Abstract:
The connection system includes input and output modules that are edge-mounted on a photovoltaic array to conduct the photon energy created from the arrays. The system circuitry includes a diode, heat sink and connector plugs for transmitting the energy from the array. A channel on the connector fits onto the edge of the photovoltaic array to accommodate small space constraints. A predetermined number of arrays may be connected in series with the connection system.

Description:
FIELD OF THE INVENTION 
   The present invention is directed to an electrical connector, and more specifically to a low-profile edge connector for connecting photovoltaic solar panels. 
   BACKGROUND 
   Photovoltaic (PV) modules or arrays produce electricity from solar energy. Electrical power produced by PV modules reduces the amount of energy required from non-renewable resources such as fossil fuels and nuclear energy. Significant environmental benefits are also realized from solar energy production, for example, reduction in air pollution from burning fossil fuels, reduction in water and land use from power generation plants, and reduction in the storage of waste byproducts. Solar energy produces no noise, and has few moving components. Because of their reliability, PV modules also reduce the cost of residential and commercial power to consumers. 
   PV cells are essentially large-area semiconductor diodes. Due to the photovoltaic effect, the energy of photons is converted into electrical power within a PV cell when the PV cell is irradiated by a light source such as sunlight. PV cells are typically interconnected into solar modules that have power ranges of up to 100 watts or greater. For large PV systems special PV modules are produced with typical power range of up to several 100 W. A photovoltaic module is the basic element of a photovoltaic power generation system. A PV module has many solar cells interconnected in series or parallel, according to the desired voltage and current parameters. PV cells are connected and placed between a polyvinyl plate on the bottom and a tempered glass on the top. PV cells are interconnected with thin contacts on the upper side of the semiconductor material. The typical crystalline modules power ranges from several W to up to 200 W/module. 
   In the case of facade or roof systems the photovoltaic system may be installed during construction, or added to the building after it is built. Roof systems are generally lower powered systems, e.g., 10 kW, to meet typical residential loads. Roof integrated photovoltaic systems may consist of different module types, such as crystalline and micro-perforated amorphous modules. Roof-integrated photovoltaic systems are integrated into the roof; such that the entire roof or a portion thereof is covered with photovoltaic modules, or they are added to the roof later. PV cells may be integrated with roof tiles or shingles. 
   PV modules/arrays require specially designed devices adapted for interconnecting the various PV modules/arrays with each other, and with electrical power distribution systems. PV connection systems are used to accommodate serial and parallel connection of PV arrays. In addition to connection boxes, a PV connection system includes connectors that allow for speedy field installation or high-speed manufacture of made-to-length cable assemblies. Connection or connection boxes may be required to receive specialized cable terminations from PV modules/arrays, with power diodes inside for controlling current flow to the load. PV arrays may be required in areas with tight space restraints and requirements, requiring the size of the PV module to be minimized. 
   What is needed is an edge connector for a photovoltaic solar array panel that satisfies one or more of these space constraint needs or provides other advantageous features. Other features and advantages will be made apparent from the present specification. The teachings disclosed extend to those embodiments that fall within the scope of the claims, regardless of whether they accomplish one or more of the aforementioned needs. 
   SUMMARY 
   One embodiment relates to an electrical connector for interconnecting adjacent photovoltaic arrays along an edge having an input module and an output module. The input module housing has at least one diode to support a predetermined voltage and current, at least one heat sink in thermal communication with the diode to dissipate heat, at least one electrically conductive connection point and at least one channel configured to receive the edge of a first photovoltaic array. A base portion houses the at least one diode, heat sink, connection point, and channel. The output module is configured to connect with the input module and has at least one connection point being electrically conductive, a channel to receive the edge of a second photovoltaic array and a base portion that houses the connection point and channel. The connector also has an electrically conductive cable connecting the input module and output module. The input module and the output module are secured to the edge of adjacent photovoltaic arrays and are in electrical communication with each other through the cable. The connection point conducts photon energy from the array to the connector. 
   Another embodiment relates to an electrical connector for interconnecting adjacent photovoltaic arrays along an edge having an input module and an output module. The input module housing has a cover portion, at least one diode to support a predetermined voltage and current, at least one heat sink in thermal communication with the diode to dissipate heat, at least one electrically conductive connection point and at least one channel to receive the edge of a first photovoltaic array. A base portion houses the at least one diode, heat sink, a connection point, and channel. The cover portion and the base portion are secured with a fastener. The output module connects with the input module and has at least one electrically conductive connection point, a channel for receiving the edge of a second photovoltaic array and a base portion for housing the connection point and channel. The connector also has an electrically conductive cable connecting the input module and output module. The input module and output module are secured to the edge of photovoltaic arrays and are in electrical communication with each other through the cable. The connection point conducts photon energy from the array to the connector. 
   One advantage of the present invention is the unique edge placement location of the connector on the array. 
   Other features and advantages of the present invention will be apparent from the following more detailed description of the preferred embodiment, taken in conjunction with the accompanying drawings which illustrate, by way of example, the principles of the invention. 

   
     BRIEF DESCRIPTION OF THE DRAWINGS 
     The application will become more fully understood from the following detailed description, taken in conjunction with the accompanying figures, wherein like reference numerals refer to like elements, in which: 
       FIG. 1  is an embodiment of the present invention. 
       FIG. 2  is an internal view of the components in the input module of the present invention. 
       FIG. 3  is a top view of the input module present invention. 
       FIG. 4  is the output module of the present invention. 
       FIG. 5  is an internal view of the output module of the present invention. 
       FIG. 6  is an embodiment of the present invention. 
       FIG. 7  is a top view of the present invention without covers. 
       FIGS. 8-11  provide alternate views of the present invention. 
       FIG. 12  is a perspective view of an embodiment of the present invention. 
       FIGS. 13-14  provide alternate view of the present invention. 
       FIG. 15  is a perspective view of an embodiment of the present invention. 
   

   DETAILED DESCRIPTION OF THE INVENTION 
   The present invention is directed to a PV box that connects to the edge of the PV array.  FIG. 1  shows an embodiment of the edge connector  10 , which includes an output plug  12  and an input module  14 . The output plug  12  and input module  14  interconnect with a cable  70  and plug  72  connection. In a PV system, the arrays  16 ,  18  are disposed side by side, where an output plug  12  is secured to the first array  16 . The input module  14  is secured to the next adjacent array  18 . Each array  16 ,  18  has one output plug  12 , one input module  14 , and a cable  70  and plug connection  72  attached. 
     FIG. 2  illustrates the components of the edge connector  10 . In the output plug  12 , a blade  20  is used to mate with the conductive foil (not shown) of the array and conduct the photon energy from the array to the edge connector  10 . A diode  22  (See e.g.  FIG. 15 ) is connected to the power circuit to ensure proper conduction of the energy, and a heat sink  24  (See e.g.  FIG. 15 ) is disposed on the diode  22  to act as an electrical contact and heat dissipater. While any suitable diode may be used, a TO-220 Schottky diode may be used with this embodiment, and while any suitable heat sink may be used, a copper iron sink may be used with this embodiment. A component shuttle  26  is used to manage the components  20 ,  22 ,  24  of the edge connector  10  during manufacture and maintain proper placement of the components  20 ,  22 ,  24  in the connector. In addition to the shuttle  26 , a rivet  28  is used to secure the heat sink  24  to the diode. In alternative to the rivet  28 , a solder or resistance weld connection may be used (not shown), such as an ultra sonic weld connection. The housing  30  is overmolded on the components and has a ‘U’ shaped channel  48  to accommodate the array. The array plates  16 , 18  fit securely and snugly into the channel  48  of the edge connector  10 . In one embodiment, Room Temperature Vulcanization (RTV) silicon is used as the epoxy to maintain a secure and waterproof hold of the connector  10  on the array  16 , 18 . However, as a person of ordinary skill in the art will appreciate, other types of epoxy may be used for securing the connector  10  to the arrays  16 , 18 . 
   Referring to  FIG. 3 , apertures  34  are located on the top surface of the housing  30  to provide receptacles for a soldering connection with the array foils. Once the conductive connection to the array  16 , 18  is made, these apertures  34  are sealed and filled in with silicon or other suitable sealing and protective material. 
     FIGS. 4 and 5  show the input module  14  of the edge connector. A crimp connection is disposed on the inside of the module  14 . The housing  40  has a foil access window  42 , which permits a conductive connection to be made from the array (not shown in  FIGS. 4 and 5 ) to the module  14 . The window  42  is filled in or covered for protection. 
   An embodiment, shown in  FIGS. 6-11 , of the output module (not shown) of the edge connector  10  includes a two-piece design, having a housing portion  44  and a cover portion  46 . When placed on the housing portion  44 , the cover portion  46  and housing portion  44  define a channel  48 . The arrays  16 ,  18  fit into the channel  48  and a connection is made between the connector  10  and the array foils  14 ,  16 .  FIG. 7  illustrates the edge connector  10  with the cover portion removed. A groove  50  is molded in the housing  44  to help contain sealant and to align the cover portion  46  when in place. The housing portion  44  also has large latch receptacles  52  that accept the latches  54  on the cover portion  46  ( FIGS. 8-11 ) when the cover portion  46  is in place. 
     FIGS. 8-11  illustrate various views of the two-piece edge connector. The inner surface of the channel  48  is ridged or ribbed to provide an enhanced surface for bonding onto the array. Once the connector  10  is placed onto the array  16 ,  18 , an adhesive product, e.g. as RTV silicon, is applied to secure the connector  10  to the array with a waterproof bond. The cover portion  46  has latches  54  to hold the cover portion  46  on the housing portion  44  when in place. The exemplary embodiment has two latches  54 , however, any number of latches may be used. The housing portion  44  has latch receptacles  52  that are designed to accept the latches  54  when in place. Once the cover portion  46  is placed on the housing portion  44 , the latches  54  are engaged in the receptacles  52  and are not easily removable. 
   Yet another embodiment of the input module of the present invention includes a two-piece design where the cover portion  46  is designed to allow for a thicker array edge shown in  FIG. 12 . Arrays  16 ,  18  may have various thicknesses, depending on the application, thus the edge connectors  10  must be designed to accommodate a range of thicknesses e.g. ¼″ to ¾″.  FIG. 12  illustrates a cover portion  46  that is two tiered. The first tier  60  rests on the housing portion  44  and the second tier  62  forms a portion of the channel  48  that fits around the array edge. The housing portion  44  has a groove  50  to contain sealant when applied to secure the connector  10  to the array and to secure the cover portion  46  to the housing portion  44 . 
     FIGS. 13-15  illustrate another embodiment of the present invention. The edge connector (not shown in  FIGS. 13-15 ) is a two-piece design with a cover portion  46  and a housing portion  44  where the channel  48  is formed to fit onto an array  16 ,  18  having a greater thickness. The cover portion  46  has a two-tiered shape, with a first tier  60  and a second tier  62 . The cover portion  46  has apertures  66  that accept fasteners  68 , e.g. screws, and secure the cover portion  46  to the housing portion  44 . The height of the channel  48  may vary, depending on the thickness of the array. 
   The cover portion  46  fits onto the top of the housing portion  44  and is secured with fasteners  68 . A diode  22  is connected to the circuitry to ensure proper conduction of the energy, and a heat sink  24  is placed in contact with the diode  22  to act as a contact and heat dissipater. A component shuttle  26  is used to manage the components of the edge connector  10  during manufacture. The shuttle  26  holds the components in place. In addition to the shuttle  26 , a rivet  28  is used to secure the heat sink  24  to the diode. An alternative to the rivet  28 , a solder or weld connection may be used, such as an ultra sonic weld connection. A connector is used to mate with an adjacent edge connector (not shown) to transmit the energy from the array. 
   The edge connector  10  may be of an size or dimensions suitable for the array, however, the dimensions may be 4″ in length, 1″ inch deep, and ⅜″ to ⅞″ thick. Typically, the array is ¼″ to 1″ thick, therefore, the channel  48  on the connector  10  be at least wide enough to accommodate the array of this thickness to fit snugly into the channel  48 . 
   Preferably, the connector operates with at least 15 amps of current, however the connector  10  accommodates a minimum of 0.5 amps to a maximum of 18 amps with the TO-220 diode. The connector may also be connected in series to a maximum of thirty connectors, where the male connection  72   a  of one connector mates with the female connection  72   b  of the adjacent connector. The edge connector  10  may also include larger heat sinks, to allow for a larger current capacity. A larger heat sink provides greater heat dissipation, and requires a correspondingly larger connector  10  housing. 
   While the invention has been described with reference to a preferred embodiment, it will be understood by those skilled in the art that various changes may be made and equivalents may be substituted for elements thereof without departing from the scope of the invention. In addition, many modifications may be made to adapt a particular situation or material to the teachings of the invention without departing from the essential scope thereof. Therefore, it is intended that the invention not be limited to the particular embodiment disclosed as the best mode contemplated for carrying out this invention, but that the invention will include all embodiments falling within the scope of the appended claims.