Frame-less encapsulated photo-voltaic solar panel supporting solar cell modules encapsulated within multiple layers of optically-transparent epoxy-resin materials

• US 10,490,682 B2
• Filed: 03/14/2018
• Issued: 11/26/2019
• Est. Priority Date: 03/14/2018
• Status: Active Grant

• Current Assignee: National Mechanical Group Corp., Sun Pacific Power Corporation (Sun Pacific Holding Corp.)
• Original Assignee: National Mechanical Group Corp.
• Inventors: Campanella, Nicholas B.
• Primary Examiner(s): Mershon, Jayne L
• Application Number:
  US15/921,458
• Publication Number:
  US 20190288138A1
• Time in Patent Office: 622 Days
• CPC Class Codes: H01L 31/0201 comprising specially adapted module bus-bar structures
• CPC Class Codes: H01L 31/048 Encapsulation of modules
• CPC Class Codes: H01L 31/0481 characterised by the composition of the encapsulation material
• CPC Class Codes: H01L 31/049 Protective back sheets
• CPC Class Codes: H01L 31/18 Processes or apparatus specially adapted for the manufacture or treatment of these devices or of parts thereof
• CPC Class Codes: H02S 40/34 comprising specially adapted electrical connection means to be structurally associated with the PV module, e.g. junction boxes
• CPC Class Codes: Y02B 10/10 Photovoltaic [PV]
• CPC Class Codes: Y02E 10/50 Photovoltaic [PV] energy
• CPC Class Codes: Y02P 80/20 using renewable energy

Abstract

A frame-less epoxy-resin encapsulated solar panel construction, in which an optically transparent epoxy-resin coating is applied over an array of photo-voltaic (PV) solar cell modules mounted on a sheet of phenolic resin, and supported in a layer of adhesive coating applied as a liquid with a viscosity and a thickness such that the thickness of the layer of adhesive coating is substantially equal to the thickness of the PV solar cell modules, and cured to a sufficient hardness, after which the epoxy-resin coating is applied over the array of PV solar cell modules and the cured layer of adhesive coating so to reinforce the strength of the sheet of phenolic resin, particularly around the perimeter of the sheet of phenolic resin.

Claims

1. A frame-less epoxy-resin encapsulated solar panel construction comprising:

a phenolic resin support sheet made of non-conductive and reinforced phenolic resin material;

an array of photo-voltaic (PV) solar cell modules connected to an electrically-conductive bus bar assembly, having top surfaces and adhesively bonded to said phenolic resin support sheet using an optically transparent layer of adhesive material;

said optically transparent layer of adhesive material having a thickness equal to said array of PV solar cell modules so that the top surfaces of said PV solar cell modules and surrounding adhesive coating reside in the same plane so as to form a planar surface;

an optically transparent epoxy-resin encapsulating layer applied over said planar surface formed by said array of (PV) solar cell modules, said electrically-conductive bus bar assembly and said optically transparent adhesive layer;

an optically transparent plastic sheet securely bonded to said optically transparent epoxy-resin encapsulating layer; and

an optically transparent epoxy-resin top coating applied over said optically transparent plastic sheet, for providing self-cleaning action when wet during rain showers;

wherein high-strength edge portions are formed all around the perimeter of said frame-less epoxy-resin encapsulated solar panel construction, between said optically transparent epoxy-resin top coating and said phenolic resin support sheet; and

wherein said high-strength edge portions of said frame-less epoxy-resin encapsulated solar panel construction are free of said array of PV solar cell modules and said electrically-conductive bus bar assembly so that mounting holes can be drilled through said high-strength edge portions without the risk of damaging said array of PV solar cell modules and said electrically-conductive bus bar assembly, and without the risk of compromising the strength and integrity of said frame-less epoxy-resin encapsulated solar panel construction.

2. The frame-less epoxy-resin encapsulated solar panel construction of claim 1, wherein said optically transparent epoxy-resin top coating is applied over said optically transparent epoxy-resin layer at a dry film thickness (DFT) of at least 0.1 mm.

3. The frame-less epoxy-resin encapsulated solar panel construction of claim 1, wherein mounting holes drilled through said high-strength edge portions of said frame-less epoxy-resin encapsulated solar panel construction allow for mounting in diverse environments including, horizontal and inclined rooftops, and vertical wall mounting applications.

4. The frame-less epoxy-resin encapsulated solar panel construction of claim 1, wherein said photo-voltaic (PV) solar cell modules are made from various photo-voltaic technologies selected from the group consisting of (i) mono-crystalline or multi-crystalline silicon photo-voltaic solar cell modules;

(ii) copper indium gallium selenide (CIGS) photo-voltaic solar cell modules;

(iii) cadmium telluride (CdTe) photo-voltaic solar cell modules;

(iv) perovskite photo-voltaic solar cell modules; and

(v) organic photo-voltaic solar cell modules, and plastic photo-voltaic solar cell modules.

5. The frame-less epoxy-resin encapsulated solar panel construction of claim 1, wherein said phenolic resin support sheet has a thickness between ⅛

to 3/16 inches.

6. The frame-less epoxy-resin encapsulated solar panel construction of claim 1, which further comprises an electrical connector junction box mounted to the rear of said phenolic resin support sheet to provide support for electrical power jacks for connection of electrical power cables that connect each frame-less epoxy-resin encapsulated solar panel construction to an electrical power system supported within a building, house or other environment in which said frame-less epoxy-resin encapsulated solar panel construction is installed.