WO2007149969A2 - Frameless photovoltaic module - Google Patents
Frameless photovoltaic module Download PDFInfo
- Publication number
- WO2007149969A2 WO2007149969A2 PCT/US2007/071761 US2007071761W WO2007149969A2 WO 2007149969 A2 WO2007149969 A2 WO 2007149969A2 US 2007071761 W US2007071761 W US 2007071761W WO 2007149969 A2 WO2007149969 A2 WO 2007149969A2
- Authority
- WO
- WIPO (PCT)
- Prior art keywords
- layer
- edge
- photovoltaic
- photovoltaic module
- polymer
- Prior art date
Links
- 229920000642 polymer Polymers 0.000 claims abstract description 46
- 238000000034 method Methods 0.000 claims description 36
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- 239000002253 acid Substances 0.000 claims description 15
- 239000011521 glass Substances 0.000 claims description 15
- VYPSYNLAJGMNEJ-UHFFFAOYSA-N Silicium dioxide Chemical compound O=[Si]=O VYPSYNLAJGMNEJ-UHFFFAOYSA-N 0.000 claims description 12
- 229920001169 thermoplastic Polymers 0.000 claims description 9
- 239000000945 filler Substances 0.000 claims description 8
- 238000003475 lamination Methods 0.000 claims description 8
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- VTYYLEPIZMXCLO-UHFFFAOYSA-L Calcium carbonate Chemical compound [Ca+2].[O-]C([O-])=O VTYYLEPIZMXCLO-UHFFFAOYSA-L 0.000 claims description 6
- OSGAYBCDTDRGGQ-UHFFFAOYSA-L calcium sulfate Chemical compound [Ca+2].[O-]S([O-])(=O)=O OSGAYBCDTDRGGQ-UHFFFAOYSA-L 0.000 claims description 6
- 239000003365 glass fiber Substances 0.000 claims description 6
- 239000000377 silicon dioxide Substances 0.000 claims description 6
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- CERQOIWHTDAKMF-UHFFFAOYSA-N Methacrylic acid Chemical compound CC(=C)C(O)=O CERQOIWHTDAKMF-UHFFFAOYSA-N 0.000 claims description 5
- 239000007767 bonding agent Substances 0.000 claims description 5
- 238000010894 electron beam technology Methods 0.000 claims description 5
- SMZOUWXMTYCWNB-UHFFFAOYSA-N 2-(2-methoxy-5-methylphenyl)ethanamine Chemical compound COC1=CC=C(C)C=C1CCN SMZOUWXMTYCWNB-UHFFFAOYSA-N 0.000 claims description 4
- NIXOWILDQLNWCW-UHFFFAOYSA-N 2-Propenoic acid Natural products OC(=O)C=C NIXOWILDQLNWCW-UHFFFAOYSA-N 0.000 claims description 4
- 239000006087 Silane Coupling Agent Substances 0.000 claims description 4
- 239000004927 clay Substances 0.000 claims description 4
- 239000002131 composite material Substances 0.000 claims description 4
- -1 polyethylene Polymers 0.000 claims description 4
- 238000007789 sealing Methods 0.000 claims description 4
- 239000005995 Aluminium silicate Substances 0.000 claims description 3
- 229920000049 Carbon (fiber) Polymers 0.000 claims description 3
- RREGISFBPQOLTM-UHFFFAOYSA-N alumane;trihydrate Chemical compound O.O.O.[AlH3] RREGISFBPQOLTM-UHFFFAOYSA-N 0.000 claims description 3
- 235000012211 aluminium silicate Nutrition 0.000 claims description 3
- 229910000019 calcium carbonate Inorganic materials 0.000 claims description 3
- 239000004917 carbon fiber Substances 0.000 claims description 3
- 239000004020 conductor Substances 0.000 claims description 3
- NLYAJNPCOHFWQQ-UHFFFAOYSA-N kaolin Chemical compound O.O.O=[Al]O[Si](=O)O[Si](=O)O[Al]=O NLYAJNPCOHFWQQ-UHFFFAOYSA-N 0.000 claims description 3
- 238000010030 laminating Methods 0.000 claims description 3
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- 239000000454 talc Substances 0.000 claims description 3
- 229910052623 talc Inorganic materials 0.000 claims description 3
- 239000010456 wollastonite Substances 0.000 claims description 3
- 229910052882 wollastonite Inorganic materials 0.000 claims description 3
- 239000004698 Polyethylene Substances 0.000 claims description 2
- 239000012802 nanoclay Substances 0.000 claims description 2
- 239000002245 particle Substances 0.000 claims description 2
- 229920000573 polyethylene Polymers 0.000 claims description 2
- 230000001678 irradiating effect Effects 0.000 claims 6
- 239000000463 material Substances 0.000 description 28
- 239000008393 encapsulating agent Substances 0.000 description 16
- 229910052782 aluminium Inorganic materials 0.000 description 12
- XAGFODPZIPBFFR-UHFFFAOYSA-N aluminium Chemical compound [Al] XAGFODPZIPBFFR-UHFFFAOYSA-N 0.000 description 12
- XLYOFNOQVPJJNP-UHFFFAOYSA-N water Chemical compound O XLYOFNOQVPJJNP-UHFFFAOYSA-N 0.000 description 10
- 239000004712 Metallocene polyethylene (PE-MC) Substances 0.000 description 6
- VGGSQFUCUMXWEO-UHFFFAOYSA-N Ethene Chemical compound C=C VGGSQFUCUMXWEO-UHFFFAOYSA-N 0.000 description 5
- 239000005977 Ethylene Substances 0.000 description 5
- 230000005855 radiation Effects 0.000 description 5
- GWEVSGVZZGPLCZ-UHFFFAOYSA-N Titan oxide Chemical compound O=[Ti]=O GWEVSGVZZGPLCZ-UHFFFAOYSA-N 0.000 description 4
- 230000008901 benefit Effects 0.000 description 4
- 238000009835 boiling Methods 0.000 description 4
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- KWKAKUADMBZCLK-UHFFFAOYSA-N 1-octene Chemical compound CCCCCCC=C KWKAKUADMBZCLK-UHFFFAOYSA-N 0.000 description 3
- 230000004888 barrier function Effects 0.000 description 3
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- 239000005341 toughened glass Substances 0.000 description 3
- 239000004711 α-olefin Substances 0.000 description 3
- RNFJDJUURJAICM-UHFFFAOYSA-N 2,2,4,4,6,6-hexaphenoxy-1,3,5-triaza-2$l^{5},4$l^{5},6$l^{5}-triphosphacyclohexa-1,3,5-triene Chemical compound N=1P(OC=2C=CC=CC=2)(OC=2C=CC=CC=2)=NP(OC=2C=CC=CC=2)(OC=2C=CC=CC=2)=NP=1(OC=1C=CC=CC=1)OC1=CC=CC=C1 RNFJDJUURJAICM-UHFFFAOYSA-N 0.000 description 2
- DGAQECJNVWCQMB-PUAWFVPOSA-M Ilexoside XXIX Chemical compound C[C@@H]1CC[C@@]2(CC[C@@]3(C(=CC[C@H]4[C@]3(CC[C@@H]5[C@@]4(CC[C@@H](C5(C)C)OS(=O)(=O)[O-])C)C)[C@@H]2[C@]1(C)O)C)C(=O)O[C@H]6[C@@H]([C@H]([C@@H]([C@H](O6)CO)O)O)O.[Na+] DGAQECJNVWCQMB-PUAWFVPOSA-M 0.000 description 2
- 125000004432 carbon atom Chemical group C* 0.000 description 2
- 239000006229 carbon black Substances 0.000 description 2
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- 239000005038 ethylene vinyl acetate Substances 0.000 description 2
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- 229920001903 high density polyethylene Polymers 0.000 description 2
- 239000004700 high-density polyethylene Substances 0.000 description 2
- 230000003301 hydrolyzing effect Effects 0.000 description 2
- 229910052751 metal Inorganic materials 0.000 description 2
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- 239000011734 sodium Substances 0.000 description 2
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- 229920002397 thermoplastic olefin Polymers 0.000 description 2
- 239000011701 zinc Substances 0.000 description 2
- VXNZUUAINFGPBY-UHFFFAOYSA-N 1-Butene Chemical compound CCC=C VXNZUUAINFGPBY-UHFFFAOYSA-N 0.000 description 1
- LIKMAJRDDDTEIG-UHFFFAOYSA-N 1-hexene Chemical compound CCCCC=C LIKMAJRDDDTEIG-UHFFFAOYSA-N 0.000 description 1
- UFHFLCQGNIYNRP-UHFFFAOYSA-N Hydrogen Chemical compound [H][H] UFHFLCQGNIYNRP-UHFFFAOYSA-N 0.000 description 1
- 239000004743 Polypropylene Substances 0.000 description 1
- XUIMIQQOPSSXEZ-UHFFFAOYSA-N Silicon Chemical compound [Si] XUIMIQQOPSSXEZ-UHFFFAOYSA-N 0.000 description 1
- XTXRWKRVRITETP-UHFFFAOYSA-N Vinyl acetate Chemical compound CC(=O)OC=C XTXRWKRVRITETP-UHFFFAOYSA-N 0.000 description 1
- HCHKCACWOHOZIP-UHFFFAOYSA-N Zinc Chemical compound [Zn] HCHKCACWOHOZIP-UHFFFAOYSA-N 0.000 description 1
- QVGXLLKOCUKJST-UHFFFAOYSA-N atomic oxygen Chemical compound [O] QVGXLLKOCUKJST-UHFFFAOYSA-N 0.000 description 1
- 230000005540 biological transmission Effects 0.000 description 1
- DQXBYHZEEUGOBF-UHFFFAOYSA-N but-3-enoic acid;ethene Chemical compound C=C.OC(=O)CC=C DQXBYHZEEUGOBF-UHFFFAOYSA-N 0.000 description 1
- IAQRGUVFOMOMEM-UHFFFAOYSA-N butene Natural products CC=CC IAQRGUVFOMOMEM-UHFFFAOYSA-N 0.000 description 1
- 125000002843 carboxylic acid group Chemical group 0.000 description 1
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- 150000001768 cations Chemical class 0.000 description 1
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- 229910021419 crystalline silicon Inorganic materials 0.000 description 1
- 238000006731 degradation reaction Methods 0.000 description 1
- BFMKFCLXZSUVPI-UHFFFAOYSA-N ethyl but-3-enoate Chemical compound CCOC(=O)CC=C BFMKFCLXZSUVPI-UHFFFAOYSA-N 0.000 description 1
- 229920001038 ethylene copolymer Polymers 0.000 description 1
- 238000013023 gasketing Methods 0.000 description 1
- 229910052739 hydrogen Inorganic materials 0.000 description 1
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- 238000010348 incorporation Methods 0.000 description 1
- 238000001746 injection moulding Methods 0.000 description 1
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- 230000001681 protective effect Effects 0.000 description 1
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Classifications
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B17/00—Layered products essentially comprising sheet glass, or glass, slag, or like fibres
- B32B17/06—Layered products essentially comprising sheet glass, or glass, slag, or like fibres comprising glass as the main or only constituent of a layer, next to another layer of a specific material
- B32B17/10—Layered products essentially comprising sheet glass, or glass, slag, or like fibres comprising glass as the main or only constituent of a layer, next to another layer of a specific material of synthetic resin
- B32B17/10005—Layered products essentially comprising sheet glass, or glass, slag, or like fibres comprising glass as the main or only constituent of a layer, next to another layer of a specific material of synthetic resin laminated safety glass or glazing
- B32B17/1055—Layered products essentially comprising sheet glass, or glass, slag, or like fibres comprising glass as the main or only constituent of a layer, next to another layer of a specific material of synthetic resin laminated safety glass or glazing characterized by the resin layer, i.e. interlayer
- B32B17/10743—Layered products essentially comprising sheet glass, or glass, slag, or like fibres comprising glass as the main or only constituent of a layer, next to another layer of a specific material of synthetic resin laminated safety glass or glazing characterized by the resin layer, i.e. interlayer containing acrylate (co)polymers or salts thereof
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B17/00—Layered products essentially comprising sheet glass, or glass, slag, or like fibres
- B32B17/06—Layered products essentially comprising sheet glass, or glass, slag, or like fibres comprising glass as the main or only constituent of a layer, next to another layer of a specific material
- B32B17/10—Layered products essentially comprising sheet glass, or glass, slag, or like fibres comprising glass as the main or only constituent of a layer, next to another layer of a specific material of synthetic resin
- B32B17/10005—Layered products essentially comprising sheet glass, or glass, slag, or like fibres comprising glass as the main or only constituent of a layer, next to another layer of a specific material of synthetic resin laminated safety glass or glazing
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B17/00—Layered products essentially comprising sheet glass, or glass, slag, or like fibres
- B32B17/06—Layered products essentially comprising sheet glass, or glass, slag, or like fibres comprising glass as the main or only constituent of a layer, next to another layer of a specific material
- B32B17/10—Layered products essentially comprising sheet glass, or glass, slag, or like fibres comprising glass as the main or only constituent of a layer, next to another layer of a specific material of synthetic resin
- B32B17/10005—Layered products essentially comprising sheet glass, or glass, slag, or like fibres comprising glass as the main or only constituent of a layer, next to another layer of a specific material of synthetic resin laminated safety glass or glazing
- B32B17/10165—Functional features of the laminated safety glass or glazing
- B32B17/10293—Edge features, e.g. inserts or holes
- B32B17/10302—Edge sealing
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B2323/00—Polyalkenes
- B32B2323/04—Polyethylene
- B32B2323/046—LDPE, i.e. low density polyethylene
-
- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01L—SEMICONDUCTOR DEVICES NOT COVERED BY CLASS H10
- H01L31/00—Semiconductor devices sensitive to infrared radiation, light, electromagnetic radiation of shorter wavelength or corpuscular radiation and specially adapted either for the conversion of the energy of such radiation into electrical energy or for the control of electrical energy by such radiation; Processes or apparatus specially adapted for the manufacture or treatment thereof or of parts thereof; Details thereof
- H01L31/04—Semiconductor devices sensitive to infrared radiation, light, electromagnetic radiation of shorter wavelength or corpuscular radiation and specially adapted either for the conversion of the energy of such radiation into electrical energy or for the control of electrical energy by such radiation; Processes or apparatus specially adapted for the manufacture or treatment thereof or of parts thereof; Details thereof adapted as photovoltaic [PV] conversion devices
- H01L31/042—PV modules or arrays of single PV cells
- H01L31/048—Encapsulation of modules
-
- H—ELECTRICITY
- H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
- H02S—GENERATION OF ELECTRIC POWER BY CONVERSION OF INFRARED RADIATION, VISIBLE LIGHT OR ULTRAVIOLET LIGHT, e.g. USING PHOTOVOLTAIC [PV] MODULES
- H02S30/00—Structural details of PV modules other than those related to light conversion
- H02S30/10—Frame structures
-
- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
- Y02E—REDUCTION OF GREENHOUSE GAS [GHG] EMISSIONS, RELATED TO ENERGY GENERATION, TRANSMISSION OR DISTRIBUTION
- Y02E10/00—Energy generation through renewable energy sources
- Y02E10/50—Photovoltaic [PV] energy
Definitions
- the invention generally relates to a photovoltaic module.
- the invention relates to a photovoltaic module that includes a non-conductive edge element, which can be light weight, easy to install, and can allow for improved sealing of the photovoltaic module.
- Photovoltaic modules particularly those made with crystalline silicon solar cells, can be formed by providing a sheet of tempered glass, depositing a transparent encapsulant on the glass, positioning solar cells on the encapsulant, depositing a second encapsulant layer on the cells, positioning a backsheet layer on top of the second encapsulant layer, securing a perimeter aluminum frame, and bonding a junction box to the backsheet on the rear of the modules.
- a junction box to the backsheet on the rear of the modules.
- Common practice is to have wires with plugs emerging from this junction box.
- bypass diodes can be incorporated in the junction box to provide for protection against localized hot spots in the module.
- a strip of some type of gasketing material is applied to the edge of the glass as a cushioning layer to protect the edge of the tempered glass from shattering due to an edge impact.
- Disadvantages of an aluminum frame include: the material and labor cost associated with it; the increase in the thickness and the weight of the module; the requirement to ground such a module in an installation; and reduced stiffness of the module as photovoltaic modules become larger. There is a limit to how much stiffness an aluminum perimeter frame can provide cost-effectively.
- the invention in one embodiment, features a frameless, light weight photovoltaic module with improved stiffness for better resistance against deflection due to wind, ice, snow loads, or other environmentally created conditions.
- the photovoltaic module can be formed with a protective edge element around the superstrate glass of the module.
- the edge element can be low cost and simple to form, can allow for a variety of mounting possibilities, can provide greater stiffness to a module than that of an aluminum frame, and/or can obviate the need for grounding a module.
- the photovoltaic module can include a stiffening and/or mounting element applied to the rear of the module so that the need for an aluminum frame and for thicker glass can be mitigated or eliminated.
- the stiffening and/or mounting element can be placed on the rear of the module so that greater resistance to deflection under load is provided. The likelihood of cracking cells due to such deflection can be reduced - an important advantage as the industry shifts to thin solar cells.
- the need for attaching grounding wires to the module when an installation is being done can be minimized or eliminated. Without exposed metal on the module, the need for grounding can be obviated entirely. Cost savings for module installers, who normally need to run a grounding wire connected to each module in an installation, can be realized.
- Aesthetically acceptable photovoltaic modules can be formed using a mold.
- the photovoltaic module can be formed within the mold, and the mold, along with the module assembly, can be placed in a laminator.
- An embodiment of the photovoltaic module described herein can eliminate the need for a mold by providing an edge element that includes sufficiently cross-linked polymers.
- the invention features a method of forming a photovoltaic module.
- the method includes extruding a polymer material to form at least one edge element.
- the at least one edge element is irradiated to cross-link the polymer material.
- the at least one edge element is bonded to a photovoltaic component, which includes a plurality of interconnected photovoltaic cells disposed between a transparent layer and a backsheet layer.
- the at least one edge element is bonded to a front surface of the transparent layer and a back surface of the backsheet layer.
- the at least one edge element and the photovoltaic component are laminated in the absence of a mold, to form the photovoltaic module.
- the invention features a method of forming a laminated photovoltaic module.
- the method includes providing a photovoltaic component with a plurality of electrically connected photovoltaic cells disposed between a backsheet layer and a transparent layer. At least one edge member including an irradiated polymer is attached to the photovoltaic component so as to contact a front surface of the transparent layer and a back surface of the backsheet layer. At least one corner member including an irradiated polymer is attached to the photovoltaic component so as to contact the front surface of the transparent layer and the back surface of the backsheet layer, and to form together with the at least one edge element at least a portion of a non-conductive frame about the photovoltaic component. The photovoltaic component together with the at least one edge member and the at least one corner member is laminated to form the laminated photovoltaic module.
- the invention features a system for protecting edges of a photovoltaic module.
- the system includes a plurality of edge members including a first irradiated polymer.
- the plurality of edge members is adapted to physically contact both an upper surface and a lower surface of the photovoltaic module.
- Each edge member seals a respective edge of the photovoltaic module.
- the system further includes a plurality of corner members including a second irradiated polymer.
- the plurality of corner members is adapted to physically contact both the upper surface and the lower surface of the photovoltaic module.
- Each corner member seals a respective corner of the photovoltaic module.
- the invention features a photovoltaic module including a lower support layer, an upper support layer, a photovoltaic layer, and a non-conductive frame.
- the upper support layer includes a transparent sheet.
- the photovoltaic layer is positioned between the lower support layer and the upper support layer.
- the photovoltaic layer includes a plurality of electrically connected photovoltaic cells.
- the non-conductive frame includes at least one irradiated polymer element adapted to contact a portion of the lower support layer and the upper support layer.
- the lower support layer, the upper support layer, the photovoltaic layer, and the non-conductive frame are laminated to form the photovoltaic module.
- the edge element can be a single member disposable around the perimeter of the photovoltaic component.
- the edge element can include edge members and corner members.
- the corner members can overlap the edge members.
- a bonding agent can be disposed on a surface of the at least one edge element prior to bonding.
- the at least one edge element can be irradiated with an energy of about 2 megarad (MR) to about 20 MR.
- the at least one edge element includes a non-electrically conductive material.
- the edge element can be irradiated to sufficiently cross-link the polymer material so that the polymer material does not flow during the lamination step.
- the bonding agent can be irradiated.
- the edge element includes a plurality of edge members. In certain embodiments, at least four edge members can be attached to the photovoltaic component. In certain embodiments, four corner elements can be attached to the photovoltaic component and the at least four edge elements. In various embodiments, each corner element can overlap two edge elements.
- a bonding layer can be disposed on a surface of each edge element, each edge member, and/or each corner member prior to attaching the piece to the photovoltaic component.
- the bonding layer can include an acid co-polymer of methacrylic acid. In various embodiments, the bonding layer can include an acid co-polymer of acrylic acid and polyethylene. In some embodiments, the bonding layer can include an ionomer.
- the bonding layer can be disposed on each corner element.
- the bonding layer and each corner element can be irradiated with an energy of about 2 MR to about 20 MR prior to attaching the corner elements to the photovoltaic component.
- a silane coupling agent can be applied to at least a portion of the transparent layer prior to attaching the at least one edge member to the photovoltaic component.
- the non-electrically conductive mounting element can be attached to the laminated photovoltaic module.
- the non-electrically conductive mounting element can include a filled polymer.
- the filled polymer can include a filler such as aluminum trihydrate, calcium carbonate, calcium sulfate, carbon fibers, glass fibers, hollow glass microspheres, kaolin clay, mica, crushed silica, synthetic silica, talc, wollastonite, nano-clay particles, and sawdust.
- the first irradiated polymer and the second irradiated polymer can be formed from the same initial polymer material. In certain embodiments, the first irradiated polymer and/or the second irradiated polymer can be irradiated at a dosage to create both thermoset and thermoplastic properties. In various embodiments, the first irradiated polymer and/or the second irradiated polymer can be irradiated at a dosage of about 2 MR to about 20 MR.
- each edge element or each edge member can be tapered.
- each edge member can have a U-shape.
- each corner member can have a hollow L-shape.
- the bonding layer can be irradiated with an electron beam.
- a bonding layer can be disposed on at least a portion of an interior surface of each edge element so as to contact at least one of the upper surface and the lower surface of the photovoltaic module.
- a bonding layer can be disposed on at least a portion of an interior surface of each corner element so as to contact at least a portion of the respective corner of the photovoltaic module.
- each of the irradiated polymer elements can overlap at least one other irradiated polymer element to form the non-conductive frame.
- the irradiated polymer elements can include at least one edge member and at least one corner member.
- the irradiated polymer elements can have both thermoset and thermoplastic properties.
- At least one non-electrically conductive mounting element can be disposed on a lower support layer side of the photovoltaic module.
- the at least one non- electrically conductive mounting element can provide an increase in stiffness to the photovoltaic module.
- the at least one non-electrically conductive mounting element can be made of a composite material including a polymer and a filler.
- Figure 1 shows a sectional view of an exemplary photovoltaic module.
- Figure 2 shows a sectional view of another exemplary photovoltaic module.
- Figure 3 shows a plan view of a photovoltaic module with an edge element.
- Figure 4 shows a plan view of a photovoltaic module with edge members and corner members.
- Figure 5 shows a perspective view of an edge element.
- Figure 6 shows a perspective view of a corner member.
- Figure 7 shows a plan view of a photovoltaic module with an element for stiffening and/or mounting disposed on a back surface.
- FIG. 1 shows a cross-section of an exemplary photovoltaic module 10.
- the photovoltaic module 10 includes a photovoltaic component 20, which includes a transparent layer 30, a photovoltaic layer 40, and a backsheet layer 50.
- the photovoltaic layer 40 includes a plurality of photovoltaic cells 60 that are interconnected using leads 70.
- An edge element 80 is disposed around the edges of the photovoltaic component 20. The edge element 80 can be bonded to a front surface 82 of the transparent layer 30 and a back surface 84 of the backsheet layer 50.
- the photovoltaic layer 40 is encapsulated in encapsulation layer 95.
- FIG. 2 shows an embodiment of a photovoltaic module 10' where the photovoltaic cells 60 are disposed on an inner surface of the backsheet layer 50.
- Photovoltaic module 10 can be formed by laminating the transparent layer 30, the photovoltaic layer 40, the backsheet layer 50, the edge element 80, and the encapsulation layer 95 in the absence of a mold.
- Figure 3 shows an exemplary photovoltaic module 10 with an edge element 80.
- the edge element 80 is a single member disposed around the perimeter edge of the photovoltaic module 10.
- Figure 4 shows an exemplary photovoltaic module 10 with an edge element 80 formed from edge members 110 and corner members 120.
- the edge members 110 can be bonded to the edges of the photovoltaic component 20, and the corner members 120 can be bonded to the corners of the photovoltaic component 20. A portion of each corner member 120 can overlap a portion of each adjacent edge member 110.
- FIG. 5 shows an exemplary embodiment of an edge element 80.
- the edge element 80 can be formed by a profile extrusion technique.
- the edge element 80 can be formed by extruding a polymer material.
- the extruded polymer material can be irradiated prior to being bound to the photovoltaic component 20.
- the edge element 80 can have a U-shape, and can have a tapered end 130.
- the taper 130 can provide better sealant properties because there is little opportunity for water to gather along the edge of a module, which can be a recurrent issue with aluminum frames.
- the edge element 80 can have a bonding layer 140 on the inside surface.
- the bonding layer 140 can allow for very strong bonds to surfaces of the transparent layer 30 and/or the backsheet layer 50.
- the bonding layer 140 can be an acid co-polymer of methacrylic acid or acrylic acid and polyethlylene.
- the bonding layer 140 can also be an ionomer.
- Figure 6 shows a corner member 120.
- the corner member 120 can have an L-shape, and include a channel 142 between opposing sides 144.
- a bonding layer 140 can be applied to inner surfaces of the opposing sides 144.
- the corner members 120 can be formed from a polymer material by an injection molding technique.
- the corner members 120 can overlap adjacent edge members during bonding to the photovoltaic component.
- the corner members 120 can be irradiated prior to being bound to the photovoltaic component.
- the material of the edge element 80, the edge member 110, or the corner member 120 can be of similar composition to the material of the backsheet layer 50.
- a polymer material can be used.
- the polymer material can possess thermal creep resistance while retaining enough thermoplasticity to be bonded to itself or other materials.
- the polymer material can be irradiated with a high energy electron beam radiation. This irradiation procedure can produce cross-linking in the polymer material. However, there is still some residue of thermoelasticity. This means that the material can be sufficiently thermoplastic to be heat bonded to other surfaces and materials.
- the irradiated polymer material shows a dramatic increase in its thermal creep resistance.
- the polymer material can be irradiated to a point where it still retains some thermoplastic properties.
- thermoset refers to a polymer's quality of solidifying when either heated or reacted chemically without being able to be re-melted or be remolded.
- thermoplastic refers to a material's quality of repeatedly softening when heated and hardening when cooled. A thermoplastic polymer material is capable of bonding to an adjacent surface and being molded during a lamination procedure.
- the polymer material can be a thermoplastic olefin, which can be composed of two different kinds of ionomers, mineral fillers, and/or pigments.
- Ionomer is a generic name which herein refers to either a co-polymer of ethylene and methacrylic acid or acrylic acid, which has been neutralized with the addition of a salt which supplies a cation such as Na + , Li + , Zn + ⁇ Al +++ , Mg ++ , etc.
- the material can have covalent bonds which polymers typically have, but can also have regions of ionic bonding. The latter can impart a built-in cross linking into the material.
- Ionomers are typically tough and weatherable polymers. The combination of two ionomers can produce a synergistic effect, which improves the water vapor barrier properties of the material over and above the barrier properties of either of the individual ionomer components.
- a mineral filler such as glass fiber
- the addition of a mineral filler, such as glass fiber, to the backsheet layer material can provide for a lower coefficient of thermal expansion. This can preserve strong, long lasting bonds to all the adjacent surfaces in a module which undergoes ambient temperature extremes.
- the glass fibers can also improve the water vapor and oxygen barrier properties of the material and increase the flexural modulus three or four times over the ionomers themselves. This can make the backsheet layer strong, but also flexible.
- a pigment, such as carbon black, can be added to the backsheet layer material to provide weathering properties such as resistance to degradation from exposure to ultraviolet light. To improve reflectivity, the backsheet or an edge element can be made white with the addition of TiO 2 .
- the polymer material can be a flexible sheet of thermoplastic polyolefin, which can include a sodium ionomer, a zinc ionomer, about 10-20% glass fibers, about 5% carbon black, or about 7% TiO 2 .
- the material can be an ionomer or an acid co-polymer with about 25% high density polyethylene, along with a mineral filler.
- One or more of the backsheet layer 50, the edge element 80, the encapsulant material 95, and the bonding layer 140 can be electron beam irradiated following profile extrusion.
- the irradiation can cross-link both the edge element 80 and the bonding layer 140.
- the electron beam irradiation produces a material that can have both thermoset and thermoplastic properties.
- the edge element 80 does not need to be set in a mold to prevent flow of the polymer during assembly of the photovoltaic module 10.
- polymers that are not sufficiently cross-linked or not contained in a mold during the lamination process flow readily under the temperature and pressure conditions of lamination, thereby creating a non-esthetically acceptable photovoltaic module.
- the radiation dosage used can be in the range of about 1 MR to about 30 MR. In various embodiments, the radiation dosage used can be in the range of about 2 MR to about 20 MR. In certain embodiments, the radiation dosage can be in the range of about 2 MR to about 12 MR. In various embodiments, the radiation dosage can be in the range of 12-16 MR.
- the encapsulant layer 95 can be an irradiated transparent layer. In some embodiments, the encapsulant layer 95 can be copolymers of ethylene. In certain embodiments, ethylene vinyl acetate (EVA), a copolymer of vinyl acetate and ethylene, can be used. In various embodiments, the irradiated transparent encapsulant layer 95 can be an ionomer.
- EVA ethylene vinyl acetate
- the irradiated transparent encapsulant layer 95 can be an ionomer.
- the acid moieties can be randomly or non-randomly distributed in the polymer chain.
- the alpha olefin content of the copolymer can range from 50-92%.
- the unsaturated carboxylic acid content of the copolymer can range from about 2 to 25 mole percent, based on the alpha olefin-acid copolymer, and the acid copolymers having from 10 to 90 percent of the carboxylic acid groups ionized by neutralization with metal ions from any of the group I, II or III type metals.
- the encapsulant layer 95 can be a layer of metallocene polyethylene disposed between two layers of ionomer.
- the layer of metallocene polyethylene can include a copolymer (or comonomer) of ethylene and hexene, octene, and butene, and the first and second layers of ionomer can have at least 5% free acid content.
- the layers of metallocene polyethylene and ionomer can be substantially transparent.
- the metallocene polyethylene can be ethylene alpha-olefin including co-monomer of octene, and the ionomer can be a sodium ionomer comprising methacrylic acid.
- An encapsulant material which is a combination of two materials can allow for the exploitation of the best properties of each material while overcoming the limitations of each material if used alone.
- the outer ionomer layers can allow the encapsulant material to bond strongly to the adjacent surfaces.
- the inner metallocene polyethylene layer can be a highly transparent, low cost thermoplastic material.
- the two ionomer layers can be thin (e.g., about 0.001" thick), and can have a high acid content (e.g., at least 5% free acid). The high acid content can provide for strong adhesion and cohesive bond failure and increased light transmission.
- the metallocene polyethylene which can have some co-monomer of octene, can have optical clarity and improved physical properties.
- the transparent layer 30 can be glass.
- a silane coupling agent can be applied as a very thin layer to the glass prior to the application of the edge element 80 onto the glass.
- the criterion of hydrolytic stability can be used to experimentally measure the strength of the bond between the edge element 80 and glass.
- an acid-copolymer can be used as the bonding agent.
- the acid- copolymer can be co-extruded during the profile extrusion of the edge element 80.
- a thin layer of a silane coupling agent can be applied to the glass edges.
- a measure of the bond strength is hydrolytic stability.
- a 1" wide strip of material bonded to a glass slide is subjected to hot water for a certain period of time. Following this, a right angle pull test is used to determine the so- called peel strength - a measure of the bond strength.
- peel strength for 4 days in boiling water is 5.2 to 1 1.3 lbs/inch.
- a photovoltaic component 20 can be formed by interconnecting a plurality of photovoltaic cells 60.
- a transparent layer 30, such as a tempered glass sheet, can be placed on a lay-up table.
- a first encapsulant layer can be disposed on the transparent layer 30.
- the plurality of photovoltaic cells 60 can be placed over the encapsulant layer.
- a second encapsulant layer can be placed over the plurality of photovoltaic cells 60.
- a backsheet layer 50 can be placed over the second encapsulant layer. In certain embodiments, the backsheet layer 50 can be placed on the plurality of photovoltaic cells 60 without an intervening second encapsulating layer.
- One or more edge elements can be disposed on the edges and/or corners of the assembly. The entire assembly can be placed in a laminator and laminated to form a photovoltaic module 10. After lamination, the excess encapsulant layer materials can be trimmed off.
- a junction box and stiffening elements 100 can be installed on the photovoltaic module 10.
- edge element 80, the edge members 110, and/or the corner members 120 can be formed of a polymer or non-metallic material, they can be positioned in direct physical contact to the photovoltaic module 10, whereas in a frame made of electrically conductive material such as aluminum, the edge element 80, need to be insulated from the photovoltaic module.
- the edge element 80 can seal the edges of the photovoltaic module 10 after reaching a sufficiently high pressure and temperature.
- a sufficiently high pressure and temperature can range from about 50 0 C to about 200 0 C. In certain embodiments, the temperature can be about 100 0 C.
- the introduction of pressure can be from the bladder of the laminator. The pressure can range from about 1 psi to about 20 psi. A gradual increase of the temperature and/or pressure allows sufficient opportunity for the air in the module to be evacuated before sealing occurs.
- the entire photovoltaic module 10 can be laminated and sealed to preserve the module in a substantially air-free environment.
- Figure 7 shows the back surface 84 of the back sheet layer 50 of photovoltaic module 10".
- the dimensions of the photovoltaic module 10" are about 3' wide and about 5' high.
- Edge element 80 is disposed on the edge of the photovoltaic component 20.
- Elements 160 are bonded to the back surface 84 of the backsheet layer 50.
- the elements can be non-metallic.
- the elements 160 can act as stiffening members to increase the rigidity of the photovoltaic module 10".
- the elements 160 can be vertical and located in a position to provide maximum stiffness to
- the elements 160 can be used to attach the photovoltaic module 10"to a mounting structure, such as, a rack or frame mounted on a roof surface.
- the elements 160 which can include bars or rods of a composite and/or non-metallic material including a polymer and/or a filler, can be positioned horizontally or diagonally on the backsheet layer 50 side of the photovoltaic module 10".
- the photovoltaic module 10" can include a junction box 170 attached to the back surface 84.
- the junction box 170 can be used to interconnect adjacent photovoltaic modules or can be used to connect photovoltaic module 10" to a load.
- Elements 160 can be placed on and bonded to the backsheet layer 50 to give the photovoltaic module 10" a desired stiffness.
- the amount of stiffness necessary can increase as photovoltaic modules become larger. Larger modules traditionally require heavier and more costly aluminum frames. Even with this, there is a limit as to how much stiffness a frame that is only on the edges of the module can provide.
- non-metallic stiffening elements 160 placed on the back of the module can also serve as mounting elements.
- the non-metallic stiffening elements 160 can have sufficient strength to withstand loads on the front surface of the module and similar loads against the rear surface of the module.
- the classes of non-metallic materials that could be used as stiffening elements and/or mounting elements 160 can include, but are not limited to, polymers that contain fillers to give them additional stiffness, mechanical strength, and/or flame retardant properties.
- traditional fillers include, but are not limited to, aluminum trihydrate, calcium carbonate, calcium sulfate, carbon fibers, glass fibers, hollow glass microspheres, kaolin clay, mica, crushed silica, synthetic silica, talc, and wollastonite.
- nano-clays such as montmorillinite can be used as fillers. The nano-clays can provide enhanced physical and/or flame retardant properties for very small quantities that are added to the polymer.
- the polymer material can be a polyolefin such as high density polyethylene and polypropylene.
- PET can be used. Some of the polyolefins and PET can be recycled materials instead of virgin resins and thereby even lower in cost.
- composites of sawdust from wood along with various polymers such as PVC and polyolefins such as plastic lumber can be used. These materials can also be blended with nanoparticles of clay to further enhance their physical properties.
- Suitable materials for photovoltaic modules and/or suitable techniques for forming one or more components of a photovoltaic module are described in one or more of the following U.S. Patents, each owned by the assignee of the present application and the entire disclosure of each incorporated by reference: 5,741,370; 6,114,046; 6,187,448; 6,320,116; 6,353,042; and 6,586,271.
Abstract
Description
Claims
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JP2009516719A JP2009542010A (en) | 2006-06-21 | 2007-06-21 | Photovoltaic module without frame |
EP07798874A EP2030248A2 (en) | 2006-06-21 | 2007-06-21 | Frameless photovoltaic module |
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US81548206P | 2006-06-21 | 2006-06-21 | |
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US8080728B2 (en) | 2004-12-07 | 2011-12-20 | E. I. Du Pont De Nemours And Company | Multilayer composite films and articles prepared therefrom |
USRE45163E1 (en) * | 2004-12-07 | 2014-09-30 | E. I. Du Pont De Nemours And Company | Multilayer composite films and articles prepared therefrom |
WO2009094343A3 (en) * | 2008-01-21 | 2010-07-22 | E. I. Du Pont De Nemours And Company | Amine-neutralized ionomer encapsulant layers and solar cell laminates comprising the same |
WO2009094343A2 (en) * | 2008-01-21 | 2009-07-30 | E. I. Du Pont De Nemours And Company | Amine-neutralized ionomer encapsulant layers and solar cell laminates comprising the same |
WO2009129068A3 (en) * | 2008-04-14 | 2010-07-01 | Bp Corporation North America Inc. | Thermal conducting materials for solar panel components |
JP2010219196A (en) * | 2009-03-16 | 2010-09-30 | Lintec Corp | Back surface protection sheet for solar cell module and solar cell module |
JP2010232294A (en) * | 2009-03-26 | 2010-10-14 | Lintec Corp | Protective sheet for solar cell module and solar cell module |
ITTO20090510A1 (en) * | 2009-07-07 | 2009-10-06 | Mario Gioco | HYDROPROTECTION FOR PHOTOVOLTAIC ELEMENTS |
WO2011019886A1 (en) | 2009-08-13 | 2011-02-17 | Dow Global Technologies, Inc. | A multi-layer laminate structure and manufacturing method |
US8163125B2 (en) | 2009-08-13 | 2012-04-24 | Dow Global Technologies Llc | Multi-layer laminate structure and manufacturing method |
US8361602B2 (en) | 2009-08-13 | 2013-01-29 | Dow Global Technologies Llc | Multi-layer laminate structure and manufacturing method |
DE102010041134A1 (en) | 2010-09-21 | 2012-03-22 | Siemens Aktiengesellschaft | Photovoltaic module i.e. frameless test specification-module, for installation on e.g. roof, has film arranged between photovoltaic layer and plate and dimensioned and shaped such that film extends over side margin of plate and covers plate |
US9123847B2 (en) | 2010-12-17 | 2015-09-01 | Dow Global Technologies Llc | Photovoltaic device |
WO2014100335A1 (en) * | 2012-12-20 | 2014-06-26 | 3M Innovative Properties Company | Anti-soiling, abrasion resistant constructions and methods of making |
CN104870575A (en) * | 2012-12-20 | 2015-08-26 | 3M创新有限公司 | Anti-soiling, abrasion resistant constructions and methods of making |
WO2016183604A1 (en) * | 2015-05-20 | 2016-11-24 | Lenzing Plastics Gmbh & Co Kg | Photovoltaic element |
Also Published As
Publication number | Publication date |
---|---|
US20080041442A1 (en) | 2008-02-21 |
CN101473450A (en) | 2009-07-01 |
WO2007149969A3 (en) | 2008-03-06 |
EP2030248A2 (en) | 2009-03-04 |
JP2009542010A (en) | 2009-11-26 |
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