Photovoltaic module with a recessed space incorporating a bypass diode

Abstract

The invention relates to a photovoltaic module, to a structural assembly, and to a method for producing such a module, this module comprising: - a photovoltaic assembly; - a recessed space (13); - two bypass conductors (10) connected to the two polarities of the photovoltaic assembly, extending longitudinally between the first-face wall (7) and the second-face wall (8), and opening into the recessed space (13), each with a connection surface (16) extending in the recessed space (13); - a bypass diode (6) arranged in the recessed space (13) and connected to the connection surface (16) of each bypass conductor (10); - a sealing coating (18) enveloping the bypass diode (6) and the two bypass conductors (10), this sealing coating (18) being contained within the thickness of the photovoltaic module as defined by the first-face wall (7) and the second-face wall (8).

Description

[0001] DESCRIPTION

[0002] Title: Photovoltaic module with offset space integrating a bypass diode

[0003] TECHNICAL FIELD

[0004] The invention relates to the field of photovoltaic energy. It relates more particularly to a photovoltaic module with an integrated bypass diode, intended particularly for applications in which the photovoltaic modules are integrated within fixed or mobile structures such as, in particular, motor vehicles.

[0005] PRIOR ART

[0006] Common photovoltaic modules, such as solar panels available on the market, are composed of several photovoltaic cells. When one or more photovoltaic cells of a module are located in a shaded area, while the other cells are illuminated by the sun, these photovoltaic cells can then be crossed by a reverse current, heat up, or even be destroyed. It is therefore necessary to protect the photovoltaic cells in the event of partial shading of a photovoltaic module.

[0007] A known solution to the problems of partial shading of photovoltaic modules consists of integrating bypass diodes (also called bypass diodes, bypass diodes, bypass diodes, bypass diodes, or bridging diodes in French) into the junction box attached to the module and which already contains the module's connectors. The photovoltaic modules are then arranged in a plurality of cell sub-assemblies connected in series. A bypass diode is present in the junction box for each of these cell sub-assemblies, and makes it possible to close the circuit by disconnecting the sub-assembly in which certain photovoltaic cells are subject to shading.

[0008] Furthermore, numerous solutions for integrating bypass diodes directly into photovoltaic modules exist in the prior art. In particular, patent applications EP1676323, EP2264782, and WO2011 / 035553 describe solutions of this type. However, the solutions of the prior art generally result in an excess thickness of one of the faces of the photovoltaic module, or lateral prominences, and degrade the reliability of assembly by the presence of boxes and connectors, which makes them unsuitable for integration into structural applications, i.e. applications where the photovoltaic module is integrated within structures such as an automobile body.

[0009] STATEMENT OF THE INVENTION

[0010] The invention aims to improve the photovoltaic modules of the prior art.

[0011] To this end, the invention relates to a photovoltaic module comprising:

[0012] - a photovoltaic assembly comprising at least one photovoltaic cell, arranged between a first-face wall and a second-face wall, and comprising two polarities;

[0013] - a setback space formed by a withdrawal, in the direction of the photovoltaic assembly, of an edge of the second-face wall relative to an edge of the first-face wall;

[0014] - two bypass conductors which: are connected to the two polarities of the photovoltaic assembly; extend longitudinally between the first-face wall and the second-face wall; open into the offset space; and each comprise a connection surface extending into the offset space;

[0015] - a bypass diode arranged in the breakaway space and connected to the connection surface of each bypass conductor;

[0016] - a sealing coating surrounding the bypass diode and the two bypass conductors, this sealing coating being contained in the thickness of the photovoltaic module defined by the first-face wall and the second-face wall.

[0017] According to another object, the invention relates to a structural assembly comprising such a photovoltaic module and a frame, and of which:

[0018] - the frame has a support surface; - the photovoltaic module is mounted on this support surface so that the first-sided wall is flush with the frame.

[0019] According to another object, the invention relates to a method of production by hot pressing of a photovoltaic module as described previously, comprising:

[0020] - a step of positioning the first face wall and the photovoltaic assembly arranged between two films of encapsulating material, as well as the bypass conductors;

[0021] - a step of positioning the second-sided wall, with said withdrawal forming the offset space;

[0022] - a step of electrical connection of the connection surfaces of the bypass diode with the bypass conductors;

[0023] - a step of laying the sealing coating.

[0024] According to one embodiment, the first face wall and the second face wall correspond to the front face wall and the rear face wall, which respectively designate the wall which is intended to receive the light radiation, and the wall which is opposite it.

[0025] The longitudinal direction is the direction in which the front and rear face walls extend, and the transverse direction is the direction normal to these walls.

[0026] The invention is particularly suitable for the integration of photovoltaic modules for civil and military applications, autonomous and / or on-board, in particular photovoltaic modules whose shape is influenced by its structural or facing function. The invention makes it possible to produce a photovoltaic module constituting a functional part (in addition to its photovoltaic function) responding to issues of integration, mechanical strength, and robustness, and is particularly suitable for solar roofs for vehicles.

[0027] The invention allows great freedom of integration of components on the periphery of the photovoltaic module.

[0028] The photovoltaic modules according to the invention allow integration within vehicles, or any other structure, without requiring any volume dedicated to the management of peripheral protections for the modules, such as bypass diode protection. Standardized photovoltaic modules, corresponding to simple predetermined locations, can thus be intended for calibrated mounting on structures.

[0029] According to the invention, no additional part or external element is necessary for the photovoltaic module, other than its external connection which is the only one to protrude from the photovoltaic module.

[0030] The photovoltaic module according to the invention may include the following additional characteristics, alone or in combination:

[0031] - the photovoltaic assembly is embedded in at least one layer of encapsulating material, the bypass conductors being, at least partially, in this layer of encapsulating material;

[0032] - the encapsulating material stops at the level of said edge of the second-face wall, outside the detachment space, the sealing coating being in contact with the first-face wall;

[0033] - the encapsulating material extends into the offset space, along the first face wall;

[0034] - the sealing coating is in contact with the encapsulating material in the detachment space;

[0035] - the sealing coating is entirely made of the encapsulating material;

[0036] - a is greater than b, the ratio a / b is approximately between 2 and 4, and

[0037] , Amin being the minimum longitudinal distance between said edge of the second face wall and said edge of the first face wall, a being the transverse distance between the inner face of the first face wall and the inner face of the second face wall, b being the thickness (in the transverse direction) of the bypass diode and the bypass conductors, I being the width (in the longitudinal direction) of the bypass diode;

[0038] - the sealing coating has a section connecting said edge of the second-face wall to said edge of the first-face wall; - the photovoltaic module comprises a spacer placed in the sealing coating, between the bypass diode and the boundaries of the sealing coating;

[0039] - the photovoltaic module comprises a dielectric film covering the sealing coating, between said edge of the second-face wall and said edge of the first-face wall;

[0040] - the first face wall is a front face wall, and the second face wall is a rear face wall.

[0041] The structural assembly according to the invention may include the following additional characteristics, alone or in combination:

[0042] - the first face wall comprises a cantilevered portion extending longitudinally beyond the sealing coating, the photovoltaic module being mounted on the support surface of the frame by this cantilevered portion;

[0043] - said cantilevered portion is mounted on the support surface of the chassis by means of a seal;

[0044] - the second-sided wall comprises a support portion, the photovoltaic module being mounted on the support surface of the frame by this support portion, the sealing coating being pressed onto the frame by means of a seal.

[0045] The method according to the invention may include the following additional characteristics, alone or in combination:

[0046] - a hot pressing step is carried out after the step of positioning the second-sided wall, the step of applying the sealing coating being carried out after this hot pressing step;

[0047] - the step of positioning the first-face wall includes the placement of additional portions of encapsulating material, and a hot-pressing step is carried out after the step of positioning the second-face wall, the step of applying the sealing coating being carried out simultaneously with this hot-pressing step, the encapsulating material also constituting the sealing coating. PRESENTATION OF THE FIGURES

[0048] Other characteristics and advantages of the invention will emerge from the non-limiting description which follows, with reference to the appended drawings in which:

[0049] - figure 1 is a top view of a photovoltaic module according to the invention;

[0050] - figure 2 illustrates the arrangement of the photovoltaic cells within the photovoltaic module of figure 1;

[0051] - figure 3 is a view along section III-III of figure 1;

[0052] - figure 4 is a detailed view of one of the side edges of the photovoltaic module, for a first embodiment of the photovoltaic module;

[0053] - Figure 5A and Figure 5B are top and side views respectively of an example of a bypass diode of the photovoltaic module;

[0054] - figure 6 is a view similar to figure 4 for a second embodiment of the photovoltaic module;

[0055] - figure 7 is a view similar to figure 4 for a third embodiment of the photovoltaic module;

[0056] - figure 8 is a top view of the front face wall of the photovoltaic module;

[0057] - figure 9 is a top view of the rear face wall of the photovoltaic module;

[0058] - figure 10 is a view of the superimposed front and rear face walls;

[0059] - figure 11, figure 12 and figure 13 illustrate a first embodiment of the method according to the invention;

[0060] - Figure 14, Figure 15 and Figure 16 illustrate a second embodiment of the method according to the invention; - Figure 17, Figure 18 and Figure 19 illustrate a third embodiment of the method according to the invention;

[0061] - figure 20, figure 21 and figure 22 illustrate a fourth embodiment of the method according to the invention;

[0062] - figure 23 illustrates a variant of the fourth embodiment of the method according to the invention;

[0063] - figure 24 illustrates a first embodiment of a structural assembly according to the invention;

[0064] - figure 25 illustrates a second embodiment of a structural assembly according to the invention;

[0065] - figure 26 illustrates the detachment space of the photovoltaic modules according to the invention.

[0066] Elements similar and common to the various embodiments bear the same reference numbers in the figures.

[0067] DETAILED DESCRIPTION

[0068] Figure 1 represents a photovoltaic module 1 according to the invention, seen from above, for an example of an automotive application for which the invention is particularly suitable. This example concerns a vehicle solar roof. The photovoltaic module largely constitutes the roof of a motor vehicle, electric or hybrid, and this photovoltaic module 1 is suitable for partially recharging the vehicle's batteries.

[0069] The photovoltaic module 1 comprises, in this example, a photovoltaic zone 2 and a panoramic zone 3 which will be devoid of photovoltaic elements to form a possibly transparent glazed roof.

[0070] Figure 2 schematically illustrates the skeleton of photovoltaic cells which will be included in photovoltaic zone 2 of module 1.

[0071] These photovoltaic cells can be arranged in any known configuration, in one or more strings. Seven strings 4 of photovoltaic cells are in this example connected in series and the photovoltaic module 1 has a single connector 5 for connecting the complete solar roof to the vehicle's electrical network. This connector 5, here conforming to automotive requirements, is the only protruding connection of the photovoltaic module 1, the bypass functions of the photovoltaic cells 4 being provided in portions internal to the photovoltaic module 1.

[0072] In the remainder of the description and in the drawings, reference 4 identifies both a string of photovoltaic cells and a single photovoltaic cell in this string.

[0073] The photovoltaic cells 4 are, for example, homo- or heterojunction solar cells based on monocrystalline silicon (c-Si) and / or multicrystalline silicon (mc-Si), or IBC, or are thin-film solar cells comprising one or more materials chosen from the group consisting of amorphous silicon (a-Si), microcrystalline silicon (pC-Si), perovskite, cadmium telluride (CdTe), copper-indium selenide (CIS), copper indium / gallium diselenide (CIGS). Cells based on crystalline silicon are preferably used. They generally have a thickness of between a few micrometers and 250 pm. The spacing between neighboring photovoltaic cells may, in this application, be of the order of -1 mm to 1 mm, or more (in the case of strings of photovoltaic cells of the "shingle" or "paving" type, where the cells of the same string overlap slightly, the spacing between the photovoltaic cells is negative).

[0074] Figure 2 functionally illustrates the bypass diodes 6 each connected to a photovoltaic assembly. The concept of photovoltaic assembly here designates a group of photovoltaic cells 4 for which a single bypass diode provides the bypass function. The photovoltaic assembly therefore consists of at least a single photovoltaic cell 4 and can comprise as many photovoltaic cells as desired, subject to suitable sizing of the bypass diode, it being understood that photovoltaic assemblies with a single photovoltaic cell 4 allow better protection against partial shading insofar as each cell has an individual bypass function.

[0075] Figure 3 is a view along section III-III of Figure 1 and illustrates the curved profile specific to this example of automotive application. Photovoltaic modules intended for structural assemblies thus generally have specific shape characteristics, limiting the possible manufacturing processes and their arrangement possibilities.

[0076] The photovoltaic module 1 comprises a first-face wall (which is, in the present example, a front-face wall 7) facing the outside of the vehicle and a second-face wall (which is, in the present example, a rear-face wall 8) facing the inside of the vehicle, as well as a middle zone 9 receiving the photovoltaic cells 4.

[0077] The front face wall 7 may be made of glass, as may the rear face wall 8, and the photovoltaic module 1 is devoid of a frame, made of aluminum or otherwise, for its direct integration as a structural part of the vehicle, which the invention allows. The front face wall 7 and the rear face wall 8 may be of the same material as in this example, or be made of two different materials. In this application, the two walls 7, 8 are preferably made of thin glass (soda-lime or another chemistry, tempered or not) with a thickness of less than 10 mm and preferably less than 3 mm. Alternatively, a suitable polymer or a composite, for example based on glass fibers, may be used.

[0078] Figure 4 is an enlarged view of Figure 3, of one edge of the photovoltaic module according to Box IV. In Figure 4, the photovoltaic module is illustrated as being planar, to simplify the figure.

[0079] In Figure 4, a photovoltaic assembly comprising one or more photovoltaic cells 4 also comprises two bypass conductors 10 which connect the polarities of the photovoltaic assembly to a bypass diode 6 (only one conductor 10 being visible in this sectional view).

[0080] The bypass conductors 10 are for example made of copper strips. The bypass conductors 10 each have a connection surface 16 on which the electrical connection is made with an electrode of the bypass diode 6. The bypass diode 6 is electrically connected to the connection surface 16 of the bypass conductors 10, for example by soldering or any other suitable means. The photovoltaic cells 4 are embedded in at least one layer of encapsulating material 12 located in the middle zone, which has a thickness of the order of 20 to 2,000 μm. This material is for example a crosslinked EVA elastomer, an elastomer based on crosslinked thermoplastic polyolefin (POR), a thermoplastic elastomer (polyolefin TPO, silicone, thermoplastic polyurethane, polyvinyl butyral PVB, functional polyolefin), or even an “ionically crosslinked” thermoplastic copolymer (lonomer). A combination of the previously mentioned materials can be considered.

[0081] The photovoltaic module further comprises a setback space 13 which is defined by a withdrawal, in the direction of the photovoltaic cells 4, of an edge 14 of the rear face wall 8 relative to an edge 15 of the front face wall 7.

[0082] The two bypass conductors 10 connecting the photovoltaic assembly (here consisting of a single photovoltaic cell 4) extend longitudinally between the front face wall 7 and the rear face wall 8 and open into the offset space 13.

[0083] The bypass conductors 10 further extend longitudinally in the breakaway space 13, and the connection surface 16, intended for the electrical connection with the bypass diode 6, is positioned in this breakaway space 13.

[0084] Figure 4 illustrates here a first embodiment of the photovoltaic module, in which the layer of encapsulating material 12 is stopped laterally at the level of the rim 14, and the detachment space 13 is only occupied by a sealing coating 18 which envelops the bypass diode 6 and the bypass conductors 10.

[0085] The sealing coating 18 is preferably made of one of the following dielectric materials: polyurethane, silicones, epoxy, acrylate.

[0086] According to this first embodiment, the sealing coating 18 has a triangular section, two sides of which are respectively adjacent to the front face wall 7, to the rim 14 of the rear face wall 8, and one side 19 of which extends directly between the rim 14 and the rim 15. The dimensions A, a, b, and I indicated in FIG. 4 correspond to the following dimensions:

[0087] - A: longitudinal distance between the edge 14 of the rear face wall 8 and the edge 15 of the front face wall 7;

[0088] - a: transverse distance between the internal face of the front face wall 7 and the internal face of the rear face wall 8, i.e. the thickness (in the transverse direction) of the rear face wall 8 plus the thickness of the middle layer consisting of the photovoltaic cell 4 and the encapsulating material 12. In this example, this value is of the order of 2.5 mm;

[0089] - b: thickness (in the transverse direction) of the bypass diode 6 and the bypass conductor 10;

[0090] - I: width (in the longitudinal direction) of the bypass diode 6. In the present example, this value is 5.7 mm.

[0091] The dimensions A, a, b, and I allow optimal sizing of the offset space 13 from the point of view of dielectric and mechanical strength. In the present example, since these are dimensions compatible with a photovoltaic module 1 for integration into a motor vehicle, these dimensions meet the following requirements:

[0092] - a > b ;

[0093] - the ratio a / b is approximately between 2 and 4, and preferably around 2 or 3.

[0094] Furthermore, the minimum value of A (Amin) is:

[0095] In this example, A is greater than or equal to 10 mm.

[0096] Figures 5A and 5B illustrate a bypass diode suitable for this type of application, with a central housing 20 and two connection strips 21 adapted to form the connection surfaces 16, and which will each be soldered onto a bypass conductor 10.

[0097] Figure 6 illustrates a second embodiment of the photovoltaic module in which the sealing coating 18 surrounding the bypass diode 6 and the bypass conductors 10, in the detachment space 13, is made directly from the encapsulating material of the encapsulating material layer 12.

[0098] Figure 7 illustrates a third embodiment of the photovoltaic module, particularly suitable for modules whose insulation class requires reinforced protection. In this third embodiment, the elements are arranged as in the previous embodiments except that a spacer 22 is placed between the bypass diode 6 and the boundaries of the sealing coating 18.

[0099] In this example, the spacer 22 is made up of a rod whose section can be of the order of 2 to 3 mm on each side by 2 to 3 mm on each side, which is suitable for a photovoltaic module of pollution degree 2, with class II insulation.

[0100] The photovoltaic module 1 further comprises a dielectric film 23 covering the sealing coating 18. This film 23 preferably has a thickness of 15 to 300 μm and is made from a polymer such as: ECTFE, FEP, ETFE, PVDF, PMMA, PC, PET, PE, PP, or even a multilayer film with these polymers.

[0101] Preferably, the film 23 has a minimum thickness of 30 μm and complies with the IEC 61730-2 standard.

[0102] This third embodiment can be implemented with a sealing coating 18 conforming to either of the first and second embodiments.

[0103] Figures 8 to 10 illustrate an example of positioning of the offset spaces 13 on the top view of the photovoltaic module 1. Figure 8 illustrates the outline of the front face wall 7. Figure 9 illustrates the rear face wall 8 alone and makes visible the recesses of the rear face wall 8, on the outline of the latter, each of these recesses allowing the formation of the offset spaces 13.

[0104] Figure 10 illustrates the superimposed front face 7 and rear face 8 walls with the offset spaces 13 thus formed, in dotted lines, each of these offset spaces 13 receiving a bypass diode 6. The bypass diodes 6 are thus integrated as much in the thickness of the photovoltaic module 1, without any element projecting from this thickness, as on the external contour of the photovoltaic module 1, which corresponds precisely to the contour of the front face wall 7, without an added frame.

[0105] The method for producing a photovoltaic module according to the invention will now be described. The photovoltaic modules 1 are produced here by hot pressing the different layers (for example by hot lamination). A single hot pressing step is necessary, for example at a temperature between 130°C and 180°C, preferably around 150°C, for a duration between 5 and 20 min, preferably 10 min. This assembly can also be carried out by other suitable means, such as by autoclave, or a combination of methods. In the case of lamination, this duration can be up to 30 min. In the case of an autoclave process, a duration of 2 to 3 h in a pressurized oven is suitable.

[0106] Figures 11 to 23 also illustrate the photovoltaic module in planar form to simplify the figures.

[0107] Figure 11 illustrates a first step in which the front face wall 7 is positioned with the photovoltaic cells 4 and their bypass conductors 10 taken between two films of encapsulating material 12.

[0108] Figure 12 illustrates the next step in which the rear face wall 8, with its recess of the flange 14 relative to the flange 15, is positioned on the assembly, and the single hot pressing step then takes place.

[0109] Figure 13 illustrates the next step of soldering (or gluing, or any other suitable electrical connection method) the bypass diode 6 to the bypass conductors 10, then applying the sealing coating 18 so as to completely envelop the bypass diode 6 and the two bypass conductors 10.

[0110] Figures 14 to 16 illustrate a second embodiment of the method.

[0111] Figure 14 illustrates a first step in which the front face wall 7 is positioned with the photovoltaic cells 4 and their bypass conductors 10 caught between two films of encapsulating material 12. Figure 15 illustrates the next step in which the rear face wall 8, with its removal of the rim 14 relative to the rim 15, is positioned on the assembly, then the bypass diode 6 is soldered onto the bypass conductors 10 (or simply deposited, the soldering being able to take place with the hot pressing step), then the single hot pressing step takes place.

[0112] Figure 16 illustrates the next step of applying the sealing coating 18 so as to completely envelop the bypass diode 6 and the two bypass conductors 10.

[0113] Figures 17 to 19 illustrate a third embodiment of the method.

[0114] Figure 17 illustrates a first step in which the front face wall 7 is positioned with the photovoltaic cells 4 and their bypass conductors 10 caught between two films of encapsulating material 12. The film of encapsulating material which is against the front face wall 7 extends over the entire surface of this wall, even in the area of ​​the offset space 13.

[0115] Figure 18 illustrates the next step in which the rear face wall 8, with its recess of the flange 14 relative to the flange 15, is positioned on the assembly, then the bypass diode 6 is soldered onto the bypass conductors 10 (or simply deposited, the soldering can take place with the hot pressing step), and then the single hot pressing step takes place.

[0116] Figure 19 illustrates the next step of applying the sealing coating 18 so as to completely envelop the bypass diode 6 and the top of the bypass conductors 10, the bottom being already coated by the encapsulating material 12.

[0117] Figures 20 to 22 illustrate a fourth embodiment of the method.

[0118] Figure 20 illustrates a first step in which the front face wall 7 is positioned with the photovoltaic cells 4 and their bypass conductors 10 caught between two films of encapsulating material 12. The film of encapsulating material which is against the front face wall 7 extends over the entire surface of this wall, even in the area of ​​the step-out space 13. Figure 21 illustrates the next step in which the rear face wall 8, with its withdrawal of the rim 14 relative to the rim 15, is positioned on the assembly, then the bypass diode 6 is soldered onto the bypass conductors 10 (or simply deposited, the soldering being able to take place with the hot pressing step), then additional portions 24 of encapsulating material 12 are positioned around the bypass diode 6.

[0119] Figure 22 illustrates the next hot pressing step, in which the encapsulating material spreads entirely into the middle zone of the module, as well as into the step space 13, to form the sealing coating 18.

[0120] Figure 23 illustrates a variant of the steps of figures 21 and 22, in which a larger quantity of encapsulating material is placed in the detachment space 13. These additional portions 24 of encapsulating material 12 in greater quantity result in the illustration of figure 23, for which the sealing coating 18 has a protruding shape compared to the triangular profiles presented previously, while remaining within the perimeter of the detachment space 13.

[0121] Figures 24 and 25 illustrate two embodiments, given as examples, of a structural assembly according to the invention.

[0122] In the present example, such a structural assembly is composed of a photovoltaic module 1 as described above and a frame 25 forming part of a structure in which the photovoltaic module 1 is intended to be integrated as a structural portion.

[0123] In the present example, this structural assembly is a motor vehicle and the chassis 25 in question is formed by the body of the vehicle, and more precisely by a frame at roof level.

[0124] Figures 24 and 25 both illustrate an edge of the photovoltaic module, seen in section at a recess space 13, and cooperating with the frame 25 of the structural assembly.

[0125] Figure 24 illustrates a first embodiment in which a photovoltaic module 1 is fixed to the chassis 25 (which is therefore here the body of a vehicle). The photovoltaic module 1 is a photovoltaic module according to any one of the preceding embodiments except that the front face wall 7 comprises a cantilevered portion 26 extending beyond the sealing coating 18.

[0126] The overhanging portion 26 is fixed to a notch or a rebate of the chassis 25 which thus has a bearing surface 27. This fixing is done for example by a seal 29 (for example a polyurethane seal, or any other suitable material), so that the front face wall 7 is flush with the chassis 25.

[0127] Figure 25 illustrates a second embodiment of the structural assembly in which the photovoltaic module 1 conforms to one of the embodiments described previously, and in which the photovoltaic module 1 is fixed on the bearing surface 27 of the frame 25. A bearing portion 28, adjacent to the rim 14, of the rear face wall 8 is placed against the bearing surface 27. A seal 29 (for example a polyurethane seal, or any other suitable material) ensures filling and support all along the sealing coating 18 as well as the rim 15 of the front face wall 7. The front face wall 7 is thus flush with the frame 25.

[0128] The photovoltaic panel 1 is thus supported by a contact at the level of the support portion 28 while the entire area of ​​the sealing coating 18 as well as the front face wall 7 itself is held by the seal 29, in a flexible manner. The sealing coating 18 is here pressed onto the frame by means of the seal 29.

[0129] These two embodiments of a structural assembly thus allow direct integration of the photovoltaic modules 1 without a frame, without any protruding elements, while integrating the bypass diodes 6 into the body of the module.

[0130] Alternative embodiments may be envisaged. In particular, the possible contours of the sealing coating 18 may be different from those given here as an example, as long as these contours remain within the perimeter of the offset space 13. Figure 26 illustrates the maximum perimeter of the offset space. This section shows that the offset space 13 is delimited transversely along a height corresponding to the dimension a of Figure 4, and is delimited longitudinally by the dimension A of Figure 4 (the distance along the longitudinal direction between the two edges 14, 15). The sealing coating 18, being contained in the offset space 13, is therefore contained in the thickness of the photovoltaic module which is defined by the front face wall 7 and the rear face wall 8, with no element projecting transversely or longitudinally.

[0131] Furthermore, the embodiments can be combined: for example, the different arrangements of the sealing coating 18 can be combined with the dimensioning rules described, or even with the presence of elements such as the spacer 22 or the dielectric film 23.

Claims

CLAIMS 1. Photovoltaic module comprising: - a photovoltaic assembly comprising at least one photovoltaic cell (4), arranged between a first face wall (7) and a second face wall (8), and comprising two polarities; characterized in that it comprises: - a setback space (13) formed by a withdrawal, in the direction of the photovoltaic assembly, of an edge (14) of the second face wall (8) relative to an edge (15) of the first face wall (7); - two bypass conductors (10) which: are connected to the two polarities of the photovoltaic assembly; extend longitudinally between the first face wall (7) and the second face wall (8); open into the offset space (13); and each comprise a connection surface (16) extending into the offset space (13); - a bypass diode (6) arranged in the breakaway space (13) and connected to the connection surface (16) of each bypass conductor (10); - a sealing coating (18) surrounding the bypass diode (6) and the two bypass conductors (10), this sealing coating (18) being contained in the thickness of the photovoltaic module defined by the first face wall (7) and the second face wall (8).

2. Photovoltaic module according to claim 1, characterized in that the photovoltaic assembly is embedded in at least one layer of encapsulating material (12), the bypass conductors (10) being, at least partially, in this layer of encapsulating material (12).

3. Photovoltaic module according to claim 2, characterized in that the encapsulating material (12) stops at the level of said edge (14) of the second face wall (8), outside the detachment space (13), the sealing coating (18) being in contact with the first face wall (7).

4. Photovoltaic module according to claim 2, characterized in that the encapsulating material (12) extends in the offset space (13), along the first face wall (7).

5. Photovoltaic module according to claim 4, characterized in that the sealing coating (18) is in contact with the encapsulating material (12) in the detachment space (13).

6. Photovoltaic module according to claim 4, characterized in that the sealing coating (18) is entirely made of the encapsulating material (12).

7. Photovoltaic module according to one of the preceding claims, characterized in that: - a is greater than b; - the a / b ratio is approximately between 2 and 4; . . there -Amin= - ■ a ~ b with: - Amin: minimum longitudinal distance between said edge (14) of the second face wall (8) and said edge (15) of the first face wall (7); - a: transverse distance between the internal face of the first face wall (7) and the internal face of the second face wall (8); - b: thickness, in the transverse direction, of the bypass diode (6) and the bypass conductors (10); - I: width, in the longitudinal direction, of the bypass diode (6).

8. Photovoltaic module according to one of the preceding claims, characterized in that the sealing coating (18) has a section connecting said edge (14) of the second face wall (8) to said edge (15) of the first face wall (7).

9. Photovoltaic module according to one of the preceding claims, characterized in that it comprises a spacer (22) placed in the sealing coating (18), between the bypass diode (6) and the boundaries of the sealing coating (18).

10. Photovoltaic module according to one of the preceding claims, characterized in that it comprises a dielectric film (23) covering the sealing coating (18), between said rim (14) of the second face wall (8) and said rim (15) of the first face wall (7).

11. Photovoltaic module according to one of the preceding claims, characterized in that the first face wall (7) is a front face wall, and the second face wall (8) is a rear face wall.

12. Structural assembly comprising a photovoltaic module (1) according to one of the preceding claims, and a frame (25), characterized in that: - the frame (25) comprises a support surface (27); - the photovoltaic module (1) is mounted on this support surface (27) so that the first face wall (7) is flush with the frame (25).

13. Structural assembly according to claim 12, characterized in that the first face wall (7) comprises a cantilevered portion (26) extending longitudinally beyond the sealing coating (18), the photovoltaic module (1) being mounted on the bearing surface (27) of the frame (25) by this cantilevered portion (26).

14. Structural assembly according to claim 13, characterized in that said cantilevered portion (26) is mounted on the bearing surface (27) of the chassis (25) by means of a joint (29).

15. Structural assembly according to claim 12, characterized in that the second face wall (8) comprises a support portion (28), the photovoltaic module (1) being mounted on the support surface (27) of the frame (25) by this support portion (28), the sealing coating (18) being pressed onto the frame (25) by means of a seal (29).

16. Method of producing by hot pressing a photovoltaic module according to one of the preceding claims, characterized in that it comprises: - a step of positioning the first face wall (7) and the photovoltaic assembly arranged between two films of encapsulating material (12), as well as the bypass conductors (10); - a step of positioning the second face wall (8), with said withdrawal forming the detachment space (13); - a step of electrically connecting the connection surfaces (16) of the bypass diode (6) with the bypass conductors (10); - a step of laying the sealing coating (18).

17. Method according to claim 16, characterized in that a hot pressing step is carried out after the step of positioning the second face wall (8), the step of laying the sealing coating (18) being carried out after this hot pressing step.

18. Method according to claim 16, characterized in that the step of positioning the first face wall (7) comprises the placement of additional portions (24) of encapsulating material (12), and a hot pressing step is carried out after the step of positioning the second face wall (8), the step of laying the sealing coating (18) being carried out simultaneously with this hot pressing step, the encapsulating material (12) also constituting the sealing coating (18).

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