LIGHTWEIGHT PHOTOVOLTAIC MODULE WITH A GLASS AND POLYMER FRONT LAYER

Description

TECHNICAL FIELD

[0001] The present invention relates to the field of photovoltaic modules, which comprise a set of photovoltaic cells electrically connected to each other, and preferably so-called "crystalline" photovoltaic cells, that is to say, those based on monocrystalline or multicrystalline silicon.

[0002] The invention can be implemented for numerous applications, including civil and / or military applications, for example autonomous and / or embedded applications, being particularly relevant to applications requiring the use of lightweight and rigid photovoltaic modules, especially those with a weight per unit area of ​​less than 5 kg / m², or even 6 kg / m². It can thus be applied in particular to buildings such as homes or industrial premises (tertiary, commercial, etc.), for example for roofing, for the design of street furniture, for example for public lighting, road signs or even electric vehicle charging, and can also be used for mobile applications (solar mobility), particularly for integration on vehicles such as cars, buses or boats, among others.

[0003] The invention thus proposes a lightweight photovoltaic module obtained by a stack comprising a first layer of glass and polymer forming the front face of the module, as well as a method for making such a photovoltaic module. PREVIOUS STATE OF THE ART

[0004] A photovoltaic module is an assembly of photovoltaic cells arranged side by side between a first transparent layer forming a front face of the photovoltaic module and a second layer forming a back face of the photovoltaic module.

[0005] The first layer forming the front face of the photovoltaic module is advantageously transparent to allow the photovoltaic cells to receive light. It is traditionally made of a single sheet of glass, particularly tempered glass, typically between 2 and 4 mm thick, but classically around 3 mm.

[0006] The second layer forming the back face of the photovoltaic module can be made of glass, metal or plastic, among other materials. It is often formed by a polymeric structure based on an electrically insulating polymer, for example polyethylene terephthalate (PET) or polyamide (PA), which may be protected by one or more layers based on fluorinated polymers, such as polyvinyl fluoride (PVF) or polyvinylidene fluoride (PVDF), and has a thickness of around 300 µm.

[0007] Photovoltaic cells can be electrically connected to each other by front and rear electrical contact elements, called connecting conductors, and formed for example by tinned copper strips, respectively placed against the front faces (faces facing the front face of the photovoltaic module intended to receive a light flux) and rear faces (faces facing the rear face of the photovoltaic module) of each of the photovoltaic cells, or even only on the rear face for IBC type photovoltaic cells (for "Interdigitated Back Contact" in English).

[0008] It should be noted that IBC (Interdigitated Back Contact) photovoltaic cells are structures in which the contacts are made on the back side of the cell in the form of interdigitated combs. They are described, for example, in US patent 4,478,879 A.

[0009] Furthermore, the photovoltaic cells, located between the first and second layers forming the front and back faces of the photovoltaic module respectively, can be encapsulated. Typically, the encapsulant chosen is an elastomer (or rubber) type polymer, and may, for example, consist of two layers (or films) of poly(ethylene-vinyl acetate) (EVA) between which the photovoltaic cells and the cell connecting conductors are arranged. Each encapsulant layer can be at least 0.2 mm thick and have a Young's modulus typically between 2 and 400 MPa at room temperature.

[0010] We have thus represented partially and schematically, respectively in cross-section on the figure 1 and in exploded view of the figure 2 , a classic example of a photovoltaic module 1 comprising crystalline photovoltaic cells 4.

[0011] As described previously, the photovoltaic module 1 has a front face 2, generally made of transparent tempered glass approximately 3 mm thick, and a rear face 5, for example made of a polymer sheet, opaque or transparent, single-layer or multi-layer, having a Young's modulus greater than 400 MPa at room temperature.

[0012] Between the front 2 and rear 5 faces of the photovoltaic module 1 are the photovoltaic cells 4, electrically connected to each other by connecting conductors 6 and immersed between two front 3a and rear 3b layers of encapsulating material, both forming an encapsulating assembly 3.

[0013] There Figure 1A also represents a variant implementation of the example of the figure 1 in which the photovoltaic cells 4 are of type IBC, the connecting conductors 6 being only arranged against the rear faces of the photovoltaic cells 4.

[0014] Furthermore, the figures 1 and 2 They also represent the junction box 7 of the photovoltaic module 1, designed to receive the wiring necessary for the operation of the module. Typically, this junction box 7 is made of plastic or rubber and is completely sealed.

[0015] Typically, the process for manufacturing the photovoltaic module 1 includes a step called vacuum lamination of the different layers described above, at a temperature greater than or equal to 120°C, or even 140°C, or even 150°C, and less than or equal to 170°C, typically between 145 and 165°C, and for a lamination cycle duration generally of at least 10 minutes, or even 15 minutes.

[0016] During this lamination stage, the encapsulation material layers 3a and 3b melt and come together to enclose the photovoltaic cells 4, at the same time as adhesion is created at all interfaces between the layers, namely between the front face 2 and the front layer of encapsulation material 3a, the front layer of encapsulation material 3a and the front faces 4a of the photovoltaic cells 4, the back faces 4b of the photovoltaic cells 4 and the back layer of encapsulation material 3b, and the back layer of encapsulation material 3b and the back face 5 of the photovoltaic module 1. The resulting photovoltaic module 1 is then framed, typically by means of an aluminum profile.

[0017] Such a structure has now become a standard which has significant mechanical resistance thanks to the use of a thick glass front panel and the aluminium frame, allowing it, in particular and in the majority of cases, to comply with the IEC 61215 and IEC 61730 standards.

[0018] However, such a photovoltaic module 1 according to the classical design of the prior art has the disadvantage of having a relatively high weight, in particular a weight per unit area of ​​about 10 to 12 kg / m 2< , and is therefore not suitable for certain applications for which lightness is a priority.

[0019] The considerable weight of photovoltaic module 1 stems primarily from the presence of thick glass, approximately 3 mm thick, forming the front face 2. The glass has a high density, on the order of 2.5 kg / m² / mm thickness, and from the aluminum frame. To withstand the stresses during manufacturing and for safety reasons, such as the risk of cuts, the glass is tempered. However, the industrial infrastructure for thermal tempering is designed to process glass at least 2 mm thick. Furthermore, the choice of a glass thickness of approximately 3 mm is also linked to a standardized mechanical resistance to pressure of 5.4 kPa. Ultimately, the glass alone accounts for almost 70% of the weight of photovoltaic module 1, and more than 80% when the aluminum frame surrounding it is included.

[0020] Also, in order to achieve a significant reduction in the weight of a photovoltaic module to allow its use in applications requiring lightness, for example commercial roofs, there is a need to find an alternative solution to the use of thick glass on the front face of the module.

[0021] One possibility is to replace the glass front face with plastic materials while maintaining the usual architecture and manufacturing method, with the primary goal of significantly reducing the surface weight. Thus, polymer sheets such as polycarbonate (PC), polyethylene terephthalate (PET), polymethyl methacrylate (PMMA), polyvinylidene fluoride (PVDF), ethylene tetrafluoroethylene (ETFE), ethylene chlorotrifluoroethylene (ECTFE), or fluorinated ethylene propylene (FEP) can represent an alternative to glass. However, when only the replacement of glass with such a thin polymer sheet is considered, the photovoltaic cell becomes highly vulnerable to impact, mechanical stress, and differential expansion.

[0022] An alternative is the use of composite materials, particularly reinforcements such as glass fibers, carbon fibers, or natural fibers like flax and hemp, among others. These are added to the standard encapsulant to form a polymer / fiber composite combined with a protective polymer film on the front face. The weight reduction can be significant, despite reduced transparency and uncertainty regarding performance over periods exceeding 20 years.

[0023] The elimination of glass on the front face of photovoltaic modules has been the subject of several patents or patent applications in the prior art. Examples include French patent application FR 2 955 051 A1, French patent application CN 107 994 086 A, US patent application US 2005 / 0178428 A1, and international applications WO 2008 / 019229 A2 and WO 2012 / 140585 A1. Other patents or patent applications have described the use of reinforcements alone or in composites, such as European patent application EP 2 863 443 A1, and international applications WO 2018 / 076525 A1, WO 2019 / 006764 A1, and WO 2019 / 006765 A1. DESCRIPTION OF THE INVENTION

[0024] There is therefore a need to design an alternative photovoltaic module solution intended to be lightweight in order to adapt to certain applications, while having sufficient mechanical properties to allow it to be resistant to shocks and mechanical load, and in particular to the IEC 61215 and IEC 61730 standards.

[0025] The invention therefore aims to remedy at least partially the needs mentioned above and the drawbacks related to prior art achievements.

[0026] The invention thus relates, according to one of its aspects, to a photovoltaic module obtained from a stack comprising: a first transparent layer forming the front face of the photovoltaic module, designed to receive a light flux, a plurality of photovoltaic cells arranged side by side and electrically connected to each other, an assembly encapsulating the plurality of photovoltaic cells, a second layer forming the rear face of the photovoltaic module, the encapsulating assembly and the plurality of photovoltaic cells being located between the first and second layers, characterized in that the first layer comprises: a front layer made of at least one polymer material, called a "polymer front layer", and at least one front assembly comprising an interface front layer and a glass front layer, the glass front layer having a thickness less than or equal to 2 mm, or even 700 µm, said at least one front assembly being located between the polymer front layer and the encapsulating assembly, and the interface front layer of said at least one front assembly being located between the polymer front layer and the glass front layer.

[0027] Advantageously, the invention allows the replacement of the standard thick glass, approximately 3 mm thick, typically used on the front panel of a conventional photovoltaic module, with a combination of polymer layer(s) and thin glass layer(s). Thus, the use of thin glass and polymer(s) makes it possible to achieve a low mass and transparency equivalent to a standard module. Compared to commercially available lightweight modules, the presence of thin glass in the structure provides improved resistance to impact, thermomechanical expansion, and moisture penetration.

[0028] Advantageously, the use of polymer-type encapsulation material with enhanced mechanical properties, particularly for the back layer of encapsulation material, of the encapsulating assembly can further improve shock resistance, particularly from hail, on the photovoltaic module, and protect the photovoltaic cells from possible mechanical damage.

[0029] The term "transparent" means that the first layer forming the front face of the photovoltaic module is at least partially transparent to visible light, allowing at least about 80% of this light to pass through.

[0030] In particular, the optical transparency, between 300 and 1200 nm, of the first layer forming the front face of the photovoltaic module, especially the polymer front layer, can exceed 80%. Similarly, the optical transparency, between 300 and 1200 nm, of the encapsulating assembly can exceed 90%, as can that of the interface front layer.

[0031] Furthermore, the term "encapsulating" or "encapsulated" should be understood to mean that the plurality of photovoltaic cells is arranged in a volume, for example hermetically sealed against liquids, at least partly formed by at least two layers of encapsulating material(s), joined together after lamination to form the encapsulating assembly.

[0032] Initially, before any lamination process, the encapsulating assembly consists of at least two layers of encapsulating material, called core layers, between which the plurality of photovoltaic cells is encapsulated. However, during the lamination process, the layers of encapsulating material melt to form, after lamination, a single solidified layer (or set) in which the photovoltaic cells are embedded.

[0033] Furthermore, thanks to the invention, it may be possible to obtain a new type of lightweight photovoltaic module which, through the use of thin glass, can have a surface weight of less than 6 kg / m², or even 5 kg / m², while maintaining the optical transparency of the front face and ensuring good reliability of the photovoltaic module with low thermomechanical expansion and high durability. In addition, the use of the polymer front layer and interface layer(s) protects the thin glass from impacts, particularly hail.

[0034] The photovoltaic module according to the invention may further comprise one or more of the following characteristics taken individually or in any possible technical combinations.

[0035] The front glass layer may advantageously have a thickness less than or equal to 1.5 mm, preferably between 500 µm and 1.1 mm, preferably between 500 µm and 1 mm. In a particular embodiment, the front glass layer may also have a thickness between 300 µm and 700 µm, in particular between 300 µm and 500 µm.

[0036] Furthermore, the front glass layer can advantageously be made of untempered glass. Untempered glass is glass that has not undergone any post-fabrication thermal or chemical treatment to harden it, unlike tempered glass. In other words, the glass does not undergo any thermal or chemical tempering. Indeed, untempered glass may be less resistant to impacts, particularly those from hailstones. However, when placed between protective polymer layers, especially between the polymer front layer and the interface front layer, untempered glass can be protected from impacts. Untempered glass can also provide a moisture barrier for the photovoltaic cells. Using untempered glass, rather than tempered glass, can significantly reduce costs, making the photovoltaic module adaptable to a wide range of applications.

[0037] The photovoltaic module may also include an adhesion layer, for example in the form of a film, located between the second layer and the back layer of encapsulation material. This adhesion layer promotes bonding between the second layer and the encapsulation assembly. The adhesion layer can be between 20 µm and 100 µm thick. A chemical or physical treatment, such as plasma treatment, can be used to clean the surface of the second layer to further enhance adhesion to the adhesion layer.

[0038] The second layer can be formed by a traditional backsheet. In particular, the second layer can be formed by a polymeric structure based on an electrically insulating polymer. It can specifically be made of at least one polymer material, notably chosen from: polycarbonate (PC), polymethyl methacrylate (PMMA), polyethylene terephthalate (PET), polypropylene (PP), polyamide (PA), a fluoropolymer, notably polyvinyl fluoride (PVF) or polyvinylidene fluoride (PVDF), ethylene tetrafluoroethylene (ETFE), ethylene chlorotrifluoroethylene (ECTFE), polytetrafluoroethylene (PTFE), polychlorotrifluoroethylene (PCTFE), fluorinated ethylene propylene (FEP), and / or a multilayer film comprising one or more of the aforementioned polymers, among others.

[0039] In the case of a second layer in the form of a polymer multilayer, one or more aluminum layers may be located within the multilayer, being sandwiched within it.

[0040] The choice of a second layer made of at least one polymer material may be preferred in the case where the final application of the photovoltaic module requires its superimposition on a rigid support.

[0041] Furthermore, removing the thick glass from the front of a conventional photovoltaic module can lead to a loss of mechanical strength. Therefore, to maintain a rigid module, the rear face of the module can be designed to provide sufficient mechanical rigidity.

[0042] In particular, according to one possibility, the second layer could thus comprise: a back layer forming a back panel of composite material, comprising a main underlayer, forming the core of the back panel, and two cover underlayers, each forming a plate of the back panel, arranged on either side of the core so that the core is sandwiched between the two plates, the core of the back panel having a honeycomb structure.

[0043] The use of a composite sandwich panel type back face can allow the photovoltaic module according to the invention to have very good mechanical and thermomechanical properties while maintaining a low weight.

[0044] The core of the rear panel may have a honeycomb structure, for example in the form of a honeycomb, in particular made of metal, for example aluminium, polyimide, polycarbonate (PC), polypropylene (PP) or high-performance synthetic fibres, for example of the Nomex ® type.

[0045] Alternatively, the core of the rear panel may include a honeycomb structure in the form of foam, in particular made of polyethylene terephthalate (PET), polyvinyl chloride (PVC) or polyurethane (PU).

[0046] In addition, the rear panel plates can be made of composite material, for example prepreg glass fiber / epoxy type, metal, in particular aluminium, polycarbonate (PC), polymethyl methacrylate (PMMA) or from prepregs.

[0047] The rear panel plates can, where appropriate, be covered with a single or multilayer polymer film, for example of the Tedlar ® type.

[0048] Furthermore, the rear panel may have a surface weight less than or equal to 3 kg / m², in particular less than or equal to 2 kg / m², in particular even less than or equal to 1 kg / m².

[0049] It should be noted that, rather than having a sandwich panel type back face, the second layer can still have a back layer with a honeycomb structure, without the use of covering underlayers, for example a honeycomb structure of the cellular polycarbonate type.

[0050] According to a second possibility, the second layer may consist of: a back layer made of at least one polymer material, referred to as the "polymer back layer", and at least one back assembly comprising an interface back layer and a glass back layer, the glass back layer having in particular a thickness less than or equal to 2 mm, preferably less than or equal to 1.5 mm, or even between 500 µm and 1.1 mm, or even between 500 µm and 1 mm, or even between 300 µm and 700 µm, or even between 300 µm and 500 µm, being in particular made of non-tempered glass, and having in particular dimensions strictly smaller than those of the polymer back layer and in particular the same dimensions and characteristics as those of the front glass layer, said at least one back assembly being located between the polymer back layer and the encapsulating assembly, and the interface back layer of said at least one back assembly being located between the polymer back layer and the glass back layer.

[0051] Thus, the second layer can be obtained using a principle similar to that used for the first layer. In particular, the second layer can also comprise a combination of thin glass(es) and polymer(s). The second layer may or may not be identical to the first layer.

[0052] According to a third possibility, the second layer may include a layer of fiber-based reinforcements.

[0053] A "fiber-based reinforcement layer" is defined as a layer consisting primarily of organic and / or inorganic fibers, and preferably a layer made of organic and / or inorganic fibers. Advantageously, a fiber-based reinforcement layer provides mechanical reinforcement to the stacked layers used to form the photovoltaic module. Before lamination, the fibers of a fiber-based reinforcement layer are preferably unimpregnated, particularly with a polymer material. Such a reinforcement layer may be described as fiber-reinforced, woven, or non-dry. In particular, such a reinforcement layer is neither a prepreg layer nor a composite layer.

[0054] The fiber-based reinforcement layer may contain woven or non-woven fibers. It may also have a surface weight between 20 g / m² and 1500 g / m², and preferably between 300 g / m² and 800 g / m². It may contain glass, carbon, aramid, and / or natural fibers, including hemp, flax, and / or silk, among others.

[0055] The glass used for the front glass layer and / or the back glass layer may include soda-lime glass, based on silica, calcium and sodium.

[0056] Advantageously, and applicable to any embodiment of the invention, the front glass layer may have dimensions, particularly length and width, strictly smaller than those of the front layer made of at least one polymer material and those of the second layer. Furthermore, the distance separating an edge of the front glass layer and an edge of the front layer made of at least one polymer material or an edge of the second layer may be strictly greater than 1 mm.

[0057] Advantageously, the front layer, made of at least one polymer material, and the second layer may have the same dimensions, particularly length and width. Further advantageously, all layers of the photovoltaic module, except for the glass layer(s), may have the same dimensions, particularly length and width, these dimensions then corresponding to the dimensions of the module, with the glass layer(s) being encapsulated within the module.

[0058] Thus, the front glass layer can have dimensions, in particular length and width, strictly smaller than those of the photovoltaic module, the distance separating an edge of the front glass layer and an edge of the photovoltaic module being strictly greater than 1 mm, so that the front glass layer is encapsulated within the photovoltaic module.

[0059] In particular, the front glass layer and / or the rear glass layer may have dimensions, including length and width, strictly smaller than the dimensions of the photovoltaic module obtained by stacking, including length and width.

[0060] In particular, the area of ​​a surface of the front glass layer and / or the rear glass layer, defined in a plane transverse to the stacking direction, is strictly less than the area of ​​a surface of any other layer of the stack in a plane transverse to the stacking direction, so that the front glass layer and / or the rear glass layer is encapsulated between two layers located on either side of the front glass layer and / or the rear glass layer respectively.

[0061] In particular, the distance separating an edge of the front glass layer and / or the rear glass layer and an edge of the photovoltaic module obtained from the stacking can be strictly greater than 1 mm.

[0062] In the specific case of non-tempered glass that is susceptible to breakage if its edges are impacted, having reduced dimensions helps to protect it from impacts, thanks to encapsulation including on the edges.

[0063] In addition, the distance between an edge of a front glass layer and / or a back glass layer and an edge of a photovoltaic cell and / or an edge of a bonding conductor connecting photovoltaic cells, adjacent to the edge of the front glass layer, may be between 0 and 15 mm, preferably on the order of 5 mm.

[0064] It should also be noted that the front and / or rear glass layers may consist of a single layer of glass or a multilayer glass system. If applicable, both the front and rear glass layers may be single layers of glass or multilayer glass systems, with each multilayer system potentially having a different number of layers. Alternatively, one may be a single layer of glass while the other is a multilayer glass system.

[0065] In particular, the front glass layer may have rounded edges at its corners, especially with a radius of curvature strictly greater than 1 mm, preferably strictly less than 25 mm.

[0066] Furthermore, the front and / or back glass layers may have rounded corners, specifically four rounded corners at the four corners of a square or rectangular layer. In mechanics, right angles represent stress concentrations and are therefore very fragile, especially with non-tempered glass. Rounding the corners thus reduces the stresses experienced at the corners. The radius of curvature may be strictly greater than 1 mm, preferably 5 mm. Alternatively, the radius of curvature may be strictly less than 25 mm.

[0067] Furthermore, the photovoltaic module obtained from the stack can be completely frameless, particularly in the case of aluminum. To provide mechanical rigidity at the edges and facilitate handling, the stack may include a polymer frame positioned around the entire periphery of a front glass layer and / or a rear glass layer.

[0068] Such a polymer frame can be added during the manufacture of the module, positioned in contact with a layer of glass in the same plane.

[0069] In particular, the photovoltaic module may include a polymer frame arranged all around the perimeter of the front glass layer, the polymer frame having in particular a width of between 5 mm and 50 mm, preferably between 20 mm and 40 mm.

[0070] Furthermore, the front polymer layer and / or the rear polymer layer may have a thickness between 15 µm and 300 µm, in particular between 20 µm and 50 µm.

[0071] In addition, the polymer material of the front polymer layer and / or the back polymer layer may be selected from: polycarbonate (PC), polymethyl methacrylate (PMMA), polyethylene terephthalate (PET), polyamide (PA), a fluorinated polymer, including polyvinyl fluoride (PVF) or polyvinylidene fluoride (PVDF), ethylene tetrafluoroethylene (ETFE), ethylene chlorotrifluoroethylene (ECTFE), polytetrafluoroethylene (PTFE), polychlorotrifluoroethylene (PCTFE), fluorinated ethylene propylene (FEP) and / or a multilayer film comprising one or more of the aforementioned polymers, among others.

[0072] Furthermore, the front polymer layer and / or the back polymer layer may incorporate a UV cutoff filter between 320 nm and 450 nm, which corresponds to the wavelength at which the transmission rate is 50%. This protects the underlying layers from aging caused by ultraviolet (UV) radiation and potentially from hydrolysis, thus extending the photovoltaic module's lifespan.

[0073] The front interface layer and / or the rear interface layer can allow bonding between the front polymer layer, respectively the rear polymer layer, and a glass layer, or between two glass layers.

[0074] The front interface layer and / or the back interface layer may have a thickness between 50 µm and 600 µm, preferably between 400 µm and 600 µm, or even between 400 µm and 500 µm.

[0075] The front interface layer and / or the back interface layer may have a Young's modulus between 2 and 300 MPa at 25°C, preferably between 100 and 200 MPa at 25°C, or even between 2 and 250 MPa at 25°C, or even between 10 and 50 MPa at 25°C, or even between 2 and 50 MPa at 25°C, or even between 2 and 20 MPa at 25°C.

[0076] The encapsulating assembly can be obtained by joining a front layer of encapsulating material and a rear layer of encapsulating material on either side of the photovoltaic cells, advantageously in direct contact with them, the front layer of encapsulating material being located between the first layer and the photovoltaic cells.

[0077] The front layer of encapsulation material can be formed by at least one layer comprising at least one polymer-type encapsulation material having a Young's modulus at 25°C strictly less than 50 MPa.

[0078] Furthermore, the back layer of encapsulation material can be formed by at least one layer comprising at least one polymer-type encapsulation material having a Young's modulus at 25°C strictly greater than 150 MPa.

[0079] Advantageously, the use of polymer-type encapsulation material with enhanced mechanical properties, particularly for the back layer of encapsulation material of the encapsulating assembly, can further improve shock resistance, especially from hail, on the photovoltaic module, and protect the photovoltaic cells from possible mechanical damage.

[0080] The front layer of encapsulation material may be formed by at least one layer comprising at least one polymer-type encapsulation material having a Young's modulus at 25°C strictly less than 50 MPa, in particular greater than 2 MPa and strictly less than 50 MPa, or even strictly less than 20 MPa, in particular between 10 and 20 MPa.

[0081] Furthermore, the back layer of encapsulation material may be formed by at least one layer comprising at least one polymer-type encapsulation material having a Young's modulus at 25°C strictly greater than 200 MPa, in particular strictly greater than 200 MPa and less than 500 MPa, in particular between 250 and 350 MPa.

[0082] Furthermore, the elongation at break of the front layer of encapsulating material and / or the rear layer of encapsulating material may advantageously be at least greater than 200%.

[0083] The use of a back layer of encapsulation material with a high Young's modulus can provide increased resistance to hail-type impacts.

[0084] The front layer of encapsulating material may be formed by at least one layer comprising at least one polymer-type encapsulating material selected from: poly(ethylene-vinyl acetate) (EVA), vinyl acetals, such as polyvinyl butyrals (PVB), polyurethanes, silicone elastomers, crosslinked thermoplastic polyolefin elastomers and / or crosslinked thermoplastic polyolefin (TPO) elastomers, among others.

[0085] The back layer of encapsulating material can be formed by at least one layer comprising at least one polymer-type encapsulating material selected from: acid copolymers, ionomers, polyvinyl chlorides and / or polyethylenes, among others.

[0086] In addition, the encapsulating assembly, the front interface layer and / or the possible rear interface layer may be formed by at least one layer comprising at least one polymer-type encapsulating material selected from: acid copolymers, ionomers, poly(ethylene-vinyl acetate) (EVA), vinyl acetals, such as polyvinyl butyrals (PVB), polyurethanes, polyvinyl chlorides, polyethylenes, such as linear low-density polyethylenes, polyolefin elastomer copolymers, α-olefin copolymers and α-, β-ethylenic carboxylic acid esters, such as ethylene-methyl acrylate copolymers and ethylene-butyl acrylate copolymers, silicone elastomers and / or crosslinked thermoplastic polyolefin-based elastomers, among others.

[0087] Preferably, the encapsulation material of the encapsulating assembly is identical to the material of the front interface layer and any rear interface layer. This may simplify the manufacturing process.

[0088] According to a particular embodiment, one of the front encapsulation material layers and rear encapsulation material layers of the encapsulating assembly, in particular the rear encapsulation material layer, may comprise an encapsulation material identical to that of the front interface layer, and the other of the front encapsulation material layers and rear encapsulation material layers of the encapsulating assembly, in particular the front encapsulation material layer, may comprise an encapsulation material different from that of the front interface layer.

[0089] The encapsulating assembly can have a thickness between 200 µm and 600 µm, particularly between 400 µm and 600 µm. Furthermore, the encapsulating assembly can have a Young's modulus between 2 MPa and 400 MPa at 25°C, or even between 2 MPa and 200 MPa at 25°C.

[0090] In addition, photovoltaic cells can be chosen from: homojunction or heterojunction photovoltaic cells based on monocrystalline silicon (c-Si) and / or multicrystalline silicon (mc-Si), and / or IBC type photovoltaic cells, and / or photovoltaic cells comprising at least one material from amorphous silicon (a-Si), microcrystalline silicon (µC-Si), cadmium telluride (CdTe), copper-indium selenide (CIS), copper-indium / gallium diselenide (CIGS), and perovskites, among others.

[0091] Furthermore, photovoltaic cells can have a thickness between 1 and 300 µm, particularly between 1 and 200 µm, and advantageously between 70 µm and 160 µm.

[0092] The photovoltaic module may also include a junction box, intended to receive the wiring necessary for the operation of the photovoltaic module, which can be positioned on the front or rear face of the module, preferably on the front face.

[0093] Furthermore, the spacing between two neighboring, consecutive, or adjacent photovoltaic cells can, in certain configurations, be greater than or equal to 1 mm, particularly between 1 mm and 30 mm, and preferably equal to 2 mm. In other configurations, notably the "shingle" type (as it is known in English), neighboring, consecutive, or adjacent photovoltaic cells can overlap or have a spacing of less than 1 mm.

[0094] According to a particular embodiment, the first layer may comprise: a first front assembly comprising a front interface layer and a front glass layer, the front glass layer having a thickness less than or equal to 2 mm, a second front assembly comprising a front interface layer and a front glass layer, the front glass layer having a thickness less than or equal to 2 mm, the first front assembly being located between the polymer front layer and the second front assembly, itself located between the first front assembly and the encapsulating assembly.

[0095] The thickness of the front glass layer of the first front assembly and the thickness of the front glass layer of the second front assembly may be the same or different. In particular, the thickness of the front glass layer of the first front assembly may be greater than the thickness of the front glass layer of the second front assembly.

[0096] The dimensions of the front glass layer of the first front assembly and the dimensions of the front glass layer of the second front assembly may advantageously be identical, and in particular such as those described previously for the front glass layer.

[0097] In addition, the second layer may include: a back layer made of at least one polymer material, referred to as the "polymer back layer", and a first back assembly comprising an interface back layer and a glass back layer, the glass back layer having, in particular, a thickness less than or equal to 2 mm, in particular less than or equal to 1.5 mm, or even between 500 µm and 1.1 mm, or even between 500 µm and 1 mm, or even between 300 µm and 700 µm, or even between 300 µm and 500 µm, and being made, in particular, of non-tempered glass, a second back assembly comprising an interface back layer and a glass back layer, the glass back layer having, in particular, a thickness less than or equal to 2 mm, in particular less than or equal to 1.5 mm, or even between 500 µm and 1.1 mm, or even between 500 µm and 1 mm, or even between 300 µm and 700 µm, or even between 300 µm and 500 µm,and being made in particular of non-tempered glass, said first back assembly being located between the polymer back layer and the second back assembly, itself located between the first back assembly and the encapsulating assembly.

[0098] The dimensions of the rear glass layer of the first rear assembly and the dimensions of the rear glass layer of the second rear assembly may advantageously be identical, and in particular such as those described previously for the front glass layer.

[0099] Furthermore, the invention also relates, according to another aspect, to a method for producing a photovoltaic module, in particular as defined above, from a stack comprising: a first transparent layer forming the front face of the photovoltaic module, intended to receive a light flux, a plurality of photovoltaic cells arranged side by side and electrically connected to each other, an assembly encapsulating the plurality of photovoltaic cells, a second layer, the encapsulating assembly and the plurality of photovoltaic cells being located between the first and second layers, characterized in that the first layer comprises: a front layer made of at least one polymer material, referred to as the "polymer front layer", and at least one front assembly comprising an interface front layer and a glass front layer, the glass front layer having a thickness less than or equal to 2 mm, said at least one front assembly being located between the polymer front layer and the encapsulating assembly, and the interface front layer of said at least one front assembly being located between the polymer front layer and the glass front layer, and in that the process comprises the step of hot and vacuum lamination of the constituent layers of the stack to obtain the photovoltaic module.

[0100] The hot and vacuum lamination step can in particular be carried out at a temperature greater than or equal to 120°C, or even 140°C, or even 150°C, and less than or equal to 170°C, or even 180°C, typically between 130°C and 180°C, or even between 145°C and 165°C, and for a lamination cycle duration of at least 5 minutes, or even 10 minutes, or even 15 minutes, in particular between 5 and 20 minutes.

[0101] Thus, it is possible to obtain total encapsulation of the thin glass, allowing it to be protected against impacts.

[0102] Furthermore, the invention also relates, according to another aspect, to the use of: of a photovoltaic module as defined above, in particular of the type comprising a sandwich structure on the back face, namely in which the second layer comprises a back layer forming a back panel of composite material, comprising a main sub-layer, forming the core of the back panel, and two covering sub-layers, each forming a plate of the back panel, arranged on either side of the core so that the core is sandwiched between the two plates, the core of the back panel comprising a honeycomb structure, and of a mounting support for the photovoltaic module comprising at least two support and mounting elements, in particular in the form of rails, spaced apart, and preferably extending substantially parallel to each other,characterized in that it comprises the step of positioning the photovoltaic module in contact only with said at least two support and fixing elements and of fixing the photovoltaic module.

[0103] In the case of a photovoltaic module comprising a traditional second back layer, of the "backsheet" type, the module is advantageously glued directly onto its support, for example a roof support.

[0104] The photovoltaic module and the method of implementation according to the invention may include any of the previously stated characteristics, taken in isolation or in any technically possible combinations with other characteristics. BRIEF DESCRIPTION OF THE DRAWINGS

[0105] The invention will be better understood upon reading the detailed description that follows, the non-limiting examples of its implementation, and upon examination of the schematic and partial figures in the attached drawing, on which: there figure 1 This represents, in cross-section, a classic example of a photovoltaic module comprising crystalline photovoltaic cells, Figure 1A represents a variant implementation of the example of the figure 1 in which the photovoltaic cells are of the IBC type, the figure 2 represents, in exploded view, the photovoltaic module of the figure 1 , there figure 3 illustrates, in perspective and exploded view, a first example of the realization of a photovoltaic module conforming to the invention, the figure 3A illustrates, in cross-section, an example of the back layer used for the photovoltaic module shown in the figure 3 , there figure 3Billustrates, from a top view, a mechanical test configuration, in particular a hail impact test according to IEC 61215, of a photovoltaic module conforming to the invention, the figure 3C illustrates, according to a perspective top view, an example of the use of a photovoltaic module according to the invention, the 3D figure illustrates, according to a perspective top view, another example of the use of a photovoltaic module according to the invention, the figure 4 illustrates, in perspective and exploded view, a second example of the realization of a photovoltaic module conforming to the invention, the figure 5 illustrates, in perspective and exploded view, a third example of the realization of a photovoltaic module conforming to the invention, the figure 6 illustrates, in perspective and exploded view, a fourth example of the realization of a photovoltaic module conforming to the invention, the figure 7is a partial top view of an example of a photovoltaic module illustrating the principle of a glass layer of reduced dimensions compared to those of the photovoltaic module, the figure 8 is a top view of an example of a glass layer, front and / or back, featuring rounded edges at its corners, the figure 9A is a partial top view of an example of a photovoltaic module having a glass layer with a polymer frame around its perimeter, and the figure 9B is a partial cross-sectional view of the photovoltaic module of the figure 9A .

[0106] Throughout these figures, identical references may designate identical or analogous elements.

[0107] Furthermore, the different parts represented in the figures are not necessarily shown on a uniform scale, in order to make the figures more legible. DETAILED DESCRIPTION OF SPECIFIC METHODS OF IMPLEMENTATION

[0108] THE figures 1, 1A and 2have already been described in the section relating to the prior art.

[0109] THE figures 3 to 9B allow us to illustrate four distinct embodiments of photovoltaic modules 1 conforming to the invention.

[0110] Here, we consider that the 4 photovoltaic cells, interconnected by soldered tinned copper strips, are similar to those shown in the figures 1, 1A and 2 , are “crystalline” cells, that is to say that they contain mono- or multi-crystalline silicon, and that they have a thickness between 1 and 250 µm.

[0111] In addition, the polymer front layer 2a can be a fluorinated polymer film, with a thickness of around 20 µm, in particular ethylene chlorotrifluoroethylene (ECTFE), for example of type Amcor ®< ECTFE 020.

[0112] The interface layers 2b, 2d, and 5b may include a polymer encapsulating film, for example, type A formed from a thermoplastic polyolefin (TPO) elastomer or type B formed from an ionically crosslinked thermoplastic copolymer, for example, a lonomer. The thickness may be between 500 and 600 µm. In particular, a type B polymer encapsulating film may be KuranSeal-ES® (PV8729D / UV CUT) from Kurabo, with a thickness of 500 µm.

[0113] The 2c, 2e and 5c glass layers may include a thin, untempered glass with a thickness between 500 and 800 µm, for example on the order of 550 µm.

[0114] The second layer 5 can be in the form of a single or multilayer polymer of the "backseet" type or a polymeric structure based on an electrically insulating polymer.

[0115] The second layer 5 can still be in the form of a back panel 5, a "sandwich" type structure, and can include a polypropylene honeycomb core 9a and composite skins or glass-reinforced polypropylene plates 9b, 9c with a thickness of, for example, between 6 and 10 mm, for example of the Nidapan ®< 8 GR 600 type with a thickness of 10 mm.

[0116] Of course, these choices are by no means exhaustive.

[0117] For all the stacking examples described with reference to figures 3 to 9B Tests were carried out against mechanical impacts of the hail type for energy levels of 2 J representative of the IEC 61215 certification standard. The results demonstrated that the integration of a thin non-tempered glass in the module makes it possible to obtain a reduced weight while having impact resistance in accordance with the standards in force.

[0118] In particular, in the case of a second layer 5 in the form of a rear panel 5 of the "sandwich" type, as seen on the figure 3A The mechanical shock tests were carried out following the configuration shown on the figure 3B Thus, the photovoltaic module 1, for example measuring 40 cm x 40 cm, was fixed to two 4 cm thick aluminum rails 12. This fixing was done using clamps 13. Apart from the contact surface between the photovoltaic module 1 and the aluminum rails 12, the rest of the module 1 did not rest on any other surface.

[0119] The results demonstrated the increased improvement in impact resistance, in accordance with current standards, with the use of thin, untempered glass, on the order of 700 µm, in a photovoltaic module 1 in a discontinuous installation configuration.

[0120] In order to describe the different configurations considered, we first refer to the figure 3 which illustrates, in perspective and exploded view, a first example of the realization of a photovoltaic module 1 conforming to the invention.

[0121] It should be noted that the figure 3 This corresponds to an exploded view of the photovoltaic module 1 before the lamination step of the process according to the invention. Once the lamination step has been carried out, ensuring hot and vacuum pressing, the different layers are actually in contact with each other, and in particular interpenetrated with each other.

[0122] The photovoltaic module 1, or more precisely the stack intended to form the photovoltaic module 1, thus comprises a first layer 2 forming the front face of the photovoltaic module 1 and intended to receive a light flux, a plurality of photovoltaic cells 4 arranged side by side and electrically connected to each other, an assembly 3 encapsulating the plurality of photovoltaic cells 4, and a second layer 5 forming the rear face of the photovoltaic module 1.

[0123] It should also be noted that a junction box 7 can be positioned on the front or rear face, as shown in the figures 1, 1A and 2 , of the photovoltaic module 1.

[0124] In accordance with the invention, and in a manner common to the examples of figures 3 to 6, the first layer 2 comprises a front layer made of a polymer material 2a, called "polymer front layer 2a", and a first front assembly 2b, 2c comprising an interface front layer 2b and a glass front layer, advantageously made of untempered glass 2c.

[0125] Advantageously, the front layer of 2c glass has a thickness e 2c less than or equal to 2 mm, or less than or equal to 1.5 mm, or even between 500 µm and 1.1 mm, or even between 500 µm and 1 mm, or even between 300 µm and 700 µm, or even between 300 µm and 500 µm.

[0126] In this example, the encapsulation front layer 3a, the encapsulation back layer 3b and the interface front layer 2b are all type A encapsulant films.

[0127] In all the examples described here with reference to figures 3 to 6, the invention may advantageously provide for having a back layer of encapsulation material with a Young's modulus at 25°C strictly greater than 150 MPa, in particular strictly greater than 200 MPa, preferably strictly greater than 200 MPa, or even 150 MPa, and less than 500 MPa, or even between 250 and 350 MPa.

[0128] The front layer of encapsulation material 3a may be identical to the back layer of encapsulation material 3b in one embodiment. Alternatively, it may be different, in particular with a Young's modulus at 25°C strictly less than 50 MPa, preferably greater than 2 MPa and strictly less than 50 MPa, or even between 10 and 20 MPa.

[0129] The front layer of encapsulating material 3a can be a type A encapsulant film while the rear layer of encapsulating material 3b is a type B encapsulant film. Alternatively, both the front layer 3a and the rear layer 3b can be type B encapsulant films.

[0130] By using a type B encapsulant film for the back layer of encapsulation material 3b, rather than using a type A encapsulant film, it is possible to limit or completely avoid any breakage of the glass and photovoltaic cells 4.

[0131] The second layer 5 can be formed by a traditional back face, also called a "backsheet" in English, as shown in the figure 3In particular, the second layer 5 can be formed by a polymeric structure based on an electrically insulating polymer. It can, in particular, be made of at least one polymeric material, notably selected from: polycarbonate (PC), polymethyl methacrylate (PMMA), polyethylene terephthalate (PET), polypropylene (PP), polyamide (PA), a fluoropolymer, notably polyvinyl fluoride (PVF) or polyvinylidene fluoride (PVDF), ethylene tetrafluoroethylene (ETFE), ethylene chlorotrifluoroethylene (ECTFE), polytetrafluoroethylene (PTFE), polychlorotrifluoroethylene (PCTFE), fluorinated ethylene propylene (FEP), and / or a multilayer film comprising one or more of the aforementioned polymers, among others. In the case of a second layer 5 in the form of a polymer multilayer, one or more aluminum layers may be located within the multilayer, sandwiched therein.

[0132] The second layer 5 can also be in the form of a "sandwich" type structure. The second layer 5 can, for example, be formed by a back panel 5 made of composite material, comprising a main sublayer, forming the core 9a of the back panel 5, and two covering sublayers, each forming a plate 9b, 9c of the back panel 5, arranged on either side of the core 9a so that the core 9a is sandwiched between the two plates 9b, 9c, the core 9a of the back panel 5 having a honeycomb structure 12. figure 3A represents, schematically in cross-section in more detail, such a second layer 5.

[0133] It should also be noted that, alternatively, the second layer 5 could include a layer of fiber-based reinforcements, woven or non-woven, including glass fibers, carbon fibers, aramid fibers and / or natural fibers, including hemp, flax and / or silk, among others.

[0134] The photovoltaic module 1 is obtained by means of a single hot lamination step under vacuum, for example at a temperature of about 150°C for about 15 minutes. It can have a surface weight of between 4 and 6 kg / cm², for example on the order of 6 kg / cm² in the case of a 5-layer type "backsheet" and on the order of 4 kg / cm² in the case of a 5-layer type sandwich structure.

[0135] It is also possible to use type B encapsulant films for the front encapsulation layer 3a, the back encapsulation layer 3b, and the front interface layer 2b. This further improves the shock resistance of the photovoltaic module 1 due to a higher Young's modulus.

[0136] In the case of a second layer 5 in the form of a sandwich structure, of the type of the figure 3A , THE figures 3C and 3Dillustrate two examples of usage configurations of such a photovoltaic module 1 conforming to the invention.

[0137] The use of a photovoltaic module 1 according to the invention consists of positioning the module 1 and fixing it on a fixing support M, T which comprises a plurality of support and fixing elements 12, and in particular rails 12 parallel to each other and defining spaces between them.

[0138] Thus, in the example of the figure 3C , the panel 5 of the photovoltaic module 1 is not glued directly onto the sealing membrane M, which would result in a lack of separation between the surface of the membrane M and the panel 5. On the contrary, rails 12 are positioned on the membrane M, spaced apart from each other, and the panel 5 of the photovoltaic module 1 is fixed directly and only in contact with the rails 12.

[0139] Furthermore, in the example of the 3D figureThe panel 5 of the photovoltaic module 1 is fixed to the ribs or corrugations, forming parallel and spaced rails 12, of a T-shaped roofing sheet, for example, made of steel. By means of a single contact on the rails 12 of the T-shaped sheet, contact with moisture and potential soiling is avoided, while also providing more space for positioning the panel 5. Conversely, this provides flexibility in choosing the dimensions of the panel 5 and / or the T-shaped sheet, the spacing between the surface of the T-shaped sheet and the panel 5, and hail resistance related to the principle of the invention.

[0140] The invention thus makes it possible to propose a photovoltaic module 1 and its use which are particularly suited to applications sensitive to overload, especially roofs, while maintaining separation between the panel 5 and the surface, particularly the roof. For almost flat roofs of the terrace type, as in the example of the figure 3C , or sloping roofs, as in the example of the 3D figure The invention reduces the contact between module 1 and the roof surface, thus limiting moisture penetration and freeze-thaw cycles, thereby protecting it and ensuring watertightness. The use of existing or custom-designed supports is possible.

[0141] Furthermore, the figure 4 illustrates a second example of an embodiment conforming to the invention.

[0142] In this example, unlike that of the figure 3The first layer 2 also includes a second front assembly 2d, 2e comprising a front interface layer 2d and a front glass layer, advantageously made of untempered glass 2e. The front glass layer 2e has a thickness e 2e less than or equal to 2 mm, or less than or equal to 1.5 mm, or even between 500 µm and 1.1 mm, or even between 500 µm and 1 mm, or even between 300 µm and 700 µm, or even between 300 µm and 500 µm. In other words, this embodiment involves doubling the glass thickness in the first layer 2. This results in a photovoltaic module 1 with a surface weight of 6 kg / cm². The impact resistance of the photovoltaic module 1 is further improved.

[0143] Furthermore, the first front interface layer 2b and the front 3a and rear 3b encapsulation layers are formed by type A encapsulant films, while the second front interface layer 2d is formed by a type B encapsulant film.

[0144] In the example of the figure 4 The first front layer of glass 2b and the second front layer of glass 2e have the same thickness. Alternatively, different glass thicknesses can be used, for example, a thickness of e 2b on the order of 500 µm and a thickness of e 2e on the order of 300 µm. Thus, if we consider that 800 µm of glass can meet the shock resistance requirements of cells 4, it is possible to use, for example, a 500 µm glass and a 300 µm glass.

[0145] Indeed, it is known that elastomeric materials have vibration and shock damping properties. Alternating rigid and elastomeric materials allows for modification of the propagation speed of shock waves, since the speed of a shock wave is directly proportional to the Young's modulus and Poisson's ratio of the material used. Inserting flexible elastomeric layers between layers of more rigid materials therefore slows the propagation of shock waves. Furthermore, at each interface, the shock wave can be partially transmitted and / or reflected. Repeating these alternating polymer layers with different Young's moduli thus allows for both the slowing of shock waves and the reduction of their intensity before they reach the photovoltaic cells.

[0146] Also, for an equivalent quantity of glass, it may be more advantageous to distribute this quantity between at least two layers of glass of different thicknesses instead of a single layer of glass.

[0147] Furthermore, the figure 5 This illustrates a third example of a design based on using the same encapsulation architecture on the rear panel as on the front panel, in a symmetrical manner. This allows for the creation of a lightweight, bifacial photovoltaic module.

[0148] Thus, the second layer 5 here comprises a back layer made of a polymer material 5a, called "polymer back layer 5a", and a first back assembly 5b, 5c comprising an interface back layer 5b and a glass back layer, preferably untempered 5c.

[0149] The back layer of 5c glass has a thickness e 5c of 550 µm, and the front layer of 2c glass also has a thickness e 2c of 550 µm.

[0150] The front interface layer 2b, the back interface layer 5b, the front encapsulation layers 3a and back 3b are here type B encapsulant films.

[0151] Furthermore, the figure 6 illustrates a fourth example of implementation corresponding to a variant of the example of the figure 5 in which the use of thin glass, preferably non-tempered, on the front and back faces is carried out asymmetrically.

[0152] In particular, two thin glasses, 2c and 2e, can be used on the front face with identical or different thicknesses, and a thin glass, 5c, can be used on the back face. More precisely, here, a first front layer of 2c glass has a thickness e 2c of 500 µm, a second front layer of 2e glass has a thickness e 2e of 300 µm, and a first back layer of 5c glass has a thickness e 5c of 550 µm.

[0153] Furthermore, the first front interface layer 2b, the second front interface layer 2d, the rear interface layer 5b, the front encapsulation layers 3a and rear 3b are here type B encapsulant films.

[0154] In all the examples described above, the front polymer layer 2a and the rear polymer layer 5a have a thickness e 2a , e 5a of the order of 20 µm.

[0155] The front interface layers 2b, 2d and the back interface layer 5b have a thickness e 2b , e 2d , e 5b of the order of 600 µm.

[0156] Furthermore, this was illustrated by means of the figures 7 to 9B other features of the invention applicable to all the examples previously described.

[0157] In particular, the figure 7illustrates the fact that a glass layer, for example a front glass layer and / or a rear glass layer, here the front layer 2c or 2e or the rear layer 5c, can have dimensions strictly smaller than the dimensions of the front polymer layer 2a and the second layer 5, and in particular those of the photovoltaic module 1 obtained by stacking when all the layers except the glass ones have the same dimensions, namely the same lengths and the same widths.

[0158] In particular, the length of such a glass layer is strictly less than the module length, and the width of such a glass layer is strictly less than the module width. In other words, the surface area of ​​such a glass layer, defined in a plane transverse to the stacking direction, is strictly less than the surface area of ​​any other layer in the stack in a plane transverse to the stacking direction.

[0159] Advantageously, such a glass layer is then encapsulated between two layers located on either side of it.

[0160] In the specific case of non-tempered glass that is susceptible to breakage if its edges are impacted, having reduced dimensions helps to protect it from impacts, thanks to the total encapsulation of the glass layer, including on the edges.

[0161] The dimension of the glass can be characterized by the dimension a representing the distance between the edge of the last conductive element and the edge of the glass, namely here the distance a between the edge of the cells 4 and the edge of the glass for sides B and C of the module, and between the edge of the last ribbon 6 and the edge of the glass for side A of the module, opposite the junction boxes 7. This distance a can be between 0 and 15 mm, and preferably on the order of 5 mm.

[0162] Furthermore, the distance b separating an edge of the glass layer and an edge of the front polymer layer 2a or the second layer 5, in particular of the photovoltaic module 1 when all the layers, except the glass layer, have the same dimensions, can be strictly greater than 1 mm, and this on the four edges A, B, C and D of the photovoltaic module 1.

[0163] In addition, for side D of the module where the junction boxes 7 are present, the glass layer is partially arranged under the junction boxes 7. The overlap can be between 1 and 30 mm, preferably between 1 and 10 mm.

[0164] The distance b' separating the edge of the glass layer 2c, 2e, 5c and the edge of the front polymer layer 2a or the second layer 5, in particular of the photovoltaic module 1 when all the layers, except the glass layer, have the same dimensions, can be at least 5 mm, preferably between 25 mm and 50 mm, or even on the order of 37 mm.

[0165] Furthermore, the figure 8 illustrates the possibility for a glass layer to have rounded edges at the corners, in particular four rounded edges at the four corners of a square or rectangular layer.

[0166] In mechanics, right angles represent stress concentrations and are therefore very fragile, especially with non-tempered glass. Rounding the corners can thus reduce the stresses experienced at the corners. The radius of curvature (Rc) can be strictly greater than 1 mm, preferably greater than 5 mm. Furthermore, the radius of curvature can be strictly less than 25 mm.

[0167] Furthermore, the Figures 9A and 9B illustrate the principle of adding a polymer frame to one or more layers of glass in order to give rigidity to the module, which lacks a classic aluminum frame.

[0168] Indeed, in order to provide mechanical rigidity on the edges and facilitate handling, the stack may include a CP polymer frame positioned all around the periphery of a front glass layer and / or a rear glass layer.

[0169] Such a CP polymer frame can be added during the manufacture of the module, positioned in contact with a layer of glass in the same plane.

[0170] The width d of the CP polymer frame can be between 1 mm and 30 mm, preferably between 10 mm and 25 mm, on the edges A, B and C of module 1. On the edge D on the side of the junction boxes 7, the width d of the CP polymer frame can be between 1 mm and 50 mm, preferably between 30 mm and 40 mm.

[0171] Advantageously, the thickness ep of the CP polymer frame, before the lamination process, is between 0.1 mm and 2 mm, preferably between 0.5 mm and 1 mm. The thermomechanical properties of this CP polymer frame can be identical to those of one of the encapsulation material layers, for example the back layer 3b of encapsulation material or one of the interface layers.

[0172] Of course, the invention is not limited to the examples of implementation that have just been described. Various modifications can be made to it by a person skilled in the art.

[0173] In particular, these examples of implementation can be declined according to various variants using one or more of the materials mentioned above to form the first layer 2 and the second layer 5.

Claims

1. A photovoltaic module (1) formed from a stack comprising: - a first transparent layer (2) forming the front face of the photovoltaic module (1), designed to receive a light flux, - a plurality of photovoltaic cells (4) arranged side by side and electrically connected to one another, - an assembly (3) encapsulating the plurality of photovoltaic cells (4), - a second layer (5) forming the rear face of the photovoltaic module (1), the encapsulating assembly (3) and the plurality of photovoltaic cells (4) being situated between the first (2) and second (5) layers, characterised in that the first layer (2) comprises: - a front layer made of at least one polymeric material (2a), referred to as the "polymeric front layer (2a)", and - at least one front assembly (2b, 2c; 2d, 2e) comprising a front interface layer (2b; 2d) and a front glass layer (2c; 2e), the front glass layer (2c; 2e) having a thickness (e2c ; e2e) of 2 mm or less, said at least one front assembly (2b, 2c; 2d, 2e) being situated between the front polymer layer (2a) and the encapsulating assembly (3), and the front interface layer (2b; 2d) of said at least one front assembly (2b, 2c; 2d, 2e) being situated between the front polymer layer (2a) and the front glass layer (2c; 2e), characterised in that the front glass layer (2c; 2e) has rounded edges at its corners.

2. A module according to claim 1, characterised in that the front glass layer (2c; 2e) has dimensions strictly smaller than those of the front layer made of at least one polymeric material (2a) and those of the second layer (5), the distance (b, b') between an edge of the front glass layer (2c; 2e) and an edge of the front layer (2a) made of at least one polymeric material or an edge of the second layer (5) being strictly greater than 1 mm3. A module according to claim 1 or 2, characterised in that the front glass layer (2c; 2e) is made of non-tempered glass.

4. A module according to one of the preceding claims, characterised in that the distance (a) between an edge of the front glass layer (2c; 2e) and an edge of a photovoltaic cell (4) and / or an edge of a connecting conductor (6) connecting photovoltaic cells (4), adjacent to the edge of the front glass layer (2c; 2e), is between 0 and 15 mm, preferably in the region of 5 mm.

5. A module according to any one of the preceding claims, characterised in that it comprises a polymer frame (CP) arranged all around the periphery of the front glass layer (2c; 2e), the polymer frame (CP) having, in particular, a width (d, d') of between 5 mm and 50 mm, preferably between 20 mm and 40 mm.

6. A module according to any one of the preceding claims, characterised in that the front glass layer (2c; 2e) has rounded edges at its corners with a radius of curvature (Rc) strictly greater than 1 mm, preferably strictly less than 25 mm.

7. A module according to any one of the preceding claims, characterised in that the front glass layer (2c; 2e) has a thickness (e2c ; e2e ) of less than or equal to 1.5 mm, in particular between 500 µm and 1.1 mm, in particular further between 500 µm and 1 mm, in particular further between 300 µm and 700 µm, in particular further between 300 µm and 500 µm.

8. A module according to any one of the preceding claims, characterised in that the second layer (5) is formed by a polymeric structure based on an electrically insulating polymer.

9. A module according to any one of the preceding claims, characterised in that the second layer (5) comprises: - a rear layer forming a rear panel (5) made of composite material, comprising a main sub-layer, forming the core (9a) of the rear panel (5), and two covering sub-layers, each forming a plate (9b, 9c) of the rear panel (5), arranged on either side of the core (9a) so that the core (9a) is sandwiched between the two plates (9b, 9c), the core (9a) of the rear panel (5) comprising a honeycomb structure (12).

10. A module according to any one of claims 1 to 7, characterised in that the second layer (5) comprises: - a rear layer made of at least one polymeric material (5a), referred to as the "polymeric rear layer (5a)", and - at least one rear assembly (5b, 5c) comprising a rear interface layer (5b) and a rear glass layer (5c), the rear glass layer (5c) having, in particular, a thickness (e5c) of 2 mm or less, in particular 1.5 mm or less, in particular between 500 µm and 1.1 mm, in particular between 500 µm and 1 mm, in particular further between 300 µm and 700 µm, in particular further between 300 µm and 500 µm, being in particular made of non-tempered glass, and having in particular dimensions strictly smaller than those of the polymeric rear layer (5a) and in particular the same dimensions and characteristics as those of the front glass layer (2c), said at least one rear assembly (5b, 5c) being situated between the polymer rear layer (5a) and the encapsulating assembly (3), and the rear interface layer (5b) of said at least one rear assembly (5b, 5c) being situated between the polymer rear layer (5a) and the glass rear layer (5c).

11. A module according to any one of claims 1 to 7, characterised in that the second layer (5) comprises a reinforcing layer based on fibres, in particular glass fibres, carbon fibres, aramid fibres and / or natural fibres, in particular hemp, flax and / or silk.

12. A module according to any one of the preceding claims, characterised in that the front polymer layer (2a) and / or the rear polymer layer (5a) have a thickness (e2a, e5a) of between 15 µm and 300 µm, in particular between 20 µm and 50 µm.

13. A module according to any one of the preceding claims, characterised in that the front interface layer (2b; 2d) and / or the rear interface layer (5b) have a thickness (e2b , e2d ; e5b ) of between 50 µm and 600 µm, in particular between 400 µm and 600 µm, in particular between 400 µm and 500 µm.

14. A module according to any one of the preceding claims, characterised in that the polymeric material of the front polymeric layer (2a) and / or the rear polymeric layer (5a) is selected from: polycarbonate (PC), polymethyl methacrylate (PMMA), polyethylene terephthalate (PET), polyamide (PA), a fluorinated polymer, in particular polyvinyl fluoride (PVF) or polyvinylidene fluoride (PVDF), ethylene tetrafluoroethylene (ETFE), ethylene chlorotrifluoroethylene (ECTFE), polytetrafluoroethylene (PTFE), polychlorotrifluoroethylene (PCTFE), fluorinated ethylene propylene (FEP) and / or a multilayer film comprising one or more of the aforementioned polymers.

15. A module according to any one of the preceding claims, characterised in that the encapsulating assembly (3), the front interface layer (2b; 2d) and / or the optional rear interface layer (5b) are formed by at least one layer comprising at least one polymeric encapsulation material selected from: acid copolymers, ionomers, poly(ethylene-vinyl acetate) (EVA), vinyl acetals, such as polyvinyl butyrals (PVB), polyurethanes, polyvinyl chlorides, polyethylenes, such as linear low-density polyethylenes, elastomeric polyolefin copolymers, copolymers of α-olefins and ethylene-based α-, β-carboxylic acid esters, such as ethylene-methyl acrylate copolymers and ethylene-butyl acrylate copolymers, silicone elastomers and / or elastomers based on cross-linked thermoplastic polyolefin.

16. A module according to any of the preceding claims, characterised in that the first layer (2) comprises: - a first front assembly (2b, 2c) comprising a front interface layer (2b) and a front glass layer (2c), the front glass layer (2c) having a thickness (e2c) of 2 mm or less, - a second front assembly (2d, 2e) comprising a front interface layer (2d) and a front glass layer (2e), the front glass layer (2e) having a thickness (e2e ) of 2 mm or less, the first front assembly (2b, 2c) being situated between the front polymer layer (2a) and the second front assembly (2d, 2e), which is itself situated between the first front assembly (2b, 2c) and the encapsulating assembly (3).

17. A module according to claim 16, characterised in that the thickness (e2c ) of the front glass layer (2c) of the first front assembly (2b, 2c) and the thickness (e2e ) of the front glass layer (2e) of the second front assembly (2d, 2e) are different.

18. A module according to claim 17, characterised in that the thickness (e2c ) of the front glass layer (2c) of the first front assembly (2b, 2c) is greater than the thickness (e2e ) of the front glass layer (2e) of the second front assembly (2d, 2e).

19. A module according to any one of the preceding claims, characterised in that the second layer (5) comprises: - a rear layer made of at least one polymeric material (5a), referred to as the "polymeric rear layer (5a)", and - a first rear assembly (5b, 5c) comprising a rear interface layer (5b) and a rear glass layer (5c), the rear glass layer (5c) having, in particular, a thickness (e5c ) of 2 mm or less, in particular 1.5 mm or less, in particular between 500 µm and 1.1 mm, in particular further between 500 µm and 1 mm, in particular further between 300 µm and 700 µm, in particular further between 300 µm and 500 µm, and being in particular made of non-tempered glass, - a second rear assembly comprising a rear interface layer and a rear glass layer, the rear glass layer having, in particular, a thickness of 2 mm or less, in particular 1.5 mm or less, in particular between 500 µm and 1.1 mm, in particular between 500 µm and 1 mm, in particular between 300 µm and 700 µm, in particular between 300 µm and 500 µm, and being in particular made of non-tempered glass, said first rear assembly (5b, 5c) being situated between the polymeric rear layer (5a) and the second rear assembly, which is itself situated between the first rear assembly (5b, 5c) and the encapsulating assembly (3).

20. A method of manufacturing a photovoltaic module (1) according to any one of the preceding claims, from a stack comprising: - a first transparent layer (2) forming the front face of the photovoltaic module (1), intended to receive a light flux, - a plurality of photovoltaic cells (4) arranged side by side and electrically connected to one another, - an encapsulating assembly (3) for the plurality of photovoltaic cells (4), - a second layer (5), the encapsulating assembly (3) and the plurality of photovoltaic cells (4) being situated between the first (2) and second (5) layers, characterised in that the first layer (2) comprises: - a front layer made of at least one polymeric material (2a), referred to as the "polymeric front layer (2a)", and - at least one front assembly (2b, 2c; 2d, 2e) comprising a front interface layer (2b; 2d) and a front glass layer (2c; 2e), the front glass layer (2c; 2e) having a thickness (e2c ; e2e ) of 2 mm or less, said at least one front assembly (2b, 2c; 2d, 2e) being situated between the front polymer layer (2a) and the encapsulating assembly (3), and the front interface layer (2b; 2d) of said at least one front assembly (2b, 2c; 2d, 2e) being situated between the front polymer layer (2a) and the front glass layer (2c; 2e), characterised in that the front glass layer (2c; 2e) has rounded edges at its corners.