Abstract: Provided are photovoltaic module assemblies configured for improved installation. The assemblies include frameless photovoltaic modules and retainers for supporting the modules on mounting structures. The retainers support the modules at least during cure of adhesive materials provided between the modules and the mounting structures. Once cured, the adhesive materials provide permanent support to the modules. The retainers may interlock with the mounting structures during installation or be integral components of the structures. In certain embodiments, retainers are used to control a gap between the modules and mounting structures. Retainers may be removable and collected after installation is completed. Alternatively, retainers may remain as parts of assemblies at least during some initial period. Retainers may be made from various degradable materials, such as biodegradable plastics, UV degradable plastics, and/or water soluble materials.

Abstract: A photovoltaic device includes at least one photovoltaic cell, a flexible glass layer formed over the at least one photovoltaic cell and a transparent and abrasion resistant film which includes an organic-inorganic hybrid material formed over the glass layer.

Abstract: A photovoltaic device includes at least one photovoltaic cell, a flexible glass layer formed over the at least one photovoltaic cell, and a transparent planarizing hardcoat formed on the glass layer. The planarizing hardcoat may be in compressive stress and the glass layer may be in tension.

Abstract: Provided are multi-module inverters and/or converters for connecting to a set of building integrable photovoltaic (BIPV) modules that are interconnected in series and arranged into photovoltaic arrays on building structures. Outputs from multiple multi-module inverters and/or converters in one array may be combined using parallel connections and then connected to an electrical grid, standalone electrical network, or central inverter. Each set is connected to a different multi-module inverter and/or converter and may have a variable number of BIPV modules. A multi-module inverter and/or converter may be positioned within or integrated into one of the BIPV modules or attached to a building structure supporting the array. In certain embodiments, a multi-module inverter and/or converter is installed in a ventilation channel on the back side of a module. A multi-module inverter and/or converter may be also integrated into an electrical routing structure connected to one of the BIPV modules.

Abstract: Multilayer articles such as thin-film solar cells can be effectively tested under thermal load in a mini-module that includes a chamber or enclosure in which one or more laminated multilayer articles are housed. The inner dimensions of the chamber, at least along the axis that is perpendicular to the plane defined by the laminated solar cells, are configured to remain substantially constant during testing. Cooling the laminated solar cells in the mini-module device causes the encapsulant material to shrink and thereby induces accelerated failures in the laminated solar cells and associated structures. A technique of detecting the presence of defects or failures is near infrared radiation thermography wherein NIR images of the laminated solar cells are taken during the cooling process. The color patterns manifested from the cooled laminated solar cells can reveal the location, nature and extent of the defect or failure.

Abstract: Provided are novel methods of fabricating photovoltaic modules using thermoplastic materials to support wire networks to surfaces of photovoltaic cells. A thermoplastic material goes through a molten state during module fabrication to distribute the material near the wire-cell surface interface. In certain embodiments, a thermoplastic material is provided as a melt and coated over a cell surface, with a wire network positioned over this surface. In other embodiments, a thermoplastic material is provided as a part of an interconnect assembly together with a wire network and is melted during one of the later operations. In certain embodiments, a thermoplastic material is provided as a shell over individual wires of the wire network. A thermoplastic material is then solidified, at which point it may be relied on to support the interconnect assembly with respect to the cell. Also provided are novel photovoltaic module structures that include thermoplastic materials used for support.

Abstract: Provided are photovoltaic module assemblies configured for improved installation. The assemblies include frameless photovoltaic modules and retainers for supporting the modules on mounting structures. The retainers support the modules at least during cure of adhesive materials provided between the modules and the mounting structures. Once cured, the adhesive materials provide permanent support to the modules. The retainers may interlock with the mounting structures during installation or be integral components of the structures. In certain embodiments, retainers are used to control a gap between the modules and mounting structures. Retainers may be removable and collected after installation is completed. Alternatively, retainers may remain as parts of assemblies at least during some initial period. Retainers may be made from various degradable materials, such as biodegradable plastics, UV degradable plastics, and/or water soluble materials.

Abstract: Provided are novel photovoltaic module structures and related fabrication techniques. According to various embodiments, the structures include a structural bond related between two sealing sheets of the photovoltaic module configured to support one sealing sheet with respect to the other and, in certain embodiments, to support photovoltaic cells with respect to both sealing sheets. In certain embodiments, a photovoltaic module is fabricated without a back encapsulant layer, and the back sealing sheet is supported by the structural bond. The structural bond may also be used as a moisture barrier in addition or instead of an edge seal. The structural bond material can include a silicone-based polymer, which provides good adhesive and UV resistance properties. The structural bond may be formed by a structural bonding material that is dispensed around the photovoltaic cells.

Abstract: Disclosed are wire assemblies for solar cells. One wire assembly includes a first polymer film and a second polymer film overlaying the first polymer film. The second polymer film has a wire embedded in it such that a surface of the wire that is facing away from the first polymer film is exposed. The gauge of the wire is about 36 to 46 gauge. The thickness of the second polymer film is about ¼ to ½ the diameter of the wire and about 0.5 to 1.5 mils.

Abstract: A photovoltaic device includes at least one photovoltaic cell and a flexible glass layer formed over the at least one photovoltaic cell. The flexible glass layer having a first major surface facing the at least one photovoltaic cell and a second major surface facing away from the at least one photovoltaic cell. A first encapsulant layer is formed over the first major surface of the flexible glass layer, the first encapsulant layer having a modulus of less than 100 MPa at room temperature. A second encapsulant layer is formed over the second major surface of the flexible glass layer, the second encapsulant layer includes a composite material including a polymer matrix containing a filler material.

Abstract: A photovoltaic device, including at least one photovoltaic cell, a flexible transparent layer formed over the at least one photovoltaic cell, a first encapsulant layer formed over a first major surface of the flexible transparent layer facing the at least one photovoltaic cell and a second encapsulant layer formed over a second major surface of the flexible transparent layer facing away from the at least one photovoltaic cell. The second encapsulant layer is made of a shear thickening polymer.

Abstract: A photovoltaic device includes at least one photovoltaic cell, a flexible glass layer formed over the at least one photovoltaic cell, and a transparent planarizing hardcoat formed on the glass layer. The planarizing hardcoat may be in compressive stress and the glass layer may be in tension.

Abstract: A photovoltaic device includes at least one photovoltaic cell, a flexible glass layer formed over the at least one photovoltaic cell and a transparent and abrasion resistant film which includes an organic-inorganic hybrid material formed over the glass layer.

Abstract: Provided are novel solar modules including electrically isolated moisture barriers. According to various embodiments, the solar modules include two distinct seals: one to electrically isolate the moisture barrier and one to protect photovoltaic cells of the module. Also provided are novel back sheets for solar module encapsulation, and novel solar modules including such back sheets. According to various embodiments, the back sheets are ungrounded and flexible. In certain embodiments, the back sheets include an integrated flexible and electrically isolated moisture barrier. The electrically isolated moisture barrier may be a thin metallic sheet, e.g., an aluminum foil. The electrically isolated, flexible moisture barrier eliminates the need for grounding.

Abstract: A solar-cell module. The solar-cell module includes a plurality of solar cells that are electrically coupled together. The solar-cell module further includes an in-laminate-diode assembly electrically coupled with the plurality of solar cells. The in-laminate-diode assembly is configured to prevent power loss. The solar-cell module also includes a protective structure at least partially encapsulating the plurality of solar cells. In addition, the solar-cell module includes a plurality of external-connection mechanisms mounted to a respective plurality of edge regions of the protective structure. An external-connection mechanism of the plurality of external-connection mechanisms is configured to enable collection of current from the plurality of solar cells and to allow interconnection with at least one other external device.

Abstract: A frameless photovoltaic module retains the required load rating by incorporation of an oriented fibrous reinforcement (e.g., fibers, scrim or mesh) in the back side encapsulant, in the back sheet, or as a separate sheet between the encapsulant and the back sheet to increase the overall stiffness of the module. The reinforcement is compatible with the materials around it, in particular having good wet out, and may be freestanding or anchored to outer edges of the module, for example to the front glass, by means of an adhesive in order to further enhance the stiffness conferred to the module.

Abstract: Provided are novel back sheets for solar module encapsulation. According to various embodiments, the back sheets are ungrounded and flexible. In certain embodiments, the back sheets include an integrated flexible and electrically isolated moisture barrier. The electrically isolated moisture barrier may be a thin metallic sheet, e.g., an aluminum foil. The electrically isolated, flexible moisture barrier eliminates the need for grounding.

Abstract: A photovoltaic module having a light transmissive front layer, a back layer, and a plurality of interconnected photovoltaic cells disposed between the light transmissive front layer and the back layer has a CTE-modified composite encapsulant is interposed between the plurality of solar cells and the light transmissive front layer. The composite encapsulant includes a bulk encapsulant transmissive to visible and near visible wavelengths of the solar spectrum and having a base coefficient of thermal (CTE) expansion, and an encapsulant CTE modifier in the bulk encapsulant. The encapsulant CTE modifier is substantially evenly distributed through the composite encapsulant thickness and interacts with the bulk encapsulant to reduce the effective CTE of the composite encapsulant below that of the bulk encapsulant.

Abstract: Provided are novel photovoltaic module structures and fabrication techniques that include a composite encapsulant disposed and substantially filling voids between at least one sealing sheet and one or more photovoltaic cells. The composite encapsulant contains a bulk encapsulant and filler uniformly distributed throughout the bulk encapsulant. In certain embodiments, at least about 30% by weight of the composite encapsulant is the filler. Adding certain fillers into polymer-based bulk encapsulants in such large amounts reduces encapsulation costs and improves certain performance characteristics of the resulting composite encapsulants. In certain embodiments, the composite encapsulants have better temperature stability, UV stability, mechanical integrity, and/or adhesion than traditional encapsulants. Also, in certain embodiments, the added fillers do not substantially alter the optical properties of initial bulk encapsulants.

Abstract: Provided are novel back sheets for solar module encapsulation. According to various embodiments, the back sheets are ungrounded and flexible. In certain embodiments, the back sheets include an integrated flexible and electrically isolated moisture barrier and a seal around the edge of the moisture barrier. The electrically isolated moisture barrier may be a thin metallic sheet, e.g., an aluminum foil. The electrically isolated, flexible moisture barrier eliminates the need for grounding.