RU2663543C1 - Method for assembling solar modules a monolithic solar module from cells of photoelectric converters by using an adhesive layer - Google Patents

Abstract

FIELD: electrical engineering.SUBSTANCE: invention relates to photoelectric converters, in particular to the technology for assembling solar modules and switching cells of photoelectric converters. Present invention can be used for monolithic solar modules based on photoelectric converters, made of single-crystal silicon, polycrystalline silicon, photoelectric converters, manufactured by heterostructural technology. Method comprises preparing a carrier with an adhesive layer. First cell with a pre-laid output bus is laid. Conductive adhesive is applied to the output bus or to the corresponding side of the cell or the first cell is laid in such a way that it protrudes beyond the carrier to allow subsequent switching. Conductive adhesive is applied to the following cells, by analogy with the first cell, wherein the frontal contact pad contacts the rear contact pad of the previous cell. Adhesive is applied to the rear contact pad of the last cell, and a second output bus is installed. Remaining strings are assembled by analogy. Received strings are commuted and encapsulated in modules. Rear cell is laid so as to provide the possibility of subsequent commutation. Front or rear glass or external polymeric carriers are used as a carrier. Laminate is used as an adhesive layer. Hotmelt adhesives, photopolymer adhesives, epoxy resins, TPO, EVA, silicones are used as an adhesive base.EFFECT: use of the claimed invention provides increased reliability and strength of assembling monolithic strings, improved reliability of half-assembly, reduced likelihood of damage to strings of photoelectric converters during assembly, as well as increased yield of suitable modules for monolithic assembly technology by reducing the rejection during assembly of strings of photoelectric converters.9 cl, 5 dwg, 4 ex

Description

FIELD OF THE INVENTION

The invention relates to photovoltaic converters, in particular to a technology for assembling solar modules and switching cells of photovoltaic converters. This invention can be used for the assembly of monolithic solar modules based on photovoltaic cells made of single-crystal silicon, polycrystalline silicon, photovoltaic cells made by heterostructure technology.

State of the art

The prior art method for connecting photovoltaic cells (US 2012/0125391 A1, 05.24.2012). The known method includes gluing two or more solar cells, wherein at least one solar cell has a contact formed on a first surface that is electrically connected to a conductive terminal of the solar cell, and the base of the second cell is physically and electrically connected to the contact. An insulator is placed between the substrate of the second cell and the first cell, which prevents a short circuit between them.

A highly efficient solar cell circuit design is also known in the art (US 2014/0124014 A1, 05/08/2014). The circuit design of solar cells consists of series-connected solar cells located on a substrate with overlapping ends of adjacent solar cells. Metallization models of the front and rear surfaces can provide a further increase in efficiency.

High-performance solar panel is known from the prior art (US 2015/0090314 A1, 04/02/2015). One embodiment of the present invention provides a solar panel. A solar panel includes many subsets of solar cells. Solar cells in a subset are connected in series, and subsets of solar cells are connected in parallel. The number of solar cells in the corresponding subset is large enough, so that the output voltage of the solar panel essentially coincides with the output voltage of a conventional solar panel with all its pseudo-square solar cells connected in series.

All of the above modules have the disadvantage that the cells of the photovoltaic cells are very fragile, and it is easy to damage them during the assembly of solar modules. In this regard, it is difficult to work with assemblies from cells (strings). Also, during the assembly process, until the conductive adhesive hardens, the cells can shift, which can lead to the complete unsuitability of the final assembly. All this greatly reduces the yield of products.

Also known from the prior art is a method for manufacturing solar cell modules with electrodes with low resistivity (US 2015/0270410 A1, 09.24.2015). One embodiment of the present invention provides a solar module. The solar module includes a front cover, a back cover and a plurality of solar cells located between the front and rear side covers. The corresponding solar cell includes a multilayer semiconductor structure, an electrode on the front side located above the multilayer semiconductor structure, and a rear electrode located below the multilayer semiconductor structure. Each of the front and rear electrodes contains a metal mesh. The corresponding metal grid contains many lines of fingers and one bus connected to the lines of the fingers. A single busbar is configured to collect current from the finger lines.

The use of electrodes reduces the effective area of the final modules, because they obscure part of the cells and are not hidden by neighboring cells. In the case of overlapping, they have the drawbacks given above.

SUMMARY OF THE INVENTION

The problem solved by the claimed invention is to ensure the assembly of the solar module using a monolithic technology, to enable the assembly of photomultiplier cells into modules, to ensure the formation of monolithic strings of photomultiplier cells of increased strength on a carrier.

The technical result of the claimed invention is to increase the reliability and durability of the assembly of monolithic strings, to increase the reliability of semi-assembly, to reduce the likelihood of damage to the FEC string during assembly, as well as to increase the yield of suitable modules using the monolithic assembly technology by reducing the reject during assembly of the FEC string.

The claimed technical result is achieved due to the fact that the method of assembling a monolithic solar module from cells of photovoltaic cells on the adhesive layer, comprising the steps of: preparing a carrier with an adhesive layer, laying the first cell with a pre-laid output bus, while applying conductive glue or the output bus or on the corresponding side of the cell, or the first cell is laid in such a way that it extends beyond the media, for the possibility of subsequent switching; conductive glue is applied to all subsequent cells by analogy with the first cell, while the front contact pad is contacted to the rear contact pad of the previous cell, glue is applied to the rear contact pad of the last cell and the second output bus is installed, and the remaining strings are assembled by analogy, In this case, the obtained thongs are switched and encapsulated in modules, while either frontal or back glass or third-party polymer carriers are used as a carrier, and as MDL laminate layer is used, and as the adhesive base used hotmelts, adhesives photopolymer, epoxy resin, TPO, EVA, silicones.

In the particular case of the implementation of the claimed technical solution, the carrier with the adhesive layer is preheated at the preparation stage, the output bus is laid, conductive glue is applied to the contact pad of the cell, the cell is contacted to the bus, the adhesive is applied to the next cell, contact is made the front contact pad to the back contact pad of the previous cell, glue is applied to the back contact pad of the last cell and a second lead is installed th tire assembly similar to produce the remaining strings, the second layer stacked SRW back sheet is output contact rails and conduct lamination process.

In the particular case of the implementation of the claimed technical solution, a layer of a one-component or two-component silicone-based laminate in liquid form is applied to the carrier, which is used as the front glass of the solar module, the output bus is laid, the conductive bus is placed on the contact pad of the cell located on the front of the cell glue, after which the cell is contacted to the tire, glue is applied similarly to the next cell, contact is made by the front contact pad glue is applied to the back contact pad of the previous cell, glue is applied to the back contact pad of the last cell, the remaining strings are assembled in the same way, the second layer of liquid laminate is filled in, the back encapsulating element is laid, contact tires are removed and the lamination process is carried out.

In the particular case of the implementation of the claimed technical solution, the adhesive layer is separately applied to the laminate.

In the particular case of the implementation of the claimed technical solution, as the adhesive layer, an adhesive layer is used on a plastic carrier on which thongs are pre-assembled, followed by lamination.

In the particular case of the implementation of the claimed technical solution in the manufacture of a solar module using technology with a frontal emitter, the stacked output bus is in contact with the p-side of the cell, in the case of the rear emitter - the n-side.

In the particular case of the implementation of the claimed technical solution, a thin adhesive layer is applied to the carrier made in the form of a polymeric material, the lead-out tire is laid, conductive adhesive is applied to the contact pad of the cell located on the front side of the cell, the cell is contacted to the bus, the adhesive is applied similarly to the next cell, while contacting is performed by the front contact pad to the back contact pad of the previous cell, the cells are applied to the back contact pad of the last cell first and second lead-establish tire assembly similar produce other strings, with the resulting assembly is encapsulated by the standard technology for solar modules between two sheets of laminate and the encapsulating member.

In the particular case of the implementation of the claimed technical solution, a laminate based on silicone and a classic laminate heated to a softening or melting point are used as a laminate used as an adhesive layer, while a silicone-based laminate is applied in bulk.

In the particular case of the implementation of the claimed technical solution, a thin adhesive layer is applied to the carrier made in the form of a polymeric material, the first cell is laid in such a way that the contact area of the cell extends beyond the medium, conductive adhesive is applied to the contact area of the cell located on the front side of the cell , after which the cell is contacted to the first cell, glue is similarly applied to the next cell, while the contact is made with the front contact pad to the rear second contact pad of the previous cell, form a string of received cells is similar to assemble the rest of the strings, and the resulting string commute and encapsulated by the standard technology for solar modules.

Brief Description of the Drawings

Details, features, and advantages of the present invention follow from the following description of embodiments of the claimed invention using the drawings, which show:

FIG. 1 is an assembly diagram of a Shingled module using an adhesive layer on a carrier, side view;

FIG. 2 is an assembly diagram of a Shingled module using an adhesive layer on a carrier. On the left is the option without a switching bus; on the right is the option with a switching bus;

FIG. 3 is a schematic diagram of an assembly of a Shingled module using an adhesive layer on a carrier with a switching bus. Side view;

FIG. 4 is a schematic illustration of a photomultiplier cell. Top / bottom view;

FIG. 5 - the appearance of the cell FEP. End view.

In the figures, the numbers indicate the following positions:

1 - cell FEP; 2 - electrical contact between cells; 3 - adhesive layer; 4 - carrier; 5 - output bus; 6 - contact area; 7 - contact grid elements; 8 - plate FEP;

Disclosure of invention

The essence of the technology lies in the fact that during the assembly of solar modules using monolithic technology, the assembly is carried out on a carrier coated with adhesive, while both glass and polymers can be used as a carrier. As the adhesive base can be used hot melt adhesives, photopolymer adhesives, epoxies, TPO, EVA, silicones.

Before assembly, glue is applied to the carrier and brought into an active state. For example, in the case of the use of hot-melt adhesives, TPO polyester elastomers, or a copolymer of ethylene and vinyl acetate EVA, the material is heated to the required temperature in order to exhibit adhesive properties.

The carrier can be either front or rear glass, or third-party polymer carriers such as polypropylene (PP), polyethylene (PE, PE-LD, PE-LLD, PE-HD, PE-UHMW), polyamide (PA) , polyimide (PI), polyvinyl terephthalate (PET), polyethylene naphthalate (PEN), plexiglass

As the laminate used as an adhesive layer, it can be either a silicone-based laminate (applied in bulk, since the silicone-based laminate is in a liquid state) and a classic laminate heated to a softening or melting point;

The adhesive layer can be separately applied to the laminate;

The adhesive layer may be on a plastic carrier, on which thongs are collected first, which are then laminated.

Stages of assembly technology: 1. Preparation of a carrier with an adhesive layer, namely: Cleaning and activation of the surface of the carrier, applying an adhesive layer, activating an adhesive layer (if necessary) (including if necessary, then warming up). This stage increases the adhesion of the adhesive layer to the carrier on which the assembly is carried out, and to the cells that are used for assembly, which subsequently increases the mechanical strength of the assembly .; 2. Before starting the installation of the cells, the output bus can be laid, if it is absent, then the first cell must protrude beyond the media to enable subsequent switching (figure 2, figure 3). This assembly feature is necessary for switching assembled strings together and pin output for subsequent connection of the module's contact box. 3. The laying of the first cell is carried out, in accordance with paragraph 3. In the event that the output bus has been laid, then conductive glue is applied to it or to the corresponding side of the cell (figure 3). This assembly feature is necessary for connecting the cells to each other in a single electrical circuit. 4. Conductive glue is applied to all subsequent cells by analogy with the first cell. This operation is repeated as many times as necessary depending on the size of the module. The module can be, for example, 1600 mm, then, with the size of the active region of the cell 16 mm, there will be 100 repetitions. The module can be made of any size. 5. In some cases, adhesive curing may be required. Depending on the selected adhesive, this can be cooling, exposure to ultraviolet light, exposure (if the adhesive does not require any exposure, but takes time to cure). This stage allows to achieve maximum strength characteristics of adhesives, which increases the strength of the assembly.

Example 1:

1. On the glass (carrier), which acts as the front glass of the solar module, lay a sheet of SRW. Then produce heating materials to a softening temperature.

2. The output bus is laid, to which the cells will be contacted by the front side. If the solar module is manufactured using technology with a frontal emitter, then the p-side of the cell will contact the stacked output bus, in the case of the rear emitter, the n-side.

3. A conductive adhesive is applied to the contact pad of the cell located on the front side of the cell, after which the cell is contacted to the bus.

4. Similarly apply glue to the next cell. Contacting is performed by the front contact pad to the rear contact pad of the previous cell. Point 4 repeats the necessary, depending on the size of the module, the number of times, for example, the size of the module can be as 1600 mm, then, with the size of the active area of the cell 16 mm, there will be 100 repetitions

5. On the back pad of the last cell, glue is applied and a second lead-out bus is installed.

6. Similarly, the assembly of the remaining strings

7. The second layer of SRW is laid on the back sheet, contact tires are removed and the lamination process is carried out.

Example 2:

1. On the glass (carrier), which acts as the front glass of the solar module, a layer of laminate is applied on a silicone base (in liquid form, one-component or two-component).

2. The output bus is laid, to which the cells will be contacted by the front side. If the solar module is manufactured using technology with a frontal emitter, then the p-side of the cell will contact the stacked output bus, in the case of the rear emitter, the n-side.

3. A conductive adhesive is applied to the contact pad of the cell located on the front side of the cell, after which the cell is contacted to the bus.

4. Similarly apply glue to the next cell. Contacting is performed by the front contact pad to the rear contact pad of the previous cell. Point 4 is repeated as many times as necessary.

5. On the back pad of the last cell, glue is applied and a second lead-out bus is installed.

6. Similarly, the assembly of the remaining strings

7. The second layer of the liquid laminate is poured, the back encapsulating element is laid, contact tires are withdrawn and the lamination process is carried out.

Example 3:

1. A thin adhesive layer is applied to the polymeric material (carrier).

2. The output bus is laid, to which the cells will be contacted by the front side. If the solar module is manufactured using technology with a frontal emitter, then the p-side of the cell will contact the stacked output bus, in the case of the rear emitter, the n-side.

3. A conductive adhesive is applied to the cell’s contact pad located on the front of the cell, after which the cell is contacted to the bus (Figure 2 right image).

4. Similarly apply glue to the next cell. Contacting is performed by the front contact pad to the rear contact pad of the previous cell. Point 4 is repeated as many times as necessary.

5. On the back pad of the last cell, glue is applied and a second lead-out bus is installed.

6. Similarly, the assembly of the remaining strings

7. The resulting assembly is encapsulated according to standard technology for solar modules between two sheets of laminate and encapsulating elements (front and rear glass, or front glass and back sheet, etc.)

Example 4:

1. A thin adhesive layer is applied to the polymeric material (carrier).

2. The laying of the first cell is performed in such a way that the contact area of the cell extends beyond the media (figure 2, left image)

3. On the contact pad of the cell located on the front side of the cell, a conductive adhesive is applied, after which the cell is contacted to the first cell (Figure 1).

4. Similarly apply glue to the next cell. Contacting is performed by the front contact pad to the rear contact pad of the previous cell. Point 4 is repeated as many times as necessary. As a result, a string of cells is formed.

5. Similarly produce the assembly of the remaining strings

6. The received thongs commute and encapsulate according to the standard technology for solar modules.

Claims (9)

1. A method of assembling a monolithic solar module from cells of photovoltaic cells on an adhesive layer, comprising the steps of: preparing a carrier with an adhesive layer, laying the first cell with a pre-laid lead-out busbar, applying conductive glue to either the lead-out bus or the corresponding side of the cell or the first cell is stacked in such a way that it extends beyond the media to enable subsequent switching; conductive glue is applied to all subsequent cells by analogy with the first cell, while the front contact pad is contacted to the rear contact pad of the previous cell, glue is applied to the rear contact pad of the last cell and the second output bus is installed and the remaining strings are assembled by analogy, while the obtained thongs are switched and encapsulated in modules, while either front or rear glass or third-party polymeric carriers are used as a carrier, and as eevogo laminate layer is used, and as the adhesive base used hotmelts, adhesives photopolymer, epoxy resin, TPO, EVA, silicones. 2. The method according to p. 1, characterized in that the carrier with the adhesive layer is preheated at the preparation stage, the output bus is laid, conductive glue is applied to the cell pad located on the front side of the cell, the cell is contacted to the bus, the glue is applied to the next cell, the front contact pad is contacted to the rear contact pad of the previous cell, glue is applied to the rear contact pad of the last cell and a second output bus is installed, similarly to they assemble the remaining strings, lay the second layer of SRW - the back sheet, remove the contact tires and carry out the lamination process. 3. The method according to p. 1, characterized in that the carrier, which is used as the front glass of the solar module, is applied a layer of one-component or two-component laminate on a silicone base in liquid form, the output bus is laid on the contact pad of the cell located on the front to the side of the cell, conductive adhesive is applied, after which the cell is contacted to the bus, the adhesive is applied to the next cell in the same way, the front contact pad is contacted to the back contact area Adhesive to the previous cell, glue is applied to the rear contact pad of the last cell and a second lead-out bus is installed, the remaining strings are assembled in the same way, the second layer of the liquid laminate is filled, the back encapsulating element is laid, the contact buses are removed and the lamination process is carried out. 4. The method according to p. 3, characterized in that the adhesive layer is separately applied to the laminate. 5. The method according to p. 3, characterized in that the adhesive layer is an adhesive layer on a plastic carrier on which thongs are pre-assembled, followed by lamination. 6. The method according to p. 3, characterized in that in the manufacture of the solar module according to the technology with a frontal emitter, the stacked output bus is in contact with the p-side of the cell, in the case of the rear emitter, with the n-side. 7. The method according to p. 1, characterized in that a thin adhesive layer is applied to the carrier made in the form of a polymeric material, the lead-out bus is laid, conductive adhesive is applied to the contact pad of the cell located on the front side of the cell, the cell is contacted to the bus, similarly, glue is applied to the next cell, while contacting is performed by the front contact pad to the back contact pad of the previous cell, glue is applied to the back contact pad of the last cell and a second the output bus, similarly, the rest of the strings are assembled, while the resulting assembly is encapsulated according to the standard technology for solar modules between two sheets of the laminate and the encapsulating elements. 8. The method according to p. 1, characterized in that as the laminate used as an adhesive layer, a silicone-based laminate is used, as well as a classic laminate heated to a softening or melting point, while the silicone-based laminate is applied in bulk . 9. The method according to p. 1, characterized in that a thin adhesive layer is applied to the carrier made in the form of a polymeric material, the first cell is laid in such a way that the contact area of the cell extends beyond the medium onto the contact area of the cell located on the front side cells, conductive glue is applied, after which the cell is contacted to the first cell, glue is similarly applied to the next cell, and the contact is made with the front contact pad to the back contact pad edyduschey cell string form of the obtained cells, similar to assemble the rest of the strings and the resulting string commute and encapsulated by the standard technology for solar modules.

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