Structures for low cost, reliable solar modules

Abstract

Methods and devices are provided for improved large-scale solar installations. In one embodiment, a photovoltaic module is provided comprising a module front layer comprising a glass plate, a module back layer comprising an electrically conductive foil, and a plurality of solar cells arranged to be protected by the front layer and the back layer. In some embodiments, the module back layer is aluminum foil. The module back layer may have an externally exposed surface. The module back layer may be electrically grounded. An electrically insulating pottant material may be used with the solar cells to separate them from the module back layer. This allows for a high voltage withstand between the cells and the outer surface of the back layer.

Description

CROSS-REFERENCE TO RELATED APPLICATION[0001]The present application claims the benefit of priority to U.S. Patent Application Ser. No. 60 / 871,670 filed Dec. 22, 2006 and Ser. No. 60 / 891,914 filed Feb. 27, 2007. All of the foregoing applications are fully incorporated herein by reference for all purposes.FIELD OF THE INVENTION[0002]This invention relates generally to photovoltaic devices, and more specifically, to improved solar cell module configurations and solar module power installations.BACKGROUND OF THE INVENTION[0003]Solar cells and solar cell modules convert sunlight into electricity. Traditional solar cell modules are typically comprised of polycrystalline and / or monocrystalline silicon solar cells mounted on a support with a rigid glass top layer to provide environmental and structural protection to the underlying silicon based cells. This package is then typically mounted in a rigid aluminum or metal frame that supports the glass and provides attachment points for securing...

AI Technical Summary

Benefits of technology

[0006]Embodiments of the present invention address at least some of the drawbacks set forth above. The present invention provides for the improved solar module designs that simplifies solar module design and reduces the materials costs associated with such modules. Although not limited to following, these improved module designs are well suited for installation at dedicated sites where redundant elements can be eliminated where some common elements or features may be shared by many modules. It should be understood that at least some embodiments of the present invention may be applicable to any type of solar cell, whether they are rigid or flexible in nature or the type of material used in the absorber layer. Embodiments of the present invention may be adaptable for roll-to-roll and / or batch manufacturing processes. At least some of these and other objectives described herein will be met by various embodiments of the present invention.

Problems solved by technology

Drawbacks associated with traditional solar module package designs, however, have limited the ability and financial rationale to install large numbers of solar panels in a cost-effective manner.

Unfortunately, traditional solar modules come with a great deal of redundancy and excess equipment cost.

These traditional module configurations are also constrained by conventional design methodology that limit the modules to certain materials and inherit a large number of legacy parts.

This combination of high material cost and conventional design hamper the ability of installers to rapidly and cost-efficiently deploy solar modules at a large scale.

Although subsidies and incentives have created some large solar-based electric power installations, the potential for greater numbers of these large solar-based electric power installations has not been fully realized.

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