Photovoltaic laminate segments and segmented photovoltaic modules

Abstract

One embodiment of the invention relates to a segmented photovoltaic (PV) module which is manufactured from laminate segments. The segmented PV module includes rectangular-shaped laminate segments formed from rectangular-shaped PV laminates and further includes non-rectangular-shaped laminate segments formed from rectangular-shaped and approximately-triangular-shaped PV laminates. The laminate segments are mechanically joined and electrically interconnected to form the segmented module. Another embodiment relates to a method of manufacturing a large-area segmented photovoltaic module from laminate segments of various shapes. Other embodiments relate to processes for providing a photovoltaic array for installation at a site. Other embodiments and features are also disclosed.

1 . A segmented photovoltaic module comprising:
 rectangular-shaped laminate segments formed from rectangular-shaped photovoltaic laminates;   non-rectangular-shaped laminate segments formed from rectangular-shaped and approximately-triangular-shaped photovoltaic laminates;   mechanical joints between laminate segments; and   electrical interconnections between the laminate segments.   
     
     
         2 . The segmented photovoltaic module of  claim 1 , further comprising:
 stiffening ribs to provide mechanical support between the laminate segments.   
     
     
         3 . The segmented photovoltaic module of  claim 1 , further comprising:
 elastomer to protect the electrical interconnections between the laminate segments.   
     
     
         4 . The segmented photovoltaic module of  claim 1 , further comprising:
 a DC-to-AC micro-inverter integrated with the module so that the module is configured to output AC power.   
     
     
         5 - 21 . (canceled) 
     
     
         22 . The segmented photovoltaic module of  claim 1 , further comprising:
 a DC-to-DC power converter integrated with the module so that the module is configured to output conditioned DC power.   
     
     
         23 . The segmented photovoltaic module of  claim 1 , wherein the electrical interconnections between the laminate segments comprise metal tabs that are soldered together. 
     
     
         24 . The segmented photovoltaic module of  claim 1 , wherein the approximately-triangular-shaped laminate segments each comprises an arrangement of rectangular-shaped photovoltaic laminates within a triangular outline. 
     
     
         25 . The segmented photovoltaic module of  claim 1 , wherein the approximately-triangular-shaped laminate segments each comprises an arrangement of rows of rectangular-shaped photovoltaic laminates in which a next row has one less rectangular-shaped photovoltaic laminate than a previous row. 
     
     
         26 . The segmented photovoltaic module of  claim 1  further comprising:
 an opening surrounded by the laminate segments. 
 
     
     
         27 . The segmented photovoltaic module of  claim 26 , wherein the opening is rectangular in shape and has a perimeter formed by edges of four rectangular-shaped laminate segments. 
     
     
         28 . The segmented photovoltaic module of  claim 1 , wherein the laminate segments fit within a predetermined build envelope. 
     
     
         29 . The segmented photovoltaic module of  claim 28 , wherein the predetermined build envelope includes a diagonal edge. 
     
     
         30 . The segmented photovoltaic module of  claim 28 , further comprising:
 a carrier frame to support the laminate segments.   
     
     
         31 . A photovoltaic module comprising:
 a plurality of laminate segments arranged in an array, each laminate segment comprising a laminate with a plurality of solar cells therein;   electrical interconnections between the laminate segments; and   mechanical joints between the laminate segments, wherein the mechanical joints at least partially enclose the electrical interconnections.   
     
     
         32 . The photovoltaic module of  claim 31 , further comprising:
 an encapsulant material surrounding the electrical interconnections to electrically insulate the electrical interconnections.   
     
     
         33 . The photovoltaic module of  claim 32 , wherein the encapsulant material is located in the mechanical joints and provides environmental protection for the electrical interconnections. 
     
     
         34 . The photovoltaic module of  claim 32 , wherein the encapsulant material is elastomeric. 
     
     
         35 . The photovoltaic module of  claim 31 , wherein the electrical interconnections comprise metal tabs from adjacent laminate segments that are soldered together. 
     
     
         36 . The photovoltaic module of  claim 31 , wherein the mechanical joints comprise back-side channels and caps at ends of the back-side channels. 
     
     
         37 . A set of segmented photovoltaic modules for creating a photovoltaic array in custom-shaped envelope, the set comprising a first segmented photovoltaic module of a first shape and a second segmented photovoltaic module of a second shape.