TW201543704A - Solar panel and method for manufacturing the same, and wall covering element including the solar panel - Google Patents

Abstract

A solar panel includes a front cover layer, a plurality of solar cells and a back-sheet layer. The plurality of solar cells is arranged between the front cover layer and the back sheet. The back-sheet layer is created from a plated honeycomb panel that includes a honeycomb plate. The honeycomb plate is arranged in between two plates of composite material. In an embodiment, the composite plate material is a reinforced plastic.

Description

Solar panel and method of manufacturing the same

The invention is related to solar panels. Furthermore, the invention is directed to a method of making such a solar panel.

In general, commercially available solar panel modules include a carrier frame and a plurality of solar cells supported by a carrier frame.

Within this framework, the solar cell is sandwiched between the front side carrier and the back side carrier. The front side carrier is provided as a light receiving surface and is therefore made of a transparent material. The solar cell is connected to a junction box. The junction box can be connected to an external energy carrier, such as an electric grid, via an adjustment unit.

The front side carrier is typically a glass or foil layer that acts as a protective layer over the light receiving surface of the solar cell.

The back side carrier is typically made of a plastic sheet or plastic layer.

In the so-called H-cells (ie with front and rear side electrical contacts) In the example of a solar cell, the solar cell is connected by a tab to form an electronic network. The electronic network is connected to a junction box.

In the case of a back-contact solar cell, all electrical contacts of the solar cell are available on the rear side of the solar cell, and the external electrical connection for the solar cell is made into the rear side carrier, and the rear side carrier is generally A carrier is provided having a contact foil comprising a conductive network pattern that is coupled to the contacts of the solar cell to transfer electrical energy from the solar cell to the junction box. The conductive network pattern is disposed on the rear side carrier.

Under such a structure, the frame and the glass layer provide mechanical rigidity and strength because the material of the rear side carrier has a relatively low rigidity. In addition, for glass front side carriers, the stiffness of the frame should also be such as to prevent external forces from being applied to the relatively fragile battery layer.

In particular, the glass layer and, to a lesser extent, the frame account for the relatively high weight of the solar panel. The weight of the solar panel limits the use of such solar panels.

First, the maximum weight of a PV (photovoltaic panel) installer on the roof without the use of a crane limits the size of the solar panel module. Second, the weight of the photovoltaic panel module limits the use of the photovoltaic panel on the roof of many of the complete photovoltaic panel systems that cannot carry multiple solar panel modules.

It is known from WO2012148279 to use a thin glazing as a front side carrier in a standard module. The relatively thin thickness of the glass layer reduces the weight of the solar panel module, but at the same time reduces the mechanical strength. The strength of the solar panel module is improved by the support structure that is bonded to the backsheet of the solar panel module.

Due to the nature of the backsheet material, it is often difficult to bond on the backsheet. of. Furthermore, as described in the patent WO2012148279, the support structure on the rear side only partially supports the module. Therefore, in order to obtain sufficient strength, the support structure still needs to be fairly extended, which may greatly offset the weight that the solar panel module intends to reduce. In addition, the application of prior art support structures to the sun block module requires adjustment of the manufacturing process and additional steps.

Further from CN202839683U, it is known that a solar panel has a glass-like front side and comprises a rear side support plate composed of an aluminum-coated honeycomb carrier.

However, the solar panel module of CN202839683U has some disadvantages, which reduces its usability.

First, because aluminum is a conductor, prior art solar panel modules require an insulating layer to be disposed on the surface of the back side plate to avoid any short circuit or leakage from the conductive network pattern. In addition, the coefficient of thermal expansion of aluminum is substantially different from the coefficient of thermal expansion of other layers in the module. Thermal stresses are thus created in the layered solar panel structure during manufacture, which can result in warping, cracking, and/or interlayer peeling of the battery.

In addition, the use of metal back supports may result in poor electrostatic charging of the module.

It is an object of the present invention to overcome or alleviate the disadvantages of one or more of the prior art.

This subject is achieved by a solar panel as defined in claim 1 of the scope of the patent application.

The plated honeycomb panel composed of such a composite plate-plated plastic honeycomb provides a rear side carrier having a relatively high rigidity. Composite board configuration It is to strengthen the strength of the hive. The solar panels are self-supporting without the need for a (metal) frame, which reduces the weight of the solar panel structure. In addition, the mechanical properties of the plated honeycomb panels reduce the need for a strong front side glass layer.

In addition, since the composite sheet material is used as a partial rear side carrier, the difference in thermal expansion coefficient between the rear side carrier and other components of the solar panel is reduced. Therefore, the risk of thermal stress in the solar panel and damage to the solar cell can be greatly reduced.

According to an aspect of the invention, there is provided a solar panel as described above, wherein the honeycomb panel is composed of hollow cells arranged adjacent to each other, the longitudinal axis of the hollow unit being oriented substantially perpendicular to the surface of the honeycomb panel .

According to an aspect of the invention, there is provided a solar panel as described above, wherein the composite panel comprises a reinforced plastic.

According to an aspect of the invention, there is provided a solar panel as described above, wherein the solar cell is of a type of H-type battery, the solar cell is internally connected by a tab, and the tab is embedded in the encapsulation layer, in the solar cell and the back sheet Between and between the solar cell and the front cover layer.

According to an aspect of the invention, there is provided a solar panel as described above, wherein the solar cell is a back contact type battery, and the solar panel comprises a back sheet layer provided with a conductive pattern, and a back sheet contact of each solar cell is provided by The conductor is connected to the conductive pattern; the back sheet layer having the conductive pattern is disposed between the back side of the encapsulation layer and the surface of the plated honeycomb panel, and the conductor extends through the opening in the encapsulation layer.

According to an aspect of the invention, there is provided a solar panel as described above, wherein said back contact type battery is selected from the group consisting of: "emitter wrap through (EWT)", "metal wrap through (MWT)" "," interdigitated back A group of types of interdigitated back-contact (IBC).

According to an aspect of the invention, there is provided a solar panel as described above, wherein the front cover layer is selected from the group consisting of a glass layer, a plastic layer or a plastic foil.

According to an aspect of the invention, there is provided a solar panel as described above, wherein the glass layer has a thickness of at most 2 mm.

According to an aspect of the invention, there is provided a solar panel as described above, wherein the encapsulating layer is selected from the group consisting of ethyl-vinyl-acetate, polyvinylbutryal and poly-olefine. One of the groups.

According to an aspect of the invention, a solar panel as described above is provided, wherein the solar panel is self-carrying.

According to an aspect of the invention, there is provided a solar panel as described above, wherein the solar panel is frameless.

The invention also relates to a wall covering element comprising a solar panel as described above.

The present invention also relates to a method of manufacturing a solar panel as described above, according to item 13 of the patent application or according to item 14 of the patent application. According to an aspect of the invention, there is provided a method as described above, further comprising: a fin for internally connecting the solar cell, wherein the solar cell is an H-type battery, during which a plurality of solar cells are disposed on the encapsulation layer.

According to an aspect of the invention, there is provided a solar panel as described above, wherein the solar cell is a back contact type battery, and the method further comprises: providing a plated honeycomb panel; an adhesive layer is disposed on a surface of the honeycomb panel; and the adhesive layer is disposed on the adhesive layer Configuring a back sheet layer provided with a conductive pattern; Configuring a conductive adhesive on the contact of the conductive pattern; arranging the encapsulation layer having an opening at a position corresponding to the contact of the conductive pattern; arranging a back contact unit having a contact disposed on the conductive adhesive; at the top of the unit A second encapsulation layer is disposed thereon; a front cover layer is configured, and the solar panel stack is exposed to elevated temperatures.

The adhesive layer between the plated honeycomb panel and the backsheet layer may also be the same as the packaging material adjacent to the unit.

According to an aspect of the invention, there is provided a solar panel as described above, wherein the solar cell is a back contact type battery, the method further comprising: providing a plated honeycomb panel provided with a conductive pattern; and disposing a conductive adhesive on the contact of the conductive pattern Configuring an encapsulation layer having an opening at a position corresponding to a contact of the conductive pattern; configuring a back contact unit having a contact disposed on the conductive adhesive; disposing the second package on the top of the unit; and configuring the front cover The layer; and exposing the solar panel stack to elevated temperatures.

The preferred embodiment is further defined by the scope of the appended claims.

10, 20, 30‧‧‧ solar panels

11‧‧‧Tag

11a‧‧‧ rear tab element

11b‧‧‧ front tab element

12‧‧‧ front cover

13‧‧‧ front encapsulation layer

14‧‧‧H type battery

15‧‧‧Encapsulation layer

16, 17, 18‧‧‧ boards

17a‧‧‧External surface

19‧‧‧ honeycomb board

21‧‧‧Solar battery

22‧‧‧ Back sheet

23‧‧‧Adhesive layer

24‧‧‧Connecting parts

25‧‧‧ openings

G‧‧‧ gap

The invention is explained in more detail below with reference to the drawings showing embodiments of the invention.

FIG. 1 illustrates a solar panel in accordance with an embodiment of the invention.

2 illustrates the fineness of the plated honeycomb panel for the rear side support of the solar panel Sectional view.

3 is a cross-sectional view of a solar panel in accordance with an embodiment of the invention.

4 is a cross-sectional view of a solar panel in accordance with an embodiment of the invention.

In the drawings, entities having the same reference symbols indicate corresponding entities.

1 is a cross-sectional view of a solar panel in accordance with an embodiment of the invention.

The solar panel 10 is provided with a so-called H-type battery 14 having a front contact and a back contact. As is known in the art, H-cells 14 are typically connected in series with one another by tabs 11 that extend between the back contact of an H-cell and the front junction of an adjacent H-cell.

The solar panel 10 includes a front cover layer 12, a front encapsulation layer 13 and a rear encapsulation layer 15, an H-type battery 14, and a plated honeycomb panel 16 as a rear side carrier.

On the plated honeycomb panel, multiple layers are stacked in order. A rear encapsulation layer 15 is disposed on the front side of the plated honeycomb panel. A solar cell of the H-type battery type is disposed on the rear package layer.

Further, the rear encapsulation layer covers the rear tab element 11a of the tab 11, and the rear tab element is connected to a back contact (not shown) of the H-type solar cell.

The front encapsulation layer 13 is disposed on the top of the H-type solar cell. The front encapsulation layer covers both the solar cell and the front tab elements 11b of the tabs 11.

Between the solar cells, the rear encapsulation layer and the front encapsulation layer are in contact with each other to fill the gap G between adjacent H-type solar cells.

The front cover layer 12 is disposed on the top of the front encapsulation layer, and the front cover layer 12 may be glass The glass layer is either a transparent plastic layer or a plastic foil.

It will be appreciated that due to the relatively high stiffness/mechanical strength of the plated honeycomb panel 16, the structure of the solar panel is strengthened and the need for the mechanical strength of the front cover layer 12 can be reduced. Thus, the thickness of the glass layer can be reduced (eg, reduced to a thickness of 2 mm or less) compared to standard photovoltaic panel modules. In addition, the glass layer can be replaced with a plastic layer or foil. Both measures are beneficial to further reduce the weight of the panel.

In one embodiment, the present invention provides that due to the relatively high stiffness of the plated honeycomb panel 16, there is no need for frame support and/or surrounding the perimeter of the solar panel to enhance the solar panel, but it may be used as a matter of course. Coupling elements for coupling adjacent solar panels.

Furthermore, the composite of the coated honeycomb panels provides an improvement in electrical isolation under high pressure conditions compared to prior art solar panels of CN202839683U.

In addition, due to the thermal properties of the composite material of the honeycomb panel 16, the solar panel according to the present invention can be used as a wall covering with improved thermal insulation.

As illustrated in detail in FIG. 2, the plated honeycomb panel 16 includes a front panel 17, a back panel 18, and an intermediate honeycomb panel 19. The front panel 17 covers a surface of the intermediate honeycomb panel 19, and the back panel 18 covers the opposite surfaces. The honeycomb panel 19 is composed of hollow cells arranged in a close packed order. The walls of the unit generally extend in the normal direction of the plated honeycomb panel 16.

The unit of the middle honeycomb panel 19 is made of a plastic material. Honeycomb materials generally consist of hollow cells arranged in a closely packed sequence. For example, each unit can have a tubular or hexagonal shape.

The middle honeycomb panel 19 is laminated between the front panel 17 and the back panel 18, and is composed of a composite material, fiber reinforced plastic (based on plastic and fiber materials).

The fibrous material can be a fiberglass material or a carbon fiber material.

Such plated honeycomb panels 16 have a relatively low weight due to the use of low weight plastic and fibrous materials. Since the reinforced plastic is used in the front and back panels, the panels 17 and 18 are provided as rigid structural members having relatively high mechanical strength and thermal expansion coefficient compared to other components in the solar module. Thus, the structure of the plated honeycomb panel 16 provides a strong and lightweight support to the solar panel.

In an embodiment, the outer surface 17A of the front panel 17 of the plated honeycomb panel is provided with a structure for improving the adhesion of the back encapsulation layer to the front panel 17 of the honeycomb panel 16.

In one embodiment, at least the plastic of the front panel 17 is selected from a plastic compatible with the back encapsulating layer material to improve adhesion. Alternatively, the outer surface 17A of the front panel 17 can be treated with an surfactant or reagent to improve adhesion between the front and back encapsulation layers.

3 illustrates a solar panel cross section in accordance with an embodiment of the invention. In one embodiment, the solar cells disposed in the solar panel 20 are selected from the group consisting of "Emitter Wrap Through" (EWT), "Metal Wrap Through (MWT), and "Intersection" Back-contact type solar cells of the type of Interdigitated Back Contact (IBC) or other "Back Contact (BC) solar cells.

These types of solar cells require a backsheet provided with a conductive contact pattern between the rear side of the solar cell and the front side panel 17 of the plated honeycomb panel 16.

In the cross-sectional view of FIG. 3, the solar panel 20 includes a front cover layer 12, a front encapsulation layer 13 and a rear encapsulation layer 15, a back contact solar cell 21, and a conductive pattern. The backsheet 22, the adhesive layer 23, and the plated honeycomb panel 16 as the backside carrier.

The adhesive layer 23 is disposed on the front side panel of the honeycomb panel 16 . Next, on the top of the adhesive layer 23 is a back sheet layer 22 provided with a conductive pattern. There is a connector 24 on the conductive pattern that provides an electrical contact to the back contact area of the back contact solar cell 21. The connector 24 extends through a partial opening 25 in the back side encapsulation layer 15 that is disposed on top of the backsheet layer 22 to prevent shorting between the back side of the solar cell and the backsheet layer 22.

The back contact solar cell 21 is embedded between the front encapsulation layer 13 and the rear encapsulation layer 15, and the gap G between the adjacent solar cells 21 is filled by the encapsulation layer, and the front cover layer 12 is disposed on the top of the front encapsulation layer 13.

In the cross-sectional view of Fig. 3, only the connecting member 24 between the back contact region of the solar cell and the back sheet provided with the conductive pattern is shown very schematically. It will be understood by those skilled in the art that the connector 24 includes both negative polarity and positive polarity connected to different portions of the conductive pattern.

In one embodiment, the front and rear panels 17 and 18 of the plated honeycomb panel 16 are comprised of a reinforced plastic or composite material comprising a plastic matrix material embedded with a fibrous material.

4 is a cross-sectional view of a solar panel in accordance with an embodiment of the invention.

Similar to FIG. 3, the solar cells disposed in the solar panel 30 are selected from the group consisting of "emitter wound perforations" (EWT), "metal wound perforations" (MWT), "interdigitated back contact" (IBC), or the like. Back contact (BC) solar cell type back contact solar cells.

In the cross-sectional view of FIG. 4, the solar panel 30 includes a front cover layer 12, a front encapsulation layer 13 and a back encapsulation layer 15, a back contact solar cell 21, a conductive pattern 26, and a plated honeycomb panel 16 as a back side carrier.

The conductive pattern 26 is disposed on the front side plate of the honeycomb panel 16 facing the back contact solar cell. There is a connector 24 on the conductive pattern 26 that provides an electrical contact to the back contact area of the back contact solar cell 21. The connector 24 extends through a partial opening 25 in the back side encapsulation layer 15 that is disposed between the back side of the solar cell and the conductive pattern 26.

The back contact solar cell 21 is embedded between the front encapsulation layer 13 and the rear encapsulation layer 15. The gap G between adjacent solar cells 21 is filled by the encapsulation layer. A front cover layer 12 is disposed on the top of the front encapsulation layer 13.

In an alternative to the embodiment illustrated in FIG. 3 or FIG. 4, the conductive contact pattern is disposed on the front side of the solar panel, wherein the conductive contact pattern is disposed between the front cover layer 12 and the layer holding the solar cell. The layer holding the conductive contact pattern is transparent.

In one embodiment, the solar panel is constructed by a method that begins with a plated honeycomb panel. Such a method of forming a solar panel stack includes a sequence of providing a plated honeycomb panel; arranging a first encapsulation layer on a surface of the honeycomb panel; arranging a plurality of solar cells on the encapsulation layer; and configuring the plurality of solar cells a second encapsulation layer; a front cover layer disposed on the second encapsulation layer, and exposing the solar panel stack to elevated temperatures.

Depending on the type of solar cell used and/or the configuration of the conductive connections between the solar cells and/or the configuration of the connections between the solar cells and external terminals (such as junction boxes), intermediate steps may be performed at certain stages of the process.

Moreover, those skilled in the art will appreciate that, alternatively, the method of constructing a solar panel can begin with a front cover layer that includes a sequence: Providing a front cover layer; arranging an encapsulation layer on the top of the front cover layer; arranging a plurality of solar cells on the encapsulation layer; arranging a second encapsulation layer on the plurality of solar cells; and arranging the plated honeycomb panel on the second encapsulation layer And exposing the solar panel stack to elevated temperatures.

The invention has been described with reference to the preferred embodiments. Upon reading and understanding the foregoing embodiments, those skilled in the art will be able to devise obvious modifications and alternatives. The invention is intended to be construed as embracing all such modifications and alternatives in the scope of the appended claims.

12‧‧‧ front cover

13‧‧‧ front encapsulation layer

15‧‧‧Encapsulation layer

16, 17, 18‧‧‧ boards

19‧‧‧ honeycomb board

20‧‧‧Sun Panel

21‧‧‧Solar battery

22‧‧‧ Back sheet

23‧‧‧Adhesive layer

24‧‧‧Connecting parts

25‧‧‧ openings

G‧‧‧ gap

Claims (16)

A solar panel comprising: a front cover layer; a plurality of solar cells; and a back structure, the plurality of solar cells being disposed between the front cover layer and the back structure, the back structure being a plated honeycomb Formed by a panel, the plated honeycomb panel comprising a honeycomb panel disposed between two composite sheets, the plurality of solar cells being embedded in an encapsulation layer between the front cover layer and the back structure Wherein the solar cell is a back contact type battery, the back structure comprises a conductive layer provided with a pattern, and a back contact point on a rear side of each of the solar cells is connected to the pattern by a conductor, a conductive layer disposed on a surface of the composite sheet of the plated honeycomb panel facing the solar cell, and the conductor extends through the rear side of the solar cell and the conductive layer An opening in the encapsulation layer. The solar panel of claim 1, wherein the honeycomb panel is composed of hollow cells disposed adjacent to each other, the longitudinal axis of the hollow cell being oriented substantially perpendicular to the honeycomb panel surface. The solar panel of claim 1 or 2, wherein the composite panel comprises a reinforced plastic. The solar panel of claim 1, wherein the solar cell is of a H-type battery, the solar cell is internally connected by a tab, and the tab is embedded in the encapsulation layer. A tab is between the solar cell and the back structure and between the solar cell and the front cover layer. The solar panel of claim 1, wherein the solar cell is a back contact type battery, and the solar panel comprises a back provided with a conductive pattern a sheet contact layer, a back sheet contact of each of the solar cells is connected to the conductive pattern by the conductor, and the back layer having the conductive pattern is disposed on a rear side of the package layer and Between the surfaces of the plated honeycomb panels, and the conductors extend through openings in the encapsulation layer. The solar panel of claim 1, wherein the back contact type battery is selected from the group consisting of "emitter wrap through (EWT)" and "metal wrap through (MWT)". ", "group of interdigitated back-contact (IBC)". A solar panel according to any one of the preceding claims, wherein the front cover layer is selected from the group consisting of a glass layer, a plastic layer or a plastic foil. The solar panel of claim 7, wherein the glass layer has a thickness of 2 mm or less. The solar panel according to any one of the preceding claims, wherein the encapsulating layer is one selected from the group consisting of ethyl vinyl acetate, polyvinyl butyral, and polyolefin. A solar panel according to any of the preceding claims, wherein the solar panel is self-contained. The solar panel of claim 9 or 10, wherein the solar panel is frameless. A wall covering member comprising the solar panel according to any one of the preceding claims. A method of manufacturing a solar panel, wherein the solar panel is a solar panel according to any one of claims 1 to 12, the method of manufacturing a solar panel comprising: Forming a solar panel stack in sequence, comprising: providing the front cover layer; disposing an encapsulation layer on a top portion of the front cover layer; disposing a plurality of the solar cells on the encapsulation layer; and forming a plurality of the solar cells Configuring a second encapsulation layer on the second encapsulation layer, the plated honeycomb panel comprising the honeycomb panel disposed between two composite sheets; Exposing the solar panel stack to an elevated temperature; wherein the solar cell is the back contact type battery, the method of fabricating a solar panel further comprising configuring the second package on the plurality of solar cells Before the layer and before configuring the plated honeycomb panel on the second encapsulation layer, the opening is generated in the second encapsulation layer, the opening corresponding to a back contact point on the solar cell a position of the composite sheet of the plated honeycomb panel facing the second encapsulation layer is provided with the patterned conductive layer, the patterned conductive layer having a corresponding The opening Position of the pattern conductors on the solar cell element, wherein the said conductor elements on the back contact of the solar cell. A method of manufacturing a solar panel, wherein the solar panel is a solar panel according to any one of claims 1 to 12, wherein the method of manufacturing a solar panel comprises: sequentially forming a solar panel stack, comprising: Provided is a coated honeycomb panel comprising a honeycomb panel disposed between two composite panels, wherein the composite panel of the plated honeycomb panel is facing Providing a patterned conductive layer to a surface of the solar cell, the patterned conductive layer having a pattern corresponding to a position of a back contact on the solar cell; and configuring a first surface on the surface of the honeycomb panel An encapsulation layer; a plurality of solar cells disposed on the first encapsulation layer; a second encapsulation layer disposed on the plurality of solar cells; a front cover layer disposed on the second encapsulation layer; and the solar panel The stack is exposed to an elevated temperature; wherein the solar cell is a back contact type battery, and the method of manufacturing the solar panel further comprises: after configuring the first encapsulation layer on the plated honeycomb panel: An opening is created in the first encapsulation layer, the opening corresponding to a position of the back contact on the solar cell. The method for manufacturing a solar panel according to claim 13, further comprising: a period during which the plurality of solar cells are disposed on the encapsulation layer: a tab configured to internally connect the solar cells, The solar cell is an H-type battery. The method of manufacturing a solar panel according to claim 13, wherein the solar cell is a back contact type battery, and the method for manufacturing a solar panel further comprises: arranging the second on the plurality of solar cells After the encapsulation layer and before the plated honeycomb panel is disposed on the second encapsulation layer, the opening is generated in the second encapsulation layer, the opening corresponding to the back on the solar cell a position of the contact; a back contact layer disposed with a conductive pattern disposed on the second encapsulation layer, the conductive pattern corresponding to a position of the back contact, the back on the solar cell The contact layer at the location of the contact has the conductor element thereon, and an insulating layer is disposed on the back contact layer.