Lightweight solar panels with solar cell structural protection

Abstract

Light-weight, flexible solar panels adapted to prevent inadvertent stress on silicon solar photovoltaic cells inside solar panels. In some examples, a solar panel comprising solar cells includes a plurality of supports, such as one support for each solar cell, with gaps between the supports to allow the panel to flex when strained while protecting the individual cells. In other examples, a solar panel comprises a plurality of solar cells and a support or plural supports designed to accept force applied to the top of the panel and divert such force around the individual cells, without the use of a heavy glass support over top. Some examples may include both individual supports for each cell, with each individual support further adapted to direct applied forces around the individual cells.

What is claimed is: 
     
         1 . A solar panel comprising:
 a plurality of solar cells electrically connected together with a plurality of electrical connectors;   one or more layers of encapsulant; and   a plurality of individual protective supports sized and shaped for each of the plurality of solar cells such that for each of the solar cells there is a corresponding one of the protective supports aligned therewith.   
     
     
         2 . A solar panel as in  claim 1  wherein:
 the solar panel has a front side for exposure to the sun and a back side; 
 the plurality of individual protective supports are each placed between a respective solar cell and the front side of the solar panel; and 
 the plurality of individual protective supports comprise a material that is substantially transparent relative to wavelengths of light to be absorbed by the solar cells. 
 
     
     
         3 . The solar panel of  claim 2  wherein the front side comprises a fluoropolymer film layer at as an outermost layer on the front size of the solar panel. 
     
     
         4 . The solar panel of  claim 2  wherein the plurality of individual protective supports are glass. 
     
     
         5 . The solar panel of  claim 1  wherein the solar panel has a front side for exposure to the sun and a back side, and the plurality of individual supports are each placed between a respective solar cell and the back side of the solar panel. 
     
     
         6 . The solar panel of  claim 5  wherein the plurality of individual supports are formed of a light weight plastic or polymer. 
     
     
         7 . The solar panel of  claim 5  wherein the plurality of individual supports comprise carbon fiber. 
     
     
         8 . The solar panel of  claim 5  wherein the solar panel does not comprise any glass. 
     
     
         9 . The solar panel of  claim 1 , further comprising a substrate layer disposed outside of the encapsulant, with the encapsulant adhering to the substrate layer. 
     
     
         10 . The solar panel of  claim 9  wherein the solar cells and the protective supports are spaced from one another to define gaps therebetween, and the substrate layer is flexible, such that the solar panel can be folded without damage at the gaps. 
     
     
         11 . The solar panel of  claim 10  wherein the individual supports maintain the solar cells in a flat position individually if the solar panel is folded at one or more of the gaps. 
     
     
         12 . The solar panel of  claim 9 , wherein at least one protective support comprises a ridge adapted to surround a corresponding solar cell, the ridge having a thickness greater than that of the solar cell, such that a force applied to the front of the solar panel is absorbed by the ridge. 
     
     
         13 . The solar panel of  claim 1 , wherein at least one protective support comprises a ridge adapted to surround a corresponding solar cell, the ridge having a thickness greater than that of the solar cell, such that a force applied to the front of the solar panel is absorbed by the ridge. 
     
     
         14 . A solar panel having a front side for receiving sunlight and a back side, the solar panel comprising:
 a plurality of solar cells electrically connected together with a plurality of electrical connectors, the plurality of solar cells having a front side and a back side;   one or more layers of encapsulant; and   at least one protective support for at least one of the solar cells, the protective support comprising a ridge member to define a ridge relative to the front side of the panel and the at least one solar cell, wherein the ridge extends beyond the front side of the at least one solar cell, such that a force applied to the front of the solar panel is diverted away from the at least one solar cell.   
     
     
         15 . The solar panel of  claim 14  wherein the panel comprises a plurality of protective supports each corresponding to one of the solar cells. 
     
     
         16 . The solar panel of  claim 15  further comprising a plurality of front protectors each corresponding to one of the solar cells, the front protectors sized to correspond to the ridges such that an impact or force received by a front protector will be translated to a ridge, and not to a corresponding solar cell. 
     
     
         17 . The solar panel of  claim 14  wherein at least one of the protective supports is configured to provide ridges around a perimeter of each of at least two of the solar cells. 
     
     
         18 . A solar panel having a front side and a back side, the panel comprising:
 a front layer of a fluoropolymer;   an encapsulant layer behind the fluoropolymer;   a plurality of solar cells behind the encapsulant layer;   for each of the plurality of solar cells, an individual support member behind the solar cell;   an encapsulant layer behind the individual support members; and   a substrate at the back side of the solar panel.   
     
     
         19 . The solar panel of  claim 18  wherein the solar cells and support members have gaps there-between, and the solar panel is capable of folding at the gaps.