RECONFIGURABLE PHOTOVOLTAIC LAMINATE(S) AND PHOTOVOLTAIC PANEL(S)
Reconfigurable PV panels can have features that include cut lines for separating full panels into smaller subpanels, connector ribbons for assembling several reconfigurable PV panels into a one-dimensional or two-dimensional array and can be stacked upon each other and unstacked by rotating them about a shared connection.
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This application claims the priority of U.S. provisional application 62/653,907, which was filed on Apr. 6, 2018 and is entitled Reconfigurable Photovoltaic Panel(s). The '907 application is incorporated herein by reference in its entirety.
BACKGROUNDPhotovoltaic (PV) cells, commonly known as solar cells, are devices for conversion of solar radiation into electrical energy. Generally, solar radiation impinging on the surface of, and entering into, the substrate of a solar cell creates electron and hole pairs in the bulk of the substrate. The electron and hole pairs migrate to p-doped and n-doped regions in the substrate, thereby creating a voltage differential between the doped regions. The doped regions are connected to the conductive regions on the solar cell to direct an electrical current from the cell to an external circuit. When PV cells are combined in an array such as a PV laminate, the electrical energy collected from all of the PV cells can be combined in series and parallel arrangements to provide power with a certain voltage and current.
A PV laminate comprises one or more PV cells and a supporting substrate. These PV cells are arranged in an array and are positioned on the PV laminate to receive light for conversion into electrical voltage. The PV laminates are manufactured in square and rectangular shapes and may have a supporting frame and their own electrical converters, in which case they are considered a DC module or AC module depending upon the type of electrical voltage output by the electrical converter. Several PV panels, i.e., laminates with support frames, may themselves be arranged in an array and these arrays may be installed on the roof of a building or other support structure configured to support the array of laminate panels. These arrays may be one-dimensional, e.g. 1 PV panel×5 PV panels, as well as two-dimensional, e.g., 2 PV panels×5 PV panels. Once installed, the arrays of PV panels may be connected in a series, daisy chain fashion, in order to deliver their electrical power to an outside load.
The following detailed description is merely illustrative in nature and is not intended to limit the embodiments of the subject matter of the application or uses of such embodiments. As used herein, the word “exemplary” means “serving as an example, instance, or illustration.” Any implementation described herein as exemplary is not necessarily to be construed as preferred or advantageous over other implementations. Furthermore, there is no intention to be bound by any expressed or implied theory presented in the preceding technical field, background, brief summary or the following detailed description.
This specification includes references to “one embodiment” or “an embodiment.” The appearances of the phrases “in one embodiment” or “in an embodiment” do not necessarily refer to the same embodiment. Particular features, structures, or characteristics may be combined in any suitable manner consistent with this disclosure.
Terminology. The following paragraphs provide definitions and/or context for terms found in this disclosure (including the appended claims):
“About” or “approximately”. As used herein, the terms “about” or “approximately” in reference to a recited numeric value, including for example, whole numbers, fractions, and/or percentages, generally indicates that the recited numeric value encompasses a range of numerical values (e.g., +/−5% to 10% of the recited value) that one of ordinary skill in the art would consider equivalent to the recited value (e.g., performing substantially the same function, acting in substantially the same way, and/or having substantially the same result).
“Comprising.” This term is open-ended. As used in the appended claims, this term does not foreclose additional structure or steps.
“Configured To.” Various units or components may be described or claimed as “configured to” perform a task or tasks. In such contexts, “configured to” is used to connote structure by indicating that the units/components include structure that performs those task or tasks during operation. As such, the unit/component can be said to be configured to perform the task even when the specified unit/component is not currently operational (e.g., is not on/active). Reciting that a unit/circuit/component is “configured to” perform one or more tasks is expressly intended not to invoke 35 U.S.C. § 112, sixth paragraph nor 35 U.S.C. § 112 (f), for that unit/component.
“First,” “Second,” etc. As used herein, these terms are used as labels for nouns that they precede, and do not imply any type of ordering (e.g., spatial, temporal, logical, etc.). For example, reconfigurable PV panels may have various topologies. These topologies may include having cut-lines for changing the shape of a single PV panel as well as having mechanical connectors for enabling an unwinding of stacked PV panels and mechanical and electrical leads to allow for obstruction avoidance or other installation challenges. Some topologies may also employ rigidity supports that can provide stabilization to an installation as well as severable noncontinuity connections, which can allow for PV panels to be cut along these connections without leaving exposed active electrical wiring after the cut is made.
“Based On.” As used herein, this term is used to describe one or more factors that affect a determination. This term does not foreclose additional factors that may affect a determination. That is, a determination may be solely based on those factors or based, at least in part, on those factors. Consider the phrase “determine A based on B.” While B may be a factor that affects the determination of A, such a phrase does not foreclose the determination of A from also being based on C. In other instances, A may be determined based solely on B.
“Coupled”—The following description refers to elements or nodes or features being “coupled” together. As used herein, unless expressly stated otherwise, “coupled” means that one element/node/feature is directly or indirectly joined to (or directly or indirectly communicates with) another element/node/feature, and not necessarily mechanically.
“Inhibit”—As used herein, inhibit is used to describe a reducing or minimizing effect. When a component or feature is described as inhibiting an action, motion, or condition it may completely prevent the result or outcome or future state completely. Additionally, “inhibit” can also refer to a reduction or lessening of the outcome, performance, and/or effect which might otherwise occur. Accordingly, when a component, element, or feature is referred to as inhibiting a result or state, it need not completely prevent or eliminate the result or state.
In addition, certain terminology may also be used in the following description for the purpose of reference only, and thus are not intended to be limiting. For example, terms such as “upper”, “lower”, “above”, and “below” refer to directions in the drawings to which reference is made. Terms such as “front”, “back”, “rear”, “side”, “outboard”, and “inboard” describe the orientation and/or location of portions of the component within a consistent but arbitrary frame of reference which is made clear by reference to the text and the associated drawings describing the component under discussion. Such terminology may include the words specifically mentioned above, derivatives thereof, and words of similar import.
In the following description, numerous specific details are set forth, such as specific operations, in order to provide a thorough understanding of embodiments of the present disclosure. It will be apparent to one skilled in the art that embodiments of the present disclosure may be practiced without these specific details. In other instances, well-known techniques are not described in detail in order to not unnecessarily obscure embodiments of the present disclosure.
This specification describes exemplary reconfigurable PV laminates, laminates with frames, i.e. PV panels, PV panels with microinverters, i.e., PV modules, and various related components and systems. Reconfigurable PV laminates and PV panels may be helpful in that during installation their shape or size may be changed to better accommodate the existing or anticipated installation site. For example, if a southerly facing roof surface is 10 meters by 10 meters and the reconfigurable PV laminates are 1.0 meters×1.5 meters some of the reconfigurable PV laminates may be installed without being reconfigured but several of the PV laminates may be cut shorter to fit within the 10 meter by 10 meter space such that a larger portion of the entire available roof space may be covered by the PV panels. In some installations, the laminates and/or panels may also employ electrical and mechanical connections to allow PV panels or PV subpanels to avoid an obstruction in as an efficient a manner as possible. In other words, if a roof penetration falls in the middle of a PV panel, the PV laminate may be cut at its closest cut line and the electrical and mechanical connections may be used to connect adjacent PV panels around the obstruction. Similarly, reconfigurable PV panels with flexible leads between them, may also be employed to avoid the obstruction, where the flexible leads can be used to space connected PV panels around the obstruction. Embodiments may also employ rigidity bars or other rigidity support structures to provide support to PV laminates and/or panels. These rigidity structures may be located along one or more edges of one or more PV laminates or panels, and may serve to position a PV laminate or panel or laminates or panels at an installation site in addition to providing rigidity to the installed laminate or panel, to provide support against uplift caused by wind or other forces, and for other purposes, as well. Moreover, the rigidity structures may also serve to reduce pressure differentials between portions of the PV laminates or PV panels including the top surface and bottom surfaces of the PV laminates or panels. The reconfigurable nature of the PV laminates and/or panels may also provide for shipping efficiencies at least attributable to reduced spacing and manufacturing improvements at least attributable less retooling to manufacture different size PV laminates or panels.
The connections, such as the swivel connection, may provide manufacturing advantages, as production may be broken down into subpanels that may be aggregated during assembly and then unfolded or unstacked into a larger system at an installation site. In other words, large runs of the same size PV laminate or PV panel may be accomplished and these same size PV laminates or PV panels may, nevertheless, be suitable for many different installation sizes and layouts.
Viability of how a reconfigurable PV laminate or PV panel can be reconfigured can be dependent on the flexibility of a microinverter servicing the reconfigurable panel. For example, a first microinverter may be sized and configured to support one-half or more of a single PV laminate or PV panel, so in this instance the PV laminate or PV panel may be cut in half, but no less. A second microinverter may be sized and configured to support three-quarters or more of a reconfigurable PV laminate or PV panel, so in this instance, only one-fourth of the PV laminate or PV panel may be removed when this second microinverter is part of the PV module system. Similarly, a microinverter or other converter may be sized to service 1.5 or 1.75 or even 2.25 laminates/panels or more, which would allow many PV subpanels/laminates to be connected to a single microinverter, even if they in total produce more power than a single PV panel or PV laminate.
Embodiments may also enable arrangement of PV laminates or PV panels wherein adjacent laminates or panels may overlap each other, which may be referred to as shingling. This shingling may be in either the X or Y direction, or in both directions, where overlap can serve to increase the available exposed PV cell surface area as well as improve water shedding capabilities of an installed PV system, or for other purposes, as well. Extension cables, connection ribbons, or other connection systems may also be employed. These extension cables or ribbons or connection systems may be long in certain instances, e.g., 0.5, 0.75, and 1 meter or more, such that subpanels may be optimally positioned around obstacles as well as roof contours at an installation site. These extension cables or ribbons or connection systems may be short in certain instances, e.g., 0.1, 0.2, and 0.25 meters or less, such that subpanels may be optimally positioned about each other and/or mimic roof contours or provide other accommodative aspects.
As shown in certain Figures, reconfigurable PV subpanels/laminates may be laminated individually with wire leads extending out of one or more of them. Multiple reconfigurable PV subpanels/laminates may be connected together. In some embodiments, when the connecting cables are long enough, extra degrees of freedom of movement for positioning the PV panels or PV laminates can be obtained, thereby allowing for extra maneuverability on the roof and in some instances can allow for conventional shingling of the PV panels or PV laminates, e.g., similar in concept to how roofs are shingled with asphalt roof shingles. Some embodiments may reduce the complexity of reconfigurable PV panels or PV laminates with elaborate connection systems by making the cables shorter and allowing shingling in only one direction but, nevertheless, maintaining the ability to avoid obstacles.
Embodiments may also provide flexibility whereby multi-conductor cabling may be employed. For example, if the cable connecting subpanels/laminates is multi-conductor, then each subpanel can be in parallel. For instance, if the voltage is <30V/panel then safety regulations may allow an installer to cut panels/laminates away in the field while leaving exposed conductors. This may be advantageous when customizing to a particular roof structure. In other words, when a reconfigurable PV panel or PV laminate is cut, if operating voltages are low, a termination cap or some type of live conductor termination system may not be required because of the low exposed potential. However, in embodiments, a termination cap or some type of live conductor termination system may be employed. Other cut connection termination topologies may also be employed in embodiments.
PV laminates 124, 125, and 126 were previously stacked upon each other and are shown connected via pivot connectors 121. Once unstacked, the PV laminates may be held relative to each other via mechanical connectors 122. A micro-inverter 123 is also shown receiving a DC voltage from the three PV laminates and supplying an AC voltage to a shared cable 103 via nodes 102. As described in more detail below with regard to
PV panels 143, 144, and 145 are shown in
PV sub-panels 151, 152, and 153 are also shown in
Thus, system embodiments may include the reconfigurable PV laminates, PV panels and components shown in
In embodiments, the microinverter 123 may be adaptable to operate and support full PV panels as well as fractions of those full PV panels. When multiple PV laminates are expected to be cut, embodiments may also provide for one or more microinverters to be removed because of the excess unnecessary and unused power handling capabilities. In embodiments, jumper cables or other connectors may be employed such that one or more PV panels or PV laminates may be joined to a single microinverter rather than each having their own. Thus, a reduction in microinverters may occur, and those microinverters that remain may operate more often in a range of full capacity as they are more likely supporting a full PV panel rather than one-half or three-quarters of a PV panel, which would occur when a microinverter supports a single cut PV panel.
In embodiments, when laminates 145 meet, their connectors may be connected to each other and jumpers may also be used when needed to cap unused connectors or to add additional PV laminates or PV panels to the joined system.
The laminates, connections and circuit topology of
Jumper connector 860 is shown positioned above jumper connector 870. The mechanical attachment 871 is shown below passage 803. Also labelled in this connection are the PV laminate 845 and the PV laminate 843. As can be seen, the bottom jumper connector 870 is sized and configured to provide a mechanical connection with the top jumper connector 860. Once mated, as shown at arrow 890, a jumper connector bridge 880 may be used to electrically connect the mechanical attachment 871, which is also shown with a positive electrical connection to the PV laminate 843, to a negative electrical connector 872, which is electrically connected to the PV laminate 845. Other PV laminates 809 of
Also labelled in
Thus,
Still further, embodiments may employ various combinations of power support circuitry as identified above, including as in
Although specific embodiments have been described above, these embodiments are not intended to limit the scope of the present disclosure, even where only a single embodiment is described with respect to a particular feature. Examples of features provided in the disclosure are intended to be illustrative rather than restrictive unless stated otherwise. The above description is intended to cover such alternatives, modifications, and equivalents as would be apparent to a person skilled in the art having the benefit of this disclosure.
The scope of the present disclosure includes any feature or combination of features disclosed herein (either explicitly or implicitly), or any generalization thereof, whether or not it mitigates any or all of the problems addressed herein. Accordingly, new claims may be formulated during prosecution of this application (or an application claiming priority thereto) to any such combination of features. In particular, with reference to the appended claims, features from dependent claims may be combined with those of the independent claims and features from respective independent claims may be combined in any appropriate manner and not merely in the specific combinations enumerated in the appended claims.
Claims
1-20. (canceled)
21. A photovoltaic laminate system comprising:
- a photovoltaic laminate comprising rows and columns of photovoltaic cells, the rows and columns of photovoltaic cells arranged in three or more groupings, wherein a cut line is present between at least two different adjacent groupings of the photovoltaic cells, the cut lines susceptible to mechanical separation of the photovoltaic laminate while maintaining electrical connectivity via at least one diode therebetween adjacent groupings of photovoltaic cells after mechanical separation along the cutline therebetween; and
- a microinverter electrically connected to at least one of the groupings of photovoltaic cells.
22. The photovoltaic laminate system of claim 21 further comprising:
- a ribbon connector electrically connecting each of the three or more groupings of photovoltaic cells to the microinverter.
23. The photovoltaic laminate system of claim 21 wherein the cut lines are parallel.
24. The photovoltaic laminate system of claim 21 wherein no wire, strand, or trace is exposed after mechanical separation along the cutline between two adjacent groupings of photovoltaic cells.
25. The photovoltaic laminate system of claim 21 further comprising a capping bar electrically connected to one of the groupings of photovoltaic cells.
26. The photovoltaic laminate of claim 25 further comprising a plurality of rigidity supports, each rigidity support of the plurality mechanically connected to the capping bar.
27. The photovoltaic laminate system of claim 26 wherein each of the rigidity supports comprises a channel, the channel receiving one of the groupings of photovoltaic cells.
28. A photovoltaic laminate system comprising:
- a photovoltaic laminate comprising at least three rows and at least three columns of photovoltaic cells, the rows and columns of photovoltaic cells arranged in a plurality of groupings, wherein a cut line is present between at least two different adjacent groupings of the photovoltaic cells, the cut lines susceptible to mechanical separation of the photovoltaic laminate while maintaining electrical connection after mechanical separation along the cut line via at least one diode.
29. The photovoltaic laminate system of claim 28 further comprising:
- a ribbon connector electrically connecting each of the groupings of photovoltaic cells to a microinverter.
30. The photovoltaic laminate system of claim 28 wherein the cut lines are parallel.
31. The photovoltaic laminate system of claim 28 wherein no wire, strand, or trace is exposed after mechanical separation along the cutline between two adjacent groupings of photovoltaic cells.
32. The photovoltaic laminate system of claim 28 further comprising a capping bar electrically connected to one of the groupings of photovoltaic cells.
33. The photovoltaic laminate of claim 32 further comprising a plurality of rigidity supports, each rigidity support of the plurality mechanically connected to the capping bar.
34. The photovoltaic laminate system of claim 33 wherein each of the rigidity supports comprises a channel, the channel receiving one of the groupings of photovoltaic cells.
35. The photovoltaic laminate system of claim 33 wherein at least one of the rigidity comprises a ventilation channel, the ventilation channel sized to permit airflow from one side of the photovoltaic laminate to another side of the photovoltaic laminate.
36. The photovoltaic laminate system of claim 33 wherein at least one of the rigidity comprises a ventilation channel, the ventilation channel sized to permit airflow from a top face of the photovoltaic laminate to a bottom face side of the photovoltaic laminate.
37. A photovoltaic laminate system comprising:
- a photovoltaic laminate comprising rows and columns of photovoltaic cells, the rows and columns of photovoltaic cells arranged in a plurality of groupings, wherein a cut line is present between at least two adjacent groupings of the photovoltaic cells, the cut lines predetermined for mechanical separation of the photovoltaic laminate along the cut line while remaining electrically connected after mechanical separation with at least one diode therebetween; and
- a microinverter electrically connected to at least one of the groupings of photovoltaic cells.
38. The photovoltaic laminate system of claim 37 further comprising:
- a ribbon connector electrically connecting each of the three or more groupings of photovoltaic cells to the microinverter.
39. The photovoltaic laminate system of claim 37 wherein the cut lines are parallel.
40. The photovoltaic laminate system of claim 37 wherein no wire, strand, or trace is exposed after mechanical separation along the cutline between two adjacent groupings of photovoltaic cells.
Type: Application
Filed: Nov 4, 2022
Publication Date: Feb 23, 2023
Applicant: SunPower Corporation (.San Jose, CA)
Inventors: Zachary S. Judkins (Berkeley, CA), David C. Okawa (Belmont, CA), Brian S. Wares (Berkeley, CA), Tamir Lance (Los Gatos, CA), Patrick L. Chapman (Austin, TX)
Application Number: 17/980,716