EP1269542A1 - Procede de production d'un module solaire dote de cellules solaires a mince couche integrees et montees en serie, et module solaire ainsi produit, notamment a l'aide de modules concentrateurs - Google Patents

Procede de production d'un module solaire dote de cellules solaires a mince couche integrees et montees en serie, et module solaire ainsi produit, notamment a l'aide de modules concentrateurs

Info

Publication number
EP1269542A1
EP1269542A1 EP01935948A EP01935948A EP1269542A1 EP 1269542 A1 EP1269542 A1 EP 1269542A1 EP 01935948 A EP01935948 A EP 01935948A EP 01935948 A EP01935948 A EP 01935948A EP 1269542 A1 EP1269542 A1 EP 1269542A1
Authority
EP
European Patent Office
Prior art keywords
layer
mask
solar
solar module
solar cells
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Withdrawn
Application number
EP01935948A
Other languages
German (de)
English (en)
Inventor
Wolfgang Harneit
Arnulf JÄGER-WALDAU
Martha Christina Lux-Steiner
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Helmholtz Zentrum Berlin fuer Materialien und Energie GmbH
Original Assignee
Hahn Meitner Institut Berlin GmbH
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Hahn Meitner Institut Berlin GmbH filed Critical Hahn Meitner Institut Berlin GmbH
Publication of EP1269542A1 publication Critical patent/EP1269542A1/fr
Withdrawn legal-status Critical Current

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Classifications

    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01L—SEMICONDUCTOR DEVICES NOT COVERED BY CLASS H10
    • H01L31/00—Semiconductor devices sensitive to infrared radiation, light, electromagnetic radiation of shorter wavelength or corpuscular radiation and specially adapted either for the conversion of the energy of such radiation into electrical energy or for the control of electrical energy by such radiation; Processes or apparatus specially adapted for the manufacture or treatment thereof or of parts thereof; Details thereof
    • H01L31/04—Semiconductor devices sensitive to infrared radiation, light, electromagnetic radiation of shorter wavelength or corpuscular radiation and specially adapted either for the conversion of the energy of such radiation into electrical energy or for the control of electrical energy by such radiation; Processes or apparatus specially adapted for the manufacture or treatment thereof or of parts thereof; Details thereof adapted as photovoltaic [PV] conversion devices
    • H01L31/054—Optical elements directly associated or integrated with the PV cell, e.g. light-reflecting means or light-concentrating means
    • H01L31/0543—Optical elements directly associated or integrated with the PV cell, e.g. light-reflecting means or light-concentrating means comprising light concentrating means of the refractive type, e.g. lenses
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01L—SEMICONDUCTOR DEVICES NOT COVERED BY CLASS H10
    • H01L31/00—Semiconductor devices sensitive to infrared radiation, light, electromagnetic radiation of shorter wavelength or corpuscular radiation and specially adapted either for the conversion of the energy of such radiation into electrical energy or for the control of electrical energy by such radiation; Processes or apparatus specially adapted for the manufacture or treatment thereof or of parts thereof; Details thereof
    • H01L31/04—Semiconductor devices sensitive to infrared radiation, light, electromagnetic radiation of shorter wavelength or corpuscular radiation and specially adapted either for the conversion of the energy of such radiation into electrical energy or for the control of electrical energy by such radiation; Processes or apparatus specially adapted for the manufacture or treatment thereof or of parts thereof; Details thereof adapted as photovoltaic [PV] conversion devices
    • H01L31/042—PV modules or arrays of single PV cells
    • H01L31/0445—PV modules or arrays of single PV cells including thin film solar cells, e.g. single thin film a-Si, CIS or CdTe solar cells
    • H01L31/046—PV modules composed of a plurality of thin film solar cells deposited on the same substrate
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01L—SEMICONDUCTOR DEVICES NOT COVERED BY CLASS H10
    • H01L31/00—Semiconductor devices sensitive to infrared radiation, light, electromagnetic radiation of shorter wavelength or corpuscular radiation and specially adapted either for the conversion of the energy of such radiation into electrical energy or for the control of electrical energy by such radiation; Processes or apparatus specially adapted for the manufacture or treatment thereof or of parts thereof; Details thereof
    • H01L31/04—Semiconductor devices sensitive to infrared radiation, light, electromagnetic radiation of shorter wavelength or corpuscular radiation and specially adapted either for the conversion of the energy of such radiation into electrical energy or for the control of electrical energy by such radiation; Processes or apparatus specially adapted for the manufacture or treatment thereof or of parts thereof; Details thereof adapted as photovoltaic [PV] conversion devices
    • H01L31/042—PV modules or arrays of single PV cells
    • H01L31/0445—PV modules or arrays of single PV cells including thin film solar cells, e.g. single thin film a-Si, CIS or CdTe solar cells
    • H01L31/046—PV modules composed of a plurality of thin film solar cells deposited on the same substrate
    • H01L31/0463—PV modules composed of a plurality of thin film solar cells deposited on the same substrate characterised by special patterning methods to connect the PV cells in a module, e.g. laser cutting of the conductive or active layers
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
    • Y02B—CLIMATE CHANGE MITIGATION TECHNOLOGIES RELATED TO BUILDINGS, e.g. HOUSING, HOUSE APPLIANCES OR RELATED END-USER APPLICATIONS
    • Y02B10/00—Integration of renewable energy sources in buildings
    • Y02B10/10—Photovoltaic [PV]
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
    • Y02E—REDUCTION OF GREENHOUSE GAS [GHG] EMISSIONS, RELATED TO ENERGY GENERATION, TRANSMISSION OR DISTRIBUTION
    • Y02E10/00—Energy generation through renewable energy sources
    • Y02E10/50—Photovoltaic [PV] energy
    • Y02E10/52—PV systems with concentrators

Definitions

  • the invention relates to methods for producing a solar module with structured and integrated series-connected thin-film solar cells and to solar modules produced with the method.
  • the solar cells can have both a substrate and a superstrate as the carrier layer.
  • Thin-film solar cells of both types have light-absorbing absorber layers made of inexpensive amorphous, polycrystalline or microcrystalline semiconductor materials, which can be deposited or built up on large-area substrates or superstrates by a variety of different methods.
  • the low layer thickness of the absorber layers and the possibility of structuring during manufacture lower the manufacturing costs further, so that thin-film solar cells represent a cost-effective alternative to the currently cost-intensive silicon solar cells, which as single-crystal or multi-layer systems only become available after production sawn into individual cells and then how high-quality semiconductor products have to be processed.
  • thin-film solar cells Through the photovoltaic conversion of solar energy into electrical power, thin-film solar cells generate voltage levels below 1 volt.
  • This Senen circuit can be integrated into the layer production process for solar cells.
  • the entire surface of the coatings is divided into narrow strips using suitable structuring methods, for example paste writing methods and lift-off techniques, and mechanical and in particular laser processing methods.
  • the aim of the structuring is to establish an electrical connection between to create the electrodes on the front and back of adjacent strip-shaped solar cells
  • US Pat. No. 4,675,467 discloses a method for connecting an integrated thin-film solar module in which both electrodes are already inserted in a pre-fabricated strip shape into an unstructured absorber layer.
  • the conductive connections between the corresponding electrodes of adjacent solar cells are then removed by a structuring step using laser radiation
  • the transparent substrate side produced in a covering area of the electrode strips.
  • With a precisely defined energy dose corresponding areas of the absorber layer are converted into low-resistance areas, but there is a risk of damage to the semiconductor material. Due to the lack of spatial structuring of the absorber layer, the semiconductor material of adjacent solar cells is not electrically opposed to one another insulated so that short-circuit currents reduce the power yield.
  • Laser treatment requires highly precise dosing, positi Onioning and focusing of the laser beam used in order to be able to achieve the desired conversion effect in a precise location. Layer separation and damage in the immediate vicinity of the structure layer cannot be ruled out. Furthermore, the use of a transparent substrate with precisely defined, homogeneous layer thickness is always necessary in order to prevent the laser beam from penetrating from the substrate side here and to be able to precisely determine its dose-dependent penetration depth into the layers to be separated or converted No. 4,999,308 describes a similar method with prefabricated electrode strips, in which the laser treatment for region conversion is also carried out at the same time for separating the absorber layer in order to produce insulation trenches here by blasting off semiconductor material lost therewith.
  • WO-9503628 a method for the antenna connection of an integrated thin-film solar cell module is known, in which all functional layers are structured separately in special process steps.
  • a metal layer previously deposited over the entire surface of a transparent substrate is first divided into closely adjacent strips by an arbitrary structuring method to form a strip-shaped back electrode.
  • two further, separate structuring steps are carried out by means of laser irradiation from the substrate side.
  • the first laser radiation is used for the stripe-shaped structuring of the absorber layer and front electrode, with the second laser radiation in turn that portion of the absorber layer is converted into a low-ohmic area that lies in the overlap area between the opposite electrode strips of adjacent solar cells, so that an integrated conductive series connection is formed between the solar cells.
  • the known method therefore requires structuring with a triple separation treatment, including two more complex laser beam treatments.
  • the first serves the separation process of front electrode and absorber layer together.
  • the second treatment for area conversion again requires precise laser energy metering with the problems already described above.
  • the described methods are based on the joint optimization task in the sense of maximized power output or a minimized area size of the solar modules produced from strip-like structured thin-film solar cells of both carrier layer types.
  • such solar cells already have a lower energy efficiency, which, in comparison with the normal case (light concentration AM 1, 5), also rapidly reduces the light conditions. This means that with the usual fluctuations in light intensity between the seasons and from day to day depending on the weather and for indoor applications (down to 10% of the maximum available radiation), thin-film solar cells have significant power losses. This is one of the reasons why thin-film solar cells have so far hardly been used in areas with very different solar radiation and generally in indoor areas.
  • 5,505,789 for single-crystalline integrated solar cell chips made of GaAs are known from DEAs with line focus lenses in or as a module cover, which are particularly suitable for strip-shaped solar modules 197 44 840 A1 shows a solar module with an upstream concentrator module made of plastic Fresnel lenses, which as a structural unit for an improved energy balance can be tracked by tilting or shifting the position of the sun.
  • EP 0 328 053 finally describes strip-shaped solar modules with a Fresnel lens in front , which are each integrated in a corner of a window pane of a double window and are intended to supply the power supply for a blind operation in the middle of the double window
  • substrate and superstrate solar cells have the same basic structure with an inverse layer sequence.
  • the substrate acts as the lower support layer and the light falls into the solar cell from above, whereas the superstrate acts as the upper support layer and the light incident through the superstrate
  • the advantages of the invention should first be explained in more detail using the method according to claim 1, especially since they also result in the inverse method according to claim 2. This is followed by a brief explanation of the differences between the two Method.
  • the inventive method according to claim 1 enables a continuous structuring of all functional layers with an extremely low structuring effort.
  • a mask which can be in particular stripe-like, saves two structuring steps that are otherwise required.
  • the jerk electrode is structured directly when coating with a corresponding metal layer with the mask in place. There is no loss of material, since the mask can be used further the method step of the otherwise customary, particularly critical subsequent structuring of the semiconductor absorber layer.
  • the absorber layer is made exactly like the jerk electrode by using the mask structured.
  • the integrated Senen wiring of the individual solar cells takes place through a simple but particularly effective process step.
  • the absorber layer Before the absorber layer is applied to the substrate and mask, it is shifted laterally by a small amount, so that narrow overlap and undercover webs are formed, which are correspondingly contacted as a front electrode by the conductive front layer to be applied over the entire surface after the mask has been removed.
  • the back electrode sections are completely enclosed on one side. An interruption of the absorber layer between the individual solar cells is achieved by the mask itself, so that no short-circuit currents can occur here.
  • a recess in the absorber layer above the rear electrode sections on its other side is achieved in the area of the covering webs and is used for later contacting by the front electrode.
  • Co-coating the mask in turn means that there is no loss of material, and at the same time the mask is also completely processed up to the absorber layer.
  • the transparent conductive front layer After the mask has been removed and the transparent conductive front layer has been applied over the entire surface, only a single subsequent structuring step by mechanical or laser-assisted methods is required in the method according to the invention.
  • the front layer is separated with the width of the separating web apart from the rear electrode, so that a correspondingly structured front electrode is formed without short circuits between the individual solar cells.
  • the position of the separation points is also not critical since they only have to be offset laterally in the area of the covering webs or in the direction of the adjacent solar cell. It is important for the location of the separation points to avoid short circuits between the back and front electrodes. This is guaranteed when cutting in the area of the active solar cell.
  • the method according to claim 1 for the production of substrate solar cells basically corresponds to the method according to claim 2 for the production of superstrate solar cells, the process steps being carried out in the reverse order.
  • the transparent conductive front layer for the front electrode on the superstrate is not as mechanically stable in superstrate cells as the metal layer for forming the back electrode on the substrate in the case of substrate cells, the mechanical separation step for structuring the front electrode cannot be carried out in the same way in the production of superstrate cells (The scoring would take place down to the superstrat). Therefore, in the method according to claim 2, the entire transparent superstrate is first covered with a conductive front layer. After the mask has been fixed, the structuring is then carried out by scratching along the full areas of the mask as on a ruler, so that the mask lies with one of its lateral edges directly next to the structuring trenches. The absorber layer is then applied and the structuring trenches are likewise filled with absorber.
  • the mask After the mask has been moved laterally, the corresponding overlapping and undercovering bars are created again. After the application of the metal layer for structuring the back electrode, which can also be designed as p-TLO, the mask, which is now also covered with a complete solar cell structure, is finally removed.
  • the metal layer for structuring the back electrode which can also be designed as p-TLO
  • the mask which is now also covered with a complete solar cell structure, is finally removed.
  • the second boundary condition is to calculate their size so that the empty areas and possibly also the full areas in the geometry pattern have approximately the same area Avoiding a current mixture that resulted in partial areas of different sizes A uniformity of the full areas is always required if - as explained below - the mask is also to be further processed into a complete solar cell, although the area of the full areas differs
  • the second boundary condition does not pose a major problem in implementation, since it can easily be included in the solar module design
  • solar modules manufactured according to the invention Because of their function, they are usually arranged in the visible area anyway.
  • solar modules manufactured with the method according to the invention can also be used as aesthetic design elements for Building facades and advertising media are used, which significantly increases their attractiveness for use.
  • the geometric pattern will consist of rectangular and straight, narrow stripes.
  • the mask can have connecting bridges on its edges. When applying the individual layers to produce the solar module, these can be used Connecting webs can then be arranged outside the respective carrier layer.
  • the individual coatings can with the generally known
  • Processes such as vapor deposition or cathode sputtering are carried out.
  • the composition of the required layer package for a solar module produced in accordance with the invention in thin-film technology takes place depending on the materials used and the application cases.
  • the following additional method step can be provided (B) application of a barrier layer to form a diffusion barrier.
  • a barrier layer can be, for example, a Cr layer that prevents interdiffusion of, for example, Na.
  • the following additional method step can advantageously be provided.
  • an adhesive and / or swelling layer to form an adhesion promoter can be, for example, a Na swelling layer (NaF) and / or an adhesion-promoting layer, for example made of ZnSe or ZnS.
  • the absorber-forming coating can optionally be used and the application of the front layer, ie before process step (1 6) or (2 5), an additional process step can advantageously be added (D) applying at least one buffer layer to form a space charge zone.
  • This layer can consist, for example, of CdS or also of ZnS
  • the use of transparent materials to form the sub- or superstrate layer and / or metal layer can be provided. This makes it particularly suitable for window and semi-transparent areas, which is a fact takes advantage of the fact that glass panes are generally used anyway as large substrates or superstrates for thin-film solar cells.
  • the material for forming the transparent metal layer can be, for example, ZnO, SnO or ITO (Indium Tin Oxide), which, in addition to other layers Different doping can also be used to form the transparent, conductive front layer (TLO).
  • Non-transparent metal layers can consist of molybdenum, tungsten or another metal.
  • this can be characterized by the use of amorphous or polycrystalline or microcrystalline silicon, dependent on the carrier layer, of polyk ⁇ stailinem CdTe or of chalcopyrite compounds of the general structure Ag x Cu ⁇ ⁇ ln y Ga ⁇ y S z Se 2 zw Te w als Semiconductor material, where x and y values between 0 and 1 and z and w values between 0 and 2 can assume such that the sum of w + z does not significantly exceed the value 2.
  • the mask can consist of different materials that provide the required mechanical strength
  • the mask can be designed as a metal mask.
  • the mask is not required to be transparent, since it is covered by the opaque absorber layer.
  • a transparent, but not necessarily metallic, mask can be used in the manufacture of superstrate cells if a separate use
  • the mask is intended to be a positive ending.
  • a transparent front electrode TLO
  • This coating can, for example similar to the coating for the formation of the back electrodes in substrate cells.
  • the essential improvement and simplification of the method is achieved in the method according to the invention by using the mask which can be configured according to predetermined wishes and boundary conditions.
  • a number of structuring processes can be omitted as separate process steps.
  • the measure of lateral displacement of the mask saves two otherwise necessary scribing cuts.
  • the measure of the lateral displacement is a placeholder for the undercovering of the electrode sections on the one side in order to provide access for the next coating here and for the overlapping on the other side in order to create a recess here from the next coating.
  • the size of the shortfall and overlap is related to the overall dimensions of the structured solar cells and is intended to ensure a secure overlap on the one hand and a secure separation on the other.
  • the method is characterized by a lateral displacement of the mask in the range of 0.1 mm.
  • Such a shift is technically easy to implement and to ensure safely and does not require a major change in the process setup between the individual process steps.
  • the mask plays an important role in various aspects of the method according to the invention. Due to their direct co-processing, no material losses occur. Particularly in the case of masks with more complex geometric patterns, which result in a higher cost for the creation, it is useful to reuse the mask several times without having to reprocess it in the meantime. The layers applied in previous process runs with their only small amounts of material do not interfere. If the mask is finally no longer used, the applied material can be recycled which is of particular importance in large-scale productions.
  • the mask also has the further advantage that it can also be used as a “positive” for its own configuration, separately from the large-area solar module that is configured as a “negative” of the mask shape , Therefore, overall, according to another embodiment of the method according to the invention, it is advantageous if it is characterized by repeated use or separate processing of the detached mask, the full areas of which are then to be designed with the same area. There is no difference in the procedure, the processing on the substrate or superstrate and the mask is identical in each case. Due to the fact that the mask can also be used, there is no loss of material at any process point, and the relatively cost-intensive materials are used optimally.
  • the usability supports the aesthetic point of view, in which the geometric patterns, in particular company logos, can also be used as positive.
  • the mask can also be used to create individual solar cells of simple geometry, which can be combined to form solar modules by means of an appropriate sene connection (see below).
  • the geometry it should be noted that there is a geometrical, aesthetically and / or informally structured structuring of the individual solar cells in compliance with identical partial patterns in the empty areas and / or in the full areas.
  • the solar cells on the negative as well as the solar cells on the positive each make an identical contribution to electricity, so that no electricity mixture is created.
  • the optimizing aspects already mentioned at the outset with regard to maximizing performance and / or minimizing the area must also be taken into account.
  • the solar modules produced in accordance with the invention of both types of support layer they are particularly advantageous if they characterized in that a light-collecting concentrator module consisting of individual concentrators in the form of imaging or non-imaging optical elements is provided, which are matched in their arrangement to the arrangement of the individual solar cells.
  • the use of concentrators enables a significant increase in the average and total energy conversion efficiency of a Solar module
  • the optical elements can be, for example, lenses in conventional semi-convex or fresnel-like form or also prisms in conical or a Acting another geometric shape
  • the solar module is encapsulated on its light incidence side by a transparent glass or plastic with or without a transparent cover plate and the concentrators are integrated in the glass or plastic or on the inside of the cover plate applied or ground into it.
  • the application can be carried out by gluing. Structuring the outside, on the other hand, is disadvantageous, since this makes cleaning more difficult and weather influences and dirt can influence the collecting effect of the concentrators.
  • the concentrators used can preferably have a geometric concentration factor C g have, which is in a number range between 1 and 10
  • Such concentrator modules are known in principle and have already been extensively appreciated in connection with the prior art, but especially in the Be Some interesting combinations are possible here for the solar modules produced by the method according to the invention.
  • the concentrator module is laterally spaced in front of the solar module 1 D
  • linear structured solar cells and is designed in the form of a blind, the individual slats of which are formed by linear concentrator lenses that can be tracked in parallel according to the position of the sun.
  • Such designs are particularly suitable for an arrangement in the window area and here in particular, of course, in particularly sunny windows. This is also because the solar module itself can be made semi-transparent so that it already contributes to shading the interior.
  • An advantageous further development of the solar blind can be characterized in that each concentrator lens is fixed at its two ends to two guide rods via two gift hanging points, which in turn run in guide slots in end blocks fixed in position with respect to the solar module and by simply pressing on movable wedge blocks are adjustable All lenses can be adjusted together. Furthermore, the concentrator lenses follow a path that ensures correct alignment with the solar cells in the event of different incidence of light.
  • the solar module is formed from the mask and the electrodes of the individual solar cells are connected in series via an integrated, metallized contact strip be designed as a transparent, flexible contact film, the width of which corresponds to the entire width of the solar module. Furthermore, it can then be provided that the solar module is mounted in front of or behind (depending on the solar cell type) a further structured and integrated series-connected solar module, which is arranged in a stationary manner, and is laterally displaceably supported by a lateral winding or unwinding of the contact film which extends beyond the solar module, the lateral winding or unwinding is simultaneously designed as electrical polarization for the solar cell current.
  • the degrees of transparency of the solar modules used can be adapted to those of the building surfaces and can be changed, for example fully transparent in front of shady windows and Glass components, semi-transparent in front of sunny windows and non-transparent in front of building walls, in the roof area or as sun protection.
  • semi-transparent solar modules the Use of concentrators, the area to be covered with solar cells is significantly reduced.This results in more flexibility for the architectural design.
  • the small distance between the solar and concentrator modules allows ready-to-use offset pieces to be made for house building without significantly increasing the space required for conventional solar modules - All in all, completely new areas of application open up, which could make the use of solar modules - also in the interior - much more attractive.
  • FIG. 1 shows the sequence of the manufacturing method according to the invention for a substrate cell
  • FIG. 2 shows the sequence of the manufacturing method according to the invention for a super cell
  • FIGS. 4a, 4b shows a solar module made from substrate cells with a concentrator module in the form of a blind in two positions
  • 5a, 5b a solar module made with the method from substrate cells with variable shading in plan view and in section and
  • Figure 6 is a diagram of the effect of the concentrator modules.
  • a thin-layer mask 100 is produced which corresponds to the desired geometry while observing the specified boundary conditions. In the exemplary embodiment shown, this is a comb-like geometry with solid areas 101 and empty areas 102 of the same area. Connecting webs 103 in the geometry pattern lie outside the solar cell structure to be produced and are therefore not considered further.
  • the mask 100 is detachably fixed on a transparent substrate layer 104 made of glass.
  • a metal layer 105 is applied to the substrate layer 104 and the fixed mask 100.
  • a metal layer 105 is also deposited on the full areas 101 of the mask 100 in method step (1.3).
  • the mask 100 is laterally displaced over the strip-shaped back electrode 106 in the direction of the arrow, for example by an amount in the range of 0.1 mm At this point, it should be pointed out that the dimensions are distorted in favor of a clear representation. With the lateral displacement, narrow undercover webs 107 and narrow overlapping webs 108 are formed
  • a photovoltaically active, thin semiconductor layer 109 for example made of the chalcopyrite compound CulnS 2 , is applied to the substrate 104 and the laterally displaced mask 100.
  • an absorber layer 110 structured via the mask 100 is formed, which also extends to the covering bridge 107, but not to the covering bridge 108.
  • the strip-like jerk electrode 106 in the region of the covering bridge 107 is enclosed by the semiconductor layer 109 and left free in the region of the covering bridge 108.
  • the mask 100 is detached and removed then separated, but processed in parallel to a “positive solar module” and differs from the “negative solar module” only in that the substrate layer 104 is omitted, but is mechanically replaced by the mask 100.
  • the Substrate 104 now also major
  • a transparent, conductive front layer 111 is applied to the jerk electrode 106 and, if necessary, separately from the removed mask 100, through which a front electrode 112 is formed.
  • the separated mask 100 is thus finished and formed an initially unconnected solar module 113 made of individual thin-film solar cells 114 in the form of the full surfaces 101 of the geometric pattern without its connecting webs.
  • the solar module can be carried out by subsequent suitable interconnection measures, which are relatively simple and integrated due to the missing substrate layer 104 and the exposed metal layer 105 113 can then be completed (analogously in FIGS. 3 and 5).
  • the light is incident in the direction of the arrow 104 on the substrate 104
  • the front electrode 112 is initially unstructured and connects all the solar cells 116 in an electrical short circuit.
  • the front layer 111 is therefore separated in separation areas 119 of the covering webs 108 by a suitable scribing method, for example using a laser beam , separated with short-circuit-canceling separating webs 117 down to the strip-like back electrode 106.
  • a thin mask 150 is again provided according to a predefined geometry pattern. If later use of the mask as an independent solar module is planned, it consists of a transparent material and is provided on its top with a separately applied front electrode, not shown in the figure.
  • a transparent, conductive front layer 152 is applied to a superstrate 151 to form a front electrode 153. In the selected embodiment, this consists of several SnO layers of different doping (ITO or ZnO also possible).
  • the mask 150 is then detachably fixed on the front layer 152 (method step (2.3)).
  • a method step (2.4) the front layer 152 is scanned along the outer edges of the mask 150, which act as mechanical or optical guide rulers, for structuring the front electrode 153.
  • a semiconductor layer 154 is formed to form a layer corresponding to the Mask geometry applied structured absorber layer 155.
  • the mask 150 in the process step (2.6) analogously to the process described above, shifted laterally by a small amount of approx. 0.1 mm. Cover webs 156 and undercover webs 157 are formed.
  • FIG. 3 shows a solar module 200 produced by the method according to the invention in a partially transparent embodiment with laterally structured solar cells 201 on one Transparent substrate 202 and with a light-collecting concentrator module 203 as an integrated light concentration.
  • a solar module 200 can be used, for example, as a window or as an element for architecturally demanding facades.
  • a housing 204 which is also the Discharge of the generated electrical current is used, and realized a front glass plate 205, which is backfilled with a transparent plastic 206 filling the space (eg epoxy or synthetic resin).
  • the concentrator module 203 is arranged on the inside 207 of the front glass plate 205 and has individual concentrators 208, which are matched in their arrangement to the arrangement of the individual solar cells 201. In the selected exemplary embodiment, these are strip-shaped, semi-convex lenses which are glued to the inside of the glass plate 205. To explain the effect of the concentrators, reference is made to FIG. 6.
  • FIG. 4 shows the embodiment of a partially transparent solar module 300 with rectilinearly structured solar cells 301 on a transparent substrate 302 and with a concentrator module 303 in the form of a “solar blind” made of trackable, linearly focusing concentrator lenses 304.
  • the solar cells 301 are mounted behind the separately suspended, louvre-like concentrator module 303. This consists of as many lamella-like, linearly focusing concentrator lenses 304 as there are strip-shaped solar cells 301 in the solar module 300.
  • Each concentrator lens 304 is attached to two at its two ends via two gifted suspension points 305 Fixed guide rods 306, which in turn run in guide slots 307 in end blocks 308.
  • the position of the end blocks 308 is fixed with respect to the solar module 300, whereby a single adjustment of the concentrator lenses 304 is not necessary.
  • the guide rods 306 become in the guide slots 307 ch simple pressure of movable wedge blocks 309 adjusted.
  • the concentrator lenses 304 follow a path that ensures correct adjustment with respect to the solar cells 301 in the event of different incidence of light.
  • the incidence of light is indicated by dashed light beams 310 for two different angles of incidence in the upper (a) and lower (b) of FIG. 4.
  • this type of light concentration is particularly suitable for superstrate cells, where the integration of the concentrators into the solar module is based Difficulties arise, and secondly, that the described type of suspension not only correctly tracks the angle of inclination of the concentrator lenses 304, but also their center of gravity.
  • the control signal for the tracking can be obtained in a simple manner from the current draw of the solar cells 301.
  • the shape of the lateral structuring of the solar cells 301 should be straight, so that correct illumination by the concentrator lenses 304 is ensured.
  • the scanning ratio solar cell clearance can also be selected differently than 2 1
  • FIG. 5 shows a partially transparent, laterally structured combination solar module 400 with variable shading, top (a) in plan view, bottom (b) in cross section.
  • the combination solar module 400 consists of a stationary solar module 401, which has rigid solar cells 402 a transparent substrate 403 is constructed, and from a portable solar module 404 arranged above the stationary solar module 401, which is implemented on a strip-like mask 405.
  • Solar cells 406 prepared on the mask 405 are provided by a flexible, transparent contact film 407 between the front and rear sides of the strip-shaped solar cells 406 electrically connected in series with one another.
  • the contact sheet 407 is metallized over a large area with a transparent, conductive oxide.
  • the contact sheet 407 can be designed over the entire width of a window, so that on the one hand there is less loss of sense resistance and on the other hand an increased mechanical Stability of the flexible solar module 404 results in the connecting contact foil 407 being wound at the ends on a cylindrical body 408, which also acts as an electrical supply to the outside.
  • the cylindrical body 408 is suspended in a frame element 409 and can be rotated from the outside, so that the flexible Solar module 404 are moved sideways.
  • the stationary solar module 401 is optionally shaded on the glass substrate 403, as a result of which Windows become semi-transparent overall with lower electricity production.
  • the portable solar cells 406 are positioned between the rigid solar cells 402 of the fixed solar module 401, making the window completely opaque and maximizing power production.
  • the solar cells 402, 406 do not necessarily have to be structured as straight strips, but they can also be structured according to aesthetic aspects, as long as their surfaces correspond to the general boundary conditions and are additionally congruent for this application. At this point, it should also be noted that when using super cells, the portable solar cells would have to be arranged below the stationary solar cells.
  • FIG. 6 shows a typical measurement curve of the efficiency of a chalcopyrite solar cell as a function of the light concentration, based on which three characteristic statements can be made:
  • the energy efficiency ⁇ of thin-film solar cells related to the radiation intensity varies in such a way that the operation at lower irradiance is unfavorable.

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  • Engineering & Computer Science (AREA)
  • Life Sciences & Earth Sciences (AREA)
  • Sustainable Development (AREA)
  • Physics & Mathematics (AREA)
  • Condensed Matter Physics & Semiconductors (AREA)
  • Electromagnetism (AREA)
  • General Physics & Mathematics (AREA)
  • Computer Hardware Design (AREA)
  • Microelectronics & Electronic Packaging (AREA)
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  • Sustainable Energy (AREA)
  • Photovoltaic Devices (AREA)

Abstract

Les procédés de production connus de modules solaires à mince couche intégrés et à grande surface dotés d'une couche absorbeur amorphe, polycristalline ou microcristalline comprennent systématiquement des structurations de séparation tout comme des structurations de transformation qui peuvent conditionner les incertitudes de la structuration et qui sont relativement coûteuses. Selon les procédés de l'invention qui permettent de produire des cellules solaires à substrat (116) tout comme des cellules solaires à couche sus-jacente, on utilise comme aide un masque (100) qui, par sa forme géométrique, veille déjà à la structuration lors du dépôt de couches de l'électrode arrière (106) et de la couche absorbeur (110). L'utilisation d'un masque (110), réutilisable comme élément autonome après son utilisation dans le procédé, permet d'obtenir une liberté de façonnage relative, ce qui autorise des utilisations en extérieur comme à l'intérieur de bâtiments même selon des considérations esthétiques et informelles, notamment une utilisation dans la zone de la fenêtre. De telles applications sont également permises par la possibilité de liaison constructive des modules solaires produits selon le procédé de l'invention avec des modules concentrateurs collecteurs de lumière destinés à augmenter considérablement son efficacité moyenne et totale de conversion d'énergie.
EP01935948A 2000-03-30 2001-03-29 Procede de production d'un module solaire dote de cellules solaires a mince couche integrees et montees en serie, et module solaire ainsi produit, notamment a l'aide de modules concentrateurs Withdrawn EP1269542A1 (fr)

Applications Claiming Priority (3)

Application Number Priority Date Filing Date Title
DE10017610A DE10017610C2 (de) 2000-03-30 2000-03-30 Verfahren zur Herstellung eines Solarmoduls mit integriert serienverschalteten Dünnschicht-Solarzellen und Verwendung davon
DE10017610 2000-03-30
PCT/DE2001/001295 WO2001075976A1 (fr) 2000-03-30 2001-03-29 Procede de production d'un module solaire dote de cellules solaires a mince couche integrees et montees en serie, et module solaire ainsi produit, notamment a l'aide de modules concentrateurs

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EP1269542A1 true EP1269542A1 (fr) 2003-01-02

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EP01935948A Withdrawn EP1269542A1 (fr) 2000-03-30 2001-03-29 Procede de production d'un module solaire dote de cellules solaires a mince couche integrees et montees en serie, et module solaire ainsi produit, notamment a l'aide de modules concentrateurs

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US (1) US7019207B2 (fr)
EP (1) EP1269542A1 (fr)
JP (1) JP4056744B2 (fr)
DE (1) DE10017610C2 (fr)
HK (1) HK1053904A1 (fr)
WO (1) WO2001075976A1 (fr)

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US20030121542A1 (en) 2003-07-03
DE10017610C2 (de) 2002-10-31
US7019207B2 (en) 2006-03-28
JP2003529938A (ja) 2003-10-07
HK1053904A1 (zh) 2003-11-07
WO2001075976A1 (fr) 2001-10-11
JP4056744B2 (ja) 2008-03-05
DE10017610A1 (de) 2001-10-18

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