DE102013219614A1 - Photovoltaic module and method of manufacturing a photovoltaic module - Google Patents

Abstract

The invention relates to a photovoltaic module (100). The photovoltaic module (100) has a photovoltaic element (105) with a light-permeable protective layer (125) and at least one photovoltaic cell (120). Furthermore, the photovoltaic module (100) has a carrier element (105) for stabilizing the photovoltaic element (105). In this case, a major portion of a contact surface (115) of the carrier element (105) is in contact with the photovoltaic element (105).

Description

State of the art

The present invention relates to a photovoltaic module and to a method of manufacturing a photovoltaic module.

Conventional photovoltaic modules can be made of a thin laminate. For example, a glass sheet, encapsulating material and a connected solar cell may be laminated with each other in layers.

In this case, an outer edge region of the laminate can be bordered by a metallic frame in order to protect the photovoltaic module from mechanical stresses. Such loads may arise during transport or installation of the photovoltaic module. For example, the frame may be pressed onto the laminate or glued to the laminate. A mechanical stability of the photovoltaic module is essentially produced by the glass pane and the frame.

A photovoltaic module with 60 photovoltaic cells can weigh about 20 kilograms. Of this, about 3 kilograms can be attributed to an aluminum frame and about 10 kilograms to the glass.

Furthermore, devices for mechanical stabilization of a photovoltaic module during transport are known.

The JP 2007 210 641 A describes a conventional device for mechanical stabilization of a photovoltaic module.

Disclosure of the invention

Against this background, a photovoltaic module and a method for producing such a photovoltaic module according to the main claims are presented with the present invention. Advantageous embodiments emerge from the respective subclaims and the following description.

A photovoltaic module is presented with the following features:
a photovoltaic element, wherein the photovoltaic element has a light-transmitting protective layer and at least one photovoltaic cell; and
a support member for stabilizing the photovoltaic element, wherein a major portion of a contact surface of the support member is in contact with the photovoltaic element.

A photovoltaic module can generally be understood to mean an electrical module which is designed to convert short-wave radiant energy, for example sunlight, into electrical energy. The photovoltaic module may include a photovoltaic element to convert the radiant energy into electrical energy. The photovoltaic element may be a composite of at least one photovoltaic cell and a light-transmitting protective layer. At least one photovoltaic cell can be understood to mean an electrical component or a plurality of interconnected electrical components, which are designed in particular to convert sunlight into electrical energy. The at least one photovoltaic cell can be designed, for example, plate-shaped in order to absorb the sunlight. A translucent protective layer may, for example, be understood as meaning a transparent glass pane or a transparent liquid encapsulation for protecting the at least one photovoltaic cell from environmental influences.

The photovoltaic element may be combined with a support element for stabilizing the photovoltaic element. A carrier element may be, for example, a frame structure corresponding to a size of the photovoltaic element or a U-shaped endless profile which is cut to length corresponding to the size of the photovoltaic element and into which the photovoltaic element can be inserted. The carrier element may have a contact surface. A contact surface can be understood as meaning a surface of the carrier element on which the photovoltaic element rests flat when the photovoltaic element is combined with the carrier element. In this case, a major portion of the contact surface may be in contact with the photovoltaic element. A majority may be understood to mean a proportion of a surface area of the contact surface which corresponds to at least one half of a total surface area of the contact surface.

The approach presented here is based on the finding that photovoltaic elements, which can be realized, for example, in the form of a laminate of photovoltaic cells and a glass layer, can be exposed to mechanical stresses which can damage the photovoltaic elements and consequently cause a loss of power of the photovoltaic elements. For example, a photovoltaic element can bend so far due to vibrations during transport or assembly or even due to its own weight that microcracks can occur in the photovoltaic cells installed in the photovoltaic element. Such damage can be avoided by the photovoltaic element as large as possible rests on a solid support member and of this is mechanically supported. The Fotovoltaikelement can then no longer or only very slightly bend.

The approach presented here offers the advantage that a particularly robust photovoltaic module can be realized with technically simple and inexpensive means to be provided. Advantageously, such a photovoltaic module on a very simple structure of a few components. Thus, the manufacturing cost and weight of the photovoltaic module can be significantly reduced.

According to one embodiment of the present approach, the at least one photovoltaic cell can be arranged between the contact surface and the light-permeable protective layer. This has the advantage that the at least one photovoltaic cell is protected particularly well from environmental influences by the light-permeable protective layer. The fact that the at least one photovoltaic cell rests directly on the contact surface, a particularly high stabilization of the at least one photovoltaic cell can be achieved.

According to one embodiment of the present approach, the majority of the contact surface may be fluidly sealed. By way of example, the at least one photovoltaic cell can be encapsulated with an encapsulating material if it is arranged between the contact surface and the light-transmitting layer. By such a seal, in particular the penetration of moisture into the photovoltaic module can be prevented. As a result, a lifetime of the photovoltaic module can be considerably extended.

According to one embodiment of the present approach, the carrier element may be at least partially filled with a hard foam or at least partially made of the hard foam. Hard foam can generally be understood to mean a hard material having a cellular, porous structure. Such hard foam can be realized for example in the form of foam glass, metal foam, ceramic foam or in the form of foamed plastic such as polyurethane. Advantageously, the foam can have a particularly low weight. Due to the greatly reduced weight, the handling of the photovoltaic module can be considerably simplified.

According to one embodiment of the present approach, the contact surface may be at least partially formed by a hard foam surface of the hard foam. In particular, in this case the hard foam surface may at least partially have a microstructure for reflecting light onto the at least one photovoltaic cell. For example, the rigid foam may be filled in the carrier element such that the photovoltaic element rests on the hard foam surface when the photovoltaic element is combined with the carrier element. The hard foam surface may, for example, correspond to the majority of the contact surface. Under a microstructure can be understood, for example, embossed grooves in the hard foam surface. For example, these grooves may be provided with a reflective coating to reflect the light on the at least one photovoltaic cell. By means of the hard foam surface, a bending of the photovoltaic element can be prevented very efficiently. Furthermore, a power of the photovoltaic module can be significantly increased by means of the microstructure.

According to one embodiment of the present approach, an outer edge region of the carrier element may be formed as at least one holding element for holding and / or fixing the photovoltaic element on the carrier element. By way of example, an outer edge region can be understood as meaning two opposing side walls of the carrier element which are each adjacent to the contact surface. The at least one retaining element can be understood to mean, for example, an edge of the side walls projecting beyond the contact surface. Such a protruding edge may be formed to secure the photovoltaic element against slipping. Thus, the photovoltaic element can be fixed with very little effort on the contact surface of the support element.

According to one embodiment of the present approach, a contact area between the at least one holding element and a side face of the photovoltaic element facing the at least one holding element can be fluidly sealed. A contact region can generally be understood to mean a region in which the side surface of the photovoltaic element and the at least one retaining element are at least partially in contact. In order to seal the contact area fluidically, the contact area can be potted, for example, with a sealant such as silicone or bitumen. As a result, the photovoltaic module can be made particularly resistant to moisture.

According to one embodiment of the present approach, an upper side of the at least one holding element has an upper stacking edge and / or an underside of the carrier element opposite the upper side of the at least one holding element has a lower stacking edge for non-slip stacking of the photovoltaic module and at least one further photovoltaic module. For example, an upper stack edge may be a beveled upper edge of the at least one holding element act. A lower stacking edge may, for example, be a beveled lower edge of an adjacent photovoltaic module opposite the bevelled upper edge. The bevelled lower edge and the bevelled upper edge can rest on one another such that the photovoltaic module and the at least one further photovoltaic module are secured against slipping. By means of the very cost-effective to be realized stacking edges a plurality of photovoltaic modules can be safely stacked. As a result, the photovoltaic module is particularly suitable for transport.

According to one embodiment of the present approach, the carrier element may have at least one gripping structure for gripping the photovoltaic module in a lateral edge region. A lateral edge region may, for example, be understood as meaning a region of an underside of the carrier element which is adjacent to the side walls of the carrier element. A handle structure may, for example, be a grip recess formed in the lateral edge region or a handle attached in the lateral edge region. By such an ergonomic handle structure, the handling of the photovoltaic module can be significantly simplified by simple means.

According to one embodiment of the present approach, the photovoltaic module can have at least one covering element for covering, in particular fluid-tight covering, of an end face of the photovoltaic module formed by the carrier element and the photovoltaic element. The at least one cover element may be, for example, a closure profile or another cover-shaped structure which is designed to close the end face of the photovoltaic module in a fluid-tight manner. Further, for example, two opposite end elements may be arranged to form a frame around the photovoltaic element together with two holding elements. As a result, the edges of the photovoltaic element can be very effectively protected against mechanical influences. Such a closure element can be provided particularly cost.

According to one embodiment of the present approach, the at least one cover element and / or the support element may have at least one fastening element and / or at least one fastening element receptacle for fastening the at least one cover element to the support element. In this case, the at least one fastening element can be inserted or introduced into the at least one fastening element receptacle. By way of example, at least one fastening element can be understood as meaning a connecting pin or hook formed on the at least one end element. The at least one fastening element receptacle may be, for example, a depression formed on the end face of the carrier element for insertion of the connecting pin or an eyelet for hooking in the hook. By means of the at least one fastening element and the at least one fastening element receptacle, the at least one covering element can be connected to the carrier element very quickly and accurately. In addition, such a connection can be realized at very low cost.

According to one embodiment of the present approach, the carrier element may have at least one recess for enlarging a cooling surface of the carrier element on a side opposite the contact surface. The side may be, for example, the underside of the carrier element. By at least one recess can be understood, for example, a pointed or round tapered groove along the underside of the support member. Two juxtaposed recesses may, for example, form a cooling fin for dissipating heat from the photovoltaic module. By means of the at least one recess, the photovoltaic module can be protected against overheating with very little cost and material expense.

According to one embodiment of the present approach, the photovoltaic module may have a cooling tube for cooling the photovoltaic element. In this case, the cooling hose can be arranged in the carrier element. In particular, the cooling hose can be arranged at least partially in the region of the main portion of the contact surface. A cooling hose can generally be understood to mean a hose for conducting a cooling medium through the photovoltaic module. In this case, the cooling hose can be arranged in the carrier element. For example, the cooling hose may be cast into the hard foam, provided that the carrier element is filled with the hard foam. Furthermore, the cooling hose can be arranged in the carrier element directly below the main portion of the contact surface on which the photovoltaic element rests. By means of the cooling hose, the photovoltaic module can be particularly reliably protected against overheating. In addition, such a cooling hose can be provided very inexpensively and installed in the support element.

According to one embodiment of the present approach, the photovoltaic module may have a reflection layer for reflecting light onto the at least one photovoltaic cell. In this case, the reflection layer between the at least one photovoltaic cell and the carrier element be arranged. A reflection layer may be, for example, a light-reflecting lacquer layer applied to the contact surface or a foil with light-reflecting properties applied to the contact surface. By means of the reflection layer, incident light beams can be purposefully reflected onto the at least one photovoltaic cell. Thus, an efficiency of at least one photovoltaic cell can be significantly increased with very little effort.

Finally, the present approach provides a method of manufacturing a photovoltaic module, the method comprising the steps of:

Providing a photovoltaic element having a light-permeable protective layer and at least one photovoltaic cell and a carrier element; and

Assembling the photovoltaic element and the carrier element such that a majority of a contact surface of the carrier element is in contact with the photovoltaic element.

The invention will now be described by way of example with reference to the accompanying drawings. Show it:

1 a cross-sectional view of a photovoltaic module according to an embodiment of the present invention;

2 a cross-sectional view of a carrier element for use in accordance with an embodiment of the present invention;

3 a cross-sectional view of a cover member for use in an embodiment of the present invention;

4 a cross-sectional view of a photovoltaic module assembly according to an embodiment of the present invention;

5 a cross-sectional view of a photovoltaic module according to an embodiment of the present invention;

6 a cross-sectional view of a photovoltaic module according to an embodiment of the present invention;

7 a cross-sectional view of a photovoltaic module according to an embodiment of the present invention;

8th a cross-sectional view of a photovoltaic module according to an embodiment of the present invention;

9 a cross-sectional view of a photovoltaic module according to an embodiment of the present invention;

10 a cross-sectional view of a photovoltaic module assembly according to an embodiment of the present invention;

11 a cross-sectional view of a photovoltaic module according to an embodiment of the present invention;

12 a cross-sectional view of a photovoltaic module according to an embodiment of the present invention;

13 a cross-sectional view of a photovoltaic module according to an embodiment of the present invention;

14 a cross-sectional view of a photovoltaic module according to an embodiment of the present invention; and

15 a flowchart of a method for manufacturing a photovoltaic module according to an embodiment of the present invention.

In the following description of favorable embodiments of the present invention, the same or similar reference numerals are used for the elements shown in the various figures and similar acting, with a repeated description of these elements is omitted.

1 shows a cross-sectional view of a photovoltaic module 100 according to an embodiment of the present invention. The photovoltaic module 100 has a carrier element 105 and a photovoltaic element 110 on. The carrier element 105 has a contact surface 115 on. The photovoltaic element 110 is arranged so that it is on a major part of the contact surface 115 the carrier element 105 rests. For example, the majority of the contact surface 115 an area share between 50 and 100 Percent of a total surface of the contact surface 115 correspond. In that the photovoltaic element 110 on the main part of the contact surface 115 rests, becomes the Fotovoltaikelement 110 mechanically supported.

The photovoltaic element 110 also has a multilayer structure of a photovoltaic cell 120 and a glass pane 125 as a translucent protective layer. The photovoltaic cell 120 and the glass pane 125 are designed plate-shaped. For example, the photovoltaic cell 120 and the glass pane 125 laminated to a composite be. Optionally, the photovoltaic cell 120 between the glass 125 and the contact surface 115 be arranged. In addition, the majority of the contact surface 115 on which the photovoltaic element 110 rests, be fluidly sealed against an outside world. This can be done between the contact surface 115 and the glass pane 125 arranged photovoltaic cell 120 encapsulated in an encapsulating material such as a gel. Between the contact surface 115 and the photovoltaic cell 120 may further include a reflective layer 130 be arranged. The reflection layer 130 can be the main part of the contact surface 115 cover and be trained to light incident on one of the contact surface 115 opposite front side of the photovoltaic cell 120 to reflect. For example, the reflective layer 130 at least partially with the carrier element 105 be fused or glued. The reflection layer 130 can also be in the form of a paint job on the contact surface 115 be upset.

The carrier element 105 is realized as a one-piece U-profile. For example, the carrier element 105 from an endless metal or plastic profile in a photovoltaic element 110 appropriate size cut out. The carrier element 105 has two opposite side walls. The side walls are each in the direction of a center of the support element 105 bent inwards. In this case, each end region of the side walls is bent such that it is perpendicular to the side walls and horizontal to the contact surface 115 arranged bearing surface 135 forms. The bearing surfaces are part of the contact surface 115 , Through the bearing surfaces 135 is a height of the contact surface 115 established. Furthermore, the bearing surfaces 135 through a central opening of the U-profile of the carrier element 105 separated from each other. The bearing surfaces 135 are formed to each have an outer edge region of the photovoltaic element 110 to support.

The side walls are further bent so that they each have a bearing surfaces 135 superior edge as a holding element 137 for the photovoltaic element 110 form. The holding elements 137 are perpendicular to the bearing surfaces 135 arranged. Between the holding elements 137 is the photovoltaic element 110 arranged. The holding elements 137 are formed to the photovoltaic element 110 on the contact surface 115 to fix. The retaining elements close 137 flush with the glass pane 125 of the photovoltaic element 110 from.

Between the holding elements 137 and one of the retaining elements 137 facing side surface of the photovoltaic element 110 is ever a gap as a contact area 140 educated. Optionally, the contact area 140 be fluidly sealed. For this, the contact area 140 for example, be filled with a sealant such as silicone or bitumen.

The bearing surfaces 135 are in the contact area 140 each with a groove 145 Mistake. The grooves 145 have a semicircular cross-section. The grooves 145 are along the retaining elements 137 arranged.

To form the contact surface 115 can the carrier element 105 with a hard foam 150 be filled. The hard foam 150 can the carrier element 105 Completely fill in to the carrier element 105 to stabilize. Between the bearing surfaces 135 can be formed a smooth hard foam surface. The hard foam surface is formed around the photovoltaic element 110 support large area.

The carrier element 105 Optionally has two handle structures 155 exhibit. The handle structures 155 For example, can be realized as recessed grips with a semicircular or semi-elliptical cross-section. The handle structures 155 can ever in one of the grooves 145 opposite bottom region of the support element 105 to be appropriate. The handle structures 155 are trained to the photovoltaic module 100 to be able to grip better.

The holding elements 137 can optionally have one upper stacking edge each 160 exhibit. The upper stacking edges 160 may be bevelled, for example. These can be the retaining elements 137 be bent so that a vertical distance of the contact surface 115 to a photovoltaic element 110 facing inner upper edge of the holding elements 137 is greater than to a photovoltaic element 110 remote outer upper edge of the holding elements 137 , Here, the inner top edge flush with the photovoltaic element 110 to lock.

Opposite the upper stacking edges 160 can in a lateral edge region of a bottom of the support element 105 lower stacking edges 165 be educated. The lower stacking edges 165 can have the same slope as the top stack edges 160 exhibit. Adjacent to the lower stacking edges 165 For example, depending on the handle structure 155 be arranged. By means of the stacking edges 160 . 165 can a plurality of photovoltaic modules 100 be slipped stacked.

2 shows a cross-sectional view of a support member 105 for use in an embodiment of the present invention. The carrier element 105 has the grooves 145 and the handle structures 155 on. In contrast to 1 has the in 2 illustrated support element 105 in addition a total of six interlocking points as fastener receptacles 200 on. The fastener shots 200 can each be in different edge areas within the support element 105 be educated. For example, the fastener element holders 200 each adjacent to the inner and outer upper edges of the retaining elements 137 and adjacent to a side edge of the underside of the carrier element 105 be arranged. The fastener shots 200 may be formed as channels for receiving corresponding connection elements. The channels can along the side walls of the support element 105 be arranged. Furthermore, the grooves can also 145 and the handle structures 155 be formed to receive corresponding connecting elements such as connecting pins or hooks.

3 shows a cross-sectional view of a cover 300 for use in an embodiment of the present invention. The cover element 300 has substantially the shape of a rectangular lid. A height and a width of the cover 300 correspond to a height and a width of the in 1 illustrated photovoltaic module 100 , The cover element 300 has a total of six fasteners 305 on. Furthermore, the cover element 300 two groove connecting elements 310 and two handle structure connecting elements 315 on. An arrangement of fasteners 305 , the grooved fasteners 310 and the handle structure connecting members 315 this corresponds to an arrangement of the fastener element holders 200 , the grooves 145 and the handle structures 155 as they are in 2 are shown. The fasteners 305 are designed to engage in the fastener element 200 to be introduced. The groove connecting elements 310 are trained to get into the grooves 145 to be introduced. The handle structure connecting elements 315 are trained to get into the handle structures 155 to be introduced. For example, it may be in the fasteners 305 , the groove connecting elements 310 and the handle structure connecting members 315 to act correspondingly shaped connecting pins which are formed to the cover 300 perfectly fitting with the carrier element 105 connect to. Alternatively or additionally, the cover 300 with the photovoltaic module 100 glued to one end face of the photovoltaic module 100 fluid-tight with the cover 300 seal. For example, two opposite end faces of the photovoltaic module 100 each with the cover 300 be provided. Here, the cover elements 300 together with the holding elements 137 an edge protection frame around the photovoltaic element 110 form around the photovoltaic element 110 , in particular the glass pane 125 to protect from damage.

4 shows a cross-sectional view of a photovoltaic module assembly 400 according to an embodiment of the present invention. The photovoltaic module assembly 400 has the photovoltaic module 100 and another photovoltaic module 405 according to the in 1 shown embodiment. The further photovoltaic module 405 is on the photovoltaic module 100 stacked. Here are the lower stacking edges 165 the further photovoltaic module 405 on the upper stacking edges 160 of the photovoltaic module 100 on, so the photovoltaic modules 100 . 405 secured against lateral slipping.

5 shows a cross-sectional view of a photovoltaic module 100 according to an embodiment of the present invention. This in 5 shown photovoltaic module 100 contrary to the 1 and 4 five recesses 505 on. The recesses 505 are each as V-shaped notches in the bottom of the support element 105 educated. This increases ever a cross section of the recesses 505 towards the bottom of the support element 105 , The recesses may be flattened in an end region with the smallest cross section. Furthermore, the recesses 505 be arranged at a uniform distance from each other. The recesses 505 are formed to a cooling surface of the support element 105 to enlarge. A shape and / or a number of recesses 505 be varied to increase the cooling surface. For example, the carrier element 105 ten or twenty recesses 505 or a multiple thereof. Alternatively or additionally, the recesses 505 For example, have a U-shaped or S shaped cross-section.

6 shows a cross-sectional view of a photovoltaic module 100 according to an embodiment of the present invention. This in 6 shown photovoltaic module 100 contrary to the 1 . 4 and 5 a cooling hose 600 on. The cooling hose 600 can be between the bearing surfaces 135 along the contact surface 115 be arranged. Between the cooling hose 600 and the photovoltaic cell 120 can the reflection layer 130 be arranged. The cooling hose 600 For example, in the hard foam 150 be incorporated. In particular, the cooling hose 600 be incorporated into the hard foam surface. For example, the cooling hose 600 in 20 be laid parallel to each other arranged webs. The cooling hose 600 is formed to a cooling medium for cooling the photovoltaic module 100 through the photovoltaic module 100 to lead. For this purpose, the cooling hose can be connected, for example, to a cooling device.

7 shows a cross-sectional view of a photovoltaic module 100 according to an embodiment of the present invention. This in 7 shown photovoltaic module 100 contrary to the 1 and 4 to 6 a microstructure 700 for reflecting light onto the photovoltaic cell 120 on. The microstructure 700 can the contact surface 115 form. This may be the microstructure 700 into the hard foam surface of the hard foam 150 being shaped. The microstructure 700 may have a plurality of mutually parallel grooves having a V-shaped cross-section or a pyramidal structure (for example, anisotropically etched Si wafer surface). The grooves can along a longitudinal axis of the photovoltaic module 100 be arranged. For example, the microstructure 700 30 . 60 or 100 Grooves or a multiple thereof. Between the microstructure 700 and the glass pane 125 can the photovoltaic cell 120 be arranged. The microstructure 700 can with the reflection layer 130 be covered. The microstructure 700 is designed to block incident light on one of the glass panes 125 facing front of the photovoltaic cell 120 to reflect.

8th shows a cross-sectional view of a photovoltaic module 100 according to the in 6 shown embodiment of the present invention. This in 8th shown photovoltaic module 100 points in contrast to 6 instead of the glass 125 a liquid encapsulation 800 as a translucent protective layer. The liquid encapsulation 800 can be flush with the top stacking edges 160 to lock. The liquid encapsulation 800 can be an entire width of the support element 105 fill out. The liquid encapsulation 800 is designed to be the photovoltaic module 100 fluidly sealed against external influences.

9 shows a cross-sectional view of a photovoltaic module 900 according to an embodiment of the present invention. The photovoltaic module 900 has a carrier element 905 on. In contrast to that in the 1 and 4 to 8th illustrated photovoltaic module 100 is ever a side wall of the support element 905 away from a center of the support member 905 bent over to the retaining elements 137 with the upper stacking edges 160 , the grooves 145 and the bearing surfaces 135 to build. The outwardly bent side walls each enclose one to the underside of the support element 905 open cavity 910 , The cavities 910 For example, can be sprayed with a plastic to a stability of the photovoltaic module 900 to increase. In the plastic can ever handle structures 155 be formed. Furthermore, the plastic in one of the handle structures 155 adjacent outer edge region of the carrier element 905 Beveled to the lower stacking edges 165 to build.

10 shows a cross-sectional view of a photovoltaic module assembly 1000 according to an embodiment of the present invention. The photovoltaic module assembly 1000 has the photovoltaic module 900 and another photovoltaic module 1005 according to the in 9 shown embodiment. The further photovoltaic module 1005 is on the photovoltaic module 1000 stacked. Here are the lower stacking edges 165 the further photovoltaic module 1005 on the upper stacking edges 160 of the photovoltaic module 1000 on, so the photovoltaic modules 1000 . 1005 secured against lateral slipping.

11 shows a cross-sectional view of a photovoltaic module 900 according to an embodiment of the present invention. In contrast to the 9 and 10 has the in 11 illustrated photovoltaic module 900 the recesses 505 according to the in 5 shown embodiment.

12 shows a cross-sectional view of a photovoltaic module 900 according to an embodiment of the present invention. In contrast to the 9 and 10 has the in 12 illustrated photovoltaic module 900 the cooling hose 600 according to the in 6 shown embodiment.

13 shows a cross-sectional view of a photovoltaic module 900 according to an embodiment of the present invention. In contrast to the 9 and 10 has the in 13 illustrated photovoltaic module 900 the microstructure 700 according to the in 7 shown embodiment.

14 shows a cross-sectional view of a photovoltaic module 900 according to an embodiment of the present invention. In contrast to the 9 and 10 has the in 14 illustrated photovoltaic module 900 the liquid encapsulation 800 according to the in 8th shown embodiment.

Hereinafter, the structure of an embodiment of the present invention will be described with reference to FIGS 1 to 15 again summarized.

The photovoltaic modules 100 . 900 , which can also be referred to as solar modules or modules, have a mechanically stabilizing frame as support elements 105 . 905 on. The carrier elements 105 . 905 can from one be made deep-drawn or formed sheet metal or a film. For example, the support elements 105 . 905 be made of aluminum, galvanized sheet steel or stainless steel. Alternatively, the support elements 105 . 905 be poured from a continuous strand. The cavities can 910 the carrier element 905 be mechanically stabilized with a plastic injection or a glued plastic profile, such as polyvinyl chloride, polypropylene or polyamide. With the mechanically stabilizing frame, a backsheet as a reflective layer 130 be merged.

In addition, the mechanically stabilizing frame with a plastic foam as hard foam 150 be filled. The plastic foam or plastic foam may for example be made of polyurethane.

The mechanically stabilizing frame can be integrated stacking corners, also stacking edges 160 . 165 called, have. For example, the integrated stacking corners may be formed as beads or structures for easy stacking and secure transport of the photovoltaic modules 100 . 900 be executed. Furthermore, the photovoltaic modules 100 . 900 Handholds as handle structures 155 for a simple and ergonomic gripping of photovoltaic modules 100 . 900 exhibit.

The photovoltaic modules 100 . 900 can integrated cooling fins as recesses 505 exhibit. The cooling fins may be configured in any shape to heat the photovoltaic modules 100 . 900 to deliver optimally to an outside environment.

Directly under a cell matrix, also photovoltaic cell 120 or called cell for short, the cooling hose can 600 be integrated in the plastic foam.

The photovoltaic modules 100 . 900 can the microstructure 700 for targeted reflection of light on a cell front side of the cell matrix. The microstructure 700 , also called microstructuring, cell connectors or structured cell connectors, can be embossed in the plastic foam. One of the contact surface 115 facing cell back of the cell matrix may be provided with a thin encapsulating foil. Recesses for receiving the cell connector may be embossed in the encapsulating foil.

The photovoltaic modules 100 . 900 can with a liquid encapsulation 800 be encapsulated fluid-tight. In this case, the mechanically stabilizing frame as a mold for the liquid encapsulation 800 serve.

The photovoltaic module 100 Can with a closing profile as a cover 300 to be introverted. The end profile may be made of aluminum or plastic, for example. The end profile is designed to be in corresponding interlocking points of the photovoltaic module 100 to be plugged. Additionally or alternatively, the end profile on the photovoltaic module 100 glued on. The end profile can be designed so that a plastic-filled profile of the support element 105 is sealed gas-tight and vapor-tight or at least watertight by the end profile above and below as possible.

In contrast to the photovoltaic module 100 requires the photovoltaic module 900 no final profile.

A sheet metal casing of the carrier element 105 can be replaced for example by a plastic or a fiber-reinforced plastic such as PA66.

A frame and a backsheet of a solar module can be optimized using an endless profile or by deep drawing a sheet. As a result, a construction of the solar module can be stiffened to avoid microcracks in the cells. A smooth and flat module surface makes it easier for slips to slide off the module. Furthermore, material in the form of aluminum and glass or in the form of a backsheet can be saved. For example, aluminum consumption can be reduced by about 70 percent compared to conventional modules. A glass thickness can be reduced to about 0.8 mm. According to one embodiment of the present invention, the module can also be embodied without a glass layer and / or without a backsheet. Thus, a module weight of less than 10 kg can be achieved compared to conventional modules with the same area. An assembly of the module can advantageously take place during the lamination of the module. As a result, a bending of a cross-connection after a QVS soldering can be avoided.

15 shows a method 1500 for producing a photovoltaic module according to an embodiment of the present invention. First, in one step 1505 providing a photovoltaic element with a light-permeable protective layer and at least one photovoltaic cell and providing a carrier element. This is then done in one step 1510 the joining of the photovoltaic element and the carrier element, so that a major portion of a contact surface of the carrier element is in contact with the photovoltaic element.

The embodiments described and shown in the figures are chosen only by way of example. Different embodiments may be combined together or in relation to individual features. Also, an embodiment can be supplemented by features of another embodiment.

Furthermore, method steps according to the invention can be repeated as well as carried out in a sequence other than that described.

If an exemplary embodiment comprises a "and / or" link between a first feature and a second feature, then this is to be read so that the embodiment according to one embodiment, both the first feature and the second feature and according to another embodiment either only first feature or only the second feature.

QUOTES INCLUDE IN THE DESCRIPTION

This list of the documents listed by the applicant has been generated automatically and is included solely for the better information of the reader. The list is not part of the German patent or utility model application. The DPMA assumes no liability for any errors or omissions.

Cited patent literature

• JP 2007210641 A [0006]

Claims (15)

Photovoltaic module ( 100 ; 900 ) comprising: a photovoltaic element ( 105 ), in particular wherein the photovoltaic element ( 105 ) a translucent protective layer ( 125 ; 800 ) and at least one photovoltaic cell ( 120 ) having; and a carrier element ( 105 ; 905 ) for stabilizing the photovoltaic element ( 105 ), wherein a major portion of a contact surface ( 115 ) of the carrier element ( 105 ; 905 ) with the photovoltaic element ( 105 ) is in contact. Photovoltaic module ( 100 ; 900 ) according to claim 1, characterized in that the at least one photovoltaic cell ( 120 ) between the contact surface ( 115 ) and the translucent protective layer ( 125 ; 800 ) is arranged. Photovoltaic module ( 100 ; 900 ) according to one of the preceding claims, characterized in that the majority of the contact surface ( 115 ) is fluidically sealed. Photovoltaic module ( 100 ; 900 ) according to one of the preceding claims, characterized in that the carrier element ( 105 ; 905 ) at least partially with a hard foam ( 150 ) is filled or at least partially made of hard foam ( 150 ) consists. Photovoltaic module ( 100 ; 900 ) according to claim 4, characterized in that the contact surface ( 115 ) at least partially by a hard foam surface of the rigid foam ( 150 ), in particular wherein the hard foam surface at least partially a microstructure ( 700 ) for reflecting light onto the at least one photovoltaic cell ( 120 ) having. Photovoltaic module ( 100 ; 900 ) according to one of the preceding claims, characterized in that an outer edge region of the carrier element ( 105 ; 905 ) as at least one retaining element ( 137 ) for holding and / or fixing the photovoltaic element ( 110 ) on the carrier element ( 105 ; 905 ) is trained. Photovoltaic module ( 100 ; 900 ) according to claim 6, characterized in that a contact area ( 140 ) between the at least one retaining element ( 137 ) and one the at least one holding element ( 137 ) facing side surface of the photovoltaic element ( 110 ) is fluidically sealed. Photovoltaic module ( 100 ; 900 ) according to claim 6 or 7, characterized in that an upper side of the at least one retaining element ( 137 ) an upper stacking edge ( 160 ) and / or one of the upper side of the at least one retaining element ( 137 ) opposite underside of the carrier element ( 105 ; 905 ) a lower stacking edge ( 165 ) for non-slip stacking of the photovoltaic module ( 100 ; 900 ) and at least one further photovoltaic module ( 405 ; 1005 ) having. Photovoltaic module ( 100 ; 900 ) according to one of the preceding claims, characterized in that the carrier element ( 105 ; 905 ) in a lateral edge region at least one handle structure ( 155 ) for gripping the photovoltaic module ( 100 ; 900 ) having. Photovoltaic module ( 100 ) according to one of the preceding claims, characterized by at least one cover element ( 300 ) for covering, in particular fluid-tight covering of a by the support element ( 105 ) and the photovoltaic element ( 110 ) formed end face of the photovoltaic module ( 100 ). Photovoltaic module ( 100 ) according to claim 10, characterized in that the at least one cover element ( 300 ) and / or the carrier element ( 105 ) at least one fastening element ( 305 ) and / or at least one fastener element receptacle ( 200 ) for fastening the at least one cover element ( 300 ) on the carrier element ( 105 ), wherein the at least one fastening element ( 305 ) in the at least one fastener element receptacle ( 200 ) is insertable or imported. Photovoltaic module ( 100 ; 900 ) according to one of the preceding claims, characterized in that the carrier element ( 105 ; 905 ) on one of the contact surfaces ( 115 ) opposite side at least one recess ( 505 ) for enlarging a cooling surface of the support element ( 105 ; 905 ) having. Photovoltaic module ( 100 ; 900 ) according to one of the preceding claims, characterized by a cooling hose ( 600 ) for cooling the photovoltaic element ( 110 ), whereby the cooling hose ( 600 ) in the carrier element ( 105 ; 905 ), in particular wherein the cooling hose ( 600 ) at least partially in the region of the main part of the contact surface ( 115 ) is arranged. Photovoltaic module ( 100 ; 900 ) according to one of the preceding claims, characterized by a reflection layer ( 130 ) for reflecting light onto the at least one photovoltaic cell ( 120 ), wherein the reflection layer ( 130 ) between the at least one photovoltaic cell ( 120 ) and the carrier element ( 105 ; 905 ) is arranged. Procedure ( 1500 ) for producing a photovoltaic module ( 100 ; 900 ), the process ( 1500 ) comprises the following steps: providing ( 1505 ) of a photovoltaic element ( 110 ) with a translucent protective layer ( 125 ; 800 ) and at least one photovoltaic cell ( 120 ) as well as a carrier element ( 105 ; 905 ); and merging ( 1510 ) of the photovoltaic element ( 110 ) and the carrier element ( 105 ; 905 ), so that a major portion of a contact surface ( 115 ) of the carrier element ( 105 ; 905 ) with the photovoltaic element ( 110 ) is in contact.

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