Lightweight, impact-resistant photovoltaic modules

Abstract

The present invention mainly relates to a photovoltaic module (1) obtained from a stack comprising a first front layer (2), a number of photovoltaic cells (4), an encapsulation assembly (3) obtained by combining a front layer (3a) and a rear layer (3b) of encapsulation material, and a second rear layer (5). The first layer (2) comprises a front assembly (2b, 2c) comprising a front layer made of a polymer material (2a), an interfacial front layer (2b) having a thickness of less than or equal to 2 mm, and a glass front layer (2c), said front assembly (2b, 2c) being placed between the polymer front layer (2a) and the encapsulation assembly (3), and the interfacial front layer (2b) being placed between the polymer front layer (2a) and the glass front layer (2c). The front layer (3a) of the encapsulant has a Young's modulus at 25°C strictly less than 50 MPa and the rear layer (3b) has a Young's modulus at 25°C strictly greater than 150 MPa.

Description

[Technical field]

[0001] The present invention relates to the field of photovoltaic modules, which comprise a set of photovoltaic cells electrically connected to one another, and preferably the photovoltaic cells are called "crystalline" photovoltaic cells, i.e. based on monocrystalline or polycrystalline silicon.

[0002] The invention is intended in particular to be fixed to a rigid base resistant to hail-type impacts according to standard IEC 61215, in particular 5 kg / m 2 Less than or even 6 kg / m 2 It can be implemented for many applications, especially civil and / or military, for example autonomous and / or embedded applications, with particular emphasis on applications that require the use of lightweight photovoltaic modules with a weight per unit area of ​​less than 10 ...

[0003] The invention therefore proposes a lightweight photovoltaic module obtained by a stack comprising a first glass and a polymer layer, which forms the front surface of the module, as well as a method for producing such a photovoltaic module. [Background technology]

[0004] A photovoltaic module is an assembly of photovoltaic cells arranged side-by-side between a first transparent layer that forms the front surface of the photovoltaic module and a second layer that forms the rear surface of the photovoltaic module.

[0005] The first layer forming the front face of the photovoltaic module is advantageously transparent in order to allow the photovoltaic cells to receive the luminous flux. The first layer is conventionally made from a single sheet of glass, in particular tempered glass, having a thickness typically comprised between 2 mm and 4 mm, conventionally about 3 mm.

[0006] The second layer forming the rear face of the photovoltaic module can furthermore be made of glass, metal or plastic, among others. 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 fluorinated polymers, such as polyvinyl fluoride (PVF) or polyvinylidene fluoride (PVDF), having a thickness of about 300 μm.

[0007] The photovoltaic cells can be electrically connected to each other by means of front and rear electrical contact elements, called connecting conductors and formed, for example, by strips of tin-plated copper, arranged on the respective front (the face opposite the front face of the photovoltaic module intended to receive the luminous flux) and rear (the face opposite the rear face of the photovoltaic module) of the photovoltaic cells or, in the case of IBC ("Interdigitated Back Contact") type photovoltaic cells, only on the rear face.

[0008] It should be noted that IBC ("Interdigitated Back Contact") type photovoltaic cells are constructed in such a way that contacts are made on the back faces of the interdigitated comb-shaped cells. These cells are described, for example, in U.S. Patent No. 4,478,879(A).

[0009] Furthermore, the photovoltaic cells placed between the first and second layers, which respectively form the front and rear faces of the photovoltaic module, can be encapsulated. Conventionally, the encapsulant chosen corresponds to an elastomeric (or rubber) type polymer, and can be made, for example, by the use of two layers (or thin films) of poly(ethylene vinyl acetate) (EVA), between which the photovoltaic cells and the cell connecting conductors are placed. Each layer of encapsulant can have a thickness of at least 0.2 mm, and a Young's modulus typically comprised between 2 MPa and 400 MPa at room temperature.

[0010] A conventional example of a photovoltaic module 1 including a crystalline photovoltaic cell 4 is therefore partially and diagrammatically represented in cross-section in FIG. 1 and in exploded view in FIG. 2, respectively.

[0011] As described above, the photovoltaic module 1 includes a front surface 2, typically made from transparent tempered glass having a thickness of approximately 3 mm, and a rear surface 5, made from an opaque or transparent, single or multi-layer, polymer sheet, for example, having a Young's modulus greater than 400 MPa at room temperature.

[0012] Located between the front face 2 and rear face 5 of the photovoltaic module 1 are photovoltaic cells 4, electrically connected to each other by connecting conductors 6 and embedded between two front and rear layers 3a and 3b of encapsulation material, both of which form an encapsulation assembly 3.

[0013] FIG. 1A further illustrates an alternative embodiment of the example of FIG. 1, in which the photovoltaic cell 4 is of the IBC type and the connecting conductors 6 are disposed only on the rear face of the photovoltaic cell 4 .

[0014] 1 and 2 also show a junction box 7 of the photovoltaic module 1, intended to receive the wiring necessary to operate the module. Conventionally, this junction box 7 is made of plastic or rubber and has a complete encapsulation.

[0015] Usually, the method for producing a photovoltaic module 1 comprises a step called vacuum lamination of the various layers mentioned above, at a temperature of at least 120°C, even at least 140°C, even at least 150°C, and up to 170°C, typically comprised between 145°C and 165°C, and for a duration of a lamination cycle generally of at least 10 minutes, even 15 minutes.

[0016] During this lamination step, the layers of encapsulant 3a and 3b melt and encapsulate the photovoltaic cell 4 while at the same time creating adhesion at all the interfaces between the layers: between the front surface 2 and the front layer of encapsulant 3a, between the front layer of encapsulant 3a and the front surface 4a of the photovoltaic cell 4, between the rear surface 4b of the photovoltaic cell 4 and the rear layer of encapsulant 3b, and between the rear layer of encapsulant 3b and the rear surface 5 of the photovoltaic module 1. The resulting photovoltaic module 1 is then bordered, typically by an aluminium profile.

[0017] Such constructions are now standardized with significant mechanical resistance due to the use of a thick glass front 2 and an aluminium frame, which enables such constructions in particular and in most cases to comply with the standards IEC 61215 and IEC 61730.

[0018] Nevertheless, such photovoltaic modules 1 according to conventional designs of the prior art have a relatively large weight, in particular of the order of 10 kg / m 2 from 12kg / m 2 , and therefore is not suitable for certain applications where light weight is a priority.

[0019] This large weight of the photovoltaic module 1 is mainly due to the fact that it is about 2.5 kg / m 2The high density of the glass, with a thickness of 1000 / mm, results from the thick glass with a thickness of approximately 3 mm to form the front surface 2 and the presence of an aluminium frame. The glass is tempered to be able to withstand the constraints during manufacture, to have a better mechanical resistance to impacts, and also for safety reasons, for example due to the risk of cuts. Nevertheless, technical difficulties also exist, as the industrial infrastructure for thermal tempering is configured to handle glass with a thickness of at least 2 mm. Furthermore, the choice to have a glass thickness of approximately 3 mm also relates to the standard mechanical resistance to a pressure of 5.4 kPa. Thus, finally, the glass alone represents almost 70% of the weight of the photovoltaic module 1, and more than 80% if an aluminium frame is present around the photovoltaic module 1.

[0020] There is also a need to find alternative solutions to the use of thick glass on the front of the modules in order to achieve a significant reduction in the weight of photovoltaic modules, so as to enable their use in applications requiring light weight, such as, for example, commercial roofs when the building structure is not designed for photovoltaic-related loads.

[0021] One possibility is to replace the glass front with a plastic material, while keeping the usual architecture and packaging methods, with the main objective of significantly reducing the surface weight. Thus, polymer sheets such as polycarbonate (PC), polyethylene terephthalate (PET), polymethyl methacrylate (PMMA), polyvinylidene fluoride (PVDF), ethylene tetrafluoroethylene (ETFE), ethylene trichlorotrifluoroethylene (ECTFE) or fluorinated ethylene propylene (FEP) can represent a substitute for glass. Nevertheless, when only the replacement of glass with such polymer sheets is considered, depending on the chosen thickness, the photovoltaic cells become very vulnerable to impacts, mechanical loads and differential expansion.

[0022] An alternative is the use of synthetic materials, including reinforcing materials such as fiberglass, carbon fiber, or natural fibers such as flax, hemp, among others, to complement the standard encapsulant to form a polymer / fiber type composite associated with a front polymer overcoat. The weight savings can be significant, albeit with a loss in transparency and uncertainties about performance behavior over periods of more than 20 years.

[0023] The removal of the front glass of a photovoltaic module has been the subject of several patents or patent applications in the prior art. Examples include patent application FR2955051A1, US patent application 2005 / 0178428(A1), or international applications WO2008 / 019229A2 and WO2012 / 140585A1. Other patents or patent applications, such as European patent application EP2863443A1, or international applications WO2018 / 076525A1, WO2019 / 006764A1, and WO2019 / 006765A1, describe the use of reinforcing materials, alone or in combination. Summary of the Invention [Problem to be solved by the invention]

[0024] There is therefore a need to design alternative solutions for photovoltaic modules designed to be lightweight for specific applications, and in particular to comply with the IEC 61215 and IEC 61730 standards, whilst having sufficient mechanical properties to enable the photovoltaic modules to withstand impacts and mechanical loads.

[0025] The present invention therefore seeks to at least partially overcome the above-mentioned needs and shortcomings associated with prior art achievements. [Means for solving the problem]

[0026] The present invention therefore provides, according to one of its aspects, a first transparent layer forming the front surface of the photovoltaic module, intended to receive the luminous flux; a plurality of photovoltaic cells arranged side by side and electrically connected to one another; - an assembly encapsulating a number of photovoltaic cells, obtained by combining a front layer of encapsulation material on either side of the photovoltaic cell and a rear layer of encapsulation material, advantageously in direct contact with the photovoltaic cell, the front layer of encapsulation material being placed between the first layer and the photovoltaic cell, a second layer forming a rear face of the photovoltaic module, the encapsulation assembly and the plurality of photovoltaic cells being interposed between the first layer and the second layer; A photovoltaic module obtained from a stack comprising: a front layer made of at least one polymeric material, called the "polymeric front layer", as well as - at least one front assembly comprising an interface front layer and a glass front layer, the glass front layer having a thickness of 2 mm or less; Equipped with the at least one front assembly being positioned between a polymer front layer and an encapsulation assembly, and an interfacial front layer of the at least one front assembly being positioned between the polymer front layer and a glass front layer; the front layer of encapsulant is formed by at least one layer comprising at least one polymeric encapsulant having a Young's modulus at 25° C. strictly less than 50 MPa; and the rear layer of encapsulant being formed by at least one layer comprising at least one polymeric encapsulant having a Young's modulus at 25° C. strictly greater than 150 MPa; The present invention relates to a photovoltaic module, characterized in that

[0027] Advantageously, the present invention allows the replacement of the standard thick glass, approximately 3 mm thick, usually used on the front side of conventional photovoltaic modules, by a combination of a polymer layer and a thin glass layer. The use of thin glass and polymer therefore makes it possible to obtain a low mass and transparency comparable to standard modules. When the present invention is compared to commercially available lightweight modules, the presence of thin glass in the structure allows a better resistance to shocks and thermomechanical expansion, and also to moisture penetration, compared to lightweight modules with a transparent polymer film on the front side.

[0028] More advantageously, the use of a polymer-type encapsulant with enhanced mechanical properties, especially for the rear layer of the encapsulant of the encapsulation assembly, can make it possible to further improve the resistance to impacts, especially hail-type impacts, on the photovoltaic module and to protect the photovoltaic cells from possible adverse mechanical effects.

[0029] The term "transparent" means that the first layer forming the front surface of the photovoltaic module is at least partially transmissive to visible light, allowing at least approximately 80% of the visible 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 polymeric front layer, between 300 nm and 1200 nm can be greater than 80%. Similarly, the optical transparency of the encapsulation assembly between 300 nm and 1200 nm can be greater than 90%, as can the optical transparency of the interfacial front layer.

[0031] Additionally, by the terms "encapsulating" or "encapsulated," it is understood that a plurality of photovoltaic cells are disposed within a volume, e.g., hermetically sealed against liquids, formed at least in part by at least two layers of encapsulating material that are bonded together after lamination to form an encapsulated assembly.

[0032] In fact, initially, i.e. before any lamination operation, the encapsulation assembly is formed by at least two layers of encapsulant material, called core layers, between which the photovoltaic cells are encapsulated, nevertheless, during the lamination operation of the layers, the layer of encapsulant material melts, so that after the lamination operation, only a single solidified layer (or assembly) is formed in which the photovoltaic cells are embedded.

[0033] Moreover, the present invention allows the use of thin glass to achieve a weight of 6 kg / m while maintaining the optical transparency of the front surface and ensuring excellent reliability of the photovoltaic module with low thermomechanical expansion and high durability. 2 Less than 5kg / m 2 It may be possible to obtain new types of lightweight photovoltaic modules, which may have a surface weight of less than 100 nm. In addition, the use of polymer front and interface layers makes it possible to protect the thin glass from impacts, in particular hail-type impacts.

[0034] The photovoltaic module according to the invention may also comprise one or more of the following features, taken alone or in any possible technical combination:

[0035] The front layer of encapsulating material may be formed by at least one layer comprising at least one polymer-type encapsulating material having a Young's modulus at 25° C. strictly less than 50 MPa, in particular greater than 2 MPa and strictly less than 50 MPa, even strictly less than 20 MPa, in particular comprised between 10 MPa and 20 MPa.

[0036] In addition, the rear layer of encapsulating material may be formed by at least one layer comprising at least one polymer-type encapsulating material having a Young's modulus at 25° C. strictly greater than 200 MPa, in particular strictly greater than 200 MPa and less than 500 MPa, in particular comprised between 250 MPa and 350 MPa.

[0037] Furthermore, the elongation at break of the front layer of encapsulant and / or the rear layer of encapsulant may advantageously be at least greater than 200%.

[0038] The use of a rear layer of encapsulant having a high Young's modulus can provide improved resistance to hail-type impacts.

[0039] The glass front layer may advantageously have a thickness less than or equal to 1.5 mm, preferably comprised between 500 μm and 1 mm.

[0040] Moreover, the glass front layer can advantageously be made of untempered glass. In other words, the glass is not thermally or chemically tempered. In fact, untempered glass may not be as resistant to impacts as tempered glass, especially with respect to hail impacts. Nevertheless, when placed between protective polymer layers, untempered glass can be protected from impacts. Untempered glass can also provide a moisture barrier for the photovoltaic cells. The use of untempered glass, rather than tempered glass, can significantly reduce the cost of making the photovoltaic module suitable for many applications.

[0041] In addition, the second layer may be made of at least one polymeric material, in particular selected from 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 trichlorotrifluoroethylene (ECTFE), polytetrafluoroethylene (PTFE), polychlorotrifluoroethylene (PCTFE), fluorinated ethylene propylene (FEP), and / or multilayers comprising one or more of said polymers. The choice of a second layer made of at least one polymeric material may be preferred if the final application of the photovoltaic module requires that the photovoltaic module is mounted on a rigid base.

[0042] Alternatively, by removing the thick glass and aluminum frame on the front of a conventional photovoltaic module, which may lead to a loss of mechanical strength of the module, as well as to maintain a rigid module, the rear of the module can be designed to have sufficient mechanical rigidity.

[0043] In particular, according to the first possibility, the second layer is therefore - a rear layer forming a rear panel made of a synthetic material, the rear layer comprising a main sub-layer forming a core of the rear panel and two covering sub-layers forming respectively the plates of the rear panel, the covering sub-layer being 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. It is possible to include:

[0044] The core of the rear panel may in particular comprise a cellular structure, for example in the form of a honeycomb, made of a metal, for example aluminum, polyimide, polycarbonate (PC), polypropylene (PP) or a high-performance synthetic fiber, 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, made from polyethylene terephthalate (PET), polyvinyl chloride (PVC), or polyurethane (PU), among others.

[0046] Furthermore, the rear panel plate can be made from metals, especially aluminum, from synthetic materials made from polycarbonate (PC), polymethyl methacrylate (PMMA), or from prepregs, for example fiberglass / epoxy prepregs.

[0047] The rear panel plate can, if desired, be covered with a single or multi-layer polymer film, for example of the Tedlar® type.

[0048] In addition, the rear panel is rated at 3kg / m 2 The following, especially 2kg / m 2 The following, especially 1 kg / m 2 It may have the following surface weights:

[0049] It should be noted that rather than having a sandwich panel type rear surface, the second layer may further include a rear layer that includes a cellular structure without the use of a covering sub-layer, such as a cellular polycarbonate type cellular structure.

[0050] According to the second possibility, the second layer is a rear layer made of at least one polymeric material, called the "polymeric rear layer", as well as at least one rear assembly comprising an interface rear layer and a glass rear layer, the glass rear layer having a thickness in particular less than or equal to 2 mm, preferably even less than or equal to 1.5 mm, in particular comprised between 500 μm and 1 mm, in particular made from non-tempered glass; wherein the at least one rear assembly is positioned between a polymer rear layer and an encapsulation assembly, and an interfacial rear layer of the at least one rear assembly is positioned between the polymer rear layer and a glass rear layer.

[0051] The second layer can therefore be obtained according to a principle similar to that used for the first layer. In particular, the second layer can 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 layer of fiber-based reinforcement.

[0053] "Fibre-based reinforcing layer" means a layer that mainly comprises organic and / or inorganic fibres, and preferably a layer that consists of organic and / or inorganic fibres. Advantageously, the fibre-based reinforcing layer allows mechanical reinforcement to the stack of layers intended to form the photovoltaic module. Prior to lamination, the fibres of the fibre-based reinforcing layer are preferably not impregnated, in particular with a polymeric material. Such a reinforcing layer can be said to be fibrous or woven. In particular, such a reinforcing layer is neither a pre-impregnated nor a synthetic layer.

[0054] The fiber-based reinforcing layer may comprise woven or non-woven fibers. The fiber-based reinforcing layer may have a fiber density of 20 g / m 2 from 1500g / m 2 and preferably between 300 g / m 2 From 800g / m 2 The fiber-based reinforcing layer may further have a surface weight comprised between 0.01 and 0.05. The fiber-based reinforcing layer may comprise, inter alia, glass, carbon, aramid fibers, and / or natural fibers, especially hemp, linen, and / or silk.

[0055] The glass used for the front glass layer and / or the rear glass layer may in particular be a soda-lime glass, based on silica, calcium and sodium.

[0056] Moreover, the polymeric front layer and / or the polymeric rear layer may have a thickness comprised between 15 μm and 300 μm, in particular between 20 μm and 50 μm.

[0057] In addition, the polymeric material of the polymeric front layer and / or the polymeric rear layer may be selected from, among others, 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 multilayers comprising one or more of the aforementioned polymers.

[0058] Furthermore, the polymer front layer and / or the polymer rear layer can have a UV cut-off filter comprised between 320 nm and 450 nm, corresponding to a wavelength where the transmittance is equal to 50%. In this way, the underlying layer can be protected from degradation by ultraviolet (UV) radiation and possibly from hydrolysis, providing an extended service life to the photovoltaic module.

[0059] The interfacial front layer and / or the interfacial rear layer can enable bonding between a polymeric front layer and a glass layer, between a polymeric rear layer and a glass layer, or between two glass layers.

[0060] The front and / or rear interface layer may have a thickness comprised between 50 μm and 600 μm, preferably between 400 μm and 600 μm, or even between 400 μm and 500 μm.

[0061] The front interface layer and / or the rear interface layer may have a Young's modulus comprised between 2 MPa and 300 MPa at 25°C, preferably between 2 MPa and 250 MPa at 25°C, even between 10 MPa and 50 MPa at 25°C, even between 2 MPa and 50 MPa at 25°C, even between 2 MPa and 20 MPa at 25°C.

[0062] Furthermore, the front interfacial layer and / or the optional rear interfacial layer may be formed by at least one layer comprising at least one polymeric encapsulating material selected from, among others, 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 polyolefin elastomers, copolymers of α-olefins and α-,β-ethylene carboxylic acid esters such as ethylene-methyl acrylate copolymer and ethylene-butyl acrylate copolymer, silicone elastomers, and / or elastomers based on crosslinked thermoplastic polyolefins.

[0063] The front layer of encapsulant may be formed by at least one layer including at least one polymeric encapsulant selected from poly(ethylene vinyl acetate) (EVA), vinyl acetals such as polyvinyl butyral (PVB), polyurethanes, silicone elastomers, elastomers based on crosslinked thermoplastic polyolefins, and / or elastomers based on crosslinked thermoplastic polyolefins (TPO), among others.

[0064] The rear layer of encapsulant may be formed by at least one layer including at least one polymeric encapsulant selected from acid copolymers, ionomers, polyvinyl chloride, and / or polyethylene, among others.

[0065] Preferably, the encapsulation material and / or the thickness of the encapsulation material of the encapsulation assembly, in particular of the front layer of encapsulation material, is identical to the material and / or the thickness of the material of the interface front layer and possibly of the interface rear layer. In this way, it is possible to facilitate the manufacturing process.

[0066] The front layer of encapsulation material and / or the rear layer of encapsulation material of the encapsulation assembly may have a thickness comprised between 200 μm and 600 μm, in particular comprised between 400 μm and 600 μm.

[0067] In addition, the photovoltaic cells may be selected from homojunction or heterojunction photovoltaic cells based on monocrystalline silicon (c-Si) and / or polycrystalline silicon (mc-Si), and / or IBC type photovoltaic cells, and / or photovoltaic cells comprising at least one material from amorphous silicon (a-Si), microcrystalline silicon (μC-Si), cadmium telluride (CdTe), copper indium selenide (CIS), copper indium / gallium diselenide (CIGS), and perovskite, among others.

[0068] Moreover, the photovoltaic cell may have a thickness comprised between 1 μm and 300 μm, in particular between 1 μm and 200 μm, advantageously between 70 μm and 160 μm.

[0069] The photovoltaic module may further include one or more junction boxes intended to receive the wiring necessary to operate the photovoltaic module, which may be located at the front or rear of the module, preferably at the front.

[0070] Furthermore, the spacing between two adjacent or consecutive or adjacent photovoltaic cells may in certain configurations be greater than or equal to 1 mm, in particular comprised between 1 mm and 30 mm, preferably equal to 2 mm. In other configurations, in particular of the "shingle" type, adjacent or consecutive or adjacent photovoltaic cells may overlap.

[0071] According to a particular embodiment, the first layer comprises: - a first front assembly comprising an interface front layer and a glass front layer, the glass front layer having a thickness of 2 mm or less; - a second front assembly comprising an interface front layer and a glass front layer, the glass front layer having a thickness of 2 mm or less; wherein a first front assembly is disposed between the polymer front layer and the second front assembly, and further between the first front assembly and the encapsulation assembly.

[0072] 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.

[0073] Furthermore, the second layer is a rear layer made of at least one polymeric material, called the "polymeric rear layer", as well as a first rear assembly comprising an interface rear layer and a glass rear layer, the glass rear layer having a thickness in particular 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 mm, in particular made from non-tempered glass, a second rear assembly comprising an interface rear layer and a glass rear layer, the glass rear layer having a thickness in particular 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 mm, in particular made from non-tempered glass; wherein the first rear assembly is disposed between the polymer rear layer and the second rear assembly, and further between the first rear assembly and the encapsulation assembly.

[0074] In addition, the present invention also provides, according to another aspect of the present invention, a first transparent layer forming the front surface of the photovoltaic module, intended to receive the luminous flux; a plurality of photovoltaic cells arranged side by side and electrically connected to one another; - an assembly encapsulating a plurality of photovoltaic cells obtained by bonding a front layer of encapsulation material and a rear layer of encapsulation material on both sides of the photovoltaic cell, the front layer of encapsulation material being placed between the first layer and the photovoltaic cell, a second layer, the encapsulation assembly and the plurality of photovoltaic cells being interposed between the first layer and the second layer; It also relates to a method for producing a photovoltaic module, in particular as defined above, from a stack comprising a first layer, a front layer made of at least one polymeric material, called the "polymeric front layer", as well as - at least one front assembly comprising an interface front layer and a glass front layer, the glass front layer having a thickness of 2 mm or less; the at least one front assembly is disposed between a polymer front layer and an encapsulation assembly, and an interfacial front layer of the at least one front assembly is disposed between a polymer front layer and a glass front layer; the front layer of encapsulant is formed by at least one layer comprising at least one polymeric encapsulant having a Young's modulus at 25° C. strictly less than 50 MPa; the rear layer of encapsulant is formed by at least one layer comprising at least one polymeric encapsulant having a Young's modulus at 25° C. strictly greater than 150 MPa; and The method is characterized in that it comprises a vacuum thermal lamination step of the constituent layers of the stack to obtain a photovoltaic module.

[0075] The vacuum thermal lamination step may in particular be carried out at a temperature of 120°C, even 140°C, even 150°C or more, and up to 170°C or even 180°C, typically comprised between 130°C and 180°C, even between 145°C and 165°C, for a duration of a lamination cycle of at least 5 minutes, even 10 minutes or even 15 minutes, in particular comprised between 5 minutes and 20 minutes.

[0076] This therefore makes it possible to achieve a total encapsulation of the thin glass, which enables the thin glass to be protected from impacts.

[0077] The photovoltaic module and the production method according to the invention may comprise any one of the aforementioned features, taken alone or in any technically possible combination with other features.

[0078] The invention can be better understood on reading the following detailed description of non-limiting examples of implementation of the invention and on considering the schematic and partial figures of the accompanying drawings. [Brief description of the drawings]

[0079] [Figure 1] 1 is a cross-sectional view of a conventional example of a photovoltaic module including a crystalline photovoltaic cell. [Figure 1A] FIG. 2 is a diagram of an alternative embodiment of the example of FIG. 1, in which the photovoltaic cell is of the IBC type. [Diagram 2] FIG. 2 is an exploded view of the photovoltaic module of FIG. 1. [Diagram 3] 1 is a perspective and exploded view of a first exemplary embodiment of a photovoltaic module according to the present invention; [Figure 3A] 4 is a cross-sectional view of an example of a back layer used as a variation of the photovoltaic module shown in FIG. 3. [Figure 4] FIG. 2 is a perspective and exploded view of a second exemplary embodiment of a photovoltaic module according to the present invention. [Diagram 5] FIG. 11 is a perspective and exploded view of a third exemplary embodiment of a photovoltaic module according to the present invention. [Figure 6] FIG. 13 is a perspective and exploded view of a fourth exemplary embodiment of a photovoltaic module according to the present invention. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0080] Throughout the figures, the same reference numbers may refer to the same or similar elements.

[0081] In addition, the different parts represented in the figures are not necessarily to scale in order to make the figures more legible.

[0082] 1, 1A and 2 have already been discussed in the Background section.

[0083] 3 to 6 illustrate four completely different embodiments of a photovoltaic module 1 according to the invention.

[0084] It is considered here that the photovoltaic cells 4 interconnected by soldered tinned copper strips similar to those shown in Figures 1, 1A, and 2 are "crystalline" cells, i.e., the photovoltaic cells 4 comprise monocrystalline or polycrystalline silicon, and that the photovoltaic cells 4 have a thickness comprised between 1 μm and 250 μm.

[0085] In addition, the polymer front layer 2a may be a fluorinated polymer thin film, in particular made from ethylene tetrafluoroethylene (ETFE), for example of the Saint-Gobain ChemFilm® ETFE-E2 type, having a thickness of about 50 μm.

[0086] The interface layers 2b, 2d and 5b may comprise a polymer encapsulation thin film of type A, for example formed by a thermoplastic elastomer based on polyolefin (TPO) having a Young's modulus at 25° C. of 18 MPa, or a polymer encapsulation thin film of type B, formed by an ionically crosslinked thermoplastic copolymer, for example of ionomer type, having a Young's modulus at 25° C. of 285 MPa. The thickness may be comprised between 500 μm and 600 μm, for example about 500 μm. In particular, in the case of a type A polymer encapsulant thin film, it may be Borealis Quentys® BPO8828UV, and in the case of a type B polymer encapsulant thin film, it may be KuranSeal-ES® (PV8729D / UV CUT) from Kurabo, having a thickness of 500 μm.

[0087] The glass layers 2c, 2e and 5c may comprise thin unstrengthened glass, for example having a thickness of about 950 μm, comprised between 500 μm and 1000 μm.

[0088] The second layer 5, when produced in the form of a polymer multilayer, is capable of integrating the aluminized layer.

[0089] The second layer 5, when in the form of a rear panel 5, may comprise a polypropylene honeycomb core 9a and synthetic skins or plates 9b, 9c made from glass reinforced polypropylene, for example of the Nidapan® 8GR600 type, having a thickness of for example 10 mm, comprised between 6 mm and 10 mm.

[0090] Of course, these choices are by no means limiting.

[0091] For all the example stacks described with reference to Figures 3 to 6, a test was performed against a hail-type mechanical impact with a diameter of 25 mm at an energy level of 2 J typical of the certification standard IEC 61215. The mechanical impact test was performed by gluing the photovoltaic module 1 to a rigid base typical of a flat roof, terrace or commercial building.

[0092] The results showed an enhanced improvement in impact resistance due to the use of an encapsulant having enhanced mechanical properties in the rear layer of the encapsulant of the encapsulation assembly.

[0093] In order to explain the different configurations considered, reference is first made to FIG. 3, which illustrates a first exemplary embodiment of a photovoltaic module 1 according to the invention in a perspective and exploded view.

[0094] 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. When the lamination step is carried out, which ensures a vacuum hot press, the different layers are in fact in contact with each other and in particular penetrate each other.

[0095] The photovoltaic module 1, or more precisely the stack intended to form the photovoltaic module 1, therefore comprises a first layer 2, which forms the front face 1 of the photovoltaic module and is intended to receive the luminous flux, a plurality of photovoltaic cells 4 arranged side by side and electrically connected to one another, an assembly 3 encapsulating the plurality of photovoltaic cells 4, comprising a front layer 3a of encapsulating material and a rear layer 3b of encapsulating material, placed on either side of the photovoltaic cells 4, and a second layer 5 forming the rear face of the photovoltaic module 1.

[0096] It should further be noted that the junction box 7 may be located on the front side, as shown in FIGS. 1, 1A, and 2, or on the rear side of the photovoltaic module 1.

[0097] According to the invention, and in a manner common to the examples of Figures 3 to 6, the first layer 2 comprises a front layer made from a polymer material 2a, called "polymer front layer 2a", and a first front assembly 2b, 2c comprising an interface front layer 2b and a glass front layer, advantageously made from non-tempered glass 2c.

[0098] Advantageously, the glass front layer 2c has a thickness e of less than or equal to 2 mm, even less than or equal to 1.5 mm, and in particular between 500 μm and 1 mm. 2c has.

[0099] In this example, the second layer 5 is made of at least one polymer material of the "backsheet" type. The second layer 5 may comprise a polymer material selected from 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 trichlorotrifluoroethylene (ECTFE), polytetrafluoroethylene (PTFE), polychlorinated trifluoroethylene (PCTFE), fluorinated ethylene propylene (FEP), and / or a multilayer comprising one or more of the aforementioned polymers. Advantageously, the second layer 5 is produced in the form of a polymer multilayer and comprises an aluminized layer.

[0100] Moreover, in this example, the front layer of encapsulant 3a and the interfacial front layer 2b are all Type A encapsulant films, as previously described.

[0101] On the other hand, in order to obtain improved impact resistance, the rear layer 3b of encapsulant is a type B encapsulant film, as described above, thus enhancing its mechanical properties.

[0102] More generally, in all the examples described herein with reference to Figures 3 to 6, the invention provides to have a front layer 3a of encapsulant having a Young's modulus at 25°C strictly less than 50 MPa, even strictly less than 20 MPa, even greater than 2 MPa and strictly less than 50 MPa, even comprised between 10 MPa and 20 MPa, and a rear layer 3b of encapsulant having a Young's modulus at 25°C strictly greater than 150 MPa, preferably strictly greater than 200 MPa, preferably even greater than 200 MPa and less than 500 MPa, even comprised between 250 MPa and 350 MPa. In particular, the front layer 3a of encapsulant is a type A encapsulant film, while the rear layer 3b of encapsulant is a type B encapsulant film.

[0103] Therefore, by using a Type B encapsulant film instead of a Type A encapsulant film for the rear layer of encapsulant 3b, any destruction phenomenon of the glass and the photovoltaic cell 4 can be avoided.

[0104] The second layer 5 may alternatively be formed by a rear panel 5 made of a synthetic material, comprising a main sub-layer forming the core 9a of the rear panel 5 and two covering sub-layers forming the plates 9b, 9c of the rear panel 5, respectively, arranged on either side of the core 9a such that the core 9a is sandwiched between the two plates 9b, 9c, it being noted that the core 9a of the rear panel 5 comprises a cell structure 12.

[0105] Figure 3A shows in more detail, diagrammatically and in cross section, this variant of the second layer 5 formed in the example of Figure 3. It should also be noted that, alternatively, the second layer 5 may comprise a layer of reinforcement material based on woven or non-woven fibres, among others, in particular glass fibres, carbon fibres, aramid fibres and / or natural fibres, in particular hemp, linen and / or silk.

[0106] The photovoltaic module 1 is obtained by a single vacuum thermal lamination step, for example at a temperature of about 150° C. for about 15 minutes. The photovoltaic module 1 has a mass of 4.4 kg / cm 2 It has a surface weight of

[0107] It was previously described that the front layer of encapsulant 3a and the interfacial front layer 2b use a Type A encapsulant film, while the rear layer of encapsulant 3b uses a Type B encapsulant film. Note that if it is desired to further improve the impact resistance of the photovoltaic module 1, the interfacial front layer 2b may also use a Type B rather than a Type A encapsulant film.

[0108] Moreover, FIG. 4 illustrates a second exemplary embodiment according to the present invention.

[0109] In this example, unlike the example of FIG. 3, the first layer 2 advantageously also comprises a second front assembly 2d, 2e, comprising an interface front layer 2d and a glass front layer made of non-tempered glass 2e. The glass front layer 2e has a thickness e of less than or equal to 2 mm, even less than or equal to 1.5 mm, and in particular comprised between 500 μm and 1 mm. 2e In other words, this exemplary embodiment allows the thickness of the glass in the first layer 2 to be doubled. 2 A photovoltaic module 1 is obtained having a surface weight equal to 0.05 mm. The impact resistance of the photovoltaic module 1 is further improved.

[0110] In addition, the first interface front layer 2b and the encapsulation front layer 3a are formed by a type A encapsulant film, while the second interface front layer 2d and the encapsulation rear layer 3b are formed by a type B encapsulant film.

[0111] In the example of FIG. 4, the first glass front layer 2b and the second glass front layer 2e have the same thickness. Alternatively, the first glass front layer 2b and the second glass front layer 2e may have a thickness e of, for example, about 500 μm. 2b , and a thickness of about 300 μm e 2eIt is possible to use different glass thicknesses, such as 500 μm glass and 300 μm glass, etc. Thus, if it is believed that 800 μm glass can meet the needs of the cell 4 resistance to impact, it is possible to use, for example, 500 μm glass and 300 μm glass.

[0112] Indeed, it has been found that elastomeric materials have vibration and shock damping properties. Since the speed of the shock waves is directly proportional to the Young's modulus and the Poisson's ratio of the material used, the replacement of rigid materials with elastomeric materials therefore makes it possible to mitigate the speed of the propagation of the shock waves. The insertion of soft elastomeric layers between layers of more rigid materials therefore makes it possible to slow down the propagation of the shock waves. In addition, at each interface encountered, the shock waves can be partially transmitted and / or reflected. The alternation of these polymer layers with different Young's moduli therefore makes it possible, on the one hand, to slow down the shock waves and, on the other hand, to reduce the intensity of the shock waves that reach the photovoltaic cells.

[0113] Also, for an equivalent amount of glass, it may be more interesting to distribute this amount between at least two layers of glass of different thicknesses, rather than a single layer of glass.

[0114] 5 illustrates a third exemplary embodiment, the principle of which is to use the same encapsulation architecture on the rear side as on the front side, but symmetrically. Thus, a bi-sided and lightweight photovoltaic module 1 can be obtained.

[0115] The second layer 5 thus includes a rear layer made from the first rear assembly 5b, 5c, comprising a polymeric material 5a, referred to herein as the "polymeric rear layer 5a", as well as an interfacial rear layer 5b, and a glass rear layer 5c, which is preferably not tempered.

[0116] The glass rear layer 5c has a thickness of 550 μm 5c and the glass front layer 2c also has a thickness e of 550 μm. 2chas.

[0117] Interfacial front layer 2b, interfacial back layer 5b, and encapsulating back layer 3b are herein Type B encapsulant films, while encapsulating front layer 3a is a Type A encapsulant film.

[0118] Moreover, FIG. 6 illustrates a fourth exemplary embodiment, corresponding to a variation of the example of FIG. 5, in which the use of thin, preferably untempered glass on the front and rear faces is performed asymmetrically.

[0119] In particular, two thin glasses 2c and 2e can be used as front faces of the same or different thickness, and the thin glass 5c can be used as rear face. More specifically, here the first glass front layer 2c has a thickness e of 500 μm. 2c and the second glass front layer 2e has a thickness e of 300 μm. 2e and the first glass rear layer 5c has a thickness e of 550 μm. 5c has.

[0120] In addition, the first interfacial front layer 2b, the second interfacial front layer 2d, the interfacial rear layer 5b, and the encapsulation rear layer 3b are herein Type B encapsulant films, while the encapsulation front layer 3a is a Type A encapsulant film.

[0121] In all the above examples, the polymer front layer 2a and the polymer rear layer 5a have a thickness e of about 50 μm. 2a , e 5a has.

[0122] The front interfacial layers 2b, 2d and the rear interfacial layer 5b have a thickness e of about 600 μm. 2b , e 2d , e 5b has.

[0123] Naturally, the invention is not limited to the exemplary embodiments just described: various modifications can be made to the invention by those skilled in the art.

[0124] In particular, these exemplary embodiments can be produced in various variations using one or more of the materials described above to form the first layer 2 and the second layer 5.

Claims

1. a first transparent layer (2) forming the front surface of the photovoltaic module (1), intended to receive the luminous flux; a plurality of photovoltaic cells (4) arranged side by side and electrically connected to one another; an assembly (3) encapsulating a number of photovoltaic cells (4) obtained by combining a front layer (3a) of encapsulation material and a rear layer (3b) of encapsulation material on both sides of said photovoltaic cells (4), said front layer (3a) of encapsulation material being placed between said first layer (2) and said photovoltaic cells (4); a second layer (5) forming the rear face of the photovoltaic module (1), the encapsulation assembly (3) and the plurality of photovoltaic cells (4) being placed between the first layer (2) and the second layer (5); In a photovoltaic module (1) obtained from a stack comprising the first layer (2), a front layer made of at least one polymer material (2a), called "polymer front layer (2a)", and at least one front assembly (2b, 2c; 2d, 2e) comprising an interface front layer (2b; 2d) and a glass front layer (2c; 2e), said glass front layer (2c; 2e) having a thickness (e) of less than or equal to 2 mm; ２ｃ ;e ２ｅ At least one front assembly (2b, 2c; 2d, 2e) said at least one front assembly (2b, 2c; 2d, 2e) being placed between said polymer front layer (2a) and said encapsulation assembly (3), said interface front layer (2b; 2d) of said at least one front assembly (2b, 2c; 2d, 2e) being placed between said polymer front layer (2a) and said glass front layer (2c; 2e), said front layer (3a) of encapsulating material is formed by at least one layer comprising at least one polymeric encapsulating material having a Young's modulus at 25° C. comprised between 2 MPa and 20 MPa; and said rear layer (3b) of encapsulating material is formed by at least one layer comprising at least one polymeric encapsulating material having a Young's modulus at 25° C. strictly greater than 200 MPa; A photovoltaic module (1).

2. 2. Module according to claim 1, characterized in that the front layer (3a) of encapsulating material is formed by at least one layer comprising at least one polymer-type encapsulating material having a Young's modulus at 25°C comprised between 10 MPa and 20 MPa, and the rear layer (3b) of encapsulating material is formed by at least one layer comprising at least one polymer-type encapsulating material having a Young's modulus at 25°C strictly greater than 200 MPa and less than 500 MPa, in particular comprised between 250 MPa and 350 MPa.

3. The glass front layer (2c; 2e) has a thickness (e ２ｃ ;e ２ｅ 3. The module according to claim 1, further comprising:

4. 4. Module according to one of claims 1 to 3, characterized in that the glass front layer (2c; 2e) is made from non-tempered glass.

5. 5. The module according to claim 1, characterized in that the second layer (5) is made of at least one polymer material, in particular chosen from polycarbonate (PC), polymethyl methacrylate (PMMA), polyethylene terephthalate (PET), polypropylene (PP), polyamide (PA), a fluorinated polymer, 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 a multilayer comprising one or more of the aforementioned polymers.

6. The second layer (5) a rear layer forming a rear panel (5) made of a synthetic material, said rear layer comprising a main sub-layer forming the core (9a) of said rear panel (5) and two covering sub-layers forming respectively said plates (9b, 9c) of said rear panel (5) arranged on either side of said core (9a) such that said core (9a) is sandwiched between two plates (9b, 9c), said core (9a) of said rear panel (5) comprising a cellular structure (12). A module according to claim 1 , characterized in that it comprises:

7. The second layer (5) a rear layer made of at least one polymer material (5a), called "polymer rear layer (5a)", and at least one rear assembly (5b, 5c) comprising an interface rear layer (5b) and a glass rear layer (5c), said glass rear layer (5c) having a thickness (e ５ｃ At least one rear assembly (5b, 5c), in particular made of non-tempered glass 5. The module according to claim 1 , characterized in that the at least one rear assembly (5b, 5c) is placed between the polymer rear layer (5a) and the encapsulation assembly (3), and the interface rear layer (5b) of the at least one rear assembly (5b, 5c) is placed between the polymer rear layer (5a) and the glass rear layer (5c).

8. 5. Module according to claim 1, characterized in that the second layer (5) comprises a layer of reinforcement material based on fibres, in particular glass fibres, carbon fibres, aramid fibres and / or natural fibres, in particular hemp, linen and / or silk.

9. The polymeric front layer (2a) and / or the polymeric rear layer (5a) have a thickness (e ２ａ , e ５ａ 9. The module according to claim 1 , further comprising:

10. The front interfacial layer (2b; 2d) and / or the rear interfacial layer (5b) have a thickness (e ２ｂ , e ２ｄ ;e ５ｂ 10. The module according to claim 1, further comprising:

11. 11. The module according to any one of claims 1 to 10, characterized in that the interface front layer (2b; 2d) and / or the optional interface rear layer (5b) are formed by at least one layer comprising at least one polymeric encapsulating material selected from 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 polyolefin elastomers, copolymers of α-olefins and α-, β-ethylene carboxylic acid esters such as ethylene-methyl acrylate copolymer and ethylene-butyl acrylate copolymer, silicone elastomers and / or elastomers based on crosslinked thermoplastic polyolefins.

12. 12. The module according to any one of claims 1 to 11, characterized in that the front layer (3a) of encapsulating material is formed by at least one layer comprising at least one polymeric encapsulating material selected from poly(ethylene vinyl acetate) (EVA), vinyl acetals such as polyvinyl butyral (PVB), polyurethanes, silicone elastomers, elastomers based on crosslinked thermoplastic polyolefins and / or elastomers based on crosslinked thermoplastic polyolefins (TPO).

13. 13. The module according to any one of claims 1 to 12, characterized in that the rear layer (3b) of encapsulating material is formed by at least one layer comprising at least one polymeric encapsulating material selected from acid copolymers, ionomers, polyvinyl chloride and / or polyethylene.

14. 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 less than or equal to 2 mm; ２ｃ a first front assembly (2b, 2c) having 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 less than or equal to 2 mm; ２ｅ ) a second front assembly (2d, 2e) 14. The module according to claim 1, characterized in that the first front assembly (2b, 2c) is placed between the polymer front layer (2a) and the second front assembly (2d, 2e) and further between the first front assembly (2b, 2c) and the encapsulation assembly (3).

15. The thickness (e ２ｃ ) and the thickness (e) of the glass front layer (2e) of the second front assembly (2d, 2e). ２ｅ ) of the glass front layer (2c) of the first front assembly (2b, 2c) is different from the thickness (e ２ｃ ) is in particular the thickness (e) of the glass front layer (2e) of the second front assembly (2d, 2e). ２ｅ 15. The module of claim 14, wherein the first and second electrodes are greater than 1.

16. The second layer (5) a rear layer made of at least one polymer material (5a), called "polymer rear layer (5a)", and a first rear assembly (5b, 5c) comprising an interface rear layer (5b) and a glass rear layer (5c), said glass rear layer (5c) having a thickness (e ５ｃ a first rear assembly (5b, 5c) having a first rear part (5c) and made in particular of non-tempered glass, a second rear assembly comprising an interface rear layer and a glass rear layer, said glass rear layer having a thickness in particular 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 mm, and in particular made from non-tempered glass; 16. The module according to claim 1, further comprising: a first rear assembly (5b, 5c) interposed between the polymer rear layer (5a) and the second rear assembly and further between the first rear assembly (5b, 5c) and the encapsulation assembly (3).

17. a first transparent layer (2) forming the front surface of the photovoltaic module (1), intended to receive the luminous flux; a plurality of photovoltaic cells (4) arranged side by side and electrically connected to one another; an assembly (3) encapsulating a number of photovoltaic cells (4) obtained by combining a front layer (3a) of encapsulation material and a rear layer (3b) of encapsulation material on both sides of said photovoltaic cells (4), said front layer (3a) of encapsulation material being placed between said first layer (2) and said photovoltaic cells (4); a second layer (5), in which the encapsulation assembly (3) and the plurality of photovoltaic cells (4) are placed between the first layer (2) and the second layer (5); 17. A method for producing a photovoltaic module (1) according to any one of claims 1 to 16, wherein the first layer (2) comprises a stack comprising a front layer made of at least one polymer material (2a), called "polymer front layer (2a)", and at least one front assembly (2b, 2c; 2d, 2e) comprising an interface front layer (2b; 2d) and a glass front layer (2c; 2e), said glass front layer (2c; 2e) having a thickness (e) of less than or equal to 2 mm; ２ｃ ;e ２ｅ At least one front assembly (2b, 2c; 2d, 2e) said at least one front assembly (2b, 2c; 2d, 2e) being placed between said polymer front layer (2a) and said encapsulation assembly (3), said interface front layer (2b; 2d) of said at least one front assembly (2b, 2c; 2d, 2e) being placed between said polymer front layer (2a) and said glass front layer (2c; 2e), said front layer (3a) of encapsulating material is formed by at least one layer comprising at least one polymeric encapsulating material having a Young's modulus at 25° C. comprised between 2 MPa and 20 MPa, said rear layer (3b) of encapsulating material is formed by at least one layer comprising at least one polymeric encapsulating material having a Young's modulus at 25° C. strictly greater than 200 MPa; and A method, characterized in that it comprises a step of vacuum thermal lamination of the constituent layers of said stack to obtain said photovoltaic module (1).

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