Improved flexible and light photovoltaic module

Abstract

The present invention relates to a photovoltaic module (1) comprising: - a first transparent layer (2) forming the front side of the photovoltaic module (1); - a plurality of photovoltaic cells (4) placed side by side and electrically connected; - a polymeric encapsulation assembly (3) capable of encapsulating the plurality of photovoltaic cells (4) between a lower portion (3b) and an upper portion (3a); - a second layer (5) made of a composite material based on a polymer resin and fibers; said encapsulation assembly and said photovoltaic cells being located between said first layer and said second layer, at least said first layer and said second layer defining the edges (1A, 1B, 1C, 1D) of the photovoltaic module (1), said plurality of photovoltaic cells being spaced apart from at least one edge (1A) of the photovoltaic module by a non-zero distance D A , said photovoltaic module further comprising a third layer (15) made of a composite material based on a polymer resin and fibers, said layer being located below the plurality of photovoltaic cells and above the lower portion of the encapsulation assembly and forming at least one peripheral strip (15A) extending from said at least one edge towards the center of the module, the width (L 15A ) of said at least one peripheral strip being greater than or equal to said distance D A .

Description

Technical Field

[0001] This invention relates to the field of photovoltaic modules, which include a group of photovoltaic cells electrically connected to each other, and preferably so-called "crystalline" photovoltaic cells, i.e., photovoltaic cells based on monocrystalline silicon or polycrystalline silicon.

[0002] More precisely, the present invention relates to ultralight (weight per unit area less than 1 kg / m²) 2 or even below 800g / m 2 or even less than 600g / m 2 And the field of flexible photovoltaic modules.

[0003] This invention can be applied to many applications, such as autonomous and / or automotive applications, and is particularly suitable for applications requiring the use of ultralight flexible (glass-free) photovoltaic modules, especially those ultralight flexible (glass-free) photovoltaic modules with a weight per unit area of ​​less than 1 kg / m². 2 And especially below 800g / m 2 or even less than 600g / m 2 It also has a small thickness, especially less than 1 mm. Therefore, it can be used in particular for: buildings such as residential or commercial sites (industrial land, office buildings, commercial places, etc.), for example for producing their roofs; the design of urban furniture, such as providing lighting for public spaces; road signs; or even the recharging of electric vehicles; or it is also used in portable applications, and especially integrated into flying objects, cars, buses or ships, etc. Background Technology

[0004] A photovoltaic module is a component of photovoltaic cells, which are arranged side-by-side between a first layer forming the front side of the photovoltaic module and a second layer forming the back side. The first layer forming the front side of the photovoltaic module is transparent to allow the photovoltaic cells to receive light flux.

[0005] Photovoltaic cells can be electrically connected to each other via front and back electrical contact elements, which are called interconnects, and are formed, for example, by tinned copper wires placed against the front side (the side facing the front of the photovoltaic module, i.e., the side intended to receive light flux) and the back side (the side facing the back of the photovoltaic module) of each photovoltaic cell, or, for IBC photovoltaic cells, the copper wires are actually only on the back side (IBC is an abbreviation for interdigitated back contact).

[0006] In addition, photovoltaic cells located between the first and second layers on the front and back sides of the photovoltaic module can be encapsulated.

[0007] Patent application WO2019224458A1 describes an ultralight photovoltaic module, which, as Figure 1 As shown in the diagram. Photovoltaic module 1 includes:

[0008] - A transparent first layer 2, forming the front side of the photovoltaic module and comprising at least one polymer with a thickness e2 less than 50 μm;

[0009] - The second layer 5, which can form the back side of the photovoltaic module, includes at least one pre-preg composite material based on polymer resin and fiber, and its weight per unit area is less than 150 g / m². 2 ;

[0010] - Multiple photovoltaic cells 4 are placed side by side and electrically connected to each other by electrical contact elements in the form of interconnecting wires;

[0011] - Module 3 (formed by two layers 3a and 3b) encapsulates multiple photovoltaic cells and has a maximum thickness e3 of less than 150 μm;

[0012] The encapsulation components and multiple photovoltaic cells are located between the first and second layers.

[0013] The arrows correspond to the light radiation that reaches through the transparent first layer 2 that forms the front side of the photovoltaic module.

[0014] Photovoltaic module 1 is produced in a single step of hot lamination of the constituent layers 2, 3, 4, and 5 used to manufacture photovoltaic module 1, including a lamination period of at least 10 minutes at a temperature between 130°C and 170°C.

[0015] like Figure 2 As shown, in practice, the first and second layers, as well as the components encapsulating the photovoltaic cells, have a protrusion D relative to the photovoltaic cells on at least one edge 1A of such a photovoltaic module 1.

[0016] In other words, the photovoltaic cells are located away from the edge of the module formed by the first and second layers and the components encapsulating the photovoltaic cells (the distance is equal to the value of the protrusion D). This allows for better protection of the cells. In this figure, the photovoltaic module also includes an additional layer 10 on the back side, which is made of the same material as the first layer 2 used to manufacture the front side of the photovoltaic module 1.

[0017] Figure 2 A single edge is shown, but protrusions are generally present on all edges of the module, and generally have the same width on all edges.

[0018] If the module is subjected to an operating voltage of 1000V, the package assembly must generally have a protrusion of at least 16mm (from the edge of the last electrical conductor, battery, or interconnect) or greater to ensure electrical insulation during lamination. This protrusion also allows for ensuring the module's impermeability to water and chemicals. The first and second layers follow the dimensions of the package assembly. If the materials used have a very high dielectric constant, if the module's operating voltage is low, or if the environmental conditions in which the module is used do not require high impermeability to water or chemicals, this protrusion may be smaller. In any case, for ease of handling, the protrusion is often at least 5mm.

[0019] Furthermore, some applications of this ultralight photovoltaic module (such as integration into flying objects) often require fastening the module to the object via fastening devices located on the edge of the module, rather than via the back side of the module, which may be the case for other photovoltaic modules and / or other applications.

[0020] However, the inventors have observed that, for the ultralight photovoltaic modules described above, after lamination, internal stresses associated with the asymmetry of the resulting structure cause bending at the edges of the module. This bending can then complicate, hinder, or even prevent the use of the aforementioned fastening devices. Bending can also create risks of entanglement or problems due to wind catching, or even aesthetic defects that are incompatible with certain applications.

[0021] The present invention aims to overcome the above-mentioned shortcomings of the prior art.

[0022] More specifically, this invention aims to provide a flexible, ultralight photovoltaic module with edges that are either not curved or have almost no curvature, while still possessing mechanical and electrical properties at least equivalent to those of prior art flexible, ultralight photovoltaic modules. In other words, this invention aims to obtain a flexible and ultralight photovoltaic module that is as flat as possible. Summary of the Invention

[0023] The first subject of the present invention, which allows for overcoming these shortcomings, is a photovoltaic module comprising:

[0024] - A transparent first layer forms the front side of the photovoltaic module, the side intended to receive light flux.

[0025] - Multiple photovoltaic cells, placed side by side and electrically connected to each other.

[0026] - An encapsulation assembly capable of encapsulating the plurality of photovoltaic cells, and comprising a lower portion and an upper portion, wherein the encapsulation assembly is preferably made of a polymer.

[0027] - The second layer comprises at least one composite material based on polymer resin and fiber.

[0028] The encapsulation component and the plurality of photovoltaic cells are located between the first layer and the second layer, and at least the first layer and the second layer define the edge of the photovoltaic module;

[0029] The feature is that the plurality of photovoltaic cells are spaced apart from at least one edge of the photovoltaic module by a non-zero distance D. A Furthermore, the photovoltaic module is characterized in that it further comprises a third layer or reinforcing layer located below the plurality of photovoltaic cells and above the lower portion of the encapsulation assembly, the third layer forming at least one peripheral strip, the at least one peripheral strip extending from the at least one edge toward the center of the module and the width of the at least one peripheral strip being greater than or equal to the distance D. A The third layer comprises at least one composite material based on polymer resin and fiber.

[0030] Preferably, the width of the at least one peripheral strip is related to the distance D between the plurality of photovoltaic cells and the at least one edge. A The difference between them is less than or equal to 30 mm, and more preferably less than or equal to 20 mm.

[0031] Preferably, the width of the at least one peripheral strip of the third layer is strictly greater than at least one distance between the photovoltaic cell and the at least one edge.

[0032] Preferably, the second layer is made of a prepreg material based on polymer resin and fiber.

[0033] Preferably, the third layer is made of a prepreg material based on polymer resin and fiber.

[0034] The term "strip" must be understood as an element that extends longitudinally in the direction of the edge, and its width is defined as being perpendicular to the edge in the plane of the photovoltaic module.

[0035] The strip is called the "peripheral" because it is positioned along the edge of the photovoltaic module. Therefore, the peripheral strip extends from one edge of the photovoltaic module and reaches or even protrudes beneath the photovoltaic cell(s) closest to the edge.

[0036] The “distance” between the edge and multiple photovoltaic cells means the shortest distance between the edge and one or more photovoltaic cells closest to the edge.

[0037] All edges of the photovoltaic module and the distances between multiple photovoltaic cells can be exactly the same. In this case, the width of the outer strip can also be exactly the same.

[0038] The thickness of the cells and each layer, and especially the thickness of the outer strip, is limited in a direction perpendicular to the plane of the photovoltaic module.

[0039] The term "transparent" means that the material of the first layer forming the front side of a photovoltaic module is at least partially transparent to visible light, allowing at least about 80% of that light to pass through.

[0040] The “front side” of a photovoltaic module corresponds to the side intended for receiving light flux. It can be designated as the “top side.” The “back side” corresponds to the opposite side of the module. It can be designated as the “bottom side.” The terms “below” and “bottom” or “lower” should be understood with reference to the back side of the photovoltaic module. In contrast, the terms “above” and “top” or “upper” should be understood with reference to the front side of the photovoltaic module.

[0041] Furthermore, it must be understood that the term “encapsulation” or “encapsulated” refers to the placement of multiple photovoltaic cells in a volume that is hermetically sealed relative to a liquid, for example, and is formed at least in part by at least two layers of encapsulation material that are bonded together after lamination to form an encapsulated assembly.

[0042] Specifically, initially, prior to any lamination operation, the encapsulated assembly consists of at least two layers of encapsulating material, referred to as the core layers, with multiple photovoltaic cells encapsulated between them. However, during the lamination operation, the layers of encapsulating material are melted to form only a single cured layer (or assembly) in which the photovoltaic cells are embedded after the lamination operation.

[0043] Therefore, the present invention aims to improve the symmetry of materials in areas without photovoltaic cells and optionally without interconnects by adding only one or more peripheral strips (reinforcing layers) to these areas and / or by modifying other constituent layers of the module. This makes it possible to avoid bending at the edges of the photovoltaic module.

[0044] These outer strips can be made from materials used to manufacture layers already present in the photovoltaic module, such as composite materials based on polymer resins and fibers for the second layer. The purpose of these outer strips located at the edges is to increase the symmetry of the photovoltaic module's structure at its edges, and better yet, to still improve the symmetry to a full stop while satisfying all other constraints, depending on the target application of the photovoltaic module.

[0045] An obvious solution is to... Figure 2The photovoltaic module begins with a second layer (in the manner of a second layer) made of a prepreg composite material based on polymer resin and fiber, placed between a transparent first layer and an upper encapsulation layer to make the layers symmetrical. The present invention differs from such a solution in that a third layer or reinforcing layer is placed between the lower portions of the multiple photovoltaic cells and encapsulation components, and in that the third layer takes the form of an outer strip (or an outer frame if strips of the third layer are provided on all edges). This allows the third layer to be protected from light (it remains below the cells) and prevents performance degradation (light does not have to pass through the additional layer before reaching the cells). The method for manufacturing the module according to the invention is as simple as the method for manufacturing ultralight photovoltaic modules in the prior art. Furthermore, placing a single strip on the edges instead of providing an entire layer allows for material savings, which can be very advantageous if the photovoltaic module is large. Finally, this avoids adding excessive weight to the photovoltaic module.

[0046] Therefore, these outer strips allow for the formation of ultralight and flat (without bending) photovoltaic modules, which is beneficial for the use of systems for securing photovoltaic modules without significantly increasing the weight and cost per unit area of ​​such modules.

[0047] The photovoltaic module according to the invention may also include one or more of the following features individually or in any technically possible combination. In other words, the embodiments described below may be combined together unless it is explicitly stated that one embodiment is a substitute for another.

[0048] According to one embodiment, the third layer and / or the second layer are made of a polymer- and fiber-based composite material, wherein the polymer is preferably selected from polyester, epoxy resin and / or acrylic acid; and / or the fiber is preferably selected from glass fiber, carbon fiber and / or aramid fiber.

[0049] According to a preferred embodiment, the third layer is made of the same composite material as the second layer.

[0050] According to a particular embodiment, the third layer forms a plurality of peripheral strips, preferably at least two opposing strips, and even more preferably four strips, each peripheral strip extending from one edge of the photovoltaic module toward the center of the module, and the width of each peripheral strip being greater than or equal to the distance D between the edge and the plurality of photovoltaic cells. A D B D C D D Preferably, the width and distance D of each outer strip A D B D C D DThe difference between them is less than or equal to 30 mm, and even more preferably less than or equal to 20 mm.

[0051] Preferably, the width of each outer strip of the third layer is strictly greater than the distance D. A D B D C D D .

[0052] According to one embodiment, the encapsulation component extends all the way to the edge of the photovoltaic module.

[0053] According to an alternative embodiment of the foregoing embodiments, the upper portion of the encapsulation assembly is spaced apart from at least one edge of the photovoltaic module by a distance D. 3A The distance D 3A It is non-zero and less than the distance D between the at least one edge and the plurality of photovoltaic cells. A The distance D A and D 3A The difference between them is preferably less than or equal to 10 mm. In particular, the upper portion of the encapsulation component can be spaced from each edge of the photovoltaic module by a non-zero distance D. 3A D 3B D 3C D 3D And distance from D 3A D 3B D 3C D 3D The distance D between the edge and the plurality of photovoltaic cells A D B D C D D The difference between them is preferably less than or equal to 10 mm.

[0054] According to one embodiment, the photovoltaic module further includes a fifth layer, preferably made of polymer, located below the second layer, the fifth layer forming a layer extending from the at least one edge toward the center of the module and having a width greater than or equal to the distance D between the at least one edge and the plurality of photovoltaic cells. A At least one outer strip. Preferably, the difference between the width and the distance is less than or equal to 30 mm, and even more preferably less than or equal to 20 mm.

[0055] According to a particular embodiment, the fifth layer forms a plurality of peripheral strips, preferably at least two opposing strips, and even more preferably four strips, each peripheral strip extending from one edge of the photovoltaic module toward the center of the module, and the width of each peripheral strip being greater than or equal to the distance D between the edge and the plurality of photovoltaic cells. A DB D C D D Preferably, the width and distance D of each outer stripe A D B D C D D The difference between them is less than or equal to 30 mm, and even more preferably less than or equal to 20 mm.

[0056] Preferably, the width of each outer strip of the fifth layer is strictly greater than the distance D. A D B D C D D .

[0057] The fifth layer is preferably made of the same polymer as the material of the encapsulation component, or at least of the same polymer having the same thermomechanical properties.

[0058] According to one particular embodiment, the size of the fifth layer is substantially equal to the size of the third layer.

[0059] According to one embodiment, the photovoltaic module further includes:

[0060] - A fourth layer is formed on the back side of the photovoltaic module, the second layer is located between the encapsulation component and the fourth layer, the fourth layer is made of the same material used to manufacture the first layer, and has a thickness less than or equal to the thickness of the first layer.

[0061] Photovoltaic modules may also have the following additional features individually or in combination with each other, and have one or more of the aforementioned features:

[0062] -The first layer is made of polymer;

[0063] - The first layer has a thickness of less than or equal to 50 μm;

[0064] -The encapsulation component has a maximum thickness of less than 150μm;

[0065] - The second layer has a content of less than 150g / m 2 The weight per unit area;

[0066] - The encapsulation assembly includes an upper encapsulation layer placed between the first layer and the plurality of photovoltaic cells and a lower encapsulation layer placed between the plurality of photovoltaic cells and the second layer.

[0067] The second subject of the invention is a method for producing such a photovoltaic module, comprising at least one step of hot lamination of layers of the photovoltaic module at a temperature and lamination period, wherein the temperature is between 130°C and 170°C, and particularly about 150°C, and the lamination period lasts for at least 10 minutes, and particularly between 10 and 20 minutes.

[0068] The photovoltaic module and manufacturing method according to the present invention may include any of the above features, alone or in any technically possible combination with other features. Attached Figure Description

[0069] Other features and advantages of the invention will become apparent upon reading the following description, which is given by way of illustration rather than limitation with reference to the accompanying drawings, wherein:

[0070] Figure 1 This illustrates a photovoltaic module based on existing technology.

[0071] Figure 2 This illustrates a specific photovoltaic module based on existing technology.

[0072] Figure 3 A first embodiment of the photovoltaic module according to the present invention is shown in cross-section and exploded view.

[0073] Figure 4 A specific example of an implementation of a first embodiment of the photovoltaic module according to the present invention, viewed from above, is shown.

[0074] Figure 5 A variant of the first embodiment of the photovoltaic module according to the present invention is shown in cross-section and exploded view.

[0075] Figure 6 A second embodiment of the photovoltaic module according to the present invention is shown in cross-section and exploded view.

[0076] Figure 7 A third variant of the photovoltaic module according to the present invention is shown in cross-section and exploded view.

[0077] Figure 8 A specific example of an implementation of a third embodiment of the photovoltaic module according to the present invention, viewed from above, is shown.

[0078] In all these figures, the same reference numerals may denote the same or similar elements.

[0079] In addition, for the sake of readability, the various parts shown in the figure are not necessarily shown to scale. Detailed Implementation

[0080] The section on existing technology has already been discussed. Figure 1and Figure 2 It has been described.

[0081] In all cross-sectional diagrams, the arrows correspond to light radiation.

[0082] It will be noted that Figure 3 , 5 6 and 7 correspond to the exploded XZ sections of three photovoltaic module embodiments and one photovoltaic module variant prior to the lamination step of the manufacturing method according to the present invention. Once the lamination step is performed, i.e., hot pressing is performed under vacuum, the individual layers actually overlap each other in the principal XY plane.

[0083] Figure 4 A top-down XY view corresponding to a specific example of the implementation of the first embodiment.

[0084] Figure 8 A top-down XY view corresponding to a specific example of the implementation of the third embodiment.

[0085] In all Figures 3 to 8 In the context of this invention, and more generally, a photovoltaic module may include one or more of the following features.

[0086] Preferably, the first layer 2 and, where appropriate, the fourth layer 12 comprise at least one polymer.

[0087] The polymer of the first layer 2 (and the polymer of the fourth layer 12, where appropriate) may be selected from: polycarbonate (PC), polymethyl methacrylate (PMMA), polyethylene terephthalate (PET), polyamide (PA), fluoropolymers, especially polyvinylidene fluoride (PVF) or polyvinylidene fluoride (PVDF), ethylene tetrafluoroethylene (ETFE), ethylene trifluorochloroethylene (ECTFE), polytetrafluoroethylene (PTFE), polychlorotrifluoroethylene (PCTFE) and / or fluorinated ethylene propylene (FEP).

[0088] The first layer 2 (and the fourth layer 12 where appropriate) has a thickness of less than 50 μm, and is advantageously included between 5 μm and 25 μm.

[0089] The encapsulation component 3 (and, where appropriate, the fifth layer 13) may be made of at least one polymer selected from: acid copolymers; ionomers; poly(ethylene vinyl acetate) (EVA); vinyl acetals, such as polyvinyl butyral (PVB); polyurethanes; poly(vinyl chloride); polyethylene, such as linear low-density polyethylene; polyolefin copolymer elastomers; copolymers of α-olefins and α,β-ethylenically unsaturated carboxylic acid esters, such as ethylene methyl acrylate copolymers and ethylene butyl acrylate copolymers; silicone elastomers; and / or epoxy resins.

[0090] The encapsulation component 3 has a total thickness e3 of less than or equal to 150 μm, and preferably between 20 and 100 μm, and more preferably between 50 μm and 75 μm.

[0091] The encapsulation component 3 can be made of two polymer layers 3a (upper encapsulation layer) and 3b (lower encapsulation layer). This may be two layers of poly(ethylene-vinyl acetate) (EVA) or two layers of ionomer, with the photovoltaic cell 4 placed between these two layers. Each layer 3a, 3b can have a thickness e3a, e3b that can be less than or equal to 75 μm, and preferably less than or equal to 50 μm. These layers 3a and 3b, while preferably having the same properties, can have different optical properties.

[0092] The photovoltaic cell 4 can be selected from: homojunction or heterojunction photovoltaic cells based on monocrystalline silicon (c-Si) and / or polycrystalline silicon (mc-Si); and / or IBC photovoltaic cells; and / or photovoltaic cells including at least one material selected from amorphous silicon (a-Si), microcrystalline silicon (μC-Si), cadmium telluride (CdTe), copper indium selenide (CIS), and copper indium / gallium diselenide (CIGS); or practically multijunction (III / V) cells. Their thicknesses range from 1 to 300 μm, and particularly from 1 to 200 μm.

[0093] The photovoltaic cell 4 may have a thickness e4 that is between 1 and 300 μm, and particularly between 1 and 250 μm, or even between 1 and 200 μm, and advantageously between 70 μm and 150 μm.

[0094] Furthermore, the spacing between two adjacent, or even successive or adjacent, photovoltaic cells can be greater than or equal to 0.5 mm, and in particular includes between 1 and 30 mm, and preferably equal to 2 mm.

[0095] Furthermore, the photovoltaic cells 4 can be interconnected via wires made of soldered tin-plated copper. The thickness of the interconnecting photovoltaic cell wires is customized to be compatible with the small thickness of the lamination method and encapsulation components. The interconnecting cell wires can have a thickness of less than 100 μm and a width of less than 3 mm.

[0096] The second layer 5 comprises a prepreg composite material based on polymer resin and fiber, and has a content of less than 150 g / m³. 2 And advantageously included in 50g / m 2 and 115g / m 2 The weight per unit area between [specific values]. It can be manufactured, for example, from at least one of the aforementioned composite materials. The woven fabric of the prepreg can have a weight of less than or equal to 50 g / m². 2 The weight per unit area, and the degree of impregnation with polymer resin can be between 30 and 70 wt%.

[0097] The composite material of the second layer 5 can be a prepreg based on polymer resin and fiber, wherein the polymer is selected from polyester, epoxy resin and / or acrylic, and the fiber is selected from glass fiber, carbon fiber and / or aramid fiber.

[0098] The second layer 5 may have a thickness e5 of less than or equal to 100 μm, and particularly includes a thickness between 50 μm and 80 μm.

[0099] In the illustrated embodiment, the third layer 15 (or reinforcing layer) is also made of a prepreg composite material based on polymer resin and fiber. This can be one of the materials listed above with reference to the second layer 5.

[0100] In a preferred embodiment, the third layer 15 is made of the same material as the second layer 5.

[0101] The third layer 15 can specifically include 50g / m 2 and 150g / m 2 The weight per unit area between. The third layer may have a thickness of less than or equal to 100 μm, and particularly includes a thickness e15 between 50 μm and 80 μm.

[0102] It should be noted that the first and / or second layers of a photovoltaic module can be formed by one or more parts, that is, they can be single-layer or multi-layer.

[0103] Figure 3 A first embodiment of the photovoltaic module 1 is shown in cross-section and exploded view, including:

[0104] - The first transparent layer 2 forms the front side of the photovoltaic module, which is intended to receive light flux.

[0105] - Multiple photovoltaic cells 4, placed side by side and electrically connected to each other.

[0106] - Encapsulation component 3 includes an upper encapsulation layer 3a placed above multiple photovoltaic cells 4 and a lower encapsulation layer 3b placed below multiple photovoltaic cells 4. The component is capable of encapsulating multiple photovoltaic cells.

[0107] - The second layer 5 comprises at least one prepreg composite material based on polymer resin and fiber.

[0108] The encapsulation component 3 and multiple photovoltaic cells 4 are located between the first and second layers.

[0109] The first layer 2 and the second layer 5 define the edge of the photovoltaic module 1, as do the encapsulation components, which extend up to the edge of the module.

[0110] Furthermore, multiple photovoltaic cells 4 are spaced D apart from one edge 1A of photovoltaic module 1. A .

[0111] The photovoltaic module 1 also includes a third layer 15 or reinforcing layer located below the plurality of photovoltaic cells 4 and above the lower encapsulation layer 3b. This third layer forms a peripheral strip 15A extending from edge 1A and protruding below the photovoltaic cells 41 (or plurality of photovoltaic cells) closest to edge 1A. The width L of this peripheral strip... 15A Therefore, it is greater than the distance D. A .

[0112] By using examples, the distance to D A It can be equal to 50mm and the width L of the outer strip is 15A. 15A It equals 70mm. More generally, the width L 15A and distance D A The difference between them is less than or equal to 30 mm, preferably less than or equal to 20 mm, and even more preferably between 10 and 20 mm.

[0113] Figure 4 Corresponding to Figure 3 A top view of an example implementation of the embodiment.

[0114] It can be seen that the distance between the photovoltaic cell and all edges 1A, 1B, 1C, and 1D of photovoltaic module 1 is D. A D B D C D D Four photovoltaic cells 41, 42, 43, and 44 have been shown, but this number is not limiting and there can be more or fewer photovoltaic cells.

[0115] Therefore, the third layer 15 forms four peripheral strips 15A, 15B, 15C, and 15D, one peripheral strip at each edge 1A, 1B, 1C, and 1D, thus forming a frame. Each peripheral strip extends from one edge and protrudes below the two photovoltaic cells closest to the edge. The width L of each peripheral strip is... 15A (L respectively) 15B L 15C L 15D The distance D between the edges of the strip and the multiple photovoltaic cells (4) is greater than that between the edges of the strip and the strip. A (D respectively) B D C D D ).

[0116] exist Figure 4 In the simplified embodiment shown, all distances are substantially equal, as are the widths of the strips; however, this is not always the case.

[0117] In the example, the distance D A D B D C D D It can be equal to 50mm and the width L of the outer strips 15A, 15B, 15C, and 15D. 15A L 15B L 15C L 15D It equals 70mm.

[0118] More generally, the width L of the third layer 15 strips 15A (L respectively) 15B L 15C L 15D The distance D between the edge of the strip and the battery. A (D respectively) B D C D D The difference between ) is less than or equal to 30 mm, preferably less than or equal to 20 mm, and even more preferably between 10 and 20 mm.

[0119] In contrast, to cover all edges without indentation and thus form a frame, the lengths of the outer strips do not necessarily have to be equal (otherwise, each outer strip could be imagined as an isosceles trapezoid at a 45° angle). Alternatively, the frame can be a one-piece design.

[0120] Figure 5 A variant of the first embodiment is shown in cross section and exploded view.

[0121] Figure 5 The photovoltaic module may include all or some of the features mentioned above, and in particular, refer to Figures 3 to 4 The features described are therefore not described again. However, in this variant, the photovoltaic module 1 includes a fourth layer 12 forming the rear side of the photovoltaic module 1, with a second layer 5 located between the fourth layer 12 and the encapsulation component 3.

[0122] The fourth layer 12 is made of the same material as the first layer 2 used to manufacture the front side of the photovoltaic module 1. Advantageously, this material corresponds to ethylene trifluorochloroethylene (ECTFE), which is also known as...

[0123] In addition, the fourth layer 12 is Figure 5 This variant has a thickness e12 that is less than or equal to the thickness e2 of the first layer 2.

[0124] The fourth layer 12 advantageously allows module 1 to be dielectrically and chemically insulating.

[0125] The fourth layer 12, which forms on the back side, is also present. Figure 6 and 7 It is shown in the image. However, it can be omitted.

[0126] Figure 6 A second embodiment of the photovoltaic module is shown in cross-section and exploded view.

[0127] Figure 6 The photovoltaic module may include all or some of the features mentioned above, and in particular, refer to Figures 3 to 5 The features described will no longer be described.

[0128] However, in this second embodiment, the upper encapsulation layer (3a) is separated from the edge 1A of the photovoltaic module by a distance D3. This distance D3 is less than the distance D. A Therefore, the upper encapsulation layer (3a) can still protect the photovoltaic cell.

[0129] The upper encapsulation layer (3a) can be located away from all edges of the photovoltaic module, and in particular, can be equidistant from all edges of the photovoltaic module by a distance D3, for example, in Figure 4 and 8 In the configuration of the type.

[0130] In the example, the distance D A It can be equal to 50mm, with the outer strip width L being 15A. 15A It equals 70mm, while the distance to D3 is 30mm.

[0131] More generally, the width L 15A (L respectively)15B L 15C L 15D ) and distance D A (D respectively) B D C D D The difference between ) is less than or equal to 30 mm, preferably less than or equal to 20 mm, and even more preferably between 10 and 20 mm, and D A (D respectively) B D C D D The difference between D1 and D2 is less than or equal to 10 mm.

[0132] Figure 7 A third embodiment of the photovoltaic module is shown in cross-section and exploded view.

[0133] Figure 7 The photovoltaic module may include all or some of the features mentioned above, and in particular, refer to Figures 3 to 5 The features described will therefore not be described again. However, in this third embodiment, the photovoltaic module includes a fifth layer 13 located below the second layer 5 and above the fourth layer 12.

[0134] The fifth layer forms at least one peripheral strip 13A extending from one edge 1A and protruding below the photovoltaic cell 41 (or multiple photovoltaic cells) closest to edge 1A. The width L of this peripheral strip is... 13A Greater than distance D A .

[0135] The fifth layer 13 is preferably made of the same material as the encapsulation component 3. Alternatively, the fifth layer may be made of a different material than the encapsulation component, but it must have at least the same thermomechanical properties.

[0136] The advantage of this fifth layer is that it makes single edges and / or multiple edges symmetrical.

[0137] By using examples, the distance to D A It can be equal to 50mm, with the outer strip width L being 15A. 15A It equals 70mm, and the width L of the outer strip 13A is... 13A It equals 70mm.

[0138] More generally, the width L 13A and distance D A The difference between them is less than or equal to 30 mm, preferably less than or equal to 20 mm, and even more preferably between 10 and 20 mm.

[0139] Preferably, the width L 13A equal to width L15A .

[0140] Figure 8 A top view corresponding to a specific example of the implementation of the third embodiment, in which only the (bottom) fourth layer 12, fifth layer 13 and four photovoltaic cells 41, 42, 43, 44 are shown (for the sake of readability of the figure, although present, layers 5, 3b, 15 between layer 13 and the cells are not shown, and the same is true for the layers above the cells).

[0141] It can be seen that the distance between the photovoltaic cell and all edges 1A, 1B, 1C, and 1D of photovoltaic module 1 is D. A D B D C D D Four batteries have been shown, but this number is not limiting and there can be more or fewer batteries.

[0142] The fifth layer, 13, can therefore form four outer stripes, one outer stripe at each edge, as shown in the example. Figure 8 As shown in the configuration, this also forms a frame. A frame can be a single piece.

[0143] exist Figure 8 In the simplified embodiment shown, all distances are substantially equal, as are the widths of the strips; however, this is not always the case.

[0144] In the example, the distance D A D B D C D D It can be equal to 50mm, and the width L of the outer strips 13A, 13B, 13C, and 13D is... 13A L 13B L 13C L 13D It equals 70mm.

[0145] More generally, the strip width L of the fifth layer 13A (L respectively) 13B L 13C L 13D ) and distance D A (D respectively) B D C D D The difference between ) is less than or equal to 30 mm, preferably less than or equal to 20 mm, and even more preferably between 10 and 20 mm.

[0146] Preferably, the strip width L of the fifth layer 13 13A (L respectively) 13B L13C L 13D The width L of the third layer is equal to 15. 15A (L respectively) 15B L 15C L 15D ).

[0147] The fifth layer 13 preferably has the same geometry as the third layer 15, so that they can overlap.

[0148] The fifth layer 13 can in particular have a thickness e13 of less than or equal to 150 μm, or even less than or equal to 100 μm.

[0149] By way of example, and for all or every embodiment presented above:

[0150] - The materials of the second layer 5 and the third layer 15 may be a prepreg composite consisting of glass cloth impregnated with epoxy resin, such as Hexply M77 from Hexcel Corporation.

[0151] - The first layer 2 forming the front side can be a membrane of ethylene trifluorochloroethylene (ECTFE) (known by the name Halar) ECT 020 from Rayotec, with a thickness of approximately 20 μm;

[0152] - Encapsulation layers 3a and 3b can be ionomer films obtained from the Jurasol™ range sold by Juraplast Formula, with a film thickness of approximately 50 μm; and when the fifth layer 13 is included, the fifth layer 13 is also like this;

[0153] - Photovoltaic cell 4 can be a heterojunction cell based on monocrystalline silicon and amorphous silicon with a thickness of about 115 μm, or an IBC cell with a thickness of about 160 μm.

[0154] The photovoltaic module 1 is produced in a single step of hot lamination of the constituent layers of the photovoltaic module 1 at the following temperature and lamination time, wherein the temperature is between 130°C and 170°C, and particularly about 150°C, and the lamination time lasts for at least 10 minutes, and particularly between 10 and 20 minutes.

[0155] Various presented embodiments can be combined together.

[0156] Furthermore, the present invention is not limited to the above embodiments, but covers any embodiments falling within the scope of the claims.

Claims

1. A photovoltaic module (1), comprising: - A transparent first layer (2) forms the front side of the photovoltaic module (1), the side being intended to receive light flux. - Multiple photovoltaic cells (4), placed side by side and electrically connected to each other. - Encapsulation component (3), capable of encapsulating the plurality of photovoltaic cells (4), and including a lower portion (3b) and an upper portion (3a). - The second layer (5) includes at least one composite material based on polymer resin and fiber. The encapsulation component (3) and the plurality of photovoltaic cells (4) are located between the first layer (2) and the second layer (5). At least the first layer (2) and the second layer (5) define the edges (1A, 1B, 1C, 1D) of the photovoltaic module (1); The photovoltaic cells (4) are characterized in that at least one edge (1A) of the photovoltaic module (1) is spaced apart by a non-zero distance D. A The photovoltaic module (1) is characterized in that it further comprises a third layer (15) or reinforcing layer located below the plurality of photovoltaic cells (4) and above the lower portion (3b) of the encapsulation assembly (3), the third layer forming at least one peripheral strip (15A), the at least one peripheral strip (15A) extending from the at least one edge (1A) toward the center of the module, and the width (L) of the at least one peripheral strip (15A) is... 15A () is greater than or equal to the distance D A The third layer comprises at least one composite material based on polymer resin and fiber.

2. The photovoltaic module (1) according to claim 1, wherein the encapsulation component is made of polymer.

3. The photovoltaic module (1) according to claim 1, wherein the width (L) of the at least one peripheral strip (15A) is... 15A The distance D between the plurality of photovoltaic cells (4) and the at least one edge (1A) A The difference between them is less than or equal to 30mm.

4. The photovoltaic module (1) according to any one of claims 1-3, wherein the third layer (15) and / or the second layer (5) are made of a polymer- and fiber-based composite material.

5. The photovoltaic module (1) according to claim 4, wherein the polymer is selected from polyester, epoxy resin and / or acrylic acid; and / or the fiber is selected from glass fiber, carbon fiber and / or aramid fiber.

6. The photovoltaic module (1) according to any one of claims 1 to 3, wherein the third layer (15) is made of the same composite material as the second layer (5).

7. The photovoltaic module (1) according to any one of claims 1 to 3, wherein the third layer (15) forms a plurality of peripheral strips (15A, 15B, 15C, 15D), each peripheral strip extending from one edge (1A, 1B, 1C, 1D) of the photovoltaic module (1) toward the center of the module, and the width (L) of each peripheral strip 15A L 15B L 15C L 15D The distance D between the edge and the plurality of photovoltaic cells (4) is greater than or equal to the distance between the edge and the plurality of photovoltaic cells (4). A D B D C D D .

8. The photovoltaic module (1) according to claim 7, wherein the third layer (15) forms at least two opposing stripes.

9. The photovoltaic module (1) according to claim 7, wherein the third layer (15) forms four stripes.

10. The photovoltaic module (1) according to any one of claims 1 to 3, wherein the encapsulation component (3) extends to the edge (1A, 1B, 1C, 1D) of the photovoltaic module (1).

11. The photovoltaic module (1) according to any one of claims 1 to 3, wherein the upper portion (3a) of the encapsulation component (3) is spaced apart from at least one edge (1A) of the photovoltaic module (1) by a distance D. 3A The distance D 3A It is non-zero and less than the distance D between the at least one edge and the plurality of photovoltaic cells. A .

12. The photovoltaic module (1) according to any one of claims 1 to 3 further comprises a fifth layer (13) located below the second layer (5), the fifth layer being formed extending from the at least one edge (1A) toward the center of the module and having a width (L) 13A The distance D between the at least one edge and the plurality of photovoltaic cells is greater than or equal to the distance D between the at least one edge and the plurality of photovoltaic cells. A At least one outer stripe (13A).

13. The photovoltaic module (1) according to claim 12, wherein the fifth layer (13) is made of polymer.

14. The photovoltaic module (1) according to claim 12, wherein the fifth layer (13) forms a plurality of peripheral strips (13A, 13B, 13C, 13D), each peripheral strip extending from one edge (1A, 1B, 1C, 1D) of the photovoltaic module (1) toward the center of the module and the width (L) of each peripheral strip is... 13A L 13B L 13C L 13D The distance D between the edge and the plurality of photovoltaic cells (4) is greater than or equal to the distance between the edge and the plurality of photovoltaic cells (4). A D B D C D D .

15. The photovoltaic module (1) according to claim 14, wherein the fifth layer (13) forms at least two opposing stripes.

16. The photovoltaic module (1) according to claim 14, wherein the fifth layer (13) forms four strips.

17. The photovoltaic module (1) according to claim 12, wherein the fifth layer (13) is made of a material having the same thermomechanical properties as the material of the encapsulation component.

18. The photovoltaic module (1) according to claim 17, wherein the fifth layer (13) is made of the same material as the encapsulation component (3).

19. The photovoltaic module (1) according to claim 12, wherein the size of the fifth layer (13) is substantially equal to the size of the third layer (15).

20. The photovoltaic module (1) according to any one of claims 1 to 3 further comprises: - A fourth layer (12) is formed on the back side of the photovoltaic module (1), the second layer (5) is located between the encapsulation component (3) and the fourth layer (12), the fourth layer is made of the same material as the material used to manufacture the first layer (2) and has a thickness less than or equal to the thickness of the first layer (2).

21. The photovoltaic module (1) according to any one of claims 1 to 3, wherein the first layer (2) is made of polymer.

22. The photovoltaic module (1) according to any one of claims 1 to 3, wherein the first layer (2) has a thickness (e2) of less than or equal to 50 μm.

23. The photovoltaic module (1) according to any one of claims 1 to 3, wherein the encapsulation component (3) has a maximum thickness (e3) of less than 150 μm.

24. The photovoltaic module (1) according to any one of claims 1 to 3, wherein the second layer (5) has a density of less than 150 g / m³. 2 The weight per unit area.

25. The photovoltaic module (1) according to any one of claims 1 to 3, wherein the encapsulation component (3) includes an upper encapsulation layer (3a) disposed between the first layer (2) and the plurality of photovoltaic cells (4) and a lower encapsulation layer (3b) disposed between the plurality of photovoltaic cells (4) and the second layer (5).

26. A method for producing a selected photovoltaic module (1) according to any one of claims 1 to 25, characterized in that, The method includes a step of thermal lamination of the layers of the photovoltaic module (1) at the following temperatures and lamination periods, wherein the temperatures are between 130°C and 170°C and the lamination period lasts for at least 10 minutes.

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