WO2001014660A1 - Solar panel - Google Patents

Solar panel Download PDF

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Publication number
WO2001014660A1
WO2001014660A1 PCT/AU2000/000989 AU0000989W WO0114660A1 WO 2001014660 A1 WO2001014660 A1 WO 2001014660A1 AU 0000989 W AU0000989 W AU 0000989W WO 0114660 A1 WO0114660 A1 WO 0114660A1
Authority
WO
WIPO (PCT)
Prior art keywords
layer
solar panel
structural
panel according
thermoplastic
Prior art date
Application number
PCT/AU2000/000989
Other languages
French (fr)
Inventor
Robert Owen Petchell
Leslie Philip Smart
Original Assignee
Melbourne Equities Pty Ltd
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Melbourne Equities Pty Ltd filed Critical Melbourne Equities Pty Ltd
Priority to AU65493/00A priority Critical patent/AU765696B2/en
Publication of WO2001014660A1 publication Critical patent/WO2001014660A1/en

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Classifications

    • H—ELECTRICITY
    • H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
    • H02S—GENERATION OF ELECTRIC POWER BY CONVERSION OF INFRARED RADIATION, VISIBLE LIGHT OR ULTRAVIOLET LIGHT, e.g. USING PHOTOVOLTAIC [PV] MODULES
    • H02S20/00—Supporting structures for PV modules
    • H02S20/20—Supporting structures directly fixed to an immovable object
    • H02S20/22—Supporting structures directly fixed to an immovable object specially adapted for buildings
    • H02S20/23—Supporting structures directly fixed to an immovable object specially adapted for buildings specially adapted for roof structures
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01L—SEMICONDUCTOR DEVICES NOT COVERED BY CLASS H10
    • H01L31/00—Semiconductor devices sensitive to infrared radiation, light, electromagnetic radiation of shorter wavelength or corpuscular radiation and specially adapted either for the conversion of the energy of such radiation into electrical energy or for the control of electrical energy by such radiation; Processes or apparatus specially adapted for the manufacture or treatment thereof or of parts thereof; Details thereof
    • H01L31/04—Semiconductor devices sensitive to infrared radiation, light, electromagnetic radiation of shorter wavelength or corpuscular radiation and specially adapted either for the conversion of the energy of such radiation into electrical energy or for the control of electrical energy by such radiation; Processes or apparatus specially adapted for the manufacture or treatment thereof or of parts thereof; Details thereof adapted as photovoltaic [PV] conversion devices
    • H01L31/042—PV modules or arrays of single PV cells
    • H01L31/048—Encapsulation of modules
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
    • Y02B—CLIMATE CHANGE MITIGATION TECHNOLOGIES RELATED TO BUILDINGS, e.g. HOUSING, HOUSE APPLIANCES OR RELATED END-USER APPLICATIONS
    • Y02B10/00—Integration of renewable energy sources in buildings
    • Y02B10/10—Photovoltaic [PV]
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
    • Y02B—CLIMATE CHANGE MITIGATION TECHNOLOGIES RELATED TO BUILDINGS, e.g. HOUSING, HOUSE APPLIANCES OR RELATED END-USER APPLICATIONS
    • Y02B10/00—Integration of renewable energy sources in buildings
    • Y02B10/20—Solar thermal
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
    • Y02E—REDUCTION OF GREENHOUSE GAS [GHG] EMISSIONS, RELATED TO ENERGY GENERATION, TRANSMISSION OR DISTRIBUTION
    • Y02E10/00—Energy generation through renewable energy sources
    • Y02E10/50—Photovoltaic [PV] energy

Definitions

  • This invention relates to a solar panel of the type used to generate electric power from solar energy and in particular to a solar panel for use in building construction.
  • Solar panels have been used for many years to replace or supplement the conventional electric power supply.
  • One of the major deterrents to more wide spread use of solar panels is the cost of fitting solar panels to roofing and providing the necessary electrical network.
  • a further limitation of solar panels rises from their fragile nature which could lead to disruption or failure of power supply and necessitates significant maintenance.
  • the present invention provides a solar panel including a structural assembly including a layer of structural material and a layer of thermal-insulation material on the underside thereof and a solar cell assembly adhered to the upper side of the structural assembly and including a photovoltaic core formed of amorphous silicon and upper and lower layers of thermoplastic material between which the photovoltaic core is laminated.
  • the photovoltaic core is generally provided with terminals for providing transmission of generated electricity through the layers of laminate.
  • the terminals of the solar cell assembly preferably cooperate with holes where required and are provided with an electrical transmitting member, such as a cable, for transmitting electricity generated by the solar cell assembly.
  • the insulation material is typically provided with an access, preferably within this medium, passing beneath one or more holes in the structural layer and within which electrical conducting member may be received.
  • the solar panels of the invention are generally interconnectable via suitable interconnecting means so that access on adjacent panels cooperate to provide a continuous entry for an electrical conducting member such as an electrical cable or like.
  • the structural assembly will generally further comprise a second structural layer disposed beneath the insulation material to provide a sandwich construction comprising two layers of the structural material disposed one on either side of the layer of insulation material.
  • the solar cell assembly is bonded to the upper layer of structural material by suitable means such as an adhesive.
  • the amorphous silicon solar cell core is generally in the form of one or more thin flexible laminates of the type commercially available and provides a flexible solar cell assembly.
  • thermoplastic layers of the solar cell assembly are preferably cross- linked and bonded with the amorphous silicon photovoltaic core.
  • the upper and lower thermoplastic layer include ethylene vinyl acetate (EVA).
  • the solar cell assembly may and generally will contain further layers. It is preferred that the photovoltaic core be laminated between thermoplastic layers at elevated temperature and under a vacuum to minimize the presence of air bubbles. To aid in eliminating air from between the layers is preferred to use a thermoplastic laminate in which the upper layer of thermoplastic is provided with a transparent matrix, particularly a non-woven optically transparent scrim. The fibrous matrix may be incorporated into the thermo-plastic layer or bonded to it. Where EVA is used as a thermoplastic layer the scrim may be incorporated or impregnated into the layer.
  • the upper surface of the solar cell assembly is preferably provided by a transparent plastic layer which is stable against weathering. Examples of suitable layers at the upper surface include polyvinyl fluoride or a suitable UV stabilized polymer layer.
  • a layer of electrical insulating material be provided between the photovoltaic core and the structural assembly.
  • the insulating material layer is disposed between the lower layer of thermoplastic laminating photovoltaic material and the structural assembly and is typically bonded to the laminate on one side and to the upper layer of structure material on the other.
  • the insulating material may be a fluoropolymer, particularly polyvinyl fluoride.
  • the layer or layers of structural material are typically formed of metal sheet such as steel or iron or the like and the layer of thermal insulation material may be formed of polystyrene, fibreglass, polyurethane or similar material.
  • the preferred structural assembly comprises a polystyrene insulation layer disposed between opposed layers of steel sheeting.
  • the thermal insulation material generally houses an access for electrical transmission.
  • the access may be formed in the insulation material, for example by forming an entry in polystyrene, or alternatively a conduit may be formed of a material such as plastics or metal disposed within the insulation material layer.
  • the invention also provides a method of forming a solar panel.
  • the preferred method includes the steps of forming a solar cell assembly including laminating one or more photovoltaic cells comprising amorphous silicon material with conductive terminals between sheets of thermoplastic material which is preferably a crosslinkable thermoplastic such as EVA.
  • the conductive terminals may include other semi-conductors such as a by-pass diode network.
  • the lamination is preferably carried out at elevated temperature and under a vacuum and preferably produces crosslinking of the thermoplastic polymer with the surfaces of the amorphous silicon photovoltaic material. Additional layers as hereinabove explained may be bonded to the upper and lower layers of the laminate prior to forming the solar cell assembly.
  • an upper laminate assembly comprising an upper layer of a weather resistant material such as a fluoropolymer, a layer of thermoplastic material such as EVA and a fibrous material such as an optical scrim disposed within the layer of thermoplastic material.
  • a lower laminated assembly may be formed by bonding a layer of insulating material, such as a fluoropolymer to the light incident surface of the upper structural material and a layer of thermoplastic material may be bonded to the insulated material. Lamination may then take place by sandwiching the photovoltaic core between the upper and lower assemblies preferably at elevated temperature and under a vacuum to produce a bonding and encapsulation of the surfaces and to evacuate air from between the layers as the crosslinking occurs.
  • the structural layer may then be combined with the insulating material and second structural layer. Generally holes in the upper structural layer may be formed to coincide with terminals of the photovoltaic cells and to allow electrical transmission of generated energy via access in the layer of insulating material.
  • Figure 1 is an exploded view of a solar panel in accordance with a fast embodiment of the invention.
  • Figure 2 is a view from above of the solar panel of figure 1.
  • Figure 3 is a cross-section of the solar panel of figure 2 along the line 3-3-
  • Figure 4 is a longitudinal section of the panel of figure 2 along the line 4-4 ⁇
  • Figure 5 is an enlarged view of a portion of the cross-section of figure
  • Figure 6 is an expanded view of a solar panel in accordance with a second embodiment.
  • Figure 7 is a view from above the solar panel of Figure 6.
  • Figure 8 is a cross section view of the solar panel of Figure 7 along the line 8-8 1 .
  • Figure 9 is a longitudinal section of the panel of Figure 4 along the line 9-9 1 .
  • Figure 10 is an enlarged view of a portion of the cross section of Figure 9 showing the arrangement of layers.
  • a solar panel (1 ) which comprises a solar cell assembly (2) that is adhered to a structural assembly (3).
  • the solar cell assembly (2) includes a photovoltaic core (4) which has an amorphous silicon power generation system in the form a thin and flexible laminate (5) and is provided with electrical terminals (6) for transmitting the generated electrical power. Suitable amorphous silicon products are available from specialized manufactures.
  • the photovoltaic core (4) is laminated between upper and lower laminate portions (7, 8).
  • the upper laminate portion (7) is a multi layer structure having an upper layer (11) of weather resistant material such as TEFZEL available from Du Pont and a lower layer of a thermoplastic polymer such as EVA which is adapted to crosslink, encapsulate and bond with the surface of the amorphous silicon photovoltaic core (4).
  • the thermoplastic layer (9) is preferably impregnated with an optical scrim (10) which is preferably a non-woven optical scrim.
  • the laminate portion disposed below the photovoltaic core includes an upper layer (12) of a thermoplastic polymer such as EVA which is crosslinked, bonded and encapsulated with the surface of the amorphous silicon core (4).
  • the lower layer of the solar cell assembly (13) is an insulator layer formed of suitable insulating material such as polyvinyl fluoride.
  • the structural assembly (3) to which the solar cell assembly (2) is bonded has an upper structural layer (14) and lower structural layer (15) formed of metal sheeting such as steel sheeting with an insulation layer (16) disposed between the upper (14) and lower (15) layers.
  • Holes (19) may be provided in the upper structural layer and cooperate with the terminals of the photovoltaic core (6) to allow the electricity produced to be transmitted through an access in a recess (17) in the insulation (16).
  • the holes in the upper structure may be provided with electrical insulation such as a cable gland (not shown).
  • Electrical cabling (20) may be provided in the access for transmitting the produced electricity from the terminals (6).
  • the panels are provided with interconnection means (21) to enable them to form a continuous panel.
  • the solar panel of the invention is particularly suitable for use in forming roofing of domestic or industrial buildings.
  • the solar panel (1) with the invention may be prepared by a range of procedures however by way of example we provide the following description of one preferred method.
  • a structural panel (14) is produced in continuous lengths and are cut at intervals according to the desired size of the panel (4). Holes (6) punched where required to allow the generated electricity to be transmitted via an access (18) located in a recess in the insulating material (17). A cable gland (not shown) may be inserted in each hole in the upper structural layer (14) to prevent short-circuiting of the wiring (20) as it may pass through the upper structural layer (14).
  • the solar cell assembly is prepared using a sheet made up of an external layer of weather resistant material (11) and an optically transparent scrim (10) which is embedded in a layer of thermoplastic polymer (12) such as EVA compound.
  • This upper assembly is brought into contact with photovoltaic core (4) which has an amorphous silicon layer (5) and electrical terminals (6).
  • the photovoltaic core (4) is contacted on the other side with a thermoplastic polymer layer to which in turn is bonded a layer of insulator material such as polyvinyl fluoride.
  • the photovoltaic core (4) is laminated between the upper laminate portion (7) and lower laminate portion (8) using an industrial laminator.
  • the lid of the laminator applies an even downward pressure while application of a controlled temperature and vacuum is made on the laminations.
  • the vacuum reaches about 1 Torr the temperature has increased to about 140°C. allowing the crosslinking process of the EVA thermoplastic polymer to take place. Pressure is maintained for about a predetermined time to enable complete crosslinking and expulsion of air from between the encapsulated layers.
  • the upper structural layer (14) and lower structural layer (15) are bonded to polystyrene insulating material (16) using an appropriate adhesive.
  • the upper surface of the insulating material is prepared with recesses (17) in which access (18) may be placed for electrical wiring (20).
  • the recesses (17) are cut to coincide with the holes (19) in the upper structural layer (14) and the terminals (6) of the photovoltaic core (4) the solar cell assembly (2) is bonded to the upper structural layer (15) and the appropriate solar connectors or terminations can be applied.
  • the solar panel of the invention can be formed at moderate cost and used as a roofing material in domestic and industrial buildings to provide an integrated system for power generation.

Abstract

A solar panel including a structural assembly including a layer of structural material and a layer of thermal-insulation material on the underside thereof and a solar cell assembly adhered to the upper side of the structural assembly and including a photovoltaic core formed of amorphous silicon and upper and lower layers of thermoplastic material between which the photovoltaic core is laminated.

Description

SOLAR PANEL
This invention relates to a solar panel of the type used to generate electric power from solar energy and in particular to a solar panel for use in building construction.
Solar panels have been used for many years to replace or supplement the conventional electric power supply. One of the major deterrents to more wide spread use of solar panels is the cost of fitting solar panels to roofing and providing the necessary electrical network. A further limitation of solar panels rises from their fragile nature which could lead to disruption or failure of power supply and necessitates significant maintenance.
The present invention provides a solar panel including a structural assembly including a layer of structural material and a layer of thermal-insulation material on the underside thereof and a solar cell assembly adhered to the upper side of the structural assembly and including a photovoltaic core formed of amorphous silicon and upper and lower layers of thermoplastic material between which the photovoltaic core is laminated.
The photovoltaic core is generally provided with terminals for providing transmission of generated electricity through the layers of laminate. The terminals of the solar cell assembly preferably cooperate with holes where required and are provided with an electrical transmitting member, such as a cable, for transmitting electricity generated by the solar cell assembly. The insulation material is typically provided with an access, preferably within this medium, passing beneath one or more holes in the structural layer and within which electrical conducting member may be received.
The solar panels of the invention are generally interconnectable via suitable interconnecting means so that access on adjacent panels cooperate to provide a continuous entry for an electrical conducting member such as an electrical cable or like. The structural assembly will generally further comprise a second structural layer disposed beneath the insulation material to provide a sandwich construction comprising two layers of the structural material disposed one on either side of the layer of insulation material. The solar cell assembly is bonded to the upper layer of structural material by suitable means such as an adhesive.
The amorphous silicon solar cell core is generally in the form of one or more thin flexible laminates of the type commercially available and provides a flexible solar cell assembly.
The thermoplastic layers of the solar cell assembly are preferably cross- linked and bonded with the amorphous silicon photovoltaic core. Preferably the upper and lower thermoplastic layer include ethylene vinyl acetate (EVA).
The solar cell assembly may and generally will contain further layers. It is preferred that the photovoltaic core be laminated between thermoplastic layers at elevated temperature and under a vacuum to minimize the presence of air bubbles. To aid in eliminating air from between the layers is preferred to use a thermoplastic laminate in which the upper layer of thermoplastic is provided with a transparent matrix, particularly a non-woven optically transparent scrim. The fibrous matrix may be incorporated into the thermo-plastic layer or bonded to it. Where EVA is used as a thermoplastic layer the scrim may be incorporated or impregnated into the layer. The upper surface of the solar cell assembly is preferably provided by a transparent plastic layer which is stable against weathering. Examples of suitable layers at the upper surface include polyvinyl fluoride or a suitable UV stabilized polymer layer.
It is particularly preferred that a layer of electrical insulating material be provided between the photovoltaic core and the structural assembly. Typically the insulating material layer is disposed between the lower layer of thermoplastic laminating photovoltaic material and the structural assembly and is typically bonded to the laminate on one side and to the upper layer of structure material on the other. The insulating material may be a fluoropolymer, particularly polyvinyl fluoride. The layer or layers of structural material are typically formed of metal sheet such as steel or iron or the like and the layer of thermal insulation material may be formed of polystyrene, fibreglass, polyurethane or similar material. The preferred structural assembly comprises a polystyrene insulation layer disposed between opposed layers of steel sheeting.
The thermal insulation material generally houses an access for electrical transmission. The access may be formed in the insulation material, for example by forming an entry in polystyrene, or alternatively a conduit may be formed of a material such as plastics or metal disposed within the insulation material layer.
The invention also provides a method of forming a solar panel. The preferred method includes the steps of forming a solar cell assembly including laminating one or more photovoltaic cells comprising amorphous silicon material with conductive terminals between sheets of thermoplastic material which is preferably a crosslinkable thermoplastic such as EVA. The conductive terminals may include other semi-conductors such as a by-pass diode network. The lamination is preferably carried out at elevated temperature and under a vacuum and preferably produces crosslinking of the thermoplastic polymer with the surfaces of the amorphous silicon photovoltaic material. Additional layers as hereinabove explained may be bonded to the upper and lower layers of the laminate prior to forming the solar cell assembly. In the preferred embodiment an upper laminate assembly is formed comprising an upper layer of a weather resistant material such as a fluoropolymer, a layer of thermoplastic material such as EVA and a fibrous material such as an optical scrim disposed within the layer of thermoplastic material. A lower laminated assembly may be formed by bonding a layer of insulating material, such as a fluoropolymer to the light incident surface of the upper structural material and a layer of thermoplastic material may be bonded to the insulated material. Lamination may then take place by sandwiching the photovoltaic core between the upper and lower assemblies preferably at elevated temperature and under a vacuum to produce a bonding and encapsulation of the surfaces and to evacuate air from between the layers as the crosslinking occurs. The structural layer may then be combined with the insulating material and second structural layer. Generally holes in the upper structural layer may be formed to coincide with terminals of the photovoltaic cells and to allow electrical transmission of generated energy via access in the layer of insulating material.
A particularly preferred embodiment of the invention will now be described with reference to the attached drawings.
In the drawings:
Figure 1 is an exploded view of a solar panel in accordance with a fast embodiment of the invention. Figure 2 is a view from above of the solar panel of figure 1.
Figure 3 is a cross-section of the solar panel of figure 2 along the line 3-3-
Figure 4 is a longitudinal section of the panel of figure 2 along the line 4-4\ Figure 5 is an enlarged view of a portion of the cross-section of figure
4 showing the arrangement of layers.
Figure 6 is an expanded view of a solar panel in accordance with a second embodiment.
Figure 7 is a view from above the solar panel of Figure 6. Figure 8 is a cross section view of the solar panel of Figure 7 along the line 8-81.
Figure 9 is a longitudinal section of the panel of Figure 4 along the line 9-91.
Figure 10 is an enlarged view of a portion of the cross section of Figure 9 showing the arrangement of layers.
In describing the invention the terms upper and lower are used to refer to the product oriented with the light incident side disposed upward. Referring to the drawings there is shown a solar panel (1 ) which comprises a solar cell assembly (2) that is adhered to a structural assembly (3). The solar cell assembly (2) includes a photovoltaic core (4) which has an amorphous silicon power generation system in the form a thin and flexible laminate (5) and is provided with electrical terminals (6) for transmitting the generated electrical power. Suitable amorphous silicon products are available from specialized manufactures. The photovoltaic core (4) is laminated between upper and lower laminate portions (7, 8). The upper laminate portion (7) is a multi layer structure having an upper layer (11) of weather resistant material such as TEFZEL available from Du Pont and a lower layer of a thermoplastic polymer such as EVA which is adapted to crosslink, encapsulate and bond with the surface of the amorphous silicon photovoltaic core (4). The thermoplastic layer (9) is preferably impregnated with an optical scrim (10) which is preferably a non-woven optical scrim.
The laminate portion disposed below the photovoltaic core includes an upper layer (12) of a thermoplastic polymer such as EVA which is crosslinked, bonded and encapsulated with the surface of the amorphous silicon core (4). The lower layer of the solar cell assembly (13) is an insulator layer formed of suitable insulating material such as polyvinyl fluoride.
The structural assembly (3) to which the solar cell assembly (2) is bonded has an upper structural layer (14) and lower structural layer (15) formed of metal sheeting such as steel sheeting with an insulation layer (16) disposed between the upper (14) and lower (15) layers. Holes (19) may be provided in the upper structural layer and cooperate with the terminals of the photovoltaic core (6) to allow the electricity produced to be transmitted through an access in a recess (17) in the insulation (16). The holes in the upper structure may be provided with electrical insulation such as a cable gland (not shown). Electrical cabling (20) may be provided in the access for transmitting the produced electricity from the terminals (6). The panels are provided with interconnection means (21) to enable them to form a continuous panel. The solar panel of the invention is particularly suitable for use in forming roofing of domestic or industrial buildings.
The solar panel (1) with the invention may be prepared by a range of procedures however by way of example we provide the following description of one preferred method.
A structural panel (14) is produced in continuous lengths and are cut at intervals according to the desired size of the panel (4). Holes (6) punched where required to allow the generated electricity to be transmitted via an access (18) located in a recess in the insulating material (17). A cable gland (not shown) may be inserted in each hole in the upper structural layer (14) to prevent short-circuiting of the wiring (20) as it may pass through the upper structural layer (14).
The solar cell assembly is prepared using a sheet made up of an external layer of weather resistant material (11) and an optically transparent scrim (10) which is embedded in a layer of thermoplastic polymer (12) such as EVA compound. This upper assembly is brought into contact with photovoltaic core (4) which has an amorphous silicon layer (5) and electrical terminals (6). The photovoltaic core (4) is contacted on the other side with a thermoplastic polymer layer to which in turn is bonded a layer of insulator material such as polyvinyl fluoride. The photovoltaic core (4) is laminated between the upper laminate portion (7) and lower laminate portion (8) using an industrial laminator. The lid of the laminator applies an even downward pressure while application of a controlled temperature and vacuum is made on the laminations. When the vacuum reaches about 1 Torr the temperature has increased to about 140°C. allowing the crosslinking process of the EVA thermoplastic polymer to take place. Pressure is maintained for about a predetermined time to enable complete crosslinking and expulsion of air from between the encapsulated layers.
To prepare the structural assembly the upper structural layer (14) and lower structural layer (15) are bonded to polystyrene insulating material (16) using an appropriate adhesive. The upper surface of the insulating material is prepared with recesses (17) in which access (18) may be placed for electrical wiring (20). The recesses (17) are cut to coincide with the holes (19) in the upper structural layer (14) and the terminals (6) of the photovoltaic core (4) the solar cell assembly (2) is bonded to the upper structural layer (15) and the appropriate solar connectors or terminations can be applied.
The solar panel of the invention can be formed at moderate cost and used as a roofing material in domestic and industrial buildings to provide an integrated system for power generation.
It is to be understood that the invention described hereinabove is susceptible to variations, modifications and/or additions other than those specifically described and that the invention includes all such variations, modifications and/or additions which fall within the spirit and scope of the above description.

Claims

1. A solar panel including a structural assembly including a layer of structural material and a layer of thermal-insulation material on the underside thereof and a solar cell assembly adhered to the upper side of the structural assembly and including a photovoltaic core formed of amorphous silicon and upper and lower layers of thermoplastic material between which the photovoltaic core is laminated.
2. A solar panel according to claim 1 wherein the photovoltaic core is provided with terminals for transmission of generated electricity through the layers of laminate.
3. A solar panel according to claim 1 wherein the terminals of the solar cell assembly cooperate with holes in the structural layer.
4. A solar panel according to claim 1 wherein the insulation is provided with an access within the insulation material passing beneath one or more holes in the structural layer and within which electrical conducting member may be received.
5. A solar panel according to claim 1 wherein the panel includes suitable interconnecting means so that access on adjacent panels cooperate to provide a continuous entry for an electrical conducting member.
6. A solar panel according to claim 1 wherein the structural assembly further comprises a second structural layer disposed beneath the insulation material to provide a sandwich construction comprising two layers of structural material disposed one on either side of the layer of insulation material.
7. A solar panel according to claim 1 wherein the thermoplastic layers of the solar cell assembly are cross-linked and bonded with the amorphous silicon photovoltaic core.
8. A solar panel according to claim 7 wherein the upper and lower thermoplastic layer include ethylene vinyl acetate (EVA).
9. A solar panel according to claim 1 wherein the solar cell assembly is formed by laminating the photovoltaic core between thermoplastic layers at elevated temperature and under a vacuum.
10. A solar panel according to claim 1 wherein the upper thermoplastic layer is provided with an optically transparent scrim incorporate or impregnated into the thermoplastic layer.
11. A solar panel according to claim 1 wherein the upper surface of the solar cell assembly is provided by a transparent plastic layer selected from polyvinyl fluoride and UV stabilized polymer compositions.
12. A solar panel according to claim 1 wherein a layer of electrical insulating material is provided between the photovoltaic core and structural assembly.
13. A solar panel according to claim 12 wherein the insulating material is disposed between the lower layer of thermoplastic laminating photovoltaic material and the structural assembly and is bonded to the laminate on one side and to the upper layer of the structural material on the other.
14. A solar panel according to claim 12 wherein the insulating material is a fluoropolymer.
15. A solar panel according to claim 1 wherein the structural assembly includes a layer or layers of structural material formed of metal sheet and the layer of thermal insulation material is formed of a material selected from the group consisting of polystyrene and/or fire resistant mineral wool or like material, fibregiass, polyurethane and mixture thereof.
16. A solar panel according to claim 1 wherein the thermal insulation material houses an access for electrical transmission.
17. A method of forming a solar panel including the steps of: forming a solar cell assembly including laminating a photovoltaic cell comprising a amorphous silicon with conductive terminals between sheets of thermoplastic material at an elevated temperature and under vacuum to produce crosslinking of the thermoplastic polymer with a surfaces of the amorphous silicon photovoltaic material; and bonding the solar cell assembly to the solar incident surface of a structural assembly including a structural material and a layer of insulating material bonded to the structural layer on the other side thereof.
18. A method according to claim 17 wherein holes in the upper structural layer are formed to coincide with the terminals of the photovoltaic cells to thereby allow electrical transmission of generated energy via access in the layer of insulating material.
PCT/AU2000/000989 1999-08-20 2000-08-18 Solar panel WO2001014660A1 (en)

Priority Applications (1)

Application Number Priority Date Filing Date Title
AU65493/00A AU765696B2 (en) 1999-08-20 2000-08-18 Solar panel

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
AUPQ2361A AUPQ236199A0 (en) 1999-08-20 1999-08-20 Solar panel
AUPQ2361 1999-08-20

Publications (1)

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Cited By (5)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
GB2463335A (en) * 2008-09-15 2010-03-17 Dragon Energy Pte Ltd Photovoltaic tile suitable for use on the roof of a building
GB2477012A (en) * 2009-11-05 2011-07-20 Kingspan Res & Dev Ltd A photovoltaic insulating roof panel
GB2488902A (en) * 2011-03-08 2012-09-12 Kingspan Res & Dev Ltd Composite insulating panel and with laminated solar electric external sheet
GB2460762B (en) * 2008-06-11 2013-01-02 Kingspan Res & Dev Ltd Composite insulating panel with solar collector
GB2496944A (en) * 2011-09-30 2013-05-29 Kingspan Holdings Irl Ltd Insulating panel with through hole for wires of solar collector

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US4860509A (en) * 1987-05-18 1989-08-29 Laaly Heshmat O Photovoltaic cells in combination with single ply roofing membranes
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GB2460762B (en) * 2008-06-11 2013-01-02 Kingspan Res & Dev Ltd Composite insulating panel with solar collector
GB2463335A (en) * 2008-09-15 2010-03-17 Dragon Energy Pte Ltd Photovoltaic tile suitable for use on the roof of a building
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GB2515916B (en) * 2011-03-08 2015-11-11 Kingspan Res & Dev Ltd A composite insulating panel
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