Classifications

• • H—ELECTRICITY
  • H10—SEMICONDUCTOR DEVICES; ELECTRIC SOLID-STATE DEVICES NOT OTHERWISE PROVIDED FOR
  • H10F—INORGANIC SEMICONDUCTOR DEVICES SENSITIVE TO INFRARED RADIATION, LIGHT, ELECTROMAGNETIC RADIATION OF SHORTER WAVELENGTH OR CORPUSCULAR RADIATION
  • H10F19/00—Integrated devices, or assemblies of multiple devices, comprising at least one photovoltaic cell covered by group H10F10/00, e.g. photovoltaic modules
  • H10F19/80—Encapsulations or containers for integrated devices, or assemblies of multiple devices, having photovoltaic cells
  • H10F19/807—Double-glass encapsulation, e.g. photovoltaic cells arranged between front and rear glass sheets
• • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
  • Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
  • Y02E—REDUCTION OF GREENHOUSE GAS [GHG] EMISSIONS, RELATED TO ENERGY GENERATION, TRANSMISSION OR DISTRIBUTION
  • Y02E10/00—Energy generation through renewable energy sources
  • Y02E10/50—Photovoltaic [PV] energy
  • Y02E10/548—Amorphous silicon PV cells

Definitions

• This invention comprises a method of manufacturing a photovoltaic cell module, the photovoltaic (PV) cell module manufactured thereby, and a kit useful therefor.
• a typical method includes vacuum-press-curing (V-P-C) a laminate.
• the laminate sequentially comprises a superstrate, a front portion of an encapsulant, interconnected PV cells, a rear portion of the encapsulant, and a substrate.
• the method of US 2010/0275992 A1 mentions, inter alia, an ultrahigh durability solar cell module that can be used semi- permanently, with an ultrahigh durability transparent substrate, solar cell element and filler, wherein the solar cell element and a liquid substance or a gel obtained by a fast sealed structure comprising a high durability crosslinking reactive adhesive provided between a glass panel and back side protective substrate, and a hot-melt adhesive.
• the module is produced by placing the sealing compound, solar cell element and liquid substance on a glass panel and finally laying the back side protective substance to form a provisional laminated body, and then compression bonding the provisional laminated body at room temperature in a vacuum for sealing.
• a focus in the art has been building laminates for use in V-P-C equipment. These laminates are assembled from the ground up by sequentially laying one of a substrate or superstrate down in a horizontal orientation, dispensing a liquid encapsulant on the substrate or superstrate, laying PV cells on the dispensed encapsulant, interconnecting the PV cells if not already done, dispensing more liquid encapsulant on the interconnected PV cells, and then laying the other of the substrate or superstrate, as the case may be, on the second dispensed encapsulant until the laminate is assembled.
• the assembled laminate is then vacuum-press-cured horizontally to minimize leakage of the liquid encapsulant from the laminate.
• An overriding a goal of this work is producing hectowatt-sized (0.1 to ⁇ 1 kilowatt) PV cell modules at ever higher output rates and ever lower manufacturing costs. This focus does not meet all industry needs.
• the inventors discovered technical problems with manufacturing PV cell modules using V-P-C equipment.
• the V-P-C method traps air bubbles during evacuation (V step) of the assembled laminate. Air bubbles reduce module efficiency.
• the V-P-C methods use more encapsulant than is necessary for coating or encapsulating the PV cells. The extra encapsulant oozes out of the module during the pressing (P) step, rendering the V-P-C method inefficient.
• the V-P-C method cracks the PV cells and/or breaks the interconnections. Any given V-P-C method may have one or more of these problems.
• This invention comprises a method of manufacturing a photovoltaic (PV) cell module, the PV cell module manufactured thereby, and a kit useful therefor.
• PV photovoltaic
• Embodiments of the invention include:
• a method of manufacturing a PV cell module comprising introducing a liquid encapsulant between a superstrate and interconnected PV cells and between the interconnected PV cells and a substrate in a preassembled laminate sequentially comprising the superstrate, interconnected PV cells, and substrate, and lacking encapsulant before the introducing step, the method giving a first PV cell module sequentially comprising the superstrate, a front portion of the liquid encapsulant, interconnected PV cells, a rear portion of the liquid encapsulant, and the substrate.
• a kit comprising components of the PV cell module and instructions for using same to manufacture the module according to the method.
• the method is useful for manufacturing PV cell modules.
• the manufactured PV cells modules are useful in a variety of applications.
• the kit is useful in the method.
• the invention may have additional uses, including those unrelated to PV applications.
• Figure (Fig.) 1 is a perspective view of an embodiment of a partial assembly to the preassembled laminate.
• Fig. 2 is a partially-exploded perspective view of an embodiment of the preassembled laminate prepared from the partial assembly of Fig. 1.
• Fig. 3 is a perspective view of another embodiment of the preassembied laminate.
• Fig. 4 is a partially exploded view of the embodiment of the preassembied laminate of Fig. 2.
• Fig. 5 is a perspective view of the embodiment of the preassembied laminate of Fig. 2 shown during the introducing step of the method.
• Fig. 6 is a perspective view of an embodiment of the PV cell module prepared from the preassembied laminate of Fig. 5.
• Fig. 7 is a perspective view of another embodiment of the preassembied laminate shown during the introducing step of the method.
• Fig. 8 is a perspective view of an embodiment of the PV cell module prepared from the preassembied laminate of Fig. 7.
• Fig. 9 is a perspective view of an alternate embodiment of a partial assembly to the preassembied laminate.
• Fig. 10 is a perspective view of another embodiment of the preassembied laminate.
• Fig. 11 is a perspective view of an embodiment of the PV cell module prepared from the preassembied laminate of Fig. 10.
• the Brief Summary and Abstract are incorporated here by reference.
• the invention embodiments include the method, PV cell module, and kit summarized above.
• the invention also includes other embodiments described below.
• the term "preassembied laminate consisting essentially of may be used herein to mean that prior to the introducing step the preassembied laminate lacks encapsulant and the PV cells are not encapsulated, and thus are in need of encapsulation.
• the method may manufacture a bubble-free PV cell module, which lacks bubbles trapped in the liquid encapsulant. That is, the liquid encapsulant may be allowed to coat the PV cells in such a way that any initial bubbles are allowed to break, float away, be absorbed, or a combination of any two or more thereof. Additionally or alternatively, the method may form a layer of the front portion of the liquid encapsulant of a uniform thickness between the superstrate and the PV cells and a layer of the rear portion of the liquid encapsulant of uniform thickness between the PV cells and the substrate without use of a vacuum and/or cell press.
• the method may prevent oozing or loss of the liquid encapsulant from the preassembied laminate and/or PV cell module. That is, the effective amount of the liquid encapsulant that is used in the method may be the quantity desired for coating the PV cells, without any excess quantity being used and lost. Additionally or alternatively, the method may be performed at ambient pressure, e.g., at 96 to 106 kilopascals. Additionally, the method is gentle and avoids cracking the PV cells and/or breaking the electrical interconnections.
• the method may be performed without vacuum and a cell press machine. Therefore, the method may be used by millions of low income people who live off- grid in remote sunny regions in diverse geographical locations that lack (reliable) access to electricity. That is, the method enables these indigenous people in India, Africa, the Middle East and other remote areas to produce their own PV cell module to meet their need for electricity where they live without relying on access to PV cell module manufacturing plants and distribution channels. Certain aspects of this invention may independently solve additional problems and/or have other advantages.
• inventions and some of these advantages may be illustrated in the accompanying drawings and/or described herein.
• the method is illustrated by the Figures and described below with reference to an embodiment wherein the liquid encapsulant is poured by hand onto a plurality of interconnected PV cells.
• the invention includes other means of introducing the liquid encapsulant such as by spraying, dripping, or squirting.
• Fig. 1 shows the perspective view of an embodiment of a partial assembly to the preassembled laminate.
• the partial assembly 10 lacks the superstrate and the seal (both not shown).
• the partial assembly 10 comprises a substrate 20, thirty-six PV cells 30, interconnection circuit comprising five horizontally disposed bus bars 49, a plurality of vertically disposed interconnects 40, bus bar connects 42 and 44, and four corner spacer/tie elements 50.
• Interconnects 40, bus bar connects 42 and 44 and bus bars 49 may comprise the same or different electrically conductive metal or metal alloy (e.g., Al, Ag, Cu, or alloy thereof).
• the substrate 20 has a first major surface 22 and a second major surface 28, which is spaced apart from the first major surface 22 by the thickness (not indicated) of the substrate 20.
• the substrate 20 defines apertures 41 and 43 therethrough.
• Each of the PV cells 30 (only two are numbered for clarity) has a first major surface 32 and a second major surface 38, which is spaced apart from the first major surface 32 by the thickness (not indicated) of the PV cell 30.
• the PV cells 30 are disposed on the second major surface 28 of the substrate 20 such that the first major surfaces 32 of the PV cells 30 are facing the second major surface 28 of the substrate 20.
• the interconnection circuit (40 and 49), and thus the PV cells 30, are affixed to the second major surface 28 of the substrate 20 using five pieces of tape 51 applied to spaced apart locations on the interconnection circuit (40 and 49).
• the PV cells 30 are electrically interconnected and in electrical communication with each other via the interconnection circuit (40 and 49).
• the interconnection circuit (40 and 49) in turn is electrically interconnected and in electrical communication with bus bar connects 42 and 44.
• Bus bar connect 42 is electrically interconnected with bus bar connect 44 via the interconnection circuit (40 and 49).
• Bus bar connects 42 and 44 travel from interconnection circuit (40 and 49) at second major surface 28 through apertures 41 and 43, respectively, of substrate 20 to exit substrate 20 at first major surface 22 thereof.
• a seal such as a piece of tape or a plug of elastomer (not shown) may be applied to substrate 20 to cover apertures 41 and 43 (e.g., tape applied over apertures 41 and 43 on first major surface 22) to prevent leakage of liquid encapsulant therethrough during the introducing step of the method.
• Bus bar connects 42 and 44 may later serve to make an external, back side electrical interconnection to a junction box, electrical grid, or electrical device.
• the four corner spacer/tie elements 50 are disposed at the four corners on the second major surface 28 of the substrate 20.
• Fig. 2 shows the partially-exploded perspective view of an embodiment 100 of the preassembled laminate.
• the preassembled laminate 100 comprises the substrate 20, the thirty-six PV cells 30, interconnection circuit (40 and 49), bus bar connects 42 and 44, and four corner spacer/tie elements 50 from the partial assembly 10 of Fig. 1.
• the preassembled laminate 100 also comprises a superstrate 60, three pieces of sealing tape 70, and a rigid spacer element 55.
• the superstrate 60 is spaced apart from substrate 20 by the four corner spacer/tie elements 50 and the rigid spacer element 55.
• the four corner spacer/tie elements 50 may be double-sided tape.
• the superstrate 60 has a first major surface (62 in Fig.
• the four corner spacer/tie elements 50 space apart the second major surface (28 in Fig. 1 or 4) of the substrate 20 from the first major surface (62 in Fig. 4) of the superstrate 60.
• the thickness (not indicated) of the four corner spacer/tie elements 50 may be slightly greater than the thickness (not indicated) of the PV cells 30.
• Sealing tape 70 wraps around and seals edges 82, 84, and 86 of the preassembled laminate 100.
• Sealing tape 70 has a partially-exploded section 74 that shows the sealing tape 70 is [-shaped for contacting superstrate 60, edges 82, 84, and 86, and substrate 20.
• Bus bar connects 42 and 44 travel from two of bus bars 49 of interconnection circuit (40 and 49) at second major surface 28 of substrate 20 (interior in the preassembled laminate 100) through apertures 41 and 43, respectively, of substrate 20 to exit substrate 20 at first major surface 22 thereof to an exterior in the preassembled laminate 100.
• the rigid spacer element 55 is disposed in fourth edge 88 of the preassembled laminate 100 and spaces substrate 20 apart from superstrate 60 and from PV cells 30.
• the thickness (not indicated) of rigid spacer element 55 is greater than the thickness of the PV cells 30 such that rigid spacer element 55 may maintain the front gap (not shown) between the first major surface (62 in Fig. 4) of the superstrate 60 and the second major surface 38 of the PV cells 30 and the rear gap (not indicated) between the first major surface 32 of the PV cells 30 and the second major surface 28 (Fig. 2) of the substrate 20 when the preassembled laminate 100 is oriented with the fourth edge 88 facing up (as shown later in Fig. 5).
• the first and second major surfaces 32 and 38 of the PV cells 30 are in fluid communication with an exterior (not indicated) of the preassembled laminate 100 via the fourth edge 88, which is open in Fig. 2.
• Fig. 3 shows the perspective view of another embodiment 1 10 of the preassembled laminate.
• a preassembled laminate 1 10 is identical to the preassembled laminate 100 of Fig. 2 except the preassembled laminate 110 lacks the four corner spacer/tie elements 50 (FIG. 2) of the preassembled laminate 100 of Fig. 2.
• Use of the four corner spacer/tie elements 50 and/or rigid spacer element 55 is optional in the method so long as the front and rear gaps (not indicated) may be maintained during the introducing step.
• the superstrate 60 is spaced apart from substrate 20 by the rigid spacer element 55.
• the rigid spacer element 55 creates the opening 85 in the fourth edge 88 of the preassembled laminate 110.
• Fig. 4 shows the partially exploded view of the preassembled laminate 100.
• the preassembled laminate 100 comprises the substrate 20, the thirty-six PV cells 30, interconnection circuit (plurality (forty) of 40 and five of 49), bus bar connects 42 and 44, and four corner spacer/tie elements 50 from the partial assembly 10.
• the PV cells 30, interconnection circuit (40 and 49), bus bar connects 42 and 44 comprise an interconnected PV cell subassembly (10 in FIG. 1 ) that is partially exploded (interconnects 40, bus bar connects 42 and 44, bus bars 49, and tapes 51 are kept together) in FIG. 4.
• the preassembled laminate 100 also comprises the superstrate 60, three pieces of sealing tape 70, and a rigid spacer element 55.
• the superstrate 60 has the first major surface 62 and second major surface 68, which is spaced apart from the first major surface 62 by the thickness (not indicated) of the superstrate 60.
• Sealing tape 70 wraps around and seals edges 82, 84, and 86 of the preassembled laminate 100 as described.
• the rigid spacer element 55 is partially disposed in fourth edge 88 of the preassembled laminate 100.
• Bus bar connects 42 and 44 travel from two of bus bars 49 of interconnection circuit (40 and 49) at second major surface 28 of substrate 20 (interior in the preassembled laminate 100) through apertures 41 and 43, respectively, of substrate 20 to exit substrate 20 at first major surface 22 thereof to an exterior in the preassembled laminate 100.
• Fig. 5 shows the perspective view of the preassembled laminate 100 during the introducing step of the method.
• the preassembled laminate 100 (Figs. 2 and 4) is disposed in a vertical orientation ( ⁇ 30° of vertical orientation) such that the fourth edge 88 of the preassembled laminate 100 is oriented up and is open.
• the first and second major surfaces 32 and 38 of the thirty-six PV cells 30 are in fluid communication with an exterior (not indicated) of the preassembled laminate 100 via the fourth edge 88.
• a liquid encapsulant 90 e.g., a liquid polyorganosiloxane encapsulant
• a liquid encapsulant 90 is being introduced by pouring same from container 99 into the preassembled laminate 100 via the opening (not indicated, similar to 85 in Fig. 3)) in the fourth edge 88 of the preassembled laminate 100.
• the liquid encapsulant 90 has reached height 92, which is slightly greater than 50% of the total height, h, of the preassembled laminate 100. This may be easily understood by observing the depth of liquid encapsulant 90 relative to the rows of PV cells 30.
• the sealing of the edges 82, 84, and 86 of the preassembled laminate 100 prevent the liquid encapsulant 90 from leaking from the preassembled laminate 100.
• the liquid encapsulant 90 is seen disposed in a front side gap (not indicated) between the first major surface (62 in Fig. 4) of the superstrate 60 and the second major surface 38 of the PV cells 30. Although it may be difficult to appreciate in Fig. 5, the liquid encapsulant 90 is also disposed in a rear side gap (not indicated) between the first major surface 32 of the PV cells 30 and the second major surface (see 28 in Fig. 2 and 4) of the substrate 20.
• Fig. 6 shows the perspective view of the embodiment of the PV cell module 500 prepared from the preassembled laminate 100.
• the PV cell module 500 has been prepared by allowing the introduced liquid encapsulant 90 (as in Fig. 5) to coat both first and second major surfaces 32 and 38 of the thirty-six PV cells 30, and then removing the three pieces of the sealing tape (not shown, see tapes 70 in Fig. 5) from edges 82, 84 and 86 and removing the rigid spacer element (not shown, see 55 in FIG. 5) from the fourth edge 88 to give the PV cell module 500.
• the introduced liquid encapsulant 90 may be cured in the PV cell module 500.
• the seal (not shown, see tapes 70 in FIG. 5) left on the PV cell module 500 and a further tape may be applied to edge optionally the three pieces of the sealing tape (not shown, see tapes 70 in Fig. 5) may be removed from the PV cell module 500.
• the liquid encapsulant 90 is curable, the rigid spacer element (not shown, see 55 in FIG. 5) is removed from the fourth edge 88, and then the PV cell module 500 is laid down in a horizontal orientation, the front and rear portions of the liquid encapsulant 90 are leveled, and the liquid encapsulant 90 is cured with the PV cell module 500 disposed in a horizontal orientation ( ⁇ 30° of horizontal orientation).
• the three pieces of the sealing tape (70 in Fig. 5) may be left in place, alternatively removed from the edges 82, 84 and 86 prior to the horizontal curing.
• the introduced liquid encapsulant 90 is cured in the vertical orientation after removing the rigid spacer element (not shown, see 55 in FIG. 5), but prior to the removing of the three pieces of the sealing tape (70 in Fig. 5) from edges 82, 84 and 86.
• the PV cell module 500 sequentially comprises a front portion (not indicated) of the liquid encapsulant 90, interconnected PV cells (PV cells 30, interconnection circuit (40 and 49), and bus bar connects 42 and 44), rear portion (not indicated) of the liquid encapsulant 90, and substrate 20.
• the sealing tapes (70 in Fig. 5) may be left in place along edges 82, 84 and 86 and the optional fourth tape (not shown) may be added to edge 88 of the PV cell module 500, which may then further comprise the sealing tapes (70 in Fig. 5).
• the liquid encapsulant 90 may be cured after the allowing step.
• the liquid encapsulant, before curing and the cured product thereof after curing may also encapsulate around an interior (to embodiment 500) portion of bus bar connects 42 and 44 where they connect to two of the bus bars 49 of interconnection circuit (40 and 49) and also plug up or fill in any remaining opening in apertures 1 and 43.
• Fig. 7 shows the perspective view of another embodiment of the preassembled laminate during the introducing step of the method.
• a preassembled laminate 120 is identical to the preassembled laminate 100 of Fig. 5 except instead of the three pieces of the sealing tape 70 in Fig. 5, the three edges 82, 84, and 86 of preassembled laminate 120 are sealed by strip seal 79.
• the strip seal 79 is disposed between substrate 20 and superstrate 60 such that strip seal 79 is in operative sealing contact with the second major surface (28 in Figs. 1 and 4) of the substrate 20 and with the first major surface (62 in Fig. 4) of the superstrate 60.
• the preassembled laminate 120 is disposed in a vertical orientation such that the fourth edge 88 of the preassembled laminate 120 is oriented up and is kept open by rigid spacer element 55.
• the first and second major surfaces 32 and 38 of the thirty- six PV cells 30 are in fluid communication with an exterior (not indicated) of the preassembled laminate 120 via the fourth edge 88.
• An effective amount of a liquid encapsulant 90 e.g., a liquid polyorganosiloxane encapsulant
• Fig. 8 shows the perspective view of the embodiment of the PV cell module 520 prepared from the preassembled laminate 120.
• the PV cell module embodiment 520 is identical to the PV cell module 500 except having been prepared using the three pieces of the sealing tape 70 used to prepare the PV cell module 500, the three edges 82, 84, and 86 of PV cell module 520 had been, and still are, sealed by strip seal 79 (e.g., a bead of silicone sealant or a silicone rubber dam).
• strip seal 79 e.g., a bead of silicone sealant or a silicone rubber dam
• the introduced liquid encapsulant 90 may be cured without removing strip seal 79 to give a cured form of PV cell module 520.
• the three edges 82, 84, and 86 may be sealed with a viscous adhesive or sealant composition, gasket, O-ring, exterior frame, or other mechanical sealing means.
• Fig. 9 is the perspective view of an alternate embodiment of a partial assembly to the preassembled laminate.
• the partial assembly 8 is identical to the prior partial assembly (10 of Fig. 1 ) except partial assembly 8 has substrate 21 , which lacks apertures (i.e., lacks apertures 41 and 43 of partial assembly 10 of Fig. 1).
• the partial assembly 8 comprises a substrate 21 , thirty-six PV cells 30, interconnection circuit comprising five horizontally disposed bus bars 49, a plurality of vertically disposed interconnects 40, Bus bar connects 42 and 44, and four corner spacer/tie elements 50. Together the PV cells 30, interconnection circuit (40 and 49), bus bar connects 42 and 44 comprise an interconnected PV cells subassembly (not indicated).
• the substrate 21 has a first major surface 22 and a second major surface 28, which is spaced apart from the first major surface 22 by the thickness (not indicated) of the substrate 21.
• Fig. 10 is the perspective view of another embodiment of the preassembled laminate.
• the preassembled laminate 130 is identical to preassembled laminate 110 except preassembled laminate 130 lacks apertures in substrate 21 (i.e., lacks apertures 41 and 43 of Fig. 3).
• the thickness (not indicated) of the PV cells 30 and front and rear gaps (not indicated) is slightly greater than thickness of the bus bar connects 42 and 44.
• Bus bar connects 42 and 44 travel from two of bus bars 49 of interconnection circuit (40 and 49) between the first major surface 62 of superstrate 60 and the second major surface 28 of substrate 21 through aperture(s) (not visible) in the sealing tape 70 at edge 86 of the preassembled laminate 130.
• Rigid spacer element 55 spaces substrate 21 and superstate 60 apart from each other and PV cells 30.
• FIG. 11 is the perspective view of the embodiment of the PV cell module 530 prepared from the prior preassembled laminate (130 of FIG. 10).
• the PV cell module 530 has been prepared by allowing the introduced liquid encapsulant 90 (introduced in a manner similar to that described for Fig. 6) to coat both first and second major surfaces 32 and 38 of the thirty-six PV cells 30, and then removing the three pieces of the sealing tape (70 in Fig. 10) from edges 82, 84 and 86 and removing the rigid spacer element (55 in Fig. 10) from the fourth edge 88 (Fig. 10) to give the PV cell module 530.
• the introduced liquid encapsulant 90 may be cured prior to, alternatively after, the removing of the three pieces of the sealing tape (70 in Fig. 10) to give a cured form of PV cell module 530.
• FIG. 10 Another alternative embodiment, not drawn, is identical to preassembled laminate 130 of FIG. 10 and PV cell module embodiment 530 of FIG. 11 except instead of the three pieces of the sealing tape (70 in Fig. 10), the edges (82, 84, and 86 in FIG. 10) are sealed by a strip seal in a manner similar to use of the strip seal 79 in Figs. 7 and 8.
• the invention may be a method (aspect 1 ) of manufacturing a PV cell module (500, 520, or 530) from a preassembled laminate (100, 1 10, 120, or 130) comprising a superstrate (60), interconnected PV cells in need of encapsulation (30), interconnection circuit (40 and 49), bus bar connects (42, and 44), a substrate (20 or 21 ) spaced apart from the superstrate (60) so as to define a volumetric space housing the PV cells (30) and a front gap (not indicated) between the superstrate (60) and the PV cells (30) and a rear gap (not indicated) between the PV cells (30) and the substrate (20 or 21 ), and a seal (70 or 79) that operatively seals at least one first edge (82, 84, and 86) of the preassembled laminate (100, 1 10, 120, or 130)) against leakage of a liquid encapsulant (90) from the volumetric space and wherein the preassembled laminate (100, 110,
• the first edge(s) (82, 84, and 86) of the preassembled laminate (100, 110, 120, or 130) typically is side and bottom edges of the preassembled laminate (100, 110, 120, or 130) and the second edge (88) of the preassembled laminate (100, 110, 120, or 130) typically is a top edge thereof such that the opening (85) in the second edge (88) faces upward.
• the front portion and rear portion of the liquid encapsulant (90) are introduced into the preassembled laminate (100, 110, 120, or 130) by the introducing step.
• the first edge(s) (82, 84, and 86) of the preassembled laminate (100, 110, 120, or 130) that is sealed with the seal (70 or 79) may be greater than 50% but less than 100% of the length of the entire periphery of the preassembled laminate (100, 110, 120, or 130).
• the sealed first edge(s) (82, 84, and 86) is at least 60%, alternatively at least 75%, alternatively at least 90% of the length of the entire periphery (82, 84, 86, and 88) of the preassembled laminate (100, 110, 120, or 130).
• the sealed first edge(s) (82, 84, and 86) is three of the sides of the square or rectangle.
• a portion of the fourth side (88) of the square or rectangular preassembled laminate (100, 110, 120, or 130) may be sealed except for an opening (85) that provides a conduit for introducing the liquid encapsulant (90).
• a portion of the opening (85) that provides the conduit for introducing the liquid encapsulant (90) into the preassembled laminate (100, 110, 120, or 130) typically remains open during the introducing step so as to provide a conduit for air to be released from the preassembled laminate (100, 110, 120, or 130) during the introducing step.
• the entire portion of the opening (85) may be blocked by the liquid encapsulant (90) during some of the introducing step, in which embodiment a small vent or vent tube (not shown) may be included (temporarily) in the sealed first edge(s) (82 and/or 86) proximal to the fourth side (88), or typically in the fourth side (88), to provide a conduit for air to be released from the preassembled laminate (100, 110, 120, or 130) during the introducing step.
• the vent may be plugged up or filled in by cured product of curing the liquid encapsulant (90) or by a seal or the vent tube, as the case may be, may be removed and any remaining hole plugged up or filled in..
• the method comprises the step of introducing the effective amount of a liquid encapsulant (90) into the gap (85) of the preassembled laminate (100, 1 10, 120, or 130).
• This introducing step is counterintuitive in that the preassembled laminate (100, 1 10, 120, or 130) is built by adding the liquid encapsulant (90) between the superstrate (60) and PV cells (30) and between the PV cells (30) and the substrate (20 or 21 ) after the superstrate (60), PV cells (30) and substrate (20 or 21 ) have already been positioned relative to each other and assembled in the preassembled laminate (100, 1 10, 120, or 130).
• the PV cells (30) are coated with the liquid encapsulant (90) while they are sandwiched between the superstrate (60) and the substrate (20 or 21 ).
• the horizontal orientation build method of the prior art could not be adapted to add the liquid encapsulant after the second one of the superstrate and substrate has been laid down.
• the front and rear gaps may be maintained by placing a rigid spacer element (55) between the superstrate (60) and the substrate (20 or 21 ) near (85) where the effective amount of the liquid encapsulant (90) is entering the preassembled laminate (100, 110, 120, or 130).
• the rigid spacer element (55) may be removed after the introducing step to enhance the allowing step.
• the preassembled laminate (100, 1 10, 120, or 130) may be oriented with open edge (88) facing up such that the preassembled laminate (100, 110, 120, or 130) is within plus or minus ( ⁇ ) 30° of vertical orientation (i.e., from - 30° to + 30° on z- axis), alternatively within ⁇ 20° of vertical orientation, alternatively within ⁇ 10° of vertical orientation, alternatively within ⁇ 5° of vertical orientation, alternatively within ⁇ 1 ° of vertical orientation.
• ⁇ 30° of vertical orientation
• the preassembled laminate (100, 1 10, 120, or 130) is disposed parallel to a z-axis and 90.0° or perpendicular to an x-axis and y-axis or horizontal plane in an x-y Cartesian coordinate.system wherein z-axis indicates height, x-axis indicates width, and y-axis indicates depth.
• the angle for measuring the ⁇ 30° of vertical orientation is measured relative to first major surface 22 of substrate 20 or second major surface 68 of superstrate 60 relative to the horizontal x-y plane.
• the liquid encapsulant (90) may be introduced under influence of gravity at ambient pressure (e.g., 97 to 107 kPa) when open edge (88) is facing up. Alternatively instead of, or additionally in addition to, gravity in the introducing step, the liquid encapsulant may be introduced into the preassembled laminate under a pressure greater than ambient pressure, e.g., pressure from 1 10 kPa to 200 kPa.
• the preassembled laminate (100, 1 10, 120, or 130) may be oriented with open edge (88) facing sideways such that the preassembled laminate (100, 110, 120, or 130) is within plus (+) 30° of horizontal orientation (i.e., from 0° to + 30° of x-y plane), alternatively within + 20° of horizontal orientation, alternatively within + 10° of horizontal orientation, alternatively within + 5° of horizontal orientation, alternatively within + 1 ° of horizontal orientation.
• the preassembled laminate (100, 1 10, 120, or 130) is disposed parallel to the x-y plane.
• the liquid encapsulant (90) may be flowed under the greater than ambient pressure into the opening (85) in the open edge (88) and into the preassembled laminate (100, 1 10, 120, or 130) at horizontal orientation.
• the effective amount of the liquid encapsulant (90) is equal to, and typically greater than a sum of the amounts of the front and rear portions of the liquid encapsulant (90) in the front and rear gaps of the PV cell module (500, 520, or 530).
• the effective amount of the liquid encapsulant (90) may be based on weight thereof. Typically, however, the effective amount of the liquid encapsulant (90) is based on a visual observation of reaching a fill level within the preassembled laminate (100, 110, 120, or 130).
• the fill level may be a quantity sufficient to fill the vertically-oriented the preassembled laminate (100, 1 10, 120, or 130) to a height of from 60 to 90 percent (%), alternatively 65% to 85%, alternatively 70% to 80% of the total height (h) of the preassembled laminate (100, 1 10, 120, or 130) in the vertical orientation.
• the fill level of the liquid encapsulant (90) may be up to 100% of the total height (h) of the preassembled laminate (100, 110, 120, or 130) in the vertical orientation, generally this may disadvantageously result in excess liquid encapsulant being squeezed out of the preassembled laminate (100, 1 10, 120, or 130) during the subsequent allowing step, thereby undesirably wasting some of the liquid encapsulant (90).
• the fill level of the liquid encapsulant may be less than 60% of the total height (h) of the preassembled laminate (100, 110, 120, or 130) in the vertical orientation so long as the quantity of the liquid encapsulant (90) is sufficient to coat the front and rear major surfaces (32 and 38), typically all surface of the PV cells (30) during the subsequent allowing step. If desired, the fill level of the liquid encapsulant (90) in the preassembled laminate (100, 110, 120, or 130) before the allowing step may be adjusted.
• the method also comprises the step of allowing the introduced liquid encapsulant (90) to coat the PV cells (30) and fill the gap between the superstrate (60) and PV cells (30) and fill the gap between the PV cells (30) and the substrate (20 or 21 ) to give the PV cell module (500, 520, or 530).
• the rigid spacer element (55), if any, is removed, the superstrate (60) and the substrate (20 or 21 ) of the preassembled laminate (100, 110, 120, or 130), now containing the liquid encapsulant (90) in the front and rear gaps, are adjusted so as to cause the liquid encapsuiant (90) spread in the front and rear gaps and completely cover or encapsulate the interconnected PV cells (30) and interconnection circuit (40 and 49) to give the PV cell module (500, 520, or 530).
• the PV cell module (500, 520, or 530) may be laid horizontally for the allowing step. If desired, the superstrate (60) and the substrate (20 or 21 ) of the resulting PV cell module (500, 520, or 530) may be held in position relative to each other and the interconnected PV cells (30) and interconnection circuit (40 and 49) by applying opposing mechanical forces to the external surface (68) of the superstrate (60) and the external surface (22) of the substrate (20 or 21 ).
• the holding in position may be accomplished by a human being or clamps holding the PV cell module (500, 520, or 530) together for a period of time, e.g., a period of time sufficient to allow curing of the liquid encapsuiant (90).
• the method may further comprise a preliminary step of assembling the
• preassembled laminate 100, 1 10, 120, or 130
• a partial assembly (10, 8) as described.
• the method may be used to manufacture any size PV cell module (500, 520, or 530), wherein the size of the PV cell module (500, 520, or 530) may expressed in performance terms as the maximum number of watts (W) of electricity it is designed to produce.
• the method may be practiced by indigenous peoples in rural environments, including by poorly educated inhabitants in locations without access to an electricity grid.
• the size PV cell module (500, 520, or 530) is relatively small (e.g., from 1 W to 100 W, alternatively from 10 W to 100 W, alternatively from 2 W to 50 W, alternatively from 5 W to 25 W, e.g., a 10 W, 20 W, 50 W, or 80 W PV cell module)
• the introducing and allowing steps, and the optional curing step of the method may be fully manual and may be performed without using any equipment or machinery such as a V-P-C machine.
• the present invention further includes the kit with components and instructions for assembling the PV cell module (500, 520, or 530).
• the components of the kit may comprise the superstrate (60), PV cells (30), interconnection components (e.g., tabbing, bus bars, electrically conductive paste, solder flux, or a combination thereof for interconnection circuit (40 and 49) and bus bar connects (42 and 44), substrate (20 or 21 ), liquid encapsuiant (90), and container (99) for the liquid encapsuiant (90).
• the components may further comprise spacing elements and sealing elements that are useful for assembling the PV cell module (500, 520, or 530) according to the method, the spacing elements comprising optional corner spacer/tie elements (50) and rigid spacer element (55), and the sealing elements comprising the seal (70 and/or 79).
• the components may further comprise any other components of a PV cell module such as an optional tie layer material (e.g., adhesion promoter), pottant material (for a junction box), and/or a junction box (not shown) and/or an inverter (not shown) for the PV cell module (500, 520, or 530).
• an optional tie layer material e.g., adhesion promoter
• pottant material for a junction box
• an inverter not shown
• the instructions may include directions for assembling the partial assembly (10 or 8) and/or the preassembled laminate (100, 1 10, 120, or 130) and directions for manufacturing the PV cell module (500, 520, or 530) therefrom according to the method.
• the instructions may further include directions for placing one or more of the PV cell modules (500, 520, or 530) in a location and orientation suitable for receiving sunlight (e.g., on a rooftop and angled for orienting solar panels towards the sun) and instructions for electrically connecting the PV cell module (500, 520, or 530) to the junction box, inverter, an electricity grid or an electrical device (e.g., light bulb, electrical charging device, electric fan or cooking stove) in need of electricity.
• the kit may be manually handled by the indigenous peoples for use in the all manual embodiment of the method.
• the superstate (60) is transparent and useful for PV applications. It allows transmission of light therethrough and functioning as a barrier layer between an environment in which the PV cell module (500, 520, or 530) may be used (e.g., outdoor environment) and the front portion of the liquid encapsulant (90).
• the superstrate (60) may be characterizable by a light transmittance of at least 70 percent as determined by UV/Vis spectrophotometry using ASTM E424-71 (2007).
• the superstrate (60) is effective for allowing transmission of sunlight therethrough.
• the superstrate (60) may be a silicate glass, e.g., a soda-lime or borosilicate glass, or may be a transparent organic polymer, e.g., polycarbonate.
• the substrate (20 or 21 ) is useful for PV applications by, among other things, supporting the PV cells (30) and functioning as a barrier layer between an environment in which the PV cell module (500, 520, or 530) may be used (e.g., outdoor environment) and the rear portion of the liquid encapsulant (90).
• the substrate (20 or 21 ) may be also called a back sheet.
• the substrate (20) may define one or more apertures (41 and 43) therethrough that may serve as conduit(s) for bus bar connects (42 and 44).
• a seal such as a piece of tape or a plug of elastomer (not shown) may be applied to substrate 20 to cover aperture(s) (41 and 43) (e.g., tape applied over apertures 41 and 43 on first major surface 22) to prevent leakage of liquid encapsulant therethrough during the introducing step of the method.
• the substrate (20 or 21 ) may be a silicate glass such as a soda-lime or borosilicate glass.
• substrate (20 or 21 ) may be a polyorganosiloxane; an organic polymer; or a blend thereof.
• the organic polymer may comprise, alternatively consist essentially of, alternatively consist of a polyolefin (e.g., a polyethylene or polypropylene), a poly(ethylene terephthalate), a poly(ethylene naphthalate), a polyvinyl fluoride) (e.g., TEDLAR, du Pont, Wilmington, Delaware), a poly(ethylene vinyl acetate), and/or any other organic polymer.
• the substrate (20 or 21 ) may be free of all polymers that are not polyorganosiloxanes, alternatively free of all polymers that are not organic polymers, alternatively free of all polymers that are not organic polymers or polyorganosiloxanes or hybrids or copolymers or blends thereof.
• the substrate (20 or 21 ) and superstrate (60) typically independently have a thickness of from 0.03 millimeter (mm) to 5 mm, alternatively from 0.1 to 4 mm, alternatively from 0.3 to 3.8 mm, alternatively from 1.3 to 3.6 mm, (e.g., 3.2 mm).
• the substrate (20 or 21 ) and superstrate (60) typically have the same length and width.
• the substrate (20 or 21 ) and superstrate (60) may have a length and width of from 5 centimeters to 2 meters, alternatively from 10 cm to 150 cm, alternatively from 20 cm to 130 cm (e.g., 20 cm square, alternatively 20 cm by 30 cm, alternatively 50 cm by 130 cm).
• the substrate (20 or 21 ) and superstrate (60) may be a geometric shape such as a square, rectangle, oval, circle, trapezoid, or other geometric shape, or an irregular shape.
• the substrate (20 or 21 ) and superstrate (60) are not limited to those dimensions or shapes.
• the preassembled laminate comprising same typically has three sealed edges (82, 84, and 86) and one unsealed edge (88).
• the preassembled laminate (100, 1 10, 120, or 130) may have three sealed sides (82, 84, and 86) and a fourth side (88) that is sealed except for a port for introducing the liquid encapsulant (90).
• the substrate (20 or 21 ) may be tacky or non-tacky and may be a gel, gum, or solid.
• the PV cells (30) may be operatively attached directly or indirectly to either the substrate (20 or 21 ) or the superstrate (60) prior to the introducing step.
• the interconnection circuit (40 and 49) may be operatively attached to the second major surface (28) of the substrate (20 or 21 ), and the PV cells (30) may be operatively attached to the interconnection circuit (40 and 49) such that the PV cells are indirectly operatively attached to the second major surface (28) of the substrate (20 or 21 ).
• the PV cells (30) may be operatively attached directly to the second major surface (28) of the substrate (20 or 21 ).
• Each of the direct and indirect operative attachments is effective for holding the PV cells (30) in place during the introducing and allowing steps of the method.
• the composition of the PV cells (30) is not particularly limited.
• the composition may be based on silicon, silicon carbide, cadmium telluride, copper indium/gallium selenide/sulfide, gallium arsenide, polyphenylene vinylene, copper phthalocyanine, carbon fullerenes, and combinations thereof.
• the composition of the PV cells (30) may be amorphous silicon, monocrystalline silicon, multicrystalline silicon, microcrystalline silicon, or nanocrystalline silicon.
• the composition of the PV cells (30) may be silicon carbide.
• the composition of the PV cells (30) may be cadmium telluride, alternatively copper indium/gallium selenide/sulfide (e.g., CIGS), alternatively gallium arsenide, alternatively poly(para-phenylene vinylene), alternatively copper phthalocyanine, alternatively carbon fullerenes, alternatively the combinations thereof.
• the PV cells (30) may be in the form of ingots, ribbons, thin films, and/or wafers.
• the PV cells (30) may also include light absorbing dyes such as ruthenium organometallic dyes. Most typically, the PV cells (30) are monocrystalline and/or multicrystalline silicon.
• a plurality of PV cells (30) are used. There are at least two, alternatively at least 10, alternatively at least 30, and typically no more than 100, PV cells (30).
• the PV cells (30) may have a thickness of from 50 to 250 micrometers (pm), alternatively from 100 to 225 pm, alternatively from 175 to 225 pm.
• the PV cells (30) may independently have a length and width of 50 to 300 millimeters (mm) each such as 125 mm, 156 mm, or 224 mm each.
• the PV cells (30) may be square shaped, alternatively rectangular shaped. The PV cells (30) are not limited to these dimensions.
• the PV cells (30) are electrically interconnected such as by an interconnection circuit (40 and 49), which is connected via bus bar connects (42 and 44) to a junction box, electrical grid, battery, or other electrical equipment.
• the interconnection circuit typically comprises bus bars (49), Interconnects (40), and electrically conductive adhesive, e.g., based on copper or silver.
• the components of the interconnection circuit (40 and 49) may be applied before placing the PV cells (30) on the substrate (20 or 21 ).
• the liquid encapsulant (90) may be non-curable, alternatively curable. When the liquid encapsulant (90) is uncurable or curable but uncured, typically the seal may not be removed from the PV cell module (500, 520, or 530). Typically, however, the liquid encapsulant (90) is curable to the cured encapsulant. When the liquid encapsulant (90) is curable, it may be an ambient temperature curable material such as a substance that can cure at a temperature of from 30° C. to 45° C. Typically the liquid encapsulant (90) is curable, and the curable liquid encapsulant is cured in situ after the allowing step of the method to give the cured encapsulant.
• the curing may be performed in ambient conditions such as where the PV cell module (500, 520, or 530) is being used to generate electricity, alternatively the curing may be performed in an oven set to a temperature of from 50° C. to 200° C. (e.g., 120° C. to 150° C.) to give the PV cell module (500, 520, or 530) with cured front portion and cured rear portion of the encapsulant.
• the composition of the liquid encapsulant (90) is not particularly important.
• the composition of the curable liquid encapsulant may be a curable organic polymer, or oligomer precursor or monomer(s) precursor thereof; alternatively a curable organosiloxane polymer, oligomer precursor or monomer(s) precursor thereof.
• the liquid encapsulant (90) may be a curable polyorganosiloxane (polymer) such as a hydrosilylation-curable polyorganosiloxane composition, condensation-curable polyorganosiloxane composition, or free radical-curable polyorganosiloxane composition.
• the free radical-curable polyorganosiloxane composition may be a radiation-curable polyorganosiloxane composition, a light-curable polyorganosiloxane composition (e.g. UV light-curable), or a peroxide-curable polyorganosiloxane composition.
• the liquid encapsulant (90) is the hydrosilylation-curable polyorganosiloxane.
• suitable hydrosilylation-curable polyorganosiloxane compositions are described in US 201 1/0203664 A1 or US 2006/0207646 A1 , such as for example in paragraphs [0023 to 0037; and 0048] of US 2006/0207646 A1.
• a typical hydrosilylation-curable polyorganosiloxane composition comprises a vinyl-terminated polydimethylsiloxane, a Si-H functional polydimethylsiloxane (i.e., a dimethyl, methylhydrogen polysiloxane), and a platinum catalyst.
• the vinyl-terminated polydimethylsiloxane typically has on average per molecule at least 1 .0, alternatively at least 2.0, alternatively up to 5 vinyl-groups.
• the Si-H functional polydimethylsiloxane typically contains on average per molecule at least 1 .0, alternatively at least 2.0, alternatively up to 5 Si-H functional groups and may function as a crosslinker.
• the Pt catalyst may be a complex of chloroplatinic acid and certain vinyl-containing organosiloxanes as described in US 3,419,593 such as the reaction product of chloroplatinic acid and l,3-diethenyl-l,l,3,3- tetramethyldisiloxane.
• the hydrosilylation catalyst may be unsupported or disposed on a solid support (e.g., carbon, silica, or alumina).
• the hydrosilylation catalyst may be a Pt- ligand complex that is microencapsulated in a thermoplastic resin shell as described in US 4,766,176 and US 5,017,654 for increased stability during storage of the hydrosilylation- curable organosiloxane before curing.
• the catalyst may be rhodium, ruthenium, palladium, osmium, or iridium, or any combination of at least two thereof.
• the hydrosilylation-curable polyorganosiloxane composition may further comprise an organosiloxane adhesion promoter.
• the liquid encapsulant (90) is a "liquid” in so far as it is a flowable material at 25° C. and 101 kilopascals pressure.
• the liquid encapsulant (90) prior to curing may have a viscosity of from 150 to 60,000 centipoise (cps).
• the viscosity of the liquid encapsulant (90) may be from 200 to 15,000 cps, alternatively from 200 to 5,000 cps, alternatively from 200 to 1 ,000 cps, alternatively from 200 to 500 cps, e.g., from 240 to 480 cps.
• the foregoing viscosity is measured according to ASTM D4287-00(2010) (Standard Test Method for High- Shear Viscosity Using a Cone/Plate Viscometer) at 25° C.
• the cured encapsulant may be a gel or thermoset.
• the spacer/tie element may function only as a spacer, only as a tie element (e.g., a thin adhesive tie layer), or as both a spacer and tie element (50).
• a tie element e.g., a thin adhesive tie layer
• One or more adhesion promoters may be used in the PV cell module (500, 520, or 530) to enhance adhesion of the cured encapsulant to the superstrate (60) and/or substrate (20 or 21 ) and/or PV cells (30).
• suitable adhesion promoters are described in US 2006/0207646 A1 , such as for example in paragraphs [0038 to 0043].
• the polyorganosiloxane composition may be prepared as a one part or multiple part composition.
• the one-part composition may be prepared by combining all ingredients by any convenient means, such as mixing. All mixing steps or just a final mixing step may be performed under conditions that minimize or avoid heating (e.g., maintain temperature below 30° C during mixing).
• a multiple part (e.g., 2 part) hydrosilylation curable composition may be prepared where at least a primary polyorganosiloxane (e.g., an alkenyl- functional polydiorganosiloxane such as a vinyl-terminated polydimethylsiloxane), and optionally any other organosilicon compound (e.g., an adhesion promoter and/or chain extender/crosslinker such as the organohydrogensilicon compound), is stored in one part (Part A), and any catalyst is stored in a separate part (Part B), and the parts A and B are combined (e.g., by mixing) shortly before use of the composition.
• a primary polyorganosiloxane e.g., an alkenyl- functional polydiorganosiloxane such as a vinyl-terminated polydimethylsiloxane
• any other organosilicon compound e.g., an adhesion promoter and/or chain extender/crosslinker such as
• the chain extender/crosslinker and the catalyst are stored in separate parts when the catalyst is catalytically active (not microencapsulated or not inhibited).
• the catalyst Part B may further comprise the alkenyl-functional polydiorganosiloxane.
• kinematic viscosity use test method ASTM-D445-11 a (Standard Test Method for Kinematic Viscosity of Transparent and Opaque Liquids (and Calculation of Dynamic Viscosity)) at 25° C. Expressed in cSt or mm 2 /s units.
• Determining state of matter Characterize state of matter as solid, liquid, or gas/vapor at 20° C and a pressure of 101 .3 kPa.
• Liquid encapsulant (90) was Composition LE1.
• Composition LE1 comprised a hydrosilylation-curable polyorganosiloxane composition that was prepared by mixing a 1 :1 w/w ratio of Parts A and B together just prior to the introducing step.
• Part A is a colorless liquid comprising > 60 wt% of a dimethylvinyl-terminated polydimethylsiloxane (CAS No. 68083-19-2) and 1.0 to 5.0 wt% of an organosilane.
• Part A had a specific gravity of 0.97 at 25° C.
• Part B is a colorless liquid comprising > 60 wt% of a dimethylvinyl-terminated polydimethylsiloxane (CAS No. 68083-19-2), 15.0 to 40.0 wt% hydrogen-terminated polydimethylsiloxane (CAS No. 70900-21-9) and 1 .0 to 5.0 wt% dimethyl, methylhydrogen polysiloxane (CAS No. 68037-59-2).
• Part B had a specific gravity of 1.01 at 25° C.
• composition further comprised a microencapsulated platinum catalyst in the form of shell-core particles that contained 0.008 wt% Pt, wherein the shell was a cured vinyl- terminated polydimethylsiloxane and the core comprised a platinum-ligand complex.
• Substrate (20) was a square-shaped silicate glass sheet defining two apertures therethrough proximal to an edge and spaced apart from each other by 2.54 cm.
• the substrate (20) was 3.2 mm thick.
• Superstate (60) was a square-shaped silicate glass sheet lacking apertures and having length and width the same as the length and wide of the silicate glass substrate.
• the superstate (60) was 3.2 mm thick.
• the PV cells (30) were based on multicrystalline silicon.
• the interconnection circuit (40 and 49) was based on Cu alloy and Al alloy, respectively, and was operatively connected at ends thereof to proximal ends of two bus bar connects (42 and 44).
• Example (Ex.) 1 production of an uncured PV cell module: Laid down the silicate glass substrate with its second major surface facing upward, and fixed the 4 by 9 array of interconnected multicrystalline silicon PV cells to the second major surface of the silicate glass substrate using five pieces of tape placed at different locations over the
• a preassembled laminate (e.g., 100 as shown in Fig. 2). Stood the preassembled laminate upright so that the remaining unsealed edge was on top, and inserted therein a rigid spacer element therein to maintain an opening between the silicate glass substrate and superstrate that was slightly wider than the thickness of the PV cells.
• a silicate glass superstrate sequentially comprising a silicate glass superstrate, a front portion of the liquid encapsulant LE1 , a 4 by 9 array of interconnected multicrystalline silicon PV cells, a rear portion of the liquid encapsulant LE1 , a silicate glass substrate, and four corner pieces of double-sided tape.
• Ex. 2 production of a cured PV cell module: placed the uncured PV cell module of Ex. 1 in a 100° C. oven for from 1 to 5 minutes and cured the liquid encapsulant LE1 to give the cured PV cell module of Ex. 2 sequentially comprising a silicate glass superstrate, a front portion of a cured polydiorganosiloxane encapsulant, a 4 by 9 array of interconnected multicrystalline silicon PV cells, a rear portion of the cured polydiorganosiloxane, a silicate glass substrate, and four corner pieces of double-sided tape.
• Ex. 3 (prophetic): production of a cured PV cell module: place the uncured PV cell module of Ex. 1 outside in direct sunlight at an ambient temperature of 30° to 40° C. for from 1 to 12 hours to give to cure the liquid encapsulant LE1 to give the cured PV cell module of Ex. 3 sequentially comprising a silicate glass superstrate, a front portion of a cured polydiorganosiloxane encapsulant, a 4 by 9 array of interconnected multicrystalline silicon PV cells, a rear portion of the cured polydiorganosiloxane, a silicate glass substrate, and four corner pieces of double-sided tape
• “Operative contact” comprises functionally effective touching, e.g., as for modifying, coating, adhering, sealing, or filling.
• the operative contact may be direct physical touching, alternatively indirect touching.
• Any Markush group comprising a genus and subgenus therein includes the subgenus in the genus, e.g., in "R is hydrocarbyl or alkenyl,” R may be alkenyl, alternatively R may be hydrocarbyl, which includes, among other subgenuses, alkenyl.
• R is hydrocarbyl or alkenyl
• R may be alkenyl
• R may be hydrocarbyl, which includes, among other subgenuses, alkenyl.
• the "x-direction” and “y-direction” respectively refer to horizontal and vertical axes of a Cartesian coordinate system.
• Embodiments of the invention also include the following numbered aspects.
• the introducing step comprises pouring the liquid encapsulant from a container through the opening in the second edge of the preassembled laminate onto an upper portion of the photovoltaic cells and the allowing step comprises allowing the introduced liquid encapsulant to coat the photovoltaic cells and fill the front gap between the photovoltaic cells and the superstrate and the rear gap between the photovoltaic cells and the substrate of the preassembled laminate, thereby coating the photovoltaic cells to give the first photovoltaic cell module.
• the liquid encapsulant may be introduced into the preassembled laminate under a pressure greater than ambient pressure, e.g., pressure from 1 10 kPa to 200 kPa.
• the allowing step comprising manipulating the first photovoltaic cell module to level the front portion of the liquid encapsulant between the superstrate and photovoltaic cells and level the rear portion of the liquid encapsulant between the photovoltaic cells and the substrate.
• the method of aspect 9 further comprising removing the seal from the third photovoltaic cell module to give a fourth photovoltaic cell module sequentially comprising the superstrate, front portion of the cured encapsulant, interconnected photovoltaic cells, rear portion of the cured encapsulant, and substrate, and lacking the seal.
• photovoltaic cell module further comprises a spacer/tie element disposed between and in operative contact with the superstrate and the substrate.
• a photovoltaic cell module prepared according to the method of any one of aspects 1 to 1 1.
• a kit comprising components and instructions for using same to manufacture a photovoltaic cell module according to the method of any one of aspects 1 -1 1.

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