LAMINATED CABLE ASSEMBLY

Abstract

Modular cable assembly for utility scale PV modules. The assemblies contain pairs of cables that connect strings of PV modules to inverters for commercial electrical production. In some versions, the pairs are sheathed or laminated to contain the cable pairs and position the modular connectors for simple connection to the PV cabling. In some versions, the inverter end of the cable assembly has the sheathing of laminate removed for efficiency of cable assembly.

Claims

1. A modular cable assembly adapted to connect PV module strings, which have pairs of end modules, to an inverter wherein the assembly comprises: cable pairs and a sheath containing the cable pairs, wherein the cable pairs have cable lengths and for a particular cable pair the cable lengths equal the distances between the inverter and a respective one of the pairs of end modules.

2. The assembly of claim 1, wherein the cables have module ends and inverter ends and for a particular cable the sheath secures the cable pair module ends spaced apart from each other.

3. The assembly of claim 2, wherein for greater than 10, 20, 30, 40, 50, 60, 70, or 80% of the cable pairs, the sheath secures the cable pair module ends spaced apart from each other.

4. The assembly of claim 3, wherein for a particular cable the sheath secures the cable pair inverter ends even with each other.

5. The assembly of claim 4, wherein for greater than 10, 20, 30, 40, 50, 60, 70, or 80% of the cable pairs, the sheath secures the cable pair inverter ends even with each other.

6. The assembly of claim 5 comprising greater than 15 cable pairs.

7. The assembly of claim 6, wherein the assembly is adapted for installation under a group of modules.

8. The assembly of claim 7, wherein the sheath groups the cables in one or more vertical layers.

9. The assembly of claim 8, wherein the assembly has an unsheathed region at the inverter end.

10. The assembly of claim 9, wherein sheath comprises 2 layers laminated around the cables.

11. The assembly of claim 10, wherein the cable comprises an insulating material and the sheath comprises a material different from the insulating material.

12. The assembly of claim 11, wherein the sheath comprises markings identifying the cable ends and the array serviced by the assembly.

13. The assembly of claim 12, wherein the assembly comprises greater than 50 cable pairs.

14. The assembly of claim 9, wherein the sheath groups the cables in one vertical layer.

15. The assembly of claim 14, wherein sheath comprises 2 layers laminated around the cables.

16. The assembly of claim 15, wherein the cable comprises an insulating material and the sheath comprises a material different from the insulating material.

17. The assembly of claim 16, wherein the sheath comprises markings identifying the cable ends and the array serviced by the assembly.

18. The assembly of claim 17, wherein connectors are solar module connectors.

19. The assembly of claim 18, wherein the assembly comprises greater than 50 cable pairs.

20. A modular cable assembly adapted to sit along an associated row of pairs of end modules of more than 200 PV module strings and connect the module strings to an inverter wherein the assembly comprises: more than 100 cable pairs each associates with a module string; and a sheath containing the cable pairs, wherein the cable pairs have cables with cable lengths, module ends, and inverter ends, each cable pair correlatable with a module string and each cable correlatable with an end module of an associated module string, for a particular cable pair the cable lengths equal the distances between the inverter and a respective end module, for greater than 10, 20, 30, 40, 50, 60, 70, or 80% of the cable pairs, the sheath secures the module ends of a cable pair spaced apart from each other, for greater than 10, 20, 30, 40, 50, 60, 70, or 80% of the cable pairs, the sheath secures the inverter ends of a cable pair even with each other, the sheath groups the cable in one vertical layer, the assembly has an unsheathed region at the inverter ends, and the assembly is adapted for installation under a group of the associated modules or a group of unassociated modules.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0014] FIG. 1A is a cross-section of a cable assembly discussed in this disclosure.

[0015] FIG. 1B is a perspective view of a cable assembly discussed in this disclosure.

[0016] FIG. 2 is a prospective view of a cable assembly discussed in this disclosure.

[0017] FIG. 3 is a schematic plan view of a cable assembly discussed in this disclosure.

[0018] FIG. 4 is a schematic plan view of a cable assembly with an associated module array.

[0019] FIG. 5 is another schematic plan view of a cable assembly with an associated module array.

[0020] FIG. 6 is a perspective view of an apparatus to prepare a cable assembly.

[0021] FIG. 7 is another perspective view of an apparatus to prepare a cable assembly.

[0022] FIG. 8 is another perspective view of an apparatus to prepare a cable assembly.

[0023] FIG. 9 is another perspective view of an apparatus to prepare a cable assembly.

DETAILED DESCRIPTION

[0024] Unless defined otherwise, all technical and scientific terms used in this document have the same meanings as commonly understood by one skilled in the art to which the disclosed invention pertains. Singular forms—a, an, and the—include plural referents unless the context indicates otherwise. Thus, reference to “fluid” refers to one or more fluids, such as two or more fluids, three or more fluids, etc. When an aspect is said to include a list of components, the list is representative. If the component choice is limited explicitly to the list, the disclosure will say so. Listing components acknowledges that exemplars exist for each component and any combination of the components—including combinations that specifically exclude any one or any combination of the listed components. For example, “component A is chosen from A, B, or C” discloses exemplars with A, B, C, AB, AC, BC, and ABC. It also discloses (AB but not C), (AC but not B), and (BC but not A) as exemplars, for example. Combinations that one of ordinary skill in the art knows to be incompatible with each other or with the components' function in the invention are excluded from the invention, in some exemplars.

[0025] When an element or layer is called being “on”, “engaged to”, “connected to” or “coupled to” another element or layer, it may be directly on, engaged, connected, or coupled to the other element or layer, or intervening elements or layers may be present. When an element is called being “directly on”, “directly engaged to”, “directly connected to”, or “directly coupled to” another element or layer, there may be no intervening elements or layers present. Other words used to describe the relationship between elements should be interpreted in a like fashion (e.g., “between” versus “directly between”, “adjacent” versus “directly adjacent”, etc.).

[0026] Although the terms first, second, third, etc., may describe various elements, components, regions, layers, or sections, these elements, components, regions, layers, or sections should not be limited by these terms. These terms may only distinguish one element, component, region, layer, or section from another region, layer, or section. Terms such as “first”, “second”, and other numerical terms do not imply a sequence or order unless indicated by the context. Thus, a first element, component, region, layer, or section discussed below could be termed a second element, component, region, layer, or section without departing from this disclosure.

[0027] Spatially relative terms, such as “inner”, “outer”, “beneath”, “below”, “lower”, “above”, “upper” may be used for ease of description to describe one element or feature's relationship to another element or feature as illustrated in the figures. Spatially relative terms may be intended to encompass different orientations of the device in use or operation besides the orientation depicted in the figures. For example, if the device in the figures is turned over, elements described as “below” or “beneath” other elements or features would then be oriented “above” the other elements or features. Thus, the example term “below” can encompass both an orientation of above and below. The device may be otherwise oriented (rotated 90 degrees or at other orientations) and the spatially relative descriptors interpreted.

[0028] The description of the exemplars has been provided for illustration and description. It is not intended to be exhaustive or to limit the invention. Individual elements or features of a particular exemplar are not limited to that exemplar but, where applicable, are interchangeable and can be used in a selected exemplar, even if not explicitly shown or described. The same may also be varied. Such variations are not a departure from the invention, and all such modifications are included within the invention's scope.

[0029] 40 PV module

[0030] 42 junction box

[0031] 44 positive module lead

[0032] 46 negative module lead

[0033] 50 inverter

[0034] 100 laminated cable assembly

[0035] 110 cable

[0036] 111 insulation

[0037] 112 conductor

[0038] 120 upper sheet

[0039] 130 lower sheet

[0040] 140 seam

[0041] 210 male connector

[0042] 220 female connector

[0043] 250 delaminated region

[0044] 600 laminating machine

[0045] 610 case

[0046] 620 large roller

[0047] 630 small roller

[0048] 640 bearings

[0049] 710 tension roller

[0050] 910 laminated cable assembly reel

[0051] The Laminated Cable Assembly (LCA) eliminates the need to run single homerun conductors from the end of the module strings to the inverter. It increases the cable length precision while reducing variable installation quality by moving some of the assembly work into a factory. This device replaces using cable reels of single-stranded 2 kV PV wire (or similar) in the field, reducing installation time, cable waste, incorrect cable connections, incorrect cable labelling, cable damage, and cable waste. In addition, the laminated sheeting or other outer shielding (collectively, sheathing) protects the connectors (Amphenol, MC4, or similar) and the cabling during transit and installation until the cables are finally terminated. The outer shielding reduces the potential for soiling and damage to connector ends typically occurring between initial delivery and field installation and final connecting and circuit testing.

[0052] The LCA is created in the factory by running the individual pre-determined length conductors (with connectors installed) between a sticky top sheet and bottom sheet. In some versions, the sheets are made of fiberglass or plastic. And the connectors sit as needed for installation and electrical connection to the module string ends. Sheathing can have pre-printed, laser-etched cable identification. Alternatively, the sheathing can be marked in other ways known to those of ordinary skill in the art. In some exemplars, these markings show the plant or array location for each conductor. In these or other exemplars, these markings indicate cable terminations, which eliminates the need for field labeling and the guesswork involved in cutting cables to length.

[0053] The LCA can be prepared as typical structured cabling or sheathed cable. Afterward, the pre-assembled LCA is then rolled onto a reusable spool, such as for shipping. This assembly alleviates damage and soiling before cable connection. In use, the installer will roll out the assembly in its respective location, slice the plastic sheet or sheathing at each pre-installed MC4 end to expose the connection point, and mate the end with its corresponding module string terminal.

[0054] At the inverter side, the installer may run the cable into the inverter, cut the ends to length, label the ends, and connect them to the respective inverter terminal.

[0055] FIG. 1A depicts a cross-section of an LCA 100. As depicted, the assembly 100 has several cables 110 lying flat sandwiched between an upper sheet 120 and a lower sheet 130. Alternative versions exist in which upper sheet 120 and lower sheet 130 are a single outer sheath extruded over LCA 110. This figure depicts upper sheet 120 and lower sheet 130 are joined at seam 140. In some exemplars, seam 140 results from a connection between upper sheet 120 and lower sheet 130. In these or other exemplars, seam 140 results from heat bonding, pressure bonding, or both.

[0056] FIG. 1A also depicts the insulation 111 of cable 110 and the cable 112 of cable 110. In some exemplary, the cable is single-stranded. In these or other exemplars, the cable is #8, #10, or #12 AWG. The cable style, gauge, conductor material, insulation material, and sheathing or laminating material may be standard material as is commonly used in related applications.

[0057] FIG. 1B depicts a perspective view of LCA 100. As with FIG. 1A, FIG. 1B shows cable 110. LCA 100 has one or more pairs of cable 110. In some examples, individual cables 110 have different lengths. In some exemplars, distinct pairs have different average lengths than other pairs.

[0058] An LCA 100 lies along a row of PV module strings and serves as the electrical connections between the positive and negative ends of the strings and the inverter. Consecutive PV module strings extend in rows. Sometimes, more than one string module lays along the row. Consecutive PV module strings extend in one direction, while the modules of an individual string may extend perpendicular to the row direction. For this disclosure, the direction perpendicular to the row direction is the column direction.

[0059] In some exemplars, the length of a string is two or more modules. When the string has only two modules, the modules lay along the row direction. In exemplars with more than two modules, sometimes the string has two modules lying in the row direction with additional string modules lying in columns at right angles to the string modules lying in the row direction. The strings are connected in series, parallel, or series and parallel and then to cables 110 in LCA 100.

[0060] The distance between the module ends of a string and the inverter is different. For example, for arrangements with an inverter at a row end, each module and each cable end are sequentially further from the inverter. Cable 110 has a length proportional to the distance between the module and the inverter connection. In some versions, the row layout causes a stair-step configuration in the lengths of cables 110. This stair-step configuration can be seen in the figures.

[0061] FIG. 1B also depicts male and female connectors attached to the module ends of cables 110. These attach to corresponding terminals of string modules.

[0062] FIG. 2 depicts LCA 100 as in FIG. 1a. In FIG. 2, LCA 100 has a delaminated region 250 in which upper sheet 120 and lower sheet 130 of the laminate have been cut or peeled back, leaving cables 110 unlimited.

[0063] In some exemplars, delaminated region 250, not having laminate around cables 110, allows cables 110 to fit through conduit or other cable runs or cable passageways.

[0064] FIG. 3 is a plan view of LCA 100. This figure also shows male connector's 210 and female connectors 220. The stair-step shape of LCA 100 can also be seen in this figure.

[0065] FIG. 4 depicts a plan view of LCA 100. This figure shows terminal ends of cables 110 as LCA 100 runs along a row of modules 40. The figure shows modules 40 in a schematic view of the module bottom. In this version of module 40, junction box 42 sits near the end of module 40 and has positive module lead 44, and negative module lead 46. These leads interact to create module strings. FIG. 5 shows a plan view like that of FIG. 4.

[0066] In some exemplars, LCA 100 is used in constructing the utility-scale photovoltaic system or array. One step of this construction process includes extending LCA 100 along a row of modules in which some modules along the row are end modules in a string of modules. In some exemplars, every module in the row of modules is a terminal module in a string of modules. In some exemplars, each module string has an end module that lies in the module row. In some exemplars, the terminal modules in the string lie adjacent to each other in the row of modules.

[0067] The row of modules may be formed before the LCA 100 is extended along the row. In other exemplars, LCA 100 is extended, and then the row of modules is placed next to LCA 100. The strings terminated by the row modules may be created before or after row modules are connected to LCA 100. One end of the cables 110 in LCA 100 connects to PV modules, while the other end of each cable 110 connects to a corresponding terminal inside the DC:AC or DC:DC inverter. Sometimes, the location of inverter 50 causes LCA 100 and its individual cables 110 to turn from the row direction to reach inverter 50. Sometimes the cables are routed through conduit or other cable passageways or raceways, and delaminated region 250 allows for easier insertion into such cable protection components.

[0068] LCA 100 can be prepared using any method though in the electrical cable technology. For instance, LCA 100 may be prepared as standard, sheathed multi-conductor cables, or other forms known in the art.

[0069] FIG. 6 depicts a laminating machine 600 or apparatus that may produce LCA 100. But many other methodologies as known to those of ordinary skill in the art can produce LCA 100 using similar or different laminating or sheathing machines. Laminating machine 600 has a case 610 with large rollers 620, small rollers 630, and tension roller 710 (see FIG. 7). FIG. 6 also shows bearings 640 for each roller. FIG. 7 depicts laminated machine 600 as before in FIG. 6 with a side of case 610 removed, showing a section of LCA 100 extending out from small rollers 630.

[0070] FIG. 8 shows tension roller 710 can be seen. Upper sheet 120 and lower sheet 130 are also depicted spooling from large rollers 620.

[0071] FIG. 9 shows laminating machine 600 and LCA reel 910. LCA reel 910 receives LCA 100 as it exits from small rollers 630.

[0072] In operation, several cables 110 are fed into laminating machine 600 between upper sheet 120 and lower sheet 130. Tension rollers 710 provide correct tension on upper sheet 120 and lower sheet 130 as the sheets and individual cables 110 enter between small roller s630. Small rollers 630 press upper sheet 120 against lower sheet 130 and sandwich the individual cables 110 into finished LCA 100. Upper sheet and lower sheet 120, 130 contain adhesive in some exemplars, which causes the sheets to connect and to the individual cables 120. In other exemplars, heat is applied by small rollers 630 to upper sheet 120 and lower sheet 130 as they pass through smaller roller 630. This heat bonds the sheets to each other through activating the substrate or heat-activated adhesives.

[0073] Various exemplars have been described above. For convenience's sake, combinations of aspects composing invention exemplars have been listed in such a way that one of ordinary skill in the art may read them exclusive of each other when they are not necessarily intended to be exclusive. But a recitation of an aspect for one exemplar discloses its use in all exemplars in which that aspect can be incorporated without undue experimentation. In like manner, a recitation of an aspect as composing part of an exemplar is an implicit recognition that a supplementary exemplar exists that specifically excludes that aspect. All patents, test procedures, and other documents cited in this specification are incorporated by reference if this material follows this specification and for all jurisdictions in which such incorporation is permitted.

[0074] Some exemplars recite ranges. When this is done, it discloses the ranges as a range and discloses every point within the range, including endpoints. For those exemplars that disclose a specific value or condition for an aspect, supplementary exemplars exist that are otherwise identical but that specifically exclude the value or the conditions for the aspect.