Photovoltaic module having an external electrical connector
A photovoltaic module having an external electrical connector is described. For example, the photovoltaic module may include a plug receptacle mounted on a module laminate, and a contact may extend from a photovoltaic cell within the module laminate into a plug channel of the plug receptacle. The plug receptacle may receive a mating electrical connector, e.g., an electrical plug, of off-panel electronics. Accordingly, the contact may be removably connected to the mating electrical connector, and the photovoltaic cell may be placed in electrical connection with the off-panel electronics.
1. A photovoltaic module, comprising:
a module laminate including a photovoltaic cell electrically connected to an electrical conductor between a front outer planar layer and a back outer planar layer;
a plug receptacle, the plug receptacle positioned within at least a portion of at least one of a perimeter of the front outer planar layer or a perimeter of the back outer planar layer and the plug receptacle mounted on at least one of the front outer planar layer or the back outer planar layer of the module laminate, wherein the plug receptacle includes a plug casing around a plug channel, and a base wall having a contact slot aligned with the plug channel; and
a contact including a contact base attached to the electrical conductor, and a contact prong having a distal end, the contact prong extending through the contact slot into the plug channel, the distal end positioned in the plug channel and externally accessible within the plug channel, the distal end in the plug channel extending away from the contact base, and the contact prong being substantially orthogonal to the contact base, the contact base positioned on the front outer planar layer and the back outer planar layer;
wherein the contact prong is supported by the base wall such that a column strength of the contact prong is greater than a column strength of the electrical conductor.
2. The photovoltaic module of claim 1 , wherein the contact prong has a prong stiffness about a contact axis, wherein the electrical conductor has a conductor stiffness about a conductor axis, and wherein the prong stiffness is greater than the conductor stiffness.
3. The photovoltaic module of claim 1 , wherein the contact slot in the base wall is sized to support the contact against lateral bending.
4. The photovoltaic module of claim 1 , wherein the contact prong is similarly sized to contact slot such that the base wall around the contact prong reinforces the column strength of the contact prong.
5. The photovoltaic module of claim 1 , wherein the contact prong includes a contact cross-sectional area and the contact slot includes a similarly sized slot cross-sectional area that conforms to the contact cross-sectional area.
6. The photovoltaic module of claim 1 , wherein the contact prong includes a contact cross-sectional area that is smaller than the slot cross-sectional area such that a gap is present between the base wall and the contact prong to support contact prong laterally when a mating connector is engaged with an external electrical connector.
7. The photovoltaic module of claim 1 , wherein the plug receptacle is directly mounted on the front outer planar layer and the back outer planar layer of the module laminate via a clip fit.
8. The photovoltaic module of claim 1 further comprising:
an encapsulant surrounding the contact base between the front layer and the back layer; and
an adhesive between the plug receptacle and the module laminate.
9. The photovoltaic module of claim 1 , wherein the contact prong is centered with the contact base and the contact base is directly mounted on the front outer planar layer and the back outer planar layer of the module laminate.
10. The photovoltaic module of claim 1 , wherein the module laminate includes a lateral edge, and wherein the plug receptacle is mounted on the lateral edge.
11. The photovoltaic module of claim 10 , wherein the plug receptacle includes a mount casing attached to the lateral edge, wherein the mount casing surrounds a contact channel on an opposite side of the base wall from the plug channel, and wherein the contact base is in the contact channel.
12. The photovoltaic module of claim 1 , wherein the module laminate includes a first sub-string of photovoltaic cells including the photovoltaic cell, and a second sub-string of photovoltaic cells including a second photovoltaic cell, and further comprising a second plug receptacle mounted on the module laminate, and a second contact electrically connected to the second photovoltaic cell and extending through the second plug receptacle.
13. The photovoltaic module of claim 1 further comprising a module frame mounted along a lateral edge of the module laminate, wherein the module frame includes the plug receptacle and a second plug receptacle, and wherein the second contact extends through a second contact slot of the second plug receptacle.
14. The photovoltaic module of claim 1 , wherein the plug receptacle is mounted on a back surface of the back layer, wherein the contact base is parallel to the back surface, and wherein the contact prong is orthogonal to the back surface.
15. A photovoltaic system, comprising:
a photovoltaic module including a module laminate including a photovoltaic cell electrically connected to an electrical conductor between a front layer and a back layer, a plug receptacle, the plug receptacle positioned within at least a portion of at least one of a perimeter of the front layer or a perimeter of the back layer and the plug receptacle mounted on the module laminate, wherein the plug receptacle includes a plug casing around a plug channel, and
a base wall having a contact slot aligned with the plug channel;
a contact including a contact base attached to the electrical conductor, and a contact prong having a distal end, the contact prong extending through the contact slot and into the plug channel, the distal end extending away from the module laminate, the distal end positioned in the plug channel, the distal end externally accessible within the plug channel, the contact prong being substantially orthogonal to the contact base, the contact base positioned on the front layer and the back layer, and wherein
the contact prong is supported by the base wall such that a column strength of the contact prong is greater than a column strength of the electrical conductor;
an off-panel electronics device; and
an external cable extending between and electrically connecting the contact and the off-panel electronics device.
16. The photovoltaic system of claim 15 , wherein the off-panel electronics device includes one or more of a bypass diode, a microinverter, or a DC optimizer.
17. The photovoltaic system of claim 15 , wherein the contact prong has a prong stiffness about a contact axis, wherein the electrical conductor has a conductor stiffness about a conductor axis, and wherein the prong stiffness is greater than the conductor stiffness.
18. The photovoltaic module of claim 15 , wherein the contact prong is centered with the plug channel.
19. The photovoltaic module of claim 15 , wherein the module laminate includes a lateral edge, and wherein the plug receptacle is mounted on the lateral edge.
20. The photovoltaic module of claim 19 , wherein the plug receptacle includes a mount casing attached to the lateral edge, wherein the mount casing surrounds a contact channel on an opposite side of the base wall from the plug channel, and wherein the contact base is in the contact channel.