Electrical interconnects for photovoltaic modules and methods thereof

System and method for interconnecting photovoltaic modules. The system includes a first photovoltaic module and a second photovoltaic module. The first photovoltaic module includes a first bus bar and a first interconnect tab connected to the first bus bar. The second photovoltaic module includes a second bus bar and a second interconnect tab connected to the second bus bar. The system for interconnecting photovoltaic modules additionally includes a module interconnector configured to interconnect the first and the second photovoltaic modules. The module interconnector includes an interconnection component and an interconnection protector. Additionally, the system for interconnecting photovoltaic modules includes a first connection component connecting the interconnection component to the first interconnect tab of the first photovoltaic module and a second connection component connecting the interconnection component to the second interconnect tab of the second photovoltaic module.

2. BACKGROUND OF THE INVENTION

The present invention is directed to interconnects for photovoltaic modules. More particularly, the invention provides electrical interconnects between conductive tabs for photovoltaic modules and methods thereof. Merely by way of example, the invention has been applied to the interconnection of photovoltaic modules with interconnection protectors. But it would be recognized that the invention has a much broader range of applicability.

A traditional photovoltaic module (“PV module) often is equipped in the factory with two wires and expensive electrical connectors. For example, these expensive electrical connectors might include push-to-connect connectors such as MC-4 compatible connectors. These conventional wires and connectors are then used at the installation site to interconnect PV modules into strings of modules or into larger photovoltaic arrays. The photovoltaic strings and modules are typically mounted in areas where they are exposed to extremes of heat and cold, are subject to thermal cycling, and are subject to hazardous weather conditions such as high winds, rain, sleet, and/or snow. Consequently, the electrical connectors interconnecting the PV modules must be weatherproof for decades, tolerant of thermal cycling, and/or allow for rapid assembly.

To minimize the total cost of a photovoltaic installation, it is often desirable to reduce both the cost of the PV module and the labor required for installation. Although the PV modules need to be weatherproof after final installation at the installation site, the requirements for weatherproofing often are not as stringent between fabrication of the PV module in the factory and installation of the PV module at the installation site. In addition, for large installations, specialized and/or automated interconnection tooling may be used. Thus, improved interconnections between PV modules in a large photovoltaic array can, for example, provide a significant reduction in material, labor, and/or construction costs. In another example, improved interconnections increases the packing density of PV modules reducing the cost of shipping PV modules to the installation site.

Hence, it is highly desirable to improve techniques for interconnecting PV modules so to optimize the hardware and/or the process for electrically interconnecting the PV modules to reduce the total cost of the photovoltaic installation.

3. BRIEF SUMMARY OF THE INVENTION

The present invention is directed to interconnects for photovoltaic modules. More particularly, the invention provides electrical interconnects between conductive tabs for photovoltaic modules and methods thereof. Merely by way of example, the invention has been applied to the interconnection of photovoltaic modules with interconnection protectors. But it would be recognized that the invention has a much broader range of applicability.

According to one embodiment, a system for interconnecting photovoltaic modules includes a first photovoltaic module and a second photovoltaic module. The first photovoltaic module includes a first bus bar and a first interconnect tab connected to the first bus bar. The second photovoltaic module includes a second bus bar and a second interconnect tab connected to the second bus bar. The system for interconnecting photovoltaic modules additionally includes a module interconnector configured to interconnect the first photovoltaic module and the second photovoltaic module. The module interconnector includes an interconnection component and an interconnection protector. Additionally, the system for interconnecting photovoltaic modules includes a first connection component connecting the interconnection component to the first interconnect tab of the first photovoltaic module and a second connection component connecting the interconnection component to the second interconnect tab of the second photovoltaic module. The interconnection protector substantially encloses the interconnection component, the first connection component, and the second connection component.

According to another embodiment, a method for installing photovoltaic modules includes providing a first photovoltaic module that includes a first bus bar, providing a second photovoltaic module that includes a second bus bar, attaching a first interconnect tab to the first bus bar, and attaching a second interconnect tab to the second bus bar. The method for installing photovoltaic modules further includes interconnecting the first photovoltaic module and the second photovoltaic module by connecting the first interconnect tab to an interconnection component with a first connection component and by connecting the second interconnect tab to the interconnection component with a second connection component. The method for installing photovoltaic modules additionally includes enclosing substantially the interconnection component, the first connection component, and the second connection component by an interconnection protector. The method for installing photovoltaic modules additionally includes packing, for shipping, at least the first photovoltaic module and the second photovoltaic module, the first photovoltaic module and the second photovoltaic module being interconnected to each other, shipping, to an installation site, at least the packed first photovoltaic module and second photovoltaic module, the first photovoltaic module and the second photovoltaic module being interconnected to each other, and installing, at the installation site, at least the first photovoltaic module and the second photovoltaic module.

According to yet another embodiment, a method for installing photovoltaic modules includes providing a first photovoltaic module that includes a first bus bar and a first interconnect tab connected to the first bus bar and providing a second photovoltaic module that includes a second bus bar and a second interconnect tab connected to the second bus bar. The method for installing photovoltaic modules further includes coating the first interconnect tab at least partially with a first protective film and coating the second interconnect tab at least partially with a second protective film. The method for installing photovoltaic modules additionally includes packing, for shipping, at least the first photovoltaic module and the second photovoltaic module, shipping, to an installation site, at least the packed first photovoltaic module and second photovoltaic module, and installing, at the installation site, at least the first photovoltaic module and the second photovoltaic module. The method for installing photovoltaic modules additionally includes interconnecting, at the installation site, the installed first photovoltaic module and the installed second photovoltaic module by connecting the first interconnect tab to an interconnection component with a first connection component and by connecting the second interconnect tab to the interconnection component with a second connection component. The method for installing photovoltaic modules additionally includes enclosing substantially the interconnection component, the first connection component, and the second connection component with an interconnection protector.

Depending upon the embodiment, one or more of these benefits may be achieved. These benefits and various additional objects, features, and advantages of the present invention can be fully appreciated with reference to the detailed description and accompanying drawings that follow.

5. DETAILED DESCRIPTION OF THE INVENTION

The present invention is directed to interconnects for photovoltaic modules. More particularly, the invention provides electrical interconnects between conductive tabs for photovoltaic modules and methods thereof. Merely by way of example, the invention has been applied to the interconnection of photovoltaic modules with interconnection protectors. But it would be recognized that the invention has a much broader range of applicability.

FIG. 1is a simplified diagram showing a planar view of a photovoltaic module interconnection system according to one embodiment of the present invention. This diagram is merely an example, which should not unduly limit the scope of the claims. One of ordinary skill in the art would recognize many variations, alternatives, and modifications. InFIG. 1, the photovoltaic interconnection system100includes a plurality of PV modules51. In one example, the PV modules51are interconnected to neighboring PV modules51using an interconnection system. In another example, each of the plurality of PV modules51includes a plurality of bus bars52and/or a plurality of interconnect tabs53. In yet another example, a first PV module51and a second PV module51are interconnected using a module interconnector57.

FIG. 2is a simplified diagram showing a side view of the photovoltaic module interconnection system100according to one embodiment of the present invention. This diagram is merely an example, which should not unduly limit the scope of the claims. One of ordinary skill in the art would recognize many variations, alternatives, and modifications.

FIG. 3is a simplified diagram showing a planar view of a photovoltaic module51as part of the photovoltaic module interconnection system100according to one embodiment of the present invention. This diagram is merely an example, which should not unduly limit the scope of the claims. One of ordinary skill in the art would recognize many variations, alternatives, and modifications. InFIG. 3, the PV module51includes a plurality of bus bars32. In one example, the plurality of bus bars32are the plurality of bus bars52. In another example, each PV module51includes two bus bars32coupled to the positive and negative ends of the array of photovoltaic cells included in the PV module51.

In some embodiments, the PV module includes a plurality of interconnect tabs33that extend beyond the edge of the PV module51and protrude from a side of the PV module51. In other embodiments, the plurality of interconnect tabs33are the plurality of interconnect tabs53. In yet another embodiment, the each of the plurality of interconnect tabs33is an extension of the respective bus bar32. In yet another embodiment, each of the plurality of interconnect tabs33is an additional conductor. In yet another embodiment, the plurality of interconnect tabs33are not rated to be weatherproof as assembled in the factory, but are potted (e.g., cemented) in a weatherproof package at the installation site. In yet another embodiment, each of the plurality of interconnect tabs33is coated at least partially with an electrically protective film.

FIG. 4is a simplified diagram showing a side view of a photovoltaic module51as part of the photovoltaic module interconnection system100according to another embodiment of the present invention. This diagram is merely an example, which should not unduly limit the scope of the claims. One of ordinary skill in the art would recognize many variations, alternatives, and modifications. As shown inFIG. 4, the PV module51includes a photovoltaic panel12that includes active and conductive layers. For example, the photovoltaic panel12includes any material such as silicon, cadmium telluride, CIGS, organics, and/or other photovoltaic active materials. In another example, the photovoltaic module51includes a plurality of interconnect tabs13. In yet another example, the plurality of interconnect tabs13are the plurality of interconnect tabs33and/or the plurality of interconnect tabs53. In yet another example, each of the plurality of interconnect tabs13is an extension of a respective bus bar connected to the photovoltaic panel12. In yet another example, each of the plurality of interconnect tabs13is a separate conductor from the respective bus bar. In yet another example, each of the plurality of interconnect tabs13is coated at least partially with an electrically protective film.

In one embodiment, the PV module51includes a first encapsulating material15protecting a front panel surface and a back panel surface of the photovoltaic panel12from the environment. For example, the first encapsulating material15includes glass, foil, polymer, and/or a laminate of multiple materials. In another example, the front panel surface is designed to face a light source (e.g., the sun) in order to generate power. In another embodiment, the PV module51includes a second encapsulating material14around a plurality of edge surfaces of the photovoltaic panel12for protecting the photovoltaic panel12from the environment. In one example, the second encapsulating material14includes a polymer and/or other mixture of materials selected to minimize the damage to the photovoltaic panel12. In yet another example, the second encapsulating material14is placed above or below and/or on the sides of each of the plurality of interconnect tabs13. In yet another embodiment, the first encapsulating material15and/or the second encapsulating material14substantially encloses the photovoltaic panel12by, for example, covering all the surfaces of the photovoltaic panel12except for the locations where the interconnect tabs13are located. In yet another embodiment, the first encapsulating material15and/or the second encapsulating material14protects the photovoltaic panel12from ambient conditions outside of the PV module51, such as moisture, abrasion, debris, and/or oxygen.

FIG. 5is a simplified diagram showing a side view of a photovoltaic module51as part of the photovoltaic module interconnection system100according to yet another embodiment of the present invention. This diagram is merely an example, which should not unduly limit the scope of the claims. One of ordinary skill in the art would recognize many variations, alternatives, and modifications. As shown inFIG. 5, the PV module51includes a plurality of bus bars42. In one example, the plurality of bus bars42are the plurality of bus bars52. In another example, each PV module51includes two bus bars42coupled to the positive and negative ends of the array of photovoltaic cells included in the PV module51. In yet another example, the PV module51includes an interconnect tab43and an interconnect tab44. In one embodiment, the interconnect tab43and the interconnect tab44are the plurality of interconnect tabs53. In another embodiment, the interconnect tab43and/or the interconnect tab44protrudes from the PV module51parallel to the bus bars42. In yet another embodiment, the interconnect tab43and/or the interconnect tab44protrudes from the PV module51at some angle relative to the respective bus bar42. In yet another embodiment, interconnect tab43and/or interconnect tab44is an extension of the respective bus bar42. In yet another example, the interconnect tab43and/or the interconnect tab44is coated at least partially with an electrically protective film.

FIG. 6is a simplified diagram showing a side view of a photovoltaic module51as part of the photovoltaic module interconnection system100according to yet another embodiment of the present invention. This diagram is merely an example, which should not unduly limit the scope of the claims. One of ordinary skill in the art would recognize many variations, alternatives, and modifications. As shown inFIG. 6, the PV module51includes a photovoltaic panel22that includes active and conductive layers. For example, the photovoltaic panel22includes any material such as silicon, cadmium telluride, CIGS, organics, and/or other photovoltaic active materials. In another example, the photovoltaic module51includes a plurality of interconnect tabs27. In yet another example, the plurality of interconnect tabs27are the plurality of interconnect tabs53. In yet another example, each of the plurality of interconnect tabs27are connected to a respective bus bar26connected to the photovoltaic panel12.

In one embodiment, each of the plurality of interconnect tabs27is composed of conductive tape and/or thin metal. In another embodiment, each of the plurality of interconnect tabs27protrudes from the side of the PV module51. In yet another embodiment, each of the plurality of interconnect tabs27extends around the first encapsulating material25to a front module surface or a back module surface of the PV module51. For example, the front module surface is designed to face a light source (e.g., the sun) in order to generate power. In yet another embodiment, the PV module51provides physical support for each of the plurality of interconnect tabs27for subsequent interconnection of multiple PV modules51. In yet another embodiment, each of the plurality of interconnect tabs27is coated at least partially with an electrically protective film.

In yet another embodiment, the PV module51includes a first encapsulating material25protecting a front panel surface and a back panel surface of the photovoltaic panel22from the environment. For example, the first encapsulating material25includes glass, foil, polymer, and/or a laminate of multiple materials. In another example, the front panel surface is designed to face a light source (e.g., the sun) in order to generate power. In yet another example, the first encapsulating material25is the first encapsulating material15. In yet another embodiment, the PV module51includes a second encapsulating material24around a plurality of edge surfaces of the photovoltaic panel22for protecting the photovoltaic panel212from the environment. In one example, the second encapsulating material24includes a polymer and/or other mixture of materials selected to minimize the damage to the photovoltaic panel22. In yet another example, the second encapsulating material24is placed above or below and/or on the sides of each of the plurality of interconnect tabs23. In yet another example, the second encapsulating material24is the second encapsulating material14. In yet another embodiment, the first encapsulating material25and/or the second encapsulating material24substantially encloses the photovoltaic panel22by, for example, covering all the surfaces of the photovoltaic panel22except for the locations where the interconnect tabs23are located. In yet another embodiment, the first encapsulating material25and/or the second encapsulating material24protects the photovoltaic panel22from ambient conditions outside of the PV module51, such as moisture, abrasion, debris, and/or oxygen.

Returning toFIGS. 1 and 2, in another embodiment, interconnection between a first PV module51and a second PV module is provided by the module interconnector57. In one example, the module interconnector57includes an interconnection component56and an interconnection protector54. In yet another embodiment, electrical interconnection between the first PV module51and the second PV module51is provided by the interconnection component56coupled through a first connection55(e.g., a first connection component) to a first interconnect tab53on the first PV module51and coupled through a second connection55(e.g., a second connection component) to a second interconnect tab53on the second PV module51. For example, the first connection55and/or the second connection55are crimped, soldered, welded, and/or ultrasonically welded. In another example, the first connection55and the second connection55are completed in the factory and/or completed at the installation site. In yet another example, the interconnection component56is made of the same type of metal as the first interconnect tab53and the second interconnect tab53to reduce the potential for corrosion. In yet another embodiment, the first connection55and the second connection55are applied directly between the first interconnect tab53and the second interconnect tab53without intervening interconnection component56.

As shown inFIGS. 1 and 2, environmental protection for the electrical interconnection is provided by interconnection protector54. For example, the interconnection protector54also provides environmental protection for the interface of the interconnect tabs53and the PV modules51. In another example, the interconnection protector54substantially encloses the interconnection component56, the first connection55, and the second connection55, but, for example, provides access points for the first interconnect tab53and the second interconnect tab54. In yet another example, the interconnection component56, the first connection55, and the second connection55are potted (e.g., cemented) in place inside the interconnection protector54using one or more potting materials. In yet another example, the one or more potting materials fill a volume inside the interconnection protector54that is not occupied by the interconnection component56, the first connection55, and the second connection55. In yet another example, the one or more potting materials include a liquid encapsulant. In yet another example, the one or more potting materials include room temperature vulcanizing silicone and/or epoxy. In yet another example, the interconnection protector54provides physical strain relief for the interconnection component56, the first connection55, the second connection55, the first interconnect tab53, and/or the second interconnect tab53.

According to another embodiment, the interconnection protector54and the interconnection component56provide strain relief to reduce strain during thermal expansion of the PV modules51and/or the system that holds the PV modules51in place. For example, interconnection component56includes a thin sheet of metal with accordion folds (e.g., accordion bends) to allow lengthening and shortening, potted in soft polymer inside the interconnection protector54. In another example, the interconnection component56includes a flexible cable with slack to allow for expansion and contraction.

According to yet another embodiment, the interconnection protector54also provides sufficient safety to prevent accidental contact to electrical conductors (e.g., the interconnection component56) at up to several thousand volts. For example, the interconnect tabs53are provided with an electrically protective film to prevent electrical shock that is subsequently removed or pierced during assembly of connections55.

According to yet another embodiment, the connections55, the interconnection component56, and the interconnection protector54are installed on a group of modules51in a factory, for shipping a partially pre-assembled set of PV modules51to the installation site. For example, the module interconnector57allows a 180 degree bend to permit front-to-front and/or back-to-back folding of PV modules51in a shipping container. In another example, the folded PV modules51can subsequently be rapidly and/or automatically unfolded at the installation site.

According to yet another embodiment, the interconnection protector54is composed of harder polymer on the outside for environmental protection, and softer polymer on the inside to allow for thermal expansion. For example, the interconnection protector54is filled with liquid and/or grease. In another example, the softer material inside the interconnection protector54is filled and/or cured in the factory and/or at the installation site.

According to yet another embodiment, the interconnection protector54allows the interconnection of the PV module51with a wiring harness at the end of a string of PV modules51.

According to yet another embodiment, the interconnection protector54extends on a front module surface (e.g., the light side) of the PV module51but does not block the module active area from being exposed to sunlight. For example, the interconnection protector54extends around the back module surface (e.g., the dark side) of the PV module51for added mechanical strength and/or environmental protection. In another example, the interconnection protector54provides a surface and/or a mating component for physically mounting the PV module51to a racking system with sufficient strength to resist forces such as gravity and wind loading.

In yet another embodiment, the interconnection protector54provides a semi-permanent interconnection. In one example, to replace the PV module51at the installation site, it may be needed to cut the interconnection component56and re-join the cut interconnection component56with another interconnection component56using solder, welding, ultrasonic welding and/or crimping. In yet another example, the interconnection component56is provided with extra length to simplify the process of cutting and re-joining. In one embodiment, the semi-permanent connection provided by the module interconnector57results in overall cost savings in a large photovoltaic installation. In another embodiment, replacing a module at the installation site is rare, so the cost savings by eliminating push-to-connect connectors is more than adequate to make up for the extra effort required to cut and re-join the interconnection component56.

According to yet another embodiment, without bulky connectors, PV modules51can be packed closely together for volume-efficient shipping to the installation site. For example, shipping two 6-mm-thick typical modules, with 12 mm thick connectors, needs a minimum width of 24 mm in a packing container. In another example, shipping two 6-mm-thick modules, with improved interconnections, needs a minimum width of 12 mm in a packing container, double the packing density of a typical module. In yet another example, pre-assembled sets of folded PV modules51, as described herein, are provided for faster installation at the installation site.

FIG. 7is a simplified diagram showing a method for installing photovoltaic modules51using the photovoltaic module interconnection system100according to one embodiment of the present invention. This diagram is merely an example, which should not unduly limit the scope of the claims. One of ordinary skill in the art would recognize many variations, alternatives, and modifications. As shown inFIG. 7, the method710includes a process700for providing PV modules; a process701for attaching interconnection tabs to PV modules; a process702for interconnecting PV modules; a process703for attaching interconnection protectors; a process704for packing interconnected PV modules for shipping; and a process705for installing PV modules at the installation site. According to certain embodiments, the method710of installing PV modules51using the photovoltaic module interconnection system100can be performed using variations among the processes700-705as would be recognized by one of ordinary skill in the art.

At the process700, PV modules51according to one or more embodiments of the present invention are provided. For example, PV modules51with the plurality of bus bars52are provided. In another example, the PV modules51include encapsulating materials (e.g., the first encapsulating material15or25and/or the second encapsulating material14or24).

At the process701, the plurality of interconnection tabs53are attached to the PV modules51. In one example, each of the plurality of interconnection tabs are an extension of the respective bus bar52. In another example, each of the plurality of interconnection tabs53are a separate conductor connected to the end of the respective bus bar52. In yet another example, each of the plurality of interconnection tabs53are attached either parallel to or at some other angle to the respective bus52. In yet another example, each of the plurality of interconnect tabs53is coated at least partially with an electrically protective film.

At the process702, the PV modules51are interconnected. In one example, a first interconnection tab53from a first PV module51is electrically connected to a second interconnection tab53from a second PV module51using a interconnection component56using connections55. In another example, the first interconnection tab53from the first PV module51is electrically connected to the second interconnection tab53from the second PV module51without intervening interconnection component56.

At the process703, the interconnection protector54is attached at each interconnection point. For example, the interconnection protector54is attached over the interconnection component56and/or the connections55. In another example, the interconnection protector54is potted in place. In yet another example, the interconnection component56, the first connection55, and the second connection55are potted in place inside the interconnection protector54using one or more potting materials. In yet another example, the one or more potting materials are injected into a volume inside the interconnection protector54that is not occupied by the interconnection component56, the first connection55, and the second connection55. In yet another example, the one or more potting materials include a liquid encapsulant. In yet another example, the one or more potting materials subsequently cure to form a weatherproof layer. In yet another example, the one or more potting materials include room temperature vulcanizing silicone and/or epoxy.

At the process704, the interconnected PV modules51are packed for shipping. In one example, the PV modules51are folded front-to-front and/or back-to-back at each interconnection point. In another example, the PV modules are packed in a shipping container.

At the process705, the PV modules51are installed at the installation site. In one example the interconnected PV modules51are unpacked from the shipping container. In another example, the interconnected PV modules51are unfolded. In yet another example, the interconnected PV modules51are mounted to a rail and/or some other type of mounting system at their final installation location.

As discussed above and further emphasized here,FIG. 7is merely an example, which should not unduly limit the scope of the claims. One of ordinary skill in the art would recognize many variations, alternatives, and modifications. For example, a process for shipping, to an installation site, at least the interconnected and packed first photovoltaic module51and second photovoltaic module51occurs between the process704for packing interconnected PV modules for shipping and the process705for installing PV modules at the installation site. In another example, a process for unpacking the interconnected and packed first photovoltaic module51and second photovoltaic module51occurs between the process704for packing interconnected PV modules for shipping and the process705for installing PV modules at the installation site.

FIG. 8is a simplified diagram showing a method for installing photovoltaic modules51using the photovoltaic module interconnection system100according to another embodiment of the present invention. This diagram is merely an example, which should not unduly limit the scope of the claims. One of ordinary skill in the art would recognize many variations, alternatives, and modifications. As shown inFIG. 8, the method810includes a process800for providing PV modules; a process801for installing PV modules; a process802for interconnecting PV modules; and a process803for attaching interconnection protectors. According to certain embodiments, the method810of installing PV modules51using the photovoltaic module interconnection system100can be performed using variations among the processes800-803as would be recognized by one of ordinary skill in the art.

At the process800, PV modules51with the plurality of interconnection tabs53according to one or more embodiments of the present invention are provided. For example, PV modules51with the plurality of bus bars52are provided. In another example, the PV modules51include encapsulating materials (e.g., the first encapsulating material15or25and/or the second encapsulating material14or24). In yet another example, the plurality of interconnection tabs53are attached to the PV modules51. In yet another example, each of the plurality of interconnection tabs are an extension of the respective bus bar52. In yet another example, each of the plurality of interconnection tabs53are a separate conductor connected to the end of the respective bus bar52. In yet another example, each of the plurality of interconnection tabs53are attached either parallel to or at some other angle to the respective bus52. In yet another example, each of the plurality of interconnect tabs53is coated at least partially with an electrically protective film. In yet another example, the electrically protective film prevents electrical shock during handling of the PV modules51.

At the process801, the PV modules51are installed at the installation site. In one example the interconnected PV modules51are unpacked from shipping containers. In another example, the interconnected PV modules51are mounted to a rail and/or some other type of mounting system at their final installation location.

At the process802, the PV modules51are interconnected. In one example, a first interconnection tab53from a first PV module51is electrically connected to a second interconnection tab53from a second PV module51using an interconnection component56and connections55. In another example, the first interconnection tab53from the first PV module51is electrically connected to the second interconnection tab53from the second PV module51without the intervening interconnection component56. In yet another example, the electrically protective film on the first interconnection tab53and the electrically protective film on the second interconnection tab53is pierced and/or removed.

At the process803, the interconnection protector54is attached at each interconnection point. For example, the interconnection protector54is attached over the interconnection component56and/or the connections55. In another example, the interconnection protector54is potted in place. In yet another example, the interconnection component56, the first connection55, and the second connection55are potted in place inside the interconnection protector54using one or more potting materials. In yet another example, the one or more potting materials are injected to a volume inside the interconnection protector54that is not occupied by the interconnection component56, the first connection55, and the second connection55. In yet another example, the one or more potting materials include a liquid encapsulant. In yet another example, the one or more potting materials subsequently cure to form a weatherproof layer. In yet another example, the one or more potting materials include room temperature vulcanizing silicone and/or epoxy.

As discussed above and further emphasized here,FIG. 8is merely an example, which should not unduly limit the scope of the claims. One of ordinary skill in the art would recognize many variations, alternatives, and modifications. For example, a process for packing, for shipping, at least the first photovoltaic module51and second photovoltaic module51occurs between the process800for providing PV modules and the process801for installing PV modules. In another example, a process for shipping, to an installation site, at least the first photovoltaic module51and second photovoltaic module51occurs between the process800for providing PV modules and the process801for installing PV modules. In yet another example, a process for unpacking the packed first photovoltaic module51and second photovoltaic module51occurs between the process800for providing PV modules and the process801for installing PV modules.

According to at least one embodiment, a system for interconnecting photovoltaic modules includes a first photovoltaic module and a second photovoltaic module. The first photovoltaic module includes a first bus bar and a first interconnect tab connected to the first bus bar. The second photovoltaic module includes a second bus bar and a second interconnect tab connected to the second bus bar. The system for interconnecting photovoltaic modules additionally includes a module interconnector configured to interconnect the first photovoltaic module and the second photovoltaic module. The module interconnector includes an interconnection component and an interconnection protector. Additionally, the system for interconnecting photovoltaic modules includes a first connection component connecting the interconnection component to the first interconnect tab of the first photovoltaic module and a second connection component connecting the interconnection component to the second interconnect tab of the second photovoltaic module. The interconnection protector substantially encloses the interconnection component, the first connection component, and the second connection component. For example, the system for interconnecting photovoltaic modules is implemented according to at leastFIG. 1,FIG. 2,FIG. 3,FIG. 4,FIG. 5, and/orFIG. 6.

In another example, the first photovoltaic module includes one selected from a group consisting of silicon, cadmium telluride, CIGS, and organics. In yet another example, the first photovoltaic module further includes an array of photovoltaic cells, the array of photovoltaic cells includes a positive end and a negative end and the first bus bar is coupled to either the positive end or the negative end. In yet another example, the first interconnect tab protrudes from a side of the first photovoltaic module. In yet another example, the first interconnect tab is an extension of the first bus bar. In yet another example, the first interconnect tab is a separate conductor from the first bus bar. In yet another example, the first interconnect tab protrudes from the side of the first photovoltaic module in parallel with the first bus bar. In yet another example, the first interconnect tab protrudes from the side of the first photovoltaic module at an angle to the first bus bar. In yet another example, the first interconnect tab is coated at least partially by a protective film.

In yet another example, the first photovoltaic module further includes a photovoltaic panel including a front panel surface, a back panel surface, and a plurality of edge surfaces. And the first photovoltaic module further includes a first encapsulating material for protecting the front panel surface of the photovoltaic panel and the back panel surface of the photovoltaic panel and a second encapsulating material for protecting the plurality of edge surfaces of the photovoltaic panel. Additionally, the first encapsulating material and the second encapsulating material substantially enclose the photovoltaic panel. In yet another example, the second encapsulating material is placed above, below, and to the sides of the first interconnect tab. In yet another example, the first photovoltaic module further includes a front module surface and a back module surface and the first interconnect tab extends around the first encapsulating material to the front module surface or the back module surface of the first photovoltaic module. In yet another example, the interconnection component is potted inside the protector using a polymer. In yet another example, the interconnection component includes a flexible cable. In yet another example, the interconnection component includes a thin sheet of metal including accordion folds. In yet another example, the first connection is formed by at least one selected from a group consisting of crimping, soldering, welding, and ultrasonic welding. In yet another example, the first connection component, the second connection component, and the interconnection component include the same metal. In yet another example, the interconnection protector provides electrical and environmental protection to the interconnection component, the first connection component, and the second connection component.

According to another embodiment, a method for installing photovoltaic modules includes providing a first photovoltaic module that includes a first bus bar, providing a second photovoltaic module that includes a second bus bar, attaching a first interconnect tab to the first bus bar, and attaching a second interconnect tab to the second bus bar. The method for installing photovoltaic modules further includes interconnecting the first photovoltaic module and the second photovoltaic module by connecting the first interconnect tab to an interconnection component with a first connection component and by connecting the second interconnect tab to the interconnection component with a second connection component. The method for installing photovoltaic modules additionally includes enclosing substantially the interconnection component, the first connection component, and the second connection component by an interconnection protector. The method for installing photovoltaic modules additionally includes packing, for shipping, at least the first photovoltaic module and the second photovoltaic module, the first photovoltaic module and the second photovoltaic module being interconnected to each other, shipping, to an installation site, at least the packed first photovoltaic module and second photovoltaic module, the first photovoltaic module and the second photovoltaic module being interconnected to each other, and installing, at the installation site, at least the first photovoltaic module and the second photovoltaic module. For example, the method is implemented according to at leastFIG. 7.

In another example, the first photovoltaic module includes one selected from a group consisting of silicon, cadmium telluride, CIGS, and organics. In yet another example, the process for packing, for shipping, at least the first photovoltaic module and the second photovoltaic module includes stacking the first photovoltaic module and the second photovoltaic module either front-to-back or back-to-front by folding the interconnection component and the interconnection protector.

According to yet another embodiment, a method for installing photovoltaic modules includes providing a first photovoltaic module that includes a first bus bar and a first interconnect tab connected to the first bus bar and providing a second photovoltaic module that includes a second bus bar and a second interconnect tab connected to the second bus bar. The method for installing photovoltaic modules further includes coating the first interconnect tab at least partially with a first protective film and coating the second interconnect tab at least partially with a second protective film. The method for installing photovoltaic modules additionally includes packing, for shipping, at least the first photovoltaic module and the second photovoltaic module, shipping, to an installation site, at least the packed first photovoltaic module and second photovoltaic module, and installing, at the installation site, at least the first photovoltaic module and the second photovoltaic module. The method for installing photovoltaic modules additionally includes interconnecting, at the installation site, the installed first photovoltaic module and the installed second photovoltaic module by connecting the first interconnect tab to an interconnection component with a first connection component and by connecting the second interconnect tab to the interconnection component with a second connection component. The method for installing photovoltaic modules additionally includes enclosing substantially the interconnection component, the first connection component, and the second connection component with an interconnection protector. For example, the method is implemented according to at leastFIG. 8.

In another example, the first photovoltaic module includes one selected from a group consisting of silicon, cadmium telluride, CIGS, and organics. In yet another example, the process for interconnecting, at the installation site, the installed first photovoltaic module and the installed second photovoltaic module includes piercing the first protective film and piercing the second protective film. In yet another example, the process for interconnecting, at the installation site, the installed first photovoltaic module and the installed second photovoltaic module removing the first protective film and removing the second protective film.

Although specific embodiments of the present invention have been described, it will be understood by those of skill in the art that there are other embodiments that are equivalent to the described embodiments. For example, various embodiments and/or examples of the present invention can be combined. Accordingly, it is to be understood that the invention is not to be limited by the specific illustrated embodiments, but only by the scope of the appended claims.