Retractable wiring system for a photovoltaic module

Patent metadata

Field	Value
Publication number	US-10063185-B2
Application number	US-201514985213-A
Country	US
Kind code	B2
Filing date	Dec 30, 2015
Priority date	Apr 17, 2015
Publication date	Aug 28, 2018
Grant date	Aug 28, 2018

Abstract

Systems and methods for assembling and wiring photovoltaic arrays are provided. The wiring systems can include retractable wires included in photovoltaic modules that may be extended during installation of photovoltaic modules in the array to connect to wires of adjacent photovoltaic modules, which can retract into a tightened position under the array as the installation is completed. The wires may be made retractable by wire retraction mechanisms mounted to a frame of the photovoltaic module, which maintain a desired tension on the wires of the photovoltaic module. The wire retraction mechanism may include springs that urge components connected to the wire to rotate a particular direction so as to maintain tension on the wire. The wiring systems may also have wire guides to keep the wires accessible for installation and adjustment.

First claim

What is claimed is:

1. A photovoltaic module comprising:
a photovoltaic panel;
a frame supporting the photovoltaic panel;
a junction-box mounted onto the photovoltaic panel;
first and second wires extending from the junction-box;
a first wire guide mounted onto the frame, wherein the first wire is received into the first wire guide; and
a wire retraction mechanism mounted onto the frame, the wire retraction mechanism configured to maintain tension on the first wire, wherein the wire retraction mechanism comprises:
a rotating lever arm mounted to the frame, and
a spring bias coupled to the rotating lever arm urging the lever arm to rotate such that the lever arm maintains tension on the first wire in the first wire guide.

2. The photovoltaic module of claim 1 , wherein the wire retraction mechanism is configured to pull the connector of the first wire in the first wire guide towards the first wire guide to maintain tension on the first wire in the first wire guide.

3. The photovoltaic module of claim 1 , wherein a free end of the rotating lever arm wraps around the first wire in the first wire guide.

4. The photovoltaic module of claim 1 , further comprising a second wire guide mounted onto the frame, wherein the second wire is received into the second wire guide, and wherein the wire retraction mechanism is configured to maintain tension on at least one of the first wire and the second wire.

5. The photovoltaic module of claim 4 , wherein the rotating lever arm is a first rotating lever arm and wherein the wire retraction mechanism further comprises:
a second rotating lever arm mounted onto the frame, and
the spring bias coupled to both the first rotating lever arm and the second rotating lever arm, urging both the lever arms to rotate such that the lever arms maintain tension on both the first wire and the second wire.

6. The photovoltaic module of claim 1 , wherein the first wire terminates in a connector configured to electrically couple the first wire to a third wire extending from a second junction-box mounted onto a second photovoltaic panel, wherein the wire retraction mechanism is configured to maintain tension in each of the first and third wires when the first and third wires are electrically coupled.

7. The photovoltaic module of claim 6 , wherein the second wire terminates in a connector configured to electrically couple to a fourth wire extending from a third junction-box mounted onto a third photovoltaic panel.

8. The photovoltaic module of claim 1 , wherein the wire retraction mechanism comprises a wire form extending from a first end mounted to the frame to a second end wrapped around the first wire.

9. The photovoltaic module of claim 8 , wherein the wire form comprises a spring disposed at the first end and configured to urge the wire form to rotate about the end mounted to the frame so as to maintain tension on the first wire.

10. A photovoltaic module comprising:
a photovoltaic panel;
a frame supporting the photovoltaic panel;
a junction-box mounted onto the photovoltaic panel;
first and second wires extending from the junction-box;
a first wire guide mounted onto the frame, wherein the first wire is received into the first wire guide; and
a wire retraction mechanism mounted onto the frame, the wire retraction mechanism configured to maintain tension on the first wire, wherein the wire retraction mechanism comprises a wire form extending from a first end mounted to the frame to a second end wrapped around the first wire, and wherein the wire form comprises a spring disposed at the first end and configured to urge the wire form to rotate about the end mounted to the frame so as to maintain tension on the first wire.

11. The photovoltaic module of claim 10 , wherein the first wire terminates in a connector configured to electrically couple the first wire to a third wire extending from a second junction-box mounted onto a second photovoltaic panel, wherein the wire retraction mechanism is configured to maintain tension in each of the first and third wires when the first and third wires are electrically coupled.

12. The photovoltaic module of claim 11 , wherein the second wire terminates in a connector configured to electrically couple to a fourth wire extending from a third junction-box mounted onto a third photovoltaic panel.

13. The photovoltaic module of claim 10 , wherein the wire retraction mechanism is configured to pull the connector of the first wire in the first wire guide towards the first wire guide to maintain tension on the first wire in the first wire guide.

14. A photovoltaic module comprising:
a photovoltaic panel;
a frame supporting the photovoltaic panel;
a junction-box mounted onto the photovoltaic panel;
first and second wires extending from the junction-box;
a first wire guide mounted onto the frame, wherein the first wire is received into the first wire guide; and
a wire retraction mechanism mounted onto the frame, the wire retraction mechanism configured to maintain tension on the first wire, wherein the wire retraction mechanism comprises a spring positioned between the first wire and the second wire, and wherein the spring urges the first wire and the second wire together.

15. The photovoltaic module of claim 14 , wherein the spring is coupled to each of the first wire and the second wire by pulleys positioned around each of the first wire and the second wire.

16. The photovoltaic module of claim 14 , wherein the first wire terminates in a connector configured to electrically couple the first wire to a third wire extending from a second junction-box mounted onto a second photovoltaic panel, wherein the wire retraction mechanism is configured to maintain tension in each of the first and third wires when the first and third wires are electrically coupled.

17. The photovoltaic module of claim 16 , wherein the second wire terminates in a connector configured to electrically couple to a fourth wire extending from a third junction-box mounted onto a third photovoltaic panel.

18. The photovoltaic module of claim 14 , wherein the wire retraction mechanism is configured to pull the connector of the first wire in the first wire guide towards the first wire guide to maintain tension on the first wire in the first wire guide.

19. The photovoltaic module of claim 14 , wherein the wire retraction mechanism comprises a wire form extending from a first end mounted to the frame to a second end wrapped around the first wire.

Assignees

• Solarcity Corp

Inventors

• Hudson Tyrus
• Karkheck Johann
• Atchley Brian
• Broussard River

Classifications

• H02S40/36 Primary

  characterised by special electrical interconnection means between two or more PV modules, e.g. electrical module-to-module connection · CPC title

• H02S40/34

  comprising specially adapted electrical connection means to be structurally associated with the PV module, e.g. junction boxes · CPC title

• Y02E10/50

  Photovoltaic [PV] energy · CPC title