Photovoltaic module with thin glass

Abstract

A photovoltaic module including: (a) a thin glass pane comprising exterior and interior facing primary surfaces and a lesser thickness therebetween; (b) a thick glass pane comprising exterior and interior facing primary surfaces and a greater thickness therebetween, the greater thickness being greater than the lesser thickness; (c) an array of photovoltaic cells disposed between the thin glass pane and the thick glass pane; and (d) an encapsulant at least partially encapsulating the array of photovoltaic cells, the encapsulant disposed between the first and second glass panes and including an elastic modulus and an encapsulant thickness, wherein (i) the lesser thickness is less than or equal to 900 µm, (ii) the greater thickness is greater than or equal to 1.0 mm, and (iii) the encapsulant thickness is less than or equal to 800 µm, and the elastic modulus of the encapsulant is less than 1000 MPa.

Description

PHOTOVOLTAIC MODULE WITH THIN GLASSCROSS-REFERENCE TO RELATED APPLICATIONS

[0001] This application claims the benefit of priority under 35 U.S.C. § 119 of U.S. Provisional Application No. 63 / 638,701 filed April 25, 2024, the content of which is incorporated herein by reference in its entirety.TECHNICAL FIELD

[0002] The present disclosure pertains to photovoltaic modules and, in particular, to photovoltaic modules that include a thin glass pane oriented to encounter impact events.BACKGROUND

[0003] Photovoltaic modules (e.g., solar panels) have been utilized to generate electricity. The solar panels can include an array of photovoltaic cells that, in general terms, absorb photons (such as from the Sun) to generate flowable electrons. The photovoltaic modules can further include relatively transparent (to photons of the desired wavelength) panes disposed on at least a front side (facing the Sun) of the array of photovoltaic cells. The photovoltaic modules are typically placed in an external environment (e.g., outside) so that photons from the Sun can be encountered.

[0004] The placement of the photovoltaic modules in the external environment subjects the photovoltaic modules to impact events such as from hail falling from the sky. There is a general desire among photovoltaic module manufacturers to represent that their photovoltaic modules can survive hail impact undamaged. For example, International Electrotechnical Commission (IEC) standard 61215-2:2021 tests whether the photovoltaic module can withstand, without damage, eleven impacts of a 25 mm diameter ice ball traveling at its terminal velocity, which results in an impact energy transfer of about 2 joules. As another example, the Renewable Energy Test Center (RETC) has developed a Hail Durability Test Program where photovoltaic modules are impacted with ice balls having diameters of 45 mm, 50.8 mm, 55 mm, and 65 mm traveling at their respective terminal velocities, which result in impact energy transfers of about 21 joules, 32 joules, 46 joules, and 89 joules respectively. The photovoltaic modules are then characterized as one of Class A through Class D depending on the damage level sustained.

[0005] The consensus in the industry is that the thickness of the front pane is the primary indicator of resistance to hail damage. For example, the RETC states that “[a]nonymized hail durability test data indicates that PV modules with thinner front glass are less resilient to large- diameter hail as compared to modules with thicker front glass.” See https: / / retc- ca.com / news / hail-risk-mitigation-tips-and-best-practices.

[0006] However, there is a problem in that the thicker the front pane, the more the photovoltaic module weighs (thus increasing shipping and installation costs), the more the photovoltaic module costs to produce, and the less optically efficient the photovoltaic module is.SUMMARY

[0007] The present disclosure addresses that problem with a photovoltaic module that includes a thin pane oriented to transmit photons from the Sun and encounter impact events and an encapsulant with an elastic modulus that is less than 1000 MPa at room temperature.

[0008] According to a first aspect of the present disclosure, a photovoltaic module comprises: (a) a thin pane comprising a thin glass composition, an exterior facing primary surface, an interior facing primary surface, and a lesser thickness between the exterior facing primary surface and the interior facing primary surface; (b) a thick pane comprising a thick glass composition, an exterior facing primary surface, an interior facing primary surface facing the array of photovoltaic cells, and a greater thickness between the exterior facing primary surface and the interior racing primary surface, the greater thickness being greater than the lesser thickness of the thin pane; (c) at least one solar functional cell, as a non-limiting example, as at least one - or an array of photovoltaic cells — disposed between the thin pane and the thick pane; and (d) an encapsulant at least partially encapsulating the array of photovoltaic cells, the encapsulant disposed between the first pane and the second pane and comprising an elastic modulus and an encapsulant thickness, wherein (i) the lesser thickness of the thin pane is less than or equal to 900 pm, (ii) the greater thickness of the thick pane is greater than or equal to 1.60 mm, and (iii) the encapsulant thickness is less than or equal to 800 pm, and the elastic modulus of the encapsulant is less than 1000 MPa at room temperature.

[0009] According to a second aspect of the present disclosure, the photovoltaic module of the first aspect is presented, wherein the lesser thickness of the thin pane is within a range of from 75 pm to 800 pm.

[0010] According to a third aspect of the present disclosure, the photovoltaic module of any one of the first through second aspects is presented, wherein the greater thickness of the thick pane is within a range of from 3 mm to 6 mm.

[0011] According to a fourth aspect of the present disclosure, the photovoltaic module of any one of the first through third aspects is presented, wherein the thin glass composition is a silicate glass composition that is substantially free of alkali ions.

[0012] According to a fifth aspect of the present disclosure, the photovoltaic module of any one of the first through fourth aspects is presented, wherein the thin glass composition comprises a boro silicate glass composition that is substantially free of alkali ions.

[0013] According to a sixth aspect of the present disclosure, the photovoltaic module of any one of the first through fifth aspects is presented, wherein the thin glass composition comprises an alkaline earth alumino boro silicate glass composition that is substantially free of alkali ions.

[0014] According to a seventh aspect of the present disclosure, the photovoltaic module of any one of the first through sixth aspects is presented, wherein the thin glass composition comprises (in mol%, on an oxide basis): SiCh: from 62 to 75; AI2O3: from 7 to 13; B2O3: from 5 to 26; MgO: from 0 to 3; CaO: from 5 to 15; BaO from 0 to 5; and SrO from 0 to 5.

[0015] According to an eighth aspect of the present disclosure, the photovoltaic module of any one of the first through seventh aspects is presented, wherein the thick glass composition is a soda lime glass composition.

[0016] According to a ninth aspect of the present disclosure, the photovoltaic module of any one of the first through eighth aspects is presented, wherein the thick glass composition is a boro silicate glass composition.

[0017] According to a tenth aspect of the present disclosure, the photovoltaic module of any one of the first through ninth aspects is presented, wherein the thick glass composition is a silicate glass composition with at least one alkali oxide.

[0018] According to an eleventh aspect of the present disclosure, the photovoltaic module of any one of the first through tenth aspects is presented, wherein the thicker pane comprises at least one region of compressive stress contiguous with the exterior facing primary surface or the interior facing primary surface.

[0019] According to a twelfth aspect of the present disclosure, the photovoltaic module of any one of the first through eleventh aspects is presented, wherein the elastic modulus of the encapsulant is within a range of from 500 MPa to 700 MPa at room temperature.

[0020] According to a thirteenth aspect of the present disclosure, the photovoltaic module of any one of the first through twelfth aspects is presented, wherein the encapsulant thickness is less than or equal to 650 pm.

[0021] According to a fourteenth aspect of the present disclosure, the photovoltaic module of the thirteenth aspect is presented, wherein the encapsulant thickness is within a range of from 200 pm to 500 pm.

[0022] According to a fifteenth aspect of the present disclosure, the photovoltaic module of any one of the first through fourteenth aspects is presented, wherein the encapsulant comprises a composition selected from the group consisting of ethylene-vinyl acetate, polyvinyl butyral, a silicone-based material, an ionomer, a thermoplastic polyolefin, and a polyolefin.

[0023] According to a sixteenth aspect of the present disclosure, the photovoltaic module of the fifteenth aspect is presented, wherein the composition of the encapsulant is ethylene-vinyl acetate.

[0024] According to a seventeenth aspect of the present disclosure, the photovoltaic module of any one of the first through sixteenth aspects is presented, wherein the photovoltaic cells each comprise a PV thickness that is less than or equal to 250 pm.

[0025] According to an eighteenth aspect of the present disclosure, the photovoltaic module of the seventeenth aspect is presented, wherein the PV thickness is less than or equal to 1 pm.

[0026] According to a nineteenth aspect of the present disclosure, the photovoltaic module of any one of the first through eighteenth aspects is presented, wherein the photovoltaic cells each comprise a material selected from the group consisting of CuIn / GaSe, cadmium telluride, amorphous silicon, polysilicon, an organic small molecule, an organic polymer, and a perovskite.

[0027] According to a twentieth aspect of the present disclosure, the photovoltaic module of any one of the first through nineteenth aspects is presented, wherein the photovoltaic cells are printed onto the interior facing primary surface of the thin pane.

[0028] According to a twenty-first aspect of the present disclosure, the photovoltaic module of any one of the first through twentieth aspects is presented, wherein the thin pane exhibits no new visible damage as a result of an impact from an ice ball having a diameter of about 25 mm traveling at a velocity sufficient to generate an impact energy of about 2 joules.

[0029] According to a twenty-second aspect of the present disclosure, the photovoltaic module of any one of the first through twenty-first aspects is presented, wherein the thin pane exhibits no new visible damage as a result of an impact from an ice ball having a diameter of about 45 mm traveling at a velocity sufficient to generate an impact energy of about 20 joules.

[0030] According to a twenty-third aspect of the present disclosure, the photovoltaic module of any one of the first through twenty-second aspects is presented, wherein the thin pane exhibits no new visible damage as a result of an impact from an ice ball having a diameter of about 45 mm traveling at a velocity sufficient to generate an impact energy of about 80 joules.

[0031] According to a twenty-fourth aspect of the present disclosure, a photovoltaic module comprises: (a) a thin pane comprising an alkaline earth alumino boro silicate glass composition that is substantially free of alkali ions, an exterior facing primary surface, an interior facing primary surface, and a lesser thickness between the exterior facing primary surface and the interior facing primary surface; (b) an array of photovoltaic cells disposed on the interior facing primary surface of the thin pane, the array of photovoltaic cells is characterized in that each ofthe photovoltaic cells is printed onto the interior facing primary surface of the thin pane; (c) a thick pane comprising a soda lime glass composition, an exterior facing primary surface, an interior facing primary surface facing the array of photovoltaic cells, and a greater thickness between the exterior facing primary surface and the interior facing primary surface, the greater thickness being greater than the lesser thickness of the thin pane; and (d) an encapsulant at least partially encapsulating the array of photovoltaic cells, the encapsulant disposed between the front pane and the rear pane and comprising an elastic modulus, an encapsulant thickness, and a composition comprising ethylene-vinyl acetate, wherein (i) the lesser thickness of the thin pane is within a range of from 100 pm to 900 pm, (ii) the greater thickness of the thick pane is within a range of from 3.00 mm to 6.00 mm, and (iii) the thin pane exhibits no new visible damage as a result of an impact from an ice ball having a diameter of about 45 mm traveling at a velocity sufficient to generate an impact energy of about 20 joules.

[0032] According to a twenty-fifth aspect of the present disclosure, the photovoltaic module of the twenty-fourth aspect is presented, wherein the elastic modulus of the encapsulant is less than or equal to 800 MPa.

[0033] According to a twenty-sixth aspect of the present disclosure, the photovoltaic module of any one of twenty-fourth through twenty-fifth aspects is presented, wherein the encapsulant thickness is less than or equal to 600 pm.

[0034] Additional features and advantages will be set forth in the detailed description which follows, and in part will be readily apparent to those skilled in the art from that description or recognized by practicing the embodiments as described herein, including the detailed description which follows, the claims, as well as the appended drawings.

[0035] It is to be understood that both the foregoing general description and the following detailed description are merely exemplary, and are intended to provide an overview or framework to understanding the nature and character of the claims. The accompanying drawings are included to provide a further understanding, and are incorporated in and constitute a part of this specification. The drawings illustrate one or more embodiments, and together with the description serve to explain principles and operation of the various embodiments.

[0036] These and other features, advantages, and objects of the present disclosure will be further understood and appreciated by those skilled in the art by reference to the following specification, claims, and appended drawings.BRIEF DESCRIPTION OF THE DRAWINGS

[0037] In the Drawings:

[0038] FIG. 1 is a perspective view of a photovoltaic module of the present disclosure in an external environment facing the Sun;

[0039] FIG. 2 is a plan view of the photovoltaic module of FIG. 1, illustrating a thin pane covering an array of photovoltaic cells;

[0040] FIG. 3 is an elevation view of a cross-section taken through line III-III of FIG. 2, illustrating the photovoltaic module including a frame holding a package;

[0041] FIG. 4 is a magnified view of area IV of FIG. 3, illustrating the package including, in relative order, a thin pane, an array of PV cells, an encapsulant, and a thick pane;

[0042] FIG. 5A, pertaining to the Example, is a schematic diagram of the package (without the array of photovoltaic cells) with an abraded area at the thin pane, and a stacked rosette strain gauge positioned on an exterior facing primary surface of the thick pane to be subjected to an impact event from an ice ball at the abraded area of the thin pane;

[0043] FIG. 5B, pertaining to the Example, is a plan view of the package;

[0044] FIG. 6, pertaining to the Example, is a plan view of the stacked rosette strain gauge of FIG. 5A, illustrating the stacked rosette strain gauge including three single direction strain gauges at specific angle increments;

[0045] FIG. 7, pertaining to the Example, is a perspective view of the package held within a test fixture (representing the photovoltaic module) and a launcher positioned to project ice balls at the thin pane of the photovoltaic module;

[0046] FIG. 8, pertaining to the Example, is a schematic illustration of the variables and responses of the testing of the Example, which is designed, among other things, to determine the energy necessary to be transferred from the ice ball to the photovoltaic module to damage the photovoltaic module (e.g., “failure energy”) as a function of the variables; and

[0047] FIG. 9, pertaining to the Example, is a table showing the statistics for the model parameter estimates derived from the failure energy testing.

[0048] The components in the Drawings are not necessarily to scale, emphasis instead being placed upon illustrating the principles described herein.DETAILED DESCRIPTION

[0049] For purposes of description herein, the terms "upper," "lower," "right," "left," "rear," "front," "vertical," "horizontal," and derivatives thereof shall relate to the disclosure as oriented in FIG. 1. Unless stated otherwise, the term "front" shall refer to the surface of the element closer to an intended viewer, and the term "rear" shall refer to the surface of the element further from the intended viewer. However, it is to be understood that the disclosure may assume various alternative orientations, except where expressly specified to the contrary. It is also tobe understood that the specific devices and processes illustrated in the attached drawings, and described in the following specification are simply exemplary embodiments of the inventive concepts defined in the appended claims. Hence, specific dimensions and other physical characteristics relating to the embodiments disclosed herein are not to be considered as limiting, unless the claims expressly state otherwise.

[0050] The terms "including," "comprises," "comprising," or any other variation thereof, are intended to cover a non-exclusive inclusion, such that a process, method, article, or apparatus that comprises a list of elements does not include only those elements but may include other elements not expressly listed or inherent to such process, method, article, or apparatus. An element preceded by "comprises a . . . " does not, without more constraints, preclude the existence of additional identical elements in the process, method, article, or apparatus that comprises the element.

[0051] Reference will now be made in detail to the present preferred embodiments, examples of which are illustrated in the accompanying drawings. Whenever possible, the same reference numerals will be used throughout the drawings to refer to the same or like parts.

[0052] Referring now to FIGS. 1-4, a photovoltaic module 10 includes a thin pane 12, a thick pane 14, an array 16 of photovoltaic cells 18, and an encapsulant 20. The thin pane 12 includes an exterior facing primary surface 22 and an interior facing primary surface 24. Likewise, the thick pane 14 includes an exterior facing primary surface 26 and an interior facing primary surface 28. The exterior facing primary surfaces 22, 26 face an external environment 30 and away from each other. The interior facing primary surfaces 24, 28 face the array 16 of photovoltaic cells 18 and toward each other. The array 16 of photovoltaic cells 18 is disposed between the thin pane 12 and the thick pane 14. The encapsulant 20 is also disposed between the thin pane 12 and the thick pane 14. The encapsulant 20 at least partially encapsulates the array 16 of photovoltaic cells 18. The thin pane 12 and the thick pane 14 thus separate the array 16 of photovoltaic cells 18 and the encapsulant 20 from the external environment 30. During use of the photovoltaic module 10, photons 32 from the Sun 34 enter the photovoltaic module 10 through one or both of the thin pane 12 and the thick pane 14 and impinge upon the array 16 of photovoltaic cells 18.

[0053] In embodiments, each photovoltaic cell 18 includes two different semi-conductor materials (an n-type material and a p-type material) that are joined together to create a p-n junction. The n-type material includes, from a dopant, unpaired electrons ready to move and thereby conduct electricity. The p-type material includes, from another dopant, valent “holes” ready to accept the electrons and thereby conduct electricity. Upon application of thermalagitation, electrons from the n-type material cross the p-n junction and occupy a hole within the p-type material but additionally leave behind a hole within the n-type material from where the electron came. An electric field is thus generated about the p-n junction (referred to as a depletion zone) with the n-type material having a positive charge (due to the loss of electrons) and the p-type material having a negative charge (due to the gain of electrons).

[0054] The Sun 34 generates the photons 32. The depletion zone absorbs some of those photons 32. Energy associated with the photons 32 transfers to the unpaired electrons within the n-type material. Of the absorbed photons 32, some photons 32 have sufficient energy to cause electrons within the n-material to move to a conduction band and thus leave a hole behind. Because of the electric field at the depletion zone, the excited electron moves away from the depletion zone and to a primary surface of the n-type material, and the created hole moves away from the depletion zone and to a primary surface of the of the p-type material. Assuming that conductors are coupled to both the primary surfaces of the n-type material and the p-type material, and the conductors are themselves electrically coupled, an electrical current is generated with the electron moving from the n-type material, to the conductor at the primary surface of the n-type material, through the conductive material coupling the conductors, to the conductor at the primary surface of the p-type material, and then into the p-type material, occupying the hole that had migrated there from the depletion zone.

[0055] The thin pane 12 has a lesser thickness 36. The lesser thickness 36 is the straight-line distance between the exterior facing primary surface 22 and the interior facing primary surface 24 of the thin pane 12. In some embodiments, the thin pane is unstrengthened. In some embodiments, the thick pane is strengthened (e.g. chemically strengthened, tempered, and / or heat treated).

[0056] In embodiments, the lesser thickness 36 of the thin pane 12 is less than or equal to 900 pm. For example, the lesser thickness 36 of the thin pane 12 can be 50 pm, 60pm, 70 pm, 75 pm, 80 pm, 90 pm, 100 pm, 125 pm, 150 pm, 175 pm, 200 pm, 225 pm, 250 pm, 15 pm, 300 pm, 325 pm, 350 pm, 375 pm, 400 pm, 425 pm, 500 pm, 525 pm, 550 pm, 575 pm, 600 pm, 625 pm, 650 pm, 675 pm, 700 pm, 725 pm, 750 pm, 775 pm, 800 pm, 825 pm, 850 pm, 875 pm, 900 pm, 925 pm, 950 pm, 975 pm, 1000 pm, or within any range bound by any two of those values (e.g., from 75 pm to 425 pm, from 100 pm to 900 pm, and so on). The lesser thickness 36 values of less than 50 pm and greater than 1000 pm are envisioned. The lesser thickness 36 can be measured via optical microscopy.

[0057] The thick pane 14 has a greater thickness 38. The greater thickness 38 is the straight- line distance between the exterior facing primary surface 26 and the interior facing primarysurface 28 of the of the thick pane 14. The greater thickness 38 of the thick pane 14 is greater than the lesser thickness 36 of the thin pane 12. “Lesser,” “greater,” “thin,” and “thick” are used herein to signify the relative thickness comparison between the thin pane 12 and the thick pane 14, and the terms are not meant to suggest any value constraints for either the lesser thickness 36 or the greater thickness 38. Any such value constraints pertain only to embodiments as explicitly described herein. Without such explicit value constraints, the thick pane 14 simply is thicker than the thin pane 12 and the terminology is a tool of convenience to distinguish between the two panes 12, 14.

[0058] In embodiments, the greater thickness 38 of the thick pane 14 is greater than or equal to 1.6 mm. For example, the greater thickness 38 of the thick pane 14 can be 1.6 mm, 1.7 mm, 1.8 mm, 1.9 mm, 2. mm, 2.25 mm, 2.5 mm, 2.75 mm, 3. mm, 3.25 mm, 3.5 mm, 3.75 mm, 4. mm, 4.25 mm, 4.5 mm, 4.75 mm, 5. mm, 5.25 mm, 5.5 mm, 5.75 mm, 6. mm, 6.25 mm, 6.5 mm, 6.75 mm, 7. mm, or within any range bound by any two of those values (e.g., from 3. mm to 6. mm, from 1.7 mm to 3.25 mm, and so on). The greater thickness 38 values of less than 1.6 mm and greater than 7. mm are envisioned. The greater thickness 38 can be measured with a micrometer.

[0059] The thin pane 12 has a composition, which is referred to herein as the “thin glass composition.” In embodiments, the thin glass composition is a silicate glass composition. In embodiments, the thin glass composition is a boro silicate glass composition that is substantially free of alkali ions. In embodiments, the thin glass composition is an alkaline earth alumino boro silicate glass composition. Further, the thin glass composition can be substantially free of alkali ions. “Substantially free” here means that raw ingredients of the glass composition as batched do not intentionally include alkali oxides or alkali ions but the alkali oxides or alkali ions may exist in the resulting glass composition in trace amounts (e.g., less than 0.01 mol%) due to raw material contamination or contamination from manufacturing equipment. As a more specific example, the thin glass composition includes (in mol%, on an oxide basis): SiCh: from 62 to 75; AI2O3: from 7 to 13; B2O3: from 5 to 26; MgO: from 0 to 3; CaO: from 5 to 15; BaO from 0 to 5; and SrO from 0 to 5.

[0060] The thick glass likewise has a composition, which is referred to herein as the “thick glass composition.” In embodiments, the thick glass composition is a soda lime glass composition. In embodiments, the thick glass composition is a boro silicate glass composition. In embodiments, the thick glass composition is a silicate glass composition with at least one alkali oxide. Alkali oxides include Li2O, Na2O, K2O, RfeO, and Cb2O.

[0061] In embodiments, the thicker pane 14 comprises at least one region 40 of compressive stress contiguous with the exterior facing primary surface 26 or the interior facing primary surface 28. For example, the thick pane 14 can have an exterior region 40e of compressive stress contiguous with the exterior facing primary surface 26 and an interior region 40i of compressive stress contiguous with the interior facing primary surface 28. A region 42 of central tension is disposed between the exterior region 40e of compressive stress and the interior region 40i of compressive stress.

[0062] The exterior region 40e of compressive stress and the interior region 40i of compressive stress can be generated as a result of thermal tempering of the thick pane 14 or via subjecting the thick pane 14 to an ion-exchange process. The thermal tempering can be performed via any process that heats and then quickly cools the thick pane 14. For example, an overall process for thermal tempering the thick pane 14 can include heating the thick pane 14 in a hot zone and then cooling the thick pane 14.

[0001] In an ion-exchange process, the thick pane 14 is immersed into a molten salt bath for a predetermined period of time. During that period of time, ions at or near the exterior facing primary surface 26 and / or interior facing primary surface 28 of the thick pane 14 are exchanged for larger metal ions from the salt bath. In embodiments, the temperature of the molten salt bath is in the range of from about 300 °C to about 500 °C, such as from about 400 °C to about 460 °C, and the predetermined time period is within a range of from about 1 hour to about 64 hours, such as from about 4 hours to about 24 hours. However, the temperature and duration of immersion may vary according to the composition of the material and the desired strength attributes. The incorporation of the larger ions into the composition of the thick pane 14 strengthens the thick pane 14 by creating the exterior region 40e of compressive stress and / or the interior region 40i of compressive stress contiguous with or adjacent to the exterior facing primary surface 26 and the interior facing primary surface 28, respectively. The region 42 of central tension is additionally induced to balance the exterior region 40e of compressive stress and / or the interior region 40i of compressive stress .

[0063] In one example, sodium ions in the thick pane 14 are replaced by larger potassium ions from the molten bath, such as a potassium nitrate salt bath, though other alkali metal ions having larger atomic radii, such as rubidium or cesium, can replace smaller alkali metal ions in the thick pane 14. As a result, in embodiments, after ion-exchange, the weight percentage of potassium ions in the composition of the thick pane 14 at or near the exterior facing primary surface 26 and / or the interior facing primary surface 28 is greater than the weight percentage of potassium ions at or near a bulk 44 of the thick pane 14. Similarly, in embodiments, afterion-exchange, the weight percentage of sodium ions in the composition of the thick pane 14 at or near the exterior facing primary surface 26 and the interior facing primary surface 28 is less than the weight percentage of sodium ions at or near the bulk 44 of the thick pane 14.

[0064] The encapsulant 20 has an elastic modulus. In embodiments, the elastic modulus of the encapsulant 20 is less than 1000 MPa, or less than 800 MPa. For example, the elastic modulus of the encapsulant 20 can be 500 MPa, 550 MPa, 600 MPa, 650 MPa, 700 MPa, 750 MPa, 800 MPa, 850 MPa, 900 MPa, 950 MPa, 1000 MPa, or within any range bound by any two of those values (e.g., from 500 MPa to 700 MPa, from 600 MPa to 800 MPa, and so on). All values for the elastic modulus are as measured at room temperature and otherwise in accordance with ASTM C623. In some embodiments, the encapsulant has an elastic modulus that is at least 500 MPa to not greater than 1000 MPa.

[0065] In addition, the encapsulant 20 has an encapsulant thickness 46. The encapsulant thickness 46 is measured perpendicular to the interior facing primary surface 24 of the thin pane 12. The encapsulant thickness 46 can be measured with optical microscopy. In embodiments, the encapsulant thickness 46 is less than or equal to 800 pm, such as less than 650 pm, or even less than 600 pm. For example, the encapsulant thickness 46 can be 100 pm, 150 pm, 200 pm, 250 pm, 300 pm, 350 pm, 400 pm, 450 pm, 500 pm, 550 pm, 600 pm, 650 pm, 700 pm, 750 pm, 800 pm, 850 pm, 900 pm, 950 pm, 1000 pm, or within any range bound by any two of those theories (e.g., from 200 pm to 500 pm, from 250 pm to 350 pm, and so on). In one embodiment, the encapsulant thickness is at least 100 pm to not greater than 1000 pm. In one embodiment, the encapsulant thickness is at least 200 pm to not greater than 500 pm. In one embodiment, the encapsulant thickness is at least 350 pm to not greater than 900 pm. Values for the encapsulant thickness 46 of less than 100 pm and greater than 1000 pm are envisioned. The less the encapsulant thickness 46 is, the less both the encapsulant 20 and the thin pane 12 bend in response to impact events. During manufacturing of the photovoltaic module 10, the encapsulant 20 may be added as a premade sheet, or the encapsulant 20 can be solution deposited, among other options.

[0066] The encapsulant 20 has a composition, e.g., material that forms the encapsulant 20. In embodiments, the composition of the encapsulant 20 is one or more of ethylene-vinyl acetate (EVA), polyvinyl butyral (PVB), a silicone-based material (e.g., SYLGARD™ 184), an ionomer (e.g., DUPONT's® PV5400, PV5300, PV5200, or PV8600), a thermoplastic polyolefin (TPO) (e.g., Quentys™ BPO from Borealis), and a polyolefin elastomer (POE) (e.g., Engage™ from Dow). Other compositions for the encapsulant 20 are envisioned.

[0067] The photovoltaic cells 18 of the array 16 each have a PV thickness 48. Like the encapsulant 20, the PV thickness 48 is measured perpendicular to the interior facing primary surface 24 of the thin pane 12. The PV thickness 48 can be measured via optical microscopy. In embodiments, the PV thickness 48 is less than or equal to 250 pm, or even less than or equal to 1 pm. For example, the PV thickness 48 can be 0.1 pm, 0.2 pm, 0.3 pm, 0.4 pm, 0.5 pm, 0.6 pm, 0.7 pm, 0.8 pm, 0.9 pm, 1. pm, 10 pm, 50 pm, 100 pm, 150 pm, 200 pm, 250 pm, 300 pm, or within any range bound by any two of those values (e.g., from 0.1 pm to 0.1 pm, from 0.5 pm to 10 pm, and so on). In one embodiment, the PV thickness is at least 0.1 pm to not greater than 0.75 pm. In one embodiment, the PV thickness is at least 0.35 pm to not greater than 1 pm. In one embodiment, the PV thickness is at least 10 pm to not greater than 50 pm. In one embodiment, the PV thickness is at least 25 pm to not greater than 150 pm. In one embodiment, the PV thickness is at least 150 pm to not greater than 300 pm. The photovoltaic cells 18 can be made of a variety of materials. In embodiments, the photovoltaic cells 18 each include CuIn / GaSe (CIGS), cadmium telluride (CdTe), amorphous silicon (a-Si), polysilicon (p-Si), an organic small molecule, an organic polymer, and a perovskite (ABX3). The material can be applied as a thin-fdm. In embodiments, the photovoltaic cells 18 are disposed onto the interior facing surface 24 of the thin pane 12 via printing. One potential advantage of thin fdm solar cells is the ability to solution process the precursors and deposit films from solution. These can be deposited as high-resolution patterns under high volume manufacturing conditions. The methods available include, but are not limited to inkjet, slot-die, and screenprinting. The encapsulant 20 is then deposited over the photovoltaic cells 18, with the array 16 of photovoltaic cells 18 sandwiched between the thin pane 12 and the encapsulant 20. Although the photovoltaic cells 18 can be printed onto the interior facing primary surface 24 of the thin pane 12, it may be impractical to print the photovoltaic cells 18 on the thick pane 14. The thick pane 14 is then disposed onto the encapsulant 20. The thin pane 12 and the thick pane 14 can be bonded together around perimeters thereof to form a package 50.

[0068] In embodiments, the photovoltaic module 10 includes a frame 52. For example, the frame 52 can include a sidewall 54, a C-channel 56 that is contiguous with the sidewall 54, and a tab 58 that extends inward relative to the sidewall 54. The C-channel 56 is disposed at or near a top 60 of the frame 52, and the tab 58 is disposed at or near a bottom 62 of the frame 52. The tab 58 forms a plane 64 that is generally parallel to the exterior facing primary surface 26 of the thick pane 14. The sidewall 54 extends around a perimeter of the package 50 with the perimeter of the package 50 secured within the C-channel 56 of the frame 52. The frame 52 can take other forms and orientations.

[0069] The photovoltaic module 10 herein described exhibits improved resistance to damage from impact events, such as from hail, while limiting weight of the photovoltaic module 10. In embodiments, the thin pane 12 exhibits no new visible damage as a result of an impact from an ice ball 66 (see FIG. 5 A) having a diameter of about 25 mm traveling at a velocity sufficient to generate an impact energy of about 2 joules. In embodiments, the thin pane 12 exhibits no new visible damage as a result of an impact from an ice ball 66 having a diameter of about 45 mm traveling at a velocity sufficient to generate an impact energy of about 20 joules. In embodiments, the thin pane 12 exhibits no new visible damage as a result of an impact from an ice ball 66 having a diameter of about 45 mm traveling at a velocity sufficient to generate an impact energy of about 80 joules. A test method further elaborating on these aspects is set forth in the Example below.

[0070] Example - For the Example, referring to FIGS. 5A-9, a series of photovoltaic modules 10 of the present disclosure was constructed, each to be impact event tested using ice balls 66 (e.g., as hail replicate). Each of the photovoltaic modules 10 included, in order of relative orientation, a thin pane 12, an encapsulant 20, and a thick pane 14. Each photovoltaic module 10 overall had a length 68 of 637 mm and a width 70 of 400 mm. The thin pane 12 had a length of 637 mm and a width of 400 mm. The thin pane 12 had an alkaline earth boro-aluminosilicate glass composition. More particularly, the composition of the thin pane 12 (given in mol %, on an oxide basis) was: 67.71% SiO2; 11.03% A12O3; 9.65% B2O3; 2.26% MgO; 8.81% CaO; and 0.54% SrO. The thick pane 14 had a soda lime glass composition, a length of 635 mm and a width of 398 mm. The thick pane 14 was tempered so that the thick pane 14 had an exterior region 40e of compressive stress and an interior region 40i of compressive stress. The encapsulant 20 was polyvinyl butyral (PVB). To simplify the experimental design, PVB was selected as the encapsulant 20 because the encapsulant thickness 46 and the elastic modulus could be adjusted independently without changing material type and viscoelastic properties.

[0071] Referring particularly to FIGS. 5A and 5B, the exterior facing primary surface 22 of the thin pane 12 was abraded at an abraded area 72, a center point of which coincided with a center point of the exterior facing primary surface 22. The abraded area 72 had a diameter of 6.35 mm.

[0072] The photovoltaic module 10 lacked an array 16 of photovoltaic cells 18 because it was assumed that the array 16, when printed upon the interior facing primary surface 24 of the thin pane 12, would have a PV thickness 48 of less than 1 pm. Because of the PV thickness 48 would have been very small compared to the thicknesses 36, 38, 46 of the thin pane 12, the encapsulant 20, and the thick pane 14, it was assumed that the array 16 of photovoltaic cells 18would have had a negligible effect on the response of the photovoltaic module 10 to the impact of the ice ball 66. The photovoltaic module 10 also lacked bus bars, an edge seal, and a frame 52.

[0073] Referring to FIG. 6, a stacked rosette strain gauge 74 was positioned on the exterior facing primary surface 26 of the thick pane 14 of each of the photovoltaic modules 10. The stacked rosette strain gauge 74 included three single direction strain gauges 76 at specific angle increments. Using the proper mathematical relationships, the full strain field can be calculated from any direction relative to each of the three single direction strain gauges 76.

[0074] The above describes what each of the photovoltaic modules 10 shared in common. Now, the differences and the variables considered among the photovoltaic modules 10 are described. More particularly, five factors were considered in this study: four design variables and one noise variable, each at two levels each as shown in Table 1 below.“Thin pane thickness” refers to the lesser thickness 36 of the thin pane 12, as defined above. “Thick pane thickness” refers to the greater thickness 38 of the thick pane 14, as defined above. “Encapsulant thickness” refers to the encapsulant thickness 46, as defined above. “Encapsulant modulus” refers to the elastic modulus of the encapsulant 20, as defined above. “Flaw depth” refers to the depth of the abraded area 72 into the lesser thickness 36 of the thin pane 12.

[0075] Referring to FIG. 7, the photovoltaic module 10 was clamped into a test fixture 78 along all four edges of the photovoltaic module 10, such that the exterior facing primary surface 22 of the thin pane 12 faced a launcher 80 configured to project ice balls 66 on a path to impact an impact location 82 centered upon the center point of the abraded area 72 of the thin pane 12. The launcher 80 included a tripod assembly 84, a pressure system 86, a barrel 88, and a laser sight. The laser sight was disposed at an end 90 of the barrel 88.

[0076] The barrel 88 was positioned to launch ice balls 66 to the impact location 82 using the laser sight. The photovoltaic module 10 was then impacted with an ice ball 66 having a spherical shape and a diameter of 45 mm. The ice balls 66 were relatively smooth.

[0077] Before commencing impacting the photovoltaic modules 10 with the ice balls 66, a plan was set to increase the pressure that the pressure system 86 generated to launch each ice ball 66 in sequence. The plan is set forth at Table 2 below.In Table 2 above, “Impact #” means the numerical order of the scheduled ice ball 66 impact events. Impact #1 thus means the first ice ball 66 scheduled to be launched to impact the photovoltaic module 10, Impact # 2 means the second ice ball 66 scheduled to be launched (after the first ice ball) to subsequently impact the photovoltaic module 10, and so on. “Pressure” means the pressure that the pressure system 86 is scheduled to generate to launch the particular ice ball 66. For example, the first ice ball 66 (Impact #1) is scheduled to be launched with a pressure of 6.01 psi, the second ice ball 66 (Impact #2) is scheduled to be launched with a pressure of 9.44 psi, and so on. “Velocity” means the speed that the particular ice ball 66 is anticipated to reach while projecting from the barrel 88. For example, the first ice ball 66 scheduled to be launched (Impact #1) is anticipated to reach a speed of 6.83 m / s, the second ice ball 66 scheduled to be launched (Impact #2) is anticipated to reach a speed of 15.26 m / s, and so on. “Energy” means the energy that the particular ice ball 66 is anticipated to transfer to the photovoltaic module 10 as a result of impacting the photovoltaic module 10. For example, the first ice ball 66 scheduled to be launched (Impact # 1) is anticipated to transfer 1 J to the photovoltaic module 10, the second ice ball 66 scheduled to be launched (Impact #2) is anticipated to transfer 5 J to the photovoltaic module 10, and so on.

[0078] After each impact from the ice ball 66 according to the schedule, the photovoltaic module 10 is inspected at and around the abraded area 72 using a light source (e.g., flashlight) at various incident angles. If the inspection observed no change, then the next ice ball 66 was projected at the photovoltaic module 10 according to the schedule. For example, if inspection of the photovoltaic module 10 after Impact 1 revealed no change, then Impact 2 of the schedulewas performed. Then, if inspection of the photovoltaic module 10 after Impact 2 revealed no change, then Impact 3 of the schedule was performed, and so on. However, if the inspection reveals new and obvious damage (e.g., cracks, chip-outs, fracture, or elongation of a crack existing before the testing began to approximately 2 mm to 5 mm), then the testing was concluded (e.g., no additional impact events) and the photovoltaic module 10 was submitted to fractography for further analysis.

[0079] In general, then, the test proceeded according to the schedule with the ice balls 66 striking the same abraded area 72 with increasing energy transfer until damage to the photovoltaic module 10 was observed. The energy transfer associated with the impact event that caused the observable damage to the photovoltaic module 10 was recorded as the “failure energy” of the photovoltaic module 10 subjected to the test. For example, if Impact #6 was the first ice ball 66 impact to cause observable damage to the photovoltaic module 10, then the “failure energy” of the photovoltaic module 10 is recorded to be 25 J. Those skilled in the art would understand that the “failure energy” determined according to the test procedure of Example 1 is more conservative than how failure is defined according to industry standard IEC or RETC definitions. That is so because, under the testing procedure of Example 1, the same abraded area 72 is impacted impact-after-impact. In other words, Impact #2 impacts the same abraded area 72 as Impact #1, Impact #3 impacts the same abraded area 72 as Impacts #1 and #2, and so on, until failure is observed. The industry standard IEC and RETC definitions do not require the same area to be impacted over and over.

[0080] The testing schedule and protocol described above were performed on each of the photovoltaic modules 10. In addition to the failure energy for each of the photovoltaic modules 10, the dynamic strain response of each ice ball 66 impact measured using the strain gauge rosette was recorded. In addition, the fractographic details including failure type, location, and defect observations were recorded.

[0081] During the testing, measures were taken to ensure accurate and precise targeting of the ice ball 66. Otherwise, the failure response would have exhibited variation due to changing the impact location 82. By aligning strain responses from the stacked rosette strain gauge 74, a method was developed for improving targeting accuracy and precision, thereby increasing the " signal -to-noise" in the dataset used to build the model. Any misalignment in the strain responses is an indication that the ice ball impact was off target. The launcher 80 could then be adjusted until all three strain responses are aligned during an impact.

[0082] The schematic illustration of FIG. 8 summarizes the variables and responses of the testing of the Example. To balance the tradeoff between the number of experiments formodeling (i.e., dataset size) and the cost of experimentation, the photovoltaic modules 10 were built and tested according to a resolution V, fractional-factorial design. From a modeling perspective, this means the main effects are only aliased with 4-way interactions, and 2-way interactions are only aliased with 3-way interactions. Typically, 3-way and 4-way interactions are not significant, and we assume this is the case here. Under this assumption, all 2-way interactions can be independently estimated (there are ten 2-way interactions in a 5 -factor experiment). Based on experience, 2-way interactions between factors are significant in the failure energy response, hence the experimental design choice described herein. Finally, to set the false and missed detection rates for the model at 5%, three replicates were run for each test configuration for the photovoltaic modules 10.

[0083] With the results of the testing performed on all the photovoltaic modules 10, an empirical model for failure energy was computed. The computations were based on the following empirical model for failure energy (Equation 1):Equation 1where p is the number of factors (both design and noise), (z=l . . .p) are the model parameters for the main effects,(m,n=l . . .p) are the model parameters for the 2-way interactions, y is failure energy, and e is the error (e.g., the residual). Estimates for the above model parameters were computed following a least-squares approach using the dataset from the design of experiment (DOE). The resulting model is shown in Equation 2 below.Equation 2 Predicted Failure Energy= 25.11 + 14.76 * Thin Pane Thickness + 1.49 * Thick Pane Thickness-I — 0.70 * Encapsulant Modulus + —10.43 * Encapsulant Thickness -I — 5.20* Flaw Depth + 2.70 Thin Pane Thickness * Thick Pane Thickness)-I — 7.22 (Thin Pane Thickness * Encapsulant Thickness)-I — 3.41 (Thin Pane Thickness * Flaw Depth) -I — 2.85 (Thick Pane Thickness* Encapsulant Modulus)+ 2.91 (Encapsulant Modulus * Encapsulant Thickness)+ 2.52 (Encapsulant Thickness * Flaw Depth)The statistics for the model parameter estimates are shown in Table 3 that is reproduced as FIG. 9. In Table 3, effects are centered & scaled to a -1 to 1 range. Parameters that are statistically significant are those with p-values less than 0.05.

[0084] Several design cases for the photovoltaic module 10 and the resulting failure energy (averaged) are presented in Table 4 below. The cases illustrate how the system model can be used in jointly selecting pane thickness and encapsulant 20 properties (e.g., elastic modulus) to achieve different objectives:

[0085] Each of the 4 design cases provides insight. Case 1 focuses on reducing total pane thickness (sum of the lesser thickness 36 of 100 pm for the thin pane 12 and the greater thickness 38 of 3.2 mm for the thick pane 14). Reducing total pane thickness reduces the weight of the photovoltaic module 10. Despite the reduced total pane thickness, the photovoltaic module 10 design still achieved an average failure energy of 21 joules, which qualifies as “hail hardened” performance. Such high average failure energy for the photovoltaic modules 10 of Case 1 contradicts the accepted industry assumption set forth in the Background that the panes receiving the impact must be thick to have “hail hardened” performance.

[0086] Case 2 is the same as Case 1 but increases the thickness 38 of the thick pane 14 from 3.2 mm to 5.0 mm, which is an increase of 56%. However, the average failure energy of the photovoltaic modules 10 increased only modestly to 24 joules from 21 joules (for Case 1), which is an increase of only 14%. Thus, Case 2 shows that increasing the thickness 36 of the thick pane 14 only marginally improves failure energy (e.g., resistance to impact events).

[0087] Case 3 is the same as Case 2 but increases the elastic modulus of the encapsulant 20 from 0.6 GPa to 1.0 GPa. The 67% increase in elastic modulus of the encapsulant 20 resulted in a decrease in the average failure energy from 24 joules (for Case 2) to 5 joules (for Case 3), a reduction of 79%. Further, Case 3 has a total pane thickness of 5.1 mm compared to the total pane thickness of 3.3 mm of Case 1. However, the failure energy of Case 3 of 5 joules is 76% less than the failure energy of 21 J of Case 1. Stated another way, the failure energy for Case 1 is four times higher than Case 3, yet the total pane thickness for Case 1 is 35% less than Case 3. The result driving difference between these two cases is the elastic modulus of theencapsulant 20, and the comparison shows how the interplay between encapsulant 20 properties and pane thickness, expressed as 2-way interactions in the model, affect impact performance. Further, Case 3 can be considered to counter the conventional wisdom in the industry that thicker panes always lead to greater impact resistance.

[0088] Case 4 represents the design parameters to maximize the failure energy of the photovoltaic module 10, with respect to the ranges of variables considered. The average failure energy for Case 4 was 82 joules. Case 4 was just like Case 2 but increased the thickness 36 of the thin pane 12 from 100 pm to 400 pm. Despite the thin pane 12 having a sub-1 mm thickness 36 of 400 pm, and the ice ball 66 impact occurring at the thin pane 12, the average energy failure was very high at 82 joules - an energy failure not suggested from conventional industry wisdom that much thinner panes 12 would necessarily result in limited damage resistance to impact events.

[0089] Cases 1, 2, and 4 collectively show that photovoltaic modules 10 can both (i) include thin panes 12 of glass positioned to encounter hail impacts and (ii) provide a failure energy in excess of 20 joules, even when the thin pane 12 has pre-existing surface damage (e.g., the abraded area 72). The failure energy in excess of 20 joules is an emerging solar-industry benchmark for hail -hardened photovoltaic modules 10.

[0090] Further, all the Cases show the interplay between the thickness 36 of the thin pane 12, the thickness 38 of the thick pane 14, the encapsulant thickness 46, and the elastic modulus of the encapsulant 20, as well as the depth of the abraded area 72 into the thin pane 12 in altering the impact resistance, as reflected in the failure energy. Because of that interplay, it is important to consider the components of the photovoltaic module 10 as a system, rather than choosing each component independently, as is typically done. Managing impact resistance (as reflected by the failure energy) by jointly selecting the thicknesses 36, 38 of the panes 12, 14 and encapsulant 20 properties using a system model of how the components work together is not known in the photovoltaic literature. Example 1, and the present disclosure generally, addresses the problems set forth in the Background by considering the system as a whole to maximize impact resistance while simultaneously minimizing total pane thickness, thereby reducing the weight of the photovoltaic module 10 and improving optical efficiency.

[0091] It will be apparent to those skilled in the art that various modifications and variations can be made without departing from the spirit or scope of the claims.

[0092] It will be understood by one having ordinary skill in the art that construction of the described disclosure and other components is not limited to any specific material. Otherexemplary embodiments of the disclosure disclosed herein may be formed from a wide variety of materials, unless described otherwise herein.

[0093] For purposes of this disclosure, the term "coupled" (in all its forms, couple, coupling, coupled, etc.) generally means the joining of two components (electrical or mechanical) directly or indirectly to one another. Such joining may be stationary in nature or movable in nature. Such joining may be achieved with the two components (electrical or mechanical) and any additional intermediate members being integrally formed as a single unitary body with one another or with the two components. Such joining may be permanent in nature or may be removable or releasable in nature unless otherwise stated.

[0094] It is also important to note that the construction and arrangement of the elements of the disclosure as shown in the exemplary embodiments is illustrative only. Although only a few embodiments of the present innovations have been described in detail in this disclosure, those skilled in the art who review this disclosure will readily appreciate that many modifications are possible (e.g., variations in sizes, dimensions, structures, shapes and proportions of the various elements, values of parameters, mounting arrangements, use of materials, colors, orientations, etc.) without materially departing from the novel teachings and advantages of the subject matter recited. For example, elements shown as integrally formed may be constructed of multiple parts or elements shown as multiple parts may be integrally formed, the operation of the interfaces may be reversed or otherwise varied, the length or width of the structures and / or members or connector or other elements of the system may be varied, the nature or number of adjustment positions provided between the elements may be varied. It should be noted that the elements and / or assemblies of the system may be constructed from any of a wide variety of materials that provide sufficient strength or durability, in any of a wide variety of colors, textures, and combinations. Accordingly, all such modifications are intended to be included within the scope of the present innovations. Other substitutions, modifications, changes, and omissions may be made in the design, operating conditions, and arrangement of the desired and other exemplary embodiments without departing from the spirit of the present innovations.

[0095] It will be understood that any described processes or steps within described processes may be combined with other disclosed processes or steps to form structures within the scope of the present disclosure. The exemplary structures and processes disclosed herein are for illustrative purposes and are not to be construed as limiting.

Claims

CLAIM(S)1 . A photovoltaic module comprising: a thin pane comprising a thin glass composition, an exterior facing primary surface, an interior facing primary surface, and a lesser thickness between the exterior facing primary surface and the interior facing primary surface; a thick pane comprising a thick glass composition, an exterior facing primary surface, an interior facing primary surface, and a greater thickness between the exterior facing primary surface and the interior facing primary surface, the greater thickness being greater than the lesser thickness of the thin pane; an array of photovoltaic cells disposed between the thin pane and the thick pane; and an encapsulant at least partially encapsulating the array of photovoltaic cells, the encapsulant disposed between the first pane and the second pane and comprising an elastic modulus and an encapsulant thickness, wherein, the lesser thickness of the thin pane is less than or equal to 900 pm, wherein, the greater thickness of the thick pane is greater than or equal to 1.6 mm, and wherein, the encapsulant thickness is less than or equal to 800 pm, and wherein, the elastic modulus of the encapsulant is less than 1000 MPa at room temperature.

2. The photovoltaic module of claim 1, wherein the lesser thickness of the thin pane is within a range of from 75 pm to 800 pm.

3. The photovoltaic module of any one of claims 1-2, wherein the greater thickness of the thick pane is within a range of from 3 mm to 6 mm.

4. The photovoltaic module of any one of claims 1-3, wherein the thin glass composition is a silicate glass composition that is substantially free of alkali ions.

5. The photovoltaic module of any one of claims 1-4, wherein the thin glass composition comprises a boro silicate glass composition that is substantially free of alkali ions.

6. The photovoltaic module of any one of claims 1-5, whereinthe thin glass composition comprises an alkaline earth alumino boro silicate glass composition that is substantially free of alkali ions.

7. The photovoltaic module of any one of claims 1-6, wherein the thin glass composition comprises (in mol%, on an oxide basis):SiCh: from 62 to 75;AI2O3: from 7 to 13;B2O3: from 5 to 26;MgO: from 0 to 3;CaO: from 5 to 15;BaO from 0 to 5; andSrO from 0 to 5.

8. The photovoltaic module of any one of claims 1-7, wherein the thick glass composition is a soda lime glass composition.

9. The photovoltaic module of any one of claims 1-8, wherein the thick glass composition is a boro silicate glass composition.

10. The photovoltaic module of any one of claims 1-9, wherein the thick glass composition is a silicate glass composition with at least one alkali oxide.

11. The photovoltaic module of any one of claims 1-10, wherein the thicker pane comprises at least one region of compressive stress contiguous with the exterior facing primary surface or the interior facing primary surface.

12. The photovoltaic module of any one of claims 1-11, wherein the elastic modulus of the encapsulant is within a range of from 500 MPa to 700 MPa at room temperature.

13. The photovoltaic module of any one of claims 1-12, wherein the encapsulant thickness is less than or equal to 650 pm.

14. The photovoltaic module of claim 13, whereinthe encapsulant thickness is within a range of from 200 pm to 500 pm.

15. The photovoltaic module of any one of claims 1-14, wherein the encapsulant comprises a composition selected from the group consisting of ethylene-vinyl acetate, polyvinyl butyral, a silicone-based material, an ionomer, a thermoplastic polyolefin, and a polyolefin.

16. The photovoltaic module of claim 15, wherein the composition of the encapsulant is ethylene-vinyl acetate.

17. The photovoltaic module of any one of claims 1-16, wherein the photovoltaic cells each comprise a PV thickness that is less than or equal to 250 pm.

18. The photovoltaic module of claim 17, wherein the PV thickness is less than or equal to 1 pm.

19. The photovoltaic module of any one of claims 1-18, wherein the photovoltaic cells each comprise a material selected from the group consisting of CuIn / GaSe, cadmium telluride, amorphous silicon, polysilicon, an organic small molecule, an organic polymer, and a perovskite.

20. The photovoltaic module of any one of claims 1-19, wherein the photovoltaic cells are printed onto the interior facing primary surface of the thin pane.

21. The photovoltaic module of any one of claims 1-20, wherein the thin pane exhibits no new visible damage as a result of an impact from an ice ball having a diameter of about 25 mm traveling at a velocity sufficient to generate an impact energy of about 2 joules.

22. The photovoltaic module of any one of claims 1-21, whereinthe thin pane exhibits no new visible damage as a result of an impact from an ice ball having a diameter of about 45 mm traveling at a velocity sufficient to generate an impact energy of about 20 joules.

23. The photovoltaic module of any one of claims 1-22, wherein the thin pane exhibits no new visible damage as a result of an impact from an ice ball having a diameter of about 45 mm traveling at a velocity sufficient to generate an impact energy of about 80 joules.

24. A photovoltaic module comprising: a thin pane comprising an alkaline earth alumino boro silicate glass composition that is substantially free of alkali ions, an exterior facing primary surface, an interior facing primary surface, and a lesser thickness between the exterior facing primary surface and the interior facing primary surface; an array of photovoltaic cells disposed on the interior facing primary surface of the thin pane, the array of photovoltaic cells is characterized in that each of the photovoltaic cells is printed onto the interior facing primary surface of the thin pane; a thick pane comprising a soda lime glass composition, an exterior facing primary surface, an interior facing primary surface facing the array of photovoltaic cells, and a greater thickness between the exterior facing primary surface and the interior facing primary surface, the greater thickness being greater than the lesser thickness of the thin pane; and an encapsulant at least partially encapsulating the array of photovoltaic cells, the encapsulant disposed between the front pane and the rear pane and comprising an elastic modulus, an encapsulant thickness, and a composition comprising ethylene -vinyl acetate, wherein, the lesser thickness of the thin pane is within a range of from 100 pm to 900 pm, wherein, the greater thickness of the thick pane is within a range of from 3.00 mm to 6.00 mm, and wherein, the thin pane exhibits no new visible damage as a result of an impact from an ice ball having a diameter of about 45 mm traveling at a velocity sufficient to generate an impact energy of about 20 joules.

25. The photovoltaic module of claim 24, wherein the elastic modulus of the encapsulant is less than or equal to 800 MPa.

26. The photovoltaic module of any one of claims 24-25, wherein the encapsulant thickness is less than or equal to 600 pm.

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