Solar module systems and related methods

Abstract

Disclosed herein are various embodiments of a solar module and related methods, the solar module comprising: at least one solar cell having a functional material positioned in electrical communication with an electrical wiring assembly; a first substrate made of a transparent material; a second substrate configured in a spaced apart relationship from the first substrate such that the functional material is disposed between the first substrate and the second material; and an encapsulant (at least one type) held in place via an encapsulant disposed between the first substrate and the solar cell and between the second substrate and the solar cell, the encapsulant is further configured to hold the solar cells in place between the first substrate and the second substrate; wherein at least one of the first substrate and the second substrate is a glass material.

Description

[0001] CROSS-REFERENCE TO RELATED APPLICATIONS

[0002] This application claims the benefit of priority under 35 U.S.C. §119 to U.S. Provisional Application No. 63 / 429,032, filed on November 30, 2022, the contents of which are incorporated herein by reference in their entirety. Background Art

[0003] For glass-glass modules, glass selection is often made without sufficient consideration of how other components in the module (e.g., the enclosure and support structure) work in combination with the glass to resist impact and deflection under load, resulting in heavier and less efficient modules due to thicker glass. Improvements are desired to reduce weight, increase efficiency, and improve performance parameters. Summary of the Invention

[0004] Utilizing the embodiments described herein, a systematic approach is embodied for designing custom solar modules having one or more improved properties / advantages, including: reduced weight, increased efficiency, and improved mechanical reliability. Without being bound by any particular mechanism or theory, the inventors have designed solar module stacks to achieve improved performance (e.g., hail impact and wind and snow load performance / load bearing requirements).

[0005] In one aspect, a solar module is provided, comprising: at least one solar cell having a functional material positioned to be electrically connected to an electrical wiring assembly, wherein the functional material of the solar cell is configured to capture photons and convert the photons into electrons; a first substrate comprised of a transparent material; a second substrate configured to be spaced apart from the first substrate such that the functional material is disposed between the first substrate and the second material; and an encapsulant (at least one) held in place by an encapsulant disposed between the first substrate and the solar cell and between the second substrate and the solar cell, the encapsulant further configured to hold the solar cell in place between the first substrate and the second substrate; wherein at least one of the first substrate and the second substrate is a glass material.

[0006] In some embodiments, the first substrate and the second substrate are selected from borosilicate glass and soda lime glass.

[0007] In some embodiments, at least one of the first substrate and the second substrate is a flexible glass ribbon (eg, Willow Glass).

[0008] In some embodiments, the first substrate and the second substrate have the same thickness.

[0009] In some embodiments, the first substrate and the second substrate have different thicknesses.

[0010] In some embodiments, the first substrate is thicker than the second substrate.

[0011] In some embodiments, the first substrate is thinner than the second substrate.

[0012] In some embodiments, the encapsulant is selected from an optically clear adhesive (OCA), an adhesive, a polymer interlayer, an ionomer, and / or combinations thereof.

[0013] In some embodiments, the solar module further comprises an electrical connector configured to receive and transmit electrons from the solar cell to a junction box.

[0014] In some embodiments, the solar module further comprises a seal configured to sealably engage the at least one solar module (ie, to protect the functional materials and / or solar cells from moisture, water, air, reactive components).

[0015] In some embodiments, the second substrate is made of a transparent, translucent or opaque material.

[0016] In some embodiments, at least one of the first substrate and the second substrate is a polymer or resin material.

[0017] In some embodiments, the module includes a frame and a gasket configured to sealingly engage the solar module.

[0018] In some embodiments, the solar module is configured as a solar panel (eg, with gasket, frame, electrical wiring, junction box).

[0019] In some embodiments, the solar module includes an antireflective coating on the first surface of the first substrate.

[0020] In some embodiments, the electrical connector is configured to transfer electrons from the solar cell to a junction box or a battery.

[0021] In some embodiments, the interlayer is selected from the group consisting of polyvinyl butyral (PVB), acoustic PVB (APVB), ionomer, ethylene vinyl acetate (EVA), thermoplastic polyurethane (TPU), polyester (PE), polyethylene terephthalate (PET), and combinations thereof; and wherein the thickness of the interlayer is in the range of 0.5 mm to 2.5 mm.

[0022] More specifically, the stacked components, including front and back glass (thickness and properties); encapsulant / interlayer; lamination process / method; and support structure (frame and / or mounts); micro-bending performance (e.g., through electrical connector design in combination with encapsulant selection); and 2D bending through design of support structure and lamination stack. BRIEF DESCRIPTION OF THE DRAWINGS

[0023] The accompanying drawings are included to provide a further understanding and are incorporated into and constitute a part of this specification. The drawings illustrate one or more embodiments and, together with the description, serve to explain the principles and operation of the various embodiments. In the drawings:

[0024] Figure 1 Schematic cross-sectional side views of embodiments of solar panels incorporating one or more aspects of the present disclosure having one or more features described herein are provided.

[0025] Figure 2 A flow chart is provided that illustrates the various performance requirements (determined by the impact and load requirements imposed by IEC standards) design considerations for various solar module components, and the potential outcomes for the embodied solar modules.

[0026] Figure 3 is a schematic cross-sectional side view of an embodiment of a solar module incorporating a frame according to one or more aspects of the present disclosure, depicting environmental effects including hail strikes, wind / snow loading, module response (e.g., deflection), and required transmittance for an efficient solar module.

[0027] Figure 4 is a schematic cross-sectional side view of an embodiment of a solar module incorporating a support rail having an adhesive material according to one or more aspects of the present disclosure.

[0028] Figures 5A to 5C Three different embodiments of support structures for solar modules according to various aspects of the present disclosure are depicted.

[0029] Figure 6 Certain aspects and features of incorporating edge protection into solar modules according to various aspects of the present disclosure are provided.

[0030] Figure 7 Depicted are non-planar configurations of solar modules retained via frames or wiring members according to one or more aspects of the present disclosure.

[0031] Additional features and advantages will be set forth in the detailed description that follows and, in part, will be apparent to those skilled in the art from that description or will be learned by practicing the embodiments described herein, including the following detailed description, claims, and accompanying drawings.

[0032] It is to be understood that both the foregoing general description and the following detailed description are merely exemplary, and are intended to provide an overview or framework for understanding the nature and character of the claims. DETAILED DESCRIPTION

[0033] The present disclosure is directed to various embodiments of glass-glass solar module embodiments having advantageous properties including improved efficiency, reliability, and / or lower weight.

[0034] Various embodiments are disclosed herein to improve hail impact resistance, microbending performance, wind and snow load performance, and weight reduction (lightweighting). As described below, one or more of these aspects are incorporated into the solar module embodiments herein.

[0035] Various embodiments for improving hail impact resistance are believed to include the features embodied below, either alone or in combination.

[0036] In some embodiments, multiple encapsulant layers are used in a laminate stack, where each encapsulant layer can be different.

[0037] In some embodiments, there are multiple encapsulant types in each "encapsulant layer," where the encapsulant type within a layer is determined by its position relative to other components in the laminate stack.

[0038] As a non-limiting example, a harder encapsulant is located at the perimeter where shear is transferred between the glass panels, while a less stiff encapsulant is located inside to maintain spacing. As used herein, harder means a higher Young's modulus of elasticity, while less stiff means a lower Young's modulus of elasticity.

[0039] In some embodiments, an encapsulant layer, wherein the material properties of the encapsulant are spatially dependent.

[0040] In some embodiments, various combinations of glass treatment (thermal strengthening, tempering), composition (chemical strengthening), and thickness are utilized to promote compressive stress / depth of layer.

[0041] In some embodiments, composite encapsulants are used to modify thermomechanical properties—high modulus and low CTE (glass particle filling)—which can help improve microbending and overall stiffness of the solar module.

[0042] In some embodiments, the edge seal is incorporated with or without a surrounding frame.

[0043] In some embodiments, different glass edge processing techniques (fire polishing, grinding, and etching) are utilized on the first substrate and the second substrate.

[0044] In some embodiments, a "damping" adhesive is incorporated into the support structure and / or into the mounts between the PV modules and the support structure.

[0045] Various embodiments for improving microbending performance are believed to include the features embodied below, either alone or in combination.

[0046] In some embodiments, the glass properties (thickness, modules, break resistance) are customized based on the desired performance of the solar module (e.g., the middle of the module is different from the edges where the frame and / or wiring (but no cells) may be located).

[0047] In some embodiments, an encapsulant layer is incorporated wherein the material properties of the encapsulant are spatially correlated based on location within the module (eg, above the solar cell, below the solar cell, adjacent to the solar cell, near the outer edge of the solar module).

[0048] In some embodiments, low-thickness electrical features are utilized to minimize localized bending and / or stresses in the substrate that may contribute to crack initiation and / or crack propagation. In some embodiments, various deposition processes, including additive manufacturing and printing / deposition techniques, are utilized to reduce the profile height (thickness) of electrical features / routing.

[0049] Various embodiments that improve wind and snow load performance are believed to include the following, alone or in combination.

[0050] In some embodiments, both frame and rail designs are incorporated into the solar modules / panels to promote improved mechanical reliability.

[0051] In some embodiments, the solar module (or upper or lower substrate) is configured with a two-dimensional curvature (eg, a curved laminate stack) to increase stiffness and improve hail resistance.

[0052] In some embodiments, the glass properties (thickness, module, break resistance) of the front and back glass are tailored to achieve the performance of a laminate system comprising laminate designs with different front and back thicknesses to achieve improved bending of the solar module.

[0053] In some embodiments, a lamination process / method is utilized to achieve two-dimensional curvature.

[0054] In some embodiments, the frame and / or mount (support structure) is configured to achieve improved two-dimensional bending.

[0055] In some embodiments, 360° tensioning of at least one glass substrate is provided to improve stiffness and / or hail resistance (eg, eardrum or trampoline concept).

[0056] In some embodiments, the structural adhesive is positioned within a portion of the stacked area to facilitate / improve two-dimensional bending and 360° tensioning to improve load bearing and / or hail impact resistance.

[0057] Various embodiments that are believed to improve module weight (weight reduction) performance include the following, alone or in combination.

[0058] In some embodiments, different glass edge processing techniques (eg, fire polishing, grinding, and etching) are included for at least one of the first substrate and the second substrate.

[0059] In some embodiments, module edge protection is utilized by constructing the edges with a softer polymer material. By utilizing such a softer polymer material, the frame can be omitted from the solar module (e.g., affecting the overall weight of the unit).

[0060] In some embodiments, the modules are configured (eg, on at least one major surface) with support structural rails configured to reduce panel deflection.

[0061] Glass substrate:

[0062] Glass substrate properties include, but are not limited to, composition, cross-sectional thickness, thermal expansion coefficient, forming method, surface roughness, edge profile, strengthened or unstrengthened, and the like.

[0063] In some embodiments, the first substrate and the second substrate have the same properties.

[0064] In some embodiments, the first substrate and the second substrate differ in at least one of the following: composition, cross-sectional thickness, coefficient of thermal expansion, molding method, surface roughness, edge profile, reinforcement.

[0065] In some embodiments, the first substrate and the second substrate differ in at least two of the following: composition, cross-sectional thickness, coefficient of thermal expansion, molding method, surface roughness, edge profile, reinforcement.

[0066] In some embodiments, the first substrate and the second substrate differ in at least three of the following aspects: composition, cross-sectional thickness, coefficient of thermal expansion, molding method, surface roughness, edge profile, and reinforcement.

[0067] In some embodiments, the first substrate and the second substrate differ in at least four of the following aspects: composition, cross-sectional thickness, coefficient of thermal expansion, molding method, surface roughness, edge profile, and reinforcement.

[0068] In some embodiments, the first substrate and the second substrate differ in at least five of the following aspects: composition, cross-sectional thickness, coefficient of thermal expansion, molding method, surface roughness, edge profile, and reinforcement.

[0069] In some embodiments, the first substrate and the second substrate differ in at least six of the following aspects: composition, cross-sectional thickness, coefficient of thermal expansion, molding method, surface roughness, edge profile, and reinforcement.

[0070] In some embodiments, the first and second substrates differ in all of the following: composition, cross-sectional thickness, coefficient of thermal expansion, molding method, surface roughness, edge profile, reinforcement.

[0071] In some embodiments, the first substrate and the second substrate differ in a type of reinforcement. In some embodiments, the first substrate and the second substrate differ in that one substrate is reinforced and the other substrate is not reinforced.

[0072] Glass composition / type:

[0073] The first substrate and the second substrate are selected from soda lime glass, boroaluminosilicate glass, alkaline earth boroaluminosilicate glass or alkali-free boroaluminosilicate glass. Exemplary commercially available glass products include but are not limited to EAGLE and Lotus TM NXT Glass.

[0074] Glass forming method:

[0075] In some embodiments, the first substrate or the second substrate is a float product, a rolled product, or a fusion drawn product.

[0076] Glass surface roughness

[0077] In one or more embodiments, the first glass substrate or the second glass substrate may be provided with a functional surface. In some embodiments, the functional surface is micro-patterned to produce a surface pattern that functions as an anti-reflective coating.

[0078] Edge Profile:

[0079] In some embodiments, at least one of the first substrate and the second substrate has an edge finish / edge profile. Some non-limiting examples of edge profiles include fire polishing, grinding, and etching.

[0080] thickness:

[0081] In embodiments, the substrate thickness is at least 0.5 mm, at least 1 mm, at least 2 mm, at least 3 mm, at least 3.3 mm, or at least 3.8 mm.

[0082] In one or more embodiments, the substrate thickness is in the range of about 0.1 mm to about 6 mm, 0.2 mm to about 6 mm, 0.3 mm to about 6 mm, 0.4 mm to about 6 mm, 0.5 mm to about 6 mm, 0.6 mm to about 6 mm, 0.7 mm to about 6 mm, 0.8 mm to about 6 mm, 0.9 mm to about 6 mm, 1 mm to about 6 mm, 1.1 mm to about 6 mm, 1.2 mm to about 6 mm, 1.3 mm to about 6 mm, 1.4 mm to about 6 mm, 1.5 mm to about 6 mm, 1.6 mm to about 6 mm, about 1.8 mm to about 6 mm, about 2 mm to about 6 mm, about 2.2 mm to about 6 mm m, about 2.4 mm to about 6 mm, about 2.6 mm to about 6 mm, about 2.8 mm to about 6 mm, about 3 mm to about 6 mm, about 3.1 mm to about 6 mm, about 3.2 mm to about 6 mm, about 3.3 mm to about 6 mm, about 3.4 mm to about 6 mm, about 3.5 mm to about 6 mm, about 3.6 mm to about 6 mm, about 3.7 mm to about 6 mm, about 3.8 mm to about 6 mm, about 3.9 mm to about 6 mm, about 4 mm to about 6 mm, about 4.2 mm to about 6 mm, about 4.4 mm to about 6 mm, about 4.5 mm to about 6 mm, about 4.6 mm to about 6 mm, about 4.8 mm to about 6 mm, about 5 mm m to about 6 mm, about 5.2 mm to about 6 mm, about 5.4 mm to about 6 mm, about 5.5 mm to about 6 mm, about 5.6 mm to about 6 mm, about 5.8 mm to about 6 mm, about 1.6 mm to about 5.8 mm, about 1.6 mm to about 5.6 mm, about 1.6 mm to about 5.5 mm, about 1.6 mm to about 5.4 mm, about 1.6 mm to about 5.2 mm, about 1.6 mm to about 5 mm, about 1.6 mm to about 4.8 mm, about 1.6 mm to about 4.6 mm, about 1.6 mm to about 4.4 mm, about 1.6 mm to about 4.2 mm, about 1.6 mm to about 4 mm, about 1.6 mm to about 3.9 mm m, about 1.6 mm to about 3.8 mm, about 1.6 mm to about 3.7 mm, about 1.6 mm to about 3.6 mm, about 1.6 mm to about 3.5 mm, about 1.6 mm to about 3.4 mm, about 1.6 mm to about 3.3 mm, about 1.6 mm to about 3.2 mm, about 1.6 mm to about 3.1 mm, about 1.6 mm to about 3 mm, about 1.6 mm to about 2.8 mm, about 1.6 mm to about 2.6 mm, about 1.6 mm to about 2.4 mm, about 1.6 mm to about 2.2 mm, about 1.6 mm to about 2 mm, about 1.6 mm to about 1.8 mm, about 3 mm to about 5 mm, or about 3 mm to about 4 mm.

[0083] Fortified or unfortified

[0084] Furthermore, in embodiments, the first glass substrate and / or the second glass substrate may be strengthened. As some non-limiting examples, the strengthening methods include thermal, chemical, and / or mechanical strengthening. As some non-limiting examples, chemical strengthening includes ion exchange treatment.

[0085] As some non-limiting examples, mechanical strengthening includes exploiting the mismatch in thermal expansion coefficients between portions of the solar module (glass portions) to create regions of compressive stress and a central region exhibiting tensile stress. As some non-limiting examples, strengthening is accomplished thermally, for example, by heating the glass to a temperature above its glass transition point and then rapidly quenching it.

[0086] In some embodiments, various combinations of chemical strengthening, mechanical strengthening, and thermal strengthening may be used to strengthen the glass. In one or more embodiments, one glass substrate is strengthened while the other is not strengthened (but may optionally be annealed).

[0087] CTE

[0088] The coefficient of linear thermal expansion (CTE) referenced herein is measured using ASTM standards E831 "Standard Test Method for Linear Thermal Expansion of Solid Materials by Thermomechanical Analysis," ASTM E228 "Test Method for Linear Thermal Expansion of Solid Materials With a Push-Rod Dilatometer," or an equivalent. As referenced herein, the coefficient of thermal expansion described herein is quantified as the coefficient of thermal expansion (CTE) measured over a temperature range of 0-300°C.

[0089] The CTE of the substrate is less than 70×10 -7 / °C and greater than zero. In some embodiments, the CTE of the substrate is less than 50×10 -7 / °C and greater than zero. In some embodiments, the CTE of the substrate is less than about 35×10 -7 / ℃ and greater than zero.

[0090] The CTE of soda-lime glass is approximately 90×10 -7 / °C. In comparison, the CTE of Corning EAGLE XG glass, as measured over the range of 0°C to about 300°C, is approximately 32×10 -7 / °C, which is approximately 1 / 3 ("one third") the CTE of soda-lime glass.

[0091] In some embodiments, the first substrate is a high CTE glass and the second substrate is a low CTE glass. In some embodiments, the first substrate is a low CTE glass and the second substrate is a high CTE glass. In some embodiments, the first substrate and the second substrate are both high CTE glasses, but have different CTEs. In some embodiments, the first substrate and the second substrate are both low CTE glasses, but have different substrates. In some embodiments, the first substrate and the second substrate have the same CTE. As a non-limiting example, the high CTE glass is greater than 50×10 -7 / ℃, while low CTE glass is less than 50×10 -7 / ℃.

[0092] Interlayer / encapsulation

[0093] In one or more embodiments, an encapsulant (also referred to as an interlayer) bonds together components and / or layers of the solar module.

[0094] Composition:

[0095] In some embodiments, the interlayer includes a polymer such as at least one of polyvinyl butyral (PVB), acoustic PVB (APVB), ionomer, ethylene vinyl acetate (EVA), and thermoplastic polyurethane (TPU), polyester (PE), polyethylene terephthalate (PET), and the like.

[0096] thickness:

[0097] The thickness of the encapsulant may be in the range of about 0.5 mm to about 2.5 mm, in particular in the range of about 0.7 mm to about 1.5 mm. In other embodiments, the thickness may be less than 0.5 mm or greater than 2.5 mm.

[0098] In the case of two encapsulant layers, the encapsulant layers can have the same thickness or different thicknesses. In some embodiments, the first encapsulant layer is thicker than the second encapsulant layer. In some embodiments, the second encapsulant layer is thicker than the first encapsulant layer.

[0099] Layer / Composite Material:

[0100] In some embodiments, the encapsulant layer is a single material. In some embodiments, the encapsulant layer is comprised of multiple layers, including two, three, or more distinct layers in a composite sandwich. In one embodiment, the encapsulant is in a sandwich configuration, where one layer is surrounded by two other layers on each major surface, with both 'outer' layers being made of the same material. In some embodiments, the sandwich has a different area for the sandwich than for the composite sandwich, depending on its position relative to the solar cells in the solar module and / or relative to the stack edge of the solar module.

[0101] In some embodiments, multiple polymer layers or films provide various functions to the laminate structure and / or PV module. For example, the interlayer may incorporate at least one of the following: solar insulation, sound suppression, antennas or electrical wiring / buses for the solar cells, anti-glare treatments or anti-reflective treatments, etc.

[0102] coating:

[0103] In one or more embodiments, the first glass substrate or the second glass substrate may be provided with a coating.

[0104] In an embodiment, the coating is an antireflective coating. In certain embodiments, the antireflective coating is applied to one or more surfaces of the first and second glass substrates. In some embodiments, the antireflective coating is applied to the outermost surfaces (e.g., the top and bottom surfaces) of the solar module. In an embodiment, the antireflective coating comprises multiple layers of low refractive index material and high refractive index material or low refractive index, medium refractive index, and high refractive index materials. For example, in an embodiment, the antireflective coating comprises two to twelve layers of alternating low refractive index material and high refractive index material, such as silicon dioxide (low refractive index) and niobium oxide (high refractive index).

[0105] In general, an antireflective coating with more layers in the stack will perform better at higher angles of incidence than an antireflective coating with fewer layers in the stack. For example, at angles of incidence greater than 60°, an antireflective coating stack with four layers will perform better (reflect less) than an antireflective coating stack with two layers. Furthermore, in embodiments, an antireflective coating stack with an ultra-low refractive index material will perform better (reflect less) than an antireflective coating stack with a low refractive index material.

[0106] Modules:

[0107] Ratio of substrate thickness:

[0108] In one or more embodiments, the second glass substrate is relatively thinner than the first substrate. In other words, the thickness of the first glass substrate is greater than the thickness of the second glass substrate.

[0109] In such embodiments, the first substrate thickness and the second substrate thickness are different from each other. For example, the first thickness is about 2.0 mm or more, about 2.1 mm or more, about 2.2 mm or more, about 2.3 mm or more, about 2.4 mm or more, about 2.5 mm or more, about 2.6 mm or more, about 2.7 mm or more, about 2.8 mm or more, about 2.9 mm or more, about 3.0 mm or more, about 3.1 mm or more, about 3.2 mm or more, about 3.3 mm or more, 3.4 mm or more, 3.5 mm or more, 3.6 mm or more, 3.7 mm or more, 3.8 mm or more, 3.9 mm or more, 4 mm or more, 4.2 mm or more, 4.4 mm or more, 4.6 mm or more, 4.8 mm or more, 5 mm or more, 5.2 mm or more, 5.4 mm or more, 5.6 mm or more, 5.8 mm or more, or 6 mm or more. In some embodiments, the first thickness is in the range of about 2.0 mm to about 6 mm, about 2.1 mm to about 6 mm, about 2.2 mm to about 6 mm, about 2.3 mm to about 6 mm, about 2.4 mm to about 6 mm, about 2.5 mm to about 6 mm, about 2.6 mm to about 6 mm, about 2.8 mm to about 6 mm, about 3 mm to about 6 mm, about 3.2 mm to about 6 mm, about 3.4 mm to about 6 mm, about 3.6 mm to about 6 mm, about 3.8 mm to about 6 mm, about 4 mm to about 6 mm, about 2.0 mm to about 5.8 ... mm to about 5.6 mm, about 2.0 mm to about 5.5 mm, about 2.0 mm to about 5.4 mm, about 2.0 mm to about 5.2 mm, about 2.0 mm to about 5 mm, about 2.0 mm to about 4.8 mm, about 2.0 mm to about 4.6 mm, about 2.0 mm to about 4.4 mm, about 2.0 mm to about 4.2 mm, about 2.0 mm to about 4 mm, about 2.0 mm to about 3.8 mm, about 2.0 mm to about 3.6 mm, about 2.0 mm to about 3.4 mm, about 2.0 mm to about 3.2 mm, or about 2.0 mm to about 3 mm.

[0110] In one or more embodiments, either or both of the first length and the first width are approximately 0.25 meters (m) or greater. For example, the first length and / or the second length may be in the range of about 1 m to about 3 m, about 1.2 m to about 3 m, about 1.4 m to about 3 m, about 1.5 m to about 3 m, about 1.6 m to about 3 m, about 1.8 m to about 3 m, about 2 m to about 3 m, about 1 m to about 2.8 m, about 1 m to about 2.8 m, about 1 m to about 2.8 m, about 1 m to about 2.6 m, about 1 m to about 2.5 m, about 1 m to about 2.4 m, about 1 m to about 2.2 m, about 1 m to about 2 m, about 1 m to about 1.8 m, about 1 m to about 1.6 m, about 1 m to about 1.5 m, about 1.2 m to about 1.8 m, or about 1.4 m to about 1.6 m.

[0111] For example, the first width and / or the second width may be in the range of about 0.5 m to about 2 m, about 0.6 m to about 2 m, about 0.8 m to about 2 m, about 1 m to about 2 m, about 1.2 m to about 2 m, about 1.4 m to about 2 m, about 1.5 m to about 2 m, about 0.5 m to about 1.8 m, about 0.5 m to about 1.6 m, about 0.5 m to about 1.5 m, about 0.5 m to about 1.4 m, about 0.5 m to about 1.2 m, about 0.5 m to about 1 m, about 0.5 m to about 0.8 m, about 0.75 m to about 1.5 m, about 0.75 m to about 1.25 m, or about 0.8 m to about 1.2 m.

[0112] In some embodiments, the weight of the solar module is less than 10 kg / m 2 , or less than 12kg / m 2 ; or less than 14kg / m 2 ; or less than 16kg / m 2 ; or less than 18kg / m 2 In some embodiments, the weight of the solar module is less than 5 kg / m 2 , or less than 7kg / m 2 ; or less than 8kg / m 2 .

[0113] One or more embodied solar modules described herein are configured to pass the following tests: IEC 61215:2016 & 61730-1:20165, CE; IEC 61701 Salt Spray Corrosion; IEC 60068-2-68 Dust and Sand Resistance; IEC 63209-1 Extended Stress Test; Long-Term Sequential Thresher Test; and / or PID Resistance.

[0114] Figure 1Schematic cross-sectional side views of embodiments of solar panels 10 having one or more substrates composed of a borosilicate composition as described herein in conjunction with various aspects of the present disclosure are provided.

[0115] refer to Figure 1 , the solar cell 40 is held between the two substrates, the first substrate 32 and the second substrate 42. The encapsulant 38 (e.g., a first encapsulant) is disposed between the solar cell 40 and the second surface 36 of the first substrate 32. The encapsulant 48 (e.g., a second encapsulant or a layer / unit integral with the encapsulant 38) is disposed between the first surface 44 of the second substrate and the solar cell 40. In this configuration, the solar cell 40 is attached to the first substrate 32 and the second substrate 42.

[0116] The solar cell 40 is configured with a functional material 50 that converts photons into electrons (the functional portion of the solar cell). The solar cell 40 is composed of the functional material 50, electrodes / electrode layers, transparent oxide layers, and / or additives or interlayers that constitute the solar cell 40. This stack, along with the edge seal 22, provides an embodiment of the solar module 12. The solar panel 10 of FIG. 18 incorporates a frame 20 (e.g., disposed circumferentially around the outer edge of the solar module 12 (e.g., at least partially overlapping the edge seal 22 of the solar module 12)). The frame optionally includes a gasket disposed between the body of the frame 20 and the outer edge of the solar module 12. Optionally, a coating (e.g., an anti-reflective coating) is applied to the first surface 34 of the first substrate 32 (and / or the second surface 45 of the second substrate 42 (not shown)).

[0117] The solar cell 40 is configured with electrical leads that connect the solar cell to electrical wiring and / or a junction box so that the solar cell is in electrical communication with the junction box and can transfer electrons out of the solar cell 40 in the form of electricity / current.

[0118] In some embodiments, the leads and wires / contacts are disposed within the edge of the frame 20, between the edge seal 22 and the frame / gasket assembly.

[0119] In some embodiments, the leads and wires are configured to extend through at least a portion of the second substrate (e.g., through a hole or discontinuous edge portion) such that electrical wiring is routed through a major surface portion of the second substrate and out of the solar panel into the junction box 24.

[0120] As shown, the first substrate can be configured as a major surface facing the sun / photon capture element. The solar panel 10 or module 12 can also be configured in a bifacial configuration, such that the photon capture element is configured through the first substrate 32 and the second substrate 42.

[0121] As non-limiting examples, the encapsulant can be configured as a sealant, a glue, an adhesive, a room temperature curing polymer, a UV curing polymer, an adhesive, an optically clear adhesive, and / or combinations thereof. In some embodiments, by incorporating a retrofit cover onto the surface of a solar panel (e.g., mounting), the uppermost surface of the solar panel can be tailored to one or more advantages of the borosilicate composition of the present invention, as described herein.

[0122] In some embodiments, an anti-reflective coating is applied to the first surface of the first substrate to reduce reflections on the surface of the glass coating, thereby improving the efficiency of the solar panel. In some embodiments, the AR coating is configured to allow more photons to enter the solar cell.

[0123] In some embodiments, the solar module is a frameless module. When the solar module is a frameless module, an edge seal is configured circumferentially around the solar stack to protect the electrical and functional material components from environmental influences (eg, water, oxygen, dust, moisture).

[0124] In some embodiments, the solar module is configured with a frame. In some embodiments, the solar module includes an edge seal configured around a perimeter edge of the solar stack.

[0125] In some embodiments, the frame cooperates with the gasket to provide a sealing engagement around the circumferential edge of the solar module and / or to provide compressive retention of the stack assembly.

[0126] In some embodiments, frit or metal is utilized between the first substrate and the second substrate, where the frit is laser bonded to create an edge seal.

[0127] In some embodiments, the encapsulant is an interlayer that is laminated with the first substrate, the second substrate, and the solar cells to form a solar module.

[0128] In some embodiments, the encapsulant is a material such as EVA or polyolefin. In some embodiments, the encapsulant is a polymer configured to protect the solar cells from water outflow and / or provide an elastic modulus to prevent cracking of the first and / or second substrates. In some embodiments, the encapsulant properties (thickness, elastic modulus) are customized based on the strength of the glass to design a solar panel that can withstand the impact and load forces required during use.

[0129] In some embodiments, the first surface of the first substrate is provided with a textured coating. The textured coating is configured to facilitate directing photons through the first glass substrate and into the solar cell. In one or more embodiments described herein, the texture of the front coating can be customized to improve efficiency.

[0130] In some embodiments, the coating on the back glass can be configured to provide a refractive index match to the second encapsulant so as to provide improved adhesion.

[0131] In some embodiments, the borosilicate compositions described herein provide crack arresting characteristics when subjected to crack initiating forces such that crack propagation and damage to the solar panel are reduced, prevented, and / or eliminated.

[0132] In some embodiments, the solar panel passes a 2-4J hail impact test.

[0133] In some embodiments, the solar panels undergo load testing sufficient to withstand snow loads, wind updrafts and downdrafts, and other environmental assessments of the solar panels and / or solar devices.

[0134] In some embodiments, solar panels are customized with appropriate design features and materials to achieve sustained performance in headwinds, tailwinds, excessive temperatures, and / or deflections caused by the aforementioned environmental conditions.

[0135] In some embodiments, the stack is 3 to 4 mm thick.

[0136] In some embodiments, the stack is symmetrical.

[0137] In some embodiments, the stacking is asymmetric.

[0138] In some embodiments, the solar panels or solar modules described in Figures 18 and 19A-C are configured with an additional substrate (with an accompanying encapsulant) on the first or second surface to further protect the solar module.

[0139] In some embodiments, the first and second substrates are configured to promote at least one of the following properties: protecting the solar cell from impact, defects, and bending, minimizing optical losses, managing surface properties, and the like.

[0140] In some embodiments, the solar panel is configured to be bifacial (capturing photons from the rear substrate / second substrate of the solar module).

[0141] In some embodiments, the solar panels are of a tandem design (having multiple solar cells stacked in a panel).

[0142] In some embodiments, glass compressive stress is tailored (eg, configured in compression) to reduce, prevent, and / or eliminate crack and / or defect migration.

[0143] In some embodiments, the solar cell is selected from the categories of silicon, semiconductor compounds, and emerging market materials. In some embodiments, the silicon solar cell comprises a crystalline (e.g., single crystal or polycrystalline) or amorphous (hydrogenated amorphous silicon) solar cell. In some embodiments, the semiconductor compound comprises a chalcogenide (e.g., cadmium telluride, copper zinc tin sulfide, copper indium gallium diselenide) or a Group III-V compound (e.g., gallium indium phosphide, gallium arsenide, etc.). In some embodiments, the solar material is an emerging market material, including dye-sensitized solar cells, colloidal quantum dots, perovskites, or organic materials.

[0144] In one or more embodiments described herein, the solar modules and / or solar panels are configured to pass IEC type tests for dynamic loading, static loading, and / or thermal cycling.

[0145] In one or more embodiments described herein, the solar module and / or solar panel is configured to pass at least one of the following: IEC 61216 module quality test (MQT) for UV pre-conditioning (MQT 10), thermal cycling (MQT 11), humidity freezing (MQT 12), damp heat (MQT 13), potential induced degradation (MQT 21), and perovskite stability test covering thermal, irradiance, electrical, and environmental protocols (such as the PACT protocol described by the IEC as of the date of this application), and / or a combination thereof. In some embodiments, the solar module and / or solar panel is configured to pass at least one of the following: IEC 61216 module quality test (MQT) for UV pre-conditioning (MQT 10), thermal cycling (MQT 11), humidity freezing (MQT 12), damp heat (MQT 13), potential induced degradation (MQT 21), and perovskite stability test covering thermal, irradiance, electrical, and environmental protocols (such as the PACT protocol described by the IEC as of the date of this application), and / or a combination thereof.

[0146] Reference numerals

[0147] Solar Panel 10

[0148] Solar Module 12

[0149] First surface 14

[0150] Second surface 16

[0151] Edge 18

[0152] Frame 20

[0153] Edge seal 22

[0154] Junction Box 24

[0155] Electrical connector 26

[0156] Electrical lead 28

[0157] Coating (e.g., AR coating / anti-reflective coating) 30

[0158] First substrate 32

[0159] The first surface 34 of the first substrate

[0160] The second surface 36 of the first substrate

[0161] First packaging member (interlayer) 38

[0162] Solar cells 40, 40'

[0163] Second packaging member 48

[0164] Second substrate 42

[0165] The first side 44 of the second substrate

[0166] The second side 46 of the second substrate

[0167] Lead hole 48

[0168] Functional Materials 50

[0169] Electrode 52

[0170] Modified cover 54

[0171] The third packaging member 56

Claims

1. A solar module comprising: a. at least one solar cell having a functional material positioned in electrical communication with an electrical wiring assembly, wherein the functional material of the solar cell is configured to capture photons and convert the photons into electrons; b. a first substrate composed of a transparent material; c. a second substrate configured to be spaced apart from the first substrate such that the functional material is disposed between the first substrate and the second material; as well as d. an encapsulant held in place via an encapsulant disposed between the first substrate and the solar cell and between the second substrate and the solar cell, the encapsulant further configured to hold the solar cell in place between the first substrate and the second substrate; e. wherein at least one of the first substrate and the second substrate is a glass material. 2 . The solar module according to claim 1 , wherein the first substrate and the second substrate are selected from borosilicate glass and soda-lime glass.

3. The solar module of claim 1 or claim 2, wherein at least one of the first substrate and the second substrate is a flexible glass ribbon. 4 . The solar module according to claim 1 , wherein the first substrate and the second substrate have the same thickness. 5 . The solar module according to claim 1 , wherein the first substrate and the second substrate have different thicknesses. 6 . The solar module according to claim 1 , wherein the first substrate is thicker than the second substrate. 7 . The solar module according to claim 1 , wherein the first substrate is thinner than the second substrate.

8. The solar module according to any one of claims 1 to 7, wherein the encapsulant is selected from the group consisting of an optically clear adhesive (OCA), an adhesive, a polymer interlayer, an ionomer, and / or combinations thereof.

9. The solar module according to any one of claims 1 to 8, further comprising: An electrical connector is configured to receive electrons and transmit the electrons from the solar cell to a junction box.

10. The solar module according to any one of claims 1 to 9, further comprising: A seal is configured to sealingly engage the at least one solar module. 11 . The solar module according to claim 1 , wherein the second substrate is made of a transparent, translucent or opaque material. 12 . The solar module according to claim 1 , wherein at least one of the first substrate and the second substrate is a polymer or resin material.

13. The solar module of any one of claims 1 to 12, wherein the module comprises a frame and a gasket configured to sealingly engage the solar module.

14. The solar module according to any one of claims 1 to 13, further configured as a solar panel.

15. The solar module according to any one of claims 1 to 14, further comprising an anti-reflective coating on the first surface of the first substrate.

16. The solar module according to any one of claims 1 to 15, wherein the electrical connector is configured to transfer the electrons from the solar cells to a junction box or a battery.

17. The solar module according to any one of claims 1 to 16, wherein the interlayer is selected from the group consisting of polyvinyl butyral (PVB), acoustic PVB (APVB), ionomer, ethylene vinyl acetate (EVA), thermoplastic polyurethane (TPU), polyester (PE), polyethylene terephthalate (PET), and combinations thereof; and wherein the thickness of the interlayer is in the range of 0.5 mm to 2.5 mm.

Images