Electrical connectors of building integrable photovoltaic modules

Abstract

Provided are novel building integrable photovoltaic (BIP) modules and methods of fabricating thereof. A module may be fabricated from an insert having one or more photovoltaic cells by electrically interconnecting and mechanically integrating one or more connectors with the insert. Each connector may have one or more conductive elements, such as metal sockets and/or pins. At least two of all conductive elements are electrically connected to the photovoltaic cells using, for example, bus bars. These and other electrical components are electrically insulated using a temperature resistant material having a Relative Temperature Index (RTI) of at least about 115° C. The insulation may be provided before or during module fabrication by, for example, providing a prefabricated insulating housing and/or injection molding the temperature resistant material. The temperature resistant material and/or other materials may be used for mechanical integration of the one or more connectors with the insert.

1 . (canceled) 
     
     
         2 . A photovoltaic module comprising:
 a front sealing sheet;   a back sealing sheet;   a plurality of electrically interconnected photovoltaic cells sealed in a sealed space between the front sealing sheet and the back sealing sheet;   a first bus bar electrically connected to the photovoltaic cells and extending outside the sealed space;   a first conductive element outside the sealed space and electrically connected to the first bus bar; and   an insulating housing that:
 comprises a temperature resistant material having a Relative Temperature Index (RTI) of at least about 115° C., 
 covers the electrical connection between the first bus bar and the first conductive element, and 
 includes an extension flap that insulates at least a portion of the first bus bar that is outside the sealed space. 
   
     
     
         3 . The photovoltaic module of  claim 2 , wherein the extension flap comprises a flexible material. 
     
     
         4 . The photovoltaic module of  claim 3 , wherein the flexible material comprises one or more of a polyethylene, a polypropylene, a thermoplastic olefin, a thermoplastic rubber, a thermoplastic elastomer, an ethylene propylene diene, a monomer (EPDM), a fluoroelastomer or a thermoplastic vulcanizate (TPV), and a flexible cast thermoset material, such as an urethane or a silicone. 
     
     
         5 . The photovoltaic module of  claim 2 , wherein the insulating housing is offset from the front sealing sheet and from the back sealing sheet. 
     
     
         6 . The photovoltaic module of  claim 2 , the temperature resistant material has a RTI of at least about 125° C. 
     
     
         7 . The photovoltaic module of  claim 6 , the temperature resistant material has a RTI of at least about 135° C. 
     
     
         8 . The photovoltaic module of  claim 2 , wherein a section of the insulating housing is positioned over one of: the front sealing sheet and the back sealing sheet. 
     
     
         9 . The photovoltaic module of  claim 2 , wherein the insulating housing is comprises a polyamide. 
     
     
         10 . The photovoltaic module of  claim 9 , wherein the insulating housing further comprises glass fibers. 
     
     
         11 . The photovoltaic module of  claim 2 , further comprising an outer portion, wherein the outer portion:
 comprises a temperature resistant material having a RTI of at least about 115° C.,   covers the insulating housing, and   is positioned over one of: the front sealing sheet and the back sealing sheet.   
     
     
         12 . The photovoltaic module of  claim 11 , wherein the outer portion provides mechanical support between the insulating housing, the front sealing sheet, and the back sealing sheet. 
     
     
         13 . The photovoltaic module of  claim 11 , wherein:
 a first section of the outer portion is positioned over the front sealing sheet, and   a first section of the insulating housing is positioned over front sealing sheet and interposed between the front sealing sheet and the outer portion.   
     
     
         14 . The photovoltaic module of  claim 13 , wherein a second section of the outer portion is positioned over the back sealing sheet. 
     
     
         15 . The photovoltaic module of  claim 11 , wherein:
 a first section of the outer portion is positioned over the back sealing sheet, and   a first section of the insulating housing is positioned over back sealing sheet and interposed between the back sealing sheet and the outer portion.   
     
     
         16 . The photovoltaic module of  claim 15 , wherein a second section of the outer portion is positioned over the back sealing sheet. 
     
     
         17 . The photovoltaic module of  claim 11 , wherein the outer portion includes a top section positioned over a first part the front sealing sheet and a bottom section positioned over a first part of the back sealing sheet. 
     
     
         18 . The photovoltaic module of  claim 11 , wherein the temperature resistant material of the outer portion has a RTI of at least about 135° C. 
     
     
         19 . The photovoltaic module of  claim 11 , wherein the outer portion comprises a polyamide. 
     
     
         20 . The photovoltaic module of  claim 19 , wherein the outer portion further comprises glass fibers. 
     
     
         21 . The photovoltaic module of  claim 2 , further comprising:
 a second bus bar electrically connected to the photovoltaic cells and extending outside the sealed space; and   a second conductive element outside the sealed space and electrically connected to the second bus bar, wherein:
 the insulating housing covers the electrical connection between the second bus bar and the second conductive element, and 
 the insulating housing further includes a second extension flap that insulates at least a portion of the second bus bar that is outside the sealed space.