WO2016077038A1

WO2016077038A1 - Device and method for reducing effects of weld splatter during formation of connections in photovoltaic components

Info

Publication number: WO2016077038A1
Application number: PCT/US2015/056351
Authority: WO
Inventors: Leonardo C. Lopez; Abhijit A. NAMJOSHI; Kurt A. Koppi; Patrick M. KELLEHER; Jay M. Tudor
Original assignee: Dow Global Technologies Llc
Priority date: 2014-11-13
Filing date: 2015-10-20
Publication date: 2016-05-19

Abstract

A photovoltaic module comprising: (a) a photovoltaic laminate including: two or more electrically conducting elements extending through the photovoltaic laminate so that power is moved from one photovoltaic module towards another photovoltaic module or towards an inverter; and (b) one or more connectors connected to each of the two or more electrically conducting elements by a connection joint, each of the one or more connectors include: two or more opposing terminals that each are connected to and extend from one of the two or more electrically conducing elements; wherein a dielectric space is located between the two or more opposing terminals and the dielectric space blocks material used to form a connection joint from passing from a first terminal to a second terminal, the material from the connection joint cools before the material passes from one terminal to a second terminal, the material fails to travel from the first terminal to the second terminal, or a combination thereof.

Description

DEVICE AND METHOD FOR REDUCING EFFECTS OF WELD SPLATTER DURING FORMATION OF CONNECTIONS IN PHOTOVOLTAIC COMPONENTS

FIELD

[0001] The present teachings provide a device and method for reducing splatter and/or a transfer of material between two adjacent electrically conducting elements and/or terminals during formation of a joint between one or more electrically conducting elements of a photovoltaic component and one or more terminals of an electrical component located within the photovoltaic component.

BACKGROUND

[0002] Photovoltaic arrays, generally, are created by combining a plurality of photovoltaic components together (e.g., photovoltaic modules and/or integrated flashing pieces). Each of the plurality of photovoltaic components are electrically connected by a combination of one or more connectors so that energy can flow through the photovoltaic components and typically to an inverter to generate electricity. Each of the photovoltaic components include one or more connectors that allow for a connection to be formed with an adjacent photovoltaic component. These connectors are joined within the photovoltaic module by forming one or more internal joints that may be created by joining two or more wires, terminals, and/or electrically conducting elements together so that a connector is joined within the photovoltaic module that can be used to create a connection between two adjacent photovoltaic modules. The connectors include two parallel terminals located side by side that extend from the connectors. During formation of a joint, connection material may transfer from one terminal, joint, electrically conducting element, or a combination thereof to an adjacent terminal, adjacent joint, adjacent electrically conducting element, or a combination thereof. The transfer of material during formation of the joints may cause arcing and/or shorting between the terminals and/or electrically conducting elements, may cause misalignment between an adjacent terminal and an adjacent electrically conducting element, may inhibit the production and/or transfer of power through the photovoltaic array, or a combination thereof. Examples of some devices and methods for forming connections in a solar module may be found in U.S. Patent No. 4,041 ,271 ; 4,390,770; 7,877,850; and 8,308,050 and Patent Application Publication No. 2008/01 10866 all of which are incorporated by reference herein for all purposes.

[0003] It would be attractive to have a device and process that forms two or more adjacent joints between two or more wires, terminals, and/or electrical conductors without transferring material from one terminal and/or electrically conducting element to an adjacent terminal and/or adjacent electrically conducting element. It would be attractive to have a device and method that creates a dielectric space between two adjacent joints. What is needed is a device that forms a dielectric space that prevents material splatter from extending from one terminal and/or electrically conducting element to an adjacent terminals and/or electrically conducting element so that shorting, arcing, or both are prevented. What is needed is a device that isolates two adjacent joints so that material transfer is prevented between the joints.

SUMMARY

[0004] The present teachings meet one or more of the present needs by providing a device comprising: a photovoltaic module comprising: (a) a photovoltaic laminate including: two or more electrically conducting elements extending through the photovoltaic laminate so that power is moved from one photovoltaic module towards another photovoltaic module or towards an inverter; and (b) one or more connectors connected to each of the two or more electrically conducting elements by a connection joint, each of the one or more connectors include: two or more opposing terminals that each are connected to and extend from one of the two or more electrically conducting elements; wherein a dielectric space is located between the two or more opposing terminals and the dielectric space blocks material used to form a connection joint from passing from a first terminal to a second terminal, the material from the connection joint cools before the material passes from one terminal to a second terminal, the material fails to travel from the first terminal to the second terminal, or a combination thereof.

[0005] The present teachings meet one or more of the present needs by providing: A method comprising: (a) locating a first terminal of a connector in an overlapped relationship with an electrically conducting element of a photovoltaic module; (b) forming a first connection joint between the electrically conducting element and the first terminal; (c) locating a second terminal of a connector in an overlapped relationship with a second electrically conducting element of a photovoltaic module; (d) forming a second connection joint between the second electrically conducting element and the second terminal; and (e) isolating the first terminal by the second terminal by a dielectric space so that material expelled during formation of the first connection joint and the second connection joint is prevented from traveling from the first terminal to the second terminal or vice versa.

[0006] The teachings herein solve one or more of these problems by providing a device and process that forms two or more adjacent joints between two or more wires, terminals, and/or electrical conductors without transferring material from one terminal and/or electrically conducting element to an adjacent terminal and/or adjacent electrically conducting element. The present teachings provide a device and method that creates a dielectric space between two adjacent joints. The present teachings provide a device that forms a dielectric space that prevents material splatter from extending from one terminal and/or electrically conducting element to an adjacent terminal and/or electrically conducting element so that shorting, arcing, or both are prevented. The present teachings provide a device that isolates two adjacent joints so that material transfer is prevented between the joints.

BRIEF DESCRIPTION OF THE DRAWINGS

[0007] FIG. 1 illustrates a top view of a photovoltaic array;

[0008] FIG. 2 illustrates a perspective view of a photovoltaic module;

[0009] FIG. 3 illustrates a bottom view of electric circuitry;

[0010]

[0011] FIG. 4 illustrates a top view of a connector including an angled terminal;

[0012] FIG. 5 illustrates top view of a connector including an isolator;

[0013] FIG. 6A illustrates a top view of a connector including connection joints;

[0014] FIG. 6B illustrates a top view of another connector including connection joints;

[0015] FIG. 6C illustrates a top view of another connector including connection joints;

[0016] FIG. 7 illustrates a top view of a connector including two electrically conducting elements separated by dielectric spacing;

[0017] FIG. 8 illustrates an integrated frame including an isolator that creates a dielectric space between terminals of a connector;

[0018] FIG. 9 illustrates a series of depictions of an integrated frame and connector in communication;

[0019] FIG. 10 illustrates a close-up view of a connection being formed between two connectors.

DETAILED DESCRIPTION

[0020] The explanations and illustrations presented herein are intended to acquaint others skilled in the art with the teachings, its principles, and its practical application. Those skilled in the art may adapt and apply the teachings in its numerous forms, as may be best suited to the requirements of a particular use. Accordingly, the specific embodiments of the present teachings as set forth are not intended as being exhaustive or limiting of the teachings. The scope of the teachings should, therefore, be determined not with reference to the above description, but should instead be determined with reference to the appended claims, along with the full scope of equivalents to which such claims are entitled. The disclosures of all articles and references, including patent applications and publications, are incorporated by reference for all purposes. Other combinations are also possible as will be gleaned from the following claims, which are also hereby incorporated by reference into this written description. The present application claims priority to U.S. Provisional Patent Application No. 62/079,245, filed on November 13, 2014 the teachings of which are incorporated by reference herein in their entirety for all purposes.

[0021] The teachings herein provide an improved device and method of creating a joint for connecting two conductive mediums (e.g., electrically conducting element, wires, terminals), joining a connector, or both so that a plurality of photovoltaic components may be connected together to create an improved photovoltaic array. A plurality of photovoltaic modules and photovoltaic components are combined together to form a photovoltaic array that collects sunlight and converts the sunlight to electricity. The photovoltaic modules of the teachings herein may be used with a housing that contains all of the individual photovoltaic modules that make up a photovoltaic array. Preferably, the photovoltaic array taught herein is free of a separate structure that houses all of the photovoltaic modules that make up a photovoltaic array. More preferably, each individual photovoltaic module and/or photovoltaic component may be connected directly to a structure such as a roof and each of the individual photovoltaic modules are electrically connected together so that a photovoltaic array is formed (i.e., a building integrated photovoltaic (BIPV)).

[0022] The plurality of photovoltaic components may be configured in any manner so that each of the plurality of photovoltaic components may be electrically connected. The photovoltaic components may be one unitary piece. If the photovoltaic component is a photovoltaic module then the photovoltaic component may include a base plate and a photovoltaic laminate that are discrete pieces connected together. The photovoltaic components may be an integrated flashing piece, a photovoltaic module, an inverter, a connector, a photovoltaic laminate, or a combination thereof. The photovoltaic components may be comprised of a plurality of laminated layers (e.g., the laminated layers may form a photovoltaic laminate that may be connected to a base plate, or may be an integral part of an overmold). One of the layers of the photovoltaic components may be electrical circuitry and the electrical circuitry may extend to an edge and/or edge region of the laminated layers. Preferably, a majority of the electrical circuitry of the photovoltaic components is located within the photovoltaic modules.

[0023] The photovoltaic module may function to capture energy from sunlight, convert the sunlight to electrical energy, and transfer the direct current to inverter. The photovoltaic module may be one discrete piece that includes all of the electrical components for converting sunlight to electricity. The photovoltaic module may include an active region and an inactive region (i.e., an overlap region). The photovoltaic module may include a base plate and a photovoltaic laminate. The base plate may form a connection with a connection structure such as a roof. The base plate may perform roofing functions when a pv laminate is present and when the pv laminate is absent. The base plate may support the pv laminate, one or more connectors, one or more pv laminate connectors, or a combination thereof. The base plate may be an inactive portion of the photovoltaic module and the pv laminate may be an active portion of the photovoltaic module. The active portion may comprise a string of interconnected cells. The cells may be interconnected by any known method such as string and tab, wire mesh, shingled or monolithic. In wire mesh interconnection for example a mesh of electrically conducting metal (or wires) contacts the front (light exposed) side of the photovoltaic cell and is connected to the backside of an adjacent cell. The photovoltaic laminate may convert sunlight to energy, connect to the base plate, or both. The photovoltaic module (e.g. pv laminate) may include one or more cells that function to capture energy from sunlight.

[0024] The one or more cells may function to capture sunlight and assist in creating electricity. The one or more cells may be joined together (e.g., electrically, mechanically, or both), may be joined to one or more electrically conducting elements (e.g., bus bars or ribbons), or both. The one or more cells may be made of any material that functions to capture energy from sunlight that can be converted into electricity. The one or more cells may be connected by one or more electrically conducting elements.

[0025] The one or more electrically conducting elements may function to transfer power through the photovoltaic array. The one or more electrically conducting elements may function to collect and/or pool electricity from the cells and/or electrical circuitry. The one or more electrically conducting elements may provide a path to the inverter. The one or more electrically conducting elements may connect cell to cell, may run the length and/or width of the photovoltaic module, or both. Preferably, as discussed herein the return electrically conducting elements are larger electrically conducting elements (e.g., electrode or bus bar) that runs the length of the photovoltaic module and the cell electrically conducting elements of the cells connect to the return electrically conducting elements (e.g., ribbons) so that the return electrically conducting elements can transfer energy from photovoltaic component to photovoltaic component and ultimately to the inverter. The electrically conducting elements as discussed herein may function to collect energy from the cells of the photovoltaic module and transmit the energy from one photovoltaic component to one or more photovoltaic components. The electrically conducting elements may terminate at a connector that functions to connect one photovoltaic component to an adjacent photovoltaic component and forms part of the electrical circuitry.

[0026] Each of the individual photovoltaic components may be electrically connected to an adjacent photovoltaic component such as a photovoltaic module by electrical circuitry. The electrical circuitry may function to transfer power through a photovoltaic component, from one photovoltaic component to another photovoltaic component, to an inverter, or a combination thereof. The electrical circuitry may function to transfer power from the cells of the pv laminate to the return electrically conducting element and out of the photovoltaic module. The electrical circuitry may function to direct power from the cells towards the inverter. The electrical circuitry may be and/or include a ribbon, a bus, a positive polarity, a negative polarity, a connector, an integrated flashing piece, an electrically conducting element, a return electrically conducting element, a cell electrically conducting element, or a combination thereof. Preferably, the electrical circuitry includes a plurality of electrically conducting elements. More preferably, the electrically conducting elements are a return electrically conducting element (e.g., a return bus or return electrode) and a cell electrically conducting element (e.g., a cell bus or cell electrode). The electrically conducting elements may have different polarities (i.e., one positive and one negative). The electrical circuitry may include one or more diodes, one or more diode bars, or both. The one or more diodes may be part of a flexible diode strip that may have one or more diodes connected in parallel with one or more of the photovoltaic cells. The diode strips may include one or more metallic strips, one or more insulating strips, or both connected together. The diodes may be connected in series with one another by attaching a metallic conductor to the anode of one diode and the cathode of a subsequent or previous diode. An insulating strip may be sandwiched between the first side of the metallic strips (e.g., cell electrically conducting element) and the photovoltaic cells. A second insulating strip may be sandwiched between the second side of the metallic strips and the photovoltaic backsheet. The diode strip may mitigate power loss when a subset of the panel or the entire panel is operating under shaded conditions, but when some remainder of the panel or array is fully illuminated by diverting current through the metallic strips and diode(s), thereby bypassing the reverse biased cell(s). The metallic strips may be made from copper, tin plated copper, aluminum, a conductive material, or a combination thereof. The insulating strips can be made from polyethylene terephthalate (PET), Polyimide such as Kapton, or other plastic insulating material. The bypass diodes may be a bare silicon die, a pre-packaged discrete device, an integrated circuit, or a combination thereof. The electrically conducting elements may be made of any material that conducts power, electricity, or both. The electrically conducting elements may include copper, silver, tin, indium, gold, steel, iron, or a mixture thereof. Preferably, the electrically conducting elements are made of oxygen free copper, electrolytic tough pitched copper, or both. The electrically conducting elements may be coated with a metal that has a lower melting temperature than the base material. For example, the electrically conducting elements may be iron and coated with silver. The electrically conducting elements may be coated with a material that prevents oxidation and/or corrosion. For example, the electrically conducting elements may be a copper material that is coated with tin or indium. The electrically conducting elements and the terminals of the connector may be made of the same material, a different material, or a combination of both. An electrically conducting element of one material may be connected with a terminal of a different material. Preferably, the electrical circuitry includes electrically conducting elements that are joined to a connector of a photovoltaic component (e.g., a pv laminate connector) and a connector attaches to the connector of the photovoltaic component and extends between two or more adjacent photovoltaic components electrically and mechanically connecting the two or more adjacent photovoltaic components. The electrical circuitry may be connected to a terminal of a connector by soldering, welding, thermo-compression welding, or a combination thereof. The electrical circuitry and the terminal of the connector may be connected using any device and method taught herein and especially using the device and method of U.S. Provisional Patent Application Publication No. 61/971 ,572, filed on March 28, 2014, the contents of which are incorporated herein for all purposes and especially the teachings in Paragraph Nos. 0005-0007, 0023-0041 , 0046-0049, and 0051-0054; and figure Nos. 3-4 and 6-9 as examples of possible methods and devices to form joints between an electrically conducting element and a terminal.

[0027] The connector may function to form an electrical connection, a physical connection, or both between one or more adjacent components. The connector may function to receive an adjacent connector, to extend into an adjacent connector, receive a connection device, or a combination thereof. The connectors as discussed herein may be a photovoltaic laminate connector, which is connected to and extends from a pv laminate of a photovoltaic module, and a connector that extends between two adjacent photovoltaic components. A connector may be a discrete piece that extends between two adjacent photovoltaic components and electrically connects the photovoltaic components together. Preferably, the photovoltaic modules include an integral connector which is referred to herein as a pv laminate connector or a connector of a photovoltaic module. Preferably, a discrete connector (referred to herein as connector) extends between and connects two adjacent pv laminate connectors together. A photovoltaic laminate connector (pv laminate connector) may have a sufficient length that it may extend into contact with an adjacent photovoltaic module. The connector may include one or more connector terminals that extend into, are incorporated into, or both a photovoltaic component so that the connector may be electrically connected, mechanically connected, or both within the photovoltaic component such as a photovoltaic module, integrated flashing piece, or both. The connectors may be a male connector, a female connector, or both. Preferably, when a pv laminate connector has a female connection port, a discrete connector includes a male piece and vice versa. The connector may include a housing that covers all or a portion of one or more terminals of the connector. [0028] The housing may function to protect the terminals, the electrically conducting elements, or both. The housing may function to prevent the terminals from being directly contacted. The housing may electrically isolate the terminals. The housing may form a dielectric space between two adjacent terminals, electrically conducting elements, or both. The housing may have an isolator that extends from the housing to a location between two adjacent terminals, electrically conducting elements, or both. The isolator may be any of the isolators and/or include any of the dielectric spacing characteristics discussed herein. The housing may form a transition between a portion of a photovoltaic component and the terminals. For example, a portion of the housing may be located with the photovoltaic module, the pv laminate, or both and a portion of the housing may extend from the photovoltaic module, the pv laminate, or both. The housing may include a portion that is integrated into a pv laminate. The housing may have an open portion so that one or more terminals of the connector are exposed and a connection may be formed. The housing may include a portion that exposes the one or more connector terminals so that the one or more connector terminals may be incorporated into the photovoltaic component.

[0029] The one or more terminals may function to provide an access point for power to flow out of a photovoltaic component, into a photovoltaic component, or both. The one or more terminals may function to allow one or more connectors to mechanically connect together, electrically connect together, or both. The one or more terminals may function to complete a circuit. The one or more terminals may function to extend out of a photovoltaic component (e.g., photovoltaic module or integrated flashing piece) so that an electrical connection may be formed between a connector and the electrical circuitry. The one or more terminals may extend from the connector and each terminal may form a joint with the one or more electrically conducting elements of the photovoltaic component. The one or more terminals may be joined with the one or more electrically conducting elements so that a joint of sufficient strength is created to retain the pv laminate connector within the photovoltaic component when a force is applied to the pv laminate connector. Preferably, the one or more terminals are joined to the one or more electrically conducting elements by a thermo-compression weld using the device and method taught herein. Preferably, the connector is joined to one or more electrically conducting elements of the photovoltaic component via one or more thermo-compression welds. The one or more terminals may be two terminals that extend from a housing and are located generally adjacent to each other. The two adjacent terminals may include one or more legs and the one or more legs may be one or more connection legs, one or more angled legs, or both.

[0030] The one or more connection legs may be a part of a terminal that may function to create a dielectric space (e.g., a gap) between two adjacent terminals. The one or more connection legs may function to create a dielectric space between ends of two adjacent terminals. The one or more connection legs may function to form a connection with the return electrically conducting element, the cell electrically conducting element, or both. The one or more connection legs may function to extend into a photovoltaic component, preferably a photovoltaic module, more preferably a pv laminate to form connection for a pv laminate connector. The one or more connection legs may be generally straight, linear, free of bends, or a combination thereof. The one or more connection legs may extend within a plane of the pv laminate connector. The one or more connection legs may extend a sufficient distance into the photovoltaic component to form a connection with one or more electrically connecting elements. All of the terminals may be connection legs and/or include connection legs (i.e., be straight). If more than one connection legs are present a sufficient distance is located between the two connection legs so that material (e.g., weld splatter, joint formation material, solder, molten material) cannot pass from one connection leg to the adjacent connection leg, cannot form a bridge between two connection legs, the material cools before reaching the adjacent connection leg, the material hardens before reaching the adjacent connection leg, or a combination thereof. The connection legs may be located a sufficient distance apart that a dielectric space is formed between the connection legs (e.g., a space where material from formation of a joint with one connection leg does not contact and affect an adjacent connection leg and/or terminal). For example, material from one terminal does not contact an adjacent terminal and create a short, arcing, or both. The one or more connection legs may include an end and the end of the connection leg may extend beyond the angled leg so that a dielectric space is formed between the end of the connection leg and the end of the angled leg, a point of joint formation of the connection leg and a point of joint formation of the angled leg, a joint of the connection leg and a closest point of an adjacent terminal, or a combination thereof.

[0031] The one or more angled legs may be a part of a terminal that may function to create a dielectric space between two adjacent terminals. The one or more angled legs may function to create a dielectric space between ends of two adjacent terminals. The one or more angled legs may extend a portion of one terminal away from an adjacent terminal. The one or more angled legs may extend away from a connection leg. One angled leg may extend away from an adjacent angled leg. The one or more angled legs may extend an end of an angled leg away from an end of an adjacent terminal and/or leg. The one or more angled legs may extend at any angle so that a dielectric space is created. The one or more angled legs may extend a portion of the terminals away from each other so that joint formation material (e.g., weld splatter) is prevented from extending from one terminal to an adjacent terminal, is cooled and/or solidified before the material contacts the adjacent terminal, or both. The one or more angled legs may be a portion of a terminal that forms an angle of about 10 degrees or more, about 30 degrees or more, about 45 degrees or more, about 60 degrees or more, preferably about 70 degrees or more, or more preferably about 85 degrees or more (i.e., about 90 degrees) from a line that extends between two adjacent terminals and bisects the connector, relative to a centerline of each terminal as the terminal extends from the housing of the connector, or both. For example, the terminal may have a portion that extends straight out of the connector housing and the angled leg may turn at about a 90 degree angle from the straight portion, a bisecting line, or both so that an end of the terminal extends away from the adjacent terminal. The angled leg may form a square turn, an arcuate turn, a sweeping turn, a series of angled turns (e.g., two 45 degree turns so that the total turn is 90 degrees), or a combination thereof. The series of angled turns may be two or more turns, a plurality of turns, three or more turns, or even four or more turns. The series of turns may all have the same angle. For example, the turns may be two turns that are each about 40 degrees so that the total angle is about 80 degrees. The series of turns may be different angles. For example, one turn may be about 30 degrees, a second turn may be about 50 degrees, and a last turn may be about 10 degrees so that a turn of about 90 degrees is formed. The angled legs, the connection legs, or both may be located adjacent to each other so that a gap is formed between the ends of the terminals, the joint formation regions of the terminals, or both and the gap is sufficiently large to form the dielectric space as is discussed herein.

[0032] The gap as discussed herein is a distance that forms a dielectric space. The gap may function to prevent joint material from traveling from one terminal to a second terminal. The gap may function to allow joint material to cool and/or solidify before reaching an adjacent terminal. The gap may be a distance between ends of the terminals. Preferably, the gap is a distance between an end of one terminal and the closest location of an adjacent terminal. More preferably, the gap is a distance between a joint formation region and a closest location of an adjacent terminal. The gap may be sufficiently large so that one terminal is not contaminated during manufacture of a joint on an adjacent terminal. The gap may be sufficiently large so that material used to form a connection joint cannot form a bridge (i.e., a combination of material that extends from one terminal to a second terminal) between two terminals, the material cannot extend between two adjacent terminals, or both. The gap may be a distance of about 9 mm or more, about 10 mm or more, preferably about 1 1 mm or more, or more preferably about 12 mm or more (i.e., about 12.7 mm). The gap may be a result of an angled leg. The gap may be a sufficient distance between two terminals that the two terminals are isolated from each other. The gap may include an isolator between two terminals. The gap, the isolator, or both may create a dielectric space.

[0033] The isolator may function to isolate the terminals from a transfer of material. The isolator may function to create a dielectric space. The isolator may function to prevent debris, splatter, liquid material, molten material, or a combination thereof from extending from one terminal to an adjacent terminal. The isolator may prevent material from forming a bridge that extends from a first terminal to a second terminal, a first connection leg to a second connection leg, or both. The isolator may extend between two adjacent terminals, two adjacent electrically conducting elements, or both. The isolator may extend around one or more side of one or more terminals. The isolator may surround all or a portion of a terminal, a conducting element, or both. The isolator may be part of a connector housing, an integrated frame, or both. The isolator may be a permanent part. The isolator may be removable. The isolator may be reused. The isolator may assist the connector in forming a fixed connection. The isolator may act as a guide that assists the connector in forming a connection in a specific configuration. The isolator may be a static piece. The isolator may be a movable piece. For example, the isolator may be folded and/or rotated from a first position to a second position. The isolator may create a dielectric space between two or more terminals, two or more electrically conducting element, or both. The isolator may be made of a material that is impervious to damage from molten material. The isolator may be made of a material that may be damaged by molten material but may prevent molten material from traveling between terminals, electrically conducting elements, or both. The isolator may be one or more pieces, two or more pieces, or even three or more pieces. For example, one piece of the isolator may be part of the connector housing and one part of the isolator may be part of an integrated frame.

[0034] The integrated frame may function to align a connector within and/or with a photovoltaic module, a pv laminate, electrical circuitry, or a combination thereof. The integrated frame may assist in joining a connector to a photovoltaic module, a pv laminate, electrical circuitry, or a combination thereof. The integrated frame may ensure proper alignment of terminals of the connector with electrically conducting elements of the pv laminate. The integrated frame may have a channel that receives the connector and prevents movement of the connector up and down, left to right, side to side, diagonally, or both. The connector may be sandwiched between a base plate and the integrated frame. The integrated frame may be attached to a connector. The integrated frame may connect to a connector housing. The integrated frame may extend around one or more side of the connector. The integrated frame may provide support to the connector, the terminals, the connection joint, or a combination thereof.

[0035] The connection joint may function to electrically and physically connect the electrically conducting elements to terminals of the connector. The connection joint may be any joint that electricity may flow through. The connection joint may have sufficient strength so that the connection joint may resist pulling in the longitudinal direction (e.g., a tensile pull). The connection joint may be a solder joint, a weld joint, and preferably may be a thermo- compression weld. The connection joint may be sufficiently strong to resist breaking when a connector extending between two adjacent photovoltaic components is pulled on and the locking arms, locking tabs, or both of the connector retain the connection such that the connection is not broken between the pv laminate connector and the connector extending between the adjacent photovoltaic components.

[0036] The locking arms may function to extend from one connector to an adjacent connector. The locking arms may function to connect two adjacent connectors together. The locking arms may guide two connectors into a predetermined position so that a proper connection may be formed. The locking arms may prevent the connectors from being offset relative to each other. The locking arms may only allow alignment of the connectors in a single configuration. The locking arms may include one or more locking features that form a fixed connection, a removable connection, or both with an adjacent connector.

[0037] The one or more locking tabs may fixedly connect two adjacent connectors together. The one or more locking tabs may extend in a recess of an adjacent connector. The one or more locking tabs may prevent one connector from being pulled away from an adjacent connector.

[0038] Figure 1 illustrates a perspective view of a photovoltaic array 2. The photovoltaic array 2 includes a plurality of rows of the photovoltaic modules 10 in an overlapped configuration. The end of each row of photovoltaic modules 10 includes an integrated flashing piece 8 that electrically connects the rows of photovoltaic modules 10 together.

[0039] Figure 2 illustrates a perspective view of a photovoltaic module 10. The photovoltaic module 10 has a base plate 1 1 and a photovoltaic laminate 12 that are two discrete pieces connected together. The photovoltaic laminate 12 had a connector 20 at each end. At one end an integrated frame 52 has been removed so that the connector 20 is exposed and at the other end the integrated frame 52 extends over the connector 20 and into contact with the base plate 1 1.

[0040] Figure 3 illustrates a bottom view of electrical circuitry 13 from an active portion of a photovoltaic module (e.g., a photovoltaic laminate). The active portion may comprise a string 16 of interconnected cells 18, the cells 18 may be connected together by any method or device discussed herein to form the string 16. The string 16 of interconnected cells 18 are all in communication with the cell electrically conducting element 14B. The electrical circuitry 13 includes electrically conducting elements 14 that allow power to flow through photovoltaic module. One of the electrically conducting elements 14 is a cell electrically conducting element 14B that allows power generated by the cells to be funneled towards a return electrically conducting element 14A so that the power is allowed to move towards an inverter (not shown). A diode strip 60 including a plurality of diodes 62 extends between a cell electrically conducting element 14B on a first end and a cell electrically conducting element 14B on a second end. The diode strip 60 is flexible and has a plurality of diodes connected in parallel with one or more of the photovoltaic cells 18. A cell electrically conducting element 14B is connected to one terminal 22 of a connector 20 and a return electrically conducting element 14A is attached to a second terminal 22 of the connector 20. As illustrated the cell conducting element 14B is attached to a connection leg 24 of a terminal 22 by a connection joint 32 and the return conducting element 14A is attached to an angled leg 26 of a terminal 22 by a connection joint 32.

[0041] Figure 4 illustrates a connector 20 having a pair of terminals 22. One terminal 22 is straight and the other terminal 22 is angled. The angled terminal 22 includes a connection leg 24 and an angled leg 26 where the angled leg 26 extends at an angle relative to the connection leg 24. The end 30 of the straight terminal 22 and the end 30 of the angled leg 26 of the terminals 22 are spaced a distance apart and extend in different directions. A connection joint (no shown) is formed at each end 30 of the terminals 22 and a dielectric space 28 is located between the ends 30 so that the ends 30 are located far enough away from the adjacent terminals 22 so that material is not expelled during manufacture of the connection joint into contact with an adjacent terminal 22.

[0042] Figure 5 illustrates a connector 20. The connector 20 includes two spaced apart terminals 22 with a gap 28 therebetween and an isolator 50 is located in the gap 28 between the terminals 22. The isolator 50 creates a barrier between the ends 30 of the terminals 22 so that the terminals 22 are isolated from one another.

[0043] Figures 6A-6C illustrate single part terminals 22 of a connector 20. Each of the connectors 20 of Figure 6A-6C include a first terminal 22 that connects to a cell electrically conducting element 14B. The terminal 22 includes a connection leg 24 that is connected to a cell electrically conducting element 14B by a connection joint 32. Figure 6A includes a terminal 22 that integrally includes both a connection leg 24 and an angled leg 26 and the angled leg 26 is connected to a return electrically conducting element 14A by a connection joint 32. The angled leg 26 is generally "L" shaped forming a square turn and extends away from the adjacent leg so that the connection joints 32 are spaced apart.

[0044] Figure 6B includes a terminal 22 that has both a connection leg 24 and an angled leg 26. The angled leg 26 is connected to a return electrically conducting element 14A by a connection joint 32. The angled leg 26 has two angled portions that are generally 45 degrees so that the connection leg 24 and the return electrically conducting element 14A are generally 90 degrees to each other. The two angled portions are a series of angled turns that form the angled leg 26.

[0045] Figure 6C includes a terminal that has both a connection leg 24 and an angled leg 26. The angled leg 26 is connected to a return electrically conducting element 14A by a connection joint 32. The angled leg 26 has an angled portion that is generally arcuate and forms a sweeping curve between the connection leg 24 and the return electrically conducting element 14A. The turn of the angled leg 26 is an arcuate turn.

[0046] Figure 7 illustrates two adjacent terminals 22 that extend from a connector 20. The terminals 22 both have a connection leg 24. One connection leg 24 includes an angled leg 26 that angles away from the connection leg 24 without the angled leg 26 so that the connection leg 24 extends substantially beyond the angled leg 26. Each of the connection legs 24 include an end 30 and the ends 30 are spaced apart so that during formation of a connection joint (not shown) material (e.g., weld, solder material, material used to form a joint) does not travel from one terminal 22 to an adjacent terminal 22. As illustrated, a dielectric space 28 extends between an end 30 of the connection leg 24 and the closest point of the angled leg 26 and the dielectric space is sufficiently long that connection material is prevented from moving from the end 30 of the connection leg 24 and into contact with the angled leg 26.

[0047] Figure 8 illustrates a connector 20 including an integrated frame 52. The integrated frame 52 includes an isolator 50 that extends between two terminals 22 of the connector 20. The isolator 50 prevents material from extending from one connection leg 24 to the other connection leg 24 during formation of a connection joint (not shown).

[0048] Figure 9 illustrates a connector 20 having a pair of terminals 22. An integrated frame 52 is connected to the connector 20 and includes an isolator 50 that extends between the terminals 22.

[0049] Figure 10 illustrates an example of a connector 20 being used to form a connection with an adjacent photovoltaic component. The connector 20 includes a pair of terminals 22 that form a connection with an electrically conducting element (not shown) by connection joints 32 on the ends 30 of each terminal 22. The connector includes a pair of opposing locking arms 40 each including locking tabs 42 for forming a fixed connection with an opposing connector.

[0050] Any numerical values recited herein include all values from the lower value to the upper value in increments of one unit provided that there is a separation of at least 2 units between any lower value and any higher value. As an example, if it is stated that the amount of a component or a value of a process variable such as, for example, temperature, pressure, time and the like is, for example, from 1 to 90, preferably from 20 to 80, more preferably from 30 to 70, it is intended that values such as 15 to 85, 22 to 68, 43 to 51 , 30 to 32 etc. are expressly enumerated in this specification. For values which are less than one, one unit is considered to be 0.0001 , 0.001 , 0.01 or 0.1 as appropriate. These are only examples of what is specifically intended and all possible combinations of numerical values between the lowest value and the highest value enumerated are to be considered to be expressly stated in this application in a similar manner. [0051] Unless otherwise stated, all ranges include both endpoints and all numbers between the endpoints. The use of "about" or "approximately" in connection with a range applies to both ends of the range. Thus, "about 20 to 30" is intended to cover "about 20 to about 30", inclusive of at least the specified endpoints.

[0052] The disclosures of all articles and references, including patent applications and publications, are incorporated by reference for all purposes. The term "consisting essentially of" to describe a combination shall include the elements, ingredients, components or steps identified, and such other elements ingredients, components or steps that do not materially affect the basic and novel characteristics of the combination. The use of the terms "comprising" or "including" to describe combinations of elements, ingredients, components or steps herein also contemplates embodiments that consist essentially of the elements, ingredients, components or steps. By use of the term "may" herein, it is intended that any described attributes that "may" be included are optional.

[0053] Plural elements, ingredients, components or steps can be provided by a single integrated element, ingredient, component or step. Alternatively, a single integrated element, ingredient, component or step might be divided into separate plural elements, ingredients, components or steps. The disclosure of "a" or "one" to describe an element, ingredient, component or step is not intended to foreclose additional elements, ingredients, components or steps.

[0054] It is understood that the above description is intended to be illustrative and not restrictive. Many embodiments as well as many applications besides the examples provided will be apparent to those of skill in the art upon reading the above description. The scope of the teachings should, therefore, be determined not with reference to the above description, but should instead be determined with reference to the appended claims, along with the full scope of equivalents to which such claims are entitled. The disclosures of all articles and references, including patent applications and publications, are incorporated by reference for all purposes. The omission in the following claims of any aspect of subject matter that is disclosed herein is not a disclaimer of such subject matter, nor should it be regarded that the inventors did not consider such subject matter to be part of the disclosed inventive subject matter.

Claims

We claim:

1 ) A photovoltaic module comprising:

a. a photovoltaic laminate including:

two or more electrically conducting elements extending through the photovoltaic laminate so that power is moved from one photovoltaic module towards another photovoltaic module or towards an inverter; and

b. one or more connectors connected to each of the two or more

electrically conducting elements by a connection joint, each of the one or more connectors include:

two or more opposing terminals that each are connected to and extend from one of the two or more electrically conducing elements; wherein a dielectric space is located between the two or more opposing terminals and the dielectric space blocks material used to form a connection joint from passing from a first terminal to a second terminal, the material from the connection joint cools before the material passes from one terminal to a second terminal, the material fails to travel from the first terminal to the second terminal, or a combination thereof.

2) The photovoltaic module of claim 1 , wherein all of the two or more opposing terminals include a connection leg and one or more of the two or more opposing terminals include an angled leg, and the angled leg extends at an angle relative to both of the connection legs.

3) The photovoltaic module of claim 2, wherein each of the connection legs and the angled legs include a region where the connection joint is formed and a gap extends between the regions where the connection joints are formed so that during formation of the connection joints, material cannot travel across the gap from the region of the angled leg, the connection leg, or both to a respective other connection leg, angled leg, or both.

4) The photovoltaic module of any of claims 2 through 3, wherein the angled leg is a discrete piece that is connected to the connection leg and the angled leg extends at an angle away from the connection leg. 5) The photovoltaic module of any of claims 2 through 3, wherein the angled leg is an integral part of the connection leg and extends from the connection leg.

6) The photovoltaic module of any of claims 4 through 5, wherein the angled leg, the angled electrically conducting element, or both create about a 90 degree turn and the 90 degree turn is formed by a single turn, two or more angled portions, a sweeping curve, or a combination thereof.

7) The photovoltaic module of any of the preceding claims, wherein the dielectric space is an isolator that extends between the two or more opposing terminals so that the isolator prevents material used to form a connection joint from passing between the two or more opposing terminals, forming a bridge between the two or more opposing terminals, or both.

8) The photovoltaic module of claim 7, wherein the isolator is part of each of the one or more connectors.

9) The photovoltaic module of claim 7, wherein the isolator is part of an integrated frame and the integrated frame is connected to the connector and assists in connecting each of the one or more connectors to the photovoltaic module.

10) The photovoltaic module of any of the preceding claims, wherein the dielectric space is a gap between the two or more of opposing terminals and the gap is sufficiently large that the material cannot move across the gap, the material cools while crossing the gap, or both.

1 1 ) A method comprising:

a. locating a first terminal of a connector in an overlapped relationship with an electrically conducting element of a photovoltaic module; b. forming a first connection joint between the electrically conducting element and the first terminal;

c. locating a second terminal of a connector in an overlapped

relationship with a second electrically conducting element of a photovoltaic module;

d. forming a second connection joint between the second electrically conducting element and the second terminal; and e. isolating the first terminal from the second terminal by a dielectric space so that material expelled during formation of the first connection joint and the second connection joint is prevented from traveling from the first terminal to the second terminal or vice versa.

12) The method of claim 1 1 , wherein the dielectric space is an isolator that extends between the first terminal and the second terminal.

13) The method of claim 1 1 or claim 12, wherein the isolator is removed after the first connection joint and the second connection joint are created.

14) The method of any of claims 1 1 through 13, wherein the dielectric space is a gap between the first terminal and the second terminal and the gap is created by the first terminal, the second terminal, or both extending at an angle away from a respective first terminal or second terminal.

15) The method of claim 14, wherein the second terminal includes an angled leg and the angled leg extends away from the first terminal so that when a connection joint is formed the expelled material cannot extend from the first terminal to the second terminal or vice versa, the expelled material cools when extending from the first terminal to the second terminal or vice versa, or both.