CN1950954A - Photovoltaic system and method of making same - Google Patents
Photovoltaic system and method of making same Download PDFInfo
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- CN1950954A CN1950954A CNA2005800115714A CN200580011571A CN1950954A CN 1950954 A CN1950954 A CN 1950954A CN A2005800115714 A CNA2005800115714 A CN A2005800115714A CN 200580011571 A CN200580011571 A CN 200580011571A CN 1950954 A CN1950954 A CN 1950954A
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- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
- Y02B—CLIMATE CHANGE MITIGATION TECHNOLOGIES RELATED TO BUILDINGS, e.g. HOUSING, HOUSE APPLIANCES OR RELATED END-USER APPLICATIONS
- Y02B10/00—Integration of renewable energy sources in buildings
- Y02B10/10—Photovoltaic [PV]
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- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
- Y02E—REDUCTION OF GREENHOUSE GAS [GHG] EMISSIONS, RELATED TO ENERGY GENERATION, TRANSMISSION OR DISTRIBUTION
- Y02E10/00—Energy generation through renewable energy sources
- Y02E10/50—Photovoltaic [PV] energy
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- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
- Y02P—CLIMATE CHANGE MITIGATION TECHNOLOGIES IN THE PRODUCTION OR PROCESSING OF GOODS
- Y02P70/00—Climate change mitigation technologies in the production process for final industrial or consumer products
- Y02P70/50—Manufacturing or production processes characterised by the final manufactured product
Abstract
The present invention relates to a photovoltaic system and methods of making same. The photovoltaic system has a plurality of layers attached to each other to form a unitary structure. More specifically, the photovoltaic system includes: a base, flexible membrane layer; a photovoltaic layer having at least one photovoltaic cell associated therewith; a semi-rigid laye for supporting the photovoltaic layer and imparting rigidity thereto; and a top, transparent, protective layer for protecting the base, flexible membrane layer, the semi-rigid layer and the photovoltaic layer from exposure to the environment. The photovoltaic layer and the semi-rigid layer are disposed between the base, flexible membrane layer and the top, protective layer. Additional layers of adhesive may be disposed between the various layers to facilitate bonding thereof.
Description
Related application
0001 the application's case is advocated in the U.S. Provisional Application case of on February 17th, 2004 application number 60/544,497, denomination of invention is the priority of " photovoltaic cell roof method " (PHOTOVOLTAIC CELLROOFING SYSTEM), and being herein incorporated in full that this case disclosed is reference.
Technical field
0002 the present invention system is about a kind of photovoltaic system and manufacture method thereof.
Background technology
0003 considers consume and the environmental problem in cumulative non-reproducible fossil fuel, and to the demand growth demand of the energy in cleaner, more cost-effective source, has caused gazing at for heliotechnics and application thereof.
The 0004 various photovoltaic devices with a plurality of semi-conductor cells are developed, light can be converted to direct current (dc).The electric energy that Dang Tong Over photovoltaic devices produces is proportional to the light time that is incident to self battery, is that photovoltaic devices must be set in the height area of illumination.The efficient of known photovoltaic cell is low relatively, then needs sizable solar energy collecting district to produce available electric flux.These situations cause photovoltaic devices to be loaded into outside structure in some instances, and the roof structure of building particularly.The roof is easy to receive the illumination of height and is easy to the sufficient active surface of tool district to hold the array of photovoltaic devices.
Yet 0005, load photovoltaic devices and have certain difficulty in roof structure.Roof structure must support the weight of this photovoltaic cell fully, and this equipment must anti-typically high wind load (wind loads) ability of tool.In some applications, use steel and shelve these problems of handling.Yet it is expensive that this solution but is tending towards.Because equipment is tending towards consuming time, thereby need special equipment and technology and hardware.In addition, these supporting constructions are tending towards heavy and this building structure need be strengthened to carry these structures.In addition, these structures are tending towards needing to safeguard to keep the operation of this photovoltaic devices on a large scale.The photovoltaic system that shortcoming such as above-mentioned becomes to making to be loaded into the roof can't be applied in dwelling house or commercial building widely.
0006 but, the pattern of photovoltaic cell to different roof systems incorporated in more existing trials into.For example, No. the 5th, 092,939, U. S. application patent case; 5,232, No. 518 and 4,189, No. 881 the photovoltaic roof structure of the clamping plate that disclose and interlayer pattern.No. the 4th, 040,867, U. S. application patent case; 4,321, No. 416 and 5,575, No. 861 various photovoltaic roofing boards that disclose.
No. the 4th, 860,509,0007 U. S. application patent case, people such as Laaly propose (be herein incorporated and be reference), the photovoltaic roof system of the laminar structure with multilayer of institute's teaching.This roof system comprises simple layer, is connected to the flexible membrane layer on roof.Be laminated on the rete to encapsulated and be sealed in the structural flexible layer of the photovoltaic cell of flexible encapsulant material (flexible pottant material).Protective layer is covered in this flexible encapsulant material.
0008 in this technical field, and it is good that people's such as Laaly photovoltaic roof system has been tending towards performance, particularly used the application of film photovoltaic cell.Yet, the crystalline silicon solar of having utilized of relatively having a rigidity, some problem that is occurred but limits its effective application in this technical field.Particularly, the easy embrittlement of crystalline silicon solar and compared to the easier be full of cracks of its film-type homologue.This characteristic tends makes crystalline silicon solar have more the test of operation.Its fragility needs special operation benchmark and equipment and technology.Moreover for fear of the be full of cracks disappearance, therefore the size of restriction individual crystalline silicon solar cell is unfavorable for the influence of this battery at the cost of efficient and manufacturing thereof.In the example as a known applications, above-mentioned restriction impels the use benchmark of this crystalline solar cells to take advantage of 2 inches for being no more than about 2 inches.
It is favourable that the use of 0009 film-type photovoltaic cell has been found in some applications, but its efficient also can't be compared with crystalline silicon solar.Moreover, if the larger crystalline silion cell can to the durability of this type of battery with minimum impact be used in photovoltaic system, on solar energy collecting efficient, can further realize.Therefore, need photovoltaic system and particularly be applicable to and carry use big relatively rigid photovoltaic cells.And further demand As uses the system of rigid photovoltaic cells, and this system's energy is durable and it is easier on operation and equipment.This photovoltaic system can utilize in many application, and is particularly conducive to rooftop applications.
Summary of the invention
The 0010 non-limiting sample attitude according to concrete example of the present invention provides a kind of photovoltaic system to comprise: base flexible membrane; Photovoltaic layer with at least one photovoltaic cell that combines with it; Be used to the semi-rigid layer that supports photovoltaic layer and give its rigidity; And the top transparent protective layer, avoid being exposed in the environment in order to protection base flexible membrane, semi-rigid layer and photovoltaic layer.This photovoltaic layer and semi-rigid layer are disposed between base flexible membrane and the top protective layer.This base flexible membrane, semi-rigid layer, photovoltaic layer and top protective layer link together and form single structure.
0011 in further feature, and semi-rigid layer is disposed on the top of base flexible membrane, and photovoltaic layer is disposed on the top of semi-rigid layer.In further further feature, first adhesion layer is disposed between base flexible membrane and the semi-rigid layer.Second adhesion layer is disposed between semi-rigid layer and the photovoltaic layer.The 3rd adhesion layer is disposed between photovoltaic layer and the top protective layer.
In 0012 another non-limiting sample attitude of concrete example, provide the method for making photovoltaic system with a plurality of laminate layers according to the present invention.This method comprises: base flexible membrane and top transparent protective layer are provided; The photovoltaic layer that semi-rigid layer is set and has at least one photovoltaic cell that combines with it is between this base flexible membrane and top protective layer; And above-mentioned layer linked together and form single structure.In further feature, setting comprises that the storehouse semi-rigid layer is on the top of base flexible membrane; And the storehouse photovoltaic layer is on the top of this semi-rigid layer.
0013 in further feature, and said method one step of Jin Qian connecting comprises: first adhesion layer is set between base flexible membrane and semi-rigid layer; Second adhesion layer is set between semi-rigid layer and photovoltaic layer; And the 3rd adhesion layer is set between photovoltaic layer and top protective layer.In another further feature, connection comprises plural layer laminated together.More in another further feature, connect and comprise that elder generation is with semi-rigid layer, adhesion layer, photovoltaic layer, another adhesion layer and top protective layer lamination together; Then this semi-rigid layer is fixed to base flexible membrane.
Description of drawings
0014 is appended graphic to be described in more detail in down by being illustrated in reference to concrete example of the present invention, can more clearly understand concrete example of the present invention, wherein:
0015 the 1st figure is the perspective view of decomposition of the photovoltaic system of one of the present invention concrete example;
0016 the 2nd figure is the section of structure that is shown in the photovoltaic system of the 1st figure;
0017 the 3rd figure is the perspective view that is shown in the photovoltaic system of the 1st figure;
0018 the 4th figure is the summary profile of photovoltaic system that is shown in another selection of the 2nd figure;
0019 the 5th figure is the decomposition diagram of the photovoltaic system of another concrete example of the present invention;
0020 the 6th figure is the summary profile that is shown in the photovoltaic system of the 5th figure; And
0021 the 7th figure is the perspective view that each layer of being used to connect photovoltaic system forms the thermal vacuum laminating machine of single structure.
Embodiment
0022 following description and be described in graphic by example of wherein concrete example, or the example of special embodiment provides principle of the present invention and sample attitude.These examples are provided for illustrating purpose of the present invention and unrestricted described principle of the present invention.Particularly, hereinafter be described in the Demonstration Application of the photovoltaic system in the technical field on roof.Yet the apprehensible the present invention of being is not subject to photovoltaic system and is used for rooftop applications.The hereinafter described photovoltaic system of the salty this paper of thinking can advantageously use in the application of broad range and can be arranged at any surface that is exposed to sufficient sunshine amount.
0023 with reference to the 1st, 2 and 3 figure, and photovoltaic system graphic refers generally to be decided to be reference number 20.Photovoltaic system 20 is suitable for being loaded into the roof structure (not graphic) of building.But these photovoltaic system 20 concrete manifestations are in the extending-board 21 (being illustrated at the 3rd figure) that is easy to be transported to the set-point in the mill through folding.This plate that shows this photovoltaic system can use the known method to set up that generally is known in technical field to lay and be connected to roof structure.For example, but this photovoltaic system 20 direct mechanical ground set or be connected to the board (not icon) of roof structure, or set or be connected to timber, concrete, waveform steel, galvanized steel plain sheet or any rigidity thermal insulation panel that generally is used for of the board that is provided with and is connected in roof structure.Perhaps, photovoltaic system 20 is with being connected the vacuum that is produced between Ke Tong Over photovoltaic system 20 and the roof structure of roof structure and the negative pressure system that forms reached.This connects the use that photovoltaic system to the means of the roof structure that underlies help minimumization set and connection, therefore promotes the setting of photovoltaic system.Similarly, these means of sticking together can help provide and reduce that roof structure is pierced or run through and guarantee that photovoltaic system fixes completely thereon with other method.
0024 photovoltaic system 20 has plural layer 22 and is connected to each other and forms single structure 24.Particularly, this photovoltaic system 20 comprises: base portion is connected to the flexible membrane layer 26 of roof structure; Has the photovoltaic layer 30 that at least one combines with photovoltaic cell 32; Give the semi-rigid layer 28 of photovoltaic layer 30 rigidity; And avoid being exposed in the environment in order to protective layer 26,28 and 30, be disposed at the top transparent protective layer 34 on these layers.
0025 base flexible membrane 26 provides its sub-roofing structure that is connected of dual-use function-protection and serves as base material and makes the remainder layer storehouse thereon.Flexible membrane layer 26 can be made by simple layer roof film material, for example thermoplastics, modified coal tar pitch, vulcanized elastomer, unvulcanised elastomer, EPDM (ethylene propylene diene monomer) rubber or the like.Be preferably base flexible membrane 26 and build, and goodly build by polyvinyl chloride (PVC) by thermoplastics.Perhaps, can use TPO (TPO) or thermoplastic alloy (TPA) and similar advantage is arranged.If needed, but this base flexible membrane 26 mat reinforcing fibre reinforcement, for example braid or non-woven fabric fiberglass fiber pad.The inclusion of these fibers becomes to making membrane layer 26 can keep the stability of its size in the temperature of broad range.This simple layer roof diaphragm mat GAF Materials Corporation of Wayne company, the registered trade mark of New Jersey
It is the example of the reinforcement PVC roof diaphragm that is used for above-mentioned application that can be suitable.It comprises the upper strata of the lower floor of carbon black PVC, grey PVC and is configured in the upper strata and the intermediate reinforced layer of following interlayer.
0026 base flexible membrane 26 is made by PVC, and the variable thickness of this layer is more between about 0.04 inch and 0.09 inch.In preferred embodiment, the thickness of this rete 26 is about 0.06 inch.
0027 in this concrete example, and semi-rigid layer 28 is arranged between base flexible membrane 26 and the photovoltaic layer 30.The rigidity that this semi-rigid layer 28 supports photovoltaic layer 30 and gives its structure.At length explained orally as followsly, this additional stiffness provides this photovoltaic layer 30 to increase the resistance to draw and abrasion.In this concrete example, semi-rigid layer 28 is made by fiberglass-reinforced plastic (FRP), and can examine what know is to use performance similar in appearance to other material of the rigidity characteristics of FRP similar advantage to be arranged.For example, aluminium, glass, some plastics or even the general roofing board that uses, all can use in semi-rigid layer 28.
The selection of the material of 0028 semi-rigid layer 28 is partly decided according to the kind that is used for the photovoltaic cell 32 of photovoltaic layer 30.Therefore the bending ability that some photovoltaic cell has limit need have more rigid support so that its suitable function to be provided.Similarly, the thickness variable of this semi-rigid layer 28 is to give its more or less rigid.When making FRP, semi-rigid layer 28 is will have the boundary in about 0.060 inch and about O.150 thickness between the inch through what carefully consider.In this case, preferably, the thickness of this semi-rigid layer is about O.125 inch.The surf zone of semi-rigid layer 28 changes according to the application of photovoltaic system 20.For example, in being provided with especially, the surf zone of semi-rigid layer 28 can have 4 Foot of being close to take advantage of 8 Foot, or more.
0029 with reference to the 3rd figure, and photovoltaic layer 30 has the photovoltaic cell 32 of plural number.The interval that provides between the individual cell 32 can increase the flexibility of photovoltaic layer 30, therefore can make photovoltaic system 20 foldings reach not folding when operating and being provided with.A plurality of photovoltaic cells 32 can distribute and arrange continuously along photovoltaic layer 30 in the two dimensional array of being expert at and being listed as.Yet can examine what know is that this demand is not to be all situations in using.A plurality of photovoltaic cells also can be with other arranged in form that is fit to.Electrical connector such as flat wire 31 or the like is provided, a plurality of photovoltaic cells 32 is connected to each other and there is the flowing of electric current of required voltage and current characteristics the conduction band.This flat wire is to connect Office feed-in terminal box 33 in output.Shunt diode 35 is provided with the spacing distance (for example being positioned at the spacing distance of per two row of photovoltaic cell) that is predetermined along photovoltaic layer 30.This shunt diode 35 guarantees that electric energy crossed photovoltaic layer 30 continuously and transmitted when some photovoltaic cell electric energy invalid because of the reason that is arranged at shady place or continue to be hurt becomes.The interconnected of a plurality of photovoltaic cells 32 can be reached in various method of general known technical field.
0030 preferably, and photovoltaic cell 32 is a crystalline silicon solar 40, and it has determined that proof can very efficient collection solar energy and convert electric energy to.As previously mentioned, crystalline silicon solar has easily crisp tendency, and with regard to itself, because the rolling through repeating or the bending of photovoltaic layer, or self has destructible tendency above load.Therefore, the fragility of crystalline silicon solar causes the problem of utilizing the battery of photovoltaic system class known, needs this system in transportation, careful especially when being provided with and keeping usually.Compared to the kind of other solar cell, the use that quite extensively reaches how frangible solar cell also can't have the efficient of raising in photovoltaic system.Yet, can examine know to be that above-mentioned drawback Tong Over Zhong photovoltaic system 20 provides support in the essence of the crystalline silicon solar 40 of semi-rigid layer 28 or filler is existing alleviate.Semi-rigid layer 28 by its additional stiffness is provided so that increase fault-resistant produced draw and abrasion and helps prolong useful life of photovoltaic cell 32.Shown in the result, the durability of whole photovoltaic system 20 is tending towards increasing.When semi-rigid layer becomes to making system 20 more easy to operate or also help to install when being connected to roof structure.Therefore, can examine what know is that photovoltaic system 20 is in semi-rigid layer 28 protection photovoltaic layers 30 and avoids the rigidity that draw provides, and transportation and install simple and easy degree required can flexibility between fine balance in
Though 0031 has used crystalline silicon solar in this concrete example, but should be appreciated that and depend on specific application, in other concrete example, can use other type of photovoltaic cell, no matter be organic or inorganic source, for example thin film solar cell, non-silicide film type solar cell, how rice structure solar cell, polysilicon solar cell or the like.
0032 preferably, and each solar cell 40 is taken advantage of 2 inches for rectangle and size greater than 2 inches.More preferably, this crystalline silicon solar 40 has 4 inches to take advantage of 4 inches.Yet can examine what know is that the solar cell (example is 5 inches and takes advantage of 5 inches, or 6 inches are taken advantage of 6 inches) of large scale also can be used for photovoltaic system and the similar advantage of tool.This solar cell also can have other selectable pattern.Each crystalline silicon solar 40 is preferably the thickness that has between about 0.010 inch to about 0.018 inch.
0033 in existing concrete example, top protective layer 34 be arranged on the photovoltaic layer 30 and encapsulation through the layer 26,28 and 30 of storehouse.When the major function of protective layer 34 is to give no matter be to the resistance of photovoltaic layer 30 or when protecting it to avoid hostile environment condition and exposure element (for example pollute, humidity), can examine what know is that photovoltaic layer 34 also provides other layer that support photovoltaic system 20 and the protection of roof structure.Particularly, this protective layer 34 also produces and reduces the demand of keeping and repairing of flexible membrane layer 26 and prolong the useful life of this film expection.
0034 in preferred embodiment, and transparent protective layer 34 is the anti-soil film, through selecting fluoropolymer membrane 42 tool durability, the anti-climate characteristic of excellence and the ability of protection moisture-resistant degree.Moreover this fluoropolymer membrane 42 has high solar radiation transmittance, so that it does not absorb solar radiation with remarkable quantity.Fluoropolymer membrane 42 can be by any following compounds manufacturing: ETFE (ETFE), ethylene, propylene fluoride (FEP), perfluoro alkoxy (PFA), tetrafluoroethylene/hexafluoropropylene/vinylidene fluoride (THV), polyvinylene fluoride or any other show UV stable/the highly transparent compound of resistance feature.Preferably, this fluoropolymer membrane 42 is to be made and had about 0.002 inch thickness by ETFE.Being used for protective layer 34 suitable ETFE examples is to be that the ETFE hair side is handled film (matte finish film), and by Saint-Gobain PerformancePlastics of Wayne, New Jersey makes, and sells to be registered trade mark Norton
TMThe ETFE film, and by E.I.Du Pont de Nemours and Company of Wilmington, Delaware makes, and sells to be registered trade mark Tefzel
TMCan examine what know is the mechanical property (for example abrasion resistance) of fluoropolymer membrane 42, can by change fluoropolymer membrane 42 on protective layer 34 orientation and improve.
Though 0035 preferably be the upper surface 44 of fluoroplymer layer 42 for quite level and smooth, this demand is not the situation in each is used.If needed, the upper surface of fluoroplymer layer can use described hereinafter stipple and make it that lines be arranged.In other concrete example, the layer of top transparent can be by the glass manufacturing of the upper surface with level and smooth or line ground.Use also can be considered to use as semi-rigid layer as the glass of protective layer.
0036 plural layer 22 (particularly, connects for the method for layer 26,28,30 and 34) Ke Tong Over adhesive agents or is assembled together.Preferably, employed adhesive agent is a heat-activated adhesive.Particularly, this heat-activated adhesive is ethene-vinyl acetate acid (EVA).Polyvinyl butyral resin (PVB) also can use the substitute as EVA.Similarly, any compression layer (pottant layer) that should consider as cement and buffering all can replace EVA.
0037 other adhesive agent that is fit to comprises non-heat-activated adhesive, for example pressure sensitive adhesive or contact adhesive agent (for example glue).Under the situation of the material that comprises base flexible membrane, can use non-heat-activated adhesive, therefore cause in this uses and be not suitable for using this adhesive agent with the softening point/fusing point that is lower than EVA.For example, this situation comprises some kinds of TPO (TPO).In this case, glue can be used to connect base flexible membrane 26 to semi-rigid layer 28.In other concrete example, base flexible membrane and semi-rigid layer Tong Over fusion engage and are connected to each other, and therefore get rid of the demand of adhesive agent.
0038 apprehensible be that photovoltaic system 20 can be crossed on another and described layer linked together and forms single structure 24 through one on many layer is set.Particularly, the preferred approach of making photovoltaic system 20 comprises: (a) storehouse semi-rigid layer 28 is to base flexible membrane 26; (b) storehouse photovoltaic layer 30 is to this semi-rigid layer 28; (c) coat this layer 26,28 and 30 with top, protective layer 34; And (d) layer 26,28,30 and 34 is linked together and form single structure 24.It should be noted, each layer need not have identical size and be preferably base flexible membrane 26 and top protective layer 34 greater than semi-rigid layer 28 and/or photovoltaic layer 34.
Though 0039 is preferably plural layer 22 according to the following order storehouse: base flexible membrane 26, semi-rigid layer 28, photovoltaic layer 30 and top protective layer 34 are that this can be modified in proper order along with slight change and material are reasonably selected can examine what know.With reference to the 4th figure, the graphic concrete example that goes out other, two intermediate layers (semi-rigid layer and photovoltaic layer) of its photovoltaic system 100 are squeezed.This photovoltaic system 100 comprises base flexible membrane 102 generally similar in appearance to photovoltaic system 20, photovoltaic layer 104, semi-rigid layer 106 and top transparent protective layer 108; All layers can link together and form single structure 110.Yet in this concrete example, plural layer is arranged as photovoltaic layer 104 and is arranged between base flexible membrane 102 and the semi-rigid layer 106.In order to determine the suitable function of photovoltaic system 100, semi-rigid layer 106 for transparent so that abundant sunshine amount arrival photovoltaic layer 104 is provided.Can therefore be appreciated that to utilize distinct methods to make photovoltaic system 100.This method comprises: (a) storehouse photovoltaic layer 104 is to base flexible membrane 102; (b) storehouse semi-rigid layer 106 is to this photovoltaic layer 104; (c) with top protective layer 108 coating layers 102,104 and 106; And (d) layer 102,104,106 and 108 is linked together and form single structure 110.In modified in addition concrete example, the top transparent protective layer can wholely leave the photovoltaic layer that is sandwiched between semi-rigid layer (now for top) and the base flexible membrane and eliminate.In this concrete example, semi-rigid layer can be made by glass.
0040 in other concrete example, and the adhesive agent that is used to bind different layers can be used so that form the independent stratum of described interlayer.With reference to the 5th and the 6th figure, graphic be that other photovoltaic system is generally with reference number 46 appointments.Generally similar in appearance to previous described photovoltaic system 20, it has flexible membrane layer 48 to photovoltaic system 46, semi-rigid layer 50, and photovoltaic layer 52 and protective clear layer 54 are through the arrangement configuration of storehouse.This layer 48,50,52 and 54 generally is equivalent to the layer 26,28,30 and 34 of photovoltaic system 20.Yet, between each adjoining course 48 and 50,50 and 52 and 52 and 54 adhesion layer is set.Particularly, adhesion layer 56 is arranged between flexible membrane layer 48 and the semi-rigid layer 50; Adhesion layer 58 is arranged between semi-rigid layer 50 and the photovoltaic layer 52; And adhesion layer 60 is arranged between photovoltaic layer 52 and the protective layer 52.In this concrete example, adhesion layer 56,58 and 60 is EVA.As in the layer 26,28,30 of photovoltaic system 20 and 34 mode, when linking together, layer 48,56,50,58,52,60 and 54 can form single structure 62.In other concrete example, can build photovoltaic system through inverted semi-rigid layer and photovoltaic layer similar in appearance to photovoltaic system 46, so photovoltaic layer is arranged between base flexible membrane and the semi-rigid layer.
The 0041 salty thickness of thinking adhesion layer 56 is between about 0.008 inch to about 0.018.Produce to connect or provide the buffering of increase can adjust the thickness of layer 56 as need.
0042 adhesion layer 58 and 60 is as compression layer, the photovoltaic cell of encapsulated layer 52 is provided and with its sealing in case the influence of environment, particularly humidity and environmental pollution.In this concrete example, the thickness of each adhesion layer 58,60 is about 0.018 inch, but if needed can be through revising.
0043 extensively, and photovoltaic system 46 Neng Tong Over are provided with 48,56,50,58,52,60 and 54 1 on layer and cross on another and for good and all connect this different layers and form single structure 62.Particularly, the method for manufacturing photovoltaic system 46 comprises: adhesion layer 56 (a) is set to the top of base flexible membrane 48; (b) semi-rigid layer 50 is set to the top of this adhesion layer 56; (c) adhesion layer 58 (d) to the top of this semi-rigid layer 50 is set and photovoltaic layer 52 is set to the top of this adhesion layer 58; (e) following layer 60 is set to the top of this photovoltaic cell layer 52; (f) protective layer 54 is set to the top of this adhesion layer 60; And (g) layer 48,56,50,58,52,60 and 54 is linked together and form single structure 62.Can examine what know is that said method can be easy to make through modification the semi-rigid layer of photovoltaic system and photovoltaic layer as discussed above and be inverted.
0044 preferred approach that connects this different layers comprises several at least plural numbers is forced together through stack layer.Betide the vacuum laminator 64 (being illustrated at the 6th figure) in general known techniques field through the lamination of stack layer.Particularly, but this vacuum laminator 64 has top 66, the lower part 70 that defines lower chambers 72 that defines upper chamber 68, the flexible silicone rubber dividing plate 74 that is arranged on top 66, uses separation upper chamber 68 and lower chambers 72, reach the heating plate 76 of position in the lower part 70 of laminating machine 64.Can examine what know is that other laminating machine with two heating plates also can be used, position thereon part and another position in the lower part.
Part comprises basal plane 78 under 0045 laminating machine 64, and it can be set at plural number on stack layer and lamination.Heating plate 76 can be formed within the basal plane 78.The top 66 of laminating machine 64 is that being arranged to its underpart 68 and form adapting to casket lid 80 movable between open position 82 and make position (not icon) of chain arranged.
0046 lamination process comprises vacuum cycle, pressures cycle, thermal cycle and cure cycle.Particularly, 48,56,50,58,52,60 and 54 place on the basal plane 78 of vacuum laminator 64, then casket lid 80 is moved to its make position through the layer of storehouse.Both air of upper chamber 68 and lower chambers 72 are found time.This vacuum cycle continues between 5 to 20 minutes and finds time before pressures cycle begins at the air through between stack layer of difference, thereby helps eliminate the bubble that is fallen into.Then, stop to extract the vacuum in upper chamber 68 and place upper chamber 68 to the atmosphere interchange of flowing.Extract equably through the upper space of stack layer and cause the pressure differential of dividing plate 70, thereby make this dividing plate 70 resist heating plate 76 and be compressed.But this flexible baffle 70 accords with the surface through stack layer, thereby guarantees that described interlayer reaches even contact really and gets rid of the space.
During 0047 thermal cycle, from room temperature or be not higher than 50 ℃ temperature and begin, heating heating plate 76 is to about 160 ℃ maximum temperature.The ramp type of heating plate 76 is warmed up to maximum temperature need be close to 5 to 10 minutes.In case when heating plate reaches maximum temperature, can keep general 3 to 5 minutes and make adhesion layer 56,58 and 60 activation, thereby begin the mutual bonding of described layer.In this period, continu to press is to described layer.Again, protective layer 54 can form cuticula through softening around other layer fully.Only 72 produce temperatures in the laminating machine 64 from the lower part.Particularly, this temperature can be transferred to flexible membrane layer 48 and is assigned to through stack layer from heating plate 76.Apprehensible be also can use be positioned at relatively laminating machine go up and the lower part having go up and down heating plate other laminating machine and help the generation of photovoltaic system.When using this laminating machine, before stopping the vacuum of upper chamber, heating plate heated barrier in advance on the Ke Tong Over.In this concrete example, go up and down the supply of heating plate can help really make heat in stack layer to distribute more even and help reduce the duration of thermal cycle thereby promote output.
After 0048 thermal cycle, can leave laminating machine 64 through stack layer and cool off time of 5 to 15 minutes.Be lower than when being close to 70 ℃ in case be cooled to through stack layer, lamination casing lid 80 can be moved to its open position 82 and should can remove and further harden at room temperature, regulate and cool off from laminating machine 64 through stack layer.
In case 0049 system is in when being close to room temperature, can carry out finishing tough to photovoltaic system 46.Finishing tough can comprise: (a) any additional material of finishing photovoltaic system comprises the thickness that removes protective layer 54 if needed; (b) electric connector is set to photovoltaic system 46 etc.; And (c) carry out photovoltaic system 46 quality controls and test.The electric connector of photovoltaic system can comprise that mounted connector is to exporting plumbous connector (not icon) and with the panel of adhesive agent and covering encapsulation discharge area.The quality control test can comprise uses digital voltage and galvanometer measuring device to test photovoltaic system 46 and verify that the described photovoltaic system 46 of this specification is to act under artificial light sources.
The end face 84 of 0050 protective layer 54 (ETFE manufacturing) if needed can be through a quarter; for example for the safety or the reason of beautifying, glass fiber mesh (fiberglass screen) or other may can be arranged on the top of protective layer 54 before being placed to laminating machine 64 through stack layer.Can make this net type sample can be permanently embossed onto the Top surface that end face 84 is created the tool lines.Can examine what know is that this step may be not suitable for glass is used as protective layer 54.In this step,, can make prerequisite for the glass that has a quarter if need point to carve.
0051 apprehensible be lamination process and/or equipment can through revise as the special layout that suitably be suitable for layer required or other may.
0052 operates or is provided with in the example of efficient at the material that comprises the flexible membrane layer with the softening point/fusing point that is lower than adhesion layer or can realizing, can use other manufacture method of utilizing for two stages built.Extensively, this other method comprises stack layer (except flexible membrane layer), as mentioned above the configuration that described layer is linked together and make and cross on another mode of lamination (for example by) and then use non-heat-activated adhesive that the layer through binding is fixed to flexible membrane layer after a while.Particularly, this selectable method comprises step: (a) place adhesion layer 58 to the top of semi-rigid layer 50; (b) place photovoltaic cell layer 52 to the top of this adhesion layer 58; (c) place adhesion layer 60 to the top of this photovoltaic cell layer 52; (d) place top protective layer 54 to the top of this adhesion layer 60; (e) layer 50,58,52,60 and 54 is connected to each other; (f) afterwards semi-rigid layer 50 being fixed to flexible membrane layer 48 becomes through storehouse and concerns.
0053 is connected to each other layer 50,58,52,60 and 54 and can comprises and use above-mentioned vacuum laminator 64 and heat lamination processing procedure to be pressed together layer by layer described.Flexible membrane layer 48 is fixed to semi-rigid layer 50 can comprises that the mode of the non-heat-activated adhesive of Tong Over connects flexible membrane layer 48 to semi-rigid layer 50.Can examine what know is after the layer through lamination cools off cmpletely, and fixing operation can for example be done in that the position is set in manufactory or in time in later stage more.Occur in being connected of flexible membrane layer through the layer of lamination the position is set, can before finishing fixing operation, flexible membrane layer 50 be secured to roof structure.
0054 gives careful consideration according to the inventor, though the as explained above and attached relevant icon of the adhoc approach of special preferred embodiment of the present invention and manufacturing will be appreciated that and can carry out different variations, modification and the procedure of adaptation not violating of the present invention opinion.
Claims (55)
1. photovoltaic system comprises:
Base flexible membrane;
Photovoltaic layer with at least one photovoltaic cell that combines with it;
Be used to the semi-rigid layer that supports photovoltaic layer and give its rigidity; And
The top transparent protective layer avoids being exposed in the environment in order to protection base flexible membrane, semi-rigid layer and photovoltaic layer;
This photovoltaic layer and semi-rigid layer are disposed between base flexible membrane and the top protective layer;
This base flexible membrane, semi-rigid layer, photovoltaic layer and top protective layer link together and form single structure.
2. photovoltaic system according to claim 1, wherein:
This photovoltaic layer is disposed on the top of base flexible membrane;
And this semi-rigid layer is disposed on the top of photovoltaic layer and for transparent.
3. photovoltaic system according to claim 1, wherein:
This semi-rigid layer is disposed on the top of base flexible membrane; And
This photovoltaic layer is disposed on the top of semi-rigid layer.
4. photovoltaic system according to claim 3, wherein this base flexible membrane, semi-rigid layer and photovoltaic layer are connected to each other by sticker.
5. photovoltaic system according to claim 4, wherein this sticker is the thermal activation sticker.
6. photovoltaic system according to claim 5, wherein this thermal activation sticker is acetate-ethylidene-vinyl acetate.
7. photovoltaic system according to claim 4, wherein this sticker is non-thermal activation sticker.
8. photovoltaic system according to claim 7, wherein this non-thermal activation sticker is a pressure sensitive adhesive.
9. photovoltaic system according to claim 8, wherein this non-thermal activation sticker is a glue.
10. photovoltaic system according to claim 3, wherein this base flexible membrane and semi-rigid layer engage by fusion and are connected to each other.
11. photovoltaic system according to claim 3 further comprises:
First adhesion coating is disposed between base flexible membrane and the semi-rigid layer;
Second adhesion coating is disposed between semi-rigid layer and the photovoltaic layer; And
The 3rd adhesion coating is disposed between photovoltaic layer and the top protective layer.
12. photovoltaic system according to claim 11, wherein this first adhesion coating has the thickness between about 0.008 inch to about 0.018 inch.
13. photovoltaic system according to claim 11, wherein this second and third adhesion coating has about 0.018 inch thickness.
14. photovoltaic system according to claim 11, wherein at least one in this first, second and third adhesion coating is acetate-ethylidene-vinyl acetate.
15. photovoltaic system according to claim 11, wherein at least one in this first, second and third adhesion coating is polyvinyl butyral resin.
16. photovoltaic system according to claim 11, wherein:
Second and third adhesion coating is acetate-ethylidene-vinyl acetate;
Base flexible membrane is that to be lower than the TPO of acetate-ethylidene-vinyl acetate by fusing point made; And
First adhesion coating is non-thermal activation sticker.
17. photovoltaic system according to claim 1, wherein this base flexible membrane is made by being selected from following individual layer roof Material:
(a) thermoplastic roof membrane;
(b) vulcanized elastomer film;
(c) unvulcanised elastomer film; Or
(d) modified coal tar pitch roof film.
18. photovoltaic system according to claim 17, wherein this base flexible membrane is reinforced.
19. photovoltaic system according to claim 1, wherein this base flexible membrane is made by polyvinyl chloride.
20. photovoltaic system according to claim 19, wherein this base flexible membrane has the thickness between about 0.04 inch and about 0.09 inch.
21. photovoltaic system according to claim 20, wherein the thickness of this base flexible membrane is about 0.06 inch.
22. photovoltaic system according to claim 3, wherein this semi-rigid layer is a fiberglass-reinforced plastic.
23. photovoltaic system according to claim 22, wherein this semi-rigid layer has the thickness between about 0.060 inch and about 0.150 inch.
24. photovoltaic system according to claim 23, wherein the thickness of this semi-rigid layer is about 0.125 inch.
25. photovoltaic system according to claim 3, wherein this semi-rigid layer is made by being selected from following material:
(a) aluminium; Or
(b) glass.
26. photovoltaic system according to claim 1, wherein this photovoltaic cell is a crystal silicon solar energy battery.
27. photovoltaic system according to claim 26, wherein the size of this photovoltaic cell is taken advantage of 2 inches greater than about 2 inches.
28. photovoltaic system according to claim 27, wherein the size of this photovoltaic cell is about 4 inches and takes advantage of 4 inches.
29. photovoltaic system according to claim 27, wherein the size of this photovoltaic cell is taken advantage of 4 inches greater than about 4 inches.
30. photovoltaic system according to claim 26, wherein this photovoltaic cell has the thickness between about 0.01 inch and about 0.018 inch.
31. photovoltaic system according to claim 1, wherein this photovoltaic layer comprises a plurality of photovoltaic cells in the two dimensional array of being expert at and being listed as that distributes.
32. photovoltaic system according to claim 31 further comprises the electric connector that is connected to each other these a plurality of photovoltaic cells so that can extract electric energy from that.
33. photovoltaic system according to claim 1, wherein this top protective layer is anti-soil, fluoro-containing copolymer film.
34. photovoltaic system according to claim 33, wherein this fluoro-containing copolymer film is the matte finish film.
35. photovoltaic system according to claim 33, wherein this fluoro-containing copolymer film is made by being selected from following compound:
(a) ethylidene-tetrafluoroethene;
(b) ethylene, propylene fluoride;
(c) perfluoro alkoxy;
(d) tetrafluoroethylene/hexafluoropropylene/vinylidene fluoride; Or
(e) polyvinylene fluoride.
36. photovoltaic system according to claim 33, wherein this fluoro-containing copolymer film is made by ethylidene-tetrafluoroethene and is had about 0.002 inch thickness.
37. photovoltaic system according to claim 1, wherein this top protective layer is made by glass.
38. photovoltaic system according to claim 1, wherein this top protective layer has level and smooth top surface.
39. photovoltaic system according to claim 1, wherein this top protective layer has the top surface of tool lines.
40. a photovoltaic system comprises:
Base flexible membrane;
Photovoltaic layer with at least one photovoltaic cell that combines with it;
Be used for giving the photovoltaic layer rigidity and protect photovoltaic layer to avoid being exposed to the top transparent semi-rigid layer of environment;
This photovoltaic layer is disposed between base flexible membrane and the top semi-rigid layer;
This base flexible membrane, photovoltaic layer and top semi-rigid layer link together and form single structure.
41. according to the described photovoltaic system of claim 40, wherein this semi-rigid layer is made by glass.
42. a method of making photovoltaic system comprises:
Base flexible membrane and top semi-rigid layer are provided;
Photovoltaic layer with at least one photovoltaic cell that combines with it is set between base flexible membrane and top semi-rigid layer;
Described layer is linked together and form single structure.
43. a method of making photovoltaic system comprises:
Base flexible membrane and top transparent protective layer are provided;
Between base flexible membrane and top protective layer, semi-rigid layer is set and has the photovoltaic layer of at least one photovoltaic cell that combines with it;
Described layer is linked together and form single structure.
44. according to the described method of claim 43, wherein setting comprises:
The storehouse photovoltaic layer is to the top of base flexible membrane; And
The storehouse semi-rigid layer is to the top of photovoltaic layer.
45. according to the described method of claim 43, wherein setting comprises:
The storehouse semi-rigid layer is to the top of base flexible membrane; And
The storehouse photovoltaic layer is to the top of semi-rigid layer.
46. according to the described method of claim 45, taking a step forward in connection comprises:
First adhesion coating is set between base flexible membrane and semi-rigid layer;
Second adhesion coating is set between semi-rigid layer and photovoltaic layer; And
The 3rd adhesion coating is set between photovoltaic layer and top protective layer.
47. according to the described method of claim 46, wherein this connection comprises and connects at least base flexible membrane to the top protective layer.
48. according to the described method of claim 46, wherein this connection comprises and being pressed together layer by layer described.
49. according to the described method of claim 48, wherein lamination comprises:
Place described layer to laminating machine, this laminating machine has:
The top of definition upper chamber,
The lower part of definition lower chambers,
Be installed on the dividing plate on top, be used to separate upper chamber and lower chambers, and
Be arranged in the heating plate of lower part;
Find time the going up and the air of lower chambers of laminating machine;
Described layer between compression dividing plate and the heating plate;
Heating plate is heated to enough temperature so that first, second and third adhesion coating activates, thereby makes described layer begin to engage one another; And
Cool off described layer.
50. according to the described method of claim 49, further be included in cooling finishing photovoltaic system afterwards, finishing comprises:
Repair any excessive material from photovoltaic system;
Electric connector is installed to photovoltaic system; And
Photovoltaic system is carried out the quality control test.
51. according to the described method of claim 48, wherein lamination comprises:
Place described layer to laminating machine, this laminating machine has:
The top of definition upper chamber,
The lower part of definition lower chambers,
Be installed on the dividing plate on top, be used to separate upper chamber and lower chambers, and
Be arranged in the last heating plate on top, and
Be arranged in the following heating plate of lower part;
Find time the going up and the air of lower chambers of laminating machine;
Heating plate is to realize the preheating of dividing plate in the heating first;
Compression preheating dividing plate reaches the described layer between the heating plate down;
Following heating plate is heated to enough temperature so that first, second and third adhesion coating activates, thereby makes described layer begin to engage one another; And
Cool off described layer.
52. according to the described method of claim 45, connecting takes a step forward comprises:
First adhesion coating is set between semi-rigid layer and photovoltaic layer; And
Second adhesion coating is set between photovoltaic layer and top protective layer.
53. according to the described method of claim 52, wherein connection comprises:
Earlier that semi-rigid layer, first adhesion coating, photovoltaic layer, second adhesion coating and top protective layer is laminated together; And
Then this semi-rigid layer is fixed to this base flexible membrane.
54. according to the described method of claim 53, wherein the step of lamination further comprises:
Place semi-rigid layer, first adhesion coating, photovoltaic layer, second adhesion coating and top protective layer to laminating machine, this laminating machine has:
The top of definition upper chamber,
The lower part of definition lower chambers,
Be installed on the dividing plate of lower part,, reach in order to separate upper chamber and lower chambers
Be arranged in the heating plate of the lower part of laminating machine;
Find time the going up and the air of lower chambers of laminating machine;
Semi-rigid layer, first adhesion coating, photovoltaic layer, second adhesion coating and top protective layer between compression dividing plate and heating plate;
Heating plate is heated to enough temperature activating first and second adhesion coating, thus the engaging one another of beginning semi-rigid layer, photovoltaic layer; And
The cooling laminate layers.
55., wherein should comprise fixedly that the method by non-thermal activation sticker made base flexible membrane adhere to semi-rigid layer according to the described method of claim 54.
Applications Claiming Priority (3)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| US54449704P | 2004-02-17 | 2004-02-17 | |
| US60/544,497 | 2004-02-17 | ||
| US10/964,612 | 2004-10-15 |
Publications (1)
| Publication Number | Publication Date |
|---|---|
| CN1950954A true CN1950954A (en) | 2007-04-18 |
Family
ID=38019412
Family Applications (1)
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| CNA2005800115714A Pending CN1950954A (en) | 2004-02-17 | 2005-02-04 | Photovoltaic system and method of making same |
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| Country | Link |
|---|---|
| CN (1) | CN1950954A (en) |
Cited By (7)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| CN102338891A (en) * | 2010-07-20 | 2012-02-01 | 麦建进 | Protection film of optical membrane |
| CN102709358A (en) * | 2012-01-05 | 2012-10-03 | 北京东方雨虹防水技术股份有限公司 | Waterproof integrated pressure-sensitive-adhesive modularized crystalline silicon solar power generation board system and preparation method thereof |
| CN102738277A (en) * | 2012-01-05 | 2012-10-17 | 北京东方雨虹防水技术股份有限公司 | Chain-plate solar power generation waterproof integrated board system and preparation method thereof |
| CN103563246A (en) * | 2011-04-01 | 2014-02-05 | 纳沃萨恩公司 | Shingle-like photovoltaic modules |
| CN105637653A (en) * | 2013-10-17 | 2016-06-01 | Das能源有限公司 | Photovoltaic panel and method for producing same |
| CN104241419B (en) * | 2014-08-28 | 2017-02-15 | 上海空间电源研究所 | Thin film type semi-rigid solar cell array and manufacturing method thereof |
| WO2018076524A1 (en) * | 2016-10-31 | 2018-05-03 | 上迈（香港）有限公司 | Preparation method for laminated structure of photovoltaic assembly, laminated structure, and photovoltaic assembly |
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2005
- 2005-02-04 CN CNA2005800115714A patent/CN1950954A/en active Pending
Cited By (11)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| CN102338891A (en) * | 2010-07-20 | 2012-02-01 | 麦建进 | Protection film of optical membrane |
| CN103563246A (en) * | 2011-04-01 | 2014-02-05 | 纳沃萨恩公司 | Shingle-like photovoltaic modules |
| CN102709358A (en) * | 2012-01-05 | 2012-10-03 | 北京东方雨虹防水技术股份有限公司 | Waterproof integrated pressure-sensitive-adhesive modularized crystalline silicon solar power generation board system and preparation method thereof |
| CN102738277A (en) * | 2012-01-05 | 2012-10-17 | 北京东方雨虹防水技术股份有限公司 | Chain-plate solar power generation waterproof integrated board system and preparation method thereof |
| CN102709358B (en) * | 2012-01-05 | 2015-09-02 | 北京东方雨虹防水技术股份有限公司 | A kind of self-adhering-type modular crystal silicon solar generating waterproof integrated board system and preparation method thereof |
| CN105637653A (en) * | 2013-10-17 | 2016-06-01 | Das能源有限公司 | Photovoltaic panel and method for producing same |
| CN105637653B (en) * | 2013-10-17 | 2018-02-02 | Das能源有限公司 | Photovoltaic panel and the method for manufacturing photovoltaic panel |
| CN104241419B (en) * | 2014-08-28 | 2017-02-15 | 上海空间电源研究所 | Thin film type semi-rigid solar cell array and manufacturing method thereof |
| WO2018076524A1 (en) * | 2016-10-31 | 2018-05-03 | 上迈（香港）有限公司 | Preparation method for laminated structure of photovoltaic assembly, laminated structure, and photovoltaic assembly |
| CN108376717A (en) * | 2016-10-31 | 2018-08-07 | 上迈（香港）有限公司 | The preparation method and laminar structure of photovoltaic module laminar structure, photovoltaic module |
| CN108376717B (en) * | 2016-10-31 | 2020-05-12 | 上迈(镇江)新能源科技有限公司 | Preparation method of photovoltaic module laminated structure, laminated structure and photovoltaic module |
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