Photovoltaic Device Assembly with Modular Connectors
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Solution Overview
Problem
Existing photovoltaic device assemblies face challenges in easy installation and serviceability, particularly in building structures, due to complex electrical connections and potential damage to components, which can lead to increased installation costs and time, as well as difficulties in replacing damaged parts.
Innovation Solution
A photovoltaic device assembly and kit that includes a plurality of photovoltaic devices arranged in rows or columns, connected by connectors, edge pieces, and spacer pieces, allowing for easy physical and electrical connection, with stepped or staggered edge pieces for fitting stacked or offset devices, and featuring a method for quick assembly and reduced structural penetrations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If multiple roof penetrations are made to electrically connect and locate photovoltaic arrays, then electrical connectivity and structural mounting are achieved, but installation time and cost increase, and roof integrity is compromised
Solution Approach 1:
The system divides the photovoltaic array into modular panels that can be independently installed and connected. Each panel is a self-contained unit with integrated electrical connections, allowing installers to work on multiple sections simultaneously without requiring sequential penetration work, thereby reducing overall installation time while maintaining electrical connectivity.
Solution Approach 2:
Electrical conductors are pre-installed within the roof structure before the photovoltaic panels are mounted. This preliminary preparation eliminates the need for time-consuming on-site electrical connections and roof penetrations during panel installation, significantly reducing installation time while ensuring reliable electrical connectivity from the start.
2Reliability
If multiple roof penetrations are made for electrical connections, then electrical connectivity is achieved, but roof integrity and sealing requirements increase
Solution Approach 1:
The electrical connection function is extracted from the roof penetration process. By pre-installing conductors within the roof structure and designing panels with integrated connection mechanisms, the system eliminates the need for additional roof penetrations specifically for electrical connections, thereby reducing leak risk while maintaining electrical connectivity through the minimized penetration points.
Solution Approach 2:
The roof penetration points serve multiple functions simultaneously: structural mounting attachment, electrical conductor passage, and sealing integration. This multi-functionality reduces the total number of penetration points needed compared to separate dedicated openings for each function, thereby minimizing roof integrity compromise and leak risk.
3Reliability
If extensive wiring is used to connect photovoltaic arrays, then electrical connectivity is achieved, but installation complexity and cost increase
Solution Approach 1:
The mounting structure and electrical conductor system are merged into a single integrated roof structure. Conductors are embedded within the roof framing members, eliminating the need for separate wiring channels and reducing the overall complexity of the electrical installation while ensuring reliable connectivity between panels.
Solution Approach 2:
Electrical conductors are pre-routed and secured within the roof structure before panel installation. This preliminary wiring setup eliminates the need for complex on-site wire routing and connections, significantly reducing installation complexity and cost while maintaining reliable electrical connectivity through pre-positioned connection points.
4Stability of the object's composition
If photovoltaic components are permanently installed, then structural stability is achieved, but serviceability and replacement difficulty increase
Solution Approach 1:
The photovoltaic system is divided into modular, independently replaceable panels that maintain structural stability when installed. Each panel is designed as a discrete unit with standardized mounting and electrical connections, allowing individual panels to be removed and replaced without disturbing adjacent panels or compromising the overall structural integrity of the array.
Solution Approach 2:
The mounting system incorporates reversible fastening mechanisms that provide stable structural attachment during operation but allow for easy removal and replacement when needed. This dynamic design enables the system to transition between a stable installed state and a serviceable removable state, facilitating maintenance and component replacement while maintaining structural stability during normal operation.
Data Source
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Figure 1A
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AI summary
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.