Abstract:
One embodiment relates to a photovoltaic (PV) module assembly with integrated junctions manufactured in a factory. The assembly includes a plurality of PV laminates and a frame surrounding and supporting each of the PV laminates in the module. A plurality of environmentally-protected electrical junctions interconnect the photovoltaic laminates. Another embodiment relates to a method of manufacturing a PV module assembly in which pin terminals of PV laminates are inserted into corresponding sockets of junction boxes that are integrated into a frame of the assembly. Another embodiment relates to a method of manufacturing a PV module assembly in which non-insulated conductors are extended from PV laminates, electrical junctions are formed between the conductors, and material is applied to encapsulate the junctions. Other embodiments and features are also disclosed.

Description:
BACKGROUND OF THE INVENTION 
       [0001]    1. Field of the Invention 
         [0002]    The present invention relates generally to photovoltaic module assemblies. 
         [0003]    2. Description of the Background Art 
         [0004]    Photovoltaic (PV) cells, also referred to as “solar cells,” are well known devices for converting solar radiation to electrical energy. Photovoltaic cells may be packaged together in a photovoltaic module. The PV module may include a plurality of interconnected photovoltaic cells in a laminate, and an external junction box attached to the laminate, including leads and connectors which allow modules to be interconnected electrically. 
         [0005]    PV modules are typically installed on a support structure at the installation site. The PV modules are typically then electrically interconnected with the leads from one module to the next in series, or to a common bus in parallel, or a combination of series and parallel connections. 
       SUMMARY 
       [0006]    One embodiment of the invention relates to a photovoltaic (PV) module assembly with integrated junctions. The assembly includes a plurality of PV laminates and a frame surrounding and supporting each of the PV laminates in the module. A plurality of environmentally-protected electrical junctions interconnect the photovoltaic laminates. The electrical interconnections are designed to be made in the factory, not the field, and may be permanent in that they are not designed to be disconnected. 
         [0007]    Another embodiment relates to a method of manufacturing a PV module assembly in which pin terminals of PV laminates are inserted into corresponding sockets of junction boxes that are integrated into a frame of the assembly. 
         [0008]    Another embodiment relates to a method of manufacturing a PV module assembly in which non-insulated conductors are extended from PV laminates, electrical junctions are formed between the conductors, and material is applied to encapsulate the junctions. 
         [0009]    These and other embodiments and features of the present invention will be readily apparent to persons of ordinary skill in the art upon reading the entirety of this disclosure, which includes the accompanying drawings and claims. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0010]      FIG. 1  is a perspective view of a frame-integrated electrical junction for a PV module assembly in accordance with a first embodiment of the invention. 
           [0011]      FIG. 2  is a top view of the frame-integrated electrical junction for a PV module assembly in accordance with the first embodiment of the invention. 
           [0012]      FIG. 3  is an exploded view showing separate components of the frame-integrated electrical junction for a PV module assembly in accordance with the first embodiment of the invention. 
           [0013]      FIG. 4  is a flow chart of a method of manufacturing a PV module assembly with a frame-integrated electrical junction in accordance with the first embodiment of the invention. 
           [0014]      FIG. 5  is a cross-sectional view of a frame-integrated electrical junction for a PV module assembly in accordance with a second embodiment of the invention. 
           [0015]      FIG. 6  is a flow chart of a method of manufacturing a PV module assembly with a frame-integrated electrical junction in accordance with the second embodiment of the invention. 
       
    
    
       [0016]    The use of the same reference label in different drawings indicates the same or like components. 
       DETAILED DESCRIPTION 
       [0017]    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. 
         [0018]      FIG. 1  is a perspective view of a frame-integrated electrical junction for a PV module assembly in accordance with a first embodiment of the invention. Shown in  FIG. 1  are two PV laminates  102 , each laminate  102  including a plurality of solar cells  104  and electrical connections between the solar cells. Bypass diodes may also be embedded within the PV laminates. The specific configuration for the electrical connections and bypass diodes within a PV laminate  102  depends on the specific implementation used. 
         [0019]    As further shown, each PV laminate  102  includes at least one pin terminal  106 . In one embodiment, each PV laminate  102  includes two pin terminals  106 . Each pin terminal  106  is electrically connected within the PV laminate  102  to at least one of the solar cells  104 . For example, a pin terminal  106  may be electrically connected to a solar cell  104  in a corner position within the PV laminate  102 . 
         [0020]    An inner frame member  108  of a frame for the PV module assembly is also shown in  FIG. 1 . As further shown, an electrical junction box  110  may be integrated within the inner frame member  108 . The electrical junction box  110  includes at least two sockets  112 . Each socket  112  is configured to receive a pin terminal  106  from a PV laminate  102  when the PV laminate  102  is inserted into the frame. 
         [0021]      FIG. 2  is a top view of the frame-integrated electrical junction for a PV module assembly in accordance with the first embodiment of the invention. This top view shows a portion of the frame which includes part of an inner frame member  108  and part of an outer frame member  202  which are joined together. Two PV laminates  102  are shown, one positioned on each side of the inner frame member  108 . The junction box  110  within the inner frame member  108  and the two sockets  112  of the junction box  110  are also shown. 
         [0022]      FIG. 3  is an exploded view showing separate components of the frame-integrated electrical junction for a PV module assembly in accordance with the first embodiment of the invention. The separate components shown are the PV laminates  102  (including solar cells  104  and the pin terminals  106 ), the inner frame member  108 , and the junction box  110  (including the sockets  112 ). 
         [0023]      FIG. 4  is a flow chart of a method  400  of manufacturing a PV module assembly with a frame-integrated electrical junction in accordance with the first embodiment of the invention. As shown, first and second PV laminates and a frame for the module assembly are provided ( 402 ,  404  and  406 , respectively). As provided, the PV laminates are configured with pin terminals, and the frame is configured with an electrical junction box integrated therein. The integrated junction box includes first and second sockets. 
         [0024]    A first pin terminal on the first laminate is inserted  408  into the first socket of the integrated junction box. This is done while installing the first laminate into its space into the frame. In addition, a second pin terminal on the second laminate is inserted  410  into the second socket of the integrated junction box. This is done while installing the second laminate into its space in the frame. 
         [0025]    In accordance with one embodiment, the junction box is provided with an electrical connection between the first and second sockets. In this case, an electrical connection is formed  412  between the first and second pin terminals once they are inserted into the first and second sockets. 
         [0026]    In accordance with one embodiment, the manufacturing of the PV module assembly may include the formation of a plurality of such electrical connections. After completion of the manufacturing of the PV module assembly in the factory, the completed PV module assembly may be transported to the installation site. Alternatively, the PV laminates may be inserted into the frame at the installation site. 
         [0027]      FIG. 5  is a cross-sectional view of a frame-integrated electrical junction for a PV module assembly in accordance with a second embodiment of the invention. Shown in  FIG. 5  are two PV laminates  502 , each laminate  502  including a plurality of solar cells and electrical connections between the solar cells. Bypass diodes may also be embedded within the PV laminates. The specific configuration for the electrical connections and bypass diodes within a PV laminate  502  depends on the specific implementation used. 
         [0028]    As further shown, each PV laminate  502  includes at least one module tab  508 . The module tab  508  comprises a non-insulated conductive portion which extends out of the PV laminate. In one embodiment, each PV laminate  502  includes two module tabs  508 . Each module tab  508  is electrically connected within the PV laminate  502  to at least one of the solar cells. For example, the module tab  508  may be electrically connected to a solar cell in a corner position within the PV laminate  502 . 
         [0029]    An optional electrical junction box or other stiffening structure (stiffener)  512  is also shown in  FIG. 5 . As shown, the stiffening structure  512  may be located on one side of the PV laminates  502  and may partially enclose the module tabbing  508 . 
         [0030]    In accordance with an embodiment of the invention, a solder connection or solder joint  510  may be formed during the manufacturing process in a factory to electrically connect in a permanent manner the module tabbing  508  from the two PV laminates  502 . After forming the solder connection  510 , an encapsulant (potting) material  506  may be introduced to electrically-insulate and environmentally-protect the module tabbing  508  and solder connection  510 . The encapsulant material  506  is preferably elastomeric so as to be resistant to cracking. 
         [0031]      FIG. 6  is a flow chart of a method  600  of manufacturing a PV module assembly with a frame-integrated electrical junction in accordance with the second embodiment of the invention. As shown, first and second PV laminates and a frame for the module assembly are provided  602 . As provided, the PV laminates are configured with module tabbing or other non-insulated conductors. The first and second PV laminates are inserted  604  into appropriate spaces in the frame. 
         [0032]    As further shown in  FIG. 6 , the non-insulated conductors are extended from the first and second PV laminates ( 606  and  608 , respectively). Thereafter, a permanent electrical junction is formed  610  between the non-insulated conductors. This electrical junction may be formed, for example, by soldering and may be advantageously performed during manufacturing in a factory setting. 
         [0033]    After the electrical junction is formed, the encapsulant material may be applied to enclose  612  the electrical junction. As mentioned above, the encapsulant material is electrically insulating and preferably an elastomeric material. 
         [0034]    The manufacturing of the PV module assembly may include the formation of a plurality of such electrical junctions and the encapsulation of those junctions. After completion  614  of the manufacturing of the PV module assembly in the factory, the completed PV module assembly may be transported  616  to the installation site. 
         [0035]    The apparatus and methods disclosed herein provide numerous advantages. The integrated junctions allow for the creation of a complete PV module assembly by mechanically and electrically integrating the PV laminates with the frame of the support structure (whether the structure is for a tracker system, a fixed tilt system, a roof system, or other system). This advantageously allows for the elimination of various jumper cables and also provides a more compact overall profile. This also allows for the optimization of the various components as part of the whole assembly, rather than requiring those components to be discrete components. 
         [0036]    In addition, the integrated junctions advantageously provide the necessary functionality of a traditional external junction box, while eliminating the need for many external cables. This provides for a reduction of the cost. Furthermore, being able to complete manufacture of the PV module assembly in a factory setting, prior to transportation to an installation site, provides for reduced time and cost of installation. A traditional installation would require the installer to connect various jumper cables to junction boxes in a proper arrangement, while the apparatus and methods disclosed herein provide for the electrical connections between PV laminates to be formed in a factory setting (prior to transportation to the installation site). 
         [0037]    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.