Photovoltaic Cell Module And Method Of Forming

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.

1 . A photovoltaic cell module comprising:
 A. a first outermost layer having a light transmittance of at least 70 percent as determined by UV/Vis spectrophotometry using ASTM E424-71;   B. a photovoltaic cell disposed on said first outermost layer; and   C. a second outermost layer opposite said first outermost layer, said second outermost layer comprising a plurality of fibers at least partially coated with a silicone composition and disposed on said photovoltaic cell sandwiching said photovoltaic cell between said second outermost layer and said first outermost layer,   wherein said silicone composition is further defined as hydrosilylation-curable and comprises:
 (i) an organosilicon compound having at least one unsaturated moiety per molecule, 
 (ii) an organohydrogensilicon compound having at least one silicon-bonded hydrogen atom per molecule, and 
 (iii) a hydrosilylation catalyst used to accelerate a hydrosilylation reaction between (i) said organosilicon compound and (ii) said organohydrogensilicon compound, 
 wherein a ratio of silicon-bonded hydrogen atoms per molecule of (ii) said organohydrogensilicon compound to unsaturated moieties per molecule of (i) said organosilicon compound is from 0.05 to 100. 
   
     
     
         2 . A photovoltaic cell module as set forth in  claim 1  wherein said plurality of fibers is further defined as a non-woven textile. 
     
     
         3 . A photovoltaic cell module as set forth in  claim 2  wherein said non-woven textile is selected from the group of fiberglass, polyester, polyethylene, polypropylene, nylon, and combinations thereof. 
     
     
         4 . A photovoltaic cell module as set forth in  claim 1  further comprising a tie layer disposed on said photovoltaic cell and sandwiched between said photovoltaic cell and said first outermost layer. 
     
     
         5 . A photovoltaic cell module as set forth in  claim 4  wherein said tie layer comprises a second silicone composition which is the same or different as said silicone composition. 
     
     
         6 . A photovoltaic cell as set forth in  claim 1  wherein said first outermost layer comprises silicone. 
     
     
         7 . (canceled) 
     
     
         8 . A photovoltaic cell module as set forth in  claim 1  wherein said silicone composition is at least partially cured. 
     
     
         9 . A photovoltaic cell module as set forth in  claim 1  wherein said silicone composition comprises a filler. 
     
     
         10 . A photovoltaic cell module as set forth in  claim 1  wherein said second outermost layer has a thickness of from 4 to 40 mils. 
     
     
         11 . A photovoltaic cell module as set forth in  claim 1  that is free of polyethylene terephthalate, polyethylene naphthalate, polyvinyl fluoride, and ethylene vinyl acetate. 
     
     
         12 . A method of forming a photovoltaic cell module comprising a first outermost layer having a light transmittance of at least 70 percent as determined by UV/Vis spectrophotometry using ASTM E424-71, a photovoltaic cell disposed on the first outermost layer, and a second layer disposed on the photovoltaic cell sandwiching the photovoltaic cell between the second layer and the first outermost layer and comprising a plurality of fibers at least partially coated with a liquid silicone composition having a viscosity of less than about 100,000 cps at 25° C., said method comprising the steps of:
 A. disposing the photovoltaic cell on the first outermost layer; 
 B. disposing the liquid silicone composition on the photovoltaic cell; and 
 C. at least partially coating the plurality of fibers with the liquid silicone composition to form the second layer; and 
 D. compressing the first outermost layer, the photovoltaic cell, and the second layer to form the photovoltaic cell module, 
 wherein the plurality of fibers extends laterally across the second layer to a periphery of the photovoltaic cell module on both ends of the module to resist leakage of the liquid silicone composition from the photovoltaic cell module during the step of compressing. 
 
     
     
         13 . A method as set forth in  claim 12  wherein the plurality of fibers is at least partially coated prior to the step of disposing the liquid silicone composition on the photovoltaic cell. 
     
     
         14 . A method as set forth in  claim 12  wherein the plurality of fibers is at least partially coated after the step of disposing the liquid silicone composition on the photovoltaic cell. 
     
     
         15 . A method as set forth in  claim 12  wherein the plurality of fibers is at least partially coated simultaneously with the step of disposing the liquid silicone composition on the photovoltaic cell. 
     
     
         16 . A method as set forth in  claim 12  wherein the step of disposing the photovoltaic cell on the first outermost layer is further defined as disposing the photovoltaic cell directly on the first outermost layer via chemical vapor deposition or physical sputtering. 
     
     
         17 . A method as set forth in  claim 12  wherein the second layer is further defined as a controlled bead disposed on the photovoltaic cell. 
     
     
         18 . A method as set forth in  claim 12  wherein the photovoltaic cell module further comprises a second outermost layer disposed on the second layer opposite the first outermost layer for supporting the photovoltaic cell module. 
     
     
         19 . A method as set forth in  claim 12  wherein the liquid silicone composition is further defined as hydrosilylation-curable and comprises:
 (i) an organosilicon compound having at least one unsaturated moiety per molecule, 
 (ii) an organohydrogensilicon compound having at least one silicon-bonded hydrogen atom per molecule, and 
 (iii) a hydrosilylation catalyst used to accelerate a hydrosilylation reaction between (i) the organosilicon compound and (ii) the organohydrogensilicon compound, 
 wherein a ratio of silicon-bonded hydrogen atoms per molecule of (ii) the organohydrogensilicon compound to unsaturated moieties per molecule of (i) the organosilicon compound is from 0.05 to 100. 
 
     
     
         20 . A photovoltaic cell module as set forth in  claim 1 :
 wherein said silicone composition is further defined as comprising 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.   
     
     
         21 . (canceled) 
     
     
         22 . (canceled) 
     
     
         23 . (canceled) 
     
     
         24 . (canceled) 
     
     
         25 . (canceled) 
     
     
         26 . (canceled) 
     
     
         27 . (canceled) 
     
     
         28 . A photovoltaic cell module as set forth in  claim 20  wherein said linear organosilicon compound is further defined as a vinyl end-blocked polydialkylsiloxane, said branched organosilicon compound is further defined as a vinyl end-blocked polydialkylsiloxane having at least one vinyl pendant group, and said organohydrogensilicon compound is further defined as a dimethyl, methylhydrogen siloxane that is trimethylsiloxy terminated. 
     
     
         29 . (canceled) 
     
     
         30 . (canceled) 
     
     
         31 . (canceled) 
     
     
         32 . (canceled) 
     
     
         33 . (canceled) 
     
     
         34 . (canceled) 
     
     
         35 . (canceled) 
     
     
         36 . (canceled)