DIODE-INCLUDED CONNECTOR, PHOTOVOLTAIC LAMINATE AND PHOTOVOLTAIC ASSEMBLY USING SAME
One embodiment relates to a connector that includes a diode. The diode has an anode and a cathode. The connector further includes a first electrical connection which connects to the anode, a second electrical connection which also connects to the anode, and a third electrical connection which connects to the cathode. Another embodiment relates to a photovoltaic laminate which includes a string of photovoltaic cells and three electrical conductors extending out of two discrete penetrations of the laminate. A first electrical conductor is connected to a first end of the string, a second electrical conductor is connected to a second end of the string, and a third electrical conductor is also connected to the second end of the string. The first and third electrical conductors extend out of the first discrete penetration, while the second electrical conductor extends out of the second discrete penetration. Other features and embodiments are also disclosed.
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This application is a continuation of U.S. application Ser. No. 12/972,153, filed on Dec. 17, 2010, which is incorporated herein by reference in its entirety.
BACKGROUND OF THE INVENTION1. Field of the Invention
The present invention relates generally to circuit devices and photovoltaic module assemblies.
2. Description of the Background Art
Photovoltaic (PV) cells, also referred to as “solar cells,” are well known devices for converting solar radiation to electrical energy. Photovoltaic cells may be packaged together in a photovoltaic module.
A conventional photovoltaic module may include a series of interconnected solar cells in a laminate. Typically, metal tabs are electrically connected to ends of the series and exit from the backside at the top center of the laminate. The metal tabs enter an external junction box which is attached to the backside at the top center of the laminate. In the junction box, input and output cables are attached to the tabs to get power from the module, and a diode may be configured to bypass cells in the module, if necessary. These elements relating to the junction box are expensive, and there are substantial installation costs to routing and managing the junction box cables.
It is highly desirable to improve photovoltaic modules such that they may be produced cost-effectively and installed more efficiently.
SUMMARYOne embodiment relates to a connector that includes a diode. The diode has an anode and a cathode. The connector further includes a first electrical connection which connects to the anode, a second electrical connection which also connects to the anode, and a third electrical connection which connects to the cathode.
Another embodiment relates to a photovoltaic laminate which includes a string of photovoltaic cells and three electrical conductors extending out of two discrete penetrations of the laminate. A first electrical conductor is connected to a first end of the string, a second electrical conductor is connected to a second end of the string, and a third electrical conductor is also connected to the second end of the string. The first and third electrical conductors extend out of the first discrete penetration, while the second electrical conductor extends out of the second discrete penetration.
Another embodiment relates to a photovoltaic assembly that includes two of the aforementioned photovoltaic laminates, each including three electrical conductors extending out of two discrete weatherized penetrations. The two photovoltaic laminates are interconnected using the aforementioned diode-included connector with three electrical connections.
Another embodiment relates to a connector that includes a diode. The diode has an anode and a cathode. The connector further includes a first electrical connection which connects to the anode, a second electrical connection which also connects to the anode, a third electrical connection which connects to the cathode, and a fourth electrical connection which connects to the anode.
Another embodiment relates to a photovoltaic laminate which includes a string of photovoltaic cells and two electrical conductors extending out of two discrete penetrations of the laminate. A first electrical conductor is connected to a first end of the string, and a second electrical conductor is connected to a second end of the string. The first electrical conductor extends out of the first discrete penetration, while the second electrical conductor extends out of the second discrete penetration.
Another embodiment relates to a photovoltaic assembly that includes two of the aforementioned photovoltaic laminates, each including two electrical conductors extending out of two discrete weatherized penetrations. The two photovoltaic laminates are interconnected using the aforementioned diode-included connector with four electrical connections and also using an external cable.
Another embodiment relates to a connector that includes two diodes. The connector includes a first electrical connection which connects to the anode of the first diode and the cathode of the second diode and a second electrical connection which connects to the cathode of the first diode. In addition, the connector includes a third electrical connection which connects to the anode of the second diode and a fourth electrical connection which connects to the cathode of the second diode and the anode of the first diode.
Another embodiment relates to a photovoltaic laminate which includes a string of photovoltaic cells and four electrical conductors extending out of at least two discrete penetrations of the laminate. A first electrical conductor is connected to a first end of the string, and a second electrical conductor is connected to an interior point of the string. In addition, a third electrical conductor is also connected to the interior point of the string, and a fourth electrical conductor is connected to a second end of the string.
Another embodiment relates to a photovoltaic assembly that includes two of the aforementioned photovoltaic laminates, each including four electrical conductors extending out of discrete weatherized penetrations. The two photovoltaic laminates are interconnected using a connector that includes two diodes.
These and other embodiments and features of the present invention will be readily apparent to persons of ordinary skill in the art upon reading the entirety of this disclosure, which includes the accompanying drawings and claims.
The use of the same reference label in different drawings indicates the same or like components.
DETAILED DESCRIPTIONThe present patent application discloses innovations relating to diode-included connectors, photovoltaic laminates, and photovoltaic assemblies utilizing the connectors and laminates. The innovations disclosed herein may be used advantageously to reduce the installation costs otherwise necessitated by the routing and managing a large number of junction box cables. In addition, in comparison to embedding bypass diodes in the laminate, the approach disclosed in the present application enables a defective diode to be readily switched out, thus avoiding the need to replace an entire module if its diode fails. Furthermore, a diode operating in a connector as disclosed herein can dissipate heat more readily without disadvantageously heating the module.
The diode device 102 includes an anode and a cathode. When forward biased, the diode device 102 typically allows electrical current to flow through it from the anode to the cathode. When reverse biased, the diode device 102 typically prevents electrical current from flowing through it. A heat sink 103 may be thermally coupled to the diode device 102 so as to provide passive cooling of the diode device 102.
The diode-included connector 100 further includes a first electrical connection 108-1 which connects to the anode, a second electrical connection 108-2 which also connects to the anode, and a third electrical connection 108-3 which connects to the cathode. A first port 114-1 may be configured to electrically connect to the first and third electrical connections (108-1 and 108-3). In one implementation, the first port may be configured as a coaxial connector so as to connect to a coaxial cable (the cable and connectors being configured with sufficient amperage carrying capacity for the electrical current flowing through them during peak operation). A second port 114-2 may be configured to electrically connect to the second electrical connection 108-2.
In accordance with an embodiment of the invention, the photovoltaic laminate 200 may include a first discrete penetration 212− in a corner of the laminate near the first end (the negative polarity end) of the string and a second discrete penetration 212+ in a corner of the laminate near the second end (the positive polarity end) of the string. A sealant may be inserted into the first and second discrete penetrations (212− and 212+) so as to seal them from external moisture. A strain relief may also be incorporated into the discrete penetration such that forces applied to the external conductors are not transferred to the discrete connection point.
A first electrical conductor 208-1 may be electrically connected to the first end of the string and may be configured to extend out of the first discrete penetration. A second electrical conductor 208-2 may be electrically connected to the second end of the string and may be configured to extend out of the second discrete penetration. A third electrical conductor 208-3 may be electrically connected to the second end of the string and may be configured to extend out of the first discrete penetration. In one implementation, a metal bus bar 220 may be embedded in the photovoltaic laminate and configured to connect the second end of the string to the second electrical conductor 208-2. An alternate embodiment which utilizes an external cable, instead of an internal bus bar, is described below in relation to
In one implementation, a first connector 214-1 may be configured at an end of the first and third electrical conductors (208-1 and 208-3). The first connector 214-1 may be of a type so as to connect with the first port 114-1 of the diode-included connector 100 of
In addition, a second connector 214-2 may be configured at an end of the second electrical conductor (208-2). The second connector 214-2 may be of a type so as to connect with the second port 114-2 of the diode-included connector 100 of
Each diode device (602-1 and 602-2) includes an anode and a cathode. A heat sink 603 may be thermally coupled to the diode devices (602-1 and 602-2) so as to provide passive cooling of the devices.
The diode-included connector 600 further includes a first electrical connection 608-1 which connects to the anode of a first diode 602-1 and the cathode of the second diode 602-2, a second electrical connection 608-2 which connects to the cathode of the first diode 602-1, a third electrical connection 608-3 which connects to the anode of the second diode 602-2, and a fourth electrical connection 608-4 which connects to the cathode of the second diode 602-2 and the anode of the first diode 602-1.
A first port 614-1 may be configured to electrically connect to the first and second electrical connections (608-1 and 608-2). A second port 614-2 may be configured to electrically connect to the third and fourth electrical connections (608-3 and 608-3). In one implementation, the first and second ports (614-1 and 614-2) may be configured as coaxial connectors so as to connect to coaxial cables (the cables and connectors being configured with sufficient amperage carrying capacity for the electrical current flowing through them during peak operation).
In accordance with an embodiment of the invention, the photovoltaic laminate 700 may include a first discrete penetration 712− in a corner of the laminate near the first end (the negative polarity end) of the string and a second discrete penetration 712+ in a corner of the laminate near the second end (the positive polarity end) of the string. A sealant may be inserted into the first and second discrete penetrations (712− and 712+) so as to seal them from external moisture. A strain relief may also be incorporated into the discrete penetration such that forces applied to the external conductors are not transferred to the discrete connection point.
A first electrical conductor 708-1 may be electrically connected to the first end (−) of the string and may be configured to extend out of the first discrete penetration 712−. A second electrical conductor 708-2 may be electrically connected to an interior point 720 of the string and may be configured to also extend out of the first discrete penetration 712−. A third electrical conductor 708-3 may be electrically connected to the interior point 720 of the string and may be configured to extend out of the second discrete penetration 712+. Finally, a fourth electrical conductor 708-4 may be electrically connected to the second end (+) of the string and may be configured to also extend out of the second discrete penetration 712+. The electrical conductors 708-3 and 708-4 may comprise, at least in part, a metal bus bar embedded in the laminate. An alternate embodiment which utilizes an external cable, instead of an internal bus bar, is described below in relation to
While a particular interior point 720 in the string of solar cells 202 is shown in
In one implementation, a first connector 714-1 may be configured at an end of the first and second electrical conductors (708-1 and 708-2). The first connector 714-1 may be of a type so as to connect with the first port 614-1 of the diode-included connector 600 of
In addition, a second connector 714-2 may be configured at an end of the third and fourth conductors (708-3 and 708-4). The second connector 714-2 may be of a type so as to connect with the second port 614-2 of the diode-included connector 600 of
The photovoltaic laminate 700 of
Instead of flowing through the leftmost two columns of the string of solar cells, the electrical current IA flows in from the second electrical conductor 708-2 at the negative polarity end, bypasses the first two columns, and flows to the interior point 720 in the string. From the interior point 720, the electrical current IA flows through the rightmost four columns of the string of solar cells and out of the fourth electrical conductor 708-4 at the positive polarity end.
Electrical current IB flows in from the first electrical conductor 708-1 at the negative polarity end and through the first two columns of solar cells in the string to reach the interior point 720. Thereafter, instead of flowing through the rightmost four columns of the string of solar cells, the electrical current IB flows out through the third electrical conductor 708-3 so as to bypasses the rightmost four columns of solar cells.
Once interconnected as described above, the photovoltaic assembly 1300 of
Once interconnected as described above, the photovoltaic assembly 1600 of
In the present disclosure, numerous specific details are provided, such as examples of apparatus, components, and methods, to provide a thorough understanding of embodiments of the invention. Persons of ordinary skill in the art will recognize, however, that the invention can be practiced without one or more of the specific details. In other instances, well-known details are not shown or described to avoid obscuring aspects of the invention.
While specific embodiments of the present invention have been provided, it is to be understood that these embodiments are for illustration purposes and not limiting. Many additional embodiments will be apparent to persons of ordinary skill in the art reading this disclosure.
Claims
1. A photovoltaic laminate comprising:
- a string of photovoltaic cells, the string of photovoltaic cells having a first end and a second end;
- a first connector;
- a first electrical conductor that is electrically connected to the first end of the string of photovoltaic cells and extends out of the first connector;
- a second connector;
- a second electrical conductor that is electrically connected to the second end of the string of photovoltaic cells and extends out of the second connector; and
- a third electrical conductor that is electrically connected to the second end of the string of photovoltaic cells and extends out of the first connector.
2. The photovoltaic laminate of claim 1, further comprising:
- a bus bar that is embedded in the photovoltaic laminate and connects the second end of the string of photovoltaic cells to the third electrical conductor.
3. The photovoltaic laminate of claim 1, further comprising:
- a first discrete penetration, wherein the first electrical conductor is electrically connected to first end of the string of photovoltaic cells by way of the first discrete penetration.
4. The photovoltaic laminate of claim 3, further comprising:
- a second discrete penetration, wherein the second electrical conductor is electrically connected to the second end of the string of photovoltaic cells by way of the second discrete penetration.
5. The photovoltaic laminate of claim 4, further comprising:
- a sealant inserted into the first and second discrete penetrations to seal the first and second discrete penetrations from external moisture.
6. The photovoltaic laminate of claim 5, wherein the first discrete penetration is located near the first end of the string of photovoltaic cells and exits the photovoltaic laminate through a back or edge of the photovoltaic laminate, and wherein the second discrete penetration is located near the second end of the string of photovoltaic cells and exits the photovoltaic laminate through a back or edge of the photovoltaic laminate.
7. The photovoltaic laminate of claim 1, wherein the third electrical conductor is electrically connected to the second end of the string of photovoltaic cells by way of a fourth electrical conductor that is external to the photovoltaic laminate.
8. The photovoltaic laminate of claim 1, wherein the first connector is removably connected to an end of a diode that is external to the photovoltaic laminate.
9. The photovoltaic laminate of claim 8, wherein the first connector is removably connected to a port that is electrically connected to the end of the diode, and
- wherein the diode is housed in a housing that is external to the photovoltaic laminate and that includes the first port.
10. A photovoltaic laminate comprising:
- a string of photovoltaic cells, the string of photovoltaic cells having a first end and a second end;
- a first discrete penetration of the photovoltaic laminate;
- a first electrical conductor that is electrically connected to the first end of the string of photovoltaic cells and extends out of the first discrete penetration;
- a second electrical conductor which is electrically connected to an interior point of the string of photovoltaic cells and extends out of the first discrete penetration;
- a second discrete penetration of the photovoltaic laminate;
- a third electrical conductor that is electrically connected to the interior point of the string of photovoltaic cells and extends out of the second discrete penetration; and
- a fourth electrical conductor that is electrically connected to the second end of the string of photovoltaic cells and extends out of the second discrete penetration.
11. The photovoltaic laminate of claim 10, further comprising:
- a sealant inserted into the first and second discrete penetrations to prevent external moisture from entering the photovoltaic laminate through the discrete penetrations; and
- a strain relief mechanism incorporated into the discrete penetration such that forces applied to the external conductors are not transferred to a connection point.
12. The photovoltaic laminate of claim 10, wherein the first discrete penetration is located near the first end of the string of photovoltaic cells, and wherein the second discrete penetration is located near the second end of the string of photovoltaic cells.
13. The photovoltaic laminate of claim 10, further comprising:
- a first connector, a second connector, a third connector, and a fourth connector,
- wherein the first electrical conductor extends out of the first connector, the second electrical conductor extends out of the second connector, the third electrical conductor extends out of the third connector, and the fourth electrical conductor extends out of the fourth connector.
14. A photovoltaic laminate comprising:
- a string of photovoltaic cells, the string of photovoltaic cells having a first end and a second end;
- a first connector;
- a first electrical conductor that is electrically connected to the first end of the string of photovoltaic cells and extends out of the first connector;
- a second electrical conductor which is electrically connected to an interior point of the string of photovoltaic cells and extends out of the first connector;
- a second connector;
- a third electrical conductor that is electrically connected to the interior point of the string of photovoltaic cells and extends out of the second connector; and
- a fourth electrical conductor that is electrically connected to the second end of the string of photovoltaic cells and extends out of the second connector.
15. The photovoltaic laminate of claim 14, further comprising:
- a first discrete penetration, wherein the first electrical conductor is electrically connected to the first end of the string of photovoltaic cells by way of the first discrete penetration.
16. The photovoltaic laminate of claim 15, further comprising:
- a second discrete penetration, wherein the fourth electrical conductor is electrically connected to the second end of the string of photovoltaic cells by way of the second discrete penetration.
17. The photovoltaic laminate of claim 15, further comprising:
- a sealant inserted into the first and second discrete penetrations to prevent external moisture from entering the photovoltaic laminate through the discrete penetrations; and
- a strain relief mechanism incorporated into the discrete penetration such that forces applied to the external conductors are not transferred to a connection point.
18. The photovoltaic laminate of claim 16, wherein the first discrete penetration is located near the first end of the string of photovoltaic cells, and wherein the second discrete penetration is located near the second end of the string of photovoltaic cells.
19. The photovoltaic laminate of claim 10, wherein the first connector is removably connected to an end of a first diode.
20. The photovoltaic laminate of claim 19, wherein the second connector is removably connected to an end of a second diode.
Type: Application
Filed: Jun 23, 2015
Publication Date: Dec 24, 2015
Applicant: SunPower Corporation (San Jose, CA)
Inventors: David DeGRAAFF (Mountain View, CA), Adam DETRICK (Petaluma, CA)
Application Number: 14/747,836