CN102959733A - 太阳能电池模块以及其制造方法 - Google Patents

太阳能电池模块以及其制造方法 Download PDF

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CN102959733A
CN102959733A CN2011800274148A CN201180027414A CN102959733A CN 102959733 A CN102959733 A CN 102959733A CN 2011800274148 A CN2011800274148 A CN 2011800274148A CN 201180027414 A CN201180027414 A CN 201180027414A CN 102959733 A CN102959733 A CN 102959733A
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glass carrier
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托比亚斯·亚马尔
拉尔斯·斯托特
彼得·尼瑞尼克斯
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Abstract

本发明涉及一种太阳能电池模块以及其制造方法，该太阳能电池模块包括一个玻璃载体（1）和安排在该玻璃载体（1）的一个装置侧表面（11）上的一个太阳能电池结构（2），其特征在于安排在该玻璃载体（1）的一个背面侧表面（12）上的一个保护层（3）与该装置侧表面（11）相对。

Description

太阳能电池模块以及其制造方法
技术领域
本发明涉及太阳能电池模块，该太阳能电池模块包括玻璃载体和安排在该玻璃载体的装置侧表面上的太阳能电池结构，以及涉及此类太阳能电池模块的制造方法。
背景技术
与由半导体晶片制成的太阳能电池相比，由于其更低的材料成本，此类太阳能电池模块越来越普及。通常，玻璃载体的装置侧表面是由多个太阳能电池结构覆盖的，该多个太阳能电池结构然后由玻璃盖罩封闭并且密封以保护它们免受外部的影响。这些太阳能电池结构通常包括一层常常是由钼制成的金属层，直接沉积到该玻璃载体上作为背面电极，跟随着半导体叠层作为光电有源结构并且最后跟随一个另外的传导层作为前面电极。该前面电极通常是由透明的导电材料制成的，以允许入射光穿过。
玻璃通常作为优良的具有保护作用的并且密封的材料用于太阳能电池结构。然而，已经表明一段时间后该太阳能电池效率显著地降低。尤其在气候测试和证书测试期间，当该太阳能电池模块经受大量的热量和/或湿度时，该太阳能电池的退化非常明显。
发明内容
本发明的目的是甚至在多年使用之后减少或者甚至防止这种退化以保持太阳能电池效率基本恒定。
在本发明中该目的是通过提供具有权利要求1所述的特征的太阳能电池模块以及具有权利要求15所述的特征的太阳能电池的制造方法实现的。本发明的有利的实施方案服从这些子权利要求。
本发明是基于以下发现：已知的太阳能电池模块的效率损耗是由于玻璃载体的退化所导致的。在湿润的环境中，该与装置侧表面相对的该玻璃载体的背面侧表面变得横向导电。背面侧表面与装置侧表面上的太阳能电池的背面电极之间的电位差在玻璃载体上形成了一个电场。这种电场驱动离子（具体地钠离子）穿过玻璃载体至该太阳能电池的背面电极。这些离子与这些背面电极的材料相互作用，导致了其功能的退化。
为了减轻这种效应，建议在该玻璃载体的背面侧表面上安排保护层。保护层能够通过减少或者甚至防止横贯玻璃载体的电场的建立来帮助减少离子流动。这可以通过调整该玻璃载体的背面侧表面上的表面电势来实现。为了这个目的，该保护层可以是由导电材料（如金属）制成，以作为等势面，可以施加任意的电压到该等势面，以抵抗该电场。
在一个可替代的方法中，该保护层可以被设计为使得甚至在湿的和热的环境中防止背面侧表面的横向导电性。这可以通过使用绝缘胶带、介电层、颜料或用于制作该保护层的适合的非导电材料的其他层或薄片。
制造这种太阳能电池模块，可以在制造过程期间的任何时间将保护层施加到该玻璃载体的背面侧表面，即太阳能电池结构的沉积之前或之后，或者甚至在太阳能电池结构的沉积的过程步骤之间。有利的是，可以将该玻璃载体输送到太阳能模块制造厂，其在其背面侧表面上具有预先沉积的保护层。
在一个有利的实施方案中，太阳能电池结构是一个单片地沉积到玻璃载体的装置侧表面上的薄膜太阳能电池结构。在玻璃载体上单片地制造太阳能电池结构具有以下优点：在玻璃载体与太阳能电池结构之间存在一个固有的连接。换言之，将太阳能电池结构一层接着一层地沉积到玻璃载体上。与单片沉积相反的会是与玻璃载体分开地生产太阳能电池结构，并且在之后将它们安排到玻璃载体上。例如，放置在玻璃载体上的太阳能电池的单片结构上的用于密封这些太阳能电池的玻璃盖罩未单片地连接到该太阳能电池结构上。
这些薄膜太阳能电池可以基于非晶硅或其他薄膜硅结构，在碲化镉上（CdTe）或在铜铟硒化镓（CIS或CIGS）上，或者它们可以包括染色敏化的（DSC）或其他有机太阳能电池。
在一个优选实施方案中，玻璃载体是用于太阳能电池结构的基底。这意味着将玻璃载体放置在太阳能电池结构的背面侧面上，与光入射侧相反。可替代地，玻璃载体可以是太阳能电池结构的多层介质覆盖，在太阳能电池结构中入射光将不得不穿过玻璃载体而到达太阳能电池结构。在后一种情况下，保护层将必须是由透明的材料制成的。
在一个优选实施方案中，有待保护免受退化的太阳能电池模块的太阳能电池结构包括与玻璃载体的装置侧表面直接接触的金属层。该金属层具体地可以是由钼制成。
在一个最小的保护层表面区域的实施方案中，太阳能电池结构所覆盖的装置侧表面区域对应的背面侧表面上的一个表面区域基本上完全由保护层覆盖。在这里，表述“对应的”意味着太阳能电池结构所覆盖的装置侧表面区域被投射到背面侧上以得到保护层所覆盖的表面区域。因此，与太阳能电池结构直接相邻的至少背面侧表面上的区域是由保护层覆盖，以直接地阻止太阳能电池结构下面的电场建立。
然而，为了更好地保护太阳能电池模块，有利的是，保护层基本地覆盖玻璃载体的整个背面侧表面。本实施方案具有以下额外的优点：在背面侧表面上的保护层不需要模式化并且太阳能电池结构和保护层不需要相互对准。
如上面所述，在一个太阳能电池模块的替代性实施方案中，保护层是由导电材料制成的，用于将不变电势施加到玻璃载体的背面侧表面上。保护层可以例如由金属或导电的氧化物制成。这种导电保护层允许将预定的或调节的电势施加到玻璃载体的背面侧表面，以抵抗在装置侧表面与背面侧表面之间的任意电位差。
还如上面所描述的，在一个不同的替代性实施方案中，保护层是由非导电材料制成的。具体地，在本实施方案中，该保护层具有优选地每平方至少1012欧姆的薄层电阻，更优选地每平方至少2x1012、5x1012、或者1013欧姆的薄层电阻。
有利的是，保护层包括施加到玻璃载体的背面侧表面上的一层颜料。例如使用所谓的卡车颜料已经获得了良好的结果。保护层可以例如包括基于带有环氧树脂底漆的聚乙烯醇缩丁醛。这种材料可以单独使用或用作颜料的基础层。如果要求的话，颜料本身可以是基于带有额外色素的聚氨酯。
根据制造方法和/或所使用的材料，保护层可以是非晶形的、纳米晶体、多晶的或者单晶的。表述“纳米晶体”还可以称为微晶，而表述“单晶的”还可以作为单一晶体的。
在多个优选实施方案中，保护层包括氧化物、氮化物和/或氮氧化物。可替代地，保护层可以是聚合物胶带、颜料（如光刻胶）、或其他适合的材料的薄膜。可以将保护层沉积到背面侧表面或通过任何其他合适的方式（如通过印制方法）施加到背面侧表面上。
在一个优选实施方案中，保护层是由氧化铝、氧化硅、氮化硅、氮氧化硅、氮氧化铝、氮氧化硅铝或这些材料之一与一种或多种另外的元素的复合物。还可以使用其他适合的材料，具体地导电材料（如导电透明氧化物），如Zn2SnO4。
在具体地有利的实施方案中，保护层是湿度屏蔽层。在一个替代性实施方案中，或者此外，背离玻璃载体的保护层的一个表面是疏水的。在此，整个保护层可以是由疏水的材料制成的，或者使保护层的表面通过表面处理变成疏水的。本实施方案对于不导电的保护层尤其有用，因为可以避免由于湿度积累不希望的导电性上升。然而，疏水特征对于已经导电的保护层还可以是有利的，以防止任何湿度到达玻璃载体表面。
应该指出沉积到本身由氧化硅制成的玻璃载体上的氧化硅薄层可以能够作为有效的保护层。由于相比于用于制造玻璃载体所需要的量，用于保护层的沉积将需要一个小的量，前者能够以更高的质量和对上面描述的目的最优的一组经选择的化学的和物理的特征。
该保护层可以优选地具有多于25nm的层厚度，优选地在25nm和500nm之间，尽管多个更厚的厚度也可以是合适的。保护层根据任何在此提到的实施方案可以是经由物理或化学气相沉积法（PVD或者CVD）被沉积，该沉积方法可以是等离子增强的化学气相沉积法（PECVD）。也可以使用其他沉积法，如溅射或外延沉积法。
附图说明
将参照附图在以下说明书中详细地描述本发明的实施方案的一个实例，其中
图1示出了一个玻璃载体；
图2示出了一个保护层所覆盖的图1的玻璃载体；
图3示出了形成在玻璃载体上的多个太阳能电池结构；以及
图4描绘了包括夹在玻璃载体和玻璃盖罩之间的太阳能电池结构的太阳能电池模块。
具体实施方式
图1至4根据一个优选实施方案展示了在太阳能电池模块的制造中的不同的阶段。正如在图1中所示，首先提供了适合的大小和厚度的玻璃载体1，包括装置侧表面11和背面侧表面12。
正如在图2中所示，玻璃载体1的背面侧表面12基本上由保护层3（例如由二氧化硅（SiO2））完全覆盖，其层厚度大致地25nm或更高。然而，与更厚的层厚度能够提供的任何优势相比较，产生远多于500nm的层厚度可能太昂贵。玻璃载体1在运输到太阳能电池制造厂时可以已经配备有保护层3。
然后，正如在图3中所示，在玻璃载体1的装置侧表面11上生产太阳能电池结构2，包括沉积到玻璃载体1上的多个层。生产为薄膜太阳电池的太阳能电池结构2可以适合本目的。最后，正如在图4中所描绘的，将盖罩玻璃4放置在这些太阳能电池结构2上，以保护它们同时允许入射光透过盖罩玻璃4从而在太阳能电池结构2中转换成电能。
而在此描述的制造过程中，在生产太阳能电池结构2之前将保护层3沉积到玻璃载体1的背面侧表面12上，相反地该过程可以被颠倒逆，或者作为替代方案可以在太阳能电池结构2的沉积步骤之间将保护层3沉积。稍后，沿着这些边缘可以将太阳能电池模块密封并且将其放置在框架中用于支持。
参考标号：
1玻璃载体
11装置侧表面
12背面侧表面
2太阳能电池结构
3保护层
4盖罩玻璃

Claims (17)

1.一种太阳能电池模块，该太阳能电池模块包括一个玻璃载体（1）和安排在该玻璃载体（1）的一个装置侧表面（11）上的一个太阳能电池结构（2），其特征在于安排在该玻璃载体（1）的一个背面侧表面（12）上的一个保护层（3）与该装置侧表面（11）相对。
2.根据权利要求1所述的太阳能电池模块，其特征在于该太阳能电池结构（2）是一个单片地沉积在该玻璃载体（1）的该装置侧表面（11）上的薄膜太阳能电池结构。
3.根据权利要求1或2所述的太阳能电池模块，其特征在于该玻璃载体（1）是用于该太阳能电池结构（2）的基底。
4.根据以上权利要求之一所述的太阳能电池模块，其特征在于该太阳能电池结构（2）包括与该玻璃载体（1）的该装置侧表面（11）直接接触的一个金属层。
5.根据权利要求4所述的太阳能电池模块，其特征在于与该装置侧表面（11）接触的该金属层是由钼制成的。
6.根据以上权利要求之一所述的太阳能电池模块，其特征在于对应于太阳能电池结构（2）所覆盖的装置侧表面（11）区域的该背面侧表面（12）上的表面区域是基本上完全由该保护层（3）覆盖。
7.根据权利要求6所述的太阳能电池模块，其特征在于该保护层（3）基本上覆盖该玻璃载体（1）的整个背面侧表面（12）。
8.根据以上权利要求之一所述的太阳能电池模块，其特征在于该保护层（3）是由一种导电材料制成的，用于将一个不变电势施加到该玻璃载体（11）的该背面侧表面（12）。
9.根据权利要求1至7之一所述的太阳能电池模块，其特征在于该保护层（3）是由一种非导电材料制成的。
10.根据权利要求9所述的太阳能电池模块，其特征在于该保护层（3）具有每平方至少1012欧姆的一个薄层电阻。
11.根据权利要求9或10所述的太阳能电池模块，其特征在于该保护层（3）包括一层颜料。
12.根据权利要求中9至11之一所述的太阳能电池模块，其特征在于该保护层（3）是非晶形的、纳米晶体、多晶的或单晶的。
13.根据权利要求中9至12之一所述的太阳能电池模块，其特征在于该保护层（3）包括一种氧化物、氮化物和/或氮氧化物。
14.根据权利要求13所述的太阳能电池模块，其特征在于该保护层（3）是由氧化铝、氧化硅、氮化硅、氮氧化硅、氮氧化铝、氮氧化硅铝或这些材料之一与一种或多种另外的元素的复合物。
15.根据以上权利要求之一所述的太阳能电池模块，其特征在于该保护层（3）是一个湿度屏蔽层。
16.根据以上权利要求之一所述的太阳能电池模块，其特征在于背离该玻璃载体（1）的该保护层（3）的一个表面是疏水的。
17.一种用于制造太阳能电池模块的方法，该方法包括以下步骤：
-提供一个玻璃载体（1）；
-将一个太阳能电池结构（2）沉积在该玻璃载体（1）的一个装置侧表面（11）上；并且
-将一个保护层（3）施加到该玻璃载体（1）的与该装置侧表面（11）相对的一个背面侧表面（12）上。
CN2011800274148A 2010-06-04 2011-05-27 太阳能电池模块以及其制造方法 Pending CN102959733A (zh)

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