CN106206820A - 太阳能板模块及其制造方法 - Google Patents

太阳能板模块及其制造方法 Download PDF

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CN106206820A
CN106206820A CN201510242432.8A CN201510242432A CN106206820A CN 106206820 A CN106206820 A CN 106206820A CN 201510242432 A CN201510242432 A CN 201510242432A CN 106206820 A CN106206820 A CN 106206820A
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solar panels
backboard
cover plate
distribution
encapsulation material
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黄庭辉
周振南
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Hawker Energy Technology Co ltd
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Abstract

本发明提供一种太阳能板模块，其具有多片彼此相邻设置的多片太阳能板。每一片该太阳能板的一侧设有一正极配线而相对的另一侧设有一负极配线。相邻的两片该太阳能板的毗邻电极配线皆为正极配线或皆为负极配线。

Description

太阳能板模块及其制造方法
技术领域
本发明关于太阳能板模块及其制造方法。
背景技术
太阳能电池的研究正如火如荼地进行。如何提高光电转换层的转换效率以及太阳能板模块的发电效率一直是热门的题目，由此可知，业界需要一种改良式的高效率太阳能板模块。
发明内容
本发明的目的在于提供一种高效率太阳能板模块的制造方法，其包括下列步骤。提供多片太阳能板。于每一片该太阳能板的正面的相对两侧形成正面正极配线与正面负极配线并将该正面正极配线与该正面负极配线反折至每一片该太阳能板的背面成为背面正极配线与背面负极配线。将该多片太阳能板平放至一背板与一盖板之间并层压贴合该多片太阳能板、该背板与该盖板，其中相邻的两片该太阳能板的毗邻正面电极配线皆为正面正极配线或皆为正面负极配线。
本发明亦提供一种高效率太阳能板模块，其包括彼此相邻设置的多片太阳能板，每一片该太阳能板的一侧设有一正极配线而相对的另一侧设有一负极配线。相邻的两片该太阳能板的毗邻电极配线皆为正极配线或皆为负极配线。
本发明亦提供一种太阳能板模块，其包括一盖板、一背板、至少一太阳能板、第一封装材、第二封装材及第一防水胶材。第一封装材位于该太阳能板与该背板之间。该第二封装材位于该太阳能板与该盖板之间。该第一防水胶材位于该盖板与该背板延伸突出该太阳能板的外环区域中，位于该盖板与该背板之间接触该太阳能板的侧边。
为让本发明的上述目的、特征和优点更能明显易懂，下文将以实施例并配合所附图式，作详细说明如下。需注意的是，所附图式中的各组件仅是示意，并未按照各组件的实际比例进行绘示。
附图说明
图1-5显示根据本发明一实施例的太阳能板模块的制造方法。
图6显示根据本发明另一实施例的太阳能板模块。
图7显示根据本发明的太阳能板模块的概略横剖面图。
图8显示根据本发明的太阳能板模块的封装材与防水胶材的概略横剖面放大图。
具体实施方式
下面将详细地说明本发明的较佳实施例，举凡本中所述的组件、组件子部、结构、材料、配置等皆可不依说明的顺序或所属的实施例而任意搭配成新的实施例，此些实施例当属本发明之范畴。
本发明的实施例及图示众多，为了避免混淆，类似的组件是以相同或相似的标号示之；为避免画面过度复杂及混乱，重复的组件仅标示一处，他处则以此类推。
现参考图1-5及7-8，图1-5显示根据本发明一实施例的太阳能板模块的制造方法，图7显示根据本发明的太阳能板模块的概略横剖面图，图8显示根据本发明的太阳能板模块的封装材与防水胶材的概略横剖面放大图。首先，准备多片如图1所示的太阳能板100。每一片太阳能板100具有一正面101与一背面102并包括多个以串联方式彼此连接的太阳能单元(solar cell unit)10a、10b及10，其中10a与10b代表位于太阳能板100两端的单元而10代表位于其间的单元。接着参考图2，太阳能板100较佳地呈矩形故具有长边与短边，在太阳能板100的正面101的两侧长边处设置正面正极配线121b与正面负极配线111a，并将正面正极配线121b与正面负极配线111a反折至太阳能板100的背面102成为背面正极配线122b与背面负极配线112a。在本发明之大部分图示中，背面正极配线122b与背面负极配线112a以虚线呈现，以与正面配线有所区别。正面正极配线121b作为太阳能板100的正极，正面负极配线111a作为太阳能板100的负极。配线例如可由铜箔(Copper foil)或铜带(Copper ribbon)构成，亦可由其它金属或合金线材构成。
如图7所示，每一片太阳能板100由下至上具有由背玻璃103、图案化的下电极层2、图案化之光电转换层1、选择性的图案化缓冲层5及图案化的透明上电极层4所构成的图案化迭层结构。图7的重点在于表达太阳能板100的细部结构以及其与背板130、盖板140之间的相对关系，故图7省略了胶材如封装材与防水胶材等，上述胶材的说明请参考图8。下电极层与透明上电极层用于传输由光电转换层所产生的电流。光电转换层用于吸收穿透过透明上电极层与选择性之缓冲层的光并将其转换为电流，光电转换层可包括由铜(Cu)、铟(In)、镓(Ga)与硒(Se)所构成的半导体材料，或可包括由Ib族元素如铜(Cu)或银(Ag)、IIIb族元素如铝(Al)、镓(Ga)或铟(In)与VIb元素如硫(S)、硒(Se)或碲(Te)所构成的化合物半导体材料。透明上电极层例如是氧化铟锡(ITO)及/或氧化锌层(ZnO)，下电极层例如是钼(Mo)。
背玻璃103为整块未图案化的绝缘结构，图案化之下电极2系形成于其上。图案化之下电极2彼此之间具有分隔间隙3，分隔间隙3中可填有树脂或其它绝缘材料以电隔绝不同的下电极2。图案化之下电极2上形成有相同图案之图案化的光电转换层1与选择性的图案化缓冲层5，一图案化之下电极2系用于串联电连接相邻的两太阳能单元(solar cell unit)10与10或10与10a或10与10b。一图案化之下电极2亦用于电连接一太阳能单元10a(10b)与一电极配线111a(121b)。在一太阳能单元10(10a/10b)中，相邻之图案化的光电转换层1与选择性的图案化缓冲层5之间具有一间隙(不具标号)被形成于上的图案化上电极4填满，使上电极4与下电极2电连接(在此例中为实体接触)；在相邻的两太阳能单元(solar cell unit)10与10或10与10a或10与10b之间，为相邻的图案化的上电极4、图案化的光电转换层1与选择性的图案化缓冲层5之间的分隔间隙6，分隔间隙6在后续制程中会被树脂或其它绝缘材料填满。在每一太阳能单元10(10a与10b)中，当光穿透图案化的上电极层4与选择性缓冲层5而到达图案化的光电转换层1时，在图案化的光电转换层1中产生电动势，造成例如自图案化的上电极层4流向图案化的下电极2的电流(如图7的虚线箭头所示)；在整个太阳能板100中，电流自正面负极配线111a经由图案化的下电极2、图案化的上电极4、图案化之光电转换层1.....流至正面正极配线121b。电子的方向与电流方向相反。应注意，在图7及本案的其它图标中组件并未依比例绘制。又，在实际的一横剖面中应无法同时见到正极配线121b、正面负极配线111a与背面正极配线122b、背面负极配线112a实体相连，但图7为了表达上述者的电连接关系，特以实体相连方式呈现。
接着参考图3与图8，将多片太阳能板100(100’)平放至一背板130上，背板130例如是如图8所示的软质背板或硬质背板且背板130的尺寸应足够大以致于其长度能延伸超过末端两太阳能板100(100’)且其宽度略大于一太阳能板100(100’)的宽度。软质背板可以是高张力的塑料薄片例如聚乙烯(Polyethylene，PE)薄片、聚醯胺(Polyamide，PA)薄片、聚对苯二甲酸乙二酯(Polyethylene terephthalate，PET)薄片、或上述者的组合；硬质背板可以是物理强化玻璃(Tempered glass)、化学强化玻璃(Chemically strengthened glass)或高分子树脂。背板亦可为上述的组合附加铝箔的薄板。图3中仅显示3片太阳能板，但应了解，本发明可应用至更多片太阳能板的情况，较佳地，本发明将大于3片的太阳能板100(100’)平放至一背板130上。太阳能板100’与100的结构相同(太阳能单元相同，但为了简化版面并未标示；配线相同，故标号方式类似)，其相异之处在于配置的位向左右相反，因此细节不再赘述。根据本发明的太阳能板模块的制造方法，在配置多片太阳能板100(100’)的相对位置时应注意，相邻之两太阳能板100与100’的毗邻电极必须为电性相同的电极，即一太阳能板100的正极与其一侧的另一太阳能100’的正极毗邻而该太阳能板100的负极与其另一侧之另一太阳能板100’的负极毗邻。当极性相异且距离过近时容易产生漏电现象，然而，本发明的相邻的两太阳能板100与100’的毗邻电极为电性相同的电极(皆为正极或皆为负极)，故可将相邻的两太阳能板的毗邻正面配线之间的距离d缩短至2mm或更短，较佳地，相邻的两太阳能板的毗邻正面配线之间的距离d不大于5mm且不小于1mm。因此，本发明的太阳能板模块在相同的面积下可配置较多的太阳能板，从而单位面积能产出较高的电力。在确认多片太阳能板100(100’)在背板130上的配置位置与彼此的相对位置后，如图8所示将第一封装材135设置于多片太阳能板100(100’)与背板130之间。背板130在对应至每一片太阳能板100(100’)之中央区域处(或其它区域处)有至少一个孔洞(未图示)，使每一片太阳能板100(100’)的背面的背面正极配线122b(122b’)与背面负极配线112a(112a’)自第一封装材135与此至少一个孔洞(未图示)穿出以向外连接并彼此连接。该第一封装材例如是热封装胶材(thermal encapsulant)如乙烯醋酸乙烯酯(EthyleneVinyl Acetate，EVA)、聚烯烃(polyolefin，PO)、聚乙烯醇缩丁醛(polyvinylbutyral，PVB)等、或UV固化胶材(UV curable encapsulant)、或上述者的组合。
接着参考图4与图8。将一盖板140覆于该多片太阳能板100(100’)上，并如图8所示于该多片太阳能板100(100’)与该盖板140之间设置第二封装材145。盖板140例如是不可挠的玻璃板且盖板140的尺寸应等于或略小于背板130的尺寸。该第二封装材145的材质类似于第一封装材135，两者的材质可相同或相异。以上述的状态，利用真空层压(laminate)法将盖板140、第二封装材145、太阳能板100(100’)、第一封装材135与背板130贴合固着。由于盖板140与背板130的尺寸足够大以致于两者的长度能延伸超过末端两太阳能板100(100’)且其宽度略大于一太阳能板100(100’)的长度，因此在盖板140与背板130延伸突出太阳能板100(100’)的外环区域(如后续将述之外框的形状)中及/或盖板140与背板130之间无太阳能板100/100’的间隙区域中，可在盖板140与背板130之间设置第一防水胶材165如热塑性聚烯烃(thermalplasticpolyolefin，TPO)或丁基胶(butyl rubber)接触太阳能板100(100’)的侧边，以保护太阳能板100’(100)以及其配线不受水气、机械力的影响。亦即，太阳能板100/100’四面八方皆可受到封装材(第一封装材135与第二封装材145)与第一防水胶材165的包覆，避免太阳能板100或100’中的光电换转层1受到水气影响而质变退化。
然后，如图5所示并参考图7与图8，在背板130的背面安装至少一接线盒150。接线盒150可设置在背板130的背侧中央区域中即其中一片太阳能板100/100’的背侧，亦可设置在背板130的背侧其它区域如图7所示的最末端之太阳能板100/100’的背侧。或者，接线盒150可设置在背板130的背侧任何区域。如图7所示，使太阳能板100(100’)自背板130之至少一孔洞(未图示)穿出的背面正极配线122b(122b’)与接线盒150的正极电连接，使太阳能板100(100’)自背板130的孔洞(未图示)穿出的背面负极配线112a(112a’)与接线盒150的负极电连接，并利用配线如每一片太阳能板100(100’)的背面正极与负极配线或额外的配线并联连接所有的太阳能板100及100’。最后，取决于盖板140与背板130的尺寸(在图5的例示中盖板140的尺寸略小于背板130的尺寸，但在图7的例示中盖板140的尺寸等于背板130的尺寸)，如图7与图8所示在盖板140或盖板140与背板130的外围设置外框160并在外框160与盖板140或盖板140与背板130之间设置具有防水性的第三封装材161。以上步骤大致上完成本发明的可挠式太阳能板模块1000的制造。第三封装材161例如是压克力胶带。接线盒150更可包括一对外的正极配线与一对外的负极配线(未图示)以使太阳能板模块1000对外电连接。在背板130的背面处可选择性地设置另一层防水胶材如热塑性聚烯烃等，以保护接线盒150与背板130背面的配线不受水气、机械力的影响。
应了解，各个图示中的强调重点不同，因此各个部件并未依比例绘制。例如，图8强调在使用可挠式背板130的情况下第一封装材135、第二封装材145及第一防水胶材165的分布，是以，太阳能板100/100’缩小绘制而封装材、胶材、太阳能板之间的间隙及背板与盖板之间的距离差异夸大绘制。由于真空层压时的真空吸附作用，背板130如为软质背板在无太阳能板100/100’的区域处(如被边框夹持的外环区域处及太阳能板之间的间隙区域处)会较靠近盖板140但在有太阳能板100/100’的区域处会较远离盖板140。然而，背板130亦可以是硬质背板(图8未示)，在此情况中背板130与盖板140之间的距离会大致上维持固定。
现参考图6，其显示根据本发明另一实施例的太阳能板模块1100。太阳能板模块1100的结构类似于太阳能板模块1000的结构，两者的差异在于背面正极配线122b(122b’)与背面负极配线112a(112a’)的配置以及背板130背面的正极配线与负极配线。在太阳能板模块1000中，背面正极配线122b(122b’)与背面负极配线112a(112a’)皆由太阳能板100(100’)的长边的同一端拉出；但太阳能板模块1100中，背面正极配线122b(122b’)与背面负极配线112a(112a’)分别由太阳能板100(100’)的长边的相对两端拉出。在太阳能板模块1100中，背板130的背面设有横跨所有太阳能板100(100’)的正极配线125与负极配线115，正极配线125与接线盒150的正极以及所有太阳能板100(100’)的背面正极配线122b(122b’)连接，负极配线115与接线盒的负极以及所有太阳能100(100’)的背面负极配线112a(112a’)连接。
图1-5的实施例皆以太阳能板100与太阳能板100’交错配置为例说明，但应了解，本发明的毗邻电极为相同电性的电极的概念可应用至其它情境如图6所示的情境或者所有太阳能板皆为相同位向之太阳能板100的情境。又，图1-6的实施例皆以太阳能板并联连接的模块为例说明，但应了解，本发明的毗邻电极为相同电性的电极的概念可应用至太阳能板串联连接的模块的情境。本发明之相邻的两太阳能板的毗邻电极为电性相同的电极，故可将相邻的两太阳能板之间的电极距离缩短至2mm或更短，以在相同的面积下配置较多的太阳能板，从而提高单位面积产出的电力。图7的太阳能板的细部结构及图8的封装材与胶材配置可适用于图1-5的实施例及图1-6的实施例，除此之外，图8的封装材与胶材配置亦适用于仅具有单片太阳能板100或100’的太阳能板模块。
上述实施例仅是为了方便说明而举例，虽遭所属技术领域的技术人员任意进行修改，均不会脱离如权利要求书中所欲保护的范围。

Claims (20)

1.一种太阳能板模块，其特征在于，包括：
彼此相邻设置的多片太阳能板，每一片该太阳能板的一侧设有一正极配线而相对的另一侧设有一负极配线，
其中相邻的两片该太阳能板的毗邻电极配线皆为正极配线或皆为负极配线。
2.如权利要求1所述的太阳能板模块，其特征在于，每一片该太阳能板包括一背玻璃以及设置于其上之图案化的光电转换层。
3.如权利要求1所述的太阳能板模块，其特征在于，每一片该太阳能板的该正极配线与该负极配线位于该太阳能板的正面，且反折至每一片该太阳能板的背面成为背面正极配线与背面负极配线。
4.如权利要求3所述的太阳能板模块，其特征在于，包括：
一盖板，位于该多片太阳能板的上方；及
一背板，位于该多片太阳能板的下方，
其中该盖板、该多片太阳能板与该背板层压贴合。
5.如权利要求4所述的太阳能板模块，其特征在于，包括：
第一封装材，位于该多片太阳能板与该背板之间；及
第二封装材，位于该多片太阳能板与该盖板之间，
其中该第一封装材或该第二封装材为乙烯醋酸乙烯酯、聚烯烃、聚乙烯醇缩丁醛或UV固化胶材或上述材料的组合。
6.如权利要求4所述的太阳能板模块，其特征在于，该背板与该盖板的尺寸使得两者的长度延伸超过该多片太阳能板的最末端的太阳能板且两者的宽度略大于该每一片太阳能板的长度，该太阳能板模块更包括：
第一防水胶材，位于该盖板与该背板延伸突出该多个太阳能板的外环区域中，位于该盖板与该背板之间接触该多片太阳能板的侧边。
7.如权利要求1所述的太阳能板模块，其特征在于，相邻的该两片太阳能板的该毗邻电极配线之间的距离不大于5mm。
8.如权利要求1所述的太阳能板模块，其特征在于，相邻的该两片太阳能板的该毗邻电极配线之间的距离不小于1mm。
9.一种太阳能板模块的制造方法，其特征在于，包括：
提供多片太阳能板；
于每一片该太阳能板的正面的相对两侧形成正面正极配线与正面负极配线并将该正面正极配线与该正面负极配线反折至每一片该太阳能板的背面成为背面正极配线与背面负极配线；
将该多片太阳能板平放至一背板与一盖板之间并层压贴合该多片太阳能板、该背板与该盖板，其中相邻的两片该太阳能板的毗邻正面电极配线皆为正面正极配线或皆为正面负极配线。
10.如权利要求9所述的太阳能板模块的制造方法，其特征在于，该背板具有多个孔洞，该制造方法更包括：
设置一接线盒对应至该多片太阳能板并使每一片该太阳能板的该背面正极配线与该背面负极配线自该多个孔洞的至少一者穿出而与该接线盒电连接。
11.如权利要求9所述的太阳能板模块的制造方法，其特征在于，包括：
于该多片太阳能板与该背板之间设置第一封装材；及
于该多片太阳能板与该盖板之间设置第二封装材，
其中该第一封装材与该第二封装材为乙烯醋酸乙烯酯、聚烯烃、聚乙烯醇缩丁醛或UV固化胶材或上述材料的组合。
12.如权利要求9所述的太阳能板模块的制造方法，其特征在于，相邻的两片该太阳能板的该毗邻正面电极配线之间的距离不大于5mm。
13.如权利要求9所述的太阳能板模块的制造方法，其特征在于，相邻的两片该太阳能板的该毗邻正面电极配线之间的距离不小于1mm。
14.如权利要求9所述的太阳能板模块的制造方法，其特征在于，包括：
于该盖板与该背板延伸突出该多个太阳能板的外环区域中设置第一防水胶材，该第一防水胶材位于该盖板与该背板之间接触该多片太阳能板的侧边。
15.如权利要求14所述的太阳能板模块的制造方法，其特征在于，包括：
于该盖板与该背板的外缘设置外框并于该外框与该盖板之间、该外框与该背板之间及该外框与该第一防水胶材之间设置第三封装材。
16.一种太阳能板模块，其特征在于，包括：
一盖板；
一背板；
至少一片太阳能板，位于该盖板与该背板之间，该盖板与该背板延伸突出该至少一片太阳能板；
第一封装材，位于该至少一片太阳能板与该背板之间；
第二封装材，位于该至少一片太阳能板与该盖板之间；及
第一防水胶材，位于该盖板与该背板延伸突出该至少一片太阳能板的外环区域中，位于该盖板与该背板之间接触该至少一片太阳能板的侧边。
17.如权利要求16所述的太阳能板模块，其特征在于，包括：
一外框，位该盖板与该背板的外缘；及
第三封装材，位于该外框与该盖板之间、该外框与该背板之间及该外框与该第一防水胶材之间。
18.如权利要求16所述的太阳能板模块，其特征在于，该第一封装材或该第二封装材为乙烯醋酸乙烯酯、聚烯烃、聚乙烯醇缩丁醛或UV固化胶材或上述材料的组合。
19.如权利要求16所述的太阳能板模块，其特征在于，该第一防水胶材为热塑性聚烯烃或丁基胶。
20.如权利要求17所述的太阳能板模块，其特征在于，该第三封装材为压克力胶带。
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