Photovoltaic module including high contact angle coating on one or more outer surfaces thereof, and/or methods of making the same

Abstract

Certain example embodiments of this invention relate to photovoltaic modules that include high contact angle coatings on one or more outermost major surfaces thereof, and/or associated methods. In certain example embodiments, the high contact angle coatings advantageously reduce the likelihood of electrical losses through parasitic leakage of the electrical current caused by moisture on surfaces of the photovoltaic modules, thereby potentially improving the efficiency of the photovoltaic devices. In certain example embodiments, the high contact angle coatings may be nitrides and/or oxides of or including Si, Ti, Ta, TaCr, NiCr, and/or Cr; hydrophobic DLC; and/or polymer-based coatings. The photovoltaic modules may be substrate-type modules or superstrate-type modules in different example embodiments.

1 - 10 . (canceled) 
     
     
         11 . A method of making a photovoltaic module, the method comprising:
 providing a first substrate with a hydrophobic coating disposed thereon;   providing a second substrate, either the first substrate or the second substrate supporting a plurality of photovoltaic device layers, the photovoltaic device layers comprising a semiconductor layer sandwiched between first and second electrode layers;   connecting the first and second substrates together in substantially parallel spaced apart orientation to one another such that the hydrophobic coating is on an exterior surface of the first substrate, and such that the photovoltaic device layers are located between the first and second substrates;   wherein the hydrophobic coating has an initial contact angle of at least 30 degrees.   
     
     
         12 . The method of  claim 11 , wherein the hydrophobic coating includes is a sputter deposited layer comprising a nitride and/or oxide of or including Si, Ti, Ta, TaCr, NiCr, and/or Cr 
     
     
         13 . The method of  claim 12 , wherein the hydrophobic coating includes a layer comprising non-conducting TaNx or TaOxNy. 
     
     
         14 . The method of  claim 12 , wherein the hydrophobic coating includes a layer comprising diamond-like carbon (DLC). 
     
     
         15 . The method of  claim 14 , removing a protective coating at least initially provided over the DLC in the making of the photovoltaic module, or allowing a protective coating to be removed during subsequent high temperature processes used in the making of the photovoltaic module. 
     
     
         16 . The method of  claim 11 , wherein the hydrophobic coating is disposed on an exterior surface of the back substrate and is opaque. 
     
     
         17 . The method of  claim 11 , wherein the hydrophobic coating is disposed on an exterior surface of the front substrate and is transparent. 
     
     
         18 . The module of  claim 17 , further comprising a multilayer antirefleetive (AR) coating comprising, in order moving away from the exterior surface of the front substrate, at least a high index and a low index layer, the hydrophobic coating being located within the multilayer AR coating at a position that corresponds to a refractive index thereof. 
     
     
         19 . The method of  claim 11 , wherein the hydrophobic coating has an initial contact angle of at least 50 degrees. 
     
     
         20 . The method of  claim 11 , wherein the hydrophobic coating has an initial contact angle of at least 70 degrees. 
     
     
         21 . A coated article including a glass substrate, wherein:
 the glass substrate supports a hydrophobic coating having an initial contact angle of at least 70 degrees on a first major surface thereof; and   a second major surface of the substrate, opposite the first major surface, is adapted to support or be in direct or indirect contact with a plurality of thin film layers to be used as at least a part of a solar cell.   
     
     
         22 . The coated article of  claim 21 , comprising means for reducing creep current between first and second electrode layers in order to improve efficiency of the solar cell, the means for reducing creep current including the hydrophobic coating.