Photovoltaic cell module and method of forming

• US 9,842,952 B2
• Filed: 02/25/2015
• Issued: 12/12/2017
• Est. Priority Date: 10/31/2008
• Status: Active Grant

• Current Assignee: Dow Silicones Corporation (Dow, Inc.)
• Original Assignee: Dow Corning Corporation (Dow, Inc.)
• Inventors: Howell, Malinda, Juen, Donnie, Ketola, Barry, Tomalia, Mary Kay
• Primary Examiner(s): Martin, Matthew
• Assistant Examiner(s): Horton, Dujuan
• Application Number:
  US14/630,998
• Publication Number:
  US 20150171249A1
• Time in Patent Office: 1,021 Days
• Field of Search: 136259, 136244, 136251
• CPC Class Codes: B32B 17/10018 comprising only one glass sheet
• CPC Class Codes: B32B 17/10798 containing silicone
• CPC Class Codes: B32B 2327/12 containing fluorine
• CPC Class Codes: H01L 31/02167 for solar cells
• 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: Y02E 10/542 Dye sensitized solar cells
• CPC Class Codes: Y02E 10/549 Organic PV cells
• CPC Class Codes: Y02P 70/50 Manufacturing or production processes characterised by the final manufactured product

Abstract

A photovoltaic cell module, a photovoltaic array including at least two modules, and a method of forming the module are provided. The module includes a first outermost layer and a photovoltaic cell disposed on the first outermost layer. The module also includes a second outermost layer disposed on the photovoltaic cell and sandwiching the photovoltaic cell between the second outermost layer and the first outermost layer. The method of forming the module includes the steps of disposing the photovoltaic cell on the first outermost layer, disposing a silicone composition on the photovoltaic cell, and compressing the first outermost layer, the photovoltaic cell, and the second layer to form the photovoltaic cell module.

Claims

1. A photovoltaic array comprising:

A. a first outermost layer that is a single layer having a light transmittance of at least 70 percent as determined by UV/Vis spectrophotometry using ASTM E424-71 and that is silicone;

B. two or more photovoltaic cells electrically connected to each other, each disposed on said first outermost layer; and

C. a second outermost layer that is a single layer disposed opposite said first outermost layer, said second outermost layer comprising a (I) silicone composition and disposed on and in direct contact with said photovoltaic cells sandwiching said photovoltaic cells between said second outermost layer and said first outermost layer,

wherein said (I) silicone composition comprises a linear organosilicon compound having two terminal unsaturated moieties per molecule and present in an amount of from 80 to 95 parts by weight, a branched organosilicon compound having two terminal unsaturated moieties per molecule and at least one pendant unsaturated moiety per molecule and present in an amount of from 5 to 20 as parts by weight, per 100 parts by weight of a sum of said linear organosilicon compound and said branched organosilicon compound, and an organohydrogensilicon compound having at least three silicon-bonded hydrogen atoms per molecule wherein a ratio of silicon-bonded hydrogen atoms per molecule of said organohydrogensilicon compound to a sum of unsaturated moieties per molecule of said linear organosilicon compound and branched organosilicon compound is from 1 to 1.7,

wherein said first outermost layer is positioned on the top of said array and said array is free of any additional layers disposed on the top of said array, and

wherein said second outermost layer is positioned on the bottom of said array and said array is free of any additional layers disposed on the bottom of said array.

2. The photovoltaic array of claim 1 that is free of any layers that include polyethylene terephthalate, polyethylene naphthalate, polyvinyl fluoride, and ethylene vinyl acetate.

3. The photovoltaic array of claim 1 that is free of any layers that include a polymer other than silicone polymers.

4. The photovoltaic array of claim 1 wherein said (I) silicone composition is at least partially cured.

5. The photovoltaic array of claim 1 wherein said (I) silicone composition further comprises a filler.

6. The photovoltaic array of claim 5 wherein said filler is a flame retardant.

7. The photovoltaic array of claim 1 wherein said (I) silicone composition further comprises a plurality of fibers.

8. The photovoltaic array of claim 1 wherein said second outermost layer comprises a non-woven textile mat at least partially coated with said (I) silicone composition.

9. The photovoltaic array of claim 8 wherein said non-woven textile mat is chosen from fiberglass, polyester, polyethylene, polypropylene, nylon, and combinations thereof.

10. The photovoltaic array of claim 1 wherein said (I) silicone composition is free of fibers.

11. The photovoltaic array of claim 1 further comprising a tie layer disposed on said photovoltaic cells and sandwiched between said photovoltaic cells and said first outermost layer such that said tie layer is disposed on and in direct contact with both said photovoltaic cells and said first outermost layer.

12. The photovoltaic array of claim 11 wherein said tie layer comprises a second silicone composition which is the same or different as said (I) silicone composition.

17. The photovoltaic array of claim 1 wherein said first outermost layer is disposed on and in direct contact with said photovoltaic cells.

13. A photovoltaic array comprising:

A. a first outermost layer that is a single layer having a light transmittance of at least 70 percent as determined by UV/Vis spectrophotometry using ASTM E424-71, and consisting essentially of silicone;

B. two or more photovoltaic cells electrically connected to each other, each disposed on and in direct contact with said first outermost layer; and

C. a second outermost layer that is a single layer disposed opposite said first outermost layer, said second outermost layer formed from an at least partially cured (I) silicone composition and disposed on and in direct contact with said photovoltaic cells sandwiching said photovoltaic cells between said second outermost layer and said first outermost layer, and

wherein said at least partially cured (I) silicone composition is formed from at least partially curing a combination of a linear organosilicon compound having two terminal unsaturated moieties per molecule and present in an amount of from 80 to 95 parts by weight, a branched organosilicon compound having two terminal unsaturated moieties per molecule and at least one pendant unsaturated moiety per molecule and present in an amount of from 5 to 20 as parts by weight, per 100 parts by weight of a sum of said linear organosilicon compound and said branched organosilicon compound, and an organohydrogensilicon compound having at least three silicon-bonded hydrogen atoms per molecule wherein a ratio of silicon-bonded hydrogen atoms per molecule of said organohydrogensilicon compound to a sum of unsaturated moieties per molecule of said linear organosilicon compound and branched organosilicon compound is from 1 to 1.7,

wherein said array is free of any layers that include polymers other than silicone polymers,

wherein said first outermost layer is positioned on the top of said array and said array is free of any additional layers disposed on the top of said array, and

wherein said second outermost layer is positioned on the bottom of said array and said array is free of any additional layers disposed on the bottom of said array.

14. A method of forming a photovoltaic array comprising a first outermost layer that is a single layer having a light transmittance of at least 70 percent as determined by UV/Vis spectrophotometry using ASTM E424-71 and that is silicone, two or more photovoltaic cells electrically connected to each other, each disposed on the first outermost layer, and a second outermost layer that is a single layer disposed opposite the first outermost layer, formed from an at least partially cured liquid silicone composition, and disposed on and in direct contact with the photovoltaic cells sandwiching the photovoltaic cells between the second outermost layer and the first outermost layer, said method comprising the steps of:

A. electrically connecting the photovoltaic cells to each other,

B. disposing the photovoltaic cells on the first outermost layer;

C. disposing the liquid silicone composition on and in direct contact with the photovoltaic cells;

D. compressing the first outermost layer, the photovoltaic cells, and the liquid silicone composition to at least partially cure the liquid silicone composition and form the second outermost layer and the array,

wherein the liquid silicone composition comprises a linear organosilicon compound having two terminal unsaturated moieties per molecule and present in an amount of from 80 to 95 parts by weight, a branched organosilicon compound having two terminal unsaturated moieties per molecule and at least one pendant unsaturated moiety per molecule and present in an amount of from 5 to 20 as parts by weight, per 100 parts by weight of a sum of said linear organosilicon compound and said branched organosilicon compound, and an organohydrogensilicon compound having at least three silicon-bonded hydrogen atoms per molecule wherein a ratio of silicon-bonded hydrogen atoms per molecule of said organohydrogensilicon compound to a sum of unsaturated moieties per molecule of said linear organosilicon compound and branched organosilicon compound is from 1 to 1.7,

wherein the photovoltaic array is free of any layers that include polymers other than silicone polymers,

wherein the first outermost layer is positioned on the top of the array and the array is free of any additional layers disposed on the top of the array, and

wherein the second outermost layer is positioned on the bottom of the array and the array is free of any additional layers disposed on the bottom of the array.

15. The method of claim 14 wherein the second outermost layer further comprises a non-woven textile mat at least partially coated with the liquid silicone composition and wherein said method further comprises at least partially coating the mat with the liquid silicone composition to form the second outermost layer, wherein the mat is at least partially coated after or simultaneously with the step of disposing the liquid silicone composition on the photovoltaic cells.

16. The method as set forth in claim 15 wherein the step of disposing the photovoltaic cells on the first outermost layer is further defined as disposing the photovoltaic cells directly on the first outermost layer via chemical vapor deposition or physical sputtering.

18. A photovoltaic array comprising:

a first outermost layer that is a single layer having a light transmittance of at least 70 percent as determined by UV/Vis spectrophotometry using ASTM E424-71 and that is silicone;

two or more photovoltaic cells electrically connected to each other, each disposed on said first outermost layer;

a first tie layer disposed on said photovoltaic cells and sandwiched between said photovoltaic cells and said first outermost layer such that said first tie layer is disposed on and in direct contact with both said photovoltaic cells and said first outermost layer,

a second outermost layer that is a single layer disposed opposite said first outermost layer, said second outermost layer comprising a (I) silicone composition and disposed on said photovoltaic cells sandwiching said photovoltaic cells between said second outermost layer and said first outermost layer,

a second tie layer disposed on said photovoltaic cells and sandwiched between said photovoltaic cells and said second outermost layer such that said second tie layer is disposed on and in direct contact with both said photovoltaic cells and said second outermost layer,

wherein said (I) silicone composition comprises a linear organosilicon compound having two terminal unsaturated moieties per molecule and present in an amount of from 80 to 95 parts by weight, a branched organosilicon compound having two terminal unsaturated moieties per molecule and at least one pendant unsaturated moiety per molecule and present in an amount of from 5 to 20 as parts by weight, per 100 parts by weight of a sum of said linear organosilicon compound and said branched organosilicon compound, and an organohydrogensilicon compound having at least three silicon-bonded hydrogen atoms per molecule wherein a ratio of silicon-bonded hydrogen atoms per molecule of said organohydrogensilicon compound to a sum of unsaturated moieties per molecule of said linear organosilicon compound and branched organosilicon compound is from 1 to 1.7,

wherein said first outermost layer is positioned on the top of said array and said array is free of any additional layers disposed on the top of said array,

wherein said second outermost layer is positioned on the bottom of said array and said array is free of any additional layers disposed on the bottom of said array,

wherein said first tie layer comprises a second silicone composition which is the same or different as said (I) silicone composition, and

wherein said second tie layer comprises an additional silicone composition which is the same or different as said (I) silicone composition and/or said second silicone composition.