Foldable, portable, lightweight photovoltaic module

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.

1 - 18 . (canceled) 
     
     
         19 . An improved method for laminating a photovoltaic module comprising:
 providing a laminate workpiece comprising a carrier layer, a substrate layer, and a photovoltaic cell layer, and providing adhesive layers of thermally fusable, transparent film material between the carrier layer and the substrate layer, and between the substrate layer and the photovoltaic cell layer; and   applying heat and pressure on the workpiece from upper and lower sides of the laminate layers through upper and lower chambers that have respective upper and lower pressure bladder layers and upper and lower heaters that are independently controllable.   
     
     
         20 . An improved method for laminating a photovoltaic module according to  claim 19 , wherein heat and pressure are independently controlled from upper and lower sides of the laminate layers in a four-part cycle in sequence wherein:
 (a) In a first cycle, air is evacuated from the upper and lower chambers to remove trapped air from between and among the layers;   (b) In a second cycle, atmospheric pressure is restored to the upper bladder so that the upper chamber applies downward pressure to mate the photovoltaic cell layer completely with the substrate layer, and the substrate layer with the carrier layer, even as heat is applied evenly from both upper and lower sides;   (c) In a third cycle, both upper and lower heaters are turned off and a temperature is maintained for curing the adhesive layers without excessive heating; and   (d) In a fourth cycle, the temperature of the upper and lower heaters is allowed to cool down below the temperature at which the adhesive layers become set, then the lower bladder is allowed to return to atmospheric pressure.   
     
     
         21 . A foldable, portable, lightweight photovoltaic module made by the improved method of laminating of  claim 19 . 
     
     
         22 . A foldable, portable, lightweight photovoltaic module according to  claim 21 , comprising:
 a carrier layer made of durable, flexible and foldable material having a given width and an extended length that is divided into a plurality of equal sections of equal section length which are separated by hinge spaces extending width-wise between adjacent sections;   a plurality of section-substrates made of a lightweight, semi-rigid material, each lying in a substrate layer and being adhered by a first adhesive film layer made of a material that is thermally fused and cross-linked to a facing surface of said carrier layer and dimensioned to fit within the given width and section-length for each section;   a plurality of photovoltaic section-modules, each lying in a photovoltaic cell layer and being adhered by a second adhesive film layer made of a material that is thermally fused and cross-linked to a facing surface of a respective one of said section substrates, and each being comprised of a plurality of photovoltaic cells dimensioned and arranged to fit within the given width and section-length for each section; and   said hinge spaces between adjacent sections each having a free space of a predetermined hinge width between opposing edges of section-substrates laminated to photovoltaic section-modules of the adjacent sections, and   a third adhesive film layer of thermally fusable material on the photovoltaic cell layer,   wherein the hinge spaces have only the carrier layer and the first, second and third adhesive film layers where the substrate layer and photovoltaic cell layer are omitted between section-modules,   wherein said photovoltaic section-modules of adjacent sections are electrically connected in series by flexible wire leads extending loosely across the hinge width of the free space for each pair of adjacent sections and being encapsulated between said third adhesive film layer and said second adhesive film layer with said first adhesive film layer which are adhered to an exposed surface of said carrier layer in the free spaces between section-modules,   whereby said carrier layer with said sections laminated with said photovoltaic cells can be repeatedly folded together in accordion-like fashion for storage and unfolded to the extended length of said carrier layer for deployment without breakage of the flexible wire leads.   
     
     
         23 . A foldable, portable, lightweight photovoltaic module according to  claim 21 , wherein said substrate boards of the sections are made of a lightweight semi-rigid material selected from the group consisting of: standard printed circuit board (PCB); glass fiber board; woven glass and epoxy; woven glass and polyester; graphite fiber composite; and basalt fiber composite. 
     
     
         24 . A foldable, portable, lightweight photovoltaic module according to  claim 21 , wherein the resulting module can produce a power output in the range of about 122 watts or more at a voltage (open circuit) output of up to 24 volts. 
     
     
         25 . A foldable, portable, lightweight photovoltaic module according to  claim 21 , wherein the total power output from deployment of the module is multiplied by combining two or more modules together. 
     
     
         26 . A foldable, portable, lightweight photovoltaic module according to  claim 21 , further comprising a top cover layer having properties of high efficiency of light transmission and reduction of reflection and glare.