CN112951943A - 太阳能电池及柔性太阳能电池模组的制备方法 - Google Patents
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Abstract
本发明太阳能电池及柔性太阳能电池模组的制备方法，提供太阳能电池，所述太阳能电池的背面通过图形印刷的方式，形成多个子电池单元，相邻子电池单元之间预留间隙；通过激光切割或机械切割裂片的方式将所述子电池单元之间预留间隙形成凹槽；在所述太阳能电池表面贴上转移用的静电膜，将所述太阳能电池沿着凹槽裂成子电池；拉伸静电膜，使得所述子电池之间产生一定的间隙；去除静电膜，用导电胶带贴在太阳能电池背面，将子电池的主栅线背面电极和相邻子电池的主栅线背面电极连接在一起；将柔性背板、第一热熔胶、串联焊接后的电池、第二热熔胶、柔性前板依次堆叠，经过高温层压形成柔性太阳能电池模组。
Description
技术领域
本发明涉及晶硅太阳能电池领域，尤其涉及太阳能电池及柔性太阳能电池模组的制备方法
背景技术
目前硅基太阳能电池一般都采用正面玻璃或双面玻璃封装成模组，无法实现柔性弯曲的功能，部分厂商也尝试采用柔性前板、柔性背板材料直接封装硅基太阳能电池，但是弯曲程度有限，且很容易引起硅片破片，只能实现半柔性或曲面封装的功能。
柔性模组与玻璃刚性模组对比，柔性模组具有重量轻、安装成本低、应用范围更广等优点。目前的柔性太阳能电池主要有非晶硅柔性太阳能电池、铜铟镓硒(CIGS)薄膜柔性太阳能电池，非晶硅柔性太阳能电池效率明显偏低，目前最高效率不超过10％，商业应用非常有限，以美国United solar为代表的非晶硅柔性电池厂家在几年前就已经宣布破产。铜铟镓硒 (CIGS)薄膜柔性太阳能电池生产成本非常高昂，是目前硅基太阳能电池的两倍以上成本，目前也无法得到很好的推广，并且无法多次弯曲。
然而硅基太阳能电池经过多年的发展，成本下降显著，目前部分光伏企业采用玻璃封装的刚性模组已经宣布可以实现平价上网，但是硅片本身易碎，特别是当硅片尺寸比较大时，弯曲后很容易破碎，所以一直无法封装成真正意义上可弯曲的柔性模组。
发明内容
针对上述问题，本发明提供了一种适合于柔性卷曲的硅基太阳能电池及其模组，其采用硅基太阳能电池制作成柔性卷曲模组。
本发明提供了一种可用于柔性太阳能电池模组的太阳能电池的制备方法，提供硅片；将所述硅片制绒清洗，形成金字塔绒面；在硅片表面形成钝化层及掺杂层；在硅片表面形成金属电极；N型和P型引出电极都位于电池的背面；在硅片的背面通过图形印刷的方式，形成多个子电池单元，相邻子电池单元之间预留间隙。
优选的，所述子电池单元之间预留间隙可通过激光切割或机械切割裂片的方式形成凹槽，所述凹槽深度为20-150um。
优选的，所述子电池单元预留间隙为横向和纵向，其切割数目为4～40 之间，由此可分割成12～800之间的子电池单元。
优选的，所述金属电极采用丝网印刷金属浆料或电镀方式形成。
本发明还提供一种柔性太阳能电池模组的制备方法，包括：提供太阳能电池，所述太阳能电池的背面通过图形印刷的方式，形成多个子电池单元，相邻子电池单元之间预留间隙；通过激光切割或机械切割裂片的方式将所述子电池单元之间预留间隙形成凹槽；在所述太阳能电池表面贴上转移用的静电膜，将所述太阳能电池沿着凹槽裂成子电池；拉伸静电膜，使得所述子电池之间产生一定的间隙；去除静电膜，用导电胶带贴在太阳能电池背面，将子电池的主栅线背面电极和相邻子电池的主栅线背面电极连接在一起；将柔性背板、第一热熔胶、串联焊接后的电池、第二热熔胶、柔性前板依次堆叠，经过高温层压形成柔性太阳能电池模组。
优选的，所述静电膜表面带胶，包括正面静电膜及背面静电膜，所述正面静电膜的粘接力大于背面静电膜的粘接力。
优选的，所述子电池之间的间隙为0.05-0.5mm。
优选的，所述金属箔为镀锡铜箔、铜箔、铝箔中的一种。
优选的，所述导电胶带可以为金属箔或复合Polyimide和镀铜层的导电胶带。
优选的，太阳能电池模组可卷折的方向为子电池平行细栅方向相同。
本发明采用把太阳能电池裂解成多个子电池单元的方案，保证模组的多次卷曲不会产生电池性能和可靠性的下降。常规焊带经过多次弯折后会产生金属疲劳，本发明采用全部背面电极的设计，发电子电池单元之间用较薄的导电胶带粘接，可以适应多次频繁卷折的要求，同时正面无金属电极遮挡，可提升模组的发电效率。制作模组时，太阳能电池裂成多个子电池，且每个子电池之间保持一定的间隙，模组弯曲时子电池之间有足够的弯曲拉伸空间，使得硅基电池模组可以实现柔性卷曲。
附图说明
构成本申请的一部分的附图用来提供对本发明的进一步理解，本发明的示意性实施例及其说明用于解释本发明，并不构成对本发明的不当限定。
在附图中：
图1为本发明实施例太阳能电池预留激光切割形成网格槽的位置示意图；
图2为本发明实施例裂成子单元并拉伸使得子单元之间产生一定间隙后的结构示意图；
图3为本发明实施例背面导电胶带贴在子电池背面，将子电池背面电极连接在一起的背面结构示意图；
图4为本发明实施例用导电胶带粘接后并在后续工艺中粘贴保护载体及前后背板形成的侧面结构示意图。
具体实施方式
为了使本发明的目的、技术方案及优点更加清楚明白，以下结合附图及实施例，对本发明进行进一步详细说明。应当理解，此处所描述的具体实施例仅仅用以解释本发明，并不用于限定本发明。
实施例：
如图1-2所示，本发明提供硅片01，在硅片01的其中一面用激光预切割形成网格状凹槽，其形成的子电池单元11长度L为3mm，宽度W为2mm (宽度方向为最后形成的模组的卷折方向)，激光切割深度为80um。所述硅片01可以为N型单晶硅片、P型单晶硅片、N型多晶硅片或P型多晶硅片中的一种。在激光切割之前，将硅片01制绒清洗，去除硅片01表面机械损伤，形成金字塔绒面；通过PECVD化学气相沉积技术，在硅片01的双面沉积本征非晶硅钝化层，正面形成N型掺杂非晶硅层、背面形成P型掺杂非晶硅层，或正面形成P型掺杂非晶硅层、背面形成N型掺杂非晶硅层；通过PVD物理气相沉积技术，在硅片01的正背面沉积透明导电膜ITO 层；在硅片01的正面丝网印刷银浆形成正面栅线电极，背面丝网印刷银浆形成背面栅线电极。优选的，正面和背面的栅线电极可采用铜电镀栅线。背面栅线电极分为主栅线N电极(12A)、细栅线N电极(12B)、主栅线 P电极(13A)、细栅线P电极(13B)。如图1所示，其中细栅线N电极 (12B)和细栅线P电极(13B)为引出电极，呈指状平行交替分布。主栅线N电极12A和主栅线P电极13A分布在子电池单元11的两端。
在上述太阳能电池正面贴上转移用的静电膜，将太阳能电池沿着凹槽裂成子电池11；拉伸静电膜，如图2所示，使得子电池之间产生一定的间隙，所述间隙宽度为0.1mm。如图3所示，用带导电胶21贴在相邻子电池11背面，将子电池的主栅线背面电极12A和相邻子电池的主栅线背面电极 13A连接在一起。所述导电胶带为镀锡铜箔、铜箔、铝箔或复合有polyimide 的耐多次弯折的胶带，胶带表面有具有较强Z向导电性的胶层。
如图4所示，将柔性前板41、第一热熔胶42、背面贴导电铜箔21的电池11、第二热熔胶43、柔性背板44依次堆叠，经过140～200的热处理层压后形成柔性模组。在子电池11的正面还粘接一种保护性的透明盖板31，在盖板31和11之间为热熔胶32。
制作模组时，电池裂成多个子电池，且每个子电池之间保持一定的间隙，模组弯曲时子电池之间有足够的弯曲拉伸空间，使得硅基电池模组可以实现柔性卷曲。本发明采用的连结方式可以避免长距离焊带的电阻损失，且全部阻挡电极材料都在模组的背面，以上措施可以提升柔性组件的短路电路和填充因子，会体现在模组发电效率的提升。
以上所述仅为本发明的较佳实施例而已，并不用以限制本发明，凡在本发明的精神和原则之内所作的任何修改、等同替换和改进等，均应包含在本发明的保护范围之内。
Claims (10)
1.一种可用于柔性太阳能电池模组的太阳能电池的制备方法，其特征在于：提供硅片；将所述硅片制绒清洗，形成金字塔绒面；在硅片表面形成钝化层及掺杂层；在硅片表面形成金属电极；N型和P型引出电极都位于电池的背面；在硅片的背面通过图形印刷的方式，形成多个子电池单元，相邻子电池单元之间预留间隙。
2.根据权利要求1所述可用于柔性太阳能电池模组的太阳能电池的制备方法，其特征在于：所述子电池单元之间预留间隙可通过激光切割或机械切割裂片的方式形成凹槽，所述凹槽深度为20-150um。
3.根据权利要求2所述可用于柔性太阳能电池模组的太阳能电池的制备方法，其特征在于：所述子电池单元预留间隙为横向和纵向，其切割数目为4～40之间，由此可分割成12～800之间的子电池单元。
4.根据权利要求1所述可用于柔性太阳能电池模组的太阳能电池的制备方法，其特征在于：所述金属电极采用丝网印刷金属浆料或电镀方式形成。
5.一种柔性太阳能电池模组的制备方法，其特征在于，包括：提供太阳能电池，所述太阳能电池的背面通过图形印刷的方式，形成多个子电池单元，相邻子电池单元之间预留间隙；通过激光切割或机械切割裂片的方式将所述子电池单元之间预留间隙形成凹槽；在所述太阳能电池表面贴上转移用的静电膜，将所述太阳能电池沿着凹槽裂成子电池；拉伸静电膜，使得所述子电池之间产生一定的间隙；去除静电膜，用导电胶带贴在太阳能电池背面，将子电池的主栅线背面电极和相邻子电池的主栅线背面电极连接在一起；将柔性背板、第一热熔胶、串联焊接后的电池、第二热熔胶、柔性前板依次堆叠，经过高温层压形成柔性太阳能电池模组。
6.根据权利要求5所述柔性太阳能电池模组的制备方法，其特征在于：所述静电膜表面带胶，包括正面静电膜及背面静电膜，所述正面静电膜的粘接力大于背面静电膜的粘接力。
7.根据权利要求5所述柔性太阳能电池模组的制备方法，其特征在于：所述子电池之间的间隙为0.05-0.5mm。
8.根据权利要求5所述柔性太阳能电池模组的制备方法，其特征在于：所述导电胶带可以为金属箔或复合Polyimide和镀铜层的导电胶带。
9.根据权利要求5所述柔性太阳能电池模组的制备方法，其特征在于：所述金属箔为镀锡铜箔、铜箔、铝箔中的一种。
10.根据权利要求5所述柔性太阳能电池模组的制备方法，其特征在于：太阳能电池模组可卷折的方向为子电池平行细栅方向相同。
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| WO2023232378A1 (de) * | 2022-05-31 | 2023-12-07 | Fraunhofer-Gesellschaft zur Förderung der angewandten Forschung e. V. | Verfahren zur herstellung eines solarzellenmoduls |
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