MODULE CONNECTOR FOR FLEXIBLE PHOTOVOLTAlC MODULE

Abstract

Disclosed are module connectors for flexible photovoltaic modules. A module connector may include a clamp and an insert configured to be inserted into the clamp. The insert may have an insert body, an electrical lead and an electrical connector. The clamp may have a body portion with a recess configured to receive the insert body, a first clamping portion configured to clamp a second portion of the electrical connector to connect it to the body portion, and a second clamping portion with a first clamping surface configured to contact a first sheet of the module and a second clamping surface configured to contact a second sheet of the module. The second clamping portion may be configured to connect the clamp to the module such that the clamp overlaps and extends around a part of the first sheet, a part of the module's exterior edge surface, and a part of the second sheet.

What is claimed is: 
     
         1 . A module connector for a flexible photovoltaic module, the module connector comprising:
 an insert that is configured to be inserted into a clamp and that includes:
 an insert body, 
 a first electrical lead with a first portion that extends into and is sealed inside the insert body, and a second portion outside the insert body that extends away from the insert body in a first direction, and 
 a first cable with a first portion that extends into and is sealed inside the insert body, and a second portion outside the insert body that extends away from the insert body in a second direction, wherein the first electrical lead and the first cable are electrically coupled to each other inside the insert body; and 
   the clamp that includes:
 a body portion that has a recess configured to receive the insert body, 
 a first clamping portion that is configured to clamp the second portion of the first cable to connect the first cable to the body portion, and 
 a second clamping portion that has a first surface and a second surface, wherein:
 the second clamping portion is configured to be connected with the body portion such that when connected to the body portion, the first surface and the second surface face each other and are offset from each other. 
 
   
     
     
         2 . The module connector of  claim 1 , wherein the second clamping portion is further configured such that when the second clamping portion is connected with the body portion, the first surface and the second surface are parallel to each other. 
     
     
         3 . The module connector of  claim 1 , wherein the second clamping portion is further configured to be connected to the body portion by an attachment means that extends through the body portion. 
     
     
         4 . The module connector of  claim 1 , wherein:
 the first surface is located on the body portion,   the clamp further comprises a flap that is connected to the body portion and that is configured to be moveable with respect to the body portion, and   the second surface is located on the flap.   
     
     
         5 . The module connector of  claim 1 , wherein the second clamping portion is further configured to connect the clamp to a flexible photovoltaic module such that the clamp overlaps and extends around a part of a first sheet, a part of an exterior edge surface, and a part of a second sheet of the flexible photovoltaic module. 
     
     
         6 . The module connector of  claim 1 , wherein the body portion, the flap, and the flexible connector are a unitary body. 
     
     
         7 . The module connector of  claim 1 , wherein:
 the first clamping portion includes a clamping member configured to be moveable between an open position and a closed position,   in the open position, the first clamping portion is configured such that the first cable is insertable into the first clamping portion, and   in the closed position, the clamping member is configured to contact the first cable, to connect to the body portion, and to connect the first cable to the body portion.   
     
     
         8 . The module connector of  claim 1 , wherein the first clamping portion includes a crimping portion that is configured to crimp the first cable. 
     
     
         9 . The module connector of  claim 1 , wherein:
 the insert further includes:
 a second electrical lead with a first portion that extends into and is sealed inside the insert body, and a second portion outside the insert body that extends away from the insert body in the first direction, and 
 a second cable with a first portion that extends into and is sealed inside the insert body, and a second portion outside the insert body that extends away from the insert body in the second direction, wherein the second electrical lead and the second cable are electrically coupled to each other inside the insert body; and 
   the clamp further includes a third clamping portion that is configured to clamp the second portion of the second cable to connect the second cable to the body portion.   
     
     
         10 . The module connector of  claim 9 , wherein:
 the insert is positioned within the recess of the body portion of the clamp,   the first clamping portion is clamping the second portion of the first cable such that the first cable is connected to the body portion, and   the third clamping portion is clamping the second portion of the second cable such that the second cable is connected to the body portion.   
     
     
         11 . The module connector of  claim 1 , wherein the first direction is orthogonal to the second direction. 
     
     
         12 . The module connector of  claim 1 , wherein the first direction is parallel to the second direction. 
     
     
         13 . The module connector of  claim 1 , wherein the first surface of the second clamping portion has a first part and a second part that are offset from and coplanar with each other. 
     
     
         14 . The module connector of  claim 1 , wherein:
 the insert body includes a first planar exterior surface and a second planar exterior surface,   the first planar exterior surface is at an angle of between about 140 degrees to about 180 degrees from the first direction, and   the second planar exterior surface is at an angle of between about 140 degrees to about 180 degrees from the first direction.   
     
     
         15 . The module connector of  claim 1 , wherein a height of the insert body is between about 6 millimeters and about 16 millimeters. 
     
     
         16 . An apparatus comprising:
 a module connector for a flexible photovoltaic module, the flexible photovoltaic module having a first sheet, a second sheet, one or more flexible photovoltaic cells positioned in a sealed space between the first sheet and the second sheet, and a seal region that spans between a first section of the first sheet and a second section of the second sheet and that forms a part of an exterior edge surface of the flexible photovoltaic module and, wherein the module connector includes:
 an insert that is configured to be inserted into a clamp and that includes:
 an insert body, 
 an electrical lead with a first portion that extends into and is sealed inside the insert body, and a second portion outside the insert body that extends away from the insert body in a first direction, 
 a cable with a first portion that extends into and is sealed inside the insert body, and a second portion outside the insert body that extends away from the insert body in a second direction, wherein the electrical lead and the cable are electrically coupled to each other inside the insert body, and 
 a first section of a first clamping portion, wherein the first clamping portion includes the first section and a second section, and wherein the first clamping portion is configured to clamp the second portion of the cable to connect the cable to the body portion; and 
 
 the clamp that includes:
 a body portion that has a recess configured to receive the insert body, 
 the second section of the first clamping portion, and 
 a second clamping portion that has a first clamping surface configured to contact the first sheet and a second clamping surface configured to contact the second sheet, and that is configured to connect the clamp to the flexible photovoltaic module such that the clamp overlaps and extends around a part of the first sheet, a part of the exterior edge surface, and a part of the second sheet. 
 
   
     
     
         17 . The module connector of  claim 16 , wherein:
 the insert body includes a first planar exterior surface and a second planar exterior surface,   the first planar exterior surface is at an angle of between about 140 degrees to about 180 degrees from the first direction, and   the second planar exterior surface is at an angle of between about 140 degrees to about 180 degrees from the first direction.   
     
     
         18 . An apparatus comprising:
 a module connector for a flexible photovoltaic module, the module connector being a monolithic unit and including:
 a first body portion that is flexibly attached to a second body portion, and 
 a recess in the first body portion, wherein:
 the recess is configured to receive an insert of the flexible photovoltaic module and to secure the insert to the module connector, and 
 the module connector is configured to be positioned on the flexible photovoltaic module such that it simultaneously contacts a top side of the flexible photovoltaic module, a bottom side of the flexible photovoltaic module, and wraps around an edge of the flexible photovoltaic module. 
 
   
     
     
         19 . The apparatus of  claim 18 , further comprising the flexible photovoltaic module, wherein:
 the insert is positioned in the recess and secured by the module connector, and   the module connector is positioned on the flexible photovoltaic module such that it simultaneously contacts the top side of the flexible photovoltaic module, the bottom side of the flexible photovoltaic module, and wraps around the edge of the flexible photovoltaic module.   
     
     
         20 . The module connector of  claim 18 , wherein:
 the insert body includes a first planar exterior surface and a second planar exterior surface,   the first planar exterior surface is at an angle of between about 140 degrees to about 180 degrees from the first direction, and   the second planar exterior surface is at an angle of between about 140 degrees to about 180 degrees from the first direction.