Patent Application
20120037313
The present invention relates to photovoltaic modules and methods of manufacturing same.
A connection assembly may be electrically connected to a contact region of a photovoltaic module, to facilitate connection between the photovoltaic module and other electrical components, including, for example, one or more additional photovoltaic modules. Tape may be used to secure one or more components of the connection assembly to the photovoltaic module. Current tools and methods for applying tape are inefficient.
Photovoltaic modules can include multiple layers (or coating) created on a substrate (or superstrate). For example, a photovoltaic device can include a barrier layer, a transparent conductive oxide (TCO) layer, a buffer layer, and a semiconductor layer formed in a stack on a substrate. Each layer may in turn include more than one layer or film. For example, the semiconductor layer can include a first film including a semiconductor window layer, such as a cadmium sulfide layer, formed on the buffer layer and a second film including a semiconductor absorber layer, such as a cadmium telluride layer formed on the semiconductor window layer. Additionally, each layer can cover all or a portion of the device and/or all or a portion of the layer or substrate underlying the layer. For example, a “layer” can include any amount of any material that contacts all or a portion of a surface.
A photovoltaic module may include a connection assembly for electrically connecting one or more electrical components to the module, including, for example, one or more additional photovoltaic modules. The assembly may contain various suitable components, including, for example, one or more bussing components or assemblies. For example, one or more conductors may be applied adjacent to a contact layer of a photovoltaic module. The conductors may include any suitable material, including, for example, one or more lead foils. A common or main conductor may be applied adjacent to the one or more conductors. For example, one or more bus bars may be applied adjacent to one or more lead foils. Tape (e.g., double-sided tape) may be used to secure conductive material to the module.
For example, a strip of tape may be applied adjacent to a contact region of a photovoltaic module. The tape strip may be distributed across the length of the module, A conductive lead foil may be applied adjacent to (e.g., directly on) the tape strip. A second tape strip may be applied adjacent to (e.g., directly on) the first tape strip and lead foil, and a second lead foil may be applied thereon. The second tape strip and lead foil may be positioned such that at least a portion of the first lead foil is exposed (i.e., not covered by the second tape strip and lead foil). The first and second lead foils may be positioned such that they do not physically and/or electrically contact one another. Thus the first and second lead foils may be capable of receiving different charges. In other words, the first lead foil may be configured to receive a positive charge, and the second lead foil may be configured to receive a negative charge, or vice versa. The first and second tape strips may contain an adhesive on both sides. Accordingly, the first and second tape strips, respectively, may fixedly secure the first and second lead foils to the module.
One or more common conductors (e.g., bus bars) may be applied adjacent to the tape strips and lead foils, to provide a common connection for the module. The tape strips may also fixedly secure the common conductor to the photovoltaic module. For example, one or more common conductors may be positioned substantially perpendicular to a deposited strip of double-sided tape and/or conductive lead foil. Each of the common conductors may form an electrical connection with any exposed portions of the lead foils. The applied tape may itself be a conductor as well. For example, a strip of conductive tape may be applied adjacent to a contact region of a photovoltaic module. The conductive tape can include a conductive component, such as a foil, metal film, inorganic film or organic film, for example, a conductive polymer. In certain embodiments, the conductive tape can be a foil tape.
The applied tape is thus a critical component for the connection assembly. Proper and expedient application of the tape is needed to ensure proper assembly configuration, as well as efficient production of the modules. Accordingly, the apparatus used to dispense the tape can play a critical role in the manufacturing process. A tape dispensing apparatus may consist of an application “head” including one or more rollers positioned on shafts for supporting and feeding tape through a guide to a designated surface. Existing tape dispensers suffer from several shortcomings. For example, the internal components within the tape dispensing head may be arranged in a compact and rigid configuration, making threading and loading of tape into the apparatus difficult. With some existing designs, the rollers may be partially hidden, further exacerbating the problem. This compact and rigid design also makes the application head difficult to clean between uses. Failure to properly clean the head can result in uneven or distorted application of the tape. Debris within the device may also impact spinning of the rollers, possibly resulting in the inability of the applicator to apply a strip of tape of the full desired length.
It would be desirable to modify existing tape dispenser designs to facilitate threading and loading of tape, as well as cleaning of the internal components within the dispensing head. According to an embodiment of the inventions disclosed herein, a tape dispensing apparatus may include one or more rollers. The one or more rollers may be positioned in a dispensing “head,” and may be aligned in any suitable configuration. For example, the one or more rollers may be assembled in a substantially horizontal configuration (i.e., parallel to a module surface). The one or more rollers may include any suitable number of rollers, including, for example, more than two rollers, more than three rollers, less than ten rollers, or less than five rollers. For example, the one or more rollers may include three rollers. The one or more rollers may be configured for holding tape, or for feeding tape to a desired location. For example, the one or more rollers may be configured to feed tape to a guide, which can direct and output the tape to a desired surface. The one or more rollers may be configured to hold tape of any desired design or configuration, and of any desired material, including, for example, any suitable polymer, paper, plastic, cloth, metal, or alloy. The tape may include an adhesive on one or both sides. Any suitable adhesive may be used, including, for example, any suitable organic or plant-based, solvent-type, animal protein-based, or synthetic polymer glue. For example, the adhesive may contain an epoxy resin, epoxy putty, ethylene-vinyl acetate, phenol formaldehyde resin, polyamide, polyester resin, polyethylene, polypropylene, polysulfide, polyurethane, polyvinyl acetate, polyvinyl alcohol, polyvinyl chloride, polyvinyl chloride, polyvinylpyrrolidone, rubber cement, silicone, styrene acrylic copolymer, acrylonitrile, cyanoacrylate, or acrylic.
The rollers may be configured to feed tape for application to a desired area. The rollers may feed the tape through a guide configured to apply the tape in a precise manner to a designated surface. The rollers may be movably secured on shafts, which may be secured inside the head via any suitable securing means, including, for example, any suitable threaded structure, such as a screw, as well as a knob, clip, or latch. The roller may be secured on the shafts by any suitable means. For example, one or more clips may be positioned along each shaft, proximate to (or touching) opposite ends of each roller. The clips may be of any suitable shape. For example, the clips may have a substantially “C” shape. The shafts may have one or more grooves, into which the clips may fit. The clips may be fixedly or movably secured within the grooves. The rollers and roller shafts may be secured within a designated compartment of the apparatus, including, for example, a “head” portion. The head of the apparatus may include a bracket for supporting the shafts and rollers. The bracket may contain any suitable material, including, for example, any suitable metal or alloy, or any suitable plastic material. For example, the bracket may be constructed substantially of aluminum.
To facilitate the threading, loading, and cleaning of the tape dispensing apparatus, the roller shafts may be fixedly secured only within one side of the apparatus, thereby allowing another side of the apparatus to be detached to expose all rollers and shafts inside. For example, an improved tape dispensing apparatus may include one or more roller shafts fixedly secured in the back side of a dispensing head of the apparatus. The roller shafts may be secured by any suitable securing means, including, for example, one or more screws, knobs, pins, or clips. The dispensing head may contain a detachable front side that is movably secured to the rest of the device. The front side may be secured by any suitable means, including, for example, one or more screws, knobs, pins, or clips. The front side may be movably secured, such that the front side may be detached for threading, loading, or cleaning. Although the front side is detachable, it may be sufficiently secured such that the apparatus remains in a closed state during operation thereof. The head also may contain a safety mechanism to further ensure unintentional opening of the apparatus during operation. For example, the tape dispensing head may include a latch to serve as a means for further securing the front side of the head to the rest of the apparatus. The front side may either detach completely, or partially. For example, the front side may be secured by a securing means, upon removal of which, the entire front side may detach from the apparatus. Alternatively, the securing means may merely allow the front side to become movable with respect to the larger apparatus, while still remaining attached in some fashion. For example, the front side may be secured to the rest of the apparatus via a hinge, allowing it to “swing” back and forth when it is in its “detached” position. The back side of the device may be reinforced with a thicker or stronger material than the front side, for providing adequate support for the roller shafts. The thicker or stronger back side material may include any suitable material, including, for example, any suitable metal or alloy. The back side may include one or more parts of varying thicknesses. The back side may provide sufficient structural support for the roller shafts to minimize bending or drooping of the shafts when the front side is in its detached state, such that the rollers are only supported on one end of the shafts.
In one aspect, a tape dispensing apparatus may include a tape dispensing apparatus may include a front section and a back section. The front section may include a base part and a removable part. The tape dispensing apparatus may include one or more rollers positioned in between the front and back sections. The tape dispensing apparatus may include one or more shafts supporting the one or more rollers. Each one of the one or more shafts may orthogonally intersect at least a first side of the back section, and at least a first side of the front section. The tape dispensing apparatus may include a fastener securing the removable part to the base part. The removable part may be positioned such that upon separation of the removable part from the base part, the one or more rollers are exposed.
The tape dispensing apparatus may include one or more fasteners fixedly securing the one or more shafts to the back section. The front or back section may include a metal. The metal may include aluminum. The fastener may include a threaded structure, knob, clip, or latch. The one or more rollers may include two or more rollers. The one or more rollers may include five or less rollers. The one or more rollers may include three rollers. Each one of the one or more rollers may be positioned substantially proximate to one another, and aligned in at least one common plane. The tape dispensing apparatus may include one or more sets of clips. Each one of the one or more sets of clips may movably secure each one of the one or more rollers along a respective shaft. Each one of the one or more sets of clips may include a first clip substantially proximate to a first side of one of the one or more rollers, and a second clip substantially proximate to a second side of one of the one or more rollers. Each one of the one or more shafts may include a first groove for securing the first clip, and a second groove for securing the second clip. The first and second clips may each include a C-shaped clip. The one or more shafts may orthogonally intersect at least a first side of the front section. The one or more shafts may be loosely secured within at least a portion of the front section. The one or more fasteners may orthogonally intersect at least a second side of the back section. The tape dispensing apparatus may include tape distributed around one of the one or more rollers. The tape may include a pressure sensitive adhesive. The tape may include double-sided tape. The tape may include at least one surface containing an adhesive. The adhesive may include a plant-based glue, a solvent-type glue, an animal protein-based glue, or a synthetic polymer-based glue. The tape may include a conductive component. The conductive component may include a metal film, a foil, an organic film, or an inorganic film. The removable part, base part, and the one or more rollers may be configured such that upon separation of the removable part from the base part, the one or more rollers are sufficiently exposed to allow loading of one or more pieces of tape. The removable part, base part, and one or more rollers may be configured such that upon separation of the removable part from the base part, the one or more rollers are sufficiently exposed to allow cleaning of the one or more rollers. The removable part, base part, and one or more rollers may be configured such that upon separation of the removable part from the base part, the one or more shafts are sufficiently exposed to allow cleaning of the one or more shafts. The removable part, base part, and one or more rollers may be configured such that upon separation of the removable part from the base part, the one or more rollers are sufficiently exposed to allow removal of one of the one or more rollers. The removable part, base part, and one or more rollers may be configured such that upon separation of the removable part from the base part, the one or more shafts are sufficiently exposed to allow removal of one of the one or more shafts. The tape dispensing apparatus may include a guide for directing a piece of tape loaded on one of the one or more rollers onto a designated surface. The designated surface may include a contact region of a photovoltaic module. The tape dispensing apparatus may include a tape dispensing head. The one or more rollers, one or more shafts, front and back sections, and fastener may be part of the tape dispensing head.
In one aspect, a method of dispensing tape may include detaching a removable part of a tape dispensing apparatus from a base portion of the tape dispensing apparatus to expose one or more rollers positioned on one or more shafts. One end of each one of the one or more shafts may be secured within the base portion. The method may include loading tape onto at least one of the one or more rollers. The method may include reattaching the removable part to the base portion so that the one or more rollers are no longer exposed. The method may include lowering the tape dispensing apparatus to a surf ice. The method may include applying at least a portion of the tape to the surface, using the tape dispensing apparatus.
The surface may include a contact region of a photovoltaic module. Applying at least a portion of the tape may include applying double-sided tape. Applying at least a portion of the tape may include applying a pressure sensitive adhesive. Detaching a removable part may include removing a fastener securing the removable part to the base portion. Reattaching the removable part may include securing the removable part to the base portion with a fastener.
Referring to
Front side 102 may be secured to dispensing head 10 via any suitable means, including, for example, fastener 106. Fastener 106 may include any suitable means for fixedly or movably securing front side 102 to dispensing head 10, including, for example, any suitable threaded structure, including, for example, a screw, knob, clip, or latch. Although only fastener 106 is depicted in
Also depicted in
Referring back to
The unsecured ends of shafts 212a-212c, i.e., those which are not secured within back side 232, may be secured (fixedly or movably) within front side 102. Although not shown in
The tape dispensing head shown in
Tape dispensing head 10 may be lowered substantially proximate to photovoltaic module 400 to apply one or more strips of tape 414. Tape 414, can contain any suitable material, including, for example, any suitable polymer, paper, plastic, cloth, metal, or alloy. Tape 414 may include an adhesive on one or both sides. Any suitable adhesive may be used, including, for example, any suitable organic or plant-based, solvent-type, animal protein-based, or synthetic polymer glue. For example, the adhesive may contain epoxy resin, epoxy putty, ethylene-vinyl acetate, phenol formaldehyde resin, polyamide, polyester resin, polyethylene, polypropylene, polysulfide, polyurethane, polyvinyl acetate, polyvinyl alcohol, polyvinyl chloride, polyvinyl chloride, polyvinylpyrrolidone, rubber cement, silicone, styrene acrylic copolymer, acrylonitrile, cyanoacrylate, or an acrylic.
The application of one or more strips of tape 414 onto a contact region of photovoltaic module 400, for example, may facilitate fabrication of a connection assembly on the module. Photovoltaic modules with such an assembly configured thereon may be incorporated into a system for generating electricity. For example, such a module may be illuminated with a beam of light to generate a photocurrent. The photocurrent may be collected and converted from direct current (DC) to alternating current (AC) and distributed to a power grid. Light of any suitable wavelength may be directed at the module to produce the photocurrent, including, for example, more than 400 nm, or less than 700 nm (e.g., ultraviolet light). Photocurrent generated from one photovoltaic module may be combined with photocurrent generated from other photovoltaic modules. For example, the photovoltaic modules may be part of a photovoltaic array, from which the aggregate current may be harnessed and distributed.
Although the inventions discussed herein are discussed in certain aspects with respect to the fabrication of a connection assembly of one or more photovoltaic modules, the inventions are not so limited. For example, the tape dispensing apparatuses and systems disclosed herein may be applicable for any occasion where applying tape to a surface is warranted, including, for example, construction use, home use, or the fabrication of any structures, materials, or devices.
The embodiments described above are offered by way of illustration and example. It should be understood that the examples provided above may be altered in certain respects and still remain within the scope of the claims. It should be appreciated that, while the invention has been described with reference to the above preferred embodiments, other embodiments are within the scope of the claims.
This application claims priority under 35 U.S.C. §119(e) to Provisional Application No. 61/373,655, filed on Aug. 13, 2010, which is incorporated herein by reference in its entirety.
| Number | Date | Country | |
|---|---|---|---|
| 61373655 | Aug 2010 | US |
