TW201334959A - A photovoltaic cell module and method of forming the same - Google Patents

Abstract

A photovoltaic (PV) cell module comprises a substrate, a cover sheet spaced from the substrate, PV cells disposed between the substrate and the cover sheet, and tabbing ribbon disposed between the PV cells. Polymeric strips formed from a first polymeric composition are disposed between the PV cells and the cover sheet. A tie-layer formed from a second polymeric composition, different than the first polymeric composition, is disposed between the substrate and the cover sheet and between the polymeric strips. The polymeric strips are formed on the cover sheet by applying the first polymeric composition to portions of the cover sheet. The PV cells are then disposed on the polymeric strips. The second polymeric composition is applied over the cover sheet between the polymeric strips and over the PV cells to form the tie-layer. The substrate and the cover sheet are then combined to form the module.

Description

Photovoltaic battery module and forming method thereof Cross-reference to related applications

The present application claims the benefit of U.S. Provisional Patent Application Serial No. 61/590,996, filed on Jan. 26, 2012, which is hereby incorporated by reference.

The present invention generally relates to a photovoltaic (PV) battery module and a method of forming the same.

A solar cell or a PV cell is a semiconductor device for converting light into electricity. In many applications, PV cells are sealed to form a PV cell module. The modules typically include a cover sheet (or "overlay") and a back cover sheet (or "substrate") such that the PV cell and encapsulant are sandwiched between the cover sheet and the substrate. The PV cells are operatively coupled to each other by interconnecting strips. Sealants and cover sheets protect PV cells from environmental factors such as wind, dust and rain. A commonly used sealant is ethyl vinyl acetate (EVA) and the other is polyfluorene. EVA has one or more disadvantages such as low UV resistance, degradation over time, discoloration over time, and the like. Thus, polyoxymethylene has been used in some applications to replace EVA in modules. A single type of polyoxygen oxide can be used to completely seal the PV cell within the module. Alternatively, a layer of first polyfluorene oxide is used between the PV cell and the cover sheet, and a layer of second polyoxymethylene is used between the PV cell and the substrate. The first polyoxygen is usually softer than the second polyoxygen, which is suitable for use in modular systems. During the manufacturing process, for example, damage to the PV cells during pressurization is prevented. In particular, if the first polyoxygen is too hard, the battery may rupture or the polyfluorene may not be properly deformed, thereby allowing trapped bubbles, which is undesirable. The second polyoxymethylene is suitable for maintaining the position of the PV cell during thermal expansion and contraction of the encapsulant. In particular, the second polyoxygen is generally harder than the first polyoxygen, and is less prone to thermal expansion and contraction after heating and cooling the module.

Unfortunately, the first layer of polyoxymethylene may still allow the PV cell to move during thermal expansion and contraction, which can cause the PV cell to rupture and/or the interconnecting strip to break or degrade. For example, the first polyfluorene oxide will expand and contract to a greater extent than the second polyfluorene oxygen, so that at the interface, the interconnecting strip will bend and break because one end of the interconnecting strip is second. The polyoxygen is trapped, and the other end of the interconnecting strip moves due to the first polyoxygen. These problems can cause the power of the module to drop or even fail completely. Modules that use only a single type of polyoxygen can be plagued by the same problem, with PV cells moving too much during expansion and contraction, which can cause the interconnect strip to degrade/fracture. Therefore, there is still an opportunity to provide an improved module with excellent durability such as improved PV cell cracking after thermal cycling and reduced power reduction. There are also opportunities to provide improved module formation methods that provide excellent productivity, cost savings and repeatability.

The invention provides a photovoltaic (PV) battery module. The module of the present invention includes a substrate having a front surface and a back surface spaced apart from the front surface of the substrate. The module also includes a cover sheet having a front face and a back face spaced from the front face of the cover sheet. A first PV cell is disposed between the substrate and the cover sheet. The first PV cell has a front face and a back face spaced from the front face of the first PV cell. A second PV cell is disposed between the substrate and the cover sheet and adjacent to the first PV cell. The second PV cell has a front face and a back face spaced apart from the front face of the second PV cell. An interconnecting strip is disposed between the PV cells. The interconnecting strip has a first end operatively coupled to the front of the first PV cell and a An operative terminal is coupled to the second end of the back side of the second PV cell. A first polymeric strip formed from the first polymeric composition is disposed between the first PV cell and the cover sheet to couple the front surface of the first PV cell to the back side of the cover sheet. A second polymeric strip, also formed from the first polymeric composition, is disposed between the second PV cell and the cover sheet to couple the front surface of the second PV cell to the back side of the cover sheet. a tie layer formed from a second polymeric composition different from the first polymeric composition disposed between the substrate and the cover sheet and between the polymeric strips to couple the back side of the cover sheet to the back The front surface of the substrate and the back surfaces of the PV cells are coupled to the front surface of the substrate.

The invention also provides a method of forming a module of the invention. The method of the present invention comprises the steps of applying the first polymeric composition to the first portion and the second portion of the back side of the cover sheet to form the first polymeric strip and the second polymeric strip in an uncured state . The method further includes the step of positioning the first PV cell and the second PV cell on the first polymeric strip and the second polymeric strip. The interconnecting strip is operatively coupled to the first PV cell and the second PV cell. The method further comprises coating the second polymeric composition between the polymeric strips on the back side of the cover sheet and on the PV cells and the interconnecting strip to form a tie layer in an uncured state A step of. The method further includes the step of combining the substrate with the cover sheet to form the module. The module can be used in a variety of applications, such as for converting many different wavelengths of light into electricity.

4‧‧‧ line

20‧‧‧Photovoltaic battery module/module

22‧‧‧Photovoltaic battery module array

24‧‧‧Substrate

26‧‧‧Before the substrate

28‧‧‧Back of the substrate

30‧‧‧ Covering film

32‧‧‧Before the cover sheet

34‧‧‧ Covering the back of the film

36‧‧‧First photovoltaic battery

36a‧‧‧Photovoltaic battery

36b‧‧‧Photovoltaic battery

38‧‧‧Second photovoltaic battery

40‧‧‧Before the first photovoltaic cell

42‧‧‧The back of the first photovoltaic cell

44‧‧‧Before the second photovoltaic cell

46‧‧‧The back of the second photovoltaic cell

48‧‧‧Connected strip

50‧‧‧The first end of the interconnection strip

52‧‧‧The second end of the interconnection strip

54‧‧‧First polymeric strip

56‧‧‧Second polymeric strip

58‧‧‧Connection layer

60‧‧‧Robot dispenser

62‧‧‧Nozzles

64‧‧‧Robot fixture

66‧‧‧Aggregate strips

68‧‧‧Connection layer

The invention may be readily understood by the following detailed description of the invention, in which: FIG. 1 is a pair of photovoltaics each comprising an embodiment of a PV cell module. A perspective view of a PV array; FIG. 2 is an exploded cross-sectional side view of one embodiment of a PV cell module including a PV cell; and FIG. 3 is an exploded cross-section of the embodiment of a PV cell module including a PV cell. Side view Figure 4 is an exploded cross-sectional elevational view of the PV cell module of Figure 3 taken along line 4-4; Figure 5 is an exploded cross-sectional schematic illustration of the application of the first polymeric composition to the cover sheet to form a polymeric strip. Figure 6 is a schematic side elevational view showing an exploded cross-section of a PV cell disposed on a polymeric strip; Figure 7 is an exploded cross-sectional view illustrating the application of a second polymeric composition to a PV cell and a cover sheet to form a tie layer. Cross-sectional schematic side view; FIG. 8 is an exploded cross-sectional schematic side view illustrating one embodiment of a combined substrate and cover sheet to form a PV cell module; and FIG. 9 is another embodiment of a PV cell module including a PV cell An exploded cross-sectional side view of an example.

Referring to the figures (where the same numbers are used throughout the drawings, the same numerals indicate the same parts), a photovoltaic (PV) battery module formed in accordance with the method of the present invention is generally shown at 20 . The PV battery module 20 is hereinafter referred to as a module 20 . The components of the module 20 of the present invention are not necessarily drawn to scale in the drawings such that they may be larger or smaller than those shown.

Referring to Figure 1, a plurality of modules 20 are connected to form a pair of arrays 22 . Array 22 can be planar or non-planar. Although shown for this configuration/configuration, the modules 20 can be used alone or in groups of two or more (eg, as shown in FIG. 1) and can be used in a variety of applications, such as structures, buildings, Vehicles, devices, etc. The invention is not limited to any particular configuration or use of module 20 or array 22 . Module 20 can be used to convert light energy into electrical energy.

Referring to FIG. 2, the module 20 includes a substrate 24 . The substrate 24 has a front face 26 and a back face 28 that are spaced apart from the front face 26 . Substrate 24 can be substantially planar or non-planar. Substrate 24 may also be referred to in the art as a back cover sheet 24 . The substrate 24 is adapted to provide support, protection and/or interface to the module 20 .

The substrate 24 can be formed from a variety of materials. Examples of suitable materials include glass, polymeric materials, composite materials, and the like. For example, the substrate 24 may be formed of glass, polyethylene terephthalate (PET), thermoplastic elastomer (TPE), polyvinyl fluoride (PVF), polyfluorene, or the like. Substrate 24 can be formed from a combination of different materials, such as polymeric materials and fibrous materials. Substrate 24 can have portions formed from one material (e.g., glass) and other portions formed from another material (e.g., polymeric material). Substrate 24 can have various thicknesses, such as on average from about 0.05 to about 5, from about 0.1 to about 4, or from about 0.125 to about 3.2 millimeters (mm), or any range between the lowest and highest of such values. . The thickness of the substrate 24 can be uniform or variable.

Other examples of suitable substrates 24 include those described in U.S. Application Publication Nos. 2008/0276983, 2011/0005066, and 2011/0061724, and WO Publication Nos. 2010/051355 and 2010/141697. Other examples of suitable substrates 24 include those described in U.S. Patent Application Serial No. 61/725,277, the entire disclosure of which is incorporated herein by reference. The above disclosure is hereinafter referred to as "incorporated references" which are hereby incorporated by reference in its entirety inso- In the event of any inconsistency between the present invention and any of the incorporated references, the subject matter of any of the incorporated references should be The references incorporated herein are incorporated by reference.

The module 20 further includes a cover sheet 30 . The cover sheet 30 has a front face 32 and a back face 34 that are spaced apart from the front face 32 . Cover sheet 30 can be substantially planar or non-planar. The cover sheet 30 is adapted to protect the module 20 from environmental conditions such as rain, snow, dust, heat, and the like. Typically, cover sheet 30 is transparent to the UV and/or visible light as understood in such techniques to concentrate light energy. In other words, the cover sheet 30 is typically optically transparent. The cover sheet 30 is generally the male side or the front side of the module 20 .

Cover sheet 30 can be formed from a variety of materials as understood in the art. Examples of suitable materials include those described above with respect to the description of substrate 24 . Other examples of suitable cover sheets 30 include those described in the incorporated references. In some embodiments, the cover sheet 30 is formed from glass. Various types of glass can be utilized, such as cerium oxide glass, polymeric glass, and the like. The cover sheet 30 can be formed from a combination of different materials. The cover sheet 30 can have a portion formed of one material (e.g., glass) and other portions formed of another material (e.g., a polymeric material). The cover sheet 30 can be the same as or different from the substrate 24 . For example, both the cover sheet 30 and the substrate 24 can be formed from glass of equal or different thickness.

The cover sheet 30 can have various thicknesses, such as on average from about 0.5 to about 10, from about 1 to about 7.5, from about 2.5 to about 5, or about 3 mm, or any between the lowest and highest of the values. range. The thickness of the cover sheet 30 can be uniform or variable. Other examples of suitable cover sheets 30 include those described in the incorporated references, such as those described in the '277 application as "top panels."

The module 20 further includes a first PV cell 36 and a second PV cell 38 . The PV cells 36 , 38 are disposed between the substrate 24 and the cover sheet 30 . As best shown in FIGS. 2 through 4, the second PV cell 38 is adjacent to the first PV cell 36 . The first PV cell 36 has a front face 40 and a back face 42 that are spaced apart from the front face 40 . The second PV cell 38 also has a front face 44 and a back face 46 that are spaced apart from the front face 44 .

As best shown in Figure 3, the PV cells 36 , 38 are substantially coplanar with each other. As shown in Figures 3 and 4, the module 20 can include more than just a pair of PV cells 36 , 38 . The PV cells 36 , 38 can be configured in a variety of patterns, such as a series of PV cells 36 , 38 in a grid-like pattern. The PV cells 36 , 38 can be offset from each other, such as in a non-planar module 20 .

The PV cells 36 , 38 can be of various sizes, are of various types and are formed from a variety of materials. Examples of suitable PV cells 36 , 38 include those described in the incorporated references. The first PV cell 36 can be the same or different than the second PV cell 38 . The PV cells 36 , 38 can have various thicknesses, such as on average from about 50 to about 250, from about 100 to about 225, from about 175 to about 225, or about 180 μm, or between the lowest and highest of the values. Any range. PV cells 36 , 38 can also have a variety of widths and lengths as understood in this technique. In certain embodiments, PV cells 36 , 38 may be referred to in the art as crystalline 矽 PV cells 36 , 38 . Other examples of suitable PV cells 36 , 38 include those described in the incorporated references, such as those described in the '277 application.

As best shown in FIG. 2, interconnect strips 48 are disposed between PV cells 36 , 38 . A series of two or more connected PV cells 36 , 38 may be referred to in the art as a battery string. The interconnect strip 48 has a first end 50 operatively coupled to the front face 40 of the first PV cell 36 and a second end 52 operatively coupled to the back face 46 of the second PV cell 38 . As best shown in FIG. 4, a pair of interconnecting strips 48 are connected between the PV cells 36 , 38 with the interconnecting strips 48 spaced apart from one another. The interconnect strip 48 is adapted to establish circuitry in the module 20 . The ends 50 , 52 of the interconnect strip 48 generally extend over the faces 40 , 42 , 44 , 46 of the PV cells 36 , 38 , as shown in Figure 2; however, they may also be longer or shorter than those described in the various figures.

The interconnect strips 48 can be formed from a variety of electrically conductive materials, such as metals, conductive polymers, or combinations thereof. Examples of other suitable materials include those described in the incorporated references. The interconnect strips 48 are adapted to connect the PV cells 36 , 38 together, and to other components, such as bussing (not shown), other modules 20, and the like. The PV cells 36 , 38 may be connected by interconnecting strips 48 in series or in parallel. The interconnect strips 48 are typically connected to busbars (not shown) to establish circuitry and carry the energy collected by the PV cells 36 , 38 .

Although referred to as interconnected strips 48 , interconnect strips 48 can have a variety of shapes and sizes, and can also be referred to in the art as interconnects, busbars, wires, or leads, depending on shape, size, location, and the like. The interconnect strips 48 can have various dimensions, such as an average of from about 0.125 to about 2 mm thick and/or wide.

As best shown in FIG. 3, a first polymeric strip 54 is disposed between the first PV cell 36 and the cover sheet 30 to couple the front face 40 of the first PV cell 36 with the back side 34 of the cover sheet 30 . "Coupled" as used herein generally means a physical connection unless otherwise indicated. The first polymeric strip 54 is formed from a first polymeric composition.

The first polymeric composition can be formed from a variety of polymer compositions. Usually, the first aggregation The composition is polyfluorene oxide, more typically a polyoxyxene elastomer. Suitable polyoxygenates include branched and unbranched, more typically unbranched oligomeric or polymeric organooxanes. Examples of suitable polymeric compositions include rhodium hydrogenation, condensation, and rhodium hydrogenation/condensation reaction curable polydecane compositions.

In certain embodiments, the first polymeric strip 54 is formed from a rhodium hydrogenation curable polydecaneoxy composition. In other embodiments, the first polymeric composition comprises a diorganopolyoxyalkylene having an alkenyl group (e.g., a vinyl group) having a hydrazine-bonded hydrogen atom reactive with the alkenyl group of the diorganopolyoxyalkylene oxide. Hydrogenated organic hydrazine and unreactive organic polyoxyalkylene. "Non-reactive" generally means that the non-reactive organopolyoxane does not react with the diorganopolyoxane or the hydrogenated organic hydrazine. Examples of suitable diorganopolyoxyalkylenes, hydrogenated organic phosphoniums, and non-reactive organic polyoxyalkylenes include those described in the incorporated references.

The diorganopolysiloxane and the hydrogenated organogermanium will generally react to form a polyoxyloxy polymer in the presence of an unreactive organopolyoxane and optionally other components. The non-reactive organopolyoxane is useful for adjusting the physical properties of the polyoxyalkylene polymer, as further described below. Examples of suitable additive components, such as catalysts, include those described in the incorporated references.

In certain embodiments, the diorganopolyoxyalkylene oxide is dimethylvinyl terminated dimethyloxane, the hydrogenated organic hydrazine is hydrogen terminated dimethyloxane, and the non-reactive organic polyoxane The alkane is polydimethyl methoxyoxane (PDMS).

In a particular embodiment, the first polymeric composition comprises, consists essentially of, or consists of: two different dimethylvinyl-terminated polydimethyloxane; dimethyl Hydrogen terminated polydimethyl siloxane; and trimethyl decyloxy terminated dimethyl methyl hydro oxane containing at least 3 SiH units per molecule. In other words, the first polymeric strip 54 can be the reaction product of such components. The reaction can be catalyzed by a rhodium hydrogenation catalyst (e.g., a platinum ligand complex), which can be included in or added to the first polymeric composition. In this embodiment, the reaction typically occurs in the presence of PDMS, which may also be included or added to the first polymeric composition. If utilized, the PDMS is non-reactive, for example, non-reactive with the above reactants of the first polymeric composition. As mentioned above, the inclusion of components such as PDMS is suitable for modulating the physical properties of the reaction product.

In the above embodiments, the components of the first polymeric composition may be included in various amounts. Typically, the first polymeric composition comprises greater than about 45, greater than about 50, greater than about 55, greater than about 60, or greater than about 65 parts by weight of the diorganopolysiloxane, each of which is based on 100 parts by weight of the first polymeric composition, Or any range between the lowest and highest of these values. Typically, the first polymeric composition comprises from about 2.5 to about 7.5, from about 3 to about 7, or from about 3.5 to about 6.5 parts by weight of hydrogenated organohydrazine, each based on 100 parts by weight of the first polymeric composition, or such Any range between the lowest and highest of the values. Typically, the first polymeric composition has from about 25 to about 65, or from about 30 to about 60 parts by weight of non-reactive organopolyoxane, each based on 100 parts by weight of the first polymeric composition, or equivalent thereto. Any range between the lowest and highest.

The first polymeric composition may also be referred to in the art as a sealant composition. Specific examples of suitable sealant compositions suitable for use as the first polymeric composition are available from Dow Corning Corporation (Midland, MI), such as Dow Corning® PV-6100 battery sealant. Other examples of suitable sealant compositions include those described in the incorporated references, such as those described in the '277 application as "polyoxygenated sealants."

As best shown in FIG. 3, a second polymeric strip 56 is disposed between the second PV cell 38 and the cover sheet 30 to couple the front face 44 of the second PV cell 38 with the back side 34 of the cover sheet 30 . As generally shown, the polymeric strips 54 , 56 are horizontally and juxtaposed. Moreover, the polymeric strips 54 , 56 are disposed generally perpendicular to the direction of the interconnecting strips 48 . Typically, the second polymeric strip 56 is also formed from the first polymeric composition. Thus, both polymeric strips 54 , 56 can be formed from the first polymeric composition as described above. As mentioned above, there may be slight differences between the polymeric strips 54 , 56 , such as the rate of cure.

Each of the polymeric strips 54 , 56 can have various thicknesses, such as an average of from about 0.125 to about 0.75, from about 0.2 to about 0.5, or from about 0.25 to about 0.45 mm, or between the lowest and highest of the values. Any range. Typically, the thickness of the polymeric strips 54 , 56 is varied to minimize the amount of use of the first polymeric composition, thereby reducing the cost of manufacturing the module 20 , while also providing the PV cells 36 , 38 and/or interconnect strips 48. The extent of bottoming out is minimized or the PV cells 36 , 38 and/or interconnecting strips 48 are prevented from bottoming out.

As used herein, "bottoming" refers to the situation where PV cells 36 , 38 and/or interconnect strips 48 will contact cover sheet 30 , which can cause damage. Such a situation may occur during the manufacture and/or use of the module 20 . This situation is not desirable. Thus, the polymeric strips 54 , 56 are adapted to cushion and protect the PV cells 36 , 38 and the interconnecting strips 48 from the cover sheet 30 in the event that the PV cells 36 , 38 and the interconnect strip 48 and the cover sheet 30 are likely to contact each other. .

Typically, each polymeric strip 54 , 56 is sandwiched between PV cells 36 , 38 , as best illustrated in Figure 3; however, between polymeric strips 54 , 56 and cover sheet 30 and/or polymeric strips 54 There may be at least one intervening layer (not shown) between the 56 and the PV cells 36 , 38 . Each of the polymeric strips 54 , 56 can have various widths, such as an average of from about 0.5 to about 25, from about 1.25 to about 13, or from about 2.5 to about 6.4 mm, or between the lowest and highest of the values. Any range. The width of the polymeric strips 54 , 56 can be uniform or variable.

As best shown in FIG. 4, the polymeric strips 54 , 56 each have a width that is less than the width of the PV cells 36 , 38 . The polymeric strips 54 , 56 can have a width equal to or greater than the width of the PV cells 36 , 38 .

As shown in Figure 3, the polymeric strips 54 , 56 each have a substantially rectangular cross section. While the edges of the polymeric strips 54 , 56 are illustrated as being convex, the edges can be straight, concave, or a combination of shapes.

As best shown in FIG. 4, the polymeric strips 54 , 56 are disposed laterally relative to the interconnecting strips 48 . Typically, the polymeric strips 54, 56 extending laterally across the module 20 to the module on the module periphery 20 of the tip 20. In general, there is at least one polymeric strip 54 , 56 for each PV cell 36 , 38 . There may be two or more narrower polymeric strips 54 , 56 for each PV cell 36 , 38 .

As best shown in FIG. 3, the tie layer 58 is disposed between the substrate 24 and the cover sheet 30 and between the polymeric strips 54 , 56 . Connector suitable for coupling layer 58 covers the back surface 30 of the sheet 34 and the front substrate 24 of the coupling 26 and the PV cells 36, 38 of the back 42, 46 and 24 of the front substrate 26. Connection layer 58 may also be referred to as polymeric connection layer 58 in the art.

The tie layer 58 is formed from a second polymeric composition. The second polymeric composition of tie layer 58 is different from the first polymeric composition of polymeric strips 54 , 56 . The first polymeric composition and the second polymeric composition can vary in various aspects, such as being chemically and/or physically different. Typically, the first polymeric composition and the second polymeric composition differ in a manner such as providing a different modulus of elasticity. Different examples are described below.

The second polymeric composition can be formed from a variety of polymer compositions. Typically, the second polymeric composition is polyfluorene oxide, more typically a polyoxyxene elastomer. Examples of suitable polymeric compositions include rhodium hydrogenation, condensation, and rhodium hydrogenation/condensation reaction curable polydecane compositions.

In certain embodiments, the tie layer 58 is formed from a rhodium hydrogenation curable polydecaneoxy composition. In other embodiments, the second polymeric composition comprises a diorganopolyoxyalkylene having an alkenyl group (e.g., a vinyl group) and a hydrazine-bonded hydrogen atom having reactivity with the alkenyl group of the diorganopolyoxyalkylene oxide. Hydrogenated organic hydrazine. Examples of suitable diorganopolyoxyalkylenes, hydrogenated organic phosphoniums, and non-reactive organic polyoxyalkylenes include those described in the incorporated references.

The diorganopolysiloxane and the hydrogenated organogermanium will generally react to form a polyoxyl polymer in the presence of other components as appropriate. Examples of suitable components, such as catalysts, include those described in the incorporated references.

In certain embodiments, the diorganopolyoxyalkylene oxide is dimethylvinyl terminated dimethyloxane, and the hydrogenated organic hydrazine is hydrogen terminated dimethyl methoxyoxane. As described above, the second polymeric composition is different from the first polymeric composition. Examples of differences between the first polymeric composition and the second polymeric composition include the inclusion of an unreactive organopolyoxane in the first polymeric composition and the non-reactive organopolyoxyalkylene in the second polymeric composition.

In a particular embodiment, the second polymeric composition comprises, consists essentially of, or consists of: dimethyl vinyl terminated polydimethyl siloxane; dimethyl hydrogen terminated poly a methyl methoxy oxane; and a trimethyl decyloxy-terminated dimethylmethylhydroquinone containing at least 3 SiH units per molecule. In other words, the tie layer 58 can be the reaction product of such components. The reaction can be catalyzed by a rhodium hydrogenation catalyst, such as a platinum ligand complex, which can be included in or added to the second polymeric composition.

In the above embodiments, the components of the second polymeric composition may be included in various amounts. Typically, the second polymeric composition comprises greater than about 55, greater than about 60, or greater than about 65 parts by weight of the diorganopolyoxyalkylene, each in terms of 100 parts by weight of the second polymeric composition, or the lowest of the equivalents Any range between the highest and the highest. Typically, the second polymeric composition comprises from about 5 to about 25, from about 5 to about 20, or from about 8 to about 22.5 parts by weight of hydrogenated organohydrazine, each based on 100 parts by weight of the second polymeric composition, or equivalent thereto Any range between the lowest and highest.

The second polymeric composition may also include other components such as decane or decane. These components can be included in various amounts. In certain embodiments, the second polymeric composition further comprises organodecane and/or dimethylmethylhydroquinone. The components may be included in various amounts, such as less than about 5 parts by weight, or from about 0.1 to about 2.5 parts by weight, each based on 100 parts by weight of the second polymeric composition, or the lowest and highest of the equivalents. Any range between the people.

In another specific embodiment, the second polymeric composition comprises, consists essentially of, or consists of: dimethylvinyl terminated polydimethyl siloxane; and at least 3 per molecule The trimethylsulfanyloxy-terminated dimethylmethylhydroquinone of the SiH unit. In other words, the tie layer 58 can be the reaction product of such components. The reaction can be catalyzed by a rhodium hydrogenation catalyst, such as a platinum ligand complex, which can be included in or added to the second polymeric composition.

In the above embodiments, the components of the second polymeric composition may be included in various amounts. Inside. Typically, the second polymeric composition comprises from about 80 to about 99.9, from about 90 to about 99.9, or from about 95 to about 99.9 parts by weight of dimethylvinyl terminated polydimethyloxane (eg, dimethyloxane) , dimethylvinyl alkoxy-terminated polymer), each in terms of 100 parts by weight of the second polymeric composition, or any range between the lowest and highest of such values. Typically, the second polymeric composition comprises from about 0.01 to about 2, from about 0.05 to about 1, or from about 0.05 to about 0.5 parts by weight of a platinum ligand complex (eg, 1,3-divinyl-1,1,3, 3-tetramethyldioxane complex (Pt)), each in terms of 100 parts by weight of the second polymeric composition, or any range between the lowest and highest of such values. Typically, the second polymeric composition comprises from about 0.01 to about 7.5, from about 0.1 to about 5, or from about 0.2 to about 2.5 parts by weight of alkoxydecane (e.g., methacryloxypropyltrimethoxydecane), each 100 parts by weight of the second polymeric composition, or any range between the lowest and highest of the equivalents. Typically, the second polymeric composition comprises from about 0.05 to about 7.5, from about 0.1 to about 5, or from about 0.5 to about 2.5 parts by weight of a trimethyldecyloxy-terminated dimethylmethyl group containing at least 3 SiH units per molecule. Hydroquinoxane (eg, dimethyl, methylhydroquinoxane, trimethyldecyloxy terminated), each based on 100 parts by weight of the second polymeric composition, or the lowest and highest of the equivalents Any range between the people. Typically, the second polymeric composition comprises from about 0.001 to about 2.5, from about 0.005 to about 1, or from about 0.005 to about 0.5 parts by weight of a decane (e.g., tetramethyltetravinylcyclotetraoxane), each at a weight of 100 The second polymeric composition, or any range between the lowest and highest of the equivalents.

The second polymeric composition may also be referred to in the art as a sealant composition. Specific examples of suitable sealant compositions suitable for use as the second polymeric composition are available from Dow Corning Corporation, such as Dow Corning® PV-6150 battery sealant. Other examples of suitable sealant compositions include those described in the incorporated references, such as those described in the '277 application as "polyoxygenated tie layers."

As best shown in FIG. 3, the interconnect strips 48 are sealed by a tie layer 58 . Sealing the interconnect strips 48 with the tie layer 58 is suitable for protecting the interconnect strips 48 . The first end 50 of the interconnect strip 48 may be covered by one of the polymeric strips 54 , 56 and/or may be covered by the tie layer 58 .

Without being bound or limited by any particular theory, it is believed that the tie layer 58 protects the interconnect strips 48 during thermal cycling of the module 20 . For example, PV modules are susceptible to movement based on thermal expansion and contraction when conventional modules are heated or cooled. Over time, the interconnect strips are stretched and pinched between the PV cells 36 , 38 , which ultimately causes the interconnect strip to break or degrade. However, the connection layer 58 substantially maintains the orientation of the PV cells 36 , 38 relative to conventional modules, and thus, the interconnect strips 48 thus reduce or even prevent the aforementioned problems associated with the thermal cycling of conventional modules. It is believed that the modulus of elasticity of the tie layer 58 helps maintain the orientation of the PV cells 36 , 38 when the module 20 is exposed to temperature changes, such as during testing or use. The modulus is described below. The PV cells 36 , 38 are still movable to some extent due to thermal fluctuations within the module 20 , i.e., they are generally not fully latched at a certain location.

The tie layer 58 can have various thicknesses, such as on average from about 0.125 to about 1.25, from about 0.2 to about 0.5, or from about 0.25 to about 0.4 mm, or any range between the lowest and highest of such values. The thickness of the tie layer 58 is generally defined between the cover sheet 30 and the substrate 24 . The thickness can also be defined by the intermediate layer, if present. Typically, the thickness of the tie layer 58 is varied to minimize the amount of use of the second polymeric composition, thereby reducing the cost of manufacturing the module 20 while also bottoming out the PV cells 36 , 38 and/or interconnecting strips 48 . The degree is minimized or the PV cells 36 , 38 and/or interconnecting strips 48 are prevented from bottoming out.

As used herein, "bottoming" refers to the situation where PV cells 36 , 38 and/or interconnect strips 48 will contact cover sheet 30 and/or substrate 24 , which can cause damage. Such a situation may occur during the manufacture and/or use of the module 20 . This situation is not desirable. Thus, the tie layer 58 is adapted to achieve buffering and protection of the PV cells 36 , 38 and interconnect strips 48 .

Typically, the tie layer 58 is sandwiched between the cover sheet 30 and the substrate 24 , as best illustrated in FIG. 3; however, there may be a connection between the tie layer 58 and the cover sheet 30 and/or between the tie layer 58 and the substrate 24 . At least one insertion layer (not shown). For example, there may be an intervening layer disposed between the tie layer 58 and the substrate 24 . Such an insert layer is suitable for thickness and strength control of the module 20 . One example of a suitable insert layer is a non-woven fiberglass (FG) layer. If an intervening layer is included, the intervening layer can also be formed from other materials such as PET, nylon or polyoxyl. In some embodiments (not shown), the module 20 includes a non-woven FG layer disposed between the substrate 24 and the tie layer 58 .

Typically, the elastic modulus of the tie layer 58 is greater than the elastic modulus of the polymeric strips 54 , 56 . In other words, the polymeric strips 54 , 56 are generally softer than the tie layer 58 . In these embodiments, having different moduli is suitable for protecting PV cells 36 , 38 and interconnect strips 48 as described above. The modulus can vary depending on the type of first polymeric composition and second polymeric composition utilized. In certain embodiments, the tie layer 58 has a shear modulus of from about 15 to about 50, from about 17.5 to about 40, or from about 20 to about 30 kilopascals (kPa), and the polymeric strips 54 and 56 are sheared. The shear modulus is from about 0.5 to about 12.5, from about 1 to about 10, from about 1 to about 7.5, from about 1 to about 5, or from about 1 to about 3 kPa, or the lowest and highest of the values. Any range between. In other embodiments, the tie layer 58 has a shear modulus of from about 50 to about 2000, from about 50 to about 1750, from about 50 to about 1500, from about 50 to about 1250, from about 50 to about 1000, from about 50 to about 750, from about 75 to about 600, from about 100 to about 500, from about 150 to about 450, from about 200 to about 400, or from about 200 to about 300 kPa, and the shear modulus of the polymeric strips 54 , 56 is such as Or any range between the lowest and highest of the values. As noted above, it is believed that the modulus of elasticity of the tie layer 58 helps maintain the orientation of the PV cells 36 , 38 when the module 20 is exposed to temperature changes (e.g., during thermal cycling, expansion/contraction, etc.).

Module 20 can have a variety of shapes, sizes, and configurations. In certain embodiments, the module 20 has a length of from about 1.6 to about 2.0 meters (m) and a width of from about 0.7 to about 1.1 m, or any range between the lowest and highest of the values. Module 20 is not limited to any particular shape, length or width.

Referring to Figure 9, another embodiment of a module 20 is depicted. The module 20 includes PV cells 36a , 36b and interconnecting strips 48 disposed between the substrate 24 and the cover sheet 30 . The polymeric strips 66 are disposed adjacent to the interconnecting strips 48 . In such embodiments, the polymeric strips 66 are generally disposed in parallel with respect to the direction of the interconnecting strips 48 . Polymeric strips 66 can be formed from the first polymeric composition. The connection layer 68 is disposed between the substrate 24 and the cover sheet 30 . Portions of the tie layer 68 are also disposed between the polymeric strip 66 , the PV cell 36a and the cover sheet 30 . The tie layer 68 can be formed from a second polymeric composition. In other embodiments (not shown), the module 20 of Figure 9 can further include polymeric strips 54 , 56 as described above.

In other embodiments (not shown), the module 20 may further include a "peripheral connection layer" as described in U.S. Patent Application Serial No. 61/591,005 (Attorney Docket No. DC11205 PSP1; 071038.00787) and/or as "Polymerized strips" as described in U.S. Patent Application Serial No. 61/59,1000 (Attorney Docket No. DC11226 PSP1; 071038.00811), the disclosure of which is hereby incorporated by the extent of The manner of full reference is incorporated herein. In the event of any conflict between the present invention and any of the incorporated references, only any part of the incorporated references that conflict with the present invention should be The entire text is deleted from the references incorporated herein by reference. In still other embodiments (not shown), the module 20 can include other components, such as at least one spacer disposed along the perimeter. These components are described in the incorporated references.

The method of the present invention for forming the module 20 of the present invention comprises the steps of applying a first polymeric composition to the first and second portions of the backside 34 of the cover sheet 30 to form the first polymeric strip 54 and the second polymeric strip 56 . . In this coating stage, the first polymeric strip 54 and the second polymeric strip 56 are generally in an uncured state, such as a liquid form, to facilitate ease of application. As shown in Figure 5, the portions are spaced apart from each other and there is a portion of each polymeric strip 54 , 56 . The first polymeric composition can be applied to the back side 34 by various means, such as by spraying, dispensing, flow coating, injecting, and the like.

In other embodiments, the first polymeric strip 54 and the second polymeric strip 56 are preformed and disposed on the back side 34 of the cover sheet 30 . For example, a polymer sheet can be made from the first polymeric composition and cut into polymeric strips 54 , 56 , or a polymeric strip can be pre-formed from the first polymeric composition and disposed on the back side 34 of the cover sheet 30 . In certain embodiments, the first polymeric composition is dispensed (or placed) on the back side 34 by a robot.

As shown in FIG. 5, the display robotic dispenser 60 applies a first polymeric composition to the cover sheet 30 such that a gap remains on the back side 34 of the cover sheet 30 . The robotic dispenser 60 typically has one or more nozzles 62 from which the first polymeric composition is dispensed. Nozzles 62 can be selectively opened or closed to provide polymeric strips 54 , 56 of various widths. Thus, one or more nozzles 62 can be used to form each of the polymeric strips 54 , 56 . The first polymeric strip 54 and the second polymeric strip 56 can be formed independently or simultaneously, i.e., at the same or different times. The robotic dispenser 60 can be on a track and/or arm (not shown) and programmed to move along the length and/or width of the cover sheet 30 to form polymeric strips 54 , 56 . In the alternative, the cover sheet 30 can also be moved relative to the robotic dispenser 60 , or both can be moved relative to each other.

The first polymeric composition can be applied to the cover sheet 30 in various amounts. For example, the first polymeric composition can be applied such that the polymeric strips 54 , 56 each have an average thickness of from about 0.125 to about 0.7 mm and an average width of from about 1.25 to about 13 mm, or the lowest of these values. Any range between the person and the highest. The polymeric strips 54 , 56 can each have the same or different dimensions.

After the first polymeric composition is applied to the cover sheet 30 to form polymeric strips 54 , 56 , the PV cells 36 , 38 are disposed on the polymeric strips 54 , 56 . In particular, the first PV cell 36 is disposed on the first polymeric strip 54 and the second PV cell 38 is disposed on the second polymeric strip 56 . The polymeric strips 54 , 56 may be allowed to level before the placement of the PV cells 36 , 38 to prevent gaps, voids or other problems. The PV cells 36 , 38 can be placed independently or simultaneously.

As shown in FIG. 6, interconnect strip 48 is operatively coupled to PV cells 36 , 38 . The interconnect strips 48 can be connected after placement of the PV cells 36 , 38 or prior to placement of the PV cells 36 , 38 .

The PV cells 36 , 38 , such as a hand or robotic fixture 64 , can be placed by various means. The robotic fixture 64 can hold the PV cells 36 , 38 using vacuum or other means. The robotic clamp 64 can be operatively coupled to a track and/or arm (not shown) for movement. PV cells may be 36, 38 is simply placed in the polymerization strips 54, 56 on top of or slightly pressed into the polymeric strips 54, 56. Pressing generally ensures that there are no gaps or voids between the respective polymeric strips 54 , 56 and the respective PV cells 36 , 38 .

The polymeric strips 54 , 56 may be cured (to a final cured state or partially cured) before or after placement of the PV cells 54 , 56 . For example, the polymeric strips 54 , 56 can be cured via an oven prior to placement of the PV cells 36 , 38 . Applying heat to the polymeric strips 54 , 56 generally aids in curing the polymeric strip from the uncured state to the final cured state. In certain embodiments, the polymeric strips 54 , 56 generally have a viscosity when placing the PV cells 36 , 38 , which allows for any air trapped between the polymeric strips 54 , 56 and the PV cells 36 , 38 . In the meantime, it migrates outward. In this way, bubbles are not formed and/or trapped because the bubbles may create a negative problem with the module 20 . The viscosity can be the initial viscosity of the first polymeric composition (i.e., prior to curing) or the higher viscosity that occurs after the polymeric strips 54 , 56 are at least partially cured. Although not required, these embodiments are applicable to the case where the module 20 is cured via a vacuum-pressure process.

Typically, after placement of the PV cells 36 , 38 , a second polymeric composition is applied over the polymeric strips 54 , 56 on the backside 34 of the cover sheet 30 and onto the PV cells 36 , 38 and interconnect strips 48 to form Connection layer 58 . During this coating stage, the tie layer 58 is typically in an uncured state, such as a liquid form, to facilitate ease of application. The second polymeric composition can be applied by various means, such as by spraying, dispensing, flow coating, injecting, and the like. In certain embodiments, the second polymeric composition is dispensed by a robot.

In certain embodiments, a portion of the second polymeric composition is applied to the gap remaining on the back side 34 of the cover sheet 30 during application of the first polymeric composition prior to placement of the PV cells 36 , 38 . In such embodiments, the second polymeric composition can be applied after or simultaneously with the first polymeric composition. After coating, at least one of the first polymeric composition and the second polymeric composition can be allowed to level and/or cure as described above, and then the PV cells 36 , 38 are disposed. In other embodiments described below, all of the second polymeric composition is applied after placement of the PV cells 36 , 38 .

As shown in Figure 7, the robotic dispenser 60 is shown applying a second polymeric composition to the cover sheet 30 . The dispenser robot 60 may be the same or different from the first coating of polymerizable composition dispenser 60 robot. The robotic dispenser 60 can be on a track and/or arm (not shown) and programmed to move along the length and/or width of the cover sheet 30 to form the tie layer 58 . In the alternative, the cover sheet 30 can also be moved relative to the robotic dispenser 60 , or both can be moved relative to each other. Nozzle 62 can be selectively opened or closed to control the amount and location of the second polymeric composition.

The second polymeric composition can be applied in various amounts to form the tie layer 58 . Typically, the second polymeric composition is applied such that the tie layer 58 has an average thickness of from about 0.2 to about 1.25 mm or any range between such equivalents.

After coating all of the second polymeric composition, substrate 24 and cover sheet 30 are combined to form module 20 . The substrate 24 and the cover sheet 30 can be combined in various ways. For example, the substrate 24 can be placed on the connection layer 58 to form the module 20 . As shown in FIG. 8, substrate 24 can be laminated to tie layer 58 to form module 20 . In some embodiments, an intermediate layer (not shown) is placed over the tie layer 58 prior to placement of the substrate 24 . The intermediate layer may also be referred to as a spacer layer in the art.

In certain embodiments, the connecting layer 58 in the substrate 24 in combination with a cover sheet 30 typically has a certain viscosity, which allows the connection may be trapped within the layer 58 to / from which migration of any entrapped air connection layer 58 outwardly. In this way, bubbles are not formed and/or trapped because the bubbles may cause problems for the module 20 . The viscosity may be the initial viscosity of the second polymeric composition (i.e., prior to curing) or the higher viscosity that occurs after the tie layer 58 is at least partially cured. Although not required, these embodiments are applicable to the case where the module 20 is cured via a vacuum-pressure process.

The polyoxymethylene composition used to form the tie layer 58 typically has a complex (dynamic) viscosity of 10,000 to 5,000,000 cP (measured at 1 ° to 5% strain at 1 radians/second at 25 ° C). More specifically, a frequency sweep was generated on a TA Instruments HR-2 parallel plate rheometer. The sample was loaded between two 25 mm parallel plates to a thickness of 2 mm. The frequency sweep was performed at 5% strain from 0.1 radians/sec to 100 radians/sec, and the dynamic (plural) viscosity (cP) was reported at 1 radians/sec. In other embodiments, the complex viscosity as measured above at 25 ° C is from 15,000 to 100,000, 20,000 to 95,000, 25,000 to 90,000, 30,000 to 85,000, 35,000 to 75,000, 40,000 to 70,000, 45,000 to 65,000, 50,000 to 60,000, or 55,000 to 60,000 cP. In other embodiments, the complex viscosity as measured above at 25 °C is 50,000 to 100,000, 55,000 to 95,000, 60,000 to 90,000, 65,000 to 85,000, 70,000 to 80,000, or 75,000 to 80,000 cP.

In other embodiments, the complex viscosity as measured above at 25 ° C is from 35,000 to 300,000, 40,000 to 295,000, 45,000 to 290,000, 50,000 to 285,000, 55,000 to 280,000, 60,000 to 275,000, 65,000 to 275,000, 70,000 to 270,000, 75,000 to 265,000, 80,000 to 260,000, 85,000 to 255,000, 90,000 to 250,000, 95,000 to 245,000, 100,000 to 240,000, 105,000 to 235,000, 110,000 to 230,000, 115,000 to 225,000, 120,000 to 220,000, 125,000 to 215,000, 130,000 to 210,000, 135,000 to 205,000, 140,000 to 200,000, 145,000 to 195,000, 150,000 to 190,000, 155,000 to 185,000, 160,000 to 180,000, 165,000 to 175,000, or 165,000 to 170,000, 80,000 to 200,000, 40,000 to 200,000, or 40,000 to 300,000.

In other embodiments, the complex viscosity as measured above at 25 ° C is 100,000 to 1,000,000, 125,000 to 975,000, 150,000 to 950,000, 175,000 to 925,000, 200,000 to 900,000, 225,000 to 875,000, 250,000 to 850,000, 275,000 to 825,000, 300,000 to 800,000, 325,000 to 775,000, 350,000 to 750,000, 375,000 to 725,000, 400,000 to 700,000, 425,000 to 675,000, 450,000 to 650,000, 475,000 to 625,000, 500,000 to 600,000, 525,000 to 575,000, or 550,000 to 575,000 cP.

In even other embodiments, the complex viscosity as measured above, at 25 ° C, is 1,125,000 to 1,975,000, 1,150,000 to 1,950,000, 1,175,000 to 1,925,000, 1,200,000 to 1,900,000, 1,225,000 to 1,875,000, 1,250,000 to 1,850,000, 1,275,000 to 1,825,000, 1,300,000 to 1,800,000, 1,325,000 to 1,775,000, 1,350,000 to 1,750,000, 1,375,000 to 1,725,000, 1,400,000 to 1,700,000, 1,425,000 to 1,675,000, 1,450,000 to 1,650,000, 1,475,000 to 1,625,000, 1,500,000 to 1,600,000, 1,525,000 to 1,575,000, 1,550,000 to 1,575,000, 2,125,000 to 2,975,000, 2,150,000 to 2,950,000, 2,175,000 to 2,925,000, 2,200,000 to 2,900,000, 2,225,000 to 2,875,000, 2,250,000 to 2,850,000, 2,275,000 to 2,825,000, 2,300,000 to 2,800,000, 2,325,000 to 2,775,000, 2,350,000 to 2,750,000, 2,375,000 to 2,725,000, 2,400,000 to 2,700,000, 2,425,000 to 2,675,000, 2,450,000 to 2,650,000, 2,475,000 to 2,625,000, 2,500,000 to 2,600,000, 2,525,000 to 2,575,000, 2,550,000 to 2,575,000, 3,125,000 to 3,975,000, 3,150,000 to 3,950,000, 3,175 , 000 to 3,925,000, 3,200,000 to 3,900,000, 3,225,000 to 3,875,000, 3,250,000 to 3,850,000, 3,275,000 to 3,825,000, 3,300,000 to 3,800,000, 3,325,000 to 3,775,000, 3,350,000 to 3,750,000, 3,375,000 to 3,725,000, 3,400,000 to 3,700,000, 3,425,000 to 3,675,000, 3,450,000 to 3,650,000, 3,475,000 Up to 3,625,000, 3,500,000 to 3,600,000, 3,525,000 to 3,575,000, 3,550,000 to 3,575,000, 4,125,000 to 4,975,000, 4,150,000 to 4,950,000, 4,175,000 to 4,925,000, 4,200,000 to 4,900,000, 4,225,000 to 4,875,000, 4,250,000 to 4,850,000, 4,275,000 to 4,825,000, 4,300,000 to 4,800,000, 4,325,000 to 4,775,000 4,350,000 to 4,750,000, 4,375,000 to 4,725,000, 4,400,000 to 4,700,000, 4,425,000 to 4,675,000, 4,450,000 to 4,650,000, 4,475,000 to 4,625,000, 4,500,000 to 4,600,000, 4,525,000 to 4,575,000, or 4,550,000 to 4,575,000 cP.

Any one or more of the above values can be increased by an order of magnitude. As just one example, the polyoxynoxy composition can have a complex viscosity of 10,000 to 50,000,000 cP (measured at 25 ° C as described above). In various non-limiting embodiments, any of the above values can vary, for example, by 1%, 2%, 3%, 4%, 5%, 10%, 15%, 20%, or 25+%. Accordingly, all values and ranges of values between the above values and including the above are also explicitly included in the various non-limiting embodiments. The above viscosity is the complex viscosity of the polyoxymethylene composition prior to curing. After curing, the curing reaction product is typically a solid, but may also be a gel.

In various embodiments, the second polymeric composition is coated to define at least one extends from module 20 to module 20 inside the periphery of the channel (not shown) to form a pattern of the connection layer 58. The pattern is not particularly limited and may be further described as a geometric, non-geometric, uniform or non-uniform pattern. In one embodiment, the polyoxymethylene composition is deposited in one, two or a plurality of columns. One or more columns may be disposed to be substantially parallel or intersect (ie, at an angle) with one or more other columns. For example, the channels formed by the polyoxo compositions can extend to opposite or different locations on the periphery of the module 20 . This can be achieved based on the configuration of one or more columns of polyoxynoxy compositions.

In other embodiments, patterning can be used with or in place of the second polymeric composition. In general, patterning is suitable for the more viscous/heavier of the two polymeric compositions. Other examples of suitable patterning/patterning methods and their benefits include those described in the '277 application incorporated.

The passage is also not subject to any special restrictions. Typically, the channels are defined on two or more sides by depositing a polyoxymethylene composition. Channels may alternatively be described as conduits, ducts, flutings, furrows, gouges, grooves, gutters, passes. , passage, trough, channel, lane, opening, or path.

Internal passage 20 extends from module to module 20 outside (e.g., external), and may be any module 20 starting from the inside of the point. The channel can extend across the entire interior or across a portion of the interior. The channels may extend to two or more points or a single point on the periphery of the module 20 . A channel may be further defined as one, two, or a plurality of individual channels that may or may not be connected to each other in one or more portions. Air (e.g., from air bubbles) may be merged together in the deposited channel-defined polyoxo composition to fill the channels and thereby pass through the channels to the periphery of the module 20 prior to eliminating the channels. Typically, the channels are defined such that air can pass through the channels and exit the module 20 to reduce or eliminate the presence of one or more layers, such as any of the bubbles in the tie layer 58 . In other words, the channel typically allows the interior air from module 20 (e.g. from the center) toward the periphery of module 20 (e.g., an edge) flows, whereby the module 20 in any entrapped in the assembly of an air layer or minus one or more To the minimum.

Pressure and/or heat may be applied to the module 20 during and/or after assembly of the substrate 24 and the cover sheet 30 for a period of time to further form the module 20 . If both pressure and heat are employed, pressure and heat can be applied independently or simultaneously. Applying heat is suitable for curing the tie layer 58 and optionally the polymeric strips 54 , 56 to a final cured state. These steps may be referred to as pressure curing or lamination in the art. Examples of suitable lamination techniques include vacuum or atmospheric pressure lamination, and may include the application of heat. Specific examples of such processes (e.g., vacuum lamination) and other optional steps are described in some of the incorporated references.

In some embodiments, the module 20 is formed with the application of heat. Suitable temperatures are from about 20 to about 200, from about 40 to about 150, or from about 70 to about 110 ° C, or any range between the lowest and highest of such values. In some embodiments, the module 20 is formed under application of pressure. Suitable pressures are from about 7 to about 350, from about 20 to about 200, or from about 30 to about 140 kPa, or any range between the lowest and highest of such values. Various combinations of temperature and pressure may be used, or only one of temperature and pressure may be used to form module 20 .

A specific implementation of forming module 20 is as follows. The first polymeric composition was partitioned portion 34 of the cover 30 on the back sheet to form a polymeric strips 54, 56, between 54, 56 to define a gap with the polymerization conditions wherein the polymerization of such PV cell strip 36, Alignment between 38 (not yet placed). The polymeric strips 54 , 56 are allowed to level and then cured through an oven. Alternatively, polymeric strips 54 , 56 are preformed and disposed on the back side 34 of the cover sheet 30 . The PV cells 36 , 38 are then pressed into the polymeric strips 54 , 56 . Prior to pressing the PV cells 36 , 38 , a portion of the second polymeric composition is dispensed into the gap as appropriate and cured via an oven to form a portion of the tie layer 58 . Alternatively, all of the second polymeric composition is dispensed onto the PV cells 36 , 38 , thereby filling the gap and forming the tie layer 58 . Next, an intermediate layer (e.g., non-woven FG) is placed on the connection layer 58 , and the substrate 24 is placed on the intermediate layer to form the module 20 . The curing module 20 is then pressurized. For example, the module 20 can be cured via a lamination process, a vacuum-layer press process, or the like.

One or more of the above values may vary by ±5%, ±10%, ±15%, ±20%, ±25%, etc., as long as the deviation is still within the scope of the present invention. Unexpected results are available to members of the Markush group and are not related to all other members. Each member may be individually and/or in combination and provide sufficient support for a particular embodiment within the scope of the appended claims. The subject matter of all combinations of independent and subsidiary claims (single and multiple affiliates) is expressly covered herein. The present invention is intended to be illustrative, and not restrictive. Many modifications and variations of the present invention are possible in the light of the teachings herein.

4‧‧‧ line

20‧‧‧Photovoltaic battery module/module

24‧‧‧Substrate

30‧‧‧ Covering film

32‧‧‧Before the cover sheet

36‧‧‧First photovoltaic battery

38‧‧‧Second photovoltaic battery

48‧‧‧Connected strip

54‧‧‧First polymeric strip

56‧‧‧Second polymeric strip

58‧‧‧Connection layer

Claims (15)

A photovoltaic (PV) battery module comprising: a substrate having a front surface and a back surface, the back surface being spaced apart from the front surface of the substrate; a cover sheet having a front surface and a back surface, the back surface The front surface of the cover sheet is spaced apart; a first PV cell is disposed between the substrate and the cover sheet, wherein the first PV battery has a front surface and a back surface, the back surface and the first PV battery a second PV cell disposed between the substrate and the cover sheet and adjacent to the first PV cell, wherein the second PV cell has a front surface and a back surface, the back surface and the first The front side of the two PV cells are spaced apart; an interconnecting strip disposed between the PV cells, wherein the interconnecting strip has a first end operatively coupled to the front of the first PV cell and an operable Connected to the second end of the back side of the second PV cell; a first polymeric strip formed by the first polymeric composition and disposed between the first PV cell and the cover sheet to couple the The front face of the first PV cell and the back of the cover sheet a second polymeric strip, which is also formed by the first polymeric composition and disposed between the second PV cell and the cover sheet to couple the front surface of the second PV cell to the cover sheet a backing layer; and a tie layer formed from a second polymer composition different from the first polymer composition and disposed between the substrate and the cover sheet and between the polymeric strips to couple the cover sheet The back surface and the front surface of the substrate and the back surfaces of the PV cells and the front surface of the substrate. The module of claim 1, wherein: i) the elastic modulus of the connecting layer is greater than the elastic modulus of the polymeric strips; ii) the elastic modulus of the connecting layer is from about 15 to about 50 kilopascals (kPa) And the polymeric modulus of the polymeric strip is from about 0.5 to about 12.5 kPa; iii) the elastic modulus of the tie layer is from about 50 to about 2000 kilopascals (kPa) and the elastic modulus of the polymeric strips is about 0.5 to about 12.5 kPa; iv) both i) and ii); or v) both i) and iii). The module of claim 1, wherein: i) the polymeric strips each have an average thickness of from about 0.125 to about 0.75 millimeters (mm) and an average width of from about 5 to about 13 mm; and/or ii) the tie layer It has an average thickness of from about 0.25 to about 1.25 mm. The module of claim 1, wherein: i) the interconnecting strip is sealed by the connecting layer; ii) the PV cells are substantially coplanar; and iii) the polymeric strips each have a substantially rectangular cross section; / or iv) the polymeric strips are disposed laterally relative to the interconnect strip. The module of claim 1, wherein: i) the cover sheet is formed of glass; and/or ii) the substrate is formed of glass, a polymeric material or a composite material. The module of claim 1, wherein the first polymeric composition and the second polymeric composition are each a hydrazine hydrogenation curable polydecaneoxy composition. The module of claim 1, wherein: i) the first polymeric composition comprises greater than about 45 parts by weight of a diorganopolyoxyalkylene having an alkenyl group, and from about 2.5 to about 7.5 parts by weight of the diorganopolyoxygen having The alkane has a reactive hydrazine-bonded hydrogen atom of hydrogenated organic hydrazine and from about 25 to about 65 parts by weight of no reaction Or organopolysiloxanes each based on 100 parts by weight of the first polymeric composition; and/or ii) the second polymeric composition comprising greater than about 55 parts by weight of a diorganopolyoxyalkylene having an alkenyl group and about 5 to about 25 parts by weight of hydrogenated organic hydrazine having a hydrazine-bonded hydrogen atom reactive with the diorganopolysiloxane, each of which is based on 100 parts by weight of the second polymerization composition. The module of any one of claims 1 to 7, wherein the first polymeric composition comprises: two different dimethyl vinyl-terminated polydimethyl fluorene; dimethyl hydrogen-terminated poly Methyl decane; and trimethyldecyloxy-terminated dimethylmethylhydroquinone containing at least 3 SiH units per molecule. The module of claim 8 wherein the second polymeric composition comprises: i) dimethyl vinyl terminated polydimethyl siloxane, dimethyl hydrogen terminated polydimethyl siloxane, and per molecule a trimethyldecyloxy-terminated dimethylmethylhydroquinone containing at least 3 SiH units; or ii) a dimethylvinyl-terminated polydimethyloxane and containing at least 3 SiH per molecule The unit of trimethylsulfanyloxy terminated dimethylmethylhydroquinone. A method for forming a photovoltaic (PV) battery module, the photovoltaic battery module comprising a substrate having a front surface and a back surface, the back surface being spaced apart from the front surface of the substrate; a cover sheet having a front surface And a back surface spaced apart from the front surface of the cover sheet, wherein the back surface has a first portion and a second portion, the second portion being spaced apart from the first portion; a first PV cell disposed therein Between the substrate and the cover sheet, wherein the first PV cell has a front surface and a back surface, the back surface being spaced apart from the front surface of the first PV cell; a second PV cell disposed on the substrate and the cover sheet Between and adjacent to the first PV cell, wherein the second PV cell has a front surface and a back surface, the back surface and the second PV battery The front strip is spaced apart; an interconnecting strip disposed between the PV cells, wherein the interconnecting strip has a first end operatively coupled to the front of the first PV cell and operatively coupled to the a second end of the back side of the second PV cell; a first polymeric strip disposed between the first PV cell and the back side of the cover sheet to couple the front face and the cover of the first PV cell a first portion of the back surface of the sheet; a second polymeric strip disposed between the second PV cell and the back surface of the cover sheet to couple the front surface of the second PV cell to the cover sheet a second portion of the back surface; and a connection layer disposed between the substrate and the cover sheet and between the polymeric strips for coupling the back surface of the cover sheet to the front surface of the substrate and the coupling And the front side of the PV cell and the front side of the substrate, the method comprising the steps of: applying a first polymeric composition to the first portion and the second portion of the back side of the cover sheet to form an uncured The first polymeric strip of the state and the second polymeric strip Striping the polymeric strips to a cured state as appropriate; placing the first PV cell and the second PV cell on the first polymeric strip and the second polymeric strip, wherein the interconnecting strip is operable Connecting the first PV cell and the second PV cell; applying a second polymeric composition different from the first polymeric composition between the polymeric strips on the back side of the cover sheet and such Forming the connection layer in an uncured state on the PV cell and the interconnection strip; and combining the substrate and the cover sheet to form the PV cell module. The method of claim 10, wherein the polymeric strips are cured prior to placing the PV cells. The method of claim 10, wherein: i) the first polymeric strip is formed simultaneously with the second polymeric strip; and/or Ii) The first PV cell is placed simultaneously with the second PV cell. The method of claim 10, further comprising the steps of: applying pressure to the PV battery module for a period of time during and/or after combining the substrate and the cover sheet to further form the PV battery module; and/ Or applying heat to the PV cell module for a period of time during and/or after combining the substrate with the cover sheet to further form the PV cell module. The method of claim 10, wherein: i) the coating step is further defined as dispensing the first polymeric composition and the second polymeric composition via a robotic dispenser; and/or ii) the curing step is It is further defined as applying heat to the polymeric strips to aid in curing the polymeric strips from the uncured state to the cured state. The method of any one of claims 10 to 14, wherein: i) coating the first polymeric composition such that the polymeric strips each have an average thickness of from about 0.125 to about 0.75 millimeters (mm) and about 5 Up to an average width of about 13 mm; and/or ii) coating the second polymeric composition such that the tie layer has a thickness of from about 10 to about 50 mils.