AT508399A1 - METHOD FOR PRODUCING A SOLAR PANEL INSTALLED FROM LAYERS - Google Patents

Description

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The invention relates to a method for producing a solar panel constructed from layers, which has a transparent plastic layer sealing a photovoltaic layer in a finished state of the solar panel, the plastic layer being formed from a material serving as an adhesive for bonding the layers of the solar panel and the finished solar panel is held together by the plastic layer. t;

The invention further relates to a system for carrying out the method according to the invention for producing a layered solar panel with one in one finished state a photovoltaic layer sealing, transparent art | layer, wherein the system comprises a laminator. j

A common process for the production of solar panels is that in | | essential normal room conditions a sandwich construction of several layers is built. This sandwich construction comprises a glass plate as a carrier material, a first layer of a plastic film laid on the glass plate, onto which a network of solar cells is laid, and a second layer of the plastic film covering the solar cells, onto which a cover film is laid. The first and the second layer of the above-mentioned plastic film form, after a lamination process, a self-bonded plastic layer in which the solar cells are embedded. These plastic films are often formed as (poly) ethylene vinyl acetate films (EVA films), polyvinyl butyral films (PVB films) or as thermoplastic polyurethanes (TPU films). The covering film, also referred to as a "backsheet", may be formed, for example, from a weather-resistant plastic which is not transparent in the visible spectral range, for example from a PVDF-PET-PVDF laminate. After manual construction of the sandwich construction, this is introduced into a laminator. Instead of using a "backsheet" made of plastic may optionally also be used a further glass plate. N2009 / 07100 • · Μ ·· Μ · · · · · · -2-

For example, a conventional laminator may have a base with a heating plate and a top with a pressure membrane, and thus essentially constitutes a heating / cooling press. The pressure membrane has a dual function. On the one hand, it serves to make the working chamber airtight. On the other hand, the pressure membrane exerts a predetermined contact pressure on the layers of the solar module to be joined together. The space between the heating plate and pressure membrane is usually evacuated.

The sandwich construction is placed at the bottom of the laminator with the carrier glass plate so that it is heated by the heating plate. During the lamination process, this glass plate is heated to a suitable temperature to ensure good bonding of the solar cells embedding plastic films (EVA films) and with the glass plate and the grid of photovoltaic cells.

Once the sandwich construction is at the melting temperature of the plastic films, a pressure is generated from above by means of the membrane in order to ensure a good temperature transfer within the layer construction and a good cross-linking of the films as well as a good bonding of the individual layers. The now taking place pressing process, typically with a pressure of about 1 bar, takes place under a vacuum or in the working chamber of the laminator to avoid inclusions of air bubbles. During the pressing process, the glass plate is heated further.

When laminating, for example, when using EVA films from the previously milky EVA films forms a clear, three-dimensionally crosslinked and no longer fusible transparent plastic layer in which the solar cells are now embedded and which is firmly connected to the glass and the backsheet. After pressing, the sandwich construction is cooled under pressure in a cooling press.

A problem associated with conventional methods of producing solar panels is that the films used to make the plastic layer sealing the photovoltaic layer may substantially degrade their quality. For example, the use of EVA films in the production of solar panels during storage has the problem that the EVA films are kept relatively cool due to their heat sensitivity, especially of the additives that provide for the cross-linking and adhesion have to. The problem with PVB films, for example, is that they are hygroscopic and must therefore be monitored during storage for temperature and humidity. Also, the storage of other materials used in the production of the plastic layer in film form is associated with a relatively large effort to maintain the quality of the films over a longer period of time to be able to. Overall, it follows that the disadvantage of costly and expensive storage of the films is associated with the production methods commonly used, in which films are used. Due to the complex storage, the production of solar panels becomes more expensive.

It is therefore an object of the invention to overcome the above-mentioned disadvantages.

This object is achieved by a method of the aforementioned type according to the invention that the material used for the production of the plastic layer is applied as a melt on a surface of a provided as a support for the photovoltaic layer support plate or at least on a coated with the photovoltaic layer support plate.

The solution according to the invention has the great advantage that films which are no longer difficult to store must be used for producing a solar panel, but the plastic granules used for the production of the films and substantially less susceptible to environmental influences can be used and the additives can be stored "in an appropriate manner". Since the respective plastic granules are much less sensitive to temperature influences, for example, than the films produced therefrom, storage is also considerably simplified and cheaper. Another advantage associated with the use of plastic granules instead of the films is that the plastic granules are much cheaper to purchase than the films made from them. A further advantage of the invention is that the plastic layer encapsulating or sealing the solar cells and applied as a melt constitutes a 1-component system, whereby the production of the solar module is simplified.

An advantageous variant of the invention provides that a glass plate is used as the carrier plate, to which the melt is applied, wherein after the deposition of the melt, a layer of solar cells is applied to the melt. In turn, a layer of the melt can be applied to the solar cells, to which then a glass plate or a cover film can be applied.

Alternatively, as the support plate, a glass plate coated with a photovoltaic layer N2009 / 07100-4-coated glass plate can be used and... be applied to the melt a glass plate or a cover sheet. In contrast to the embodiment of the invention mentioned in the previous paragraph, no solar cells are applied to the melt here, but the glass to which the melt is applied is already coated with a photovoltaic layer. The hergestelite solar panel is commonly referred to as glass-glass or glass-film thin-film module.

The manufacturing process can be optimized by applying the melt substantially uniformly. In order to ensure as uniform a coating as possible with the melt, the melt can be applied by means of a curtain coating.

For producing and applying the melt, in particular, a heatable extruder is suitable in which a granulate of the material used to produce the plastic layer can be fed.

In order to reduce the residence time in the laminating press and to ensure a good connection with the melt, the glass plate or the photovoltaic layer-coated glass plate can be preheated before the melt is applied.

As materials for the production of the plastic layer advantageously EVA, PVB or TPU can be used.

The above object can also be achieved with a system of the type mentioned above in that the system comprises a heater for producing a melt of the material used to produce the plastic layer and a Auftragungsvorrichturig for uniform orders of the melt on a layer of the solar panel.

A particularly good and uniform application of the melt can be achieved by providing at least one conveying means for carrying out at least one layer of the solar panel onto which the melt is to be applied, through a curtain of the melt exiting from an outlet opening of the application device.

According to a preferred variant of the invention, the system has a heatable extruder, which can be fed with a granulate of the material used to produce the plastic layer in order to produce the melt. The extruder can in this case have a nozzle for producing a uniform curtain of the melt. N2009 / 07100 ·· ·· t ····· ···· ···· ····· ·········································································· ··················································

The invention together with further advantages will be explained below with reference to some non-limiting embodiments, which are illustrated in the drawings, in which show schematically:

1 shows a block diagram of a system according to the invention for producing a solar panel;

Fig. 2 shows a first variant of an application device for orders a

Melt of a material used for producing a solar cell-sealing plastic layer of the solar panel material;

Fig. 3 shows a second variant of an application device for orders a

Melt of a material used for producing a solar cell-sealing plastic layer of the solar panel material;

Fig. 4 shows a third variant of an application device for orders a

Melt of a material used for producing a solar cell-sealing plastic layer of the solar panel material;

5 shows a fourth variant of an application device of an application device for applying a melt from a material used for producing a solar cell-sealing plastic layer of the solar panel.

6 shows a cross section through a first variant of a solar module, as can be produced by the method according to the invention;

7 shows a cross section through a second variant of a solar module, as can be produced by the method according to the invention;

8 shows a cross section through a third variant of a solar module, as can be produced by the method according to the invention and

9 shows a cross section through a third variant of a solar module, as can be produced by the method according to the invention.

By way of introduction, it should be noted that in the differently described embodiments, the same parts are provided with the same reference numerals or the same component designations, wherein the disclosures contained in the entire description mutatis mutandis to the same parts with the same reference numerals or the same component designation N2009 / 07100

Tions can be transmitted. Also, the location information chosen in the description, such as top, bottom, side, etc. related to the immediately described and illustrated figure and are to be transferred to the new situation mutatis mutandis when a change in position. Furthermore, individual features or combinations of features from the different exemplary embodiments shown and described can also represent independent, inventive or inventive solutions.

The figures are described coherently and comprehensively. Same components bear the same reference numerals. Similar components or functionally similar components bear the same reference numerals with different indices.

According to FIG. 1, a system 1 according to the invention for producing a solar panel 2 constructed of layers has one or more heaters 3 for producing a melt 4 of a material 5 of a transparent plastic layer 7 sealing a photovoltaic layer 6 in a finished state of the solar panel 2. The term "melt" in this document means a liquid or viscous mass of a molten material. An average temperature of the melt is thus at least the value of the melting temperature of the material, but the temperature of the melt can also be well above the melting temperature of the starting material.

The material 5 for producing the melt 4 is preferably present as plastic granules, wherein as materials, for example EVA, PVB or TPU can be used. At this point, however, she mentions that the solution according to the invention is not limited to the just mentioned materials. Other materials can also be used which make it possible to connect the individual layers of the solar panel 2 and to ensure transparent and permanent sealing or encapsulation of the photovoltaic layer. By "photovoltaic layer" is meant in this document quite generally a photovoltaic coating of a carrier material as well as solar cells 6a applied to a carrier material.

In FIGS. 1 to 3, reference numeral 6a denotes a layer of solar cells applied to the melt, while in FIGS. 4 and 5 reference numeral 6b denotes a photovoltaic coating connected to a glass plate. N2009 / 07100 • · • · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · ·

Furthermore, the system 1 has one or more application devices 9 9 'for uniform application of the melt 4 to a layer or support plate, for example a glass plate 8, of the solar panel 2. Preferably, the heaters 3, 3 'for melting the material 5 are integrated into the application devices 9, 9', i. built into this.

The application devices 9, 9 'can be set up, for example, to apply the melt 4 to the carrier plate by means of a curtain coating. In this case, the system 1 may comprise one or more conveying means for guiding the carrier plate or the carrier plate and at least one further layer thereon, onto which the melt 4 is to be applied, for example solar cells 6a, through one of an outlet opening of the application device 9, 9 'exiting curtain of melt 4 perform. The conveyor may be formed, for example, as a conveyor belt or formed by rollers, etc. Various variants of application devices are explained in more detail below.

In addition, the system 1 according to the invention may have a heating device 10a for preheating the carrier plate to be coated.

Furthermore, a laminator 10 is provided in order to connect all the layers 8, 7, 6a, 8 'of the solar panel 2 by pressing together and optionally with heating.

According to the method according to the invention, the carrier plate can be preheated in the heating device 10a. However, the preheating is not essential, but has the advantage, inter alia, that a better connection of the melt 4 can be ensured with the support plate. Also, by pre-heating, the residence time of the layer structure of the individual layers 8, 7, 6a, 8 'of the solar panel 2 in the laminator 10 can be reduced. The preheating process is indicated by I in FIG.

The direction of the process sequence is indicated by arrows in FIG.

After preheating, the material 5 used for the production of the plastic layer 7 can be applied as a melt 4 to an upper side or surface of the carrier plate. Depending on the type of solar panel 2 to be produced, for example a glass plate already coated with a photovoltaic layer or an uncoated glass plate 8 can be used here. The application of the melt 4 can be carried out, for example, by a curtain coating method. N2009 / 07100 ···· ····································································· 8th-

The step of applying the melt 4 to the support plate is indicated in FIG. 1 by II.

When using an uncoated glass plate 8, a layer of solar cells 6a can be applied to the melt 4 after the deposition of the melt 4. Hereupon, in the step designated as ΙΓ in FIG. 1, a layer 4 'of the melt 4 can again be applied to the solar cells 6a. This can be done with the application device 9 'shown by dashed lines in FIG. On the last applied layer 4 'of the melt 4, a glass plate 8' or a cover sheet can then be applied. This can be done inside or outside the laminator 10 and performed manually and / or automatically. Instead of applying the layer 4 'of the melt 4 to the solar cells 6a, the layer 4' could also be applied to the glass plate 8 ', the glass plate 8' then being applied to the solar cells 6a with the layer 4 '.

The layer structure of glass plate 8, melt 4, solar cells, melt 4 and glass plate 8 'or covering film can then be pressed or laminated together in the laminator 10. In this case, the pressing or lamination can take place under a heating of the layer structure taking place in the laminator 10. For this purpose, the laminator 10 may have a heater. However, the preheating of the glass plate 8 in step I also opens up the possibility of being able to dispense with heating in the laminator 10 due to the relatively high heat capacity of glass. Furthermore, the pressing process in the laminator 10 can be carried out under vacuum. Alternatively, the pressing process in the laminator 10 could also take place under a protective gas atmosphere of a protective gas soluble in the melt 4. When using EVA, PVB or TPU as materials for producing the plastic layer 7 or the melt 4, e.g. C02 or CO can be used as inert gas. The step of compression is indicated in Fig. 1 with III. The still hot Solarpaneei 2 is ejected after pressing or laminating from the laminator 10 and fed to other subsequent processing stages. The subsequent processing steps of the solar panel will not be explained in detail here, since they are not essential to the invention.

According to FIG. 2, the application device designated by the reference symbols 9, 9 'in FIG. 1 can be designed as a heatable extruder 11. The embodiment shown here is particularly well suited for curtain coating of the carrier plate, for example the glass plate 8. A granulate of the material 5 used to produce the plastic layer 7 is fed into the extruder 11 and then compressed and compressed.

• * • • φ «·· •» · · • φ · · ···· -9-melted. The carrier plate is carried out by means of a conveying means, for example a conveyor belt 12, under the extruder 11. The direction of movement of the support plate is indicated in the figures 2 to 5 with arrows. Via a nozzle 13, the melt 4 is applied to the underlying carrier plate. The nozzle 13 in this case has no contact with the carrier plate while the melt 4 is applied. The nozzle 13 may have an opening extending over the width of the carrier plate, for example a gap, for discharging the melt 4.

The melt 4 drops like a curtain after exiting the nozzle 13 on the moving therethrough support plate. The non-contact coating of the carrier plate produces a uniform coating film 4a. Depending on the speed with which the support plate is passed under the nozzle, the thickness of the coating film 4a can be varied.

Fig. 3 shows an embodiment of the invention in which two or more conveyor belts 12a, 12b can be used. Between the two conveyor belts 12a, 12b there is a gap 13 over which the discharge device is mounted. The melt 4 is in this case in a container 14, which has an outlet opening 15 in its bottom. Through the outlet opening 15, a curtain of the melt 4 can fall down. The container 14 can be heated, so that a granulate of the material 5 can be filled directly into the container 14 and melted there. As an alternative to producing the melt 4 in the container 14, however, the melt 4 can also be filled into the container 14 only after its production, the container 14 in this case serving merely to discharge the melt 4.

The carrier plates run from one conveyor belt 12a to the other conveyor belt 12b and traverse the curtain of the melt 4 in the region below the outlet opening 15. Excess melt 4 does not drip onto the conveyor belts 12a, 12b but into the gap 13. The melt 4 can flow in the illustrated embodiment, either by means of a pressure medium, such as a piston 16 or the like, and / or due to the influence of gravity conditionally pressed out of the outlet opening 15 out. Of course, the positioning of the container 14 shown in Fig. 3 can also be selected for the extruder 11 shown in FIG.

4 shows a further possibility of applying the melt 4 to the carrier plate. In this case, the melt 4 is applied to the carrier plate from an outlet opening 15a. N2009 / 07100 ♦ *

··· # ··· ···· • · · · ········································. The application of the melt 4 does not have to be done in this case with a method for curtain coating. Advantageously, the outlet opening 15a extends substantially over the entire width of the carrier plate, so that the melt 4 can be applied over the entire width of the carrier plate. The melt 4 can also be applied unevenly on the carrier plate in this embodiment of the invention. By means of a fixed mechanical coating device 17, for example in the form of a plate mounted above the carrier plate, the melt 4 can then be distributed uniformly over the carrier plate. For this purpose, the provided with the melt 4 carrier plate is pulled through a conveyor belt 12 or other suitable conveying means under a lower edge of the coating device 17, whereby excess melt 4 can be removed from the support plate. The distance between the lower edge of the coating device 17 and the carrier plate determines the resulting thickness of the coating film 4a of the melt 4 on the carrier plate.

Fig. 5 shows a further embodiment of a discharge device. The variant shown here differs from that shown in Fig. 4 in that instead of the mechanical coating device 17, an air knife 18, in which a strong air jet is blown through a nozzle 19 is used.

The coating device 17 shown in FIG. 1 or the air knife 18 shown in FIG. 5 can also be used in the variants shown in FIGS. 2 and 3 in order to possibly achieve an even more uniform distribution of the melt 4 on the carrier plate.

FIG. 6 shows the structure of the solar panel 2 from FIG. 1 as it leaves the laminator 10. The plastic layer 7 encapsulating the solar cells 6a is applied to the glass plate 8 and covered by a glass plate 8 '. The entire layer structure or the solar panel is held together by the plastic layer 7.

According to FIG. 7, as an alternative to the use of the second glass plate 8 ', the plastic layer 7 of the solar panel 2' may also be connected to a cover film ("backsheet") 19.

8 shows the structure of a solar panel 2 ", which has a glass plate 8a coated with a photovoltaic layer 6b. The plastic layer 7 seals the photovoltaic layer 6b and connects the coated glass plate 8a to an uncoated glass plate 8b. For the production of this solar panel 2 "with the erfindungsge- N2009 / 07100

···· ···· ···· • · · • · · · "♦ · · ν 11

In accordance with the method or system, the melt 4 is applied in step II in FIG. The step ΙΓ, which has a further application of the melt 4 to the content, can be omitted here. The glass plate 8b is then applied to the melt 4 inside or outside the laminator 10. In the laminator 10 is then a pressing and laminating the individual layers to the solar panel 2 ". Of course, in step II, the melt 4 may be applied to the uncoated glass plate 8b instead of the glass plate 8a. The coated glass plate 8a is then applied to the glass plate 8b provided with the melt 4 and pressed in step III with this.

The structure of a solar panel 2 "'shown in FIG. 9 differs from that shown in FIG. 8 only in that instead of the glass plate 8b, a covering film 19 is used. However, the production method of this solar module 2 "'corresponds to the production method described above for the solar panel 2" with the difference that instead of the glass plate 8b after step II in Fig. 1, the cover 19 is applied to the melt 4.

At this point it should be mentioned that in all the above-mentioned embodiments of solar panels 2, 2 ', 2 ", 2"' in addition to the above-mentioned film layers and layers still further intermediate layers can be provided, for example, a voltage applied to the non-photoactive side of the solar cell tile ,

Finally, it should be noted that the embodiments show only possible embodiments of the inventive solution, the invention is not limited to the specifically illustrated embodiments. In particular, combinations of the individual embodiments are possible with each other, these variations are due to the teaching of technical action of the subject invention in the skill of those working in this technical field expert. There are also all conceivable embodiments that realize the solution ideas underlying the invention and are not explicitly described or illustrated or by combinations of individual details of the illustrated and described embodiments are possible, includes the scope of protection. Likewise, the protection also extends to the individual components of the device according to the invention, insofar as they are in themselves essential to the realization of the invention. N2009 / 07100

Claims (15)

1. A method for producing a layer (6a, 6b, 7, 8, 8 ', 8a, 8b, 19) constructed solar panels (2, 2', 2 ", 2" '), soft one in a finished state of the solar panel (2) a photovoltaic layer (6a , 6b) has a sealing, transparent plastic layer (7), wherein the plastic layer (7) consists of a bonding agent for bonding the layers (6a, 6b, 7, 8, 8 ', 8a, 8b, 19) of the solar panel (2, 2 ', 2 ", 2"') serving material (5) and the finished solar panel (2, 2 ', 2 ", Τ') is held together by the plastic layer (8), characterized in that for the production of the plastic layer (7) used material (5) as a melt (4) on a surface of a support provided for the photovoltaic layer (6a) support plate or at least one with the photovoltaic layer (6b) besc coated carrier plate is applied. 2. The method according to claim 1, characterized in that as a carrier plate, a glass plate (8) is used, on which the melt (4) is applied, wherein after the orders of the melt (4) as a photovoltaic layer (6) a layer of solar cells (6a) is applied to the melt (4). 3. The method according to claim 2, characterized in that on the solar cell (6a) a layer (4 ') of the melt (4) is applied to which a glass plate (8') or a cover film (19) is applied. 4. The method according to claim 1, characterized in that as a support plate with the photovoltaic layer (6b) coated glass plate (8a) is used and on the melt (4) a glass plate (8b) or a cover (19) is applied. 5. The method according to any one of claims 1 to 4, characterized in that the melt (4) is applied substantially uniformly. N2009 / 07100 Wi ♦ ♦ * · ··· ♦ * · «· ············································· ······································ 6. The method according to any one of claims 1 to 5, characterized in that the melt (4) is applied by means of a curtain coating. 7. The method according to any one of claims 1 to 6, characterized in that for the production of the melt (4), a heatable extruder (11) is used, in which a granulate of the material used for producing the plastic layer (7) material (5) is fed , 8. The method according to any one of claims 2 to 7, characterized in that the glass plate (8) or with a photovoltaic layer (6b) coated glass plate (8a) is preheated before applying the melt (4). 9. The method according to claim 1 to 7, characterized in that is used as the material (5) for the production of the plastic layer (7) EVA. 10. The method according to claim 1 to 7, characterized in that as a material (5) for the production of the plastic layer (7) PVB is used. 11. The method according to claim 1 to 7, characterized in that as the material (5) for the production of the plastic layer (7) TPU is used. 12. System (1) for carrying out the method according to one of claims 1 to 11 for the production of a layer (6a, 6b, 7, 8, 8 ', 8a, 8b, 19) constructed solar panel (2, 2', 2 " , 2 "') having a transparent plastic layer (7) sealing a photovoltaic layer (6a, 6b) in a finished state, the system (1) comprising a laminator (10), characterized in that the system (1) is at least a heater (3, 3 ') for producing a melt (4) of the material (5) used for producing the plastic layer (7) and at least one application device (9, 9', 11, 14) for uniform application of the melt (4) on a layer (8, 6a, 6b) of the solar panel (2, 2 ', 2 ", 2"'). 13. System according to claim 12, characterized in that at least one conveying means is provided to at least one layer (8, 6a, 6b) of the solar panel (2, N2009 / 07100 ♦ * • · • • * · • · ··· « 2 ', 2 ", 2"'), to which the melt (4) is to be applied, by a curtain of the melt (4) emerging from an outlet opening (15) of the application device (9, 9 ', 11, 14). 14. System according to claim 12 or 13, characterized in that it comprises a heatable extruder (11) which can be fed to produce the melt (4) with a granulate of the material used for the preparation of the plastic layer (7) material (5). 15. System according to claim 14, characterized in that the extruder (11) has a nozzle (13) for generating a uniform curtain of the melt (4). 3S Swiss Solar Systems AG N2009 / 07100