Floating solar array

Technical field

This disclosure relates generally to solar power generation, and in particular, relates to floating solar power generation.

Background information

As societies continue to industrialize throughout the world, the demand for affordable and plentiful electricity continues to grow. Renewable sources of electricity are increasingly being relied upon to meet this ever growing demand. One popular renewable source of electricity is solar power generation.

The construction of solar power plants is expensive and labor intensive. Each solar power module must be mechanically supported and electrically connected. Additionally, solar power plants may consume acres of otherwise usable land. A solar power module that can be economically fabricated, that is quickly, efficiently, and safely deployable in areas that are otherwise not being used, would be desirable and likely increase the adoption rate of commercial scale solar power generation.

Brief description of the drawings

Non-limiting and non-exhaustive embodiments of the invention are described with reference to the following figures, wherein like reference numerals refer to like parts throughout the various views unless otherwise specified. Not all instances of an element are necessarily labeled so as not to clutter the drawings where appropriate. The drawings are not necessarily to scale, emphasis instead being placed upon illustrating the principles being described.

FIG. 1 is a block diagram illustrating components of a floating photovoltaic (“PV”) power generation system, in accordance with an embodiment of the disclosure.

FIG. 2 is a profile illustration of the floating PV power generation system including a shore power cable connection to a shore substation, in accordance with an embodiment of the disclosure.

FIG. 3 is a block diagram illustrating electrical connections to a PV array using multiple power combiners, in accordance with an embodiment of the disclosure.

FIG. 4 illustrates details of a mooring assembly and edge protection members of the floating PV power generation system, in accordance with an embodiment of the disclosure.

FIGS. 5A and 5B are plan and side view illustrations of an edge protection member, in accordance with an embodiment of the disclosure.

FIG. 6 illustrates a floating PV power generation system including a floating platform moored alongside the PV array, in accordance with an embodiment of the disclosure.

FIG. 7 illustrates a mooring leg including an anchor tensioner assembly, in accordance with an embodiment of the disclosure.

FIG. 8 is a flow chart illustrating a process of deploying a floating PV power generation system, in accordance with an embodiment of the disclosure.

FIGS. 9A-G illustrate various stages of deployment for a floating PV power generation system, in accordance with embodiments of the disclosure.

FIG. 10 is a functional block illustration of a demonstrative PV module, in accordance with an embodiment of the disclosure.

FIG. 11 is a functional block illustration of a junction box including centralized circuitry of a PV module, in accordance with an embodiment of the disclosure.

FIG. 12A is a backside illustration of a floating PV module, in accordance with an embodiment of the disclosure.

FIG. 12B is profile illustration of a floating PV module, in accordance with an embodiment of the disclosure.

FIG. 13 is a cross-sectional material stack illustration of a demonstrative laminated support structure for a PV module, in accordance with an embodiment of the disclosure.

Detailed description

Embodiments of an apparatus, system and method of deployment for a floating photovoltaic (“PV”) power generation system are described herein. In the following description numerous specific details are set forth to provide a thorough understanding of the embodiments. One skilled in the relevant art will recognize, however, that the techniques described herein can be practiced without one or more of the specific details, or with other methods, components, materials, etc. In other instances, well-known structures, materials, or operations are not shown or described in detail to avoid obscuring certain aspects.

Reference throughout this specification to “one embodiment” or “an embodiment” means that a particular feature, structure, or characteristic described in connection with the embodiment is included in at least one embodiment of the present invention. Thus, the appearances of the phrases “in one embodiment” or “in an embodiment” in various places throughout this specification are not necessarily all referring to the same embodiment. Furthermore, the particular features, structures, or characteristics may be combined in any suitable manner in one or more embodiments.

FIG. 1 is a block diagram illustrating components of a floating PV power generation system 100 , in accordance with an embodiment of the disclosure. The illustrated embodiment of PV power generation system 100 includes a PV array 105 , edge protection members 110 , a mooring assembly, a waterproof enclosure 120 , an electrical interconnect assembly 125 , a shore substation 130 , and a shore power cable 135 . The illustrated embodiment of PV array 105 includes PV modules 140 . The illustrated embodiment of the mooring assembly includes mooring legs 145 and tensioning frame 150 . The illustrated embodiment of waterproof enclosure 120 houses a power combiner 155 , a controller 160 , a monitoring system 165 , and communication adapters 170 and 175 . The illustrated embodiment of shore substation 130 includes a power converter 180 , a controller 185 , a monitoring system 190 , and a communication adapter 195 .

PV power generation system 100 is a solar power generation system that floats on waterbodies, such as reservoirs, lakes, or even protected coastal waters, though reservoirs may be the most suitable locations for a variety of reasons. For instance, reservoirs are typically shallow protected waterbodies. Floating solar power generation can compare favorably to land-based solar power generation systems because the surface of reservoirs often represents unused space that is not amenable to other productive purposes. In contrast, land-based solar power generation systems often compete with other productive land uses, such as agriculture. Inherent attributes of a water based deployment can be leveraged for effective cooling that increases operational efficiency, extends expected service lifespans, and otherwise increases a return on investment (“ROI”) for a commercial-scale power generation system. Additionally, floating solar power systems, such as PV power generation system 100 , reduces water evaporation, which is an important benefit for many reservoirs.

During operation, PV power generation system 100 is moored in a waterbody 101 and coupled to deliver solar power to shore substation 130 disposed on a shore of waterbody 101 . Shore substation 130 may be coupled to deliver the solar power to a power grid or directly coupled to a local community or nearby facility (e.g., factory). PV array 105 includes a number of PV modules 140 mechanically bound together to form a contiguous block of PV modules 140 . While PV power generation system 100 can be deployed with a variable number of PV modules 140 , which may each have a variety of different sizes, in one embodiment, each PV module 140 is 100 m long by 2 m wide and outputs 20 kW. In one embodiment, 50 PV modules 140 are connected to form a square contiguous PV array 105 having an overall power generation of 1 MW. Of course, PV arrays 105 having larger or smaller individual PV modules 140 and/or having a greater or smaller number of connected PV modules 140 may be implemented. FIG. 1 illustrates just eight PV modules 140 included within PV array 105 for simplicity of illustration.

Each PV module 140 includes solar cells connected in series in one or more solar cell strings to generate solar power. The solar cells are embedded within a laminated structure forming a sort of floating solar mat, which is compliant to folding or bending in response to wave action on a surface of waterbody 101 . Since PV modules 140 use their buoyancy to float on or near the surface of waterbody 101 , extensive (and often expensive) support housings and infrastructure that typify land based solar power systems are not necessary. By floating PV modules 140 on or near the surface of waterbody 101 , PV modules 140 intimately contact the water for inherent heat dissipation and thermal cooling.

In the illustrated embodiment, PV array 105 is held in place by the mooring assembly, which includes mooring legs 145 and tension frame 150 . Tension frame 150 maintains tension on PV array 105 to ensure the individual PV modules 140 do not tangle or otherwise experience compression that could damage PV modules 140 . Tension frame 150 is tethered to mooring legs 145 so that the overall PV array 105 maintains a desired location within waterbody 101 . Mooring legs 145 may be anchored to a bottom of the waterbody using various types of anchors (e.g., gravity anchor, embedment anchor, etc.).

The illustrated embodiment of PV power generation system 100 further includes edge protection members 110 that extend around multiple sides (e.g., all sides in the embodiment of FIG. 1 ) of PV array 105 to protect PV modules 140 from floating debris in waterbody 101 . In the illustrated, edge protection members 110 are disposed between tension frame 150 and PV array 105 and also serve as a mechanical intermediary between tension frame 150 and PV array 105 . In one embodiment, edge protection members 110 further serve as a wind block to prevent wind from getting under the edges of PV array 105 and lifting PV array 105 off the surface of the waterbody in high wind storms.

PV modules 140 are electrically coupled to the functional units housed within waterproof enclosure 120 via electrical interconnect assembly 125 . In one embodiment, electrical interconnection assembly 125 is a waterproof wiring harness having individual power leads of variable length that match the variable distances between waterproof enclosure 120 and the connection points on PV modules 140 . A single wiring harness allows for a quick and organized deployment in the field. In various embodiments, the connection points on PV modules 140 may include pigtail connections or socket connections mounted to a junction box integrated into one end of PV modules 140 .

Waterproof enclosure 120 houses power combiner 155 , controller 160 , monitoring system 165 , and communication adapters 170 and 175 . Waterproof enclosure 120 is placed in the waterbody and provides environmental protection to these internal components and in particular provides thermal heat dissipation to the surrounding water for the power electronics of power combiner 155 . In one embodiment, waterproof enclosure is a metal enclosure (e.g., aluminum) that dissipates heat via convection to the surrounding water. To promote heat transfer via convection, waterproof enclosure 120 may include vertical fins on the sides of the enclosure that encourage vertical water movement through/pass the fins to promote convective cooling.

Power combiner 155 operates to combine the solar power generated by PV modules 140 to which it is connected. In one embodiment, power combiner 155 connects to all PV modules 140 in PV array 105 . In other embodiments, a separate power combiner 155 is allocated to each group of PV modules 140 (e.g., ten PV modules 140 per group) within a single PV array 105 and the outputs of the multiple power combiners are subsequently combined (discussed in greater detail in connection with FIG. 3 below).

In one embodiment, power combiner 155 is implemented with a DC-to-DC power converter that steps up the voltage output from PV modules 140 . For example, each PV module 140 may output a direct current (“DC”) voltage of 1 kV, while the power combiner 155 steps up the voltage to 3 kV or greater for transport over shore power cable 135 to shore substation 130 . In various embodiments, the stepped up voltage may range from 3 kV to 21 kV on the water for power transport over shore power cable 135 . In yet other embodiments, power combiner 155 is implemented with a DC-to-AC power inverter that converts the DC voltage output from PV modules 140 to an AC voltage for transport to shore substation 130 over shore power cable 135 . In some embodiments, the DC-to-AC power conversion may also step up the voltage for increased transport efficiency over the potentially longer shore power cable 135 . An example AC power signal for transport over shore power cable 135 is three phase AC, which may include four conductors within shore power cable 135 (three power conductors and a neutral/ground conductor). However, due to capacitive and inductive loss between the conductor and the water surrounding shore power cable 135 , a DC voltage may provide increased transport efficiency. An example shore power cable 135 for transporting a DC power signal may include three conductors (a positive conductor, a negative conductor, and a ground conductor). In various other embodiments (not illustrated) the function of power conversion may be separated from power combiner 155 and housed in a separate waterproof enclosure for each PV module 140 , or even integrated on-board each PV module 140 . Power conversion may include one or both of a voltage step up and DC-to-AC inversion.

Monitoring system 165 is included within waterproof enclosure 120 to monitor electrical interconnect assembly 125 and shore power cable 135 for upstream and/or downstream fault conditions and other operational signals (e.g., power up or power down signals). In one embodiment, monitoring system 165 includes an impedance monitor (e.g., ohm meter) that monitors the impedances on the various conductors of electrical interconnect assembly 125 and shore power cable 135 . If the impedances are determined to be outside of expected operational ranges, then a fault may be determined and controller 160 sends shut downs signals both upstream to PV array 105 and downstream to shore substation 130 . For example, low impedances may be indicative of an insulation fault (e.g., cable breach) while high impedances may be indicative of an open circuit (e.g., severed cable). Monitoring system 165 may also include voltage and current monitors to monitor operational conditions of PV array 105 . For example, a high voltage but low current condition may be indicative of nightfall, in which case controller 165 may place its connected PV modules 140 into a safe sleep state. Monitoring system 190 and controller 185 within shore substation 130 may also perform similar monitoring and control functions over shore power cable 135 .

Communication adapters 170 , 175 , and 195 provide data communications between shore substation 130 and PV modules 140 . In one embodiment, shore substation 130 communicates with the components in waterproof enclosure 120 using optical communication protocols over an optical fiber bundled with shore power cable 135 while the components of waterproof enclosure 120 communicate with PV modules 140 using power line communication protocols over electrical interconnect assembly 125 . Accordingly, in this embodiment, communication adapters 170 and 195 are optical fiber communication adapters coupled to either ends of an optical fiber in shore power cable 135 while communication adapter 175 is a power line communication adaptor coupled to electrical interconnect assembly 125 . Optical communications over shore power cable 135 enables longer runs between shore substation 130 and waterproof enclosure 120 while power line communications over electrical interconnect 125 simplifies the wiring harness and reduces the number of cable connections between waterproof enclosure 120 and PV array 105 .

As mentioned above, shore substation 130 includes power converter 180 . Power converter 180 serves to step up the voltage of the power signal received over shore power cable 135 to a grid-level voltage. In embodiments where the power signal output from power combiner 155 within waterproof enclosure 120 is a DC voltage, power converter 180 is an inverter that also converts the DC voltage to an AC voltage. Power converter 180 also isolates the grid from any fault in PV power generation system 100 .

Controller 160 choreographs the operation of the other functional elements within waterproof enclosure 120 while controller 185 choreographs the operation of the other functional elements within shore substation 130 . Controllers 160 and 185 may be implemented as hardware logic (e.g., application specific integrated circuit, field programmable gate array, etc.), software or firmware instructions executing on a microcontroller, or a combination of both.

FIG. 2 is a profile illustration of a floating PV power generation system 200 , in accordance with an embodiment of the disclosure. PV power generation system 200 is one possible implementation of PV power generation system 100 . As illustrated, mooring legs 205 anchor PV array 105 in place within waterbody 101 . The illustrated embodiment of mooring legs 205 each include an anchor 210 , an anchor line (rode) 215 , and a mooring buoy 220 . It is worth repeating that the components in FIG. 2 (or any of the other drawings) are not illustrated to scale.

In the illustrated embodiment, shore power cable 135 extends along an underground path 225 (e.g., conduit) from shore substation 130 to an entry point 230 where it exits underground path 225 and enters waterbody 101 . In one embodiment, entry point 230 is positioned below a mean low water elevation 235 of waterbody 101 . Providing a year around underwater entry point increases safety by reducing the likelihood people, wildlife, or vehicles in the vicinity of the shoreline will directly encounter shore power cable 135 , which carries high voltage power. Shore power cable 135 may also be routed along or under various shoreline structures, such as docks.

FIG. 3 is a block diagram illustrating how the solar power of PV modules 140 of a single PV array 105 may be combined using multiple power combiners 155 A and 155 B (collectively power combiners 155 ), in accordance with an embodiment of the disclosure. As illustrated, each power combiner 155 is coupled to a different subset or group of PV modules 140 via a separate electrical interconnect assembly 125 .

As illustrated, power combiner 155 A is coupled to collect and combine the solar power generated by PV modules 140 of group A while power combiner 155 B is coupled to collect and combine the solar power generated by PV modules 140 of group B. Power combiner 155 B is coupled to relay its collected solar power to power combiner 155 A while only power combiner 155 A is directly coupled to shore substation 130 via shore power cable 135 . Accordingly, power combiners 155 are coupled in series to relay and combine the solar power collected from their respective group for common transmission to shore substation 130 over shore power cable 135 . Although FIG. 3 illustrates just two power combiners 155 each coupled to eight PV modules 140 , it should be appreciated that in practice more than two power combiners 155 may be coupled in series and each power combiner 155 may be coupled to combine the solar power of more or less PV modules 140 . For example, PV array 105 may include 50 PV modules 140 organized into five groups such that each power combiner 155 combines the solar power output from ten PV modules 140 .

Reducing the number of PV modules 140 directly coupled in parallel via a single power combiner 155 , increases the operational efficiency of PV modules 140 . This is because the PV module 140 outputting the lowest voltage of a given group can reduce the efficiency of the other directly coupled PV modules 140 within the same group. In one embodiment, power combiners 155 operate to regulate their output voltages (e.g., step up to a common output voltage such as 3 kV), which reduces inefficient power coupling when combining solar power relayed between power combiners 155 .

FIG. 4 illustrates details of a mooring assembly and edge protection members of a floating PV power generation system 400 , in accordance with an embodiment of the disclosure. PV power generation system 400 is one possible implementation of PV power generation system 100 ; however, certain components (e.g., waterproof enclosure, electrical interconnect assembly, shore power cable, shore substation, etc.) have been omitted from FIG. 4 so as not to clutter the drawing. The illustrated embodiment of the mooring assembly includes a tensioning frame 405 and mooring legs 410 . The illustrated embodiment of tensioning frame 405 includes main lines 415 , adjustable tensioning tethers 420 , and boom ties 425 . The illustrated embodiment of the edge protection members includes floating boom sections 430 and boom-to-array connectors 435 .

Tensioning frame 405 serves as a connection between mooring legs 410 and PV array 401 . Tensioning frame 405 maintains tension on the PV modules of PV array 401 to prevent them from experiencing compression that damages the PV modules or twisting on themselves. In the illustrated embodiment, tensioning frame 405 physically connects to floating boom sections 430 while boom-to-array connectors 435 translate the tensile force to PV array 401 . In other embodiments, tensioning frame 405 may couple directly to PV array 401 . In one embodiment, floating boom sections 430 are disposed along the outside perimeter of main lines 415 (not illustrated).

Main lines 415 are mainlines extended between mooring legs 410 . Main lines 415 form an arc between their connecting mooring legs 410 , which maintains tension on boom ties 425 . Boom ties 425 extend between the main lines 415 and floating boom sections 430 and serve to apply tensile forces around all sides of PV array 401 . In one embodiment, tensioning frame 405 is formed as a rope rigging. For example, tensioning frame 405 may be fabricated of a low weight, stretch resistant, UV stable line. In one embodiment, tensioning frame 405 is a sheathed polymer line.

In the illustrated embodiment, boom ties 425 exerted a tensile force onto the outer sides of floating boom sections 430 , which in turn translate the tensile force to PV array 401 via boom-to-array connectors 435 . FIG. 5A illustrates an example implementation of floating boom sections 430 and boom-to-array connectors 435 . In the illustrated embodiment of FIG. 5A , boom-to-array connector 435 is a fabric tab/flap with eyeholes 505 (e.g., grommets) that are lashed (or otherwise mechanically connected) to outer edges of those PV modules that fall along the perimeter of PV array 401 . Other mechanical connections than eyeholes 505 may be used (e.g., straps, buckles, clips, snaps, hook and loop connectors, quick ties, zipper, etc.). In other embodiment, boom ties 425 may connect directly to the PV modules by passing through or over floating boom sections 430 .

Returning to FIG. 4 , adjustable tensioning tethers 420 provide a mechanism for adjusting the tension on tensioning frame 405 by adjusting their lengths. For example, each adjustable tensioning tether 420 may be implemented as a pulley assembly (e.g., block and tackle) with a lock, replaceable tethers of variable lengths, cinch-tight straps, or otherwise. Adjustable tensioning tethers 420 allow the system to be deployed and interconnected while tensioning frame 405 is relaxed, then subsequently pulled taut to a desired tensile force to ensure PV array 401 is appropriately held in place. If tensioning frame 405 stretches after the initial deployment or a wind or wave storm, adjustable tensioning tethers 420 can readily be retightened as needed.

FIG. 5B illustrates a profile view of an edge protection member including a barrier 510 extending beneath floating boom section 430 . The illustrated embodiment of barrier 510 is a sort of boom skirt that connects to the bottom side of floating boom section 430 , extends below the waterline 515 , and operates as a water surface windscreen to block wind from getting underneath PV array 401 . Barrier 510 may be implemented using a variety of different structures having different shapes that extend below the surface of the water including a weighted curtain, a water filled curtain, or otherwise. Although FIGS. 5A and 5B illustrate floating boom 430 as having a circular cross-sectional shape, the term floating boom is defined broadly herein to include a variety of different cross-sectional shapes.

FIG. 6 illustrates a floating PV power generation system 600 , in accordance with an embodiment of the disclosure. PV power generation system 600 is similar to PV power generation system 400 except for the addition of a floating platform 605 moored along one side of PV array 401 . Floating platform 605 provides an on-water staging area for deployment and maintenance access to one side of PV array 401 . Floating platform 605 may be implemented as a barge, wharf, pontoon, dock or other floating structure. In one embodiment, floating platform 605 is moored with independent anchors 610 ; however, in other embodiments, floating platform 605 may be coupled into the mooring assembly surrounding PV array 401 . In the illustrated embodiment, floating platform 605 replaces one section of floating boom section 430 ; however, in other embodiments, floating platform 605 may be coupled between one side of tensioning frame 405 and one of the floating boom sections 430 . In FIG. 6 floating platform 605 is approximately the length of one side of PV array 401 ; however, in other embodiments, floating platform 605 may be substantially shorter (e.g., 1/10 the length) and incrementally moved along the length of one side of PV array 401 during deployment of the PV modules.

FIG. 7 illustrates a mooring leg 700 , in accordance with an embodiment of the disclosure. Mooring leg 700 is one possible implementation of mooring leg 145 illustrated in FIG. 1 . The illustrated embodiment of mooring leg 700 includes a mooring buoy 705 , an anchor 710 , an anchor line 715 , and an anchor tensioner assembly 720 . The illustrated embodiment of anchor tensioner assembly 720 includes a pulley 725 mounted to anchor 710 and a float 730 coupled to the opposite end of anchor line 715 as mooring buoy 705 .

During operation, anchor tensioner assembly 720 maintains tension on anchor line 715 despite limited fluctuations in water elevations of waterbody 101 . Maintaining tension on anchor line 715 ensures tensioning frame 150 can keep PV array 105 under tension. In the illustrated embodiment, float 730 maintains a constant buoyancy force on anchor line 715 so long as float 730 remains under water. In one embodiment, pulley 725 is pivot mounted to anchor 710 so it may rotate and allow anchor line 715 to extend in any direction. In this manner, the deployment of anchor 710 is not orientation dependent. As mentioned above, anchor 710 may be implemented using a variety of anchor types including gravity anchors, embedment anchors driven into the bottom of waterbody 101 , or otherwise.

FIG. 8 is a flow chart illustrating a process 800 of deploying floating PV power generation system 100 , in accordance with an embodiment of the disclosure. Process 800 is described with reference to FIGS. 9A-F , which illustrate various stages of deployment. The order in which some or all of the process blocks appear in process 800 should not be deemed limiting. Rather, one of ordinary skill in the art having the benefit of the present disclosure will understand that some of the process blocks may be executed in a variety of orders not illustrated, or even in parallel.

In a process block 805 , a bottom survey of waterbody 101 is obtained. The bottom survey may be retrieved from a database of previously recorded surveys or obtained on-site at the time of deployment. In one embodiment, the bottom survey includes depth readings in the vicinity of where anchors are to be deployed. In a process block 810 , anchors are deployed in specified locations. Referring to FIG. 9A , four anchors 905 are deployed in a rectangular pattern. In other embodiments, more or less anchors 905 may be deployed in other patterns. In a process block 815 , the remaining elements of the mooring legs 910 are installed and attached to anchors 905 . In one embodiment, the remaining components of mooring legs 910 include at least attaching an anchor line and mooring buoy. In other embodiments, an anchor tensioner assembly is also deployed. Although the figures herein all illustrate round mooring buoys, it should be appreciated that the term mooring buoy is broadly defined herein to include a floating device having a variety of different shapes and sizes.

After mooring legs 910 are installed in the appropriate locations, two sections 915 A and 915 B of the tensioning frame are strung between a group of the mooring buoys. Referring to FIG. 9B , two sections 915 A and 915 B are attached between mooring buoys 920 A, B, and C. In particular, sections 915 A and 915 B are adjoining sections that attach to a common mooring buoy 920 B. Additionally, in process 820 , edge protection members 925 A and 925 B (e.g, floating boom sections) are installed along respective sections 915 A and 915 B of the tensioning frame. Installation of edge protection members 925 A and 925 B includes attaching boom ties (e.g., boom ties 425 ; see FIG. 4 ) to the floating boom of edge protection members 925 A and 925 B. In one embodiment, each section 915 (e.g., including main line and boom ties) is pre-bundled with its corresponding edge protection member 925 such that the two components can be unrolled, or otherwise deployed, together as a single bundled unit. After the bundled unit is stretched out into its rough position between its corresponding mooring buoys 920 , the strapping holding the two components together can be removed (e.g., cut away).

With two adjoining sections 915 A and 915 B of the tensioning frame installed, PV modules can be positioned for deployment (process block 825 ). In one embodiment, PV modules are wound on floating spools that are floated into position along section 915 B of the tensioning frame. In other embodiments, PV modules are loaded onto floating platform 605 and deployed therefrom. Once in position, the first PV module 930 is unrolled from its position adjacent to section 915 B and extended away from section 915 B (see FIG. 9C ). In one embodiment, a boat is used to both position the spools and to drag a PV module out into the water as it unrolls from its spool. In the illustrated embodiment, PV module 930 is unrolled along a path that is substantially parallel to section 915 A of the tensioning frame. Once unrolled, PV module 930 is mechanically attached into position with the PV array. As the first PV module that is immediately adjacent to section 915 A and edge protection member 925 A, PV module 930 is mechanically bound into position via boom-to-array connector 935 A along its long edge and to boom-to-array connector 935 B along its short edge.

Process blocks 825 through 835 are sequentially repeated for each subsequent PV module until all PV modules are positioned, unrolled and mechanically bound to each other and to boom-to-array connector 935 B (see FIG. 9D ) to form a contiguous PV array 940 (decision block 840 ). In various embodiments, each PV module may include various edge treatments (e.g., snaps, buckles, zipper, hook and loop, etc.) for mechanically linking the long edges of adjoining PV modules. In the illustrated embodiments, only two adjoining sections 915 A and 915 B of the tensioning frame are initially deployed to allow a boat easy access into the workspace to both position the spools at their respective locations and drag the PV modules from their spools. In some embodiments, three sections 915 A, 915 B, and 915 C of the tensioning frame may be deployed in process block 820 before the individual PV modules are unrolled into position. A three section initial deployment of the tensioning frame still enables access to the workspace. However, if all four sections of the tensioning frame are initially deployed, access to the water workspace is obstructed.

In yet other embodiments, the PV modules may be unrolled from a first floating platform and drawn along towards a second floating platform using cables. FIG. 9G illustrates this alternative embodiment using two floating platforms 970 and 975 . In the illustrated embodiment, opposing sections 915 A and 915 C of the tensioning frame are initially installed between mooring buoys 920 . In one embodiment, the initially deployed sections 915 A and 915 C do not share a common mooring leg. Optionally, section 915 B (see FIG. 9B ) may also be initially deployed along the side of floating platform 975 . The PV modules are deployed from floating platform 970 and a cable used to draw each PV module toward floating platform 975 . A field technician can stand on floating platform 975 and pull on cable 980 to causes the PV module to unroll from its material spool located on or adjacent to floating platform 970 . Once a given PV module is in position and mechanically attached to the either section 915 A or an adjacent already deployed PV module, floating platform 970 is moved laterally to the next position and the process repeats. In one embodiment, a guide cable 980 is extended between mooring buoys 920 A and 920 D. Guide cable 980 may be used to move floating platform 970 laterally to the next position. Once all of the PV modules are secured into a contiguous PV array, one or both of floating platforms 970 and 975 may be removed.

Returning to FIG. 8 , in a process block 845 , the remaining edge protection members (e.g., 925 C and 925 D) are attached to the exposed edges of PV array 940 . Additionally, the remaining sections (e.g., 915 C and 915 D) of the tensioning frame are attached between a second group of the mooring buoys (e.g., mooring buoys 920 A, D, and C). See FIG. 9E . With all mechanical members installed and interconnected, the tension on the tensioning frame is adjusted up to tension using the adjustable tensioning tethers 945 (process block 850 ).

With the mechanical members installed and tensioned, the electrical components are installed. In a process block 855 , one or more waterproof enclosures 950 with integrated power combiners are electrically coupled to the PV modules of PV array 940 using a corresponding number of electrical interconnect assemblies 955 . Although FIG. 9F only illustrates a single waterproof enclosure 950 and single electrical interconnect assembly 955 , as discussed in connection with FIG. 3 , multiple waterproof enclosures 950 each with a separate power combiner may each couple to a different sub-group of the PV modules. The electrical interconnect assemblies 955 may be implemented as waterproof wiring harnesses with wire leads have tailored lengths for connecting to their respective PV module.

In a process block 860 , a single shore power cable 960 is run between waterproof enclosure 950 and shore substation 965 . Will all electrical connections coupled, setup and diagnostic utilities can be run from shore substation 965 over a fiber optic cable embedded within shore power cable 960 to test the interconnections and operational health of each PV module.

FIG. 10 is a functional block illustration of a demonstrative PV macro-module 1000 , in accordance with an embodiment of the disclosure. PV macro-module 1000 is one possible implementation of PV modules 140 illustrated in FIG. 1 . It should be appreciated that PV modules 140 may be implemented with a variety of other PV module structures as well. The illustrated embodiment of PV macro-module 1000 includes laminated support structure 1005 , solar cell strings 1010 including solar cells 1015 , distributed circuitry 1020 , a junction box 1025 , power lines 1030 , signal lines 1035 , edge connections 1040 , end connections 1045 , output ports 1050 .

Solar cell strings 1010 each includes a plurality of solar cells 1015 electrically connected in series to generate solar power and a current in response to light incident upon a frontside of PV macro-module 1000 . PV macro-module 1000 may include any number of solar cell strings 1010 each having any number of solar cells 1015 . However, PV macro-module 1000 is well-suited for kilowatt power generation and may be coupled with additional instances of PV macro-module 1000 for mega-watt power generation. For example, each solar cell 1015 may be designed to output 10 A @ 1V, each solar cell string 1010 may include between 50 and 1000 series connected solar cells 1015 to generate up to 10 A @ 1000V on output ports 1050 . Of course, the actual number of solar cell strings 1010 , number of solar cells 1015 per solar cell string 1010 , amperage and voltage output may be selected by design and vary outside the above demonstrative ranges and/or that illustrated in FIG. 10 . PV macro-module 1000 is referred to as a “macro” module to indicate that the design of PV macro-module 1000 is well-suited for integrating large numbers (e.g., 100's or 1000's) of solar cells 1015 into a single contiguous module or form factor for commercial grade power generation. However, it is also anticipated that the designs disclosed herein are also applicable to sub-kilowatt power generation applications.

In the illustrated embodiment, PV macro-module 1000 encases solar cell strings 1010 within laminated support structure 1005 . Laminated support structure 1005 is fabricated as a multi-layer laminated structure that is durable, environmentally benign/inert, and relatively low cost when compared to conventional commercial grade solar power generating systems that include rigid housings and bulky support structures. Laminated support structure 1005 is a mat-like protective encasement that surrounds solar cell strings 1010 and is compliant to rolling or folding. By embedding solar cell strings 1010 in a laminated structure, expensive frames and mechanical support infrastructures can be avoided thereby facilitating simplified storage and quick deployment in a variety of environmental conditions. PV macro-module 1000 can be temporarily deployed for short-term power generation (e.g., portable deployments, deployments in the event of unexpected power grid failure, deployments in the event of natural disasters, etc.), seasonal power generation, or long-term/quasi-permanent deployments (e.g., multi-year or multi-decade).

In one embodiment, solar cells 1015 are fabricated of monocrystalline silicon; however, in other embodiments, solar cells 1015 may be implemented using polycrystalline silicon, thin film technologies, other semiconductor materials (e.g., gallium arsenide), or other solar cell technologies. The illustrated embodiment of each solar cell string 1010 includes a plurality of solar cells 1015 coupled in series. In other embodiments, solar cell strings 1010 may also include a group of parallel coupled solar cells 1010 that are coupled in series with other parallel coupled solar cells 1010 . Furthermore, the physical layout of these series coupled solar cells 1015 may assume a variety of different patterns and routes. For example, a given solar cell string 1010 may follow a straight path, a zigzag or serpentine path, a curved path, a spiral path, or trace out any number of geometric patterns (e.g., concentric rectangles, etc.). In one embodiment, solar cells 1015 within a solar cell string 1010 are interconnected via embedded conductive interconnects that alternate physical connections on the frontside and backside of consecutive cells (e.g., see FIG. 13 ). Furthermore, solar cell strings 1010 may be interconnected to each other (series or parallel) via power lines 1030 also embedded within laminated support structure 1005 .

The description continues in the full USPTO document.