Method of manufacturing a large-area segmented photovoltaic module
View Patent ↗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.
1. 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.
2. The method of manufacturing of claim 1 , wherein the shapes of the photovoltaic laminate segments include non-rectangular shapes.
3. The method of manufacturing of claim 2 , wherein the non-rectangular shapes include approximately-triangular shapes.
4. 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.
5. 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.
6. The method of manufacturing of claim 5 , further comprising:
encapsulating the electrically interconnections by filling the stiffening ribs with an elastomer.
7. 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.