Abstract: A foldable, portable, lightweight photovoltaic module has a carrier layer divided into equal sections separated by hinge spaces, a substrate layer on the carrier layer, and a photovoltaic cell layer on the substrate layer, wherein the hinge spaces each have a free space between opposing edges of the adjacent sections to enable them to be folded in accordion-like fashion for storage. The carrier layer may be made of rip-stop fabric and preferably supports 6 sections each with 6 PV cells of crystalline silicon of up to about 22% conversion efficiency. The module has a power output of about 122 watts at 24 volts, and weighs about 7.4 pounds (3.36 kg), with a power-to-size ratio of 14 watts/sft or more, and a power-to-weight ratio of 16.5 watts/pound or more. An improved method of lamination applies heat and pressure on upper and lower sides of the laminate layers through upper and lower chambers with respective pressure bladders and heaters that are independently controllable.

Abstract: A foldable, portable, lightweight photovoltaic module has a carrier layer divided into equal sections separated by hinge spaces, a substrate layer on the carrier layer, and a photovoltaic cell layer on the substrate layer, wherein the hinge spaces each have a free space between opposing edges of the adjacent sections to enable them to be folded in accordion-like fashion for storage. The carrier layer may be made of rip-stop fabric and preferably supports 6 sections each with 6 PV cells of crystalline silicon of up to about 22% conversion efficiency. The module has a power output of about 122 watts at 24 volts, and weighs about 7.4 pounds (3.36 kg), with a power-to-size ratio of 14 watts/sft or more, and a power-to-weight ratio of 16.5 watts/pound or more. An improved method of lamination applies heat and pressure on upper and lower sides of the laminate layers through upper and lower chambers with respective pressure bladders and heaters that are independently controllable.

Abstract: A foldable, portable, lightweight photovoltaic module has a carrier layer divided into equal sections separated by hinge spaces, a substrate layer on the carrier layer, and a photovoltaic cell layer on the substrate layer, wherein the hinge spaces each have a free space between opposing edges of the adjacent sections to enable them to be folded in accordion-like fashion for storage. The carrier layer may be made of rip-stop fabric and preferably supports 6 sections each with 6 PV cells of crystalline silicon of up to about 22% conversion efficiency. The module has a power output of about 122 watts at 24 volts, and weighs about 7.4 pounds (3.36 kg), with a power-to-size ratio of 14 watts/sft or more, and a power-to-weight ratio of 16.5 watts/pound or more. An improved method of lamination applies heat and pressure on upper and lower sides of the laminate layers through upper and lower chambers with respective pressure bladders and heaters that are independently controllable.

Abstract: The present invention relates to a photovoltaic system and methods of making same. The photovoltaic system has a plurality of layers attached to each other to form a unitary structure. More specifically, the photovoltaic system includes: a base, flexible membrane layer; a photovoltaic layer having at least one photovoltaic cell associated therewith; a semi-rigid layer for supporting the photovoltaic layer and imparting rigidity thereto; and a top, transparent, protective layer for protecting the base, flexible membrane layer, the semi-rigid layer and the photovoltaic layer from exposure to the environment. The photovoltaic layer and the semi-rigid layer are disposed between the base, flexible membrane layer and the top, protective layer. Additional layers of adhesive may be disposed between the various layers to facilitate bonding thereof.