Method of making and utilizing partially cured photovoltaic assemblies

A process for producing photovoltaic devices, comprising the steps of:

• fabricating a photovoltaic subassembly in a photovoltaic plant by electrically connecting a set of solar cells, said solar cells comprising at least one active region selected from the group consisting of polycrystalline silicon, monocrystalline silicon, hydrogenated amorphous silicon, hydrogenated amorphous silicon carbon, and hydrogenated amorphous silicon germanium,
• contacting said solar cells with at least one curable plastic sheet comprising ethylene vinyl acetate,
• securely fixing said solar cells to said plastic sheet by partially laminating said plastic sheet to said solar cells in a laminator at a temperature ranging from about 90.degree. C. to about 120.degree. C. at a vacuum pressure,
• preventing polymerization of said plastic sheet during said partially laminating,
• cooling said partially laminated plastic sheet to about room temperature before said plastic sheet has polymerized, and
• covering said plastic sheet with a water-impervious dirt-resistant protective coating of transparent plastic selected from the group consisting of polyvinyl fluoride and polyethylene;
• shipping said photovoltaic subassembly from said photovoltaic plant to a manufacturing facility selected from the group consisting of an automobile plant and a glass plant, said shipping including transport in an airplane, ship, train, truck, bus, van or vehicle;
• assembling a photovoltaic device selected from the group consisting of a solar roof, moon roof, architectural glass, and photovoltaic facade, at the manufacturing facility by
• placing said photovoltaic subassembly on at least one support member selected from the group consisting of metal and a transparent glass pane, said support member providing a substrate or superstrate, and
• heating said photovoltaic subassembly and support member in an autoclave or laminator at said manufacturing facility at a melting temperature of at least about 135.degree. C. at a vacuum pressure to completely cure and polymerize said ethylene vinyl acetate plastic sheet around said solar cells and securely thermally bond said ethylene vinyl acetate plastic sheet to said support member to resist creep and prevent subsequent melting of said plastic sheet in said photovoltaic devices from heat of the sun during use of said photovoltaic devices.