FABRICATION TECHNIQUES OF A PHOTOVOLTAIC MACRO-MODULE FOR SOLAR POWER GENERATION

1 . A method of fabricating a photovoltaic (“PV”) macro-module for solar power generation, the method comprising:

unrolling a frontside encapsulant layer, a backside encapsulant layer, a substrate layer from first, second, and third material spools, respectively, wherein the substrate layer provides physical environmental protection to a back side of the PV macro-module;

placing solar cells and distributed circuitry onto one of the backside encapsulant layer or the frontside encapsulant layer such that the solar cells and the distributed circuitry end up sandwiched in direct contact between both the frontside and backside encapsulant layers after unrolling;

forming electrical connections between the solar cells and the distributed circuitry; and

applying heat and pressure to fuse the frontside encapsulant layer, the backside encapsulant layer, and the substrate layer into a laminated support structure with the solar cells and the distributed circuitry embedded therein, wherein the laminated support structure with the solar cells and the distributed circuitry embedded therein is compliant to being rolled or folded for transport or storage of the PV macro-module.

2 . The method of claim 1 , further comprising:

unrolling a stiffener layer along the frontside encapsulant layer, wherein the stiffener layer comprises a polymer material that adds stiffness to reduce incidence of fracture of the solar cells due to external mechanical disturbances;

unrolling a superstrate layer along the stiffener layer to provide physical environmental protection to a frontside of the solar cells; and

applying an ultraviolet blocking layer between the superstrate layer and the stiffener layer,

wherein applying the heat and the pressure comprises applying heat and pressure to fuse the frontside encapsulant layer, the backside encapsulant layer, the substrate layer, the stiffener layer, and the superstrate layer into the laminated support structure.

3 . The method of claim 2 , wherein the pressure is applied with rollers, a press, an inflatable bladder, or a vacuum and the heat is applied as the frontside encapsulant layer, the backside encapsulant layer, the substrate layer, the stiffener layer, and the superstrate layer are moving along.

4 . The method of claim 2 , further comprising:

positioning a water block layer between the substrate layer and the backside encapsulate layer.

5 . The method of claim 4 , wherein the water block layer comprises a metal foil layer or an oxide layer.

6 . The method of claim 1 , further comprising:

cutting a hole in the laminated support structure;

mounting a junction box into the hole such that at least a portion of the junction box is exposed through the hole for cooling to an environment, wherein the junction box includes a power multiplexer and a controller coupled to the distributed circuitry, the controller including logic to control selective routing of current generated by the solar cells using the distributed circuitry.

7 . The method of claim 6 , further comprising:

attaching first flotation pads disposed along an underside of the laminated support structure beneath the solar cells to provide buoyancy to the solar cells and the distributed circuitry, wherein the first flotation pads cover less than 75% of the underside; and

attaching second flotation pads to the underside of the laminated support structure adjacent to the hole to provide buoyancy to the junction box.

8 . The method of claim 6 , further comprising:

attaching an external electrode to the underside of the laminated support structure, wherein the external electrode is exposed to the environment; and

electrically connecting an impedance sensor disposed within the junction box to the external electrode and to one or more internal connection points within the laminated support structure, wherein the controller is coupled to monitor the impedance sensor to determine whether a fault condition exists between the one or more internal connection points within the laminated support structure and the environment.

9 . The method of claim 1 , further comprising:

mechanically attaching edge connections that extend along side edges of the laminated support structure for mechanically connecting the PV macro-module to other PV macro-modules; and

adding end connections that extend along end edges of the PV macro-module for mechanically holding the PV macro-module when unfolded or unrolled.

10 . A method of fabricating a photovoltaic (“PV”) macro-module for solar power generation, the method comprising:

positioning a plurality of solar cell strings between backside layers and frontside layers of a laminate stack, wherein each of the solar cell strings includes a plurality of solar cells connected together;

laminating the laminate stack with the solar cell strings there between into a laminated support structure to form a PV segment;

electrically connecting a plurality of PV segments, including the PV segment, together; and

laminating the plurality of PV segments into a single contiguous module, wherein the single contiguous module is compliant to folding or rolling.

11 . The method of claim 10 , further comprising:

positioning distributed circuitry between the backside layers and frontside layers of the laminated stack, wherein the distributed circuitry selectively routes current generated by the solar cell strings; and

electrically connecting the distributed circuitry to the solar cell strings.

12 . The method of claim 11 , further comprising:

cutting a hole in the laminated support structure proximate to one end of the single contiguous module; and

mounting a junction box into or over the hole such that at least a portion of a backside of the junction box is exposed through the hole for backside cooling to an environment, wherein the junction box includes a power multiplexer for coupling to the solar cell strings and a controller coupled to the distributed circuitry, the controller including logic to control selective routing of the current generated within the solar cell strings using the distributed circuitry.

13 . The method of claim 10 , wherein the one or more backside layers of the laminate stack comprise:

a substrate layer to provide physical environment protection to a backside of the solar cells strings; and

a backside encapsulant layer disposed between the substrate layer and the solar cell strings, the backside encapsulant layer conforming to and molding around the backside of the solar cell strings after lamination.

14 . The method of claim 13 , wherein the one or more backside layers of the laminate stack further comprise:

a water block layer disposed between the substrate layer and the backside encapsulant layer.

15 . The method of claim 13 , wherein the one or more frontside layers of the laminate stack comprise:

a frontside encapsulant layer conforming to and molding around a frontside of the solar cell strings after lamination;

a stiffener layer disposed across the frontside encapsulant layer, wherein the stiffener layer comprises a first polymer material that adds stiffness to reduce incidence of fracture of the solar cells when the PV macro-module is rolled;

a superstrate layer disposed over the stiffener layer to provide physical environmental protection to the frontside of the solar cell strings, wherein the superstrate layer comprises a second polymer material; and

an ultraviolet blocking layer disposed between the superstrate layer and the stiffener layer.

16 . The method of claim 10 , wherein laminating the plurality of PV segments into the single contiguous module comprises:

forming laminated joint sections around electrical connections between adjacent ones of the PV segments.

17 . The method of claim 16 , wherein the laminated joint sections comprise fold zones, wherein the fold zones have a reduced rigidity compared to the PV segments.

18 . The method of claim 17 , wherein the frontside layers of the laminate stack comprise:

a frontside encapsulant layer conforming to and molding around a frontside of the solar cell strings after lamination; and

a glass panel layer fixed to the frontside encapsulant layer, wherein the glass panel layer extends over the PV segments including the solar cell strings but does not extend over the fold zones.

19 . The method of claim 10 , further comprising:

mechanically attaching edge connections that extend along side edges of the single contiguous module for mechanically connecting the single contiguous module to another single contiguous module; and

adding end connections that extend along end edges of the single contiguous module for mechanically holding the single contiguous module taut when unfolded or unrolled.