Low thermal distortion silicone composite molds

Abstract

Photovoltaic modules, and methods for fabricating said photovoltaic modules, are provided and include a photovoltaic cell operable to convert photons to electrons having a light transparent superstrate material with a superstrate absorption coefficient and a superstrate refractive index, and an encapsulant having an encapsulant absorption coefficient and an encapsulant refractive index, wherein an absorption coefficient relationship between the superstrate absorption coefficient and the encapsulant absorption coefficient and a refractive index relationship between the superstrate refractive index and the encapsulant refractive index are selected such that there is a gain in efficiency.

What is claimed is: 
     
         1 . A photovoltaic module with controlled refractive index mismatch comprising:
 a photovoltaic cell operable to convert photons to electrons;   a light transparent superstrate material; and   a silicone encapsulant, such that the encapsulant surrounds the photovoltaic cell and separates the superstrate from the photovoltaic cell, wherein—the silicone encapsulant has a refractive index greater than the refractive index of the superstrate.   
     
     
         2 . The photovoltaic module of  claim 1  wherein the silicone encapsulant comprises a silicone homopolymer or copolymer selected from the group consisting of polydimethylsiloxane, polydiphenylsiloxane, polymethylphenylsiloxane, and mixtures thereof. 
     
     
         3 . The photovoltaic module of  claim 1  wherein the silicone encapsulant comprises nanoparticles having a refractive index greater than the encapsulant. 
     
     
         4 . The photovoltaic module of  claim 1  wherein the photovoltaic cell comprises a mono-crystalline silicon cell. 
     
     
         5 . The photovoltaic module of  claim 4  wherein the photovoltaic cell further comprises a screen-printed cell. 
     
     
         6 . The photovoltaic module of  claim 4  wherein the photovoltaic cell further comprises a rear-contact cell. 
     
     
         7 . A photovoltaic module with controlled refractive index mismatch comprising:
 a photovoltaic cell operable to convert photons to electrons;   a light transparent superstrate material; and   a silicone encapsulant, such that the encapsulant surrounds the photovoltaic cell and separates the superstrate from the photovoltaic cell, wherein the encapsulant has a refractive index greater than the refractive index of the superstrate and an absorption coefficient selected such that the reduction in optical loss of the module achieved through an increase in internal reflection as dictated by escape cone losses, is more than the optical loss associated with reflections at the encapsulant superstrate interface.   
     
     
         8 . The photovoltaic module of  claim 7  wherein the silicone encapsulant comprises a silicone homopolymer or copolymer selected from the group consisting of polydimethylsiloxane, polydiphenylsiloxane, polymethylphenylsiloxane, and mixtures thereof. 
     
     
         9 . The photovoltaic module of  claim 7  wherein the silicone encapsulant comprises nanoparticles having a refractive index greater than the encapsulant. 
     
     
         10 . The photovoltaic module of  claim 7  wherein the photovoltaic cell comprises a mono-crystalline silicon cell. 
     
     
         11 . The photovoltaic module of  claim 10  wherein the photovoltaic cell further comprises a screen-printed cell. 
     
     
         12 . The photovoltaic module of  claim 10  wherein the photovoltaic cell further comprises a rear-contact cell.