# US 10,121,911 B2 · Photovoltaic device assembly and method

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- Number: US 10,121,911 B2
- Document ID: US10121911B2
- Status: Granted
- Kind: B2
- Application number: 14/797,857
- Filed: 2015-07-13
- Published: 2015-11-05
- Granted: 2018-11-06
- Earliest claimed: 2008-05-05
- Assignees: Dow Global Technologies LLC
- Applicants: Dow Global Technologies LLC
- Inventors: James R. Keenihan; Joseph A. Langmaid; Robert J. Cleereman; Andrew T. Graham
- Web page: https://patentgrep.com/patent/US10121911B2

## CPC

- H10F 77/939: {Output lead wires or elements}
- H01R 12/79: connecting to rigid printed circuits or like structures
- H01R 13/639: Additional means for holding or locking coupling parts together, after engagement, {e.g. separate keylock, retainer strap}
- H01R 13/7032: {making use of a separate bridging element directly cooperating with the terminals}
- H01R 31/00: Coupling parts supported only by co-operation with counterpart
- H02S 20/23: specially adapted for roof structures
- H02S 20/25: Roof tile elements
- H02S 40/34: comprising specially adapted electrical connection means to be structurally associated with the PV module, e.g. junction boxes
- H02S 40/36: characterised by special electrical interconnection means between two or more PV modules, e.g. electrical module-to-module connection
- H10F 19/80: Encapsulations or containers for integrated devices, or assemblies of multiple devices, having photovoltaic cells
- H10F 19/90: Structures for connecting between photovoltaic cells, e.g. interconnections or insulating spacers (between thin-film photovoltaic cells on a single substrate H10F19/35)
- H10F 19/904: {characterised by the shapes of the structures}
- H10F 77/935: {for photovoltaic devices or modules}
- H01R 13/055: {co-operating with sockets having a rectangular transverse section}
- H01R 13/113: {co-operating with pins or blades having a rectangular transverse section}
- Y02A 30/60: Planning or developing urban green infrastructure
- Y02B 10/10: Photovoltaic [PV]
- Y02E 10/50: Photovoltaic [PV] energy
- Y10T 29/49117: Conductor or circuit manufacturing
- Y10T 29/49355: Solar energy device making
- Y10T 29/49826: Assembling or joining
- H10F: INORGANIC SEMICONDUCTOR DEVICES SENSITIVE TO INFRARED RADIATION, LIGHT, ELECTROMAGNETIC RADIATION OF SHORTER WAVELENGTH OR CORPUSCULAR RADIATION
- H01R: ELECTRICALLY-CONDUCTIVE CONNECTIONS; STRUCTURAL ASSOCIATIONS OF A PLURALITY OF MUTUALLY-INSULATED ELECTRICAL CONNECTING ELEMENTS; COUPLING DEVICES; CURRENT COLLECTORS
- H02S: GENERATION OF ELECTRIC POWER BY CONVERSION OF INFRARED RADIATION, VISIBLE LIGHT OR ULTRAVIOLET LIGHT, e.g. USING PHOTOVOLTAIC [PV] MODULES (obtaining electrical energy from radioactive sources G21H1/12; light sensitive inorganic semiconductor devices H10F; light sensitive organic semiconductor devices H10K30/00; thermoelectric devices H10N10/00; pyroelectric devices H10N15/00)
- Y02A: TECHNOLOGIES FOR ADAPTATION TO CLIMATE CHANGE
- Y02B: CLIMATE CHANGE MITIGATION TECHNOLOGIES RELATED TO BUILDINGS, e.g. HOUSING, HOUSE APPLIANCES OR RELATED END-USER APPLICATIONS
- Y02E: REDUCTION OF GREENHOUSE GAS [GHG] EMISSIONS, RELATED TO ENERGY GENERATION, TRANSMISSION OR DISTRIBUTION
- Y10T: TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION

## Abstract

The present invention is premised upon a connector device and method that can more easily electrically connect a plurality of PV arrays and/or locate these arrays upon a building or structure. It also can optionally provide some additional components (e.g. a bypass diode and/or an indicator means) and can enhance the serviceability of the array.

## Claims

### Claim 1

A method comprising the steps of:
a. providing a plurality of individual photovoltaic devices on a surface of a structure, wherein the individual photovoltaic devices each include:
i. a photovoltaic cell assembly including:
1. at least one peripheral edge, and
2. at least one photovoltaic cell inboard of the at least one peripheral edge, wherein the at least one photovoltaic cell includes a photoactive portion, and a surface that allows transmission of light energy to the photoactive portion for conversion into electrical energy;
ii. at least one bus terminal for transferring current to or from the photovoltaic cell assembly; and
iii. a body portion including:
1. a lower surface portion that contacts the structure, and
2. an upper surface portion that receives a fastener that attaches the individual photovoltaic devices to the structure,
wherein the body portion is at least partially joined to at least one edge portion of the at least one peripheral edge of the photovoltaic cell assembly along at least a portion of a bottom segment of the body portion while leaving the surface of the at least one photovoltaic cell exposed;
b. providing a plurality of edge pieces;
c. attaching a first individual photovoltaic device to the surface of the structure;
d. attaching the second individual photovoltaic device to the first individual photovoltaic device;
e. attaching the second individual photovoltaic device to the surface of the structure;
f. repeating steps c-e until a first row or column is attached to the surface;
g. attaching a second row or column of individual photovoltaic devices immediately adjacent to and in partial contact with the first row or column, using the same steps as the first row or column;
h. attaching one of the plurality of edge pieces via a connector assembly to a first end of each of the first row or column and the second row or column;
i. attaching a third row or column of individual photovoltaic devices immediately adjacent to and in partial contact with the second row or column, using the same steps as the first row or column; and
j. attaching a second of the plurality of edge pieces via a connector assembly to a second end of each of the second row or column and the third row or column;
wherein the at least one bus terminal extends along the first row or column through the one of the plurality of edge pieces located at the first end to the second row or column then through the second of the plurality of edge pieces to the third row or column so that the at least one bus terminal has a serpentine configuration; and
wherein some of the plurality of edge pieces include:
a main body portion;
two connector assemblies that connect to two respective rows or columns so that the two respective rows or columns are electrically connected, the two connector assemblies being a separate element from the main body portion, wherein each connector assembly includes electrical connectors housed within a connector housing, and wherein the connector housing is connected to a surface of the main body portion of the edge piece; and
electrical elements that span between the two connector assemblies, the electrical elements at least partially defining the at least one bus terminal.

### Claim 2 (depends on 1)

The method according to claim 1, wherein some or all of the connector assemblies have a first end portion that is integral to the plurality of edge pieces, the plurality of photovoltaics devices, or both.

### Claim 3 (depends on 1)

The method of claim 1, wherein the structure is a building.

### Claim 4 (depends on 1)

The method of claim 1, includes a step of providing at least one connector assembly located integrally within the at least one peripheral edge, as a separate connector, or both.

### Claim 5 (depends on 1)

The method of claim 1, wherein the method includes a step of connecting a pass-through electrical connector or electrical lead assembly to the first row or column opposite the edge piece connected to the end of the first row or column.

### Claim 6 (depends on 1)

The method of claim 1, wherein the plurality of edge pieces include a starter edge piece, an end edge piece, and edge pieces that include two or more edge connector assemblies that connect two rows or columns of photovoltaic devices together.

### Claim 7 (depends on 1)

The method of claim 1, wherein the connector housing of each connector assembly is inserted into the main body portion of the edge piece.

### Claim 8 (depends on 1)

The method according to claim 1, including the step of providing a spacer device between two of the individual photovoltaic devices.

### Claim 9 (depends on 8)

The method according to claim 8, wherein the first row or column, second row or column, or both, include at least one spacer device in place of at least one of the individual photovoltaic devices.

### Claim 10 (depends on 1)

The method according to claim 1, wherein the steps c-h are repeated to create a photovoltaic device assembly with a plurality of rows or columns.

### Claim 11 (depends on 10)

The method of claim 10, wherein the method includes a step of connecting the plurality of edge pieces to the plurality of rows or columns.

### Claim 12 (depends on 11)

The method of claim 11, wherein the method includes a step of connecting a pass-through electrical connector or electrical lead assembly to the first row or column opposite the edge piece connected to the first end of the first row or column.

### Claim 13 (depends on 10)

The method of claim 10, wherein the at least one bus terminal is two bus terminals and method includes a step of connecting the two bus terminals together by connecting a starter piece to an end of the first row or column opposite the edge piece connected to the first end of the first row or column.

### Claim 14 (depends on 13)

The method of claim 13, wherein the method includes a step of connecting an end piece to an end of a last row or column and the end piece includes a pass-through electrical connector.

### Claim 15 (depends on 1)

The method of claim 1, wherein the method includes a step of attaching a fourth row or column of individual photovoltaic devices immediately adjacent to in partial contact with the third row or column, using the same steps as the first row or column.

### Claim 16 (depends on 15)

The method of claim 15, wherein the method includes a step of attaching a third of the plurality of edge pieces via a connector assembly at a first end of the third row or column and the fourth row or column opposite the second edge piece connected to the second row or column and the third row or column.

### Claim 17 (depends on 1)

The method of claim 1, wherein the main body portion of some of the plurality of edge pieces includes an inner surface portion that is solid or has geometric features.

### Claim 18 (depends on 17)

The method of claim 17, wherein the geometric features are ribs.

### Claim 19 (depends on 18)

The method of claim 18, wherein the method includes a step of press-fitting the electrical elements spanning between the two connector assemblies into cuts in the ribs.

### Claim 20 (depends on 1)

The method of claim 1, wherein the method includes a step of inserting the two connector assemblies into a housing that is integral to the main body portion of the edge pieces.

### Claim 21 (depends on 20)

The method of claim 20, wherein the housing integral to the edge piece is a receptacle housing that receives the two connector assemblies and connects the two connector assemblies to the electrical elements that span between the two connector assemblies.