Retractable wiring system for a photovoltaic module

Patent metadata

Field	Value
Publication number	US-2016308489-A1
Application number	US-201514985213-A
Country	US
Kind code	A1
Filing date	Dec 30, 2015
Priority date	Apr 17, 2015
Publication date	Oct 20, 2016
Grant date	—

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 retractable wiring system for a photovoltaic module having a frame, the system comprising:
a junction-box mounted onto the photovoltaic module; a pair of wires extending from the junction-box, each wire terminating in a respective connector; a wire guide mounted onto the frame, wherein one of the pair of wires is received into the wire guide; and a wire retraction mechanism configured to maintain tension on the wire in the wire guide.

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

3 . The system of claim 1 , 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 wire in the wire guide.

4 . The system of claim 3 , wherein a free end of the rotating lever arm wraps around the wire in the wire guide.

5 . The system of claim 1 , wherein the wire guide is one of a pair of wire guides mounted onto the frame, each wire guide receiving one of the pair of wires, and wherein the wire retraction mechanism is configured to maintain tension on one of the pair of wires.

6 . The system of claim 5 , wherein the wire retraction mechanism is configured to maintain tension on both of the wires.

7 . The system of claim 5 , wherein the wire retraction mechanism comprises:
a pair of rotating lever arms mounted onto the frame, and spring biases urging the lever arms to rotate such that the lever arms maintain tension on the wires.

8 . The system of claim 1 , wherein the wire retraction mechanism comprises a spring positioned between the pair of wires, wherein the spring urges the pair of wires together.

9 . The system of claim 8 , wherein the spring is coupled to each of the pair of wires by pulleys positioned around each of the pair of wires.

10 . A method of assembling and wiring a photovoltaic array, the method comprising:
placing successive photovoltaic modules into an array, wherein each photovoltaic module has a junction box mounted thereto, first and second wires extending from the junction box, and a wire tensioning mechanism for maintaining tension on a first one of the wires, by:
(a) positioning a first photovoltaic module into an installed position in the array;
(b) positioning a second photovoltaic module into a pre-installed position in the array;
(c) pulling the first wire of the first photovoltaic module into an extended position;
(d) connecting an end of the first wire of the first photovoltaic module to an end of the second wire of the second photovoltaic module; and
(e) positioning the second photovoltaic module into an installed position in the array.

11 . The method of claim 10 , wherein an installer holds the second photovoltaic module in the pre-installed position with one hand and pulls the first wire in the first photovoltaic module with the other hand.

12 . The method of claim 10 , further comprising:
repeating steps (a) to (e) with successive photovoltaic modules.

13 . The method of claim 12 , wherein the successive photovoltaic modules are positioned in the array in successive rows and the orientation of the modules are reversed in the successive rows such that the junction boxes are near a bottom side of the module when in the installed position in a first row, and are positioned near a top side of the module when in the installed position in a second row.

14 . The method of claim 13 , wherein the first and second module rows are adjacent to one another.

15 . The method of claim 10 , wherein the second photovoltaic module is pivoted downwardly from the pre-installed position to the installed position.

16 . 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 wire guide mounted onto the frame, wherein the first wire is received into the wire guide; and a wire retraction mechanism mounted onto the frame, the wire retraction mechanism configured to maintain tension on the first wire.

17 . The photovoltaic module of claim 16 , 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.

18 . The photovoltaic module of claim 17 , 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.

19 . The photovoltaic module of claim 16 , 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.

20 . The photovoltaic module of claim 19 , 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.

Assignees

• Solarcity Corp

Inventors

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

Classifications

• H02S40/34

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

• H02S30/10

  Frame structures · CPC title

• H02S40/36 Primary

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

• Y02E10/50

  Photovoltaic [PV] energy · CPC title