Process for encapsulating a solar cell in a polymer matrix

Abstract

The present invention relates to a process for encapsulating one or more solar cell(s) in a polymer matrix, said process comprising: (a) applying a matrix composition comprising at least one polymerizable compound to the surface of a first solid carrier material, the matrix composition being a structurally viscous liquid having a yield point; (b) placing the one or more solar cell(s) onto the matrix composition applied to the surface of the first carrier material; (c) applying the matrix composition to the surface of the solar cell; (d) placing a second solid carrier material onto the matrix composition applied to the surface of the solar cell; (e) pressing the structure composed of solar cell, matrix composition, and first and second carrier materials, such that the one or more solar cell(s) is/are surrounded by a continuous layer of matrix composition; and (f) polymerizing the matrix composition in order to form the polymer matrix, and to the use of this process for producing solar modules and to the solar modules obtainable by means of this process.

1 . A process for producing a solar module, comprising:
 a. applying a matrix composition comprising at least one polymerizable compound to a surface of a first solid carrier material,   b. placing one or more solar cell(s) onto the matrix composition applied to the surface of the first carrier material;   c. applying the matrix composition to the surface of the one or more solar cell(s);   d. placing one or more spacers with projections disposed between the first and a second carrier material, such that a first distance between the first and second carrier materials is maintained at least at the edge of the structure composed of solar cell, matrix composition, and first and second carrier materials;   e. placing the second solid carrier material onto the matrix composition applied to the surface of the one or more solar cell(s);   f. pressing the structure composed of solar cell(s), matrix composition, and first and second carrier materials, such that the one or more solar cell(s) is/are surrounded by a layer of matrix composition and a second distance is achieved between the first and second carrier materials; and   g. polymerizing the matrix composition in order to form a polymer matrix encapsulating the one or more solar cell(s).   
     
     
         2 . The process of  claim 1 , wherein the second distance is smaller than the first distance. 
     
     
         3 . The process of  claim 1 , wherein the one or more spacers are formed from at least one first element and at least one second element joined to the first element, the first element engaging with an assembly formed from solar cell(s), polymer matrix, first carrier material and second carrier material so as to form the first distance between first and second carrier materials, and the second element being arranged such that it at least partly overlaps an outer edge of the assembly. 
     
     
         4 . The process of  claim 1 , wherein the one or more spacers further comprise at least one positional protruding element which aligns and holds a position of the second carrier material prior to pressing, and maintains the position of the second carrier material after pressing. 
     
     
         5 . The process of  claim 1 , wherein the one or more spacers have a first geometry configured to provide the first distance between the first and second carrier materials prior to pressing, and wherein the first geometry is configured to transform into a second geometry to provide the second distance between the first and second carrier materials after pressing. 
     
     
         6 . The process of  claim 1 , wherein the matrix composition is structurally viscous and imparts a yield point thereto prior polymerization. 
     
     
         7 . A solar module, comprising:
 a. a first transparent solid carrier material;   b. a second solid carrier material;   c. a polymer matrix between the first and the second solid carrier materials;   d. one or more solar cell(s) encapsulated within the polymer matrix; and   e. a frame profile extending along one edge of the first and the second solid carrier materials with one or more spacers with projections disposed between the first and the second solid carrier materials.   
     
     
         8 . The solar module of  claim 7 , wherein the frame profile provides a cavity for excess of polymer matrix material. 
     
     
         9 . The solar module of  claim 7 , wherein the spacer projections are discontinuing and separated from each other, wherein two separated spacer projections form a channel for excess flow of polymer matrix material into the frame profile cavity. 
     
     
         10 . The solar module of  claim 7 , wherein at least one spacer projection comprises an undercut configured to prevent the frame profile from slipping off the first and second solid carrier materials during lamination. 
     
     
         11 . The solar module of  claim 7 , wherein the spacer projections are collapsed from a first position into a second position, wherein the second position maintains a smaller distance between the first and the second solid carrier materials than the first position. 
     
     
         12 . The solar module of  claim 7 , wherein the one or more spacers are formed from at least one first element and at least one second element joined to the first element, the first element engaging with an assembly formed from solar cell(s), polymer matrix, first carrier material and second carrier material so as to form a first distance between first and second carrier materials, and the second element being arranged such that it at least partly overlaps an outer edge of the assembly. 
     
     
         13 . The solar module of  claim 7 , wherein the one or more spacers have a first geometry configured to provide a first distance between the first and second carrier materials prior to pressing, wherein the first geometry is configured to transform into a second geometry to provide a second distance between the first and second carrier materials after pressing. 
     
     
         14 . The solar module of  claim 7 , wherein the polymer matrix comprises at least one polymerizable compound and is produced by curing a matrix composition, wherein the matrix composition had been a structurally viscous liquid having a yield point prior to polymerization. 
     
     
         15 . The solar module of  claim 7 , wherein at least one spacer comprises a positional protruding element which is elastically biased to secure the first and second carrier materials at a second position from a first position, wherein the second position maintains a smaller distance between the first and second carrier materials than the first position. 
     
     
         16 . The solar module of  claim 7 , wherein the projections maintain a separation between the one or more solar cells and both the first and second carrier materials. 
     
     
         17 . The solar cell module of  claim 7 , wherein the spacers are arranged in at least one corner of the solar module. 
     
     
         18 . The solar cell module of  claim 7 , wherein the spacers are arranged in at least part of one side of the solar module. 
     
     
         19 . The solar cell module of  claim 7 , wherein the spacers are arranged in at least two sides of the solar module.