Flexible photovoltaic modules having junction box supporting flaps

Abstract

Provided are flexible photovoltaic modules having flaps for supporting junction boxes. Junction boxes are used for making electrical connections to photovoltaic cells sealed inside the modules. A flap may be formed by one or two flexible sealing sheets extending beyond the boundary of the photovoltaic cells. A junction box is attached to the front surface of the flap. In certain embodiments, a flap is formed by one sealing sheet, such as a back side sheet. Materials of the back side sheet may be different from materials of the front side sheet and be selected to ensure support to the junction box. Additional support to the junction box may be provided by extending one of its edges in between the two sealing sheets. This edge extension or other features may be used for mechanical protection of electrical leads extending between the junction box and photovoltaic cells.

1 . A flexible photovoltaic module comprising:
 a front side flexible sealing sheet having a front sheet edge;   a back side flexible sealing sheet;   a sealed space formed between the front side flexible sealing sheet and the back side flexible sealing sheet, and bounded at least in part by an edge seal;   one or more flexible photovoltaic cells positioned in the sealed space between the front side flexible sealing sheet and the back side flexible sealing sheet;   a first electrical lead electrically connected to the one or more flexible photovoltaic cells, positioned in the sealed space, and extending outside of the sealed space and through the edge seal;   a first conductive element positioned outside the sealed space and electrically connected to the first electrical lead; and   a housing that includes a first extension and a second extension, and that encloses the electrical connection between the first electrical lead and the first conductive element, encloses at least a part of the first electrical lead, and encloses at least a part of the first conductive element, wherein:
 the first extension extends over a portion of the front side flexible sealing sheet, 
 the second extension extends over a portion of the back side flexible sealing sheet, and 
 the housing is connected to one of the front side flexible sealing sheet or the back side flexible sealing sheet. 
   
     
     
         2 . The flexible photovoltaic module of  claim 1 , wherein a portion of the housing extends through the edge seal. 
     
     
         3 . The flexible photovoltaic module of  claim 1 , further comprising:
 a second electrical lead electrically connected to the one or more flexible photovoltaic cells, positioned in the sealed space, and extending outside of the sealed space and through the edge seal; and   a second conductive element positioned outside the sealed space and electrically connected to the second electrical lead, wherein the housing further encloses the electrical connection between the second electrical lead and the second conductive element, at least a part of the second electrical lead, and at least a part of the second conductive element.   
     
     
         4 . The flexible photovoltaic module of  claim 3 , wherein the first electrical lead has an opposite polarity of the second electrical lead. 
     
     
         5 . The flexible photovoltaic module of  claim 1 , wherein at least a section of the housing is comprised of a rigid material. 
     
     
         6 . The flexible photovoltaic module of  claim 1 , wherein the housing is positioned away from the edge seal by a gap. 
     
     
         7 . The flexible photovoltaic module of  claim 1 , wherein:
 the first extension contacts the front side flexible sealing sheet, and   the second extension contacts the back side flexible sealing sheet.   
     
     
         8 . The flexible photovoltaic module of  claim 1 , wherein:
 the first extension is attached to the front side flexible sealing sheet, and   the second extension is attached to the back side flexible sealing sheet.   
     
     
         9 . The flexible photovoltaic module of  claim 1 , wherein the housing extends around a portion of the edge seal. 
     
     
         10 . A flexible photovoltaic module comprising:
 a front side flexible sealing sheet having a front sheet edge;   a back side flexible sealing sheet;   a sealed space formed between the front side flexible sealing sheet and the back side flexible sealing sheet, and bounded at least in part by an edge seal;   one or more flexible photovoltaic cells positioned in the sealed space between the front side flexible sealing sheet and the back side flexible sealing sheet;   a housing positioned outside the sealed space and including a first portion that extends at least partially into the edge seal; and   an electrical lead that is positioned at least partially in the sealed space, electrically connected to the one or more flexible photovoltaic cells, and that extends into the first portion of the housing.   
     
     
         11 . The flexible photovoltaic module of  claim 10 , wherein the first portion of the housing is tapered. 
     
     
         12 . The flexible photovoltaic module of  claim 10 , wherein the first portion of the housing extends only partially into the edge seal. 
     
     
         13 . The flexible photovoltaic module of  claim 10 , wherein the first portion of the housing extends through the edge seal. 
     
     
         14 . The flexible photovoltaic module of  claim 10 , wherein:
 the housing further comprises a body,   the first portion extends away from the body, and   the body directly contacts the edge seal.   
     
     
         15 . The flexible photovoltaic module of  claim 10 , wherein:
 the housing further comprises a body,   the first portion extends away from the body, and   the body is offset from the edge seal by a gap.   
     
     
         16 . The flexible photovoltaic module of  claim 15 , further comprising a sealant positioned in the gap between the body of the housing and the edge seal. 
     
     
         17 . The flexible photovoltaic module of  claim 10 , further comprising a flap outside the sealed space, wherein:
 the front side flexible sealing sheet has a front sheet edge,   the flap extends away from the sealed space in a direction perpendicular to the front sheet edge and the edge seal, and   the housing is attached to the flap.   
     
     
         18 . The flexible photovoltaic module of  claim 17 , wherein the back side flexible sealing sheet comprises the flap. 
     
     
         19 . The flexible photovoltaic module of  claim 17 , wherein the flap comprises two or more layers. 
     
     
         20 . The flexible photovoltaic module of  claim 10 , further comprising an external electrical connector that extends into the housing and is electrically connected to the electrical lead inside the housing.