GB2077995A - Panels incorporating photo-cells and method of manufacturing same - Google Patents

Panels incorporating photo-cells and method of manufacturing same Download PDF

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Publication number
GB2077995A
GB2077995A GB8117095A GB8117095A GB2077995A GB 2077995 A GB2077995 A GB 2077995A GB 8117095 A GB8117095 A GB 8117095A GB 8117095 A GB8117095 A GB 8117095A GB 2077995 A GB2077995 A GB 2077995A
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GB
United Kingdom
Prior art keywords
panel
cells
panel according
metal foil
film
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Granted
Application number
GB8117095A
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GB2077995B (en
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BFG Glassgroup GIE
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BFG Glassgroup GIE
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Filing date
Publication date
Application filed by BFG Glassgroup GIE filed Critical BFG Glassgroup GIE
Priority to GB8117095A priority Critical patent/GB2077995B/en
Publication of GB2077995A publication Critical patent/GB2077995A/en
Application granted granted Critical
Publication of GB2077995B publication Critical patent/GB2077995B/en
Expired legal-status Critical Current

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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
    • 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
    • B32B17/10009—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 number, the constitution or treatment of glass sheets
    • B32B17/10018—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 number, the constitution or treatment of glass sheets comprising only one glass sheet
    • 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
    • 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
    • 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

Abstract

In a light-responsive panel incorporating one or more photo-cells which is or are sealed between front and rear plies of the panel, to provide an economical panel in which the cells are protected from the atmosphere, the cells (5-6) are enclosed between a light- transmitting front ply (1), preferably of glass, which gives rigidity to the panel and a flexible moisture-proof metal foil (4) which are laminated together by means of adhesive material so that the metal foil (4) is hummocked attributably to the presence of each cell (5-6). Manufacture is facilitated if the adhesive material used is one or more preformed films (2, 3) of thermoplastics material. In a preferred method of manufacture, the panel is assembled and placed in a flexible envelope (14) which is evacuated via a tube (15). The enveloped assembly is then heated and allowed to cool. <IMAGE>

Description

SPECIFICATION Light responsive panels This invention relates to light-responsive units in the form of a panel incorporating one or more photocells which is or are sealed between front and rear plies of the panel.
Panels of that kind and incorporating one or more photo-voltaic cells are useful as solar panels.
Various proposals have been made for incorporating photo-voltaic cells into a structural unit which has adequate mechanical strength for convenient handling and installation and which affords protection to the cell or cells and associated electrically conductive connections against degradation by exposure to the atmosphere for prolonged periods of time. There is a persistent search in industry for panel compositions which will combine the most favourable combination of properties.
Among the factors which determine the suitability of a panel for particular environments of use are its weathering resistance, in particular its resistance to penetration by moisture and atmospheric vapours, the compatibility of the panel construction with automated fabrication and reasonably low production costs, and of course the efficiency of the panel as an energy transducer. Another factor which is of importance is the efficiency/weight ratio of the panel.
Panel constructions have been proposed wherein the cell or cells is or are enclosed between rigid members, at least one of which is transparent. In some of such panels the rigid members are formed and joined to form a shallow box in which the cells are located and surrounded by a void or by a sealing composition. In other cases the rigid members are plies which are united by means of intervening bonding material to form a laminate. Neither of these types of construction is very well suited to low cost production methods. The box-like structures require to be evacuated prior to hermetic sealing, or a sealing composition has to be applied so that it fills the interior of the box, around the cells.The laminate type structures either require application of a bonding medium around the cells so as to form a uniformly thick layer which becomes sandwiched between the plies, or the latter are bonded by means of preformed sheets of thermoplastics material in which one or more apertures have been formed for accommodating the cell(s).
It is an object of the present invention to provide a panel construction which can be more easily and cheaply produced while still ensuring effective protection to the photo-cell(s) against the influence of the environment so that the panel can be exposed to the atmosphere for long periods of time without loss of its efficiency as an energy transducer.
According to the present invention there is provided a light-responsive panel incorporating one or more photo-cells which is or are sealed between front and rear plies of the panel, characterised in that said cell or cells is or are enclosed between a light transmitting front ply which gives rigidity to the panel and a flexible moisture-proof metal foil which are laminated together by means of adhesive material so that the metal foil is hummocked attributably to the presence of the or each said cell.
A panel of such construction can be easily and cheaply produced. The cell enclosure is formed from a front structural or strength member (said "front ply") and one or more thin flexible plies which have simply to be cut to the shape of the panel. The said metal foil is flexible so that it can conform to a hummocked surface profile imposed by the difference in the thickness of the panel between the region(s) where the cell(s) is or are located and surrounding bonding zone(s). Consequently the need for cutting one or more apertures in any interior ply in order to accommodate the ceil(s), and the necessity of ensuring proper registration of such an apertured ply with the cell(s) during assembly of the panel components, are avoided.
Metal foil which is very flexible so that it can easily be laid to conform to a hummocked surface profile, and which will remain highly impervious to moisture over long periods of time while it is exposed to out-of-doors climatic conditions, is readily available at favourably low cost. Additionally the foil can be selected to have a relatively low emissivity to the exterior of the panel, which will in some cases improve the efficiency of the performance of the cell(s).
Preferably the bonding material extends close up to the periphery or peripheries of the cell(s) so that the laminate is substantially without internal void spaces, and it is also preferred that said metal foil be the rear ply of the laminate.
In certain embodiments of the invention, aluminium foil is used. It is suitable for example to use aluminium foil up to about 80 microns in thickness.
Preferably aluminium foil of a thickness in the range 5 to 50 microns is used. Copper foil, to name one further example, is also very suitable.
In preferred embodiments of the invention, the said front ply and metal foil are bonded together wholly or in part by means of a bonding layer or bonding layers formed from one or more intervening films of thermoplastics material. Preferably such intervening film or at least one of them if there is more than one extends between the cell(s) and the flexible metal foil. This is particularly advantageous because one or more intervening films in that position can serve as insulation between the cell(s) and the said metal foil. It is however possible as hereinafter described to incorporate local insulation at the site(s) of the cell(s).
When a said intervening bonding film or a plurality of said intervening bonding films is or are present between the cell(s) and the flexible metal foil, the or at least one of such film(s) preferably adheres over its whole area to that foil. In these circumstances the metal foil and that or those intervening bonding film(s) together form a laminated rear panel wall the mechanical strength of which does not depend upon the metal foil alone and this foil can be very thin.
Advantageously, said thermoplastics material comprises a film between the cells and the front ply.
Preferably the cell(s) is or are sandwiched between two thermoplastics films which are directly or in directly adherent over their whole areas to said front ply and said metal foil of the panel and are bonded together in the zone(s) surrounding the cell(s). One of such films serves for bonding the cell(s) to the rigid front ply and must of course be a lighttransmitting film. The said two thermoplastics films can be of the same or of different composition. In the case of a panel wherein there is no bonding film between the cell(s) and the relatively rigid front ply, the cell(s) can be secured to the said front ply by means of a suitable locally applied adhesive.
The thermoplastics film(s) used for bonding purposes should be capable of being transformed to bonding condition without having to be heated to a temperature which may adversely affect the cell(s).
A preferred bonding material is polyvinylbutyral.
Other suitable materials are ployurethane and polyvinylchloride. Generally speaking it is suitable to employ one or more bonding films having or each having a thickness of from 0.3 to 1 mm.
The rigid front ply can be a sheet made of glass or plastics. Preferably the said ply is a glass sheet e.g. a sheet of ordinary soda-lime glass. This sheet can be a tempered sheet. Tempering can be effected thermally or chemically. If it is desired to use a plastics instead of glass, the front ply can for example be composed of polycarbonate or polymethylmethacrylate.
As already mentioned, the use of a metal foil for forming a rear ply of the panel is particularly advantageous because of its combination of useful properties, in particular its efficiency as a moisture barrier combined with its durability and flexibility.
These advantages of a metal foil are not dependent for their realisation on the employment of one or more thermoplastics films for bonding the foil to the light-transmitting front ply and the metal foil can be effectively laminated to the light-transmitting front ply in other ways, e.g. by using an adhesive composition, which may for example be applied to a face of the foil and/or to a face of the rigid ply before they are assembled. The adhesive composition may for example be of thermo-setting type.
For bonding the metal foil to a front ply made of glass use can be made of acrylic or other suitable adhesives. If a sheet of plastics is employed for forming the rigid front ply, the metal foil can be bonded to that front ply e.g. by means of acrylic or other suitable adhesives.
The invention is applicable to panels incorporating one or more photovoltaic or photoconductive cells.
The most important field of use for the invention is the manufacture of panels incorporating one of more photo-voltaic cells, and particularly the manufacture of solar panels.
The invention includes a method of manufacturing a panel as herein defined wherein said metal foil and said front ply of the panel are laminated together using at least one preformed film of thermoplastics material. The use of preformed film thermoplastics material greatly simplifies the manufacturing process.
In the most preferred manufacturing method, said light-transmitting front ply, said flexible moistureproof metal foil, the photo-cells and associated conductors and said thermoplasticsfilm material are assembled in the required order, the assembly is enclosed in a flexible envelope from which air is then withdrawn to cause environmental pressure to be brought to bear on the assembly and the envelope and the enclosed assembly are heated to cause softening of the thermoplastics film or films whereafter the assembly is allowed to cool.
The bonding of the light-transmitting front ply and the flexible metal foil so as to enclose the cell(s) can be achieved by exposing the assembly to heat and appropriate environmental pressure conditions. Because the metal foil is flexible, environmental pressure will be effectively distributed over the bonding zone(s) in the thinner region(s) of the assembly.
By way of example, the assembly of panel components can be enclosed in a flexible envelope from which air is then withdrawn to cause the required environmental pressure to be brought to bear on the assembly and the envelope with the enclosed assembly can be simultaneously or subsequently heated. The evacuation of the envelope may for instance be sufficient to create an internal vacuum of the order of 1 Torr. Such vacuum conditions can be maintained for, say, 5 to 10 minutes. The temperature to which the assembly is heated must in part depend upon the composition of the thermoplastics film(s) used for bonding purposes. When using one or more films of polyvinylbutyral it is suitable to heat the assembly to a temperature of the order of 140"C.
When placing the assembly in an envelope as above referred to, some form of spacing means,#e.g. pieces of wire trellis, can be located between the panel assembly and the opposed walls of the envelope in order to facilitate the extraction of air from the envelope.
The panel can be provided with a frame. In such circumstances the margin of the panel can be sealed in the frame against access of moisture to the edges of the panel. However, provided the cell(s) is or are sufficiently spaced from the panel edges, the risk of any significant amount of moisture reaching the cell(s) by ingress along the thermoplastics layer(s) from the edges of the panel may be considered negligible.
Certain embodiments of the invention, selected by way of example, are illustrated in the accompanying drawings comprising Figures 1 and 2 which are cross-sections of parts of two panels according to the invention, and Figure 3 which illustrates a method of manufacturing the panel of Figure 1.
The panel represented in Figure 1 comprises a sheet of glass 1,which may e.g. be a sheet of ordinary soda-lime glass, polyvinylbutyral films 2 - and 3 each having a thickness of 0.76 mm and an aluminium foil 4 having a thickness of 15 microns.
Between the two polymer films there is an array of photovoltaic cells and associated conductors (not shown) for connecting the panel to an output circuit.
Any required number of cells, e.g. five cells, may be incorporated in the panel. Figure 1 shows two cells, designated 5 and 6.
In order to manufacture the panel shown in Figure 1, the glass sheet 1, two flat polyvinylbutyral films 2 and 3 located one on each side of the cells 5, 6 and the associated conductors, and a flat aluminium foil 4 are assembled in the appropriate order and the assembly is placed in a flexible bag 14 as shown in Figure 3. The bag 14 has atube 15 for evacuating air from its interior so that the assembly is placed under sub-atmospheric pressure to aspirate the inter-ply spaces of the assembly. Under the environmental pressure which is thus brought to bear on the assembly, the glass, plastics and metal foil plies become firmly pressed together. The polymer foil 3 and the aluminium foil 4 are forced into conformity with the hummocked surface formed by the polymer film 2 and the cells 5, 6.Then the assembly, enclosed in the evacuated bag 14, is placed in an oven and heated to about 140 C. At this temperature the polyvinylbutyral films soften. The assembly is withdrawn from the oven and allowed to cool. During cooling the polymer film 2 becomes firmly bonded to the glass sheet 1, to the cells 5, 6 and, in the bonding zones surrounding the cells, to the polymer film 3. The latter film becomes firmly bonded to the cells and to the metal foil 4.
By way of modification of the panel shown in Figure 1 an aluminium foil 50 microns in thickness can be used. A sheet of transparent synthetic poiymeric material, e.g. polycarbonate, can be used instead of the glass sheet 1. The illustrated structure can alternatively or additionally be modified by using two or more polymer films in face to face relationship in place of film 2 and/or by using more than one polymer film in place of film 3.
A further panel according to the invention corresponds with that shown in Figure 1 except that the bonding film 3 is dispensed with and discs of electrically insulating material of a diameter a little larger than that of the cells are incorporated in the assembly so that they cover the rear faces of the cells and their peripheral edges and thereby insulate the cells from the metal foil. In this panel therefore the metal foil is bonded to the glass sheet solely by the film 2.
In the panel shown in Figure 2, a single thermoplastics film 7 is used for bonding a flexible metal foil 8 to a transparent glass front ply 9 of the panel with photo-cells 10, 11 between the thermoplastics and the front ply. The photo-cells 10, 11 are secured to the front ply 9 by adhesive layers 12, 13. These adhesive layers should be so constituted, for example they should be of such thickness, that they prevent the cells from becoming damaged by the glass front ply when the assembly is subjected to pressure for bonding purposes, for example as described with reference to Figure 3.

Claims (17)

1. A light-responsive panel incorporating one or more photo-cells which is or are sealed between front and rear plies of the panel, characterised in that said cell or cells (5-6, 10-11) is or are enclosed between a light-transmitting front ply (1,9) which gives rigidity to the panel and a flexible moistureproof metal foil (4, 8) which are laminated together by means of adhesive material (2-3,7) so that the metal foil (4,8) is hummocked attributably to the presence of the or each said cell (5-6, 10-11).
2. A panel according to Claim 1, wherein the adhesive material (2-3, 7) extends close up to the periphery or peripheries of the cell or cells so that the laminate is substantially without internal void spaces.
3. A panel according to Claim 1 or 2, wherein said metal foil (4, 8) is the rear ply of the laminate.
4. A panel according to any preceding claim, wherein said foil (4, 8) is aluminium foil.
5. A panel according to Claim 4, wherein said aluminium foil (4, 8) has a thickness between 5 and 50 microns.
6. A panel according to any preceding claim, wherein said adhesive material comprises a thermoplastics film (3, 7) between the cells (5-6, 10-11) and the metal foil (4, 8).
7. A panel according to Claim 7, wherein the metal foil (4, 8) adheres over its whole area to the or at least one said thermoplastics film (3, 7).
8. A panel according to any preceding claim, wherein said adhesive material comprises a thermoplastics film (2) between the cells (5-6) and the front ply (1).
9. A panel according to Claims 7 and 8, wherein the cell is or the cells (5-6) are sandwiched between two thermoplastics films t2, 3) which are directly or indirectly adherent over their whole areas to said front ply (1) and said metal foil (4) and are bonded together in the zone(s) surrounding the cells (5-6).
10. A panel according to any preceding claim, wherein said adhesive material comprises at least one film (2, 3, 7) of polyvinylbutyral.
11. A panel according to Claim 10, wherein the or each polyvinylbutyral film (2, 3, 7) has a thickness between 0.3 and 1.0 mm.
12. A panel according to any preceding claim, wherein there is at least one photo-cell which is a photovoltaiccell (5-6,10-11).
13. A panel according to Claim 12, constructed for use as a solar panel.
14. A method of manufacturing a panel according to any preceding claim, wherein said metal foil (4, 8) and said front ply (1, 9) of the panel are laminated together using at least one preformed film (2-3, 7) of thermoplastics material.
15. A method according to Claim 14, wherein said light-transmitting front ply (1, 9) said flexible moisture-proof metal foil (4, 8), the photo-cells (5-6, 10-11) and associated conductors and said thermoplastics film material (2-3, 7) are assembled in the required order, the assembly is enclosed in a flexible envelope (14) from which air is then withdrawn to cause environmental pressure to be brought to bear on the assembly and the envelope (14) and the enclosed assembly are heated to cause softening of the thermoplastics film (7) or films (2-3) whereafter the assembly is allowed to cool.
16. A method of manufacturing a lightresponsive panel according to Claim 1, substantially as herein described.
17. A light-responsive panel according to Claim 1 and substantially as herein described with reference to Figure 1 or 2 of the accompanying drawings.
GB8117095A 1980-06-05 1981-06-04 Panels incorporating photo-cells and method of manufacturing same Expired GB2077995B (en)

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GB8117095A GB2077995B (en) 1980-06-05 1981-06-04 Panels incorporating photo-cells and method of manufacturing same

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GB8018520 1980-06-05
GB8117095A GB2077995B (en) 1980-06-05 1981-06-04 Panels incorporating photo-cells and method of manufacturing same

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GB2077995B GB2077995B (en) 1984-03-14

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Cited By (7)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
FR2550385A1 (en) * 1983-08-01 1985-02-08 Matsushita Electric Ind Co Ltd SOLAR MODULE
FR2566962A1 (en) * 1984-06-29 1986-01-03 Thomson Csf Photosensitive integrated circuit including a transparent plate bonded to its photosensitive region
EP0199233A1 (en) * 1985-04-17 1986-10-29 Siemens Aktiengesellschaft Building construction element and its use
WO1995002793A1 (en) * 1993-07-12 1995-01-26 Thermo-Solar Energietechnik Gmbh Hybrid solar collector
CN107146823A (en) * 2017-06-21 2017-09-08 南方科技大学 A kind of method for packing of solar cell encapsulation structure and solar cell
US10131118B2 (en) * 2013-01-07 2018-11-20 Corning Incorporated Strengthened laminated glass structures
CN111391420A (en) * 2018-12-28 2020-07-10 汉能移动能源控股集团有限公司 Laminating method of thin film solar module and thin film solar module

Cited By (7)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
FR2550385A1 (en) * 1983-08-01 1985-02-08 Matsushita Electric Ind Co Ltd SOLAR MODULE
FR2566962A1 (en) * 1984-06-29 1986-01-03 Thomson Csf Photosensitive integrated circuit including a transparent plate bonded to its photosensitive region
EP0199233A1 (en) * 1985-04-17 1986-10-29 Siemens Aktiengesellschaft Building construction element and its use
WO1995002793A1 (en) * 1993-07-12 1995-01-26 Thermo-Solar Energietechnik Gmbh Hybrid solar collector
US10131118B2 (en) * 2013-01-07 2018-11-20 Corning Incorporated Strengthened laminated glass structures
CN107146823A (en) * 2017-06-21 2017-09-08 南方科技大学 A kind of method for packing of solar cell encapsulation structure and solar cell
CN111391420A (en) * 2018-12-28 2020-07-10 汉能移动能源控股集团有限公司 Laminating method of thin film solar module and thin film solar module

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PCNP Patent ceased through non-payment of renewal fee

Effective date: 19940604