Method of manufacturing a large-area segmented photovoltaic module
AssigneeSunPower Corporation
InventorCarl Lenox
Life of this patent
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Abstract
One embodiment of the invention relates to a segmented photovoltaic (PV) module which is manufactured from laminate segments. The segmented PV module includes rectangular-shaped laminate segments formed from rectangular-shaped PV laminates and further includes non-rectangular-shaped laminate segments formed from rectangular-shaped and approximately-triangular-shaped PV laminates. The laminate segments are mechanically joined and electrically interconnected to form the segmented module. Another embodiment relates to a method of manufacturing a large-area segmented photovoltaic module from laminate segments of various shapes. Other embodiments relate to processes for providing a photovoltaic array for installation at a site. Other embodiments and features are also disclosed.
Claims7
A method of manufacturing a large-area segmented photovoltaic module from photovoltaic laminate segments of various shapes, the method being performed at a manufacturing facility and comprising:
- mechanically joining a plurality of the photovoltaic laminate segments of various shapes to fill a predetermined envelope for the segmented photovoltaic module;
- electrically interconnecting the plurality of photovoltaic laminate segments;
- forming a protective cover for the electrical interconnections;
- and
- integrating a junction box with the module for connecting to the segmented photovoltaic module.
A method of manufacturing a large-area segmented photovoltaic module from laminate segments of various shapes, the method being performed at a manufacturing facility and comprising:
- mechanically joining a plurality of the laminate segments of various shapes to fill a predetermined envelope for the segmented photovoltaic module;
- electrically interconnecting the plurality of laminate segments;
- forming a protective cover for the electrical interconnections;
- integrating a junction box with the module for connecting to the segmented photovoltaic module;
- and
- soldering tabbing together to form the electrical interconnections between the laminate segments.
A method of manufacturing a large-area segmented photovoltaic module from laminate segments of various shapes, the method being performed at a manufacturing facility and comprising:
- mechanically joining a plurality of the laminate segments of various shapes to fill a predetermined envelope for the segmented photovoltaic module;
- electrically interconnecting the plurality of laminate segments;
- forming a protective cover for the electrical interconnections;
- integrating a junction box with the module for connecting to the segmented photovoltaic module;
- and
- attaching stiffening ribs to form the mechanical interconnections between the laminate segments and to protect the electrical interconnections.
A method of manufacturing a large-area segmented photovoltaic module from laminate segments of various shapes, the method being performed at a manufacturing facility and comprising:
- mechanically joining a plurality of the laminate segments of various shapes to fill a predetermined envelope for the segmented photovoltaic module;
- electrically interconnecting the plurality of laminate segments;
- forming a protective cover for the electrical interconnections;
- integrating a junction box with the module for connecting to the segmented photovoltaic module;
- and
- integrating a DC-to-AC micro-inverter or DC-to-DC power converter with the segmented photovoltaic module so that the module outputs AC or conditioned DC power.
Dependencies are inferred from the claim text.