Structures for low cost, reliable solar modules

Abstract

Methods and devices are provided for improved large-scale solar installations. In one embodiment, a photovoltaic module is provided comprising a module front layer comprising a glass plate, a module back layer comprising an electrically conductive foil, and a plurality of solar cells arranged to be protected by the front layer and the back layer. In some embodiments, the module back layer is aluminum foil. The module back layer may have an externally exposed surface. The module back layer may be electrically grounded. An electrically insulating pottant material may be used with the solar cells to separate them from the module back layer. This allows for a high voltage withstand between the cells and the outer surface of the back layer.

1 . A photovoltaic module comprising:
 a module front layer comprising a glass plate, a module back layer comprising an electrically conductive foil, and a plurality of solar cells arranged to be protected by the front layer and the back layer.   
   
   
       2 . The module of  claim 1  wherein the foil is a metal foil. 
   
   
       3 . The module of  claim 1  wherein the foil is one of the following: a stainless steel foil, a copper foil, an aluminum foil, a tin foil, or a steel foil. 
   
   
       4 . The module of  claim 1  wherein the foil is anodized on one or more sides to improve high voltage withstand. 
   
   
       5 . The module of  claim 1  wherein the foil is electrically grounded. 
   
   
       6 . The module of  claim 1  wherein the foil is externally exposed. 
   
   
       7 . The module of  claim 1  wherein the foil has a cross-sectional thickness of about 25 microns or more. 
   
   
       8 . The module of  claim 1  wherein the foil has an externally exposed surface. 
   
   
       9 . The module of  claim 1  wherein the foil comprises of one or more substantially planar sheets of metallic material. 
   
   
       10 . The module of  claim 1  wherein the foil is a flexible sheet of material. 
   
   
       11 . The module of  claim 1  wherein the foil includes an outer protective layer. 
   
   
       12 . The module of  claim 1  wherein the foil includes an outer moisture barrier layer. 
   
   
       13 . The module of  claim 1  wherein the foil includes an outer corrosion protection layer. 
   
   
       14 . The module of  claim 1  wherein the foil has a thickness between about 50 microns to about 500 microns. 
   
   
       15 . The module of  claim 1  wherein the foil has a thickness between about 50 microns to about 200 microns. 
   
   
       16 . The module of  claim 1  wherein the foil has a thickness between about 100 microns to about 150 microns. 
   
   
       17 . The module of  claim 1  wherein the foil and the glass plate are substantially similar in size. 
   
   
       18 . The module of  claim 1  wherein the foil is separated from the cells through a pottant layer of sufficient thickness and dielectric resistance to withstand about 600V between the cells and the foil. 
   
   
       19 . A photovoltaic module comprising:
 a rigid transparent front layer, an electrically conductive foil back layer, and a plurality of solar cells arranged to be protected by the front layer and the back layer,   wherein the conductive foil is wrapped around to cover an edge of the front layer and/or an edge and a portion of the front surface of the front layer.   
   
   
       20 . A method comprising:
 forming a module comprising a rigid transparent front layer, an electrically conductive foil back layer, and a plurality of solar cells arranged to be protected by the front layer and the back layer.