Lightweight solar module containing glass and polymer front layer

Abstract

The main object of the invention is a photovoltaic module (1) obtained from a stack comprising: a first transparent layer (2) forming the front face; a plurality of photovoltaic cells (4); an assembly (3) encapsulating the plurality of cells (4); and a second layer (5) forming the rear face. The first layer (2) comprises a front layer made of at least one polymeric material (2a); and at least one front assembly (2b, 2c) comprising an interface front layer (2b) and a glass front layer (2c) having a thickness of less than or equal to 2 mm. Said at least one front assembly (2b, 2c) is located between the polymeric front layer (2a) and the encapsulation assembly (3), and the interface front layer (2b) of said at least one front assembly (2b, 2c) is located between the polymeric front layer (2a) and the glass front layer (2c).

Description

[Technical field]

[0001] The present invention relates to the field of photovoltaic modules comprising an array of solar cells electrically connected to one another, in particular so-called "crystalline" solar cells, i.e. based on monocrystalline or polycrystalline silicon. The present invention is particularly useful for civil and / or military applications, e.g. standalone and / or mounted applications, in particular applications which require the use of light and rigid solar modules, in particular those with a weight per unit area of ​​less than 5 kg / m 2 Less than 6kg / m if possible 2 It can be implemented for the following applications: It can thus be applied in particular in residential and industrial (tertiary, commercial, etc.) buildings, for example for making their roofs, or in the design of street furniture, for example for public lighting, road signs, charging of electric vehicles, etc., and possibly also in nomadic applications (solar mobility), in particular for integration in vehicles, for example cars, buses, boats, etc.

[0002] The invention thus provides a lightweight solar module obtained by a stack including a first glass and a polymer layer forming the front side of the module, and a method for manufacturing such a solar module.

[0003] A solar module is an assembly of solar cells arranged between a transparent first layer, which forms the front surface of the solar module, and a second layer, which forms the rear surface of the module.

[0004] Advantageously, the first layer forming the front side of the solar module is transparent so that the solar cells can receive the luminous flux and is usually made from a single sheet of glass, in particular tempered glass, with a thickness in the range of 2 to 4 mm, usually 3 mm.

[0005] Conversely, the second layer forming the rear face of the solar module can be made of glass, metal, plastic, etc. It is often formed by a polymer structure based on an electrically insulating polymer, for example of the polyethylene terephthalate (PET) or polyamide (PA) type, which can be protected by one or more layers based on a fluorinated polymer, for example polyvinyl fluoride (PVF) or polyvinylidene fluoride (PVDF), and can have a thickness in the range of 300 μm.

[0006] The solar cells can be electrically connected to each other by means of front and rear electrical contact elements, so-called connecting conductors, formed for example by tinned copper strips, which are arranged against the front and rear faces of each solar cell on the front face (the face facing the front face of the solar module intended to receive the luminous flux) and rear face (the face facing the rear face of the solar module) of the solar module respectively, or only on the rear face of IBC type solar cells (which means "Interdigitated Back Contact" in English).

[0007] It should be noted that IBC type solar cells ("Interdigitated Back Contact") are structures in which the contacts are made in the form of interdigitated combs on the rear face of the cell. They are described, for example, in US Pat. No. 5,399,363.

[0008] The solar cells may also be located and encapsulated between a first and a second layer, which respectively form the front and rear faces of the solar module. Usually, the encapsulant chosen corresponds to a polymer of the elastomeric (or rubber) type and may consist, for example, of the use of a bilayer (or film) of poly(ethylene-vinyl acetate) (EVA), between which the solar cells and the connecting conductors of the cells are placed. Each encapsulant layer has a thickness of at least 0.2 mm and its Young's modulus at room temperature is usually in the range of 2 to 400 MPa.

[0009] Thus, a conventional example of a solar module 1 including crystalline solar cells 4 is shown partially and diagrammatically in cross-section in FIG. 1 and in exploded view in FIG.

[0010] As mentioned above, the solar cell module 1 comprises a front surface 2, typically made of transparent tempered glass with a thickness of about 3 mm, and a rear surface 5, for example formed by a polymer sheet, the latter being opaque or transparent, single-layered or multi-layered, with a Young's modulus at room temperature of 400 MPa or more.

[0011] The photovoltaic cells 4 are electrically connected by connecting conductors 6 and immersed between two layers of encapsulant on the front face 3a and the rear face 3b, which form an encapsulation assembly 3. These are located between the front face 2 and the rear face 5 of the photovoltaic module 1.

[0012] FIG. 1A also shows a variant of the example of FIG. 1, in which the photovoltaic cell 4 is of the IBC type and the connecting conductors 6 are arranged only on the rear side of the photovoltaic cell 4 .

[0013] 1 and 2 also show a connection box 7 for the photovoltaic module 1 to receive the wiring necessary for the operation of the module. This connection box 7 is usually made of plastic or rubber to ensure a perfect seal.

[0014] Typically, the method for making a photovoltaic module 1 includes the so-called lamination step of laminating the different aforementioned layers under vacuum at a temperature above 120° C., possibly above 140° C., possibly above 150° C. but not exceeding 170° C., typically between 145° C. and 165° C. This step typically lasts for at least 10 minutes, possibly 15 minutes.

[0015] During this lamination process, the layers 3a and 3b of encapsulant melt and encapsulate the photovoltaic cell 4, while at the same time creating adhesion at all interfaces, i.e. between the front surface 2 and the front layer 3a of encapsulant, between the front layer 3a of encapsulant and the front surface 4a of the photovoltaic cell 4, between the rear surface 4b of the photovoltaic cell 4 and the rear layer 3b of encapsulant, and between the rear layer 3b of encapsulant and the rear surface 5 of the photovoltaic module 1. The resulting photovoltaic module 1 is then framed, typically using an aluminium profile.

[0016] Such constructions have become standard due to their high mechanical strength, thanks to the use of a thick glass front2 and an aluminium frame, and in most cases are able to meet the standards IEC 61215 and IEC 61730.

[0017] Nevertheless, the photovoltaic conversion module 1 based on such a conventional design has a weight per unit area of ​​about 10 to 12 kg / m 2 However, it has the disadvantage of being relatively heavy, making it unsuitable for some applications where light weight is a priority.

[0018] The large weight of this photovoltaic module 1 is mainly due to the presence of a thick glass, about 3 mm thick, forming the front face 2; indeed, glass has a high density of about 2.5 kg / m per mm of thickness. 2 and the presence of an aluminium frame. To withstand the stresses during manufacture and for safety reasons (e.g. risk of cutting), the glass is tempered. However, the industrial infrastructure for thermal tempering is set up to handle glass with a thickness of at least 2 mm. Furthermore, the choice of a glass thickness of around 3 mm is also related to its mechanical strength at a standard pressure of 5.4 kPa. After all, the glass represents around 70% of the weight of the photovoltaic module 1, and more than 80% if the aluminium frame around the photovoltaic module 1 is included.

[0019] Therefore, to significantly reduce the weight of photovoltaic modules to enable their use in lightweight applications, such as commercial roofing, an alternative solution to using thick glass on the front of the module needs to be found.

[0020] One possibility is to replace the glass front with a plastic material, mainly to reduce the weight of the large area, while keeping the usual architecture and packaging methods. Thus, polymer sheets such as polycarbonate (PC), polyethylene terephthalate (PET), polymethyl methacrylate (PMMA), polyvinylidene fluoride (PVDF), ethylene tetrafluoroethylene (ETFE), ethylene chlorotrifluoroethylene (ECTFE) or fluoroethylene propylene (FEP) could be a glass replacement. However, if only a simple replacement of the glass by such thin polymer sheets is considered, the photovoltaic cell becomes very vulnerable to shocks, mechanical loads and differential expansion.

[0021] One alternative is to use reinforcing materials, especially glass fiber, carbon fiber or natural fibers such as flax or hemp, and combine these with standard encapsulants to form a polymer / fiber composite, then bond a polymer protective film to the front. Despite reduced transparency and uncertainties over performance over a 20+ year period, the weight savings are significant.

[0022] The elimination of glass from the front surface of photovoltaic modules has been the subject of several existing patents and patent applications, such as those in US Pat. No. 5,399,623, US Pat. No. 5,493,662, US Pat. No. 5,493,394 and US Pat. No. 5,529,636. Other patents and patent applications describe the use of reinforcing materials alone or in composites, such as those in US Pat. No. 5,493,623 or US Pat. Nos. 5,529,613 and 5,529,613. [Prior art documents] [Patent documents]

[0023] [Patent Document 1] U.S. Pat. No. 4,478,879 [Patent Document 2] French Patent Application Publication No. 2955051 [Patent Document 3] US Patent Application Publication No. 2005 / 0178428 [Patent Document 4] International Publication No. 2008 / 019229 [Patent Document 5] International Publication No. 2012 / 140585 [Patent Document 6] European Patent Application Publication No. 2863443 [Patent Document 7] International Publication No. 2018 / 076525 [Patent Document 8] International Publication No. 2019 / 006764 [Patent Document 9] International Publication No. 2019 / 006765 DISCLOSURE OF THEINVENTION

[0024] Therefore, there is a need for alternative photovoltaic module designs that aim to be lightweight to accommodate some applications, have sufficient mechanical properties and can withstand shocks and mechanical loads, especially in line with IEC 61215 and IEC 61730 standards.

[0025] SUMMARY OF THE PRESENT EMBODIMENT Accordingly, the present invention seeks to address, at least in part, the above-mentioned needs and shortcomings associated with prior art embodiments.

[0026] Thus, an object of the invention according to one of its aspects is a photovoltaic module obtained from a stack comprising: - a transparent first layer intended to receive the luminous flux and forming the front surface of the photovoltaic module; - a plurality of photovoltaic cells arranged in parallel and electrically connected to each other; - an assembly including a plurality of photovoltaic cells; a second layer forming a back surface of the photovoltaic module, the enclosure assembly and the plurality of photovoltaic cells being located between the first layer and the second layer; Features of the first layer include: - a front layer made of at least one polymer material, the so-called "polymer front layer", and - at least one front assembly comprising an interface front layer and a glass front layer, the thickness of the glass front layer being not more than 2 mm, preferably not more than 700 μm; The at least one front assembly is positioned between the polymer front layer and the enclosure assembly, and the interface front layer of the at least one front assembly is positioned between the polymer front layer and the glass front layer.

[0027] Advantageously, the invention allows replacing the standard thick glass, about 3 mm thick, commonly used at the front of conventional photovoltaic modules, with a combination of polymer and thin glass layers. The use of thin glass and polymers therefore allows obtaining a low mass and transparency comparable to standard modules. Comparing the invention with the lightweight modules available on the market, the presence of thin glass in the structure improves resistance to shocks, thermo-mechanical expansion and moisture ingress.

[0028] Further advantageously, the use of a polymer type encapsulation material with enhanced mechanical properties, particularly as an encapsulation material for the rear layer of the encapsulation assembly, may further improve resistance to impacts, particularly hail, and may protect the photovoltaic conversion cells from possible mechanical damage.

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

[0030] In particular, the optical transparency of the first layer forming the front surface of the photovoltaic module, in particular the polymer front surface layer, may be 80% or greater between 300 and 1,200 nm. Similarly, the optical transparency of the containment assembly may be 90% or greater, similar to that of the interface front surface layer.

[0031] Furthermore, by the terms "encapsulation" or "encapsulated" it should be understood that a plurality of photovoltaic conversion cells are disposed within a volume, for example sealed from a liquid, and formed at least in part by at least two layers of encapsulation material, which after lamination are integrated together to form an encapsulation assembly.

[0032] Indeed, initially, i.e. before any lamination operation, the encapsulation assembly consists of at least two layers of encapsulation material, so-called core layers, between which a number of photovoltaic cells are encapsulated, but during the lamination operation the layers of encapsulation material melt and after the lamination operation form one solidified layer (or assembly) in which the photovoltaic cells are embedded.

[0033] Furthermore, the present invention allows the surface weight to be reduced to 6 kg / m through the use of thin glass. 2 Less than 5kg / m if possible 2 It may be possible to obtain new lightweight photovoltaic modules that maintain the optical transparency of the front surface and ensure the reliability of the photovoltaic module with low thermomechanical expansion and high durability. Furthermore, the use of polymer front and interface layers allows protection of the thin glass, especially against impacts such as hail.

[0034] The photovoltaic conversion module according to the present invention may further include the following features, either alone or in any technically possible combination.

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

[0036] Furthermore, it may be advantageous for the glass front layer to be untempered glass. Untempered glass is glass that has not undergone any chemical or chemical treatment after production to harden it, and is different from so-called tempered glass. In other words, the glass is not subjected to thermal or chemical tempering. Untempered glass may in fact be less resistant to impacts, in particular those associated with hail impacts. However, by virtue of a polymer protective layer, in particular arranged between the polymer front layer and the interface front layer, untempered glass may be protected from impacts. Untempered glass may also be able to ensure a moisture protection barrier for the photovoltaic cells. The use of untempered glass rather than tempered glass may make it possible to significantly reduce the costs of adapting photovoltaic modules to numerous applications.

[0037] The photovoltaic module may also include an adhesive layer, for example in the form of a film, located between the second layer and the rear layer of the containment material. The adhesive layer may promote adhesion between the second layer and the containment assembly. The thickness of the adhesive layer may be between 20 μm and 100 μm. A plasma type chemical or physical treatment may be used to clean the surface of the second layer to promote adhesion with the adhesive layer.

[0038] The second layer can be formed by a conventional back surface, also called "backsheet" in English. In particular, the second layer can be formed by a polymer structure based on an electrically insulating polymer. In particular, it can consist of at least one polymer material, in particular chosen from the following: polycarbonate (PC), polymethyl methacrylate (PMMA), polyethylene terephthalate (PET), polypropylene (PP), polyamide (PA), fluorinated polymers, in particular polyvinyl fluoride (PVF) or polyvinylidene fluoride (PVDF), ethylene tetrafluoroethylene (ETFE), ethylene chlorotrifluoroethylene (ECTFE), polytetrafluoroethylene (PTFE), polychlorotrifluoroethylene (PCTFE), fluorinated ethylene propylene (FEP) and / or multilayer films containing one or more of the above polymers.

[0039] Where the second layer is in the form of a polymeric multilayer, one or more aluminium layers may be located within and sandwiched within the latter.

[0040] If the final application of the photovoltaic module requires the latter to be laminated onto a rigid support, the choice of a second layer consisting of at least one polymeric material may be preferred.

[0041] Furthermore, the removal of the thick glass on the front side of a conventional photovoltaic module may cause a loss of mechanical strength of the module, and the rear side of the module may be provided with sufficient mechanical rigidity to hold the rigid module.

[0042] In particular, according to the first possibility, the second layer may include: - the main sub-layer, i.e. the rear layer forming the rear panel, made of a composite material including the core of the rear panel and two covering sub-layers, each forming a plate of the rear panel, and placed on either side of the core so that the core is sandwiched between the two plates.

[0043] The use of a composite sandwich panel type rear face may enable the photovoltaic module according to the invention to retain a low weight whilst having very good mechanical and thermomechanical properties.

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

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

[0046] Furthermore, the plate of the rear panel may consist of a composite material, for example of the fiberglass / epoxy prepreg type, in particular of aluminum, polycarbonate (PC), polymethyl methacrylate (PMMA) or prepreg.

[0047] If desired, the rear panel plate may be covered with a polymeric single or multi-layer film, for example of the Tedlar® type.

[0048] In addition, the rear panel has a surface weight of 3kg / m 2 Below, especially 2kg / m 2 The following, more particularly 1 kg / m 2 It may be the following:

[0049] Rather than having a sandwich panel type rear surface, the second layer may include a rear layer that includes a cellular structure, for example of the cellular polycarbonate type, without the use of a covering sub-layer.

[0050] According to the second possibility, the second layer may include: a rear layer made of at least one polymeric material, the so-called "polymer rear layer", and at least one rear assembly comprising an interface rear layer and a glass rear layer, the glass rear layer in particular having a thickness of less than or equal to 2 mm, more preferably less than or equal to 1.5 mm, preferably between 500 μm and 1.1 mm, preferably between 500 μm and 1 mm, preferably between 300 μm and 700 μm, preferably between 300 μm and 500 μm, in particular made of untreated glass, in particular having dimensions strictly smaller than those of the polymer rear layer and in particular having the same dimensions and properties as the glass front layer, said at least one rear assembly being located between the polymer rear layer and the containment assembly, and the interface rear layer of said at least one rear assembly being located between the polymer rear layer and the glass rear layer.

[0051] The second layer may therefore be obtained by a principle similar to that used for the first layer. In particular, the second layer may also comprise a combination of thin glass and polymer. The second layer may or may not be identical to the first layer.

[0052] According to a third possibility, the second layer may comprise a fiber-based fiber-reinforced layer. By "fiber-based fiber-reinforced layer" is meant a layer which mainly comprises organic and / or inorganic fibers, preferably consisting of organic and / or inorganic fibers. Advantageously, the fiber-based fiber-reinforced layer allows mechanical reinforcement of the stack of layers for forming the photovoltaic module. Before lamination, the fibers of the fiber-based fiber-reinforced layer are preferably not impregnated, in particular by a polymeric material. Such a reinforcement layer may be so-called fiberized, non-woven "dry". In particular, such a reinforcement layer is neither a prepreg layer nor a composite layer.

[0053] The fibre-based fibre reinforcement layer may contain woven or non-woven fibres and has a weight per unit area of ​​20 g / m 2 to 1,500 g / m 2 Between 300g / m and 500g / m 2 From 800g / m 2It may contain glass, carbon, aramid fibres and / or natural fibres, in particular hemp, flax and / or silk fibres.

[0054] In particular, the glass used in the front glass layer and / or the rear glass layer may be a soda-lime glass based on silica, calcium, and sodium.

[0055] In a manner advantageously applicable to any embodiment according to the invention, the glass front layer may have dimensions, in particular length and width, strictly smaller than the front layer and the second layer of at least one polymeric material, respectively, and furthermore, the distance between an edge of the glass front layer and an edge of the front layer or an edge of the second layer of at least one polymeric material may be strictly greater than 1 mm.

[0056] Advantageously, the front layer and the second layer of at least one polymer material may have the same dimensions, in particular length and width, and even more advantageously, all layers of the photovoltaic module, except the glass layer, may have the same dimensions, in particular length and width, which correspond to the dimensions of the module, the glass layer being encapsulated within the module. The glass front layer may therefore have dimensions, in particular length and width, that are strictly smaller than each of the photovoltaic modules, and the distance between the edges of the glass front layer and the edges of the photovoltaic modules is strictly greater than 1 mm, such that the glass front layer is encapsulated within the photovoltaic modules.

[0057] In particular, the glass front layer and / or the glass rear layer may have dimensions, in particular length and width, which are strictly smaller than the dimensions of the photovoltaic module obtained by the stack.

[0058] More particularly, the area of ​​the surface of the glass front layer and / or the glass rear layer, i.e. the area defined in a plane transverse to the stacking direction, is strictly smaller than the area of ​​the surface of any other layer of the stack in a plane transverse to the stacking direction, so that the glass front layer and / or the glass rear layer are encapsulated between two layers located on either side of the glass front layer and / or the glass rear layer, respectively.

[0059] More particularly, the distance between the edge of the photovoltaic module resulting from the stack and the edge of the front glass layer and / or the rear glass layer may be strictly greater than 1 mm.

[0060] In the particular case of untreated glass, which is sensitive to fracture by impact on its edges, the reduced dimensions allow them to be protected from impact by an encapsulation that includes the edges.

[0061] Furthermore, the distance between the edge of the glass front layer and / or the glass rear layer and the edge of the photovoltaic cell and / or the edge of the connecting conductor connecting the photovoltaic cell adjacent to the edge of the glass front layer may be in the range of between 0 and 15 mm, preferably 5 mm.

[0062] Also, the front and / or rear glass layers may comprise one single glass layer or may correspond to a glass laminate. If desired, the two front and rear glass layers may each comprise separate glass layers or glass laminates, whether or not they comprise the same number of layers in each laminate. Alternatively, one may be a separate glass layer and the other a glass laminate.

[0063] In particular, the glass front layer may have rounded edges at its corners, in particular with a radius of curvature strictly greater than 1 mm, preferably smaller than 25 mm.

[0064] Furthermore, the glass front layer and / or the glass rear layer may have four rounded edges, especially at the four corners of layers with a square or rectangular shape. Indeed, mechanically, right angles form stress concentrations and are therefore very fragile, especially in the case of untempered glass. A fillet at the corners can therefore reduce the stress experienced at the corners. The radius of curvature may be strictly greater than 1 mm, preferably 5 mm. The radius of curvature may also be strictly smaller than 25 mm.

[0065] Furthermore, the photovoltaic module resulting from the stack may be completely devoid of a metal frame, especially made of aluminum.To provide mechanical rigidity to the edges and ease of handling, the stack may include a polymer frame placed all around the glass front layer and / or the glass rear layer.

[0066] Such a polymer frame may be added during manufacture of the module and placed in contact with the glass layers in the same plane.

[0067] In particular, the photovoltaic module may comprise a polymer frame arranged all around the periphery of the glass front layer, the polymer frame in particular having a width between 5 mm and 50 mm, preferably between 20 mm and 40 mm.

[0068] Furthermore, the polymeric front layer and / or the polymeric rear layer may have a thickness between 15 μm and 300 μm, in particular between 20 μm and 50 μm.

[0069] Furthermore, the polymeric material of the polymeric front layer and / or the polymeric rear layer may be selected from: polycarbonate (PC), polymethyl methacrylate (PMMA), polyethylene terephthalate (PET), polyamide (PA), fluorinated polymers, in particular polyvinyl fluoride (PVF) or polyvinylidene fluoride (PVDF), ethylene tetrafluoroethylene (ETFE), ethylene chlorotrifluoroethylene (ECTFE), polytetrafluoroethylene (PTFE), polychlorotrifluoroethylene (PCTFE), fluorinated ethylene propylene (FEP) and / or multilayer films comprising one or more of the above polymers, etc.

[0070] Furthermore, the polymer front layer and / or the polymer rear layer may have a UV cut-off filter (in English "UV cutoff") comprised between 320 nm and 450 nm, which corresponds to a wavelength at which the transmission is 50%. In this way, the underlying layers are protected from ultraviolet (UV) radiation and possibly from hydrolytic ageing, which increases the lifetime of the photovoltaic module.

[0071] The interfacing front layer and / or the interfacing rear layer may enable adhesion between the polymeric front layer, respectively the polymeric rear layer, and the glass layer, or between two glass layers.

[0072] The interface front layer and / or the interface rear layer may have a thickness of between 50 μm and 600 μm, preferably between 400 μm and 600 μm, possibly between 400 μm and 500 μm.

[0073] The interface front layer and / or the interface rear layer may have a Young's modulus between 2 and 300 MPa at 25°C, preferably between 100 and 200 MPa at 25°C, preferably between 2 and 250 MPa at 25°C, preferably between 10 and 50 MPa at 25°C, preferably between 2 and 50 MPa at 25°C, preferably between 2 and 20 MPa at 25°C.

[0074] The encapsulation assembly is obtained by combining a front layer and a rear layer of encapsulation material on either side of the photovoltaic conversion cell, advantageously in direct contact with the latter, the front layer of encapsulation material being located between the first layer and the photovoltaic conversion cell.

[0075] The front layer of inclusion material may be formed by at least one layer including at least one polymer type inclusion material having a Young's modulus at 25° C. strictly less than 50 MPa.

[0076] Furthermore, the rear layer of inclusion material may be formed by at least one layer including at least one polymer type inclusion material having a Young's modulus at 25° C. strictly greater than 150 MPa.

[0077] Advantageously, the use of a polymer-type encapsulation material with enhanced mechanical properties, in particular for the rear layer of encapsulation material of the encapsulation assembly, makes it possible to further improve resistance to impacts, in particular hail, on the photovoltaic conversion module and to protect the photovoltaic conversion cells from possible mechanical damage.

[0078] The front layer of the inclusion material may be formed by at least one layer comprising at least one polymer type inclusion material having a Young's modulus at 25°C strictly less than 50 MPa, in particular greater than 2 MPa and less than 50 MPa, preferably less than 20 MPa, in particular between 10 MPa and 20 MPa.

[0079] Furthermore, the rear layer of inclusion material may be formed by at least one layer comprising at least one polymer type inclusion material having a Young's modulus at 25° C. strictly higher than 200 MPa, in particular strictly higher than 200 MPa and less than 500 MPa, in particular between 250 MPa and 350 MPa.

[0080] Furthermore, the elongation at break of the front and / or rear layers of the containment material is advantageously at least 200% or more.

[0081] The use of a rear layer of a high Young's modulus containment material may provide increased resistance to hail-type impacts.

[0082] The front layer of containment material may be formed by at least one layer comprising at least one polymer type of containment material selected from the following: poly(ethylene vinyl acetate) (EVA), vinyl acetal, such as polyvinyl butyral (PVB), polyurethane, silicone elastomer, crosslinked thermoplastic polyolefin-based elastomer and / or crosslinked thermoplastic polyolefin (TPO)-based elastomer, and the like.

[0083] The rear layer of containment material may be formed by at least one layer including at least one polymer type containment material selected from the following: acid copolymers, ionomers, polyvinyl chloride, and / or polyethylene.

[0084] Furthermore, the containment assembly, the interface front layer and / or the possible interface rear layer may be formed by at least one layer comprising at least one polymer type of containment material selected from the following: acid copolymers, iomers, poly(ethylene-vinyl acetate) (EVA), vinyl acetals such as polyvinyl butyral (PVB), polyurethanes, polyvinyl chloride, polyethylenes such as linear low density polyethylene, copolymers of elastomeric polyolefins, copolymers of α-,β-esters of ethylene carboxylic acids such as ethylene-methyl acrylate copolymers and ethylene-butyl acrylate copolymers, silicone elastomers and / or crosslinked thermoplastic polyolefin-based elastomers.

[0085] Preferably, the containment material of the containment assembly is the same as the material of the interface front layer and possibly the material of the interface rear layer, in this way it may be possible to facilitate the manufacturing process.

[0086] According to certain embodiments, one of the front and rear layers of the containment material of the containment assembly, particularly the rear layer of the containment material, may comprise the same containment material as the containment material of the interface front layer, and the other of the front and rear layers of the containment material of the containment assembly, particularly the front layer of the containment material, may comprise a containment material different from the containment material of the interface front layer.

[0087] The containment assembly may have a thickness between 200 μm and 600 μm, in particular between 400 μm and 600 μm. Further, the containment assembly may have a Young's modulus between 2 MPa and 400 MPa at 25° C., preferably between 2 MPa and 200 MPa at 25° C.

[0088] Furthermore, the photovoltaic conversion cells may be selected from the following: homojunction or heterojunction photovoltaic conversion cells based on monocrystalline silicon (c-Si) and / or polycrystalline silicon (mc-Si), and / or IBC type photovoltaic conversion cells, and / or photovoltaic conversion cells including at least one material such as amorphous silicon (a-Si), microcrystalline silicon (μC-Si), cadmium telluride (CdTe), copper indium selenide (CIS), copper indium / gallium selenide (CIGS), and perovskite.

[0089] Furthermore, the photovoltaic cell may have a thickness between 1 and 300 μm, in particular between 1 and 200 μm, advantageously between 70 μm and 160 μm.

[0090] The photovoltaic module may further include a connection box for receiving wiring necessary for operation of the photovoltaic module, which is located on the front or rear of the module, preferably on the front.

[0091] Furthermore, the spacing between adjacent, consecutive or adjacent photovoltaic cells may be 1 mm or more in some configurations, particularly between 1 mm and 30 mm, preferably 2 mm. In other configurations, particularly according to the English name "single" type (or French "bardeau"), adjacent, consecutive or adjacent photovoltaic cells may overlap or have a spacing less than 1 mm.

[0092] According to certain embodiments, the first layer may comprise: - a first front assembly including an interface front layer and a glass front layer, the thickness of the glass front layer being 2 mm or less; - a second front assembly including an interface front layer and a glass front layer, the thickness of the glass front layer being 2 mm or less; The first front face assembly is positioned between the polymeric front face layer and the second front face assembly, which is itself positioned between the first front face assembly and the containment assembly.

[0093] The thickness of the glass front layer of the first front assembly and the thickness of the glass front layer of the second front assembly may be the same or different, in particular the thickness of the glass front layer of the first front assembly may be greater than the thickness of the glass front layer of the second front assembly.

[0094] Advantageously, the dimensions of the glass front layer of the first front assembly and the dimensions of the glass front layer of the second front assembly are identical, in particular as described above for the glass front layers. Additionally, the second layer may include: a rear layer made of at least one polymeric material, the so-called "polymer rear layer", and - a first rear assembly comprising an interface rear layer and a glass rear layer, the glass rear layer having in particular a thickness of less than or equal to 2 mm, in particular less than or equal to 1.5 mm, preferably between 500 μm and 1.1 mm, preferably between 500 μm and 1 mm, preferably between 300 μm and 700 μm, preferably between 300 μm and 500 μm, in particular made of untempered glass, - a second rear assembly comprising an interface rear layer and a glass rear layer, the glass rear layer having in particular a thickness of not more than 2 mm, in particular not more than 1.5 mm, preferably between 500 μm and 1.1 mm, preferably between 500 μm and 1 mm, preferably between 300 μm and 700 μm, preferably between 300 μm and 500 μm, in particular made of untempered glass, The aforementioned first rear assembly is located between the polymeric rear layer and the second rear assembly, which is itself located between the first rear assembly and the containment assembly. Advantageously, the dimensions of the glass rear layer of the first rear assembly and the dimensions of the glass rear layer of the second rear assembly are identical, in particular as described above for the glass front layer. Furthermore, the object of the invention is also a method for manufacturing a photovoltaic module, in particular as defined above, from a stack comprising: - a transparent first layer intended to receive the luminous flux and forming the front surface of the photovoltaic module; - a plurality of photovoltaic cells arranged in parallel and electrically connected to each other; - an assembly including a plurality of photovoltaic cells; - the second layer, the containment assembly and the plurality of photovoltaic conversion cells are located between the first layer and the second layer; Features of the first layer include: - a front layer made of at least one polymer material, the so-called "polymer front layer", and - at least one front assembly including an interface front layer and a glass front layer, the thickness of the glass front layer being 2 mm or less; the at least one front assembly is positioned between the polymer front layer and the containment assembly, and the interface front layer of the at least one front assembly is positioned between the polymer front layer and the glass front layer; The method is characterized in that it includes a step of thermal lamination under vacuum of the constituent layers of the stack.

[0095] In particular, the step of thermal lamination under vacuum is carried out at a temperature of at least 120°C, preferably at least 140°C, preferably at least 150°C, but not more than 170°C, preferably not more than 180°C, typically between 130°C and 180°C, preferably between 145°C and 165°C, and the duration of the lamination cycle is at least 5 minutes, preferably 10 minutes, preferably 15 minutes, in particular between 5 minutes and 20 minutes.

[0096] It is thus possible to obtain a total encapsulation of thin glass, which provides protection against impacts.

[0097] Furthermore, another object of the present invention is the use of: - a photovoltaic module as defined above, in particular of the type having a sandwich structure at the rear face, i.e. comprising a rear layer forming a rear panel of composite material, a main sublayer, i.e. a core of the rear panel, and two covering sublayers, each forming a plate of the rear panel and arranged on either side of the core, such that the core is sandwiched between the two plates, the core of the rear panel comprising a cellular structure, and - a support for fixing a photovoltaic conversion module, comprising at least two support and fixing elements, in particular in the form of rails, which are arranged at a distance from one another and preferably extend substantially parallel, characterized in that it comprises a step of placing the photovoltaic conversion module in contact only with said at least two support and fixing elements and fixing the photovoltaic conversion module.

[0098] In the case of a photovoltaic module comprising a conventional second rear layer of the "backsheet" type, the module is advantageously glued directly to its support, for example a roof support.

[0099] The photovoltaic conversion module and its manufacturing method according to the invention may comprise any of the above mentioned characteristics either individually or in any technically possible combination with other characteristics.

[0100] The invention will be better understood by studying the schematic and partial drawings attached in the following drawings and by reading the detailed description of the embodiments that follow. [Brief description of the drawings]

[0101] [Figure 1] FIG. 1 shows a cross section of a conventional example of a photovoltaic conversion module including a crystalline photovoltaic conversion cell. [Figure 1A] FIG. 1A shows a modification of the example of FIG. 1 in which the photovoltaic conversion cell is of the IBC type. [Diagram 2] FIG. 2 shows an exploded view of the photovoltaic conversion module of FIG. [Diagram 3] FIG. 3 shows a perspective view and an exploded view of a first embodiment of a photovoltaic conversion module according to the present invention. [Figure 3A] FIG. 3A illustrates in cross section an example of a rear layer used in the photovoltaic module shown in FIG. [Figure 3B] FIG. 3B shows, in a top view, a mechanical test setup, in particular for hail impact tests according to IEC 61215, of a photovoltaic module according to the invention. [Figure 3C] FIG. 3C shows, in a top perspective view, an example of use of the photovoltaic conversion module according to the present invention. [Figure 3D] FIG. 3D shows, in a top perspective view, another example of the use of a photovoltaic conversion module according to the present invention. [Figure 4] FIG. 4 shows a perspective view and an exploded view of a second embodiment of a photovoltaic conversion module according to the present invention. [Diagram 5] FIG. 5 shows a perspective view and an exploded view of a third embodiment of a photovoltaic conversion module according to the present invention. [Figure 6] FIG. 6 shows a perspective view and an exploded view of a fourth embodiment of a photovoltaic conversion module according to the present invention. [Figure 7] FIG. 7 is a partial top view of an example photovoltaic module illustrating the principle of reduced-scale glass layers relative to the photovoltaic module. [Figure 8]FIG. 8 is a top view of an example front and / or rear glass layer including rounded edges at its corners. [Figure 9A] FIG. 9A is a partial top view of an example photovoltaic module including a glass layer with a polymer frame around its perimeter. [Figure 9B] FIG. 9B is a partial cross-sectional view of the photovoltaic conversion module of FIG. 9A.

[0102] In all these figures, the same reference numbers may designate the same or similar elements. Moreover, the different parts shown in the figures are not necessarily drawn according to a uniform scale in order to make the figures easier to read. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0103] 1, 1A and 2 have already been described in the prior art section.

[0104] 3 to 9B are used to illustrate four different embodiments of the photovoltaic module 1 according to the present invention.

[0105] Here, the photovoltaic cells 4 interconnected by welded tinned copper strips as shown in Figures 1, 1A and 2 are considered to be "crystalline" cells, i.e., they contain monocrystalline or polycrystalline silicon and are between 1 and 250 μm thick.

[0106] Furthermore, the polymer front layer 2a is a fluorinated polymer film, in particular made of ethylene chlorotrifluoroethylene (ECTFE), the thickness of which may be in the range of 20 μm, for example Amcor® ECTFE 020 type.

[0107] The interface layers 2b, 2d and 5b may comprise a polymer-containing film of type A, for example made of a thermoplastic polyolefin-based elastomer (TPO) or type B, made of an ionically crosslinked thermoplastic copolymer. The thickness may be between 500 and 600 μm. In particular, for the polymer-containing film of type B, it is for example KuranSeal-ES® (PV8729D / UV CUT) of Kurabo, and has a thickness of 500 μm.

[0108] Glass layers 2c, 2e and 5c may comprise untempered thin glass having a thickness between 500 and 800 μm, for example in the range of 550 μm.

[0109] The second layer 5 may take the form of a polymer layer or multilayer of the "backsheet" type or may take the form of a polymer structure based on an electrically insulating polymer.

[0110] The second layer 5 may also take the form of a rear panel 5 having a "sandwich" type structure, comprising a core 9a made of polypropylene honeycomb and composite skins or plates 9b, 9c made of glass-reinforced polypropylene, for example of a thickness between 6 and 10 mm, for example of the Nidapan® 8 GR 600 type having a thickness of 10 mm. Of course, these choices are in no way limiting.

[0111] All stack examples described with reference to Figures 3 to 9B have been tested for hail-type mechanical impacts representative of an energy level of 2 J. The results show that by incorporating thin untreated glass into the modules it is possible to obtain impact resistance in accordance with current standards while reducing the weight.

[0112] In particular, for photovoltaic modules in which the second layer 5 is in the form of a "sandwich" type rear panel 5 as shown in Fig. 3A, the mechanical shock test was carried out according to the setup shown in Fig. 3B. Thus, for example, a photovoltaic module 1 with dimensions of 40 cm x 40 cm was fixed on two aluminium rails 12 with a thickness of 4 cm. This fixing was carried out by means of clamps 13. The remaining parts of the module 1, apart from the contact surfaces between the photovoltaic module 1 and the aluminium rails 12, were not in contact with any other surface.

[0113] The results show that the use of non-annealed thin glass in the range of 700 μm, in accordance with current standards, increases the improvement of the impact resistance in the photovoltaic module 1 in discontinuous installation configuration.

[0114] To explain the different configurations, reference is first made to Figure 3, which shows in perspective and exploded view a first embodiment of a photovoltaic module 1 according to the invention.

[0115] It should be noted that figure 3 corresponds to an exploded view of the photovoltaic module 1 before the lamination step of the method according to the invention. Once the lamination step is completed, by ensuring heating and pressing under vacuum, the different layers are actually in contact with each other and in particular penetrate each other.

[0116] Thus, the photovoltaic module 1, or more specifically the stack for forming the photovoltaic module 1, comprises a first layer 2 forming the front side of the photovoltaic module 1 intended to receive a light flux, a plurality of photovoltaic cells 4 arranged in parallel and electrically connected to one another, an assembly 3 encapsulating the plurality of photovoltaic cells 4, and a second layer 5 forming the rear side of the photovoltaic module 1. A connection box 7 may also be arranged on the front or rear side of the photovoltaic module 1, as shown in Figures 1, 1A and 2.

[0117] According to the invention and in common with the examples of figures 3 to 6, the first layer 2 comprises a front layer made of a polymer material 2a, the so-called "polymer front layer 2a", and a first front assembly 2b, 2c comprising an interface front layer 2b and a glass front layer. Advantageously, the glass front layer 2c has a thickness e2c of less than or equal to 2 mm, preferably less than or equal to 1.5 mm, preferably between 500 μm and 1.1 mm, preferably between 500 μm and 1 mm, preferably between 300 μm and 700 μm, preferably between 300 μm and 500 μm. In this example, the front encapsulation layer 3a, the rear encapsulation layer 3b and the interface front layer 2b are all encapsulation films of type A.

[0118] In all the examples shown in figures 3 to 6, the invention can advantageously provide for having a rear layer of encapsulant having a Young's modulus at 25°C strictly higher than 150 MPa, in particular strictly higher than 200 MPa, preferably strictly higher than 200 MPa, possibly lower than 150 MPa, less than 500 MPa, possibly between 250 and 350 MPa. The front layer of encapsulant 3a can be identical to the rear layer of encapsulant 3b according to one embodiment. Alternatively, it can be different, in particular having a Young's modulus at 25°C strictly lower than 50 MPa, preferably higher than 2 MPa and strictly lower than 50 MPa, possibly between 10 and 20 MPa.

[0119] The front layer of encapsulant 3a can be an encapsulating film of type A, while the back layer of encapsulant 3b can be an encapsulating film of type B. Alternatively, the front 3a and back 3b layers can be encapsulating films of type B.

[0120] Thus, through the use of an encapsulation film of type B for the back layer 3b of encapsulant, it is possible to limit or completely avoid the phenomenon of breakage of the glass and the photovoltaic cell 4 compared to the use of an encapsulation film of type A.

[0121] The second layer 5 may be formed by a conventional back surface, i.e. also called "backsheet" in English, as shown in FIG. 3. In particular, the second layer 5 may be formed by a polymer structure based on an electrically insulating polymer. In particular, it may consist of at least one polymer material, in particular chosen from the following: polycarbonate (PC), polymethyl methacrylate (PMMA), polyethylene terephthalate (PET), polypropylene (PP), polyamide (PA), fluorinated polymers, in particular polyvinyl fluoride (PVF) or polyvinylidene fluoride (PVDF), ethylene tetrafluoroethylene (ETFE), ethylene chlorotrifluoroethylene (ECTFE), polytetrafluoroethylene (PTFE), polychlorotrifluoroethylene (PCTFE), fluorinated ethylene propylene (FEP) and / or multilayer films containing one or more of the aforementioned polymers. In the case of the second layer 5 in the form of a polymer multilayer, one or more aluminum layers may be located within the multilayer and sandwiched by the latter.

[0122] The second layer 5 may also be in the form of a "sandwich" type structure. For example, the second layer 5 may be formed by a back panel 5 of composite material consisting of a main sublayer, i.e. the core 9a of the back panel 5, and two covering sublayers, each forming a plate 9b, 9c of the back panel 5. These sublayers are arranged on either side of the core 9a, such that the core 9a is sandwiched between the two plates 9b, 9c. The core 9a of the back panel 5 includes a cell structure 12. Figure 3A shows such a second layer 5 in more detail and in cross section in a schematic manner.

[0123] Furthermore, alternatively, the second layer 5 may comprise a reinforcing layer, whether woven or not, in particular based on fibres such as glass, carbon, aramid and / or natural fibres, in particular hemp fibres, flax and / or silk.

[0124] The photovoltaic module 1 is obtained through a single process of thermal lamination under vacuum, for example at about 150° C. for about 15 minutes. It has a weight per unit area of ​​4 to 6 kg / cm 2 for example 6 kg / cm for layer 5 of the "backsheet" type. 2 and 4kg / cm for layer 5 of the "sandwich" structure. 2 The range is.

[0125] It is also possible to use encapsulation films of type B for the encapsulation front layer 3a, the encapsulation back layer 3b and the interface front layer 2b. The impact resistance of the photovoltaic module 1 is then further improved due to the higher Young's modulus.

[0126] In the case of the second layer 5 in the form of a "sandwich" structure, of the type of FIG. 3A, FIGS. 3C and 3D show two examples of settings for the use of such a photovoltaic module 1 according to the invention.

[0127] The use of the photovoltaic module 1 according to the invention consists in positioning the module 1 and fixing it to supports M, T which comprise supporting and fixing elements 12, in particular rails 12 parallel to one another and defining a space between them.

[0128] 3C, the panel 5 of the photovoltaic conversion module 1 is not directly bonded to the sealing membrane M resulting in no separation between the surface of the membrane M and the panel 5. Conversely, the rails 12 are arranged on the membrane M and spaced apart from each other, and the panel 5 of the photovoltaic conversion module 1 is fixed directly and only in contact with the rails 12.

[0129] Moreover, in the example of Fig. 3D, the panels 5 of the photovoltaic conversion modules 1 are fixed to parallel and spaced apart ribs or corrugations, i.e. rails 12, of a sheet metal T, for example made of steel. The unique contact of the sheet metal T on the rails 12 avoids contact of moisture and potential contamination and provides more space for the placement of the panels 5. Conversely, flexibility is obtained in the selection of the dimensions of the panels 5 and / or the sheet metal T, the spacing between the surface of the sheet metal T and the panels 5, and the resistance to hail in relation to the principles of the invention.

[0130] The invention can therefore provide a photovoltaic module 1 and its use particularly suitable for applications sensitive to overloads, especially on roofs, maintaining a separation between the panel 5 and the surface, especially the roof. In the case of a substantially flat roof of the terrace type, as in the example of FIG. 3C, or in the case of a sloping roof, as in the example of FIG. 3D, the invention can reduce the contact of the module 1 with the roof surface and thus allow the limitation of the penetration of moisture or the phenomenon of freezing and thawing, protecting it and ensuring sealing. The use of existing or specific supports may be taken into account.

[0131] Furthermore, FIG. 4 shows a second embodiment according to the invention.

[0132] In this example, unlike that of FIG. 3, the first layer 2 also comprises a second front assembly 2d, 2e consisting of an interface front layer 2d and a glass front layer, advantageously non-annealed glass 2e. The glass front layer 2e has a thickness e 2e is less than or equal to 2 mm, preferably less than or equal to 1.5 mm, preferably between 500 μm and 1.1 mm, preferably between 500 μm and 1 mm, preferably between 300 μm and 700 μm, preferably between 300 μm and 500 μm. In other words, this embodiment provides for doubling the thickness of the glass of the first layer 2, so that the surface weight is less than 6 kg / cm 2 Thus, the photovoltaic conversion module 1 is obtained. The impact resistance of the photovoltaic conversion module 1 is further improved.

[0133] Furthermore, the first interface front layer 2b and the encapsulation layers of the front 3a and back 3b are formed by an encapsulation film of type A, while the second interface front layer 2d is formed by an encapsulation film of type B.

[0134] In the example of Figure 4, the first glass front layer 2b and the second glass front layer 2e have the same thickness. Alternatively, different thicknesses of glass can be used, for example thickness e 2b is in the range of 500 μm, and the thickness e 2e Thus, considering using 800 μm glass to meet the impact resistance needs of cell 4, it is possible to use, for example, 500 μm glass and 300 μm glass.

[0135] In fact, it is known that elastomeric materials have vibration and shock absorbing properties. The alternating use of hard and elastomeric materials therefore makes it possible to modify the speed of propagation of the shock waves, since their speed is directly proportional to the Young's modulus and the Poisson's coefficient of the material used. The propagation of the shock waves can therefore be slowed down by inserting flexible elastomeric layers between layers of harder materials. Moreover, at each interface that is encountered, the shock waves can be partially transmitted or reflected. The alternating repetition of these polymer layers therefore makes it possible to slow down the shock waves on the one hand and to reduce the intensity of the latter that reaches the photovoltaic cell on the other hand.

[0136] Also, when using an equivalent amount of glass, it may be more advantageous to distribute this amount between at least two layers of glass of different thicknesses, instead of one single layer of glass.

[0137] 5 also shows a third embodiment based on the principle of symmetrically using the same encapsulation architecture on the back as on the front, thus making it possible to obtain a bifacial and lightweight photovoltaic module 1.

[0138] The second layer 5 here therefore comprises a back layer made of a polymer material 5a, the so-called "polymer back layer" 5a, and a first back assembly 5b, 5c comprising an interface back layer 5b and a glass back layer, preferably non-annealed 5c.

[0139] The glass back layer 5c has a thickness e 5c 550 μm, and the glass front layer 2c also has a thickness e 2c is 550 μm.

[0140] The interface front layer 2b, the interface back layer 5b, the front 3a and back 3b encapsulation layers here consist of type B encapsulation film.

[0141] Furthermore, FIG. 6 shows a fourth embodiment corresponding to a variant of the example of FIG. 5, in which the use of non-annealed thin glass at the front and rear is asymmetric.

[0142] In particular, two thin glasses 2c and 2e are used at the front, which may be of the same or different thickness, and a thin glass 5c is used at the rear. More specifically, here, the first glass front layer 2c has a thickness e 2c 500 μm, the second glass front layer 2e has a thickness e 2e 300 μm, the first glass back layer 5c has a thickness e 5c is 550 μm.

[0143] Moreover, the first interface front layer 2b, the second interface front layer 2d, the interface back layer 5b, the encapsulation layers of the front side 3a and the back side 3b here are composed of type B encapsulation film.

[0144] In all the above examples, the polymer front layer 2a and the polymer back layer 5a have a thickness e in the range of 20 μm. 2a , e 5a has.

[0145] The interface front layers 2b, 2d and the interface back layer 5b have a thickness e in the range of 600 μm.2b , e 2d , e 5b has.

[0146] Additionally, Figures 7 through 9B illustrate another feature of the invention that is applicable to all of the above examples.

[0147] In particular, Figure 7 shows the fact that the glass layers, e.g. the glass front layer and / or the glass rear layer, here the front layer 2c or 2e or the rear layer 5c, can have dimensions strictly smaller than the dimensions of the polymer front layer 2a and the second layer 5, in particular the dimensions of the photovoltaic conversion module 1 obtained by a stack in which all layers have the same dimensions except for the glass, i.e. the same length and the same width.

[0148] In particular, the length of such a glass layer is strictly less than the length of the module and the width of such a glass layer is strictly less than the width of the module, in other words, the surface area of ​​such a glass layer, defined in a plane transverse to the stacking direction, is strictly less than the surface area of ​​any other layer of the stack in a plane transverse to the stacking direction.

[0149] Advantageously, such a glass layer is then encapsulated between two layers located on either side of it.

[0150] If an unannealed glass has the property of breaking upon impact at its edges, the reduced dimensions make it possible to protect it from impact by total encapsulation of the glass layer, including the edges.

[0151] The dimensions of the glass are characterized by the distance between the edge of the last conductive element and the edge of the glass, i.e. here the distance a between the edge of the cell 4 and the edge of the glass on sides B and C of the module, and the distance a between the edge of the last strip 6 and the edge of the glass on side A of the module facing the connection box 7. This distance a is between 0 and 15 mm, preferably in the range of 5 mm.

[0152] Furthermore, the distance b between the edge of the glass layer and the edge of the polymer front layer 2a or the second layer 5, in particular the edge of the photovoltaic module 1 when all layers except the glass layer have the same dimensions, can be strictly greater than 1 mm, which applies to all four edges A, B, C and D of the photovoltaic module 1.

[0153] Furthermore, on side D of the module where the connection box 7 is present, the glass layer is partially located underneath the connection box 7. The overlap can be between 1 and 30 mm, preferably between 1 and 10 mm.

[0154] The distance b' between the edge of the glass layer 2c, 2e, 5c and the edge of the polymer front layer 2a or the second layer 5, particularly in the case where all layers except the glass layer have the same dimensions, of the photovoltaic conversion module 1, is at least 5 mm, preferably between 25 mm and 50 mm, possibly in the range of 37 mm.

[0155] Additionally, Figure 8 illustrates the possibility of the glass plies having rounded edges at the corners, particularly four rounded edges at the four corners of a square or rectangular shaped ply.

[0156] Indeed, mechanically, right angles form stress concentrations and are therefore very fragile, especially in the case of non-annealed glasses. A fillet of the corners can therefore reduce the stress experienced at the corners. The radius of curvature Rc is strictly greater than 1 mm, preferably 5 mm. The radius of curvature can even be strictly smaller than 25 mm.

[0157] Additionally, Figures 9A and 9B illustrate the principle of adding a polymer frame to one or more glass layers to provide rigidity to the module, which lacks a traditional aluminum frame.

[0158] Indeed, the stack may include a polymer frame CP arranged all around the periphery of the front and / or rear glass layers to provide mechanical stiffness to the edges and ease of handling.

[0159] Such a polymer frame CP can be added during the manufacture of the module and placed in contact with the glass layers in the same plane.

[0160] The width d of the polymer frame CP can be between 1 mm and 30 mm, preferably between 10 mm and 25 mm, at the edges A, B, C of the module 1. At the edge D on the side of the connection box 7, the width d of the polymer frame CP can be between 1 mm and 50 mm, preferably between 30 mm and 40 mm.

[0161] Advantageously, the thickness ep of the polymer frame CP is between 0.1 mm and 2 mm, preferably between 0.5 mm and 1 mm, before the lamination process. The thermomechanical properties of this polymer frame CP can be, for example, identical to those of the rear encapsulant layer 3b or one of the interface layers.

[0162] Of course, the invention is not limited to the above embodiments, and various modifications can be made thereto by those skilled in the art.

[0163] In particular, these embodiments can be declared by various modifications using one or more of the aforementioned materials for forming the first layer 2 and the second layer 5 .

Claims

1. A photovoltaic module (1) obtained from a stack of layers, a transparent first layer (2) forming the front surface of said photovoltaic module (1) intended to receive a luminous flux; a plurality of photovoltaic cells (4) arranged side by side and electrically connected to one another; an assembly (3) encapsulating said plurality of photovoltaic cells (4), a second layer (5) forming the back surface of said photovoltaic module (1); Including, the encapsulated assembly (3) and the plurality of photovoltaic cells (4) are located between the first layer (2) and the second layer (5); The first layer (2) is a face layer (2a) made of at least one polymer material, the so-called "polymer face layer (2a)", at least one front side assembly (2b, 2c; 2d, 2e) comprising an interface front side layer (2b; 2d) and a glass front side layer (2c; 2e), Including, the glass front layer (2c; 2e) has a thickness (e2c; e2e) of 2 mm or less, the at least one front assembly (2b, 2c; 2d, 2e) is located between the polymer front layer (2a) and the encapsulated assembly (3), and the interface front layer (2b; 2d) of the at least one front assembly (2b, 2c; 2d, 2e) is located between the polymer front layer (2a) and the glass front layer (2c; 2e); the glass front layer (2c; 2e) has rounded edges at its corners, Photovoltaic module (1).

2. A photovoltaic module (1) as described in claim 1, wherein the glass front layer (2c; 2e) has dimensions strictly smaller than the dimensions of the front layer (2a) made from the at least one polymer material and the dimensions of the second layer (5), and the distance (b, b') separating the edge of the glass front layer (2c; 2e) from the edge of the front layer (2a) made from the at least one polymer material or the edge of the second layer (5) is strictly greater than 1 mm.

3. 2. The module according to claim 1, wherein the glass front layer (2c; 2e) is made from non-tempered glass.

4. 2. The module according to claim 1, wherein the distance (a) between the edge of the glass front layer (2c; 2e) and the edge of the photovoltaic cell (4) adjacent to the edge of the glass front layer (2c; 2e) and / or the edge of the connecting conductor (6) connecting the photovoltaic cells (4) is comprised between 0 and 15 mm, preferably in the range of 5 mm.

5. 2. The module according to claim 1, comprising a polymer frame (CP) arranged around the entire periphery of the glass front layer (2c; 2e), the polymer frame (CP) having a width (d, d') comprised in particular between 5 mm and 50 mm, preferably between 20 mm and 40 mm.

6. 2. The module according to claim 1, wherein the glass front layer (2c; 2e) has rounded edges at its corners, in particular edges with a radius of curvature (Rc) strictly greater than 1 mm, preferably strictly less than 25 mm.

7. The glass front layer (2c; 2e) has a thickness (e) of less than or equal to 1.5 mm, in particular comprised between 500 μm and 1.1 mm, more particularly comprised between 500 μm and 1 mm, even more particularly comprised between 300 μm and 700 μm, even more particularly comprised between 300 μm and 500 μm. ２ｃ ;e ２ｅ 10. The module of claim 1, further comprising:

8. 2. The module according to claim 1, wherein the second layer (5) is formed by a polymer structure based on an electrically insulating polymer.

9. The second layer (5) is 2. A module according to claim 1, comprising a back layer forming a back panel (5) made of a composite material comprising a main sub-layer forming the core (9a) of the back panel (5) and two covering sub-layers each forming a plate (9b, 9c) of said back panel (5), said two plates (9b, 9c) being arranged on either side of said core (9a) so as to sandwich said core (9a) between them, said core (9a) of said back panel (5) comprising a cellular structure (12).

10. The second layer (5) is a back layer made of at least one polymer material (5a), the so-called "polymer back layer (5a)", at least one backside assembly (5b, 5c) comprising an interface backside layer (5b) and a glass backside layer (5c); Including, said glass back layer (5c) has a thickness (esc) in particular of less than or equal to 2 mm, in particular less than or equal to 1.5 mm, in particular comprised between 500 μm and 1.1 mm, more particularly between 500 μm and 1 mm, even more particularly between 300 μm and 700 μm, even more particularly between 300 μm and 500 μm, in particular made from non-tempered glass and in particular strictly smaller than the dimensions of said polymer back layer (5a), in particular having the same dimensions and properties as said glass front layer (2c), the at least one backside assembly (5b, 5c) is located between the polymer backside layer (5a) and the encapsulated assembly (3), and the interface backside layer (5b) of the at least one backside assembly (5b, 5c) is located between the polymer backside layer (5a) and the glass backside layer (5c); The module of claim 1 .

11. 2. The module according to claim 1, wherein the second layer (5) comprises a layer of reinforcing fibers, in particular based on fibers of glass, carbon, aramid and / or natural, in particular hemp, flax and / or silk fibers.

12. The polymeric front layer (2a) and / or the polymeric back layer (5a) may have a thickness (e ２ａ , e ５ａ 10. The module of claim 1, further comprising:

13. The interface front layer (2b; 2d) and / or the interface back layer (5b) have a thickness (e ２ｂ , e ２ｄ ;e ５ｂ 10. The module of claim 1, further comprising:

14. 2. The module according to claim 1, wherein the polymer material of the polymeric front layer (2a) and / or the polymeric back layer (5a) is selected from among polycarbonate (PC), polymethyl methacrylate (PMMA), polyethylene terephthalate (PET), polyamide (PA), fluoropolymers, in particular polyvinyl fluoride (PVF) or polyvinylidene fluoride (PVDF), ethylene tetrafluoroethylene (ETFE), ethylene chlorotrifluoroethylene (ECTFE), polytetrafluoroethylene (PTFE), polychlorotrifluoroethylene (PCTFE), fluorinated ethylene propylene (FEP), and / or multilayers comprising one or more of the aforementioned polymers.

15. 2. The module of claim 1, wherein the encapsulating assembly (3), the interface front layer (2b; 2d), and / or the optional interface back layer (5b) are formed by at least one layer comprising at least one polymer type encapsulating material selected from among acid copolymers, ionomers, poly(ethylene vinyl acetate) (EVA), vinyl acetals such as polyvinyl butyral (PVB), polyurethanes, polyvinyl chloride, polyethylenes such as linear low density polyethylene, copolymeric elastomeric polyolefins, copolymers of α-, β-esters of ethylene carboxylic acids and α-olefins such as ethylene-methyl acrylate copolymer and ethylene-butyl acrylate copolymer, silicone elastomers, and / or cross-linked thermoplastic polyolefin-based elastomers.

16. The first layer (2) is a first front assembly (2b, 2c) comprising an interface front layer (2b) and a glass front layer (2c), said glass front layer (2c) having a thickness (e) of 2 mm or less; ２ｃ a first front side assembly (2b, 2c) having a a second front assembly (2d, 2e) comprising an interface front layer (2d) and a glass front layer (2e), said glass front layer (2e) having a thickness (e) of 2 mm or less; ２ｅ a second front assembly (2d, 2e) having Including, the first front assembly (2b, 2c) is located between the polymeric front layer (2a) and the second front assembly (2d, 2e), which is itself located between the first front assembly (2b, 2c) and the encapsulating assembly (3); The module of claim 1 .

17. The thickness (e ２ｃ ) and the thickness (e) of the glass front layer (2e) of the second front assembly (2d, 2e). ２ｅ 17. The module of claim 16, wherein:

18. The thickness (e ２ｃ ) is the thickness (e) of the glass front layer (2e) of the second front assembly (2d, 2e). ２ｅ 18. The module of claim 17, wherein the module is greater than 1 / 2.

19. The second layer (5) is a back layer made of at least one polymer material (5a), the so-called "polymer back layer (5a)", a first backside assembly (5b, 5c) comprising an interface backside layer (5b) and a glass backside layer (5c), said glass backside layer (5c) having a thickness (e) of at most 2 mm, in particular at most 1.5 mm, in particular between 500 μm and 1.1 mm, more particularly between 500 μm and 1 mm, even more particularly between 300 μm and 700 μm, even more particularly between 300 μm and 500 μm; ５ｃ a first rear assembly (5b, 5c) having a first back side (5b, 5c) and made in particular from non-tempered glass; a second backside assembly comprising an interface backside layer and a glass backside layer, said glass backside layer having a thickness in particular of less than or equal to 2 mm, in particular of less than or equal to 1.5 mm, in particular comprised between 500 μm and 1.1 mm, more particularly between 500 μm and 1 mm, even more particularly between 300 μm and 700 μm, even more particularly between 300 μm and 500 μm, and in particular made from non-tempered glass; Including, the first backside assembly (5b, 5c) is located between the polymer backside layer (5a) and the second backside assembly, which is itself located between the first backside assembly (5b, 5c) and the encapsulating assembly (3); The module of claim 1 .

20. A method for producing a photovoltaic module (1) according to claim 1 from a stack, comprising: a transparent first layer (2) forming the front surface of said photovoltaic module (1) intended to receive a luminous flux; a plurality of photovoltaic cells (4) arranged side by side and electrically connected to one another; an assembly (3) encapsulating said plurality of photovoltaic cells (4), a second layer (5), Including, the encapsulated assembly (3) and the plurality of photovoltaic cells (4) are located between the first layer (2) and the second layer (5); The first layer (2) is a face layer made of at least one polymer material (2a), the so-called "polymer face layer (2a)", - at least one front side assembly (2b, 2c; 2d, 2e) comprising an interface front side layer (2b; 2d) and a glass front side layer (2c; 2e); Including, The glass front layer (2c; 2e) has a thickness (e ２ｃ ;e ２ｅ ) the at least one front assembly (2b, 2c; 2d, 2e) is located between the polymer front layer (2a) and the encapsulated assembly (3), and the interface front layer (2b; 2d) of the at least one front assembly (2b, 2c; 2d, 2e) is located between the polymer front layer (2a) and the glass front layer (2c; 2e); the glass front layer (2c; 2e) has rounded edges at its corners, A method for making a photovoltaic module (1).

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