CN108352415A - 在太阳能电池上形成抗应力增强的前金属接触件 - Google Patents

在太阳能电池上形成抗应力增强的前金属接触件 Download PDF

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CN108352415A
CN108352415A CN201680061819.6A CN201680061819A CN108352415A CN 108352415 A CN108352415 A CN 108352415A CN 201680061819 A CN201680061819 A CN 201680061819A CN 108352415 A CN108352415 A CN 108352415A
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杨琳琳
L·蓝
C·弗朗斯
何甘
E·李
J·科尔巴乔
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Zishi Energy Co.,Ltd.
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Abstract

提供光伏(PV)电池(200)的系统和方法，该PV电池(200)具有缓冲层(260,411,412)以缓解前金属接触件(220)和薄膜PV层(230)之间的应力影响。该缓冲层由非导电材料制成并且具有多个通孔(420)，所述多个通孔(420)填充有导电材料(430)以提供汇流条与PV层之间的电连续性。该缓冲层可以由柔性材料制成，优选具有与基板相匹配的刚性的柔性材料。因此，该缓冲层可以有效地保护PV层免受由于与前金属接触件的实体接触而造成的物理损伤。

Description

在太阳能电池上形成抗应力增强的前金属接触件
相关申请的交叉引用
本申请要求2015年10月20日提交的美国申请No.14/918,043的优先权。该在先申请的公开内容通过引用整体并入本文。
技术领域
本公开主要涉及光伏装置领域，并且更具体地涉及光伏装置上的接触件金属化领域。
背景技术
太阳能电池或光伏(PV)电池是通过光伏效应将光能直接转换成电的电气装置。太阳能电池产生的能量为化石燃料提供了可再生、环保和易于获得的替代品。通常，太阳能电池利用p-n结形式的半导体材料进行能量转换。将金属层铺设在半导体材料的表面，以例如通过与铺设在提取电极顶部的金属线(或在此称为“前金属接触件”)接触而将产生的电压和电流传导至用于电力存储或运输的外部电路。在典型的配置中，PV电池的前金属层包括散布在PV电池的前表面上的多个分立电极和连接到所有分立电极用于从其收集电流的引出电极。太阳能电池阵列可以互连并组装成太阳能模块或太阳能面板以聚集由各个太阳能电池产生的电流。
随着便携式电子装置的日益普及，对柔性太阳能模块的需求已经急剧增加，因为它们可以容易地集成到电子装置中。由于这些电子装置施加的尺寸和重量限制，提供高效率和高柔性的小体积太阳能模块是优选的。已经证实，在已经开发的大量PV材料中单晶太阳能电池具有出色的转换效率。
不幸的是，单晶材料本质上是脆性的并且倾向于在应力下断裂或者产生缺陷。传统上，设置在PV电池顶部的前金属接触件通常由比晶体PV层刚性更强的金属条(或金属线或带)制成。即使非常低的应力也会在晶体层上引起微裂纹和其他缺陷。不期望的应力可能源于层叠损伤、材料失配(例如，热膨胀系数(CTE)失配)、外力、弯曲等。PV层中的缺陷可能导致热点并且最终导致PV电池效率降低。例如，具有柔性基板的太阳能电池例如在太阳能模块的制造、组装或安装过程中受到外部压力时容易弯曲或变形。当变形时，晶体PV层受到来自金属条的应力影响并且容易受到物理损伤。
图1示出根据现有技术的PV装置100沿着电池的引出电极的截面。PV装置100包括封装层110、前金属接触件120、前金属层125、PV层130、后金属层140和基板(或载体层)150。封装层110是PV装置100的顶部表面并且用于当PV电池在使用时接收光束。前金属层125、PV层、后金属层140和基板150总称为PV电池。前金属层125对应于PV电池的引出电极(或称为“汇流条”)。例如，前金属层125通过电镀形成。前金属接触件设置在前金属层125的顶部并且由主要由Cu构成的金属条制成。
根据传统的前接触件金属化方法，前金属接触件与PV电池直接接触。PV层被制造成晶体薄膜结构并且比金属接触件刚性小。PV电池和前金属接触件之间的材料刚性的失配倾向于导致PV层130中的缺陷或其他损伤，尤其是在引出电极下面的区域，这是因为其尺寸大于分立电极。
发明内容
因此，提供能够保护光伏层免受由于通过前接触件金属化施加的应力而造成的物理损伤的晶体太阳能模块将是有利的。
本公开的实施例利用设置在前金属接触件和光伏(PV)电池之间的缓冲层缓解来自施加在PV电池上的金属接触件的应力影响。在一些实施例中，前金属接触件被布置在PV电池的引出电极的顶部上，其为PV电池的前接触栅格的一部分。缓冲层由非导电材料制成并且具有多个通孔，所述多个通孔填充有导电材料以提供前金属接触件和引出电极之间的电连续性。在一些实施例中，太阳能电池具有薄膜单晶PV层和柔性基板。因此，缓冲层由柔性材料制成，优选具有与基板匹配的刚性或硬度。
尽管在PV层和金属接触件之间刚性失配，但是将前金属接触件与缓冲层结合可以有效地减少来自施加在下面的晶体PV电池上的金属接触件的应力影响。因此，PV层上的物理损伤的风险有利地且显著地降低，这有助于提高太阳能装置的柔性和可靠性。
根据一个实施例，一种光伏组件包括：PV电池，其配置为将光能转换为电能；前接触层，其设置在所述PV电池的顶部上；缓冲层，其设置在所述前接触层和所述PV电池之间；和基板。所述前接触层配置为将源自所述PV电池的PV层的电流传导到外部电路。所述缓冲层比所述前接触层刚性小。
以上是概述，因此必要时包含细节的简化、概括和省略；因此，本领域技术人员将认识到，该概述仅是说明性的，并不意图以任何方式进行限制。如由权利要求单独限定的本发明的其它方面、发明特征和优点将在以下阐述的非限制性详细描述中变得显而易见。
附图说明
结合附图阅读以下详细描述，将会更好地理解本发明的实施例，在附图中相同的附图标记表示相似的元件，并且其中：
图1示出根据现有技术的PV装置的沿着该PV装置中的PV电池的引出电极的截面；
图2A示出根据本公开的实施例的示例性PV装置的沿着该PV装置中的PV电池的引出电极的截面；
图2B是描绘根据本公开的实施例的在包括缓冲层的PV电池上形成前金属接触件的示例性过程的流程图；
图3示出根据本公开的实施例的包括设置在前接触层和PV电池之间的缓冲层的示例性PV模块的俯视图；
图4A-4D示出根据本公开的实施例的将缓冲层集成在前金属接触件和PV电池之间的示例性过程；
图5A-5C示出根据本公开的实施例的将缓冲层集成在前金属接触件和PV电池之间的另一个示例性过程。
具体实施方式
现在将详细参考本发明的优选实施例，其示例在附图中示出。尽管将结合优选实施例描述本发明，但应理解的是，它们并不意图将本发明限制于这些实施例。相反，本发明旨在覆盖可以包括在由所附权利要求限定的本发明的精神和范围内的替换、修改和等同物。此外，在对本发明的实施例的以下详细描述中，阐述了许多具体细节以便提供对本发明的透彻理解。然而，本领域普通技术人员将认识到，可以在没有这些具体细节的情况下实践本发明。在其他情况下，没有详细描述公知的方法、过程、部件和电路，以免不必要地模糊本发明的实施例的各方面。虽然为了清楚起见可以将方法描绘为一系列编号的步骤，但编号不一定指示步骤的顺序。应该理解的是，一些步骤可以被跳过，并行执行，或者不需要保持严格的系列顺序地执行。示出本发明实施例的附图是半示意性的，并且没有按比例绘制，特别地，一些尺寸是为了清晰呈现并且在附图中被夸大示出。类似地，虽然附图中的视图为了便于描述通常示出类似的方位，但附图中的这种描述大部分是任意的。通常，本发明可以以任何方位操作。
在太阳能电池上形成抗应力增强的前金属接触件
总体而言，本公开的实施例提供在前金属接触件和光伏(PV)电池之间设置有缓冲层的太阳能装置，以保护PV电池免受来自前金属接触件的应力影响。缓冲层有效地补偿了前金属接触件与PV层之间的材料刚性失配，并增强了PV电池的整体弹性。结果，PV层上的物理损伤的风险可以被有利地且显著地降低。
这里，术语“太阳能面板”和“PV面板”可互换使用；术语“太阳能电池”和“PV电池”可互换使用。这里，术语“前”、“后”、“顶部”和“下面”用于参考PV电池被安装在用于能量转换的位置时的预期取向。例如，PV电池的前侧旨在面对日光或应用光源。
本公开不限于太阳能电池的任何特定配置、结构、尺寸、几何形状、材料组成、制造工艺或应用。在一些实施例中，太阳能电池的PV层可以包括基于GaAs、铜铟镓硒(CIGS)、碲化镉(CdTe)、无定形硅、无定形微晶串联、薄膜多晶硅等的一个或多个薄膜子层。太阳能电池的基板可以是柔性的或刚性的并且由聚合物、硅、玻璃等制成。
图2A示出根据本公开的实施例的示例性PV装置200沿着PV电池的引出电极的截面。PV装置200包括作为最前面的表面的封装层210、前金属接触件220以及包括前金属层225、PV层230、后金属层240和基板(或载体层)250的PV电池。前金属层225和后金属层240用作PV电池的相对电极。
在一些实施例中，PV电池阵列串联电耦合以实现更高的发电量，其中各PV电池的前金属层例如与另一个PV电池的后金属层电连接。
应该认识到，图1和图2中呈现的每个单独的层都是可以根据具体实施例包括多个子层。前金属层225对应于PV电池的引出电极。前金属接触件220由例如主要由Cu构成并且厚度约为50μm的金属条制成。PV层230包括单层或薄膜叠层，其总厚度通常远小于前金属接触件220，例如小于10μm。
在一些实施例中，PV层包括单晶薄膜材料并且刚性比前金属层小得多。根据本公开，由软的且柔性的材料制成的缓冲层260设置在前金属接触件220和PV电池之间，并且更具体地，设置在前金属接触件220和前金属层225之间，以补偿它们在硬度(或刚性)上的差异。在太阳能电池组件制造、组装、安装等过程中，外力可能导致太阳能电池弯曲或变形。弯曲的前金属接触件倾向于对PV层施加显著的应力影响。另外，例如，在封装期间，应力可能由太阳能电池、导电粘合剂、带和封装材料之间的材料堆叠的CTE失配而引起。根据本公开，中间缓冲层260可以至少部分地吸收并且因此减轻通过前金属接触件220施加在PV层230上的机械应力。因此，可以有利地且有效地保护PV层230免受由这种机械应力诱导的物理损伤。结果，缓冲效应可以有利地改善PV电池的整体柔性、生产率和质量。
本公开不限于用作前金属接触件和PV电池之间的缓冲层的任何特定材料构成。应该理解的是，缓冲材料和厚度是基于PV层相对于前金属接触件的硬度来选择的。在一些实施例中，缓冲层260由非导电材料制成并且具有多个通孔261，这些通孔填充有导电材料以提供前金属接触件220和PV层230之间的电连续性。在一些实施例中，缓冲层是由聚合物材料制成并且可以具有与柔性基板层相同或相似的材料构成。然而，在一些其他实施例中，缓冲层260由导电材料制成。
本公开不限于在PV装置中集成缓冲层的任何特定方法或工艺。图2B是描绘根据本公开的实施例的形成包括PV电池上的缓冲层的前金属接触件的示例性工艺的流程图。在该示例中，前金属接触件铺设在提取电极的顶部上，以聚集来自分布在太阳能电池上的多个分立电极的电流。因此，聚集的电流通过前金属接触件传导到外部电路。
在271处，将由非导电材料制成的缓冲层层叠在前金属接触件的一侧上。然而，在不脱离本公开的范围的情况下，也可以使用本领域中公知的各种其他合适的机构将缓冲层施加并结合到前金属接触件上。
在272处，在缓冲层上的选定位置形成多个通孔以部分地暴露前金属接触件的后面。通孔可以以公知的任何合适的方式并且根据缓冲层和PV电池的其它相关部件的性质形成，例如机械钻孔、激光烧蚀、蚀刻等。通孔可以制成各种形状和大小。在一些其他实施例中，在将缓冲层附接到前金属接触件之前，在缓冲层上产生通孔。
在273处，将导电材料分配在通孔中以形成与前金属接触件的电接触。例如，导电材料是墨水或糊状的形式，并且主要由Ag和聚合物材料的混合物构成。然而，本公开不受用于填充通孔的导电材料的材料构成的限制。在274处，通过将包括前金属接触件和具有通孔的缓冲层的复合接触层附接到PV电池的表面而与PV装置的其他层集成。这样，由于缓冲层不导电，通孔中的导电填充物提供了PV电池与前金属接触件之间的电连续性。
图3示出根据本公开的实施例的包括设置在前接触层311和321与PV电池310和320之间的缓冲层(未明确示出)的示例性PV模块300的俯视图。在基本形式中，PV模块300包括串联电耦合的两个PV电池310和320。前接触层311和321(例如，由金属丝或带制成)设置在PV电池310和320的引出电极(或汇流条)的顶部上。如下面更详细描述的，每个PV电池310或320包括设置在PV层314或324的相对侧上的前金属层和后金属层。后接触层设置在不导电的柔性基板上，该柔性基板具有填充有导电材料的通孔(在此称为“后通孔”)。两个PV电池310和320部分重叠，使得铺设在底部PV电池320上的前接触件321与顶部PV电池310的后通孔中的导电填充物直接接触。以这种方式，底部PV电池320的汇流条321电连接到顶部PV电池310的后接触层。
本公开不受每个PV电池的前电极(或前接触件)的材料构成、配置和布置的限制。在该示例中，每个PV电池310或320的前金属层被配置成梳状，并且包括两个部分：分布在PV层(例如，314)的顶部上的多个平行的指状电极(例如，312))以及连接到所有指状电极的汇流条。缓冲层仅设置在具有更大面积的汇流条的顶部上，因此比指状电极更可能对PV层(例如，314)施加应力。然而，可以理解，在不脱离本公开的范围的情况下，可以在前金属层的任何部分下施加缓冲层。缓冲层311上的通孔与指状电极对准，但是本公开不限于此。在一个实施例中，每个PV层314或324包括由掺杂的GaAs基薄膜形成的一个或多个p-n结。可以通过本领域中公知的各种合适的薄膜工艺在基板上形成PV层，例如分子束外延、金属有机化学气相沉积、物理沉积、电镀等。
图4A-4D示出根据本公开的实施例的将缓冲层集成在前金属接触件和PV电池之间的示例性工艺。例如，该PV电池具有与参照图3描述的类似的前电极配置。图4A示出在前金属接触件和缓冲层层叠之后的复合前金属接触件410的顶视图和截面。前金属接触件413由例如具有50mm厚度和1mm宽度的Cu带制成。缓冲层是柔性的，并且包括压敏粘合剂(PSA)层412和聚对苯二甲酸乙二醇酯(PET)层411的组合。例如，缓冲层的厚度约为几个或几十个微米。
图4B示出贯通缓冲层411和412钻出一排通孔420，直到暴露出Cu层413。图4C示出导电材料430例如通过沉积或注入而分配在通孔中。例如，通孔的直径为400mm，这足以形成有效的电接触，同时不会导致导电填充物从复合前接触件410中拖出。在一些实施例中，导电填充材料是粘合剂。
图4D示出复合前接触件410与包括指状电极414、PV层415、后金属层417和基板416的PV电池集成。例如，基板由多层制成并且厚度约为100μm；而PV电池的总厚度约为110μm。指状电极和汇流条可以通过电镀或本领域公知的任何其他合适的技术形成在PV层表面上。在该示例中，汇流条的取向垂直于指状电极。前金属接触件的填充通孔420与指状电极440对准并直接接触。
在该示例中，缓冲层由与基板相同的材料制成。然而，本公开不限于此。在将前金属接触件放置在PV电池的表面上之后，PV电池经受热固化程序以实现导电填充物和前金属层之间的高结合强度。之后，为了防止湿气和机械损伤、绝缘、抗反射等，将封装层施加在PV电池的顶部上。
可以理解的是，如图4A-4D中所示的PV装置的每个组成部分都可以具有各种合适的材料构成并且可以以本领域公知的任何合适的方式制造或者与PV电池集成。而且，根据特定实施例，集成各个构成层的顺序也不同。
图5A-5C示出根据本公开的实施例的将缓冲层集成在前金属接触件和PV电池之间的另一个示例性工艺。图5A-5C中的PV电池具有与图4A-4C中所示的示例基本相同的配置。缓冲层由不导电的柔性聚合物制成，但具有与基板不同的材料构成。
在该示例中，前金属接触件513、缓冲层512和防粘衬里511的组合可作为现货获得，例如与非导电层(例如，聚酰亚胺)和防粘片结合的Cu带。例如根据汇流条的设计，首先将具有非导电层512和防粘衬里的Cu带制备成期望的尺寸。图5A示出在缓冲层512和防粘衬里511中产生通孔520。图5B示出去除防粘衬里511，并且用导电材料530填充通孔520。因此，该示例中的缓冲层没有粘合剂层，这与图4A-4D中所示的例子不同。
图5C示出前金属接触件与PV电池的其他部件附接，其中通孔覆盖指状电极。结果，该PV装置沿汇流条的截面从前到后包括前金属接触件513、缓冲层512、前金属层514、PV层515、后金属层518和复合基板层。例如，基板层516包括PSA层517和PET层516。可选地，复合前接触件的纵向过量被折叠并包裹PV电池的边缘，如底部两层512和513所示。然后将封装层(未示出)铺设在PV电池的顶部上。
虽然本文已经公开了某些优选实施例和方法，但从前述公开内容显而易见的是，本领域技术人员可以在不脱离本发明的精神和范围的情况下对这些实施例和方法进行变化和修改。意图是，本发明仅限于所附权利要求和适用法律的规则和原则所要求的范围。

Claims (20)

1.一种光伏组件，包括：
光伏电池，其配置为将光能转换为电能，其中所述光伏电池包括：前金属层、光伏层和设置在所述光伏层下面的基板层；
前接触件，其设置在所述前金属层的顶部上并配置为将源自所述光伏电池的电流传导到外部电路；和
缓冲层，其设置在所述前接触件和所述光伏电池之间，其中所述缓冲层的刚性小于所述前接触件。
2.根据权利要求1所述的光伏组件，其中所述缓冲层包括非导电材料并且包括填充有导电材料的多个通孔，其中所述导电材料配置为在所述前导电接触件和所述光伏层之间传导电流。
3.根据权利要求1所述的光伏组件，其中所述缓冲层的所述刚性与所述基板层的刚性匹配，并且其中所述缓冲层用于保护所述光伏电池免受由与所述前接触件的实体接触引起的物理损伤。
4.根据权利要求1所述的光伏组件，其中所述基板层和所述缓冲层包括相同的柔性聚合物材料。
5.根据权利要求4所述的光伏组件，其中所述相同的柔性聚合物材料包括与压敏粘合剂(PSA)结合的聚对苯二甲酸乙二醇酯(PEA)。
6.根据权利要求1所述的光伏组件，其中所述光伏层的厚度小于10μm并且包括GaAs层。
7.根据权利要求1所述的光伏组件，其中所述前接触件包括Cu并且具有小于50μm的厚度。
8.根据权利要求1所述的光伏组件，其中所述前接触件设置在所述前金属层的顶部上，所述前金属层对应于所述光伏电池中的引出电极。
9.根据权利要求1所述的光伏组件，还包括后金属层，所述后金属层设置在所述光伏层下面并且配置为将所述光伏层与所述光伏组件中的另一光伏层互连，并且其中进一步地所述后金属层设置在所述基板层的顶部上。
10.一种光伏模块，包括：
基板；
光伏电池阵列，其配置为将光能转换成电能，其中所述光伏电池阵列的各光伏电池包括：光伏层；互连栅格，其设置在所述光伏层的顶部上并且配置为将源自所述光伏层的电流传导到外部电路，其中所述互连栅格包括分立指状电极和耦合到所述分立指状电极的引出电极；
前金属接触件，其设置在所述互连栅格的顶部上；和
缓冲层，其设置在所述前接触件和所述各光伏电池之间，以保护所述各光伏电池免受由于与所述前金属接触件的实体接触而造成的物理损伤。
11.根据权利要求10所述的光伏模块，其中所述各光伏电池还包括后金属层，所述后金属层设置在所述基板和所述光伏层之间并且配置为与所述阵列中的另一个光伏电池的互连栅格互连，并且还包括
封装层，其设置在所述前金属接触件的顶部上。
12.根据权利要求10所述的光伏模块，其中所述缓冲层包括比所述引出电极刚性小的柔性聚合物材料。
13.根据权利要求12所述的光伏模块，其中所述缓冲层承载填充有导电材料的多个通孔。
14.根据权利要求10所述的光伏模块，其中所述基板包括聚合物材料；所述前金属接触件包括Cu；并且所述光电层包括薄膜GaAs。
15.一种制造光伏模块的方法，所述方法包括：
将前导电层与缓冲层附接以产生复合前层，其中所述缓冲层比所述前导电层刚性小；和
将所述复合前层与配置为将光能转换成电能的光伏电池附接，其中所述缓冲层设置在所述前导电层和所述光伏电池之间并且配置为保护所述光伏电池免受由于与所述前导电层实体接触而导致的物理损伤。
16.根据权利要求15所述的方法，其中所述缓冲层包括非导电材料层，并且还包括：
贯穿所述缓冲层钻出多个通孔；
在所述多个通孔中分配导电材料以在所述光伏电池的前电极和所述前导电层之间形成电接触。
17.根据权利要求15所述的方法，其中所述将所述前导电层与所述缓冲层附接包括将所述前导电层与所述缓冲层层叠。
18.根据权利要求15所述的方法，还包括将后电极和基板层与所述光伏电池的光伏层附接，其中所述后电极设置在所述基板层和所述光伏层之间。
19.根据权利要求18所述的方法，其中：所述前导电层包含Cu；所述基板层包含聚合物材料；所述缓冲层包含聚合物材料；并且所述光伏层包括薄膜GaAs。
20.根据权利要求15所述的方法，其中所述将所述前导电层与所述缓冲层附接还包括剥离与所述缓冲层结合的防粘衬里。
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