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A reliable and inexpensive solar module is disclosed. The solar module comprises a thin-film type photovoltaic cell array formed on a glass superstrate, leaving a margin of an appropriate width along the periphery of the glass superstrate, and a resin layer coated on the photovoltaic cell array and the peripheral margin of the glass superstrate. The solar module further comprises a backcover adhered by the resin layer to cover the photovoltaic cell array and the peripheral margin of the glass superstrate. The resin layer is preferably made of a fluoropolymer derived from a compound containing a perfluoroalkylene and active hydrogen atoms.
Determine the combined electrical demand of all devices that will be powered by the panel. For example, if the panel is to power a 10-watt ventilation fan that will run 24 hours a day, it will consume 240 watts.
Determine the necessary power output of the panel to meet that demand. An average day is supposed to have 6 hours of peak sunlight, and most solar electric computations are based on that. So, the entire 240 watt output must be met during those 6 hours, which means the panel must produce 40 watts per hour.
Most of the conventional solar modules comprise crystalline-type cells such as single crystal silicon cells and polycrystal silicon cells. A comprehensive discussion of available encapsulation techniques and data for silicon flat-plate solar modules is presented, for example, in "Photovoltaic- Module Encapsulation Design and Materials Selection: Volume 1" by E. Cuddihy, W. Carroll, C. Coulbert, A. Gupta and R. Liang, by Jet Propulsion Laboratory (JPL) (June 1, 1982). A few of the techniques are applicable to modules comprising thin film-type solar cells but most are not. Therefore, it has been desired to develop a new technique for modules comprising thin film-type solar cells.
Choose the specific solar cell that you want to use, and then sketch a plan. In this example, 10 watt cells that are 15 by 9 inches are chosen, and an inch of padding is included between the cells, the resulting plan is for a 2 by 2 cell arrangement that will have a backing of 33 by 21 inches.
An object of the present invention is to provide an inexpensive, reliable, simple, and lightweight solar module.
This object can be accomplished by a solar module comprising: a solar cell array comprised of plural solar panel formed on a glass superstrate with a margin of a specified width remaining along the periphery of the substrate; and a resin layer coated to cover the solar cell array and the peripheral margin on the substrate. The solar module may further comprises a backcover provided on the resin layer for protecting the solar cell array, where the resin layer is used as an adhesive to adhere the backcover.
The solar cells are thin-film type photovoltaic cells such as CdS/CdTe type photovoltaic cells. It is preferable to use as the resin layer material a fluoropolymer derived from a compound containing a perfluoroalkylene group and active hydrogen atoms.
By use of the construction in which a margin along the periphery of the glass superstrate is provided and coated with the resin layer, the solar cells are completely isolated from the surroundings so as to be protected from water or water vapor.
Nail the borders onto the backing, using 2 or 3 nails per side. This will create a shallow box, which is now your solar panel manufacturer .
Use a box cutter to cut a section of corkboard that will fit the backing. Use wood glue to fasten this to the inside of the panel to serve as a substrate for the solar cells.
A CdS/CdTe type photovoltaic cell array was formed on a glass superstrate leaving a margin of 5 mm width along the periphery of the glass superstrate. Then a mixture of 100 parts of LF302C and 20 parts of Coronate EH was coated on the photovoltaic cell array and the peripheral margin of the glass superstrate and cured at 120° C. for 20 minutes, thereby forming the resin layer. Thus, a solar module having a construction as shown in FIG. 4 was obtained. In the same way, other samples were obtained by using various materials for the resin layer. The thus obtained solar module samples were subjected to a temperature of 80° C. and relative humidity of 95% for 1000 hours. Thereafter, the samples were tested for changes in appearance and photovoltaic properties. The test results are shown in Table 1.
Use the caulk gun and silicon caulk to glue the solar cells into their positions, keeping about an inch of padding on all sides of the cells. Put a big, inch-sized glob of caulk onto the three or four spots on the cell, and press it into position on the corkboard.
Bridge the cells together. In this example, there are four cells. All the cells will have short negative and positive leads extending from them. First join these leads to wires by twisting them together with wire nuts. Then join the wires of two cells together using wire nuts in the same way, positive to positive and negative to negative. Repeat the process again, and all the cells will be running through the same wire. source:bloggumsolar module
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