Flexible laminates for solar modules

Patent metadata

Field	Value
Publication number	US-10355152-B2
Application number	US-201514976256-A
Country	US
Kind code	B2
Filing date	Dec 21, 2015
Priority date	Dec 21, 2015
Publication date	Jul 16, 2019
Grant date	Jul 16, 2019

Abstract

A solar module includes a laminate structure having at least two solar cells. Each of the solar cells has an individual reinforcement laminated to one face of each of the solar cells. The solar cells are spaced apart from each other and the individual reinforcements are spaced apart from each other such that a gap is defined between each of the solar cells. The solar module includes flexible conductors that extend through the gap between the solar cells and electrically connect the solar cells to each other.

First claim

What is claimed is:

1. A solar module comprising:
a laminate structure including:
an active layer having at least two solar cells, each of the solar cells having a first face and a second face and including a separate reinforcement laminated to the first face; and
a cover layer attached to at least one of (i) an outer face of each of the reinforcements and (ii) a second face of each of the solar cells; and

a module interconnection interface for electrically connecting the solar module to another solar module, the module interconnection interface comprising at least two terminal interconnections, wherein
the solar cells are spaced apart from each other and the reinforcements are spaced apart from each other such that a gap is defined between each of the solar cells, and
the solar cells are electrically connected to each other by flexible wiring conductors that extend through the gap.

2. The solar module according to claim 1 , wherein the separate reinforcements are each made of a hard plastic material.

3. The solar module according to claim 1 , wherein the separate reinforcements are each made of glass.

4. The solar module according to claim 1 , wherein the first face of the solar cells comprises a back face of the solar cells.

5. The solar module according to claim 1 , wherein the flexible conductors comprise ribbon-type conductors or multi-wire conductors.

6. The solar module according to claim 1 , wherein the solar module is a frameless module.

7. A solar module comprising:
a laminate structure including:
an active layer having at least two solar cells, each of the solar cells having a first face and a second face and including a separate reinforcement laminated to the first face; and
a cover layer attached to at least one of (i) an outer face of each of the reinforcements and (ii) a second face of each of the solar cells, wherein

the solar cells are spaced apart from each other and the reinforcements are spaced apart from each other such that a gap is defined between each of the solar cells, and
the solar cells are electrically connected to each other by flexible wiring conductors that extend through the gap;
a mounting system for mounting the solar module to a mounting surface, wherein
the mounting system includes one or more stand offs that are configured to be placed between the solar module and the mounting surface, and
the laminate structure includes one or more anchor points at which the laminate structure is supported on the one or more stand offs.

8. A solar module comprising:
a laminate structure including:
an active layer having at least two solar cells, each of the solar cells having a first face and a second face and including a separate reinforcement laminated to the first face; and
a cover layer attached to at least one of (i) an outer face of each of the reinforcements and (ii) a second face of each of the solar cells, wherein

the solar cells are spaced apart from each other and the reinforcements are spaced apart from each other such that a gap is defined between each of the solar cells,
the solar cells are electrically connected to each other by flexible wiring conductors that extend through the gap,
the laminate structure includes a peripheral region, the peripheral region including one or more anchor points, and
the anchor points of the peripheral region are secured to a mounting surface using at least one of nails, screws, staples, and adhesive.

9. The solar module according to claim 1 , wherein the cover layer is formed of glass or plastic, and
wherein the cover layer includes a peripheral region located outside of the solar cells,
wherein the peripheral region defines one or more openings for receiving fasteners for securing the solar module to a mounting surface, and
wherein the one or more openings are defined by grommets integrated into the cover layer in the peripheral region.

10. The solar module according to claim 1 , further comprising at least one electronic device, the at least one electronic device comprising at least one of a DC/AC micro inverter, a DC/DC converter, and a DC/DC optimizer,
wherein the at least one electronic device is incorporated into the laminate structure.

11. The solar module according to claim 1 , further comprising at least one electronic device, the at least one electronic device comprising at least one of a DC/AC micro inverter, a DC/DC converter, and a DC/DC optimizer,
wherein the at least one electronic device is secured to an outer face of the cover layer by an adhesive.

12. The solar module of claim 1 , wherein the gap includes a filler material that limits flexing of the flexible conductors in the gap.

Assignees

• Sunpower Corp

Inventors

• Stoddard Nathan
• Dulani Mukesh

Classifications

• H02S20/00

  Supporting structures for PV modules · CPC title

• H02S20/23

  specially adapted for roof structures · CPC title

• H02S30/00

  Structural details of PV modules other than those related to light conversion (semiconductor device aspects of modules of electrolytic light sensitive devices H01G9/20, of inorganic PV modules H10F10/00, H10F19/00, of organic PV modules H10K30/00) · CPC title

• H02S40/36

  characterised by special electrical interconnection means between two or more PV modules, e.g. electrical module-to-module connection · CPC title

• H02S40/32

  comprising DC/AC inverter means associated with the PV module itself, e.g. AC modules · CPC title