CN101371367B - 光伏器件和封装的方法 - Google Patents
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Abstract
一种在基板和覆盖板之间包括光伏层的光伏器件,该覆盖板在光伏层上方的区域中是透明的,其中该覆盖板与光伏层重叠,而其中在与光伏层相邻的区域中的覆盖是不透明的;一种利用这种覆盖板封装光伏器件的方法,且使用这种覆盖来封装光伏器件的用途,用于保护与光伏层相邻存在的聚合密封材料免于受光引起的降解和/或保护封装的光伏器件免受光辐射导致的热应力。
Description
技术领域
本发明涉及一种光伏(photovoltaic)器件、一种封装光伏器件的方法以及用于封装光伏器件的覆盖的用途。
背景技术
太阳能电池通常由基板上布置的光伏层形成,并且将其封装以防止环境的影响。在接收光侧上提供覆盖,其通常为透明材料,尤其经常使用钢化玻璃。
通常将薄膜太阳能电池布置在玻璃基板上。在薄膜太阳能电池中,光伏层是一种薄膜,其包括一个或多个形成光敏pn结的薄层且包含必要的电极。特殊的薄膜太阳能电池是所谓的黄铜矿(chalkopyrite)或I-III-VI太阳能电池。另外的薄膜太阳能电池是非晶硅太阳能电池。
太阳能电池的光伏层通常没有覆盖整个基板区。具体地,在沿着基板周围的边界区域中不布置光伏层,或者在封装之前,例如在该区域中通过激光清除而将其从该区域中去除。
对于封装来讲,能够沿着基板的周围布置诸如聚合带之类的聚合密封材料,并且将覆盖层叠到具有光伏层的基板上。
能够将多个太阳能电池布置在普通覆盖下以形成太阳能模块。可以将太阳能电池或太阳能模块布置在框架中。在说明书中和在权利要求中将使用光伏器件的表述来通常地表示太阳能电池、太阳能模块或产生光伏能量的其它器件。
封装将防止光伏器件受到诸如机械冲击、温度波动和潮湿之类的环境影响。光伏器件必须通过诸如IEC 61646的潮湿漏电流之类的质量检测。商用光伏器件通常以10至25年的保质期来销售,所以对长期耐久性的要求较高。
2005年1月3-7日,在佛罗里达的奥兰多举办的第31次IEEE光伏专家会议的学报的、Robert Wieting等人的“CIS THIN FILMMANUFACTURING AT SHELL SOLAR:PARTICALTECHNIQUES IN VOLUME MANUFACTURING”文章中,陈述了覆盖玻璃可以选择性地利用黑釉料周边而丝网印刷在内部表面上,从而提供更为美观的外观——如同用在汽车挡风玻璃上的那些一样。
本发明的目的在于提高封装的光伏器件的稳定性,尤其是长期耐久性,特别是针对黄铜矿(chalkopyrite)光伏器件。
发明内容
本发明提供了一种在基板和覆盖板之间包括薄膜光伏层的光伏器件,所述覆盖板在所述光伏层上方的区域中是透明的,其中该覆盖板与所述光伏层重叠,并且其中所述覆盖板在与所述光伏层相邻的区域中是不透明的,其中在所述不透明区域中,所述覆盖板至少在面向所述基板的一侧上被涂覆,或者该覆盖板具有改变(modified)的主体,以使其在该区域中是不透明的。
本发明还提供了一种在基板和覆盖板之间包括薄膜光伏层的光伏器件,所述覆盖板在所述光伏层上方的区域中是透明的,其中该覆盖板与所述光伏层重叠,并且其中所述覆盖板在与所述光伏层相邻的区域中是不透明的,其中在所述不透明区域中,所述覆盖板至少在背向所述基板的一侧上被涂层所涂覆,并且其中所述涂层不是带。
申请人意识到在与光伏层相邻的区域中的不透明覆盖板有助于提高封装的光伏器件的稳定性。可以以这种方式解决的特定问题是热应力。光伏层通常是暗的,而在黄铜矿光伏器件的情况下,基本上是黑的。没有被光伏层覆盖的区域通常颜色更浅或透明。所以,在阳光的辐射下,使得光伏器件区域和其余的区域受热不同,从而导致热应力。这对于易碎基板的边界区域是特定的问题。对于薄膜光伏器件来讲,经常将非钢化的浮法玻璃用作基板。将浮法玻璃经常切割成在周围出现微裂纹的大小。在边界区域中的热应力可以导致基板的肉眼可见的裂纹。不透明覆盖减轻了这种问题,这是因为由于在与光伏层区域相邻的区域中太阳光也被吸收,由此减少了热应力的不均匀性。
通过本发明可以减轻的进一步的问题是尤其沿着太阳能电池或模块的边缘的材料的光(包括紫外(UV)光)降解,所述材料特别是聚合物材料。这种聚合材料可以是施加在光伏层和覆盖板之间的诸如EVA(乙烯醋酸乙烯酯)或PVB(聚乙烯醇缩丁醛)之类的叠片箔、尤其是例如为了密封防止潮湿的侵入可以施加在基板周围的聚合密封剂。随着时间的推移使许多聚合物降解,而经常由于光、尤其是UV辐射引起降解。不透明覆盖可以阻挡辐射到聚合物的光,尤其是到聚合物的UV辐射,从而阻止或防止在不透明区下、优选地沿着边缘(在该区域中的边缘密封和/或部分叠片箔)的降解。
合适地是,不透明区基本包括可以接收光的所有区域,并且在该区域下不存在光伏层。这样最大化了上述的有益效果。同样合适地是,不透明区域与光伏层在实际可能的生产容差内仅最小地重叠,从而最小化光伏器件效率的任何损失。
通过涂覆覆盖板可以提供不透明区,例如通过涂绘(painting)或丝网印刷,合适地是,接着进行热处理。
覆盖板通常是平直的并且具有0.5-10mm范围的厚度,优选为1-5mm,而覆盖板可以是在光伏层上方具有足够透明度的任何材料。合适地是,覆盖板是覆盖玻璃,优选为钢化玻璃。
在实践中,在与诸如黄铜矿电池的薄膜光伏器件非常关联的实施例中,基板是诸如非钢化玻璃的易碎材料。在这种情况下,有利的是,利用不透明覆盖来覆盖薄膜之外的所有区域,从而防止由于热应力导致的破裂。
合适地是,不透明区域具有被调整为光伏层颜色的颜色。具体地,在黑色光伏层的情况下,不透明区域可以是黑色。换句话讲,合适地是,在不透明区域中每单位面积从入射光转换为热的能量吸收基本与在光伏层的区域中转换为热的能量吸收相匹配。
合适地是,不透明区域还基本阻挡UV辐射。如果在光(尤其UV)辐射下可以降解的聚合材料(尤其聚合密封剂)存在于不透明区域下,那么这将是特别有益的。对于光或特别是UV来讲,基本阻挡住光(尤其UV)辐射分别意味着光(尤其UV)或者特别是UV的辐射的透射率小于20%,优选地小于10%,更为优选地小于5%,最为优选地是基本上为零的透射率。
本发明还提供了一种封装光伏器件的方法,包括如下步骤:
提供基板,所述基板在其部分区域上具有带有薄膜光伏层的区域;
提供具有透明区域和与该透明区域相邻的不透明区域的覆盖板;
在所述光伏层上方布置所述覆盖板,使得所述不透明区域覆盖所述基板区域的其上布置有所述光伏层的所述部分区域之外的至少部分。
在特定实施例中,将聚合密封材料布置在基板上,并且布置所述覆盖,使得聚合密封材料由不透明区域覆盖。在许多实际情况下,尤其在密封剂只围绕基板的周围的情况下,不透明区域适宜围绕透明区域。然而,也可以将密封材料布置于除了基板周围之外的区域,例如,在将多个光伏器件布置在一个模块中并且由一个覆盖进行覆盖的情况下。
本发明还提供覆盖板的用途,该覆盖板具有透明区域以及与透明区域相邻的不透明且吸收UV的区域,用于封装包括布置在基板上的薄膜光伏层的光伏器件以及用于保护与光伏层相邻存在的受UV可降解的材料(尤其是聚合材料,更具体为聚合密封材料)免于UV引起的降解。
此外,本发明提供覆盖板的使用,该覆盖板被提供有透明区域和与该透明区域相邻的不透明区域,用于封装包括布置在基板上的薄膜光伏层的光伏器件,以及用于保护封装的光伏器件免于由于光辐射期间引起的热应力,该基板大于光伏层。
参考本发明的光伏器件所讨论的合适和优选的实施例也适合本发明的方法和用途的特定实施例。
附图说明
现在根据附图来更为详细地描述本发明,其中:
图1示意性地示出了通过边缘部分的横截面的本发明第一实施例;
图2示意性地示出了通过边缘部分的横截面的本发明第二实施例;
图3示意性地示出了顶视图的第三实施例;
图4示意性地示出了沿着图3的线IV-IV的视图。
其中,将相同的附图标记用于不同的附图中,相同的附图标记是指相同的或类似的对象。
具体实施方式
对示意性地示出通过根据本发明的薄膜光伏器件10的边缘部分的横截面的图1进行说明。光伏器件10被支撑在基板12上,该基板12通常是大约1至3毫米厚的玻璃。后触层(back contact)包括沉积在基板12上的金属层14。在优选实施例中,层14通常包括或包含钼,其通过溅射而沉积到大约0.2至2微米的厚度。在后电极14的顶部,布置p-型黄铜矿半导体层16,其具有大约0.2至2微米的厚度。
特定类型的薄膜光伏器件具有由族I-III-VI半导体形成的吸收层,也将其称作黄铜矿半导体。这种半导体通常是硒化铜铟(“CIS”)型,其中将理解这种表达,由此铟可以被镓和/或铝部分或完全代替,而硒可以被硫部分或完全代替。CIS型半导体包括由化学式CuInxGayAl(1-x-y)SezS(2-z)表征的那些半导体,其中x+y≤1且z≤2。CIS型层的特殊情况是例如也表示为CIGS或CIGSS。CIS型层可以进一步包括一种或更多种元素或混合物的掺杂浓度或低浓度、微量,尤其诸如钠、钾、铷、铯和/或钫的碱金属,或者碱性混合物。这种添加成分的浓度通常是5wt%或更低,优选为3wt%或更低。
可以通过现有技术中可用的任何方法来形成CIS层16。优选方法包括一系列包含CIS层的金属成分的层的溅射沉积、可选地通过蒸镀沉积来沉积Se层、接着进行快速热处理。在Solar Energy的2004年卷77、第757-765页的J.Palm、V.Probst和F.H.Karg的“Secondgeneration CIS solar module”中描述了优选的工艺,其通过参考被并入。
在层12和14之间,可以布置诸如氧化硅或氮化硅之类的扩散阻挡层(未示出),其用于抑制碱金属从玻璃基板扩散到CIS层16。此外,CIS层优选地包含受控量的Na,如在USA专利号5626688中所公开的,其通过参考而被包括。
通常在CIS型层的顶部上布置了缓冲层18。该缓冲层可以是例如CdS、诸如Zn(O,S)之类的无Cd的也能包括氢氧化物的无机层,但是也可以省略缓冲层。也可以布置本征ZnO层,即,具有大于1Ohm.cm的体积电阻率的ZnO层,优选地高于100Ohm.cm,诸如在1和10×103Ohm.cm之间。优选地,该层厚度在10nm和150nm之间。
光伏器件10还包括n型ZnO层20。该层被适当地掺杂以提供相对低的电阻率,例如,比大约2.0×10-3Ohm.cm更好,而优选地比1.0×10-3Ohm.cm更好。层20的厚度在0.5至2微米是适当的。
未详细示出所述层的电连接,但是示出了导体带24,其被配置用于集合来自整个模块的电流,并且其被连接或可连接到该模块外侧的电触点。
在本实施例中,后电极14、CIS型层16、缓冲层18和ZnO前电极20的堆叠结构一起形成了薄膜光伏层。
通过覆盖板(钢化玻璃的覆盖玻璃30)覆盖光伏器件,该覆盖板通过诸如EVA(乙烯醋酸乙烯酯)或PVB(聚乙烯醇缩丁醛)之类的透明聚合物而层压到具有光伏层的基板,该透明聚合物填充了中间空间并在周围提供了密封。将理解附图是示意性的并且结构的厚度没有按比例画出。在本实施例中的玻璃基板的背面布置有被称作TPAT的泰德拉(Tedlar)/聚酯/铝/泰德拉的保护层。代替覆盖玻璃,也可以应用其它材料的覆盖板,诸如(在光伏层上方)透明的聚合物。
框架38固定和支撑光伏器件。
覆盖玻璃30处于光伏器件的接收光侧。
根据本发明,在与光伏层相邻的区域中的覆盖玻璃30是不透明的。这将通过在边界区域中的覆盖玻璃上的涂层42来实现的。涂层可以被涂绘、丝网印刷和加热,但也可以例如是带(tape)。例如,陶瓷膏体可以被丝网印刷和被炼硬(temper)。代替涂层,例如通过添加颜料或通过包含不透明层或物质也可以在边界区域中改变覆盖玻璃的主体,使其成为不透明的。将参考图2来讨论不透明涂层处于面向基板的玻璃侧上的实施例。在光伏器件上布置覆盖板之前,提供覆盖板30的主体的涂层或改变。涂层优选为不传导的。
不透明区域正好从光伏层的光敏部分的上方(基本上是CIS型层16的边缘)延伸到框架38的边缘的下方。期望在基本上是整个光敏区域上方具有完全透明的覆盖,使得在光伏层上方的、与覆盖的透明区域相邻的不透明区域的重叠被保持为最小。如果没有框架,那么不透明区域适当地延伸到覆盖板的边缘且可以围绕着该边缘延伸。
以这种方式,不透明区域基本包括可以接收光的所有区域,而在该区域下不存在光伏层。
不透明区域为暗是合适的,优选为黑。优选地,不透明区域也基本阻挡UV辐射。以这种方式,减缓并抑制了边缘区域中的聚合树脂32的降解。
现在参考图2,图2示出了根据本发明的光伏器件50的第二实施例。该器件与图1中的附图标记极为相似,与图1中相同的附图标记被用来表示相同或类似的部分,并且参考以上有关它的讨论。讨论与图1的实施例的不同的足够了。沿着光伏器件的边缘,布置带52形式的聚合密封材料。边缘密封可以优选地包括抗湿材料和/或干燥剂。合适边缘密封材料的示例包括丁基橡胶、氨基甲酸乙酯和聚氨酯材料;聚异丁烯材料;环氧化物材料;聚氨基磺酰胺(polysulfamide)材料和氰基丙烯酸。在使后侧层和面向光的层在一起之前,可以以带或条的形式来施加上述边缘密封剂。
在基板的后侧没有保护层36。
将不透明区域54布置成在玻璃覆盖板30的内向侧上的涂层。因为保护了涂层本身,因此这是优选的。
参考图3和图4,其以顶视图和沿线IV-IV的横截面图示意性示出了根据本发明的光伏器件70的第三实施例。图3示出了在普通覆盖玻璃30下和在普通框架38中的由四个太阳能电池71a、b、c、d形成的太阳能模块。该模块与图2的器件50非常类似,事实上,能将图2认为是沿线II-II的横截面。然而,在由多个太阳能电池形成的模块中,可以存在除了可以应用本发明的周边之外的区域。在图4的横截面中,示出了可以类似地将不透明区域54布置在光伏器件的中央部分。图3中的实线框75a、b、c、d表示覆盖的透明区域,而可以接收光的覆盖玻璃的其余区域(诸如框架的外部)整个不透明是合适的。很清楚,图3和图4不是按比例的,扩大了部分不透明区域。边缘密封52a、52b和示意性示为56a、56b的光伏层外部的区域遮蔽了光和UV。
在基板的周围没有被光敏层覆盖的区域的宽度通常是1-2cm,在例如通过激光清除的处理步骤中,从那里去除CIS层,从而通过IEC质量测试的分支,如IEC 61646的湿漏电流测试。当暴露于阳光时的最终太阳能模块在电路的有效区域中高度地进行吸收,然而,在没有本发明的情况下,其在外围的膜去除区域是高度透明的。结果,在有效区域的基板和覆盖玻璃在阳光中温度升高并热膨胀,但是外围却没有或较少地变热。以这种方式,张应力在基板的外围增大,对于易碎的基板,这是有害的,而且这增加了破碎的概率。认为对于这种类型基板破碎的概率是随着模块基板的尺度而增加的。根据本发明的覆盖的使用克服了这样的问题,即:也使不透明部分变热,使得不产生或较小地产生张应力,而破碎的概率极大地降低了。
根据本发明的覆盖的使用也可以通过保护聚合密封剂免于降解,特别是由于UV造成的降解,从而提高太阳能模块的寿命。这种材料的示例是在边界区域中的聚合物32和边缘密封剂54,它们都与光伏层相邻。其它示例是聚合填充物材料或施加于边界的胶。优选地,在覆盖被布置在其上之前,将密封剂施加于基板上。已经发现这种材料在UV下将降解和分解,而这个问题可以通过本发明来克服。
本发明的进一步的优点在于:与诸如CIS型层的光伏层的均匀黑表面相比,某个模块组装组件在美观上不会引起注意。这些组件包括电路接触带、涂覆钼的电路接触区和太阳能电池边缘带以及透明去膜电路周界。不透明区覆盖了这些组件。
Claims (16)
1.一种在基板和覆盖板之间包括薄膜光伏层的光伏器件,所述覆盖板在所述光伏层上方的区域中是透明的,其中该覆盖板与所述光伏层重叠,并且其中所述覆盖板在与所述光伏层相邻的区域中是不透明的,其中在所述不透明区域中,所述覆盖板至少在面向所述基板的一侧上被涂覆,或者该覆盖板具有改变的主体,以使其在该区域中是不透明的,其中所述覆盖板具有1-5mm范围的厚度。
2.如权利要求1所述的光伏器件,其中,通过涂绘或丝网印刷来涂覆所述覆盖板从而提供涂层。
3.如权利要求1或2所述的光伏器件,其中,所述不透明区域包括可以接收光而在其下不存在光伏层的所有区域。
4.如权利要求1所述的光伏器件,其中,所述覆盖板是覆盖玻璃。
5.如权利要求1所述的光伏器件,其中,所述基板为非钢化玻璃。
6.如权利要求1所述的光伏器件,其中,所述不透明区域的颜色被调整为所述光伏层的颜色。
7.如权利要求1所述的光伏器件,其中,所述不透明区域还阻挡UV辐射。
8.如权利要求1所述的光伏器件,其中,所述基板和所述覆盖板之间存在可光降解的材料,并且其中所述覆盖板被布置为使得所述可光降解的材料至少部分地被所述不透明区域所覆盖。
9.如权利要求1所述的光伏器件,其中,在所述基板上沿着所述基板的边缘存在聚合密封材料,并且其中所述覆盖板被布置为使得所述聚合密封材料被所述不透明区域所覆盖。
10.一种封装光伏器件的方法,包括如下步骤:
提供基板,所述基板在其部分区域上具有带有薄膜光伏层的区域;
提供具有透明区域和与该透明区域相邻的不透明区域的覆盖板,其中所述覆盖板具有1-5mm范围的厚度;
在所述光伏层上方布置所述覆盖板,使得所述不透明区域覆盖所述基板区域的其上布置有所述光伏层的所述部分区域之外的至少一部分。
11.如权利要求10所述的方法,其中,在将所述覆盖板布置在所述基板上方之前,所述覆盖板被设置为具有不透明涂层或改变的主体,由此使得所述覆盖板不透明。
12.如权利要求10或11所述的方法,进一步包括将聚合材料布置在所述基板和所述覆盖板之间的步骤。
13.如权利要求11所述的方法,其中,所述聚合材料是所述基板上的聚合密封材料;并且其中所述覆盖板被布置为使得所述聚合密封材料被所述不透明区域所覆盖。
14.一种设置有透明区域和与所述透明区域相邻的不透明且吸收UV的区域的覆盖板的用途,用于封装包括布置在基板上的薄膜光伏层的光伏器件,以及用于保护与所述光伏层相邻存在的可光降解的材料免于经受因光而导致的降解,其中该可光降解的材料是聚合材料,其中所述覆盖板具有1-5mm范围的厚度。
15.如权利要求14所述的用途,其中,所述聚合材料是聚合密封材料。
16.一种设置有透明区域和与所述透明区域相邻的不透明区域的覆盖板的用途,用于封装包括布置在基板上的薄膜光伏层的光伏器件,并且用于保护所封装的光伏器件免受由于光辐射期间而导致的热应力,其中该基板大于所述光伏层,其中所述覆盖板具有1-5mm范围的厚度。
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