Electrical interconnects for photovoltaic modules and methods thereof

Abstract

System and method for interconnecting photovoltaic modules. The system includes a first photovoltaic module and a second photovoltaic module. The first photovoltaic module includes a first bus bar and a first interconnect tab connected to the first bus bar. The second photovoltaic module includes a second bus bar and a second interconnect tab connected to the second bus bar. The system for interconnecting photovoltaic modules additionally includes a module interconnector configured to interconnect the first and the second photovoltaic modules. The module interconnector includes an interconnection component and an interconnection protector. Additionally, the system for interconnecting photovoltaic modules includes a first connection component connecting the interconnection component to the first interconnect tab of the first photovoltaic module and a second connection component connecting the interconnection component to the second interconnect tab of the second photovoltaic module.

What is claimed is: 
     
         1 . A system for interconnecting photovoltaic modules, comprising:
 a first photovoltaic module including a first bus bar and a first interconnect tab connected to the first bus bar;   a second photovoltaic module including a second bus bar and a second interconnect tab connected to the second bus bar;   a module interconnector configured to interconnect the first photovoltaic module and the second photovoltaic module, the module interconnector including an interconnection component and an interconnection protector;   a first connection component connecting the interconnection component to the first interconnect tab of the first photovoltaic module; and   a second connection component connecting the interconnection component to the second interconnect tab of the second photovoltaic module;   wherein the interconnection protector substantially encloses the interconnection component, the first connection component, and the second connection component.   
     
     
         2 . The system of  claim 1  wherein the first photovoltaic module includes one selected from a group consisting of silicon, cadmium telluride, CIGS, and organics. 
     
     
         3 . The system of  claim 1  wherein:
 the first photovoltaic module further includes an array of photovoltaic cells, the array of photovoltaic cells including a positive end and a negative end; and 
 the first bus bar is coupled to either the positive end or the negative end. 
 
     
     
         4 . The system of  claim 1  wherein the first interconnect tab protrudes from a side of the first photovoltaic module. 
     
     
         5 . The system of  claim 4  wherein the first interconnect tab is an extension of the first bus bar. 
     
     
         6 . The system of  claim 4  wherein the first interconnect tab is a separate conductor from the first bus bar. 
     
     
         7 . The system of  claim 4  wherein the first interconnect tab protrudes from the side of the first photovoltaic module in parallel with the first bus bar. 
     
     
         8 . The system of  claim 4  wherein the first interconnect tab protrudes from the side of the first photovoltaic module at an angle to the first bus bar. 
     
     
         9 . The system of  claim 1  wherein the first interconnect tab is coated at least partially by a protective film. 
     
     
         10 . The system of  claim 1  wherein the first photovoltaic module further includes:
 a photovoltaic panel including a front panel surface, a back panel surface, and a plurality of edge surfaces; 
 a first encapsulating material for protecting the front panel surface of the photovoltaic panel and the back panel surface of the photovoltaic panel; and 
 a second encapsulating material for protecting the plurality of edge surfaces of the photovoltaic panel; 
 wherein the first encapsulating material and the second encapsulating material substantially enclose the photovoltaic panel. 
 
     
     
         11 . The system of  claim 10  wherein the second encapsulating material is placed above, below, and to the sides of the first interconnect tab. 
     
     
         12 . The system of  claim 10  wherein:
 the first photovoltaic module further includes a front module surface and a back module surface; and 
 the first interconnect tab extends around the first encapsulating material to the front module surface or the back module surface of the first photovoltaic module. 
 
     
     
         13 . The system of  claim 1  wherein the interconnection component is potted inside the protector using a polymer. 
     
     
         14 . The system of  claim 1  wherein the interconnection component includes a flexible cable. 
     
     
         15 . The system of  claim 1  wherein the interconnection component includes a thin sheet of metal including accordion folds. 
     
     
         16 . The system of  claim 1  wherein the first connection is formed by at least one selected from a group consisting of crimping, soldering, welding, and ultrasonic welding. 
     
     
         17 . The system of  claim 1  wherein the first connection component, the second connection component, and the interconnection component include the same metal. 
     
     
         18 . The system of  claim 1  wherein the interconnection protector provides electrical and environmental protection to the interconnection component, the first connection component, and the second connection component. 
     
     
         19 . A method for installing photovoltaic modules, comprising:
 providing a first photovoltaic module including a first bus bar;   providing a second photovoltaic module including a second bus bar;   attaching a first interconnect tab to the first bus bar;   attaching a second interconnect tab to the second bus bar;   interconnecting the first photovoltaic module and the second photovoltaic module by connecting the first interconnect tab to an interconnection component with a first connection component and by connecting the second interconnect tab to the interconnection component with a second connection component;   enclosing substantially the interconnection component, the first connection component, and the second connection component by an interconnection protector;   packing, for shipping, at least the first photovoltaic module and the second photovoltaic module, the first photovoltaic module and the second photovoltaic module being interconnected to each other;   shipping, to an installation site, at least the packed first photovoltaic module and second photovoltaic module, the first photovoltaic module and the second photovoltaic module being interconnected to each other; and   installing, at the installation site, at least the first photovoltaic module and the second photovoltaic module.   
     
     
         20 . The method of  claim 19  wherein the first photovoltaic module includes one selected from a group consisting of silicon, cadmium telluride, CIGS, and organics. 
     
     
         21 . The method of  claim 19  wherein the process for packing, for shipping, at least the first photovoltaic module and the second photovoltaic module includes stacking the first photovoltaic module and the second photovoltaic module either front-to-back or back-to-front by folding the interconnection component and the interconnection protector. 
     
     
         22 . A method for installing photovoltaic modules, comprising:
 providing a first photovoltaic module including a first bus bar and a first interconnect tab connected to the first bus bar;   providing a second photovoltaic module including a second bus bar and a second interconnect tab connected to the second bus bar;   coating the first interconnect tab at least partially with a first protective film;   coating the second interconnect tab at least partially with a second protective film;   packing, for shipping, at least the first photovoltaic module and the second photovoltaic module;   shipping, to an installation site, at least the packed first photovoltaic module and second photovoltaic module; and   installing, at the installation site, at least the first photovoltaic module and the second photovoltaic module;   interconnecting, at the installation site, the installed first photovoltaic module and the installed second photovoltaic module by connecting the first interconnect tab to an interconnection component with a first connection component and by connecting the second interconnect tab to the interconnection component with a second connection component; and   enclosing substantially the interconnection component, the first connection component, and the second connection component with an interconnection protector.   
     
     
         23 . The method of  claim 22  wherein the first photovoltaic module includes one selected from a group consisting of silicon, cadmium telluride, CIGS, and organics. 
     
     
         24 . The method of  claim 22  wherein the process for interconnecting, at the installation site, the installed first photovoltaic module and the installed second photovoltaic module includes piercing the first protective film and piercing the second protective film. 
     
     
         25 . The method of  claim 22  wherein the process for interconnecting, at the installation site, the installed first photovoltaic module and the installed second photovoltaic module removing the first protective film and removing the second protective film.