JP2012518908A - System and method for improved photovoltaic module structure and enclosure - Google Patents

Abstract

An improved photovoltaic module structure and system and method for encapsulation are described. One embodiment includes a photovoltaic module including a front substrate, a photovoltaic structure attached to the front substrate and including at least one photovoltaic cell, and a membrane. The membrane and front substrate substantially enclose the photovoltaic structure.
[Selection] Figure 10

Description

RELATED APPLICATIONS This application is a jointly owned and assigned application entitled “Systems and Methods for Improved Photovoltaic Module Structures and Encapsulates” filed on Feb. 24, 2009. Claims the priority of US Patent Application No. 12 / 392,053 (Attorney Docket No .: AVAS-001 / 00US 307834-2001) of "Methods for Improved Photovoltaic Module Structure and Encapsulation" and is jointly owned And the title of the invention filed on February 24, 2009, "Systems and Methods for Improved Photovoltaic Module Structure and Encapsulation" No. 12 / 392,055 (Attorney Docket No .: AVAS-002 / 00US 30783). Claims priority to -2002), which are incorporated herein by reference.

  The present invention relates to a photovoltaic module and a manufacturing method. Specifically, the present invention relates to a module structure that improves durability against weathering environments, improves safety in the event of breakage, and reduces manufacturing costs compared to the current state of the art.

  The photovoltaic module converts solar energy into electricity by the photovoltaic effect. Photovoltaic modules are therefore a symbol of clean renewable energy sources in international markets that are biased towards traditional fossil fuel technologies such as coal-fired and oil-fired power plants. However, in order to become a major energy source in the international market, photovoltaic modules must be manufactured in large quantities and at a cost competitive with existing fossil fuel technologies.

  One such type of photovoltaic module that meets commercial manufacturing requirements is a cadmium telluride (CdTe) photovoltaic module. CdTe photovoltaic modules typically take the form of thin film polycrystalline devices, where the CdTe layer is paired with a cadmium sulfide (CdS) layer to form a heterojunction. Thin films for CdTe / CdS photovoltaic modules can be produced by various vacuum and non-vacuum processes, but physical vapor deposition techniques for CdTe and CdS thin films, especially vacuum sublimation deposition, are products of CdTe / CdS photovoltaic modules. Suitable for manufacturing. For example, vacuum sublimation of CdS and CdTe thin films can result in thin film deposition rates that are 10 to 100 times higher than other suitable deposition techniques. The semiconductor material used by cadmium sulfide / cadmium telluride solar cells can be up to 100 times less than crystalline silicon devices and can therefore be manufactured cheaper.

The process for manufacturing a CdS / CdTe module includes the following steps. 1) cleaning a glass plate coated with a transparent conductive oxide (TCO), 2) heating the glass plate, 3) depositing an n-type CdS layer, and 4) p-type CdTe layer. Depositing, 5) performing CdCl ₂ treatment to improve the grain structure and electrical properties of CdTe, 6) forming a p + low resistance region to improve current collection in CdTe, and 7) a film layer. Scribing to individual cells, 8) depositing one or more metal layers to form a back electrode metallization, and 9) scribing the back electrode metallization to interconnect the cells sequentially ( A separate scribe) step of forming a photovoltaic structure; 10) a step of providing a bus for electrical connection to the photovoltaic structure; and 11) a photovoltaic structure. Attaching a back substrate to sandwich the body to form a photovoltaic module; 12) enclosing the photovoltaic module; and 13) attaching external leads.

  Cadmium telluride solar cells degrade when exposed to moisture for a long time, and effective encapsulation is required to remain highly reliable. Usually, CdTe solar cells are deposited on a glass plate having a TCO layer. This front substrate, also called a superstrate, faces the sun during operation. The light must pass through the superstrate before being absorbed by the photovoltaic structure. This front substrate may also be called a top plate or a top glass.

  In order to complete the photovoltaic module, a back substrate is attached to the back of the module and sandwiches the photovoltaic structure. The back substrate is often a glass plate and is held on the front substrate using various sealing materials, adhesives, or polymer laminate films. The back substrate may be a polymer or a coated metal. In some module construction methods, particularly construction methods using edge seals on the outer periphery of the module, there may be a space or gap between the front substrate and the back substrate. The back substrate and polymer adhesive together form the encapsulation of the photovoltaic module.

  The industry standard photovoltaic guarantee is 20-25 years. The enclosure and module structure must be resistant to several stresses during transport and operation during the useful life of the module. Modules are frequently tested against certification and testing standards such as American National Standards Institute / Underwriters Laboratories (UL) 1703 and International Electrotechnical Commission (IEC) 61646 and 61730. Modules must withstand the tests described in these certification specifications. In order to pass the tests described in these standards, the module enclosure must protect the photovoltaic structure from moisture and other potential environmental degradation sources. The front and back substrates must provide significant mechanical strength to withstand mechanical loads from wind and snow. In addition, the module must withstand the impact of debris blown by kites and wind. Photovoltaic devices lose performance as the temperature increases. An effective module enclosure minimizes the operating temperature of the module. The photovoltaic module encapsulation method must be high throughput and low cost to facilitate manufacturing.

  If the module breaks due to improper handling or extreme impact, it is undesirable for large glass fragments to be ejected from the module. These debris can cause personal injury and can be a potential source of penetration of materials containing heavy metals into the environment. A large array of photovoltaic modules can operate up to 1000 volts. In the event of damage within the field, there is a risk of electric shock or fire if the internal bus or lead is exposed. The IEC 61730 and UL 1703 standards specify the requirements for module cohesion on catastrophic failure. An effective photovoltaic module encapsulation system must maintain sufficient cohesive strength to prevent the release of dangerous glass fragments and provide some protection from high voltage areas. This can be accomplished either by increasing the overall robustness of the module to prevent breakage or by holding the breakage pieces in the module if breakage occurs.

  All of the encapsulation methods for the thin films, particularly CdTe, photovoltaic modules described in the prior art have limitations with respect to meeting the above-mentioned requirements. The present invention addresses these limitations and facilitates increased reliability and manufacturing efficiency.

  CdTe photovoltaic modules are often composed of a glass front substrate and a back substrate. The front glass and the rear glass are laminated together with an ethylene vinyl acetate (EVA) film sheet having substantially the same size as the glass plate. However, since the EVA material has poor water vapor transmission characteristics, moisture penetrates into the module and comes into contact with the photovoltaic structure. Furthermore, acetic acid is formed in the EVA due to the EVA / water interaction. Acetic acid can cause the photovoltaic structure to degrade and corrode. To solve the poor moisture performance of EVA, a strip of low water vapor permeable material is laminated around the module to reduce moisture ingress. This material typically includes butyl rubber and a desiccant. This method is an improved enclosure using only EVA and is sold by companies such as First Solar. However, this method still has limitations. There may be gaps where the strips are joined together. The strip material does not adhere to the glass as effectively as EVA and may have air bubbles and gaps that may facilitate the ingress of moisture into the EVA. The strip may have a lower water vapor transmission rate than EVA, but moisture ingress has not been ruled out. The strip material can also be degraded by UV radiation and further allow moisture to penetrate. If moisture enters the panel either through gaps, cracks, penetration or strip degradation, the photovoltaic structure will be degraded and corroded by acetic acid.

  EVA lamination is a time-consuming batch-type manufacturing process. The EVA stacking process includes the following manufacturing steps. 1) First, EVA material is cut and placed on the front glass plate. 2) The strip seal is carefully positioned. 3) A back glass plate is placed on the stack. 4) This stack is then placed in a stacking machine. 5) Apply vacuum to remove trapped air. 6) The stack is heated to soften the EVA and initiate crosslinking. 7) Apply pressure to the stack. The vacuum / heating / pressure lamination cycle takes 15-20 minutes. A large vacuum laminator is required to maintain production throughput. These large vacuum laminators require significant factory floor space and are expensive.

  Attempts have been made to develop encapsulation systems that replace EVA stacking. Although an important example is outlined, both of these methods have limitations on module reliability or manufacturing efficiency when compared to the present invention.

  Albright et al., US Pat. No. 5,460,660, describes a method for encapsulating a photovoltaic module. This expired patent shows a series of designs where photovoltaic modules are supported in a complex frame and channel arrangement. The front glass plate containing the photovoltaic structure is paired with another back substrate, usually glass. An edge seal is located on the outer periphery of the module to prevent moisture from entering. A gap is between the front substrate and the back substrate. The desiccant is between the front and back substrates and in some embodiments completely fills the gap between the sheets. Panel frames and channel supports are provided to absorb normal forces and shocks. In some embodiments, a polymer bumper is placed between the glass plates to absorb the impact.

  The modular structure described by Albright et al. Is too complex. Industry experience shows that complex frame systems are not required to reliably handle vertical impacts. This complexity increases manufacturing and deployment costs. Although peripheral edge seals can be effective for sealing photovoltaic modules, this patent teaches a method that requires too many materials and application steps. Edge spacers that release the plates add to the cost of the module and make it bulky. The gap between the plates created by the relatively large spacers forms a thermal barrier. Large spacers and resulting large gaps are similar in function to insulated glass windows, causing the module to operate at high temperatures and reducing performance. A panel support positioned in the gap between the two plates can be effective in absorbing normal force, but is insufficient to allow thermal conditions between the plates to cool the module. . There is no teaching of how to hold the glass fragments if they break.

  Oswald describes a method for encapsulating photovoltaic modules in US Patent Application No. 2003/0116185. In this application, the front substrate and the rear substrate are separated by an outer peripheral edge seal to form a photovoltaic module. In Oswald, the photovoltaic elements are exposed to an internal volume that can be dried. Oswald teaches that thin film photovoltaic materials are not covered or protected within the sealed volume between the front and back substrates.

  The modular structure described by Oswald has significant limitations. The gap between the front substrate and the back substrate increases the operating temperature of the module in a manner similar to a heat insulating glass window. No means for promoting heat conduction is provided between the front substrate and the rear substrate in order to lower the operating temperature. If a desiccant is placed in the area between the front substrate and the back substrate, no means for holding or containing the desiccant is described. The absence of an internal structure between the front and back substrates makes the module susceptible to breakage due to impact or other mechanical loads. The modular design taught in this application is particularly prone to emitting large glass fragments and exposing high voltage internal structures upon failure.

  Blieske et al. Describe photovoltaic module design in US Pat. No. 6,673,997. An edge seal containing a desiccant is used to seal the front and back glass plates. This sealing material is arranged around the outer periphery slightly inside the glass edge. An adhesive is disposed around the outer periphery between the glass edge and the sealant. Brieske further describes that liquid casting material can be injected into the gap between the glass plates via a tube.

  The modular structure described by Brieske has significant limitations. If the optional cast resin is not used, the module will operate at high temperatures in a manner similar to an insulated glass window. Without the optional casting resin, if the module breaks, large glass fragments are released, exposing the high voltage area.

  As in Brieske, resin injection requires a gap or tube in the edge seal to inject liquid and remove air displaced by the casting medium. These gaps or tubes are unnecessarily complex to implement in a manufacturing environment and significantly degrade the original module seal. The cast resin requires further curing in an autoclave. Autoclave curing is a batch process that adds additional complexity, inefficiency, and cost to the manufacturing process. Adding a desiccant to the edge seal is unnecessarily complicated and may reduce adhesion. The desiccant can be placed inside the module more easily and cheaply. Moisture can penetrate into the module through areas other than the edges, for example through the back electrical box. When a cast resin is used, this moisture is not easily absorbed by the desiccant in the outer periphery seal and remains and damages the module.

  Current devices are functional but not accurate enough or satisfactory. Therefore, there is a need for systems and methods that address the shortcomings of current technology and provide other new innovative features.

  Exemplary embodiments of the present invention shown in the drawings are outlined as follows. These and other embodiments are described in more detail in the detailed description section. However, it should be understood that the invention is not intended to be limited to the forms described in the summary or detailed description of the invention. Those skilled in the art will recognize numerous modifications, equivalents, and alternative constructions that fall within the spirit and scope of the invention as set forth in the claims.

  The present invention can provide systems and methods for improved photovoltaic module structures and enclosures. In one exemplary embodiment, the present invention includes a front substrate, a photovoltaic structure attached to the front substrate, and a membrane, the photovoltaic structure including at least one photovoltaic cell; The membrane and front substrate can include a photovoltaic module that substantially encloses the photovoltaic structure.

  In another exemplary embodiment, the present invention can include a method of manufacturing a photovoltaic module, the method comprising forming a photovoltaic structure on a front substrate and on the photovoltaic structure. Adding a membrane, the photovoltaic structure includes at least one photovoltaic cell, and the membrane and the front substrate substantially enclose the photovoltaic structure.

  In another exemplary embodiment, the present invention includes a front substrate, a photovoltaic structure attached to the front substrate, a bus bar assembly, and a membrane, wherein the photovoltaic structure includes a first edge and a second edge. Including an edge and the membrane is configured to allow the bus bar assembly to connect to the photovoltaic structure at a first edge and a second edge, the membrane and the front substrate encapsulate the remainder of the photovoltaic structure A photovoltaic module can be included.

  The present invention can further provide systems and methods for improved photovoltaic module structures. In one exemplary embodiment, a front substrate, a photovoltaic structure attached to the front substrate, a rear substrate, and a structural component, the photovoltaic structure includes at least one photovoltaic cell, and the rear surface The substrate can be spaced from the photovoltaic structure and the structural component can include a photovoltaic module disposed between the back substrate and the photovoltaic structure. Structural components can include ribs, foams (eg, porous foams, corrugated foams, embossed foams, high density foams, etc.), and / or solid interlayers. In some embodiments, 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 holds the front substrate and / or the back substrate in the event of failure. Configured as follows.

  In another exemplary embodiment, the present invention can include a method of manufacturing a photovoltaic module, the method comprising forming a photovoltaic structure on a front substrate and attaching a structural component to the photovoltaic structure. Positioning the body and the back substrate and connecting the back substrate to the front substrate using a seal, the photovoltaic structure including at least one photovoltaic cell, and the structural component comprising the front substrate Configured to provide distributed heat conduction from the substrate to the back substrate.

  In another exemplary embodiment, the present invention includes a front substrate, a photovoltaic structure attached to the front substrate, a back substrate, and a structural component, the back substrate being spaced from the photovoltaic structure. The structural component may include a photovoltaic module that extends into a gap between the back substrate and the photovoltaic structure.

  As noted above, the above-described embodiments and implementations are for illustrative purposes only. Numerous other embodiments, implementations, and details of the invention will be readily recognized by those skilled in the art from the following description and claims.

  The accompanying drawings, which are incorporated in and form a part of this specification, illustrate one or more embodiments of the invention and, together with the following description, further explain the principles of the invention and allow those skilled in the art to use the invention. Makes it possible to make and use.

Table 1 lists drawing reference numbers for components that are incorporated into and form a part of this specification. Level 1 indicates a component group. Level 2 shows the subcomponents of the group. Level 3 shows specific component parts. In the drawing, the level 1 (X000) indicator represents every sub-level component. In the drawings, like reference numbers can indicate identical or functionally similar elements.

  Various objects and advantages of the present invention, as well as a more complete understanding thereof, will be apparent from and more readily understood by reference to the following detailed description and appended claims when taken in conjunction with the accompanying drawings. Let's be done.

It is a figure which shows a basic module. It is an exploded view of a basic module. It is a detailed view of a bus collector configuration. It is a top view of a bus collector structure. FIG. 3 is a detailed view of an insulated bus assembly. FIG. 4 is an exploded view of an insulating bus assembly. It is detail drawing of a double seal. It is an exploded view of a double seal. Single undercoat membrane module. It is an exploded view of a single undercoat membrane module. It is a figure which shows a single overcoat membrane module. It is an exploded view of a single overcoat membrane module. It is a figure which shows a double coat membrane module. It is an exploded view of a double coat membrane module. It is a figure which shows a membrane module with a reinforcing material. It is an exploded view of a membrane module with a reinforcing material. It is a figure which shows the mesh module with a reinforcing material. It is an exploded view of a mesh module with a reinforcing material. It is a figure which shows the membrane module containing a filler. It is an exploded view of a membrane module with a filler. It is a figure which shows the module with a rib. It is an exploded view of a module with a rib. It is a figure which shows the module with a reinforcement rib. It is an exploded view of the module with a reinforcement rib. It is a figure which shows a holding | maintenance tape module. It is an exploded view of a holding | maintenance tape module. It is a figure which shows a holding | maintenance tape horizontal module. It is an exploded view of a holding tape horizontal module. It is a figure which shows a holding | maintenance tape perpendicular | vertical module. It is an exploded view of a holding tape vertical module. It is a figure which shows an intermediate | middle layer foam module. It is an exploded view of an intermediate | middle layer foam module. It is a figure which shows an intermediate | middle layer structure module. It is an exploded view of an intermediate layer structure module. It is a figure which shows an intermediate | middle layer solid module. It is an exploded view of an intermediate | middle layer solid module.

  This specification discloses one or more embodiments that incorporate the features of this invention. The disclosed embodiments are merely illustrative of the invention. The scope of the invention is not limited to the disclosed embodiments.

  References to the described embodiments and "one embodiment", "embodiments", "exemplary embodiments" in the specification, and the like refer to specific features, structures, or characteristics of the described embodiments. Although shown, each embodiment may not necessarily have a particular feature, structure, or characteristic. Moreover, such phrases are not necessarily referring to the same embodiment. Also, when a particular feature, structure, or characteristic is described in connection with an embodiment, that feature, structure, or characteristic is realized in connection with another embodiment, whether explicitly described or not. It will be understood that this is within the knowledge of those skilled in the art.

  The present invention describes an encapsulation system and method for a photovoltaic device, an improved modular structure, and a method for a photovoltaic device. Embodiments include a photovoltaic encapsulating method that incorporates a membrane (6000) positioned between a front substrate (1000) and a back substrate (2000). The membrane (6000) may have multiple attributes that increase the reliability, performance, and safety of the photovoltaic module while minimizing cost and manufacturing complexity. Further, in some embodiments, other structures such as reinforced scrim sheets (7100), mesh fibers (7200) or ribs (8000) are added between the front substrate (1000) and the back substrate (2000). Improve the reliability, performance, and safety of photovoltaic modules. In some embodiments, additional structures such as scrim sheets, meshes and fibers may be incorporated into the membrane (6000) to achieve various advantages, or the front substrate (1000) and the back substrate (2000) You may position separately between.

  In many exemplary embodiments of the invention, the membrane (6000) improves safety by helping to prevent large pieces of glass from being ejected from the module if breakage occurs. Can do. This is because, at least in part, structural components such as the membrane (6000) and / or ribs (8000) or intermediate layer (10000) can be connected to the front substrate (1000) and / or the back substrate (2000). is there. In the event of a failure, the broken pieces of the front substrate (1000) and / or the back substrate (2000) can be separated from the front substrate (1000) and / or the back substrate (2000) with the membrane (6000) and / or other structural components. The module structure is held by an adhesive bond between the two. The membrane (6000) and other structural components may be used in combination or may be used separately.

  For example, in one embodiment, the membrane (6000) may be bonded to a semiconductor photovoltaic structure (4000) formed on the front substrate (1000). When the front substrate (1000) is damaged, the membrane (6000) is damaged by the broken pieces of the photovoltaic structure (4000) and the front substrate (1000) on which the photovoltaic structure (4000) is formed. Provide additional structure to hold the piece. In another embodiment, additional structural components can be connected to the membrane (6000) and the back substrate (2000). In yet another embodiment, additional structures can be connected to the photovoltaic structure (4000) and the back substrate (2000). Additional structural components may be directly connected or bonded to the semiconductor photovoltaic structure (4000) and the back substrate (2000), or the additional structural components may be the photovoltaic structure (4000), the front substrate (1000). ), And the back substrate (2000) via other elements. These additional connections increase the structural integrity and help to retain the module debris in the event of failure. In addition, these additional structural components help to prevent debris loss of photovoltaic structures (4000) coated with heavy metal containing materials such as cadmium from CdTe (cadmium telluride) films.

  Further advantages of the present invention include: 1) Protection of back electrode metallization during module manufacture and protection from potential contact with back substrate (2000) under mechanical load, 2) Bus tape bonding to prevent peeling of bus bonding Strengthening of the busbar assembly (5000) including, 3) Providing the photovoltaic structure (4000) with an additional barrier against water vapor penetration, 4) Providing further electrical insulation, 5) Front substrate (1000) and back substrate (2000) ) Providing a drying medium that absorbs moisture that permeates through the seal between, 6) providing additional structural robustness to the module, and 7) from the inside of the module for improved module performance. Lower module temperature by providing more thermal conductivity, 8) Module performance without significantly increasing cost or weight To improve the body.

  Many possible materials can be used to form a membrane (6000) consistent with the present invention. The membrane (6000) should be formed using materials that have the appropriate mechanical properties for the planned implementation. Mechanical properties to consider include structural stability, shock absorption, and the ability to hold broken pieces and prevent them from being released if the module breaks. Other material properties of the membrane (6000) such as electrical insulation, thermal conductivity, and ability to resist water vapor penetration are also important. Furthermore, in addition to the properties of the formed membrane (6000), it is also important to study material properties that affect the ability to properly form the membrane (6000) on the photovoltaic structure (4000). Those skilled in the art will readily recognize membrane (6000) materials consistent with the present invention.

  In some embodiments, the membrane (6000) can comprise a conformal polymeric material. For example, the membrane (6000) may be composed of a conformal membrane or coating. Conformal coatings may be used to achieve benefits in module performance and module production efficiency. During production, the conformal coating membrane (6000) protects the photovoltaic structure (4000). During the subsequent module construction process, the membrane (6000) prevents damage to the fragile photovoltaic structure (4000). In the field of module applications, conformal coatings provide advantageous structural and electrical properties to protect the photovoltaic structure (4000) and improve module reliability.

  In other embodiments, the membrane (6000) may be composed of a thermoplastic material. In yet another embodiment, the membrane (6000) may be comprised of a thermosetting material that is cured using, for example, chemical additives, ultraviolet radiation, electron beams, or heat. In yet another embodiment, the membrane (6000) may be composed of an elastic material such as a thermoset elastomer or a thermoplastic elastomer. As an example, the membrane (6000) may be composed of urethane acetate, thermoset acrylic, silicone RTV, and / or epoxy. One skilled in the art will recognize membrane (6000) materials that can be selected consistent with the present invention. The selected membrane (6000) material includes, but is not limited to, material characteristics of the photovoltaic structure (4000), other structural characteristics of the module, processing conditions, environment in which the photovoltaic module is used, cost, etc. It can depend on many different factors that are readily understood by the vendor. For example, in order to improve the tact time, the membrane (6000) may be formed using UV curable urethane acetate.

  In one embodiment, the membrane (6000) may be formed from an elastic material to provide additional shock absorption to the module. For example, many elastomeric polymers undergo considerable elongation under stress prior to failure. The elastic membrane can be added directly to the back metal electrode of the photovoltaic structure (4000). The flexibility of the elastic membrane (6000) upon impact allows some absorption of the impact load. When the module breaks, the elastic membrane (6000) bends with the crushed glass without breaking, thus providing a holding force. Additional strength can be imparted to the membrane (6000) by using a reinforcing material. In another embodiment, a silicone-based conformal membrane (6000) may be placed in a soft thick coating.

  The membrane (6000) may also provide an elastic surface that protects the photovoltaic structure (4000) during manufacture, storage, transport, and end use. The membrane (6000) provides durability to the photovoltaic module and adds an additional barrier to moisture penetration by substantially encapsulating the photovoltaic structure (4000). The membrane (6000) further assists in the electrical insulation of a series of interconnected photovoltaic cells of the thin film photovoltaic structure (4000).

  FIG. 1 shows a possible embodiment of the basic structure of a photovoltaic module, in which the photovoltaic is connected to an external connection via a bus bar assembly (5000). FIG. 2 shows an exploded view of the basic module structure. As shown in FIG. 2, the photovoltaic structure (4000) is formed on the front substrate (1000). A bus bar assembly (5000) connects the photovoltaic structure (4000) to the outside of the photovoltaic structure module. The bus bar assembly (5000) includes a bus bar collector (5100) attached to the front battery and the rear battery of the photovoltaic power generation series, and terminates at the bus assembly connection (5200). The bus bar assembly (5000) is insulated from the remaining photovoltaic cells by the bus assembly insulator (5300). Details of a possible busbar collector configuration (5100) are shown in the plan views of FIGS. The bus bar collector configuration (5100) consists of four sections, with the anode edge collector bus (5110) and the cathode edge collector bus (5120) connected to the edge cell of the photovoltaic structure (4000). The anode edge collector bus (5110) is connected to the anode central main bus (5130), and the cathode edge collector bus (5120) is connected to the cathode central main bus (5140).

  FIG. 5 illustrates one embodiment of a method in which the bus bar collector (5100) is incorporated into the bus bar assembly (5000). As shown in the exploded view of the bus bar assembly (5000) in FIG. 6, the anode central main bus (5130) and the cathode central main bus (5140) are for connection to an external wiring system (not shown). To the bus assembly connection (5200). The bus assembly connection (5200) supplies current to a box (not shown) on the back and external wiring (not shown). Meanwhile, the anode edge collector bus (5110) and cathode edge collector bus (5120) are in contact with the module's edge photovoltaic cells, and the anode central main bus (5130) and cathode central main bus (5140) are bus assembly insulated. The body (5300) is insulated from the internal battery of the photovoltaic structure (4000). In one embodiment, the bus assembly insulator (5300) may be an insulating tape strip that is added to the photovoltaic structure (4000). In another embodiment, bus assembly insulator (5300) may be added to the surfaces of anode central main bus line (5130) and cathode central main bus line (5140) facing photovoltaic structure (4000). .

  One embodiment of sealing the front and back of the basic photovoltaic module together is by using a double perimeter seal. FIG. 7 shows a dual seal structure comprised of an inner water vapor barrier seal (3100) and an outer liquid barrier edge seal (3200) as shown in the exploded view of FIG. One embodiment of a dual seal structure may be composed of a polyisobutylene moisture barrier with a silicone edge seal. FIG. 8 further shows a connection seal (3300) that seals the bus connection. The connection seal may also be a polyisobutylene moisture barrier if a liquid barrier such as silicone is used to seal the next back box connection.

  In two different embodiments, the membrane (6000) may be added prior to or after the addition of the bus bar assembly (5000). When added prior to the bus bar assembly (5000), the membrane (6000) can serve as an alternative to the insulation of the central main bus collector (5130, 5140) from the module's internal battery. When added after the addition of the bus bar assembly (5000), the membrane (6000) electrically insulates any conductive areas in the module except the bus assembly insulator (5300), providing additional safety. Embodiments that include an electrically insulative membrane (6000) may further allow the use of a low cost polymer back sheet or metal back sheet.

  FIG. 9 shows an external view of one embodiment of the present invention using a single membrane module structure in which an undercoat membrane (6100) is added prior to the bus bar assembly (5000).

  FIG. 10 shows an exploded view of the structure of the single undercoat membrane (6100). As shown in FIG. 10, the photovoltaic structure (4000) is formed on the front substrate (1000). The undercoat membrane (6100) is added prior to the basic module busbar assembly (5000) and substantially encapsulates the photovoltaic structure (4000) by covering at least the majority of the module's internal cells. Similar to the basic module bus bar assembly (5000), the photovoltaic structure (4000) is connected to the anode edge collector bus (5110) and cathode edge collector bus (5120) of the bus bar assembly (5000). The undercoat membrane (6100) cannot cover the edge cell to which the edge collector bus (5110, 5120) must be attached, or the bus bar assembly can be insulated from photovoltaics. The anode central main bus (5130) and the cathode central main bus (5140) are connected to the anode edge collector bus (5110) and the cathode edge collector bus (5120), respectively. The central main bus is routed across the undercoat membrane (6100) and further connected to the bus assembly connection (5200). The anode central main bus (5130) and cathode central main bus (5140) are insulated from the photovoltaic structure (4000) by a bus assembly insulator (5300). In one embodiment, the bus assembly insulator (5300) may be an insulating tape strip that is added to the photovoltaic structure (4000). In another embodiment, the bus assembly insulator (5300) may be added to the surfaces of the anode central main bus line (5130) and the cathode central main bus line (5140) facing the photovoltaic structure (4000). In a further embodiment, the bus assembly insulator (5300) is implemented such that the undercoat membrane (6100) is sufficient to insulate the anode and cathode central main collector without the additional insulation provided by the insulating tape. It may be omitted in the form.

  FIG. 11 shows an external view of one embodiment of the present invention using a single membrane module structure in which an overcoat membrane (6200) is added after the bus bar assembly (5000).

  FIG. 12 shows an exploded view of a single membrane structure. As shown in FIG. 12, like the basic module, the photovoltaic structure (4000) is formed on the front substrate (1000). The two outer edge cells of the photovoltaic structure (4000) are connected to the anode edge collector bus (5110) and the cathode edge collector bus (5120) of the bus bar assembly (5000). The anode edge collector bus (5110) and the cathode edge collector bus (5120) are connected to the anode central main bus (5130) and the cathode central main bus (5140), respectively, and the anode central main bus (5130) and the cathode central main bus (5140). ) Is further connected to the bus assembly connection (5200). The anode central main bus (5130) and cathode central main bus (5140) are insulated from the photovoltaic structure (4000) by a bus assembly insulator (5300). In one embodiment, the bus assembly insulator (5300) may be an insulating tape strip that is added to the photovoltaic structure (4000). In another embodiment, bus assembly insulator (5300) may be added to the surface of anode central main bus (5130) and cathode central main bus (5140) facing photovoltaic structure (4000). The bus assembly insulator (5300) is essential in the single overcoat embodiment of the present invention. This is because the membrane is not placed under the anode central main bus (5130) and cathode central main bus (5140) and cannot provide photovoltaic internal cell insulation from the bus assembly. . Unlike the single undercoat embodiment of the present invention, the overcoat membrane (6200) has a bus bar assembly (5000) other than the bus assembly connection (5200) that is left uncoated to allow external connections. The photovoltaic structure (4000) is covered throughout.

  The bus bar assembly (5000) and the photovoltaic structure (4000) are substantially encapsulated within the membrane overcoat (6200). In FIG. 12, the printing of the bus bar assembly (5000) is shown in the conformal membrane overcoat (6200). The back substrate (2000) is attached to the front substrate (1000) by an external seal assembly (3000). In this embodiment, the outer seal assembly (3000) includes a double seal having a vapor barrier (3100) made of butyl rubber or polyisobutylene and an edge seal (3200) made of silicone, and a connection seal made of butyl rubber or polyisobutylene ( 3300). In this embodiment, this seal arrangement creates an internal gap between the overcoat membrane coat (6200) and the back substrate (2000). The overcoat membrane (6200) may be desiccated to absorb moisture that permeates through the outer seal assembly (3000). The use of a double seal arrangement is exemplary only and is not intended to limit the invention. Those skilled in the art will readily recognize other sealing arrangements that may be used consistent with the present invention.

  In another embodiment, a membrane coating (6000) may be added prior to and after the addition of the anode and cathode baths. FIG. 13 shows an external view of an embodiment of the present invention using a double membrane module structure.

  FIG. 14 shows an exploded view of the double membrane structure. In FIG. 14, the photovoltaic structure (4000) is formed on the front substrate (1000). There is a first undercoat membrane (6100) in the vicinity of the photovoltaic structure (4000), and the first undercoat membrane (6100) is attached to the photovoltaic structure (4000) prior to the addition of the bus bar assembly (5000). The photovoltaic structure (4000) is substantially enclosed by covering the interior. A portion of the photovoltaic structure (4000) to which the anode and cathode edge collector buses (5110 and 5120) are to be attached remains uncoated. The first undercoat membrane (6100) generally protects the photovoltaic structure (4000) and insulates the photovoltaic structure (4000) from the anode central main bus (5130) and the cathode central main bus (5140). Therefore, it is added prior to the bus bar assembly (5000).

  The bus bar assembly (5000) and the photovoltaic structure (4000) are further encased within an overcoat membrane (6200) to provide additional protection to the photovoltaic structure (4000) and to protect the bus bar assembly (5000). Printing of the bus bar assembly (5000) is shown in the conformal membrane overcoat (6200). A second overcoat membrane (6200) added after the bus bar assembly (5000) encapsulates and protects the electrical connection to the device. One skilled in the art will recognize that the bus assembly connection (5200) cannot be fully encapsulated for connection to a back electrical box (not shown). In some embodiments, the bus assembly connection (5200) is not encapsulated by the overcoat membrane (6200). In other embodiments, the bus assembly connection (5200) may be encapsulated by an overcoat membrane (6200) for transport and assembly, but a portion of the overcoat (6200) on the bus assembly connection (5200). Are removed at some point before use. Those skilled in the art will appreciate variations and modifications consistent with the present invention.

  In some embodiments, one or both membrane coatings (6100, 6200) are loaded with a desiccant to absorb moisture that permeates through the outer seal assembly (3000) during the useful life of the module. sell. The two membrane coats (6100, 6200) may be the same material or different materials to provide a combination of physical properties. In one embodiment, two polymers with different chemistries may be used. In one exemplary embodiment, a second polymeric elastic overcoat membrane (6200) may be used with the first conformal undercoat membrane (6100).

  One of several advantages of the dual membrane structure is that the dual membrane structure can eliminate a separate production process that places the insulating tape prior to the addition of the bus. The first undercoat membrane (6100) insulates the bus from the back electrode metallization on the photovoltaic structure (4000). Further, the two additions of membrane material prior to and after the addition of the bus bar assembly (5000) incorporates the advantages of each addition separately.

  The protective membrane (6000) added on the photovoltaic structure (4000) prevents damage to the photovoltaic structure (4000) during the subsequent module manufacturing process. When the front substrate (1000) and the photovoltaic structure (4000) need to be stored or transported prior to final module assembly, the membrane (6000) physically attaches the photovoltaic structure (4000). Protects and provides a barrier to moisture ingress. This membrane (6000) further encapsulates any heavy metal containing material such as CdTe in the module. This further helps to contain heavy metals and prevent exposure to heavy metals if the module breaks. The addition of a membrane (6000) also improves electrical safety. Even if the module is damaged, only the thin edge of the photovoltaic structure (4000) is exposed. Module (6000) provides electrical isolation from back electrode metallization and bus bar collector (5100).

  In some embodiments, the undercoat membrane (6100) can be applied after the final insulating scribe of the photovoltaic structure (4000). The undercoat membrane (6100) can fill in the scribed area to prevent scribe line contamination and possible shorting of the module.

  The membrane coat (6100 and / or 6200) can be applied using a number of preferred methods. Additional methods include brushing, spraying, precision spraying, stenciling, screening, printing, vapor deposition, bonding, rolling or squeegeeing. Each membrane coat (6100, 6200) may be applied using the same addition method, or the addition method may differ depending on the membrane coat. For example, referring to the dual membrane module assembly of FIG. 13, the first undercoat membrane (6100) can be applied using a squeegee, while the overcoat membrane (6200) can be added using a spray. In other embodiments, it may be desirable to use the same addition method for the various membrane coats (6100, 6200). Those skilled in the art will recognize variations and combinations of these addition methods, as well as various other addition methods not described herein.

  In another embodiment of the invention, the membrane (6000) is formed by combining the membrane (6000) with a membrane reinforcement (7000) such as a mesh layer or a scrim layer. In one embodiment, membrane reinforcement (7000) is added between coats of membrane (6000) (eg, 6100 and 6200) or embedded within individual layers of membrane (6000). The membrane reinforcement (7000) can be used with a membrane (6000) that includes various material properties (eg, conformal coating, elastomeric polymer, thermoset resin, etc.).

  The addition of the membrane reinforcement (7000) enables a stronger protective layer for the photovoltaic structure (4000) and the photovoltaic module to be reinforced, and the front and rear substrates (1000) and (2000) in case of damage. ) And promote retention. The reinforcement (7000) may constrain the membrane to relieve stress in the photovoltaic structure caused by thermal coefficient mismatch. Membrane reinforcement (7000) may take the form of mesh material (7200) or scrim material (7100). The membrane reinforcement (7000) may be composed of fibers, strips, bands or thin rods and may be woven uniaxially or randomly in the module. Polymer or fine glass fiber is a suitable material for constructing the membrane reinforcement (7000). Conductive materials such as metals can cause an arc discharge between the bus and the back metal electrode.

  In one embodiment, a photovoltaic module having a reinforced membrane (eg, 6000 and 7000) may be constructed. First, an undercoat membrane (6100) is applied on the photovoltaic structure (4000). The undercoat membrane (6100) is followed by attachment of the collector bus to the anode and cathode cells. Next, a bus is placed on the undercoat membrane (6100) that extends perpendicular to the interconnect scribing and carries current to the back box and external wiring. The undercoat membrane (6100) functions as an electrical insulator between the back metal electrode of the photovoltaic structure (4000) and the bus bar assembly (5000). The bath attachment is followed by the addition of a layer of membrane reinforcement (7000), after which the layer of membrane reinforcement is covered by an overcoat membrane (6200).

  The overcoat membrane (6200) provides encapsulation of the photovoltaic structure (4000) and also encapsulates the bus bar assembly (5000). By adding the membrane reinforcing material (7000) after the addition of the bus, an encapsulating module in which only the end of the bus assembly connection (5200) is accessible is formed. This protects the photovoltaic structure (4000) that is fragile during subsequent manufacturing steps and during future operations. Composite membranes (6100, 7000, 6200) provide structural reinforcement to the front substrate (1000) in case of failure. Subsequent addition of back electrode (2000) and external seal assembly (3000) is added for additional module structural strength and environmental protection.

  FIG. 15 shows an external view of an embodiment of the present invention that uses a reinforced dual membrane module structure, where the front substrate ( 1000) component is used to help retain 1000). FIG. 16, which is an exploded view of the reinforced dual membrane structure, shows an exploded view of the reinforced dual membrane structure, where the scrim sheet reinforcement (7100) is an undercoat membrane (6100). Configured as in a dual membrane structure placed between the coat and the overcoat membrane (6200) coat. Printing of the bus bar assembly (5000) is shown in the conformal membrane overcoat (6200). The reinforced scrim sheet reinforcement (7100) may be placed prior to or after the bus bar assembly (5000). FIG. 16 shows the scrim sheet reinforcement (7100) placed after the bus bar assembly (5000).

  FIG. 17 shows an external view of an embodiment of the present invention using a double membrane module structure reinforced with mesh. In the double membrane module structure reinforced with mesh, a mesh sheet reinforcement (7200) is shown. ) Is used in place of the scrim sheet reinforcement (7100).

  FIG. 18 shows an exploded view of a double membrane structure reinforced with mesh, in which the mesh sheet reinforcement (7200) is an undercoat membrane (6100). And in a double membrane structure placed between the overcoat membrane (6200). Printing of the bus bar assembly (5000) is shown in the conformal membrane overcoat (6200). The mesh sheet reinforcement (7200) may be placed prior to or after the bus bar assembly (5000). FIG. 18 shows a mesh sheet reinforcement (7200) placed after the busbar assembly (5000).

  Alternatively, the membrane (6000) may be mixed with fine pieces of membrane reinforcement (7000) material and the combination is added. By mixing the fine pieces of the membrane reinforcing material (7000) and the membrane (6000), the number of steps required at the time of manufacture is reduced, and the engineering properties incorporated in the composite membrane are more diverse. FIG. 19 shows an external view of an embodiment of the present invention using a fiber-reinforced reinforced dual membrane module structure, wherein the fiber-reinforced reinforced dual membrane module includes an overcoat The membrane (6200) is impregnated with a scrim impregnated reinforcement (7300). The exploded view of the structure in FIG. 20 shows a dual membrane structure having an overcoat membrane (6200) with a scrim impregnated reinforcement (7300).

  In yet another embodiment of the present invention, structural components such as polymer ribs (8000) are incorporated between the back substrate (2000) of the module and the photovoltaic structure (4000). These rib elements (8000) are periodically spread over the entire area of the module.

  FIG. 21 shows an external view of an embodiment of the present invention using a membrane module structure having ribs. These rib elements (8000) perform several functions, including lowering the operating temperature of the module by increasing heat transfer from the front substrate (1000) exposed to the sun to the back substrate (2000). Further module strength is achieved by using structural polymer ribs (8000). Ribs (8000) extend into the gap between the photovoltaic structure (4000) and membrane (6000) (whether conformal coating or elastic membrane) and the back substrate (2000). In doing so, the ribs (8000) distribute the module load between the front substrate (1000) and the back substrate (2000). By spreading in the gap between the front and back of the module, the outer seal assembly (3000) dual seal module can have the mechanical properties of a laminated structure. Polymer ribs (8000) can be added on the module bus to maintain the adhesion of the bus and prevent peeling of the bus from the metallization. Placing ribs on the connection between the edge bus and the central bus increases the integrity of the joint.

  FIG. 22 shows an exploded view of the ribbed structure, in which the module has a single unit with a polymer rib (8000) disposed between the membrane (6000) and the backsheet (2000). Configured as in one or double membrane structures. The ribs (8000) provide a heat transfer path between the module front substrate (1000) and the back substrate (2000) and provide structural support in the gap between the front and back of the module. provide.

  In order to achieve the mechanical and thermal benefits of the polymer rib (8000), the rib material must be flexible. That is, when the back substrate (2000) is assembled into a module structure, it must match both sides of the module. Advantageously, the rib (8000) has some degree of connectivity to the adjacent surface and the rib (8000) material is pressed to ensure tight contact when the back substrate (2000) is assembled to the module. The structural rib (8000) may be composed of the same polymer as the double edge seal vapor barrier (3100) for ease of manufacture.

  The compliant material may not adequately assist in holding the front substrate (1000) and the back substrate (2000) in the event of failure. To supplement the flexibility of the ribs (8000), a reinforced conformal and elastic membrane structure is used to provide additional substrate (1000, 2000) retention. In FIG. 23, the external view of one Embodiment of this invention using the reinforced membrane module structure with a rib is shown.

  FIG. 24 shows an exploded view of the reinforced ribbed structure in which the module is a polymer rib placed between the membrane (6000) and the back substrate (2000). Constructed with a membrane reinforced structure (7000) having (8000). One skilled in the art will appreciate that it is not necessary to have a membrane (6000). The ribs (8000) provide a heat transfer path between the module's front substrate (1000) and the back substrate (2000) and provide structural support in the gap between the front and back of the module. give. In some embodiments, the ribs (8000) provide a distributed thermal conduction path across the inner surface of the front substrate (1000) and the back substrate (2000). For example, the ribs (8000) provide a distributed conduction path from the front substrate (1000) through the photovoltaic structures (4000) and ribs (8000) to the back substrate (2000). It can be arranged periodically throughout the body (4000). In some embodiments, the ribs may be further connectable (directly or indirectly) to the front substrate (1000) and the back substrate (2000) to assist in holding debris in the event of failure. . By using periodically arranged ribs (8000), the ribs help hold debris over the entire surface of the front substrate (1000) and the back substrate (2000).

  Ribs (8000) or membranes (6000), or both, can be desiccated to absorb moisture that permeates through the outer seal assembly (3000) over the useful life of the module. In one embodiment, the polymer rib (8000) material may include a desiccant to protect the photovoltaic structure (4000) from moisture damage. The rib (8000) has a large surface area and thus provides additional moisture absorption.

  Furthermore, the structural nature of the ribs (8000) provides an advantage over the free desiccant between the front substrate (1000) and the back substrate (2000). For example, if moisture penetrates through the outer seal and only the free desiccant is used, the moisture will clump the freed desiccant. The mass may contact a portion of the bus bar assembly (5000) or photovoltaic structure (4000), causing a short circuit. If the desiccant is incorporated into a structural component such as a rib (8000), the desiccant can help eliminate problems due to the free-drying desiccant.

  The drying member within the module structure absorbs moisture that permeates through the outer seal assembly (3000) over the useful life of the module. The amount of desiccant required depends on the permeability of the outer seal assembly (3000) and the desired service life of the module. In one embodiment, the module can be dried by incorporating desiccant into the ribs (8000) and / or adding desiccant to the membrane (6000). Since the material selected for the membrane (6000) can be different from the material selected for the edge seal (3200) and the vapor barrier (3100), the membrane (6000) material can be the edge seal (3200) and the vapor barrier (3100). ) Can have a different permeability than the material. The drying of these layers takes place depending on their level of permeability.

  In another embodiment of the present invention, a retention sheet (9000) having suitable properties is used to facilitate the retention of the front substrate (1000) and the back substrate (2000) in the event of a module failure. ), Instead of the membrane (6000) or as the membrane (6000). In one embodiment, the retaining sheet (9000) is a polymer sheet that can be used with an undercoat membrane (6100) or overcoat membrane (6200), such as a conformal polymer coat. For example, if the undercoat membrane (6100) is composed of a more brittle material, the holding sheet (9000) can be used as an overcoat membrane (6200) that is added to assist in holding broken pieces when breakage occurs. Can be used. In this regard, the retention sheet (9000) allows the use of various membrane (6000) materials while still providing the benefits of debris retention if the module fails. In another embodiment, the undercoat membrane (6100) or overcoat membrane (6200), or the function of both membranes, can be used in place of the undercoat membrane (6100) or overcoat membrane (6200). (9000). In one embodiment, the holding sheet (9000) may be unwound and affixed (eg, adhered) to cover the photovoltaic structure (4000).

  In one exemplary embodiment, the retaining sheet (9000) may be a retaining tape sheet (9100). These holding tape sheets (9100) can be composed of a thin polymer film with an adhesive on one side. These holding tape sheets (9100) hold glass fragments in the event of module failure and can protect the photovoltaic structure (4000) from wear during manufacture and module use. Similar to the conformal membrane coating, the holding sheet (9000) can be directly attached to the back metal electrode of the photovoltaic structure (4000). In another embodiment, the retention sheet (9000) can be applied over the undercoat membrane (6100) or overcoat membrane (6200), or both. The holding sheet (9000) can be attached in the form of a single sheet that substantially covers and encloses the surface of the photovoltaic structure (4000) by covering at least the majority of the photovoltaic cell. The holding sheet (9000) can be in the form of a simple film with an adhesive on one side, such as those available from 3M, Poly-Film, and Mitsubishi. In some embodiments, the retaining sheet (9000) may be reinforced with fibers to increase strength. The retaining sheet (9000) may be composed of a polymeric material such as polyethylene, polyester, polyurethane, and paper with suitable dielectric properties such as those used for transformer windings. The holding sheet (9000) may be used in the vicinity of the bus bar assembly (5000).

  Referring to FIG. 25, there is shown an external view of an embodiment of the present invention using a ribbed module structure that holds the front and back substrates (1000, 2000) when broken. A holding tape sheet (9100) is used.

  FIG. 26 shows an exploded view of the tape holding structure in which the holding tape sheet (9100) is disposed on the membrane (6000). The retaining tape sheet (9100) does not fill the gap between the front and back of the module. Ribs (8000) can be used to extend into this gap, or in some cases to fill the gap, and to provide thermal and structural support. In one embodiment, the ribs (8000) can be used with a membrane (6000), a membrane reinforcement (7000) and a retaining sheet (9000). In other embodiments, one or more of these elements may not be used. Those skilled in the art will be aware of many different embodiments and combinations of these structures consistent with the present invention. In many embodiments, the rib (8000) is the last of these materials that are applied in sequence and may be applied over these other elements.

  Referring to FIG. 27, in another embodiment, a holding tape strip (9200) can be used to hold the front and back substrates (1000, 2000) in case of failure. FIG. 28 shows an exploded view of a parallel strip structure in which the retaining tape strip (9200) is placed on the membrane (6000) parallel to the bus arrangement.

  In some embodiments, the retaining tape strip (9200) takes the form of a polymer tape strip that is arranged periodically or in a pattern suitable for retaining glass fragments in the event of module failure. With the retention tape strip (9200), in addition to material savings, a tape dispenser machine that is readily available for application can be used.

  FIG. 29 shows a ribbed module structure that uses a holding tape strip (9200) to hold module debris in the event of failure instead of the holding tape sheet (9100). The exploded view of FIG. 30 shows the retaining tape strip (9200) placed on the membrane (6000) perpendicular to the edge bath array. In both parallel (see FIG. 28) and vertical (see FIG. 30) arrangements, the retaining tape strip (9200) is one or more relative to the plane of the bus as a continuous strip or as a strip fold. Can be oriented.

  In yet another embodiment of the present invention, a foam intermediate layer (10100) structural component may be used in the vicinity of the back substrate (2000) to provide a lightweight and uniform filler for the space within the module. An adhesive may be used to adhere the foam to the internal module structure. In one embodiment, the foam interlayer (10100) may be a porous foam that may be covered with a sheet of adhesive material, or an adhesive to allow better adhesion of the foam. May be applied by spraying. In one embodiment, the adhesive may be a retaining tape sheet (9100) or a retaining tape strip (9200). The foam intermediate layer (10100) converts the double seal module into a structure having similar mechanical and thermal properties as the laminated module. The foam intermediate layer (10100) dissipates load evenly throughout the module with minimal added weight and is substantially uniform between the front substrate (1000) and back substrate (2000) surfaces. Provides good heat transfer, thereby lowering the operating temperature of the module. The foam intermediate layer (10100) can provide substantially uniform heat conduction by dispersing heat conduction across the entire surface of the front substrate (1000) and the back substrate (2000). When adhered, the foam intermediate layer (10100) provides further retention of both the front substrate (1000) and the back substrate (2000) in case of failure. In some embodiments, the foam intermediate layer (10100) may be applied directly to the back metal electrode of the photovoltaic structure (4000). The foam intermediate layer is used with the undercoat membrane (6100) as a substitute for the undercoat membrane (6100), but is used in place of the second conformal coating, or the membrane (6100 and / or 6200). ) And may be added. In another embodiment, the foam intermediate layer (10100) may be used with any or all of the membrane (6000), membrane reinforcement (7000), ribs (8000), and retaining sheet (9000). Those skilled in the art will recognize various embodiments of each of these components and various combinations of these components that may be used consistent with the present invention.

  FIG. 31 shows an external view of an embodiment of the present invention using a foam intermediate layer (10100) module structure, in which the gap between the front and back of the module is shown. Foam sheets are used to spread out and at least in some cases to fill the gaps. FIG. 32 shows an exploded view of this structure, in which the module uses a foam intermediate layer (10100) placed with ribs (8000) between the membrane (6000) and the back substrate (2000). Configured. One skilled in the art will appreciate that it is not necessary to have a membrane (6000).

  The material comprising the foam intermediate layer (10100) can be selected to include a desiccant. For example, a foam intermediate layer (10100) having a high moisture permeability combined with a desiccant allows moisture that permeates through the outer seal assembly (3000) to be absorbed. Materials with improved thermal conductivity and / or reinforcing properties may be incorporated into the foam intermediate layer (10100).

  In certain embodiments, it may be beneficial to cut the foam intermediate layer (10100) to a specific shape prior to assembly of the module. For example, if the foam intermediate layer (10100) is used with ribs (8000), the foam intermediate layer (10100) can be cut to fill the area around the ribs (8000). Heat transfer can be assisted by the addition of ribs (8000) if the porosity of the foam intermediate layer (10100) prevents proper heat transfer. A desiccant polymer material (not shown) may be used around the foam intermediate layer (10100) to facilitate absorption of moisture that permeates through the outer seal assembly (3000).

  FIG. 33 shows an external view of an embodiment of the present invention using a structural intermediate layer (10200) structure, which extends into the gap between the front and rear of the photovoltaic module. As such, or in some cases, a structural interlayer (10200) is used to fill the gap. The structural interlayer (10200) can be designed to provide thermal properties, structural properties, and drying properties. In one embodiment, the structural interlayer (10200) may be formed using a foam made in a corrugated or embossed shape to reduce weight and material usage. The corrugated or embossed shape may be formed using a precast layer of polymer that may include a reinforcement and a desiccant. FIG. 34, which is an exploded view of the structural intermediate layer module (10200) structure, shows the structural intermediate layer (10200) between the membrane (6000) and the back substrate (2000). Those skilled in the art will recognize the various embodiments of each of these components and the various combinations of components that may be used consistent with the present invention.

  In situations where a very robust modular structure is required, a high density foam or a precast structural intermediate with a very low cell rate can be formed to effectively form a solid intermediate layer (10300) that is inserted during module construction. Layers may be used. FIG. 35 shows an external view of one embodiment of the present invention using a solid interlayer (10300) that spans the gap between the front and back of the module. The solid interlayer (10300) improves thermal and structural module properties, but requires a perimeter with a desiccant. FIG. 36 shows an exploded view of the intermediate layer structure in which the solid intermediate layer (10300) and the intermediate layer outer peripheral portion (10400) containing the desiccant are positioned between the membrane (6000) and the back substrate (2000).

  As shown in FIG. 36, there may be a gap between the edge seal (3200) and the solid intermediate layer (10300) around the outer periphery of the solid intermediate layer (10300). This gap may be filled and / or widened using the solid intermediate layer perimeter (10400). The solid intermediate layer outer periphery (10400) includes a desiccant that absorbs moisture that permeates through the edge seal (3200). One advantage of the solid interlayer (10300) is that a scrim can be embedded to increase strength. In some embodiments, the solid interlayer (10300) can be composed of a solid durable polymer / scrim to increase the robustness of the overall module. Even in the event of module failure at high loads, the solid interlayer (10300) can retain the integrity of the module. Further, if the solid intermediate layer (10300) is connected (directly or via other structures) to the front substrate (1000) and the back substrate (2000), the solid intermediate layer (10300) retains debris upon failure. To help.

  In conclusion, while various embodiments of the present invention have been described above, it should be understood that they have been presented by way of example only and not limitation. It will be apparent to those skilled in the art that various changes in form and detail can be made without departing from the spirit and scope of the invention. Accordingly, the scope of the invention should not be limited by any of the above-described exemplary embodiments, but should be defined only in accordance with the scope and spirit of the claims and their equivalents.

Claims (79)

A front substrate;
A photovoltaic structure attached to the front substrate and having at least one photovoltaic cell;
A membrane,
The photovoltaic module, wherein the membrane and the front substrate substantially enclose the photovoltaic structure.   The photovoltaic module according to claim 1, further comprising a back substrate disposed apart from the photovoltaic structure.   The photovoltaic module according to claim 1, wherein the membrane is attached to the photovoltaic structure using a spray.   The membrane is affixed to the photovoltaic structure using a method selected from the group consisting of brushing, spraying, precision spraying, stenciling, screening, vapor deposition, adhesion, printing, rolling and squeezing. The photovoltaic module according to 1.   The photovoltaic module of claim 1, wherein the membrane comprises a conformal coating.   The photovoltaic module of claim 1, wherein the membrane comprises a polymer material.   The photovoltaic module of claim 6, wherein the membrane comprises an elastomeric polymer material.   The photovoltaic module according to claim 1, wherein the membrane comprises a thermoplastic material.   The photovoltaic module according to claim 1, wherein the membrane includes a desiccant.   The photovoltaic module according to claim 1, wherein the membrane includes a holding tape. A bus bar assembly;
The bus bar assembly is
An anode edge collector bus connected to the photovoltaic structure;
A cathode edge collector bus connected to the photovoltaic structure;
An anode central main bus connected to the anode edge collector bus;
The photovoltaic module according to claim 1, further comprising a cathode central main bus connected to the cathode edge collector bus. The membrane is
An undercoat membrane in the vicinity of the photovoltaic structure;
An overcoat membrane,
The photovoltaic module according to claim 11, wherein the anode central main bus and the cathode central main bus are positioned between the undercoat membrane and the overcoat membrane.   The photovoltaic module according to claim 12, wherein the overcoat membrane and the undercoat membrane are made of different materials.   The photovoltaic module according to claim 12, wherein the overcoat membrane and the undercoat membrane are added by using different attaching methods.   The photovoltaic module according to claim 1, wherein the membrane includes a membrane reinforcing material embedded in the membrane.   The photovoltaic module of claim 15, wherein the membrane reinforcing material is selected from the group consisting of a mesh, a scrim, a fiber, a strip, a band, and a thin bar.   16. The photovoltaic module according to claim 15, wherein the membrane reinforcing material is selected from the group consisting of a polymer, glass, fiber glass, polymer composite material, and glass composite material.   The photovoltaic module of claim 2, further comprising a desiccant material disposed between the front substrate and the back substrate. A gap between the membrane and the back substrate;
The photovoltaic module according to claim 2, further comprising a structural component extending in the gap.   The photovoltaic module of claim 19, wherein the structural component comprises a rib.   The photovoltaic module of claim 19, wherein the structural component comprises a foam.   The photovoltaic module of claim 19, wherein the structural component is connected to the membrane and the back substrate.   The structural component is configured to dissipate a load distributed throughout the photovoltaic module, and the structural component is configured to provide distributed heat conduction between the front substrate and the back substrate. The photovoltaic module according to claim 19. Further comprising at least one retaining tape strip connected to the membrane;
The photovoltaic module of claim 1, wherein the at least one holding tape strip is coated with an adhesive on at least one surface.   25. The photovoltaic module of claim 24, wherein the at least one retaining tape strip comprises a material selected from the group consisting of a polymer, polyethylene, polyester, polyurethane, and dielectric paper. A method of manufacturing a photovoltaic module,
Forming a photovoltaic structure comprising at least one photovoltaic cell on a front substrate;
Adding a membrane on the photovoltaic structure,
The membrane and the front substrate substantially encapsulate the photovoltaic structure.   27. The method of claim 26, further comprising connecting a back substrate to the front substrate using a seal.   Connecting the back substrate to the front substrate using the seal comprises connecting the back substrate to the front substrate using an external seal assembly, the external seal assembly comprising a vapor barrier and an edge seal. 28. The method of claim 27.   27. The method of claim 26, wherein adding the membrane on the photovoltaic structure includes spraying the membrane on the photovoltaic structure.   The step of adding the membrane on the photovoltaic structure is performed using a method selected from the group consisting of brushing, spraying, precision spraying, stenciling, screening, bonding, printing, rolling and squeezing. Item 27. The method according to Item 26.   Adding the membrane on the photovoltaic structure includes adding a membrane material selected from the group consisting of conformal coatings, polymers, elastomeric polymers, thermoplastic materials, and thermosetting materials. 27. The method of claim 26.   27. The method of claim 26, wherein adding the membrane to the photovoltaic structure includes adhering the membrane to the photovoltaic structure. Further comprising connecting a bus bar assembly to the photovoltaic structure;
28. The method of claim 27, wherein the membrane substantially encloses the bus bar assembly. The step of adding the membrane includes
Adding an undercoat membrane in the vicinity of the photovoltaic structure;
27. A method according to claim 26, comprising applying an overcoat membrane. Connecting an anode edge collector bus to the photovoltaic structure;
Connecting a cathode edge collector bus to the photovoltaic structure;
Adding the undercoat membrane;
Connecting an anode central main bus insulated from the photovoltaic structure by the undercoat membrane to the anode edge collector bus;
Connecting a cathode central main bus insulated from the photovoltaic structure by the undercoat membrane to the cathode edge collector bus;
Connecting the anode central main bus and the cathode central main bus to a bus connection configured to supply current to the back box;
35. The method of claim 34, further comprising adding the overcoat membrane that substantially encloses the anode central main bath and the cathode central main bath.   33. The method of claim 32, wherein the undercoat membrane is applied prior to connecting the photovoltaic structure to the anode edge collector bus or the cathode edge collector bus.   27. The method of claim 26, wherein adding the membrane comprises adding the membrane comprising a reinforcing material. Adding the membrane comprising the reinforcing material,
Adding an undercoat membrane in the vicinity of the photovoltaic structure;
Adding the reinforcing material in the vicinity of the undercoat membrane;
A step of adding an overcoat membrane,
38. The method of claim 37, wherein the overcoat membrane and undercoat membrane substantially encapsulate the membrane reinforcing material. Adding the membrane comprising the reinforcing material,
38. The method of claim 37, comprising adding a material selected from the group consisting of mesh, scrim, fiber, strip, band, or wand. Positioning a structural component in the vicinity of the membrane;
Connecting a back substrate to the front substrate using a seal, and further comprising:
27. The method of claim 26, wherein the structural component is configured to provide distributed heat conduction from the front substrate to the back substrate.   41. The method of claim 40, wherein the structural component comprises a rib and a foam.   42. The method of claim 41, wherein the foam is selected from the group consisting of porous foam, corrugated foam, embossed foam, and high density foam. Connecting the structural component to the membrane;
41. The method of claim 40, further comprising connecting the structural component to the back substrate.   27. The method of claim 26, further comprising adhering a retention tape to the membrane. A front substrate;
The photovoltaic structure attached to the front substrate and having a first edge and a second edge;
A busbar assembly;
A membrane configured to allow the bus bar assembly to connect to the photovoltaic structure at the first edge and the second edge;
The photovoltaic module, wherein the membrane and the front substrate enclose the remaining portion of the photovoltaic structure. A front substrate;
A photovoltaic structure attached to the front substrate and having at least one photovoltaic cell;
A back substrate spaced from the photovoltaic structure;
A photovoltaic module comprising: a structural component disposed between the back substrate and the photovoltaic structure.   47. The photovoltaic module of claim 46, wherein the structural component comprises a rib.   48. The photovoltaic module of claim 47, wherein the ribs are periodically arranged on the photovoltaic structure.   48. The photovoltaic module of claim 47, wherein the rib comprises polyisobutylene.   48. The photovoltaic module of claim 47, wherein the rib comprises a flexible material.   47. The photovoltaic module of claim 46, wherein the structural component comprises a foam.   52. The photovoltaic module of claim 51, wherein the foam is selected from the group consisting of a porous foam, a corrugated foam, and an embossed foam.   47. The photovoltaic module of claim 46, wherein the structural component comprises a solid interlayer.   54. The photovoltaic module of claim 53, wherein the solid intermediate layer comprises a high density foam.   47. The photovoltaic module of claim 46, wherein the structural component comprises a foam and a rib.   49. The photovoltaic module of claim 46, wherein the structural component incorporates a desiccant.   47. The photovoltaic module of claim 46, wherein the structural component is configured to connect to the front substrate and the back substrate.   58. The photovoltaic module of claim 57, wherein the structural component is configured to provide distributed heat conduction between the front substrate and the back substrate.   47. The photovoltaic module of claim 46, wherein the structural component is configured to connect to the front substrate to hold the front substrate in the event of failure.   47. The photovoltaic module of claim 46, wherein the structural component is configured to connect to the back substrate to hold the back substrate in the event of failure.   47. The photovoltaic module of claim 46, wherein the structural component is configured to provide load dissipation across the photovoltaic module. An external seal assembly configured to form a seal between the front substrate and the back substrate;
54. The photovoltaic module of claim 53, further comprising a solid intermediate layer outer periphery that is filled with a desiccant and disposed between the outer seal assembly and the solid intermediate layer.   47. The photovoltaic module of claim 46, further comprising an external seal assembly configured to form a seal between the front substrate and the back substrate.   The photovoltaic module according to claim 46, further comprising a membrane, wherein the membrane and the front substrate substantially enclose the photovoltaic structure.   65. The photovoltaic module of claim 64, further comprising at least one retaining tape strip that adheres to the membrane.   47. The photovoltaic module of claim 46, further comprising at least one retaining tape strip that adheres the structural component to the back substrate. A method of manufacturing a photovoltaic module,
Forming a photovoltaic structure having at least one photovoltaic cell on a front substrate;
Positioning a structural component configured to provide distributed heat conduction from the front substrate to the back substrate between the photovoltaic structure and the back substrate;
Connecting the back substrate to the front substrate using a seal.   48. The method of claim 47, wherein the structural component comprises a rib.   68. The method of claim 67, wherein the structural component comprises a foam.   68. The method of claim 67, further comprising connecting the structural component to the front substrate to hold the front substrate in case of failure. Connecting the structural component to the front substrate comprises:
The method of claim 70, comprising gluing the structural component to the photovoltaic structure. Connecting the structural component to the front substrate comprises:
Adding a membrane on the photovoltaic structure;
Attaching the structural component to the membrane,
70. The method of claim 69, wherein the membrane and the front substrate substantially encapsulate the photovoltaic structure.   48. The method of claim 47, further comprising connecting the structural component to the back substrate to hold the back substrate in case of failure. Connecting the structural component to the back substrate comprises:
Bonding the first surface of the holding tape to the structural component;
75. The method of claim 73, comprising adhering a second surface of the holding tape to the back substrate. A front substrate;
A photovoltaic structure attached to the front substrate;
A back substrate that is spaced apart from the photovoltaic structure to form a gap;
A photovoltaic module comprising: a structural component extending in the gap between the back substrate and the photovoltaic structure.   76. The photovoltaic module of claim 75, wherein the structural component is configured to provide distributed heat conduction between the front substrate and the back substrate.   The photovoltaic module of claim 75, wherein the structural component is configured to provide load dissipation distributed throughout the photovoltaic module.   The photovoltaic module of claim 75, wherein the structural component is configured to hold the front substrate in the event of failure.   The photovoltaic module of claim 75, wherein the structural component fills a gap between a back substrate and the photovoltaic structure.

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