CN104094413B - 光伏电池和形成光伏电池的方法 - Google Patents

光伏电池和形成光伏电池的方法 Download PDF

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CN104094413B
CN104094413B CN201280069140.3A CN201280069140A CN104094413B CN 104094413 B CN104094413 B CN 104094413B CN 201280069140 A CN201280069140 A CN 201280069140A CN 104094413 B CN104094413 B CN 104094413B
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metal mesh
expanded metal
photovoltaic
photovoltaic cell
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CN104094413A (zh
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B·D·哈克特曼
C·蔡
T·M·瓦莱里
H·德拉罗萨
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Dow Global Technologies LLC
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NuvoSun Inc
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Abstract

形成光伏电池的方法，所述方法包括提供第一卷的光伏材料和第二卷的扩张金属网。所述光伏材料包含与柔性衬底相邻的光活性材料，并且所述扩张金属网包含多个孔。接着，提供与所述光伏材料的边缘部分相邻的电绝缘材料。使来自所述第一卷的光伏材料然后可以接近来自所述第二卷的扩张金属网以形成初生光伏电池。所述电绝缘材料可以布置在所述扩张金属网与所述光伏材料之间。接着，将初生光伏电池切割成单个节段以形成多个光伏电池。

Description

光伏电池和形成光伏电池的方法
交叉引用
本申请要求2011年12月7日提交的美国临时专利申请No.61/568,134的优先权，所述申请全部通过引用并入本文中。
背景
非晶硅、二硒化铜铟镓(CIGS)、和碲化镉(CdTe)是当今仅有的以商业规模生产的薄膜太阳能电池。目前可得到的在柔性衬底上的薄膜太阳能电池包括在薄金属箔(通常不锈钢)上的非晶硅和在金属或聚酰亚胺箔上的CIGS。迄今，薄膜碲化镉太阳能电池只在玻璃上生产，但是正在进行在柔性衬底上的工作。适合在柔性衬底上使用的其他类型的太阳能电池材料可能变得可用。例如，正在进行针对利用锌和锡代替铟和镓的CIGS变体的工作，以及对有机和染料敏化太阳能电池材料的持续研究。
概要
本公开提供了从柔性薄膜太阳能电池材料卷制造太阳能电池、和电互连所述电池以形成可用于形成太阳能组件的串的自动化方法。
本公开提供了从大卷的柔性太阳能电池材料制造单个薄膜太阳能电池的高度自动化方法。本公开还通过使用便宜的平面扩张金属网(expanded metallic mesh)，提供了集流栅图案和互连。
本公开的一个方面提供了形成光伏组件的方法，所述方法包括提供第一光伏电池和第二光伏电池。所述第一和第二光伏电池的单个光伏电池包含与柔性薄膜光活性器件相邻布置的扩张金属网、和布置在所述扩张金属网和所述柔性薄膜光伏器件之间的所述柔性薄膜光活性器件的边缘部分处的电绝缘材料。接着，使所述第一光伏电池的扩张金属网与所述第二光伏电池的下侧面接触，从而电连接所述光伏电池的薄膜光活性器件以形成所述光伏组件。
本公开的另一个方面提供了形成光伏电池的方法，所述方法包括提供第一光伏材料卷和第二扩张金属网卷。所述光伏材料包含与柔性衬底相邻的光活性材料，并且其中所述扩张金属网包含多个孔。接着，提供与所述光伏材料的边缘部分相邻的电绝缘材料。使来自所述第一卷的光伏材料接近来自所述第二卷的扩张金属网以形成初生光伏电池。所述电绝缘材料布置在所述扩张金属网和所述光伏材料之间。接着，将所述初生光伏电池切割成单个节段以形成多个光伏电池。
本公开的另一个方面提供了光伏电池，其包含光伏器件和与所述光伏器件相邻的扩张金属网，所述光伏器件包含与光活性材料相邻的柔性衬底。所述扩张金属网包含多个孔以允许电磁辐射接触到所述光活性材料。所述光伏电池还包含布置在所述扩张金属网和所述光伏器件之间的所述光伏器件边缘部分处的电绝缘材料。
根据下面的详细说明，本公开的其他方面和优点对本领域技术人员将变得很容易明白，所述详细说明中只显示和描述了本公开的说明性实施方式。正如将认识到的，本公开能够有其他和不同的实施方式，并且它的若干细节能够在各种显而易见的方面加以修改，它们全都没有背离本公开。因此，附图和描述本质上被认为是说明性的，而不被认为是限制性的。
通过引用并入
本说明书中提到的所有出版物、专利和专利申请在此通过引用并入，其程度如同专门并且分别地指出各个单独的出版物、专利或专利申请通过引用并入一样。
附图简要说明
要求保护的本发明的新特征在所附权利要求中详细阐明。通过参考下面阐述利用本发明原理的说明性实施方式的详细说明、以及附图或图，将获得对本发明的特征和优点的更好理解，在所述附图中：
图1是示意图，示出了适合于制造用于柔性薄膜太阳能电池的集流栅和互连装置的平面扩张金属网的性质。
图2a是示意图，显示了利用一段图1中描述的平面扩张金属网的成品薄膜太阳能电池的几何形状的平面图。
图2b是厚度尺度放大的横截面示意图，显示了利用一段图1中描述的平面扩张金属网的成品薄膜太阳能电池的几何形状。
图3是示意图，描绘了通过从大得多的成品太阳能电池原料卷自动将其切割成条来制造柔性太阳能电池材料卷盘的初始步骤的透视图。
图4是透视示意图，示出了利用平面扩张金属网导体自动地将柔性太阳能电池材料卷盘转变成成品电池的工艺或方法中的基本步骤。
图5是在图4中描述的层压步骤之后一段太阳能电池条带的示意图，显示了所述扩张金属网如何应用于所述电池，并生成用于将所述条带切割成单个太阳能电池的空白区域(blank area)。
图6是大致按比例绘制的示意图，显示了利用图4中描述的基本方法从柔性太阳能电池材料卷盘和扩张金属网卷中形成单个太阳能电池的机器的横截面图。
图7a是示意性平面图，显示了通过本发明中描述的自动化方法制造的柔性太阳能电池的串联互连。
图7b显示了通过本发明中描述的自动化方法制造的柔性太阳能电池的串联互连的横截面图。
图8a是在串的末端的2个硅电池的示意性横截面图，示出了将所述电池串联连接在一起的典型Z-连接带(Z-tab)方法和将所述末 端电池与用于互连电池串的导电带连接的方式。
图8b是在串的末端的柔性电池的示意性横截面图，示出了一个串的末端与第二个串的末端串联连接的改进方法。
具体描述
虽然本文中显示和描述了本发明的优选实施方式，但对本领域技术人员显而易见的是，这样的实施方式只作为实例提供。本领域技术人员现在将在不背离本发明下想到许多变更、改变和替代。应该理解，在实践本发明中可以使用本文中描述的本发明实施方式的各种替代方案。
术语“光伏电池”(本文中也称为“太阳能电池”)，在本文中使用时，通常是指包含光伏器件的装置，所述光伏器件包含光活性材料(或吸收体)，所述光活性材料被构造成在所述装置暴露于电磁辐射(或能量)、或给定的波长或波长分布的电磁辐射时产生电子和空穴(或电)。光伏器件可以包括与所述光活性材料相邻的衬底。
术语“光伏组件”，在本文中使用时，通常是指包含一个或多个光伏电池的装置。
为了可用于太阳能系统，任何的各种类型太阳能电池(本文中也称为“电池”)可以与其他类似的太阳能电池串联型电互连，以提高电压水平和最小化否则将由于强电流而发生的电阻损耗。沉积在大的刚性片上的电池可以利用划线系统，所述划线系统在不同的加工步骤之间和在特定的位置应用，以在整个片上产生串联互连的电池。这种程序有时称为“单片集成”，并且它利用顶部导电氧化物(TCO)作为载流子代替硅电池通用的金属栅。虽然它消除了栅，但本文中认识到所述方法的许多缺点，并且在任何情况下，由于所述划线的布置和深度二者需要的精确度，在柔性衬底上执行是困难且昂贵的。另外，柔性衬底使得能够卷对卷加工，如果所述过程必须中断来执行划线操作，所述卷对卷加工可能变得经济上较不理想，即使那些操作可充分而经济地完成。
传统的晶体或多晶硅太阳能电池在单个晶片上形成，它们然后可以互连。集流栅和汇流条通常通过用随后在高温(700℃左右)下固化的含 银墨丝网印刷图案而形成。硅电池具有氮化硅形成的抗反射涂层，它是透明的但是不导电。固化阶段期间，银渗透氮化硅涂层并与硅电池产生欧姆接触。通常的栅图案包括一系列间隔两至三毫米的细直线和平行线，有两或三条较宽的线(汇流条)垂直于所述细线的图案通过。所生成的结构在汇流条上提供了表面，互连用“Z”连接带可通过传统焊接方法与所述表面相连。所述电池暴露于光后，电池电流被窄栅局部收集并被传输到比较宽的汇流条，汇流条然后变成下一个电池的连接点。所述“Z”连接带结构提供电池之间的柔性互连，它帮助减少在使用期间由于热膨胀和收缩所致的损害。这种方法优于单片集成的优点在于在组件装配之前可以根据性能来测试和挑选电池。以这种方式，总组件性能不受串中性能最低的电池限制，这可能是单片集成的问题。
然而，用于硅电池的丝网印刷工艺当应用于薄膜柔性太阳能电池时，只得到有限的成功。如本文中认识到的，通常遇到两个问题限制了所述电池的性能。第一个问题与温度有关。薄膜电池经受不住用于硅电池上固化银墨所需要的同样的高温。由于固化温度较低，一些墨载体和溶剂留在栅线结构中，造成金属粒子不能充分融合在一起。虽然正在开发可在较低温度下更完全固化的更新的墨，但这种机制仍然降低了栅线和汇流条的传导性，并且限制了将连接带焊接到所述印刷的汇流条的能力。可替代地，电池之间的互连可以用银掺杂的导电环氧树脂制成，但是它通常不如焊接并且它通常导致额外的固化时间。另外，最近银价的上涨使得所述工艺在经济上较不理想。
其次，因为金属柔性衬底的表面光洁度通常比玻璃或硅晶片的表面光洁度粗糙得多，存在多得多的缺陷，如果让导电墨流入它们的话，所述缺陷可能变成潜在的分流部位。通过首先印刷导电性低得多的材料，如碳基墨，以便初始填充任何缺陷，然后用银墨罩印，可稍微减轻该问题。因为缺乏完美的印刷重合(registration)的任何事物都引起额外的阴影损失(shading loss)以及增加的潜在的分流，所以难以达到一致的良好结果。另外，材料和设备的成本比较高，并且由于大规模印刷和固化过程以及高机械容差要求，自动化是困难的。
光伏组件
本公开提供了柔性薄膜太阳能(或光伏)电池卷，其可用于基本上自动化的工艺中以产生单个电池，所述单个电池然后互连形成组件。利用银基墨印刷，可通过使用平面扩张金属网避免潜在的分流、精确印刷图案重合和长久的热固化时间，所述平面扩张金属网对银印刷墨图案具有优异的传导性、更快施加、并且执行起来经济得多。
在一些实施方式中，光伏电池包含光伏器件和与所述光伏器件相邻的扩张金属网，所述光伏器件包含与光活性材料相邻的柔性衬底。所述光伏器件可以是柔性薄膜光伏器件。所述扩张金属网包含多个孔(或开口)，以允许电磁辐射接触到所述光活性材料。所述光伏电池还可包含布置在所述扩张金属网和所述光伏器件之间的在所述光伏器件边缘部分处的电绝缘材料。所述电绝缘材料可以是光学透明的。
所述扩张金属网的孔可以具有任何形状、尺寸或构造。孔可以具有圆形、三角形、正方形、长方形、五角形、六角形、七角形、八角形、或九角形，或任何部分形状(例如，半圆形)或其组合。
所述光活性材料可以是构造成经暴露于电磁辐射(或光)后产生电子和空穴的吸收体。所述金属网可适合于从光伏器件中收集和传导出电子并传导到负载物，例如储能系统(例如电池)、电栅、或者电子器件或系统。
所述光活性材料可以由各种材料形成。光活性材料的实例包括但不限于非晶硅、二硒化铜铟镓(CIGS)、碲化镉(CdTe)和CdZnTe/CdTe。
在某些情况下，所述光伏电池还包含将所述金属网固定到所述光伏器件上的光学透明膜。所述光学透明膜可以是压敏粘合剂。作为替代方案，所述扩张金属网可通过导电环氧树脂固定到所述光伏器件上。作为另一种替代方案，所述扩张金属网可通过低熔点焊料附着于所述光伏器件。
所述扩张金属网可具有各种形状、尺寸和构造。扩张金属网的宽度可以从约1英寸到10英寸，或1.5英寸到6.0英寸。扩张金属网的厚 度可以从约0.001英寸到0.05英寸，或0.002英寸到0.01英寸。在某些情况下，所述扩张金属网包含单独线状元件，每个线状元件的宽度约0.001英寸到0.01英寸、或0.002英寸到0.006英寸。
所述扩张金属网可以由金属材料例如铜、铁、锡、镍、金、银、铂、钯、铬、钨、钛、钽或其任何组合形成。在某些情况下，所述扩张金属网由涂有金属材料的聚合材料形成。例如，所述扩张金属网可以包含聚合芯和金属壳。在某些情况下，所述扩张金属网可包含一个或多个涂层。所述一个或多个涂层可包含镍和/或锡。
所述柔性衬底可包括不锈钢、铝或聚合材料。所述光伏器件可具有从约1英寸到10英寸、或1.5英寸到6.0英寸的厚度。
在某些情况下，光伏组件包含多个光伏电池。所述多个光伏电池可以彼此处于串联电接触(即串联构造)。在某些实例中，一个光伏电池的金属网与相邻光伏电池的下侧面电接触。在光伏电池“串”中，光伏电池可以彼此相邻布置。
现在将参考附图，其中同样的数字始终是指同样的部件。要理解，所述图和其中的结构不一定按比例绘制。
图1示出了一段平面扩张金属网1的几何形状。金属网1可以安装在光伏器件上以形成太阳能电池。所述网1具有宽度Wm并具有沿箭头2方向的相当长的长度。所述网可以由比成品网的宽度稍宽的金属箔卷形成。所述箔从输入的箔卷被切割、扩张和展平以产生网卷。展开图3示出了所述网几何形状的细节。通常，在所述网中的孔具有宽度Wo、长度Lo、和侧高度Ho。Ho可以是Lo的大约1/3至1/2，因此所述孔类似细长的六角形，但是Ho可以是零。在那种情况下，网孔采取边长为d的菱形形状(虚线)。如果所述金属继续扩张直到Wo等于Lo，那么孔可以更对称，并且如果Ho也接近零，则所述菱形可以是正方形。网孔的实际尺寸是厘米的分数。例如Lo可以是9毫米左右，而Wo是4毫米至5毫米。
所述网的孔可以具有任何形状、尺寸或构造。孔可以具有圆形、三角形、正方形、长方形、五角形、六角形、七角形、八角形、或九角形，或任何部分形状(例如，半圆形)或其组合。
所述网1可以由金属材料例如铜、铁、锡、镍、金、银、铂、钯、铬、钨、钛、钽或其任何组合形成。在某些实例中，网1可以由涂有金属材料的聚合材料形成。
虽然任何可能的网孔形状都可用于在太阳能(或光伏)电池上形成集流栅，但可进行一些优化。构成所述网的长方形横截面“导线”的宽度可由狭缝之间的距离与可利用的扩张量控制。在图1的视图3中，宽度W1可由狭缝之间的距离决定，而宽度W2可由扩张量决定。如果在扩张之前，狭缝之间的所有距离是相同的，则W2可小于W1。W1的典型尺寸是大约千分之几英寸。对于图1显示的不对称图案，跨所述网宽度的电阻可低于沿着所述网长度相等距离的电阻。因此，对于给定的所述网对太阳光的阻断(例如4％或5％)，可针对跨所述电池的低电阻来优化网的几何形状并且使得能够从材料卷自动装配。所述网在扩张之前或之后可用其他材料涂层。例如，所述网可由铜形成并且镀有锡以改进环境性能，并且它可在一面或两面接收薄层的低熔点焊料以供随后的粘合操作。许多实施方式是可能的。
图2a和2b显示了成品光伏电池。从材料卷生产单个电池的方法可通过执行所描述的功能的机器的实例来描述。本文中提供了所述电池串联互连成串并且所述串成为组件。
图2a显示了单个光伏电池的平面视图。所述活性光伏(或太阳能)器件4(本文中也称为“器件”)具有宽度Wc和长度Lc。它是从具有宽度Wc和一定的任意更长长度的柔性光伏材料卷盘中切割的一段。如图1所示的具有宽度Wm的一段网1可施加在器件4上。网1只延伸超过器件4的一个边缘，而不是两个。在器件4的左侧，网1短(距器件4的边缘)了“e”量，所述量例如具有从约1至3毫米(即，网孔的分数)的尺寸。所述网重叠器件4的一个长边的量为“s”，其可以是Lo的数倍，例如，Lo的至少1.1、1.2、1.3、1.4、1.5、2、3、4、5、6、7、8、9、 或10倍。所述网可沿着重叠区在器件4的边缘引起电短路或分流。这通过预先施加薄条5的绝缘透明压敏粘合剂(PSA)来防止，条5的宽度大约为2e，如所示，其大约一半可粘附于器件4的边缘。网1可通过固定构件附着于器件4，所述固定构件例如PSA或温度敏感的透明胶带，其尺寸可与所述网的尺寸减去悬伸区域s大致相同。网1可包含单独线状元件，每个线状元件的宽度从约0.001英寸至0.01英寸，或0.002英寸至0.006英寸。
图2b是图2a的光伏电池的横截面示意图。光伏器件4包括至少三个部分：光活性电池(或材料)4a，导电柔性衬底4b，和在某些情况下的反面涂层4c。如果光活性电池4a是CIGS电池，则它可如Probst等的美国专利No.5,626,688、Kushiya等的美国专利No.6,040,521、和Nath等的美国专利No.8,021,905中所述，每个专利全部通过引用并入本文。所述光活性电池4a的总厚度可在数纳米至微米的级别。衬底4b可由不锈钢或其他金属箔形成。衬底4b可以是导电的并充当光活性电池4a的背面电极的延伸以在本文描述的自动化工艺中适当地发挥功能。在某些实例中，柔性衬底4b的厚度可以从大约千分之一英寸(约25微米)至千分之几英寸。反面涂层4c是薄的金属涂层(约一微米或更薄)，用于提供与相邻电池之间网互连的电化相容性。例如，所述网可以由铜制造并镀有薄的锡涂层。在这种情况下，涂层4c也可以是锡，尽管所述结构在最佳环境封装条件下，例如如果所述电池在真空或在惰性(例如Ar，He)环境下封装的话，没有涂层4c也可以长时间发挥功能。柔性光伏器件4具有厚度tc，所述厚度取决于电池4a、衬底4b和涂层中每一个的厚度。在某些实例中，衬底4b可具有从约0.001英寸至0.01英寸、或0.002英寸至0.005英寸的厚度。
透明绝缘条5沿着器件4的一个长边的边缘施加，可防止网1的悬伸区域s沿着器件4的边缘引起分流。网1的厚度tm可以变化，以得到足够低的电阻，同时最小化阴影损失；然而，在某些情况下，tm是从约tc直至约2x tc。网1可以通过透明胶带6(例如PSA)保持紧靠器件4，所述透明胶带6的宽度大致等于Wc，并且其厚度ta可以是 大约千分之几英寸。在图2b中，在网1没有悬伸出器件4的边缘上，显示胶带6悬伸出网1的所述边缘的距离为e；然而，这不是关键尺寸。所述胶带可以在该边上覆盖网1，但是没有在两个边上都延伸过器件4的边缘，因此有比较宽的容差。
形成光伏电池和组件的系统和方法
本公开提供了形成光伏电池和组件的方法。所述方法可以至少部分或完全自动化。在某些情况下，光伏电池通过在辊执行的工艺中把材料合在一起而形成。
在一些实施方式中，形成光伏电池的方法包括提供第一卷的光伏材料和第二卷的扩张金属网。所述光伏材料包含与柔性衬底相邻的光活性材料，并且所述扩张金属网包含多个孔。接着，提供与所述光伏材料的边缘部分相邻的电绝缘材料。使来自所述第一卷的光伏材料然后接近来自所述第二卷的扩张金属网以形成初生光伏电池。所述电绝缘材料可以布置在所述扩张金属网与所述光伏材料之间。接着，将初生光伏电池切割成单个节段以形成多个光伏电池。
形成光伏电池的方法可以完全自动化，并且在某些情况下由具有一个或多个编制程序来执行所述方法的计算机处理器的计算机系统调节。在所述方法中用于制造单个光伏电池的自动化操作可以始于从大得多的柔性光伏电池材料卷形成光伏(电池)材料卷盘。所述光伏材料包括光活性材料(例如CIGS、CdTe)，并且在某些情况下包括衬底，例如柔性衬底。该工艺示意性地在图3中示出，其显示大卷的光伏电池材料7正在被切割成较小的卷盘8。所述大卷可以包括任何太阳能电池材料，例如CIGS。光伏电池材料7可以是在本文中别处描述的光伏电池4。所述切割由一组旋转切割构件9(例如刀、刀片)完成，可以调节所述构件以产生各种宽度Wc的卷盘8。在某些情况下，每个卷盘8的重量可以限制在一般工人可以方便地用手处理的重量，例如40磅至50磅左右。在每处位置都可以从大得多的卷7产生若干个卷盘8。切割操作可以明显比生产初始大卷的过程快，因此一个切割机可以处理若干个制造电池 材料的制造线的生产能力。大量的卷盘可以储存比较长的时间段，并且它们可以运输到别的加工场所以转变成单个光伏电池和随后转变成组件。
图4是系统的示意性的透视侧视图，所述系统用于将柔性太阳能电池材料卷盘转变成单个光伏电池的自动化步骤。这些步骤可以称为卷到电池或RTC转变。所述图不是按比例的并且只意在示出基本概念，而不是描述那些概念在功能RTC机器中的实际实施方式。
使可来自图3的切割操作(或制备卷盘8的任何其他操作)的光伏器件4的卷盘(或卷)8与形成太阳能电池的其他材料接触。透明边缘绝缘条5的卷10连续进给到小的辊组11(例如轧辊)以将所述条施加到器件4的一个边缘。所述辊可向PSA材料施加压力和/或它们可被加热以用于热固材料。压力和/或加热可帮助绝缘条5与来自卷盘8的器件4材料发生接触(并且在某些情况下与之粘附)。扩张金属网1可以从卷12进给并且透明胶带6可以从卷13进给到辊14中。这种操作可将网1固定到胶带6，在某些情况下固定程度只足以使它作为合为一体的接合材料15被处理。接合的胶带和网15向真空筒真空筒16前进，所述滚筒可在与器件4(沿着卷盘8)同步的边缘速度下并且沿箭头17的方向旋转。辊14可以在稍低的速度下推进所述胶带/网接合材料15，使得起初所述接合材料15稍微地在真空筒真空筒16上。
接着，使接合材料15靠近切割构件18，所述切割构件可以是旋转切割构件(例如旋转刀、旋转刀片)。切割构件18可以沿着选定的长度切割所述接合材料15。所述长度可以随切割构件18的尺寸而变。在切割构件18是旋转切割构件的情况下，所述切割构件以2*π*r的间隔切割接合材料15，其中“r”是所述旋转切割构件的半径。接合材料15的切割片以与滚筒16的旋转速度一致的速度围绕滚筒16顺序前进。所述速度可以适合于将所述切割的接合材料15初始固定于器件4材料和绝缘条5。滚筒16下游的压力辊19可以帮助将所述切割的接合材料15与器件4材料和绝缘条5接触。所述切割的接合材料15与所述器件4材料和绝缘条5的最后层压可以借助于辊20进行。辊14与真空筒真空筒16 之间小的速度差异可以当每片切割的接合材料15附着于器件4和绝缘条5时在每片之间产生小的(可调节的)间隙。间隙区域由虚线21指示，并且光伏电池长度Lc是从一个间隙的中心到下一个间隙的中心的距离。辊20下游的切割构件22可以将完成的初生光伏电池条在每个间隙的中心处切割成单个光伏电池。切割构件22可以包括能够操作切断机刀的视觉或其他标示系统，例如机器人视觉系统。所述光伏电池然后可以累积在盒子或箱23中。图5示出了图4的Lc区域中一段电池条的放大图。在所述间隙的中心(例如宽度约2e)切割所述材料可以产生如在本文中别处描述的光伏电池，例如在图2a和2b的情况下描述的光伏电池。
网1可以涂有其他材料。例如与光伏器件4的顶部接合的边可以具有薄的低温熔融焊料层，其可以预先施加于网1。一种这样的候选物可以是在大约118℃下熔化的铟/锡低共熔物。在这种情况下，图4的辊20可以在升高的温度下运行以在胶带/网与光伏器件4层压时熔融所述焊料。在这种方法中将必须使用具有适当耐温性的胶带。可替代地，薄层导电环氧树脂可以通过辊传送到图4的轧辊14与真空筒真空筒16之间的网上而施加，以提供在层压之后所述网和所述光伏器件4之间更刚性的粘合。本领域技术人员将会想到其他可能的替代方案。
图6是从电池材料卷形成单个太阳能电池的系统的示意性横截面侧视图。在某些情况下，材料卷可具有可能需要不同材料的插层(interleaf)以防止粘住或物质传送的性质。在图6中，给卷8、12和13提供了用于累积可能的插层材料的辊。它们全部标记为24。所述插层材料可帮助防止一种材料粘住另一种材料。为了控制条中的张力，所谓的“张力调节辊(dancer)”可用于所述处理系统。张力调节辊可用于许多位置。一个这样的位置被确定为三个一组的小辊25，其中所述张力调节辊的动作由双头箭头提示。其他辊可用于操作、定向、和引导一个条通过所述系统。在所述示出的实例中，在输入卷8和胶带卷10之间提供空间以添加设备，以抛光所述太阳能电池条的切割边缘而消除分流，如果分流可 能是由切割操作引起的问题的话。如果需要的话，插层材料26的卷可用于在盒子23中的电池之间提供隔离。
图6的系统包括多个加工组件，其可以彼此相邻安装以形成辊执行系统。可安装所述加工组件以形成具有所述辊执行系统的外壳。所述外壳可以被抽空(例如，借助于泵系统)或保持在惰性气氛下，例如在Ar或He的气氛下。在所说明的实例中，加工组件各具有约1米的宽度。
在单个光伏电池构建成串并安装以形成太阳能电池组件之前，可以测试它们的性能并以类似的电流(或功率)输出分级放入箱子中。可商购的标准机器人可用于在这样的操作中操纵电池。
在一些实施方式中，形成光伏组件的方法包括提供第一光伏电池和第二光伏电池。所述第一和第二光伏电池的单个光伏电池包含(i)与柔性薄膜光伏器件相邻布置的扩张金属网，和(ii)布置在所述扩张金属网和所述柔性薄膜光伏器件之间的在所述柔性薄膜光伏器件的边缘部分处的电绝缘材料。接着，使所述第一光伏电池的扩张金属网与所述第二光伏电池的下侧面接触，从而电连接所述光伏装置的薄膜光伏器件以形成所述光伏组件。
根据本文中别处描述的方法形成的单个光伏电池可以并排构造安装并互连以形成光伏(太阳能)电池组件。图7a是柔性光伏电池50的长互连串的一部分的向光(例如太阳)面的示意性平面图。每个光伏电池可以包括网1、光伏器件4、和绝缘条5。光伏电池50可以利用在本文中别处描述的系统和方法生成。各个光伏电池5隔开间隙(g)。取决于用所述机器人系统可以达到的精确度，所述间隙可以是大约一毫米或更小，所述机器人系统从运载盒子中拾取电池50并把它们一个挨着另一个放置。这些柔性电池50的串在电池50之间可以有利地具有比它们的硅相应物更小的面积损失，因为该技术中的Z-连接带互连可能需要更多的距离以允许使用期间遇到的热膨胀应力。与标准硅电池技术相比，本公开的电池的组件面积损失的降低可以是至少约1％、2％、3％、4％、5％、10％、20％、30％、或40％。在一个实例中，本公开的电池的组件面积损失的降低可多达约10％。这是明显的经济优势。
图7b是图7a的互连电池50的部分的示意性横截面侧视图。图7b显示了两个稍微不同的电池互连的实例。
在一个实例中，第二电池放置在第一电池的网1的悬伸区s上，电池之间的间隙为g。比较宽的连接构件(例如PSA)27的条将所述两个电池保持在一起并且与第一电池的网与第二电池的背面部分(例如，背向光的部分)之间的电连接对准。绝缘条5防止第一电池的边缘与弯曲的网发生接触(并且例如，被所述网分流)。在某些情况下，绝缘条5防止网1使电池4的顶(光接收)部与所述电池的底部短路，例如当使相邻的电池4横向接近彼此以形成光伏组件时。用这种方式可制造给定长度的电池串，并且由于它们的连接，它们可作为一个单位处理。接着所述串放在一起，用导电带状导线互连，配备适当的薄膜二极管，并且层压成成品组件。
在另一个实例中，边缘绝缘条5可以由如图所示的较宽的条5a代替。在这样的构造中可以排除条5。这种较宽的胶带5a可以容纳在图4和6中卷盘到电池描述的卷10上，并且它可能需要插层材料。这种胶带可以具有基本上覆盖面向网1的面的粘合剂，但是在相反面上可能只在它可能附着于电池50的区域(宽度大致为e)中需要粘合剂。因而，可以消除连接构件27，节约材料和成本。然而，在电池形成过程中，可能需要图6中来自卷26的插层材料，以防止电池50在它们堆叠在盒子23中时粘在一起。所述电池串如前所述装配成组件。
光伏组件可以包括若干串单个光伏电池，其中至少一些以串联构造连接。在比较大的电池例如硅的情况下，所述串被串联连接以提高所述光伏组件的总电压——亦即，所述光伏组件的电压大致等于处于串联构造的光伏组件的单个电池的电压之和。在采用光伏电池串的情况下，单个串包含多个串联连接的光伏电池，一个太阳能电池串末端的第一个电池的顶部导体可以与第二光伏串末端的第二个电池的背面导体连接。利用扩张网可提供制造这种串与串连接的特别有利的方法。
在某些情况下，为了串联连接两串电池，一个串末端的一个电池的背面可与另一个串末端的电池的顶部网导体连接。在利用硅电池的组 件中，这可用Z-连接带材料实现，所述Z-连接带材料从电池的背面、或从电池上的汇流条延伸到宽大约1/4英寸的外部导电带。图8a是放大比例的典型硅连接的示意性横截面图示。硅基光伏电池29的汇流条28通过Z-连接带30与相邻的硅基光伏电池的背面连接。在最后的电池处，Z-连接带状材料31连接汇流条28与导电带32，或它连接所述电池背面与所述导电带，如底部虚线连接件31a所示，取决于哪种是所述串的串联需要的。如指出的，这种结构占据的组件区域可具有约半英寸或更大的宽度。它可延伸跨越所述组件的顶部和底部边缘二者，在某些情况下减少了可暴露于光的有效光伏面积，因此显著降低了组件的孔径效率。
相比之下，本公开的网互连可允许以相对简单和有效的方式形成不显著牺牲孔径效率的光伏串互连。图8b显示了互连柔性光伏电池的扩张横截面侧视图。不在电池串末端的光伏电池可用图7描述的方式互连。为了制造从一个电池4的悬伸网1到在下一串末端的电池的背面的连接，可以沿着电池4的边缘施加足够宽的连接构件(例如绝缘PSA条)33。接着，网1的悬伸区域和一部分绝缘条5可以围绕电池4的边缘在背面上折叠。网1可以通过连接构件33防止与电池1的金属箔衬底的短路。导电带32然后可以在串的末端只与所述网连接，从而避免任何短路。所述导电带可以沿着不具有所述悬伸网的电池边缘与下一个串的末端串联连接。在某些实例中，网1和绝缘条5只有千分之几英寸厚。在这种情况下，沿着产生串互连的所述组件的边缘实际上可以没有孔径损失，因为它们隐藏在所述电池的后面。与硅基电池组件(参见，例如图8a)相比，这种方式可以导致薄膜太阳能电池的孔径效率的明显增益。
本公开的光伏组件可以彼此以串联、并联或二者电耦接。在某些实例中，光伏组件串联连接。例如，一个光伏组件的正极端子可以与另一个光伏组件的负极端子连接。在其他实例中，光伏组件并联连接。例如，一个光伏组件的正极端子可与另一个光伏组件的正极端子连接，或者一个光伏组件的负极端子可与另一个光伏组件的负极端子连接。
本文中提供的系统和方法可以与其他系统和方法组合或被它们修改，所述其它系统和方法例如美国专利公布No.2011/0300661(“SOLAR CELL INTERCONNECTION METHODUSING AFLAT METALLIC MESH(利用平面金属网的太阳能电池互连方法)”)(其全部通过引用并入本文)中提供的系统和方法。
从上文应该理解，虽然已经说明和描述了具体的实施，但可对其进行各种修改，所述各种修改是本文中考虑到的。也不旨在由本说明书内提供的具体实例限制本发明。虽然本发明已经参考前述的说明书进行了描述，但本文中优选实施方式的描述和说明不意味着视为限制性意义。此外，应该理解，本发明的所有方面不限于本文中阐述的具体的叙述、构造或相对比例，它们取决于各种条件和变量。本发明实施方式的形式和细节的各种修改对本领域技术人员将是显而易见的。因此预期本发明也应该覆盖任何这样的修改、变化和等效物。旨在下面的权利要求限定本发明的范围并且由其覆盖在这些权利要求范围内的方法和结构以及它们的等效物。

Claims (37)

1.形成光伏组件的方法，所述方法包括：
(a)提供第一光伏电池和第二光伏电池，其中所述第一和第二光伏电池的单个光伏电池包含：
i.与柔性薄膜光活性器件的顶部表面相邻布置的平面扩张金属网，其中所述平面扩张金属网包含具有长方形横截面的单独线状元件；和
ii.布置在所述平面扩张金属网和所述柔性薄膜光活性器件之间的在所述柔性薄膜光活性器件边缘部分处的电绝缘材料；
(b)使所述第一光伏电池的所述平面扩张金属网的悬伸区域和所述电绝缘材料弯曲，防止所述平面扩张金属网的所述悬伸区域与所述第一光伏电池的所述柔性薄膜光活性器件的所述边缘部分和底部中的至少一者接触；和
(c)使所述第一光伏电池的所述平面扩张金属网的悬伸区域与所述第二光伏电池的下侧面接触，从而电连接所述光伏电池的所述薄膜光活性器件以形成所述光伏组件。
2.权利要求1的方法，其中所述单个光伏电池包含将所述平面扩张金属网固定于所述柔性薄膜光活性器件的光学透明膜。
3.权利要求2的方法，其中所述光学透明膜是压敏粘合剂。
4.权利要求1的方法，其中所述平面扩张金属网通过导电环氧树脂固定于所述柔性薄膜光活性器件。
5.权利要求1的方法，其中所述平面扩张金属网用低熔点焊料附着于所述柔性薄膜光活性器件。
6.权利要求1的方法，其中所述平面扩张金属网包含孔。
7.权利要求1的方法，其中所述平面扩张金属网和所述柔性薄膜光活性器件的宽度在1.5英寸和6.0英寸之间。
8.权利要求1的方法，其中所述平面扩张金属网的厚度在0.002英寸和0.01英寸之间。
9.权利要求1的方法，其中所述平面扩张金属网包含单独线状元件，每个线状元件具有0.002英寸和0.006英寸之间的宽度。
10.权利要求1的方法，其中所述平面扩张金属网由铜形成。
11.权利要求1的方法，其中所述平面扩张金属网包括一个或多个涂层。
12.权利要求11的方法，其中所述一个或多个涂层包含镍。
13.权利要求11的方法，其中所述一个或多个涂层包含锡。
14.权利要求1的方法，其中所述柔性薄膜光活性器件包含与柔性衬底相邻的光活性材料。
15.权利要求14的方法，其中所述柔性衬底包含不锈钢。
16.权利要求1的方法，其中使所述第一光伏电池的所述平面扩张金属网与所述第二光伏电池的下侧面接触包括用所述平面扩张金属网围绕所述第一光伏电池的所述边缘部分包裹。
17.权利要求1的方法，其中所述平面扩张金属网重叠所述柔性薄膜光活性器件的一个边缘但不重叠所述柔性薄膜光活性器件的相反边缘。
18.形成光伏电池的方法，所述方法包括：
(a)提供第一卷的光伏材料和第二卷的平面扩张金属网，其中所述光伏材料包含与柔性衬底相邻的光活性材料，并且其中所述平面扩张金属网包含多个孔和具有长方形横截面的单独线状元件；
(b)提供与所述光伏材料的边缘部分相邻并且沿着所述光伏材料的边缘部分的电绝缘材料；
(c)使来自所述第一卷的所述光伏材料接近来自所述第二卷的所述平面扩张金属网以形成初生光伏电池，其中所述电绝缘材料布置在所述平面扩张金属网的底部表面和所述光伏材料的顶部表面之间；和
(d)将所述初生光伏电池切割成单个节段以形成多个光伏电池。
19.权利要求18的方法，其中在(b)中提供所述电绝缘材料包括使来自第三卷的所述电绝缘材料接近来自所述第一卷的所述光伏材料。
20.权利要求18的方法，其中(c)还包括使来自第四卷的固定构件接近所述平面扩张金属网，其中所述固定构件将所述平面扩张金属网紧靠所述光伏材料固定。
21.权利要求18的方法，所述方法还包括将所述多个光伏电池整合成光伏组件。
22.权利要求18的方法，其中(c)还包括将所述光伏材料和所述平面扩张金属网引导到真空筒内以压迫所述光伏材料紧靠所述平面扩张金属网。
23.权利要求18的方法，其中(c)还包括在使所述光伏材料接近所述平面扩张金属网之前，将所述平面扩张金属网切割成单个节段。
24.光伏电池，其包括：
(a)包含与光活性材料相邻的柔性衬底的光活性器件；
(b)与所述光活性器件的顶部表面相邻的平面扩张金属网，其中所述平面扩张金属网包含多个孔以允许电磁辐射接触到所述光活性材料，其中所述平面扩张金属网包含具有长方形横截面的单独线状元件，其中所述平面扩张金属网具有构造成弯曲的悬伸区域；和
(c)在所述平面扩张金属网和所述光活性器件之间沿着所述光活性器件边缘部分布置的、并且设置成防止所述平面扩张金属网的所述悬伸区域与所述光活性器件的所述边缘部分和底部中的至少一者接触的电绝缘材料。
25.权利要求24的光伏电池，其还包含将所述平面扩张金属网固定于所述光活性器件的光学透明膜。
26.权利要求25的光伏电池，其中所述光学透明膜是压敏粘合剂。
27.权利要求24的光伏电池，其中所述平面扩张金属网通过导电环氧树脂固定于所述光活性器件。
28.权利要求24的光伏电池，其中所述平面扩张金属网通过低熔点焊料附着于所述光活性器件。
29.权利要求24的光伏电池，其中所述平面扩张金属网的宽度在1.5英寸和6.0英寸之间。
30.权利要求24的光伏电池，其中所述平面扩张金属网的厚度在0.002英寸和0.01英寸之间。
31.权利要求24的光伏电池，其中所述平面扩张金属网包含单独线状元件，每个线状元件具有0.002英寸和0.006英寸之间的宽度。
32.权利要求24的光伏电池，其中所述平面扩张金属网包含铜。
33.权利要求24的光伏电池，其中所述平面扩张金属网包括一个或多个涂层。
34.权利要求33的光伏电池，其中所述一个或多个涂层包含镍。
35.权利要求33的光伏电池，其中所述一个或多个涂层包含锡。
36.权利要求24的光伏电池，其中所述柔性衬底包含不锈钢。
37.权利要求24的光伏电池，其中所述平面扩张金属网重叠所述光活性器件的一个边缘但不重叠所述光活性器件的相反边缘。
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