WO2014046810A1

WO2014046810A1 - Systems and methods for press curing photovoltaic cell module preassemblies

Info

Publication number: WO2014046810A1
Application number: PCT/US2013/054815
Authority: WO
Inventors: Richard Sibbick
Original assignee: Dow Corning Corporation
Priority date: 2012-09-24
Filing date: 2013-08-14
Publication date: 2014-03-27

Abstract

A system generally comprises a first conveyor including a receptacle configured to receive a photovoltaic (PV) cell module preassembly; a vacuum applicator; a pressure applicator; a curing applicator; and a second conveyor; wherein the second conveyor is arranged opposing the first conveyor to seal the receptacle, and configured to function as a press bladder for the pressure applicator; wherein the vacuum applicator, the pressure applicator, and the curing applicator are configured to respectively process the PV cell module preassembly at spatially distinct positions of the receptacle; wherein the first or second conveyor is configured to transport the receptacle from position to position from the vacuum applicator to the pressure applicator and from the pressure applicator to the curing applicator; and wherein the system is configured and operable to form a cured PV cell module. A method employs the system to press cure PV cell module preassemblies to prepare cured PV cell modules.

Description

SYSTEMS AND METHODS FOR PRESS CURING PHOTOVOLTAIC CELL MODULE

PREASSEMBLIES

BACKGROUND

[001 ] Embodiments described herein relate generally to systems and methods for press curing photovoltaic cell module preassemblies.

[002] Photovoltaic (PV) cell modules typically include at least one PV cell (PV semiconductor device) sandwiched between a backing substrate, and a protective superstrate. PV cell modules may be deployed in harsh environments, where they need to withstand exposure to rain, dust, atmospheric pollutants, and any other debris. Such contamination would decrease the efficiency of the PV cell modules. Therefore the PV cells are typically encapsulated, and the encapsulated PV cells are laminated with the substrate and superstrate to protect them from the harsh environments.

[003] One known process of laminating PV cell modules is forming a PV cell module preassembly comprising, sequentially, a backing substrate layer, curable encapsulated PV cell(s) layer, and protective superstrate layer. The preassembly is then subject to an evacuate-press-cure process to give cured PV cell modules.

[004] Current known systems for forming the cured PV cell modules employ batch processing of PV cell module preassemblies in a batch laminator. The batch processing comprises evacuating, pressing, and curing, which are sequentially applied within the same enclosure of the batch laminator. The batch laminator contains an enclosure for controlling local environment such as atmosphere, temperature and pressure. For example, the local environment comprises loading/unloading conditions comprising ambient atmosphere (e.g., air) and pressure when loading preassemblies into the batch laminator and unloading the resulting modules from the batch laminator. During the evacuating, pressing, and curing, the local environment comprises laminating conditions comprising reduced pressure (typically a full vacuum condition) and elevated temperature (curing condition). Every time a new preassembly is introduced into the batch laminator the local environment within the enclosure of the batch laminator must first be restored to the loading/unloading conditions. Every time a new preassembly is processed by the batch laminator, the local environment within the enclosure must be restored to the laminating conditions. However, such systems do not allow resource- effective scaling of production throughput without the use of more than one batch laminator, or the use of a batch laminator that can handle a plurality of preassemblies, e.g., a stacked batch laminator whereby preassemblies are stacked in a single large 1 vacuum chamber that may have individual means of applying pressure to each preassembly. Consequently, such batch systems drive up equipment costs, require relatively longer processing time that reduces module output rates, and also occupy a relatively large space within a manufacturing facility. Further, batch laminators require complex and powerful vacuum pumps, since the enclosure of the batch laminator is large relative to a single preassembly and needs to be effectively evacuated, and the complete vacuum is lost with processing each batch of preassemblies when the equipment is opened to allow removal of processed cured PV cell modules and replacement with unprocessed preassemblies.

[005] Thus there is a need for systems and methods to overcome these and other known drawbacks of current batch press curing systems.

[006] SUMMARY

[007] A system for forming cured photovoltaic (PV) cell modules is described, according to various embodiments of the present invention. The system includes a first conveyor including a receptacle configured to receive a PV cell module preassembly comprising, inter alia, a curable composition. The system also includes a vacuum applicator configured to substantially evacuate a gas from the receptacle; a pressure applicator configured to press the PV cell module preassembly against a press bladder when the PV cell module preassembly is disposed in the receptacle; and a curing applicator configured to apply a curing condition to the curable composition of the PV cell module preassembly in the receptacle. Further, the system also includes a second conveyor configured to move in tandem with the first conveyor. The second conveyor is arranged opposing the first conveyor to seal the receptacle, and configured to function as a press bladder for the pressure applicator. The vacuum applicator, the pressure applicator, and the curing applicator are configured to respectively process the PV cell module preassembly at spatially distinct positions of the receptacle. The first or the second conveyor is configured to transport the receptacle from position to position from the vacuum applicator to the pressure applicator and from the pressure applicator to the curing applicator. The system is configured and operable to form a cured PV cell module from the PV cell module preassembly. The system may form the cured PV cell module using the following method.

[008] A method of forming a cured photovoltaic module is described, according to various embodiments of the present invention. The method comprises a receiving step, sealing step, evacuating step, pressing step, curing step, and separating step. The 1 method receives a photovoltaic (PV) cell module preassembly in a receptacle of a conveyor line. The PV cell module preassembly has a curable composition that is in need of curing. The conveyor line includes a first conveyor comprising the receptacle, and a second conveyor opposed to and configured to move in tandem with the first conveyor. The method performs the receiving step at a first position of the sealed receptacle of the conveyor line. Next, the method seals the receptacle containing the PV cell module preassembly with the second conveyor. The method then evacuates at least some gas from the sealed receptacle at a second position of the sealed receptacle of the conveyor line. Further, the method presses the PV cell module preassembly in the sealed receptacle with at least some gas evacuated therefrom at a third position of the sealed receptacle of the conveyor line. The method also applies a curing condition to the pressed PV cell module preassembly in the sealed receptacle, to obtain a cured PV cell module. The method may apply the curing condition at the third position or at an optional fourth position of the sealed receptacle of the conveyor line. Finally, the method separates the cured PV cell module from the receptacle at a fifth position of the receptacle of the conveyor line. Each of the positions of the receptacle are spaced apart from each other.

BRIEF DESCRIPTION OF THE DRAWINGS

[009] Various embodiments will now be described in conjunction with accompanying drawings, wherein:

[010] FIG. 1 is a cross section view of an example photovoltaic (PV) cell module preassembly to be cured, according to an embodiment of the present invention;

[011 ] FIG. 2 is an example system for forming cured PV cell modules, according to an embodiment of the present invention;

[012] FIGS. 3A-3C illustrate an exemplary receptacle at different positions in a system for forming cured PV cell modules, according to an embodiment of the present invention;

[013] FIG. 4 is an example system for forming cured PV cell modules, according to another embodiment of the present invention;

[014] FIGS. 5A-5C illustrate an exemplary receptacle at different positions in a system for forming cured PV cell modules, according to another embodiment of the present invention; and

[015] FIG. 6 is a flowchart of an exemplary method of forming a cured PV cell module, according to various embodiments of the present invention.

DETAILED DESCRIPTION 1

[016] Various embodiments of the present invention presented herein describe systems and methods for staged or pipelined techniques of press curing laminate preassemblies. Such staged or pipelined techniques may be implemented as a continuous process or a step wise process, using an apparatus, such as those described in conjunction with FIGS. 2, 3A-3C, 4, and 5A-5C. As referred to herein, the staged or pipelined techniques refer to systems and methods that perform the different steps of the press cure process, i.e. evacuation, pressing, and curing of the laminate preassembly at distinct spatial locations (in other words, at distinct stations) within the conveyor apparatus. The systems and methods may operate either as a discrete step wise process where the system advances the laminate preassembly between the distinct stations, and pauses or stops for predefined time intervals at the distinct stations. Alternatively the systems and methods may operate as a continuous process where the system advances the laminate preassembly in a continuous manner without stopping at each of the distinct stations. Such a staged or pipelined process may thus exhibit higher throughput as compared to a comparative batch processing method employing a single unit for evacuating, pressing and curing steps. In the comparative batch processing method a batch of laminate preassemblies are introduced into a unit and a lid is closed. The steps of evacuating the closed unit, pressing the laminate preassemblies, and applying a curing condition to the laminate preassemblies are then carried out in sequence within the closed unit. The lid of the unit is then opened to extract cured laminate assemblies. Time may be lost in closing and opening the lid after every batch. Vacuum is also lost after each batch, thus requiring use of a high power vacuum pump, or requiring longer time for creating the vacuum using a lower power vacuum pump.

[017] The cure step of the process preferably lasts enough time to provide a sufficient cure. The term "sufficient cure" as used herein, may mean: enough cure so that surfaces are bound together and panel has good visual properties (i.e. no bubbles) yet not completely cured so as to allow for post curing (completing the process) in a further process eg. oven. Alternatively, the term "sufficient cure" may mean that the cure is completed and no further processing is needed. Cured laminate can be sent for further processing; j-box, frame, and so forth.

[018] Referring now to the Figures, FIG. 1 is a cross section view of an exemplary photovoltaic (PV) cell module preassembly 100 to be cured, according to various embodiments. The PV cell module preassembly 100 sequentially includes a back sheet 1 10, a first layer of liquid encapsulant 120, a photovoltaic cell 130, a second layer of 1 liquid encapsulant 140, and a superstrate 150. The first layer of liquid encapsulant 120, or the second layer of liquid encapsulant 140, or both comprise the curable composition and may be in need of curing. The first layer of liquid encapsulant 120 and the second layer of liquid encapsulant 140 may be one of a silicone encapsulant, or poly(ethylene- co-vinyl acetate) (EVA), or other suitable curable encapsulant composition. The superstrate 150 may include a suitable transparent material, such as soda-lime glass (vitreous silica). During the method, the PV cell module preassembly 100 may be disposed in the receptacle such that the back sheet 1 10 is oriented facing up and the superstrate 150 is oriented facing down. Although a PV Cell is illustrated in FIG. 1 , and described in the following paragraphs, embodiments presented herein may also be applied for other thin film modules. Particular embodiments of the present invention, as described herein, may be applied to thin film modules having a thin film device (in place of the PV cell 130), and a superstrate 150 such as soda-lime glass (vitreous silica).

[019] In various embodiments, the liquid encapsulant 120 and 140 may be an addition- cure silicone. Such an addition cure silicone may typically be a hydrosilylation-reaction cure type of liquid encapsulant 120 or 140. The addition-cure silicone may include a catalyst and an inhibitor. The addition-cure silicone may start to cure as soon as the catalyst and the inhibitor are mixed in a ratio effective therefor. Curing of the addition- cure silicone may depend on various factors such as amount of catalyst, amount of inhibitor, if any, and the temperature, for example. The addition-cure silicone may be mixed such that the addition-cure silicone stays in the liquid form for dispensing, for example, but cures quickly enough to ensure that the curing process is economical to operate. Typically, once the catalyst and inhibitor are balanced, i.e. in the effective ratio or amounts, and at the effective temperature, additional heat may be supplied to accelerate the curing of the addition-cure silicone.

[020] Compared to EVA, press time and cure time for silicone in the method is much quicker; for example, the cure time may be approximately 1 or 2 minutes for silicone versus 10 or 15 minutes for EVA. Thus, with silicone, the system can be physically shorter and/or the method may provide for a shorter cycle time / higher throughput than with EVA.

[021 ] FIG. 2 illustrates an exemplary system 200 for forming cured photovoltaic modules, according to one embodiment. The system 200 includes a first conveyor 210, one or more receptacles 220, a second conveyor 230, a vacuum applicator 240, a pressure applicator 250, and a curing applicator 260. As illustrated in FIG. 1 , the 1 vacuum applicator 240, the pressure applicator 250, and the curing applicator 260 are arranged such that they respectively process the PV cell module preassembly 100 at spatially distinct positions A to E along the first conveyor 210. In other words, a receptacle 220 receives the PV cell module preassembly 100 at a first position A. In various embodiments, the PV cell module preassembly 100 may be received by the receptacle 220 with the superstate 150 (FIG. 1 ) facing down towards the first conveyor 210, and the back sheet 1 10 (FIG. 1 ) facing up towards the second conveyor 230. The vacuum applicator 240 processes the PV cell module preassembly 100 at a second position B, the pressure applicator 250 processes the PV cell module preassembly 100 at a third position C, and the curing applicator 260 processes the PV cell module preassembly 100 at a fourth position D. In some implementations, the curing applicator 260 may also partially process the PV cell module preassembly 100 at the third position C. Stated another way, the pressure applicator 250 and curing applicator 260 may process the PV cell module preassembly 100, at the same position, for example, the third position C or the fourth position D. The cured PV cell module exits the system 200 at fifth position E, onto another conveyor or another apparatus for allow for post curing (completing the process) in a further process. Alternatively, the cured PV cell module exits the system 200 at fifth position E onto a conveyor or another receiving apparatus where it may be process as required before shipping, for example, installing j-box, frame, and so forth. The arrangement of the vacuum applicator 240, the pressure applicator 250, and the curing applicator 260 may also allow for a continuous processing of the PV cell module preassembly 100. That is, the first conveyor 210 may continuously advance the receptacle 220 through the positions A-E, without stopping or pausing at one or more of the positions A-E. In such an implementation, the curing applicator 260 may process the PV cell module preassembly 100, while the pressure applicator 250 processes the PV cell module preassembly 100 at the third position C. The curing applicator may continue to process the PV cell module preassembly 100 at the fourth position D. Any friction may be overcome by use of low friction support structures (not shown) such as rollers, toothed conveyors, low friction material coatings, or heating elements in the bottom and/or top of the first conveyor 210 or the second conveyor 230.

[022] As shown in FIG. 2, the first conveyor 210 may transport each of the receptacles 220 from position to position, e.g., from first position A to second position B, to third position C, to fourth position D, and finally to fifth position E. Alternatively, the second 1 conveyor 230 may transport each of the receptacles 220 from position to position such as after the sealing and evacuating of the receptacle containing the PV cell module preassembly 100 or in embodiments wherein the second conveyor 230 is in operative contact with the receptacle via a friction fit. At the first position A, the system 200 receives the PV cell module preassembly 100. At the second position B the system 200 seals and substantially evacuates the receptacle 220. At the third position C the system 200 presses the PV cell module preassembly 100 within the receptacle 220. Additionally at the third position C, or at the fourth position D the system 200 applies a curing condition to the PV cell module preassembly 100. Finally at the fifth position E the system 200 separates the cured PV cell module from the receptacle 220. In various implementations, separating the cured PV cell module from the receptacle includes releasing the vacuum in the receptacle 220. In other words, a gas such as air or an inert gas is allowed to enter the evacuated receptacle to equalize pressure within the receptacle with ambient pressure. Next, the second conveyor 230 may be separated from the receptacle 220 so as to unseal the receptacle 220. Finally, the cured PV cell module is separated from the receptacle 220. The first conveyor 210 may include a plurality of such receptacles 220, arranged along the length of the first conveyor 210. The plurality of receptacles 220 may be disposed on the first conveyor 210 touching each other, such that they form a continuous chain of receptacles, as illustrated in FIG. 2. Alternatively, the receptacles may be disposed on the first conveyor 210 with a predetermined gap (not indicated) between successive receptacles 220, such that they form a discontinuous chain of receptacles, alternating with the predetermined gap.

[023] In the system 200 of FIG. 2, the second conveyor 230 may be a flexible conveyor belt, made of silicone, or any other suitable flexible material. The second conveyor 230 is arranged opposing the first conveyor 210. The second conveyor 230 may be configured to move in tandem with the first conveyor 210. In other words, the second conveyor 230 may be configured to move at the same speed as the speed of the first conveyor 210. The second conveyor 230 is configured to seal the receptacle 220, at position B. The second conveyor 230 maintains the sealing condition of the receptacle 220 through positions C and D as well. The second conveyor 230 may be configured to form a substantially gas tight sealing condition for the receptacle 220. The second conveyor 230 may form the sealing condition with face 228 of the walls 226 of the receptacle 220. The sealing condition as referred to herein, is a leak-minimized or leak- free condition of the receptacle 220, such that little or no gas passes in or out of the 1 receptacle 220 in the sealing condition. Such a sealing condition enables the vacuum applicator 240 to evacuate at least a portion of gas from the sealed receptacle 220. The flexible construction, opposed arrangement to the first conveyor 210, and the speed matched to the speed of the first conveyor 200, allow a portion of the second conveyor 230 to be configured as a sealing lid for the receptacle 220. For the purpose of clarity of this description, the receptacle 220 sealed by the sealing portion of the second conveyer 230 is referred to herein as the sealed receptacle 220. One embodiment of the sealed receptacle 220 is illustrated in FIG. 3B.

[024] In the system 200 of FIG. 2, the vacuum applicator 240 may be configured to evacuate at least some gas from the sealed receptacle 220. In one implementation, the vacuum applicator 240 may be configured to substantially evacuate a gas from the receptacle 220, thus creating a substantial vacuum in the sealed receptacle 220. In another implementation, the vacuum applicator 240 may be configured to evacuate a portion of the gas from receptacle 220, thus creating a partial vacuum in the sealed receptacle 220. In some implementations, gas may be evacuated from the receptacle 220, such that the pressure within the receptacle 220 may be between about 0.5 kilopascal (kPa) and about 5 kPa, for example. In any event, the amount of gas evacuated from the sealed receptacle 220 is sufficient to enable the pressing step of the method. Referring to FIG. 3B, various elements of the vacuum applicator 240 are illustrated. The vacuum applicator 240 may include a vacuum pump 242 to create a vacuum. The vacuum applicator 240 may further include any combination of fluid coupling members 244 and 246, such as, but not limited to, piping, manifolds, valves, and vacuum chambers to apply the vacuum to the receptacle 220. The fluid coupling members may be arranged to place the vacuum pump 242 in fluid communication with the ports 222 disposed on the receptacle 220.

[025] In one implementation of system 200 of FIG. 2, the vacuum applicator 240 may include multiple vacuum pumps 242 and corresponding fluid coupling members 244, and 246, to re-apply the vacuum at different positions B, C, and D of the sealed receptacle 220. In such an implementation, the different vacuum pumps 242 may apply the same level of vacuum, or distinct levels of vacuum at the different positions B, C, and D. For example, the vacuum applicator 240 may apply a partial vacuum at position B, a substantial vacuum at position C, and maintain the substantial vacuum at position D. Exemplary values of pressure within the receptacle 220 may range from about 0.5 kPa 1 to about 5 kPa. Such a staged approach may allow a more energy efficient utilization of the vacuum applicator 240.

[026] In system 200 of FIG. 2, the pressure applicator 250 may be configured to press the PV cell module preassembly in the receptacle 220.

[027] Referring to FIG. 2, the curing applicator 260 may be configured to apply a curing condition to the PV cell module preassembly in the receptacle 220. The curing condition may be defined as an environment or agent that triggers, enhances rate of, increases the speed of, or effects (is effective for) the curing of the liquid encapsulant 120, 140, or 120 and 140. The curing condition may include one or more of electromagnetic radiation, such as ultraviolet radiation, one or more electron beams, heating, or exposure to a curing agent such as a curing catalyst. The curing catalyst may be a particulate metal that is coated or inhibited with an inhibitor ligand, and curing may be triggered by separating the coating or inhibitor ligand from the metal. The curing condition may be selected based on the specific liquid encapsulant 120 and 140 used in the PV cell module preassembly 100. For example, heat may be applied as the curing condition for heat curable liquid silicone encapsulants, poly(ethylene-co-vinyl-acetate) encapsulants, and so forth; UV radiation may be applied as the curing condition for free radical curable liquid silicone encapsulants; or moisture may be applied as the curing condition for condensation curable liquid silicone encapsulants..

[028] In some implementations of the system 200 of FIG. 2, the curing applicator 260 comprises a curing heat applicator (not shown). The curing heat applicator may apply heat such that the PV cell module preassembly 100 may be heated to temperatures ranging from about 50 degrees Celsius (°C) to about 200 °C, for example. The curing heat applicator may apply heat for a time duration ranging from about 90 seconds to about 10 minutes, for example. The temperature and duration of heat application may depend on the type and material of the liquid encapsulant 120 and 140. The temperature and duration of heat application may also depend on the type of PV cell module preassembly 100, materials of the back sheet 1 10, PV cell 130, and the superstate 150. The curing heat applicator may include a heating unit (not shown) for heating a heat transfer fluid, and a heat exchange assembly (not shown) for contacting the receptacle 220 with the heat transfer fluid. For example, if the heat transfer fluid is a gas, the heating unit may be an electric heating filament (not shown) to heat air, or the exhaust air of a combustion type heater (not shown). In such an implementation, the heat exchange assembly may include ducting (not shown) to flow the heated gas over at 1 least one surface of the receptacle 220. Hot gas jets (not shown) may also be used as the heat exchange assembly. The heat applicator may further include associated piping (not shown), tubing (not shown), valves (not shown), and pumps (not shown) to pump the heat transfer fluid from the heating unit, to the heat exchange assembly, and in recirculation type curing heat applicators, back to the heating unit. The heat transfer fluid may be spaced apart from the PV cell module preassembly 100 by at least the receptacle 220 and does not contact the PV module preassembly 100 disposed in the receptacle 220. In some embodiments of the method that employ the heating unit, the heat exchange assembly may function to conduct heat from the heat transfer fluid to the receptacle 220 and ultimately to the PV cell module preassembly 100. Alternatively the heat exchange assembly may function to conduct heat from the PV cell module preassembly 100 to the receptacle 220 and ultimately to the heat transfer fluid. In some embodiments, the conduction of heat may be effected in both directions between the receptacle 220 and the PV cell module preassembly 100. The heat exchange assembly may be disposed in the interior space 212 of the first conveyor 210. Alternatively, the heat exchange assembly may be disposed in the interior space 232 of the second conveyor 230. In the method, the heat transfer fluid may cause heating of a PV cell module preassembly 100 having a heat curable encapsulant so as to at least partially cure the heat curable encapsulant.

[029] In some other implementations of the system 200 of FIG. 2, the curing heat applicator (not shown) may include an induction heating unit (not shown) to directly apply curing heat to the PV cell module preassembly in the receptacle 220. The induction heating unit may include an electric heater filament (not shown), an infrared lamp (not shown), or the like. The induction heating unit may be disposed within the first conveyor 210 or the second conveyor 230 or both. Alternatively, the induction heating unit may be disposed in at least one wall (not shown) or floor (not shown) of the receptacle 220. In such implementations, the complete length of the first conveyor 210 or the second conveyor 230, or both may include electric heater filaments. The curing heat applicator may also include a control unit (not shown) to activate or deactivate the induction heating unit, based on the position of the receptacle 220. Alternatively the induction heating unit may be capable of receiving activation or deactivation signals from an external control unit (not shown) or microprocessor (not shown).

[030] The system 200 may also include a microprocessor based control system 270 as shown in FIG. 2. The microprocessor based control system 270 may monitor and 1 control various elements of the system 200, such as the first conveyor 210, the second conveyor 230, the vacuum applicator 240, the pressure applicator 250, and the curing applicator 260. The microprocessor based control system 270 may include any combination of sensors (not shown) such as speed sensors (not shown) for detecting speed of the first conveyor 210, and the second conveyor 230; position sensors (not shown) for detecting the position of the receptacle 220, absolute or relative pressure sensors (not shown) for detecting gas pressure within the receptacle 220, and within the press bladder; temperature sensors (not shown) within the receptacle 220, and/or within the curing heat applicator, and so forth. The microprocessor based control system 270 may simply record the data gathered by the sensors, or may utilize the sensor data to control the system 200 through a feedback, a feed-forward loop, or a combination thereof.

[031 ] Referring to FIG. 2, the microprocessor based control system 270 may also include actuators (not shown) such as relays, solenoids, and so forth, to control components of the vacuum applicator 240 such as the valves, the vacuum pump 242, and so forth; components of the pressure applicator 250, such as the pressure valves 254; and components of the curing applicator 260.

[032] Referring to FIG. 2, the microprocessor based control system 270 has a central processing unit (not shown). The central processing unit may be a microprocessor, a microcontroller, or the like. The central processing unit may be programmed to control the various elements of the system 200 either by a preset process algorithm, or based on the sensor data, or any combination thereof. The central processing unit may also be configured to receive operator input to manually adjust the process parameters of the press-cure process, such as the conveyor speeds, vacuum time, press time, vacuum absolute pressure, pressure of the pressure applicator 250, curing time, curing condition intensity (for example, amount of heat applied, temperature of PV cell module preassembly 100), and so forth.

[033] Referring now to FIG. 3A, an exemplary receptacle 220 is illustrated. The receptacle 220 may be configured to receive the PV cell module preassembly 100 and capable of being substantially sealed with the PV cell module preassembly 100 disposed therein. FIG. 3A is an enlarged view of an exemplary receptacle 220, according to one embodiment. The receptacle 220 may include one or more ports 222 configured to remove at least some gas from the receptacle 220. The ports 222 may be capable of being placed in fluid communication with a vacuum pump (not shown). The receptacle 1

220 may include a floor 224 and walls 226. In one implementation, the receptacle 220 may be a part of the first conveyor 210 formed as a hollow pocket with a floor 224, within the first conveyor 210. In another implementation, the receptacle 220 may include a portion of the first conveyor 210 as the floor 224, and having walls 226 fixedly attached to the first conveyor 210 at the periphery of the portion demarcated as the floor 224 of the receptacle 220. In yet another implementation, the receptacle 220 may be a tray (not shown), for example a rectangular tray, having a flexible floor 224, and at least two flexible walls 226. Such a receptacle 220 may be a single link (not shown) of a multi- flexing chain type (not shown) conveyor belt. A plurality of such receptacles 220 may be chain linked to form the first conveyor 210. Although some implementations of the receptacle 220 have been described above, other implementations are within the scope of this disclosure. The receptacle 220 may be configured to be fluid tight between the floor 224 and the walls 226 and also fluid tight mutually between adjacent walls 226. The more ports 222 may be disposed on at least one wall 226.

[034] Referring to FIG. 3B, various elements of the vacuum applicator 240 (FIG. 2) are illustrated. The vacuum applicator 240 may include a vacuum pump 242, a vacuum chamber 244, and valves 246. The valves 246 may be configurable to place the vacuum pump 242 in fluid communication with the vacuum chamber 244.

[035] Also illustrated in FIG. 3B, are various elements of the pressure applicator 250 (FIG. 2). The pressure applicator 250 may include a pressure chamber 252, and one or more valves 254. The pressure chamber 252 may be disposed in the interior space 232 of the second conveyor 230. The second conveyor 230 may also be configured to function as a portion of the press bladder 256 for the pressure applicator 250. The flexible construction, opposed arrangement to the first conveyor 210, and the speed matched to the speed of the first conveyor 200, allow the second conveyor 230 to be configured as a press bladder 256 for the pressure applicator 250. The pressure chamber 252 may be sealed by a portion of the second conveyor 230 adjacent to the pressure chamber 252. The pressure chamber 252 and the sealing portion of the second conveyor 230 that is adjacent to the pressure chamber 252 together define a press bladder 256, capable of being inflated. The press bladder 256 when inflated presses the PV cell module preassembly 100 in the receptacle 220. Pressing the PV cell module preassembly 100 in the receptacle 220 may inhibit movement of the PV cell module preassembly within the receptacle 220. Further, pressing the PV cell module preassembly 100 may bring all laminate components 1 10-150 of the PV cell module 1 preassembly 100 into close contact with each other, such that adhesion of all components 1 10-150 is even, and curing of the liquid encapsulant 120 and 140 is consistent.

[036] FIG. 3C illustrates an inflated press bladder 256 pressing the PV cell module preassembly 100 within the receptacle 220. The valves 254 are configured to apply fluid pressure to the pressure chamber 252 to inflate the press bladder 256, thus pressing the PV cell module preassembly 100 in the receptacle 220 with the gas evacuated therefrom. The applied fluid pressure may be atmospheric pressure, or applied as pressurized air or another suitable gas, or pressurized water, for example.

[037] FIG. 4 illustrates an exemplary system 400 for forming cured photovoltaic modules, according to another embodiment. The system 400 includes a first conveyor 410, one or more receptacles 420, a second conveyor 430, a vacuum applicator 440, a pressure applicator 450, and a curing applicator 460. As illustrated in FIG. 4, the vacuum applicator 440, the pressure applicator 450, and the curing applicator 460 are arranged such that they respectively process the PV cell module preassembly 100 at spatially distinct positions along the first conveyor 410. In other words, a receptacle 420 receives the PV cell module preassembly 100 at a first position A. In various embodiments, the PV cell module preassembly 100 may be received by the receptacle 420 with the superstrate 150 (FIG. 1 ) facing down towards the first conveyor 410, and the back sheet 1 10 (FIG. 1 ) facing up towards the second conveyor 430. The vacuum applicator 440 processes the PV cell module preassembly 100 at a second position B, the pressure applicator 450 processes the PV cell module preassembly 100 at a third position C, and the curing applicator 460 processes the PV cell module preassembly 100 at a fourth position D. The cured PV cell module exits the system 400 at fifth position E, onto another conveyor or another apparatus for allow for post curing (completing the process) in a further process. Alternatively, the cured PV cell module exits the system 400 at fifth position E onto a conveyor or another receiving apparatus where it may be processed as required before shipping, for example, installing j-box, frame, and so forth. In some implementations, the curing applicator 460 may also partially process the PV cell module preassembly 100 at the third position C. Stated another way, the pressure applicator 450 and curing applicator 460 may process the PV cell module preassembly 100, at the same position, for example, the third position C or the fourth position D. The arrangement of the vacuum applicator 440, the pressure applicator 450, and the curing applicator 460 may also allow for a continuous processing of the PV cell module 1 preassembly 100. That is, the first conveyor 210 may continuously advance the receptacle 220 through the positions A-E, without stopping or pausing at one or more of the positions A-E. In such an implementation, the curing applicator 460 may process the PV cell module preassembly 100, while the pressure applicator 450 processes the PV cell module preassembly 100 at the third position C. The curing applicator may continue to process the PV cell module preassembly 100 at the fourth position D. Any friction may be overcome by use of low friction support structure (not shown) such as rollers, toothed conveyors, low friction material coatings, or heating elements in the bottom and/or top of the first conveyor 410 or the second conveyor 430.

[038] As shown in FIG. 4, the first conveyor 410 may transport each of the receptacles 420 from position to position, from position A where the system 400 receives the PV cell module preassembly, to position B where the system 400 seals and substantially evacuates the receptacle 420, to position C where the system 400 presses the PV cell module preassembly within the receptacle 420, to position D where the system 400 applies a curing condition to the PV cell module preassembly, and finally to position E where the system 400 separates the cured PV cell module from the receptacle 420. In various implementations, separating the cured PV cell module from the receptacle includes releasing the vacuum in the receptacle 420. In other words, a gas such as air or an inert gas is allowed to enter the evacuated receptacle to equalize pressure within the receptacle with ambient pressure. Next, the second conveyor 430 may be separated from the receptacle 420 so as to unseal the receptacle 420. Finally, the cured PV cell module is separated from the receptacle 420. Alternatively, the second conveyor 430 may transport each of the receptacles 420 from position to position such as after the sealing and evacuating of the receptacle containing the PV cell module preassembly 100 or in embodiments wherein the second conveyor 430 is in operative contact with the receptacle via a friction fit. The first conveyor 410 may include a plurality of receptacles 420, arranged along the length of the first conveyor 410. The plurality of receptacles 420 may be disposed on the first conveyor 410 touching each other, such that they form a continuous chain of receptacles, as illustrated in FIG. 4. Alternatively, the receptacles may be disposed on the first conveyor 410 with a predetermined gap (not shown) between successive receptacles 420, such that they form a discontinuous chain of receptacles, alternating with the predetermined gap. The receptacle 420 may be configured to receive the PV cell module preassembly 100. 1

[039] Referring to FIG. 4, the second conveyor 430 may be a flexible conveyor belt, made of silicone, or any other suitable flexible material. The second conveyor 430 is arranged opposing the first conveyor 410. The second conveyor 430 may be configured to move in tandem with the first conveyor 410. In other words, the second conveyor 430 may be configured to move at the same speed as the first conveyor 410. The second conveyor 430 is configured to seal the receptacle 420, at position B. The second conveyor 430 maintains the sealing condition of the receptacle 420 through positions C and D as well. The second conveyor 430 may be configured to form a substantially gas tight sealing condition for the receptacle 420. The second conveyor 430 may form the sealing condition with face 428 of the walls 426 of the receptacle 420. The sealing condition is a leak-minimized or leak-free condition of the receptacle 420, such that little or no gas passes in or out of the receptacle 420 in the sealing condition. Such a sealing condition enables the vacuum applicator 440 to effectively evacuate at least some gas from the sealed receptacle 420. The flexible material of the second conveyor 430, opposed arrangement to the first conveyor 410, and the speed matched to the speed of the first conveyor 400, allow the second conveyor 430 to be configured as a sealing lid of the receptacle 420. For the purpose of clarity of this description, the receptacle 420 sealed by a portion of the second conveyer 430 is referred to herein as the sealed receptacle 420. One embodiment of the sealed receptacle 420 is illustrated in FIG. 5B.

[040] In the system 400 of FIG. 4, the vacuum applicator 440 may be configured to evacuate at least some gas from the sealed receptacle 420. In one implementation, the vacuum applicator 440 may be configured to substantially evacuate a gas from the receptacle 420, thus creating a substantial vacuum in the sealed receptacle 420. In another implementation, the vacuum applicator 440 may be configured to evacuate a portion of the gas from receptacle 420, thus creating a partial vacuum in the sealed receptacle 420. In some implementations, gas may be evacuated from the receptacle 420, such that the pressure within the receptacle 420 may be between about 0.5 kPa and about 5 kPa, for example. The amount of gas evacuated from the sealed receptacle 420 may be sufficient to enable the pressing step of the method.

[041 ] In one implementation of the system 400 of FIG. 4, the vacuum applicator 440 may include multiple vacuum pumps (not shown) and corresponding fluid coupling members (not shown), to re-apply the vacuum at different positions B, C, and D of the sealed receptacle 420. In such an implementation, the different vacuum pumps may apply the same level of vacuum, or distinct levels of vacuum at the different positions B, 1

C, and D. For example, the vacuum applicator 440 may apply a partial vacuum at position B, a substantial vacuum at position C, and maintain the substantial vacuum at position D. Exemplary values of pressure within the receptacle 420 may range from about 0.5 kPa to about 5 kPa. Such a staged approach may allow a more energy efficient utilization of the vacuum applicator 440.

[042] In the system 400 of FIG. 4, the pressure applicator 450 may be configured to press the PV cell module preassembly 100 in the receptacle 420.

[043] In reference to FIG. 4, the curing applicator 460 may be configured to apply a curing condition to the PV cell module preassembly in the receptacle 420. The curing condition may be defined as before, in conjunction with FIG. 2.

[044] In some implementations of the system 400 of FIG. 4, the curing applicator 460 comprises a curing heat applicator (not shown). The curing heat applicator may supply heat to the PV cell module preassembly 100 to maintain a temperature of about 30 °C to about 200 'Ό, for example. The curing heat applicator may supply heat, for example, for a duration ranging from about 90 seconds to about 10 minutes. The curing heat applicator may be configured to maintain a curing temperature for a preset duration, based on the type and material of components 1 10-150 of the PV cell module preassembly 100. The curing heat applicator may include a heating unit (not shown) for heating a heat transfer fluid, and a heat exchange assembly (not shown) for contacting the receptacle 420 with the heat transfer fluid. For example, if the heat transfer fluid is a gas, the heating unit may be an electric heating filament (not shown) to heat air, or the exhaust air of a combustion type heater (not shown). In such an implementation, the heat exchange assembly may include ducting (not shown) to flow the heated gas over at least one surface of the receptacle 420. Hot gas jets (not shown) may also be used for the heat exchange assembly. The heat applicator may further include associated piping (not shown), tubing (not shown), valves (not shown), and pumps (not shown) to pump the heat transfer fluid from the heating unit, to the heat exchange assembly, and in recirculation type curing heat applicators, back to the heating unit. The heat transfer fluid may be spaced apart from the PV cell module preassembly 100 by at least the receptacle 420 and does not contact the PV module preassembly 100 disposed in the receptacle 420. In some embodiments of the method that employ the heating unit, the heat exchange assembly may function to conduct heat from the heat transfer fluid to the receptacle 420 and ultimately to the PV cell module preassembly 100. Alternatively the heat exchange assembly may function to conduct heat from the PV cell module 1 preassembly 100 to the receptacle 420 and ultimately to the heat transfer fluid. In some embodiments, the conduction of heat may be effected in both directions between the receptacle 420 and the PV cell module preassembly 100. The heat exchange assembly may be disposed in the interior space 412 of the first conveyor 410. Alternatively, the heat exchange assembly may be disposed in the interior space 432 of the second conveyor 430. In the method, the heat transfer fluid may cause heating of a PV cell module preassembly 100 having a heat curable encapsulant (e.g. 120, 140 of FIG. 1 ) so as to at least partially cure the heat curable encapsulant.

[045] In some other implementations of the system 400 of FIG. 4, the curing heat applicator may include an induction heating unit (not shown) to directly apply curing heat to the PV cell module preassembly in the receptacle 420. The induction heating unit may include an electric heater filament (not shown), an infrared lamp (not shown), or the like. The induction heating unit may be disposed within the first conveyor 410 or the second conveyor 430. In such implementations, the complete length of the first conveyor 410 or the second conveyor 430, or both may include electric heater filaments. Alternatively, the induction heating unit may be disposed in at least one wall (not shown) or floor (not shown) of the receptacle 420. The curing heat applicator may also include a control unit (not shown) to activate or deactivate the induction heating unit, based on the position of the receptacle 220. Alternatively the induction heating unit may be capable of receiving activation or deactivation signals from an external control unit (not shown) or microprocessor (not shown).

[046] In various implementations, the system 400 of FIG. 4 may also include a microprocessor based control system 470. The microprocessor based control system 470 may monitor and control various elements of the system 400, such as the first conveyor 410, the second conveyor 430, the vacuum applicator 440, the pressure applicator 450, and the curing applicator 460. The microprocessor based control system 470 may include any combination of sensors (not shown) such as speed sensors (not shown) for detecting speed of the first conveyor 410, and the second conveyor 430; position sensors (not shown) for detecting the position of the receptacle 420, absolute or relative pressure sensors (not shown) for detecting gas pressure within the receptacle 420, and within the press bladder; temperature sensors (not shown) within the receptacle 420, and/or within the curing heat applicator, and so forth. The microprocessor based control system 470 may simply record the data gathered by the 1 sensors, or may utilize the sensor data to control the system 400 through a feedback, a feed-forward loop, or a combination thereof.

[047] In the system 400 of FIG. 4, the microprocessor based control system 470 may also include actuators (not shown) such as relays, solenoids, and so forth, to control components of the vacuum applicator 440 such as the evacuation valves, the vacuum pump 452, and so forth; components of the pressure applicator 450, such as the pressure valves 452; and components of the curing applicator 460.

[048] The microprocessor based control system 470 illustrated in FIG. 4 has a central processing unit (not shown). The central processing unit may be a microprocessor, a microcontroller, or the like. The central processing unit may be programmed to control the various elements of the system 400 either by a preset process algorithm, or based on the sensor data, or any combination thereof. The central processing unit may also be configured to receive operator input to manually adjust the process parameters of the press-cure process, such as the conveyor speeds, vacuum time, press time, vacuum absolute pressure, pressure of the pressure applicator 450, curing time, curing condition intensity, and so forth.

[049] FIG. 5A is an enlarged view of an exemplary receptacle 420, according to one embodiment. The receptacle 420 may include a floor 424 and walls 426. In one implementation the receptacle 420 may be a part of the first conveyor 420 formed as a hollow pocket with a floor 424, within the first conveyor 420. In another implementation, the receptacle 420 may include a portion of the first conveyor 410 as the floor 424, and having walls 426 fixedly attached to the first conveyor 410 at the periphery of the portion demarcated as the floor 424 of the receptacle 420. In yet another implementation, the receptacle 420 may be a tray (not shown), for example a rectangular tray, having a flexible floor 424, and at least two flexible walls 426. Such a receptacle 420 may be a single link (not shown) of a multi-flexing chain type (not shown) conveyor belt. A plurality of such receptacles 420 may be chain linked to form the first conveyor 410. Although some implementations of the receptacle 420 have been described above, other implementations are within the scope of this disclosure. The receptacle 420 may be configured to be fluid tight between the floor 424 and the walls 426 and also fluid tight mutually between adjacent walls 426.

[050] Referring to FIG. 5B, one embodiment of the sealed receptacle 420 is illustrated. The second conveyor 430 may include one or more ports 434 disposed thereon. In other words, the second conveyor 430 may be a perforated conveyor belt. The ports 1

434 may be capable of being placed in fluid communication with the vacuum applicator 440 (FIG. 4). The vacuum applicator 440 may be configured to evacuate at least some gas from the sealed receptacle 420, through the ports 434.

[051 ] Referring to FIG. 5B, various elements of the vacuum applicator 440 (FIG. 4) are illustrated. The vacuum applicator 440 may include a vacuum pump 442 to create a vacuum. The vacuum applicator 440 may further include any combination of fluid coupling members 444 and 446, such as, but not limited to, piping, manifolds, valves, and vacuum chambers to apply the vacuum to the receptacle 420. The fluid coupling members may be arranged to place the vacuum pump 442 in fluid communication with the ports 434 formed on the second conveyor 430.

[052] Further, in FIG. 5B, various elements of the pressure applicator 450 (FIG. 4) are illustrated. The pressure applicator 450 may include a pressure chamber 452, and one or more valves 454. The pressure chamber 452 may be disposed in the interior space 432 of the second conveyor 430. The second conveyor 430 may also be configured to function as a portion of the press bladder 456 for the pressure applicator 450. The flexible material of the second conveyor 430, opposed arrangement to the first conveyor 410, and the speed matched to the speed of the first conveyor 400, allow the second conveyor 430 to be configured as a press bladder 456 for the pressure applicator 450. The pressure chamber 452 may be sealed by a portion of the second conveyor 430 adjacent to the pressure chamber 452. The pressure chamber 452 and the portion of the second conveyor 430 that is adjacent to the pressure chamber 452 together define a press bladder 456. The press bladder 456 when inflated presses the PV cell module preassembly 100 in the receptacle 420, thus inhibiting movement of the PV cell module preassembly 100 within the receptacle 420.

[053] FIG. 5C illustrates an inflated press bladder pressing the PV cell module preassembly 100 within the receptacle 420. The valves 454 are configured to apply fluid pressure to the pressure chamber 452 to inflate the press bladder 456, thus pressing the PV cell module preassembly 100 in the receptacle 420 with the gas evacuated therefrom. The applied fluid pressure may be atmospheric pressure, or greater than atmospheric pressure, which may be applied as pressurized air or another suitable gas, or pressurized water, for example.

[054] System 200 and system 400 illustrate two embodiments of systems for forming cured PV cell modules using the evacuate-press-cure process. Systems 200 and 400 illustrate the staged or pipelined approach for forming cured PV cell modules. In the 1 staged or pipelined approach, the evacuation, pressing, and curing of the PV cell module preassembly is effected at spatially distinct locations along a conveyor system, such as those illustrated in FIG. 2 and 4. One exemplary method of the functioning of systems 200, and 400 will now be described, in conjunction with FIG. 6.

[055] FIG. 6 is a flowchart of an exemplary method 600 of forming a cured PV cell module. As shown in FIG. 6, method 600 comprises sequential steps 610, 620, 630, 640, 650, and 660. Step 610 comprises receiving a PV cell module preassembly (e.g., 100 in FIG. 1 ) in the receptacle (not shown) of the first conveyor (not shown) to give a received PV cell module preassembly (not shown), wherein the receptacle is at the first position (not shown) and the PV cell module preassembly has a curable composition that is in need of curing. Step 620 comprises sealing the receptacle containing the received PV cell module preassembly with the second conveyor (not shown) to give a sealed receptacle (not shown) containing the PV cell module preassembly. Step 630 comprises evacuating the sealed receptacle at the second position to give an evacuated receptacle (not shown) containing the PV cell module preassembly. Step 640 comprises pressing the PV cell module preassembly in the evacuated receptacle (not shown) at the third position to give a pressed PV cell module preassembly. Step 650 comprises applying a curing condition to the pressed PV cell module preassembly during the pressing of step 640 at the third position or after the pressing of step 640 and at the optional fourth position to give the cured PV cell module (not shown). Step 660 comprises separating the cured PV cell module from the receptacle at the fifth position to give a separated and cured PV cell module (not shown). The method 600 may further comprise steps of moving the receptacle containing the PV cell module preassembly from the first position to the second position; then from the second position to the third position; and then optionally from the third position to the optional fourth position and then moving the cured PV cell module to the firth position. Alternatively method 600 may further comprise steps of moving the receptacle containing the PV cell module preassembly from the first position to the second position; then from the second position to the third position; and then from the third position directly to the fifth position. The moving may be continuous, alternatively step-wise, or a combination thereof wherein the moving is continuous between some positions (e.g., continuous from first to third positions) and step-wise between other positions (step-wise from third position to fifth position). 1

[056] An embodiment of the method 600 of FIG. 6 will now be described in conjunction with first to fifth positions A through E of the receptacle 220 or 420, as illustrated in FIGS. 2, 3A to 3C, and FIGS. 3A to 3C, 5 respectively.

[057] In step 610 of the embodiment of the method 600 of FIG. 6, at first position A the receptacle 220 or 420 (FIG. 2 or 4) receives the PV cell module preassembly (e.g., 100) to be press cured. The PV cell module preassembly may include a laminate comprising a back sheet, a first layer of liquid encapsulant, a photovoltaic device, a second layer of liquid encapsulant, and a superstrate. The first layer of liquid encapsulant, or the second layer of encapsulant, or both are in need of curing. The first conveyor 210 or 410 (FIG. 2 or 4) transports the receptacle 220 or 420 to the second position B.

[058] In step 620 of the embodiment of method 600 of FIG. 6, the second conveyor 230 or 430 (FIG. 2 or 4) then seals the receptacle 220 or 420 (FIG. 2 or 4). The second conveyor 230 or 430 may seal the receptacle 220 at the beginning of second position B, or at second position B. The second conveyor 230 or 430 may maintain the seal of the receptacle 220 or 420 through the subsequent third and fourth positions C and D.

[059] In step 630 of the embodiment of method 600 of FIG. 6, at second position B, the vacuum applicator 240 or 440 (FIG. 2 or 4) then evacuates at least some gas from the sealed receptacle 220 or 420. In various embodiments, the vacuum applicator 240 or 440 creates a high vacuum within the sealed receptacle 220 or 420. The first conveyor 210 or 410 (FIG. 2 or 4) then transports the sealed receptacle 220 or 420 to third position C.

[060] In step 640 of the embodiment of method 600 of FIG. 6, at third position C, the pressure applicator 250 or 450 (FIG. 2 or 4) presses the PV cell module preassembly (e.g., 100) in the sealed receptacle 220 or 420 (FIG. 2 or 4) evacuated at least partially. As described above in conjunction with FIGS. 1 and 3A to 3C, the pressure applicator 250 or 450 presses the PV cell module preassembly in the sealed receptacle 220 or 420 by applying fluid pressure through the second conveyor 230 or 430 (FIG. 2 or 4). Pressing the PV cell module preassembly in the sealed receptacle 220 or 420 substantially inhibits movement of the PV cell module preassembly within the sealed receptacle 220 or 420.

[061 ] In step 650 of the embodiment of method 600 of FIG. 6, in addition to the pressure applicator 250 or 450 (FIG. 2 or 4) pressing the PV cell module preassembly (e.g., 100) at third position C, the curing applicator 260 or 460 (FIG. 2 or 4) may also apply a curing condition to the PV cell module preassembly in the sealed receptacle 220 1 or 420 (FIG. 2 or 4) at the third position C. Alternatively, the first conveyor 210 or 410 (FIG. 2 or 4) may transport the sealed receptacle 220 or 420 to fourth position D, without the curing applicator 260 or 460 applying the curing condition at third position C. At fourth position D, the curing applicator 260 or 460 applies a curing condition to the pressed PV cell module preassembly in the sealed receptacle 220 or 420 to obtain a partially or completely cured PV cell module.

[062] The curing condition may be defined as before.

[063] In one implementation of the curing step 650 of the embodiment of the method 600 of FIG. 6, the composition in need of curing is a heat-curable silicone encapsulant composition. In such an implementation, the curing condition is heat. As described above, the curing heat may be to trigger the curing process, to maintain the curing process, or to accelerate the curing process, based on the materials and composition of the liquid encapsulant 120 and 140 (FIG. 1 ). A curing heat applicator may apply curing heat to the heat-curable silicone encapsulant composition to obtain a cured silicone encapsulant. The curing heat applicator may apply curing heat by contacting the sealed receptacle 220 or 420 (FIG. 2 or 4) to a heat transfer fluid such that the heat-curable silicone encapsulant composition is heated to a temperature effective for curing same. Alternatively, the curing heat applicator may apply curing heat by exposing the heat- curable silicone encapsulant composition to radiant heat. Upon forming the partially or completely cured PV cell module, the first conveyor 210 or 410 (FIG. 2 or 4) transports or moves the receptacle to fifth position E.

[064] In step 660 of the embodiment of the method 600 of FIG. 6, at fifth position E the system 200 or 400 (FIG. 2 or 4) separates the cured PV cell module from the receptacle 220 or 420 (FIG. 2 or 4). As discussed in conjunction with FIG. 2 and FIG. 4, separating the cured PV cell module from the receptacle 220 or 420 (FIG. 2 or 4) includes releasing the vacuum in the receptacle 220 or 420 (FIG. 2 or 4), separating the second conveyor 230 or 430 (FIG. 2 or 4) from the receptacle 220 or 420 (FIG. 2 or 4) to unseal the receptacle 220 or 420 (FIG. 2 or 4), and separating the cured PV cell module from the receptacle 220 or 420 (FIG. 2 or 4). In case of a partially cured PV cell module, the partially cured PV cell module may then be transported to another apparatus (not shown) to complete the curing of the partially cured PV cell module. Alternatively, in case of a satisfactorily cured PV cell module, the satisfactorily cured PV cell module may then be transported to testing, assembling, sorting, and/or packaging equipment where the cured PV cell module can move to other processing steps such as testing; 1 assembling such as attaching a j-box, framing the cured PV cell module, or both; sorting of the cured PV cell module; and packing the cured PV cell module for shipment to storage, customers or installation sites.

[065] In the embodiment of method 600 in FIG. 6, the first conveyor 210 or 410 (FIG. 2 or 4) may transport the receptacle 220 or 420 (FIG. 2 or 4) from first position A through fifth position E, in a smooth, continuous motion. Alternatively, the first conveyor 210 or 410 may transport the receptacle 220 or 420 from first position A through fifth position E, in a discrete step-wise motion. Alternatively, the first conveyor 210 or 410 may transport receptacle 220 or 420 in a continuous motion between some positions and step-wise motion between other positions.

[066] The various embodiments of systems and methods described herein have been presented by way of example, and not limitation. It will be apparent to persons skilled in the relevant art(s) that various changes in form and detail can be made therein without departing from the spirit and scope of the present invention. Thus, the present disclosure should not be limited by any of the above described exemplary embodiments, but should be defined only in accordance with the following claims and their equivalents.

Claims

1 CLAIMS:

1 . A system for forming cured photovoltaic (PV) cell modules, the system comprising:

a first conveyor including a receptacle configured to receive a PV cell module preassembly;

a vacuum applicator configured to substantially evacuate a gas from the receptacle;

a pressure applicator configured to press the PV cell module preassembly against a press bladder when the PV cell module preassembly is disposed in the receptacle;

a curing applicator configured to apply a curing condition to the PV cell module preassembly in the receptacle; and

a second conveyor configured to move in tandem with the first conveyor;

wherein the second conveyor is arranged opposing the first conveyor to seal the receptacle, and configured to function as the press bladder for the pressure applicator; wherein the vacuum applicator, the pressure applicator, and the curing applicator are configured to respectively process the PV cell module preassembly at spatially distinct positions of the receptacle; wherein the first or second conveyor is configured to transport the receptacle from position to position from the vacuum applicator to the pressure applicator and from the pressure applicator to the curing applicator; and wherein the system is configured and operable to form a cured PV cell module from the PV cell module preassembly.

2. The system of claim 1 , wherein:

the vacuum applicator includes a vacuum pump to evacuate gas from and create a vacuum in the receptacle; and

the receptacle defines one or more ports disposed in at least one wall, wherein the one or more ports are coupled to and capable of being placed in fluid communication with the vacuum pump.

3. The system of claim 1 or 2, wherein:

the vacuum applicator includes a vacuum pump to evacuate gas from and create a vacuum in the receptacle; and 1 the second conveyor defines one or more ports; wherein the one or more ports are coupled to and capable of being placed in fluid communication with the vacuum pump.

4. The system of claim 1 , 2, or 3, wherein the press bladder is formed by a portion of the second conveyor and defines a pressure chamber in an interior space of the second conveyor; and

wherein the pressure applicator further comprises: one or more valves configured to apply atmospheric pressure or greater into the pressure chamber to inflate the press bladder, thereby pressing the PV cell module preassembly in the receptacle with the gas evacuated therefrom.

5. The system of any one of claims 1 to 4, wherein the curing applicator comprises a curing heat applicator

6. The system of claim 5, wherein the curing heat applicator comprises a heating unit for heating a heat transfer fluid and a heat exchange assembly for flowing the heat transfer fluid in contact with the receptacle when the receptacle is sealed by the second conveyor.

7. The system of claim 6, wherein the first conveyor or the second conveyor defines an interior space and the heat exchange assembly is disposed in the interior space of first conveyor or the second conveyor.

8. The system of claim 5, wherein the curing heat applicator comprises:

an induction heating unit disposed within at least one of the first conveyor and the second conveyor.

9. The system of any one of claims 1 to 8, further comprising:

a microprocessor configured to control at least one of the vacuum applicator, the pressure applicator, the curing applicator, the first conveyor, and the second conveyor to control one or more of a conveyor speed, a vacuum time or pressure, a press time, and a cure time. 1

10. The system of any one of claims 1 to 9, wherein the first conveyor includes a plurality of receptacles.

1 1 . A method of forming a cured photovoltaic module, the method comprising:

receiving a photovoltaic (PV) cell module preassembly in a receptacle of a conveyor line, wherein the PV cell module preassembly has a curable composition that is in need of curing and the conveyor line includes a first conveyor comprising the receptacle, and a second conveyor opposed to and configured to move in tandem with the first conveyor, wherein the receiving step is performed at a first position of the sealed receptacle of the conveyor line;

sealing the receptacle containing the PV cell module preassembly with the second conveyor;

substantially evacuating at least some gas from the sealed receptacle at a second position of the sealed receptacle of the conveyor line;

pressing the PV cell module preassembly in the sealed receptacle with the at least some gas evacuated therefrom at a third position of the sealed receptacle of the conveyor line;

applying a curing condition to the pressed PV cell module preassembly in the sealed receptacle, to obtain a cured PV cell module, wherein the applying step is performed at the third position or at an optional fourth position of the sealed receptacle of the conveyor line; and

separating the cured PV cell module from the receptacle, wherein the separating step is performed at a fifth position of the receptacle of the conveyor line, and wherein each of the positions of the receptacle are spaced apart from each other.

12. The method of claim 1 1 , wherein the conveyor line is configured to move in a continuous motion from position to position and the method comprises moving the conveyor line in a continuous motion from position to position.

13. The method of claim 1 1 , wherein the conveyor line is configured to move in a discrete step-wise motion from position to position and the method comprises moving the conveyor line in a step-wise motion from position to position. 1

14. The method of any one of claims 1 1 to 13, wherein the PV cell module preassembly comprises a back sheet, a first layer of first liquid encapsulant, a photovoltaic device, a second layer of second liquid encapsulant, and a superstrate, wherein the curable composition in need of curing is the first liquid encapsulant of the first layer, the second liquid encapsulant of the second layer, or both; and wherein at least one of the first and second liquid encapsulant compositions is at least partially cured during the applying step at the second or third position of the sealed receptacle of the conveyor line.

15. The method of claim 14, wherein the curable composition comprises a curable liquid silicone encapsulant or curable poly(ethylene-co-vinyl acetate) and wherein after the applying step the cured PV cell module comprises a cured silicone encapsulant or cured poly(ethylene-co-vinyl acetate).

16. The method of any one of claims 1 1 to 15, wherein pressing the PV cell module comprises applying fluid pressure through the second conveyor to the PV cell module.

17. The method of any one of claims 1 1 to 16, wherein the composition in need of curing is a heat-curable silicone encapsulant composition and the applying a curing condition comprises applying curing heat to the heat-curable silicone encapsulant composition to obtain a cured silicone encapsulant.

18. The method of claim 17, wherein the applying curing heat comprises flowing a heat transfer fluid in contact with the sealed receptacle such that the heat-curable silicone encapsulant composition is heated to a temperature effective for curing same.

19. The method of claim 17, wherein the applying curing heat comprises exposing the heat-curable silicone encapsulant composition to radiant heat.

20. The method of any one of claims 1 1 to 19, wherein the first conveyor comprises a plurality of receptacles, each receptacle containing a PV cell module preassembly, and wherein each PV cell module preassembly independently is evacuated, pressed, and cured by the method.