NL2007935C2 - A method of and a system for assembling a photovoltaic module, a sub-assembly for use in this method, and an assembled photovoltaic module. - Google Patents

A method of and a system for assembling a photovoltaic module, a sub-assembly for use in this method, and an assembled photovoltaic module. Download PDF

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Publication number
NL2007935C2
NL2007935C2 NL2007935A NL2007935A NL2007935C2 NL 2007935 C2 NL2007935 C2 NL 2007935C2 NL 2007935 A NL2007935 A NL 2007935A NL 2007935 A NL2007935 A NL 2007935A NL 2007935 C2 NL2007935 C2 NL 2007935C2
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layer
assembly
sub
layers
cells
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NL2007935A
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Dutch (nl)
Inventor
Achard Van Enschut Johannes Franciscus Martinus D
Andre Reinoud Wit
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Solland Solar Energy Holding B V
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Application filed by Solland Solar Energy Holding B V filed Critical Solland Solar Energy Holding B V
Priority to NL2007935A priority Critical patent/NL2007935C2/en
Priority to PCT/NL2012/050860 priority patent/WO2013085387A2/en
Application granted granted Critical
Publication of NL2007935C2 publication Critical patent/NL2007935C2/en

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    • 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
    • H01L31/05—Electrical interconnection means between PV cells inside the PV module, e.g. series connection of PV cells
    • H01L31/0504—Electrical interconnection means between PV cells inside the PV module, e.g. series connection of PV cells specially adapted for series or parallel connection of solar cells in a module
    • H01L31/0516—Electrical interconnection means between PV cells inside the PV module, e.g. series connection of PV cells specially adapted for series or parallel connection of solar cells in a module specially adapted for interconnection of back-contact solar cells
    • 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
    • B32B17/10788—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 ethylene vinylacetate
    • 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

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  • Physics & Mathematics (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)
  • Life Sciences & Earth Sciences (AREA)
  • Sustainable Development (AREA)
  • Photovoltaic Devices (AREA)

Description

Title A Method of and a System for Assembling a Photovoltaic Module, a Sub-Assembly for Use in this Method, and an Assembled Photovoltaic Module.
5
Technical Field
The present invention relates to Photovoltaic, PV, modules and, in particular, to PV modules comprised of a plurality of back or rear contact PV cells.
10
Background PV modules or solar panels convert optical energy, such as solar radiation, into electrical energy. These devices are essentially composed of a plurality of 15 electrically interconnected PV cells. PV cells are series connected to obtain a higher output voltage. PV cells are parallel connected to provide a higher output current.
European patent application EP 2.139.050 discloses a method for assembling a PV module comprised of a plurality of stacked layers, including a first 20 planar layer or sheet comprised of a first fusible foil. A second layer comprised of a
plurality of PV cells having a light receiving front side and a back side comprising a plurality of electrical contacts positioned opposite the first fusible foil. A third planar layer or sheet comprised of an interconnect foil, having a pattern of electrically conductive tracks comprising connecting means positioned opposite the first layer, 25 such that the connecting means are in an aligned relationship with the plurality of electrical contacts. A fourth planar layer or sheet comprised of a second fusible foil positioned opposite the front side of the second layer, and a fifth planar layer comprised of a transparent or translucent cover panel positioned opposite the fourth layer. The stack or package is heated in a kiln or heating station thereby fusing and 30 curing the stacked layers together so as to provide a laminated assembled PV
module or solar panel.
The various layers are aligned with respect to one another and stacked in a relatively loosely manner in an assembly station. For lamination, the thus formed 2 stack is moved or transported from the assembly station to the heating station. The non-laminated stack needs to be treated very carefully since a relative displacement of some or all of the layers may result in a misalignment of, for example, PV cells and the interconnect foil, which may result in an improper or absent electrical 5 connection between connecting means of the interconnect foil and electrical contacts of the PV cells, or even short circuiting between connecting means and electrical contacts. Thus yielding faulty or non-optimally operating PV modules.
Further, dependent on the production process, the stacking and fusing or 10 curing of the layers can not be done in the same orientation. That is, before the lamination the stack has to be turned upside down, such that the transparent or translucent cover panel forms a bottom layer of the stack. In this turning or handling of the loosely packed stack there is also a risk of displacement and misalignment of the stacked layers, in particular of the very light-weighted PV cells which, again, may 15 cause improper or absent electrical connections, short circuiting and even breakage of the PV cells.
To prevent such misalignment and other risks by transporting and handling of the stacked layers, European patent application EP 2.139.050 discloses 20 placement of the stack or package in an auxiliary heating station so as to fixate the stack or package as whole before transporting and/or further manipulating and handling of the stack or package for lamination thereof in a kiln or primary heating station.
25 Although this auxiliary heating for the greater part prevents misalignment of the stacked layers, it introduces a further risk of air inclusion between layers of the stack in that the layers, by the auxiliary heating, are fixated at their outer edges. In such a case, when laminating the stack in a vacuum pressure laminator or a roll-based laminator, the thus included air is not or removed or insufficiently removed 30 form the assembled PV module. Air inclusion between the layers of the stack may result in unreliable mechanical contact of the layers which, eventually, may cause breakage of PV cells and unreliable electrical connections, for example.
3
Further, transporting to and placing in and removing of the stack from the auxiliary heating station is a relatively time consuming operation, by which the time required for manufacturing of a PV module or solar panel is considerably increased.
5 Summary
It is an object to improve the assembling of PV modules, in particular to provide an improved method of and a system for high precision assembly of PV modules.
10
In a first aspect, there is provided a method of assembling a PV module comprising the steps of providing a sub-assembly including a first layer comprised of a first fusible foil, and a second layer comprised of a plurality of PV cells having a light receiving front side and a back side comprising a plurality of electrical contacts 15 positioned opposite the first fusible foil. The thus formed sub-assembly is first preheated at discrete locations, such that the first and second layers are fixated at the discrete locations. Next, a third layer is provided, comprised of an interconnect foil having a pattern of electrically conductive tracks comprising connecting means positioned opposite the first layer, such that the connecting means are in an aligned 20 relationship with the plurality of electrical contacts. A fourth layer is provided, comprised of a second fusible foil positioned opposite the front side of the second layer, and a fifth layer comprised of a transparent or translucent cover panel positioned opposite the fourth layer. The thus stacked first to fifth layers, i.e. the fixated sub-assembly of the first and second layer, and the third, fourth and fifth 25 layers are heated for fusing the stack together so as to provide the assembled PV module or solar panel.
The invention is based on the insight that by fixating the PV cells and the first fusible foil, also called the first encapsulant, at discrete positions, relative 30 displacement of the plurality of PV cells, which in general comprise an array of polygonal, i.e. in general rectangular, silicon plate-shaped or planar pn-junction wafers, is effectively prevented while fusion or sealing of the fusible foil and the PV cells at their outer edges is prevented. Accordingly, any air or other gas included between the PV cells and the first fusible foil can be effectively removed in a heating 4 station or laminator, such as a vacuum pressure laminator or a roll-based laminator, when heating and curing or laminating the layered stack as a whole to produce the PV module or solar panel.
5 In the context of the present description and the appended claims, the term discrete location is to be construed as an area being part of a the total surface area of a layer, such as a surface spot or surface patch, a linear or circular shaped surface strip, or any other shaped part of the surface area of a layer.
10 In a further improvement, the sub-assembly is provided including the stacked first, second and third layers, and wherein the sub-assembly is pre-heated such that at least the first and second layers are fixated by the pre-heating at discrete locations of the sub-assembly. Preferably the first, second and third layers are fixated by the pre-heating at discrete locations of the sub-assembly.
15
While maintaining the benefit of easy air removal due to the fixation of the layers of the sub-assembly at discrete positions, fixation of the interconnect foil, also called back foil, and the PV cells prevents misalignment of the electrical contacts and the corresponding connection means of the interconnect foil, while handling and 20 transporting the stack, i.e. the fixated sub-assembly. The physical sturdiness of this sub-assembly is relatively high because of the inclusion of the interconnect foil.
In a still further improvement, the sub-assembly is provided including the first, second, third and fourth layers, and wherein the sub-assembly is pre-heated 25 such that at least the first and second layers are fixated by the pre-heating at discrete locations of the sub-assembly. Preferably the first, second, third and fourth layers are fixated by the pre-heating at discrete locations of the sub-assembly.
With the inclusion, in the sub-assembly, of the second fusible foil, also called 30 the second encapsulant, and fixation of all four layers, the PV cells are also at their light receiving front side effectively prevented against displacement, while maintaining easy air removal between all the layers of the sub-assembly when laminating same. The physical sturdiness of this is sub-assembly is further improved compared to the sturdiness of the three layer arrangement.
5
Whether only the first and second layers or all the layers of a sub-assembly are fixated depends, inter alia, on the duration of the pre-heating of a discrete location. With a relatively short pre-heating time only the first and second layers of a sub-assembly are fixated. With a longer pre-heating time all the layers of the sub-5 assembly are fixated.
In an embodiment, the discrete locations at which the several layers are fixated are located at or near the outer circumference of the PV cells. In the event that The PV cells have a polygonal shape, the discrete locations are selected at 10 corner points of the PV cells. That is, for example, in the case of rectangular planar PV cells, each cell is fixated by at least one corner, preferably by least two, but also with three or at all corners.
Pre-heating of the sub-assembly at discrete positions may include applying 15 electromagnetic radiation energy at discrete locations of the PV cells from the light receiving front side for absorption by the PV cells. That is, the PV cells are locally heated by absorption of the electromagnetic radiation energy. In an example, the electromagnetic radiation comprises radiation having a wavelength between 350 nm and 20.000 nm, more preferably between 350 nm and 8000 nm, or between 780 nm 20 and 3000 nm or between 780 nm and 1500 nm.
In addition to or as an alternative for the local electromagnetic heating, the pre-heating may include applying electromagnetic induction energy at discrete locations of the PV cells for absorption by the PV cells and/or corresponding 25 electrically conductive tracks and/or electrically conductive connecting means, if applicable.
In addition to or as an alternative for the local electromagnetic heating and/or the local electromagnetic induction heating, the pre-heating may comprises applying 30 thermal energy at discrete locations of the sub-assembly, this thermal energy is preferably applied at a side of the sub-assembly opposite the light receiving front side of the PV cells. The thermal energy applied may include any or all of thermal radiation, thermal contact and thermal conduction heating.
6
To shorten the pre-heating time, in an example, a plurality of discrete positions is simultaneously pre-heated. In practice, pre-heating times of 1 -60 sec., in particular between 1-15 sec. to a heating temperature between 100 - 240 °C are observed to provide a sufficient local or discrete fixation of the layers of the sub-5 assembly. The total heating time and the heating temperature depends, inter alia, on the physical properties of the fusible foil, the number of layers of the sub-assembly to be fixated and the number of PV cells and their shape.
It is noted that the pre-heating, different from the prior art disclosure, may be 10 applied at a temperature near or even as high as the temperature at which the stack as a whole is fused and cured. This, because the pre-heating in accordance with the invention is locally applied for achieving fixation at discrete points of the sub-assembly, without already finally fusing or curing the layers of the sub-assembly.
15 The first fusible foil is provided with holes or cut-outs opposite the electrical contacts of the PV cells, for electrically connecting the contacts by the connection means of the interconnect foil. In practice, these holes are cut from the first fusible foil. This cutting process negatively affects the flatness or evenness of the foil. To improve the local fixation of the layers of the sub-assembly, in an example, the sub-20 assembly is subjected to a pressure force during the pre-heating, for mechanically contacting the layers of the sub-assembly. To this end, a smooth non-contaminant frame or any other non-contaminant device for applying a pressure force at the upper and/or lower surface of the sub-assembly may be used.
25 Pre-heating of the sub-assembly may be applied by a pre-heating module arranged in an assembly station, i.e. forming part of an assembly station by which the layers are stacked. Such an assembly station, among others, comprises a workbench for preparing a stack and manipulating or handling devices for picking, aligning and placing the components, i.e. the PV cells and layers of the stack. In an 30 embodiment, the pre-heating module comprises a plurality of energy sources positioned in front of and/or in contact with the sub-assembly for heating same at discrete positions of the PV cells.
7
It has been observed that during lamination, i.e. fusing and curing the stack by heating same in a kiln, laminator or heating station, while evacuating air included between the stacked layers, the PV cells may be subjected to drift or lateral displacement, because the local fixations thereof will be (partially) broken.
5
Such a drift or displacement of the PV cells is effectively prevented, in a further embodiment, in that a flexible non-stretching support layer is provided on the third layer, i.e. the interconnect foil or back foil, forming a top layer of the stack, and such that the support layer sideways circumferentially covers the stack during 10 heating, thereby preventing lateral or co-planar shear movement of the layers. Wherein the layers, while the stack is heated in the heating station, are mechanically contacted by applying a pressure force at the support layer.
In an example, the support layer comprises a heat resistant fibre reinforced 15 fabric, such as a carbon or aramide fibre reinforced fabric. The pressure force may be applied by an inflatable membrane movably positioned on top of the support layer, such as a rubber membrane.
In a second aspect, there is provided a system for assembling a PV module 20 comprising: - an assembly station arranged for providing a sub-assembly including: - a first layer comprised of a first fusible foil, and - a second layer comprised of a plurality of PV cells having a light receiving front side and a back side comprising a plurality of electrical contacts positioned 25 opposite the first fusible foil, - a pre-heating module for pre-heating the sub-assembly at discrete locations such that the first and second layers are fixated at the discrete locations, and wherein the assembly station is further arranged for providing and handling: - a third layer, comprised of an interconnect foil, having a pattern of 30 electrically conductive tracks comprising connecting means positioned opposite the first layer, such that the connecting means are in an aligned relationship with the plurality of electrical contacts, - a fourth layer comprised of a second fusible foil positioned opposite the front side of the second layer, and 8 - a fifth layer comprised of a transparent or translucent cover panel positioned opposite the fourth layer, - handling equipment, for handling and transporting the stacked first to fifth layers, and 5 - a heating station arranged for fusing the stack together so as to provide the assembled PV module.
In a further arrangement, the assembly station is arranged for providing a sub-assembly including the stacked first, second and third layers, and wherein the 10 pre-heating module is arranged for pre-heating the sub-assembly at discrete locations such that at least the first and second layers are fixated at the discrete locations, and wherein the assembly station is further arranged for providing and handling the fourth and fifth layers.
15 In an other arrangement, the assembly station is arranged for providing a sub-assembly including the stacked first, second, third and fourth layers, and wherein the pre-heating module is arranged for pre-heating the sub-assembly at discrete locations such that at least the first and second layers are fixated at the discrete locations, and wherein the assembly station is further arranged for providing 20 and handling the fifth layer.
Preferably, the assembly station is arranged for pre-heating the sub-assembly such that all layers thereof are fixated at discrete locations.
25 The handling equipment may be arranged for turning the fixated sub- assembly up side down or for turning the stacked first to fifth layers up side down, such that the fifth layer forms a bottom layer of the stack.
The pre-heating module, in a further arrangement, comprises a plurality of 30 electromagnetic energy sources for locally providing electromagnetic radiation for absorption by a plurality of PV cells. Such as electromagnetic energy sources arranged for producing electromagnetic radiation comprising a wavelength between 350 nm and 20.000 nm, more preferably between 350 nm and 8000 nm, or between 9 780 nm and 3000 nm or between 780 nm and 1500 nm. Energy sources of this type are halogen lamps, Infra Red, IR, radiators and the like.
In an other arrangement the pre-heating module comprises a plurality of 5 electromagnetic induction energy sources, such as a plurality of electrically energized induction coils, for locally providing electromagnetic induction energy for absorption by a plurality of PV cells and/or conductive tracks and/or connection means of the interconnect foil. Such energy sources may comprise, among others, small RF induction coils.
10
The pre-heating module further may comprise a plurality of thermal energy sources for providing thermal energy at a plurality of discrete locations of the sub-assembly opposite the light receiving front side of the PV cells. Thermal energy sources to be used for heating discrete positions of the sub-assembly are known in 15 practice.
Those skilled in the art will appreciate that the pre-heating according to the invention may be applied in a separate pre-heating station. However, using a preheating module that can be positioned at the position in the assembly station at 20 which the layers of the PV module are stacked, provides the advantage of not having to transport the sub-assembly to, loading in and removing the sub-assembly from a separate heating station. Thereby minimizing any risks connected to the handling and the transporting of a non-fixated sub-assembly, as previously discussed.
25
In a third aspect, the invention relates a sub-assembly for use in assembling a PV, module, the sub-assembly including: - a first layer comprised of a first fusible foil, and - a second layer comprised of a plurality of PV cells having a light receiving 30 front side and a back side comprising a plurality of electrical contacts positioned opposite the first fusible foil, wherein the first and second layers are fixated by pre-heating at discrete locations of the sub-assembly.
10
In a further arrangement the sub-assembly comprises a third layer, comprised of an interconnect foil, having a pattern of electrically conductive tracks comprising connecting means positioned opposite the first layer, such that the connecting means are in an aligned relationship with the plurality of electrical 5 contacts, wherein the first and second layers, and preferably the first, second and third layers are fixated by pre-heating at discrete locations of the sub-assembly.
In another arrangement, the sub-assembly further comprises a fourth layer comprised of a second fusible foil positioned opposite the front side of the second 10 layer, wherein at least the first and second layers, and preferably the first, second, third and fourth layers are fixated by pre-heating at discrete locations of the sub-assembly.
In an embodiment, the first and second fusible foil are comprised of a 15 thermoplast or thermosetting material, such as ethylene vinyl acetate, EVA, or a foil material commercially known as XUS, and wherein the transparent or translucent cover panel is a glass panel, for example. The material of the first and second fusible foil, i.e. the first and second encapsulant, shall be capable of flowing when heat is applied.
20
In an embodiment, the connecting foil or back foil, also called the back contact foil, is a laminate of polyethylene terephthalate, PET, and TEDLAR® on which electrically conducting copper or aluminium traces or tracks or conductors or the like are fixed. The connecting means may comprise a thermally activatable 25 electrically conductive adhesive, such as a solder paste or a quick-setting silver-based adhesive.
In a fourth aspect, the invention relates to a Photovoltaic, PV, module produced in accordance with the method disclosed above.
30
The invention will now be described in more detail by means of specific embodiments, with reference to the enclosed drawings, wherein equal or like parts and/or components are designated by the same reference numerals. The invention is in no manner whatsoever limited to the embodiments disclosed.
11
Brief Description of the Drawings
Fig. 1 shows schematically, not to scale, in exploded view, an example of a prior art PV module, comprising a plurality of back contact PV cells.
5
Fig. 2 shows schematically, not to scale, a cross-section of part of the PV module of Fig. 1 along the line II - II.
Figs. 3-5 show schematically, not to scale, in cross-section view according 10 to Fig. 2, examples of different sub-assemblies according to the invention.
Fig. 6 shows schematically, not to scale, an example of a system for assembling a PV module according to the invention.
15 Fig. 7 shows schematically, not to scale, a top view of an example of a pre heating module for pre-heating of a sub-assembly according to the invention.
Fig. 8 shows schematically, not to scale, partly in cross section, a heating station or laminator for fusing and curing a stack together, so as to provide an 20 assembled PV module.
Detailed Description
Fig. 1 shows, in exploded view, parts of a prior art Photovoltaic module or solar panel 10 comprising plate-shaped or planar polygonal PV cells or wafers 11, 25 each having a light receiving front side or front surface 12 for receiving optical radiation, i.e. solar radiation, a back or rear side or surface 13 opposite to the front surface 12 and an outer circumference 14. In the example embodiment shown, the PV cells 11 are adjacently arranged in an array or matrix of PV cells. The PV cells 11 are of the so-called back contact or rear contact device type, which means that 30 the electrical contacts 15 for electrically connecting the PV cells 11 are provided at the back side 13 of a PV cell 11. The electrical contacts 15 may be shaped as dotlike contact points, for example, generally produced from a copper or silver material, aluminium and mixtures or alloys thereof.
12
The array of PV cells 10 forms a second planar layer 20 of the PV module 10, a first planar layer 21 of which is formed by a first fusible foil or first encapsulant of a thermoplast or thermosetting material, capable of fusing when heat above a certain threshold is applied. A typical first encapsulant material is ethylene vinyl 5 acetate, EVA, or a foil material commercially known as XUS.
The first layer 21 comprises holes or cut outs 22. In use, the first layer 21 is positioned opposite the back side 13 of the second layer 20 and aligned therewith, such that an opening 22 is exactly opposite of an electrical contact 15 of a PV cell 10 11. For clarity purposes, just a part of the holes 22 is shown.
The PV module 10 further comprises a third layer 25 comprised of a planar interconnect foil or back foil, having a pattern of electrically conductive traces, wires or tracks 26 comprising connecting means 27. Typical interconnect or back foil 15 material is a laminate of polyethylene terephthalate, PET, and TEDLAR® on which the electrically conducting tracks or conductors 26 or the like are fixed. This laminate may comprise a layer for providing a required mechanical strength, i.e. the interconnect foil should be highly non-stretchable, and an other layer acting as a moisture barrier also containing a solder mask (isolation layer). The electrically 20 conductive tracks 26 are typically formed of a copper or an aluminium material. Typical connecting means 27 comprise a thermally activatable electrically conductive adhesive, such as a solder paste or a quick-setting silver-based adhesive. For clarity purposes, just a part of the connecting means 27 is shown.
25 The third layer 25 is arranged such that the first layer 21 is located between the second layer 20 and the third layer 25 and in that the first layer 21, the second layer 20 and the third layer 25 are aligned such that the electrical contacts 15 of the PV cells 11 will come into contact with the connecting means 27 of the tracks 26. The pattern of electrically conductive tracks 26 terminates in contact terminals 28, 30 29 for electrically connecting the PV module 10. The design of the pattern of electrically conductive tracks 26 is within the reach of the skilled person, and need no further elaboration.
13
Opposite the front side 12 of the PV cells 11, a fourth planar layer 30 is positioned. This fourth layer 30 is transparent and formed by a second fusible foil or second encapsulant of a thermoplast or thermosetting material capable of fusing when heat above a certain threshold is applied. A typical second encapsulant 5 material is also ethylene vinyl acetate, EVA, or a foil material commercially known as XUS.
A fifth layer 31, comprised of a transparent or translucent, i.e. a light transmissive, cover panel, such as a glass material, forms an external layer 10 protecting the PV cells and the electrical connections against dirt, moisture and other contaminants and provides sufficient physical rigidness to the PV module 10. The fifth layer 31 may comprise anti-reflection properties or structured surfaces to trap impinging light inside the PV module.
15 For fusing and curing or laminating together the first to fifth layers 21, 20, 25, 30, 31, respectively, of the stack 35 so as to provide an assembled PV module 10, the layers are brought in mechanical contact, for example by stacking same on top of each other. Thereafter the stack 35 is turned upside down, such that the transparent or translucent fifth layer 31 forms the bottom layer. In this position the 20 stack 35 is transported to and loaded inside a heating station. By heating the stack 35 during a certain time period, for example during 5-20 minutes to a temperature of about 150 - 240 °C, the layers of the stack adhere together and the electrical connections are prepared, such that after cooling down the finished PV module 10 is obtained.
25
During the lamination process air between the layers is evacuated and a pressure force is exerted on the stack, to provide durable electrical contacts and preventing breakage of the PV cells 11 during use of the PV module 10.
30 When applying connecting means 27 comprised of a thermally activatable electrically conductive adhesive, such as a solder paste or a quick-setting silver-based adhesive, a post-processing step may be required by locally applying heat to the connecting means, for example by a laser source from the front side 12 of the PV cells 11. This to reduce the electrical resistance and to improve the reliability of 14 the electrical connections of the connecting means 27 and the electrical contacts 15 of the PV cells 11. Reference is made to NL patent 2001958.
In practice, the dimensions of the PV module 10 typically are 1 x 2 m.
5 However, other dimensions are possible. The first, third, fourth and fifth layers are in one piece.
Fig. 2 shows part of the stack 35 along the line II - II in Fig. 1 before lamination thereof. It is noted that the layers are not drawn to scale. The figure is 10 merely illustrative of nature. In practice, the length and width dimensions of a PV module 10 may vary between about 0.3 and 2 m, whereas the length and width of a PV cell are in the range of 5 - 30 cm.
As discussed in the background part above, while handling and transporting 15 the stack 35, there is a risk of displacement of the aligned layers of the stack 35.
Fig. 3 shows part of the stack 35 along the line II - II in Fig. 1 forming a first sub-assembly 40 or first semi-product in accordance with an embodiment of the invention. The sub-assembly 40 is comprised of the first layer 21, i.e. the first fusible 20 foil or first encapsulant, and the second layer 20 of PV cells 11. The first layer 21 is arranged essentially parallel with and opposite the back side 13 of the PV cells 11 and such that the contacts 15 are aligned with the openings 22 of the first layer 21.
Fig. 4 shows part of the stack 35 along the line II - II in Fig. 1 forming a 25 second sub-assembly 41 or second semi-product in accordance with an embodiment of the invention. In addition to the first sub-assembly 40, the second sub-assembly 41 comprises the third layer 25, i.e. the interconnect foil or back foil comprising the electrically conductive tracks 26 and the connecting means 27. The third layer 25 is arranged essentially parallel with and opposite the first layer 21, 30 such that the first layer 21 is arranged between the second layer 20 and the third layer 25. The third layer 25 is aligned with the first layer 21 such that the connecting means 27 engage in the openings 22 of the first layer 21, for connecting the corresponding contacts 15 of the second layer, i.e. the PV cells 11.
15
Fig. 5 shows part of the stack 35 along the line II - II in Fig. 1 forming a third sub-assembly 42 or third semi-product in accordance with an embodiment of the invention. In addition to the second sub-assembly 41, the third sub-assembly 42 comprises the fourth layer 30, i.e. the second fusible foil or second encapsulant. The 5 fourth layer 30 is arranged essentially parallel with and opposite the light receiving front side 12 of the PV cells 11 of the second layer 20.
Dash-dot lines 43, 43’ and 43” schematically indicate discrete locations at which the respective layers of a sub-assembly 40, 41, 42 are fixated by pre-heating. 10 That is, where the respective layers of a sub-assembly 40, 41, 42 are mechanically connected by local fusing and curing due to the pre-heating of the first and second fusible foil, if applicable.
In the context of the present description and the appended claims, the term 15 discrete location is to be construed as an area being part of a the total surface area of a layer, such as a surface spot or surface patch, a linear or circular shaped surface strip, or any other shaped part of the surface area of a layer.
Lines 43 indicate the fixation of the first 21 and second layer 20 of each sub-20 assembly 40, 41, 42. Lines 43’ indicate the fixation of the first 21 and third layer 25 in the sub-assemblies 41 and 42, and lines 43” illustrate the fixation of the second 20 and fourth layer 30 in the sub-assembly 42. The fixations indicated by lines 43’ and 43” depend, inter alia, on the duration of the pre-heating of a particular discrete location of a sub-assembly. Preferably, of a sub-assembly 40, 41, 42 all the layers 25 are fixated at discrete positions 43, 43’, 43”, however in any case the pre-heating should be sufficient for fixating the first 21 and second layer 20 of each sub-assembly 40, 41, 42.
The discrete locations 43, 43’, 43” are preferably located at or near the 30 circumference 14 of the PV cells 11, for example at one, a plurality or all corners of polygonal shaped PV cells 11. However, the sub-assembly may also connect at one or a plurality of discrete locations arranged at other positions of the PV cells 11, such as in the middle thereof, as schematically indicated by reference numeral 44 in Fig. 4.
16
Arrow 45 in Fig. 5 represents are pressure force that may be applied at any of the sub-assemblies 40, 41, 42 during pre-heating for providing a suitable mechanical contact between the opposite layers of a sub-assembly 40, 41, 42. In principle any means for applying such a pressure force is applicable, such as the 5 weight of a light weight frame or mesh or the like resting on the sub-assembly. However care has to be taken not to contaminate the assembly or applying a too high pressure with the risk of breakage of PV cells 11.
Fig. 6 shows a system 47 for assembling a PV module 46 in an embodiment 10 of the invention. The system 47 comprises an assembly station 48 arranged for stacking the several layers of the PV module 46. In the embodiment shown, by way of example, a second sub-assembly 41 is produced at the assembly station 48.
After stacking and aligning the first, second and third layers of the sub-15 assembly 41 as disclosed above with reference to Fig. 4, for example wherein the third layer 25 forms a bottom layer atop of which the first layer 21 is positioned and wherein the PV cells 11 are placed atop the first layer 21, pre-heating is applied by a pre-heating module 51.
20 The pre-heating module 51 comprises a plurality of energy sources 53, providing energy 54 for simultaneously invoking local fusing and curing of the first, second an third layers at a plurality of discrete locations 43, 43’ as shown in Fig. 4.
The energy sources 53 may comprise any or a combination of 25 electromagnetic radiation energy sources, applying electromagnetic radiation having a wavelength between 350 nm and 20.000 nm, more preferably between 350 nm and 8000 nm, or even more preferably between 780 nm and 3000 nm or more specific between 780 nm and 1500 nm at discrete locations 43 of the PV cells 11 from the light receiving front side 12 thereof, for local absorption by the PV cells 11. 30
In an embodiment the pre-heating module 51 comprises an array of 75 W narrow beam halogen lamps at a distance of about 2 cm from the front side 12 of the PV cells 11.
17
In another embodiment, the pre-heating module 51 comprises a plurality of energy sources, such as electrically RF energized coils, inducing electromagnetic RF induction energy at the discrete locations 43 in the electrically conducting parts of the PV cells 11 and at the discrete location 43’ of the connecting means 27 and 5 the electrically conductive tracks 26 of the third layer 25.
In yet another embodiment, the pre-heating at the discrete locations 43, 43’ is provided by energy sources 53 generating thermal energy. Such thermal energy is preferably applied at discrete locations 43’ from the interconnect foil or third layer 10 25. The thermal energy applied may include any or all of thermal radiation, thermal contact and thermal conduction heating.
Local pre-heating by absorption of electromagnetic radiation energy or RF induction energy by the PV cells 11 is preferred to avoid undue mechanical stress in 15 the interconnect or back foil.
In an example the discrete locations 43, 43’, 43”, whenever applicable, are pre-heated at a temperature between 100 - 240 °C during a time period between 1 -15 sec. The upper limit of this time period is sufficient for fixating all four layers of 20 the sub-assembly 42.
The pre-heating module 51 is preferably located at the same position in the system 47 as the assembly station 48, such to avoid transport and handling of the non-fixated sub-assembly 41 after stacking of the layers 20, 21 and 25 thereof.
25
Next, as indicated by arrow 57, the fourth and fifth layers 30, 31 are provided and handled at the assembly station, by positioning the fourth layer 31 atop the fixated sub-assembly 41 and by positioning the fifth layer 31 atop the fourth layer 30, providing a stack 55 of the first to fifth layers. The handling of the fourth and fifth 30 layers 30, 31 may be performed in a separate station 49.
Before heating and curing, i.e. laminating, the stack 55 in the heating station or kiln or laminator 52, the stack 55 needs to be turned upside down by handling 18 equipment of the system 47, schematically indicated by the circular arrow 56. Such handling equipment 56 is known to skilled person in PV module manufacturing.
Because the first, second and third layers are fixated, i.e. forming the sub-5 assembly 41, the risk of misalignment of the layers 20, 21 and 25 when turning the stack 55 upside down is effectively reduced. With the fifth layer 31 forming a bottom layer of the stack 55, same is transported 58 and loaded into the heating station 52 for fusing and curing the layers of the stack 55 together by applying heat 60. The fusing and curing takes about 5-20 minutes to a temperature of about 150 - 240 10 °C. After sufficiently cooling down, the stack is removed 59 from the heating station 52, providing the assembled PV module 46. A post-processing may be applied for improving the respective electrical connections between the connecting means 27 and the electrical contacts 15 of the PV cells 11 in a separate post-processing station 50, as disclosed above.
15
When using connecting means 27 in the form of a thermally activatable electrically conductive adhesive, such as a solder paste or a quick-setting silver-based adhesive, while fusing and curing in the heating station 52, the electrical contacts 15 of the PV cells are electrically connected to the respective electrically 20 conductive tracks 26 of the connecting foil 25.
The heating station 52 is arranged for laminating the stack 55 while evacuating any air inclusions between the layers of the stack 55, i.e. forming a vacuum inside the heating station 52. With the fixation of the layers of the sub-25 assembly 41 at discrete positions 43 and 43’, if applicable, according to the invention, any air between the layers can be effectively evacuated in the heating station 52.
It is noted that several stacks 55 may be laminated simultaneously in the 30 heating station 52.
Instead of the sub-assembly 41 as shown in Fig. 6, likewise the sub-assemblies 40 or 42 may be pre-heated by the pre-heating module 51 and 19 manipulated by the handling equipment 56 after positioning the third, fourth and fifth layers or the fifth layer in the assembly station 48, respectively.
The invention is not limited to the manufacturing of PV modules wherein the 5 complete stack 55 is turned upside down by the handling equipment 56. Alternatively the sub-assembly 40, 41, 42 when fixated with the first 21 or third layer 25 forming a bottom layer of the sub-assembly, may be turned upside down and positioned on the third, fourth or fifth layer, respectively. On the other hand, a sub-assembly 40, 41,42 may be fixated with the second layer or the fourth layer forming 10 a bottom layer. The manipulating equipment 56 then just needs to lift the sub-assembly for positioning same on the fourth or the fifth layer.
Fig. 7 shows a top view at the pre-heating module 51 comprised of an array of halogen lamps 61 operating as the energy sources 53 providing electromagnetic 15 radiation energy to be absorbed by the PV cells 11, as indicated by the discrete spot or patch formed locations 62. For a PV module comprised of sixty rectangular PV cells 11, i.e. ten rows of six PV cells 11, seventy seven lamps 61 are required for simultaneously pre-heating all the PV cells 11 at their four corners. For clarity purposes, not all the PV cells are shown in Fig. 7.
20
For other numbers of PV cells or other shaped discrete locations 43, 43’, 43” other numbers and arrangements of lamps are feasible, such a line-shaped lamps for fixating a sub-assembly 40, 41, 42 at line-shaped discrete locations, for example. Although simultaneous pre-heating of all the PV cells provides the fastest process, it 25 is also feasible to have an array of less lamps 61, or less other energy sources 53, which need to be displaced a number of times with respect to the stack, for fixating all the PV cells 11 of the stack, i.e. the sub-assembly.
For effectively preventing or reducing displacement of the layers of a stack 30 while fusing in the heating station, a non-stretchable flexible support layer is provided on the interconnect foil or back foil, forming a top layer of the stack, such as illustrated in Fig. 8.
20
Fig. 8 shows schematically, a cross section of a heating station or laminator 70 for fusing and curing a PV module stack 65 together, so as to provide an assembled PV module. The heating station 70 comprises a vacuum chamber 71 in which a hot plate or table 74 is arranged for receiving and heating the stack 65 to be 5 laminated. The chamber 70 connects by a valve 72 to a vacuum pump 73 or the like, for evacuating air or other gasses from the chamber 70.
A non-stretchable, substantially planar, support layer 75 rests on top of the stack 65. This support layer is arranged in a movably supported frame or carrier 76. 10 The frame 76 may be movable in a direction transverse to the hot plate 74, as indicated by arrow 81. The dimensions of the support layer 75 are such that the support layer 75 sideways circumferentially covers the stack 65 during lamination.
In the chamber 71, opposite the support layer 75, an inflatable, flexible 15 membrane or bellow 77 is arranged. The membrane 77 is supported by a movable frame or carrier 78, which is movable in the direction transverse to the support layer 75, as indicated by arrow 82. The membrane 77 connects by a valve 79 that opens to the outside of the chamber 70 and by a valve 80 that opens to the inside of the chamber 70. The valves 72, 79, 80, the vacuum pump 73 and the movable frames 20 76, 78 may be automatically operated and controlled by a suitable controller or processor (not shown).
In an example operation mode of the heating station 70, first the stack 65 is placed on the hot plate 74 by transporting means (not shown). Next, the support 25 layer 75 is positioned to rest at the top of the stack 65, by moving the frame 76. The support layer 75 is positioned such that same extends across and beyond the stack 65, such to sideways circumferentially covering the stack 65 during lamination.
After closing the chamber 71, the membrane 77 is moved in the direction of 30 the support layer 75, by operating the frame 78. Valve 72 and 80 are opened and valve 79 is closed. Air and other gasses are drawn from the chamber 71 by operating the vacuum pump 73. After reaching a sufficient vacuum in the chamber 71, valves 72 and 80 are closed. Valve 3 is now opened to inflate the membrane 77 by atmospheric pressure from the outside of the chamber 71. The volume of the 21 membrane 77 expands such that the membrane comes into contact with the support layer 75 and pressure is applied at the stack 65.
Now the fusing and curing of the stack 65 takes place by heating same to a 5 temperature between 150 - 240 °C by the hot plate 74. This process may take 3-10 minutes, for example, after which the membrane 77 and the support layer 75 are moved in a direction away from the hot plate 74. The chamber 71 is opened and vented and the laminated PV module is moved to a cooling position outside the heating station 70.
10
The support layer 75 reduces or prevents lateral or co-planar or shear forces on the stack 65 during the lamination, which forces originate from the compression forces acting on the layers of the stack 65 during evacuation and vertical or transverse compression by the flexible membrane 77) 15
In an example, the support layer is made of a heat resistant non-stretchable, fibre reinforced fabric, such as a carbon or aramide fibre reinforced fabric, having a very small thickness, such as less than 1 mm. The membrane 77, in an example, is made of rubber having a thickness of about 1 cm.
20
The invention may be practiced otherwise than specifically described herein, and the above mentioned embodiments and examples are merely intended as an illustration to the skilled reader. Those skilled in the art will appreciate that PV modules of different shapes may be formed, for example, applying the teachings of 25 the invention. The scope of the invention is only limited by the appended claims.

Claims (35)

1. Werkwijze voor het assembleren van een fotovoltaïsche (“Photovoltaic”), PV, module omvattende de stappen van het: 5. verschaffen van een deelsamenstel omvattende: - een eerste laag omvattende een eerste smeltfolie, en - een tweede laag omvattende een veelheid PV-cellen met een licht-ontvangende voorzijde en een achterzijde omvattende een veelheid elektrische contacten gepositioneerd tegenover de eerste smeltfolie, 10. voorverwarmen van het deelsamenstel op discrete locaties zodanig dat de eerste en tweede lagen op deze discrete locaties worden gefixeerd, - verschaffen van een derde laag omvattende een verbindingsfolie met een patroon van elektrisch geleidende sporen omvattende verbindingsmiddelen 15 gepositioneerd tegenover de eerste laag, zodanig dat de verbindingsmiddelen in een opgelijnde relatie zijn met de veelheid elektrische contacten, - verschaffen van een vierde laag omvattende een tweede smeltfolie gepositioneerd tegenover de voorzijde van de tweede laag, - verschaffen van een vijfde laag omvattende een transparant of 20 doorschijnend afdekpaneel gepositioneerd tegenover de vierde laag, en - verwarmen van de gestapelde eerste tot en met vijfde lagen voor het versmelten van de stapel teneinde de geassembleerde PV-module te verschaffen.A method for assembling a photovoltaic (PV) module comprising the steps of: 5. providing a subassembly comprising: - a first layer comprising a first melting film, and - a second layer comprising a plurality of PV cells with a light-receiving front side and a back side comprising a plurality of electrical contacts positioned opposite the first melting film, 10. preheating the sub-assembly at discrete locations such that the first and second layers are fixed at these discrete locations, - providing a third layer comprising a connecting foil with a pattern of electrically conductive tracks comprising connecting means 15 positioned opposite the first layer, such that the connecting means are in a aligned relationship with the plurality of electrical contacts, - providing a fourth layer comprising a second melting foil positioned opposite the front of the second layer, - v providing a fifth layer comprising a transparent or translucent cover panel positioned opposite the fourth layer, and heating the stacked first to fifth layers to fuse the stack to provide the assembled PV module. 2. Werkwijze volgens conclusie 1, waarin het deelsamenstel wordt verschaft omvattende de gestapelde eerste, tweede en derde lagen, en waarin het deelsamenstel 25 wordt voorverwarmd zodanig dat ten minste de eerste en tweede lagen door deze voorverwarming op discrete locaties van het deelsamenstel worden gefixeerd.2. Method according to claim 1, wherein the sub-assembly is provided comprising the stacked first, second and third layers, and wherein the sub-assembly 25 is pre-heated such that at least the first and second layers are fixed by this pre-heating at discrete locations of the sub-assembly. 3. Werkwijze volgens conclusie 1, waarin het deelsamenstel wordt verschaft omvattende de eerste, tweede, derde en vierde lagen, en waarin het deelsamenstel wordt voorverwarmd zodanig dat ten minste de eerste en tweede lagen door deze 30 voorverwarm ing op discrete locaties van het deelsamenstel worden gefixeerd.3. Method as claimed in claim 1, wherein the sub-assembly is provided comprising the first, second, third and fourth layers, and wherein the sub-assembly is pre-heated such that at least the first and second layers are pre-heated at discrete locations of the sub-assembly fixed. 4. Werkwijze volgens een van de voorgaande conclusies, waarin de discrete locaties op een omtrek van de PV-cellen zijn gelegen.The method of any one of the preceding claims, wherein the discrete locations are located on a perimeter of the PV cells. 5. Werkwijze volgens conclusie 4, waarin de PV-cellen een veelhoekige vorm hebben en waarin de discrete locaties op hoeken van de PV-cellen zijn gelegen.The method of claim 4, wherein the PV cells have a polygonal shape and wherein the discrete locations are at corners of the PV cells. 6. Werkwijze volgens een van de voorgaande conclusies, waarin de voorverwarming omvat het toevoeren van elektromagnetische stralingsenergie op discrete 5 locaties van de PV-cellen aan de licht-ontvangende voorzijde voor absorptie door de PV-cellen.6. Method as claimed in any of the foregoing claims, wherein the pre-heating comprises supplying electromagnetic radiation energy at discrete locations of the PV cells to the light-receiving front side for absorption by the PV cells. 7. Werkwijze volgens conclusie 6, waarin de elektromagnetische straling straling omvat met een golflengte tussen 350 nm en 20.000 nm, meer bij voorkeur tussen 350 nm en 8000 nm, of tussen 780 nm en 3000 nm of tussen 780 nm en 1500 nm.Method according to claim 6, wherein the electromagnetic radiation comprises radiation with a wavelength between 350 nm and 20,000 nm, more preferably between 350 nm and 8000 nm, or between 780 nm and 3000 nm or between 780 nm and 1500 nm. 8. Werkwijze volgens een van de voorgaande conclusies, waarin de voorverwarming omvat het toevoeren van elektromagnetische inductie-energie op discrete locaties van de PV-cellen voor absorptie door de PV-cellen.A method according to any one of the preceding claims, wherein the preheating comprises supplying electromagnetic induction energy at discrete locations of the PV cells for absorption by the PV cells. 9. Werkwijze volgens een van de voorgaande conclusies, waarin de voorverwarming omvat het toevoeren van thermische energie op discrete locaties van het 15 deelsamenstel tegenover de licht-ontvangende voorzijde van de PV-cellen.9. Method as claimed in any of the foregoing claims, wherein the pre-heating comprises supplying thermal energy at discrete locations of the sub-assembly opposite the light-receiving front side of the PV cells. 10. Werkwijze volgens een van de voorgaande conclusies, waarin een veelheid discrete posities gelijktijdig wordt voorverwarmd.The method of any one of the preceding claims, wherein a plurality of discrete positions are preheated simultaneously. 11. Werkwijze volgens een van de voorgaande conclusies, waarin een discrete locatie wordt voorverwarmd tot een temperatuur tussen 100 - 240 °C gedurende een 20 tijdsperiode van 1-60 sec.11. Method as claimed in any of the foregoing claims, wherein a discrete location is pre-heated to a temperature between 100 - 240 ° C for a time period of 1-60 sec. 12. Werkwijze volgens een van de voorgaande conclusies, waarin de lagen van het deelsamenstel gedurende de voorverwarming mechanisch in aanraking zijn door het aanleggen van een drukkracht op het deelsamenstel.A method according to any one of the preceding claims, wherein the layers of the sub-assembly are mechanically in contact during preheating by applying a compressive force to the sub-assembly. 13. Werkwijze volgens een van de voorgaande conclusies, waarin de 25 voorverwarming van het deelsamenstel in een assemblagestation wordt uitgevoerd.13. Method as claimed in any of the foregoing claims, wherein the pre-heating of the sub-assembly is carried out in an assembly station. 14. Werkwijze volgens een van de voorgaande conclusies, waarin de gestapelde eerste tot en met vijfde lagen in een verwarmingsstation worden verwarmd, waarin de vijfde laag een bodemlaag van de stapel vormt, en waarin voorafgaand en tijdens verwarming lucht aan de stapel wordt onttrokken.A method according to any one of the preceding claims, wherein the stacked first to fifth layers are heated in a heating station, wherein the fifth layer forms a bottom layer of the stack, and wherein air is extracted from the stack before and during heating. 15. Werkwijze volgens conclusie 14, waarin op de derde laag een flexibele ondersteuningslaag wordt verschaft welke een bovenlaag van de stapel vormt, zodanig dat de ondersteuningslaag zijdeling omtreksgewijs de stapel omhult voor het verhinderen van foutuitlijning van de lagen van de stapel tijdens verwarming, en waarin de lagen tijdens het verwarmen van de stapel in het verwarmingsstation mechanisch in aanraking zijn door het op de ondersteuningslaag aanleggen van een drukkracht.A method according to claim 14, wherein a flexible support layer is provided on the third layer which forms an upper layer of the stack such that the support layer laterally circumscribes the stack to prevent misalignment of the layers of the stack during heating, and wherein the layers are mechanically in contact during heating of the stack in the heating station by applying a compressive force to the supporting layer. 16. Werkwijze volgens conclusie 15, waarin de ondersteuningslaag een vezelversterkt weefsel omvat, zoals een koolstof- of aramidevezel versterkt weefsel.The method of claim 15, wherein the support layer comprises a fiber-reinforced fabric, such as a carbon or aramid fiber-reinforced fabric. 17. Werkwijze volgens conclusie 15 of 16, waarin de drukkracht wordt aangelegd door een bovenop de ondersteuningslaag geplaatst opblaasbaar membraan.17. Method as claimed in claim 15 or 16, wherein the compressive force is applied by an inflatable membrane placed on top of the support layer. 18. Deelsamenstel voor gebruik in het assembleren van een fotovoltaïsche (“Photovoltaic”), PV, module, welk deelsamenstel omvat: - een eerste laag omvattende een eerste smeltfolie, en 10 - een tweede laag omvattende een veelheid PV-cellen met een licht- ontvangende voorzijde en een achterzijde omvattende een veelheid elektrische contacten gepositioneerd tegenover de eerste smeltfolie, waarin de eerste en tweede lagen door voorverwarming op discrete locaties van het deelsamenstel zijn gefixeerd.18. Sub-assembly for use in assembling a photovoltaic ("Photovoltaic"), PV, module, which sub-assembly comprises: - a first layer comprising a first melting film, and - a second layer comprising a plurality of PV cells with a light receiving front side and a back side comprising a plurality of electrical contacts positioned opposite the first melting film, wherein the first and second layers are fixed by preheating at discrete locations of the sub-assembly. 19. Deelsamenstel volgens conclusie 18, verder omvattende een derde laag, omvattende een verbindingsfolie met een patroon van elektrisch geleidende sporen omvattende verbindingsmiddelen gepositioneerd tegenover de eerste laag, zodanig dat de verbindingsmiddelen in een opgelijnde relatie zijn met de veelheid elektrische contacten, waarin ten minste de eerste en tweede lagen door voorverwarming op discrete 20 locaties van het deelsamenstel zijn gefixeerd.19. Sub-assembly according to claim 18, further comprising a third layer, comprising a connecting foil with a pattern of electrically conductive tracks comprising connecting means positioned opposite the first layer, such that the connecting means are in a aligned relationship with the plurality of electrical contacts, wherein at least the first and second layers are fixed by preheating at discrete locations of the sub-assembly. 20. Deelsamenstel volgens conclusie 19, verder omvattende een vierde laag omvattende een tweede smeltfolie gepositioneerd tegenover de voorzijde van de tweede laag, waarin ten minste de eerste en tweede lagen door voorverwarming op discrete locaties van het deelsamenstel zijn gefixeerd.The subassembly according to claim 19, further comprising a fourth layer comprising a second melting film positioned opposite the front side of the second layer, wherein at least the first and second layers are fixed by heating at discrete locations of the subassembly. 21. Deelsamenstel volgens conclusie 18, 19 of 20, waarin de voorverwarming is uitgevoerd in overeenstemming met de werkwijze volgens een van de conclusies 4-13.21. Partial assembly according to claim 18, 19 or 20, wherein the pre-heating is carried out in accordance with the method according to any of claims 4-13. 22. Deelsamenstel volgens conclusie 18, 19, 20 of 21, waarin de eerste en tweede smeltfolie een thermoplastisch of thermohardend materiaal omvatten, zoals ethyleenvinylacetaat, EVA, waarin het transparante of doorschijnende afdekpaneel een 30 glaspaneel is.22. Partial assembly according to claim 18, 19, 20 or 21, wherein the first and second melting film comprise a thermoplastic or thermosetting material, such as ethylene vinyl acetate, EVA, wherein the transparent or translucent cover panel is a glass panel. 23. Deelsamenstel volgens conclusie 18, 19, 20, 21 of 22, waarin de verbindingsmiddelen een thermisch activeerbaar elektrisch geleidend kleefmiddel omvatten, zoals een soldeermiddel.A component assembly as claimed in claim 18, 19, 20, 21 or 22, wherein the connecting means comprise a thermally activatable electrically conductive adhesive, such as a solder. 24. Systeem voor het assembleren van een fotovoltaïsche (“Photovoltaic”), PV, module omvattende: - een assemblagestation ingericht voor het verschaffen van een deelsamenstel omvattende: 5. een eerste laag omvattende een eerste smeltfolie, en - een tweede laag omvattende een veelheid PV-cellen met een licht ontvangende voorzijde en een achterzijde omvattende een veelheid elektrische contacten gepositioneerd tegenover de eerste smeltfolie, - een voorverwarmingsmodule voor het voorverwarmen van het 10 deelsamenstel op discrete locaties zodanig dat de eerste en tweede lagen op deze discrete locaties worden gefixeerd, en waarin het deelsamenstel verder is ingericht voor het verschaffen en hanteren van: - een derde laag, omvattende een verbindingsfolie met een patroon van elektrisch geleidende sporen omvattende verbindingsmiddelen gepositioneerd tegenover 15 de eerste laag, zodanig dat de verbindingsmiddelen in een opgelijnde relatie zijn met de veelheid elektrische contacten, - een vierde laag omvattende een tweede smeltfolie gepositioneerd tegenover de voorzijde van de tweede laag, en - een vijfde laag omvattende een transparant of doorschijnend afdekpaneel 20 gepositioneerd tegenover de vierde laag, - hanteringsapparatuur voor het hanteren en transporteren van de gestapelde eerste tot en met vijfde lagen, en - een verwarmingsstation ingericht voor het versmelten van de stapel teneinde de geassembleerde PV-module te verschaffen.A system for assembling a photovoltaic ("Photovoltaic"), PV, module comprising: - an assembly station adapted to provide a sub-assembly comprising: 5. a first layer comprising a first melting film, and - a second layer comprising a plurality PV cells with a light receiving front side and a back side comprising a plurality of electrical contacts positioned opposite the first melting film, - a preheating module for preheating the subassembly at discrete locations such that the first and second layers are fixed at these discrete locations, and wherein the sub-assembly is further adapted to provide and handle: - a third layer, comprising a connecting foil with a pattern of electrically conductive tracks comprising connecting means positioned opposite the first layer, such that the connecting means are in a aligned relationship with the plurality of electrical contacts, - a fourth layer comprising a second melting film positioned opposite the front side of the second layer, and - a fifth layer comprising a transparent or translucent cover panel 20 positioned opposite the fourth layer, - handling equipment for handling and transporting the stacked first to fifth and a heating station adapted to fuse the stack to provide the assembled PV module. 25. Systeem volgens conclusie 24, waarin het assemblagestation is ingericht voor het verschaffen van een deelsamenstel omvattende de gestapelde eerste, tweede en derde lagen, en waarin de voorverwarmingsmodule is ingericht voor het voorverwarmen van het deelsamenstel op discrete locaties zodanig dat ten minste de eerste en tweede lagen op deze discrete locaties worden gefixeerd, en waarin het assemblagestation 30 verder is ingericht voor het verschaffen en hanteren van de vierde en vijfde lagen.The system of claim 24, wherein the assembly station is adapted to provide a subassembly comprising the stacked first, second and third layers, and wherein the preheating module is adapted to preheat the subassembly at discrete locations such that at least the first and second layers are fixed at these discrete locations, and wherein the assembly station 30 is further adapted to provide and handle the fourth and fifth layers. 26. Systeem volgens conclusie 24, waarin het assemblagestation is ingericht voor het verschaffen van een deelsamenstel omvattende de gestapelde eerste, tweede, derde en vierde lagen, en waarin de voorverwarmingsmodule is ingericht voor het voorverwarmen van het deelsamenstel op discrete locaties zodanig dat ten minste de eerste en tweede lagen op deze discrete locaties worden gefixeerd, en waarin het assemblagestation verder is ingericht voor het verschaffen en hanteren van de vijfde laag.The system of claim 24, wherein the assembly station is adapted to provide a subassembly comprising the stacked first, second, third and fourth layers, and wherein the preheating module is adapted to preheat the subassembly at discrete locations such that at least the first and second layers are fixed at these discrete locations, and wherein the assembly station is further adapted to provide and handle the fifth layer. 27. Systeem volgens conclusie 24, 25 of 26, waarin de hanteringsapparatuur is 5 ingericht voor het ondersteboven keren van het gefixeerde deelsamenstel.27. System as claimed in claim 24, 25 or 26, wherein the handling equipment is adapted to turn the fixed sub-assembly upside down. 28. Systeem volgens conclusie 24, 25 of 26, waarin de hanteringsapparatuur is ingericht voor het ondersteboven keren van de gestapelde eerste tot en met vijfde lagen, zodanig, dat de vijfde laag een bodemlaag van de stapel vormt.A system according to claim 24, 25 or 26, wherein the handling equipment is adapted to turn the stacked first to fifth layers upside down, such that the fifth layer forms a bottom layer of the stack. 29. Systeem volgens conclusie 24, 25, 26, 27 of 28, waarin de 10 voorverwarmingsmodule een veelheid elektromagnetische energiebronnen omvat voor het verschaffen van elektromagnetische straling voor absorptie door een veelheid PV-cellen.29. System as claimed in claim 24, 25, 26, 27 or 28, wherein the pre-heating module comprises a plurality of electromagnetic energy sources for providing electromagnetic radiation for absorption by a plurality of PV cells. 30. Systeem volgens conclusie 29, waarin de elektromagnetische energiebronnen zijn ingericht voor het produceren van elektromagnetische straling 15 omvattende een golflengte tussen 350 nm en 20.000 nm, meer bij voorkeur tussen 350 nm en 800 nm, of tussen 780 nm en 3000 nm of tussen 780 nm en 1500 nm.30. System as claimed in claim 29, wherein the electromagnetic energy sources are adapted to produce electromagnetic radiation comprising a wavelength between 350 nm and 20,000 nm, more preferably between 350 nm and 800 nm, or between 780 nm and 3000 nm or between 780 nm and 1500 nm. 31. Systeem volgens conclusie 24, 25, 26, 27, 28, 29 of 30, waarin de voorverwarmingsmodule een veelheid elektromagnetische inductie-energiebronnen omvat voor het verschaffen van elektromagnetische inductie-energie voor absorptie door een 20 veelheid PV-cellen.31. A system according to claim 24, 25, 26, 27, 28, 29 or 30, wherein the preheating module comprises a plurality of electromagnetic induction energy sources for providing electromagnetic induction energy for absorption by a plurality of PV cells. 32. Systeem volgens conclusie 31, waarin de elektromagnetische energiebronnen een veelheid elektrisch bekrachtigde inductiespoelen omvatten.The system of claim 31, wherein the electromagnetic energy sources comprise a plurality of electrically powered induction coils. 33. Systeem volgens conclusie 24, 25, 26, 27, 28, 29, 30, 31 of 32 waarin de voorverwarmingsmodule een veelheid thermische energiebronnen omvat voor het 25 verschaffen van thermische energie op een veelheid discrete locaties van het deelsamenstel tegenover de licht-ontvangende voorzijde van de PV-cellen.33. A system according to claim 24, 25, 26, 27, 28, 29, 30, 31 or 32 wherein the preheating module comprises a plurality of thermal energy sources for providing thermal energy at a plurality of discrete locations of the subassembly opposite the light-receiving front of the PV cells. 34. Systeem volgens conclusie 24, 25, 26, 27, 28, 29, 30, 31, 32 of 33, omvattende een veelheid stations, waarin elk station is ingericht voor het afzonderlijk uitvoeren van een deel van de hantering van het assemblagestation.The system of claim 24, 25, 26, 27, 28, 29, 30, 31, 32 or 33, comprising a plurality of stations, wherein each station is adapted to separately perform part of the handling of the assembly station. 35. Fotovoltaïsche (“Photovoltaic”), PV, module vervaardigd in overeenstemming met een werkwijze volgens een van de conclusies 1-17.A photovoltaic ("Photovoltaic"), PV, module made in accordance with a method according to any of claims 1-17.
NL2007935A 2011-12-08 2011-12-08 A method of and a system for assembling a photovoltaic module, a sub-assembly for use in this method, and an assembled photovoltaic module. NL2007935C2 (en)

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PCT/NL2012/050860 WO2013085387A2 (en) 2011-12-08 2012-12-07 A method of and a system for assembling a photovoltaic module, a sub-assembly for use in this method, and an assembled photovoltaic module

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ITTV20130192A1 (en) * 2013-11-21 2015-05-22 Vismunda Srl "AUTOMATIC PLANT AND MANUFACTURING PROCEDURE OF A CONDUCTIVE BACKSHEET WITH AN INCAPSULATING LAYER AND INTEGRATED DIELECTRIC, FOR PHOTOVOLTAIC PANELS"
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