Solar cell modules and method of making same

A method of manufacturing a laminated photovoltaic module comprising the steps of:

• (a) providing one or more strings of electrically interconnected photovoltaic cells, each having a front light-receiving surface and a rear surface, with first and second contacts attached to said front and rear surfaces respectively;
• (b) providing first and second sheets of glass and first and second sheets of ionomer;
• (c) providing at least one deformable sealing strip;
• (d) placing said first ionomer sheet in overlying relation with one surface of said first sheet of glass;
• (e) engaging said one surface of said first sheet of glass with said at least one sealing strip so that said sealing strip is positioned between the edge of said first sheet of glass and said first ionomer sheet;
• (f) placing said one or more strings of cells in overlying relation with said first ionomer sheet;
• (g) covering said one or more strings of cells with said second ionomer sheet;
• (h) placing said second sheet of glass in overlying relation with said second ionomer sheet and said at least one deformable sealing strip;
• (i) heating and compressing the resulting assembly of said cells, said at least one sealing strip, and said ionomer and glass sheets so as to cause said first and second ionomer sheets to soften enough to flow and form a mass that encapsulates said cells;
• and
• (j) cooling said assembly so as to cause said mass of ionomer to bond to said first and second glass sheets, said at least one sealing strip, and said cells.

A method of manufacturing a laminated photovoltaic module comprising the steps of:

• (a) providing one or more strings of electrically interconnected photovoltaic cells, each cell having a front light-receiving surface and a rear surface and first and second contacts attached to said front and rear surfaces respectively;
• (b) providing first and second sheets of glass and first and second sheets of ionomer;
• (c) providing a plurality of deformable sealing strips;
• (d) placing said first ionomer sheet in overlying relation with one surface of said first sheet of glass;
• (e) engaging said one surface of said first sheet of glass with said sealing strips so that each of said sealing strips is positioned between an edge of said glass and said first ionomer sheet;
• (f) placing said one or more strings of cells in overlying relation with said first ionomer sheet;
• (g) covering said one or more strings of cells with said second ionomer sheet;
• (h) placing said second sheet of glass in overlying relation with said second ionomer sheet and said deformable sealing strips;
• (i) placing the resulting assembly of said cells, said strips, and said ionomer and glass sheets into a vacuum press and operating said press so as to evacuate air from said assembly and heat said assembly to a temperature at which said first and second ionomer sheets soften enough to encapsulate said cells;
• and
• (j) cooling said assembly so as to cause said ionomer to form a solid mass that is bonded to said first and second glass sheets, said strips, and said cells.

A method of manufacturing a laminated photovoltaic module comprising the steps of:

• (a) providing one or more strings of electrically interconnected photovoltaic cells, each cell having a front light-receiving surface and a rear surface and first and second contacts attached to said front and rear surfaces respectively;
• (b) providing first and second sheets of glass and first and second discrete sheets of ionomer;
• (c) providing a deformable sealing strip having a thickness in excess of the combined thicknesses of said sheets of ionomer and said cells;
• (d) assembling the components of steps (a) to (c) so as to form a sandwich wherein said cells are disposed between and engaged by said ionomer sheets and said ionomer sheets are disposed between and engaged by said glass sheets, and said sealing strip is positioned between and engaged by said glass sheets and is in surrounding relation with said sheets of ionomer;
• (e) placing said sandwich into a vacuum press and operating said press so as to heat and compress said sandwich while evacuating air from said sandwich, said sandwich being heated to a temperature of about 170 degrees C. so as to cause said first and second ionomer sheets soften enough to flow into encapsulating relation with said cells;
• and
• (f) cooling said sandwich so as to cause said ionomer to solidify into a mass that is bonded to said first and second glass sheets, said strip, and said cells.

A preform sandwich adapted for forming a laminated photovoltaic module comprising:

• first and second stiff support sheets, at least said first sheet being made of a light transparent material;
• first and second preformed sheets of ionomer, said first sheet of ionomer extending along and engaging an inner surface of said first support sheet, with said first sheet of ionomer terminating short of the edges of said first support sheet, said second sheet of ionomer extending along and engaging an inner surface of said second support sheet, with said second sheet of ionomer terminating short of the edges of said second support sheet;
• and
• an array of electrically interconnected photovoltaic cells disposed between and engaged by said first and second ionomer sheets.

A laminated photovoltaic module comprising:

• first and second stiff support sheets, at least said first support sheet being made of a light-transparent material;
• an array of electrically interconnected photovoltaic cells disposed between said first and second support sheets, said cells comprising a polycrystalline silicon substrate having first and second surfaces with said first surface facing said first support sheet, a shallow P-N junction adjacent said first surface, a first contact bonded to said first surface, and a rear contact bonded to said second surface;
• and
• a mass of light-transmitting ionomer disposed between and bonded directly to said first and second support sheets and fully encapsulating said cells.