Solar panel comprising recoverable package encapsulating photovoltaic cell

Abstract

Aspects of the invention include: a solar panel having (a) a photovoltaic (PV) cell array, and (b) an encapsulation encapsulating the PV cell array, and wherein top and bottom sections of the encapsulation are bonded together at a bonding perimeter of the encapsulation to form a hermetic seal around the PV cell array; wherein (i) the top section of the package comprises a glass composition or a glass ceramic composition; and (ii) the bottom section of the package comprises a glass composition, a glass ceramic composition, or a metal.

Description

[0001] Cross-reference to related applications

[0002] This application claims priority to U.S. Provisional Application No. 63 / 467,714, filed May 19, 2023, pursuant to 35 USC § 119, the contents of which are incorporated herein by reference in their entirety. Technical Field

[0003] This disclosure relates to solar panels, and more specifically, to solar panels with more recyclable contents. Background Technology

[0004] Fossil fuels have been widely used as a primary energy source, especially since the Industrial Revolution began in the mid-to-late 19th century. However, fossil fuels are finite and produce air pollution and greenhouse gases when burned. To reduce dependence on fossil fuels as an energy source, renewable energy sources such as solar and wind power are currently being used to generate electricity.

[0005] Specifically, solar energy is a form of energy that can be obtained from photons emitted by the sun. Solar energy can be utilized in various ways, such as through photovoltaic (PV) cells and solar thermal energy. In the case of PV cells, some photons emitted by the sun can be absorbed by the semiconductor material of the PV cell. The absorption of photons excites electrons in the semiconductor material to move from the valence band to the conduction band. The movement of electrons to the conduction band generates an electric current. This current can be directed to an external circuit to power electrical devices or converted into chemical energy within the cell for subsequent use.

[0006] Sometimes, PV cell arrays are arranged together in a solar panel. Within the solar panel, the PV cells are electrically coupled and encapsulated. Encapsulation protects the PV cell array from degradation and physical damage. Sometimes, the encapsulation is formed of ethylene vinyl acetate (EVA) or polyvinyl butyral (PVB). Additionally, the solar panel sometimes includes a polymer backing. The polymer backing helps protect the PV cell array from damage and provides structural rigidity to the solar panel. Furthermore, the solar panel includes a transparent glass or polymer layer on top of the encapsulation.

[0007] However, EVA and PVB encapsulations have the following problems: (i) they are not easily recyclable after the solar panel's lifespan; (ii) they degrade under ultraviolet (UV) radiation from the sun; (iii) they have poor ability to prevent the migration of alkali and moisture from the glass layer and the external environment to the PV cell, respectively; and (iv) they have poor heat transfer ability from the PV cell to the external environment, which reduces the conversion efficiency of the PV cell. Regarding problem (ii), adding UV absorbers and antioxidants to the EVA and PVB encapsulations can only delay the final degradation of the polymer, but it will also reduce the transmittance of UV light through the encapsulation to the PV cell. Therefore, an alternative solution is needed. Summary of the Invention

[0008] This disclosure addresses the problems of PV cell encapsulation, wherein the PV cell encapsulation (i) is made of recyclable materials, such as glass, glass-ceramic, and / or metal, which encapsulate the PV cell, and the PV cell is hermetically sealed to prevent moisture migration, and (ii) alkali-resistant ion-resistant materials, such as SiO2 and SiN, are used above and below the PV cell. x (iii) To prevent alkali migration, and to enhance heat transfer from the PV cell to the external environment by using high surface area bonding and heat transfer materials between the PV cell and the bottom section of the package.

[0009] According to a first aspect of this disclosure, a solar panel includes: (a) a photovoltaic (PV) cell array, each of the PV cells including a top main surface and a bottom main surface facing away from the top main surface; and (b) an encapsulation encapsulating the PV cell array, the encapsulation including a top segment and a bottom segment, wherein the top main surface of each of the PV cells faces the top segment, and the bottom main surface of each of the PV cells faces the bottom segment, and wherein the top segment and the bottom segment of the encapsulation are bonded together at a bonding periphery of the encapsulation to form a hermetically sealed seal around the PV cell array; wherein (i) the top segment of the encapsulation includes a glass composition or a glass-ceramic composition; and (ii) the bottom segment of the encapsulation includes a glass composition, a glass-ceramic composition, or a metal.

[0010] According to a second aspect of this disclosure, a solar panel of the first aspect is proposed, wherein the top region is substantially composed of a glass composition or a glass-ceramic composition.

[0011] According to a third aspect of this disclosure, a solar panel of the first aspect is proposed, wherein the top region is composed of a glass composition or a glass-ceramic composition.

[0012] According to a fourth aspect of this disclosure, a solar panel of the first aspect is proposed, wherein the top region comprises a glass composition, and the glass composition comprises soda-lime glass with low iron content, a glass composition with low alkali content, or a glass composition having mechanical advantages.

[0013] According to the fifth aspect of this disclosure, a solar panel of any one of the first to fourth aspects is proposed, wherein the encapsulated top and bottom sections are bonded together at the bonding periphery by anodic bonding.

[0014] According to the sixth aspect of this disclosure, a solar panel of any one of the first to fourth aspects is proposed, wherein the encapsulated top and bottom segments are bonded together at the bonding periphery by laser bonding.

[0015] According to the seventh aspect of this disclosure, a solar panel of any one of the first to fourth aspects is proposed, wherein the encapsulation further includes a bonding material for bonding the top and bottom segments of the encapsulation together at the bonding periphery.

[0016] According to the eighth aspect of this disclosure, a solar panel of the seventh aspect is proposed, wherein the bonding material is a polymer.

[0017] According to the ninth aspect of this disclosure, a solar panel of the seventh aspect is proposed, wherein the bonding material is glass or glass-ceramic.

[0018] According to the tenth aspect of this disclosure, a solar panel of any one of the first to fourth aspects is proposed, wherein (i) the package further includes an intermediate segment disposed between the top segment and the bottom segment at the bonding periphery of the package, and (ii) the top segment, the intermediate segment and the bottom segment are bonded together.

[0019] According to the eleventh aspect of this disclosure, a solar panel of the tenth aspect is proposed, wherein the top section, the middle section and the bottom section are anode-bonded together.

[0020] According to the twelfth aspect of this disclosure, a solar panel of any one of the tenth to eleventh aspects is proposed, wherein the middle section exhibits a lower glass transition temperature than the top and bottom sections.

[0021] According to the thirteenth aspect of this disclosure, a solar panel of any one of the first to twelfth aspects is proposed, wherein (i) the encapsulation further includes an anti-reflective coating disposed on the bottom surface of the top section of the encapsulation and facing the top main surface of the PV cell, and (ii) the anti-reflective coating comprises at least one SiO2 or SiN x layer.

[0022] According to the fourteenth aspect of this disclosure, the solar panel of any one of the first to thirteenth aspects further includes an inert gas disposed between the top and bottom sections of the encapsulation and within the bonding periphery of the encapsulation.

[0023] According to the fifteenth aspect of this disclosure, a solar panel of any one of the first to fourteenth aspects is proposed, wherein each of the PV cells comprises a crystalline silicon wafer.

[0024] According to the sixteenth aspect of this disclosure, the solar panel of any one of the first to fifteenth aspects further includes SiO2 or SiN. x A layer is disposed between the bottom main surface of the PV cell and the top surface of the bottom section of the package.

[0025] According to the seventeenth aspect of this disclosure, the solar panel of any one of the first to sixteenth aspects further includes a thermally conductive suspension disposed between the bottom main surface of each of the PV cells and the bottom section of the package; wherein the thermally conductive suspension includes oil, surfactant and inorganic filler, the inorganic filler improving the thermal conductivity of the thermally conductive suspension relative to oil alone.

[0026] According to the eighteenth aspect of this disclosure, a solar panel of any one of the first to seventeenth aspects is proposed, wherein each PV cell is bonded to the bottom segment of the encapsulation using a glass composition, a glass-ceramic composition, an anodic bonding, laser bonding, or thermally conductive bonding material.

[0027] According to the nineteenth aspect of this disclosure, a solar panel of any one of the first to eighteenth aspects is proposed, wherein (i) adjacent PV cells are electrically connected by incorporating solder, (ii) the solder comprises one or more conductive metals, and (iii) the solder is substantially free of cadmium, lead, mercury and hexavalent chromium.

[0028] According to the twentieth aspect of this disclosure, a solar panel of any one of the first to nineteenth aspects is proposed, wherein (i) adjacent PV cells are electrically connected by incorporating conductive paste, (ii) the conductive paste comprises a mixture of conductive metal particles and adhesive material, and (iii) the conductive metal particles are substantially free of cadmium, lead, mercury and hexavalent chromium.

[0029] According to the twenty-first aspect of this disclosure, a solar panel of any one of the first to twentieth aspects is proposed, wherein (i) the encapsulated bottom section further includes a recess for accommodating each of the PV cells and the current collection and transmission components; and (ii) the top surface of the bottom section within each of the recesses for the PV cells is flat.

[0030] According to the twenty-second aspect of this disclosure, the solar panel of any one of the first to twenty-first aspects further includes: a current collection and transmission assembly comprising a wiring grid made of coated copper diced sheets.

[0031] According to aspect twenty-three of this disclosure, the solar panel of any one of aspects one to twenty-two further includes a stamped flat spring that secures the PV cell at least partially within the package.

[0032] According to aspect twenty-four of this disclosure, the solar panel of any one of aspects one through twenty-three further includes a backing for supporting encapsulation, the backing comprising a metal sheet or a metal film.

[0033] According to the twenty-fifth aspect of this disclosure, a solar panel of the twenty-fourth aspect is proposed, wherein the backing metal sheet or metal film comprises aluminum having an aluminum oxide surface layer.

[0034] According to the twenty-sixth aspect of this disclosure, a solar panel of any of the twenty-fourth to twenty-fifth aspects is proposed, wherein the back anode is bonded to the encapsulation.

[0035] According to aspect twenty-seven of this disclosure, the solar panel of any of aspects twenty-four to twenty-six further includes a heat transfer fluid disposed between the backing and the encapsulation.

[0036] According to aspect twenty-eight of this disclosure, the solar panel of any one of aspects twenty-four to twenty-seven further includes at least one of a heat sink and a reinforcing member integrated with the backing.

[0037] According to the twenty-ninth aspect of this disclosure, a solar panel of the twenty-eighth aspect is proposed, wherein at least one heat sink is directly bonded to a backing.

[0038] According to the thirtieth aspect of this disclosure, any one of the first to twenty-ninth aspects is proposed, wherein the bottom section of the encapsulation includes a thermal expansion coefficient of 1×10⁻⁶. -6 / ℃ to 5×10 -6 Glass compositions within the range of / ℃.

[0039] According to the thirty-first aspect of this disclosure, a thirtieth aspect is proposed, wherein a glass composition or glass-ceramic composition for PV batteries is bonded to the bottom section of the package, the coefficient of thermal expansion of said glass composition or glass-ceramic composition also being within 1×10⁻⁶. -6 / ℃ to 5×10 -6 Within the range of / ℃.

[0040] According to the thirty-second aspect of this disclosure, a solar panel of any one of the first to thirty-first aspects is proposed, wherein the solar panel has an asymmetric structure, wherein the encapsulated top and bottom sections have at least one of the following: different compositions, different compressive stress distributions, different thicknesses, and non-mirror spatial relationships relative to the PV cell array.

[0041] According to the thirty-third aspect of this disclosure, a solar panel includes: (a) a photovoltaic (PV) cell array, each of the PV cells including a top main surface and a bottom main surface facing away from the top main surface; (b) an encapsulation encapsulating the PV cell array, the encapsulation including a top segment and a bottom segment, the top segment comprising a glass composition, wherein the top main surface of each of the PV cells faces the top segment, and the bottom main surface of each of the PV cells faces the bottom segment, and wherein the top segment and the bottom segment of the encapsulation are bonded together at a bonding periphery of the encapsulation to form a hermetically sealed seal around the PV cell array; (c) SiO2 or SiN. x (d) an anti-reflective coating disposed on the bottom main surface of the PV cell and the top surface of the bottom segment of the package; and (d) an anti-reflective coating disposed on the bottom surface of the top segment of the package and facing the top main surface of the PV cell, the anti-reflective coating comprising at least one SiO2 or SiN layer. x layer.

[0042] According to a thirty-fourth aspect of this disclosure, a solar panel includes: (a) a photovoltaic (PV) cell array, each of the PV cells including a top main surface and a bottom main surface opposite to the top main surface; (b) an encapsulation encapsulating the PV cell array, the encapsulation including a top segment and a bottom segment, the top segment comprising a glass composition, wherein the top main surface of each of the PV cells faces the top segment, and the bottom main surface of each of the PV cells faces the bottom segment, and wherein the top and bottom segments of the encapsulation are bonded together at a bonding periphery of the encapsulation to form a hermetically sealed seal around the PV cell array; (c) a backing material supporting the encapsulation, the backing material comprising a sheet of metal or a metal film; and (d) a heat transfer fluid disposed between the backing material and the encapsulation.

[0043] According to aspect thirty-five of this disclosure, the solar panel of aspect thirty-four also includes a heat sink integrally formed by metal extrusion and backing.

[0044] According to the thirty-sixth aspect of this disclosure, the solar panel of any of the thirty-fourth to thirty-fifth aspects further includes a thermally conductive suspension disposed between the bottom main surface of each of the PV cells and the bottom section of the package; wherein the thermally conductive suspension includes oil, surfactant and inorganic filler, the inorganic filler improving the thermal conductivity of the thermally conductive suspension relative to oil alone.

[0045] Additional features and advantages will be set forth in the detailed description below, and will be apparent to those skilled in the art from the description or will be recognized by practice of the embodiments described herein, including the detailed description below, the claims, and the drawings.

[0046] It should be understood that 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 characteristics of the claimed disclosure.

[0047] The accompanying drawings are included to provide a further understanding of the principles of this disclosure, and are incorporated in 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 this disclosure by way of example. It should be understood that the various features of this disclosure disclosed in this specification and drawings can be used in any and all combinations. By means of non-limiting examples, the various features of this disclosure can be combined with each other in accordance with the following aspects. Attached Figure Description

[0048] These and other features, aspects, and advantages of this disclosure will be better understood when read in the following detailed description with reference to the accompanying drawings, in which:

[0049] Figure 1 It is a perspective view of a solar array including the solar panels of this disclosure;

[0050] Figure 2 yes Figure 1 An exploded perspective view of a solar panel, showing a solar panel including a photovoltaic (PV) cell array and a package encapsulating the PV cells;

[0051] Figure 3 yes Figure 1 A cross-sectional view of a solar panel shows an encapsulation including a top section and a bottom section, which are bonded together at a bonding perimeter to form a cavity in which PV cells are housed.

[0052] Figure 4 yes Figure 3 An enlarged view of region IV shows the bonding material that bonds the top and bottom segments of the package together at the bonding periphery;

[0053] Figure 5 yes Figure 3 A magnified view of region V shows... Figure 1 An alternative implementation of the solar panel, wherein the middle section laterally defines the cavity and is bonded at the bonding periphery between the top and bottom sections;

[0054] Figure 6 yes Figure 3 An enlarged view of region VI shows the anti-reflective coating placed on the bottom surface of the top section of the package;

[0055] Figure 7 yes Figure 3An enlarged view of region VII shows that the bottom section forms a recess for housing a PV battery, and a stamped flat spring hangs down from the top section and applies force to the PV battery to hold it in place within the recess.

[0056] Figure 8 yes Figure 3 An enlarged perspective view of region VIII shows adjacent recesses where adjacent PV cells are disposed, and a current collection and transmission assembly 80 electrically connected to the PV cells.

[0057] Figure 9 Is with Figure 8 The same view, but this time the PV cell is shown in dashed lines to show that the bottom section of the encapsulation at the recess provides a flat top surface; and

[0058] Figure 10 yes Figure 3 A perspective view of region X, showing the heat transfer fluid disposed between the bottom section of the package and the backing that provides structural support for the package. Detailed Implementation

[0059] In the following detailed description, exemplary embodiments with specific details disclosed are set forth for purposes of explanation and not limitation to provide a thorough understanding of the various principles of this disclosure. However, it will be apparent to those skilled in the art who will benefit from this disclosure that this disclosure may be practiced in other embodiments that depart from the specific details disclosed herein. Furthermore, descriptions of well-known apparatuses, methods, and materials may be omitted to avoid obscuring the description of the various principles of this disclosure. Finally, wherever applicable, the same reference numerals refer to the same elements.

[0060] refer to Figures 1 to 3 The solar panel 10 includes an array of photovoltaic cells (PV cells) 12 and an encapsulation 14 encapsulating the array of PV cells 12. The array of PV cells 12 can be any number of PV cells 12. For example, the array of PV cells 12 can range from 20 to 80 PV cells 12, such as 60 to 72 PV cells 12. The solar panel 10 can be part of a solar array 16, which includes a group of more than one solar panel 10.

[0061] Each PV cell 12 includes a top main surface 18 and a bottom main surface 20. The top main surface 18 is positioned to face the sun. For example, a semiconductor material that converts sunlight into electricity is exposed to sunlight at the top main surface 18. The bottom main surface 20 faces away from the top main surface 18. The top main surface 18 and the bottom main surface 20 may be generally flat.

[0062] The package 14 encapsulating the array of PV cells 12 includes a top section 22 and a bottom section 24. The top section 22 is configured to face the sun. For example, the top section 22 has sufficient penetration to allow electromagnetic radiation of a desired wavelength from the sun to allow the array of PV cells 12 to generate electricity using electromagnetic radiation of the desired wavelength transmitted through the top section 22. The top main surface 18 of each of the PV cells 12 faces the top section 22 of the package 14. The bottom main surface 20 of each of the PV cells 12 faces the bottom section 24 of the package 14.

[0063] The top segment 22 and bottom segment 24 of package 14 are bonded together at a bonding periphery 26 of package 14. For example, in one embodiment, the bottom segment 24 includes a recessed portion 28 and a protruding portion 30 relative to the recessed portion 28, the protruding portion being disposed around the recessed portion 28. The recessed portion 28 and the protruding portion 30 together form a cavity 32. An array of PV cells 12 is disposed within the cavity 32. The protruding portion 30 of the top segment 22 and the bottom segment 24 are bonded together at a bonding periphery 26. The bonding periphery 26 laterally surrounds the cavity 32.

[0064] The top section 22 of the package 14 comprises a glass composition or a glass-ceramic composition, is substantially composed of a glass composition or a glass-ceramic composition, or is composed of a glass composition or a glass-ceramic composition. A suitable glass composition is soda-lime glass, particularly soda-lime glass with low iron content. "Low iron content soda-lime glass" means soda-lime glass with an Fe2O3 content of less than 200 ppm as measured by X-ray fluorescence (XRF). Such soda-lime glass has high permeability to electromagnetic radiation of typical wavelengths from the sun, which the PV cell 12 utilizes to convert into electrical energy. Reducing the iron and iron oxide content improves the transparency of soda-lime glass. Additionally, soda-lime glass can be heat-tempered. Furthermore, soda-lime glass is easily recyclable. Another suitable glass composition is a glass composition with low alkali content, meaning that the total concentration of alkali oxides Li2O, Na2O, and K2O is less than 0.1 mol%. Other suitable glass compositions include those with mechanical advantages, meaning that the glass has been mechanically strengthened by heat tempering, chemical strengthening (e.g., ion exchange), or lamination. Regarding lamination, glass is strengthened by forming a three-layer glass structure, wherein the outer glass layer of the laminate has a different composition and its coefficient of thermal expansion (CTE) is lower than that of the middle glass layer. This causes the middle layer of the laminate to shrink more significantly upon cooling, thereby placing the outer glass layer under compressive stress. Other suitable glass compositions include borosilicate glass compositions and aluminosilicate glass compositions, especially those that can be chemically or thermally strengthened. Suitable glass-ceramic compositions include lithium aluminosilicate glass-ceramic compositions, β-quartz glass-ceramic compositions, and spinel glass-ceramic compositions. In an embodiment, the top section 22 has at least one compressive stress region, which can be formed by ion exchange or thermal tempering, for example, adjacent to the top surface 34 of the top section.

[0065] The bottom section 24 of package 14 comprises a glass composition, a glass-ceramic composition, or a metal, and is substantially composed of, or composed of, a glass composition, a glass-ceramic composition, or a metal. Any glass composition or glass-ceramic composition discussed with respect to the top section 22 of package 14 is applicable to the bottom section 24 of package 14. An exemplary metal is aluminum, but other metals, such as steel and various other alloys, are contemplated. The recessed portion 28 and the raised portion 30 can be formed by etching the glass composition or glass-ceramic composition of the bottom section 24. In embodiments where the bottom section 24 is made of metal, the bottom section 24 is electrically isolated from the PV cell 12. For example, the top surface 66 of the bottom section 24 may be anodized, and / or an alumina ceramic sheet or strip may be disposed between the top surface 66 of the bottom section 24 and the PV cell 12 to electrically isolate the metallic bottom section 24 from the PV cell 12.

[0066] In one embodiment, the top segment 22 and bottom segment 24 of package 14 are anodicly bonded together at a bonding perimeter 26. To anodicly bond the top segment 22 and bottom segment 24 together, the top segment 22 and bottom segment 24 are assembled in a desired orientation, the temperature of the top segment 22 and bottom segment 24 is raised to the operating temperature of the anodic bonding, and a potential is applied across the top segment 22 and bottom segment 24, causing one segment to become negatively charged. The negatively charged component attracts positive ions from the other component. The accumulation of positive ions at the interface between the top segment 22 and bottom segment 24 induces a chemical reaction, thereby forming a covalent bond at the interface between the top segment 22 and bottom segment 24. To facilitate anodic bonding, the glass composition of the top segment 22 may include positive ions, such as alkali ions (e.g., Li₂). + Na + K + The method of ion-exchange treatment of the top segment 22 to generate one or more of the aforementioned compressive stress zones can also be used to fill the bottom surface 36 of the top segment 22 with positive ions, which then participate in the anodic bonding process. Anodic bonding can be used to bond the top segment 22 and the bottom segment 24 together, regardless of whether the bottom segment 24 has a glass composition, a glass-ceramic composition, or a metal. In the case where the top segment 22 has a glass composition and the bottom segment 24 is a metal, the metal carries a negative charge during the anodic bonding process. The negatively charged metal attracts positive base ions from the glass composition of the top segment 22. The presence of the base ions causes them to react with the metal of the bottom segment 24, and the reaction results in the formation of a covalent bond at the interface between the glass composition or glass-ceramic composition of the top segment 22 and the metal of the bottom segment 24.

[0067] In one embodiment, the top segment 22 and the bottom segment 24 are laser-bonded together at a bonding perimeter 26, particularly when both the top segment 22 and the bottom segment 24 comprise a glass composition or a glass-ceramic composition. For example, the laser beam can be focused at the interface between the top segment 22 and the bottom segment 24, i.e., at the location of the bonding perimeter 26. The top segment 22, the bottom segment 24, or both the top segment 22 and the bottom segment 24 absorb at least a portion of the energy from the laser beam at or near the interface between the top segment 22 and the bottom segment 24. The absorbed energy raises the temperature of the materials sufficiently to soften the materials at the interface and induce diffusion between the two materials. Then, after bonding is formed at the interface, the top segment 22 and the bottom segment 24 are cooled. A third material, which has a better absorption capacity for the laser beam wavelength than the top segment 22 and the bottom segment 24, can be disposed between the top segment 22 and the bottom segment 24. In this case, a third material (e.g., a thin metal film) absorbs the laser energy, heats up, and diffuses into both the top segment 22 and the bottom segment 24, thereby bonding the top segment 22 and the bottom segment 24 together.

[0068] In the implementation method, reference is now made to Figure 4 Package 14 includes bonding material 38 that bonds the top segment 22 and bottom segment 24 of package 14 together at a bonding perimeter 26. Bonding material 38 can be any material that bonds the top segment 22 and bottom segment 24 together while providing a hermetically tight seal within cavity 32. For the purposes of this disclosure, "hermetically tight" means that package 14 exhibits a helium leak test result of less than or equal to 1 × 10⁻⁶ during a helium leak test conducted in accordance with International Electrotechnical Commission (IEC) standard 60068-2-17. -8 atm·cm 3 The leakage rate is / s. For example, the bonding material 38 can be a polymer. The polymer can be applied as a thermosetting resin, which is then cured to bond the top segment 22 and the bottom segment 24. Suitable resins include epoxy resins, silicone resins, polyurethane resins, and acrylic resins, etc. Curing of the resin can be initiated by applying light of a suitable wavelength that transmits through the top segment 22 or by applying heat and other means. Alternatively, the polymer can be applied between the top segment 22 and the bottom segment 24 by injection molding. Suitable injection molding polymers are polyaryletherketones (PAEKs), such as polyetheretherketone (PEEK), polyetherketone (PEK), and polyetherketoneketone (PEKK).

[0069] In this embodiment, the bonding material 38 is glass or glass-ceramic. For example, a glass frit may be applied between the top section 22 and the bottom section 24 (i.e., where the bonding perimeter 26 is located). The glass frit may have a glass transition temperature (Tg) below 500°C or below the Tg of soda-lime silicate glass. The glass frit may include multiple components, such as a low-Tg glass component and a filler particle component, wherein the filler particles may be glass or ceramic with a high Tg or high melting temperature, and filler particles may be added to adjust the effective coefficient of thermal expansion (CTE) of the glass frit mixture. The glass frit is then heated at least to the softening point of the low-Tg glass component of the glass frit. The molten glass frit is bonded to the top section 22 and the bottom section 24. Upon cooling, depending on the composition of the glass frit used, the glass frit re-solidifies into glass or glass-ceramic. In edge-sealing applications (where the bonding material glass is not directly bonded to silicon), a preferred bonding material may include a CTE of 7 to 12 × 10⁻⁶. -6 Glass compositions within the range of / ℃ are used to achieve a CTE in the same range as soda-lime silicate glass. Such a CTE can be achieved by adjusting the ratio of low Tg glass to filler particles, as further described in the following literature: Morena, R. “Phosphate glasses as alternatives to Pb-based sealing frits.” Journal of Non-Crystalline Solids 263 (2000): 382-387, and U.S. Patent 5,246,890 (Aitken et al.), which are incorporated herein by reference.

[0070] In the implementation method, refer to Figure 5 The package 14 also includes an intermediate segment 40, instead of bonding material 38, disposed between the top segment 22 and the bottom segment 24 at the bonding periphery 26 of the package 14. The top segment 22, intermediate segment 40, and bottom segment 24 are bonded together at the bonding periphery 26 to hermetically seal the cavity 32 between the top segment 22 and the bottom segment 24. It should be noted that when the intermediate segment 40 is used, the bottom segment 24 does not need to have a recessed portion 28 and a protruding portion 30 to form the cavity 32. In fact, the intermediate segment 40 separates the top segment 22 and the bottom segment 24 and laterally forms the cavity 32.

[0071] The intermediate segment 40 can be bonded to both the top segment 22 and the bottom segment 24 in any of the previously described methods, such as anodic bonding, laser bonding, glass frit bonding, bonding with bonding material 38, etc. In an embodiment, the top segment 22, the intermediate segment 40, and the bottom segment 24 are all glass compositions or glass-ceramic compositions, and the intermediate segment 40 exhibits a lower glass transition temperature than the top segment 22 and the bottom segment 24.

[0072] Now for reference Figure 6 In one embodiment, the package 14 further includes an anti-reflective coating 42. The anti-reflective coating 42 may be disposed on the top section 22. For example, the anti-reflective coating 42 may be disposed on the top surface 34 of the top section 22 (e.g., the sun-facing surface). Alternatively, the anti-reflective coating 42 may be disposed on the bottom surface 36 of the top section 22, such as the portion of the bottom surface 36 exposed to the cavity 32, or otherwise facing the top main surface 18 of the PV cell 12. The anti-reflective coating 42 reduces the amount of sunlight reflected away from the PV cell 12 by the top section 22. Therefore, the anti-reflective coating 42 increases the amount of sunlight converted into electricity by the PV cell 12. The anti-reflective coating 42 may be disposed on both the top surface 34 and the bottom surface 36 of the top section 22.

[0073] The antireflective coating 42 may include material layers with different compositions and exhibiting different refractive indices. This configuration relies on the principle of destructive interference to reduce the amount of light reflected from the top section 22 away from the PV cell 12. The thickness can be individually adjusted to minimize reflection of electromagnetic radiation at the desired wavelength and / or maximize the transmittance of electromagnetic radiation at the desired wavelength through the top section 22. The anti-reflective coating 42 may include at least one SiO2 layer. The anti-reflective coating 42 may also include at least one SiN layer. x Layers. A layer was envisioned. Many other components.

[0074] Return to reference Figure 3As described above, the package 14 is hermetically sealed around the cavity 32 where the PV cell 12 is housed. In this embodiment, the solar panel 10 also includes an inert gas 46 disposed around the PV cell 12 within the cavity 32. For example, the inert gas 46 is disposed between the top section 22 and the bottom section 24 of the package 14 and within the bonding periphery 26 of the package 14. The PV cell 12 comprises a semiconductor material, such as silicon. Exposure of the semiconductor material to oxygen and moisture can cause degradation of the semiconductor material. As the semiconductor material degrades, the efficiency of the PV cell 12 in converting sunlight into electricity decreases. Vacuuming the cavity 32 where the PV cell 12 is housed and injecting the inert gas 46 can prevent such problems. The inert gas 46 can be argon, nitrogen, a mixture of argon and nitrogen, etc.

[0075] Now for reference Figure 7 In this embodiment, each of the PV cells 12 includes a silicon wafer 48. The silicon wafer 48 may be made of amorphous silicon or crystalline silicon. The crystalline silicon wafer 48 may be monocrystalline or polycrystalline, and the term "crystalline" is intended to include both monocrystalline and polycrystalline types. The silicon wafer 48 has regions 50, 52 and a pn junction 54 therebetween, one of regions 50, 52 being an n-type region and the other a p-type region. The PV cell 12 may include additional layers between the silicon wafer 48 and the bottom segment 24 of the package 14, such as a metal layer 56 below the silicon wafer 48 and a backplane 58 below the metal layer 56. The PV cell 12 may include other layers above the silicon wafer 48, such as an anti-reflective coating 60 and a glass layer 62.

[0076] In one embodiment, the solar panel 10 further includes a barrier layer 64 disposed between the bottom main surface 20 of the PV cell 12 and the top surface 66 of the bottom segment 24 of the package 14. The barrier layer 64 may be designed to block alkaline ions (e.g., Na+). + Any material diffuses from the bottom segment 24 of the package 14 into the PV cell 12. The presence of alkaline ions on the surface of the silicon wafer 48 of the PV cell 12 can cause a positive charge imbalance. This positive charge imbalance degrades the performance of the PV cell 12, and this degraded performance is sometimes referred to as potential-induced degradation (PID). In this embodiment, the barrier layer 64 is SiO2 or SiN. x Other materials have also been envisioned. Notably, the anti-reflective coating 42 disposed on the top section 22, between the top section 22 and the PV cell 12, typically comprises one or more SiO2 and / or SiN. x This layer serves the same purpose as the barrier layer 64, namely, to prevent PID.

[0077] In one embodiment, the solar panel 10 also includes a thermally conductive suspension 68 disposed between the bottom main surface 20 of each of the PV cells 12 and the bottom section 24 of the package 14. The thermally conductive suspension 68 transfers heat from the PV cells 12 to the bottom section 24 of the package 14. Generally, the more heat transferred from the PV cells 12, the higher the efficiency of the PV cells 12. The thermally conductive suspension 68 may include oil, surfactants, and inorganic fillers. Inorganic fillers increase the thermal conductivity of the suspension compared to oil alone. Suitable inorganic fillers include boron nitride (BN), alumina (Al2O3), and silicon carbide (SiC), etc. Surfactants can stabilize the suspension and allow the suspension to be washed with organic detergents during the recycling of the solar panel 10. Suitable surfactants include sodium dodecylbenzene sulfonate, but other surfactants are contemplated, including plant-based surfactants (e.g., cocoyl glucoside, lauryl glucoside, decyl glucoside, sodium lauryl sulfoacetate, and sodium cocoamphoacetate).

[0078] In this embodiment, each PV cell 12 is bonded to the bottom segment 24 of the package 14. Any of the methods described above used to bond the top segment 22 and bottom segment 24 of the package 14 together is applicable to bonding the PV cell 12 to the bottom segment 24 of the package 14. For example, glass frit bonding, anodic bonding, laser bonding, and bonding materials can be used. In embodiments where the bottom segment 24 of the package 14 is a glass layer bonded to the PV cell 12, it is likely preferable to use a glass composition with a CTE substantially matched to silicon for the bottom segment 24. The coefficient of thermal expansion is very well matched to silicon glass (e.g., CTE in 1 × 10⁻⁶). -6 / ℃ to 5×10 -6 Examples of glass within the range of / ℃ include alkaline earth aluminoborosilicate glass, which may be alkali-free, including, for example, Corning Eagle XG glass.

[0079] In the case of glass frit bonding, the result is that layers of glass composition or glass-ceramic composition bond each PV cell 12 to the bottom segment 24. The glass frit can be thermally conductive, such as a glass frit material mixed with a thermally conductive material (e.g., carbon particles, carbon fibers, or alumina particles). Examples of such "bonding glass" compositions that can be used for the glass frit (for directly bonding the bottom segment 24 to the PV cell 12, or for forming glass-glass or glass-metal bonds around the bonding perimeter 26 of the package 14) may include tin silicate, tin phosphate, zinc tin phosphate, or tin borophosphate, all of which may be fortified with ZnO or Al2O3 and are all lead-free. The coefficient of thermal expansion can be substantially matched to silicon (e.g., CTE = 1 to 5 × 10⁻⁶). -6Examples of such glass frit compositions (at / ℃) can be found in: Morena, R. “Phosphate glasses as alternatives to Pb-based sealing frits.” Journal of Non-Crystalline Solids 263 (2000) 382-387, which is incorporated herein by reference. Such glass frits can be advantageously used to bond silicon PV cells 12 to the bottom segment 24 of the glass, and have a coefficient of thermal expansion substantially matching that of silicon to have a value of 1 × 10⁻⁶. -6 / ℃ to 5×10 -6 CTE within the range of / ℃. In this embodiment, the coefficient of thermal expansion of the glass frit (and the resulting glass or glass-ceramic composition) is lower than that of the bottom section of the package.

[0080] In some embodiments, the solar panel 10 may include an asymmetric structure. The solar panel 10 can be constructed in various asymmetric forms. These asymmetric forms of the solar panel 10 may include one or more of the following designs, which may also be used in combination. First, the PV cell 12 may be directly bonded to the bottom segment 24, which includes metal or glass, using any of the methods described above (e.g., anodic bonding or glass frit bonding), and the PV cell 12 may not be directly bonded to the top segment 22. In this embodiment, an air gap, an inert gas, or a transparent polymer bonding layer (which may be removable or recyclable) may exist between the PV cell 12 and the top segment 22, wherein the top segment 22 is preferably glass. This construction can improve the heat removal efficiency of the PV cell 12 while also effectively protecting the top segment 22 from the effects of hail or other impacts. Second, both the top segment 22 and the bottom segment 24 may include glass, wherein the thickness of the top segment 22 is different from that of the bottom segment 24. In some cases, it is preferable that the top section 22 has a greater thickness, such as 2 to 3.5 mm, to withstand the impact of hail, while the bottom section 24 may have a smaller thickness, such as 0.1 to 2 mm, to reduce weight, lower cost, or improve thermal management. Such a solar panel 10 can also be double-sided; for example, because the glass forming the top section 22 and the bottom section 24 is transparent, energy can be harvested from light incident from both sides of the solar panel 10. As described above, either or both of the top section 22 and the bottom section 24 can be thermally strengthened, chemically strengthened, or laminated strengthened. Third, both the top section 22 and the bottom section 24 can comprise glass, but the glass of the top section 22 and the bottom section 24 may have different compositions, different constructions, different stress levels, or be strengthened using different methods. For example, the glass of the top section 22 can be alkali-containing glass or strengthened laminated glass, while the glass of the bottom section 24 can be alkali-free glass with a CTE close to that of silicon. The bottom section 24 is directly bonded to the PV cell 12, while the top section 22 is not directly bonded to the PV cell 12. In similar embodiments, the top section 22 can be a laminated strengthened glass that also has a controlled average CTE, which can be lower than that of soda-lime glass or close to that of silicon, for example, a CTE between 1 and 50 × 10⁻⁶. -6 Within the range of / ℃. Generally, a solar panel has an asymmetric structure when the top section 22 and the bottom section 22 have different compositions, different compressive stress distributions, different thicknesses, and at least one of the following: a non-mirror spatial relationship relative to the array of PV cells 12.

[0081] For further reference Figure 8Adjacent PV cells 12 are electrically connected to each other. For example, each PV cell 12 includes a busbar 70, which can be used to make electrical contact at the top main surface 18 and the bottom main surface 20 of the PV cell 12. A busbar 70 available at the top main surface 18 of the PV cell 12 can be electrically connected to a busbar 70 available at the bottom surface 36 of the adjacent PV cell 12 using a tab wire 72. The tab wire 72 can be attached to the busbar 70 by soldering the tab wire 72 and the busbar 70 together with solder 74. Simply put, adjacent PV cells 12 are electrically connected by incorporating solder 74. Solder 74 comprises one or more conductive metals. In embodiments, the solder 74 used to electrically connect adjacent PV cells 12 to each other is substantially free of cadmium, lead, mercury, and hexavalent chromium (e.g., hexavalent chromium). "Substantially free" means that those materials are not intentionally included in the solder 74 but may be present as trace amounts. Metals suitable for solder 74 include tin-silver-copper alloys, tin-copper alloys, tin-silver alloys, bismuth-tin-silver alloys, and zinc-aluminum alloys.

[0082] In this embodiment, adjacent PV cells 12 are electrically connected by incorporating conductive paste 76. Conductive paste 76 can be used as a substitute for solder 74 or as a supplement to solder 74. For example, conductive paste 76 can be used to attach solder ribbon 72 to the main grid 70 of adjacent PV cells 12. Conductive paste 76 comprises a mixture of conductive metal particles and binder material. In this embodiment, conductive paste 76 is substantially free of cadmium, lead, mercury, and hexavalent chromium (e.g., hexavalent chromium). Metals suitable for conductive paste 76 include tin, silver, or copper, or alloys thereof. "Substantially free" means that the elements are intentionally added to the relevant material (e.g., conductive paste 76) but are present in trace amounts (e.g., less than 100 ppm).

[0083] For further reference Figure 9In one embodiment, package 14 further includes recesses 78 for receiving each of the PV cells 12 and the current harvesting and transport components 80. For example, recesses 78 may be formed into (e.g., etched into or molded) in or otherwise disposed in the bottom segment 24 of package 14. Recesses 78 receive each of the PV cells 12 and the current harvesting and transport components 80, such as solder ribbons 72 connecting adjacent PV cells 12. The top surface 66 of the bottom segment 24 within each recess 78 of the PV cells 12 may be flat. The flatness of the top surface 66 within the recesses 78 facilitates bonding the PV cells 12 to the bottom segment 24 of package 14 and promotes heat transfer from the PV cells 12 to the bottom segment 24 of package 14. In addition to the recesses 78 formed in the bottom segment 24 of the package, recesses 78 (not shown separately) may also be formed in the bottom surface 36 of the top segment 22 of package 14. The top section 22 can be patterned by molding or etching to accommodate the PV cell 12 and the current collection and transmission assembly 80.

[0084] Mesh 82 separates adjacent recesses 78. Mesh 82 may have a height 83 from the top surface 66 of the bottom segment 24 of the package 14 below the PV cell 12, which is greater than the height 84 of the PV cell 12. The height difference between heights 83 and 84 helps maintain the spacing between the top main surface 18 of the PV cell 12 and the top segment 22 of the package 14, thereby limiting the migration of alkaline ions from the top segment 22 of the package 14 to the PV cell 12. The package 14 can also be patterned using etching to accommodate wave soldering of the PV cell 12 and other current harvesting and transmission components 80 of the solar panel 10.

[0085] The current harvesting and transmission assembly 80 may also include a main grid 85, which connects adjacent PV cells 12 near the bonding periphery 26 of the package 14. The main grid 85 may be a wire mesh made of cut sheets of metal (e.g., copper or coated copper).

[0086] In one embodiment, the solar panel 10 also includes a stamped flat spring 86 that at least partially secures the PV cells 12 within the package 14. For example, the stamped flat spring 86 may be secured to the bottom surface 36 of the top section 22 of the package 14. The stamped flat spring 86 extends downward toward the bottom section 24 of the package 14. The stamped flat spring 86 is positioned to press against the top main surface 18 of each of the PV cells 12. Thus, the stamped flat spring 86 helps to retain the PV cells 12 within a recess 78 formed in the bottom section 24 of the package 14. In an embodiment where the recess 78 is formed in the top section 22 of the package 14, the stamped flat spring 86 may be secured to the top surface 66 of the bottom section 24 and push the PV cells 12 upward into the recess 78.

[0087] In one embodiment, the stamped flat spring 86 is part of the current harvesting and transmission assembly 80. In this embodiment, the stamped flat spring 86 is positioned to contact the main grid 70 available at the top main surface 18 of the PV cell 12. Thus, the stamped flat spring 86 serves a dual purpose: both mechanically securing the PV cell 12 within the package 14 and conducting the current generated by the PV cell 12.

[0088] Return to reference Figure 2 and 3 In this embodiment, the solar panel 10 also includes a backing 88. The backing 88 supports the package 14. The backing 88 is positioned below the package 14. The backing 88 is attached to the bottom surface 91 of the bottom section 24 of the package 14. The backing 88 can be a metal sheet or a metal film. The metal can be aluminum, etc. The metal can be anodized. In these cases, anodizing forms a metal oxide surface layer on the metal sheet or metal film. For example, if the backing 88 is an aluminum sheet, anodizing the aluminum forms an aluminum oxide (Al2O3) surface layer. The metal oxide surface layer helps to slow down or prevent corrosion of the backing 88. The backing 88 can be adhered to the bottom section 24 of the package 14 by any of the aforementioned bonding mechanisms, such as anodic bonding, laser bonding, resin, etc. The backing 88 can be extruded aluminum.

[0089] refer to Figure 10 In one embodiment, the solar panel 10 also includes a heat transfer fluid 90 disposed between the backing 88 and the bottom surface 91 of the bottom section 24 of the encapsulation 14. Examples of suitable heat transfer fluids 90 include propylene glycol, ethylene glycol, and silicone oil. This list is not intended to be limiting.

[0090] Return to reference Figures 1 to 3 In one embodiment, the solar panel 10 includes a heat sink 92. The heat sink 92 may include a plurality of heat sink fins 94. The heat sink 92 increases the surface area from which heat can be transferred from the heat sink 92 (and consequently from the solar panel 10) to the external environment 96. The heat sink 92 may be made of a metal such as aluminum. The heat sink fins 92 may be directly bonded to a backing 88. In one embodiment, the backing 88 is integrated with the heat sink 92. For example, the backing 88 and the heat sink fins 82 may be formed together from extruded aluminum.

[0091] In one embodiment, the solar panel 10 further includes one or more reinforcing members 98. The one or more reinforcing members 98 may be integrated with the backing 88. The one or more reinforcing members 98 may be directly bonded to the backing 88. The one or more reinforcing members 98 may include hollow metal beams. The one or more reinforcing members 98 increase the stiffness of the backing 88, thereby increasing the stiffness of the solar panel 10. The reinforcing members 98 are considered distinct from the outer frame 100, which may also be made of a metal such as aluminum.

[0092] The solar panel 10 disclosed herein addresses the aforementioned problems of previous solar panels in several ways. First, the solar panel 10 is fully recyclable, unless the PV cell 12 itself is not recyclable. The solar panel 10 does not use typically non-recyclable polymer encapsulations or polyvinyl fluoride (e.g., Tedlar®) backing 88. Instead, the solar panel 10 hermetically seals the PV cell 12 with an encapsulation 14 made of a fully recyclable glass, glass-ceramic, or metal composition. The backing 88 is metal, which is easier to recycle than polyvinyl fluoride. Furthermore, the solar panel 10 uses solder 74 and conductive materials that are free of lead or other suboptimal metals.

[0093] Secondly, the solar panel 10 protects the PV cell 12 by preventing the migration of alkaline ions and moisture into it. SiO2 or SiN is disposed between (i) the top main surface of the PV cell 12 and the top section 22 of the package 14, and (ii) the bottom main surface 20 of the PV cell 12 and the bottom section 24 of the package 14. x The layer restricts the migration of alkaline ions from the encapsulation 14 to the PV cell 12. Previous polymer-based encapsulations in solar panels were insufficient to restrict alkaline ion migration. Furthermore, the described bonding method, which bonds the top segment 22 and bottom segment 24 of the encapsulation 14 together, restricts or prevents the migration of moisture from the external environment to the PV cell 12. Anodic bonding, laser bonding, and glass frit bonding can all form a seal.

[0094] Third, the solar panel 10 efficiently transfers heat from the PV cell 12 to the external environment 96. The solar panel 10 may include a thermally conductive suspension 68 between the PV cell 12 and the bottom section 24 of the encapsulation 14. The solar panel 10 may include a metal backing 88 attached to the encapsulation 14. A heat transfer fluid 90 may be disposed between the backing 88 and the encapsulation 14. A heat sink 92 may be integrated with the backing 88 (e.g., formed as a single piece by extrusion). All these measures, individually and collectively, improve heat transfer from the PV cell 12 to the external environment 96. The described heat transfer conditioning and the alkaline ion migration barrier layer enable the solar panel to have a long service life, potentially exceeding 25 years or even 30 years or longer.

[0095] The directional terms used in this article, such as up, down, right, left, front, back, top, and bottom, are for reference only with reference to the accompanying drawings and are not intended to imply absolute orientation.

[0096] Unless otherwise expressly stated, no method described herein is intended to be construed as requiring its steps to be performed in a particular order. Therefore, if a method claim does not actually describe the order in which its steps should be followed, or if the claims or description do not otherwise specifically state that the steps should be limited to a particular order, then in no way is it implied that the order should be inferred. This applies to any possible non-expressive basis of interpretation, including: logical matters relative to the arrangement of steps or operational procedures; literal meaning derived from grammatical organization or punctuation; and the number or type of embodiments described in the specification.

[0097] Unless the context explicitly specifies otherwise, as used herein, the singular forms “a,” “an,” and “the” include multiple referents. Thus, for example, unless the context explicitly indicates otherwise, the term “component” includes aspects having two or more such components.

[0098] Many variations and modifications may be made to the above embodiments of this disclosure without departing substantially from the spirit and principles thereof. All such modifications and variations are intended to be included within the scope of this disclosure and are protected by the appended claims.

Claims

1. A solar panel comprising: an array of photovoltaic (PV) cells, each of the PV cells comprising a top major surface and a bottom major surface facing away from the top major surface; and an encapsulant encapsulating the array of PV cells, the encapsulant comprising a top section and a bottom section, wherein the top major surface of each of the PV cells faces the top section and the bottom major surface of each of the PV cells faces the bottom section, and wherein the top section and the bottom section of the encapsulant are bonded together at a bond perimeter of the encapsulant to form a hermetic seal around the array of PV cells; wherein the top section of the encapsulant comprises a glass composition or a glass-ceramic composition; and wherein the bottom section of the encapsulant comprises a glass composition, a glass-ceramic composition, or a metal.

2. The solar panel of claim 1, wherein the top section consists essentially of a glass composition or a glass-ceramic composition.

3. The solar panel of claim 1, wherein the top section consists of a glass composition or a glass-ceramic composition.

4. The solar panel of claim 1, wherein the top section comprises the glass composition, and the glass composition comprises a low-iron containing soda-lime glass, a low-alkali containing glass composition, or a glass composition with mechanical advantages.

5. The solar panel of any one of claims 1 to 4, wherein the top section and the bottom section of the encapsulant are bonded together at the bond perimeter by anodic bonding.

6. The solar panel of any one of claims 1 to 4, wherein the top section and the bottom section of the encapsulant are bonded together at the bond perimeter by laser bonding.

7. The solar panel of any one of claims 1 to 4, wherein the encapsulant further comprises a bonding material bonding the top section and the bottom section of the encapsulant together at the bond perimeter.

8. The solar panel of claim 7, wherein the bonding material is a polymer.

9. The solar panel of claim 7, wherein the bonding material is a glass or a glass-ceramic.

10. The solar panel of any one of claims 1 to 9, wherein the encapsulant further comprises an intermediate section disposed between the top section and the bottom section at the bond perimeter of the encapsulant, and the top section, the intermediate section, and the bottom section are bonded together.

11. The solar panel of claim 10, wherein the top section, the intermediate section, and the bottom section are anodically bonded together.

12. The solar panel of claim 10, wherein the intermediate section exhibits a lower glass transition temperature than the top section and the bottom section.

13. The solar panel of any one of claims 1 to 12, wherein the encapsulant further comprises an anti-reflective coating disposed on a bottom surface of the top section of the encapsulant and facing the top major surface of the PV cells, and The antireflection coating comprises at least one SiO2or SiN x layer.

14. The solar panel of any one of claims 1 to 13, further comprising: An inert gas disposed between the top section and the bottom section of the encapsulant and within the bonding perimeter of the encapsulant.

15. The solar panel of any one of claims 1 to 14, wherein Each of the PV cells comprises a crystalline silicon wafer.

16. The solar panel of any one of claims 1 to 15, further comprising: SiO2or SiN x a layer disposed between the bottom major surface of the PV cell and the top surface of the bottom section of the encapsulant.

17. The solar panel of any one of claims 1 to 16, further comprising: A thermally conductive suspension disposed between a bottom major surface of each of the PV cells and the bottom section of the encapsulant; wherein the thermally conductive suspension comprises an oil, a surfactant, and an inorganic filler, the inorganic filler increasing the thermal conductivity of the thermally conductive suspension relative to the oil alone.

18. The solar panel of any one of claims 1 to 17, wherein Each PV cell is bonded to the bottom section of the encapsulant with a glass composition, a glass-ceramic composition, an anodic bond, a laser bond, or a thermally conductive bonding material.

19. The solar panel of any one of claims 1 to 18, wherein Adjacent PV cells are in electrical communication by incorporation of a solder, the solder comprises one or more electrically conductive metals, and the solder is substantially free of cadmium, lead, mercury, and hexavalent chromium.

20. The solar panel of any one of claims 1 to 18, wherein Adjacent PV cells are in electrical communication by incorporation of an electrically conductive paste, the electrically conductive paste comprises a mixture of electrically conductive metal particles and a binder material, and the electrically conductive metal particles are substantially free of cadmium, lead, mercury, and hexavalent chromium.

21. The solar panel of any one of claims 1 to 20, wherein the bottom section of the encapsulant further comprises a recess for accommodating each of the PV cells and a current collection and transmission assembly; and a top surface of the bottom section within each of the recesses for the PV cells is planar.

22. The solar panel of any one of claims 1 to 21, further comprising: a current collection and transmission assembly comprising a tabbing mesh made of a coated copper cut sheet.

23. The solar panel of any one of claims 1 to 22, further comprising: a stamped flat spring at least partially securing the PV cells within the encapsulant.

24. The solar panel of any one of claims 1 to 23, further comprising: a backing supporting the encapsulant, the backing comprising a metal sheet or a metal film.

25. The solar panel of claim 24, wherein the metal sheet or the metal film of the backing comprises aluminum having an alumina surface layer.

26. The solar panel of claim 24, wherein the backing is anodically bonded to the encapsulant.

27. The solar panel of claim 24 or 25, further comprising: a heat transfer fluid disposed between the backing and the encapsulant.

28. The solar panel of any one of claims 24 to 27, further comprising: at least one of a heat sink and a stiffener integrated with the backing.

29. The solar panel of claim 28, wherein the at least one heat sink is directly bonded to the backing.

30. The solar panel of any one of claims 1-29, wherein The bottom section of the package comprises a glass composition having a coefficient of thermal expansion in the range of 1 x 10 -6 / °C to 5 x 10 -6 / °C.

31. The solar panel of claim 30, wherein The PV cell is bonded to the encapsulant with a glass or glass-ceramic composition having a coefficient of thermal expansion in the range of 1 x 10 -6 / °C to 5 x 10 -6 / °C.

32. The solar panel of any one of claims 1-31, wherein the solar panel has an asymmetric construction, wherein the top section and the bottom section of the encapsulant have at least one of: different compositions, different compressive stress profiles, different thicknesses, and non-mirror spatial relationships relative to the array of PV cells.

33. A solar panel, comprising: an array of photovoltaic (PV) cells, each of the PV cells including a top major surface and a bottom major surface facing away from the top major surface; an encapsulant encapsulating the array of PV cells, the encapsulant including a top section and a bottom section, the top section including a glass composition, wherein the top major surface of each of the PV cells faces the top section and the bottom major surface of each of the PV cells faces the bottom section, and wherein the top section and the bottom section of the encapsulant are bonded together at a bond perimeter of the encapsulant to form a hermetic seal around the array of PV cells; SiO2or SiN x a layer disposed between the bottom major surface of the PV cell and the top surface of the bottom section of the encapsulant; and An anti-reflective coating is disposed on the bottom surface of the top section of the package and faces the top major surface of the PV cell, the anti-reflective coating comprising at least one layer of SiO2 or SiN x .

34. A solar panel, comprising: an array of photovoltaic (PV) cells, each of the PV cells including a top major surface and a bottom major surface facing away from the top major surface; an encapsulant encapsulating the array of PV cells, the encapsulant including a top section and a bottom section, the top section including a glass composition, wherein the top major surface of each of the PV cells faces the top section and the bottom major surface of each of the PV cells faces the bottom section, and wherein the top section and the bottom section of the encapsulant are bonded together at a bond perimeter of the encapsulant to form a hermetic seal around the array of PV cells; a backing supporting the encapsulant, the backing including a metal sheet or a metal film; and a heat transfer fluid disposed between the backing and the encapsulant.

35. The solar panel of claim 34, further comprising: a heat sink integrally formed with the backing by metal extrusion.

36. The solar panel of claim 34 or claim 35, further comprising: a thermally conductive suspension disposed between the bottom major surface of each of the PV cells and the bottom section of the encapsulant; wherein the thermally conductive suspension includes an oil, a surfactant, and an inorganic filler, the inorganic filler increasing thermal conductivity of the thermally conductive suspension relative to the oil alone.

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