the
body of the insert and another section located within the module.
For example, as seen in FIGS. 1 and 2, a first portion of the first
electrical lead 114 and a first portion of the second electrical
lead 116 extend into and are sealed within an insert body 120. This
seal of the electrical leads in the insert body 120 may be
waterproof and may have an IP (i.e., international protection
marking or ingress protection marking) of IP68, or may have a
National Electrical Manufacturers Association (NEMA) enclosure
rating of 6P. For instance, referring to FIG. 2, the first portion
122 of the first electrical lead 114 can be seen extending into the
insert body 120. A second portion 124 of the first electrical lead
114 is outside the insert body 120 and extends through the seal
region 110A and into the sealed space 108. The seal region 110A
extends around a portion of each of the electrical leads 114 and
116 such that they are sealed within the seal region 110A and the
sealed space 108 remains sealed.
[0072] In some embodiments, like that seen in FIG. 2, a second
portion 126 of the first electrical lead 114 may be clad with
electrical insulation material while a fourth portion 128 of the
first electrical lead 114 may not have be clad with any electrical
insulation and may instead be an exposed electrical element, such
as a bare wire, within the material of the seal region 110A and the
seal spaced 108. An example insulation material may be a
Kapton.RTM. polyimide. This fourth portion 128 of the first
electrical lead 114 may be located in both the sealed space 108 and
the seal region 110A. Having a partially insulated electrical lead
within the seal region may help retain the moisture seal of the
seal region. The second electrical lead 116 may be similarly
configured.
[0073] As stated above, the module includes one or more electrical
connectors that are configured to electrically connect to
components that are external to the module, such as electrical
connectors of adjacent modules. The electrical connectors may also
include, or may be configured to make electrical connections to,
standard MC4 photovoltaic connectors or other types of external
photovoltaic connectors. The module 100 of FIG. 1 includes at least
two such electrical connectors, which are depicted as a first cable
130 and a second cable 132. The first cable 130 includes a first
portion that extends into and is sealed inside the insert body 120
and a second portion that is outside and extends away from the
insert body 120; the second cable 132 also includes a first portion
that extends into and is sealed inside the insert body 120 and a
second portion 128 that is outside and extends away from the insert
body 120. The sealing of the first and second cables 130 and 132 in
the insert body 120 is done in the same manner as described above
with respect to the electrical leads and the insert body 120.
Additionally, the first electrical lead 114 is electrically coupled
to the first cable 130 inside the insert body 120 and the second
electrical lead 116 is electrically coupled to the second cable 132
inside the insert body 120. For instance, in FIG. 2, a part of the
first portion of the first cable 130 inside the insert body 120 is
electrically connected to the first portion 122 of the first
electrical lead 114. The insert body may, in some embodiments, be
overmolded around the first and second electrical leads and the
first and second cables and may be made of a glass filled nylon. In
some embodiments, an "insert" may be considered to include the
insert body, the first and second cables, and the first and second
electrical leads.
[0074] In some embodiments, the first and the second electrical
leads 114 and 116 may extend away from the insert body in a first
direction 134 like can be seen in FIG. 3, which depicts a side view
of an insert of a module connector. As can also be seen in FIG. 3,
the insert body 120 may also include a first surface 136 that is
angled with respect to the first direction 134 by a first angle
138. The insert may be configured such that it may be present
during the manufacturing of the module and does not adversely
affect the manufacturing processes. Such configuration may include
the insert body being made of a material that is able to withstand
the temperatures utilized during the manufacturing processes, such
as between about 130.degree. C. and about 170.degree. C., and the
insert body being shaped so that it does not interfere with the
lamination process. For instance, the insert body may be offset
from the module by a first offset distance 129 seen in FIG. 2,
which may be, for instance, about 5 millimeters, and may have one
or more angled surfaces and a height that allow a press (e.g., a
diaphragm) to press uniformly on the module during a lamination
process. An example diaphragm press is described in U.S. patent
application Ser. No. 12/550,314, filed on Aug. 28, 2009 and titled
"INTEGRATED FRAME FOR CONTROL OF VACUUM LAMINATION" which is hereby
incorporated by reference in its entirety and for all purposes. In
FIG. 3, the first angle 138 may range between about 140.degree. and
180.degree., including about 155.degree.. The height 140 of the
insert body 120 may also be between about 6 millimeters to about 16
millimeters. In some embodiments, a second surface 142 of the
insert body 120 may be angled with respect to the first direction
134 by a second angle 144, which may be between about 140.degree.
to about 180.degree..
[0075] The cables of the insert may extend away from the insert
body in a variety of directions. In some embodiments, the first
cable 130 and the second cable 132 may extend away from the insert
body 120 in opposite directions along a second axis that is
perpendicular to the first direction 134, like depicted in FIG. 1.
FIG. 4 depicts an isometric exploded view of a module connector
that includes the insert of FIG. 1 and a clamp; the clamp is
discussed below. As can be seen in FIG. 4, the insert 146 includes
the insert body 120, the first electrical lead 114, the second
electrical lead 116, the first cable 130, and the second cable 132.
The first cable 130 extends away from the insert body 120 along the
second axis 147 in one direction while the second cable extends
away from the insert body 120 along the second axis 147 in an
opposite direction. In some other embodiments, the first cable 130
and the second cable 132 may extend away from the insert body 120
along a second axis that is parallel to the first direction
134.
[0076] Embodiments of the clamp will now be discussed. As stated
above, the clamp may be configured to connect at least one cable of
the insert to the clamp body so that external forces (e.g., pushing
or pulling) exerted on the cable are transferred to the clamp and
not transferred to the insert body or to the electrical lead. This
connection reduces or prevents the external forces from adversely
affecting the cable, the insert, the electrical leads, the seal of
the module, and the electrical connection between the electrical
lead and the cable. The clamp may also be configured to connect the
clamp body to the flexible photovoltaic module such that, in
conjunction with the connection between the cable and the clamp
body, external forces exerted on the cable are transferred to the
module via the clamp. This connection also reduces or prevents the
external forces from adversely affecting the edge seal, and the
electrical and physical connections of the electrical lead to the
module. For example, if a cable is pulled during the installation
of a module, that pull force will be transferred to the clamp body
and to the module itself, as opposed to being transferred to the
electrical lead that may remove the electrical lead from the
module, tear the module edge, or cause the electrical lead to
disconnect from an internal electrical component.
[0077] The clamp 448 of FIG. 4 includes a body portion 450, a first
clamping portion 452, and a second clamping portion 454. The body
portion 450 includes a recess 456, identified with light shading,
that is configured to receive the insert body 120 such that the
insert body 120 can be inserted into the recess 456. The recess 456
may be shaped and sized such that it matches some of the exterior
surfaces of the insert body 120 and it may have features configured
to removably retain the insert body 120. For instance, the insert
body 120 may be insertable into and removable from the recess 456.
The clamp 448 includes two first clamping portions, 452A and 452B
(452A may also be referred to as the first clamping portion while
452B may be referred to as a third clamping portion), which are
generally located within the dashed boxes. Each first clamping
portion is configured to clamp a cable such that the cable is
connected to the body portion 450 of the clamp 448.
[0078] In some embodiments, each first clamping portion may have a
cable insertion portion 458 and a clamping member 460 (both of
which are shown in dark shading), with the cable insertion portion
458 configured to receive a cable (e.g., first cable 130) and the
clamping member 460 configured to be moveable so that it may
contact the cable and cause the cable to be clamped. In some such
embodiments, the first clamping portion may be configured to be
moveable between an open position and a closed position. In the
open position, like depicted in FIG. 4, the first clamping portion
is configured such that the cable is insertable into the first
clamping portion. In the closed position, the clamping member 460
is configured to contact the cable, to connect to the body portion
450, and to connect the cable to the body portion 450, like
discussed below and shown in FIG. 6.
[0079] FIG. 5 depicts an isometric view of the module connector of
FIG. 4 with the insert inserted into the clamp. The insert body 120
is positioned in the recess of the clamp 448, but the first and
second electrical leads are not depicted for illustration purposes.
As can also be seen, the second portion of the first cable 130 is
positioned in the cable insertion portion 458 of the first clamping
portion 452A and the second portion of the second cable 132 is
similarly positioned in the first clamping portion 452B.
Additionally, the arrows indicate the movement of the clamping
members (e.g., clamping member 460) of the first clamping portions
452A and 452B to contact and clamp the first and second cables 130
and 132 to the body portion 450. The first clamping portions 452A
and 452B may also include surface features that are configured to
better clamp the cables, such as protrusions 462 that can be seen
in FIGS. 4 and 5. The first clamping portions 452A and 452B may
also be configured to crimp the cables. The first clamping portions
may also include fastening features that are configured to retain
the first clamping portions in place, such as snaps or clips. These
features may also be configured to allow the release of the
clamping members so the cable and insert may be removed from the
clamp.
[0080] FIG. 6 depicts another isometric view of the module
connector of FIG. 4. Here, the first clamping portions 452A and
452B are each clamping the first and second cables 130 and 132,
respectively. Each moveable portion has been moved such that it
contacts the cable in its corresponding cable insertion portion 458
and is causing, at least in part, the cable to be connected to the
body portion 450.
[0081] Turning to the second clamping portion 454, it can be seen
generally located within the dotted shape in FIG. 4 and identified
with light shading in FIG. 6. The second clamping portion 454 is
configured to connect the clamp to the module such that the second
clamping portion contacts both the first sheet 102 and the second
sheet 104 of the module 100 and overlaps with and extends around
parts of the first sheet 102, the exterior edge surface 112, and
the second sheet 104. Referring to FIG. 6, the second clamping
portion 454 may therefore include a first clamping surface (here
the first clamping surface has two sections 464A and 464B that are
offset from each other and coplanar with each other) that is
configured to contact the first sheet 102 and a second clamping
surface 466 that is configured to contact the second sheet 104. The
second clamping surface 466 may be located on a moveable portion of
the clamp, such as a flap 468 that is moveably connected to the
body portion 450. In some embodiments, the clamp may include a
flexible connector that flexibly, or movably, connects the flap to
the body portion. In some such embodiments, the body portion, the
flap, and the flexible connector may be a unitary, single body
(i.e., a monolithic body or unit).
[0082] Such moveable connection between the flap 468 and the body
portion 450 enables them to be moveable with respect to each other,
such as indicated by the arrow in FIG. 6, and in some embodiments,
enables the first clamping surface 464A and 464B and the second
clamping surface 466 to be facing each other, including being
parallel to each other. FIG. 7 depicts yet another isometric view
of the module connector of FIG. 4. Here, the flap 468 has been
moved with respect to the body portion 450 such that the first
clamping surface 464A and 464B and the second clamping surface 466
face each other, although such surfaces are not visible in this
Figure.
[0083] FIG. 8 depicts a side view of the clamp of FIG. 4. As can be
seen, the first clamping surface 464A and the second clamping
surface 466 face each other, are parallel to each other, and are
offset from each other by a first separation distance 467. This
first separation distance may be substantially the same (e.g.,
within +/-5%) as the thickness of the module. In some embodiments,
the first clamping surface and/or the second clamping surface may
be planar surfaces. A flexible connector 470 can also be seen which
flexibly connects (e.g., so that it is movably connected) the flap
468 to the body portion 450.
[0084] It should also be noted that the electrical leads are
configured to be flexible to allow the insert to be inserted into
the recess of the clamp and the movement of the clamp as described
herein. For example, when the insert is placed into the recess of
the clamp, the first and second electrical leads may bend or other
wise move to accommodate the insert's positioning within the
recess. Additionally, referring to FIG. 5, the recess 456 may be
configured to receive portions of the electrical leads, which may
include having a first region 457 where sections of the electrical
leads may be located within the recess, as identified in the shaded
portion in FIG. 5. Also, when the flap is moved, the first and
second electrical leads may also move and may protrude from the
clamp as depicted in FIG. 9, which depicts the insert and clamp of
the module connector of FIG. 7 along with two electrical leads.
Here, the first electrical lead 114 and the second electrical lead
116 protrude from the clamp in a direction different than the first
direction.
[0085] To further explain the assembly and configurations of the
insert, the clamp, and the module, the following example clamping
sequence of the module connector of FIG. 4 is provided in FIGS.
10A-10D. FIGS. 10A-10D depict an isometric view of a portion of the
module of 100 along with the insert 146 and the clamp 448. As
identified in FIG. 10A, one flexible photovoltaic cell 106 is
electrically connected to the second electrical lead 116 while the
first electrical lead 114 is electrically connected to the bus bar
118. Additionally, the first sheet 102 of the module can be seen
while the flap and the second clamping are depicted as dashed lines
because they are underneath and obscured by the module 100. In this
configuration and position, the second clamping surface may be
considered facing the second sheet 104.
[0086] In FIG. 10A, like in FIG. 5, the insert body 120 (after it
has already been placed and laminated into a module) is positioned
within the recess 456 of the body portion 450 of the clamp 448, the
first clamping portions 452A and 452B (not identified) are in an
open position, the second portion of the first cable 130 and the
second portion of the second cable 132 are positioned in the first
clamping portions 452A and 452B, respectively, and the clamping
members 460 are moveable in the direction of the arrows.
[0087] FIG. 10B depicts each first clamping portion clamping one of
the cables, like described above and depicted in FIG. 6. Following
this, the clamp 448 and the insert 446 may be moved such that the
first clamping surface (e.g., first part 464A and second part 464B)
contacts the top sheet 102, as indicated by the arrow.
[0088] FIG. 10C depicts the first clamping surface (not seen) of
the second clamping portion of the clamp 448 in contact with the
first sheet 102 of the module because the clamp 448 has been
partially rotated around the module. The flap 468, as stated above,
may be moved such that the second clamping surface can contact the
second sheet 104 (not seen in FIG. 10C). After the first and second
clamping surfaces are in contact with the first and second sheets,
respectively, of the module, the clamp 448 may look how it is
depicted in FIG. 10D. It should be noted that FIGS. 10B and 10C may
be performed in the reverse order or simultaneously with the end
result being the depiction in FIG. 10D.
[0089] FIG. 11 depicts a partial cross-sectional detail view of the
insert, the clamp, and the module along the line B-B in FIG. 10D.
Here in FIG. 11, the insert and clamp are positioned in an example
final clamping position in which the clamp is connected to the
module. Due to the location of the cross-section, the first
clamping surface cannot be seen but it should still be understood
that the first clamping surface is contacting the first sheet 102.
As can be seen, the second clamping surface 466 is contacting the
second sheet 104 and the clamp overlaps and extends around a part
of the first sheet 102, a part of the exterior edge surface 112,
and a part of the second sheet 104. In some embodiments, like in
FIG. 11, the first surface 136 of the insert body 120 is in direct
contact with the first sheet 102.
[0090] The module connector may be connected to the module using
various attachment means including mechanical means, such as teeth,
clamps, rivets, or bolts that extend through the clamp and
penetrate partially into or fully through the module, including the
seal region. In some such embodiments, the module connector is
connected to the module without the use of adhesives, which may be
advantageous to the manufacturing process of the module and
installation because adhesive applying steps are not needed and the
materials of the clamp and the module may be selected without the
consideration of adhesive properties between the adhesives and the
clamp and the module. This mechanical connection may also be
advantageous because it may be a stronger connection than those
connections made with adhesives and it may enable the footprint of
the module connector to be smaller because a particular amount of
surface area is not needed for adhesion to the module.
[0091] In some embodiments, the attachment means attach the module
connector to the module such that the module connector is in the
position depicted in FIGS. 10D and 11. For example, the clamp seen
in FIGS. 4-7,9, and 10A-10D includes holes that extend through the
body portion of the clamp and the flap so that screws, rivets, or
bolts may extend through the clamp and the module to connect the
module connector to the module. A cross-sectional view of these
holes is seen in FIG. 12, which depicts a partial cross-sectional
detail view of the insert and the clamp along the line C-C in FIG.
10D. Here, a first hole 472 extends through the body portion 450
and a second hole 474 extends through the flap 468; these holes, in
some embodiments, do not extend through the insert body 120. A
third hole may also be made in the module which penetrates and
extends through the first sheet 102, the seal region 110A, and the
second sheet 104 so that a bolt may pass through the first hole
472, the second hole 474, and the third hole and therefore attach
the module connector, including the clamp and insert, to the
module.
[0092] In some embodiments, the seal region 110A and/or the first
and second holes 472 and 474 of the module connector are configured
such that the third hole through the module is located a first
distance 1276 away from the sealed space 108 of the module, as seen
in FIG. 12. This first distance 1276 may be based on a minimum seal
requirement for the module that may require that the module have a
non-punctured or uncompromised seal region for at least the first
distance 1276, which may be about or at least about 10 millimeters;
in some embodiments, the overall length of the seal region 110A may
be about or at least about 20 millimeters.
[0093] It should be noted that the clamp and insert are configured
such that the orientation of the clamp may be reversed relative to
what is shown in the Figures; the insert body may instead contact
the second sheet, which may be a bottom sheet of a module. This
enables the insert body to be contacting the first sheet or the
second sheet, e.g., a top sheet or a bottom sheet, of the
module.
[0094] In some embodiments, the first clamping surface 464, the
second clamping surface 466, or both are substantially planar
surfaces (e.g., within 5% of flat). Such planarity may assist in
contact with the first and second sheets of the module.
Additionally, the clamp may be comprised of a polymeric material,
such as a glass filled nylon, polyphenylene ether (PPE),
polyphenylene oxide (PPO), and a blend of polypropylene and
polyethylene-popylenediene (PP-EPDM). The clamp may have a UV
resistance of about 25 years and thermal resistance of at least
about 90.degree. C.
[0095] Some of the embodiments of the module connectors disclosed
herein, including the size of the clamp and its contact with the
module, are configured such that they satisfy the applicable
electrical and safety standards, such as safety and performance
standards of the UL (Underwriters Laboratories) and the IEC
(International Electrotechnical Commission). Some of these
standards may require physical strength requirements as well as a
minimum particular distance (e.g., at least 12.7 millimeters) from
a hot electrical pathway (e.g., where the electrical leads are
located within the clamp as depicted in FIG. 10D) to an interface
of two different materials (e.g., where the clamp and top sheet
meet). In some such embodiments, the clamp has a unitary body which
may remove the existence of an interface between two portions of
the clamp and therefore increase the module connector's ability to
meet some such requirements.
[0096] As noted above, in some embodiments the first and second
cables may extend away from the insert body in a plane that is
parallel to the first direction. FIG. 13 depicts an isometric view
of a second example module connector and FIG. 14 depicts an
exploded isometric view of the second example module connector of
FIG. 13. Referring to FIG. 14, the insert body 1420 is seen with a
first electrical lead 1414 and a second electrical lead 1416 that
extend away from the insert body 1420 in the first direction 1434.
Additionally, the first cable 1430 and the second cable 1432 also
extend away from the insert body 1420 in a direction opposite but
parallel to the first direction 1434; both directions may be
considered along the first axis 1478. In some embodiments, the
cable may each extend in a plane that is parallel to the first axis
178. The first electrical lead 1414, the second electrical lead
1416, the first cable 1430 and the second cable 1432 each have the
first and second portions discussed above with respect to at least
FIGS. 1, 2, and 4. For instance, the first cable 1430 is
electrically connected to the first electrical lead 1414 in the
insert body 1420 and sealed within the insert body 1420. In some
embodiments, the directions of the electrical directions are not
limited to parallel or perpendicular directions, but may extend at
any angle or angles.
[0097] The second example module connector of FIGS. 13 and 14 also
includes a clamp 1448 but here, the clamp 1448 includes a top part
1448A and a bottom part 1448B. In some embodiments, like in FIGS.
14 and 13, these two parts of the clamp may not be a unitary body
or may not be connected to each other before being connected to a
module; in other embodiments, these two parts may be a unitary body
or flexibly connected such that they are moveable with respect to
each other, similar to the body portion and flap described above.
The clamp 1448 includes a recess 1456 (identified with a dotted
line) in FIG. 14 and each part of the clamp may include a portion
of the recess 1456 such that the insert body 1420 is insertable
into both the top part 1448A and the bottom part 1448B of the
clamp.
[0098] First clamping portions and a second clamping portion are
also included on the clamp 1448. Like above, the clamp 1448 may
have two first clamping portions that are each configured to clamp
a cable and connect that cable to the body portion of the clamp.
Here in FIG. 14, each first clamping potion may have a first
section, 1452A1 and 1452B1, located on the top part 1448A and a
second section 1452A2 and 1452B2 located on the bottom part 1448B.
These two sections of each first clamping portion may be configured
to receive a cable (e.g., first cable 1430), clamp the cable so
that the cable is connected to the clamp 1448, and crimp the
cable.
[0099] Also like above, the second clamping portion of the second
example module connector of FIGS. 13 and 14, may have a first
clamping surface that is located on the top part 1448A (not visible
in FIGS. 13 and 14) and a second clamping surface 1466B that is
located on the bottom part 1448B. The second clamping portion here
is also configured like the second clamping portion discussed
above, including configured to connect the clamp to the module such
that the clamp overlaps and extends around a part of first sheet, a
part of the exterior edge surface, and a part of the second
sheet.
[0100] The clamp 1448 includes holes that are configured to enable
attachment means to connect the clamp to the module. This includes
a first hole 1472 in the top part 1468A and a second hole 1474 in
the bottom part 1468B.
[0101] In some embodiments, the insert body may be configured to,
at least in part, clamp the cable to the body portion of the clamp.
In such embodiments, the module connector of FIGS. 15 and 16 has a
first clamping portion separated into two sections, with one
section on the insert body and the other section on the body
portion of the clamp. FIG. 15 depicts an isometric view of a third
example module connector while FIG. 16 depicts an exploded
isometric view of the third example module connector of FIG. 15. In
FIG. 16, the insert body 1620 is inserted into a recess of the body
portion 1650 of the clamp, similar to described above. The module
connector of FIG. 15 is similar to that described above with
respect to FIGS. 4-9. In FIG. 15, the insert 1646 includes the
insert body 1520, the first electrical lead 1514, the first cable
1530, the second electrical lead 1516, and the second cable 1532,
which may be configured and arranged like described above. The
first electrical lead 1514 extends away from the insert body 1520
in the first direction 1534 and the first cable 1530 extends away
from the insert body 1520 along the second axis 1547.
[0102] In FIG. 16, the insert body 1520 includes a first section
1558A (shown with dark shading) of a first clamping portion that is
depicted as a first wing that extends away from the insert body in
a direction along the second axis 1547. The body portion 1550 of
the clamp 1548 includes a second section 1560A (shown with dark
shading) of the first clamping portion and together the first
section 1558A and the second section 1560A are configured to clamp
the first cable 1530 to the body portion 1550 of the clamp 1548,
like can be seen in FIG. 15. Here, the second section 1560A of the
first clamping portion may be configured like above, such as
configured to receive the first cable 1530. The first clamping
portion may also be configured to crimp the cable. The module
connector of FIGS. 15 and 16 also has another first clamping
portion that has another first section 1558B and another second
section 1560B configured to clamp the second cable 1532 to the body
portion 1550.
[0103] The clamp 1548 of FIGS. 15 and 16 is configured similar to
the clamp 448 described above, including the body portion 1550, the
recess 1556, the flap 1568, the second clamping portion 1554, the
first clamping surface 1564A and 1564B, and the second clamping
surface 1566. Also like above, the module connector of FIGS. 15 and
16 is configured to be connected to the module with mechanical
means, e.g., without any adhesives, which includes having first and
second holes, 1572 and 1574, as well as connected to the module
like described in FIGS. 10B-10D, 11, and 12.
[0104] In some embodiments, the insert disclosed herein may be
configured such that the electrical connections between the
electrical leads and the cables are made and sealed inside the
insert body, e.g., via overmolding, before or during the module
manufacturing. This reduces the manufacturing and/or installation
steps, as well as reduces the potential for disconnections, loose
connections, or other adverse effects on these electrical
connections, and thus increases reliability and safety of the
module. As also noted above, the connection of the cable to the
body portion of the clamp and the corresponding connection of the
clamp to the module also increases the structural stability and
safety of the electrical leads and electrical connectors of the
module. Because of the electrical configuration of the insert
disclosed herein, in some embodiments the module connector of the
present disclosure may not be considered to be or to have a
junction box as commonly understood in the art. With such junction
boxes, electrical junctions are made within the junction boxes by a
user after the module has been fabricated, e.g., by welding or
soldering the electrical junction between to electrical components
during installation, and the junction boxes typically involve
sealing procedures, such as the use of an O-ring or potting.
[0105] It should also be noted that some embodiments of the module
connector disclosed herein reduce the surface area that the module
takes up after installation. For example, less surface area may be
required for a module because the majority of the module connector
is located on or within the surface area of the module; the module
connector may add a small amount of area to the effective surface
area of the module. Additionally, the area of the module that may
be used for mounting the module connector may be reduced as
compared to the area used in traditional modules, thereby
increasing the available surface area for photovoltaic cells within
the module of the present disclosure, i.e., increasing the total
module area efficiency.
* * * * *