Photovoltaic modular connector system

Patent metadata

Field	Value
Publication number	US-10312856-B2
Application number	US-201615274293-A
Country	US
Kind code	B2
Filing date	Sep 23, 2016
Priority date	Sep 23, 2016
Publication date	Jun 4, 2019
Grant date	Jun 4, 2019

Abstract

A photovoltaic modular connector system is disclosed. Electrically conductive contacts embedded into the surface of each of one or more photovoltaic (PV) modules provide the connection point for two PV modules to be connected together.
PV modules are connected together by removing a protective backing material from an adhesive area surrounding a first set of contacts of a first PV module, and adhering to an adhesive area surrounding a second set of contacts of a second PV module, the adhesive making the connection and sealing and protecting the contact area.
No external wiring, connectors or devices are required to make the electrical connection between two PV modules. Contacts are integral and embedded into the surface of each individual PV module. The PV modules have adhesive on the back to allow them to be adhesively attached to a surface without additional mounting hardware.

First claim

The invention claimed is:

1. A photovoltaic (PV) modular connector system comprising:
two or more photovoltaic (PV) modular connectors, each modular connector comprising:
electrical wiring connected to a first photovoltaic (PV) module;
two or more contacts connected to the electrical wiring, wherein the two or more contacts comprise an electrically conductive material, embedded into a surface of the first PV module;
the surface of the first PV module further comprising an area comprising electrically insulating adhesive separating the two or more contacts from each other;
wherein the first PV module is adhesively attached and electrically connected to a second PV module;
wherein at least two parallel contacts of the two or more contacts are flat and parallel to the surface and parallel to a long side of a bottom surface of the first PV module;
wherein the second PV module further comprises a set of perpendicular contacts that are flat and parallel to the surface and perpendicular to a long side of a top surface of the second PV module; and
wherein the parallel contacts of the first PV module are configured to allow a misaligned mating with the perpendicular contacts of the second PV module when the first PV module is placed on top of the second PV module.

2. The PV modular connector system of claim 1 , wherein the electrical wiring connected to the two or more contacts is completely encapsulated and electrically insulated; and wherein all but one surface of the two or more contacts are encapsulated, allowing only one surface of each of the two or more contacts to be exposed on an exterior surface of the first PV module.

3. The PV modular connector system of claim 1 , wherein the two or more contacts and the set of contacts are comprised of one or more of electrically conductive materials comprising alloys of copper, aluminum, nickel, stainless steel, silver, graphite, tungsten, and carbide.

4. The PV modular connector system of claim 1 , wherein the two or more contacts and the set of contacts are coated with an electrically conductive adhesive.

5. The PV modular connector system of claim 4 , wherein the electrically conductive adhesive comprises one or more electrically conductive materials of carbon, graphite, tungsten, graphene, carbon nanotubes and carbide.

6. The PV modular connector system of claim 4 , wherein the electrically conductive adhesive area covers an entire area of one or more contacts and extends at least 0.5 cm beyond each boundary edge of a surface of the one or more contacts.

7. The PV modular connector system of claim 1 , wherein the two or more contacts in the first PV module are embedded with a foam backing providing load deflection forcing the two or more contacts outward from the first PV module towards the set of contacts in the second PV module.

8. The PV modular connector system of claim 1 , wherein the two or more contacts and the set of contacts are coated with an electrically conductive metal with a melting point in the range of between 28 and 45 degrees Celsius from one or more alloys comprising: gallium, rubidium and phosphorus.

9. The PV modular connector system of claim 1 , wherein the electrically insulating adhesive allows for expansion and contraction.

10. The PV modular connector system of claim 1 , wherein the electrically insulating adhesive of the first PV module are adhesively connected to the second PV module creating an air tight and moisture tight seal encapsulating the two or more contacts and the set of contacts.

11. The PV modular connector system of claim 10 , wherein a surface area of the electrically insulating adhesive creating an air tight and moisture tight seal surrounding the two or more contacts is at least 2 cm. in width.

12. The PV modular connector system of claim 1 , wherein the two or more contacts are rated for a total combined electrical current flow of the first PV module, the second PV module, and additional one or more connected PV modules.

13. The PV modular connector system of claim 1 , wherein a surface area between two adjacent contacts of the two or more contacts on the first module is at least 2.0 cm. in width.

14. The PV modular connector system of claim 1 , wherein the first PV module has a notch for viewing an alignment line printed on the surface of the second PV module.

15. The PV modular connector system of claim 1 , wherein the first PV module has an alignment line printed on the surface for visual alignment of the second PV module.

16. The PV modular connector system of claim 1 , wherein the electrically insulating adhesive area is covered by a protective backing material; wherein the protective backing material is removed at the time of installation, exposing the adhesive.

17. The PV modular connector system of claim 1 , wherein each area of an attachment surface of the first PV module is covered with module adhesive and a module protective backing material, allowing the module protective backing material to be removed and exposing the module adhesive.

Assignees

• Hall David R
• Myer Seth
• Hall Labs Llc

Inventors

• Hall David R
• Myer Seth

Classifications

• H02S20/30

  Supporting structures being movable or adjustable, e.g. for angle adjustment · CPC title

• H02J3/46

  Controlling the sharing of generated power between the generators, sources or networks · CPC title

• H02J3/383

  Electricity · mapped topic

• H01L31/048

  Electricity · mapped topic

• H02S20/26

  Building materials integrated with PV modules, e.g. façade elements (H02S20/25 takes precedence) · CPC title