ELECTRICAL AND/OR ELECTRONIC DEVICE COMPRISING A SYSTEM FOR MECHANICALLY PROTECTING AT LEAST ONE ELECTRICAL AND/OR ELECTRONIC COMPONENT

Abstract

An electrical and/or electronic device including at least two electrical and/or electronic components, each including two opposite faces, at least one electrical contact element arranged against at least one of the two opposite faces of each of the at least two electrical and/or electronic components, and each of them is mechanically protected by a mechanical protection system including at least one protective element, superimposed on one or plural electrical and/or electronic components that it protects such that at least one of the two opposite faces of the electrical and/or electronic components is arranged facing the at least one protective element, and at least one deformation absorption element is arranged in at least one space formed between the at least one protective element and at least one electrical and/or electronic component that it protects.

Claims

1-20. (canceled)

21: An electrical and/or electronic device comprising: at least two electrical and/or electronic components, each of the at least two electrical and/or electronic components comprising two opposite faces; at least one electrical contact element arranged against at least one of the two opposite faces of each of the at least two electrical and/or electronic components; wherein each electrical and/or electronic component is mechanically protected by two protective elements which are specific thereto, being taken between the two protective elements, a first protective element being arranged in superposition with respect to the electrical and/or electronic component that it protects, facing one of its two opposite faces, and a second protective element being arranged in superposition with respect to the electrical and/or electronic component that it protects, facing the other of its two opposite faces; and wherein least one deformation absorption element is arranged in at least one space formed between at least one protective element and the electrical and/or electronic component that it protects.

22: A device according to claim 21, wherein the first protective element and the second protective element are assembled together.

23: A device according to claim 21, wherein the first protective element and the second protective element form respectively, at least in part, front and rear faces of the electrical and/or electronic device, between which are only arranged the electrical and/or electronic component, that the first and second protective elements protect, the at least one electrical contact element that is associated with it and at least one first deformation absorption element and a second absorption element arranged on either side of the electrical and/or electronic component.

24: A device according to claim 21, comprising a plurality of protective elements, and wherein at least one part of the protective elements of the electrical and/or electronic device forms a substantially regular arrangement of polygonal.

25: A device according to claim 21, wherein the at least one protective element comprises at least one openwork channel enabling passage of the at least one electrical contact element.

26: A device according to claim 21, wherein the at least one protective element is made of a material having a hardness greater than 60 on the Rockwell M scale, according to the Standard Test Method for Rockwell Hardness of Plastics and Electrical Insulating Materials ASTM D785.

27: A device according to claim 21, wherein the at least one protective element is made from a material selected from: polymethyl methacrylate (PMMA), polycarbonate, or glass.

28: A device according to claim 21, wherein the at least one deformation absorption elements comprises a deformable material.

29: A device according to claim 28, wherein the at least one deformation absorption element comprises a compressible material.

30: A device according to claim 28, wherein the at least one deformation absorption element comprises transparent polystyrene.

31: A device according to claim 21, which is a photovoltaic module, the at least two electrical and/or electronic components being photovoltaic cells, and the at least one electrical contact element comprising at least one strip of electrically conducting material arranged against the photovoltaic cells and electrically connecting the photovoltaic cells together.

32: A device according to claim 21, comprising a plurality of protective elements, and being more rigid at a level of the protective elements than at a level of the connection parts between the protective elements, suppleness of the connection parts defining flexibility of the electrical and/or electronic device.

33: A device according to claim 31, comprising a plurality of protective elements, and wherein the protective elements are formed by association of at least two layers of protective material, partially assembled together, superimposed and non-assembled areas of the at least two layers of protective material comprising a gas to form corresponding deformation absorption elements.

34: A device according to claim 21, wherein the at least one electrical contact element is at least partially flexible, in a part thereof situated between the at least two electrical and/or electronic components.

35: A method for producing an electrical and/or electronic device, comprising: a) producing at least two electrical and/or electronic components each comprising two opposite faces; b) producing at least one electrical contact element arranged against at least one of the two opposite faces of each of the at least two electrical and/or electronic components; c) producing at least one protective element mechanically protecting each of the at least two electrical and/or electronic components, each electrical and/or electronic component being mechanically protected by two protective elements which are specific thereto, being taken between the two protective elements, a first protective element being arranged in superposition with respect to the electrical and/or electronic component that it protects, facing one of its two opposite faces, and a second protective element being arranged in superposition with respect to the electrical and/or electronic component that it protects, facing the other of its two opposite faces; d) producing at least one deformation absorption element, arranged in at least one space formed between the at least one protective element and the electrical and/or electronic component that it protects.

36: A method according to claim 35, comprising successively: a) assembling a plurality of electrical and/or electronic components together through intermediary of a plurality of electrical contact elements; b) laminating at least two layers of encapsulation material on either side of the plurality of electrical and/or electronic components to form an assembly encapsulating the electrical and/or electronic components, each of the two opposite faces of the electrical and/or electronic components being arranged facing one of the two layers of encapsulation material, and lamination on one of the two layers of encapsulation material of at least one base layer; c) assembly of a plurality of protective elements on the other of the two layers of encapsulation material.

37: A method according to claim 35, comprising successively: a) assembling a plurality of electrical and/or electronic components together through intermediary of a plurality of electrical contact elements; b) positioning at least two layers of encapsulation material on either side of the plurality of electrical and/or electronic components to form an assembly encapsulating the electrical and/or electronic components, each of the two opposite faces of the electrical and/or electronic components being arranged facing one of the two layers of encapsulation material, positioning on one of the two layers of encapsulation material at least one base layer, and positioning a plurality of protective elements on the other of the two layers of encapsulation material; c) laminating the assembly thereby formed during the preceding steps such that the plurality of protective elements sinks at least partially into the other of the two layers of encapsulation material leading to fixation thereof to the other of the two layers of encapsulation material.

38: A method according to claim 35, comprising successively: a) assembling a plurality of electrical and/or electronic components together through intermediary of a plurality of electrical contact elements; b) laminating at least two layers of encapsulation material on either side of the plurality of electrical and/or electronic components to form an assembly encapsulating the electrical and/or electronic components, each of the two opposite faces of the electrical and/or electronic components being arranged facing one of the two layers of encapsulation material, and lamination on one of the two layers of encapsulation material of at least one base layer; c) overmolding on the other of the two layers of encapsulation material of an imprint in a compressible material, to form a plurality of deformation absorption elements; d) overmolding on the plurality of deformation absorption elements thus formed of a plurality of protective elements.

39: A method according to claim 35, comprising successively: a) assembling a plurality of electrical and/or electronic components together through intermediary of a plurality of electrical contact elements; b) laminating at least two layers of encapsulation material on either side of the plurality of electrical and/or electronic components to form an assembly encapsulating the electrical and/or electronic components, each of the two opposite faces of the electrical and/or electronic components being arranged facing one of the two layers of encapsulation material, and lamination on one of the two layers of encapsulation material of at least one base layer; c) partial assembly, of at least two layers of protective material to form assembled areas, and non-assembled areas between the at least two layers of protective material; d) lamination on the other of the two layers of encapsulation material of the assembly formed during b), of the at least two layers of protective material partially assembled together, obtained during c); e) injection of a gas into the non-assembled areas of the at least two layers of protective material obtained during c), to form a plurality of deformation absorption elements of a plurality of protective elements.

40: A method according to claim 35, comprising successively: a) assembling a plurality of electrical and/or electronic components together through intermediary of a plurality of electrical contact elements; b) assembling on either side of the electrical and/or electronic components first protective elements and second protective elements, such that the first protective elements, the electrical and/or electronic components and the second protective elements are superimposed together, the first protective elements being assembled on the second protective elements.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0089] The invention will be better understood on reading the detailed description that follows of exemplary embodiments thereof and by examining the schematic and partial figures of the appended drawing, in which:

[0090] FIG. 1 represents, in perspective, a first example of embodiment of an electrical and/or electronic device in compliance with the invention,

[0091] FIG. 2 represents a detail of embodiment of the electrical and/or electronic device of FIG. 1,

[0092] FIGS. 3A and 3B illustrate, in section, two steps of a first variant of the method for producing an electrical and/or electronic device in compliance with the invention,

[0093] FIGS. 4A and 4B illustrate, in section, two steps of a second variant of the method for producing an electrical and/or electronic device in compliance with the invention,

[0094] FIGS. 5A and 5B illustrate, in section, two steps of a third variant of the method for producing an electrical and/or electronic device in compliance with the invention,

[0095] FIGS. 6A, 6B and 6C illustrate, respectively in section view, in top view and in section view, three steps of a fourth variant of the method for producing an electrical and/or electronic device in compliance with the invention,

[0096] FIG. 7A represents, in perspective, another example of producing an electrical and/or electronic device in compliance with the invention,

[0097] FIG. 7B is an in section view of the electrical and/or electronic device of FIG. 7A, and

[0098] FIG. 8 illustrates, in section, a variant of producing an electrical contact element of an electrical and/or electronic device in compliance with the invention.

[0099] In all of these figures, identical references may designate identical or analogous elements.

[0100] In addition, the different parts represented in the figures are not necessarily according to a uniform scale, in order to make the figures more legible.

DETAILED DESCRIPTION OF PARTICULAR EMBODIMENTS

[0101] In all the examples described hereafter with reference to FIGS. 1 to 8, it is considered that the electrical and/or electronic devices 1 according to the invention correspond to photovoltaic modules 1, comprising at least four electrical and/or electronic components in the form of photovoltaic cells 2a, 2b, 2c and 2d, notably crystalline photovoltaic cells. Obviously, this choice is in no way limiting.

[0102] Reference will firstly be made to FIG. 1 which represents, in perspective, a first example of embodiment of a photovoltaic module 1 in compliance with the invention.

[0103] The photovoltaic module 1 comprises four photovoltaic cells 2a, 2b, 2c and 2d, electrically connected together by electrical contact elements 3a, 3b, 3c and 3d, for example in the form of copper strips. In particular, two electrical contact elements 3a and 3b connect the photovoltaic cells 2a and 2b together, and two other electrical contact elements 3c and 3d connect the photovoltaic cells 2c and 2d electrically together.

[0104] In addition, the four photovoltaic cells 2a, 2b, 2c and 2d comprise respectively opposite faces 2a.sub.1 and 2a.sub.2, 2b.sub.1 and 2b.sub.2, 2c.sub.1 and 2c.sub.2, and 2d.sub.1 and 2d.sub.2.

[0105] Each of the electrical contact elements 3a, 3b, 3c and 3d may be arranged against one of the two opposite faces of each of the photovoltaic cells 2a, 2b, 2c and 2d, and notably in an alternating manner. Thus, as an example, as may easily be seen in FIG. 3A, the electrical contact element 3a may for example be arranged against the front face 2a.sub.1 of the photovoltaic cell 2a and against the rear face 2b.sub.2 of the photovoltaic cell 2b.

[0106] Furthermore, in accordance with the invention, each of the photovoltaic cells 2a, 2b, 2c and 2d is mechanically protected by a protective element 4a, 4b, 4c and 4d.

[0107] In particular, in the example of FIG. 1, the four photovoltaic cells 2a, 2b, 2c and 2d are respectively mechanically protected by the four protective elements 4a, 4b, 4c and 4d.

[0108] Each of the four protective elements 4a, 4b, 4c and 4d may more particularly be likened to a protective shell or cup.

[0109] In the example of FIG. 1, each photovoltaic cell 2a, 2b, 2c and 2d is covered with a single protective shell 4a, 4b, 4c and 4d that is specific thereto. In a variant, although not represented, it could be possible to have a protective element common to at least two photovoltaic cells, that is to say covering at least two photovoltaic cells to protect them mechanically.

[0110] The covering of one or more photovoltaic cells by a protective element may in particular depend on the degree of flexibility desired for the photovoltaic module.

[0111] Advantageously, the protective shells 4a, 4b, 4c and 4d may be identical, notably in terms of dimensions.

[0112] Moreover, in accordance with the invention, the photovoltaic module 1 comprises four deformation absorption elements 5a, 5b, 5c and 5d which are arranged respectively in four spaces 6a, 6b, 6c and 6d formed between the protective shells 4a, 4b, 4c and 4d and the photovoltaic cells 2a, 2b, 2c and 2d.

[0113] More particularly, as becomes clearer from the section views of FIGS. 3A to 5B, the spaces 6a, 6b, 6c and 6d comprising the deformation absorption elements 5a, 5b, 5c and 5d are situated respectively between the protective shells 4a, 4b, 4c and 4d and the photovoltaic cells 2a, 2b, 2c and 2d.

[0114] Advantageously, the presence of the deformation absorption elements 5a, 5b, 5c and 5d may make it possible to avoid any contact between the photovoltaic cells 2a, 2b, 2c and 2d, and the front face of the photovoltaic module 1, in the present case formed by the four protective shells 4a, 4b, 4c and 4d.

[0115] In this way, the association of the protective shells 4a, 4b, 4c and 4d and the absorption elements 5a, 5b, 5c and 5d makes it possible to impart mechanical strength to the photovoltaic module 1, in order to limit, or better to avoid, any risk of damaging the photovoltaic cells 2a, 2b, 2c and 2d, and notably in order to avoid any risk of fissuring. In other words, the photovoltaic cells 2a, 2b, 2c and 2d may be covered by a rigid envelope formed by the protective shells 4a, 4b, 4c and 4d which makes it possible to protect against any mechanical contact with the exterior environment.

[0116] It is thus possible to protect the photovoltaic cells 2a, 2b, 2c and 2d while also preserving a maximum of flexibility in the photovoltaic module 1, thanks to the use of a protective shell specific to each photovoltaic cell and to the formation of supple parts of the photovoltaic module 1 between the protective shells 4a, 4b, 4c and 4d.

[0117] Throughout the description, and in particular for the protective shells 4a, 4b, 4c and 4d described here, each protective shell may for example be in the form of a main panel with a plurality of peripheral ribs, substantially perpendicular to the main panel, so as to define a reversed U-shaped section. In particular, each protective shell may be geometrically composed of a main panel, substantially planar, horizontal and of rectangular, square or circular shape, and parts forming ribs, substantially vertical and of rectangular, square or circular shape, extending from each side of the main panel. In the case where the main panel is of circular shape, there may exist a single part forming a substantially vertical rib extending from the periphery of the main panel. The parts forming the ribs may optionally be open-worked in order not to bear at the level of the electrical elements. Each protective shell may be produced by assembly of different parts, namely the main panel and the part(s) forming the ribs, in a single piece, for example moulded or thermoformed, inter alia.

[0118] The flexibility of the photovoltaic module 1 may enable it to take different shapes to adapt to different types of surfaces on which the photovoltaic module 1 has been arranged, for example surfaces that are stepped, undulating or even of imperfect flatness.

[0119] The thickness of the protective shells 4a, 4b, 4c and 4d may be variable, and notably more reduced when it is wished to confer more flexibility to the photovoltaic module 1 according to the invention. In any event, the thickness of the protective shells 4a, 4b, 4c and 4d may depend on the mechanical stresses applied to the photovoltaic module 1.

[0120] Furthermore, in the example of FIG. 1 but also in the examples of embodiment of FIGS. 3A to 6C, unlike the exemplary embodiment of FIGS. 7A and 7B, the photovoltaic module 1 further comprises two layers of encapsulation material 7a and 7b, between which the four photovoltaic cells 2a, 2b, 2c and 2d are encapsulated, the protective shells 4a, 4b, 4c and 4d and the deformation absorption elements 5a, 5b, 5c and 5d being arranged relatively to one 7a of the two layers of encapsulation material 7a and 7b such that it extends between the assembly formed by the protective shells 4a, 4b, 4c and 4d and the deformation absorption elements 5a, 5b, 5c and 5d, and the photovoltaic cells 2a, 2b, 2c and 2d that they protect.

[0121] The other 7b of the two layers of encapsulation material 7a and 7b is furthermore covered with a base layer 8, notably of the polymeric type, which defines the rear face of the photovoltaic module 1, whereas the protective shells 4a, 4b, 4c and 4d, preferentially transparent, define the front face of the photovoltaic module 1.

[0122] It should be noted that, advantageously, the four protective shells 4a, 4b, 4c and 4d form between them a regular pattern, notably in the form of a bar of chocolate.

[0123] This regular shape in the arrangement of the protective shells 4a, 4b, 4c and 4d may make it possible to improve the modularity and the flexibility of the photovoltaic module 1, and also makes it possible to respond to aesthetic expectations.

[0124] Thanks to the presence of the protective shells 4a, 4b, 4c and 4d associated with the use of deformation absorption elements 5a, 5b, 5c and 5d, it is thus possible to avoid loading the photovoltaic cells 2a, 2b, 2c and 2d by external mechanical stresses. The invention thus makes it possible to impart the necessary robustness to the photovoltaic module 1 to protect the photovoltaic cells 2a, 2b, 2c and 2d.

[0125] It should moreover be noted that each of the protective shells 4a, 4b, 4c and 4d may be made of a flexible material, such that the photovoltaic module may, if need be, be folded or rolled as a function of the needs of the targeted applications.

[0126] Each of the protective shells 4a, 4b, 4c and 4d may for example be made from a material selected from: polymethyl methacrylate (PMMA), polycarbonate or glass.

[0127] Moreover, each of the deformation absorption elements 5a, 5b, 5c and 5d advantageously comprises a deformable material. In particular, in the example of FIG. 1 and FIGS. 3B, 4A-4B, 6C and 7B, the deformation absorption elements comprise a highly pressurised gas, notably with a pressure comprised between 5 and 15 bars.

[0128] In a variant, the deformation absorption elements may be selected from other types of materials, and notably comprise transparent polystyrene, as will be described with reference to FIGS. 5A and 5B hereafter.

[0129] A detail of embodiment of the photovoltaic module 1 of FIG. 1, and in particular the area situated between the two photovoltaic cells 2a and 2b, is furthermore represented in FIG. 2.

[0130] As may be seen in this FIG. 2, each of the protective shells 4a, 4b, 4c and 4d may comprise at least one openwork channel 9a or 9b to enable the passage of an electrical contact element 3a, 3b, 3c or 3d.

[0131] More specifically, in FIG. 2, the protective shell 4a comprises an openwork channel 9a to enable the passage of the electrical contact element 3a and an openwork channel 9b to enable the passage of the electrical contact element 3b. Similarly, the protective shell 4b comprises an openwork channel 9a to enable the passage of the electrical contact element 3a and an openwork channel 9b to enable the passage of the electrical contact element 3b.

[0132] In this manner, thanks to the presence of openwork channels 9a and 9b formed in the protective shells 4a and 4b, it may be possible to protect the electrical contact elements 3a and 3b from any mechanical pressure that could be exerted on the protective shells 4a and 4b.

[0133] Four variants of the method for producing a photovoltaic module 1 in compliance with the invention will now be described hereafter, with reference to FIGS. 3A to 6C.

[0134] In each of these variants, the method comprises at least the steps consisting in: [0135] a) producing four photovoltaic cells 2a, 2b, 2c and 2d each comprising two opposite faces 2a.sub.1 and 2a.sub.2, 2b.sub.1 and 2b.sub.2, 2c.sub.1 and 2c.sub.2, and 2d.sub.1 and 2d.sub.2, [0136] b) producing four electrical contact elements 3a, 3b, 3c and 3d to connect the four photovoltaic cells 2a, 2b, 2c and 2d electrically together, [0137] c) producing four protective elements or shells 4a, 4b, 4c and 4d to protect mechanically each of the four photovoltaic cells 2a, 2b, 2c and 2d, [0138] d) producing four deformation absorption elements 5a, 5b, 5c and 5d which are arranged respectively in four spaces 6a, 6b, 6c and 6d formed between the four protective shells 4a, 4b, 4c and 4d and the four photovoltaic cells 2a, 2b, 2c and 2d.

[0139] FIGS. 3A and 3B firstly illustrate, in section, two steps of a method for producing a photovoltaic module 1 in compliance with the invention, by lamination then bonding.

[0140] Thus, photovoltaic cells 2a, 2b, 2c and 2d having for example the shape of a square of side equal to 100 mm are firstly produced, these photovoltaic cells 2a, 2b, 2c and 2d being for example mini-cells cut from cells of larger dimensions, and for example cells having a square shape with sides equal to 156 mm.

[0141] These four photovoltaic cells 2a, 2b, 2c and 2d are then assembled together by welding, in accordance with the method of assembly according to the prior art, through the intermediary of electrical contact elements 3a, 3b, 3c and 3d, for example in the form of tinned copper strips.

[0142] Then, as is illustrated in FIG. 3A, once the photovoltaic cells 2a, 2b, 2c and 2d are electrically connected together, they are laminated on either side with layers of encapsulation material 7a and 7b, and a base layer 8 constituting the rear face of the photovoltaic module 1.

[0143] The layers of encapsulation materials 7a and 7b may for example be constituted of the resin EVA. Nevertheless, in a variant, the use of the resin EVA could be replaced by other types of transparent resins, and for example selected from the family of polyurethanes, polyolefins, for example modified polyolefin or ionomer, or instead polyvinyl butylene. As an example, it is possible for example to use commercially available products such as Apolhya of the Arkema company, CVF of the DNP Solar Company or Jurasol DG3 of the Juraplast Company.

[0144] The base layer 8 is for example constituted of a multilayer polymer, for example based on polyvinyl fluoride (PVF) or polyethylene terephthalate (PET). As an example, Tedlar of the Dupont Company may be cited.

[0145] The nature of the base layer 8, as well as its thickness, may vary as a function of the desired type of protection vis--vis the rear face of the photovoltaic module 1, and also as a function of the flexibility expected for the photovoltaic module 1.

[0146] In a variant, the base layer 8 may also comprise a metal layer for example made of steel, optionally protected by an additional covering, notably an insulating covering, for example of the polyurethane type, for example of the Pu Damival type of the Vonrol Company.

[0147] Furthermore, the protective shells 4a, 4b, 4c and 4d are made of PMMA, in particular made of the so-called impact PMMA material sold by the Arkema Company under the reference Altugas ShieldUp. In a variant, the protective shells 4a, 4b, 4c and 4d may also be made of polycarbonate, such as for example from Macrolon of the Bayer Company, or even more preferentially for impact resistance, from Lexan sold by the Sabic Company.

[0148] Then, as illustrated in FIG. 3B, the protective shells 4a, 4b, 4c and 4d are bonded onto the layer of encapsulation material 7a, for example by means of an acrylic adhesive. The protective shells 4a, 4b, 4c and 4d are for example spaced apart by at least 10 mm.

[0149] Furthermore, before assembly of the protective shells 4a, 4b, 4c and 4d on the layer of encapsulation material 7a, a highly pressurised gas is introduced between each protective shell 4a, 4b, 4c and 4d and the layer of encapsulation material 7a to form each of the four deformation absorption elements 5a, 5b, 5c and 5d. The use of a highly pressurised gas may also make it possible to reduce the thickness of the protective shells 4a, 4b, 4c and 4d. In a variant, although this is less satisfactory, each deformation absorption element 5a, 5b, 5c and 5d could be formed by the surrounding air.

[0150] Advantageously, the four deformation absorption elements 5a, 5b, 5c and 5d make it possible to compensate for potential deformations linked to mechanical pressure on the protective shells 4a, 4b, 4c and 4d, and above all to prevent contact between the protective shells 4a, 4b, 4c and 4d and the photovoltaic cells 2a, 2b, 2c and 2d.

[0151] In FIGS. 4A and 4B are also illustrated, in section, the steps of another variant of method for producing a photovoltaic module 1 in compliance with the invention.

[0152] In this variant, the photovoltaic module 1 is produced by a complete lamination of its constituent layers.

[0153] In particular, as illustrated in FIG. 4A, the layers of encapsulation material 7a and 7b may be positioned on either side of the photovoltaic cells 2a, 2b, 2c and 2d. In addition, the base layer 8 may also be positioned in contact with the layer of encapsulation material 7b. The protective shells 4a, 4b, 4c and 4d are also positioned in contact with the layer of encapsulation material 7a. This positioning of the layers relatively to each other is carried out before lamination.

[0154] Then, as illustrated in FIG. 4B, a phase of lamination of the layers is engaged, during which the resin of the layer of encapsulation material 7a is going to melt such that each of the protective shells 4a, 4b, 4c and 4d is going to sink in and be fixed in this layer of encapsulation material 7a.

[0155] Furthermore, as described previously, it may be provided to inject a highly pressurised gas to form the deformation absorption elements 5a, 5b, 5c and 5d. FIGS. 5A and 5B illustrate, in section, another alternative embodiment of the method according to the invention. In this variant, overmoulding is used.

[0156] In particular, as illustrated in FIG. 5A, after lamination of the layers of encapsulation material 7a and 7b on either side of the photovoltaic cells 2a, 2b, 2c and 2d and lamination of a base layer 8, above the photovoltaic cells 2a, 2b, 2c and 2d, on the layer of encapsulation material 7a, is overmoulded a print (or guide) made of a very compressible material, such as for example transparent expanded polystyrene, to form the deformation absorption elements 5a, 5b, 5c and 5d. Then, as illustrated in FIG. 5B, secondly, on the deformation absorption elements 5a, 5b, 5c and 5d is overmoulded the robust material constituting the protective shells 4a, 4b, 4c and 4s, for example made of PMMA.

[0157] Another example of carrying out a method in compliance with the invention is furthermore illustrated in FIGS. 6A to 6C. In this variant, a blowing method is used to form the protective shells 4a, 4b, 4c and 4d and the deformation absorption elements 5a, 5b, 5c and 5d.

[0158] Thus, as illustrated in FIG. 6A, in section, the first step consists in heat welding together two layers of protective material 10a and 1013, for example formed by films made of PMMA, in order to form squares (visible in FIG. 6B).

[0159] In particular, the two layers of protective material 10a and 10b are partially heat welded together so as to form areas assembled by heat welding 11 and areas 12 superimposed but not assembled together.

[0160] Thus, as illustrated in front view in FIG. 6B, a set of non-assembled areas 12 in the form of squares are obtained, on which is provided furthermore an opening to give the possibility of injection of a gas, for example air or nitrogen, during the third step described with reference to FIG. 6C.

[0161] During this third step, illustrated in FIG. 6C in section, the two layers of protective material 10a and 10b, such as obtained during the step illustrated with reference to FIG. 6B, are laminated on an assembly of the photovoltaic module 1 such as obtained for example with reference to FIG. 3A.

[0162] Then, into the photovoltaic module 1, at the level of the opening 13 as represented in FIG. 6B, is injected a highly pressurised gas, for example at a pressure comprised between 5 and 15 bars, so that it penetrates inside the non-assembled areas 12 to form the deformation absorption elements 5a and 5b, as well as the protective shells 4a and 4b.

[0163] Another example of producing a photovoltaic module 1 in compliance with the invention is moreover illustrated in perspective in FIG. 7A and in section in FIG. 7B.

[0164] In this example, the photovoltaic module 1 is without a base layer 8 and layers of encapsulation material 7a and 7b as described previously.

[0165] In reality, each of the four photovoltaic cells 2a, 2b, 2c and 2d is covered on either side by a first protective element 4a, 4b, 4c and 4d and a second protective element 4e, 4f, 4g and 4h. In particular, as represented in FIG. 7B, the first protective elements 4a, 4b, 4c and 4d are superimposed on the second protective elements 4e, 4f, 4g and 4h, such that each of the photovoltaic cells 2a, 2b, 2c and 2d is enveloped by these first and second protective elements.

[0166] In this way, the photovoltaic cells 2a, 2b, 2c and 2d no longer rest on a supple substrate such as formed by encapsulation by use of layers of encapsulation material 7a and 7b, as described previously. On the contrary, they are sandwiched between two protective shells.

[0167] This embodiment may enable a simplified assembly of the photovoltaic cells together. In particular, it may no longer be necessary to encapsulate the photovoltaic cells together.

[0168] Similarly, it may no longer be necessary to assemble, notably by welding, the electrical contact elements over the whole width of the photovoltaic cells. Indeed, a welding is normally carried out over the whole width of the photovoltaic cells for the assembly of the electrical contact elements in order to avoid being hindered by the resin constituting the layers of encapsulation material 7a and 7b. Nevertheless, without use of such layers of encapsulation material 7a and 7b, a partial welding may be sufficient.

[0169] Advantageously, this embodiment of FIGS. 7a and 7b may make it possible to protect the photovoltaic cells 2a, 2b, 2c and 2d from exterior stresses at the level of each of their opposite faces. This embodiment may make it possible to obtain a bifacial configuration of the photovoltaic module 1.

[0170] Furthermore, FIG. 8 illustrates, in section and in a simplified manner, the possibility of having an electrical contact element 3a which is at least partially flexible, and notably in the part thereof situated between two photovoltaic cells 2a and 2b.

[0171] More specifically, in certain configurations of use of the photovoltaic module 1, the electrical contact elements may be mechanically loaded and may consequently weaken the photovoltaic cells. In this case, it may be necessary to provide sufficiently supple electrical contact elements.

[0172] To do so, a first possibility may consist in playing on the ratio between the thickness and the width of each electrical contact element.

[0173] A second possibility may consist in replacing the usual copper strip forming the electrical contact element by a desoldering braid, as taught for example by the international patent application WO 2012/028537 A1.

[0174] Finally, a third possibility, illustrated with reference to FIG. 8, may consist in using at least one flexible portion 14b in the area of the electrical contact element 3A situated between the photovoltaic cells 2a and 2b.

[0175] Thus, the electrical contact element 3a may for example comprise two rigid portions 14a and 14c respectively assembled to the two photovoltaic cells 2a and 2b, for example by welding or bonding, and comprise a central flexible portion 14b making the link between the two rigid portions 14a and 14c.

[0176] Obviously, the invention is not limited to the examples of embodiment that have been described. Various modifications may be made thereto by those skilled in the art.

[0177] The expression comprising a should be understood as being synonymous with comprising at least one, unless specified otherwise.