Solar cell modules with integral mounting structure and methods for forming same

A method of manufacturing a solar cell module comprising:

• providing a front support layer formed of light transmitting material and having first and second surfaces;
• placing a transparent encapsulant layer adjacent the second surface of the front support layer;
• positioning a plurality of interconnected solar cells having first and second surfaces adjacent the transparent encapsulant layer;
• placing a backskin layer formed of thermoplastic olefin comprising at least a first ionomer and a second ionomer adjacent a second surface of the interconnected solar cells to thereby form an assembly;
• laminating the assembly to encapsulate the interconnected solar cells with the encapsulant layer and the backskin layer;
• and
• bonding at least one mounting bracket directly to a second surface of the backskin layer.

A laminated solar cell module comprising:

• a rigid front support layer formed of light transmitting material and having first and second surfaces;
• a transparent encapsulant layer having a first surface disposed adjacent the second surface of the front support layer;
• a plurality of interconnected solar cells having a first surface disposed adjacent a second surface of the transparent encapsulant layer;
• a backskin layer formed of a thermoplastic olefin comprising at least a first ionomer and a second ionomer and having a first surface disposed adjacent a second surface of the interconnected solar cells, a portion of the backskin layer being wrapped around at least one edge of the module for contacting the first surface of the front support layer to form an edge seal;
• the transparent encapsulant layer and the backskin layer, in combination, encapsulating the interconnected solar cells;
• and
• at least one mounting bracket bonded directly to a second surface of the backskin layer.

A method of manufacturing a solar cell module comprising:

• providing a front support layer formed of light transmitting material and having first and second surfaces;
• placing a transparent encapsulant layer adjacent the second surface of the front support layer;
• positioning a plurality of interconnected solar cells having first and second surfaces adjacent the transparent encapsulant layer;
• placing a backskin layer formed of thermoplastic olefin comprising at least a first ionomer and a second ionomer adjacent a second surface of the interconnected solar cells to thereby form an assembly;
• wrapping an end portion of the backskin layer around at least one edge of the assembly for contacting the first surface of the front support layer, to form an edge seal;
• and
• laminating the assembly to encapsulate the interconnected solar cells with the encapsulant layer and the backskin layer;
• and
• bonding at least one mounting bracket directly to a second surface of the backskin layer.

A laminated solar cell module comprising:

• a stiff front support layer formed of light transmitting material and having first and second surfaces;
• a transparent encapsulant layer formed of at least one ionomer and disposed adjacent the second surface of the front support layer;
• a plurality of interconnected solar cells having a first surface disposed adjacent the transparent encapsulant layer;
• a flexible backskin layer formed of a thermoplastic olefin comprising at least a first ionomer and a second ionomer and having a first surface disposed adjacent a second surface of the interconnected solar cells;
• the transparent encapsulant layer and the backskin layer, in combination, encapsulating the interconnected solar cells;
• and
• at least one mounting bracket bonded directly to a second surface of the backskin layer.

A method of manufacturing a solar cell module comprising:

• providing a stiff front support layer formed of light transmitting material and having first and second surfaces;
• placing a transparent encapsulant layer formed of at least one ionomer adjacent the second surface of the front support layer;
• positioning a plurality of interconnected solar cells having first and second surfaces adjacent the transparent encapsulant layer;
• placing a flexible backskin layer formed of thermoplastic olefin comprising at least a first ionomer and a second ionomer adjacent a second surface of the interconnected solar cells to thereby form an assembly;
• subjecting the assembly to heat and pressure to encapsulate the interconnected solar cells with the encapsulant layer and the backskin layer;
• and
• bonding at least one mounting bracket directly to a second surface of the backskin layer.