Method of encapsulating a photovoltaic device
First Claim
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1. A method of manufacturing an encapsulated flexible photovoltaic device, said method including the steps of:
- providing a flexible, thin film photovoltaic device;
providing a first roll of adhesive material;
unwinding a portion of said first adhesive roll, while maintaining said first roll under tension;
disposing said photovoltaic device on said unwound portion of the tensioned first adhesive roll, such that said portion supports said device;
providing a roll of flexible back encapsulant material;
unwinding a portion of said flexible back encapsulant material roll, while maintaining said back encapsulant roll under tension;
providing a roll of front encapsulant material;
unwinding a portion of said front encapsulant material roll, while maintaining said front encapsulant roll under tension;
interleaving said materials so as to provide a layered structure comprising, in order, front encapsulant material, photovoltaic device, first adhesive material, and back encapsulant material;
rolling up said layered structure while maintaining tension on said rolls of materials so as to flex said photovoltaic device and to provide a tightly wound composite roll of said layered structure; and
heating said roll of layered structure for a period of time sufficient to activate said adhesive material.
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Abstract
A flexible encapsulated photovoltaic device is prepared by disposing photovoltaic devices on a sheet of thermoplastic material, disposing a front encapsulant material atop the devices, and disposing a bottom encapsulant layer so as to provide a multi-layered structure. The multi-layered structure is rolled under tension so as to compress the layers and the roll is heated to activate the thermoplastic material and bond the layers together. Additional layers may be interposed prior to rolling.
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Citations
21 Claims
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1. A method of manufacturing an encapsulated flexible photovoltaic device, said method including the steps of:
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providing a flexible, thin film photovoltaic device; providing a first roll of adhesive material; unwinding a portion of said first adhesive roll, while maintaining said first roll under tension; disposing said photovoltaic device on said unwound portion of the tensioned first adhesive roll, such that said portion supports said device; providing a roll of flexible back encapsulant material; unwinding a portion of said flexible back encapsulant material roll, while maintaining said back encapsulant roll under tension; providing a roll of front encapsulant material; unwinding a portion of said front encapsulant material roll, while maintaining said front encapsulant roll under tension; interleaving said materials so as to provide a layered structure comprising, in order, front encapsulant material, photovoltaic device, first adhesive material, and back encapsulant material; rolling up said layered structure while maintaining tension on said rolls of materials so as to flex said photovoltaic device and to provide a tightly wound composite roll of said layered structure; and heating said roll of layered structure for a period of time sufficient to activate said adhesive material. - View Dependent Claims (2, 3, 4, 5, 6, 8, 9, 10, 11, 12, 13, 14, 15, 16, 17, 18, 19, 20)
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7. The method of claim wherein the step of providing a flexible, thin film photovoltaic device comprises providing a single, continuous solar panel.
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21. A method of manufacturing an encapsulated photovoltaic device, said method including the steps of:
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providing a flexible, thin film photovoltaic device; providing a first roll of adhesive material; unwinding a portion of said first adhesive roll while maintaining said first roll under tension; disposing said photovoltaic device on said unwound portion such that said portion supports said device; providing a roll of flexible back encapsulant material; unwinding a portion of said roll of back encapsulant material while maintaining said back encapsulated roll under tension; providing a second roll of adhesive material; unwinding a portion of said second roll of adhesive material while maintaining said second roll under tension; providing a roll of flexible front encapsulant material; unwinding a portion of said roll of front encapsulant material while maintaining said front encapsulant roll under tension; interleaving said materials so as to provide a layered structure comprising, in order, front encapsulant material, second adhesive material, photovoltaic device, first adhesive material, and back encapsulant material; rolling up said layered structure while maintaining tension on said rolls of material so as to flex said photovoltaic device and to provide a tightly wound roll of said layered structure; and heating said roll of layered structure for a period of time sufficient to activate said adhesive materials.
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Specification