DE102010030559A1 - Method of making a thin film solar module and thin film solar module - Google Patents

Abstract

The invention relates to a method for producing a thin-film solar module with the following steps: providing a first transparent substrate with an active area for converting solar energy, providing a second substrate, holding the first and second substrate parallel to one another at a predetermined distance from one another, with the active area between first and second substrate is arranged, filling the gap with a liquid material and curing the liquid material, whereby the active area is encapsulated. The invention further relates to a method for producing a thin-film solar module with the steps of providing a first transparent substrate with an active area for converting solar energy, applying a liquid material to the side of the transparent substrate with the active area, and curing the liquid material, thereby creating the active area is encapsulated. The invention also relates to correspondingly manufactured solar modules.

Description

The invention relates to a method for producing a thin-film solar module and to thin-film solar modules produced in this way.

Such modules are known. A thin film solar module comprises a first translucent substrate, typically of glass. This element is also referred to as a front glass, as it faces the sun and light is incident on this element in the photovoltaic module. On the translucent substrate is a transparent conductive layer. This is followed by at least one photovoltaically active layer. In this layer, the incident light is converted into electricity. On the other side of the active layer is a second conductive layer, in particular a second transparent layer, which is for example made of the same material as the first transparent conductive layer. These layers form the so-called active area. Via a plastic film, for example made of PVB or EVA, the structure with a second substrate, preferably made of glass (also called back glass) or TEDLA film, whereby the active area is encapsulated to protect it from negative environmental influences.

These modules are produced in a lamination process using a vacuum laminator or autoclave. This is time consuming and can only be done in batch mode.

It is therefore an object of the invention to simplify the production process in order to be able to provide a continuous process.

This object is achieved with the method for producing a thin-film solar module according to claim 1. According to the invention, the method comprises the steps of: a) providing a first translucent substrate having an active region for converting solar energy, b) providing a second substrate, c) holding the first and second substrates parallel to one another at a predetermined distance from each other, wherein the active region between the first and second substrates, d) filling the gap with a liquid material, and e) curing the liquid material thereby encapsulating the active region. With this method, one can dispense with the use of the autoclave and the process can be carried out in a continuous process. This simplifies the manufacturing process.

The object is further achieved with the method for producing a thin-film solar module according to claim 2. This comprises the steps of: f) providing a first translucent substrate having an active region for converting solar energy, g) applying a liquid material to the side of the translucent substrate with the active region, and h) curing the liquid material thereby encapsulating the active region becomes. Also according to this method, one can dispense with the use of an autoclave and perform the process in a continuous process. In addition, it is still possible to dispense with the use of the second substrate, which is usually made of glass and therefore quite heavy in this process. The modules become lighter and the construction easier.

Preferably, prior to step h), one or more fasteners may be provided for attaching the thin film solar module to a substructure and / or one or more electrical connection devices and / or one or more reinforcing elements over the side of the translucent substrate having the active region and after step h) the hardened material integrated, in particular positively connected, be. Thus, in one process step, the further elements required for the use of a module can be integrated. Additional glue steps are therefore no longer necessary. The connection devices can be designed so that means for strain relief of the connection cable of the active area can be poured simultaneously with the encapsulation.

Preferably, in step g), a mold can be provided in which the liquid material is filled. With the help of the mold thus any geometric structures for the encapsulation can be achieved.

According to a further preferred embodiment of the invention, the steps g) and h) are performed several times to form a plurality of layers. Preferably, different shapes can be used for the multiple layers. So you can selectively arrange more material at predetermined locations.

Advantageously, after step h), the hardened material may have different thicknesses, in particular in the form of reinforcing ribs. When using reinforcement areas, the necessary stability can be ensured by the encapsulation material and thus the use of steel, aluminum or stainless steel elements, as is still common in the known modules, can be considerably reduced. Thanks to the areas with different thicknesses, the module can be load-optimized, voltages can be compensated and / or voltage peaks can be recorded.

Preferably, the one or more fasteners and / or the one or more Connecting devices and / or the one or more reinforcing elements are arranged so that they are after step h) in thicker areas of the cured material. As a result, the use of materials is further improved.

Advantageously, the reinforcing ribs may be at least partially arcuate. In such geometries can be made possible with optimization of the material use nevertheless a uniform load on the module, since the thicker areas can extend along areas of higher voltages.

According to a preferred embodiment, the liquid material can be provided so that after step h) the cured material protrudes laterally at least in sections over the edge of the substrate and / or surrounds the edge of the substrate. This also provides a protection area in a process step in order to prevent damage to the light-transmitting substrate.

Further advantageously, the cured material may have reflective properties, in particular a white color, and / or protective or stabilizing properties. This eliminates the need for additional reflective layers and the structure of the module can be further simplified. With protective or stabilizing properties, the lifetime can be extended. Preferably, the liquid material may be a polymer material, in particular a polyurethane plastic. Polymer materials are lightweight and can be cast in any shape. Thus, lighter modules can be provided, which nevertheless ensure the requirements for a long-lasting encapsulation.

Further preferably, fillers, in particular fiber reinforcements and / or fillers for influencing thermal and / or electrical properties, may be added in step d) or g). As a result, the structure of the module can be further optimized and optionally adapted to different purposes.

Particularly preferably, the additions can be designed so that inhomogeneous distributions result in the cured material. The inhomogeneous distributions can be formed laterally as well as in the direction of the layer thickness. For example, the layers provided by repeating steps g) and h) may have different properties from each other to achieve such inhomogeneous distributions. For example, one layer can be made electrically conductive, while another layer is particularly reinforced. Overall, the properties of the module can be further improved by the inhomogeneous addition.

The object of the invention is also achieved by the solar module according to claim 14. This module may in particular be a thin-film solar module and comprises a first transparent substrate having an active region for converting solar energy, a second substrate and a layer connecting the transparent substrate and the second substrate, wherein the active region is arranged between the first and second substrates characterized in that the connecting layer is made of a cured polymer material. This provides a solar module that is easier to manufacture than conventional plastic-film modules.

The object of the invention is likewise achieved with a solar module according to claim 15. This may in particular relate to a thin-film solar module and comprises a first translucent substrate with an active region for converting solar energy, characterized in that the active region is covered by an encapsulation unit made of a cured polymer material, which also forms the back construction of the solar module. As a result, a lighter module can be provided compared to the known glass-glass thin-film solar modules.

The polymer material may preferably have filling materials for influencing thermal and / or electrical properties. As a result, the structure of the module can be further optimized and optionally adapted to different purposes.

Advantageously, the encapsulation unit can have a plurality of layers, in particular with different thermal and / or electrical properties. The encapsulation unit can thus fulfill a number of tasks in addition to the encapsulation: provision of electrically conductive regions, for example to simplify the arrangement of the interfaces, rigidity of the module, etc.

Preferably, the encapsulation unit projects laterally beyond the edge of the substrate at least in sections and / or surrounds the edge of the substrate. This allows the substrate to be protected against breakage. In particular, the assembly is facilitated.

Advantageously, the encapsulation unit can have different thicknesses. Thus, for example, in thicker areas, further elements of a module can be inserted, or else the structure of the module can be stiffened.

In this case, one or more fastening elements for attaching the thin-film solar module to a substructure and / or one or more electrical connection devices and / or one or more reinforcement elements can be integrated into the encapsulation unit over the side of the light-transmissive substrate with the active region. Particularly advantageous is a positive connection. This eliminates the need for expensive attachment steps such as gluing or screwing.

Hereinafter, with reference to the following figures, embodiments of the present invention will be described and explained in detail. Show it

1a - 1c a first embodiment of the invention,

2a - 2d a second embodiment of the invention,

3 a variant of the solar module resulting from the method according to the second embodiment,

4 a second variant of a solar module, which results from the method according to the second embodiment,

5 a schematic cross-sectional view along the section line AA of 4 .

6 A third variant of a solar module, which results from the method according to the second embodiment,

7 schematically a cross-sectional view according to a fourth variant and

8th schematically a cross-sectional view according to a fifth variant.

The 1a to 1c show schematically a first embodiment of the invention. The solar modules are shown in cross section.

According to the steps a), b) and c) of claim 1 are in 1a a first translucent substrate 1 with an active area 3 for converting solar energy into electrical energy and a second substrate 5 provided. The second substrate 5 is spaced from the active area 3 but arranged essentially in parallel. The distance can be ensured for example via spacers, not shown here, which are arranged in the intermediate space. Alternatively, the two structures can also be arranged in each case on a holding device, which ensure the distance.

In this embodiment, the first light-transmissive substrate 1 and the second substrate made of glass. This element is also referred to as a front glass, as it faces the sun and light is incident on this element in the photovoltaic module.

The active area 3 is formed by a succession of different layers. On the translucent substrate 1 is usually a transparent conductive layer. This is followed by an active layer, for example a Si layer or a CdTe layer or a CiGSSe layer or else a tandem cell comprising a microcrystalline and an amorphous Si layer. In this layer, the incident light is converted into electricity. On the other side of the active layer is provided a second conductive layer, in particular a second transparent layer, which is usually but not necessarily made of the same material as the first transparent conductive layer. For example, SnO 2, ZnO or a metallic back contact can also be used here.

Maybe on the free surface 7 the active layer and / or the surface 9 the second substrate, a reflector layer can be provided. This may be a metal layer, a white film or a white-colored layer, in order to re-supply light not yet absorbed in the active layer.

According to step d) is then, as in 1b indicated schematically, the gap with a liquid material 11 filled. For this purpose, for example, a frame around the arrangement 13 be placed to prevent leakage of the material. The liquid material is a polymer material, in particular a polyurethane plastic.

According to step e) of claim 1, the liquid material is then cured whereby the active region 3 is encapsulated, so isolated from the environment. This is shown schematically in 1c ), wherein the cured layer is the reference numeral 15 wearing. To harden the material, an oven, preferably a continuous furnace, is used.

With this method can be dispensed with the use of a plastic film and thus on the more complex lamination process using an autoclave.

Particularly preferably, the liquid material is chosen so that it has reflective properties, whereby an additional Reflector layer is avoidable. This is achieved for example by a suitable color choice. Optionally, fillers may also be added to the liquid material to provide protective or stabilizing properties. This can for example affect the strength, the thermal expansion or the electrical properties.

The 2a to 2d schematically show a second inventive method.

According to step f) of the second claim, a first translucent substrate 1 with an active area 3 provided for converting solar energy into electrical energy. This will be in 2a illustrated. The substrate 1 and the active area 3 is structured the same way as already in connection with the 1a described. This description is hereby incorporated by reference.

2 B shows a shape 21 that have the free surface 7 of the active area 3 is put over. Form 21 includes one or more inlet nozzles 23 over the a liquid material in between the form 21 and the surface resulting free space 25 according to feature g) of claim 2 can be filled.

After filling the liquid material 11 , which has the same properties as already explained in connection with the first embodiment, in the free space 25 (please refer 2c ), the material is again cured in a furnace by thermal treatment, thereby forming the active region 3 is encapsulated. After that, the shape 21 , as in 2d are shown, removed and you get a thin-film solar module 27 which is composed of the first substrate 1 , the active area 3 and an encapsulation unit 29 ,

In addition to the advantages of the first embodiment, according to the second embodiment, it is possible to manufacture a solar module by using an encapsulation unit 29 made of plastic is lighter than the conventional glass glass products.

By using the form 21 also results in the possibility of encapsulation unit 29 to give any shapes. So the thickness of the layer needs 29 not to be constant over the module surface. As a result, it is possible, for example, to achieve reinforcing elements, such as ribbed structures, in one process step.

By repeating the steps in 2 B and 2c In addition, a multi-layer encapsulation unit can be used 29 provide, wherein the individual layers may have different properties in terms of strength, electrical conductivity, expansion coefficient, etc. This can be achieved, for example, by the incorporation of filler materials, such as electrically conductive particles or reinforcing fibers, into the liquid material 11 be achieved. In particular, different forms come 21 for use.

In a further embodiment of the second embodiment may also be a shape 21 are used, the lateral over the edges 31 of the active area 3 and possibly also over the edges 33 of the substrate 1 survives (see 2 B ). During curing, it then forms in the layer 29 ' an edge that protrudes laterally and possibly even the edges 33 of the substrate 1 covered and thus serves as edge protection. This is schematically in 3 shown. In one variant, the cured material may also partially over the edge 33 also on a border area 34 on the surface of the substrate 1 be present to further optimize the edge protection.

4 illustrates a second variant of a solar module resulting from the method according to the second embodiment. Shown is a solar module 41 with substrate 1 and active area 3 , these are no longer described in detail. It is merely referred to the description above. The encapsulation unit 29 '' in this embodiment includes arcuate reinforcing ribs 43 and 45 that serve the load on the module 41 to be optimized, to balance voltages and / or to pick up voltage peaks. To make these, it is enough a form 21 to use with appropriate structure. The structure may be in one or more steps by using a single mold or multiple molds 29 getting produced. For example, have the ribs 43 and 45 different material properties compared to the base area 47 you become two forms 21 deploy.

Naturally, more or less ribs can also be used according to the invention. These can also be straight.

In this embodiment, in addition, the electrical connection areas 51 and 53 of the module into the reinforcing ribs 43 and 45 integrated. The connection area 51 and 53 can represent their own components in the still liquid material 11 were inserted and then connected during curing of the material with the encapsulation unit, or be made directly by appropriate shaping of the encapsulation unit. In this case, for example, even a strain relief for the out of the active area 3 upcoming connection strips are provided.

The arrangement of the connection areas in the ribs is to be seen here only as a variant. Of course, the connection areas could also be outside of the ribs 43 and 45 be arranged.

4 also shows four fasteners 55 . 57 . 59 . 61 with the module 41 can be attached to a substructure. According to the invention, these may be integral with the encapsulation unit 29 '' be formed or represent their own elements, such as steel or stainless steel, in the production in the liquid material 11 held and then after curing in the encapsulation unit 29 '' integrated, for example via a positive connection, are.

5 shows this in a cross-sectional view along the section line AA. There you can recognize the substrate again 1 and the active area 3 , as well as the encapsulation unit 29 '' with the two ribs 43 and 45 , At the height of the fasteners 55 and 59 are in the encapsulation unit profiles 63 and 65 admitted. These are part of the fasteners 55 and 59 , Due to the open structure is the liquid material 11 entered the open profile and after curing, the fastener 55 and 59 thus in the encapsulation unit 29 '' held. The profiles 63 and 65 may in one embodiment each of the one fastener 55 respectively. 59 to the opposite fastener 57 respectively. 61 extend.

6 shows a third variant of a solar module 71 that results from the method according to the second embodiment. Shown is a solar module 71 with substrate 1 and active area 3 , these are no longer described in detail. It is merely referred to the description above. The encapsulation unit 29 ''' includes several layers 73 . 75 . 77 with different geometry. every layer 73 to 77 was with its own form 21 please refer 2 B , produced. The material properties of the individual layers, in particular the thermal and / or electrical properties, can be adapted from one layer to the next, for example by adding filler materials. This allows the mechanical, electrical and / or optical properties of the encapsulation unit 29 ''' be optimized. The illustrated geometries are shown here by way of example only. Other geometries are also conceivable and according to the invention. In the 6 illustrated embodiment may further by integrated electrical connection devices and / or fasteners according to the in 4 completed manner are completed.

7 shows a fourth variant with substrate 1 and active area 3 , The encapsulation unit 29IV , In this encapsulation unit are reinforcing struts 81 . 83 . 85 . 87 embedded, this preferably over the entire width of the module 89 can extend. In this variant, the reinforcing struts 81 and 87 simultaneously provided as fasteners and formed thicker accordingly. Typically, these struts are made of steel, aluminum or stainless steel. The thickness of the cured material is adapted to the different heights of the reinforcing struts, so that forms a wavy, smooth surface.

8th shows a fifth variant. In contrast to the fourth variant, here are the areas between the reinforcing struts 91 . 93 . 95 the encapsulation unit 29V thicker to the desired bending stiffness of the module 97 to ensure.

The individual features of the different embodiments can be combined with each other as desired. With respect to the first and second embodiments and the various variants of the resulting modules, the invention is not limited only to thin-film solar modules. Rather, it is also applicable to crystalline modules.

With the modules according to the invention, on the one hand, the production process is simplified and, on the other hand, a weight reduction can be achieved when using the encapsulation unit. Thanks to the integrated reinforcement elements as well as the integrable fastening elements and connecting devices, the structure of the modules and their manufacture can be further simplified

Claims (20)

Method for producing a thin-film solar module with the steps a) providing a first translucent substrate having an active region for converting solar energy b) providing a second substrate c) holding the first and second substrates parallel to each other at a predetermined distance from each other, wherein the active region between the first and second substrate is arranged d) filling the gap with a liquid material e) curing the liquid material whereby the active area is encapsulated. Method for producing a thin-film solar module with the steps f) providing a first translucent substrate having an active region for converting solar energy g) applying a liquid material to the side of the translucent substrate with the active region, and h) curing the liquid material thereby encapsulating the active region. The method of claim 2, wherein prior to step h) one or more fasteners are provided for attaching the thin film solar module to a substructure and / or one or more electrical connection devices and / or one or more reinforcing elements over the side of the translucent substrate having the active region Step h) integrated into the cured material, in particular positively connected, are. The method of claim 2 or 3, wherein in step g) a mold is provided in which the liquid material is filled. The method of any one of claims 2 to 4, wherein steps g) and h) are performed a plurality of times to form a plurality of layers. A method according to claim 4 and 5, wherein different shapes are used for the plurality of layers. Method according to one of claims 2 to 6, wherein after step h) the cured material has different thicknesses, in particular in the form of reinforcing ribs. The method of claim 3 and 7, wherein the one or more fasteners and / or the one or more electrical connection devices and / or the one or more reinforcing elements are arranged so that they are after step h) in thicker areas of the cured material. The method of claim 7 or 8, wherein the reinforcing ribs are at least partially arcuate. Method according to one of claims 2 to 9, wherein the liquid material is provided so that after step h) the cured material projects at least partially laterally over the edge of the substrate and / or surrounds the edge of the substrate. Method according to one of claims 1 to 10, wherein the cured material has reflective properties, in particular a white color, and / or protective or stabilizing properties. Method according to one of claims 1 to 11, wherein the liquid material is a polymer material, in particular a polyurethane plastic. Method according to one of claims 1 to 12, wherein filler materials, in particular fiber reinforcements and / or fillers for influencing thermal and / or electrical properties, are added. Solar module, in particular thin-film solar module, with a first light-transmitting substrate ( 1 ) with an active area ( 3 ) for converting solar energy, a second substrate ( 5 ) and a layer connecting the translucent substrate and the second substrate ( 15 ), where the active area ( 3 ) between first and second substrates ( 1 . 5 ), characterized in that the connecting layer is made of a cured polymer material. Solar module, in particular thin-film solar module, with a first light-transmitting substrate ( 1 ) with an active area ( 3 ) for converting solar energy, characterized in that the active region is surrounded by an encapsulation unit ( 29 ) is covered by a cured polymer material, which also forms the back construction of the solar module. Solar module according to claim 14 or 15, wherein the polymer material has filling materials for influencing thermal and / or electrical properties. Solar module according to one of claims 15 or 16, wherein the encapsulation unit has a plurality of layers, in particular with different thermal and / or electrical properties. Solar module according to one of claims 15 to 17, wherein the encapsulation unit ( 29 ' ) projects laterally beyond the edge of the substrate at least in sections and / or the edge of the substrate ( 1 ) encloses. Solar module according to one of claims 15 to 18, wherein the encapsulation unit has different thicknesses. Solar module according to one of claims 15 to 19, wherein in the encapsulation unit ( 29 ) One or more fasteners for attaching the thin film solar module to a substructure and / or one or more electrical connection devices and / or one or more Reinforcing elements over the side of the transparent substrate with the active region are arranged positively.

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