Photovoltaic module having an external electrical connector

Abstract

A photovoltaic module having an external electrical connector is described. For example, the photovoltaic module may include a plug receptacle mounted on a module laminate, and a contact may extend from a photovoltaic cell within the module laminate into a plug channel of the plug receptacle. The plug receptacle may receive a mating electrical connector, e.g., an electrical plug, of off-panel electronics. Accordingly, the contact may be removably connected to the mating electrical connector, and the photovoltaic cell may be placed in electrical connection with the off-panel electronics.

What is claimed is: 
     
         1 . A photovoltaic module, comprising:
 a module laminate including a photovoltaic cell electrically connected to an electrical conductor between a front layer and a back layer;   a plug receptacle mounted on the module laminate, wherein the plug receptacle includes a plug casing around a plug channel, and a base wall having a contact slot aligned with the plug channel; and   a contact including a contact base attached to the electrical conductor, and a contact prong extending through the contact slot into the plug channel.   
     
     
         2 . The photovoltaic module of  claim 1 , wherein the contact prong has a prong stiffness about a contact axis, wherein the electrical conductor has a conductor stiffness about a conductor axis, and wherein the prong stiffness is greater than the conductor stiffness. 
     
     
         3 . The photovoltaic module of  claim 2 , wherein the contact prong includes a contact cross-sectional area, wherein the contact slot includes a slot cross-sectional area, and wherein the contact cross-sectional area is smaller than, and conforms to, the slot cross-sectional area. 
     
     
         4 . The photovoltaic module of  claim 3 , wherein the plug receptacle is mounted on a back surface of the back layer, wherein the contact base is parallel to the back surface, and wherein the contact prong is orthogonal to the back surface. 
     
     
         5 . The photovoltaic module of  claim 4  further comprising:
 an encapsulant surrounding the contact base between the front layer and the back layer; and 
 an adhesive between the plug receptacle and the module laminate. 
 
     
     
         6 . The photovoltaic module of  claim 3 , wherein the module laminate includes a lateral edge, and wherein the plug receptacle is mounted on the lateral edge. 
     
     
         7 . The photovoltaic module of  claim 6 , wherein the plug receptacle includes a mount casing attached to the lateral edge, wherein the mount casing surrounds a contact channel on an opposite side of the base wall from the plug channel, and wherein the contact base is in the contact channel. 
     
     
         8 . The photovoltaic module of  claim 1 , wherein the module laminate includes a first sub-string of photovoltaic cells including the photovoltaic cell, and a second sub-string of photovoltaic cells including a second photovoltaic cell, and further comprising a second plug receptacle mounted on the module laminate, and a second contact electrically connected to the second photovoltaic cell and extending through the second plug receptacle. 
     
     
         9 . The photovoltaic module of  claim 8  further comprising a module frame mounted along a lateral edge of the module laminate, wherein the module frame includes the plug receptacle and the second plug receptacle, and wherein the second contact extends through a second contact slot of the second plug receptacle. 
     
     
         10 . A photovoltaic system, comprising:
 a photovoltaic module including
 a module laminate including a photovoltaic cell electrically connected to an electrical conductor between a front layer and a back layer, 
 a plug receptacle mounted on the module laminate, wherein the plug receptacle includes a plug casing around a plug channel, and 
 a contact including a contact base attached to the electrical conductor, and a contact prong extending into the plug channel; 
   an off-panel electronics device; and   an external cable extending between and electrically connecting the contact and the off-panel electronics device.   
     
     
         11 . The photovoltaic system of  claim 10 , wherein the plug receptacle includes a base wall having a contact slot aligned with the plug channel, and wherein the contact prong extends through the contact slot into the plug channel. 
     
     
         12 . The photovoltaic system of  claim 11 , wherein the plug receptacle is mounted on a back surface of the back layer, wherein the contact base is parallel to the back surface, and wherein the contact prong is orthogonal to the back surface. 
     
     
         13 . The photovoltaic system of  claim 12  further comprising:
 an encapsulant surrounding the contact base between the front layer and the back layer; and 
 an adhesive between the plug receptacle and the module laminate. 
 
     
     
         14 . The photovoltaic system of  claim 10 , wherein the module laminate includes a first sub-string of photovoltaic cells including the photovoltaic cell, and a second sub-string of photovoltaic cells including a second photovoltaic cell, and further comprising a second plug receptacle mounted on the module laminate, and a second contact electrically connected to the second photovoltaic cell and extending through the second plug receptacle. 
     
     
         15 . The photovoltaic system of  claim 14  further comprising a module frame mounted along a lateral edge of the module laminate, wherein the module frame includes the plug receptacle and the second plug receptacle, and wherein the second contact extends through a second contact slot of the second plug receptacle. 
     
     
         16 . The photovoltaic system of  claim 10 , wherein the off-panel electronics device includes one or more of a bypass diode, a microinverter, or a DC optimizer. 
     
     
         17 . A method, comprising:
 connecting a photovoltaic cell, an electrical conductor, and a contact between a front layer and a back layer, wherein the contact includes a contact base between the front layer and the back layer and a contact prong extending outward through the back layer;   surrounding the photovoltaic cell, the electrical conductor, and the contact with an encapsulant between the front layer and the back layer;   curing the encapsulant; and   attaching a plug receptacle having a contact slot to the back layer, wherein the contact prong extends through the contact slot.   
     
     
         18 . The method of  claim 17  further comprising:
 covering the contact prong with a protector before surrounding the photovoltaic cell, the electrical conductor, and the contact with the encapsulant. 
 
     
     
         19 . The method of  claim 17 , wherein attaching the plug receptacle includes applying an adhesive between the plug receptacle and the back layer. 
     
     
         20 . The method of  claim 19 , wherein connecting the photovoltaic cell, the electrical conductor, and the contact includes welding the contact base to the electrical conductor.