Electrical interconnection system for connecting multiple electrical modules to an electrical device

Patent metadata

Field	Value
Publication number	US-9923320-B1
Application number	US-201615383341-A
Country	US
Kind code	B1
Filing date	Dec 19, 2016
Priority date	Dec 19, 2016
Publication date	Mar 20, 2018
Grant date	Mar 20, 2018

Abstract

An electrical interconnection system is disclosed. An electrically conductive material is embedded into a membrane providing both an electrical pathway to connect multiple electrical modules and a connection system to connect the modules to the membrane. Electrical modules are connected to the membrane by removing a protective backing material from an adhesive area covering electrical contacts on a bottom side of an electrical module, and adhering to an adhesive area on the membrane, connecting the contacts to the electrically conductive material in the membrane. No external wiring, connectors or devices are required to make the electrical connection between the modules and the membrane. Contacts are integral and embedded into the surface of each individual module. The modules have adhesive on the back to allow them to be adhesively attached to the membrane without any additional mounting hardware.

First claim

The invention claimed is:

1. An electrical interconnection system comprising:
one or more linear lengths of partially insulated electrical conductors;
a membrane having a raised area for interfacing with one or more electrical modules, wherein the partially insulated electrical conductors are embedded within the raised area of the membrane;
a conductive surface of the partially insulated electrical conductors being exposed on an exterior surface of the raised area of the membrane; and
electrical wires connected to each of the one or more linear lengths of partially insulated electrical conductors and extending outside of the membrane.

2. The electrical interconnection system of claim 1 , wherein the conductive surface is adhesively attached and electrically connected to the one or more electrical modules.

3. The electrical interconnection system of claim 2 , wherein the electrical modules further comprising electrical contacts that provide the electrically connected pathway from the one or more electrical modules to the conductive surface.

4. The electrical interconnection system of claim 2 , wherein the conductive surface is coated with electrical connection materials enabling electrical conduction from the electrical contacts to the conductive surface.

5. The electrical interconnection system of claim 4 , wherein an electrically insulating adhesive coats a surface area between a first side of the membrane and the electrical modules, creating an air tight and moisture tight seal encapsulating the electrical connection area.

6. The electrical interconnection system of claim 1 , wherein the membrane further comprises an adhesive backing on a second side of the membrane opposite the first side of the membrane, which is covered by a protective backing material; and
wherein the protective backing material is removed at a time of installation, exposing the adhesive.

7. The electrical interconnection system of claim 2 , wherein the conductive surface on the exterior surface of the membrane is only exposed in areas that align to contacts of the one or more electrical modules to be electrically connected.

8. The electrical interconnection system of claim 2 , wherein the one or more electrical modules comprise solar photovoltaic roof shingles.

9. The electrical interconnection system of claim 1 , wherein the membrane is placed on a roof running from a top ridge and extending down to a bottom edge near the soffit, rain gutter or drip edge.

10. The electrical interconnection system of claim 3 , wherein the membrane is placed on a roof surface, interfacing with roof underlayment covering a surface area of a roof, the membrane thickness matching the thickness of the roof underlayment allowing the one or more electrical modules to be placed on top of the roof underlayment and membrane.

11. The electrical interconnection system of claim 1 , wherein the membrane further includes an interface area that interlocks with the roof underlayment, forming a seal.

12. The electrical interconnection system of claim 1 , wherein the electrical conductors and conductive surface is comprised of one or more of electrically conductive materials including alloys of copper, aluminum, nickel, stainless steel, silver, graphite, tungsten, and carbide.

13. The electrical interconnection system of claim 4 , wherein the electrical connection materials comprise an electrically conductive adhesive.

14. The electrical interconnection system of claim 13 , wherein the electrically conductive adhesive comprises one or more electrically conductive materials of carbon, graphite, tungsten, graphene, gallium, rubidium, phosphorus, carbon nanotubes and carbide.

15. The electrical interconnection system of claim 5 , wherein the electrically insulating adhesive allows for expansion and contraction.

16. The electrical interconnection system of claim 1 , wherein the membrane is waterproof.

17. The electrical interconnection system of claim 1 , wherein a top surface area of the membrane is covered with an adhesive or primer that enhances the adhesion of the adhesive connection between the electrical modules and the membrane.

18. The electrical interconnection system of claim 5 , wherein the electrically insulating adhesive coating a surface area between a first side of the membrane and the electrical modules comprising: one part of a two-part epoxy system on the membrane; and
a second part of the two-part epoxy system on the electrical modules.

19. The electrical interconnection system of claim 1 , wherein the membrane can be cut to length as needed to fit the requirements of the specific application, the cut end being sealed by a weather proof and electrically insulating material.

20. The electrical interconnection system of claim 5 , wherein the electrically insulating adhesive area is covered by a protective backing material; wherein the protective backing material is removed at a time of installation, exposing the adhesive.

Assignees

• Hall David R
• Myer Seth

Inventors

• Hall David R
• Myer Seth

Classifications

• H02S40/36

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

• H01R25/145 Primary

  Details, e.g. end pieces or joints (H01R25/147 takes precedence) · CPC title

• H02S20/23

  specially adapted for roof structures · CPC title

• H10F19/80

  Encapsulations or containers for integrated devices, or assemblies of multiple devices, having photovoltaic cells · CPC title

• H02S20/25

  Roof tile elements · CPC title