CN105027302B - 薄型太阳能电池的模块组装 - Google Patents

薄型太阳能电池的模块组装 Download PDF

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CN105027302B
CN105027302B CN201380072136.7A CN201380072136A CN105027302B CN 105027302 B CN105027302 B CN 105027302B CN 201380072136 A CN201380072136 A CN 201380072136A CN 105027302 B CN105027302 B CN 105027302B
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加芙列拉·布内亚
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Abstract

本发明公开了通过将太阳能电池放置在包封物片材之间来封装太阳能电池(320)。将包封物暴露于紫外(UV)光以固化所述包封物，并且将所述包封物粘结在一起以包封所述太阳能电池(321)。可执行UV固化步骤以将所述包封物中的一者粘结到透明顶盖和所述太阳能电池，并且将另一个包封物粘结到所述太阳能电池和背板(322)。然后将包括所述透明顶盖、包封的太阳能电池和所述背板的保护性封装任选地安装在框架上(323)。

Description

薄型太阳能电池的模块组装
技术领域
本文中所述主题的实施例整体涉及太阳能电池。更具体地讲，所述主题的实施例涉及太阳能电池模块。
背景技术
太阳能电池是为人们所熟知的用于将太阳辐射转换成电能的装置。太阳能电池具有在正常工作期间面向太阳以收集太阳辐射的正面，以及与正面相背对的背面。照射在太阳能电池上的太阳能辐射产生迁移至扩散区的电子和空穴，从而在扩散区之间形成电压差。形成到对应的扩散区的金属触点，以允许连接到外部电路例如负载并由太阳能电池为其供电。
可将太阳能电池串联和封装在一起以形成太阳能电池模块。所述封装为太阳能电池提供环境保护，并且可包括位于正面上的顶盖、包封太阳能电池的包封物，以及在背面上提供绝缘的背板。本发明的实施例涉及太阳能电池封装工艺，所述工艺允许准确的太阳能电池放置。
发明内容
在一个实施例中，通过将太阳能电池放置在包封物片材之间来封装太阳能电池。将包封物暴露于紫外(UV)光以固化包封物，并且将包封物粘结在一起以包封太阳能电池。可执行UV固化步骤以将包封物中的一者粘结到透明顶盖和太阳能电池，并且将另一个包封物粘结到太阳能电池和背板。包括透明顶盖、包封的太阳能电池和背板的保护性封装可以但并非必须安装在框架上。
所属领域的技术人员在阅读本公开内容的全文时将易于明了本发明的这些特征和其他特征，本公开内容包括附图和权利要求书。
附图说明
结合以下附图考虑时，可通过参考具体实施方式和权利要求得到对主题的更完整理解，其中在所有这些附图中，相似标号指代类似元件。附图未按比例绘制。
图1示出了根据本发明实施例的太阳能电池模块。
图2至图5为剖视图，示意性地示出了根据本发明实施例的制造图1的太阳能电池模块的方法。
图6示出根据本发明实施例的制造太阳能电池模块的方法的流程图。
图7至图9为剖视图，示意性地示出了根据本发明另一个实施例的制造图1的太阳能电池模块的方法。
图10示出了根据本发明另一个实施例的制造太阳能电池模块的方法的流程图。
具体实施方式
在本发明中，提供了许多具体细节，诸如部件、材料和方法的例子，以提供对本发明实施例的全面理解。然而，所属领域的技术人员将认识到，可在不具有这些具体细节中的一个或多个具体细节的情况下实践本发明。在其他示例中，不显示或不描述众所周知的细节以避免混淆本发明的方面。
图1示出了根据本发明实施例的太阳能电池模块100。太阳能电池模块100为所谓的“地面太阳能电池模块”，因为它是专为用于固定应用而设计，诸如在屋顶上使用或由光伏电站使用。在图1的例子中，太阳能电池模块100包括互连太阳能电池101的阵列。为了清楚地举例说明，仅在图1中标记了太阳能电池101中的一些。在图1的例子中，太阳能电池101包括背面接触式太阳能电池。在背面接触式太阳能电池中，所有扩散区以及与扩散区相连的金属触点均形成在太阳能电池的背面上。也就是说，P型扩散区和N型扩散区两者以及与其相连的金属触点位于太阳能电池的背面上。在其他实施例中，太阳能电池101也可为正面接触式太阳能电池或其他类型的太阳能电池。
图1中可以看到太阳能电池101的正面。太阳能电池101的正面也称为“光照面”，因为其在正常工作期间面向太阳以收集太阳辐射。太阳能电池101的背面与正面相背对。框架102为太阳能电池101提供机械支撑。太阳能电池模块100的前部103与太阳能电池101的正面在相同侧，并可见于图1中。太阳能电池模块100的后部104在前部103的下方。太阳能电池模块100的后部104与太阳能电池101的背面在相同侧。
图2-图5为剖视图，示意性地示出了根据本发明实施例的制造太阳能电池模块100的方法。图2-图5未按比例绘制。
在图2的例子中，包封物210片材放置在透明顶盖220上。在一个实施例中，透明顶盖220包括厚度介于1mm至4mm(例如，3.2mm)之间的玻璃。太阳能电池101放置在包封物210上。将太阳能电池101对准放置，其正面面向包封物210。例如，太阳能电池101可以距离D相对于彼此放置，该距离在50μm至100μm的精度内。可由形成在太阳能电池101背面上的互连金属(例如，图5所示的互连金属251)来电串联太阳能电池101。
包封物210可包括多层包封物。在图2的例子中，包封物210包括包封层211、包封层212和包封层213。包封层211可具有25μm至50μm的厚度，包封层212可具有250μm的厚度，并且包封层213可具有25μm至50μm的厚度。包封层的厚度可根据具体实施细节而变化。包封层211可包括在固化时允许将该包封层粘结到透明顶盖220的添加剂。相似地，包封层213可包括在固化时将该包封层粘结到太阳能电池101的添加剂。
包封物210可包括可光固化的包封物。在一个实施例中，可通过暴露于紫外(UV)光来固化包封物210。在一个实施例中，可通过暴露于第一波长λ1的UV光来将包封层211固化以粘结到玻璃透明顶盖220，并且可通过第二波长λ2的UV光来将包封层213固化以粘结到太阳能电池101。包封物210可包括保护性地包封太阳能电池的改性聚烯烃包封物。聚烯烃在主链或侧链中具有小于5重量％的氧和氮。换句话讲，聚烯烃分子结构中任何位置处的氧和氮的合并重量百分比小于5。UV固化波长范围为300nm至400nm。
在图2的例子中，UV光源231发射第一波长λ1的高强度UV光，并且面向太阳能电池101的正面。由UV光源231发射的UV光从透明顶盖220进入并穿过该透明顶盖220以照射在包封层211上，从而使包封层211暴露于UV光。UV光固化包封层211，使透明顶盖220粘结到包封层211。
在图3的例子中，UV光源232发射第二波长λ2的高强度UV光，并且也面向太阳能电池101的正面。由UV光源232发射的UV光从透明顶盖220进入并穿过该透明顶盖220，并且穿过包封层211和212以照射在包封层213上，从而使包封层213暴露于UV光。UV光固化包封层213，使太阳能电池101粘结到包封层213。
UV光源232和231可包括可被构造成发射不同波长的UV光的不同光源或相同光源。在制造环境下，透明顶盖220可被放置在平台上，诸如工作台或传送装置，其具有切口以允许光从平台下方照射透明顶盖220。包封物210被放置在透明顶盖220的顶部上。然后太阳能电池101被准确地放置在包封物210上(例如，使用机械手)。一旦透明顶盖、包封物210和太阳能电池101堆叠在一起，则相继地打开置于平台下方的UV光源231和232以执行上述的UV固化步骤来固化包封物210。包封物210的层的固化顺序可根据制造工艺的细节而有所不同。
继续参考图4，包封物240片材放置在太阳能电池101的背面上，并且背板241放置在包封物241上。背板241可包括为太阳能电池模块的其他部件提供环境保护的单层或多层材料。背板241可包含例如含氟聚合物、聚偏二氟乙烯、聚四氟乙烯、聚丙烯、聚苯硫醚、聚酯、聚碳酸酯或聚苯醚。
包封物240可包括单层或多层可UV固化的包封物。在一个实施例中，包封物240可包含在主链或侧链中具有小于5重量％的氧和氮的改性聚烯烃。换句话讲，聚烯烃分子结构中任何位置处的氧和氮的合并重量百分比小于5。
在图4的例子中，UV光源233发射高强度UV光，并且面向太阳能电池101的背面。由UV光源233发射的UV光的具体波长取决于包封物240和背板241的成分。UV光源233发射UV光，该UV光从背板241进入并穿过该背板241以照射在包封物240上，从而使包封物240暴露于UV光。UV光固化包封物240，从而将太阳能电池101粘结到包封物240，并且将包封物240和210粘结在一起以包封太阳能电池101。
在上述制造环境例子中，可将UV光源233放置在支撑正在制造的太阳能电池模块的平台上方。包封物240放置在太阳能电池101的背面上，并且背板241放置在包封物240上。然后激活UV光源233以固化包封物210，从而形成包括顶盖220、包封的太阳能电池101和背板241的保护性封装。
由于UV固化步骤使用的是光而不是热，因此材料叠堆包括透明顶盖220、包封物210和240，并且背板241在固化期间并不翘曲。这允许相对准确地放置太阳能电池101。与UV固化相关的低温也有助于防止保护性封装的分层。具体地讲，虽然UV固化步骤可在大体工厂环境温度(诸如，介于18℃至28℃)下执行，但通常用于形成太阳能电池模块的保护性封装的真空辊层压和其他热工艺在高于100℃的温度下执行。
在图5的例子中，包封物240和210在上述UV固化步骤之后被共同标记为包封物245。图5还示出了将太阳能电池101电连接在背面上的互连金属251。包括透明顶盖220、包封物245和背板241的所得保护性封装任选地安装在框架102(参见图1)上以形成太阳能电池模块100。在框架化时，透明顶盖220在前部103上，并且背板241在后部104上。
一旦包封物210的与顶盖220和太阳能电池101接触的部分被UV固化，并且包封物240的与太阳能电池101和背板241接触的部分被UV固化，则可执行后续的热工艺而不影响太阳能电池101的间距。这是因为包封物210和240的UV固化固定了太阳能电池101的间距，即使在顶盖220于稍后的热工艺步骤中弯曲时也是如此，诸如层压机或烘箱回流中模块芯的最终固化。
图6示出根据本发明实施例的制造太阳能电池模块的方法的流程图。在图6的例子中，第一可UV固化包封物放置在透明顶盖上，该透明顶盖在该例子中包括玻璃(步骤251)。随后将太阳能电池在第一可UV固化包封物上对准放置，使太阳能电池的正面朝向第一可UV固化包封物(步骤252)。UV光朝向太阳能电池的正面发射，进入并穿过透明盖并照射在第一可UV固化包封物上，从而固化第一可UV固化包封物以将透明顶盖粘结到第一可UV固化包封物(步骤253)。UV光再次朝向太阳能电池的正面发射，进入并穿过透明盖并照射在第一可UV固化包封物上，从而固化第一可UV固化包封物以将太阳能电池粘结到第一可UV固化包封物(步骤254)。
在固化第一可UV固化包封物之后，将第二可UV固化包封物放置在太阳能电池的背面上(步骤255)。然后将背板放置在第二可UV固化包封物上(步骤256)。UV光朝向太阳能电池的背面发射，进入并穿过背板并照射在第二可UV固化包封物上，从而固化第二可UV固化包封物以将太阳能电池粘结到第二可UV固化包封物，将第一可UV固化包封物和第二可UV固化包封物粘结在一起而且包封太阳能电池，并且将背板粘结到第二可UV固化包封物(步骤257)。然后将所得保护性封装任选地安装在框架上(步骤258)。
图7-图9为剖视图，示意性地示出了根据本发明另一个实施例的制造太阳能电池模块100的方法。图7-图9未按比例绘制。
在图7的例子中，太阳能电池101放置在可UV固化包封物即包封物301和302的片材之间。包封物301和302可包括单层或多层可UV固化的包封物。包封物301和302可包含在主链或侧链中具有小于5重量％的氧和氮的改性聚烯烃。换句话讲，聚烯烃分子结构中任何位置处的氧和氮的合并重量百分比小于5。在图7的例子中，包封物301在太阳能电池101的正面上，并且包封物302在太阳能电池101的背面上。
在图8的例子中，UV光源303朝向太阳能电池101的背面发射UV光，并且UV光源304朝向太阳能电池101的正面发射UV光。由UV光源303和304发射的UV光的具体波长取决于包封物301和302的成分。由UV光源303发射的UV光固化包封物302，并且由UV光源304发射的UV光固化包封物301。UV固化使包封物302和301粘结在一起以包封太阳能电池101。应当理解，可在相同的UV固化步骤中或分别在独立的UV固化步骤中将包封物302和301固化在一起。
在图9的例子中，包封物301和302被共同标记为包封物310以指示UV固化步骤将包封物301和302粘结在一起从而包封太阳能电池101。图9还示出了电连接太阳能电池101的互连金属251。应当理解，太阳能电池101在被包封之后相对于彼此固定对准。因此，随后执行的热工艺步骤将对太阳能电池101的放置产生极小的影响或没有影响。
在图9的例子中，包封太阳能电池101的包封物310放置在透明顶盖220上，该透明顶盖在该例子中包括玻璃。包封物310被放置为使得太阳能电池101的正面面向透明顶盖220。背板241放置在包封物310上，面向太阳能电池101的背面。然后可将透明顶盖220、包封物310和背板241层合在一起以形成保护性封装。例如，可通过真空辊层压来形成保护性封装。虽然层压工艺涉及加热至高于100℃的温度，但层压工艺不会影响太阳能电池101相对于彼此的对准，因为太阳能电池101在层压工艺之前被包封。然后将包括透明顶盖220、包封物310和背板241的保护性封装任选地安装在框架上。图10示出了根据本发明另一个实施例的制造太阳能电池模块的方法的流程图。在图10的例子中，太阳能电池放置在可UV固化包封物的片材之间(步骤320)。执行涉及将包封物暴露于UV光的一个或多个UV固化步骤以固化可UV固化包封物，从而将包封物粘结在一起以包封太阳能电池(步骤321)。然后使用背板和透明顶盖将包封的太阳能电池层合在一起以形成保护性封装(步骤322)。例如，可通过真空辊层压将包封的太阳能电池、背板和透明顶盖层合在一起。然后将保护性封装任选地安装在框架上以完成太阳能电池模块(步骤323)。
本发明已公开了用于包封太阳能电池模块的太阳能电池的技术。虽然已提供了本发明的具体实施例，但是应当理解，这些实施例是用于举例说明的目的，而不用于限制。通过阅读本发明，许多另外的实施例对于本领域的普通技术人员而言将是显而易见的。

Claims (10)

1.一种制造太阳能电池模块的方法，所述方法包括：
将第一包封物放置在透明顶盖上；
将多个太阳能电池的正面放置在所述第一包封物上，所述太阳能电池的正面面向太阳以在正常工作期间收集太阳辐射；
通过将所述第一包封物暴露于穿过所述透明顶盖的第一波长的紫外光来在第一固化步骤中固化所述第一包封物的第一层以将所述透明顶盖粘结到所述第一包封物的第一层；以及
通过将所述第一包封物暴露于穿过所述透明顶盖的第二波长的紫外光来在第二固化步骤中固化所述第一包封物的第二层以将所述多个太阳能电池粘结到所述第一包封物的第二层，所述第二波长不同于所述第一波长。
2.根据权利要求1所述的方法，还包括：
将第二包封物放置在所述多个太阳能电池的背面上，所述背面与所述正面相背对；
将背板放置在所述第二包封物上；以及
通过将所述第二包封物暴露于穿过所述背板的紫外光来固化所述第二包封物以将所述第一包封物和所述第二包封物粘结在一起，从而包封所述多个电池。
3.根据权利要求2所述的方法，其中所述固化所述第二包封物还将所述背板粘结到所述第二包封物。
4.根据权利要求3所述的方法，还包括：
将保护性封装安装在框架上，所述保护性封装包括由所述第一包封物和所述第二包封物、所述透明顶盖以及所述背板包封的所述多个太阳能电池。
5.根据权利要求1所述的方法，其中所述多个太阳能电池包括背触式太阳能电池。
6.根据权利要求1所述的方法，其中所述透明顶盖包括玻璃。
7.一种制造太阳能电池模块的方法，
在第一固化步骤中使用第一波长的紫外光固化第一包封物以将透明顶盖粘结到所述第一包封物；
在第二固化步骤中使用第二波长的紫外光固化所述第一包封物以将多个太阳能电池粘结到所述第一包封物，所述第二波长不同于所述第一波长；
在第三固化步骤中使用紫外光固化第二包封物以将所述第一包封物和所述第二包封物粘结在一起，包封所述多个太阳能电池，并且将背板粘结到所述第二包封物，所述第三固化步骤中使用的紫外光的波长取决于所述第二包封物和所述背板的成分；以及
将包括被包封的所述多个太阳能电池、所述透明顶盖和所述背板的保护性封装安装到框架上。
8.根据权利要求7所述的方法，其中在所述第一固化步骤中使用紫外光固化所述第一包封物将所述第一包封物的第一层粘结到所述透明顶盖。
9.根据权利要求8所述的方法，其中在所述第二固化步骤中使用紫外光固化所述第一包封物将所述第一包封物的第二层粘结到所述多个太阳能电池。
10.根据权利要求7所述的方法，其中所述透明顶盖包括玻璃。
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