Photovoltaic Cell Module And Method Of Forming

Abstract

A photovoltaic cell module, a photovoltaic array including at least two modules, and a method of forming the module are provided. The module includes a first outermost layer and a photovoltaic cell disposed on the first outermost layer. The module also includes a second outermost layer disposed on the photovoltaic cell and sandwiching the photovoltaic cell between the second outermost layer and the first outermost layer. The method of forming the module includes the steps of disposing the photovoltaic cell on the first outermost layer, disposing a silicone composition on the photovoltaic cell, and compressing the first outermost layer, the photovoltaic cell, and the second layer to form the photovoltaic cell module.

Description

FIELD OF THE INVENTION[0001]The present invention generally relates to a photovoltaic cell module and a photovoltaic array. More specifically, the present invention relates to a photovoltaic cell module including a first outermost layer, a photovoltaic cell, and a second outermost layer that has particular properties and that is disposed on the photovoltaic cell sandwiching the photovoltaic cell between the second outermost layer and the first outermost layer. The present invention also relates to a method of forming a photovoltaic cell module.DESCRIPTION OF THE RELATED ART[0002]Solar or photovoltaic cells are semiconductor devices used to convert light into electricity. There are two general types of photovoltaic cells, wafers and thin films. Wafers are thin sheets of semiconductor material that are typically formed from mechanically sawing the wafer from a single crystal or multicrystal ingot. Alternatively, wafers can be formed from casting. Thin film photovoltaic cells usually i...

AI Technical Summary

Benefits of technology

"The present invention provides an improved photovoltaic cell module and method of forming the module that includes a first outermost layer with specific properties and a second outermost layer that is a silicone composition. The second outermost layer is sandwiched between the photovoltaic cell and the first outermost layer. The module has several advantages, including improved thickness control, reduced waste of silicone composition, increased consistency of thickness and size, and reduced flammability. The method of forming the module includes disposing the photovoltaic cell on the first outermost layer, coating a plurality of fibers with silicone composition, and compressing the first and second outermost layers to form the module. The plurality of fibers helps to resist leakage of the silicone composition and provides structural strength to the module. The invention also provides a cost-effective and repeatable production method for the module."

Problems solved by technology

These types of modules are usually made using processes that are slow and inefficient due to a need to control the dispersion of the tie layers and to minimize leakage of the tie layers from the substrates and superstrates to reduce waste.

In both types of modules, it is difficult to control a thickness of the tie layers because the tie layers can flow across the substrates and superstrates in inconsistent patterns.

Additionally, methods of forming both types of modules results in increased expense, increased processing times, and increased processing complexity.

These all result in increased cost for the end purchaser.

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