CN102782872A - 太阳能电池模块及制造太阳能电池模块的方法 - Google Patents

太阳能电池模块及制造太阳能电池模块的方法 Download PDF

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CN102782872A
CN102782872A CN2010800075084A CN201080007508A CN102782872A CN 102782872 A CN102782872 A CN 102782872A CN 2010800075084 A CN2010800075084 A CN 2010800075084A CN 201080007508 A CN201080007508 A CN 201080007508A CN 102782872 A CN102782872 A CN 102782872A
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G·C·杜贝尔达姆
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    • H—ELECTRICITY
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    • H05K—PRINTED CIRCUITS; CASINGS OR CONSTRUCTIONAL DETAILS OF ELECTRIC APPARATUS; MANUFACTURE OF ASSEMBLAGES OF ELECTRICAL COMPONENTS
    • H05K5/00—Casings, cabinets or drawers for electric apparatus
    • H05K5/06—Hermetically-sealed casings
    • H05K5/066—Hermetically-sealed casings sealed by fusion of the joining parts without bringing material; sealed by brazing
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    • B29C66/51—Joining tubular articles, profiled elements or bars; Joining single elements to tubular articles, hollow articles or bars; Joining several hollow-preforms to form hollow or tubular articles
    • B29C66/53—Joining single elements to tubular articles, hollow articles or bars
    • B29C66/534—Joining single elements to open ends of tubular or hollow articles or to the ends of bars
    • B29C66/5346—Joining single elements to open ends of tubular or hollow articles or to the ends of bars said single elements being substantially flat
    • B29C66/53461—Joining single elements to open ends of tubular or hollow articles or to the ends of bars said single elements being substantially flat joining substantially flat covers and/or substantially flat bottoms to open ends of container bodies
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    • H01—ELECTRIC ELEMENTS
    • H01L—SEMICONDUCTOR DEVICES NOT COVERED BY CLASS H10
    • H01L31/00—Semiconductor devices sensitive to infrared radiation, light, electromagnetic radiation of shorter wavelength or corpuscular radiation and specially adapted either for the conversion of the energy of such radiation into electrical energy or for the control of electrical energy by such radiation; Processes or apparatus specially adapted for the manufacture or treatment thereof or of parts thereof; Details thereof
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    • H01L31/048—Encapsulation of modules
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    • H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
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Abstract

本发明涉及一种太阳能电池模块，所述太阳能电池模块包括太阳能电池和包封物，其中所述太阳能电池模块具有通过导电连接与外部载流体相连的电流连接区域，其中所述导电连接具备经由激光焊接接合而接合到所述包封物的外壳。已发现通过激光焊接接合将所述外壳接合到包封层使得接合牢固且具有良好的绝缘特性。

Description

太阳能电池模块及制造太阳能电池模块的方法
背景技术
太阳能电池(也称为光伏电池)通常包括光伏(PV)层，所述光伏层包括在前电极(在电池的光接收侧)与后电极(在电池背面)之间提供的半导体材料。前电极是透明的或尽可能薄，使得入射光能够到达半导体材料，在半导体材料处使用入射辐射产生电流。
为了提高太阳能电池对所暴露环境条件的抵抗能力，太阳能电池通常具备保护层，也称为包封层。包含具备包封层的太阳能电池的组件还将被称为太阳能电池模块。
在太阳能电池模块中，通过诸如集电网格或汇流条之类的一个或多个集电区收集由太阳能电池产生的电流。为了能够使用由太阳能电池模块产生的电力，所述模块内的集电区经由导电连接与外部载流体相连。外部载流体的形式可以例如为导线或诸如条带(stripe)之类的其他导电物体。
为了提供与外部载流体具有导电连接的集电区，必须局部除去或穿透包封物。有必要密封包封物的开口点以防止外部影响，例如，防止潮气进入导电连接。为此而应用接合到包封层的外壳。在本申请的上下文中，外壳一词指围绕导电连接并为其提供电绝缘和防止机械和气候因素影响的物体。外壳被接合到包封层。
在本领域中，使用接线盒提供借助外壳保护的导电连接。借助粘合剂或经由机械手段将接线盒接合到太阳能电池模块的包封层。已发现在使用粘合剂时，在外壳的外部部分与导电连接之间的粘合剂层的宽度必须相对较大，以确保外壳到太阳能电池模块的接合的正常绝缘特性。外壳与包封层之间的分界面也必须相对较大以确保具有足够机械强度的接合。这导致接线盒的大小相对较大。
日本专利申请JP 2007 129014披露了一种包括反面保护层和端接盒的太阳能电池模块。所述端接盒借助粘合部分接合到所述太阳能电池模块。
使用机械手段提供接线盒外壳到太阳能电池模块的接合在本领域中也是公知的。但是，实现此接合的机械手段可以相当复杂。
因此，需要备选方法来将外壳接合到具备包封物的太阳能电池模块。如上所述，出于若干原因，应用粘合剂不能产生充分耐久的密封。由于外壳必须尽可能小，所以粘合表面的宽度是有限的。此外，取决于粘合剂的性质，并非总是能够将外壳牢固而持久地粘贴到包封物，因为胶粘物并非总是能够与包封材料相容。对于应用溶剂接合包封物材料，寻找适合的溶剂会很困难。
对于热焊接，接触表面的温度会非常高(例如，在250℃以上的量级)并且必须将待焊接的部位压紧在一起。对于热焊接，所施加的热必须集中在待焊接的表面以防损害基础太阳能电池结构。必须在待焊接表面产生热量。多数焊接技术都不满足该要求。
发明内容
本领域中需要一种经由具备外壳的导电连接将太阳能电池模块连接到外部载流体的方法，所述方法满足多个要求。外壳到太阳能电池模块的接合必须可实现长期密封。此外，外壳到包封层的接合应牢固并且不导电。本发明提供了这样的方法。本发明还提供了具备带有外壳的导电连接的太阳能电池模块，所述外壳满足上述要求。从以下说明书，本发明的其他优点将变得清楚。
本发明涉及一种太阳能电池模块，所述太阳能电池模块包括太阳能电池和包封物，其中所述太阳能电池模块具有通过导电连接与外部载流体相连的电流连接区域，其中所述导电连接具备经由激光焊接接合而接合到所述包封物的外壳。
本发明还涉及一种制造太阳能电池模块的方法，所述太阳能电池模块包括太阳能电池和包封物，所述太阳能电池模块具有通过导电连接与外部载流体相连的电流连接区域，其中所述导电连接具备接合到所述包封物的外壳，其中通过激光焊接实现所述接合。
已发现使用激光焊接可产生电绝缘的牢固接合。这种特性组合允许使用具有相对较小的接合界面的相对较小的外壳，同时仍满足寄予外壳与太阳能电池模块之间的电绝缘和接合强度的要求。
在本发明中使用的一个或多个电池包括：能够从入射光产生电流的光伏层；在所述光伏层的一侧并接近和平行于所述光伏层的后电极层；以及在所述光伏层的另一侧并接近和平行于所述光伏层的透明导体层(或前电极层)。所述光伏层、透明导电氧化物以及所述后电极的性质对本发明而言并非是关键的。用于这些层的适当材料在本领域中是公知的。
如上所述，所述太阳能电池具备集电区。此特性在本领域中也是公知的并且无需进一步阐明。
在一个实施例中，所述太阳能电池模块是包括一个或多个太阳能电池的挠性太阳能电池箔(foil)，所述太阳能电池具备在透明导体层之上的第一包封层以及可选地在后电极层之下的第二包封层。
在另一个实施例中，所述太阳能电池模块是硬太阳能电池模块，其中将硬的透明载流体(例如，玻璃片)作为载流体叠置在所述透明导体层之上。
在本发明中，所述外壳接合到所述太阳能电池模块的所述包封层。在本说明书的上下文中，包封层是在所述前电极之上或在所述后电极之下或在这两个位置处存在的聚合物层。所述包封层用于将所述太阳能电池与外部环境隔离。所述包封层自身可以包括具有不同成分和特性的子层。如对本领域技术人员将显而易见的，任何在所述前电极之上存在的包封层都将是透明的。包封层在本领域中是公知的。
在本发明中，所述外壳经由激光焊接接合到所述包封物。
借助激光焊接，高强度激光束被聚集在焊接位置处，即，聚集在所述外壳与所述包封物的界面处。为了允许适当的焊接，有必要使激光能量到达此界面。从所述外壳的方向或者从所述包封物的方向将激光对准此界面。为了使得激光能够到达所述界面，激光源与所述界面之间的材料对激光而言应是透明的。换言之，可使激光的波长与聚合物的性质匹配以实现此目的。
在一个实施例中，在激光与所述界面之间的交界面一侧上的材料(可以是所述外壳，也可以是所述包封物)对激光而言是透明的，而在所述界面另一侧上的材料对在所应用的波长处的激光而言是不透明的。
在另一个实施例中，所述外壳的材料和所述包封物的材料两者在所应用的波长处都是完全透明的。在此情况下，将形式例如为薄碳层的激光吸收材料施加在所述包封物与所述外壳之间的界面处，使得在该位置处产生热量，这将确保焊接发生。此实施例的优点在于，焊接仅在施加所述吸收材料的位置处发生。通过选择大量吸收光的材料而限制了到达下伏层的辐射。
通过调整激光束的强度和照射的持续时间，所产生的热量被设置为足以融化所述界面的表面层并且加热时间足够短以限制融化区的穿透深度。可以使用可从市场上购买的扫描头在待焊接的路径上移动激光束。
要指出的是，已发现本领域中公知的其他焊接技术并不适合于将外壳连接到太阳能电池模块的包封物。更具体地说，已发现对于超声波焊接，无法获得适当的粘附。微波焊接不太适合，因为其可能因导电有源层也吸收微波能量而损坏太阳能电池模块。
所述外壳可以接合到所述前电极之上的包封层、接合到所述后电极之下的包封层，或接合到两者。
在本发明的一个实施例中，所述外壳仅施加到所述太阳能电池模块的一侧并且不施加到另一侧。此实施例可以是有吸引力的，其中优选地使所述太阳能电池模块的正面和背面是平的。在此情况下，所述外壳必须在不使用背板的情况下粘附到太阳能电池模块(PV模块)的表面。这在本发明中可以容易地实现。
相应地，在一个实施例中，所述外壳仅施加到所述太阳能电池模块的一侧，而无需连接到所述模块的另一侧。所述外壳可以连接到所述太阳能电池模块的正面的包封层(即，光线入射侧)或连接到所述太阳能电池模块的背面。
在一个实施例中，在多个外壳接合到太阳能电池模块的情况下，所有外壳都接合到所述模块的同一侧，该侧可以是所述模块的正面或背面。这使得具有一个平坦表面成为可能，这对于进一步处理(例如，将其粘附到载流体)是有吸引力的。此外，在聚合物包封层仅存在于所述模块的一侧的情况下，例如，在所述模块的另一侧具备玻璃片的情况下，所述外壳(多个)将仅接合到所述模块的一侧。
在所述太阳能电池模块在模块正面具有包封层并在模块背面具有一个层的实施例中，也可以使所述外壳接合到所述模块的两侧上的包封物。
所述外壳(或至少所述外壳的将接合到所述太阳能电池模块的部分)通常为聚合物材料。在一个实施例中，选择所述外壳的材料或所述外壳的相关部分的材料以及要接合的包封物的材料以使得它们能够容易地被焊接在一起。在一个实施例中，所述外壳的材料或所述外壳的相关部分的材料以及所述包封物都基于相同类型的聚合物。在此情况下，可以获得具有特别有利的特性的接合。例如，所述包封物和所述外壳两者都可以基于热塑性氟聚合物。
在焊接期间，可能需要将压力施加在所述界面上以获得持续的牢固接合。为此，可以例如通过诸如工作台之类的硬支撑表面来支撑所述太阳能电池模块。可选地，可以将压力施加在所述外壳上。为了将更均匀分布的压力施加在所述外壳上，可以使用压力件。优选地，所述压力件至少对于激光频谱的波长是透明的。为了避免划痕或污染妨碍压力件的透明度，可以使用一次性(disposable)压力件。
具体实施方式
通过参考附图进一步说明了本发明。在附图中，图1以截面图示意性地示出了接线盒，所述接线盒具有用于连接到线缆(未示出)的外壳1以及箔2(具体地说，由聚合物包封层保护的太阳能箔)中的导电层。所述连接可以例如是夹持连接、焊接连接或导电粘合剂提供的连接。外壳1包括具有开口端4的中心体3并且与开口端4一起置于箔2的包封层上。开口端4具有向外延伸的平坦凸缘5，凸缘5安置在箔2的顶部包封层上。
透明聚合物材料的压力件6具有中心开口7并安置在外壳1的凸缘5上，中心开口7装配在外壳1的中心体3之上。
可以使用激光焊接设备(未示出)将凸缘5焊接在箔2上。在焊接期间，经由压力件6将压力施加在凸缘5上。压力件6、外壳1的凸缘5以及箔2的包封层由对激光波长(通常约为700-800纳米)透明的聚合物材料制成。到目前为止，多数聚合物材料对这些波长都是透明的。
激光吸收材料层8被施加在箔2与外壳1的凸缘5之间的界面处。光吸收材料层8可以例如是碳层或任何其他适合类型的光吸收材料层(例如，用于可记录CD的制造技术中公知的光吸收材料层)。光吸收材料实现仅在焊接位置处产生热量，以便将热影响区限于焊接两侧的薄层。

Claims (13)

1.一种太阳能电池模块，所述太阳能电池模块包括至少一个太阳能电池和包封层，其中所述太阳能电池模块具有通过导电连接与外部载流体相连的电流连接区域，其中所述导电连接具备经由激光焊接接合而接合到所述包封层的外壳。
2.根据权利要求1的太阳能电池模块，其中所述外壳仅接合到所述太阳能电池模块的一侧上的包封层而不连接到所述模块的另一侧。
3.根据权利要求2的太阳能电池模块，其中将具有多个外壳的多个导电连接接合到所述太阳能电池模块并且所有外壳都接合到同一侧，所述同一侧是所述模块的正面或背面。
4.根据权利要求1的太阳能电池模块，其中所述外壳接合到所述太阳能电池模块的两侧上的包封层。
5.根据上述权利要求中的任一权利要求的太阳能电池模块，其中所述模块是在所述模块的一侧具备第一包封层并在所述模块的对侧具备第二包封层的挠性模块。
6.根据上述权利要求中的任一权利要求的太阳能电池模块，其中所述外壳或所述外壳的相关部分以及所述外壳所接合的包封层基于相同类型的聚合物。
7.根据权利要求6的太阳能电池模块，其中所述外壳和所述包封层基于热塑性氟聚合物。
8.一种制造太阳能电池模块的方法，所述太阳能电池模块包括一个或多个太阳能电池和包封层，所述太阳能电池模块具有通过导电连接与外部载流体相连的电流连接区域，其中所述导电连接具备接合到所述包封层的外壳，其中通过激光焊接实现所述接合。
9.根据权利要求8的方法，其中所述外壳和所述包封层对在所施加的波长处的激光而言都是透明的，并且在所述外壳与所述包封层之间的界面处施加激光吸收材料。
10.根据权利要求8的方法，其中所述外壳和所述包封层中的一个对在所施加的波长处的激光而言是透明的，且所述外壳和所述包封层中的另一个对在所施加的波长处的激光而言是不透明的，且激光被从对激光透明的组件的一侧导引到外壳与包封层之间的界面。
11.根据权利要求8-10中的任一权利要求的方法，其中在焊接期间，在将所述太阳能模块支撑在支撑表面上时，将压力施加于所述外壳上。
12.根据权利要求11的方法，其中借助对在所施加的波长处的激光而言透明的压力件施加所述压力。
13.根据权利要求11或12的方法，其中所述压力件是一次性部件。
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