CN102549768A - 太阳能电池模块及其制造方法 - Google Patents
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Abstract
讨论了一种太阳能电池模块及其制造方法。所述太阳能电池模块包括:多个背接触式太阳能电池;互连接件,所述互连接件位于所述多个背接触式太阳能电池的背面上并且将相邻的背接触式太阳能电池彼此电连接;上保护层和下保护层,所述上保护层和所述下保护层用于保护所述多个背接触式太阳能电池;透明构件,所述透明构件位于在所述多个背接触式太阳能电池的光接收表面上的所述上保护层上;和背板,所述背板位于在所述多个背接触式太阳能电池的与所述光接收表面相背对的表面上的所述下保护层下。所述上保护层和所述下保护层由不同的材料制成。
Description
技术领域
本发明的示例实施方式涉及太阳能电池模块及其制造方法。
背景技术
近年来,作为现有的能源,诸如石油和煤预期将被耗尽,对用于代替现有能源的可再生能量的关注正在增加。作为可再生能量,已经特别地聚焦于用于从太阳能生成电能的太阳能电池。最近已经研究出了能够通过在基板的后表面(即,没有光入射到其上的基板表面)上形成电子电极和空穴电极两者来增加光接收区域的大小的背接触式太阳能电池。因此,改善了背接触式太阳能电池的效率。
通过串联或并联连接多个均具有上述结构的背接触式太阳能电池而制造的太阳能电池模块被用来获得期望的输出。该太阳能电池模块是以平板形式制造的防潮模块。
发明内容
问题的解决方案
在一个方面,提出了一种太阳能电池模块,所述太阳能电池模块包括:多个背接触式太阳能电池;互连接件,所述互连接件位于所述多个背接触式太阳能电池的背面上并且将相邻的背接触式太阳能电池彼此电连接;保护层,所述保护层用于保护所述多个背接触式太阳能电池;透明构件,所述透明构件位于所述多个背接触式太阳能电池的光接收表面上;和背板,所述背板与所述多个背接触式太阳能电池的所述光接收表面相背对地布置,其中,所述保护层包括固化的液体填充剂。在该情形中,所述固化的液体填充剂覆盖位于所述背接触式太阳能电池之间的所述互连接件的整个表面,从而直接接触所述互连接件。
在另一个方面,提出了一种太阳能电池模块,所述太阳能电池模块包括:多个背接触式太阳能电池;互连接件,所述互连接件位于所述多个背接触式太阳能电池的背面上并且将相邻的背接触式太阳能电池彼此电连接;上保护层和下保护层,所述上保护层和所述下保护层用于保护所述多个背接触式太阳能电池;透明构件,所述透明构件位于在所述多个背接触式太阳能电池的光接收表面上的所述上保护层上;和背板,所述背板位于在所述多个背接触式太阳能电池的与所述光接收表面相背对的表面上的所述下保护层下,其中,所述上保护层和所述下保护层由不同的材料制成。
所述下保护层可以由固化的硅氧烷例如聚二烷基硅氧烷制成。所述上保护层可以由膜形式的乙烯醋酸乙烯酯(EVA)制成。
在将液体硅氧烷前体施敷到所述多个背接触式太阳能电池之后,由于硅氧烷前体的流动属性,施敷的硅氧烷前体的一部分填充在背接触式太阳能电池之间的空间中,并且通过热处理而固化。因此,固化的硅氧烷前体附接于所述上保护层。
所述互连接件的前表面可以被处理为具有与所述多个背接触式太阳能电池的半导体基板或背板相同的颜色,例如黑色或白色,从而防止通过太阳能电池模块的光接收表面看到互连接件的金属色。
在另一个方面,提出了一种制造太阳能电池模块的方法,所述方法包括:将膜形式的上保护层布置在透明构件上;以恒定的间隔将多个背接触式太阳能电池布置在所述上保护层上;利用互连接件将相邻的背接触式太阳能电池彼此电连接;将液体硅氧烷前体施敷到所述多个背接触式太阳能电池,从而将施敷的液体硅氧烷前体的一部分填充在所述相邻的背接触式太阳能电池之间的空间中;以及利用热处理执行固化过程,从而将所述液体硅氧烷前体附接于所述膜形式的上保护层并且固化所述液体硅氧烷前体。
可以在背板位于所述液体硅氧烷前体上的状态下执行所述热处理,并且可以在200℃到400℃的温度下执行所述热处理。
所述固化的硅氧烷前体可以包含聚二烷基硅氧烷。所述上保护层可以由膜形式的乙烯醋酸乙烯酯(EVA)制成。
附图说明
图1是根据本发明的示例实施方式的移除了背板的太阳能电池模块的平面图;
图2是图1中所示的太阳能电池模块的局部横截面图;
图3是图1中所示的背接触式太阳能电池的局部横截面图;以及
图4是顺序地例示了根据本发明的示例性实施方式的制造太阳能电池模块的方法的框图。
具体实施方式
下面将参照附图更加全面地描述本发明,附图中示出了本发明的示例实施方式。然而,本发明可以以许多不同形式来具体实施,并且不应当解释为限于这里阐述的实施方式。
在附图中,为了清楚,夸大了层、膜、板、区域等的厚度。整个说明书中相同的附图标记表示相同的元件。将理解的是,当提到诸如层、膜、区域或基板这样的元件“在另一个元件上”时,它可以直接在其它元件上或者也可以存在介于中间的元件。相反,当提到元件“直接在到另一元件上”时,不存在介于中间的元件。此外,将理解的是,当提到诸如层、膜、区域或基板这样的元件“完全”在另一个元件上时,它可以在其它元件的整个表面上并且可以不在其它元件的边缘的一部分上。
下面将详细描述本发明的实施方式,在附图中例示出了其示例。
参考图1到3详细地描述根据本发明示例实施方式的太阳能电池模块。
图1是根据本发明的示例实施方式的移除了背板的太阳能电池模块的平面图。图2是图1中所示的太阳能电池模块的局部横截面图。图3是图1中所示的背接触式太阳能电池的局部横截面图。
如在图1和图2中所示,根据本发明示例实施方式的太阳能电池模块包括:多个背接触式太阳能电池110,位于背接触式太阳能电池110的背面上并且将相邻的背接触式太阳能电池110相互电连接的互连接件120,用于保护背接触式太阳能电池110的上保护层130和下保护层140,位于在背接触式太阳能电池110的光接收表面上的上保护层130上的透明构件150,和位于在背接触式太阳能电池110的与光接收表面相背对的表面上的下保护层140下的背板160。
虽然图1和图2仅示出了两个背接触式太阳能电池110,但是在本发明的示例实施方式中,背接触式太阳能电池110的数量是不受限制的。
背板160防止湿气或氧气侵入太阳能电池模块的背面,由此保护背接触式太阳能电池110免受外部环境影响。背板160可以具有多层结构,该多层结构包括湿气/氧气侵入防止层、化学腐蚀防止层、具有绝缘特性的层等。
在上保护层130置于背接触式太阳能电池110上的状态下,上保护层130附接于下保护层140。因此,上保护层130、下保护层140和背接触式太阳能电池110构成一个整体。上保护层130和下保护层140防止由湿气侵入导致的背接触式太阳能电池110的腐蚀,并且保护背接触式太阳能电池110免受碰撞的影响。
在示例实施方式中,上保护层130和下保护层140由不同的材料制成。更具体地,上保护层130由诸如以膜形式制造的乙烯醋酸乙烯酯(EVA)这样的材料制成。下保护层140由通过对液体化合物执行热处理而获得的固化材料(例如,包含聚二烷基硅氧烷(poly dialkyl siloxane)的固化硅氧烷)制成。所述固化材料(或液体填充剂)可以覆盖位于背接触式太阳能电池110之间的互连接件120的整个表面,从而直接接触互连接件120。
当液体硅氧烷前体施敷到背接触式太阳能电池110时,由于硅氧烷前体的流动属性,施敷的硅氧烷前体的一部分填充在背接触式太阳能电池110之间的空间中,并且通过热处理而被固化。
在太阳能电池模块的结构中,利用液体化合物形成下保护层140的原因在于,用于制造太阳能电池模块的过程能够通过移除在现有技术中使用的护罩(shield)而自动化。在下面将描述的用于制造太阳能电池模块的方法中详细地描述该原因。
在上保护层130上的透明构件150由具有高透射率和良好的防止损坏特性的钢化玻璃制成。钢化玻璃可以是包含少量铁的低铁钢化玻璃。透明构件150可以具有浮雕的内表面以增加光的散射效果。
互连接件120由导电金属制成并且被焊接到在背接触式太阳能电池110中形成的突片(tabbing)金属电极,从而将相邻的背接触式太阳能电池110彼此电连接。互连接件120的多个部分可以具有梯形形状或三角形形状,但是并不限于此。
在示例实施方式中,下保护层140保持在相邻的背接触式太阳能电池110之间的距离并且提供在相邻的背接触式太阳能电池110之间的电绝缘。因此,当通过太阳能电池模块的光接收表面观察互连接件120时,互连接件120可以被观察到在相邻的背接触式太阳能电池110之间的空间中或被观察到设置在相邻的背接触式太阳能电池110之间的空间上。
然而,互连接件120由与背接触式太阳能电池110不同的颜色的导电金属制成。因此,互连接件120的一个表面(即,互连接件120的朝着太阳能电池模块的光接收表面的表面)可以利用与背接触式太阳能电池110的半导体基板111或背板160相同的颜色来处理,或者处理为具有该颜色,例如黑色或白色,从而改善太阳能电池模块的外观。
互连接件120可以具有用于减小由互连接件120因热或热的缺少而产生的扩展或收缩所导致的应变的缝122。
如在图3中所示,在太阳能电池模块中使用的背接触式太阳能电池110包括:第一导电类型的半导体基板111,在半导体基板111的一个表面(例如,光接收表面)形成的前面场(FSF)层112,在FSF层112上形成的防反射层113,在半导体基板111的另一个表面形成并且重掺杂有第一导电类型杂质的第一掺杂区域114,在与第一掺杂区域114相邻的位置在半导体基板111的所述另一个表面形成并且重掺杂有与第一导电类型杂质相反的第二导电类型杂质的第二掺杂区域115,暴露第一掺杂区域114和第二掺杂区域115的每一个的一部分的背钝化层116,电连接到第一掺杂区域114的暴露部分的空穴电极117(下文中称为“第一电极”),和电连接到第二掺杂区域115的暴露部分的电子电极118(下文中称为“第二电极”)。
半导体基板111的光接收表面被纹理化以形成与具有多个不平坦部分的不平坦表面相对应的纹理化表面。在该情形中,FSF层112和防反射层113中的每一个均具有纹理化表面。
尽管没有要求,但是半导体基板111由第一导电类型(例如,n型)的单晶硅制成。或者,半导体基板111可以是p型并且可以由多晶硅制成。此外,半导体基板111可以由除了硅以外的其它半导体材料制成。
因为半导体基板111的光接收表面是纹理化表面,所以光的吸收比增加。因此,改善了背接触式太阳能电池110的效率。
在半导体基板111的纹理化表面形成的FSF层112是比半导体基板111更重掺杂有例如V族元素(例如磷(P)、砷(As)和锑(Sb))的杂质的区域。FSF层112执行与背面场(BSF)层相似的操作。因此,防止或减少了由在半导体基板111的光接收表面周围的入射光分离的电子和空穴的复合和/或消失。
在FSF层112的表面上的防反射层113由氮化硅(SiNx)和/或二氧化硅(SiO2)等制成。防反射层113降低了入射光的反射比并且增加了预定波长带的选择性,由此增加了背接触式太阳能电池110的效率。
第一掺杂区域114是p型重掺杂区域,并且第二掺杂区域115是比半导体基板111更重地掺杂有n型杂质的区域。因此,第一掺杂区域114和n型半导体基板111形成p-n结。第一掺杂区域114和第二掺杂区域115用作载流子(电子和空穴)的移动路径并且分别收集空穴和电子。
暴露第一掺杂区域114和第二掺杂区域115的每一个的一部分的背钝化层116由氮化硅(SiNx)、二氧化硅(SiO2)或它们的组合制成。背钝化层116防止或减少了从载流子分离的电子和空穴的复合和/或消失并且将入射光反射到背接触式太阳能电池110的内部,从而入射光没有被反射到背接触式太阳能电池110的外部。即,背钝化层116防止入射光的损失并且降低了入射光的损失量。背钝化层116可以具有单层结构或者诸如双层结构或三层结构这样的多层结构。
第一电极117形成在没有被背钝化层116覆盖的第一掺杂区域114上以及背钝化层116的与第一掺杂区域114相邻的一部分上。第二电极118形成在没有被背钝化层116覆盖的第二掺杂区域115上以及背钝化层116的与第二掺杂区域115相邻的一部分上。因此,第一电极117电连接到第一掺杂区域114,并且第二电极118电连接到第二掺杂区域115。第一电极117和第二电极118彼此分离恒定距离并且在一个方向上彼此平行地延伸。
如上所述,因为第一电极117和第二电极118中的每一个的一部分与背钝化层116的一部分重叠并且连接到汇流条区域,所以当第一电极117和第二电极118接触外部驱动电路等时,接触电阻和串联电阻降低。因此,提高了背接触式太阳能电池110的效率。
现在参考图4描述根据本发明的示例实施方式的制造太阳能电池模块的方法。
图4是顺序地例示了根据本发明的示例性实施方式的制造太阳能电池模块的方法的框图。
如在图1到图4所示,首先,将膜形式的上保护层130布置在透明构件150上。如上所述,上保护层130由乙烯醋酸乙烯酯(EVA)制成。
在布置了上保护层130后,将多个背接触式太阳能电池110以恒定间隔布置在上保护层130上。将互连接件120焊接到相邻的背接触式太阳能电池110的突片金属电极,从而将相邻的背接触式太阳能电池110彼此电连接。
接下来,将液体硅氧烷前体例如聚二烷基硅氧烷施敷到背接触式太阳能电池110。在其它实施方式中,液体硅氧烷前体可以为或包括丙烯酸二甲基甲硅烷基氧酯(dimethylsilyl oxy acrylate)。施敷的液体硅氧烷前体的一部分填充在相邻的背接触式太阳能电池110之间的空间中。在该情形中,可以在适当的范围内调整施敷的液体硅氧烷前体的量。
接下来,将背板160布置在液体硅氧烷前体上,并且在200℃到400℃的温度执行热处理以固化液体硅氧烷前体。当通过热处理执行固化处理时,固化的硅氧烷前体附接于上保护层130和背板160。在上保护层130和透明构件150之间的附接可以通过热处理或单独的层压处理来实现。
在根据本发明的示例实施方式的制造太阳能电池模块的方法中,下保护层维持在相邻的背接触式太阳能电池之间的距离,并且还提供了在相邻的背接触式太阳能电池之间的电绝缘。因为利用液体化合物形成下保护层,所以可以自动化用于布置太阳能电池模块的部件的过程。
尽管参照多个示例性实施方式描述了实施方式,但是,应理解的是,本领域技术人员可设计落入本公开的原理的范围内的许多其它修改和实施方式。更具体地说,可以在本公开、附图及所附权利要求的范围内对本主题组合装置的组成部件和/或布置进行各种变换和修改。除对组成部件和/或布置的变换和修改外,替代性使用对本领域技术人员也是明显的。
Claims (23)
1.一种太阳能电池模块,所述太阳能电池模块包括:
多个背接触式太阳能电池;
互连接件,所述互连接件位于所述多个背接触式太阳能电池的背面上并且将相邻的背接触式太阳能电池彼此电连接;
保护层,所述保护层用于保护所述多个背接触式太阳能电池;
透明构件,所述透明构件位于所述多个背接触式太阳能电池的光接收表面上;以及
背板,所述背板与所述多个背接触式太阳能电池的所述光接收表面背对地布置,
其中,所述保护层包括固化的液体填充剂。
2.根据权利要求1所述的太阳能电池模块,其中,所述固化的液体填充剂覆盖位于所述背接触式太阳能电池之间的所述互连接件的整个表面,从而直接接触所述互连接件。
3.一种太阳能电池模块,所述太阳能电池模块包括:
多个背接触式太阳能电池;
互连接件,所述互连接件位于所述多个背接触式太阳能电池的背面上并且将相邻的背接触式太阳能电池彼此电连接;
上保护层和下保护层,所述上保护层和所述下保护层用于保护所述多个背接触式太阳能电池;
透明构件,所述透明构件位于在所述多个背接触式太阳能电池的光接收表面上的所述上保护层上;以及
背板,所述背板位于在所述多个背接触式太阳能电池的与所述光接收表面相背对的表面上的所述下保护层下,
其中,所述上保护层和所述下保护层由不同的材料制成。
4.根据权利要求3所述的太阳能电池模块,其中,所述下保护层填充在所述相邻的背接触式太阳能电池之间的空间中。
5.根据权利要求4所述的太阳能电池模块,其中,所述互连接件的与所述下保护层接触的前表面被处理为具有与所述多个背接触式太阳能电池的半导体基板相同的颜色。
6.根据权利要求3所述的太阳能电池模块,其中,所述下保护层由固化的硅氧烷制成。
7.根据权利要求6所述的太阳能电池模块,其中,所述下保护层填充在所述相邻的背接触式太阳能电池之间的空间中。
8.根据权利要求7所述的太阳能电池模块,其中,所述互连接件的与所述下保护层接触的前表面被处理为具有与所述多个背接触式太阳能电池的半导体基板相同的颜色。
9.根据权利要求6所述的太阳能电池模块,其中,所述固化的硅氧烷包含聚二烷基硅氧烷。
10.根据权利要求9所述的太阳能电池模块,其中,所述下保护层填充在所述相邻的背接触式太阳能电池之间的空间中。
11.根据权利要求10所述的太阳能电池模块,其中,所述互连接件的与所述下保护层接触的前表面被处理为具有与所述多个背接触式太阳能电池的半导体基板相同的颜色。
12.根据权利要求6所述的太阳能电池模块,其中,所述上保护层由膜形式的乙烯醋酸乙烯酯(EVA)制成。
13.根据权利要求12所述的太阳能电池模块,其中,所述下保护层填充在所述相邻的背接触式太阳能电池之间的空间中。
14.根据权利要求13所述的太阳能电池模块,其中,所述互连接件的与所述下保护层接触的前表面被处理为具有与所述多个背接触式太阳能电池的半导体基板相同的颜色。
15.一种制造太阳能电池模块的方法,所述方法包括:
将膜形式的上保护层布置在透明构件上;
以恒定的间隔将多个背接触式太阳能电池布置在所述上保护层上;
利用互连接件将相邻的背接触式太阳能电池彼此电连接;
将液体硅氧烷前体施敷到所述多个背接触式太阳能电池,从而利用所施敷的液体硅氧烷前体的一部分填充在所述相邻的背接触式太阳能电池之间的空间;以及
利用热处理执行固化过程,从而将所述液体硅氧烷前体附接于所述膜形式的上保护层并且固化所述液体硅氧烷前体。
16.根据权利要求15所述的方法,其中,所述液体硅氧烷前体包含聚二烷基硅氧烷。
17.根据权利要求16所述的方法,其中,所述上保护层由膜形式的乙烯醋酸乙烯酯(EVA)制成。
18.根据权利要求15所述的方法,其中,在背板位于所述液体硅氧烷前体上的状态下执行所述热处理。
19.根据权利要求18所述的方法,其中,所述液体硅氧烷前体包含聚二烷基硅氧烷。
20.根据权利要求19所述的方法,其中,所述上保护层由膜形式的乙烯醋酸乙烯酯(EVA)制成。
21.根据权利要求18所述的方法,其中,在200℃到400℃的温度下执行所述热处理。
22.根据权利要求21所述的方法,其中,所述液体硅氧烷前体包含聚二烷基硅氧烷。
23.根据权利要求22所述的方法,其中,所述上保护层由膜形式的乙烯醋酸乙烯酯(EVA)制成。
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Also Published As
Publication number | Publication date |
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EP2483932A4 (en) | 2013-06-12 |
WO2011037374A2 (en) | 2011-03-31 |
KR20110034182A (ko) | 2011-04-05 |
CN102549768B (zh) | 2016-07-06 |
WO2011037374A3 (en) | 2011-08-25 |
KR101145927B1 (ko) | 2012-05-15 |
EP2483932A2 (en) | 2012-08-08 |
US20110073166A1 (en) | 2011-03-31 |
US9564547B2 (en) | 2017-02-07 |
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