Photovoltaic module and method of manufacturing such a module

Abstract

Photovoltaic module and method for manufacturing such a module Photovoltaic module, comprising a stack comprising successively in a direction, called stacking, at least: a layer (FAV), called transparent, in the visible range; a first encapsulation layer (EFAV), a set of photovoltaic cells, a second encapsulation layer (EFAR); and a cellular layer (CA); the second encapsulation layer (EFAV) having an internal face facing the set of photovoltaic cells and an external face facing the cellular layer (CA); the cellular layer has a material shrinkage so as to create an edge of the cellular layer, the edge forming an opening cavity, and at least one layer taken from among the first and second encapsulation layers forms a joint between the edge of the cellular layer and the transparent layer. Figure for the abstract: Fig.12

Description

Title of the invention: Photovoltaic module and method of manufacturing such a module Technical field

[0001] The present invention relates to a photovoltaic module, and more particularly to the manufacture of photovoltaic modules. STATE OF THE ART

[0002] Photovoltaic modules comprise several photovoltaic cells interconnected with each other. These modules are generally assembled together to form a photovoltaic panel.

[0003] There are modules with transparent glass on the front of the module, in particular to protect and stiffen the modules. The glass can also be located on the rear face. In the case where the glass is located on the front face only, these modules include a frame to stiffen the structure of the module and allow it to be fixed within the panel. This process then requires additional material and additional cost.

[0004] Other modules do not have transparent glass and have a honeycomb-type structure on the rear face, i.e. a structure comprising cells, called a honeycomb structure.

[0005] The honeycomb structure allows, in particular, to support the photovoltaic cells and provides a certain rigidity to the module. In general, the honeycomb structure comprises a layer of cells which do not act as a barrier to humidity. It is therefore useful to provide means for sealing the honeycomb structure against liquids and humidity which may come, for example, from rainwater.

[0006] The manufacture of a module is also long and delicate. Furthermore, depending on the type and quantity of materials used, manufacturing can be expensive, and depending on the manufacturing process used, modules can be obtained that are more or less light.

[0007] For example, a method for manufacturing photovoltaic modules equipped with a honeycomb-type structure can be cited, which uses, to cover the honeycomb structure, a layer used on the front face which matches the shape of the honeycomb and is applied to the front face of the module, the front face being larger than the honeycomb. However, this method requires an additional step and material, which makes the method more complex and makes the module heavier.

[0008] We can also cite patent application FR3052595, which discloses a method for manufacturing a photovoltaic module comprising a honeycomb layer, in which three layers of materials are arranged around the honeycomb layer in such a way that to form a frame for the module. The arrangement consists of folding the layers and folding the folds to bring the layers into contact with each other. But this process involves several steps to arrange the different layers, and the waterproofing of the module is not guaranteed because a lack of waterproofing may appear between certain layers brought into contact during the arrangement.

[0009] An object of the present invention is therefore to propose means for overcoming the drawbacks mentioned above, and in particular, to propose means for improving the sealing of a module provided with a honeycomb layer, while reducing manufacturing costs.

[0010] Another object is to limit the amount of material used to make the module lighter.

[0011] Another object is to limit the number of steps in the manufacturing process.

[0012] Other objects, features and advantages of the present invention will become apparent from a consideration of the following description and accompanying drawings. It is understood that other advantages may be incorporated. SUMMARY

[0013] To achieve this objective, a method for manufacturing a photovoltaic module is proposed, comprising providing a stack, the stack successively comprising, in a direction, called stacking, at least: • a layer, called transparent, in the visible range; • a first encapsulation layer, a set of photocells voltaic, a second encapsulation layer; and • an alveolar layer; the second encapsulation layer having an internal face facing the set of photovoltaic cells and an external face facing the alveolar layer; and the method comprising, after supply, lamination of the stack.

[0014] Before lamination, the alveolar layer has a material shrinkage so as to create an edge of the alveolar layer, the edge forming an opening cavity, the opening cavity extending in the stacking direction between the external face of the second encapsulation layer and the edge, and during lamination, at least one layer taken from among the first and second encapsulation layers is deformed so as to form a joint between the edge of the alveolar layer and the transparent layer.

[0015] Thus, a simplified method is provided which improves the sealing of the module against humidity. More particularly, the seal produced makes it possible to hermetically close the module, i.e. to close cells open to the outside of the stack, and thus to increase its reliability. Advantageously, this closure makes it possible to seal the module without having to form a frame prior to the lamination step. The lamination step (also called rolling) consists of exerting pressure on the layers of the stack while heating all of the layers. In addition, this closure is carried out during the lamination step, and does not require an additional operation and avoids that of framing. The process avoids, in particular, cutting off excess encapsulation layers. According to another advantage, it avoids adding additional material during the manufacture of the module. Thus, manufacturing costs are reduced, by reducing the number of complex manufacturing steps (which reduces the cost of purchasing additional equipment) and by reducing the costs of the module by the absence of a frame, that is to say by reducing the quantity of material used.

[0016] According to another aspect, a photovoltaic module is proposed, comprising a stack comprising successively in a direction, called stacking, at least • a layer, called transparent, in the visible domain; • a first encapsulation layer, a set of photocells voltaic, a second encapsulation layer; and • an alveolar layer; the second encapsulation layer having an internal face facing the set of photovoltaic cells and an external face facing the alveolar layer.

[0017] The alveolar layer has a material shrinkage so as to create an edge of the alveolar layer, the edge forming an opening cavity, the opening cavity extending in the stacking direction between the external face of the second encapsulation layer and the edge, and at least one layer taken from among the first and second encapsulation layers forms a joint between the edge of the alveolar layer and the transparent layer. BRIEF DESCRIPTION OF THE FIGURES

[0018] The aims, objects, as well as the characteristics and advantages of the invention will emerge more clearly from the detailed description of an embodiment thereof which is illustrated by the following accompanying drawings in which:

[0019] [Fig.l]

[0020] [Fig.2]

[0021] [Fig.3]

[0022] [Fig.4]

[0023] [Fig.5]

[0024] [Fig.6]

[0025] [Fig.7]

[0026] [Fig.8] Figures 1 to 8 schematically represent different modes of implementing the step of providing a stack;

[0027] [Fig.9]

[0028] [Fig. 10]

[0029] [Fig. 11] Figures 9 to 11 schematically represent different modes of implementation of the lamination step;

[0030] [Fig. 12]

[0031] [Fig.13]

[0032] [Fig. 14]

[0033] [Fig. 15]

[0034] [Fig. 16]

[0035] [Fig. 17] Figures 12 to 17 schematically represent different modes of rea installation of a photovoltaic module;

[0036] [Fig. 18] [Fig. 18] schematically represents another mode of implementation of the lamination step; and

[0037] [Fig. 19] [Fig. 19] schematically represents another embodiment of a photovoltaic module.

[0038] The drawings are given as examples and are not limiting of the invention. They constitute schematic representations of principle intended to facilitate the understanding of the invention and are not necessarily on the scale of practical applications. DETAILED DESCRIPTION

[0039] Before beginning a detailed review of embodiments and implementations of the invention, optional features are set out below which may optionally be used in combination or alternatively.

[0040] According to one example, the removal of material is carried out by ablation of material, the ablation of material being carried out in a perpendicular direction and a longitudinal direction relative to the stacking direction, such that the emerging cavity has a first face oriented perpendicular to the stacking direction and a second face extending from the first face and oriented parallel to the stacking direction.

[0041] According to one example, the material ablation is performed according to a shrinkage thickness having a dimension comprised between 50% and 95%, preferably comprised between 80% and 95%, of the thickness of the alveolar layer, the shrinkage thickness and the thickness of the alveolar layer being measured according to the stacking direction, and the material ablation is further performed according to a shrinkage length having a dimension between 2 mm and 20 mm, preferably between 5 mm and 10 mm, the shrinkage length being measured in a direction perpendicular to the stacking direction.

[0042] According to one example, the removal of material is carried out by cutting out the material, the cutting out the material having a slope at an angle relative to the stacking direction.

[0043] According to one example, the slope is inclined relative to the stacking direction by an angle of between 35° and 60°, preferably by a value close to 45°.

[0044] According to one example, the alveolar layer has at least one face oriented perpendicular to the stacking direction, and the oblique slope is produced so as to reach said at least one face of the alveolar layer.

[0045] According to one example, the alveolar layer has an internal face facing the second encapsulation layer and an external face opposite the internal face, and the slanted slope extends from the internal face of the alveolar layer to the external face of the alveolar layer.

[0046] According to one example, the lamination is carried out by placing the transparent layer in contact with a heating plate and using a membrane in contact with the foam layer.

[0047] According to one example, the lamination is carried out by placing the foam layer in contact with a heating plate and using a membrane in contact with the transparent layer.

[0048] According to one example, the stack comprises a barrier layer between the second encapsulation layer and the alveolar layer.

[0049] According to one example, the removal of material extends, at least in part along the contour of the alveolar layer, preferably over the entire contour of the alveolar layer.

[0050] In figures 111, 118 and 18 the main steps of a method of manufacturing a photovoltaic module 1 are shown. In figures 12 to 17 and 19, different embodiments of a photovoltaic module 1 are shown.

[0051] The manufacturing method comprises a step of providing a stack 2, and a step of laminating the stack 2.

[0052] The stack comprises successively in a direction A, called stacking, at least: • a FAV layer, called transparent, in the visible domain; • a first EF AV encapsulation layer, • a set of CPV photovoltaic cells, • a second EFAR encapsulation layer; and • an alveolar layer CA, also called honeycomb.

[0053] The photovoltaic cells can be of different technologies, for example heterojunction type, and be connected to each other by different types of electrical connections, by ribbons, wires, and different connection modes, by gluing or welding.

[0054] The transparent layer FAV has an external face 3 facing the exterior of the stack 2, and intended to receive light radiation B, and an internal face 4 facing the first encapsulation layer EF AV. In the context of the present invention, a transparent layer is defined as a layer transparent to a given wavelength, that is to say, a layer which makes it possible to transmit at least 70% of a light flux of this given wavelength.

[0055] The transparent FAV layer may comprise a composite material of polypropylene, polyethylene terephthalate, polymethyl methacrylate, polycarbonate, or ethylene tetrafluoroethylene type with one or more adhesive layers. The thickness of the FAV layer may be between 25 μm and 1 mm, preferably between 50 and 300 μm.

[0056] The first encapsulation layer EF AV has an internal face 5 facing the transparent layer FAV, and an external face 6 facing the set of CPV cells.

[0057] The second EFAR encapsulation layer has an internal face 7 facing the set of CPV cells, and an external face 8 facing the alveolar layer CA.

[0058] Preferably, the encapsulation layers EFAR, EF AV, comprise the same material, for example, of the thermoplastic type, crosslinkable, that is to say which can be chemically or physically transformed by crosslinking (for example of the polyolefin elastomer or ethylene-vinyl acetate type), expanded polymer, or ionomer. The thickness of an encapsulation layer, after lamination, is between 100 μm and 600 μm.

[0059] The alveolar layer CA has an internal face 9 facing the second encapsulation layer EFAR, and an external face 10 facing the exterior of the stack 2.

[0060] The honeycomb layer may comprise different honeycomb core materials, for example paper, polypropylene, polyethylene terephthalate, polycarbonate, or polymethyl methacrylate. The CA honeycomb layer makes it possible to stiffen the module 1 and to prevent the structure of the module 1 from being crushed. The honeycomb layer also makes it possible to protect the cells against humidity, ultraviolet rays and fouling.

[0061] Furthermore, the alveolar layer CA may comprise at least one reinforcing layer 50, 51, also called skin, deposited on at least one of these internal and external faces 9, 10. A reinforcing layer 50, 51 may comprise fiberglass. The optional addition of one of these reinforcing layers 50, 51 aims to improve the support cells, and in particular to increase the rigidity of the stack 2, and also aims to improve the sealing of the honeycomb.

[0062] A reinforcing layer 50, 51 may comprise, for example, polypropylene, polyethylene terephthalate, polycarbonate, or polymethyl methacrylate.

[0063] The CA alveolar layer may comprise closed or open cells 13 of size between 0.1 mm and 50 mm. For example, the cells 13 have an average diameter between 1 mm and 15 mm and a thickness between 2 mm and 20 mm. The CA alveolar layer may have a thickness of 10 mm.

[0064] For example, the thickness of the alveolar layer can be between 1 mm and 25 mm.

[0065] Advantageously, as illustrated in [Fig. 6], the stack 2 may comprise a barrier layer CB comprised between the second encapsulation layer EFAR and the alveolar layer CA. In other words, the barrier layer CB has an internal face 40 facing the second encapsulation layer EFAR, and an external face 41 facing the alveolar layer CA. The barrier layer CB makes it possible to add protection of the cells against humidity. The barrier layer CB may be fluorinated or aluminized. The barrier layer CB preferably has a thickness comprised between 50 μm and 300 μm.

[0066] In the context of the present invention, a stack of layers means that one layer is deposited on another layer. Thus, for example, the deposition, transfer, bonding, assembly or application of a first layer on a second layer does not necessarily mean that the two layers are in direct contact with each other, but means that the first layer at least partially covers the second layer by being either directly in contact with it or by being separated from it by at least one other layer or at least one other element. In other words, it will be said that a first layer is directly in contact with a second layer when there is no intermediate layer deposited between the first and second layers.

[0067] Thus, the CA alveolar layer is deposited on the second EFAR encapsulation layer. For example, the CB barrier layer is deposited on the second EFAR encapsulation layer. For example, the CA alveolar layer is directly in contact with the second EFAR encapsulation layer. For example, the CA alveolar layer is directly in contact with the CB barrier layer.

[0068] Furthermore, the second encapsulation layer EFAR is deposited on the first encapsulation layer EF AV so that the set of photovoltaic cells is arranged between the two encapsulation layers EFAR, EF AV. For example, the second encapsulation layer EFAR is directly in contact with the set of CPV cells. For example, the first encapsulation layer EF AV is directly in contact with the CPV cell assembly.

[0069] Further, the first EF AV encapsulation layer is deposited on the transparent FAV layer. For example, the first EF AV encapsulation layer is directly in contact with the transparent FAV layer.

[0070] Generally, after the providing step, the method comprises a lamination step.

[0071] In particular, before the lamination step, the cellular layer CA has a material shrinkage 11 so as to create an edge 12 of the cellular layer CA. The material shrinkage 11 can be carried out before, or during the step of providing the stack 2. The material shrinkage 11 can be carried out after the providing step and before the lamination step. [Fig.l] shows a prior cellular layer CA, i.e. one without a material shrinkage.

[0072] The edge 12 forms an opening cavity, that is to say an unclosed cavity, in particular a cavity open to the outside. When the alveolar layer CA is placed within the stack 2, the opening cavity is open to the outside of the stack 2.

[0073] In particular, the opening cavity extends in the stacking direction A between the external face 8 of the second EFAR encapsulation layer and the edge 12.

[0074] Furthermore, the opening cavity forms cells 13 open to the outside of the stack. Preferably, the cellular layer CA comprises cells 13 extending between the internal face 9 and the external face 11 of the cellular layer CA. The section of the cells 13 may be hexagonal, square, rectangular, triangular, or even circular, or even oval. Thus, in general, the prior cellular layer CA comprises a major portion of closed cells 13, for example all the cells 13 are closed. After an ablation step to form the withdrawal 11, certain cells 13 are open to the outside.

[0075] In [Fig.2] an embodiment of the removal 11 is shown. The provision comprises an ablation of material to form the removal of material 11. In other words, the removal of material is carried out by an ablation of material. For example, the ablation of material is carried out in a direction X perpendicular and a direction Y longitudinal relative to the stacking direction A. In this case, the emerging cavity has a first face 20 oriented perpendicular to the stacking direction A and a second face 21 extending from the first face 20 and oriented parallel to the stacking direction A. In other words, material is selectively removed from the alveolar layer CA, in the direction X, called longitudinal, that is to say according to a removal length 52 of the alveolar layer CA, and in the direction Y perpendicular to the direction X, that is to say according to a removal thickness 53 of the alveolar layer CA.The thickness of a layer of . stack 2 being measured along stacking direction A.

[0076] The shrinkage thickness 53 has a dimension between 50% and 95%, preferably between 80% and 95% of the thickness ECA of the alveolar layer CA.

[0077] The withdrawal length 52 has a dimension between 2 mm and 20 mm, preferably between 5 mm and 10 mm.

[0078] In [Fig. 3], another embodiment of the recess 11 is shown. The supply comprises a material cutout to form the material recess 11, the material cutout having a slanted slope 22 relative to the stacking direction A. In other words, the material removal is achieved by a material cutout. For example, the slanted slope 22 is achieved so as to reach at least one face 9, 10 of the cellular layer CA. According to another example, illustrated in FIGS. 4 and 9, the slanted slope 22 extends from the inner face 9 of the cellular layer CA to the outer face 10 of the cellular layer CA. In other words, the cellular layer CA is cut at an angle strictly greater than 0° and strictly less than 90°, preferably between 35° and 60°, and more preferably a value close to 45°.

[0079] Other more complex geometric shapes to machine are possible.

[0080] Furthermore, the removal of material 11 may extend at least partly along the contour of the alveolar layer CA, the contour extending in a plane oriented perpendicular to the stacking direction A. In other words, the contour extends in a plane oriented parallel to the internal 9 and external 10 faces of the alveolar layer CA.

[0081] In projection along a plane perpendicular to the stacking direction A, the recess 11 forms a main contour. According to one embodiment, the main contour extends over at least one side of the alveolar layer CA. According to another embodiment, the main contour extends over several sides of the alveolar layer CA. According to a preferred embodiment, the main contour forms a closed contour. For example, the main contour has a polygon shape, preferably a rectangle or square shape.

[0082] Furthermore, in projection along a plane containing the stacking direction A, the withdrawal 11 forms a secondary contour. This secondary contour has a first face facing the internal face 9 of the alveolar layer CA, a wall face facing the external face 10 of the alveolar layer CA.

[0083] More particularly, during lamination, at least one layer EFAR, EF AV, taken from among the first and second encapsulation layers EF AV, EFAR is deformed so as to form a joint 14 between the edge 12 of the alveolar layer CA and the transparent layer FAV.

[0084] Thus, the module 1 can be closed, in particular using the seal 14 formed.

[0085] Furthermore, the removal of material makes it possible to weaken the material of the CA cellular layer and makes it possible to give the CA cellular layer the ability to deform during the lamination step. The deformation of the CA cellular layer facilitates the production of the joint 14.

[0086] Furthermore, the seal 14 is configured to at least partially seal at least open cells 13 formed by the cavity. Preferably, the seal 14 is configured to seal all open cells 13 formed by the cavity.

[0087] Thus, it is possible to close the edges of the alveolar layer CA, that is to say to close the cells 13 which were open to the outside of the stack 2 before the lamination.

[0088] The lamination of the stack 2 is preferably carried out using a process, called membrane, in which the honeycomb CA is placed on the side of a membrane 31. The edge 12 will be placed at the level of the membrane 31 so that the closure is done at this location. Indeed, during such a process, the pressure exerted by the membrane 31 is slightly different depending on whether it is measured at the center of the stack 2 on a flat part relative to the edges of the stack 2, or on an angular part, that is to say at the level of the edge 12 of the alveolar layer. Furthermore, a heating plate 30 is used located on the side opposite the membrane 31, the membrane presses on the stack 2. The pressure exerted at the edge of the stack 2 is greater and allows the edge 12 to be crushed at this location.

[0089] The lamination pressure during the pressure lamination phase can be between 300 mbar and 1500 mbar. The temperature will be adapted according to the chemical nature of the alveolar layer with a target temperature close to the finishing temperature of the alveolar layer CA and higher than the melting temperature of the encapsulation layers EFAR, EF AV + / - 15 °C.

[0090] In other words, during the lamination step, the stack 2 is pressed by heating. Thus, the encapsulation layers EF AV, EFAR will flow between the alveolar layer CA and the transparent layer FAV. In particular, the encapsulation layers EF AV, EFAR will be introduced into the opening cavity, for example by at least partially filling the cavity, preferably by filling the entire opening cavity. For example, the seal 14 is formed so that the external face 6 of the first encapsulation layer EF AV comes into contact with the internal face 7 of the second encapsulation layer EFAR. In other words, the encapsulation layers EF AV, EFAR do not mix, as illustrated in FIGS. 12, 14, 16, 17 and 18.According to another example, the seal 14 is formed so that the encapsulation layers EFAR, EF AV mix during the lamination step, and the mixture comes between the edge 12 and the transparent layer FAV, as illustrated in Figures 13 and 15.

[0091] Furthermore, by controlling the dimensions of the FAV and encapsulation layers EFAR, EF AV, it is then possible to not have to cut after lamination. In addition, the encapsulation layers allow the addition of a seal 14 at the level of the honeycomb ensuring its impermeability and improving its reliability over time.

[0092] In Figures 9 and 10, an embodiment of the lamination step is shown. For this implementation, the lamination is carried out by placing the transparent layer FAV in contact with the heating plate 30 and by using the membrane 31 in contact with the alveolar layer CA. Thus, during the lamination, a crushing of the edge 12 is obtained, that is to say a bringing together of the edge 12 towards the transparent layer FAV, the bringing together being carried out in the stacking direction A. Such a crushing makes it possible to obtain a module 1 having a thinned edge.

[0093] In [Fig. 18], another embodiment of the lamination step is shown. For this other implementation, the lamination is carried out by placing the alveolar layer CA in contact with the heating plate 30 and by using the membrane 30 in contact with the transparent layer FAV.

[0094] This other embodiment is particularly suitable when using a membrane 31 which is also heated. The direction of the stacking can then be reversed, compared to the previous embodiment illustrated in FIGS. 9 and 10, which will allow the membrane 31 and therefore the different upper layers, FAV, EF AV, EFAR, to closely match the profile of the honeycomb CA and therefore to close the latter without necessarily thinning it.

[0095] In order to ensure closure with a seal 14 ensuring the sealing of the module 1 while avoiding additional cutting after lamination, a control of the dimensions of the encapsulation layers EFAR, EF AV is to be provided.

[0096] For example, depending on the dimension of the honeycomb CA, a dimension of the encapsulation layers EFAR, EF AV of 5 mm greater than the dimensions of the honeycomb is preferred. This means that for a module of 1 m x 1 m the dimensions of the encapsulation layers EFAR, EF AV will be 1010 mm x 1010 mm, as schematically illustrated in [Fig.7].

[0097] Figures 12 and 13 show the crushing of the edge 12 which occurs during lamination. The honeycomb no longer having sufficient capacity to withstand the pressure exerted, the latter collapses. The encapsulation layers then close the module 1 on its edge by creating the seal 14, which may have the shape of a bead. The bead obtained does not require rework after lamination.

[0098] At the end of the lamination process, the edge 12 of the honeycomb has formed with the encapsulation layers, a seal 14 allowing closure of the module, preferably over its entire contour.

[0099] After the lamination step, a closed module 1 is obtained, i.e. with closed cells 13, as shown in Figures 12 to 17 and 19.

Claims

Claims

1. Method for manufacturing a photovoltaic module, comprising providing a stack, the stack comprising successively in a direction, called stacking, at least: • a layer (FAV), called transparent, in the visible range; • a first encapsulation layer (EFAV), a set of photovoltaic cells, a second encapsulation layer (EFAR); and • a honeycomb layer (CA); the second encapsulation layer (EFAR) having an internal face facing the set of photovoltaic cells and an external face facing the honeycomb layer (CA);and the method comprising, after the supply, a lamination of the stack, characterized in that, before the lamination, the alveolar layer has a shrinkage of material so as to create an edge of the alveolar layer, the edge forming an opening cavity, the opening cavity extending in the stacking direction between the external face of the second encapsulation layer and the edge, and during the lamination, at least one layer taken from among the first and second encapsulation layers is deformed so as to form a joint between the edge of the alveolar layer and the transparent layer.;

2. Method according to the preceding claim, in which the removal of material is carried out by ablation of material, the ablation of material being carried out in a perpendicular direction and a longitudinal direction relative to the stacking direction, so that the emerging cavity has a first face oriented perpendicular to the stacking direction and a second face extending from the first face and oriented parallel to the stacking direction.

3. Method according to the preceding claim, in which the ablation of material is carried out according to a removal thickness (53) having a dimension comprised between 50% and 95%, preferably comprised between 80% and 95%, of the thickness of the alveolar layer (CA), the removal thickness (53) and the thickness of the alveolar layer (CA) being measured according to the stacking direction, and the ablation of material is further carried out according to a removal length (52) having a dimension between 2 mm and 20 mm, preferably between 5 mm and 10 mm, the shrinkage length (52) being measured in a direction perpendicular to the stacking direction.

4. A method according to any preceding claim, wherein the material removal is achieved by cutting material, the material cutting having a slope at an angle relative to the stacking direction.

5. Method according to the preceding claim, in which the slope is inclined relative to the stacking direction by an angle of between 35° and 60°, preferably by a value close to 45°.

6. Method according to any one of claims 4 and 5, in which the alveolar layer has at least one face oriented perpendicular to the stacking direction, and the oblique slope is produced so as to reach said at least one face of the alveolar layer.

7. Method according to the preceding claim, in which the alveolar layer has an internal face facing the second encapsulation layer and an external face opposite the internal face, and the slanted slope extends from the internal face of the alveolar layer to the external face of the alveolar layer.

8. A method according to any preceding claim, wherein the lamination is carried out by placing the transparent layer in contact with a heating plate and using a membrane in contact with the foam layer.

9. A method according to any one of claims 1 to 7, wherein the lamination is carried out by placing the foam layer in contact with a heating plate and using a membrane in contact with the transparent layer.

10. Method according to any one of the preceding claims, in which the stack comprises a barrier layer (CB) between the second encapsulation layer (EFAR) and the alveolar layer (CA).

11. A method according to any one of the preceding claims, wherein the removal of material extends, at least partly along the contour of the alveolar layer, preferably over the entire contour of the alveolar layer.

12. Photovoltaic module, comprising a stack comprising successively in a direction, called stacking, at least: • a layer (FAV), called transparent, in the visible domain; • a first encapsulation layer (EFAV), a set of photovoltaic cells, a second encapsulation layer (EFAR); and • an alveolar layer (CA); the second encapsulation layer (EFAV) having an internal face facing the set of photovoltaic cells and an external face facing the alveolar layer (CA); characterized in that the alveolar layer has a material shrinkage so as to create an edge of the alveolar layer, the edge forming an opening cavity, the opening cavity extending in the stacking direction between the external face of the second encapsulation layer and the edge, and at least one layer taken from among the first and second encapsulation layers forms a joint between the edge of the alveolar layer and the transparent layer.

13. Module according to the preceding claim, in which the removal of material extends, at least partly along the contour of the alveolar layer, preferably over the entire contour of the alveolar layer.

14. Module according to any one of claims 12 and 13, in which the stack comprises a barrier layer (CB) between the second encapsulation layer (EFAR) and the alveolar layer (CA).

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