Frame-less encapsulated photo-voltaic (pv) solar power panel supporting solar cell modules encapsulated within optically-transparent epoxy-resin material

Abstract

A frame-less epoxy-resin encapsulated solar power panel, in which an optically-transparent epoxy-resin coating is applied over an array of photo-voltaic (PV) solar cell modules mounted on a support sheet of phenolic resin, and supported in a layer of adhesive coating applied as a liquid with a viscosity and a thickness such that the thickness of the layer of adhesive coating is substantially equal to the thickness of the PV solar cell modules, and cured to a sufficient hardness. The optically-transparent epoxy-resin coating, and the cured layer of adhesive coating, reinforce the strength of the sheet of phenolic resin, particularly around the perimeter of the frame-less epoxy-resin encapsulated solar power panel.

What is claimed is: 
     
         1 . A frame-less epoxy-resin encapsulated solar panel construction comprising:
 a support sheet made of non-conductive and reinforced material;   an array of photo-voltaic (PV) solar cell modules connected to an electrically-conductive bus bar assembly and having top surfaces, and being adhesively bonded to said support sheet and encapsulated in an optically transparent layer of adhesive coating material;   wherein said optically transparent layer of adhesive coating material has a thickness equal to said array of PV solar cell modules so that the top surfaces of said PV photo cell modules and surrounding adhesive coating material reside in the same plane so as to form a planar surface;   an optically transparent epoxy-resin encapsulating layer applied over said planar surface formed by said array of (PV) solar cell modules, said electrically-conductive bus bar assembly and said optically transparent layer of adhesive coating material; and   an optically transparent epoxy-resin top coating applied over said optically transparent epoxy-resin encapsulating layer, for providing self-cleaning action when wet during rain showers;   wherein a high-strength edge portion is formed all around the perimeter of said frame-less epoxy-resin encapsulated solar panel construction, between said optically transparent epoxy-resin top coating and said support sheet; and   wherein said high-strength edge portion of said frame-less epoxy-resin encapsulated solar panel construction is free of said array of PV solar panel modules and said electrically-conductive bus bar assembly so that mounting holes can be drilled through said high-strength edge portion without the risk of damaging said array of PV solar panel modules and said electrically-conductive bus bar assembly, and compromising the strength and integrity of said frame-less epoxy-resin solar panel construction.   
     
     
         2 . The frame-less epoxy-resin encapsulated solar panel construction of  claim 1 , wherein said support sheet is made of non-conductive and reinforced phenolic resin material. 
     
     
         3 . The frame-less epoxy-resin encapsulated solar panel construction of  claim 1 , wherein said optically transparent epoxy-resin top coating is applied over said optically transparent epoxy-resin layer at a dry film thickness (DFT) of at least 0.1 mm. 
     
     
         4 . The frame-less epoxy-resin encapsulated solar panel construction of  claim 1 , wherein said mounting holes drilled through said high-strength edge portion of said frame-less epoxy-resin encapsulated solar panel construction allow for the mounting of said frame-less epoxy-resin encapsulated solar panel construction in diverse environments including, horizontal and inclined rooftops, and vertical wall mounting applications. 
     
     
         5 . The frame-less epoxy-resin encapsulated solar panel construction of  claim 1 , wherein said photo-voltaic (PV) solar cell modules are made from various photo-voltaic technologies selected from the group consisting of (i) mono-crystalline or multi-crystalline silicon photo-voltaic solar cell modules, (ii) copper indium gallium selenide (CIGS) photo-voltaic solar cell modules, (iii) cadmium telluride (CdTe) photo-voltaic solar cell modules, (iv) perovskite photo-voltaic solar cell modules, and (v) organic photo-voltaic solar cell modules, and plastic photo-voltaic solar cell modules. 
     
     
         6 . The frame-less epoxy-resin encapsulated solar panel construction of  claim 1  wherein said support sheet has a thickness between ⅛ to 3/16 inches. 
     
     
         7 . The frame-less epoxy-resin encapsulated solar panel construction of  claim 1 , which further comprises an electrical connector junction box mounted to the rear of said support sheet to provide support for electrical power jacks for connection of electrical power cables that connect said frame-less epoxy-resin encapsulated solar panel to an electrical power system supported within a building, house or other environment in which said frame-less epoxy-resin encapsulated solar panel construction is installed. 
     
     
         8 . A method of manufacturing a frame-less epoxy-resin encapsulated solar power panel along a solar power panel production line in a solar panel factory system, said method comprising the steps of:
 (a) supplying a stack of support sheets to a conveyor transport system of a solar power panel production line, wherein each said support sheet is made of non-conductive and reinforced material, and has a top surface and a bottom surface;   (b) applying an optically transparent layer of adhesive coating material to the top surface of one said support sheet;   (c) placing an array of photo-voltaic (PV) solar cell modules connected to an electrically-conductive bus bar assembly on said optically transparent layer of adhesive coating applied to the top surface of said support sheet,   wherein said optically transparent layer of adhesive coating material has a thickness equal to said array of PV solar cell modules so that the top surfaces of said PV photo cell modules and surrounding adhesive coating material reside in the same plane so as to form a planar surface;   (d) applying an optically transparent epoxy-resin encapsulating layer over said planar surface formed by said array of (PV) solar cell modules, said electrically-conductive bus bar assembly and said optically transparent layer of adhesive coating material;   (e) curing said optically transparent epoxy-resin encapsulating layer applied over said array of PV solar cell modules, said electrically-conductive bus bar assembly and said optically transparent layer of adhesive coating material;   (f) applying an optically transparent epoxy-resin top coating over said cured optically transparent epoxy-resin encapsulating layer, for providing self-cleaning action when wet during rain showers;   (g) curing said optically transparent epoxy-resin top coating applied over said cured optically transparent epoxy-resin encapsulating layer;   wherein a high-strength edge portion is formed all around the perimeter of said frame-less epoxy-resin encapsulated solar power panel construction, between said optically transparent epoxy-resin top coating and said support sheet; and   wherein said high-strength edge portion of said frame-less epoxy-resin encapsulated solar power panel construction is free of said array of PV solar cell modules and said electrically-conductive bus bar assembly so that mounting holes can be drilled through said high-strength edge portion without the risk of damaging said array of PV solar cell modules and said electrically-conductive bus bar assembly, and without the risk of compromising the strength and integrity of said frame-less epoxy-resin solar power panel construction;   (h) mounting an electrical connector to the bottom surface of said support sheet;   (i) testing said frame-less epoxy-resin encapsulated solar power panel construction under an artificial-sun light source, and determining that said frame-less epoxy-resin encapsulated solar power panel construction meets a set of minimum electrical and mechanical performance specifications; and   (j) packaging each said frame-less epoxy-resin encapsulated solar power panel construction produced from said solar power panel production line of said solar panel factory system.   
     
     
         9 . The method of  claim 8 , wherein said optically transparent epoxy-resin top coating is applied over said optically transparent epoxy-resin layer at a dry film thickness (DFT) of at least 0.1 mm. 
     
     
         10 . The method of  claim 8 , which further comprises drilling said mounting holes through said high-strength edge portion of said frame-less epoxy-resin encapsulated solar power panel construction so as to allow for the mounting of said frame-less epoxy-resin encapsulated solar power panel construction in diverse environments including, horizontal and inclined rooftops, and vertical wall mounting applications. 
     
     
         11 . The method of  claim 8 , wherein said photo-voltaic (PV) solar cell modules are made from various photo-voltaic technologies selected from the group consisting of (i) mono-crystalline or multi-crystalline silicon photo-voltaic solar cell modules, (ii) copper indium gallium selenide (CIGS) photo-voltaic solar cell modules, (iii) cadmium telluride (CdTe) photo-voltaic solar cell modules, (iv) perovskite photo-voltaic solar cell modules, and (v) organic photo-voltaic solar cell modules, and plastic photo-voltaic solar cell modules. 
     
     
         12 . The method of  claim 8 , wherein each said support sheet is a phenolic resin support sheet. 
     
     
         13 . The method of  claim 8 , wherein each said support sheet has a thickness between ⅛ to 3/16 inches. 
     
     
         14 . The method of  claim 8 , which further comprises mounting an electrical connector junction box to said electrical connector so as to provide support for electrical power jacks for connection of electrical power cables that connect said frame-less epoxy-resin encapsulated solar power panel to an electrical power system supported within a building, house or other environment in which said frame-less epoxy-resin encapsulated solar power panel construction is installed.