Innovative Design‐for‐Recycling for Critical Material‐Free Interconnection of PV Modules

ABSTRACT Both metallization material consumption and module recycling are growing concerns in photovoltaic (PV) sector. In order to overcome these challenges, we present a module designed to facilitate recycling with no dispersive material consumption in interconnection while maintaining high module performances. Our approach aims to overcome these limitations by integrating a liquid optical coupling layer and carefully optimized front cover. This new glass‐glass module architecture comprises six elements. First, a solid polymer layer is melt on the intern side of the glass plates in which are embedded the connectors blocks their movements. Second, a transparent liquid layer around the cells maintains an optical index progression all along the light path to the cell surface as well as it separates the polymer layer from sticking to the cell surface. Finally, an edge sealant is melt on the periphery of glass plates to form a mechanical contact between connectors and metallization, and to seal the liquid layer. Optical simulations have been performed to ensure the optical relevance of this structure. A simple thermal model has also been developed to verify the thermal heat dissipation potential of this architecture. Last but not least, proof of concept modules have been fabricated and submitted to accelerated aging tests.