Building integrable interconnection structures having field-configurable shapes

Abstract

Provided are novel building integrable interconnection structures having field-configurable shapes and methods of installing thereof. An interconnection structure may be cut or otherwise modified in the field during installation to form one or more openings. These openings can then be positioned around various obstacles that are frequently present in building installation areas. Some examples of such obstacles include chimneys, vents, and skylights. In some embodiments, the interconnection structures can be provided as part of a set or configured to be installed in an array with building integrable photovoltaic (BIPV) modules of the same size. This installation configuration allows preserving an offset between adjacent rows of the array. Furthermore, the interconnection structures can have the same perimeter features as the BIPV modules, such as electrical connectors and moisture flaps. These features provide electrical continuity and sealing characteristics in an array of BIPV modules despite the presence of obstacles on building structures.

What is claimed is: 
     
         1 . A building integrable interconnection structure for installation on a building structure in a row with one or more building integrable photovoltaic modules and for electrically connecting to the one or more building integrable photovoltaic modules, the building integrable interconnection structure comprising:
 a base portion having a first edge and a second edge, the first edge opposite to the second edge;   a first electrical connector positioned along the first edge; and   a second electrical connector positioned along the second edge, the second electrical connector electrically connected to the first electrical connector,   wherein the base portion is configured to form one or more openings during installation while maintaining the electrical connection between the first electrical connector and the second electrical connector; and   wherein the building integrable interconnection structure and the one more building integrable photovoltaic modules have substantially same size.   
     
     
         2 . The building integrable interconnection structure of  claim 1 , wherein at least about 80% of a surface of the base portion is configured to form the one or more openings. 
     
     
         3 . The building integrable interconnection structure of  claim 1 , wherein one or more edges of the base portion are configured to overlap with the one or more openings. 
     
     
         4 . The building integrable interconnection structure of  claim 1 , wherein the first electrical connector and the second electrical connector are electrically connected by an electrical wire provided adjacent to a back side of the base portion. 
     
     
         5 . The building integrable interconnection structure of  claim 4 , wherein the electrical wire is flexible and configured to be rerouted in between the one or more openings depending on location and size of the one or more openings determined during installation. 
     
     
         6 . The building integrable interconnection structure of  claim 5 , wherein the back side comprises multiple interlocking features for supporting the electrical wire in different positions. 
     
     
         7 . The building integrable interconnection structure of  claim 5 , wherein the electrical wire is sufficiently long for routing beyond boundaries of the base portion. 
     
     
         8 . The building integrable interconnection structure of  claim 5 , wherein the electrical wire comprises at least two insulated conductors. 
     
     
         9 . The building integrable interconnection structure of  claim 1 , further comprising a moisture flap portion attached to a third edge of the base portion and extending substantially parallel to the first edge and the second edge. 
     
     
         10 . The building integrable interconnection structure of  claim 1 , further comprising multiple mechanical fastener sleeves attached to a back side of the base portion, the multiple mechanical fastener sleeves configured for receiving and retaining mechanical fasteners protruding through the base portion. 
     
     
         11 . The building integrable interconnection structure of  claim 10 , wherein a front side of the base portion comprises multiple markings corresponding to the multiple mechanical fastener sleeves. 
     
     
         12 . The building integrable interconnection structure of  claim 10 , wherein the multiple mechanical fastener sleeves form channels. 
     
     
         13 . The building integrable interconnection structure of  claim 12 , wherein the channels are used for routing an electrical wire between the first electrical connector and the second electrical connector. 
     
     
         14 . The building integrable interconnection structure of  claim 13 , wherein the channels comprise interlocking features for supporting the electrical wire within the channels. 
     
     
         15 . The building integrable interconnection structure of  claim 1 , further comprising one or more photovoltaic cells positioned on a front side of the base portion and in electrical communication with the first electrical connector and the second electrical connector. 
     
     
         16 . The building integrable interconnection structure of  claim 15 , wherein the first electrical connector comprises two electrical terminals, one of which is not electrically connected to the one or more photovoltaic cells. 
     
     
         17 . The building integrable interconnection structure of  claim 15 , wherein the one or more photovoltaic cells occupy between about 25% and 75% of the front side and leave a remaining part of the base portion for forming the one or more openings. 
     
     
         18 . The building integrable interconnection structure of  claim 15 , wherein a voltage output rating of the one or more photovoltaic cells is substantially the same as for the one or more building integrable photovoltaic modules. 
     
     
         19 . The building integrable interconnection structure of  claim 15 , wherein a size of each the one or more photovoltaic cells is substantially the same as in the one or more building integrable photovoltaic modules. 
     
     
         20 . A building integrable interconnection structure for installing on a building structure in a row with one or more building integrable photovoltaic modules and for electrically connecting to the one or more building integrable photovoltaic modules, the building integrable interconnection structure comprising:
 a base portion having a first edge and a second edge, the first edge opposite to the second edge;   a first electrical connector positioned along the first edge; and   a second electrical connector positioned along the second edge, the second electrical connector electrically connected to the first electrical connector,   wherein a larger area of the base portion is free from wiring and photovoltaic cells; and   wherein the building integrable interconnection structure and the one or more building integrable photovoltaic modules have substantially same size.   
     
     
         21 . A method of installing a photovoltaic array comprising:
 installing a first building integrable photovoltaic module on a building structure adjacent to an obstacle, the first building integrable photovoltaic module comprising a first module connector disposed on an edge facing the obstacle;   determining size and location of the obstacle with respect to the first building integrable photovoltaic module;   providing a building integrable interconnection structure comprising a base portion, a first structure connector positioned along one edge of the base portion, and a second structure connector positioned along an opposite edge of the base portion, the first structure connector electrically connected to the second structure connector,   forming an opening in the base portion of the building integrable interconnection structure such that the first structure connector remains electrically connected to the second structure connector; and   installing the building integrable interconnection structure onto the building structure while protruding the obstacle through the opening and establishing an electrical connection between the first structure connector and the first module connector, the first building integratable photovoltaic module and the building integrable interconnection structure forming a row.   
     
     
         22 . The method of  claim 21 , further comprising:
 providing a second building integrable photovoltaic module comprising a second module connector; and   installing the second building integrable photovoltaic module on the building structure in the row and establishing an electrical connection between the second structure connector and the second module connector.   
     
     
         23 . The method of  claim 21 , further comprising selecting the building integrable interconnection structure from a set of building integrable interconnection structures based on size and location of photovoltaic sections on the building integrable interconnection structures in the set. 
     
     
         24 . The method of  claim 21 , further comprising:
 positioning a sealing sleeve around the obstacle and in contact with the building integrable interconnection structure; and   securing the sealing sleeve to the building integrable interconnection structure using one or more mechanical fasteners protruding into corresponding multiple mechanical fastener sleeves of the base portion of the building integrable interconnection structure.