CN111916515A - 一种超薄柔性太阳电池组件 - Google Patents
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Abstract
Description
本申请要求于2019年5月8日提交中国国家知识产权局、申请号为201910381102.5、发明名称为“一种超薄柔性太阳电池组件”的中国专利申请的优先权,其全部内容通过引用结合在本申请中。
技术领域
本申请涉及光伏技术领域,尤其涉及一种超薄柔性太阳电池组件。
背景技术
在光伏发电应用领域中,市场大部分采用晶体硅太阳电池组件。一般情况下,晶体硅太阳电池组件的结构由前板钢化玻璃、EVA或POE、晶体硅电池、PET背板材料或背板钢化玻璃等组成。这种晶体硅电池组件往往质量较大,产品具有刚性,柔韧性差。近年来,随着光伏发电成本的不断下降,终端应用领域也不断扩展。在一些外部环境比较复杂的条件下,比如光伏建筑一体化(BIPV)领域,当建筑物表面不规则、不平整时,以钢化玻璃作为封装材料的普通晶体硅光伏组件便出现了应用的局限性。
另外,在一些对光伏组件的重量和尺寸要求极其苛刻的情况下,普通晶体硅光伏组件更是一筹莫展。比如,在当前快速发展的太阳能无人机领域,普通晶体硅由于效率低、质量大、柔性差等缺点,难以达到太阳能无人机的各项技术要求。在光伏行业中,也有具备柔性特点的铜铟镓硒(CIGS)、砷化镓(GaAs)等薄膜太阳电池及其组件,但是CIGS薄膜太阳电池由于光电转换效率低发电量少、而GaAS薄膜太阳电池由于异常昂贵的制造成本使得它们都无法获得真正市场化的应用。
发明内容
为了解决上述技术问题,本申请提供了一种可量产的超薄柔性太阳电池组件,能够实现较高的光电转换效率,并且质量轻,厚度薄、柔韧性好。
本申请实施例提供的具体技术方案如下:
本申请提供的超薄柔性太阳电池组件,(1)能够解决光电转换效率低的问题,采用的柔性异质结太阳电池具有结构上的高度对称性,具备双面发电、温度系数低、无光致衰减、无电势诱导衰减等特点,其实际户外发电量比普通晶体硅电池高出20%以上。
(2)解决质量较大的问题,从而实现轻质化,本申请采用的柔性异质结太阳电池由于采用了非晶硅薄膜沉积技术来制作PN结,可使用更薄的单晶硅片,获得的电池重量不到普通电池的五分之一,制作的超轻异质结组件的功率重量比则高达0.35W/g以上。
(3)解决厚度较大的问题,实现轻薄,本申请采用的柔性异质结太阳电池的厚度可以减薄至20μm左右,并采用厚度为25μm左右的透明聚合物材料和胶膜来封装组件,使得太阳组件产品的厚度降至150μm。
(4)解决柔性较差的问题,提高产品的柔韧性,本申请采用的柔性异质结太阳电池本身具有非常好的柔韧性,再配合超薄柔性的聚合物材料和胶膜,封装成的组件同样具有很好的柔韧性,可满足不同的弯曲面设计与应用。
本申请的其它特征和优点将在随后的说明书中阐述,并且,部分地从说明书中变得显而易见,或者通过实施本申请而了解。本申请的目的和其他优点可通过在说明书、权利要求书以及附图中所特别指出的结构来实现和获得。
附图说明
附图用来提供对本申请技术方案的进一步理解,并且构成说明书的一部分,与本申请的实施例一起用于解释本申请的技术方案,并不构成对本申请技术方案的限制。
图1和图2为本申请一个实施例的超薄柔性太阳电池组件的结构示意图;
图3为本申请一个实施例的柔性异质结太阳电池的结构示意图;
图4为本申请一个实施例的柔性异质结太阳电池与其他结构的硅太阳电池的反射率对比曲线。
具体实施方式
为使本申请实施例的目的、技术方案和优点更加清楚,下面将结合本申请实施例的附图,对本申请实施例的技术方案进行清楚、完整地描述。显然,所描述的实施例是本申请的一部分实施例,而不是全部的实施例。基于所描述的本申请的实施例,本领域普通技术人员在无需创造性劳动的前提下所获得的所有其他实施例,都属于本申请保护的范围。
随着光伏发电应用领域的不断扩大,为了克服传统以钢化玻璃封装组件的局限性,本申请提供一种超薄柔性太阳电池组件,这种太阳电池组件具有高效、轻、薄、柔的特性,可广泛应用于各种复杂环境,包括BIPV建筑一体化、太阳能无人机、高空飞行器、电动汽车、可穿戴设备等应用领域,也可大规模应用于光伏电站发电。
本申请提供一种超薄柔性太阳电池组件。图1和图2为该种超薄柔性太阳电池组件的结构示意图,如图1或图2所示,超薄柔性太阳电池组件包括依次层叠的第一透明氟材料薄膜层11、第一热熔胶膜层12、柔性异质结太阳电池13、第二热熔胶膜层14、第二透明氟材料薄膜层15,其中,所述柔性异质结太阳电池13的厚度为
值得一提的是,本申请中所述柔性异质结太阳电池由多个柔性异质结太阳电池片串联和/或并联而成,具体的柔性异质结太阳电池的连接方式,可以包括以下两种。
第一种可能的方式中,如图1所示,所述多个柔性异质结太阳电池片之间通过镀锡铜带串联和/或并联焊接而成,所述镀锡铜带的厚度为这种连接方式组成的所述超薄柔性太阳电池组件的厚度为所述超薄柔性太阳电池组件的功率重量至少大于0.30W/g。
第二种可能的方式中,如图2所示,所述多个柔性异质结太阳电池片之间通过导电胶串联和/或并联而成,这种连接方式组成对的所述超薄柔性太阳电池组件的厚度为所述超薄柔性太阳电池组件的功率重量至少大于0.35W/g。
需要说明的是,本申请中实施例中,所述第一透明氟材料薄膜层11和所述第二透明氟材料薄膜层15的材料为ECTFE材料或ETFE材料、UBSF512材料。所述第一透明氟材料薄膜层和所述第二透明氟材料薄膜层的厚度为
图3为超薄柔性太阳电池组件中的柔性异质结太阳电池的结构示意图,如图3所示,该柔性异质结太阳电池包括依次层叠的透明导电层5、n型掺杂层3、第一本征钝化层2、单晶硅片1、第二本征钝化层8、p型掺杂层4和半透半反功能层6。
所述单晶硅片1为n型单晶硅片,厚度<130μm,电阻率0.1-10Ω·cm。本申请的一个实施例中,所述单晶硅片的厚度为60-90nm。
所述第一本征钝化层2为非晶硅基本征钝化层,可以是a-Si:H(i)、a-SiOx:H(i)和a-SiC:H(i)薄膜的单层或者多层结构,厚度<10nm。
所述n型掺杂层3为n型非晶硅或者微晶硅基薄膜,厚度<30nm,可以是a-Si:H(n)或者c-SiOx:H(n)等。
所述p型掺杂层4为p型非晶硅或者微晶硅基薄膜发射极,厚度<30nm,可以是a-Si:H(p)或者c-Si:H(p)等。
所述透明导电层5为透明导电氧化物层,可以是ITO、IWO、ICO等单层或者多层结构。
所述半透半反功能层6的主要作用是透过短波段的光、反射长波段的光,既不影响电池吸收组件背面的杂散光,又可以再次反射和利用透射到电池背面的长波段光,提升电池的短路电流密度。具体地,所述半透半反功能层6包括至少一层TCO材料层和至少一层金属层。其中,金属层提升了背电极的横向导电性能,降低电阻损失,提升电池的填充因子(FF)。
图1示出的一种实施例中,所述TCO材料层为两层,分别为第一TCO材料层61,第二TCO材料层63;所述金属层也为两层,分别为第一金属层62和第二金属层64。所述TCO材料层和所述金属层的位置可以不做限制。当TCO材料层和金属层均为多层时,各个层的位置也可以不做限制。图1中所示的实施例中,所述TCO材料层和金属层交替设置,即按照第一TCO材料层,第一金属层,第二TCO材料层,第二金属层的顺序层叠设置。当然,图1仅是一种位置设置的示意,其还可以按照其他可能的方式设置,比如可以按照第一TCO材料层,第二TCO材料层,第一金属层,第二金属层的顺序层叠设置。
所述TCO材料为ITO或AZO。所述金属为Ag、Al或者Cu。当所述TCO材料层为多层时,各个层的材质可以相同也可以不同。当所述金属层为多层时,各个层的材质可以相同也可以不同。例如,图1所示的实施例中,所述第一TCO材料层61为ITO层,第二TCO材料层63为AZO层,第一金属层62为Ag层,第二金属层64为Ag。
当所述TCO材料层为多层时,各个层的厚度可以相同也可以不同。当所述金属层为多层时,各个层的厚度可以相同也可以不同。例如,图1所示的实施例中,所述第一TCO材料层61的厚度为60-80nm,优选为70nm,第二TCO材料层63的厚度为80-100nm,优选为90nm,第一金属层62的厚度为4-8nm,优选为6nm,第二金属层64的厚度为10-15nm,优选为12nm。
如图3所示,所述的柔性异质结太阳电池还包括分别设置在所述透明导电物层5和半透半反功能层6上的金属电极7。其中,所述金属电极为银电极或铜电极。
为了对本申请提供的柔性异质结太阳电池的性能进行说明,申请人对常规硅异质结太阳电池、包含另一种组成的半透半反功能层的柔性异质结太阳电池A以及本申请图3所示的柔性异质结太阳电池B分别进行了各项性能测试,具体结果如下表1所示。
表1:
其中柔性异质结太阳电池A中的半透半反功能层为普通的ITO材料,厚度为80nm;柔性异质结太阳电池B中的半透半反功能层6为多层膜结构:第一TCO材料层61为厚度是70nm的ITO层,第一金属层62为厚度是6nm的Ag层,第二TCO材料层63为厚度是90nm AZO,第二金属层64为厚度是12nm的Ag层。
申请人还对上述电池A和B的半透半反功能层的反射率进行了对比测试,图4示出了该两种不同材料功能层的反射率对比曲线。通过优化不同膜层的折射率和厚度,我们可以得到短波(<700nm)透过率大于80%且长波(>900nm)反射率大于60%的功能层,从而将到达硅片背表面的长波段光进行再次反射利用,提升电池的短路电流密度。另外,第一金属层62和第二金属层64的加入,提升了光生空穴在背电极的横向收集能力,降低了电阻损失,提升了电池的FF,并最终获得了电池效率~23.4%的柔性超薄硅电池。该电池的重量为5.38g,折算到每瓦电池的克重为0.95g/W。
综上所述,(1)本申请采用柔性异质结太阳电池实现的超薄柔性太阳电池组件,具有较高的光电转换效率:本申请采用的柔性异质结太阳电池具有双面发电、温度系数低、无衰减、发电性能稳定等特点,其实际户外发电量比普通晶体硅电池高出20%以上。
(2)本申请采用超薄柔性异质结太阳电池的电池重量不到普通电池的五分之一,制作的超薄柔性太阳电池组件的功率重量比则高达0.35W/g以上,组件的厚度<150μm。
(3)本申请采用柔性异质结太阳电池片和柔性封装材料制作柔性可弯曲的太阳电池组件,由于柔性异质结太阳电池片本身具有非常好的柔韧性,再配合超薄柔性的聚合物材料和胶膜,封装成的太阳电池组件同样具有很好的柔韧性,可满足不同的弯曲面设计或应用。
需要理解的是,本申请中使用的“第一”、“第二”以及类似的词语并不表示任何顺序、数量或者重要性,而只是用来区分不同的组成部分。
虽然本申请所揭露的实施方式如上,但所述的内容仅为便于理解本申请而采用的实施方式,并非用以限定本申请。任何本申请所属领域内的技术人员,在不脱离本申请所揭露的精神和范围的前提下,可以在实施的形式及细节上进行任何的修改与变化,但本申请的专利保护范围,仍须以所附的权利要求书所界定的范围为准。
Claims (20)
2.根据权利要求1所述的超薄柔性太阳电池组件,其特征在于,所述第一透明氟材料薄膜层和所述第二透明氟材料薄膜层的材料为ECTFE材料或ETFE材料、UBSF512材料。
4.根据权利要求1所述的超薄柔性太阳电池组件,其特征在于,所述第一热熔胶膜层和所述第二热熔胶膜层的材料为离子交联高分子材料或EVA、POE。
6.根据权利要求1所述的超薄柔性太阳电池组件,其特征在于,所述柔性异质结太阳电池由多个柔性异质结太阳电池片串联和/或并联而成。
9.根据权利要求6所述的超薄柔性太阳电池组件,其特征在于,所述多个柔性异质结太阳电池片之间通过导电胶串联和/或并联而成。
11.根据权利要求1-10任一项所述的超薄柔性太阳电池组件,其特征在于,所述柔性异质结太阳电池包括:依次层叠的透明导电层、n型掺杂层、第一本征钝化层、单晶硅片、第二本征钝化层、p型掺杂层以及半透半反功能层,其中,所述半透半反功能层包括至少一层TCO材料层和至少一层金属层。
12.根据权利要求11所述的超薄柔性硅太阳电池,其中,所述TCO材料层为两层,所述金属层为两层。
13.根据权利要求12所述的超薄柔性硅太阳电池,其中,所述TCO材料层和所述金属层交替设置。
14.根据权利要求11所述的超薄柔性硅太阳电池,其中,所述TCO材料为ITO或AZO。
15.根据权利要求11所述的超薄柔性硅太阳电池,其中,所述金属为Ag、Al或者Cu。
16.根据权利要求11所述的超薄柔性硅太阳电池,其中,所述单晶硅片的厚度为60-80nm。
17.根据权利要求12所述的超薄柔性硅太阳电池,其中,所述两个TCO材料层的厚度分别为60-80nm和80-100nm。
18.根据权利要求12所述的超薄柔性硅太阳电池,其中,所述两个金属层的厚度分别为4-8nm和10-15nm。
19.根据权利要求11所述的超薄柔性硅太阳电池,其中,还包括分别设置在所述透明导电物层和半透半反功能层上的金属电极。
20.根据权利要求19所述的超薄柔性硅太阳电池,其中,所述金属电极为银电极或铜电极。
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