EP2401767A2 - Systèmes et procédés d'amélioration de structure et d'encapsulation de module photovoltaïque - Google Patents

Systèmes et procédés d'amélioration de structure et d'encapsulation de module photovoltaïque

Info

Publication number
EP2401767A2
EP2401767A2 EP10746690A EP10746690A EP2401767A2 EP 2401767 A2 EP2401767 A2 EP 2401767A2 EP 10746690 A EP10746690 A EP 10746690A EP 10746690 A EP10746690 A EP 10746690A EP 2401767 A2 EP2401767 A2 EP 2401767A2
Authority
EP
European Patent Office
Prior art keywords
membrane
photovoltaic
photovoltaic module
structural component
buss
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Withdrawn
Application number
EP10746690A
Other languages
German (de)
English (en)
Inventor
Kurt L. Barth
John C. Powell
Neil Morris
Nader Mahvan
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Abound Solar Inc
Original Assignee
Abound Solar Inc
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Priority claimed from US12/392,053 external-priority patent/US20100212740A1/en
Priority claimed from US12/392,055 external-priority patent/US20100212725A1/en
Application filed by Abound Solar Inc filed Critical Abound Solar Inc
Publication of EP2401767A2 publication Critical patent/EP2401767A2/fr
Withdrawn legal-status Critical Current

Links

Classifications

    • H—ELECTRICITY
    • H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
    • H02S—GENERATION OF ELECTRIC POWER BY CONVERSION OF INFRARED RADIATION, VISIBLE LIGHT OR ULTRAVIOLET LIGHT, e.g. USING PHOTOVOLTAIC [PV] MODULES
    • H02S40/00—Components or accessories in combination with PV modules, not provided for in groups H02S10/00 - H02S30/00
    • H02S40/30—Electrical components
    • H02S40/34—Electrical components comprising specially adapted electrical connection means to be structurally associated with the PV module, e.g. junction boxes
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01L—SEMICONDUCTOR DEVICES NOT COVERED BY CLASS H10
    • H01L31/00—Semiconductor devices sensitive to infrared radiation, light, electromagnetic radiation of shorter wavelength or corpuscular radiation and specially adapted either for the conversion of the energy of such radiation into electrical energy or for the control of electrical energy by such radiation; Processes or apparatus specially adapted for the manufacture or treatment thereof or of parts thereof; Details thereof
    • H01L31/02—Details
    • H01L31/02002—Arrangements for conducting electric current to or from the device in operations
    • H01L31/02005—Arrangements for conducting electric current to or from the device in operations for device characterised by at least one potential jump barrier or surface barrier
    • H01L31/02008—Arrangements for conducting electric current to or from the device in operations for device characterised by at least one potential jump barrier or surface barrier for solar cells or solar cell modules
    • H01L31/02013—Arrangements for conducting electric current to or from the device in operations for device characterised by at least one potential jump barrier or surface barrier for solar cells or solar cell modules comprising output lead wires elements
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01L—SEMICONDUCTOR DEVICES NOT COVERED BY CLASS H10
    • H01L31/00—Semiconductor devices sensitive to infrared radiation, light, electromagnetic radiation of shorter wavelength or corpuscular radiation and specially adapted either for the conversion of the energy of such radiation into electrical energy or for the control of electrical energy by such radiation; Processes or apparatus specially adapted for the manufacture or treatment thereof or of parts thereof; Details thereof
    • H01L31/04—Semiconductor devices sensitive to infrared radiation, light, electromagnetic radiation of shorter wavelength or corpuscular radiation and specially adapted either for the conversion of the energy of such radiation into electrical energy or for the control of electrical energy by such radiation; Processes or apparatus specially adapted for the manufacture or treatment thereof or of parts thereof; Details thereof adapted as photovoltaic [PV] conversion devices
    • H01L31/042—PV modules or arrays of single PV cells
    • H01L31/048—Encapsulation of modules
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01L—SEMICONDUCTOR DEVICES NOT COVERED BY CLASS H10
    • H01L31/00—Semiconductor devices sensitive to infrared radiation, light, electromagnetic radiation of shorter wavelength or corpuscular radiation and specially adapted either for the conversion of the energy of such radiation into electrical energy or for the control of electrical energy by such radiation; Processes or apparatus specially adapted for the manufacture or treatment thereof or of parts thereof; Details thereof
    • H01L31/04—Semiconductor devices sensitive to infrared radiation, light, electromagnetic radiation of shorter wavelength or corpuscular radiation and specially adapted either for the conversion of the energy of such radiation into electrical energy or for the control of electrical energy by such radiation; Processes or apparatus specially adapted for the manufacture or treatment thereof or of parts thereof; Details thereof adapted as photovoltaic [PV] conversion devices
    • H01L31/06—Semiconductor devices sensitive to infrared radiation, light, electromagnetic radiation of shorter wavelength or corpuscular radiation and specially adapted either for the conversion of the energy of such radiation into electrical energy or for the control of electrical energy by such radiation; Processes or apparatus specially adapted for the manufacture or treatment thereof or of parts thereof; Details thereof adapted as photovoltaic [PV] conversion devices characterised by potential barriers
    • H01L31/072—Semiconductor devices sensitive to infrared radiation, light, electromagnetic radiation of shorter wavelength or corpuscular radiation and specially adapted either for the conversion of the energy of such radiation into electrical energy or for the control of electrical energy by such radiation; Processes or apparatus specially adapted for the manufacture or treatment thereof or of parts thereof; Details thereof adapted as photovoltaic [PV] conversion devices characterised by potential barriers the potential barriers being only of the PN heterojunction type
    • H01L31/073—Semiconductor devices sensitive to infrared radiation, light, electromagnetic radiation of shorter wavelength or corpuscular radiation and specially adapted either for the conversion of the energy of such radiation into electrical energy or for the control of electrical energy by such radiation; Processes or apparatus specially adapted for the manufacture or treatment thereof or of parts thereof; Details thereof adapted as photovoltaic [PV] conversion devices characterised by potential barriers the potential barriers being only of the PN heterojunction type comprising only AIIBVI compound semiconductors, e.g. CdS/CdTe solar cells
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
    • Y02E—REDUCTION OF GREENHOUSE GAS [GHG] EMISSIONS, RELATED TO ENERGY GENERATION, TRANSMISSION OR DISTRIBUTION
    • Y02E10/00—Energy generation through renewable energy sources
    • Y02E10/50—Photovoltaic [PV] energy
    • Y02E10/543—Solar cells from Group II-VI materials

Definitions

  • TITLE SYSTEMS AND METHODS FOR IMPROVED PHOTOVOLTAIC MODULE STRUCTURE AND ENCAPSULATION
  • the present invention relates to photovoltaic modules and methods of fabrication. Specifically the present invention relates to a module structure with improved durability to weathering environments, increased safety if broken and reduced manufacturing costs when compared to the current state of the art.
  • Photovoltaic modules convert solar energy into electricity through the photovoltaic effect.
  • photovoltaic modules represent a clean source of renewable energy in a global marketplace dominated by traditional fossil-fuel technologies, such as coal-fired and oil-fired power plants.
  • traditional fossil-fuel technologies such as coal-fired and oil-fired power plants.
  • photovoltaic modules must be manufactured as a commodity in quantities and at costs that are competitive with existing fossil fuel technologies.
  • CdTe photovoltaic module One such photovoltaic module type that satisfies the requirements for commodity manufacturing is the cadmium telluride (CdTe) photovoltaic module.
  • CdTe photovoltaic modules generally take the form of thin film polycrystalline devices in which CdTe layer is paired with a cadmium sulfide (CdS) layer to form a hetero-junction.
  • CdS cadmium sulfide
  • CdS and CdTe thin films can result in thin-film deposition rates ten to one hundred times higher than other suitable deposition techniques.
  • Cadmium sulfide / cadmium telluride solar cells can use up to 100 times less semiconductor material than crystalline silicon devices and can be manufactured less expensively.
  • a process for manufacturing CdS/CdTe modules includes the following steps:
  • Cadmium telluride solar cells can be degraded by prolonged exposure to moisture and require effective encapsulation to remain reliable.
  • CdTe solar cells are deposited on a glass plate with TCO layers.
  • This front substrate also called a superstrate, faces the sun during operation. Light must pass through the superstrate before being absorbed by the photovoltaic structure.
  • This front substrate is also may be referred to as the top plate or top glass.
  • a back substrate is affixed to the rear of the module, sandwiching the photovoltaic structure.
  • the back substrate is often a glass plate which is held to the front substrate with different sealants, glues or polymer lamination films.
  • Back substrate can also be polymer or coated metal. With some module construction methods, particularly those using an edge seal around the module perimeter, an open space or gap between may be present between the front substrate and back substrate. Together the back substrate and the polymer adhesive materials form the encapsulation of the photovoltaic module.
  • CdTe, photovoltaic modules all have limitations in fulfilling requirements described above.
  • the subject invention addresses these limitations, facilitating an increase in reliability and manufacturing efficiency.
  • CdTe photovoltaic modules are constructed with front and back substrates made of glass.
  • the front and back glass are laminated together with an ethylene vinyl acetate (EVA) film sheet of nearly identical size as the glass plates.
  • EVA ethylene vinyl acetate
  • the EVA material has poor moisture vapor transmission properties, allowing moisture to permeate into the modules and contact the photovoltaic structure.
  • the EVA / moisture interaction enables the formation of acetic acid in the EVA. Acetic acid can degrade and corrode the photovoltaic structure.
  • strips of lower moisture vapor transmission materials are laminated around the perimeter of the module to reduce moisture ingress. These materials often contain butyl rubber and desiccants.
  • This method is an improvement on EVA only encapsulation and is used in commercial application by companies such as First Solar.
  • This method still has limitations. Gaps can be present where the strips join each other.
  • the strip material does not bond as effectively to the glass as EVA and may have bubbles or voids which can facilitate moisture entry into the EVA.
  • the strips may have a lower moisture vapor transmission than the EVA but moisture ingress is not eliminated.
  • the strip material may also degrade due to UV radiation further enabling moisture ingress. When moisture does enter into the panel either through a gap, breach, permeation or strip degradation, the photovoltaic structure will be degraded and corroded by acetic acid.
  • EVA lamination is a time consuming, batch type manufacturing process.
  • EVA lamination process includes the following manufacturing steps: 1) first the EVA material is cut and is laid on the front glass plates; 2) the strip seals are carefully positioned; 3) the back glass plate is placed on the stack; 4) this stack is then placed in a lamination machine; 5) vacuum to remove entrapped air; 6) the stack is heated to soften the EVA and initiate cross linking; and 7) pressure is applied to the stack.
  • the vacuum / heat / pressure lamination cycle can take 15 to 20 minutes. In order to maintain production throughput, large vacuum laminators are required. These require significant factory floor space and are expensive.
  • Albright et al. describes methods for photovoltaic module encapsulation in US patent 5,460,660.
  • a series of designs are shown in which a photovoltaic module is supported in a complex frame and channel arrangement.
  • a front glass plate containing the photovoltaic structure is paired with another back substrate, most often glass.
  • Edge seals are present around the perimeter of the module to impede moisture ingress.
  • a gap exists between the front substrate and back substrate.
  • Desiccant is present between the front and back substrate, completely filling the gap between the sheets in some embodiments.
  • Panel frame and channel supports are provided to absorb vertical forces and impacts.
  • polymer bumpers are disposed between the glass plates to absorb impact.
  • Oswald describes methods for photovoltaic module encapsulation in US patent application US 2003/0116185 Al.
  • the front and back substrate are separated by perimeter edge seals to form the photovoltaic module.
  • a photovoltaic element is exposed to the internal volume which could be desiccated.
  • Oswald teaches that the thin film photovoltaic material is not to be covered or protected inside the sealed volume between the front and back substrate.
  • the module structure described by Oswald has significant limitations.
  • the gap between the front and back substrate will cause elevated module operating temperatures in a manner similar to an insulated glass window. No means are provided to facilitate thermal conduction between the front and back substrate to lower the operating temperature. If desiccants are disposed in the regions between the front and back substrate, no means of holding or containing the desiccant is described.
  • the lack of internal structures between the front and back substrate will leave the module susceptible to breakage by impact or other mechanical loading.
  • the module design taught in this application is particularly susceptible to ejecting large glass shards and exposing internal structures at elevated voltage upon breakage.
  • a border seal containing desiccant is used to seal front and back glass plates. This seal material is placed around the perimeter, just inboard of the glass edge. An adhesive is placed around the perimeter between the glass edge and the sealant. Blieske et al. further describe that a liquid casting material can be injected in the gap between the glass plates through tubes.
  • the module structure described by Blieske has significant limitations. If the optional casting resin is not used, the module will operate at elevated temperatures in a manner similar to an insulated glass window. Without the optional casting resin, large glass shards could be ejected and high voltage regions exposed if the module is broken.
  • the casting resin will require additional curing in an autoclave.
  • the autoclave cure is a batch process which adds further complexity, inefficiency and cost to the manufacturing process.
  • Adding desiccant to the border seal is unnecessarily complex and could compromise adhesion. Desiccant can be more easily and less expensively placed inside the module. Moisture can penetrate into the module through areas other than the edge, for example, through the back electrical box. If casing resins are used, this moisture will not be readily absorbed by the desiccant in the perimeter seal and will remain to damage the module.
  • the present invention can provide a system and method for improved photovoltaic module structure and encapsulation.
  • the present invention can include a photovoltaic module, comprising a front substrate, a photovoltaic structure attached to the front substrate, wherein the photovoltaic structure comprises at least one photovoltaic cell, and a membrane, wherein the membrane and the front substrate substantially encapsulate the photovoltaic structure.
  • the present invention can include a method for making a photovoltaic module, the method comprising forming a photovoltaic structure on a front substrate, wherein the photovoltaic structure comprises at least one photovoltaic cell, and applying a membrane on the photovoltaic structure, wherein the membrane and the front substrate substantially encapsulate the photovoltaic structure.
  • the present invention can include a photovoltaic module comprising a front substrate, the photovoltaic structure attached to the front substrate, the photovoltaic structure comprising a first edge and a second edge, a buss bar assembly, and a membrane, wherein the membrane is configured to permit the buss bar assembly to connect to the photovoltaic structure at the first edge and the second edge, and wherein the membrane and the front substrate encapsulate the remaining portion of the photovoltaic structure.
  • the present invention can also provide a system and method for improved photovoltaic module structure.
  • the present invention can include a photovoltaic module comprising a front substrate, a photovoltaic structure attached to the front substrate, wherein the photovoltaic structure comprises at least one photovoltaic cell, a back substrate, wherein the back substrate is spaced apart from the photovoltaic structure, and a structural component, wherein the structural component is located between the back substrate and the photovoltaic structure.
  • the structural component may comprise ribbing, foam (e.g., porous foam, corrugated foam, embossed foam, a high density foam, etc.), and/or a solid interlayer.
  • the structural component is configured to connect to at least one of the front substrate and the back substrate. In some embodiments, the structural component is configured to provide thermal conduction between the front substrate and the back substrate, and/or the structural component is configured to retain the front substrate and/or back substrate during breakage.
  • the present invention can include a method for making a photovoltaic module, the method comprising forming a photovoltaic structure on a front substrate, wherein the photovoltaic structure comprises at least one photovoltaic cell, positioning a structural component between the photovoltaic structure and a back substrate, and connecting the back substrate with the front substrate using a seal, wherein the structural component is configured to provide distributed thermal conduction from the front substrate to the back substrate.
  • the present invention can include a photovoltaic module comprising a front substrate, a photovoltaic structure attached to the front substrate, a back substrate, wherein the back substrate is spaced apart from the photovoltaic structure to form a gap, and a structural component, wherein the structural component spans the gap between back substrate and the photovoltaic structure.
  • Table 1 lists the drawing reference numbers for the components which are incorporated herein and form a part of the specification.
  • Level 1 indicates a component group.
  • Level 2 indicates a sub-component of the group.
  • Level 3 indicates a specified component part.
  • a Level 1 (XOOO) indicator represents all sublevel components.
  • like reference numbers can indicate identical or functionally similar elements.
  • FIGURE 1 Basic Module
  • FIGURE 2 Basic Module Exploded View
  • FIGURE 3 Buss Collector Configuration Detailed View
  • FIGURE 4 Buss Collector Configuration Top View
  • FIGURE 5 Insulated Buss Assembly Detailed View
  • FIGURE 6 Insulated Buss Assembly Exploded View
  • FIGURE 7 Dual Seal Detailed View
  • FIGURE 8 Dual Seal Exploded View
  • FIGURE 9 Single Undercoat Membrane Module
  • FIGURE 10 Single Undercoat Membrane Module Exploded View
  • FIGURE 11 Single Overcoat Membrane Module
  • FIGURE 12 Single Overcoat Membrane Module Exploded View
  • FIGURE 13 Dual Coat Membrane Module
  • FIGURE 14 Dual Coat Membrane Module Exploded View
  • FIGURE 15 Reinforced Membrane Module
  • FIGURE 16 Reinforced Membrane Module Exploded View
  • FIGURE 17 Reinforced Mesh Module
  • FIGURE 18 Reinforced Mesh Module Exploded View
  • FIGURE 19 Filled Membrane Module
  • FIGURE 20 Filled Membrane Module Exploded View
  • FIGURE 21 Ribbed Module
  • FIGURE 22 Ribbed Module Exploded View
  • FIGURE 23 Reinforced Ribbed Module
  • FIGURE 24 Reinforced Ribbed Module Exploded View
  • FIGURE 25 Retention Tape Module
  • FIGURE 26 Retention Tape Module Exploded View
  • FIGURE 27 Retention Tape Horizontal Module
  • FIGURE 28 Retention Tape Horizontal Module Exploded View
  • FIGURE 29 Retention Tape Vertical Module
  • FIGURE 30 Retention Tape Vertical Module Exploded View
  • FIGURE 31 Interlayer Foam Module
  • FIGURE 32 Interlayer Foam Module Exploded View
  • FIGURE 33 Interlayer Structural Module
  • FIGURE 34 Interlayer Structural Module Exploded View
  • FIGURE 35 Interlayer Solid Module
  • FIGURE 36 Interlayer Solid Module Exploded View
  • the present invention describes encapsulation systems and methods for photovoltaic devices and improved module structures and methods for photovoltaic devices.
  • Embodiments include photovoltaic encapsulation methods which incorporate a membrane (6000) positioned between a front substrate (1000) and back substrate (2000).
  • the membrane (6000) can have a number of attributes which increase the photovoltaic module's reliability, performance and safety while minimizing cost and fabrication complexity.
  • other structures such as a reinforcing scrim sheets (7100), mesh fibers (7200) or ribbing (8000), can be added between the front substrate (1000) and back substrate (2000) to improve the photovoltaic module's reliability, performance and safety.
  • additional structure(s) such as scrim sheets, mesh and fibers, can be incorporated into the membrane (6000), or separately positioned between the front substrate (1000) and back substrate (2000) to achieve various benefits.
  • the membrane (6000) can improve safety by helping prevent large shards of glass from being ejected from the module if breakage occurs. This is, at least in part, because the membrane (6000), and/or structural components, such as ribbing (8000) or interlayers (10000), may be connected with the front substrate (1000) and/or back substrate (2000). If breakage occurs, the broken pieces of the front substrate (1000) and/or back substrate (2000) are retained with the module's structure by the adhesive bond between the front substrate (1000) and/or back substrate (2000) and the membrane (6000) and/or other structural components.
  • the membrane (6000) and other structural components may be used in combination or separately.
  • a membrane (6000) may be adhered to the semiconductor photovoltaic structure (4000) formed on the front substrate (1000). If the front substrate (1000) should break, the membrane (6000) would add additional structure to retain the broken pieces of the photovoltaic structure (4000), and the front substrate (1000) upon which the photovoltaic structure (4000) is formed.
  • additional structural components could be connected with the membrane (6000) and the back substrate (2000).
  • additional structures could be connected with the photovoltaic structure (4000) and back substrate (2000).
  • the additional structural components could be directly connected to or adhered to the semiconductor photovoltaic structure (4000) and back substrate (2000) or the additional structural components could be connected with the photovoltaic structure (4000), front substrate (1000) and back substrate (2000) through other elements. These additional connections improve structural integrity and assist in retaining pieces of the module if breakage occurs. Moreover, these additional structural components can also help prevent the loss of photovoltaic structure (4000) pieces coated with heavy-metal-containing materials, such as cadmium from the CdTe films.
  • Additional benefits of the present invention include the following: 1) protection of the back electrode metallization during module manufacturing and from potential contact with the back substrate (2000) under mechanical loading; 2) reinforcement of the buss bar assembly (5000), including buss tape adhesive junctions, preventing the buss- junctions from de-bonding; 3) providing an additional barrier against moisture vapor permeation to the photovoltaic structure (4000); 4) providing additional electrical insulation, 5) providing a desiccating medium to absorb moisture permeating through a seal between the front substrate (1000) and back substrate (2000); 6) providing added structural robustness to the module; 7) providing added thermal conduction through the interior of the module to reduce module temperature for improved module performance; and 8) improving overall module performance without significant cost or weight increases.
  • Membrane (6000) should be formed using materials with suitable mechanical properties for the planned implementation. Mechanical properties to consider include structural stability, shock absorption, and the ability to retain broken pieces and prevent them from being ejected if module breakage occurs. Other material properties of a membrane (6000), such as electrical insulation, thermal conduction, and the ability to resist vapor permeation are also important. Moreover, in addition to the properties of the formed membrane (6000), it is also important to consider material properties that affect the ability to properly form the membrane (6000) over the photovoltaic structure (4000). Those of skill in the art will be readily aware of membrane (6000) materials consistent with the present invention.
  • the membrane (6000) may comprise a conformal polymer material.
  • the membrane (6000) may be comprised of a conformal film or coating.
  • a conformal coating may be used to achieve advantages in module performance as well as module production efficiency.
  • a conformal coating membrane (6000) protects the photovoltaic structure (4000).
  • the membrane (6000) prevents damage to the fragile photovoltaic structure (4000).
  • the conformal coating provides beneficial structural and electrical properties to protect the photovoltaic structure (4000) improving on the reliability of the module.
  • the membrane (6000) may be comprised of a thermoplastic material.
  • the membrane (6000) may be comprised of a thermosetting material that is, for example, cured using chemical additives, ultraviolet radiation, electron beam or heat.
  • the membrane (6000) may be comprised of an elastic material, such as a thermosetting elastomer or a thermoplastic elastomer.
  • the membrane (6000) may be comprised of an urethane acetate, a thermally cured acrylic, a silicone RTV, and/or an epoxy.
  • the membrane (6000) material selected may depend on many various factors readily understood by those of skill in the art, including, but not limited to, the material properties of the photovoltaic structure (4000), the other structural properties of the module, processing conditions, the environment in which the photovoltaic module will be used, cost, etc. For example, in order to improve takt time an UV curable urethane acetate may be used to form the membrane (6000).
  • the membrane (6000) may be formed of an elastic material to add additional shock absorbing capability to the module.
  • an elastic material for example, many elastomeric polymers can undergo significant elongation under stress before failure.
  • the elastic membrane could be applied directly to the back metal electrode of the photovoltaic structure (4000).
  • the ability of the elastic membrane (6000) to flex during impact allows for some absorption of the impact load.
  • Reinforcement materials could be utilized to provide an added degree of strength to the membrane (6000).
  • a silicone based conformal membrane (6000) could be put down in a soft thick coat.
  • a membrane (6000) can also provide a resilient surface which protects the photovoltaic structure (4000) during production, storage, transportation and end usage.
  • the membrane (6000) adds durability for the photovoltaic module and adds an additional barrier to moisture permeation by substantially encapsulating the photovoltaic structure (4000).
  • the membrane (6000) also aids in the electrical isolation of the scribe lines for the series interconnected photovoltaic cells of the thin film photovoltaic structure (4000).
  • FIG. 1 A possible embodiment of the basic structure of a photovoltaic module is represented in Figure 1 in which the photovoltaic is connected through a buss bar assembly (5000) to an exterior connection.
  • FIG 2. An exploded view of a basic module construction is shown in Figure 2.
  • a photovoltaic structure (4000) is formed on a front substrate (1000).
  • a buss bar assembly (5000) connects the photovoltaic structure (4000) to the exterior of the module.
  • the buss bar assembly (5000) is made up of buss bar collectors (5100) attached to the leading and final edge cells of the photovoltaic series and terminating at the buss assembly connection (5200).
  • the buss bar assembly (5000) is insulated from the remaining photovoltaic cells by a buss assembly insulator (5300).
  • a detail of a possible buss bar collector configuration (5100) is illustrated in Figure 3 and in the top view of the collectors in Figure 4.
  • the buss bar collectors configuration (5100) is made up of four sections: the anode edge collector buss (5110) and cathode edge collector buss (5120) are connected to the edge cells of the photovoltaic structure (4000).
  • the anode edge collector buss (5110) is connected to the anode central main buss (5130) and cathode edge collector buss (5120) is connected to the cathode central main buss (5140).
  • Figure 5 depicts one embodiment of how the buss bar collectors (5100) are incorporated into buss bar assembly (5000). As illustrated in the exploded view of the buss bar assembly (5000), Figure 6, the anode central main buss (5130) and cathode central main buss (5140) terminate at the buss assembly connection (5200) to allow connection to an exterior wiring system (not shown).
  • the buss assembly connection (5200) provides current to a back box (not shown) and external wires (not shown).
  • the anode central main buss (5130) and cathode central main buss (5140) are insulated from the interior cells of the photovoltaic structure (4000) by a buss assembly insulator (5300).
  • the buss assembly insulator (5300) could be an insulating tape strip applied to the photovoltaic structure (4000).
  • the buss assembly insulator (5300) could be applied to the surface of the anode central main bus line (5130) and cathode central main buss line (5140) facing the photovoltaic structure (4000).
  • FIG. 7 illustrates a dual seal configuration consisting of an inner moisture vapor barrier seal (3100) and an outer liquid barrier edge seal (3200) as denoted in the exploded view in Figure 8.
  • One embodiment of a dual seal configuration would consist of a Polyisobutylene moisture barrier with a silicone edge seal.
  • connection seal (3300) that seals the buss connection.
  • the connection seal could be also a Polyisobutylene moisture barrier if a liquid barrier such as silicone is used to seal subsequent back box connection.
  • the membrane (6000) can be applied prior to or after the application of the buss bar assembly (5000). If applied prior to the buss bar assembly (5000), the membrane (6000) can assist or substitute for the insulation of the central main buss collectors (5130, 5140) from the interior cells of the module. If applied after the application of the buss bar assembly (5000), the membrane (6000) electrically insulates all conductive regions in the module except for the buss assembly insulator (5300), adding additional safety.
  • An embodiment comprising an electrically insulating membrane (6000) could also enable the use of a low cost polymer back sheet or a metal back sheet.
  • Figure 9 illustrates an exterior view of one embodiment of the invention using a single membrane module construction in which an undercoat membrane (6100) is applied prior to the buss bar assembly (5000).
  • An exploded view of a single undercoat membrane (6100) construction is shown in Figure 10.
  • a photovoltaic structure (4000) is formed on a front substrate (1000).
  • the undercoat membrane (6100) is applied prior to the basic module buss bar assembly (5000) and substantially encapsulates the photovoltaic structure (4000) by covering at least a majority of the interior cells of the module.
  • the photovoltaic structure (4000) is connected to an anode edge collector buss (5110) and cathode edge collector buss (5120) of the buss bar assembly (5000).
  • the undercoat membrane (6100) cannot cover the edge cells to which the edge collector buss (5110, 5120) must attach or the buss bar assembly would be insulated from the photovoltaic.
  • the anode central main buss (5130) and cathode central main buss (5140) are connected to the anode edge collector buss (5110) and cathode edge collector buss (5120), respectively.
  • the central main busses are routed across the undercoat membrane (6100) and are further connected to a buss assembly connection (5200).
  • the anode central main buss (5130) and cathode central main buss (5140) are insulated from the photovoltaic structure (4000) by a buss assembly insulator (5300).
  • the buss assembly insulator (5300) could be an insulating tape strip applied to the photovoltaic structure (4000).
  • the buss assembly insulator (5300) could be applied to the surface of the anode central main buss line (5130) and cathode central main buss line (5140) facing the photovoltaic structure (4000).
  • buss assembly insulator (5300) could be omitted in embodiments in which the undercoat membrane (6100) is sufficient to insulate the anode and cathode central main collectors without the added insulation provided by the insulating tape.
  • Figure 11 illustrates an exterior view of one embodiment of the invention using a single membrane module construction in which an overcoat membrane (6200) is applied after the buss bar assembly (5000).
  • a photovoltaic structure (4000) is formed on a front substrate (1000).
  • the two outer edge cells of the photovoltaic structure (4000) are connected to an anode edge collector buss (5110) and a cathode edge collector buss (5120) of a buss bar assembly (5000).
  • the anode edge collector buss (5110) and cathode edge collector buss (5120) are connected to an anode central main buss (5130) and a cathode central main buss (5140), respectively, which are further connected to a buss assembly connection (5200).
  • the anode central main buss (5130) and cathode central main buss (5140) are insulated from the photovoltaic structure (4000) by a buss assembly insulator (5300).
  • the buss assembly insulator (5300) could be an insulating tape strip applied to the photovoltaic structure (4000).
  • the buss assembly insulator (5300) could be applied to the surface of the anode central main buss (5130) and cathode central main buss (5140) facing the photovoltaic structure (4000).
  • the buss assembly insulator (5300) is required in single overcoat embodiments of the invention since the membrane is not placed under the anode central main buss (5130) and the cathode central main buss (5140) and cannot provide insulation of the interior cells of the photovoltaic from the buss assembly.
  • the overcoat membrane (6200) covers the entire photovoltaic structure (4000) along with the complete buss bar assembly (5000) except for the buss assembly connection (5200), which remain uncoated to allow for external connection.
  • the buss bar assembly (5000) and photovoltaic structure (4000) are substantially encapsulated within a membrane overcoat (6200).
  • the impressions of the buss bar assembly (5000) are shown in the conforming membrane overcoat (6200).
  • An external seal assembly (3000) attaches the back substrate (2000) to the front substrate (1000).
  • the external seal assembly (3000) comprises a dual seal, including a vapor barrier (3100) of butyl rubber or Polyisobutylene and edge seal (3200) of silicone, along with a butyl rubber or Polyisobutylene connection seal (3300).
  • this seal arrangement creates an interior gap between the overcoat membrane coat (6200) and the back substrate (2000).
  • the overcoat membrane (6200) can be desiccated to absorb moisture permeating through the external seal assembly (3000).
  • the use of a dual seal arrangement is exemplary only and not intended to limit the present invention. Those skilled in the are will be readily aware that other sealing arrangements could be used consistent with the present invention.
  • a membrane coating (6000) can be applied both before and after the application of the anode and cathode busses.
  • Figure 13 illustrates an exterior view of one embodiment of the invention using dual membrane module construction.
  • Figure 14 shows an exploded view of a dual membrane construction.
  • FIG. 14 a photovoltaic structure (4000) is formed on a front substrate (1000). Adjacent to the photovoltaic structure (4000) is an initial undercoat membrane (6100) which substantially encapsulates the photovoltaic structure (4000) by covering the interior portion of the photovoltaic structure (4000) prior to application of the buss bar assembly (5000). The portions of the photovoltaic structure (4000) to which the anode and cathode edge collector busses (5110 and 5120) are to be attached are left uncoated.
  • the initial undercoat membrane (6100) is applied prior to the buss bar assembly (5000) in order to both generally protect the photovoltaic structure (4000) and to insulate the photovoltaic structure (4000) from the anode central main buss (5130) and the cathode central main buss (5140).
  • the buss bar assembly (5000) and photovoltaic structure (4000) are further encased within an overcoat membrane (6200) to add further protection to the photovoltaic structure (4000) and to protect the buss bar assembly (5000).
  • the impressions of the buss bar assembly (5000) are shown in the conforming membrane overcoat (6200).
  • a secondary overcoat membrane (6200), applied after the buss bar assembly (5000), encapsulates and protects the electrical connections to the device.
  • the buss assembly connection (5200) cannot be fully encapsulated for connection to a back electrical box (not shown). In some embodiments, the buss assembly connection (5200) will not be encapsulated by the overcoat membrane (6200).
  • buss assembly connection (5200) may be encapsulated by the overcoat membrane (6200) for transport and assembly, but the portion of the overcoat membrane (6200) on the buss assembly connection (5200) is removed at some point before use. Variations and modifications consistent with present invention will be known to those of skill in the art.
  • one or both of the membrane coatings (6100, 6200) can be desiccated to absorb moisture permeating through the external seal assembly (3000) over the life of the module.
  • the two membrane coats (6100, 6200) can be of the same material or different materials in order to provide a combination of physical properties.
  • two polymers with differing chemistry may be used.
  • a secondary polymer elastic overcoat membrane (6200) could be used in conjunction with an initial conformal undercoat membrane (6100).
  • the initial undercoat membrane (6100) insulates the busses from the back electrode metallization on the photovoltaic structure (4000). Moreover, two applications of membrane material, both before and after the buss bar assembly (5000) application, incorporate the benefits of each of the separate applications.
  • a protective membrane (6000) applied over the photovoltaic structure (4000) prevents damage to the photovoltaic structure (4000) during subsequent module manufacturing processes.
  • the membrane (6000) physically protects the photovoltaic structure (4000) and adds a barrier against moisture ingress.
  • This membrane (6000) also encapsulates any heavy-metal-bearing material, such as CdTe, within the module. This further contains the heavy metal and helps prevent subsequent exposure to the heavy metals if the module is compromised.
  • the addition of the membrane (6000) also improves electrical safety. Only a thin edge of the photovoltaic structure (4000) will be exposed upon module breakage.
  • the module (6000) provides electrical isolation from the back electrode metallization and buss bar collectors (5100) surfaces.
  • the undercoat membrane (6100) can be applied after the final isolation scribe of the photovoltaic structure (4000).
  • the undercoat membrane (6100) could fill in the scribed regions preventing contamination of the scribe lines and possible shorting of the module.
  • the membrane coat(s) (6100 and/or 6200) could be applied using a number of acceptable methods. Application methods include brushing, spraying, precision spray, stenciling, screening, printing, vapor deposition, adhering, rolling or squeegee. Each membrane coat (6100, 6200) could be applied using the same application method, or the application method may vary between membrane coats.
  • the initial undercoat membrane (6100) may be applied using squeegee while the overcoat membrane (6200) may be applied using spraying.
  • the membrane (6000) is formed by combining the membrane (6000) with membrane reinforcement (7000) such as a mesh or scrim layer.
  • membrane reinforcement (7000) is applied between coats (e.g., 6100 and 6200) of the membrane (6000) or embedded within an individual layer of the membrane (6000).
  • the membrane reinforcement (7000) can be used in conjunction with a membrane (6000) comprising various material properties (e.g., conformal coatings, elastomeric polymers, thermosets, etc.).
  • the addition of the membrane reinforcement (7000) enables a stronger layer of protection for the photovoltaic structure (4000), greater reinforcement of the photovoltaic module, and facilitates retention of the front substrate (1000) and back substrate (2000) on breakage.
  • the reinforcement (7000) also constrains the membrane to alleviate thermal coefficient mismatch induced stresses in the photovoltaic structure.
  • the membrane reinforcement (7000) could take the form of a mesh (7200) or scrim materials (7100).
  • the membrane reinforcement (7000) could be comprised of fibers, strips, bands or thin rods and could be in a woven, uniaxial or random orientation in the module. Polymers or fine glass fibers are the preferred materials for constructing the membrane reinforcement (7000). Electrically conductive materials such as metals could cause arcing across the buss and back metal electrode.
  • a photovoltaic module with a reinforced membrane e.g.,
  • an undercoat membrane (6100) would be applied over the photovoltaic structure (4000).
  • the undercoat membrane (6100) is followed by the attachment of the collector buss to the anode and cathode cells.
  • the buss which run perpendicular to the interconnection scribing and which carry current to the back box and external wires are laid over the undercoat membrane (6100).
  • the undercoat membrane (6100) acts as an electrical insulator between the photovoltaic structure's (4000) back metal electrode and the buss bar assembly (5000).
  • the attachment of the buss is followed by the application of a layer of membrane reinforcement (7000) that is subsequently covered in a overcoat membrane (6200).
  • the overcoat membrane (6200) adds to the encapsulation of the photovoltaic structure (4000) and also encapsulates the buss bar assembly (5000).
  • the composite membrane (6100, 7000, 6200) provides structural reinforcement to the front substrate (1000) on breakage.
  • the subsequent back substrate (2000) and external seal assembly (3000) application are added for additional module structural strength and environmental protection.
  • Figure 15 illustrates an exterior view of one embodiment of the invention using a reinforced dual membrane module construction in which a membrane reinforcement (7000) component is used to aid in retaining the front substrate (1000) if breakage occurs.
  • the exploded view of the reinforced dual membrane construction shows an exploded view of a reinforced dual membrane construction in which the module is constructed as in dual membrane construction with a scrim sheet reinforcement (7100) placed between the undercoat membrane (6100) and overcoat membrane (6200) coats. The impressions of the buss bar assembly (5000) are shown in the conforming membrane overcoat (6200).
  • the reinforcement scrim sheet reinforcement (7100) can be placed prior to or after the buss bar assembly (5000).
  • Figure 16 depicts the scrim sheet reinforcement (7100) being placed after the buss bar assembly (5000).
  • Figure 17 shows an exterior view of one embodiment of the invention using a mesh reinforced dual membrane module construction in which a mesh sheet reinforcement (7200) is used in lieu of the scrim sheet reinforcement (7100).
  • Figure 18 illustrates an exploded view of a mesh reinforced dual membrane construction in which the module is constructed as in dual membrane construction with a mesh sheet reinforcement (7200) placed between the undercoat membrane (6100) and overcoat membrane (6200). The impressions of the buss bar assembly (5000) are shown in the conforming membrane overcoat (6200). The mesh sheet reinforcement (7200) can be placed prior to or after the buss bar assembly (5000). Figure 18 depicts the mesh sheet reinforcement (7200) being placed after the buss bar assembly (5000).
  • the membrane (6000) could be mixed with fine pieces of a membrane reinforcement (7000) material and the combination applied. Mixing fine pieces of membrane reinforcement (7000) with the membrane (6000) reduces the steps required during production and provides a greater degree of engineering properties to be designed into the composite membrane.
  • Figure 19 illustrates an exterior view of one embodiment of the invention using fiber filled reinforced dual membrane module construction in which the overcoat membrane (6200) is impregnated with a scrim impregnated reinforcement (7300).
  • the exploded view of the construction in Figure 20 shows a dual membrane construction with the overcoat membrane (6200) with a scrim impregnated reinforcement (7300).
  • a structural component such as polymer ribbing (8000) is incorporated between the module back substrate (2000) and the photovoltaic structure (4000). These ribbed element(s) (8000) are spread periodically across the area of the module.
  • FIG 21 shows an exterior view of one embodiment of the invention using a ribbed membrane module construction.
  • These ribbed elements (8000) perform a number of functions including reducing the module operating temperature by increasing thermal heat transfer from the front substrate (1000), which is exposed to the sun, to the back substrate (2000). Additional module strength is achieved through the use of structural polymer ribbing (8000).
  • the ribbing (8000) spans the gap between the photovoltaic structure (4000), membrane (6000) (whether conformal coatings or elastic membranes) and back substrate (2000). In doing so, the ribbing (8000) provides distribution of the module loading between the front substrate (1000) and back substrate (2000).
  • the external seal assembly (3000) dual seal module is able to take on the mechanical characteristics of a laminated structure.
  • the polymer ribbing (8000) could be applied over the module busses to maintain buss adhesion and prevent debonding of the buss from the metallization. Placement of the ribbing over the connection between the edge and central busses adds to the integrity of the junction.
  • Figure 22 shows an exploded view of a ribbed construction in which the module is constructed as in the single or dual membrane construction with polymer ribs (8000) placed between the membrane (6000) and the back sheet (2000).
  • the ribbing (8000) provides a conductive thermal path between the front substrate (1000) and back substrate (2000) of the module and provides structural support in the gap between the front and back of the module.
  • the ribbing material In order to achieve the mechanical and thermal benefits from the polymer ribbing (8000), the ribbing material must be compliant - conforming to both surfaces of the module when the back substrate (2000) is assembled to the module structure. It is beneficial that the ribbing (8000) have some bonding with the adjoining surfaces and that that the ribbing (8000) material compresses to ensure an intimate contact when the back substrate (2000) is assembled to the module.
  • the structural ribbing (8000) can be composed of the same polymer as the vapor barrier (3100), of the dual edge seal, to facilitate manufacturing.
  • Compliant material may not sufficiently assist in the retention of the front substrate (1000) and back substrate (2000) on breakage.
  • reinforced conformal and elastic membrane constructions can be used to provide additional substrate (1000, 2000) retention capability.
  • An exterior view of one embodiment of the invention using reinforced ribbed membrane module construction is shown in Figure 23.
  • Figure 24 shows an exploded view of a reinforced ribbed construction in which the module is constructed with a membrane reinforcement construction (7000) with polymer ribs (8000) placed between the membrane (6000) and the back substrate (2000). It will be understood by those of skill in the art that the membrane (6000) does not have to be included.
  • the ribbing (8000) provides a conductive thermal path between the front substrate (1000) and back substrate (2000) of the module as well as provides structural support in the gap between the front and back of the module.
  • the ribbing (8000) will provide thermal conduction paths distributed across the internal surfaces of the front (1000) and back (2000) substrates.
  • the ribbing (8000) can be arrayed periodically over the photovoltaic structure (4000) in order to provide distributed conduction paths from the front substrate (1000), through the photovoltaic structure (4000), through the ribbing (8000) and to the back substrate (2000).
  • the ribbing can also be connected with (directly or indirectly) with the front substrate (1000) and back substrate (2000) to assist in retention of pieces during breakage.
  • a ribbing (8000) that is arrayed periodically it will assist in retaining pieces across the entire surfaces of the front substrate (1000) and back substrate (2000).
  • Either the ribbing (8000) or membrane (6000), or both, can be desiccated to absorb moisture permeating through the exterior seal assembly (3000) over the life of the module.
  • a polymer ribbing (8000) material can contain desiccant to protect the photovoltaic structure (4000) from moisture damage. Since the ribbing (8000) has a high surface area it provides additional moisture absorption capability.
  • the structural nature of the ribbing (8000) provides benefits over a loose desiccant between the front substrate (1000) and back substrate (2000).
  • the moisture will cause the loose desiccant to clump.
  • the clumps can contact portions of the buss bar assembly (5000) or the photovoltaic structure (4000) and cause a short.
  • the desiccant is incorporated with a structural component such as the ribbing (8000) it can help eliminate the problems caused by the loose desiccant.
  • a desiccated member within the module structure provides for absorption of moisture permeating through the external seal assembly (3000) over the life of the module.
  • the amount of desiccant required is dependent on the permeability of the external seal assembly (3000) and the desired life of the module.
  • module desiccation can be obtained by incorporating desiccant into the ribbing (8000) and/or adding desiccant to the membrane (6000). Since the materials selected for the membrane (6000) may be different than those selected for the edge seal (3200) and vapor barrier (3100), the membrane (6000) material may have a different permeability than the edge seal (3200) and vapor barrier (3100) material. Desiccation of these layers is done depending on their level of permeability.
  • a retention sheet (9000) of suitable properties may be used in conjunction with, instead of, or as the membrane (6000) to promote retention of the front substrate (1000) and back substrate (2000) if the module breaks.
  • the retention sheet (9000) is a polymer sheet that may be used in conjunction with an undercoat membrane (6100) or overcoat membrane (6200), such as a conformal polymer coat.
  • an undercoat membrane (6100) is comprised of a more brittle material
  • a retention sheet (9000) may be used as the overcoat membrane (6200) added to aid retention of broken pieces should breakage occur.
  • a retention sheet (9000) allows for a broader range of membrane (6000) materials to be used while still providing the advantages of piece retention when a module breaks.
  • the functionality of the undercoat membrane (6100) or the overcoat membrane (6200) or both membranes could be performed by one or more retention sheets (9000) used in lieu of the undercoat membrane (6100) or the overcoat membrane (6200).
  • the retention sheet (9000) may be unrolled and applied (e.g., adhered) to cover the photovoltaic structure (4000).
  • the retention sheet (9000) may be a retention tape sheet (9100).
  • These retention tape sheet(s) (9100) can be comprised of thin polymer film(s) with adhesive on one side. These retention tape sheets (9100) can retain glass shards upon module breakage and protect the photovoltaic structure (4000) from abrasion during manufacturing and module usage.
  • the retention sheet (9000) could be applied directly to the photovoltaic structure's (4000) back metal electrode.
  • the retention sheet(s) (9000) can be applied on top of either the undercoat membrane (6100) or overcoat membrane (6200), or both.
  • the retention sheet (9000) could be applied in the form of single sheet that substantially covers and encapsulates the photovoltaic structure's (4000) surface by covering at least a majority of the photovoltaic cells.
  • the retention sheet (9000) could be in the form of a simple film with adhesive on one side, such as those available from 3M, Poli-Film and Mitsubishi.
  • the retention sheet (9000) could be reinforced with fibers to increase strength.
  • the retention sheet (9000) may be comprised of polymer materials such as polyethylenes, polyesters, polyurethanes, and paper with suitable dielectric properties, such as those used in transformer windings.
  • the retention sheet (9000) may be used adjacent to the buss bar assembly (5000).
  • FIG. 25 illustrated is an exterior view of one embodiment of the invention using ribbed module construction in which a retention tape sheet (9100) is used to retain the front and back substrates (1000, 2000) on breakage.
  • Figure 26 shows an exploded view of a tape retention construction in which the retention tape sheet (9100) is placed upon the membrane (6000).
  • the retention tape sheet (9100) does not fill the gap between the front and back of the module.
  • Ribbing (8000) may be employed to span, and in some cases fill, this gap and to provide thermal and structural support.
  • a ribbing (8000) can be used in conjunction with a membrane (6000), membrane reinforcement (7000), and retention sheet (9000). In other embodiments, one or more of those elements will not be used.
  • the ribbing (8000) would be the last of these materials applied in sequence, and would be applied on top of these other elements.
  • Figure 28 shows an exploded view of a parallel strip construction in which the retention tape strips (9200) are placed upon the membrane (6000) parallel to the buss alignment.
  • the retention tape strips (9200) take the form of polymer tape strips which are placed periodically or in a pattern suitable to retain glass shards under module breakage. In addition to a material savings, using retention tape strips (9200) enables the use of readily available tape dispensing machines for application.
  • Figure 29 shows a ribbed module construction in which retention tape strips
  • FIG. 30 shows the retention tape strips (9200) placed upon the membrane (6000) perpendicular to the edge buss alignment.
  • the retention tape strips (9200) can be placed in a preferential orientation or orientations to the plane of the buss as a series of strips or an interlacing of strips.
  • a foam interlay er (10100) structural component can be used to provide a light weight, uniform filler for the air space inside the module, adjacent to the back substrate (2000).
  • An adhesive may be used to adhere the foam to the inner module structure.
  • the foam interlayer (10100) may be a porous foam that can be sheathed with sheets of adhesive bearing materials or adhesive can be spray applied to allow even better adhesion of the foam.
  • the adhesive may be the retention tape sheet (9100) or retention tape strips (9200).
  • the foam interlayer (10100) converts the dual seal module into a structure that has similar mechanical and thermal properties as a laminated module.
  • the foam interlayer (10100) provides uniform load dissipation through the module with minimal added weight and provides substantially uniform thermal conduction between the front substrate (1000) and back substrate (2000) surfaces, lowering module operating temperatures.
  • the foam interlayer (10100) can provide substantially uniform thermal conduction by distributing the thermal conduction over the entire surfaces of the front (1000) and back substrates (2000). When adhered, the foam interlayer (10100) provides additional retention for both the front (1000) and back substrate (2000) on breakage.
  • the foam interlayer (10100) could be applied directly to the photovoltaic structure's (4000) back metal electrode.
  • the foam interlayer (10100) could be used in conjunction with any or all of the membrane (6000), membrane reinforcement (7000), ribbing (8000), and retention sheet (9000).
  • Figure 31 shows an exterior view of one embodiment of the invention using a foam interlay er (10100) module construction in which a foam sheet is used to span, and in at least some cases fill, the gap between the front and back of the module.
  • the exploded view of the construction is shown in Figure 32 in which the module is constructed with a foam interlayer (10100) placed in conjunction with ribbing (8000) between the membrane (6000) and the back substrate (2000). It will be understood by those of skill in the art that the membrane (6000) does not have to be included.
  • the materials that comprise the foam interlayer (10100) can be selected to include desiccants.
  • a foam interlayer (10100) with high moisture permeability combined with desiccant would allow for moisture that permeates through the external seal assembly (3000) to be absorbed.
  • Materials with improved thermally conductivity and/or reinforcement characteristics could be incorporated with the foam interlayer (10100).
  • the foam interlayer (10100) may be cut into specific shapes prior to module assembly.
  • the foam interlayer (10100) could be cut to fill in the regions around the ribbing (8000).
  • the addition of ribbing (8000) could aid in thermal transfer if the foam interlayer (10100) porosity prevented adequate thermal transfer.
  • Desiccated polymer material can be used along the perimeter of the foam interlayer (10100) to aide in absorption of moisture permeating through the external seal assembly (3000).
  • Figure 33 shows an exterior view of one embodiment of the invention using a structural interlay er (10200) construction in which a structural interlay er (10200) is used to span, and in some cases fill, the gap between the front and back of the photovoltaic module.
  • the structural interlay er (10200) can be designed to provide thermal, structural and desiccating properties.
  • the structural interlayer (10200) can be formed using a foam fabricated in a corrugated or embossed configuration to reduce weight and materials usage.
  • the corrugated or embossed configuration could also be formed using a polymer pre-cast layer that could contain reinforcement and desiccant.
  • FIG. 34 The exploded view of the structural interlayer module (10200) construction, Figure 34, shows the structural interlayer (10200) between the membrane (6000) and the back substrate (2000).
  • FIG 35 illustrates an exterior view of one embodiment of the invention using a solid interlayer (10300) to span the gap between the front and back of the module.
  • the solid interlayer (10300) improves thermal and, structural module properties but requires a desiccated perimeter.
  • Figure 36 shows an exploded view of a interlayer construction in which the solid interlayer (10300) and a desiccated interlayer perimeter (10400) are positioned between the membrane (6000) and the back substrate (2000).
  • the solid interlay er perimeter (10400) includes desiccant to absorb any moisture that permeates through the edge seal (3200).
  • One advantage of the solid interlayer (10300) is the ability to embed a scrim for added strength.
  • the solid interlayer (10300) may be comprised of solid durable polymer or polymer/scrim to provide increased overall module robustness. If module breakage occurs at higher loading, the solid interlayer (10300) can retain module integrity. Moreover, if the solid interlayer (10300) is connected with the front substrate (1000) and back substrate (2000) (directly or through other structures) the solid interlayer (10300) can assist in retaining pieces on breakage.

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Abstract

L'invention porte sur un système et un procédé d'amélioration de structure et d'encapsulation de module photovoltaïque. Un mode de réalisation comprend un module photovoltaïque comprenant un substrat avant, une structure photovoltaïque attachée au substrat avant, la structure photovoltaïque comprenant au moins une cellule photovoltaïque, et une membrane, la membrane et le substrat avant encapsulant sensiblement la structure photovoltaïque.
EP10746690A 2009-02-24 2010-02-23 Systèmes et procédés d'amélioration de structure et d'encapsulation de module photovoltaïque Withdrawn EP2401767A2 (fr)

Applications Claiming Priority (3)

Application Number Priority Date Filing Date Title
US12/392,053 US20100212740A1 (en) 2009-02-24 2009-02-24 Systems and methods for improved photovoltaic module structure and encapsulation
US12/392,055 US20100212725A1 (en) 2009-02-24 2009-02-24 Systems and methods for improved photovoltaic module structure
PCT/US2010/024985 WO2010099080A2 (fr) 2009-02-24 2010-02-23 Systèmes et procédés d'amélioration de structure et d'encapsulation de module photovoltaïque

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WO2010099080A3 (fr) 2011-01-27
WO2010099080A2 (fr) 2010-09-02

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