DE102009022725A1 - Process for the production of a solar module - Google Patents

Abstract

The present invention relates to a method for producing a solar module. In this case, a support structure (28) is partially flooded by means of a low-viscosity, crosslinking material, after the at least partial reactivation of the crosslinking material photovoltaic cells (52) are applied to the flooded support structure, wherein contact lines (54) protrude beyond the coating and each with connecting conductors can be brought into contact. Subsequently, an electrically conductive connection between the contact lines and the connecting tracks is produced, flooded the top of the photovoltaic cells (52) and the contact lines and the connecting tracks with a low-viscosity crosslinking material, which is translucent in the cured state, and after the at least partial curing of the crosslinking, translucent material applied to a cover plate on the at least partially cured, translucent material.

Description

The The present invention relates to a process for the preparation of a Solar module (also called solar panel), in which photovoltaic cells or elements poured and applied to a support structure are.

It is known to produce solar modules in which photovoltaic cells are embedded in a casting system, in particular in a polyurethane material. Such an approach is from the DE 101 01 770 A1 known. The solar module is at least provided on the front side with a transparent polyurethane material.

Incidentally, is generally on the DE 20 2006 015928 , the DE 10 2008 033 313 and the DE 10 2008 048 160 pointed out, in the latter two documents, inter alia, certain process steps for the production of solar modules are given.

task The present invention is another method of preparation specify a complete solar module with which the photovoltaic cells preferably not be damaged, which is efficient is durable and with that against environmental influences durable solar modules can be produced.

These Task is procedurally by in the Claims 1 and 2 mentioned features solved.

Accordingly, become the photovoltaic cells (sometimes called photovoltaic elements) gradually in a cross-linking material, for example a polyurethane material, shrouded (flooded or flooded). Between The individual flooding steps are the electrical Supply and return (hereinafter also referred to as electrical Contact lines referred to) to the individual photovoltaic cells by making electrically conductive connections (eg through Soldering) between those coming from the photovoltaic cells Contact lines and the general supply lines Connection points made. These contact lines and connection points are up to electrical contacting with the connecting conductors - finally also completely wrapped in the cross-linking material, so this as Protective layer not only the photovoltaic cells, but also the Top of the support structure and the entire wiring surrounds.

alternative to the arrangement with the electrical contact lines can also be provided that the individual photovoltaic elements directly on associated connection points, in the support structure are embedded, come to rest and so an electrical connection is made. However, then make sure that at the coating of the corresponding position with a cross-linking Material the contact points are kept free.

At the The end of the manufacturing process becomes the topmost crosslinking layer preferably covered with a pane that is as possible with the upper, translucent, crosslinking layer connects to an integral unit. The disc ensures in particular a high weather resistance and durability of the solar module. As a disk can be a glass plate or disk or a plastic disc (commonly referred to as a cover plate) used become. When using a plastic cover plate this example consist of PMMA.

Corresponding an alternative of the production process according to the invention can during the first flooding process, the support structure partially flooded and in a second step the photovoltaic cells applied to the thus coated support structure become. In this second step come the photovoltaic cells preferably over the entire surface and just on the coating which avoids that, in the event of further and pouring the photovoltaic cells by a pressure load damaged or even destroyed. This is especially the case when the cross-linking material between Carrier structure and photovoltaic element hardens, so the photovoltaic cells are fully supported are.

there protrude the contact lines leading to the photovoltaic cells and connect them both with each other and later with the connectors, via the coating addition, so that it with the connection contacts, - too Connection points or connecting conductors called - in Contact are brought.

The Production of the electrically conductive connections between the contact lines and the associated connection points, for example, by means of a soldering, bonding, mechanical clamping connection or other connection techniques are realized. Insofar is in the Following the term "soldering" or "soldering" representative of Connection techniques in general. Then the topside becomes the photovoltaic cells and the contact lines and the connecting tracks with flooded with a low-viscosity crosslinking material, which translucent in the cured state is. In this respect, the electrical contact between the electrical Contact lines and the connection points embedded in a cross-linked material.

alternative for applying the first flooding process on the Carrier structure can also be the photovoltaic cells first be flooded with a cross-linking material, wherein also in this case, the contact lines on through the flooding created protrude coating so that following a contact with the connection points on the Carrier structure is possible. The flooded Photovoltaic elements are then applied to the support structure applied, with the contact lines each with connection points must be brought into contact. After the production of electrical connection between contact lines and connection points be the front of the photovoltaic cells and the contact lines and the connection points in turn with a low-viscosity crosslinking Material flooded, which in the cured Condition is translucent.

When Carrier structure are suitable almost all materials. Especially however, the use of polybutylene terephthalate has proven advantageous proven, in particular, if this is reinforced by means of fibers.

The positioning of the photovoltaic cells can be done, for example, by pivoting together specially created mold halves or simply by a robotic device that positions the interconnected photovoltaic cells on the coated support structure. In this regard is on the DE 10 2008 033 313 and the DE 10 2008 048 160 pointed.

For the case that while a cross-linking material (eg., On the top the support structure) is not yet fully reacted when joining a connection between the individual elements instead, making these elements after curing the networked Materials are firmly joined together. To a liability of the to ensure that the material is cross-linked with another component, can be the surface of the component to which the cross-linking Material is applied or with the cross-linking material comes into contact, be activated. This is for example possible by a plasma. But others too Activations of the surfaces are possible.

There the photovoltaic cells by electrical lines (so-called strings) are connected, which meander, for example between the individual photovoltaic cells, there is a risk that the photovoltaic cell structure is not complete just rests on the tool part. To avoid this risk, The individual cells are aspirated with vacuum to just put them on to place the tool surface. It can be helpful be when the tool surface on which the cells are placed are at least slightly elastic, so that at least the strings are something in the surface of the can dive elastic surface. With This measure would also be a full-scale Assurance of individual photovoltaic cells ensured on the coating.

Should it in any Übergießprozess or in the Compress to an overflow of material, so this excess material will be below separated. Preferably, however, such an overflow should be prevented, for example by the use of appropriate seals.

Around the glass plate as free of bubbles on the translucent Apply layer, it is preferably first on placed on one side and then applied with a folding movement, allowing them to gradually move from one page to the next with the material for the translucent layer comes into contact and the air evenly escape can. Before putting the glass plate, it can first fitted into the tool and then to the tool fixed with its own device to one ensure later exact fit. This can be, for example done by means of its own framework, with which the tool inserted glass plate opposite the tool in defined and fixed in relation to the frame so that they are subsequently removed and reinserted can be.

The Connection between the electrical contact lines and the connection points can be achieved for example by a respective soldering become. This soldering can be done in an alternative when closed Tool through an opening of a tool part through respectively. Alternatively, the compound may in particular be the soldering as well be carried out with the tool open.

With However, not only the photovoltaic cells can be under-pressure be fixed to a tool part, but also the support structure at the in the associated tool part. With such vacuum fixations It is possible to align the respective parts in Way to fix a handling (eg pivoting) of tool parts to allow without them facing each other Move a fixed position.

With but it is not only possible to to generate a corresponding negative pressure, but also an overpressure. Such can be phased when removing parts or products to be helpful.

adversely it is when in the cross-linked top layer, so the polyurethane layer, especially on the surface, air bubbles or air pockets available. Such air pockets reduce selectively the transmission of the cover layer and thus the photoelectric Yield of the entire module. For that reason should be ensured be that such air pockets are not present. Especially if the risk of such air pockets should these, after the application of the cross-linking material - at least of the material for the surface of the solar cell - removed become. This can, for example, by applying a vacuum or by applying heat to the surface by means of a heat source happen.

Around to avoid, for example, that introduced into a tool Moving photovoltaic cells out of their order structure can do this arranged on a foil prior to application or application (attached) be. This film is then on after applying the photovoltaic cells the coated support structure removed so that then the tops of the photovoltaic cells freely accessible are.

Further Features and advantages of the present invention are set forth in the claims formulated.

The The present invention will now be described by way of concrete embodiments and explained in more detail with reference to the accompanying drawings. The Drawings show in

1 a schematic perspective view of a tool including frame for aligning the glass pane for carrying out the method according to the invention,

2 a schematic exploded view of the lower part of the tool,

3 a schematic exploded views of the upper part of the tool,

4 a schematic exploded view of the frame for alignment of the glass frame,

5 a schematic perspective view of an open tool with inserted photovoltaic cells and support structure,

6 a schematic perspective view of an open tool with aligned glass and mounted frame,

7 a schematic perspective view of a closed tool with inserted photovoltaic cells and support structure,

8th a schematic perspective view of a closed and opposite to the 7 180 ° turned tool,

9 a schematic perspective view of an open tool with applied on the support structure photovoltaic cells,

10 a schematic perspective view of an open tool, wherein the glass plate is applied to the not completely cured, translucent coating with the frame

11 a schematic perspective view of an open tool with fully applied glass plate,

12 a schematic perspective view of an open tool with a fully manufactured solar panel,

13 a schematic perspective view of an open tool with a fully manufactured and removed from the tool solar panel,

14 a schematic sectional view through a closed tool,

15 an enlarged detail of the sectional view 14 and

16 an enlarged detail like 15 , but now with inserted glass plate.

In the 1 - 16 a concrete embodiment of the present invention is shown. This describes a possibility of a method. However, this is not to be understood as limiting the scope of protection. Other process sequences or combinations of processes may also readily fall within the scope of the present invention.

In 1 a tool is shown in the closed state, with which the present method can be carried out. The tool 10 consists of a tool shell 12 and a tool lower part 14 , which are both pivotally connected to each other via a hinge at the rear. Over two oppositely arranged locking devices with locking lever 18 can the two tool parts 12 and 14 be set closed to each other in the closed state.

In 1 above the tool 10 is still one handling framework 16 which will be explained later and whose function will become clear later.

First, the tool should 10 be explained in its rough components.

In 2 is the tool base 14 shown in an exploded view. It consists essentially of a housing with a square recess, which the application space 32 for an insert 30 represents. This insert 30 can be kept variable so that different solar panels can be made. The insert part 30 becomes the mission space 32 inserted positively. At the in 2 shown top of the insert 30 is formed a circumferential groove into which a seal 26 , which is slightly over the groove, is inserted. Moreover, in the insert part 30 - not specified - a Luftabsaugkanal (see also 14 ) and Luftabsaugnuten arranged so that one on the insert part 30 arranged carrier plate via a negative pressure on the insert part 32 and within the tool base 14 can be recorded and held. The seal is used 26 to seal the negative pressure area against the outside environment and thus to maintain the negative pressure.

In 2 can still be seen here, the joint bearing separately shown 24 , which on the housing of the tool base 14 is screwed on.

In 3 is the tool shell 12 shown in more detail. It essentially comprises a plate with an upwardly projecting plate, on which a dipping edge 36 , is formed. At the top of the plate 34 comes the photovoltaic element 52 to lie. The top of the plate 34 has various grooves, including an outer circumferential groove in which a likewise circumferential and slightly protruding seal 38 is included. In addition, four substantially rectangular and uniformly juxtaposed sealing and suction channels are provided, wherein in the sealing channels in each case a segmental seal 50 can be used.

In 3 not to be recognized (see, however 8th ) Intake channels for negative pressure or positive pressure generation are provided in each segment, so that individual elements of the photovoltaic cells 52 safely by means of negative pressure on the top of the plate 34 can be kept. Here are the seals 50 again to maintain the negative pressure, so that the photovoltaic cells can be held on the tool upper part.

In 3 is a photovoltaic element with four individual cells 52 represented, whereby the cells over two so-called strings 54 - Also called electrical contact lines - are connected together. In the present case, the strings meander the cells so that they come to lie alternately on one side on the back and then again on the other front. This is due to the electrical interconnection of the different cells.

In 4 is the handling frame 16 shown in detail. This comprises a substantially rectangular frame 62 , is attached to the double-cross a support structure. This entire construction of the handling frame 16 can be grasped and moved in two easy steps. At the support structure 60 At the bottom four suction cups are arranged (as shown in the exploded view in 4 becomes clear) to a glass plate 66 safe to hold.

Now starting with 5 the process of the invention explained in more detail. When an open tool is in the tool shell 12 the photovoltaic element 52 with the four cells inserted, in such a way that the individual photovoltaic cells on the respective sealing and suction channels 40 come to rest and by conditioning of negative pressure corresponding to the upper tool 12 can be kept. This negative pressure is so strong that the photovoltaic cells are securely fixed on the one hand. On the other hand, they are due to the meandering string now firmly to the possibly slightly elastic upper side 34 of the tool shell 12 pressed that a flat photovoltaic element surface is created.

It is essential that the electrical contact lines of the photovoltaic element 52 project beyond an area in which later a cross-linked element is introduced. This area is limited by the seal 38 , so that in this case the electrical contact elements 54 about this seal 38 reach out and into the area where two breakthroughs 56 (see also 8th ) in the tool shell 12 are arranged.

The photovoltaic cells 52 are thus also within the seal 38 arranged, which ensures that a crosslinking material to be filled later does not overflow.

In the tool lower part 14 is a carrier plate 28 or carrier structure inserted. This is in the present case formed from a polybutylene terephthalate in fiber-reinforced form. The support structure adjoins directly to the housing walls and lies on the seal 26 on.

In the next (intermediate) step will be in 6 the glass plate 66 initially loose on the support structure 28 hung up. Subsequently, the frame becomes 16 in relation to the tool base 14 defined manner, so that it is aligned with respect to the tool in a precise, replicable position. In this position, the suction cups capture 64 the glass plate and fix it to the frame 16 , Subsequently, the glass plate 66 by means of the frame 16 lifted.

In the next process step, a crosslinking polyurethane material is applied to the photovoltaic cells 52 within the scope of the seal 38 applied. By taking the photovoltaic cells 52 inside the seal it is avoided that the polyurethane material expires. In this respect, the polyurethane material is maximum up to the upper limit of the protruding seal 38 be filled. Eventually, before the step of introducing the polyurethane material, the surface of the photovoltaic elements must 52 are still activated, for example via an application of a plasma jet.

After application of the polyurethane material, as in 6 is shown, the lower tool part 14 on the tool top 12 pivoted, resulting in the lower tool 14 held carrier structure 28 placed on the polyurethane layer and connects with this conclusive. After curing or curing of the polyurethane material, the tool - as in 8th can be seen - rotated by 180 °. Now the two openings 56 to recognize, in which over the coating of the photovoltaic element 52 protruding electrical contact lines 54 can be seen. These contact lines 54 are now on connection points (not shown) of the support structure 28 and can be soldered through the opening. Alternatively, the soldering could also be done with the tool open. Is the polyurethane material between the support structure 28 and the photovoltaic element 52 Hardened, the tool can after releasing the locking lever 18 opened and the tool shell 12 be swung away.

This is in 9 that on the support structure 28 to see connected via the polyurethane layer photovoltaic element, on which now another polyurethane material is introduced. This polyurethane material is chosen so that it is translucent after curing. With this flooding, the area of the contact points and the connection points is now flooded, so that an overall uniform surface is created.

Before complete curing of this translucent polyurethane layer is now - as in 10 shown - the frame 16 with the glass plate fixed on it 66 in a defined way on the lower tool part 14 arranged and applied with a pivoting movement on the intermediate product or not yet completely cured polyurethane material on the surface of the photovoltaic elements. After the complete placement of the glass plate 66 is reached a procedural stage as it is in 11 is shown. After curing of the last applied polyurethane material of the handling frame 16 be removed and there is now a substantially completely manufactured product in the tool base 14 in front. Now this product can be removed after switching off the vacuum, which is in 13 is shown.

In 14 the construction of the tool in cross section can be seen in detail, wherein in the closed tool between the lower tool part 14 and tool shell 12 or between the variable insert 30 and the tool shell 12 the support structure 28 is arranged with polyurethane layer and photovoltaic element. Clear are now both the vacuum channels 42 in the tool upper part 12 as well as to detect a vacuum channel in the lower part of the tool.

In 15 is an enlarged detail from 14 shown. It can be seen on the one hand, that the support structure 28 full surface on the variable insert 30 rests and over a seal 26 the vacuum for holding the support structure to the insert part 30 can be held. Moreover, this is the photovoltaic element 52 represented, which is indeed on the seal 50 out, but not to the seal 38 extends. The seal 38 in turn forms the conclusion for the polyurethane layer with which the photovoltaic elements 52 are flooded.

In 16 the glass plate is shown superimposed, which in turn extends over the entire solar panels.

In this way, a solar panel can be integrally formed, which has a support frame or a support structure, between the and a photovoltaic element 52 a polyurethane layer is arranged with different cells, which, however, does not extend into the region of the connection to the respective connecting points. This connection between electrical contact and connection points is produced by means of a soldering and then the overall construction is covered with a further polyurethane layer, which is translucent in the cured state, and a glass plate. These solar panels can now be used and, for example, placed on a roof, wherein the support structure is placed in corresponding brackets, wherein the contact points are guided to the outside to electrical connection contacts.

Naturally in the present case can manually move to workpieces also be designed automatically in the form of a manufacturing cell. The handling frame may then be, for example, by a robotic arm be replaced. The individual components can also be over Feeding devices are supplied.

typical Component thicknesses can be used for the support structure 3 to 10 mm, for the polyurethane coating 1 to 3 mm and for the PMMA disc be 1 to 4 mm.

10

Tool

12

Upper die

14

Lower die

16

handling framework

18

Locking lever

20

joint

22

handle

24

Joint-stock

26

poetry

28

support plate

30

Variables insert

32

Situation room in the tool lower part

34

top

36

dipping edge

38

circumferential seal

40

Seals and intake ducts

42

channels for underpressure and overpressure generation

50

segment seal

52

Photovoltaic element with strings

54

strings

56

breakthrough in the tool upper part

60

holding structure

62

frame

64

suction cup

66

Glass / cover plate

70

With PUR doused intermediate

72

end product

QUOTES INCLUDE IN THE DESCRIPTION

This list The documents listed by the applicant have been automated generated and is solely for better information recorded by the reader. The list is not part of the German Patent or utility model application. The DPMA takes over no liability for any errors or omissions.

Cited patent literature

• - DE 10101770 A1 [0002]
• - DE 202006015928 [0003]
• - DE 102008033313 [0003, 0014]
• - DE 102008048160 [0003, 0014]

Claims (20)

Method for producing a solar module comprising the steps of: - partially flooding a support structure ( 28 ) by means of a low-viscosity, crosslinking material, in particular by means of a polyurethane material, - at least partially reacting the crosslinking material, whereby the carrier structure ( 28 ) is partially coated, - applying with electrical contact lines ( 54 ) connected photovoltaic cells ( 52 ) on the flooded support structure ( 28 ), whereby the contact lines ( 54 ) are dimensioned such that they protrude beyond the coating and each with electrical connection points of the support structure ( 28 ) can be brought into electrical contact, - connecting the contact lines ( 54 ) with the associated electrical connection points to produce an electrically conductive connections, - Flooding the top side of the photovoltaic cells ( 52 ), the freely accessible contact lines ( 54 ) and the electrical connection points with a low-viscosity crosslinking material, which is translucent in the cured state, and - at least partial curing of the crosslinking, translucent material. Process for producing a solar module comprising the steps of: flooding the backs of electrical contact lines ( 54 ) connected photovoltaic cells ( 52 ) by means of a low-viscosity, crosslinking material, in particular by means of a polyurethane material, wherein the contact lines ( 54 ) protrude beyond the coating created by the flooding, - at least partially reacting the crosslinking material, whereby the photovoltaic cells ( 52 ) are partly poured or doused, - application of the intermediate thus produced to a support structure ( 28 ) such that the intermediate in electrical contact lines ( 54 ) connected photovoltaic cells ( 52 ) with its rear side of the carrier structure ( 28 ) and the contact lines can each be brought into contact with electrical connection points, - electrical connection of the contact lines ( 54 ) with the associated electrical connection points to produce an electrically conductive connection, - complete flooding of the front side of the photovoltaic cells ( 52 ) and the freely accessible contact lines and the electrical connection points with a low-viscosity crosslinking material which is translucent in the cured state, and - at least partial curing of the crosslinking, translucent material. A method according to claim 1 or 2, characterized in that finally a cover plate ( 66 ) is applied to the at least partially cured, translucent material. Method according to claim 3, characterized in that the cover plate ( 66 ) already before the coating of the carrier structure ( 28 ) in a tool part ( 14 ) on the support structure ( 28 ) or applied and with respect to the support structure ( 28 ) is aligned. Method according to one of the preceding claims, characterized in that a two-part tool ( 12 . 14 ) is used, wherein in a tool part ( 12 ) the photovoltaic cells ( 52 ) and in another tool part ( 14 ) the support structure ( 28 ) is recorded. Method according to one of the preceding claims, characterized in that the support structure ( 28 ) is formed from polybutylene terephthalate, in particular reinforced with fibers. Method according to one of the preceding claims, characterized in that the preparation of the electrically conductive Connection by soldering happens. A method according to claim 7, characterized in that the soldering through a recess ( 56 ) of a tool part ( 12 ) through. Method according to one of the preceding claims, characterized in that the photovoltaic cells ( 52 ) by means of negative pressure on a tool part ( 12 ) being held. Method according to claim 9, characterized in that the photovoltaic cells ( 52 ) are sucked by means of negative pressure to a pad so that they are aligned. A method according to claim 10, characterized in that the orientation of the cover plate ( 66 ) with an alignment frame ( 16 ) is carried out. Method according to one of claims 10 or 11, characterized in that each element of the photovoltaic cells ( 52 ) separately by means of a vacuum device ( 40 ) is held. Method according to one of the preceding claims, characterized in that the application of the photovoltaic cells ( 52 ) on the flooded support structure ( 28 ) is performed when not fully reacted state of the crosslinking material, so that the photovoltaic cells ( 52 ) at least slightly into the crosslinking material pressed or connecting pressed. Method according to one of the preceding claims, characterized in that the cover plate ( 66 ) is carried out on the translucent material in the not yet fully reacted state of the crosslinking material, so that the glass plate ( 66 ) can be pressed at least slightly or can be pressed on connecting. Method according to one of the preceding claims 2 to 8, characterized in that the cover plate ( 66 ) is pressed by a folding movement. Method according to one of the preceding claims, characterized in that after the application of the crosslinking Material any air pockets are removed. Method according to claim 16, characterized in that a vacuum is applied to remove the trapped air becomes. Method according to claim 17, characterized in that that for removing the air bubbles a heat source is used, with the heat at the surface is applied. Method according to one of the preceding claims, characterized in that the photovoltaic cells ( 52 ) are arranged on a film prior to application to the flooded carrier structure and that this film after application of the cross-linking material to the photovoltaic cells ( 52 ) is removed. Method according to one of the preceding claims, characterized in that prior to mounting or introducing the crosslinking Materials the surface on which the crosslinking material is applied, is activated.