Functional device with direct electrical outputs and method for manufacturing such a functional device

Abstract

The invention relates to a functional device (100) comprising a multilayer stack successively including: - a first protective film (101) disposed on the front face of said device (100), - an encapsulating assembly (107), - a second protective film (105) disposed on the rear face of the device, - at least one electrically or optically active element (110) being embedded in the encapsulating assembly, and - an electrical connection element (160) directly connected to said electrically or optically active element and adapted to carry electricity from or to said electrically or optically active element, one end (162) of said electrical connection element exiting directly from said functional device.According to the invention, the electrical connection element is integrated into the stack and comprises an outer sheath free of halogen elements and one end of which exits directly from the functional device, so as to eliminate the need for an intermediate junction box on the front or rear face of the functional device (100). Figure for the abstract: Fig. 1.

Description

Title of the invention: Functional device with direct electrical outputs and method of manufacturing such a functional device Technical field of the invention

[0001] The present invention relates to the technical field of functional devices, for example multilayer structures, comprising electrically or optically active elements, such as photovoltaic cells, light-emitting diodes or resistive films.

[0002] The invention finds a preferred application in the field of solar roads. The invention can, for example, be integrated into roadways that can be traveled by pedestrians and / or vehicles, whether motorized or not, such as roadways or roads, cycle paths, industrial or airport platforms, squares, sidewalks or parking lots.

[0003] The invention also finds a preferred application in transport vehicles (for example car, truck, train or boat) or the envelope of a building, on which the functional device can be fixed.

[0004] It relates in particular to a functional device with direct electrical outputs and a method of manufacturing such a functional device, intended to be integrated into a roadway and a functionalized traffic or pedestrian roadway comprising such a device. State of the art

[0005] Functionalized pavements are pavements comprising electrically or optically active elements such as photovoltaic cells or other electrically or optically active elements such as light-emitting diodes (LEDs), electrical, electronic, optical, optoelectric, piezoelectric and / or thermoelectric elements. These elements can be used to generate, receive and / or communicate data, or to generate and transfer energy.

[0006] In particular, the principle of solar roads consists of using roads or roadways as means of producing electrical energy, from solar irradiation during the day.

[0007] To do this, solar modules are inserted into so-called trafficable roadways (roads, sidewalks, etc.), and covered with a transparent textured surface, resistant to the passage of vehicles, and meeting the grip requirements applicable to roads and other traffic lanes.

[0008] Conventionally, photovoltaic modules include:

[0009] - a transparent plate on the front face of the module, generally made of glass; the front face being the one exposed to incident solar radiation when the modules are installed on the ground,

[0010] -a set of interconnected photovoltaic cells, coated in an encapsulation layer,

[0011] - a plate on the rear face of the photovoltaic module, generally made of glass or a “backsheet” formed of multi-layer polymers.

[0012] These photovoltaic modules generally comprise, mainly on the rear face, a junction box. This allows in particular to make the transition between the electrical connections inside the photovoltaic module (generally in flat copper tape) and the electrical connections outside the photovoltaic module (generally in round or flat cables). This junction box generally also contains one or more bypass diodes, necessary for the proper functioning and protection of the photovoltaic module in the event in particular of a malfunction of the photovoltaic cells included in this module.

[0013] However, in the case of installing a photovoltaic module on a roadway, the presence of a junction box on the module results in high installation costs because it is necessary to make a trench in the roadway to embed the junction box. This trench must then be filled with a material compatible with the roadway and with the passage of traffic. A similar problem exists in any application of photovoltaic modules fixed over the entire surface of their rear face on a support. Presentation of the invention

[0014] In this context, the present invention proposes to improve the manufacture of functional devices, in particular those intended to be integrated into a roadway, so as to reduce their installation costs on the support concerned. This support is preferably a trafficable roadway. It can also be any other support such as surfaces of buildings, boats, cars and more generally, any surface on which the functional device could be placed by gluing or any other fixing means.

[0015] In particular, the invention relates to a functional device comprising a multilayer stack. This multilayer stack successively comprises:

[0016] - a first transparent protective film placed on the front face of said device,

[0017] - an encapsulating assembly,

[0018] - a second protective film, transparent or not, placed on the rear face of the device,

[0019] - at least one electrically or optically active element being coated in the encapsulating assembly, and

[0020] - an electrical connection element connected to said element electrically or op electrically active and adapted to transport electricity from or to said electrically or optically active element,

[0021] According to the invention, the electrical connection element is integrated into the multilayer stack. In addition, the electrical connection element comprises an outer sheath free of halogen elements and one end of which comes directly out of said functional device, so as to avoid the use of an intermediate junction box on the front or rear face of the functional device.

[0022] Thus, the absence of halogen elements in the outer sheath of the electrical connection element, for example of an electric cable, makes it possible to obtain good adhesion between the encapsulating assembly of the functional device and the outer sheath of the electrical connection element. This is an essential factor for ensuring good sealing and avoiding risks of delamination at the outlet of the electrical connection element of the functional device.

[0023] Furthermore, this arrangement, directly integrating the electrical connection element into the functional device, this electrical connection element also exiting directly outside this device, makes it possible to dispense with the use of an intermediate junction box on the front or rear face of the functional device. This also makes it possible to ensure the reliability of the functional device with respect to the ambient conditions of this device, in particular physical, mechanical or chemical influences to which the device is subjected.

[0024] Other non-limiting and advantageous characteristics of the device according to the invention, taken individually or in all technically possible combinations, are the following:

[0025] - the electrically or optically active element is a photovoltaic cell, said photovoltaic cell being connected to at least one bypass diode embedded in the encapsulating assembly; - the outer sheath of the electrical connection element is free of fluoropolymer and / or chloropolymer and / or bromopolymer; - the encapsulating assembly comprises a passage allowing the electrical connection element to exit, through the encapsulating assembly, towards the outside of the functional device; - the encapsulating assembly includes: a) a first outer encapsulating film, (b) an inner encapsulating film, and c) a second outer encapsulating film; - the electrical connection element is coated with encapsulating material along its passage through said functional device, said encapsulating material being selected from one or more of the materials forming the first outer encapsulating film, the inner encapsulating film or the second outer encapsulating film; - the second outer encapsulating film comprises a first orifice and the second protective film comprises a second orifice, the first orifice and the second orifice being aligned so as to form a through orifice allowing the passage of the electrical connection element through the second outer encapsulating film and the second protective film; - a space between walls of said through-hole and the electrical connection element passing through said through-hole is filled with the same material as that forming the second outer encapsulating film; - the first outer encapsulating film comprises a third orifice and the first protective film comprises a fourth orifice, the third orifice and the fourth orifice being aligned so as to form a through orifice allowing the passage of the electrical connection element through the first outer encapsulating film and the first protective film; - a space between walls of said through-hole and the electrical connection element passing through said through-hole is filled with the same material as that forming the first outer encapsulating film; - a passage allowing the exit of the electrical connection element through the inner encapsulating film is included in the inner encapsulating film;

[0026] - a passage allowing the exit of the electrical connection element through the inner encapsulating film is comprised between the first outer encapsulating film and the inner encapsulating film;

[0027] - a passage allowing the exit of the electrical connection element through the inner encapsulating film is comprised between the inner encapsulating film and the second outer encapsulating film; - a bare metal end of said electrical connection element is directly welded to an electrically conductive part of said electrically or optically active element; - a bare metal end of the electrical connection element is connected to an electrically conductive part of said electrically or optically active element by means of an intermediate connection element, for example a flat copper strip; - the intermediate connection element comprises a terminal; - the electrical connection element is an electrical cable, round or flat; - the electrical connection element is a flat metal braid covered with a heat-shrinkable sheath; and - the electrical connection element has a cross-section less than or equal to 2.5 mm2.

[0028] The invention also relates to a method for manufacturing a functional device as defined above. The method comprises: - a step of connecting the electrical connection element to the electrically or optically active element; and - a step of forming the multilayer stack making it possible to coat the electrically or optically active element in the encapsulating assembly between the first protective film and the second protective film, one end of the electrical connection element emerging directly from said functional device. Other non-limiting and advantageous characteristics of the manufacturing method according to the invention, taken individually or in all technically possible combinations, are as follows: - the step of forming the multi-layer stack is carried out by hot lamination; - a step of forming a passage in said encapsulating assembly is provided, said passage allowing the electrical connection element to exit through said encapsulating assembly; - a step of forming a through-hole through said encapsulating assembly and said second protective film is provided so as to allow the passage of the electrical connection element through said functional device; and - a step of forming a through-hole through said encapsulating assembly and said first protective film is provided so as to allow the passage of the electrical connection element through said functional device.

[0029] The invention also relates to a functionalized traffic or pedestrian roadway, comprising a traffic or pedestrian roadway on which a functional device as defined above is fixed.

[0030] The invention also relates to a transport vehicle comprising a functional device as described above.

[0031] The invention finally relates to a building envelope comprising a functional device as described above.

[0032] Of course, the various features, variants and embodiments of the invention may be combined with each other in various combinations to the extent that they are not incompatible or mutually exclusive. Detailed description of the invention

[0033] Furthermore, various other characteristics of the invention emerge from the appended description given with reference to the drawings which illustrate non-limiting forms, of carrying out the invention and where:

[0034] [Fig.l] schematically represents a sectional view of a functional device according to a first embodiment of the invention in which an electrical connection element exits through the rear face of the functional device,

[0035] [Fig.2] schematically represents a sectional view of a functional device according to a second embodiment of the invention in which an electrical connection element exits through the front face of the functional device,

[0036] [Fig.3] schematically represents a sectional view of a functional device according to a third embodiment of the invention in which an electrical connection element exits through the lateral flank of the functional device,

[0037] [Fig.4] schematically represents an example of electrical connection between an electrical connection element and an electrically conductive connector according to the invention,

[0038] [Fig.5] schematically represents a sectional view of a functional device according to the first embodiment of the invention in which an electrical connection element exits through the rear face of the functional device and comprising photovoltaic cells and at least one bypass diode, and

[0039] [Fig.6] represents an electrical diagram of the arrangement of the photovoltaic cells and the bypass diodes.

[0040] As a preliminary point, it will be noted that the identical or similar elements of the different embodiments of the invention shown in the different figures will, as far as possible, be referenced by the same reference signs and will not be described each time.

[0041] [Fig.l] schematically represents a sectional view of a functional device 100. This functional device 100 is for example integrated into a trafficable area such as a trafficable or pedestrian roadway.

[0042] As shown in [Fig.l], the functional device 100 comprises a multi-layer stack successively comprising:

[0043] - a first plate also called first protective film 101, arranged in front face of the functional device 100, transparent, having a first thickness eb made of a first material, having a first Young's modulus Ei and a first coefficient of thermal expansion CTEb

[0044] - an encapsulating assembly 107 coating at least one electrically or op element tically active element 110 (also referred to as active element 110 in the remainder of this description), and

[0045] - a second plate also called second protective film 105, arranged on the rear face of the functional device 100, transparent or not, having a second thickness e5, in a second material, having a second Young's modulus E5 and a second coefficient of thermal expansion CTE5.

[0046] Preferably according to the invention, the encapsulating assembly 107 comprises:

[0047] - a first outer encapsulating film 102, having a third thickness e2, in a third material, having a third Young's modulus E2 and a third coefficient of thermal expansion CTE2,

[0048] - an inner encapsulating film 103, coating the active elements 110, the film in inner encapsulant 103 having a fourth thickness e3, being made of a fourth material, having a fourth Young's modulus E3 and a fourth coefficient of thermal expansion CTE3, and

[0049] - a second outer encapsulating film 104, having a fifth thickness e4, in a fifth material, having a fifth Young's modulus E4 and a fifth coefficient of thermal expansion CTE4.

[0050] Alternatively (not shown), the encapsulating assembly may be formed by only two encapsulating films. Alternatively (not shown), the encapsulating assembly may be formed by a single encapsulating film.

[0051] In this description, all Young's modulus values ​​and thermal expansion coefficient values ​​are given at room temperature (20-25°C).

[0052] First plate 101 and second plate 105:

[0053] The first plate 101 and the second plate 105 are the elements of the functional device 100 in direct contact with the external environment.

[0054] The materials of the plates 101, 105 are materials having a high Young's modulus. Preferably, their Young's moduli E are greater than 2 GPa, advantageously greater than 5 GPa, even more advantageously greater than 10 GPa. The Young's moduli remain high at least over the entire operating temperature range of the functional device 100 (from -40°C to +85°C).

[0055] The first plate 101 and the second plate 105 have high mechanical rigidity, are not very deformable and are impact resistant.

[0056] The first plate 101 and the second plate 105 are made of materials having a low coefficient of thermal expansion. Preferably, their coefficients of thermal expansion CTE are less than 200x10 6 / K, more preferably less than 100x10 6 / K, and even more preferably less than 50x10 6 / K. They have high dimensional stability under temperature variation.

[0057] Preferably, the Young's moduli of the first plate 101 and of the second plate 105 are greater than 10 GPa and their coefficients of thermal expansion are less than 50x10 6 / K.

[0058] Advantageously, to avoid having a material which expands more than the other under the effect of heat and / or contracts more than the other under the effect of cold, and therefore to avoid inducing inhomogeneous mechanical stresses in assembly, materials having Young's modulus (E) and coefficient of thermal expansion (CTE) values ​​as close as possible to each other will be used for the first plate 101 and for the second plate 105. By closest, it is meant that these values ​​will differ by 0 to 30% maximum, preferably by 0 to 20% and more preferably by 0 to 10%, and advantageously they are identical.

[0059] As the two protective plates (or films) 101, 105 are in contact with the external environment, they can also act as barriers to external influences (in particular to humidity). They advantageously have the following additional characteristics:

[0060] - high resistance to water penetration,

[0061] - intrinsic stability against structural degradation by water molecules,

[0062] - high resistance to exposure to chemical fluids.

[0063] For example, the first 101 and second 105 plates are made of a material having the lowest possible water vapor transmission rate (WVTR).

[0064] Advantageously, the first plate 101 and the second plate 105 are made of a material comprising from 50% to 70% by mass of glass to best meet the requirements of the thermomechanical parameters E and CTE.

[0065] For example, the first plate 101 and the second plate 105 are made of composite materials of glass fibers and resin or of a composite of glass fibers and polymer. For example, it is an epoxy or acrylic resin, a thermoplastic polymer, such as a thermoplastic polyolefin, such as polypropylene (PP), an ionomer, a polyamide, a polyvinyl chloride, a (meth)acrylate, a polycarbonate, a fluoropolymer, or even a polyester such as polyethylene terephthalate (PET or PETG).

[0066] The glass fibers advantageously represent from 55% to 65% by mass of the composite material. They can be woven (uni- or bi-directional) or non-woven.

[0067] The materials of the first and second plates may be different from each other, provided that they remain similar in terms of Young's modulus E and coefficient of thermal expansion CTE.

[0068] Preferably, the materials of the first and second plates are identical.

[0069] The first plate 101 and the second plate 105 have a thickness ranging from 0.25 to 3.0 millimeters (mm), advantageously ranging from 0.5 to 1.5 mm.

[0070] The first plate 101 and the second plate 105 may have identical or different thicknesses. Preferably, they are of the same thickness.

[0071] The first plate 101 on the front face, facing the active faces of the elements active 110, is transparent, so as to allow solar radiation to pass through. By transparent, it is meant in this description that the first plate 101 is formed from a material allowing more than 70% of the incident radiation to pass through, and preferably at least 80% of the incident radiation, in the visible spectrum.

[0072] The second plate 105 positioned on the rear face can be opaque or transparent.

[0073] First outer encapsulating film 102 and second outer encapsulating film 104:

[0074] The first outer encapsulating film 102 and the second outer encapsulating film 104 are made of materials having average Young's moduli, preferably from 100 to 800 MPa, more preferably from 200 to 600 MPa.

[0075] The outer encapsulating films 102, 104 have average mechanical rigidity, are moderately deformable and impact resistant.

[0076] They are made of materials having an average thermal expansion coefficient of 200x10 6 / K to 700x10 6 / K, preferably of 300x10 6 / K to 600x10 6 / K. They have average dimensional stability under temperature variation.

[0077] The materials of the outer encapsulating films 102, 104 may be different from each other, provided that they remain similar in terms of Young's modulus E and coefficient of thermal expansion CTE.

[0078] Preferably, the outer encapsulating films 102, 104 have a Young's modulus E of the order of 500 MPa and a coefficient of thermal expansion CTE of the order of 400x10 6 / K.

[0079] The external encapsulating films 102, 104 are, advantageously, made of materials making it possible to reinforce the barrier function of the materials of the protective plates (or films), with respect to external influences (in particular with respect to humidity).

[0080] For example, the outer encapsulating films 102, 104 are made of polymers, such as homopolymers or copolymers of ethylene vinyl acetate (EVA), ethylene methylacrylate (EMA), ethylene butylacrylate (EBA), ethylene propylene (EPDM), polyvinyl butyral (PVB), polydimethylsiloxanes, polyurethanes (PU), thermoplastic polyolefins, ionomers, polypropylene (PP), polyamide, polyvinyl chloride, polycarbonate, fluorinated polymers, or even a polyester such as polyethylene terephthalate (PET or PETG). Preferably, it is an ionomer.

[0081] Preferably here, the materials of the two outer encapsulating films are identical.

[0082] The first outer encapsulating film 102 and the second outer encapsulating film 104 have a thickness of between 0.25 mm and 1.0 mm, preferably between 0.25 mm and 0.75 mm.

[0083] Preferably, the first outer encapsulating film 102 and the second outer encapsulating film 104 have the same thickness.

[0084] Inner encapsulating film 103:

[0085] The material of the inner encapsulating film 103 has a low Young's modulus, lower than that of the outer encapsulating films 102, 104. Its Young's modulus E3 is here between 5 and 100 MPa, preferably between 10 and 50 MPa.

[0086] The inner encapsulating film 103 has low mechanical rigidity and good deformation capacity to be able to absorb mechanical stresses and impacts. The mechanical stability of the entire structure is ensured by the other layers of the functional device 100.

[0087] The material of the inner encapsulating film 103 has a high coefficient of thermal expansion, preferably between 800 to 2000x10 6 / K, even more preferably between 800 to 1400x10 6 / K.

[0088] Preferably, the material is characterized by a Young's modulus E3 of the order of 20 MPa and a thermal expansion coefficient CTE3 of the order of 900x10 6 / K.

[0089] The inner encapsulating film 103 is, for example, an encapsulant commonly used in the field of photovoltaics.

[0090] It may be a polymer material, such as homopolymers or copolymers of ethylene vinyl acetate (EVA), ethylene methylacrylate (EMA), ethylene butylacrylate (EBA), ethylene propylene (EPDM), polyvinyl butyral (PVB), polydimethylsiloxanes, polyurethanes (PU), thermoplastic polyolefins, ionomers, polypropylene (PP), polyamide, polyvinyl chloride, polycarbonate, fluorinated polymers, or a polyester such as polyethylene terephthalate (PET or PETG). It may also be a (meth)acrylic type resin, or a heat- or photochemically crosslinkable silicone. Preferably, it is a thermoplastic polyolefin (TPO).

[0091] The inner encapsulating film 103 has a thickness of between 0.4 and 2.0 mm, preferably between 0.8 and 1.4 mm.

[0092] The inner encapsulating film 103 may exhibit high water penetration resistance, high intrinsic stability against structural degradation by water molecules, and high resistance to exposure to chemical fluids.

[0093] Advantageously here, the resistance to moisture penetration of the different materials increases from the inner encapsulating film 103 towards the protective plates (or films) 101 and 105, on the front face and on the rear face.

[0094] Electrically or optically active elements 110:

[0095] The functional device 100 comprises at least one electrically or optically active element 110, and preferably, a plurality of electrically or optically active elements 110 as shown in [Fig.l].

[0096] In this description, the term "electrically active element" means an element that transmits and / or receives electrical signals. The term "optically active element" means an element that transmits and / or receives optical signals, or an element that transforms optical signals into electrical signals or vice versa.

[0097] According to a first embodiment, the electrically or optically active elements 110 are arranged between the inner encapsulating film 103 and the second outer encapsulating film 104.

[0098] Alternatively, the electrically or optically active elements 110 are disposed between the inner encapsulating film 103 and the first outer encapsulating film 102.

[0099] As a further variant, the electrically or optically active elements 110 are completely coated, whether centered or not, in the thickness of the inner encapsulating film 103 (as shown in FIGS. 1 to 3).

[0100] The electrically or optically active elements could also, according to another variant, be coated in the second outer encapsulating film 104. As a further variant, the electrically or optically active elements could be coated in the first outer encapsulating film 102.

[0101] The optically active elements are, for example, light-emitting diodes, or a photosensitive sensor (such as a photodiode).

[0102] According to a particular embodiment here, the active elements 110 are, for example, photovoltaic cells. They are, for example, based on silicon wafers, monocrystalline, multicrystalline or quasi-monocrystalline also known by the Anglo-Saxon name of “mono-like”.

[0103] The photovoltaic cells are arranged next to each other. Advantageously here, the photovoltaic cells are regularly spaced.

[0104] Photovoltaic cells are generally interconnected with each other, by electrically conductive metal connections, intended to collect the electricity generated by the photovoltaic cells. Electrically conductive connectors, also called electrically conductive parts in this description, are metal connections attached to the metallization of the cell. For example, these are flat ribbons or copper wires. The connection is made, for example, by soldering or gluing. The assembly formed by the photovoltaic cells and the connectors forms a skeleton of interconnected photovoltaic cells.

[0105] Advantageously according to the invention, one of these electrically conductive connectors of the photovoltaic cell skeleton (represented as the electrically conductive connector 150 in FIGS. 1 to 3 and 5) is electrically connected to an electrical connection element 160 making it possible to transport the electricity generated from or to the active elements 110.

[0106] As shown in Figures 1 to 3 and 5, a free end 162 of the electrical connection element 160 comes directly out of the functional device 100. In other words, this electrical connection element 160 allows the direct transport of electricity between the active elements 110 and the exterior of the functional device 100 without a box of intermediate junction, on the rear face or on the front face, of the functional device 100.

[0107] Thus, advantageously according to the invention, the electrical connection element 160 is connected to the active elements 110. It is integrated into the multilayer stack and also emerges directly from the functional device 100, without an intermediate junction box, on the rear face or on the front face of the functional device 100.

[0108] In the case where the active elements 110 are photovoltaic cells, the functional device 100 also comprises at least one bypass diode 120 ([Fig.5]). Preferably, the functional device comprises a plurality of bypass diodes.

[0109] These bypass diodes 120 are embedded in the encapsulating assembly 107 at the same level as the active elements 110, according to the different embodiments described previously for the positioning of the active elements 110 inside the encapsulating assembly 107.

[0110] Alternatively, the bypass diodes can be mounted on a support, such as a printed circuit (or PCB for “Printed Circuit Board” according to the commonly used acronym of Anglo-Saxon origin) for example.

[0111] Advantageously, the bypass diode used has a small thickness, that is to say a thickness compatible with the thickness of the encapsulating assembly 107. Preferably, the thickness of the bypass diodes is close to the thickness of the active elements 110.

[0112] In the case of the variant mentioned above and using a printed circuit on which the bypass diodes are mounted, the assembly formed by the printed circuit and the bypass diodes advantageously has a small thickness, that is to say a thickness compatible with the thickness of the encapsulating assembly, more preferably a thickness close to the thickness of the active elements.

[0113] These bypass diodes are connected to the skeleton of photovoltaic cells. More particularly, as shown in [Fig.6], the bypass diodes 120 are arranged according to an electrical diagram in parallel with the photovoltaic cells (in a manner similar to the conventional diagram for photovoltaic modules).

[0114] Advantageously according to the invention, several bypass diodes are interconnected, in parallel with each other in the electrical diagram ([Fig.6]). Thanks to the division of the electric current by this plurality of bypass diodes in parallel, this arrangement makes it possible to reduce the ohmic heating of each of the individual bypass diodes. This also makes it possible to distribute the total thermal load over a larger area, and thus to limit the maximum temperature reached in the materials of the encapsulating assembly.

[0115] Thus, this arrangement makes it possible to dispense with a conventional intermediate junction box on the external casing of the functional device while retaining its functions thanks to the integration of the electrical connection element and the bypass diodes directly into the functional device, and more particularly into the multilayer stack.

[0116] The electrical connection element 160 is for example an electrical cable. Conventionally, an electrical cable 160 is formed of a conductive part formed for example of several wires made of conductive material, and of an outer sheath, an insulating part coating the different wires made of conductive material. For example here, the electrical cable comprises a metallic conductive part and an outer sheath is formed of a polymer material.

[0117] In the present description, a bare metal end of the electrical cable refers to a portion of this cable without an outer sheath. Thus, the electrical connection of the electrical cable 160 to the electrically conductive connector 150 is carried out by means of a bare metal end of the electrical cable 160. This bare metal end is for example welded to the electrically conductive connector 150 so as to carry out the electrical connection.

[0118] As shown in Figures 1 to 3 and 5, the electrical cable 160 is integrated into the different layers of the functional device 100 in order to make a direct electrical connection between the active elements 110 and the exterior of the functional device 100. The electrical cable 160 extends through the different layers of the functional device 100. More particularly, advantageously according to the invention, the encapsulating assembly 107 comprises a passage, through the encapsulating assembly 107, allowing the electrical connection element 160 to exit to the exterior of the functional device 100. In this description, the term “passage” means an area of ​​the encapsulating assembly crossed by the electrical connection element 160.

[0119] As shown in Figures 1 to 3 and 5, the electrical connection element 160 is coated with a material along its passage through the functional device 100. In practice, this coating material is for example chosen from one or more of the materials forming the encapsulating assembly 107 (therefore here from one or more of the materials forming the first outer encapsulating film 102, the inner encapsulating film 103 or the second outer encapsulating film 104).

[0120] According to a first embodiment shown in [Fig. 1] or in [Fig. 5], a first orifice 104a is formed in the second outer encapsulating film 104 and a second orifice 105a is formed in the second protective plate 105. This first orifice 104a and this second orifice 105a are aligned so as to form a through-hole 180 the second outer encapsulating film 104 and the second protective plate 105 (a single and continuous through-hole 180 is therefore formed). This through-hole 180 then allows the passage of the electric cable 160. As shown in Figures 1 and 5, in this embodiment, the electric cable 160 therefore exits the functional device 100 through the rear face of the latter.

[0121] In this description, the term “orifice” means an opening in the form of a conduit which connects the interior of the functional device with the exterior thereof.

[0122] The through-orifice 180 here has the shape of a slot or a hole. This through-orifice 180 is for example produced in practice using a drill, introduced through the second outer encapsulating film 104 and the second protective plate 105. Alternatively, this through-orifice 180 can be produced using a cutting tool or a water jet cutting machine.

[0123] According to this first embodiment, the electrical cable 160 is therefore also integrated into the inner encapsulating film 103. Alternatively, the electrical cable may be integrated between the inner encapsulating film and the second outer encapsulating film. Alternatively, it may be integrated into the second outer encapsulating film.

[0124] In particular, the electrical connection between the electrical cable 160 and the electrically conductive connector 150 of the active elements 110 is also integrated into the inner encapsulating film 103. Alternatively, this connection may be integrated between the inner encapsulating film and the second outer encapsulating film. Alternatively, it may be integrated into the second outer encapsulating film.

[0125] The space between the electrical cable 160 and the walls of the through-hole 180 is here filled with the same material as that of the second outer encapsulating film 104. This also guarantees a seal of the functional device. No area can thus facilitate the penetration of moisture into the functional device.

[0126] Alternatively, according to a second embodiment shown in [Fig. 2], a third orifice 102a is formed in the first outer encapsulating film 102 and a fourth orifice 101a is formed in the first protective film 101. This third orifice 102a and this fourth orifice 101a are aligned so as to form a through orifice 182 in the first outer encapsulating film 102 and the first protective plate 101. This through orifice 182 then allows the passage of the electric cable 160. As shown in [Fig. 2], in this embodiment, the electric cable 160 therefore exits the functional device 100 via the front face of the latter.

[0127] As for the first embodiment described above, the through-orifice 182 here has the shape of a slot or a hole. This through-orifice 182 is for example produced in practice using a drill introduced through the first outer encapsulating film 102 and the first protective film 101. Alternatively, this orifice crossing 182 can be made using a cutting tool or a water jet cutting machine.

[0128] According to this second embodiment, the electric cable 160 is therefore also integrated here into the inner encapsulating film 103.

[0129] Alternatively, the electrical cable may be integrated between the inner encapsulating film and the first outer encapsulating film. Alternatively, it may be integrated into the first outer encapsulating film.

[0130] In particular, the electrical connection between the electrical cable 160 and the electrically conductive connector 150 of the active elements 110 is integrated into the inner encapsulating film 103.

[0131] Alternatively, this connection may be integrated between the inner encapsulating film and the first outer encapsulating film. Alternatively, it may be integrated into the first outer encapsulating film.

[0132] The space between the electrical cable 160 and the walls of the through-hole 182 is here filled with the same material as that of the first outer encapsulating film 102. This also guarantees a seal of the functional device. No area can thus facilitate the penetration of moisture into the functional device.

[0133] This second embodiment is particularly advantageous for use in which the mounting of the functional device on its support does not allow an electrical cable to exit through the rear face.

[0134] As a further variant, according to a third embodiment shown in [Fig. 3], the electrical cable 160 can exit from the functional device 100 through the edge of the functional device 100. More specifically, in this example, the encapsulating assembly 107 comprises a passage allowing the electrical cable 160 to exit to the outside of the functional device 100. Unlike the first two embodiments, no orifice is pierced in this third embodiment (the cable exits directly from the functional device).

[0135] In this case, the electrical cable 160, as well as its connection point to the active elements 110, extend through the inner encapsulating film 103. In this example, the electrical cable 160 therefore exits directly through the lateral flank of the functional device 100.

[0136] Alternatively, the electrical cable and its connection point to the active elements may be integrated between the inner encapsulating film and the second outer encapsulating film. Alternatively, the electrical cable and its connection point to the active elements may be integrated between the inner encapsulating film and the first outer encapsulating film.

[0137] Advantageously according to the invention, the electric cable 160 has an outer sheath whose material is free of halogen elements (such as for example chlorine, fluorine or bromine). In particular, the outer sheath of the cable is free of fluoropolymers. Alternatively, the outer sheath of the electrical cable is free of chloropolymers and / or bromopolymers. This ensures good adhesion between the different materials of the encapsulating assembly of the functional device 100 and the outer sheath of the electrical cable 160. This is an essential factor in ensuring good sealing and avoiding the risk of delamination at the exit of the electrical cable from the functional device.

[0138] The cross-section of the electrical cable 160 integrated in the functional device 100 is determined according to the level of electrical current that the cable will have to support. Advantageously, this cross-section is less than or equal to 2.5 mm2, or even advantageously less than or equal to 1.5 mm2.

[0139] In practice, the electrical cable chosen for the present invention has a range of operating temperatures compatible with the actual conditions of use of the functional device (from -40°C to +85°C). The electrical cable chosen is also compatible with usual lamination processes (for example having a lamination temperature of the order of 130 to 170°C and a pressure of the order of 1 bar) used for photovoltaic modules. The electrical cable chosen also has good resistance to ultraviolet radiation, humidity, ozone and chemical products such as oils, gasolines or acid products.

[0140] The electrical cable may also include flame retardants so as to delay the occurrence of flames during use.

[0141] Examples of electrical cables suitable for use in the present invention are for example the following: Energyflex cable (Nexans) 2.5 mm2, Flamex EN 50264-3-1 cable 1.5 mm2 - 2.5 mm2 (Nexans), Varpren ST cable 1.5 mm2 - 2.5 mm2 (Omerin), Varpren 155 UL cable 1.5 mm2 - 2.5 mm2 (Omerin).

[0142] Alternatively, as an alternative to the electric cable, a flat metal braid can be used. This flat braid has a cross-section advantageously less than 2 mm2. This is, for example, a 30A earthing braid.

[0143] In this case, the flat braid is covered with a resin-coated heat-shrinkable sleeve, for example a TE Connectivity heat-shrinkable sleeve, Dia. 4.8mm Black shrink 3:1, 300mm. This protects the flat braid from moisture and provides mechanical protection to the assembly.

[0144] Alternatively, as an alternative to the direct connection of the electrical cable 160 to the electrically conductive connector 150, the electrical connection can be made by means of an intermediate element, such as a terminal 190.

[0145] [Fig. 4] schematically represents such an electrical connection by means of a terminal 190. For example, in the case where the electrically conductive element is a flat metal strip 155, one end of the flat strip 155 is crimped in a first flat part 192 of the terminal 190. This connection is reinforced by adding tin to the front and rear faces of the flat strip 155. This makes it possible in particular to ensure good electrical contact between the flat strip 155 and the terminal 190.

[0146] On the other side of the terminal 190, the stripped metal end of the electric cable 160 is crimped into a second part 194 of the terminal 190. This second part 194 of the terminal 190 has, for example, a diameter of the order of 4.5 mm.

[0147] The use of an intermediate element, such as a terminal 190 for example, makes it possible in particular to improve the manufacturability (i.e. the industrial manufacturing) of the connection between the electrical cable 160 and the electrically conductive connector 150, because it makes it possible to avoid directly soldering a bare metal end of the electrical cable to the electrically conductive element.

[0148] Examples of terminals compatible with the present invention are for example the following: RS PRO non-insulated female terminals 4-6 mm2 (RS), RS PRO non-insulated blade terminals 4-6 mm2 (RS), Flag Krimptite Quick Disconnect, Female, for 10-12 (3.30 to 5.00mm2) Wire, Tab 6.35 x 0.81mm (Molex) or RS PRO Crimp Receptacle, 6.35 x 0.8mm, 2.5mm2 to 6mm2, 14AWG to 10AWG, Tin Plated (RS), RS PRO non-insulated female terminals 1.5 - 2.5 mm2 (RS).

[0149] Method of manufacturing the functional device 100:

[0150] Generally speaking, the method of manufacturing the functional device 100 comprises the following successive steps: - a step of connecting the electrical connection element 160 to the electrically or optically active element 110; and - a step of forming the multilayer stack making it possible to coat the electrically or optically active element 110 in the encapsulating assembly 107 between the first protective film 101 and the second protective film 105, one end 162 of the electrical connection element 160 emerging directly from said functional device 100.

[0151] In the case where the electrically or optically active elements are photovoltaic cells, the method also comprises, before the step of forming the multilayer stack, a step of connecting at least one bypass diode 120 to the photovoltaic cells. This bypass diode 120 is or is not mounted on a printed circuit support.

[0152] The bypass diode 120 is then also embedded in the encapsulating assembly 107 during the step of forming the multilayer stack.

[0153] The step of forming the multilayer stack is for example carried out by hot lamination. Alternatively, it can be implemented by thermocompression, or by infusion, or even by resin transfer molding (or RTM for “Resin Transfer Molding” according to the acronym of Anglo-Saxon origin).

[0154] More specifically, in the case of a first embodiment of the method for manufacturing the functional device 100 (shown in [Fig.l]), the method for manufacturing the functional device 100 comprises, in this order, the following steps:

[0155] - positioning of the second protective film 105 arranged behind said functional device 100,

[0156] - positioning of the encapsulating assembly,

[0157] - formation of the through-orifice 180 through said assembly in encapsulating and said second protective film 105 so as to allow the passage of the electrical connection element 160 through said functional device 100, - positioning of the electrical connection element 160 and of the electrically or optically active element 110, the electrical connection element 160 passing through the through-orifice 180 so that one end 162 of the electrical connection element 160 comes directly out of the functional device,

[0158] - connection of the electrical connection element 160 to the electrically or optically active 110,

[0159] - positioning of the first protective film 101 arranged in front of said device functional 100, and

[0160] - hot lamination of the assembly.

[0161] According to this first embodiment, the functional device 100 is therefore manufactured by stacking from the rear face to the front face of the device.

[0162] In this embodiment, the method also comprises a step of providing a Teflon layer, temporarily during the lamination, positioned between the second protective film 105 and a portion of the electrical connection element 160 emerging from said functional device 100. This Teflon layer makes it possible in particular to prevent the electrical connection element 160 from being irreversibly embedded in the second protective film 105 during the manufacturing process.

[0163] According to a second embodiment of the method for manufacturing the functional device 100 (shown in [Fig.2]), the method for manufacturing the functional device 100 comprises, in this order, the following steps:

[0164] - positioning of the first protective film 101 arranged in front of said device functional 100,

[0165] - positioning of the encapsulating assembly 107,

[0166] - formation of the through-orifice 182 through said assembly in encapsulating 107 and said first protective film 102 so as to allow the passage of the electrical connection element 160 through said functional device,

[0167] - positioning of the electrical connection element 160 and the electrical element electrically or optically active 110, the electrical connection element 160 passing through the through-hole 182 so that one end 162 of the electrical connection element 160 comes directly out of the functional device,

[0168] - connection of the electrical connection element 160 to the electrically or optically active 110,

[0169] - positioning of the second protective film 105 arranged behind said functional device 100, and

[0170] - hot lamination of the assembly.

[0171] According to this second embodiment, the functional device 100 is manufactured by stacking from the front face to the rear face of the functional device 100.

[0172] According to a third embodiment of the method for manufacturing the functional device 100 (shown in [Fig.3]), the method for manufacturing the functional device 100 comprises, in this order, the following steps:

[0173] - positioning of the second protective film 105 arranged behind said functional device 100,

[0174] - positioning the encapsulating assembly so as to form a passage in the encapsulating assembly, this passage allowing the exit of the electrical connection element towards the outside of the functional device 100, - positioning the electrical connection element 160 and the electrically or optically active element 110, the electrical connection element 160 extending through the passage formed in the encapsulating assembly so that one end 162 of the electrical connection element 160 exits directly from the functional device,

[0175] - connection of the electrical connection element 160 to the electrically or optically active 110,

[0176] - positioning of the first protective film 101 arranged in front of said device functional 100, and

[0177] - hot lamination of the assembly.

[0178] Alternatively, for this third embodiment of the method for manufacturing the functional device 100 (shown in [Fig.3]), the method for manufacturing the functional device 100 comprises, in this order, the following steps:

[0179] - positioning of the first protective film 101 arranged in front of said device functional 100,

[0180] - positioning the encapsulating assembly so as to form a passage in the encapsulating assembly, this passage allowing the exit of the electrical connection element towards the outside of the functional device 100, - positioning the electrical connection element 160 and the electrically or optically active element 110, the electrical connection element 160 extending through the passage formed in the encapsulating assembly so that one end 162 of the electrical connection element 160 exits directly from the functional device,

[0181] - connection of the electrical connection element 160 to the electrically or optically active 110,

[0182] - positioning of the second protective film 105 arranged behind said functional device 100, and

[0183] - hot lamination of the assembly.

[0184] In other words, this third embodiment of the manufacturing method can be implemented, indifferently, by stacking from the rear face to the front face of the device or vice versa.

[0185] The through-hole allows the passage of the electrical connection element in order to exit its free end 162 from the functional device 100 (the other end being connected to an electrically conductive element connected to the electrically or optically active element). The through-hole is made in the layers concerned by drilling, for example using a drill or a cutting tool or a water jet cutting machine as mentioned previously.

[0186] Hot lamination of the assembly (also called lamination) allows not only to melt and then crosslink or polymerize the polymer materials but also to constitute good adhesion between all the layers, the electrically or optically active elements and the electrical connection element, forming the entire structure.

[0187] Each encapsulating film 102, 103 and 104; as well as the protective plates or films 101 and 105; can be obtained from one or more stacked layers of the same material; in order to obtain the desired thickness for each film or plate in its final state; after lamination.

[0188] Lamination is carried out using equipment called a laminator (also called a rolling mill) which may be, for example, a membrane press or a double-platen press.

[0189] The lamination process is carried out hot under vacuum and mechanical pressure. The lamination temperature is between 120°C and 200°C, and advantageously between 140 and 170°C, with an adjustable process time. This process time is for example between 15 and 30 minutes. The pressure applied is typically of the order of one bar.

[0190] Applications

[0191] The present invention advantageously relates to functional devices for solar roads, and in particular to photovoltaic modules. The invention also advantageously applies to functional devices intended for be positioned on a roadway and integrating other electrically or optically active or passive elements.

[0192] In particular, the functional device 100 can be integrated into the surface of trafficable roadways - for any rolling, motorized and / or non-motorized, and / or pedestrian means of transport. More details on the characteristics of such a roadway can be found in document FR3093116.

[0193] The invention also advantageously applies to transport vehicles, such as motor vehicles, trains or boats. The functional device according to the invention is, for example, integrated on an outer surface of a transport vehicle.

[0194] Finally, the invention also finds a preferred application in all the usual fields in which photovoltaic modules are included. In particular, the functional device according to the invention can be integrated into the surface of a building envelope. By building envelope is meant here the roof or the facade of a building. The functional device according to the invention can advantageously be installed on a flat roof or a sloping roof.

Claims

Claims

1. Functional device (100) comprising a multilayer stack successively comprising: - a first transparent protective film (101) arranged on the front face of said device (100), - an encapsulating assembly (107), - a second protective film (105), transparent or not, arranged on the rear face of the device, - at least one electrically or optically active element (110) being coated in the encapsulating assembly (107), and - an electrical connection element (160) connected to said electrically or optically active element (110) and adapted to transport electricity from or to said electrically or optically active element (110), characterized in that the electrical connection element (160) is integrated in the multilayer stack and, in that said electrical connection element (160) comprises an outer sheath devoid of halogenated elements and one end (162) of which comes directly out of said functional device (100),so as to avoid the use of an intermediate junction box on the front or rear face of the functional device (100).,

2. A functional device (100) according to claim 1, wherein the electrically or optically active element (110) is a photovoltaic cell, said photovoltaic cell being connected to at least one bypass diode embedded in the encapsulating assembly (107).

3. A functional device (100) according to claim 1 or 2, wherein the outer sheath of the electrical connection element (160) is free of fluoropolymer and / or chloropolymer and / or bromopolymer.

4. A functional device (100) according to any one of claims 1 to 3, wherein the encapsulating assembly (107) comprises a passage allowing the electrical connection element (160) to exit, through the encapsulating assembly (107), to the outside of the functional device (100).

5. Functional device (100) according to any one of claims 1 to 4, wherein the encapsulating assembly (107) comprises: - a first outer encapsulating film (102), - an inner encapsulating film (103), and - a second outer encapsulating film (104).

6. A functional device (100) according to claim 5, wherein the electrical connection element (160) is coated with encapsulating material along its passage through said functional device (100), said encapsulating material being selected from one or more of the materials forming the first outer encapsulating film (102), the inner encapsulating film (103) or the second outer encapsulating film (104).

7. A functional device (100) according to claim 5 or 6, wherein the second outer encapsulating film (104) comprises a first orifice (104a) and the second protective film (105) comprises a second orifice (105a), the first orifice (104a) and the second orifice (105a) being aligned so as to form a through orifice (180) allowing the passage of the electrical connection element (160) through the second outer encapsulating film (104) and the second protective film (105).

8. A functional device (100) according to claim 7, wherein a space between walls of said through-hole (180) and the electrical connection element (160) passing through said through-hole (180) is filled with the same material as that forming the second outer encapsulating film (104).

9. A functional device (100) according to claim 5 or 6, wherein the first outer encapsulating film (102) comprises a third orifice (102a) and the first protective film (101) comprises a fourth orifice (101a), the third orifice (102a) and the fourth orifice (101a) being aligned so as to form a through orifice (182) allowing the passage of the electrical connection element (160) through the first outer encapsulating film (102) and the first protective film (101).

10. A functional device (100) according to claim 9, wherein a space between walls of said through-hole (182) and the electrical connection element (160) passing through said through-hole (182) is filled with the same material as that forming the first outer encapsulating film (102).

11. A functional device (100) according to claim 5 or 6, wherein a passage allowing the exit of the electrical connection element through the inner encapsulating film (103) is included in the inner encapsulating film

12.

13.

14.

15.

16.

17.

18.

19.

20.

21. inner encapsulant (103) or between the first outer encapsulant film (102) and the inner encapsulant film (103) or between the inner encapsulant film (103) and the second outer encapsulant film (104). A functional device (100) according to any one of claims 1 to 11, wherein a bare metal end of said electrical connection element (160) is directly soldered to an electrically conductive portion (150) of said electrically or optically active element (110). Functional device (100) according to any one of claims 1 to 11, wherein a bare metal end of the electrical connection element (160) is connected to an electrically conductive part (150) of said electrically or optically active element (110) by means of an intermediate connection element (190), for example a flat copper strip. The functional device (100) of claim 12, wherein the intermediate connecting element (190) comprises a terminal. Functional device (100) according to any one of claims 1 to 14, wherein the electrical connection element (160) is a round electrical cable. Functional device (100) according to any one of claims 1 to 14, wherein the electrical connection element (160) is a flat metal braid covered with a heat-shrinkable sheath. Functional device (100) according to any one of claims 1 to 16, wherein the electrical connection element (160) has a section less than or equal to 2.5 mm2. Functionalized traffic or pedestrian roadway, comprising a traffic or pedestrian roadway on which is fixed a functional device (100) as defined in any one of claims 1 to 17. Transport vehicle comprising a functional device (100) according to any one of claims 1 to 17. Building envelope comprising a functional device (100) according to any one of claims 1 to 17. A method of manufacturing a functional device (100) according to any one of claims 1 to 17, said method comprising: - a step of connecting the electrical connection element (160) to the electrically or optically active element (110); and - a step of forming the multilayer stack allowing to coat the electrically or optically active element (110) in the encapsulating assembly (107) between the first protective film (101) and the second protective film (105), one end (162) of the electrical connection element (160) directly exiting said functional device (100).

22. A manufacturing method according to claim 21, wherein the step of forming the multi-layer stack is carried out by hot lamination.

23. A manufacturing method according to claim 21 or 22, comprising a step of forming a passage in said encapsulating assembly (107), said passage allowing the exit of the electrical connection element (160) through said encapsulating assembly (107).

24. A manufacturing method according to any one of claims 21 to 23, comprising a step of forming a through-hole (180) through said encapsulating assembly (107) and said second protective film (105) so as to allow the passage of the electrical connection element (160) through said functional device (100).

25. A manufacturing method according to any one of claims 21 to 23, comprising a step of forming a through-hole (180) through said encapsulating assembly (107) and said first protective film (101) so as to allow the passage of the electrical connection element (160) through said functional device (100).

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