Solar Module

Abstract

1. A solar module comprising: one or more solar cells having a front surface and a back surface, the solar cells electrically connected to terminals via one or more electrically conductive interconnect members and surrounded by an encapsulant; an insulating back sheet disposed on a back surface side of the module overlying the one or more solar cells and the encapsulant; and a laminated interlayer interposed between the encapsulant and the back sheet, the laminated interlayer comprising an electrically insulating layer and a metallic barrier film, in that order, disposed from the front surface side of the module to the back surface side of the module, the laminated interlayer having a lateral extent smaller than the lateral extent of the back sheet.

Description

[Technical field]

[0001] The present invention relates to a solar module and a method for manufacturing a solar module. [Background technology]

[0002] Solar modules for providing electrical energy from sunlight typically comprise an array of solar cells (also referred to herein as photovoltaic cells or PV cells). A typical solar module architecture includes a transparent front sheet (typically glass), an encapsulant layer surrounding the array of solar cells, a protective back sheet (sometimes also referred to as a "backing sheet" or "backing layer"), and an aluminum perimeter frame. The main purpose of the front sheet, encapsulant layer, back sheet, and perimeter frame is to physically (e.g., against mechanical impact) and chemically (e.g., against moisture penetration) protect the solar cells. Providing a suitable module architecture can increase the expected life and efficiency of the solar cells, thereby reducing the average cost of electrical energy generated by the solar module.

[0003] Traditionally, photovoltaic module backing sheets are made from insulating materials such as polymers. Using insulating materials for the backing sheet has many advantages, such as facilitating the provision of a suitable amount of insulation around the junction box of the module to meet international safety standards, such as those described in IEC 61730-1:2016 "Safety Conformity Certification of Photovoltaic (PV) Modules - Part 1: Construction Requirements," which is incorporated herein by reference.

[0004] However, for some solar modules, particularly for relatively high-power modules such as heterojunction cell (HJT) products, the polymer backing sheet does not provide suitable heat dissipation and / or moisture resistance. Therefore, for some solar modules including heterojunction cell (HJT) products, it is typical to use an aluminum backing sheet. The use of an aluminum backing sheet can provide improved heat dissipation and moisture resistance compared to the use of a polymer backing sheet.

[0005] Some back sheet configurations are known in which a metal layer and a polymer layer are used in combination. For example, WO2010 / 073735A1 discloses a back surface protection sheet for a solar cell module in which an electrically insulating base sheet is laminated to at least one surface of an aluminum-iron alloy sheet.

[0006] US 2008 / 053512 A1 discloses a backing sheet for a solar module, the backing sheet being a laminate comprising, in that order, a front-side resin film, a barrier film, and a back-side resin film, the front-side resin film comprising a polyolefin as a main component.

[0007] The present invention has been devised in light of the above considerations. Summary of the Invention

[0008] The inventors have realised that the provision of a suitable lamination interlayer within a solar module can provide an improved architecture for a solar module that may mitigate or avoid several known problems associated with existing solar module architectures.

[0009] Thus, in a first aspect, the present invention provides a solar module comprising: one or more solar cells having a front surface and a back surface, the solar cells being electrically connected to terminals via one or more electrically conductive interconnect members and surrounded by an encapsulant; an insulating backing sheet disposed on a back surface side of the module overlying the one or more solar cells and the encapsulant; and a laminated interlayer interposed between the encapsulant and the backing sheet, the laminated interlayer comprising an electrically insulating layer and a metallic barrier film, disposed in that order from the front surface side of the module to the back surface side of the module, the laminated interlayer having a lateral extent smaller than the lateral extent of the backing sheet.

[0010] By providing a module having an insulating backing sheet and a lamination interlayer comprising an electrical insulating layer and a metal barrier film interposed between the encapsulant surrounding the solar cells and the backing sheet, the lamination interlayer having a lateral extent smaller than that of the backing sheet, it is possible to provide a module with similar or improved reliability compared to a conventional module having a pure aluminum backing sheet (by providing a suitable reduction in the penetration of ingress gases and / or liquid molecules into the solar module and by providing improved heat transfer away from the solar cells), but with a reduced risk of electrostatic build-up and discharge between the conductive parts of the module due to the lateral spacing provided between the lamination interlayer and other parts of the solar module. In contrast, in modules having an aluminum backing sheet, a relatively high short circuit rate can be observed between the junction box connectors containing the electrical terminals of the module and the backing sheet. The increased risk of short circuits is a safety risk and can further lead to a reduction in the energy yield of the module, leading to the scrapping of the module. Another problem is that due to the short distance between the backing sheet and the junction box, the aluminum backing sheet has a tendency to be charged with high voltage. This can result in electrostatic discharge to the surrounding frame of the module at high voltage, which is undesirable.

[0011] A further advantage is that the above-mentioned module architecture can reduce the need to provide additional insulating materials in certain parts of the module, and in particular can eliminate the need to separate the backing sheet itself from other parts of the module, thereby reducing the complexity and cost of manufacturing the solar module. In comparison, known aluminum or composite backing sheets incorporating one or more polymer layers typically need to provide suitable insulation between the metal layer and other electrically active or conductive parts of the solar module, such as the aluminum perimeter frame and / or junction box, because the metal layer of the composite backing sheet, if present, has the same lateral extent as the other layers of the backing sheet (including the insulating layer). This can increase the complexity and cost of manufacturing solar modules incorporating such backing sheets due to the additional components and processes introduced to ensure proper separation of the metal-containing backing sheet.

[0012] The term "laminate interlayer" is used herein to describe an interlayer having a laminated structure. It is an element comprising one or more layers of materials laminated together. The one or more layers may be laminated together via physical and / or chemical bonding. In this arrangement, the one or more layers include at least two different materials, namely an electrical insulating layer and a metallic barrier film. Further details regarding the structure and composition of the laminate interlayer are described below.

[0013] When an element such as a film, sheet, or substrate is referred to as being "on," "adjacent," or "on the opposite side of" an element, it will be understood that it may be "directly on," "directly adjacent," or "directly opposite" that further element, or, alternatively, there may be one or more intervening elements. In contrast, when an element is referred to as being "directly on," "directly adjacent," or "directly opposite" another element, there are no intervening elements.

[0014] A solar module comprises a width, a length, and a height (sometimes referred to as a thickness). Typically, the height (or thickness) of a solar module is substantially less than its length and width. The length and width of the module may be substantially equal (for a square module) or different (for a rectangular module). A solar module has a front surface (alternatively referred to as a front surface) and a back surface (alternatively referred to as a back surface), with the front side and back side being defined based on the typical orientation of the solar cells in the module in use. The solar cells have a front surface and a back surface. In this specification, the terms "front" and "forward" are used to refer to a direction that faces the light source (e.g., the sun) in use and perpendicular to the front surface of the solar module, and the terms "back", "backward", and "backwards" are intended to refer to a direction opposite to the front / forward direction.

[0015] The term "lateral", for example in the context of "lateral extent", is used herein to refer to a direction lying in a plane substantially perpendicular to the height direction of the solar module and substantially parallel to the upper and lower surfaces of the solar module. The term "lateral extent" thus refers to an area in such a plane. Since the lamination interlayer has a lateral extent smaller than the lateral extent of the backing sheet, the lamination interlayer may have at least one edge that partially overlaps a respective edge of the backing sheet in the lateral direction. In some arrangements, each edge of the lamination interlayer may overlap a respective edge of the backing sheet in the lateral direction.

[0016] The terms "electrically conductive" and "insulating" as used herein are expressly intended to mean electrically conductive and electrically insulating, respectively. The meaning of these terms will be particularly clear in view of the technical context of this disclosure, namely, the context of photovoltaic solar modules.

[0017] Next, optional features are described, which can be applied alone or in any combination with any aspect.

[0018] First, optional features relating to the construction of the laminate interlayers and their placement within the module are considered, followed by optional features relating to the overall architecture of the module.

[0019] Since the laminate comprises a metal barrier film that is a conductive element, it may be preferable to provide a minimum predetermined creepage distance between the lamination interlayer and the conductive elements of the module in order to minimize the risk of static electricity build-up and discharge between the conductive parts of the module. Here, the creepage distance is defined according to the definition provided in IEC 61730-1:2016. That is, the creepage distance is defined as the shortest distance along the surface of a solid insulating material between two conductive active parts or between a conductive active part and an accessible part (accessible here refers to a part that is accessible during normal use). The creepage distance is sometimes abbreviated as "cr". Preferably, the predetermined minimum creepage distance is provided between the metal barrier film layer of the lamination interlayer and one or more conductive active parts or conductive accessible parts of the module.

[0020] A solar module typically includes many conductive active and / or accessible parts. For example, a solar module may include a frame, or one or more frame elements (discussed in more detail below in the section on overall module architecture). When a solar module includes a conductive frame or frame member (e.g., a metal frame or frame member), a first predetermined minimum creepage distance is preferably provided between an edge of the laminate interlayer and the conductive frame or frame member. The first predetermined minimum creepage distance may be provided between an edge of a metal barrier film layer of the laminate interlayer and the conductive frame or frame member, where the metal barrier film layer and the edge of the laminate interlayer are not aligned. However, in some arrangements, a solar module may not include a conductive frame.

[0021] As discussed in more detail below in the section on the overall module architecture, one or more conductive interconnect members provided for electrical connection of one or more solar cells to the terminals of the module may extend through the horizontal plane in which the laminate interlayer is located. In this case, a second predetermined minimum creepage distance is preferably provided between the edge of the laminate interlayer and the one or more conductive interconnect members. The second predetermined minimum creepage distance may be provided between the edge of the metal barrier film layer of the laminate interlayer and the one or more conductive interconnect members, where the edge of the metal barrier film layer and the edge of the laminate interlayer are not aligned. However, in some arrangements, the one or more conductive interconnect members may not extend through the horizontal plane in which the laminate interlayer is located.

[0022] If necessary, the first and / or second predetermined minimum creepage distances may be selected based on Table 3 of IEC 61730-1:2016, taking into account the transmitted system voltage and pollution degree, as shown in this table, which is incorporated herein by reference.

[0023] The pollution degree is a numerical classification characteristic of the expected pollution of the microenvironment. The pollution degree can be 1, 2, or 3, but is preferably 1. For parts that are closed or enclosed to provide protection from the ingress of dust and moisture, the pollution degree can be considered to be 1 if the test requirements according to IEC 61730-2, including test sequence B.1, are met.

[0024] The system voltage is the operating voltage under operating conditions. In the case of a single module, this is the voltage delivered by that single module in use (the "single module delivery voltage"), or the module V OC However, for enhanced safety, in systems in which multiple modules are connected as part of a single installation, the total system voltage of the entire installation including the multiple modules may be considered for determining either or both of the first or second predetermined creepage distances.

[0025] Therefore, the first predetermined minimum creepage distance is at least a single module voltage or V OC , and the pollution degree of the module may be selected to be equal to or greater than the values ​​given in row 1(a) or row 3 of Table 3 of IEC 61730-1:2016 (these values ​​are the same for all system voltages and pollution degrees). For example, for a voltage or V of 100 V DC OC , and for a module having a pollution degree of 1, the first predetermined minimum creepage distance may be 0.5 mm or more. OC For a module having a voltage of 1000V DC or V OC , and for a module having a pollution degree of 1, the first predetermined minimum creepage distance may be 6.4 mm or greater.

[0026] This is the minimum preferred creepage distance, as discussed above, although a greater creepage distance may be used than is required based on a single module voltage. For example, as discussed above, when a module is installed in a system incorporating multiple such modules, it may be preferable to consider the total system voltage of the entire installation including the multiple modules. Thus, in one example, when a single module having a Voc of about 50V and a pollution degree of 1 (i.e., a required minimum creepage distance of only 0.5mm based on Table 3 of IEC 61730-1:2016) is installed in a system incorporating multiple such modules, and the total system voltage is 1000V, the first predetermined minimum creepage distance may be selected to be 6.4mm or greater, in line with the values ​​shown in Table 3 for a system voltage of 1000V.

[0027] The second predetermined minimum creepage distance is at least the single module system voltage or V OC , and the pollution degree of the module may be selected to be equal to or greater than the values ​​given in row 1(a) or row 3 of Table 3 of IEC 61730-1:2016 (these values ​​are the same for all system voltages and pollution degrees). For example, for a voltage or V of 100 V DC OC, and for modules having a pollution degree of 1, the second predetermined minimum creepage distance may be 0.5 mm or more. OC , and for a module having a pollution degree of 1, the second predetermined minimum creepage distance may be 1.4 mm or more. OC , and for a module having a pollution degree of 1, the second predetermined minimum creepage distance may be 6.4 mm or greater. As above, this is the minimum preferred creepage distance for the module, and for safety reasons a larger creepage distance may be selected (e.g., based on the total system voltage of a system incorporating multiple such modules).

[0028] As mentioned above, the lamination interlayer is interposed between the encapsulant and the back sheet. That is, the lamination interlayer is provided on the back side of the solar cells. The lamination interlayer may substantially overlap all of the one or more solar cells on the back side. In other words, the lateral extent of the lamination interlayer may be greater than the total lateral extent of the one or more solar cells. This may provide improved reliability of the module by allowing favorable heat transfer away from each of the stacked solar cells and also providing a degree of protection for each of the stacked solar cells against the penetration of intruding gas and / or liquid molecules.

[0029] In some arrangements, the laminated interlayer comprises two or more discontinuous regions. In other words, the laminated interlayer can comprise two or more separate parts, each part comprising an electrical insulating layer and a metal barrier film, in that order, arranged from the front side of the module to the back side of the module. When the laminated interlayer comprises two or more discontinuous regions, the regions preferably extend in substantially the same horizontal plane. The regions preferably have the same structure. This may allow for improved ease of assembly of the module, since the separate parts of the laminated interlayer can be arranged simultaneously or in close succession during the manufacturing process. An arrangement in which the laminated interlayer comprises two or more discontinuous regions may provide certain advantages when the module comprises one or more conductive elements extending through the module in a central region of the module, since this may reduce the need for the laminated interlayer to be formed into a complex shape to avoid direct connection with such conductive elements. For example, when the module comprises one or more conductive interconnect members extending through the horizontal plane in which the laminated interlayer resides, the laminated interlayer may be arranged such that one or more conductive interconnect members extend through gaps between the discontinuous regions of the interlayer. This reduces the manufacturing complexity of the module.

[0030] As discussed above, the minimum structure of the laminate interlayer includes an electrical insulating layer and a metallic barrier film, disposed in that order from the front side of the module to the back side of the module. Providing an insulating layer on the front side of the laminate interlayer allows for an insulator of suitable thickness to be provided between the solar cells surrounded by the encapsulant and the metallic barrier film of the laminate interlayer.

[0031] The electrical insulation layer may have a thickness that is significantly smaller than its length and width. The electrical insulation layer may have a thickness selected based on Table 3 of IEC 61730-1:2016, specifically based on the layer thickness requirements given in the row headed "Thickness of Thin Layer". Thus, the electrical insulation layer may have a thickness of 0.01 mm or more. Thus, the electrical insulation layer may have a thickness of 0.05 mm or less. For example, the thickness of the electrical insulation layer may be about 0.01 mm, about 0.02 mm, about 0.03 mm, about 0.04 mm, or about 0.05 mm. It may be advantageous for the electrical insulation layer to be as thin as possible while still meeting the standards set forth in IEC 61730-1:2016. Thus, the preferred thickness of the insulation layer is 0.01 mm to 0.03 mm. The electrical insulation film thickness may be substantially uniform. The electrical insulation layer may be substantially planar.

[0032] The electrical insulation layer may be formed from a material having a relative thermal index (RTI) greater than 90° C. RTI is the temperature in degrees Celsius (C) at which a property (e.g., electrical insulation performance) degrades to 50% of its initial value after prolonged exposure to that temperature. Although RTI is an index, it is typically given in degrees Celsius, but is sometimes referred to in the art as a unitless value. RTI is determined according to IEC 60216-5 or IEC 60216-1.

[0033] If this electrical insulation layer is formed from a material with a suitable relative thermal index, it can meet the IEC standards included in calculating the insulation, creepage (cr), or clearance (cl) distances for Class II PV modules as defined in IEC 61730-1:2016. Specifically, materials used as insulation must have a minimum RTI equal to or greater than the maximum normalized operating temperature of the material measured in a particular mounting situation (e.g., roof mounted) during temperature testing (MST21) or 90°C, whichever is higher, according to IEC 60216-5 or IEC 60216-1. For PV modules mounted in an open rack, the normalized measured maximum PV module operating temperature can be assumed to be 90°C, so the insulation is required to be at least 90°C. Materials with an RTI less than 90°C do not meet the IEC standards included in calculating the insulation, creepage (cr), or clearance (cl) distances for Class II PV modules as defined in IEC 61730-1:2016.

[0034] Thus, the electrically insulating layer may comprise a material selected from the group consisting of polyethylene terephthalate (PET), polyolefin (PO), polyamide (PA), and polycarbonate (PC). Preferably, the electrically insulating layer comprises PET with an RTI of 105° C.

[0035] The metallic barrier film may be formed from any suitable metallic material. Preferably, the metallic barrier film is formed from aluminum, although the use of other metallic materials, such as copper, is contemplated. The use of aluminum has advantages such as high corrosion resistance and low oxidation rate in air. Furthermore, aluminum has a low density that can help reduce the overall weight of the module. It will be understood that the term "film" refers to an element that defines a substantially thin layer, e.g., a foil, or a thin strip of material. The barrier film may have a thickness that is significantly less than its length and width. In a preferred arrangement, the metallic barrier film is formed from aluminum foil. Aluminum foil has a low density (and therefore light weight), is cost-effective, and is easy to work with during manufacturing.

[0036] The thickness of the metal barrier film may be 0.005 mm or more (i.e., 5 μm or more), such as 0.006 mm or more, or 0.007 mm or more. The thickness of the metal barrier film may be 0.011 mm or less, such as 0.010 mm or less, or 0.009 mm or less. Preferably, the thickness of the metal barrier film is in the range of 0.007 mm to 0.009 mm. The exact thickness of the metal barrier film used may depend on the manufacturer's capabilities and material costs.

[0037] The barrier film may have a substantially uniform thickness. The barrier film may be substantially planar.

[0038] The barrier film may be configured to be substantially continuous. In other words, the barrier film may be provided as a single continuous piece of (e.g., planar) material. In this manner, the barrier film may be configured to lack any holes, openings, spaces, or apertures that would otherwise provide a path by which an intruding element (e.g., gas and / or liquid molecules) could flow toward the solar cell. In an arrangement in which the laminated interlayer comprises two or more discontinuous regions, the barrier film may be substantially continuous within each defined region of the laminated interlayer. In this manner, the number of holes, openings, spaces, or apertures through the laminated interlayer may be limited only to the spaces between the discontinuous regions.

[0039] The electrical insulation layer may be laminated onto the metal barrier film via an adhesive layer. Any suitable adhesive may be used. One example of a suitable adhesive is an acrylic adhesive. Thus, the lamination interlayer may comprise or consist of an electrical insulation layer, an adhesive layer, and a metal barrier film (in that order, from the front side of the module to the back side of the module).

[0040] The laminating interlayer may include one or more primer layers disposed on the front side and / or back side of the interlayer. The provision of such a primer layer may provide improved adhesion between the laminating interlayer and adjacent layers of the solar module during manufacture. For example, the use of a primer layer may provide stronger adhesion with EVA of about 150 N / cm compared to an arrangement in which the laminating interlayer is directly attached to adjacent layers of the solar module with, for example, acrylic glue, which would provide an adhesive strength of about 5-10 N / cm.

[0041] Preferably, the laminated interlayer comprises both a front primer layer and a back primer layer. Thus, the structure of the laminated interlayer may comprise or consist of a front primer layer, an electrical insulating layer, an adhesive layer, a metal barrier film, and a back primer layer (in that order, from the front side of the module to the back side of the module).

[0042] One or more of the primer layers may comprise a polyolefin material. Polyolefins are polymers made from simple olefin monomers (e.g., C n H 2n It will be understood that the term "polyolefin" defines a type of polymer produced from a thermoplastic resin and an elastomer. A polyolefin material may refer to a polymer / filler blend formed at least in part from a thermoplastic resin and an elastomer. Each of the one or more primer layers comprises a material selected from the group consisting of ethylene vinyl acetate (EVA), polyethylene (PE), including linear low density polyethylene (LLDPE), or polyolefin elastomer (POE).

[0043] When one or more primer layers are present as part of the lamination interlayer, they may be laminated onto the electrical insulation layer and / or the metal barrier film via an adhesive layer. Any suitable adhesive may be used. One example of a suitable adhesive is an acrylic adhesive. Thus, the lamination interlayer may comprise or consist of a front primer layer, an adhesive layer, an electrical insulation layer, an adhesive layer, a metal barrier film, an adhesive layer, a back primer layer (in that order, from the front side of the module to the back side of the module).

[0044] We now consider optional features related to the overall architecture of the device.

[0045] The particular structure and configuration of the one or more solar cells is not particularly limited, and some advantages of the proposed laminated interlayer may be realized independently of the particular nature of the solar cells in the module. However, while the present invention is applicable to virtually all types of solar cells, the present invention may have particular advantages when the solar cells are heterojunction technology (HJT) type solar cells. HJT type solar cells are so named because they combine two different materials to create a charge separation field at the p-n junction. They can provide improved performance compared to more conventional solar cells, but typically require solar modules that incorporate such cells and provide better heat dissipation and better moisture resistance to ensure suitable product reliability. As discussed above, the provision of a suitable laminated interlayer can allow both reduced penetration of intruding gas and / or liquid molecules into the solar module and improved heat transfer away from the solar cells, while reducing problems associated with known alternative module architectures suitable for use with HJT solar cells. Thus, the solar module is preferably a heterojunction technology (HJT) solar module comprising one or more heterojunction technology (HJT) solar cells.

[0046] A solar module comprises one or more solar cells. Preferably, a solar module includes a plurality of solar cells. When a solar module comprises a plurality of solar cells, these may be arranged in an array. The array of solar cells may be arranged in an array extending longitudinally (e.g., along the length) and / or laterally (e.g., across the width) of the solar module. The solar cells may be arranged in a grid, such as a rectangular or square grid pattern.

[0047] When multiple solar cells are present, some or all of the solar cells may be arranged in substantially the same plane. Thus, the solar cells may be arranged in a substantially planar array. The solar cells may each be arranged such that they are aligned in the same reference plane. For example, a first solar cell may be arranged, e.g., oriented, such that the horizontal plane of the first solar cell is aligned with the horizontal plane of the second solar cell. The reference planes of the first and second solar cells may be substantially aligned (e.g., parallel) with the horizontal plane of the solar module. Alternatively, some or all of the solar cells may be arranged in a shingle-like or shingle arrangement. Thus, the first solar cell may be arranged to at least partially overlap the second solar cell.

[0048] Typically, one or more solar cells in a module are electrically connected to each other in series or in parallel. In some arrangements, all solar cells in a module may be connected in series. In other arrangements, a selected number of solar cells may be connected in series as a solar cell string. Multiple solar cell strings may be connected in parallel through one or more bypass diodes. Multiple possible solar cell arrangements are well known in the art, and any suitable arrangement may be used with the present modules.

[0049] The one or more solar cells are electrically connected to a terminal of the module through one or more conductive interconnect members. In this context, the term "terminal" is intended to refer to a point where the electrical circuit of the module terminates. This may be, for example, an electrical connector. The term "via" is used in this context to indicate that the one or more conductive interconnect members may form only a part of the conductive path from the one or more solar cells to the terminal. One or more further conductive elements (e.g., electrodes, wires, and / or bus bars) may be provided as part of the conductive path.

[0050] The one or more conductive interconnect members may be connected, directly or indirectly, at a first end to one or more electrodes provided on each of the one or more solar cells. The one or more electrodes may be configured to extract photo-generated charge carriers from the solar cells. The one or more electrodes may comprise a front electrode disposed on a front surface of the respective solar cell and / or a back electrode disposed on a back surface of the respective solar cell. In other words, the solar cells may be front contact cells, back contact cells, or cells having both front and back contacts. The front and / or back electrodes may each comprise a plurality of finger electrodes. Each finger electrode may be configured to have an axial length substantially greater than its width. Both the width and the axial length of the finger electrodes may be measured in a vertical direction within the plane of the respective surface of the solar cell. The finger electrodes may extend in a lateral direction parallel to the width direction of the solar cell. The finger electrodes within each of the plurality of front finger electrodes and / or back finger electrodes may be spaced apart across the respective front and back surfaces of the solar cell to define laterally extending spaces between the finger electrodes. The finger electrodes may be spaced apart in a longitudinal direction that is substantially parallel to the length of the solar cell. Each of the plurality of finger electrodes may be substantially parallel to one another. Thus, the plurality of back finger electrodes may form an array of parallel longitudinally spaced (e.g., equally spaced) finger electrodes.

[0051] The one or more conductive interconnect members may be connected directly or indirectly to the terminals of the module at the second end. They may be connected to the terminals via one or more bypass diodes. The terminals are located in a junction box of the solar module. The junction box typically comprises one or more plug connectors that may enable efficient connection of the solar module to one or more further solar modules or other devices such as a battery or an inverter. If the module comprises a junction box, this may comprise a housing component disposed on the back side of the solar module. In some arrangements, the solar module may comprise multiple junction boxes (e.g., a split junction box arrangement), as disclosed, for example, in European Patent No. EP3017520B1 in the name of REC Solar Pte.Ltd. If the solar module comprises multiple junction boxes, separate conductive interconnect members may be provided for connecting to each separate junction box. For example, if there are two junction boxes, at least two conductive interconnect members may be provided to enable connection of a solar cell to each of the two junction boxes.

[0052] The conductive interconnect members themselves may be formed as conductive wire sections, foil strips, and / or bus bars. Preferably, one or more of the conductive interconnect members are interconnect bus bars (ICBs). When the one or more conductive interconnect members are interconnect bus bars, they may have conventional construction, for example, a copper core with tin / lead plating or any solderable alloy.

[0053] At least a portion of the one or more conductive interconnect members may extend substantially in the height / thickness direction of the solar module. The portion may extend in the thickness direction from a horizontal plane in which the one or more solar cells are located to a terminal of the module. If the terminal is located on the back side of the module, the portion of the conductive interconnect member may therefore extend in the thickness direction from a horizontal plane in which the one or more solar cells are located to a back side of the module. The portion may therefore extend through one or more layers that make up the solar module. For example, the portion may extend through an encapsulant that surrounds the one or more solar cells. The portion may extend through a horizontal plane in which a laminate interlayer is located.

[0054] The encapsulant may be configured to provide encapsulation of one or more solar cells. In general, this may be defined as a means of physically protecting the solar cells from external environmental conditions, which may include humidity, moisture, rain, and ultraviolet (UV) radiation. The encapsulant may also be configured to hold the components of the solar module (e.g., solar cells) in place within the module. The encapsulant may be configured to protect the solar cells from mechanical stresses, such as twisting or bending, and low-energy impacts caused by hail or errant projectiles.

[0055] The encapsulant may comprise a front encapsulant layer and a back encapsulant layer. The front encapsulant layer may be disposed directly or indirectly on the front side of the solar cell. The back encapsulant layer may be disposed directly or indirectly on the back side of the solar cell. The front encapsulant layer and the back encapsulant layer may be formed of the same material. Alternatively, the front encapsulant layer and the back encapsulant layer may be formed of different materials. The material of the front and / or back encapsulant layer may be selected from ethylene vinyl acetate (EVA), polyolefin elastomer (POE) material, or any other suitable encapsulant material known in the art. The selection of the material of the front and back encapsulant layers depends on the properties of the cell. For example, POE may be used when better volume resistivity and water vapor transmission rate (WVTR) are required. EVA may be used when lower cost material is required. In one preferred arrangement, the front encapsulant is formed from polyolefin-elastomer (POE) and the back encapsulant is formed from ethylene vinyl acetate (EVA).

[0056] The encapsulant may have a thickness that is significantly less than its length and width. For example, the thickness of the encapsulant may range from 0.40 mm to 0.65 mm, such as about 0.45 mm, about 0.5 mm, about 0.55 mm, or about 0.6 mm. The lateral extent of the encapsulant may be substantially the same as the lateral extent of the backing sheet of the module.

[0057] The solar module may comprise an outer casing, the insulating backing sheet forming part of the outer casing, the outer casing may further comprise a front sheet or plate disposed on a front side of the solar module, the front sheet may be formed from a transparent material such as glass.

[0058] The insulating backing sheet may be formed from any suitable insulating material. In a preferred arrangement, the backing sheet is a polymer, for example, formed from polyethylene terephthalate (PET). The use of a polymer can provide a cost-effective backing sheet that nevertheless provides suitable protection for the other module components.

[0059] The solar module may include a frame, or one or more frame elements. The frame may be configured to hold the components of the solar module in place and provide a seal around the outer casing (e.g., the front sheet and the back sheet). If the solar module includes a front sheet and a back sheet, the frame may apply a compressive force between the front sheet and the back sheet to hold the components of the solar module in place, as would be readily understood by one of ordinary skill in the art.

[0060] According to a second aspect, there is provided a method for manufacturing a solar module, the method comprising: providing one or more solar cells which, in use, are electrically connected to terminals via one or more conductive interconnect members; disposing an encapsulant surrounding the one or more solar cells; disposing a backing sheet overlying the one or more solar cells and the encapsulant on a back side of the module; and disposing a laminated interlayer having a lateral extent smaller than a lateral extent of the backing sheet interposed between the encapsulant and the backing sheet of the solar module, the laminated interlayer comprising an electrically insulating layer and a metallic barrier film, in that order, disposed from a front side of the module to a back side of the module.

[0061] The steps described in the above methods do not have to be performed in the order described. For example, the step of disposing a laminated interlayer between the encapsulant and the backing sheet of a solar module can be performed between the steps of disposing the encapsulant surrounding the one or more solar cells and disposing the backing sheet overlying the one or more solar cells and the encapsulant on the back side of the module.

[0062] In some methods, the laminating interlayer can be attached to the backing sheet before the backing sheet is placed over one or more solar cells and the encapsulant on the back side of the module. In such methods, the steps of "place the backing sheet over one or more solar cells and the encapsulant on the back side of the module" and "place the laminating interlayer having a lateral extent smaller than the lateral extent of the backing sheet between the encapsulant and the backing sheet of the solar module" can therefore be performed in the same single method step of placing the combined interlayer backing sheet over one or more solar cells and the encapsulant on the back side of the module. This can reduce the total number of manufacturing steps required during the manufacture of the solar module. If the laminating interlayer is attached to the backing sheet before the final module is assembled, such attachment can be achieved by chemical and / or physical attachment, for example by applying an adhesive or by attaching the laminating interlayer and the backing sheet using a mechanical press.

[0063] The step of providing one or more solar cells may include providing the one or more solar cells via a manufacturing process, or may alternatively include obtaining the one or more solar cells from another party, e.g., a manufacturer.

[0064] The step of disposing an encapsulant around the one or more solar cells may include the substeps of disposing a front encapsulant layer on a front side of the one or more solar cells and disposing a back encapsulant layer on a back side of the one or more solar cells.

[0065] As discussed above, in some cases, the laminate interlay may include one or more discontinuous regions. Thus, the step of disposing a laminate interlayer having a lateral extent smaller than the lateral extent of the backing sheet between the encapsulant and the backing sheet of the solar module may include the substeps of disposing a first portion of the laminate interlay and disposing a second portion of the laminate interlayer.

[0066] The method may include one or more steps of applying heat and / or pressure. The application of heat and / or pressure may promote adhesion of one or more elements of the module to one another.

[0067] Those skilled in the art will understand that, unless mutually exclusive, a feature or parameter described in connection with any one of the above embodiments may be applied to any other embodiment. Further, unless mutually exclusive, any feature or parameter described herein may be applied to any embodiment and / or may be combined with any other feature or parameter described herein. [Brief description of the drawings]

[0068] BRIEF DESCRIPTION OF THE DRAWINGS Embodiments and experiments illustrating the principles of the present invention will now be discussed with reference to the accompanying drawings.

[0069] [Figure 1A] 1 shows a schematic diagram of a solar module according to the invention; [Figure 1B] 1 shows a cross-sectional side view of a solar module according to the present invention. [Figure 2A] 1 shows a schematic partial cross-section through a solar module according to the invention; [Figure 2B] 1 shows a schematic plan view of the relative placement of a lamination interlayer with respect to selected other components of the same module. [Diagram 3] 2 is a flowchart showing a method for manufacturing the solar module of FIG. 1. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0070] Aspects and embodiments of the present invention will now be discussed with reference to the accompanying drawings. Further aspects and embodiments will be apparent to those skilled in the art. All documents mentioned in this specification are incorporated herein by reference.

[0071] In the drawings, the relative dimensions of the various elements of the solar module are shown diagrammatically and not to scale. For example, thicknesses of sheets, layers, films, etc. are exaggerated for clarity. Furthermore, when an element such as a layer, film, region, or substrate is referred to or illustrated as being "on" or "adjacent" another element, it will be understood that it may be directly on the other element, or that intervening elements may also be present. In contrast, when an element is referred to as being "directly on" or "directly adjacent" another element, there are no intervening elements present.

[0072] 1A and 1B show a solar module 10 according to the present invention. The solar module 10 includes an array of solar cells 12 arranged in a grid-like pattern. The solar cells 12 are sandwiched between a transparent glass sheet 24a on a front side 26 of the solar module 10 and an insulating backing sheet 24b disposed on a back side 28 of the solar module 10. The insulating backing sheet 24b and the transparent glass sheet 24a thus define front and back outer casings of the solar module 10, respectively.

[0073] Solar module 10 is mounted within a rectangular frame 102 that extends around the perimeter of solar module 10. Frame 102 protects the edges of solar module 10 and provides a means for mounting solar module 10 to a structure (e.g., the roof of a building). Frame 102 includes four elongated frame members 104 that each are attached to and extend along a respective edge of solar module 10. The frame is formed from a conductive material, such as aluminum.

[0074] Figure 1A shows a top (front) view of solar module 10, and Figure 1B shows a cross-section of solar module 10 taken along dashed line AA as shown in Figure 1A. Solar module 10 has a length, which is the horizontal dimension in Figure 1A (i.e., along direction AA), and a width, which is the vertical dimension in Figure 1A (i.e., perpendicular to direction AA).

[0075] 1B shows a plurality of solar cells 12 arranged on a substantially horizontal reference plane RP of the solar module 10. The reference plane RP is substantially parallel to and extends substantially centrally between the front and back outer casings of the solar module 10. Each of the plurality of solar cells 12 is a heterojunction technology (HJT) solar cell.

[0076] The arrows at the top of FIG. 1B indicate the direction of solar radiation incident on the solar module 10. Each of the solar cells 12 has a front surface 16 (where light is incident in normal use) and a back surface 18 opposite the front surface 16. The front surfaces are configured to face substantially toward the sun during use. A transparent glass sheet 24a allows light to pass through to a central chamber in which the solar cells 12 are mounted. The front encapsulant 20a is also transparent to allow incident light to reach the solar cells 12. The back encapsulant 20b may also be transparent, but this is not required.

[0077] The solar cells 12 are arranged in a planar array that extends both the length and width of the solar module 10, as shown in Figure 1A. The planar array comprises two subarrays with a space provided between the two subarrays such that conductive elements extending from the solar cells in each subarray can be located in this spaced gap between the two subarrays.

[0078] The solar cells 12 are surrounded by encapsulants 20a, 20b, which help secure the various components of the solar module 10 in place. The encapsulants 20a, 20b protect the solar cells 12 from both mechanical and chemical damage that may otherwise degrade the solar cells 12. The front encapsulant 20a is formed from polyolefin-elastomer (POE) and the back encapsulant 20b is formed from ethylene vinyl acetate (EVA). Both the front encapsulant 20a and the back encapsulant 20b have a thickness in the range of 0.40 mm to 0.65 mm.

[0079] A laminated interlayer 14a, 14b is interposed between the encapsulant and the backing sheet. The laminated interlayer is formed from a first portion 14a and a second portion 14b, the first and second portions of the laminate extending in both the length and width directions, respectively, of the solar module to overlap the plurality of solar cells 12 on the back side. The lateral extent of the laminated interlayer is smaller than the lateral extent of the insulating backing sheet. The laminated interlayer comprises an electrically insulating layer 36 and a metallic barrier film 38. The structure of the laminated interlayer and its relative positioning with respect to other elements of the solar module are discussed in more detail in connection with FIG. 2 below.

[0080] The solar cells 12 are electrically connected to terminals 32 located in a junction box 34 via conductive interconnect members 30. The junction box 34 is located on the back side of the solar module 10. The one or more conductive interconnect members 30 form only a part of the conductive path from the one or more solar cells to the terminals, the rest of the conductive path being provided by further conductive elements (e.g., electrodes, wires, and / or bus bars) not shown here but whose configuration and layout are within the general knowledge of the person skilled in the art. The conductive interconnect members 30 extend in the thickness direction of the solar module from the horizontal reference plane RP where the solar cells are located to the back side 28 of the module. Thus, a portion of the conductive interconnect member extends through one or more layers that make up the solar module, where it extends through the back encapsulant layer 20b and the insulating back sheet 24b. This portion also extends through the horizontal plane where the laminated interlayers are located, but does not cross or contact the laminated interlayers. Rather, lateral spacing is provided between the laminate interlayer and the conductive interconnect members, as discussed below in connection with FIG.

[0081] Figures 2A and 2B show in more detail the relative arrangement of the laminated intermediate layer with respect to the other elements of the solar module. Figure 2A shows a schematic partial cross-section through the solar module according to the invention. For the sake of simplicity, the cross-section shows only the layers of the solar module between the back encapsulant layer 20b and the insulating backsheet 24b. Figure 2B shows a schematic plan view of the relative arrangement of the laminated intermediate layers 14a, 14b with respect to the backsheet 24b, the surrounding frame 102, and the conductive interconnecting members 30.

[0082] The lateral extent of the laminated intermediate layer is smaller than the lateral extent of the insulating backsheet. In fact, in this arrangement, each edge of the laminated intermediate layer partially overlaps each edge of the backsheet in the lateral direction.

[0083] In this embodiment, the laminated intermediate layer comprises two separate parts 14a, 14b that do not contact each other or cross in any other way, i.e., they are formed as discontinuous regions. However, in other arrangements, the laminated intermediate layer can be formed as a single continuous region of regular or irregular shape. The two regions 14a and 14b of the laminated intermediate layer are substantially identical in shape, size, and structure. Thus, from Figures 2A and 2B, it can be seen that the laminated intermediate layer extends in the longitudinal direction of the solar module over the total length of L1 + L2. The backsheet extends in the longitudinal direction of the solar module by a length L3. The laminated intermediate layer extends in the width direction of the solar module, and the total width is W1 + W2. The backsheet extends in the width direction of the solar module by a width W3. Thus, the total lateral extent (i.e., area) of the laminated intermediate layer is calculated as (L1 * W1) + (L2 * W2). The total lateral extent of the backsheet is calculated as L3 * W3. (L1 * W1) + (L2 * W2) < L3 * W3. In this exemplary embodiment, L1 and L2 are each 830 mm, W1 and W2 are each 985 mm, L3 is 1713 mm, and W3 is 1020 mm. The lateral extent of the laminated intermediate layer is about 1.64 m 2 and the total lateral extent of the backsheet is about 1.75 m 2

[0084] ​Because the lateral extent of the laminated interlayer is smaller than the lateral extent of the insulating backing sheet by virtue of each edge of the laminated interlayer overhanging laterally below a respective edge of the backing sheet, the backing sheet and one or more further elements of the solar module (e.g., encapsulant) can directly contact the frame 102 at each major edge, while the laminated interlayer remains spaced apart from the frame.

[0085] The laminated interlayer comprises an electrical insulation layer 36 and a metal barrier film 38, arranged in that order from the front side of the module to the back side of the module. The laminated interlay further comprises both a front side primer layer 40a and a back side primer layer 40b. The front side primer layer is disposed on the front side of the electrical insulation layer 36 via an adhesive layer (not shown). The back side primer layer is disposed on the back side of the metal barrier film 38 via an adhesive layer (not shown). Thus, the structure of the laminated interlayer is, in order, a front side primer layer, adhesive, electrical insulation layer, metal barrier film, adhesive, and back side primer layer.

[0086] Electrical insulation layer 36 is a PET layer having a thickness of about 0.01 mm, which was selected based on the layer thickness requirements given in the row headed "Thickness of Thin Layer" in Table 3 of IEC 61730-1:2016. PET has an RTI greater than 90°C and therefore meets the IEC standard for distance through insulation as defined in IEC 61730-1:2016, and therefore provides a suitable insulation between the solar cell (not shown in FIG. 2) and the metal barrier film. This is advantageous because materials typically used for encapsulant layers (here EVA) do not have a suitable high RTI that qualifies them as suitable materials for providing distance through insulation as described in Table 3 of IEC 61730-1:2016.

[0087] The metal barrier film is an aluminum foil layer. Commercially available aluminum foil layers are typically available in thicknesses of, for example, 7 μm, 9 μm, 11 μm or more. Advantageously, the metal barrier film in this embodiment is a commercially available aluminum foil having a thickness of 7 μm. Using a thinner foil can reduce the weight of the overall module. The barrier film 38 is substantially continuous within each defined area 14a, 14b of the laminate interlayer. In this manner, the number of holes, openings, spaces, or apertures through the laminate interlayer can be minimized.

[0088] The front primer layer 40a and the back primer layer 40b each comprise a polyolefin material, which allows for improved adhesion of the lamination interlayer to the back encapsulant layer 20b and the insulating backing sheet 24b.

[0089] 1A and 1B, the solar module 10 is mounted within a rectangular frame 102 that extends around the perimeter of the solar module 10. The frame 102 protects the edges of the solar module 10 and provides a means for mounting the solar module 10 to a structure (e.g., the roof of a building). The frame 102 includes four elongated frame members 104 that are each attached to and extend along a respective edge of the solar module 10. The frame is formed from a conductive material, such as aluminum.

[0090] The module has a single module V of about 50V. OC and is intended for installation in a system comprising several such modules, the total system voltage being approximately 1500 V. The pollution degree of the module for all creepage distance calculations is 1.

[0091] A first predetermined minimum creepage distance X1 is provided between the edge of the laminate interlayer and the conductive frame member. This first predetermined minimum creepage distance is selected to be equal to or greater than the value shown in row 1(a) of table 3 of IEC 61730-1:2016 for at least a single module voltage and pollution degree of the module. In this case, a total system voltage of 1500V is considered, and therefore the first predetermined minimum creepage distance is selected to be equal to or greater than 10.4mm based on table 3 of IEC 61730-1:2016, which is 12mm in this embodiment. This first minimum creepage distance is defined as the shortest distance along the surface of the solid insulating material (here along the front side of the insulating backing sheet) between the metal barrier film 38 of the laminate interlayer and the conductive frame member 104. For the avoidance of doubt, the distance along the edge of the primer layer is not included in calculating this creepage distance, since the RTI value of the primer layer is typically less than 90°C. Therefore, they do not meet the IEC standards to be included when calculating the distance through insulation, creepage (cr), or clearance (cl) for Class II PV modules as defined in IEC 61730-1:2016.The term "insulating material" in this context therefore includes materials with an RTI value of 90°C or greater.

[0092] 1B, the conductive interconnect members 30 extend through the thickness of the solar module from a horizontal reference plane RP (not shown) where the solar cells are located to the back side 28 of the module. Thus, a portion of the conductive interconnect members extends through the back encapsulant layer 20b and the insulating back sheet 24b, as well as through the horizontal plane in which the laminate interlayer resides. A second predetermined minimum creepage distance X2 is provided between the edge of the laminate interlayer and the conductive interconnect members 30. This second predetermined minimum creepage distance is selected based on Table 3 of IEC 61730-1:2016. In this case, a single module V OCis taken into consideration, thus the second predetermined minimum creepage distance is selected to be 0.5 mm or more based on Table 3 of IEC 61730-1:2016, which is 0.5 mm in this embodiment. This second minimum creepage distance is defined as the shortest distance along the surface of the solid insulating material (here, along the front side of the insulating backing sheet) between the metal barrier film 38 of the laminate interlayer and the conductive interconnect member 30. For the avoidance of doubt, the distance along the edge of the primer layer is not included in calculating this creepage distance, since the RTI value of the primer layer is typically less than 90°C. Thus, it does not meet the IEC standard to be included in calculating the distance through insulation, creepage (cr), or clearance (cl) of a Class II PV module, as defined in IEC 61730-1:2016. Thus, the term "insulating material" in this context includes materials having an RTI value of 90°C or more.

[0093] An exemplary method for manufacturing the solar module 10 will now be described with reference to FIG. 3, which shows a flow chart of the corresponding method steps.

[0094] The method 200 begins at a first step 202 where a plurality of solar cells 12 are provided. According to an exemplary arrangement, the plurality of solar cells 12 are arranged in a planar array or grid, as described above with reference to Figures 1A and 1B.

[0095] The method then proceeds to step 204 where a front encapsulant 20a is overlaid on the front side of the solar cell and a back encapsulant 20b is overlaid on the back side of the solar cell to enclose the cell. Method step 204 includes the optional step of applying heat and pressure to the front and back encapsulants to adhere them to the respective surfaces of the solar cell 12. According to an exemplary method, the front and back encapsulants are configured such that heat at least partially melts the encapsulant and then pressure secures them to the cell 12 as the encapsulant layers cool.

[0096] The method then proceeds to step 206 where a lamination interlayer 14a, 14b including an electrical insulation layer 36 and a metallic barrier film 38 is laid down on the back side of the back encapsulant 20b. The lamination interlayer is laid down on the encapsulant such that the electrical insulation layer and the metallic barrier film are disposed, in that order, from the front side of the module to the back side of the module. The lamination interlayer has a smaller lateral extent than the lateral extent of the back sheet that will be laid down in a subsequent step.

[0097] The method then proceeds to step 208 where a transparent glass sheet 24a is laminated to the front surface of the pre-encapsulant 20a and an insulating backing sheet is laminated to the back surface of the lamination interlayer, thereby assembling the exemplary solar module 10 as shown in Figure 1. Method step 208 optionally includes further application of heat and pressure to bond the pre-encapsulant 20a to the transparent glass sheet 24a and the lamination interlayers 14, 14b to the backing sheet 24b, respectively.

[0098] The module architecture described herein results in modules with comparable or improved reliability (by providing a suitable reduction in the permeation of ingress gases and / or liquid molecules into the solar module, as well as by providing improved heat transfer away from the solar cells) compared to conventional modules with pure aluminum backing sheets, but with reduced risk of static build-up and discharge between conductive parts of the module due to the lateral spacing provided between the laminate interlayer and other parts of the solar module. Additionally, the modules are relatively simple to manufacture while still meeting safety standards as set forth in IEC 61730-1:2016.

[0099] The features disclosed in the foregoing specification, or the following claims, or the accompanying drawings, may be utilized separately or in any combination of such features to realize the invention in various of its forms, as appropriate in terms of their specific forms, or means for performing a disclosed function, or a method or process for obtaining a disclosed result.

[0100] While the present invention has been described in conjunction with the exemplary embodiments set forth above, many equivalent modifications and variations will be apparent to those skilled in the art given this disclosure. Accordingly, the exemplary embodiments of the invention set forth above are considered to be illustrative rather than limiting. Various changes to the described embodiments can be made without departing from the spirit and scope of the invention.

[0101] For the avoidance of any doubt, any theoretical explanations provided herein are provided for the purpose of enhancing the understanding of the reader, and the inventors do not wish to be bound by any of these theoretical explanations.

[0102] Any section headings used herein are for organizational purposes only and are not to be construed as limiting the subject matter described.

[0103] Unless the context requires otherwise, throughout this specification, including the claims which follow, the words "comprise" and "include", as well as variations such as "comprises", "comprising" and "including", are understood to imply the inclusion of a stated integer or step or group of integers or steps, but not the exclusion of any other integer or step or group of integers or steps.

[0104] It should be noted that, as used in this specification and the appended claims, the singular forms "a," "an," and "the" include plural references unless the context clearly dictates otherwise. Ranges may be expressed herein as from "about" one particular value and / or to "about" another particular value. When such a range is expressed, another embodiment includes from the one particular value and / or to the other particular value. Similarly, when values ​​are expressed as approximations by use of the antecedent "about," it is understood that the particular value forms another embodiment. In connection with numerical values, the term "about" is optional and may mean, for example, + / - 10%.

Claims

1. A solar module, comprising: one or more solar cells having a front surface and a back surface, the solar cells being electrically connected to terminals via one or more conductive interconnect members and surrounded by an encapsulant; an insulating backing sheet positioned overlying the one or more solar cells and encapsulant on a back side of the module; a lamination interlayer interposed between the encapsulant and the backing sheet, the lamination interlayer comprising an electrical insulation layer and a metal barrier film, disposed in that order from a front side of the module to the back side of the module; Equipped with A solar module, wherein the laminated interlayer has a lateral extent that is smaller than the lateral extent of the backing sheet.

2. 、 (i) the solar module further comprises a conductive frame, and a first predetermined minimum creepage distance is provided between an edge of the lamination interlayer and the conductive frame; (ii) the one or more conductive interconnect members extend through a horizontal plane in which the laminate interlayer lies, and a second predetermined minimum creepage distance is provided between an edge of the laminate interlayer and the one or more conductive interconnect members; Either or both of the following apply: The solar module according to claim 1 .

3. The solar module according to claim 2 , wherein the first and / or second predetermined minimum creepage distances are selected based on Table 3 of IEC 61730-1:2016.

4. (i) is applied, and the first predetermined minimum creepage distance is at least a single module voltage or V ＯＣ , and the degree of contamination of the module is selected to be equal to or greater than the value given in row 1 (a) or row 3 of table 3 of IEC 61730-1: 2016. The solar module according to claim 2 or 3.

5. (ii) applies, and the second predetermined minimum creepage distance is at least a single module voltage or V ＯＣ and the pollution degree of the module is selected to be equal to or greater than the value given in row 1(a) or row 3 of table 3 of IEC 61730-1: 2016. The solar module according to claim 2, 3 or 4.

6. The solar module according to claim 1 , wherein the laminated interlayer substantially overlaps all of the one or more solar cells on a back side.

7. 7. The solar module of claim 1, wherein the laminated interlayer comprises two or more discontinuous regions.

8. 8. The solar module of claim 7 when dependent on claim 2, wherein (ii) applies and the one or more electrically conductive interconnect members extend through gaps between the discontinuous regions of the intermediate layer.

9. 9. The solar module of claim 1, wherein the one or more electrically conductive interconnect members comprise an interconnect bus bar.

10. 10. The solar module according to claim 1, wherein the terminals are located on a rear side of the module.

11. 11. The solar module according to claim 1, wherein the electrical insulation layer has a relative thermal index (RTI) of greater than 90°C.

12. 12. The solar module according to claim 1, wherein the electrical insulation layer comprises a material selected from the group consisting of polyethylene terephthalate (PET), polyolefin (PO), polyamide (PA), and polycarbonate (PC).

13. The solar module according to claim 1 , wherein the electrical insulating layer has a thickness of 0.01 mm or more.

14. 14. The solar module according to claim 1, wherein the metal barrier film comprises a foil layer, optionally an aluminum foil layer or a copper foil layer.

15. The solar module according to claim 1 , wherein the metal barrier film has a thickness of 5 μm or more.

16. 16. The solar module of claim 1, wherein the laminated interlayer comprises one or more primer layers disposed on a front side and / or a back side of the interlayer.

17. The solar module of claim 16 , wherein the one or more primer layers comprise a polyolefin material.

18. 20. The solar module of claim 17, wherein each of the one or more primer layers comprises a material selected from the group consisting of ethylene vinyl acetate (EVA), polyethylene (PE), including linear low density polyethylene (LLDPE), and polyolefin elastomer (POE).

19. The solar module according to any one of claims 16 to 18, wherein the one or more primer layers are laminated to the electrical insulation layer and / or the metal barrier film via an adhesive layer.

20. 20. The solar module according to any one of claims 1 to 19, wherein the backing sheet is a polymeric backing sheet.

21. 21. The solar module according to any one of claims 1 to 20, wherein the one or more solar cells are heterojunction technology (HJT) cells.

22. 1. A method for manufacturing a solar module, the method comprising: (i) providing one or more solar cells, the solar cells being electrically connected to terminals via one or more conductive interconnect members; (ii) disposing an encapsulant around the one or more solar cells; (iii) placing a backing sheet overlying the one or more solar cells and encapsulant on a back side of the module; (iv) placing a lamination interlayer having a lateral extent smaller than the lateral extent of the backing sheet between the encapsulant and the backing sheet of the solar module, the lamination interlayer comprising an electrical insulating layer and a metal barrier film, in that order, from the front side of the module to the back side of the module; A method comprising:

23. 23. The method of claim 22, wherein the step (iv) of disposing a laminated interlayer between the encapsulant and the backing sheet of the solar module is performed between the step (ii) of disposing an encapsulant around the one or more solar cells and the step (iii) of disposing a backing sheet overlying the one or more solar cells and the encapsulant on a back side of the module.

24. 23. The method of claim 22, wherein the laminated interlayer is attached to the backing sheet before the backing sheet is positioned to overlie the one or more solar modules and encapsulant on a back side of the module, and steps (iii) and (iv) are performed as a single method step of positioning a combined interlayer-backing sheet to overlie the one or more solar cells and encapsulant on a back side of the module.

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