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
  • H01L31/18—Processes or apparatus specially adapted for the manufacture or treatment of these devices or of parts thereof
  • H01L31/1876—Particular processes or apparatus for batch treatment of the devices
  • H01L31/188—Apparatus specially adapted for automatic interconnection of solar cells in a module
• • 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
  • B32B37/14—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding characterised by the properties of the layers
  • B32B37/16—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding characterised by the properties of the layers with all layers existing as coherent layers before laminating
  • B32B37/20—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding characterised by the properties of the layers with all layers existing as coherent layers before laminating involving the assembly of continuous webs only
  • B32B37/203—One or more of the layers being plastic
  • B32B37/206—Laminating a continuous layer between two continuous plastic layers
• • 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
  • H01L31/0248—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 characterised by their semiconductor bodies
  • H01L31/036—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 characterised by their semiconductor bodies characterised by their crystalline structure or particular orientation of the crystalline planes
  • H01L31/0392—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 characterised by their semiconductor bodies characterised by their crystalline structure or particular orientation of the crystalline planes including thin films deposited on metallic or insulating substrates ; characterised by specific substrate materials or substrate features or by the presence of intermediate layers, e.g. barrier layers, on the substrate
  • H01L31/03926—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 characterised by their semiconductor bodies characterised by their crystalline structure or particular orientation of the crystalline planes including thin films deposited on metallic or insulating substrates ; characterised by specific substrate materials or substrate features or by the presence of intermediate layers, e.g. barrier layers, on the substrate comprising a flexible 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
  • H01L31/048—Encapsulation of modules
  • H01L31/0488—Double glass encapsulation, e.g. photovoltaic cells arranged between front and rear glass sheets
• • 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
  • B32B2309/02—Temperature
• • 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
  • B32B2309/04—Time
• • 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

• a method and an apparatus for producing a solar module with flexible solar cells, in particular flexible thin-film solar cells, as well as a solar module produced with such a device / according to such a method are described.
• the procedure described here, the corresponding device for producing a solar module and the resulting product, ie the solar module, can also be realized with rigid solar cells (for example silicon solar cells) instead of the flexible thin-film solar cells explained in detail here.
• Solar or photovoltaic modules convert incident sunlight directly into electrical energy.
• the most important components of a solar module contains several solar cells.
• a solar module is characterized by its electrical connection values (in particular open circuit voltage and short-circuit current). These depend on the properties of the individual solar cells and the quality of the interconnection of the solar cells within the module.
• a solar module usually has, in addition to the electrically interconnected solar cells an embedding material and a back construction.
• a cover layer protects against mechanical and weather influences.
• the back construction protects the solar cells and the potting material from moisture and oxygen. In addition, it serves as a mechanical protection when mounting the solar modules and as electrical insulation.
• the back construction may be formed of glass or a composite foil.
• a first electrode usually on the bottom of the solar cell is the positive pole
• a second electrode usually on the top of the solar cell is the negative pole.
• WO2009148562A1 - Solexant - relates to the interconnection of solar cells, in which a substrate is provided with a plurality of holes, a metallic electrode layer is applied on both sides of the substrate to form a bottom and a back electrode. A portion of the metal layer is scored from the periphery of one or more of the holes to insulate the respective hole from the bottom electrode.
• the bottom and rear electrodes are scribed longitudinally to define adjacent cells. The adjacent cells are electrically connected to each other by contact between the bottom electrode of one cell and the back electrode of another cell through at least one hole positioned between the bottom electrode and the back electrode.
• An absorber layer and a transparent conductor layer are applied.
• the transparent conductor layer is longitudinally scribed across a cell on one side of the row of interconnecting vias, and a transparent conductor electrode is longitudinally scribed over a cell on the opposite side of the same row of interconnecting vias, with the scribes positioned in close proximity to the row of interconnection vias and the scribe removes the transparent conductive layer (TCO).
• TCO transparent conductive layer
• DE 10 239 845 C1 describes an electrode for contacting an electrically conductive surface of a photovoltaic element, with an electrically insulating, optically transparent film, with an adhesive layer applied to a surface of the film, and with a first group of parallel, electrically conductive wires are embedded in the adhesive layer, protrude from the adhesive layer with a portion of its surface and on the surface emerging from the adhesive layer with a layer of a low alloy
• the wires are electrically connected to the first group with a first contact strip.
• DE 10 2008 046 327 AI relates to an arrangement of several production devices as a system for processing solar cells to a module.
• This system has production devices for the following steps: provision of the carriers, pre-fabrication of the solar cells by attaching contact wires, arranging transverse contact wires on the carrier, placing the prefabricated solar cells on the carrier, longitudinal connection of the prefabricated solar cells to the contact wires, cross-connection of the prefabricated solar cells the transverse contact wire and merging the solar cells located on the carrier to a carrier glass for the production of the module.
• WO 94/22 172 relates to the use of a roll laminator instead of previously used Vakuumplattenlaminatoren.
• the plastic films used are only partially suitable for the encapsulation of solar modules.
• the films are neither impact-resistant enough nor sufficiently weather-resistant, nor is the adhesive layer soft enough to effectively protect the easily fragile solar cells mechanically.
• EP 0 111 394 A2 discloses a method in which the solar cells are electrically connected prior to application to the lower encapsulation layer.
• the conductive strips are welded to the exposed areas of the stainless steel substrate.
• the lower and upper encapsulation layers are applied to the modules.
• DE 34 23 172 C2 discloses a method for manufacturing a solar battery. Electrical conductors protrude into the space between the solar cells, however the electrical conductors are assigned to the substrate films. By pressing quartz glass press plates, the electrodes are sandwiched in pressure contact with the solder layers on the conductors of the films. Laser beams supplied via fiber optic cables cause melting of the solder layers. The electrodes for the top and the bottom of the solar cell are first applied simultaneously and then contacted simultaneously.
• US 2002/0056473 A1 discloses a method in which bus bars are sprayed onto a solar cell.
• US 2001/0029975 A1 discloses a method for producing a module of photovoltaic elements. In this case, overlapping contact points and laser welding are connected. This document shows neither a first film web nor a second film web. Rather, the document discloses a manufacturing method for conventional solar cell strings. Since the solar cells are already connected to one another by laser welding, it is no longer necessary to apply first and second contact points to the first film web, or to apply the provided solar cells in the form defined in the claims to the first film web.
• connection types and connection types of the types described above there are several distinct drawbacks with the connection types and connection types of the types described above.
• the wires for the serial interconnection of the solar cells are less flexible than the very thin and sensitive photovoltaic layers of the solar cells. Therefore, when laying or because of the different coefficients of thermal expansion of the wire material relative to the materials of the solar cells, it can happen that the wire ends build up mechanical stresses relative to the photovoltaic layers. These mechanical stresses can cause wire ends to separate from the solar cells or the wire ends to damage the surface of the solar cells.
• connection types and connection manufacturing manners are not particularly efficient in production.
• the solar cells Due to the temperature differences between see the hot solder joint and the cooler environment, the solar cells can tend to crack. In other modules, it may happen that the metal tracks forming the tracks or emitters does not provide firm cohesion. Wind and snow loads acting on a solar panel in a daily or seasonal cycle can then break the emitters. This separates many of the solar cells from the electrical network of the solar module and reduces its performance. For thin-film modules, the internal electrical cell connection can easily become defective; For example, the cells may be bonded to copper tapes that are attached with an insufficiently cured conductive adhesive. Thus, the line resistance of the solar modules increases significantly and their performance decreases.
• the task is now to provide a cost-effective, fast process and a corresponding device for connecting solar cells in a solar module to allow cost-effective production of solar power by the manufacturing costs compared to previous solutions lower and the durability of the complete solar modules over previous solutions is improved ,
• a method for producing a solar module with flexible solar cells, in particular with flexible thin-film solar cells can have the following steps:
• a first side which is at least partially configured as a first electrically conductive pole and
• a second side which is at least partially configured as a second electrically conductive pole
• At least one electrical conductor is assigned to contact the first pole
• a front contact usually printed silver conductive paste as a guide material.
• the materials used can be optimally adapted to the solar cell materials.
• the contact point with its two regions can be formed from one or else from two different electrically conductive materials, which adjoin one another and are in electrically conductive connection with one another.
• the contact point can be formed by a corresponding contact adhesive low-resistance and mechanically stable gebil ⁇ det.
• the front contact of the neighboring cell is then connected by means of electrical conductors such as a number of copper or aluminum conductors.
• the electrical conductor may be a wire with or without insulating jacket, an electrical strip conductor with or without insulating jacket, an electrically conductive grid, an elongated conductor, a loop, meander, spiral or zigzag form of an electrical conductor.
• the at least one electrical conductor of the first side of the respective thin-film solar cell can be assigned to the first film web either before the respective thin-film solar cell is applied to the first film web or after the application of the respective thin-film solar cell to the respective thin-film solar cell.
• the at least one electrical conductor of the first side of the respective thin-film solar cell can be at least partially embedded in respect of its cross-section and / or its longitudinal extent either in the thermoplastic second film web or in a carrier tape. When embedding in the carrier tape this is applied together with the / the electrical conductors on the first side of the respective thin-film solar cell before the thermoplastic second film web is laminated.
• thermoplastic adhesive for example a thermoplastic adhesive, which partially envelopes the electrical conductor, onto the electrical conductor before / when it is applied to the photovoltaically active layer structure.
• the first pole of the solar cell can be contacted independently of the lamination. This step is then independent of the usually less critical contacting / positioning of the electrical conductor to the second contact point by applying the thin-film solar cell to the first film. This has the effect that the first pole can be contacted more accurately by the electrical conductor, since the inaccuracies and displacements within the plastic adhesive layer caused by the lamination of the plastic adhesive films no longer have to be taken into account.
• connection of the contact point with the electrical conductors can in turn be carried out by contact adhesive or by laser welding, welding, soldering or other connection technologies.
• the contacting of the first electrically conductive pole on the upper side of the solar cell with the electrical conductor preferably takes place with a (roller) lamination process.
• the electrical conductors together with the envisaged encapsulation material / the thermoplastic (covering) film made of EVA (ethylene vinyl acetate) TPU (thermoplastic polyurethane), etc. are applied to the cell surface (eg TCO, ie translocation).
• the electrical conductors can already be fixed on the encapsulation material in a pre-process step by applying pressure and temperature for a certain period of time, preferably in a roll-to-roll process Sinking or embedding of the electrical conductor in the encapsulation material / the thermoplastic (cover) film of EVA, TPU, etc. are made.
• a flexible cover layer partially surrounding the electrical conductor may be applied to the first side of the layer structure and the electrical conductors of each of the flexible thin film solar cells.
• a preferable alternative to this may be to heat the electrical conductor prior to application to the photovoltaic active layer structure and then partially embed or sink the electrical conductor in the flexible cover layer.
• the flexible cover layer for example a thermoplastic film web or the shape of the electrical conductor in its longitudinal extent in approximately corresponding film with a corresponding protruding edge, heated and softened, then partially to the electrical conductor in the flexible cover layer to embed.
• This intermediate electrical conductor and flexible cover layer can then be provided as a "continuous product" on a roll or as a portioned area or strip product to be applied to each of the series of flexible thin-film solar cells.
• the endless product from the roll can also be appropriately portioned before or after application to the sequence of flexible thin-film solar cells.
• partially surrounding is meant here that the electrical conductor is based on its cross section and / or based on its longitudinal extent only partially embedded or recessed in the flexible cover layer.
• the method described here can also be used with rigid solar cells.
• the first film web may preferably be a weather-resistant flexible film which is coated with a self-adhesive layer.
• the first film web can also be a weather-resistant flexible film which is covered with a thermoplastic layer. Then, by a heat input, the connection between the first film web and the flexible thin-film solar cells can be achieved.
• a plurality of flexible thin-film solar cells can be arranged in the longitudinal and / or transverse direction to the conveying direction of the first film web.
• the desired configuration of serial and / or parallel connection of the individual flexible thin-film solar cells to a cell field forming the solar module can be determined very flexibly.
• the electrically conductive contact strips can be applied to the flexible thin-film solar cells in the longitudinal direction of the conveying direction of the first film web from a plurality of dispensers with roller-conducting contact strips or dispensers with electrically conductive paste, which are adjacent to one another and are arranged substantially in the longitudinal direction relative to the conveying direction of the first film web.
• the electrically conductive contact strips of at least one and arranged substantially in the transverse direction to the conveying direction of the first film web dispenser can be applied with a roll of conductive contact strip or a donor with electrically conductive paste on the flexible thin-film solar cells in the transverse direction of the conveying direction of the first film web , This makes it possible, very variable and efficient interconnect the flexible thin-film solar cells in series and / or parallel electrically.
• the singulated flexible thin film solar cells may also be provided as separate sections in a container. Similarly, flexible thin film solar cells can be provided in a stacking area.
• the stacking area may have a removable container in which the flexible thin-film solar cells are provided.
• the second film web can be laminated to the first film web and the flexible thin-film solar cells with a roll laminator.
• the roll laminator has at least two counter-rotating rolls which rotate at a defined speed and with a defined pressure the thin-film solar cells - film- railway - Pressing on each other at a defined temperature. This allows to produce high quality solar modules.
• the contact between the electrical conductor and the second region of the second contact point can be produced by pressing.
• the pressing may be carried out by applying a temperature in a range of about 120 ° C to about 170 ° C for a period of time of less than 20 seconds and optionally at least for a part of the period of time with negative pressure.
• the first film web may be conveyed in a conveying direction and configured to apply side-by-side juxtaposed multiple sequences of spaced electrically conductive contact pads, and preferably simultaneously apply flexible thin-film solar cells to the first film web and the sequences of spaced electrically conductive contact pads.
• a solar module string formed from the first and the second film web and the flexible thin-film solar cells located therebetween can be wound up into a roll.
• Each of the electrically conductive pads may be made of a conductive tape material with or without an adhesive layer toward the first film web, metal strip material with or without adhesive layer toward the first film web, or conductive paste or metal foil (eg, copper or aluminum-containing film) with or without Adhesive layer to the first film web to be formed.
• a conductive tape material with or without an adhesive layer toward the first film web
• metal strip material with or without adhesive layer toward the first film web
• conductive paste or metal foil eg, copper or aluminum-containing film
• the electrical conductor may be formed of a conductive strip material, of metal strip material, of wire material, or of conductive paste.
• each flexible thin-film solar cell may at least partially comprise a metal layer, and this metal layer may be configured as a second electrically conductive pole, which is a positive pole, and / or in which the opposite, first side of the flexible thin-film layer facing away from the film Solar cell may be at least partially configured as the first electrically conductive pole, which is a negative terminal.
• the second film web may be vacuum laminated at a temperature ranging from about 120 ° C to about 170 ° C for a period of less than 10 minutes, and optionally at least part of the time.
• thermoplastic polyurethane film or other weather-resistant (back) film may be used as the first and / or the second film web.
• the pressing can be done with a roller press, which has at least one roller and an abutment or two opposing rollers that rotate at a defined speed and with a defined pressure a composite of the first film web and the flexible thin-film solar cells at a defined temperature each other press.
• a device for manufacturing a solar module may have the following components or components: A device for providing a first film web; means for applying a train of spaced electrically conductive contact pads to the first sheet of film; a device for providing a series of flexible thin-film solar cells, which is configured as a first electrically conductive pole at least in sections and a second side, which is at least partially configured as a second electrically conductive pole, a photovoltaic active layer structure on its at least one electrical conductor is assigned to the first side in order to contact the first pole, and to protrude laterally beyond the photovoltaically active layer structure; a device for applying a thin-film solar cell from the provided sequence on the first film web such that the second electrically conductive pole contacts a first of the contact points on the first film web in a first region, and the electrical conductor contacting the first electrically conductive pole contacting the first contact point adjacent second contact point on the first film web in a second region, and a feeding and a laminating device
• a pressing device may be provided for establishing / improving the contact between the electrical conductor and the second region of the second contact point.
• the pressing device may also include a heating device to maintain a temperature in a range of about 120 ° C to about 170 ° C for a period of less than 20 seconds and possibly at least part of the time duration
• a conveyor may convey the first film web in a conveying direction, and a plurality of devices may be provided for depositing a succession of spaced electrically conductive contact pads side by side, and a plurality of means may be provided for applying a succession of flexible thin film solar cells to the first film web and the sequences of spaced electrically conductive pads.
• a winding device can be provided for a solar module strand formed from the first and the second film web and the flexible thin-film solar cells located therebetween.
• the feed device for each of the electrically conductive contact points may be configured to supply a conductive strip material with or without adhesive layer to the first film web, a metal strip material with or without adhesive layer to the first film web or conductive paste.
• the electrical conductor feeder may be configured to supply a conductive strip material, a metal strip material, a wire material, or a conductive paste.
• a plurality of dispensers with rollers of electrical conductors or dispensers with electrically conductive paste that are adjacent to one another and are arranged essentially in the longitudinal direction to the conveying direction of the first film web and / or substantially transversely to the conveying direction may be provided for electrical conductors on the flexible thin-film solar cells in the longitudinal direction or in the transverse direction of the conveying direction of the first film web, in order to interconnect the flexible thin-film solar cells electrically and / or in parallel with one another.
• a roller press can be provided which has at least two counter-rotating rollers which rotate at a defined speed and press a composite of the first film web and the flexible thin-film solar cells at a defined temperature to each other with a defined pressure.
• a supplied electrical conductor this may be a wire, an electrical strip conductor, an electrically conductive grid, an elongated conductor, a loop, meander, spiral or zigzag shape of an electrical conductor.
• This electrical conductor may also be applied to the electrically conductive pads and the flexible thin-film solar cells with the flexible cover layer as the above-mentioned intermediate product from the dispenser.
• the covering layer AS can be divided on the solar cell into individual pieces which have approximately the dimension of a solar cell and project beyond the corresponding solar cell to the respective contact point.
• a further film (EVA, TPU) may possibly be necessary beforehand in order to compensate for any unevenness.
• the electrical conductor with the covering layer can be applied together to the thin-film solar cells, or the electrical conductor is applied in front of the flexible covering layer. It is also possible to dispense with the flexible cover layer.
• a thin-film solar module can therefore be provided with the following features: a first film web; a spaced apart on the first film web sequence of electrically conductive contact points with respective first and second regions; a series of flexible thin-film solar cells, which has a first side, which is at least partially configured as a first electrically conductive pole and a second side, which is at least partially configured as a second electrically conductive pole, a photovoltaically active layer structure, a flexible covering layer located on the first side of the layer structure, and at least one between the
• Layer structure and the covering layer located electrical conductor which contacts the first pole, wherein the flexible cover layer and the electrical conductor laterally project beyond the photovoltaic active layer structure; wherein the thin-film solar cells on the first film web such that the electrically conductive second pole contacts a first of the contact points on the first film web in the first region, and the electrical conductor contacting the first electrically conductive pole has a second contact point adjacent to the first contact point contacted the first sheet in the second area.
• Fig. 1 shows flexible thin film solar cells for use in the manner described herein in a schematic cross-sectional view.
• FIG. 2 illustrates a process flow for producing thin film solar modules in the manner described herein.
• FIG. 3 the contacting of two series-connected thin-film solar cells of Fig. 1 is shown enlarged in schematic cross-section.
• FIG. 5 schematically illustrates, in a plan view, the fixing of thin-film solar cells; that can z. B. cells with metal substrate or polymer substrate (self-adhesive).
• FIG. 6 is a schematic plan view of the embedding of electrical conductor strips in adhesive foil, e.g. EVA, TPU for contacting (e.g., copper wire or plastic foil with electrical conductor structure) is illustrated.
• adhesive foil e.g. EVA, TPU for contacting
• contacting e.g., copper wire or plastic foil with electrical conductor structure
• FIG. 7 schematically illustrates, in a lateral sectional view along the lines A - A in FIG. 6, how the electrical conductor strips are embedded in parallel and at a distance from one another in the adhesive film.
• FIG. 8 schematically illustrates, in a lateral plan view, a variant of how the wires of copper or aluminum guided in parallel extend into the carrier tape, e.g. embedded in EVA, TPU or the like under the influence of pressure and / or temperature.
• a further variant is schematically illustrated in a lateral plan view, as with parallel next to each other alsspendenden rollers with separating devices (cutting knife) the web goods with the electr. Conductors are applied and contacted under the action of pressure and / or temperature on the thin-film solar cells, which are already on the first film web.
• such a flexible thin-film solar cell has the following structure: A first side OS (the upper side) of the absorber material AM is configured at least in sections as the first electrically conductive pole PI. A second side US (the underside) of the absorber material AM is designed as a second electrically conductive pole P2.
• the absorber material AM comprises a photovoltaically active layer structure PV.
• the absorber material AM has a flexible covering layer AS located on the first side OS of the layer structure PV and at least one electrical conductor CIO, C20 located between the layer structure PV and the covering layer AS which contacts the first electrically conductive pole PI.
• the cover layer AS and the electrical conductor CIO, C20... May be an intermediate product in which the electrical conductor CIO, C20...
• the cover layer AS Is partially fixed on / on the cover layer AS with respect to its cross section, but along its longitudinal extent at least partially exposed electrically conductive that he contacted the photovoltaic active layer structure PV, more specifically the first side OS (eg the TCO layer) of the absorber material AM electrically conductive.
• the electrical conductor CIO, C20 ... be partially embedded in the cover layer AS.
• the flexible covering layer AS and the electrical conductor CIO, C20 laterally project beyond the photovoltaically active layer structure PV.
• the flexible covering layer AS and the electrical conductor CIO, C20 project laterally beyond the photovoltaically active layer structure PV laterally at an edge of the layer structure PV such that the flexible covering layer AS and the electrical conductor CIO, C20, ... down to the level of the second side US (the underside) of the absorber material AM next to the layer structure PV.
• the flexible covering layer AS and the electrical conductor CIO, C20 Form a horizontally oriented contact section KA (approximately in alignment with the second side US of the absorber material AM).
• variants are also possible in which the electrical conductor is processed without the flexible covering layer AS.
• this protective or insulating layer K10 can also be angled toward the first side OS of the absorber material AM.
• this protective or insulating layer K10 may extend to the edge region adjacent to the side surface of the layer structure PV (for example approximately 5% to 20% of the total area) of the first side OS of the absorber material AM. This serves to reliably prevent damage to the layer structure PV by the electrical conductor CIO, C20... On the edge of the absorber material AM.
• the electrical conductors CIO, C20... Can be conductor strips or wires arranged parallel to one another for each thin-film solar cell and project laterally beyond an edge of the layer structure PV.
• the electrical conductors CIO, C20 ... can for each thin-film solar cell but also spiral or meandering or The like be routed conductor strips, grid structures or wires, one end of which extends laterally beyond an edge of the layer structure PV.
• the solar cells are connected stepwise as follows (see also FIG. 2).
• the back contact of one of the two solar cells is connected to the prepared contact point KS10 by direct contact and / or by means of suitable contact material, for example a contact adhesive.
• suitable material polyimide film tape, eg KAPTON® or other insulation tape, insulation adhesive.
• the encapsulation material AS prepared with the electrical conductor CIO, C20... Is applied to the upper side OS of the solar cells and cut off so that the electrical conductors CIO, C20. Protrude beyond the upper solar cell surface and are located above the contact point KS10.
• the electrical conductors CIO, C20... Are here located on the side of the encapsulation material facing the cell surface.
• the electrical connection and the fixing of the electrical conductor material is done by the electrical connection process with the contact surface K10 by laser welding, welding, soldering or other suitable connection techniques).
• the resulting, initially one-sided connection of the electrical conductor can be completed by a subsequent roll lamination process, in which material-dependent pressure and temperature for a certain period of time can act on the arrangement.
• the electric contact is pressed and fixed on the entire surface (front surface (e.g., TCO layer)) of the solar cell for contacting.
• This is done by means of the encapsulation material, which in the lamination process step (pressure, time, temperature and possibly negative pressure) becomes temporarily liquid and then takes over the fixation as a transparent adhesive layer.
• the method described here can in principle also be applied to rigid solar cells (for example silicon solar cells).
• An essential advantage resulting from the two-part connection contact structure is (i) the adaptable material pairings of the electrical conductor material (eg copper, aluminum) and the contact point which can be adapted to one another (ii) Optimal connection technology (laser welding, welding, soldering, contact bonding, etc.) and (iii) the selectability of the back or bottom material of the solar cells (eg steel foil, stainless steel foil, aluminum, etc.) to the electrical connection to the subsequent cell.
• the most favorable materials can be selected both for the qualitative, technical certification of the solar module, as well as for the cost-optimized production.
• the roll-to-roll manufacturing concept is ideal for this process while providing the prerequisite for optimum productivity.
• Fig. 3 shows flexible thin film solar cells as used herein.
• the second side (in this case the side facing away from the energy-dispensing light source during operation, ie the underside) of each flexible thin-film solar cell has at least sections of an electrically conductive layer.
• This conductive layer is designed as an electrically conductive positive pole (anode).
• the first side of the flexible thin-film solar cell (in this case, the side which faces the energy-emitting light source during operation, ie the top side) is designed as an electrically conductive negative pole (cathode).
• a first flexible film web FlO is provided by a roll.
• an adhesive or adhesive layer HS is laminated from a roll to the film web FlO by means of a roll laminator RL15.
• the arrangement of the first film web F1 and adhesive layer HS is conveyed through the roll laminator RL15 in step S15.
• a further step S20 is applied to the film web FlO (or, if present on the adhesive or adhesive layer HS) a sequence - in the conveying direction F of the film FlO - spaced electrically conductive contact points KS10 applied to the first film web FlO.
• These electrically conductive contact points KS10 can be formed from a conductive strip material with or without an adhesive layer toward the first film web FlO, from metal strip material with or without an adhesive layer toward the first film web FlO, or from conductive paste.
• a sequence of flexible thin-film solar cells DSZ10, DSZ20 of the type described above is applied to the first film web FlO (or, if present, to the adhesive or adhesion layer HS) with a magnetic or film Vacuum gripper UG applied.
• the respective first and second regions BIO, B20 of a pad are adjacent to each other.
• step S50 the contact between the electrical conductor and the second region B20 of the second contact point KS20 is produced by pressing, for example by means of a roller press RP55.
• step S50 the contact between the second electrically conductive pole P2 and the first contact point KS20 on the first film web F10 in the first region BIO can also be produced or intensified by pressing, for example by means of the roller press RP55.
• the arrangement of the first film web F10, flexible thin-film solar cells DSZ10, DSZ20, ... is conveyed through the roller press RP55 in step S50.
• the first film web F10 can be conveyed in a conveying direction F.
• a plurality of sequences of spaced electrically conductive contact points KS10 are applied side by side at a lateral distance.
• a plurality of sequences of flexible thin-film solar cells DSZ10, DSZ20 ... are applied to the first film web F10 and the sequences of spaced electrically conductive contact points KS10 side by side in the manner described above.
• a plurality of dispensers which are adjacent to each other and oriented substantially in the longitudinal direction and / or in the transverse direction to the conveying direction of the first film web are provided.
• These dispensers have rollers of electrical conductors or provide electrically conductive paste to the flexible thin-film solar cells to interconnect the flexible thin-film solar cells in series and / or parallel electrically.
• a second film web F2 is laminated onto the first film web F10 and the flexible thin-film solar cells.
• This second film web F2 is thermoplastic, transparent, flexible and very resistant to ultraviolet light.
• the second film web F2 is laminated to the first film web F10 and the flexible thin-film solar cells with a roll laminator RL.
• the roller laminator RL has at least one roller pair of two counter-rotating rollers Wl, W2 between which the stack of the first film web F10 with the flexible thin-film solar cells and the second film web F2 is conveyed through.
• the counter-rotating rollers W1, W2 rotate at a defined speed and compress a composite of the second film web, the first film web and the flexible thin-film solar cells at a defined temperature with a defined pressure.
• the individual components of the composite enter into a cohesive, bubble-free and intimate connection with one another.
• the roller laminator RL exemplified herein has one or more roller pairs Wl, W2 formed of rollers; Wl ', W2' to laminate a self-adhesive cover film DF on the film web F10.
• a film without an adhesive layer may be conveyed through an adhesive application station to then laminate it onto the film web F10 and the flexible thin-film solar cells.
• Such a roll laminator can also be used in the preceding steps as RL15 or as RP55.
• the pressing of the contacts or the second film web F2 can be carried out while introducing a temperature in a range of about 120 ° C to about 170 ° C for a period of less than 20 seconds and possibly at least for a portion of the period of time with negative pressure.
• the resulting solar modules are then tested and then optionally split or rolled up as a tape product.
• a connecting device serves to connect a carrier tape with an electrical conductor or an electrically conductive paste.
• the electrical conductor or the electrically conductive paste is partially embedded by the connecting device in the carrier tape.
• a plurality of wires or strip material made of Cu or Al fed in parallel to each other are preferably embedded in the carrier tape. Thereafter, the wires / strip material may be sections along the conveying direction of the Carrier tape are cut off. Alternatively, this intermediate can also be further processed as an endless product.
• the electrical conductor or the electrically conductive paste in the carrier tape in the example shown here in the form of an endless thermoplastic film web, which is for example an adhesive or non-adhesive film of EVA or TPU, so partially by pressure and / or temperature embedded in that an intermediate conductor of electrical conductor and flexible cover layer is provided as a continuous product on a roll for subsequent application to each of the series of flexible thin-film solar cells either as an endless product from the roll.
• this intermediate product can be pulled over a Abspendekante, so that the flexible cover layer with the / the electrical conductor (s) on the the flexible thin-film solar cells can be applied.
• the electrical conductor may be introduced as a non-ferrous metal (for example, aluminum or copper) containing wire or web by means of opposite roles in the carrier tape TB.
• a non-ferrous metal for example, aluminum or copper
• metal wires or metal tracks are introduced side by side in the carrier tape.
• the carrier tape and the / the electrical / n conductor can also be wound as a continuous web into a roll or portioned by means of a Trenneinrich ⁇ tion and stacked (see Fig. 8).
• the carrier tape coming from the connection device is fed with the electrical conductor (s) of the first film web FlO as an endless web or portioned (see FIG. 9) to the photovoltaically active layer structure PV in the merging device on the first side OS of the photovoltaically active layer structure PV is assigned so that he / she each contacted the first pole PI, and the photovoltaically active layer structure PV laterally surmounted.
• the product, device and process details discussed above are presented in context. It should be noted, however, that they are also independent of each other and can also be freely combined with each other.
• the ratios of the individual parts and sections thereof to one another and their dimensions and proportions shown in the figures are not to be understood as limiting. Rather, individual dimensions and proportions may differ from those shown.

Landscapes

• Engineering & Computer Science (AREA)
• Computer Hardware Design (AREA)
• General Physics & Mathematics (AREA)
• Power Engineering (AREA)
• Microelectronics & Electronic Packaging (AREA)
• Physics & Mathematics (AREA)
• Condensed Matter Physics & Semiconductors (AREA)
• Electromagnetism (AREA)
• Sustainable Development (AREA)
• Life Sciences & Earth Sciences (AREA)
• Manufacturing & Machinery (AREA)
• Sustainable Energy (AREA)
• Chemical & Material Sciences (AREA)
• Crystallography & Structural Chemistry (AREA)
• Photovoltaic Devices (AREA)

Applications Claiming Priority (3)

Publications (1)

Family

ID=47747647

Family Applications (1)

Country Status (4)

Families Citing this family (12)

Family Cites Families (22)

• 2013
  • 2013-02-22 IN IN1621KON2014 patent/IN2014KN01621A/en unknown
  • 2013-02-22 EP EP13705500.0A patent/EP2817830A2/de not_active Withdrawn
  • 2013-02-22 WO PCT/EP2013/053599 patent/WO2013124438A2/de active Application Filing
  • 2013-02-22 CN CN201380010738.XA patent/CN104137271A/zh active Pending

Non-Patent Citations (1)

Also Published As

Similar Documents

Legal Events