Solar Module with a Stiffening Layer
A solar module includes a plurality of interconnected photovoltaic cells, an encapsulant layer encapsulating the photovoltaic cells, the encapsulant layer having a first side, a protective layer coupled to the first side of the encapsulant layer, and a stiffening layer coupled to the protective layer, the stiffening layer having an open support structure that provides stiffness to the solar module.
1 . A solar module comprising:
a plurality of interconnected photovoltaic cells;
an encapsulant layer encapsulating the photovoltaic cells, the encapsulant layer having a first side;
a protective layer coupled to the first side of the encapsulant layer; and
a stiffening layer coupled to the protective layer, the stiffening layer having an open support structure that provides stiffness to the solar module.
2 . The solar module of claim 1 , wherein the open support structure includes a corrugated structure.
3 . The solar module of claim 2 , wherein the corrugated structure is a sinusoidal wave shape, a square wave shape, or a trapezoidal wave shape.
4 . The solar module of claim 1 , wherein the open support structure includes a geometrical structure.
5 . The solar module of claim 4 , wherein the geometrical structure includes a honeycomb structure.
6 . The solar module of claim 1 , wherein the open support structure is formed from a metal or metal alloy.
7 . The solar module of claim 1 , wherein the open support structure is formed from a polymer.
8 . The solar module of claim 1 , further comprising a transparent superstrate adjacent to a second side of the encapsulant layer.
9 . The solar module of claim 1 , further comprising a frame disposed at the perimeter of the photovoltaic cells, the encapsulant layer, the protective layer and the stiffening layer for supporting the solar module.
10 . The solar module of claim 1 , wherein the stiffening layer includes a support layer on at least one side of the open support structure.
11 . The solar module of claim 10 , wherein the support layer is formed from a metal or metal alloy.
12 . The solar module of claim 1 , wherein the stiffening layer includes one or more openings formed therein.
13 . A method of producing a solar module, the method comprising:
providing a plurality of interconnected photovoltaic cells in an encapsulant layer, the encapsulant layer having a first side;
forming a protective layer on the first side of the encapsulant layer; and
forming a stiffening layer on the protective layer, the stiffening layer having an open support structure that provides stiffness to the solar module.
14 . The method of claim 13 , wherein the open support structure includes a corrugated structure.
15 . The method of claim 14 , wherein the corrugated structure is a sinusoidal wave shape, a square wave shape, or a trapezoidal wave shape.
16 . The method of claim 13 , wherein the open support structure includes a geometrical structure.
17 . The method of claim 16 , wherein the geometrical structure includes a honeycomb structure.
18 . The method of claim 13 , wherein the open support structure is formed from a metal or metal alloy.
19 . The method of claim 13 , wherein the open support structure is formed from a polymer.
20 . The method of claim 13 , wherein the stiffening layer includes a support layer on at least one side of the open support structure.
21 . The method of claim 13 , wherein the support layer is formed from a metal or metal alloy.
22 . A solar module comprising:
a plurality of interconnected photovoltaic cells;
an encapsulant layer encapsulating the photovoltaic cells, the encapsulant layer having a first side; and
a stiffening layer coupled to the first side of the encapsulant layer, the stiffening layer having an open support structure that provides stiffness to the solar module.
23 . The solar module of claim 22 , wherein the open support structure includes a corrugated structure.
24 . The solar module of claim 22 , wherein the open support structure includes a geometrical structure.
25 . The solar module of claim 22 , wherein the open support structure is formed from a metal or metal alloy.
26 . The solar module of claim 22 , wherein the open support structure is formed from a polymer.
27 . The solar module of claim 22 , wherein the stiffening layer includes a support layer on at least one side of the open support structure.
28 . The solar module of claim 27 , wherein the support layer is formed from a metal or metal alloy.