Frame-less encapsulated photo-voltaic solar panel supporting solar cell modules encapsulated within multiple layers of optically-transparent epoxy-resin materials
First Claim
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.
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Accused Products
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.
503 Citations
6 Claims
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1. A frame-less epoxy-resin encapsulated solar panel construction comprising:
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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. - View Dependent Claims (2, 3, 4, 5, 6)
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Specification