Classifications

• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B32—LAYERED PRODUCTS
  • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
  • B32B37/00—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding
  • B32B37/10—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding characterised by the pressing technique, e.g. using action of vacuum or fluid pressure
  • B32B37/1009—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding characterised by the pressing technique, e.g. using action of vacuum or fluid pressure using vacuum and fluid pressure
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B32—LAYERED PRODUCTS
  • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
  • B32B17/00—Layered products essentially comprising sheet glass, or glass, slag, or like fibres
  • B32B17/06—Layered products essentially comprising sheet glass, or glass, slag, or like fibres comprising glass as the main or only constituent of a layer, next to another layer of a specific material
  • B32B17/10—Layered products essentially comprising sheet glass, or glass, slag, or like fibres comprising glass as the main or only constituent of a layer, next to another layer of a specific material of synthetic resin
  • B32B17/10005—Layered products essentially comprising sheet glass, or glass, slag, or like fibres comprising glass as the main or only constituent of a layer, next to another layer of a specific material of synthetic resin laminated safety glass or glazing
  • B32B17/1055—Layered products essentially comprising sheet glass, or glass, slag, or like fibres comprising glass as the main or only constituent of a layer, next to another layer of a specific material of synthetic resin laminated safety glass or glazing characterized by the resin layer, i.e. interlayer
  • B32B17/10559—Shape of the cross-section
  • B32B17/10577—Surface roughness
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B32—LAYERED PRODUCTS
  • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
  • B32B17/00—Layered products essentially comprising sheet glass, or glass, slag, or like fibres
  • B32B17/06—Layered products essentially comprising sheet glass, or glass, slag, or like fibres comprising glass as the main or only constituent of a layer, next to another layer of a specific material
  • B32B17/10—Layered products essentially comprising sheet glass, or glass, slag, or like fibres comprising glass as the main or only constituent of a layer, next to another layer of a specific material of synthetic resin
  • B32B17/10005—Layered products essentially comprising sheet glass, or glass, slag, or like fibres comprising glass as the main or only constituent of a layer, next to another layer of a specific material of synthetic resin laminated safety glass or glazing
  • B32B17/1055—Layered products essentially comprising sheet glass, or glass, slag, or like fibres comprising glass as the main or only constituent of a layer, next to another layer of a specific material of synthetic resin laminated safety glass or glazing characterized by the resin layer, i.e. interlayer
  • B32B17/10688—Adjustment of the adherence to the glass layers
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B32—LAYERED PRODUCTS
  • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
  • B32B17/00—Layered products essentially comprising sheet glass, or glass, slag, or like fibres
  • B32B17/06—Layered products essentially comprising sheet glass, or glass, slag, or like fibres comprising glass as the main or only constituent of a layer, next to another layer of a specific material
  • B32B17/10—Layered products essentially comprising sheet glass, or glass, slag, or like fibres comprising glass as the main or only constituent of a layer, next to another layer of a specific material of synthetic resin
  • B32B17/10005—Layered products essentially comprising sheet glass, or glass, slag, or like fibres comprising glass as the main or only constituent of a layer, next to another layer of a specific material of synthetic resin laminated safety glass or glazing
  • B32B17/1055—Layered products essentially comprising sheet glass, or glass, slag, or like fibres comprising glass as the main or only constituent of a layer, next to another layer of a specific material of synthetic resin laminated safety glass or glazing characterized by the resin layer, i.e. interlayer
  • B32B17/10761—Layered products essentially comprising sheet glass, or glass, slag, or like fibres comprising glass as the main or only constituent of a layer, next to another layer of a specific material of synthetic resin laminated safety glass or glazing characterized by the resin layer, i.e. interlayer containing vinyl acetal
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B32—LAYERED PRODUCTS
  • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
  • B32B17/00—Layered products essentially comprising sheet glass, or glass, slag, or like fibres
  • B32B17/06—Layered products essentially comprising sheet glass, or glass, slag, or like fibres comprising glass as the main or only constituent of a layer, next to another layer of a specific material
  • B32B17/10—Layered products essentially comprising sheet glass, or glass, slag, or like fibres comprising glass as the main or only constituent of a layer, next to another layer of a specific material of synthetic resin
  • B32B17/10005—Layered products essentially comprising sheet glass, or glass, slag, or like fibres comprising glass as the main or only constituent of a layer, next to another layer of a specific material of synthetic resin laminated safety glass or glazing
  • B32B17/10807—Making laminated safety glass or glazing; Apparatus therefor
  • B32B17/10816—Making laminated safety glass or glazing; Apparatus therefor by pressing
  • B32B17/10871—Making laminated safety glass or glazing; Apparatus therefor by pressing in combination with particular heat treatment
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B32—LAYERED PRODUCTS
  • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
  • B32B37/00—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding
  • B32B37/10—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding characterised by the pressing technique, e.g. using action of vacuum or fluid pressure
• • 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
  • H01L31/048—Encapsulation of modules
  • H01L31/0481—Encapsulation of modules characterised by the composition of the encapsulation material
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B32—LAYERED PRODUCTS
  • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
  • B32B2309/00—Parameters for the laminating or treatment process; Apparatus details
  • B32B2309/60—In a particular environment
  • B32B2309/68—Vacuum
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B32—LAYERED PRODUCTS
  • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
  • B32B2457/00—Electrical equipment
  • B32B2457/12—Photovoltaic modules
• • 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

Definitions

• the invention relates to a process for the preparation of
• Photovoltaic modules under elevated temperature and reduced gas ambient pressure using a polyvinyl acetal based film are Photovoltaic modules under elevated temperature and reduced gas ambient pressure using a polyvinyl acetal based film.
• Photovoltaic modules consist of a photosensitive semiconductor layer, which is provided to protect against external influences with a transparent cover.
• a photosensitive semiconductor layer monocrystalline solar cells or polycrystalline, thin semiconductor layers can be used on a support.
• Thin-film solar modules consist of a photosensitive semiconductor layer coated on a mostly transparent plate, e.g. by vapor deposition, vapor deposition, sputtering or wet deposition is applied.
• Both systems are sandwiched between a pane of glass and a rigid, rear cover plate, e.g. laminated from glass or plastics using a transparent adhesive.
• Curing resins or crosslinkable systems based on ethylene-vinyl acetate (EVA) are frequently used as transparent adhesives, as disclosed, for example, in DE 41 22 721 C1 or DE 41 28 766 A1.
• thermosetting adhesive systems are the use of plasticized films based on polyvinyl acetals, such as polyvinyl butyral (PVB) known from the manufacture of laminated glass.
• PVB polyvinyl butyral
• the solar cell units are covered with one or more PVB films and bonded under elevated pressure and temperature with the desired covering materials into a laminate.
• Methods of this kind are e.g. From DE 40 26 165 C2, DE 42 278 60 A1, DE 29 237 70 C2, DE 35 38 986 C2 or US 4,321,418 known.
• the currently most common method for the production of solar modules is the lamination in Vakuumlaminator.
• the module is vented in a vacuum chamber and heated by IR radiation, microwave radiation or direct contact with one or more heating plates.
• EVA-containing modules For the bubble-free production of EVA-containing modules is usually a process vacuum of 1 millibar or less required in the vacuum chamber, as only so the originating from the crosslinking of the EVA reaction products can be safely removed.
• the object of the present invention was therefore to provide a process for the production of solar modules in vacuum laminator using plasticized interlayer films, which has a significant reduction in the tendency to plasticizer residues.
• the present invention is therefore a process for the preparation of photovoltaic modules, comprising a laminate of a) a transparent front cover b) one or more photosensitive semiconductor layers or coated therewith carriers c) at least one plasticizer-containing, based on polyvinyl acetal film and d) a rear cover wherein one of the layers a) to d) existing composite body is bonded in a process chamber at a temperature of 120-190 0 C and a gas pressure of 200 to 5 * 10 4 Pa to form a laminate.
• Process chamber i.e., a vacuum laminator
• FIG. 1 a) the upper and b) the lower part of the vacuum chamber, which are separated by the membrane c) from each other and can be acted upon with different gas pressures.
• the module is heated via the heating plate d) either directly or by convection.
• About the conveyor belts e) of the collapsed composite body or the laminated module f) are transported into or out of the process chamber.
• the temperature of the process chamber may preferably be 130 to 180 ° C, more preferably 140 to 170 ° C, wherein the temperatures of the process chamber are equated with the temperature of the heat source.
• a heat source IR radiation, microwave radiation, convection or direct contact with one or more heating plates can be used.
• the heat sources may be mounted above and / or below the laminate.
• the temperature of the process chamber may be constant over the process time or varied.
• Process chamber ie in the lower part of the laminator is preferably more than 2000 Pa, more preferably more than 2 * 10 4th
• the upper limit of the gas pressure in the process chamber can be specified as 5 * 10 4 Pa. This vacuum can remain constant or varied over the process time.
• the process times depend on the thickness of the laminate, i. the glass thickness, the thickness of the cover sheets and the thickness of the used vitell. Encapsulant from and usually be 10 to 35 min.
• the laminates may optionally be additionally applied
• the applied pressing force can be applied via a membrane (c in Fig. 1) which separates the upper (a in Fig. 1) and the lower part (b in Fig. 1) of the vacuum chamber from each other.
• a membrane c in Fig. 1 which separates the upper (a in Fig. 1) and the lower part (b in Fig. 1) of the vacuum chamber from each other.
• the upper part of the process chamber is fully or partially vented or even subjected to an overpressure, so that by the differential pressure between the upper and lower process chamber, a pressure i. a surface load is exerted on the laminate or the module.
• the surface load necessary for pressing can also be applied hydraulically, pneumatically or mechanically via a stable plate. Also conceivable is a combination of these methods.
• the laminate can be pressed with a surface load of 1 * 10 4 Pa to 12 * 10 5 Pa.
• Polyvinyl acetal based films preferably contain uncrosslinked polyvinyl butyral (PVB), which is obtained by acetalization of polyvinyl alcohol with butyraldehyde.
• PVB polyvinyl butyral
• crosslinked polyvinyl acetals in particular crosslinked polyvinyl butyral (PVB) is also possible.
• Suitable crosslinked polyvinyl acetals are described, for example, in EP 1527107 B1 and WO 2004/063231 A1 (thermal self-crosslinking of polyvinyl acetals containing carboxyl groups), EP 1606325 A1 (polyvinyl acetals crosslinked with polyaldehydes) and WO 03/020776 A1 (crosslinked with glyoxylic acid Polyvinyl acetals).
• Aldehydes having 2-10 carbon atoms e.g., valeraldehyde.
• polyvinyl alcohol terpolymers of hydrolyzed vinyl acetate / ethylene copolymers can be used in the context of the present invention. These compounds are typically hydrolyzed to greater than 98 mole percent and contain from 1 to 10 weight percent ethylene based units (e.g., "Exceval" type from Kuraray Europe GmbH).
• hydrolyzed copolymers of vinyl acetate and at least one further ethylenically unsaturated monomer can also be used within the scope of the present invention.
• polyvinyl alcohols can be used in the context of the present invention, pure or as a mixture of polyvinyl alcohols with different degrees of polymerization or degree of hydrolysis.
• Polyvinyl acetals still contain in addition to the acetal units
• the polyvinyl acetals used according to the invention preferably have a polyvinyl alcohol content of less than 22% by weight, 20% by weight or 18% by weight, less than 16% by weight or 15% by weight and in particular less than 14% by weight. A polyvinyl alcohol content of 12% by weight should not be exceeded.
• Polyvinyl acetal is preferably less than 3% by weight or less than 1% by weight, more preferably less than 0.75% by weight, very preferably less than 0.5% by weight and in particular less than 0.25% by weight.
• the degree of acetalization can be determined by calculation.
• the films preferably have a plasticizer content of at most 40% by weight, 35% by weight, 32% by weight, 30% by weight, 28% by weight, 26% by weight, 24% by weight or 22% by weight. on, with a plasticizer content of 15 wt.% Should not be exceeded for reasons of processability of the film (each based on the total film formulation).
• Films or photovoltaic modules used according to the invention can contain one or more plasticizers.
• Suitable plasticizers for the films used according to the invention are one or more compounds selected from the following groups:
• Esters of polyhydric aliphatic or aromatic acids e.g. Dialkyladipates such as Dihexyladipat, Dioctyladipat, Hexylcyclohexyladipat, mixtures of heptyl and nonyl adipates, Diisononyladipat, heptylnonyl adipate and esters of adipic acid with cycloaliphatic or ether-containing ester alcohols, dialkyl sebacates such as dibutyl sebacate and esters of sebacic acid with cycloaliphatic or ether-containing ester alcohols, esters of phthalic acid such as butyl benzyl phthalate or bis-2-butoxyethyl phthalate
• Esters or ethers of polyhydric aliphatic or aromatic alcohols or oligoether glycols having one or more unbranched or branched aliphatic or aromatic substituents e.g. Esters of di-, tri- or tetraglycols with linear or branched aliphatic or cycloaliphatic carboxylic acids;
• Esters of di-, tri- or tetraglycols with linear or branched aliphatic or cycloaliphatic carboxylic acids may serve diethylene glycol bis (2-ethylhexanoate), triethylene glycol bis (2-ethylhexanoate), tri-ethylene glycol bis (2-ethylbu-ta-no-ate) .
• Phosphates with aliphatic or aromatic ester alcohols e.g. Tris (2-ethylhexyl) phosphate (TOF), triethyl phosphate, diphenyl-2-ethylhexyl phosphate, and / or tricresyl phosphate
• plasticizers for the films used according to the invention are one or more compounds selected from the following group: di-2-ethylhexyl sebacate (DOS), di-2-ethylhexyl adipate (DOA), dihexyl adipate (DHA), dibutyl sebacate (DBS), Triethylene glycol bis-n-heptanoate (3G7), tetraethylene glycol bis-n-heptanoate (4G7), triethylene glycol bis-2-ethylhexanoate (3GO or 3G8) tetraethylene glycol bis-n-2-ethylhexanoate (4GO or 4G8) di-2-butoxy-ethyl adipate (DBEA), di-2-butoxyethoxyethyl adipate (DBEEA) di-2-butoxyethyl sebacate (DBES), di-2-eth-ethyl
• Cyclohexane-i-dicarboxylic acid diisononyl ester (DINCH) and dipropylene glycol zoate.
• Glass can be replaced by the addition of adhesion regulators such.
• adhesion regulators such as WO 03/033583 A1 alkali and / or alkaline earth metal salts of organic acids can be adjusted. Be particularly suitable potassium acetate and / or magnesium acetate have been found. To obtain high adhesion values it may be necessary to use films without the addition of adhesion regulators such as alkali and / or alkaline earth salts.
• the based on plasticized polyvinyl acetal film preferably has a one-sided or more preferably applied on both sides surface structure with a roughness of Rz between 10 and 180 microns, preferably Rz> 20 microns and Rz ⁇ 180 microns, more preferably Rz> 35 microns and Rz ⁇ 150 ⁇ m and in particular of Rz> 35 ⁇ m and Rz ⁇ 130 ⁇ m.
• the surface structure of the film can be produced in the extrusion process by the so-called flow or melt fracture method according to EP 0 185 863 B1. This process leads to an irregular, approximately isotropic roughness.
• the measured value of the roughness is measured here approximately the same across all directions, but the individual elevations and depressions are arranged irregularly in their height and distribution.
• the surface structure of the film may be formed by embossing, e.g. according to EP 06112163 or EP 06112159. This results in a regular roughness / roughness structure of the surface.
• the measurement of the surface roughness Rz or the roughness value Rz is carried out according to DIN EN ISO 4287.
• the measurements indicated were a roughness measuring device of the company Mahr type S2, feed device PGK with mechanical single-use button MFW-250 carried out.
• the cut-off wavelength Ic is 8 mm, the total measuring distance in the 40 mm, consisting of five individual measuring sections Ie of 8 mm each with a leading and trailing distance Iv or In of 8 mm.
• Foils are usually 0.38, 0.51, 0.76, 1.14, 1.52 or 2.28 mm.
• the basic preparation and composition of films based on polyvinyl acetals is z.
• EP 185 863 B1 EP 1 118 258 B1, WO 02/102591 A1.
• the photosensitive material in another variant of the invention, the photosensitive organic compound
• Deposited semiconductor layers on a support for example by vapor deposition, vapor deposition, sputtering or wet deposition. These supported photosensitive semiconductor layers are embedded between two films c) and thus bonded to the covers a) and d).
• photosensitive semiconductor layer directly to one of the covers a) or d) (eg by vapor deposition, vapor deposition, sputtering or wet separation). Encapsulation is not possible or required in this variant of the invention.
• one or more photosensitive semiconductor layers b) are applied to a transparent front cover a) or a rear cover d) and by at least one plasticizer-containing, based on polyvinyl acetal film c) glued together.
• the transparent front cover is usually made of glass or transparent plastics such as ETFE or PMMA.
• the rear cover of the photovoltaic module can be made of glass, plastic or metal or their composites, wherein at least one of the carriers can be transparent. It is also possible to use one or both covers as a composite glazing (i.e., as a laminate of at least two glass sheets and at least one PVB sheet) or as insulating glazing with a gas gap. Of course, the combination of these measures is possible.
• the photosensitive semiconductor layers used in the modules need not have any special properties. Mono-, polycrystalline, organic or amorphous systems can be used.
• Photovoltaic modules produced according to the invention can be used in solar power plants, as a facade component, roof surfaces, conservatory cover, soundproof wall, balcony or parapet element or as part of window surfaces.
• a thin-film module of size L 130 cm ⁇ W 110 cm with a glass thickness of 3.2 mm with internal longitudinal and transverse contacts and a contact hole on the back glass is laminated in a vacuum laminator.
• the film used is the product TROSIFOL R40 in a thickness of 0.76 mm.
• the film was conditioned for at least 12 hours at 23 ° C and a relative humidity of 25%.
• the edge overhang is 5mm circumferential.
• the heating plate has a temperature of 150 ° C, the vacuum is less than 100 Pa.
• the module is first evacuated for 11 min, then the upper process chamber is over Ventilated period from 5 min to 600 mbar. The module is then held under these process conditions for 12 minutes. This gives a bubble-free ready-connected laminate with light

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• Physics & Mathematics (AREA)
• Fluid Mechanics (AREA)
• Condensed Matter Physics & Semiconductors (AREA)
• Electromagnetism (AREA)
• General Physics & Mathematics (AREA)
• Engineering & Computer Science (AREA)
• Computer Hardware Design (AREA)
• Microelectronics & Electronic Packaging (AREA)
• Power Engineering (AREA)
• Thermal Sciences (AREA)
• Photovoltaic Devices (AREA)
• Laminated Bodies (AREA)
• Joining Of Glass To Other Materials (AREA)

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• 2008
  • 2008-05-09 DE DE102008001684A patent/DE102008001684A1/de not_active Withdrawn
• 2009
  • 2009-05-08 WO PCT/EP2009/055581 patent/WO2009135929A2/de active Application Filing
  • 2009-05-08 TW TW098115213A patent/TW201010111A/zh unknown
  • 2009-05-08 EP EP09742147A patent/EP2288498A2/de not_active Withdrawn

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