TW200849632A - A method of producing solar modules by the roller laminate process - Google Patents

A method of producing solar modules by the roller laminate process Download PDF

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Publication number
TW200849632A
TW200849632A TW097103620A TW97103620A TW200849632A TW 200849632 A TW200849632 A TW 200849632A TW 097103620 A TW097103620 A TW 097103620A TW 97103620 A TW97103620 A TW 97103620A TW 200849632 A TW200849632 A TW 200849632A
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TW
Taiwan
Prior art keywords
solar photovoltaic
photovoltaic module
manufacturing
module according
film
Prior art date
Application number
TW097103620A
Other languages
English (en)
Other versions
TWI485874B (zh
Inventor
Andreas Karpinski
Bernhard Koll
Original Assignee
Kuraray Europe Gmbh
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Publication of TW200849632A publication Critical patent/TW200849632A/zh
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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
    • H01L31/18—Processes or apparatus specially adapted for the manufacture or treatment of these devices or of parts thereof
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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    • B29C65/00—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor
    • B29C65/48—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor using adhesives, i.e. using supplementary joining material; solvent bonding
    • B29C65/4805—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor using adhesives, i.e. using supplementary joining material; solvent bonding characterised by the type of adhesives
    • B29C65/481—Non-reactive adhesives, e.g. physically hardening adhesives
    • B29C65/4815—Hot melt adhesives, e.g. thermoplastic adhesives
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    • B29C65/48—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor using adhesives, i.e. using supplementary joining material; solvent bonding
    • B29C65/50—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor using adhesives, i.e. using supplementary joining material; solvent bonding using adhesive tape, e.g. thermoplastic tape; using threads or the like
    • B29C65/5057—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor using adhesives, i.e. using supplementary joining material; solvent bonding using adhesive tape, e.g. thermoplastic tape; using threads or the like positioned between the surfaces to be joined
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    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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    • B29C65/02—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure
    • B29C65/14—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure using wave energy, i.e. electromagnetic radiation, or particle radiation
    • B—PERFORMING OPERATIONS; TRANSPORTING
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    • B29C65/02—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure
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    • B29C65/02—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure
    • B29C65/14—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure using wave energy, i.e. electromagnetic radiation, or particle radiation
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    • Y02E10/50—Photovoltaic [PV] energy

Description

200849632 九、發明說明： 【發明所屬之技術領域】 本發明係關於藉由利用一聚乙烯基丁醛(PVB)基膜之輥層 壓製程製造薄膜太陽光電模組。 【先前技術】 .薄膜太陽光電模組通常係由光敏半導體膜（於下文中稱為 太陽能電池單元)所組成，其中該膜係如藉由蒸鐘、氣相沈 積、濺鍍或濕分離施用於主要透明板上並經提供以在必要 時以類似透明外蓋給予提供以防外部影響。該等太陽能電 池單元經常被層壓在一塊玻璃與如藉由視情況透明之黏著 劑的幫助由玻璃所製成之蓋板之間。該黏著劑必須完全密 封該等太陽能電池元件、係UV安定的並在該層壓製程後 完全無氣泡。 例如，如DE 41 22 721 C1或DE 41 28 766 A1中所揭示般， 硬化澆鑄樹脂或可交聯乙烯乙酸乙烯酯（EVA)基系統經常 用作透明黏著劑。這些黏著劑系統可經調整以未硬化狀態 具有可無氣泡地覆蓋該太陽能電池單元之低黏度。一旦加 入硬化劑或交聯劑，獲得一具機械抗性之黏著劑層。此類 太陽光電模組之缺點係其高製造成本；特別係在大尺寸表 面元件的情況下，將太陽能電池單元嵌入液態澆鑄樹脂及 其受控硬化係一不易監測之製程。而且，部分澆鑄樹脂在 5 200849632 數年後具有起泡或分層之傾向。 硬化黏著劑系統之替代方法係使用聚乙烯基丁醛(1^抝基 膜。在此情況下，太陽能電池單元係經一或多層PVB膜覆 盍且這些在高壓及高溫下與所需覆蓋材料組合以製造一層 壓板。藉由PVB膜的幫助製造太陽光電模組之方法係（例如) 由 DE 40 26 165 C2、DE 42 278 60 Al、DE 29 237 70 C2、 De 35 38 986 C2、DE 197 32 217、DE 40 26 165、US 6，160,215、WO 02/103809、US 6,660,556、US 2005/0115667 或US 4,321，418所揭示。在這些論文中係將PVB膜用於喪 入晶質太陽能電池單元中；但未曾描述薄膜太陽光電模組 之單層系統或適合用於這些模組之製造方法。 將PVB膜用於太陽光電模組中作為層壓玻璃係揭示(例如） 於 DE 20 302 045 Ul、EP 1617487 A1 及 DE 35 389 86 C2。 這些專利說明書同樣係關於將太陽能電池封裝於兩PVB膜 之間。 在薄膜太陽光電模組之情況下，將太陽能電池直接施用在 載體，如一塊玻璃或可撓曲聚合物或金屬載體上。視載體 之組態而定，封裝太陽能電池係不可能的。而且，薄膜太 陽光電模組可以任何尺寸且大量製成。製造具有太陽能電 池嵌在PVB膜間之太陽光電模組之已知方法無法十分自動 化地以工業規模製造具有薄膜太陽光電模組之層壓板。 6 200849632 再者，DE 35 38 986 C2及DE 42 27 860揭示藉由〆層壓製 程在較高溫度及壓力下製造太陽光電模組。將一對輥用於 此目的中係未曾描述過。 本發明目的因此係提供—種利用熱塑性中間膜製造薄膜太 陽光電模組之方法，其有助於連續及/或可自動化製造。 令人驚訝地發現一種利用一對輥之層壓製程亦適合用於層 壓機械上不適合的太陽能電池。 【發明内容】 本發明目的因此係一種製造一太陽光電模組之方法，其係 藉於50至150°C之溫度下，特別係於60至150°C下在至少 一對輥之間擠壓一層體而以至少一基於含塑化劑之聚乙烯 縮醛之中間膜層壓該層體，其中該層體係由施用至少一太 陽能電池單元之第一載體及第二載體所組成。 車父佳係將〇·5牛頓/毫米（N/mm)至100牛頓/亳米，特別係 !°牛頓/鼋米至50牛頓/毫米之線壓力施用於壓搾機處。線 壓力係指該對輥相對於該膜寬度之表面壓力。 7 200849632 移開上擠壓輥而降低至零。 而且，若該層體中有缺陷存在，如電接點或導體路徑，可 能必須降低該層體通過該輥壓榨機之傳送速率，因此線壓 力有較長時間可發揮作用。依此方式可達到較佳空氣去除 及缺陷對聚乙烯縮醛之黏性。 圖1顯示具有兩對輥之適合設備的概要設計圖。 根據本發明方法係利用一或多個，較佳係各由一對擠壓輥 所組成之兩個壓榨機進行。在此情沉下，該層體係在至少 一對輥之間以相同或不同線壓力並在相同或不同溫度下擠 壓。 此種設備已知係用於製造層壓玻璃且通常具有至少一個加 熱隧道以提高溫度或確保在具有兩個壓榨機之設備中第一 壓榨機前後之溫度固定。亦可想到加工應在具有至少一個 加熱隧道以提高或確保最後一個壓榨機下游之溫度固定的 設備或裝有超過兩個壓榨機並各具有加熱隧道上游之設備 中進行。
上述溫度至少與最後一對必須通過之輥前的層體有關。視 情沉可在最後一對輥之前插入額外對有或無加熱區上游之 輥，其中在此情況下，該層體可呈現上述溫度或亦低於50°C 8 200849632 或60°C之溫度。 根據本發明’該等層體係在撥壓前於加熱隨道中如利用 IR、微波照射或對流分別加熱至5(TC或60。(：至l5(rCi^ 度’較佳係分別為70°C和80°C至100。(：。該等層壓板之浪 度可如利用無接觸輪射南溫計測量。 ' 基於含塑化劑之聚乙烯縮醛之膜較佳係包含非交聯聚乙烤 基丁醛(PVB)，其係藉由丁醛縮醛化聚乙烯基醇所獲得。 同樣可使用交聯聚乙烯縮醛，特別係交聯聚乙烯基丁齡 (PVB)。適合的交聯聚乙烯縮醒:係（例如）描述於ΕΡ 1527107 Β1及WO 2004/063231 Α1(含羧基之聚乙烯縮醛之熱自交 聯）、ΕΡ 1606325 Α1(經聚酸交聯之聚乙烯縮駿）及w〇 03/020776 Al(經乙醛酸交聯之聚乙烯縮醛）。完全引用這些 專利申請案之揭示内容。
亦可以其他或額外醛，如彼等具有5-1〇個碳原子之醛，例 如戍酸進行縮酸化Q 為製造聚乙烯縮醛所需之聚乙烯基醇亦可為本發明架構内 由水解乙婦基乙酸醋/乙烯共聚物所製成之三聚物。這些化 合物通常係超過98%水解度並包含丨至1〇重量％乙烯基單 位（如獲自 Kururay Europe 之，’Exceval”型）。該縮醛 9 200849632 化可如用於聚乙烯基醇般進行。 婦縮Γ，特別係PVB之適合膜另外包含5“5 里05 重里〇/〇之聚乙烯縮齡、50-20重量％或50_15 尸二，，化劑及小量黏性調節劑、抗結塊劑及W安定 係㈣❹。祕層杉全賴之PVB =t ^及組成物係插述於(例如)EP 185譲、EP 1 118 258 B1 或 W〇 02/102591 A1 中。 =膜4♦财至少—者歸隔音特性。pvb基隔 述於如砂1 118 258的或迎387 148]51申，本 招祕凡王引用該揭不内容。根據dinenis〇717所量得， i"omiEPl U8 258 m之隔音膜增加層壓安全玻璃在範圍從 1_至3,5赃之符合頻率中的聲阻尼至少遞。
化㈣乙烯祕之膜的厚度較佳係约為這些膜之 業厚度，如0·38、0·51、^-⑸或U ^ =塑化劑聚乙烯縮齡之膜具有較佳係以Rz〉35微米且 R 彳政米，較佳係Rz>50微米且Rz<150微米，特佳係 蚴本说米且RZ<130微米’特別係Rz>90微米且Rz<130 "N粗k度知用於一侧或特佳係施用於兩侧之表面結 10 200849632 構。若表面粗糙度Rz低於35微米 ，在為使該物質流至該 導體路彳f «他配件附近所需之溫度下，該層壓板邊緣在 已^全擠出空氣之前過早密合。此結果係在層壓板中間產 生氣穴（氣泡）。若有過度表面粗糙度(Rz>l80微米）存在， 為溶钱粗链度波峰所需能量增加並使該製程變成無法接受 的長。 根據ΕΡ 0 185 863 B1，該膜之表面結構可藉由塑膠熔化物 自擠壓噴嘴出現之前立刻擠壓通過所謂流動或熔態破裂製 ^而製得。不同粗糙程度可藉由改變出口模間隙及就在喷 嘴出口處之喷嘴口溫度。此方法產生一不規則，幾乎係等 =粗链度。在此情況下，粗糙度測量實際上由所有方向所 里件係相等的’雖然個別高處及凹地的高度及分布係不規 則的。 f者’該膜表面結構可如根據EP 06112163或EP 06112159 藉由壓花施用。在此情況下，在該表面上產生一均勻粗糙 度/粗糙結構。 ，面板糙度Rz或粗糙值RZ係根據DIN EN ISO 4287所量 ^ °該等測量值指示係利用Mahr型S2粗糙度測量單元、 具有機械單階段按鈕MFW-250之進料裝置PGK所取得。 然種:在各情況下可使擠壓體暴露在較大或較低壓力及較高 200849632 溫度下。此可根據已知蒸壓、真空環或真空袋製程，如根 據 EP 1 235 683 B1 進行。 乂 在真空袋製程之情況下，將擠壓層體置於塑膠或橡膠袋 中。然後此經氣密封並具有真空閥，較佳係位於該塊中間。 涉及大尺寸體處，亦可提供兩個真空閥。利用真空泵，先 產生一 200毫巴以下之真空度並在室溫下進行抽真空至少 5分鐘。錄’在循環空氣箱中將夾層加熱至14代並 ΐ空门。在此期間加熱逮率為4至❿分鐘，視熱輸出量而 疋，因此在20至30分鐘狳、去 里而 將溫度降低至最低的。〇事1驗在去除真空之前’必需 與3〇〇亳巴之較低壓力及介貝上’令擠壓體暴露在介於0.01 ’丨於100與200°C間之溫度下。 或者，可使用蒸壓製程。 層壓玻璃之製程。其係在等熟諳此技者將熟悉這些製造 145。(：之溫度下進行1() 至15巴之較高壓力及130至 UQ分鐘。 根據本發明可使用之膜必須、 陽能電池單元及其電連接·、貝…、軋泡地覆蓋或密封太 能之整體厚度。為了達到’ ^時太陽光電模組需要最小可 件下，，產生，，太陽能電池單的。該物係適合在製造條 呈現特定流減力。 ·^其電連接，即在層壓條件下 .200849632 聚乙烯縮醛基膜黏接玻璃之能力可經由黏性調節劑如揭示 於WO 03/033583之有機酸之驗金屬及/或驗土‘二鹽的二 加而設定。已證實乙酸鉀及/或乙酸鎂係特别適合的了為了 獲得高黏性值，可能必碰賴而不添㈣^節劑如驗 金屬及/或驗土金屬鹽鹽。 根據本發明太陽光電模組之第一及/或第二载體可由玻 璃、塑膠或金屬或這些材料之層壓板所組成，其^該等載 體中至少一者必須係透明的。一或兩載體同樣可能呈層壓 玻璃（即由至少兩塊玻璃與至少一膜所製成之層屋板）^其 間具有氣體m絕緣玻璃形式。自然地，亦可組合這些
曰"斤不變化例中較佳係使用可撓曲载體T3 歹月b電池不必具有任何特殊特 無機或有機半導體系統施用於 太陽光電模組中所用之太陽能 性。可使用晶質或非晶質、無 13 200849632 第一載體中。為了供應一適當電壓，數個太陽能電 電互連。太陽能電池，在薄膜模型的情沉下亦稱為功萨 之厚度係至少〇·ι微米。太陽能電池之電連接所需之ϋ 路徑的厚度通常為>50微米。 ^體 代表太陽能 圖2顯示一太陽光電模組之概要設計，其中s 電池且Ρ代表導體路徑。 根據本發明所製成之太陽光電模組亦可用作表面元件、 面、溫室屋頂、隔音牆、陽台或攔杆元件或作為窗戶纟且件至 【實施方式】 實例 在根據圖1之設備中各情況下90°c之溫度（最後一個壞梅< 之後)及3S牛頓/¾米之線墨力下以3米/分鐘之線速度输严 一薄膜模組，其量得為L 30公分X B 20公分且具有〜 橐米之玻璃厚度及兩條各離邊緣20毫米且寬為2亳米及^ 為近250微米之縱向導體路徑。該層壓板之進行方向係= 選擇以致導體路徑離開模組之點係在背面且最後擠壓。= 糙度Rz為近1〇〇微米之Trosif〇i HR 100型膜(Kuraray Europe GmbH)係用作含塑化劑之聚乙烯縮醛膜。 該等壓榨機之線壓力係由該膜體之前1〇〇毫米及最後3〇毫 米降低至上輥之靜重。 14 200849632 獲得具有低混濁之無氣泡層壓板。 可在後續蒸壓製程中140°C及12巴下以30分鐘之保持時間 完全除去混濁。取代蒸壓製程，混濁亦可在真空製程中 145°C及150毫巴下以2小時之保持時間去除。 根據本發明方法因此係適合用於製造太陽光電模組；視情 況可藉由下游製程階段除去混濁。 【圖式簡單說明】 圖1顯示具有兩對輥之適合設備的概要設計圖。 圖2顯示一太陽光電模組之概要設計。 圖3顯示根據本發明所製成層壓板之概要設計 圖4顯示根據本發明所製成層壓板之概要設計 圖5顯示根據本發明所製成層壓板之概要設計 【主要元件符號說明】 P1 導體路徑 P2 導體路徑 S 太陽能電池 T1 載體材料 T3 載體材料 F 含塑化劑之聚乙烯縮醛膜或層 15 200849632 E 電接點 T2 載體材料 16

Claims (1)

  1. 200849632 十、申請專利範圍： 1· 一種製造一太陽光電模組之方法，其係藉於50至150°C 之溫度下在至少一對輥之間擠壓一層體以至少一基於含 塑化劑之聚乙烯縮醛之中間膜層壓該層體，其中該層體 係由施用至少一太陽能電池單元之第一載體及第二載體 所組成。 2,根據申請專利範圍第1項之製造一太陽光電模組之方 法，其特徵在於該等輥對間之擠壓係在0.5牛頓/毫米至 100牛頓/毫米之線壓力下進行。 3·根據申請專利範圍第1或2項中任一項之製造一太陽光 電模组之方法，其特徵在於該層體係在至少兩對輥之間 相同或不同線壓力及相同或不同溫度下擠壓。 4·根據申請專利範圍第1至3項中任一項之製造一太陽光 電模組之方法，其特徵在於該基於含塑化劑之聚乙烯縮 醛之膜一侧或兩侧上的粗糙值Rz係介於35微米與180 微米之間。 5·根據申請專利範圍第1至4項中任一項之製造一太陽光 電模組之方法，其特徵在於該基於含塑化劑之聚乙烯縮 醛之膜具有一規則粗糙結構。 17 200849632 6·根據申請專利範圍第1至4項中任一項之製造一太陽光 電模組之方法，其特徵在於該基於含塑化劑之聚乙烯縮 醛之膜具有一不規則粗糙結構。 7·根據申請專利範圍第1至6項中任一項之製造一太陽光 電模組之方法，其特徵在於該第一及/或第二載體係由玻 璃、塑膠、金屬或這些材料之層壓板、層壓玻璃及/或絕 緣玻璃所組成，前提係該等載體中至少一者係透明的。 8.根據申請專利範圍第1至7項中任一項之製造一太陽光 電模組之方法，其特徵在於令該擠壓體處於一較高或較 低壓力及一較高溫度下。 9·根據申請專利範圍第8項之製造一太陽光電模組之方 法，其特徵在於令該擠壓體暴露於一 0,01至300毫巴之 較低壓力及一 100至200°C之溫度下。 10·根據申請專利範圍第8項之製造一太陽光電模組之方 法，其特徵在於令該擠壓體暴露於一 7至15巴之較高壓 力及一 130至145°C之溫度下。 18
TW097103620A 2007-02-01 2008-01-31 以輥層壓製程製造太陽光電模組之方法 TWI485874B (zh)

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