FIELD
The present disclosure relates to solar panels for capturing the energy of the sunlight for heat, electricity, and air conditioning. More particularly, the present technology relates to a solar panel which can function individually or be linked together to create a source of thermal and electrical energy.
BACKGROUND
The statements in this section merely provide background information related to the present disclosure and may not constitute prior art.
Each day, the sun provides 10,000 times the amount of energy utilized by the human race. In a single day, it provides more energy than our current population would consume in 27 years. In North America alone, it is believed that close to two trillion dollars are spent annually on energy, much of which is designated towards non-renewable, carbon-based sources, such as oil, coal, and other fossil fuels. When energy consumption for the average U.S. household is approximately 65-80% thermal and approximately 20-35% electrical, it makes sense to derive a means of satisfying both of these requirements through renewable sources.
There have been many advances in the past few decades toward the capture of renewable energy resources, such as water turbines (which convert the kinetic energy of moving water into electricity), wind generators (which convert the energy of the wind into electrical energy), geothermal heating (which utilizes the stability of the subterraneous temperature to provide thermal energy), and solar cells (which allow the capture and conversion of solar energy into electrical energy).
Solar panels are manufactured by joining individual solar cells to form a strip or series of individual cells which are mounted in a tray having a substantially flat mounting surface. The cells are adhered to the tray and are surrounded or encapsulated within a transparent material in such a manner that light entering the solar panel will pass substantially unobstructed through the transparent encapsulant for the cells and will impinge upon exposed surfaces of the individual solar energy cells. Typically, a solar panel is formed from at least one solar energy cell in the form of a thin 3-inch diameter wafer that has one of its two planar surfaces adhered to the flat base of the tray that comprises the base element of the solar panel and the other planar surface of the cell directed toward the open top of the tray and in position to receive light impinging thereupon. The transparent material is usually selected from those that will not only provide minimal obstruction to the passage of light through the encapsulating material to the exposed planar surface of the cell, but which will also have optimal weathering characteristics to protect the encapsulated cells from ambient conditions. An example of this can be found in U.S. Pat. No. 4,057,439, issued to Lindmayer.
An alternative type of renewable energy is a solar thermal heat exchanger, which utilizes the energy of sunlight to heat a liquid, thereby providing thermal energy for heating or cooling. In this type of energy harnessing, typically a flat plate is blackened on the front to improve absorption of solar radiation and is arranged with its blackened surface facing the sun and sloped at a suitable angle to optimize the energy collected. A series of tubes is secured to the panel, and water to be heated is circulated through these tubes to extract the heat received by the panel. The back of the panel is often insulated by a layer of insulating material such as glass, wool, or plastic foam.
In most cases, these panels include a frontal screen made of glass or transparent plastics material, such as transparent acrylic or PVC, which allows solar radiation to pass through the screen onto the panel and retains the heat by reducing losses caused by re-radiation or convection cooling.
The warmed water from solar panels is normally circulated through a separate tank so that the temperature may build up to a maximum value being a balance between the heat input and heat losses in the system. This water is then used as feed water for the main hot water tank, as hot water is drawn off from the system. As this water is generally only warm, except in very hot weather or when the panel is used in hot climates, it cannot be used directly as hot water, and a separate heater in the main hot water tank is necessary to heat the water to usable temperatures. It is also clear that water from the solar panel cannot be used generally for maintaining the temperature of the hot water in the main tank. An example of this type of renewable energy source can be found in U.S. Pat. No. 4,089,957, issued to Bennett.
While these types of solar energy harnessing are efficient in their own capacity, they do not provide for an economical source of both thermal and electrical energy which can be utilized throughout households of the world.
SUMMARY
It is therefore an object of the present technology to provide a power panel which may provide thermal energy and electrical energy from the conversion of the light emitted from the sun.
In one aspect, a power panel for generating thermal and electric energy from solar radiation is provided. The power panel for generating thermal and electric energy from solar radiation includes: a transparent panel facing a source of the solar radiation; and a photovoltaic (PV) panel for generating electrical power positioned on an opposite side of the transparent panel from the source of the solar radiation. The photovoltaic panel includes: a PV cell tray having a first face directed toward the source of the solar radiation; a first layer of an adhesive applied to the first face of the PV cell tray; and multiple solar cells arranged in series in individual cell columns. The solar cells are fixedly connected to the PV cell tray first face by the first layer of the adhesive.
In a further aspect, a power panel for generating thermal and electric energy from solar radiation includes a synthetic molded enclosure having a solar radiation top surface, bottom surface and sidewalls. A photovoltaic (PV) panel for generating electrical power has multiple solar cells each fixedly connected to a first face of a metal PV cell tray. The PV cell tray is positioned in contact with the synthetic molded enclosure and spaced above the top surface. The PV cell tray has a second face oppositely directed with respect to the first face in contact with a fluid flowing on the top surface. A transparent panel positioned in direct contact with the synthetic molded enclosure side walls and spaced above the photovoltaic panel insulates thermal energy contained within the enclosure.
In still a further aspect, a power panel for generating thermal and electric energy from solar radiation includes a photovoltaic (PV) cell tray having a first face directed toward the source of the solar radiation and a raised outer wall defining a perimeter of the PV cell tray. A first layer of an adhesive applied to the first face of the PV cell tray is bounded by opposed side wall portions of the outer wall, and spaced from opposed end walls portions of the outer wall thereby creating first and second un-coated portions of the first face. A first energy collection strip is located at a first end of the array and a second energy collection strip is located at an opposite second end of the array. The first and second terminal strips are connected to the PV cell tray first face using the first layer of the adhesive. Multiple solar cells are configured in an array having multiple rows and columns. The solar cells are fixedly connected to the PV cell tray first face by the first layer of the adhesive and have the columns positioned between the first and second energy collection strips.
These and other objects will become apparent from the present technology comprising a power panel designed to incorporate a means of both thermal energy production and electrical energy production from the solar energy produced by the sun. The panels can be utilized individually or linked together to provide a greater net energy production, depending upon the application. The individual panels are manufactured by a cost-effective, automotive-style manufacturing process already utilized in other fields, which would significantly lower consumer installed energy costs. The power panels are manufactured in three configurations: the first, a photovoltaic and thermal panel (PVT), which would provide 8%-40 watts of electrical energy and up to 500 watts of thermal energy per panel; a second, thermal-only power panel, which would provide up to 550 watts of thermal energy; and, lastly, a concentrated photovoltaic thermal panel (CPVT), which would provide 32%-240 watts of electrical energy and up to 300 watts of thermal energy per panel. All three embodiments vastly reduce the typical solar-per-watt costs and eliminate the problem of current tight supply of traditional silicon solar cells.
Further areas of applicability will become apparent from the description provided herein. It should be understood that the description and specific examples are intended for purposes of illustration only and are not intended to limit the scope of the present disclosure.
DRAWINGS
The drawings described herein are for illustration purposes only and are not intended to limit the scope of the present disclosure in any way.
FIG. 1 is a perspective view of the two linked power panels comprising the preferred embodiment of the present technology;
FIG. 1A is a partial, cross-sectional side view of the connection element linking one or more power panels together;
FIG. 2 is a partial perspective view of a prior art heat exchanger collector plate known in the art;
FIG. 3 is an exploded, assemblage view of the components according to the present teaching;
FIG. 3A is a top view of the enclosure illustrating a top surface of the enclosure shown in FIG. 3.
FIG. 3B is a partial plan view magnification of FIG. 3A, illustrating the liquid pathways and vented air paths defined by the partitions and turning veins of the enclosure.
FIG. 3C is a cross section view of two attached power panels in series.
FIG. 3D is a cross section of a magnified corner portion of FIG. 3C showing the relative position of the top cover, photovoltaic panel, and flow of liquid.
FIG. 3E is a cross section of a magnified center portion of FIG. 3C showing the relative position of the top cover, photovoltaic panel puck, and flow of liquid.
FIG. 4 is a perspective view of the bottom surface of the enclosure element of the power panel of the present technology;
FIG. 4A is a perspective view of an alternate embodiment of the power panel 10 with the photovoltaic panel placed within and on top of the enclosure;
FIG. 5 is a perspective illustration of a plurality of power panels comprising the preferred embodiment of the present technology implemented in series upon a building structure;
FIG. 6 is a top right perspective view of an assembled photovoltaic panel of the present disclosure;
FIG. 7 is an exploded assembly view of a power panel having the photovoltaic panel of FIG. 6;
FIG. 8 is a top right perspective view of a photovoltaic panel tray of the present disclosure;
FIG. 9 is a top right perspective view of the photovoltaic panel tray of FIG. 8 after application of an adhesive layer;
FIG. 10 is a top right perspective view of the photovoltaic panel tray of FIG. 9 after application of bus bars and terminal strips;
FIG. 11 is a top right perspective view of the photovoltaic panel tray of FIG. 10 after application of a second adhesive layer;
FIG. 12 is a top right perspective view of the photovoltaic panel tray of FIG. 11 after installation of a first column of solar cells;
FIG. 13 is a top right perspective view of the photovoltaic panel tray of FIG. 12 after installation of a second column of solar cells;
FIG. 14 is a top right perspective view of the photovoltaic panel tray of FIG. 13 after installation of a third column of solar cells;
FIG. 15 is a top right perspective view of the photovoltaic panel tray of FIG. 14 after installation of a fourth column of solar cells;
FIG. 16 is a top right perspective view of area 16 of FIG. 15;
FIG. 17 is a bottom right perspective view of the photovoltaic panel tray of FIG. 6;
FIG. 18 is a perspective view of a junction box of the present disclosure; and
FIG. 19 is a perspective view of the junction box of FIG. 18 after potting.
DETAILED DESCRIPTION
The following description is merely exemplary in nature and is not intended to limit the present disclosure, application, or uses. It should be understood that throughout the drawings, corresponding reference numerals indicate like or corresponding parts and features.
Referring now to the figures, particularly FIGS. 1, 1A, and 3, an embodiment of the present technology comprising a power panel 10 is shown. The power panel 10 comprises a generally rectangular-shaped, expanded polypropylene enclosure 12 having a solar energy absorption portion 20. The solar energy absorption portion 20 includes a series of longitudinal channels, indicated by the arrows of FIG. 1. The channels are defined by parallel segmented partitions disposed on the top surface of the enclosure 12 through which liquid is conducted. The liquid, for example, distilled water, is pumped into the input port 16 wherein it travels through an input trough, which disperses the liquid evenly along the longitudinal channels. The liquid travels down the longitudinal channels of the absorption portion 20 and is collected in a lower, perpendicular output trough which directs the flow out to the output port 14.
As stated, the power panel 10 can be installed as stand-alone units or can be linked together in series to form a larger energy-production means, for example a power generating panel array as shown in FIGS. 1 and 5. In order to link two or more panels 10 together, the enclosures 12 are molded so as to allow the input port 16 and output port 14 to align horizontally with adjacent panels. A journal conduit 18 connects adjacent input port 16 and output port 14 on adjacent power panels, wherein a sealing and securing means 19 is implemented between the conduit 18 and each enclosure input 16 or output 14 to ensure a secure, leak-free connection as shown in FIG. 1A.
In some embodiments of the present technology, the power panel 10 can consist of a synthetic molded enclosure 12 comprising a solar radiation absorption top surface 20, a bottom surface, and sidewalls. The top absorption surface 20 of the enclosure 12 can be painted black to enhance solar radiation absorption and heat the liquid circulating on the top surface of the enclosure 12. The enclosure also includes a transparent panel 22 disposed on the enclosure 12. The transparent panel 22 is adapted to insulate the thermal energy contained within the enclosure 12. Liquid is channeled through the power panel 10 by adding a plurality of segmented partitions 40 which are adapted to form liquid pathways for channeling a liquid through the pathways when the transparent panel 22 is disposed on the segmented partitions 40, thereby forming a liquid boundary in proximate contact with the segmented partitions 40 and with the liquid in said enclosure 12.
The power panel 10 can also be manufactured having an electrical generation, in addition to its thermal energy capture capability, by including a photovoltaic panel 23 as shown in FIGS. 10 and 3. The photovoltaic panel 23 can generate electrical power directly from the solar radiation contacting the surface of the power panel 10. The photovoltaic panel 23 forms a liquid boundary or “lid” that is in proximate contact with the liquid circulating through the enclosure 12. This contact between the photovoltaic panel 23 and the circulating liquid serves to provide a thermal and liquid seal between the enclosure 12 and the external environment, but also captures any incident heat generated by the solar cells disposed on the photovoltaic panel 23.
The power panel 10 described herein is superior over conventional flat plate heat exchange collectors 30 illustrated in FIG. 2. These collectors 30 typically consist of an enclosure 31 having a liquid inlet 35, a liquid outlet 33, and a series of longitudinal liquid pipes 34 connecting the two. The longitudinal pipes 34 are generally copper and attached to a copper absorber plate 36, which absorbs the solar energy, transferring the heat to the liquid within the pipes 34. A cover sheet 32, typically made of glass, is implemented to protect the pipes 34 and absorber plate 36. The absorber plate 36 is insulated at 38 from the enclosure and structure to which the collector 30 is attached. The present power panel 10 is superior in design and efficiency over these prior art collectors in that the channels through which the liquid flows is molded into the enclosure 12 and is insulated from the outside of the enclosure 12 as well as the structure to which the power panel 10 is mounted.
In some embodiments of the present technology, best illustrated in FIGS. 3, 3A, and 3B, the power panel 10 is shown having an electric photovoltaic panel 23 which is comprised of a plurality of solar cells fitted over the absorption portion 20 of the enclosure 12. The type of photovoltaic panel 23 is not critical, other than the requirement that the photovoltaic panel 23 must be dimensioned to fit within the sides of enclosure 12 and form an insulating seal with respect to liquid flowing in contact with the photovoltaic panel 23. The number of solar cells disposed on the photovoltaic panel 23 is not critical. In some embodiments, suitable photovoltaic panels for use as the photovoltaic panel 23 of the present technology are also commercially available, e.g., the thin-film photovoltaic panel: EPV-42 sold by Energy Photovoltaics, Inc. (Robbinsville, N.J., USA). This allows for the collection of electrical energy, which is transferred through conduit 24 attached to the photovoltaic panel 23 to a remote power storage unit (not shown), as well as the collection of thermal energy from the channels of liquid flowing through the enclosure 12 below. The photovoltaic panel 23 serves as the top boundary for the liquid traveling through the liquid pathways 54 within the enclosure 12 and acts as an insulator for the fluid flow. A clear, tempered-glass top glazing 22 is fitted over the assembly and is not only sealed to the enclosure 12 by a weather-tight seal 21, yielding a closed system, but further insulates the assembly, providing much greater energy efficiency for the power panel 10.
Referring now to FIGS. 3, 3A, and 3B, the enclosure 12 is shown in plan view exposing the solar radiation exposed top surface. The enclosure 12 can be manufactured from a one-piece molded material. In general, the enclosure 12 is rectangular in shape. The enclosure 12 can be molded, for example, compression molded, from a synthetic material that is resistant to UV radiation and compatible with liquids such as water. In some embodiments, the enclosure 12 is molded from a thermoplastic polyolefin. In some embodiments, the thermoplastic polyolefin can include one or more well-known thermoplastic polyolefins comprising a mixture of polypropylene and an olefinic based rubber. In some embodiments, suitable compositions for use in compression molding of the enclosure 12 are also commercially available e.g., the thermoplastic polyolefin (TPO): SEQUEL E3000 sold by Solvay Engineered Polymers Inc. (Auburn Hills. Mich., USA).
The top surface 39 of enclosure 12 also includes a plurality of segmented partitions 40 which are generally placed on the top surface 39 of enclosure 12. The segmented partitions 40 are placed on the top surface 20 to create liquid pathways 54 shown as dashed arrows in FIGS. 3A and 3B. The liquid pathways 54 originate from the inlet trough 49 and terminate at the outlet trough 50. The liquid pathways 54 are generally serpentine is shape but can be customized to form any shape as defined by the placement of the segmented partitions 40 and turning veins 42. As shown in FIG. 3A, the top surface 39 is divided into two general regions, each region containing a plurality of segmented partitions 40 and a plurality of turning veins 42. In some embodiments, the generally L-shaped segmented partitions 40 as shown in FIG. 3A can be separated by a distance ranging between 1.0 cm and about 10 cm. The top surface 39 is shown with two liquid pathways 54. However, it is envisioned, the arrangement of segmented partitions 40 and turning veins 42 to define different liquid pathways 54 that are adapted to channel a liquid through the enclosure in a predetermined manner can be modified. In general, the flow of liquid from the inlet trough 49 to the outlet trough 50 is dependent on gravity flow and the pitch of the power panel 10 on the surface of a solar radiation exposed surface, for example the slope of the roof on which the power panel 10 is attached in relation with the surface of the ground.
In some embodiments, the segmented partitions 40 and turning veins 42 are made from a structured sealant. The structured sealant is applied to the top surface 39 of molded enclosure 12 prior to the mounting of the photovoltaic panel 23 onto the enclosure. Once the photovoltaic panel 23 is mounted on the top surface 39 of enclosure 12, a contained space between the photovoltaic panel 23 and the top surface of enclosure 12 is formed. The segmented partitions 40 and turning veins 42 are disposed in the top surface 39 of enclosure 12 and have a height of about 0.01 mm and about 10.0 mm, providing a contained space between the photovoltaic panel 23 and the top surface 39 of enclosure 12 of about 0.01 mm to about 10 mm, more preferably from about 0.1 mm to about 5.0 mm, and still most preferably from about 0.125 mm to about 3.0 mm. The contained space between the photovoltaic panel 23 and the top surface 39 of enclosure 12 will provide liquid pathways that are defined by the segmented partitions 40 and the turning veins 42 as shown by the dashed arrows. The photovoltaic panel 23 is disposed on top of the segmented partitions 40 and turning veins 42, which aids in adhering the photovoltaic panel 23 to the enclosure 12. The segmented partitions 40 and turning veins 42 can be made from a structured sealant/adhesive having the adhesion and mechanical properties of urethane, along with the flexibility and ultraviolet radiation resistance of silicone. The structured sealant can comprise a single polymer or a mixture of polymers. In some embodiments, the structured sealant can include one or more silyl modified polymers. Silyl modified polymers are cross-linkable by treatment with a water/silanol condensation catalyst. Silyl modified polymers can include, for example, copolymers of ethylene, propylene, or 1-butene with unsaturated silane compounds; graft polymers prepared by grafting unsaturated hydrolysable sane compounds onto polyethylene or other suitable polymers; or polymers which have hydrolysable groups introduced therein by transesterification. Useful silyl modified polymers for use as the segmented partitions 40 and turning veins 42 are described in U.S. Patent Publication Number 2006/0036008, Ser. No. 11/140,230, published Feb. 16, 2006.
In some embodiments, suitable structured sealant/adhesive compositions for use as the segmented partitions 40 and turning veins 42 disposed on the top surface 39 of enclosure 12 are also commercially available e.g., the moisture cured silyl modified polymer structured sealant: 940 FS sold by Bostik (Wauwatosa, Wis., USA). FIG. 3B shows in particular the liquid pathways 54 created by the segmented partitions 40 and turning veins 42 which are made from a structured sealant or adhesive. The segmented partitions 40 and turning veins 42 as shown in FIG. 3B not only define liquid pathways 54 shown in dashed arrows, but also provide a path for air in the enclosure to escape to exterior of enclosure 12 through vented air flow paths as indicated by the solid arrows 56. Thus, the enclosure 12 also provides for ventilated air flow within the enclosure 12. In some embodiments, the volume of water circulated through enclosure 12 ranges from about 0.38 L/min (0.1 gal/min) to about 7.57 L/min (2.0 gal/min). In operation, the temperature of the circulating liquid, for example, water, can range from about 20° C. to about 70° C.
As best illustrated in FIG. 3B, a bridge 46 is mounted onto the top surface 39 of enclosure 12. Bridge 46 can be made from any material that is compatible with segmented partition 40 and can be mounted onto the top surface 39 of the enclosure 12. In some embodiments, the bridge 46 can be made from a thermoplastic polyolefin. Bridge 46 connects the venting system of enclosure 12 to a reservoir (not shown) attached to the power panel 10. The bridge 46 is adapted to release the air present in the enclosure 12 along air flow path marked by the solid arrows 56 to exit the enclosure 12 and into the reservoir (not shown). Bridge 46, when properly bonded to the enclosure 12 and sealed to the photovoltaic panel 23 (using a segmented partition 40), acts as a snorkel when power panel 10 is laid at an angle. The bridge 46 allows the evacuated air to flow to a point higher than the water level in the inlet trough 49, while also keeping the water out of the air venting system. Due to the different densities found in the liquid and the air, as the power panel 10 fills with water, air is pushed through these corners and evacuate ‘up’ and then over bridge 46, into the volume of air in the inlet trough 49. FIGS. 3D-3E illustrate the general top surface layers of power panel 10. As shown in FIGS. 3D-3E, the partitions 40 and turning veins 42 along with photovoltaic panel 23 define the walls for channels or flow paths 54 for the passage of liquid. The present enclosure advantageously provides the flow of liquid through flow paths 54 from a first end of enclosure 12 to a second end of enclosure 12. The passage of liquid through flow paths 54 enables the collection of heat incident to the sun's rays. Furthermore, heat emitting from the photovoltaic panel 23 which is in contact with liquid in flow paths 54 is collected by the liquid and improves the efficiency of the photovoltaic panel 23. In addition, as illustrated in FIGS. 3B, 3D and 3E the partitions 40 provide a path for air to vent and equilibrate the power panel 10. Flow of venting air is shown as solid arrows 56. Thus, the arrangement and position of the partitions and turning veins 42 define flow paths 54 and 56 which improve the efficiencies of the heat collection and air flow within the enclosure 12. The vented air eventually travels up through the panel 10 and exits through the bridge 46.
In some embodiments, the segmented partitions 40 can be linear and in horizontal rows, where the path of liquid flow is vertical with respect to the inlet trough 49 and the outlet trough 50. As shown in FIG. 4A, the alternative embodiment comprises a plurality of parallel segmented partitions 40. The enclosure is sealed with the placement of a photovoltaic panel 23 on top and in contact with the segmented partitions 40. The photovoltaic panel 23 is then overlayed with a transparent panel 22 to protect the solar cells disposed on the solar radiation exposed surface of photovoltaic panel 23.
The enclosure 12 has great chemical and weather-resistance and may be attached alone or in series to a multitude of surfaces, providing they fall within the preset slope parameters, allowing the liquid to flow efficiently through the power panel 10. As shown in FIG. 4, a plurality of raised platforms 13 are molded into the enclosure 12 bottom, allowing the mounting of the power panel 10 to the desired solar radiation exposed surface (for example, a roof of a dwelling or commercial property, a mounted post with an attached board facing the solar radiation and the like) via simple lag screws. A power generating panel array operable to generate hot water and solar derived electrical energy can be made using the power panel 10 described herein. The power panel 10 can be installed in a series of 1 by X, in any number allowable for the given area along the solar radiation exposed surface of any structure 11, as illustrated in FIG. 5.
Referring to FIG. 6, a photovoltaic (PV) panel 58 for a power panel of the present disclosure includes a PV cell tray 60 which according to several embodiments is made from an aluminum material having an anodized coating. A plurality of photovoltaic cells 62 are fixedly connected to PV cell tray 60, each having a plurality of bus bars 64 that are interconnected in series to adjoining photovoltaic cells 62. The plurality of photovoltaic cells 62 is arranged in each of a plurality of cell rows 66 and a plurality of cell columns 68. According to several embodiments, each photovoltaic panel 58 includes 28 photovoltaic cells 62 arranged in four (4) columns.
Referring to FIG. 7, assembled photovoltaic panels 58 are attached at an upper surface of enclosure 12 as previously described herein. The transparent panel 22 is then disposed above the photovoltaic panel 58 and spaced therefrom. Installation of the transparent panel 22 and the photovoltaic panel 58 completes the assembly of a power panel 10.
Referring to FIG. 8, individual PV cell trays each include an upper first face 70 which is substantially planar and an oppositely directed lower second face 72. A raised outer wall 74 which is raised with respect to upper first face 70 defines an outer perimeter wall of PV cell tray 60. Raised outer wall 74 can be an integral extension of the material of first face 70 and second face 72, and according to several embodiments is oriented perpendicular to upper first face 70. According to several embodiments, a plurality of dimples 76 forming a pattern of raised surfaces and cavities are created at least on second face 72 to assist in creating turbulent flow of a fluid which is in contact with lower second face 72. Dimples 76 therefore help increase the thermal energy transferred across PV cell tray 60.
PV cell tray 60 further includes a tray first end 78 having a plurality of first raised nodules 80 created from the material of upper first face 70 and extending above upper first face 70, located proximate to tray first end 78. Power transfer wire apertures 82 are also provided proximate to tray first end 78 to permit power leads collecting the energy of photovoltaic cells 62 to be routed from first face 70 to a second face 72 side. A tray second end 84 has a plurality of second raised nodules 86, similar to first raised nodules 80, which are raised above upper first face 70 and are located proximate to tray second end 84. Each of the first and second raised nodules 80, 86 are positioned at predefined locations whose purpose will be better described in reference to FIG. 10. Each of the first and second raised nodules 80, 86 are also dimensionally controlled and can be provided, for example, by a stamping process acting on lower second face 72 to push material away from first face 70 when PV cell tray 60 is manufactured.
Referring to FIG. 9, in a first assembly step to create photovoltaic panels of the present disclosure, a first layer of adhesive 88 is applied, for example by a spraying or rolling operation onto upper first face 70 of PV cell tray 60. First layer of adhesive 88 is applied to substantially all of the upper first face 70 with the exception of first and second uncoated portions 90, 92 which are rectangular in shape and are located at tray first end 78 and tray second end 84. First layer of adhesive 88 also covers each of the first and second raised nodules 80, 86. According to several embodiments, the material of first layer of adhesive 88 can be Dow Corning® Cell Encapsulant PV-6010 material which is a two-part silicone encapsulant applied as a flowable liquid. Other types of adhesive materials can also be used for first layer of adhesive 88 which have properties adapted for adhesion to solar cells and are substantially transparent or clear.
Referring to FIG. 10 and again to FIG. 8, after a time period permitting material of first layer of adhesive 88 to cure, a first energy collection strip 94 made for example of an aluminum material having an anodized coating to reduce oxidation of the aluminum material, is applied onto first layer of adhesive 88. Individual ones of multiple alignment apertures 96 extending through first energy collection strip 94 are co-axially aligned with and receive individual ones of the first raised nodules 80. Receipt of first raised nodules 80 in the alignment apertures 96 positions the first energy collection strip 94 at a predefined location on PV cell tray 60 proximate to but not extending into first un-coated portion 90. Either prior to or following application of first energy collection strip 94, a plurality of ribbon connection areas 98 are created on an outside-facing surface of first energy collection strip 94. Ribbon connection areas 98 can be created for example using a spot-face operation which locally removes the anodized material coating from a surface of first energy collection strip 94, thereby leaving un-coated aluminum material at locations used for subsequent electrical connection of the photovoltaic cells.
Following or during the application of first energy collection strip 94, each of a first and second bus plate 100, 102 are applied onto first layer of adhesive 88 abutting or proximate to each other and also proximate to but not directly contacting first energy collection strip 94. Similar to first energy collection strip 94, each of the first and second bus plates 100, 102 can include at least one and according to several embodiments a plurality of alignment apertures 96′ which also receive individual ones of the first raised nodules 80 to align the first and second bus plates 100, 102 at predefined positions on PV cell tray 60.
At PV cell tray second end 84, each of a second and a third energy collection strip 104, 106 are applied to first layer of adhesive 88. A gap 108 is retained between proximate ends of the second and third energy collection strips 104, 106 to prevent electrical shorting between second and third energy collection strips 104, 106. Similar to first energy collection strip 94, each of the second and third energy collection strips 104, 106 also include one or more alignment apertures 96′ which co-axially align with individual ones of the second raised nodules 86, shown and described in reference to FIG. 8, which are used for the similar purpose of positioning each of the second and third energy collection strips 104, 106 at predefined locations on PV cell tray 60. Each of the second and third energy collection strips 104, 106 are positioned out of second un-coated portion 92 of PV cell tray 60. According to several embodiments, second and third energy collection strips 104, 106 are longitudinally aligned with each other and are both oriented parallel with respect to first energy collection strip 94. Also, according to several embodiments, each of the first, second, and third energy collection strips 94, 104, 106 are made from an electrically conductive metal such as 3003 H14 aluminum which has a hard coat anodized material applied thereto to minimize oxidation. Similar to first energy collection strip 94, each of the second and third energy collection strips 104, 106 also include at least one and according to several embodiments multiple ribbon connection areas 98′, where anodized material is locally removed, leaving exposed aluminum surfaces for subsequent electrical connection of the photovoltaic cells to individual ones of the second and third energy collection strips 104, 106.
Referring to FIG. 11, following application of the second and third energy collection strips 104, 106, a second layer of adhesive 110 is applied over the second and third energy collection strips 104, 106. Material of second layer of adhesive 110 can be the same as the material of first layer of adhesive 88. The second layer of adhesive 110 is omitted at first and second bus plate uncoated portions 112, 114 of each of the first and second bus plates 100, 102. First and second bus plate uncoated portions 112, 114 are provided to allow electrical connection of individual ones of the photovoltaic cells.
Referring to FIG. 12, according to several embodiments photovoltaic cells 62 can be Bosch Solar Cells M 3BB, C3 1220 provided by Bosch Solar Energy AG, Erfurt, Germany. Photovoltaic cells 62 are electrically connected to adjacent cells in series to create a first cell column 68a. First cell column 68a can be created in an electrical connection operation remote from PV cell tray 60 and applied as an entire unit to first face 70. The individual photovoltaic cells 62 of first cell column 68a are aligned as shown such that the electrical connection tabs or flexible ribbons at a defined positive end of cell column 68a of a photovoltaic cell 62a is electrically connected to second bus plate 102 at second bus plate uncoated portion 114. The electrical connection tabs or flexible ribbons of a photovoltaic cell 62b defining an opposite negative end of cell column 68a are electrically connected to second energy collection strip 104.
Referring to FIG. 13, a second cell column 68b is created remote from PV cell tray 60 similar to first cell column 68a. A photovoltaic cell 62′c is electrically connected to first bus plate uncoated portion 112 of first bus plate 100. A photovoltaic cell 62′d is then electrically connected to third energy collection strip 106. The electrical orientation of the photovoltaic cells of second cell column 68b are reversed from those of first cell column 68a such that the negative cell end connections of second cell column 68b are connected at first bus plate uncoated portion 112 and the positive cell end connections of photovoltaic cell 62′d are connected to third energy collection strip 106.
Referring to FIG. 14, a third cell column 68c of photovoltaic cells 62″ are located outward of second cell column 68b and have their positive and negative terminal ends reversed from the photovoltaic cells of second cell column 68b. A photovoltaic cell 62″e of third cell column 68c is connected to first energy collection strip 94. A photovoltaic cell 62″f of third cell column 68c is electrically connected to third energy collection strip 106.
Referring to FIG. 15, to complete the installation of photovoltaic cells 62 of photovoltaic panel 58, a fourth cell column 68d has the positive and negative orientation of its photovoltaic cells reversed with respect to those of first cell column 68a. A photovoltaic cell 62′″g is electrically connected to first energy collection strip 94. A photovoltaic cell 62′″h of fourth cell column 68d is electrically connected to second energy collection strip 104.
Referring to FIG. 16, the exemplary electrical connections used to connect the photovoltaic cells includes use of first, second, and third flexible ribbons 116, 118, 120 which have flexible ribbons individually connected to a bus bar 64a, 64b, and 64c of photovoltaic cell 62″f of third cell column 68c. A first flexible ribbon 116 is connected using a spot-welding, contact-welding or similar joining procedure to ribbon connection area 98′ of third energy collection strip 106. Similarly, a second flexible ribbon 118 extending from bus bar 64b is fixedly connected to ribbon connection area 98″, and a third flexible ribbon 120 is electrically connected to ribbon connection area 98″. Also clearly visible in this view is one of the second raised nodules 86 which is received in co-axial alignment with aperture 96′ of third energy collection strip 106. According to several embodiments, the individual perimeter wall sections of raised outer wall 74, such as raised outer wall section 74b and raised outer wall section 74c, can be joined using a wall connection portion 122. Wall connection portion 122 can be an extension of either of raised outer wall portion 74b or 74c and can be welded to the proximate one of the raised outer wall portions. Raised outer wall 74 is provided for several reasons. These can include, but are not limited to, the stiffening properties provided by raised outer wall 74 which is oriented substantially perpendicular to upper first face 70 of PV cell tray 60. Raised outer wall 74 also provides a boundary preventing overflow of first layer of adhesive 88 during application of first layer of adhesive 88.
Referring to FIG. 17 and again to FIGS. 6 and 8, after the installation of the photovoltaic cells 62 is complete onto upper first face 70 of PV cell tray 60, wire leads connected to various ones of first and second bus plates 100, 102 and first energy collection strip 94 are routed through wire apertures 82 into a junction box assembly 124 which is mounted on lower second face 72. The various wire leads are collected in a junction box 126 and first and second power leads 128, 130 extend outwardly from junction box 126 to route to a power panel (not shown) collecting power from one or more of the photovoltaic panels 58.
Referring to FIG. 18, junction box 126 includes a junction box body 132 wherein a plurality of connection wires 134 are routed in a cavity 136 of junction box 126. First and second power leads 128, 130 are stripped and electrically connected within cavity 136.
Referring to FIG. 19, to complete the junction box assembly 124, a junction box cover 138 is applied to junction box body 132. A fill aperture 140 is provided in junction box cover 138 for injection of a potting material (not shown) into the cavity of junction box body 132. A vent aperture 142 is also provided in junction box cover 138 to allow venting during the potting material fill operation.
Patent Application
20110259402
