Cord Plate Attachment to Photovoltaic Modules
A method of attaching a cord plate to a photovoltaic module is disclosed. The photovoltaic module has a cover plate.
1 . A method of attaching a cord plate to a photovoltaic module having a cover plate comprising:
positioning a conductor adjacent to a cover plate of a photovoltaic device, the conductor comprising a first end configured to be connected to the photovoltaic device and a second end located proximate to a connector on a first surface of the cover plate;
positioning the cord plate on the first surface of the cover plate over the connector to form a space defined by the cover plate, the connector, and the cord plate, the cord plate comprising a base having a top surface and bottom surface and configured to be sealed to the cover plate, a junction configured to intersect the conductor and a second conductor, and a channel configured to receive a flowable sealant; and
positioning an acrylic foam sheet between the bottom surface of the cord plate and the first surface of the cover plate.
2 . The method of claim 1 , further comprising the steps of:
introducing a flowable sealant into the cord plate channel;
causing the flowable sealant to flow into the defined space and contact the channel, the cover plate and the connector; and
curing the flowable sealant to connect the cord plate to the cover plate.
3 . The method of claim 1 , wherein the cover plate comprises glass.
4 . The method of claim 1 , wherein the connector comprises an impression formed in the first surface of the cover plate.
5 . The method of claim 1 , wherein the connector comprises a hole formed through the cover plate.
6 . The method of claim 1 , wherein the conductor comprises a foil strip.
7 . The method of claim 1 , wherein the cord plate comprises plastic.
8 . The method of claim 1 , wherein the base comprises a rectangular plate.
9 . The method of claim 1 , wherein the base comprises a recess formed in the bottom surface.
10 . The method of claim 1 , wherein the junction comprises a receptacle formed on the top surface of the base and configured to position the second conductor in contact with the conductor.
11 . The method of claim 10 , further comprising electrically connecting the conductor and second conductor.
12 . The method of claim 1 , wherein the channel comprises an opening in the base.
13 . The method of claim 1 , further comprising the step of milling an opening in the base of the channel.
14 . The method of claim 12 , wherein the channel comprises a partition extending perpendicular from a surface of the base and encircling the opening.
15 . The method of claim 1 , wherein the second conductor comprises insulated electrical wiring configured to carry electrons either to or from the conductor.
16 . The method of claim 1 , wherein the flowable sealant comprises a silicone, an acrylic, a polysulfide, a butyl polymer, or a polyurethane.
17 . The method of claim 1 , further comprising the step of priming the bottom surface of the base before positioning on the cover plate.
18 . The method of claim 17 , wherein the bottom surface of the base is primed with a liquid primer.
19 . The method of claim 17 , wherein the bottom surface of the base is primed with flame treatment.
20 . The method of claim 1 , further comprising the step of positioning a seal on the first surface of the cover plate over the connector before positioning the cord plate on the first surface of the cover plate over the connector.
21 . The method of claim 20 , wherein the seal comprises an acrylic foam core.
22 . The method of claim 21 , wherein the seal comprises a pressure sensitive adhesive on a surface of the acrylic foam core.
23 . A photovoltaic module comprising:
a photovoltaic device;
a cover plate positioned adjacent to the photovoltaic device, wherein the cover plate comprises a connector formed on a first surface of the cover plate;
a conductor comprising a first end connected to the photovoltaic device and a second end located proximate to the connector;
a cord plate comprising a base comprising a top surface and bottom surface and configured to be sealed to the cover plate, a junction configured to intersect the conductor and a second conductor, and a channel configured to receive a flowable sealant, wherein the cord plate is positioned on the first surface of the cover plate, over the connector, to form a space defined by the cover plate, the connector and the cord plate; and
an acrylic foam sheet positioned between the bottom surface of the cord place and the first surface of the cover plate.
24 . The photovoltaic module of claim 23 , further comprising a sealant introduced into the cord plate channel, the sealant contacting the channel, the cover plate and the connector.
25 . The photovoltaic module of claim 23 , further comprising a primer contacting the acrylic foam sheet.
26 . The photovoltaic module of claim 25 , wherein the primer comprises a water based primer.
27 . The photovoltaic module of claim 25 , wherein the primer comprises a compound which fluoresces when ultraviolet light is directed at the compound.
28 . The photovoltaic module of claim 23 , further comprising a pressure sensitive adhesive on a surface of the acrylic foam sheet.