Abstract:
A flexible solar cell assembly having solar cells that are positioned within a sealed module chamber. A sealed wiring chamber is positioned on an end of the sealed module chamber and is interposed between the sealed module chamber and a junction box. Wiring interconnecting the junction box to the solar cells in the sealed module chamber is routed through the sealed wiring chamber to inhibit water entry into the sealed module chamber via the wiring.

Description:
RELATED APPLICATIONS 
       [0001]    This application is related to U.S. application Ser. No. ______ (Atty Docket No. SPOW.001P1) entitled METHOD OF MANUFACTURING SOLAR MODULES and U.S. application Ser. No.______. 
     
    
     BACKGROUND 
       [0002]    1. Field of the Inventions 
         [0003]    The aspects and advantages of the present inventions generally relate to apparatus and methods of photovoltaic or solar module design and fabrication and, more particularly, to roll-to-roll or continuous packaging techniques for flexible modules employing thin film solar cells. 
         [0004]    2. Description of the Related Art 
         [0005]    Solar cells are photovoltaic (PV) devices that convert sunlight directly into electrical energy. Solar cells can be based on crystalline silicon or thin films of various semiconductor materials, that are usually deposited on low-cost substrates, such as glass, plastic, or stainless steel. 
         [0006]    Thin film based photovoltaic cells, such as amorphous silicon, cadmium telluride, copper indium diselenide or copper indium gallium diselenide based solar cells, offer improved cost advantages by employing deposition techniques widely used in the thin film industry. Group IBIIIAVIA compound photovoltaic cells including copper indium gallium diselenide (CIGS) based solar cells have demonstrated the greatest potential for high performance, high efficiency, and low cost thin film PV products. 
         [0007]    As illustrated in  FIG. 1 , a conventional Group IBIIIAVIA compound solar cell  10  can be built on a substrate  11  that can be a sheet of glass, a sheet of metal, an insulating foil or web, or a conductive foil or web. A contact layer  12  such as a molybdenum (Mo) film is deposited on the substrate as the back electrode of the solar cell. An absorber thin film  14  including a material in the family of Cu(In,Ga)(S,Se) 2 , is formed on the conductive Mo film. The substrate  11  and the contact layer  12  form a base layer  13 . Although there are other methods, Cu(In,Ga)(S,Se) 2  type compound thin films are typically formed by a two-stage process where the components (components being Cu, In, Ga, Se and S) of the Cu(In,Ga)(S,Se) 2  material are first deposited onto the substrate or the contact layer formed on the substrate as an absorber precursor, and are then reacted with S and/or Se in a high temperature annealing process. 
         [0008]    After the absorber film  14  is formed, a transparent layer  15 , for example, a CdS film, a ZnO film or a CdS/ZnO film-stack is formed on the absorber film  14 . Light enters the solar cell  10  through the transparent layer  15  in the direction of the arrows  16 . The preferred electrical type of the absorber film is p-type, and the preferred electrical type of the transparent layer is n-type. However, an n-type absorber and a p-type window layer can also be formed. The above described conventional device structure is called a substrate-type structure. In the substrate-type structure light enters the device from the transparent layer side as shown in  FIG. 1 . A so called superstrate-type structure can also be formed by depositing a transparent conductive layer on a transparent superstrate such as glass or transparent polymeric foil, and then depositing the Cu(In,Ga)(S,Se) 2  absorber film, and finally forming an ohmic contact to the device by a conductive layer. In the superstrate-type structure light enters the device from the transparent superstrate side. 
         [0009]    In standard CIGS as well as Si and amorphous Si module technologies, the solar cells can be manufactured on flexible conductive substrates such as stainless steel foil substrates. Due to its flexibility, a stainless steel substrate allows low cost roll-to-roll solar cell manufacturing techniques. In such solar cells built on conductive substrates, the transparent layer and the conductive substrate form the opposite poles of the solar cells. Multiple solar cells can be electrically interconnected by stringing or shingling methods that establish electrical connection between the opposite poles of the solar cells. Such interconnected solar cells are then packaged in protective packages to form solar modules or panels. Many modules can also be combined to form large solar panels. The solar modules are constructed using various packaging materials to mechanically support and protect the solar cells contained in the packaging against mechanical damage. Each module typically includes multiple solar cells which are electrically connected to one another using the above mentioned stringing or shingling interconnection methods. 
         [0010]    In standard silicon, CIGS and amorphous silicon cells that are fabricated on conductive substrates such as aluminum or stainless steel foils, the solar cells are not deposited or formed on the protective sheet. Such solar cells are separately manufactured, and the manufactured solar cells are electrically interconnected by a stringing or shingling process to form solar cell circuits. In the stringing or shingling process, the (+) terminal of one cell is typically electrically connected to the (−) terminal of the adjacent solar cell. For the Group IBIIIAVIA compound solar cell shown in  FIG. 1 , if the substrate  11  is a conductive material such as a metallic foil, the substrate, which forms the bottom contact of the cell, becomes the (+) terminal of the solar cell. The metallic grid (not shown) deposited on the transparent layer  15  is the top contact of the device and becomes the (−) terminal of the cell. When interconnected by a shingling process, individual solar cells are placed in a staggered manner so that a bottom surface of one cell, i.e. the (+) terminal, makes direct physical and electrical contact to a top surface, i.e. the (−) terminal, of an adjacent cell. Therefore, there is no gap between two shingled cells. Stringing is typically done by placing the cells side by side with a small gap between them and using conductive wires or ribbons that connect the (+) terminal of one cell to the (−) terminal of an adjacent cell. Solar cell strings obtained by stringing or shingling individual solar cells are interconnected to form circuits. Circuits may then be packaged in protective packages to form modules. Each module typically includes a plurality of strings of solar cells which are electrically connected to one another. 
         [0011]    Generally, the most common packaging technology involves lamination of circuits in transparent encapsulants. In a lamination process, in general, the electrically interconnected solar cells are covered with a transparent and flexible encapsulant layer. A variety of materials are used as encapsulants, for packaging solar cell modules, such as ethylene vinyl acetate copolymer (EVA), thermoplastic polyurethanes (TPU), polyolefins, and silicones. However, in general, such encapsulant materials are moisture permeable; therefore, they must be further sealed from the environment by a protective shell, which provides resistance to moisture transmission into the module package. 
         [0012]    The nature of the protective shell determines the amount of water that can enter the package. The protective shell includes a front protective sheet through which light enters the module and a back protective sheet and optionally an edge sealant that is at the periphery of the module structure. The top protective sheet is typically transparent glass which is water impermeable. The back protective sheet may be a sheet of glass or a polymeric sheet of TEDLAR® (a product of DuPont) and polyeyhylene teraphthalate (PET). The back protective polymeric sheet may or may not have a moisture barrier layer in its structure such as a metallic film like an aluminum film. The edge sealant is a moisture barrier material that may be in the form of a viscous fluid which may be dispensed from a nozzle to the peripheral edge of the module structure or it may be in the form of a tape which may be applied to the peripheral edge of the module structure. 
         [0013]    A junction box is typically attached on the exposed surface of the back protective sheet, right below the interconnected solar cells, using moisture barrier adhesives. Terminals of the interconnected solar cells are typically connected to the junction box through holes formed in the back protective sheet. In this way, the size of the module can be reduced as the frame holding the cells can be positioned very close to the solar cells. The holes in the back protective sheet must be very carefully sealed against moisture leakages using, for example, potting materials such as silicone, epoxy, butyl, and urethane containing materials. If the seal in the holes fails, such holes allow moisture to enter the module and can cause device failures. 
         [0014]    Thin film solar cells are more moisture sensitive than the crystalline Si devices; therefore, materials with moisture barrier characteristics need to be used in the module structure and any potential moisture sources such as holes in the back and front protective sheets are problematic. For a flexible module to last 25 years, all the packaging components are also required to preserve mechanical, thermal, and chemical stability in the outdoors. The front protective sheet for thin film devices can be either glass or a flexible sheet depending on the product design requirements. A flexible front sheet can be composed of a combination of one or more weatherable films, such as fluoropolymers, for example, ETFE (ethylene-tetrafluoroethylene) or FEP (fluoro ethylene propylene) or polyvinylidene fluoride (PVDF) and a transparent inorganic moisture barrier layer such as Al 2 O 3  or SiO 2 . In one product, a weatherable film (ETFE, FEP or PVDF) can be laminated onto one or more inorganic moisture barrier layers to form a front protective sheet. However, during the lamination, stresses resulting from UV exposure, temperature cycle and humidity can deteriorate the front protective sheet which can result in severe inorganic moisture barrier-layer delaminations from the weatherable films. One can alleviate these problems by first incorporating the inorganic barrier layers onto a carrier film like poly(ethylene teraphthalate) PET and poly(ethylene naphthalate) PEN and then applying the weatherable film onto the carrier film instead of the barrier layer. Such carrier polymers are thermally and mechanically more stable. Although PET and PEN films are not as weatherable as the ETFE and FEP films, any temperature cycling on the solar panel would not impose as much stress as it would on a fluoropolymer like ETFE, FEP. 
         [0015]    A further difficulty that presents itself during manufacturing of solar cells is that the placement of the junction box on the solar cell module can vary depending upon the application of the solar cell. In some instances, the junction box is placed on the front surface which results in additional layers being added to the front surface to enhance adherence of the junction box. In other instances, the junction box is mounted on the back surface. In either circumstance, the module is usually custom fabricated for each mounting location which results in reduced manufacturing efficiencies for each different mounting location. 
         [0016]    Thus, there is a need for a manner of manufacturing the solar cells that allows for greater efficiencies and still permits flexible mounting locations for the junction boxes. To this end, there is a need for a solar cell module and method of manufacturing the same that allows for a standardized module to be fabricated and laminated and also permits subsequent flexible mounting of the junction boxes in a plurality of different locations. 
       SUMMARY 
       [0017]    The aforementioned needs are satisfied by the present invention which in one aspect comprises a flexible solar power apparatus comprising a solar power module having a flexible bottom sheet and a flexible top sheet and side sealing regions, wherein the solar power module defines a first edge and an interior space that houses at least one solar cell and wherein the at least one solar cell includes a conductive pathway that allows for current generated by the at least one solar cell to be transmitted outside of the solar power module. In this aspect, the apparatus further comprises a mounting module that is coupled to the first edge of the solar power module adjacent a first side sealing region wherein the mounting module defines a first mounting surface and a second mounting surface proximate the first flexible bottom sheet and the second flexible top sheet respectively of the solar power module. In this aspect the module further comprises a junction box that is mounted on the mounting module, wherein the mounting module is adapted to receive the junction box on either the first or second surfaces and wherein the junction box is electrically coupled with the conductive pathway to receive the current generated by the at least one solar cell. 
         [0018]    In another aspect, the invention comprises a method of forming a solar cell, the method comprising forming a solar panel module wherein at least one solar panel is sealed within an enclosure having a first sealed edge and wherein the solar panel module has a conductive pathway that extends through the first sealed edge. The method further comprises forming a junction box module that is configured to receive a junction box in a plurality of different locations and is further configured to be attached to the solar panel adjacent the first sealed edge. The method further comprises attaching the junction box module to the solar panel module and mounting the junction box on one of the plurality of different locations of the junction box module. 
         [0019]    These and other objects and advantages will become more apparent from the following description taken in conjunction with the accompanying drawings. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0020]      FIG. 1  is a schematic view a thin film solar cell; 
           [0021]      FIGS. 2A-2C  are side views of embodiments of a solar panel assembly after lamination, indicating how a bus ribbon can be extracted from the solar cell and where junction boxes can be mounted on the assembly; 
           [0022]      FIG. 3  is a top view of the solar panel assembly of  FIG. 2B ; 
           [0023]      FIG. 4  is a side view of the solar panel assembly of  FIG. 2B  with an additional mechanical support; 
           [0024]      FIG. 5  is a top view of the solar panel assembly of  FIG. 4 ; 
           [0025]      FIG. 6  is a side perspective view of another embodiment of a solar panel assembly after lamination having a clamp mounting tab; 
           [0026]      FIGS. 7A  and B are side perspective views of another embodiment of a solar panel assembly after lamination where the bus ribbon is clamped between two substrates; 
           [0027]      FIGS. 8A-8D  are top views of different implementations of the solar panel assembly of  FIGS. 6 and 7 ; 
           [0028]      FIG. 9A-9B  are side views of another embodiment of a solar panel assembly having a mounting tab that can accommodate a junction box on either side; 
           [0029]      FIG. 10A-10B  are side views of another embodiment of a solar panel assembly having a step-on mounting tab that can receive a junction box on either surface; 
           [0030]      FIG. 11A-11B  are side views of another embodiment of a solar panel assembly that has the bus ribbon that can be wrapped onto a top or bottom surface to receive a junction box thereon; and 
           [0031]      FIG. 12A-12B  are side views of another embodiment of a solar panel assembly that has the bus ribbon that can be wrapped onto a top or bottom surface to receive a junction box thereon. 
       
    
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS 
       [0032]    The preferred embodiments described herein provide methods of manufacturing a flexible photovoltaic power apparatus or solar panel including one or more flexible solar modules employing interconnected thin film solar cells, preferably Group IBIIIAVIA compound solar cells. The photovoltaic power apparatus or solar panel preferably includes a sealed module chamber and various embodiments of mechanisms and methods for attaching a junction box to the solar power module in the module chamber. 
         [0033]    Reference will now be made to the drawings wherein like numerals refer to like parts throughout.  FIG. 2A  shows a partial side view of an embodiment of a flexible solar panel assembly  100  of the present invention. 
         [0034]    The flexible solar panel assembly  100  may comprise a module  102  having a module housing  102 A, that contains thin film solar cells  104  of the type described above in connection with  FIG. 1 . As shown, the solar cells  104 , which may be interconnected to form a circuit, are positioned within the module housing  102 A. The module housing may include a front sheet  114  and a back sheet  116  and may be sealed on the edges or the perimeter of the module, by a peripheral sealant wall  112  or edge sealant. The peripheral sealant wall  112  extends about the module  102  and includes a region  112 A on the opposite side of the junction box to thereby fully seal the module  102  from moisture intrusion. The solar cells  104  may preferably be encapsulated by an encapsulant layer  106  or encapsulant in the housing  102 A Preferred materials for the encapsulant  106  may be ethylene vinyl acetate (EVA), thermoplastic polyurethane (TPU), polysiloxane, polyvinyl butyral, ionomer, thermoplastic polyolefins or some combination thereof. The encapsulant  106  fills the space surrounding the solar cells  104  and is preferably made of a transparent encapsulant material that tightly seals the solar cells  104  and other module structures such as busbars or conductors used to interconnect the solar cell by covering their surfaces. 
         [0035]    The front sheet  114  may comprise a top flexible protective sheet formed of a flexible and transparent material. The material may include a polymer such as ethylene tetrafluoroethylene (ETFE) under TEFZEL® commercial name or fluorinated ethylene propylene (FEP) from DuPont or poly vinylidene fluoride (PVDF) under KYNAR commercial name. Alternatively, the front sheet  114  may be a multilayer transparent structure including at least an outer polymeric layer, such as ETFE, FEP or PVDF, covering a transparent inorganic moisture barrier layer such as Al 2 O 3  or SiO 2 . The back sheet  116  may be a polymeric back sheet material such as TEDLAR, PVDF, PET, perfluoro-alkyl vinyl ether, PA or PMMA. 
         [0036]    The solar cells  104  include a number of solar cells  104  interconnected using a stringing technique that employs conductive leads such as conductive wires or ribbons, to electrically connect the solar cells, preferably in series. However, the solar cells  104  may also be formed using shingling techniques to interconnect the solar cells  104  without using conductive leads, such shingling principles are described above in the background section. As shown in  FIG. 1 , Each solar cell  104  generally includes a substrate  11 , an absorber layer  14  formed over the substrate and a transparent layer  15  formed over the absorber layer  11 . The absorber layer may be a Group IBIIIAVIA absorber layer such as a Cu(In,Ga) Se e  compound layer, which is often referred to as CIGS. The substrate may be a flexible foil substrate such as a stainless steel foil or an aluminum foil. There may be a back contact layer  12 , such as a molybdenum layer between the substrate and the absorber layer. A current collecting structure (not shown) including a busbar and fingers is deposited onto a top surface of the transparent layer  15 , which is also the light receiving side of the solar cells  104 . 
         [0037]    The module housing  102 A further includes the peripheral sealant wall  112  or edge sealant that may comprise either a moisture sealant or an edge tape. If an edge tape is used as the edge seal, the edge tape seals the side walls of the housing  102 A and may be made of a moisture barrier sealant tape. The moisture sealant may be of a viscous moisture barrier sealant. An exemplary material for the edge sealant and may be butyl rubber with desiccants having 5 to 13 mm width and 0.5 mm to 1.5 mm thickness. 
         [0038]    As is also shown in  FIG. 2A , a bus conductor  110  or conductive lead is electrically connected to the solar cells  104  so as to convey the electrical current produced by the solar cells outward of the solar module assembly  100  for subsequent collection and use. The bus conductor  110  may be made of a wire or multiple wires, such as micro wires or a metal strip or a ribbon. The bus conductor  110  may be covered by an insulating film or tubing  111  which can be formed of the following materials: polyethylene terephthalate (PET), which is available under the commercial names Mylar, Melinex, heat shrink. Mylar; polyimide (Kapton); polyolefins (EPS 300); and polyethylene napthalate (PEN). 
         [0039]    As is shown in  FIG. 2A , the bus conductor  110 , which is examplified as a conductive ribbon in this embodiment, extends out through the edge of the panel with the insulating film or tubing  111  being positioned about it. The insulating film or tubing  111  may begin in the middle of the edge sealant  112 . The front sheet  114  only extends over a portion of the edge sealant  112  whereas the back sheet  116  extends over the entire edge of the edge sealant  112 . The module  100  of  FIG. 2A  can then be used to interconnect with a junction box mounting module  120  on either the front or back sides of the assembly in the manner shown in  FIGS. 2B and 2C  respectively. As is illustrated, the module  100  is sealed against moisture intrusion thereby protecting the solar cells  104  positioned therein. The only element that extends outward therefrom may be the bus conductor  110  which is sealed to limit access paths for moisture to enter the module  100 . As will be discussed in greater detail below, the various ways of mounting the junction box are preferably accomplished in a manner that preserves the moisture seal integrity of the module  100 . 
         [0040]    More specifically, referring to  FIG. 2B , the junction box mounting module  120  comprises a sealant  122 , such as a sealant tape or layer, that is potentially formed of the same material as the edge sealant  112 . Mounting pads or layers  124   a ,  124   b , which may be sheet shaped and may be made of the material of the back sheet  116 , is then positioned on the upper and lower surfaces of the edge or sealant  122 . The back sheet material such as the above mentioned TEDLAR, PVDF, PET, etc., is better suited for mounting a junction box  126  to the assembly  100  because of its moisture barrier properties. If the back sheet material used is non transparent to light, it provides better protection to the underlying materials and protects them from the degradation by exposure to sunlight. As shown in  FIGS. 2B and 2C  respectively, the junction box  126  can be mounted to either the top or bottom of the module by using a tape or sealant  128  to adhere to mounting pads  124   a ,  124   b  made of the back sheet material. The bus conductor  110  extends outward of the module  100  and can then be routed through the sealant  122  and holes can be formed through the mounting pads  124   a ,  124   b  to permit the bus conductor  110  to be routed into the junction box  126 . 
         [0041]    The junction box  126  may be made of Noryl, PPE (poly phenylene ether), PET, Nylon, Polycarbonate, or PPE with PS (poly styrene) materials. Exemplary adhesives or sealant layers  128  that can be used to attach the junction box  126  to the mounting pads  124   a ,  124   b  may be silicone sealants such as Dow Corning PV804, Shinetsu KE220/CX220, Tonsan 15276 or adhesive tapes like 3M VHB 5952, Duplomont 9182. The adhesive tapes may need a primer to apply them to the surface materials. 
         [0042]      FIG. 3  is a top view of the solar cell assembly  100  illustrated in  FIGS. 2A-2C . As shown, the solar cell module  102  has the sealant  122  that extends, in this embodiment, substantially across the width of the module  100 . The mounting pads  124  then extend outward from the sealant  122  in only the location of the junction box  126 . As illustrated, the junction box  126  is attached to the mounting pads  124  via the sealant  128 . The exact size and configuration of the junction box  126 , the mounting pads  124  and the sealant  122  can, of course, vary depending upon the implementation. 
         [0043]    Referring to  FIGS. 4 and 5 , the attachment of the junction box  126  can be enhanced through the use of mechanical supports  130 . The mechanical supports  130  can be in the form of rivets that extend through the pads  124   a ,  124   b , the edge sealant  112 , and the portions of the sealant  122   a ,  122   b  that are interposed between the back sheet material pads  124   a ,  124   b  and the edge sealant  112  and the back sheet  116 . In one implementation, support members  130  may be added following the lamination process to provide mechanical support for the module assembly. As shown in  FIG. 5 , the supports members  130  can be added on either side of the junction box  126  to provide support on either side and to better adhere the junction box  126  to the module  102 . As shown, the junction box module  120  mounts to the outer side of the module  100  without affecting or penetrating the sealing components of the module  100 . Thus, the moisture barrier integrity of the module  100  is maintained. 
         [0044]      FIG. 6  illustrates another laminated solar cell assembly  200  that discloses another manner in which a junction box can be mounted to the solar cell assembly  200 . As shown, a solar cell module  102  that includes the solar cells  104  that is surrounded by an encapsulant  106  and a front sheet  114  and a back sheet  116  is disclosed. The edges of the module  102  can also be sealed by an edge sealant  112  such as an edge sealant tape. The components of the solar cell assembly  200  that define the module  102  are substantially the same as the components described above with respect to the  FIGS. 2A-5 . 
         [0045]    As shown in  FIG. 6 , a mounting module  220  comprising two cantilevered support members  132   a ,  132   b  that extend through the edge sealant  112  where the bus conductor or ribbon  110  is sandwiched between the cantilevered support members  132   a ,  132   b  can be attached to the solar module  102 . The cantilevered support members  132   a ,  132   b  provide a surface upon which a junction box  126  can be mounted on either side depending upon the application. Providing a standard mounting module  220  that can receive a junction box on either side greatly enhances the flexibility of the manufacturing process as the solar modules  102  and mounting modules  220  can be formed in bulk and then adapted to receive the junction boxes as needed by the particular costumer application. 
         [0046]    The cantilevered support members  132   a ,  132   b  in one implementation are layers or sheets that are preferably formed of an electrical insulator material such as InsulPatch™ or electrical insulator material EPE that is formed of a material that permits the junction box to be adequately adhered to the cantilevered support members  132   a , or  132   b . EPE material could be made of EVA/PET/EVA layers laminated to each other. Usually Each EVA layer can be 25 um to 250 um thick, and PET layer thickness can also vary from 25 um to 250 um. EVA layers can be replaced by other thermoplastic encapsulants. The same multilayer film can also be made of single layer film such as PET, ETFE, Kynar, Kapton. Upon lamination, the cantilevered support members  132   a ,  132   b  are clamped using tapes, hot melt or a dispensable thermoset foam and a window can then be opened on either the front side or the back side of the substrate to receive the junction box. 
         [0047]      FIGS. 7A and 7B  illustrate the manner in which a junction box  126  can be attached to either the front or bottom surface or side of the mounting module  220  shown in  FIG. 6 . As shown, the cantilevered support members  132   a ,  132   b  includes a first region  133  that preferably extends across the width of the module  220  and a narrower region  135  that extends outward from the first region  133  that covers the bus conductor  110 . As shown, the narrow region  135  has two layers with the bus conductor  110  interposed therebetween so as to provide protection to the bus conductor  110 . An adhering tab  134   a  or  134   b  is then mounted on either the upper surface of the cantilevered support members  132   a ,  132   b  or the lower surface of the cantilevered support members  132   a ,  132   b . The adhering tabs  134  can also be mounted on both the upper and the lower surfaces the cantilevered support members  132   a ,  132   b . The adhering tab  134   a ,  134   b  may preferably be a moisture resistant sealant layer, for example a junction box bonding tape like VHB tape. A layer of back sheet material forming a mounting pad  124  is then mounted on the adhering tab  134   a  or  134   b  depending upon whether a front surface or back surface mount of the junction box  126  is desired. The bus conductor may be routed through the adhering tab  134   a  or  134   b  and the mounting pad  124  for the junction box connection. Once the location of the junction box is determined and the bus conductor is taken out. The other side of the mounting module is completed by placing another piece of mounting pad  124 , or alternatively placing both an adhering tab  134  and mounting pad  124  together. The edge of the mounting module may or may not be sealed using an edge sealant. The junction box  126  is secured to the mounting pad  124  using epoxy, silicone sealant, or tape in the same manner as described above. Thus, the module  102  and the mounting module  220  can be manufactured and laminated in one manufacturing process and these modules can then be used to make two different types of solar cells depending upon where the junction box  126  is desired to be mounted. Once the junction box  126  is mounted, a conductor  136  can then interconnect the junction box  126  to other solar modules or to a power circuit in a manner well known in the art. 
         [0048]    As is shown in  FIG. 7B , the junction box  126  is positioned on the top and the bus conductor  110  is routed to the junction box  126  through the adhering tab  134   a  and the mounting pad  124 . As shown, the bus conductor  110  may be sandwiched between the upper adhering tabs  134   a  and  134   b . Again, the module  220  for mounting the junction box  126  to the solar cell module  200  attached to the peripheral surfaces of the module  200  which further enhances the moisture integrity of the module  200 . 
         [0049]      FIGS. 8A-8D  illustrate that the configuration of the module  220  and a mounting pad  124  can vary depending upon the implementation without departing from the spirit of the present invention. In some instances, the solar panel assembly  200  may be used in environments where the module  220  may be subjected to larger mechanical forces and the mounting pad  124  can extend across the entire width of the solar cell module  102  as is shown in  FIG. 8A . Alternatively, to conserve materials the module  220  and the mounting pad  124  in other implementations may be sized so as to accommodate the junction box  126  as is shown in  FIG. 8B . The degree of attachment of the module  102  and the mounting tab is thus variable as is the configuration. For example, the mounting pad  124  may have tapered corners as is shown in  FIG. 8C  and mechanical supports  130  such as rivets shown in  FIG. 8D  may also be used to enhance the interconnection of the mounting module, the mounting pad  124  to the solar cell module  102 . It will be understood that the exact configuration of the mounting pad  124  and its interconnection to the module  102  will be dependent upon the intended use of the solar cell  100 , the size of the junction box  126  and other related considerations. 
         [0050]    The foregoing description of a mounting module  220  having a mounting pad  124  for mounting a junction box  126  has been described in conjunction with a system that uses edge sealant  112  such as an edge tape. However, it will be appreciated that the same type of mounting method can also be used in conjunction with module  102  that don&#39;t use edge sealant  112 . In those implementations, an encapsulant  106  will cover the panel footprint and the bus conductor  110  or ribbon may extend out of the encapsulant  106  and the bus conductor  110  may then be embedded between an insulating film like EPE and the encapsulant  106  may extend outward from the main body of the module the same amount as the insulating film. The mounting pad  124  can then be mounted on the encapsulant and the insulating film. 
         [0051]      FIGS. 9A and 9B  illustrate another mounting module  320  that can be prefabricated for use with both upper or lower surface mounting of junction boxes  126 . In this implementation, an assembly  300  is manufactured that has a solar cell module  102  that has a solar cell  104  positioned within encapsulant layers  106 . The encapsulant layers  106  are then interposed between a front sheet  114  and a back sheet  116  in the manner described above. The edges are then sealed using an edge sealant  112  in substantially the same manner as described above. 
         [0052]    As shown in  FIG. 9A , however, the back sheet layer  116  extends beyond the edge sealant  112  so as to define a cantilevered section  116   a  which is a portion of a mounting module  320 . A mounting pad  124 , preferably formed of the material of the back sheet  116  can then be positioned adjacent the front sheet  114  so as to extend outward from the edge sealant  112  in a cantilevered fashion to form part of the mounting module  320 . The bus conductor  110  then extends out of the edge sealant  112  so as to be interposed between the mounting pad  124  and the cantilevered section  116   a  of the back sheet  116 . 
         [0053]    This configuration also permits mounting of junction boxes  126  on either the mounting pad  124  adjacent the front sheet  114  or adjacent the back sheet  116  depending upon the desired implementation. As shown in  FIG. 9B , the junction box  126  can be mounted as desired and the bus conductor  110  then bent to extend into the junction box  126  through openings formed in either the cantilevered section  116   a  or the mounting pad  124  in a known manner. The gap between the cantilevered section  116   a  and the mounting pad  124  can then be sealed using an insert member  140  which can comprise an insert tape, a hot melt, a thermosetting foam or something equivalent that seals the space and protects the conductive bus conductor  110  from shorts and environmental contamination. Again, this mounting module  320  mounts to the periphery of the module  300  which maintains the moisture tight integrity of the module  300  while permitting flexible mounting of the junction box  126  on either the top or the bottom surface. 
         [0054]      FIGS. 10A and 10B  illustrate another assembly  400  very similar to the assembly  300  described above in conjunction with  FIGS. 9A and 9B . In this implementation, a portion of the back sheet  116  extends beyond the edge sealant  112  so as to define the cantilevered section  116   a  that is part of a mounting module  420 . If a back mounted junction box  126  is described, an insert member  140  like those described above is positioned on the cantilevered section  116   a  to cover the bus conductor  110  and the junction box  126  is mounted on the cantilevered section  116   a  opposite the insert member  140  in the manner shown in  FIG. 10   b . Alternatively, if a top mounted junction box  126  is desired, then the mounting pad  124  with the junction box  126  formed thereon can then be mounted and the insert member  140  can then be used to fill the gap in the manner described above. Thus, the embodiments of  FIGS. 9A ,  9 B and  10 A,  10 B can both be manufactured ahead of time and then adapted to the desired mounting configuration for the junction box  126 . 
         [0055]      FIGS. 11A and 11B  illustrate yet another embodiment of an assembly  500  that can be used in conjunction with both top or bottom mounted junction boxes  126 . In this implementation, the module  102  includes a solar cell module  102  that has a solar cell  104  that is positioned between encapsulant layers  106  which are interposed between a front sheet  114  and a back sheet  116  in substantially the same manner as described above. The edge of the back sheet  116  and front sheet  114  are sealed with edge sealant  112  or an equivalent. The bus conductor  110  is positioned on top of an extended member  116   b  that extends outward from the edge sealant  112  and forms part of a mounting module  520 . The extended member  116   b  may be made of a piece of the material of the back sheet  116 . A release liner can be used to protect the bus conductor  110  during the lamination process. 
         [0056]    As shown in  FIG. 11B , the extended member  116   b  can then be bent to either the top sheet  114  or to the bottom sheet  116  as desired and provide a mounting surface for the junction box  126 . The extended member  116   b  can be secured to the top sheet  114  or the back sheet  116  using a mounting member  142  which can comprise a hot melt, a pressure sensitive tape or a dispensable thermoset foam. Again, the mounting module  520  provides a basic module that can be used for either a top or bottom mounted junction box. 
         [0057]      FIGS. 12A and 12B  illustrate yet another assembly  600  that can be formed and adapted for use with both a top or bottom mounted junction box  126 . In this implementation, the module  102  includes a solar cell  104  that is sandwiched between two encapsulant layers  106  and the top sheet  114  and back sheet  116  as described above. The edge of the module  102  is sealed with the edge sealant  112  in the above-described manner with the bus conductor  110  extending outwardly therefrom in substantially the center of the edge sealant  112 . A two sided wrapped mounting tab  144  that forms a mounting module  620  formed in one implementation of the same material as the back sheet is then formed. As shown in  FIG. 12B , the two sided wrapped mounting tab  144  has a C-shape with an upper surface  146   a  that mounts to the top sheet  114  and a bottom surface  146   b  that mounts to the bottom sheet  116 . The two sided wrapped mounting tab  144  is secured to the edge of the module  102  using hot melt, dispensable thermoset foam or tape  148  in the manner described above and the bus conductor  110  can then be routed through an opening formed in the upper or lower surface  146   a ,  146   b  of the two sided mounting member  144  to thereby be connected to the junction box  126 . 
         [0058]    Again, the embodiment of  FIGS. 12A and 12B  allows for a single module to be made that can accommodate junction boxes mounted on either the top surface or the bottom surface and this mounting can be accomplished without affecting the moisture integrity of the module containing the solar cells  104 . Manufacturing efficiencies can be gained by manufacturing a single module that can be readily adapted for different mounting locations of junction boxes as opposed to custom manufacturing a module for a specific junction box mounting location. 
         [0059]    Although aspects and advantages of the present inventions are described herein with respect to certain preferred embodiments, modifications of the preferred embodiments will be apparent to those skilled in the art. The scope of the present invention should not be limited to the foregoing discussion but should be defined by the appended claims.