TW201543707A - 太陽能板模組及其製造方法 - Google Patents

太陽能板模組及其製造方法 Download PDF

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TW201543707A
TW201543707A TW104109142A TW104109142A TW201543707A TW 201543707 A TW201543707 A TW 201543707A TW 104109142 A TW104109142 A TW 104109142A TW 104109142 A TW104109142 A TW 104109142A TW 201543707 A TW201543707 A TW 201543707A
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solar panel
solar
wiring
solar panels
cover plate
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TW104109142A
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TWI612684B (zh
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Ting-Hui Huang
Chen-Nan Chou
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Hulk Energy Technology Co Ltd
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Priority to TW104109142A priority Critical patent/TWI612684B/zh
Priority to EP15165204.7A priority patent/EP3073636A3/en
Priority to CN201510242432.8A priority patent/CN106206820A/zh
Priority to US14/711,826 priority patent/US20160284903A1/en
Publication of TW201543707A publication Critical patent/TW201543707A/zh
Priority to US15/397,731 priority patent/US20170117420A1/en
Priority to US15/397,735 priority patent/US20170117427A1/en
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Publication of TWI612684B publication Critical patent/TWI612684B/zh

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Abstract

提供一種太陽能板模組，其具有複數片彼此相鄰設置的複數片太陽能板。每一片該太陽能板之一側設有一正極配線而相對的另一側設有一負極配線。相鄰之兩片該太陽能板的毗鄰電極配線係皆為正極配線或皆為負極配線。

Description

太陽能板模組及其製造方法
本發明係關於太陽能板模組及其製造方法。
  太陽能電池的研究正如火如荼地進行。如何提高光電轉換層之轉換效率以及太陽能板模組的發電效率一直是熱門的題目，由此可知，業界需要一種改良式的高效率太陽能板模組。
 本發明之目的在於提供一種高效率太陽能板模組的製造方法，其包含下列步驟。提供複數片太陽能板。於每一片該太陽能板之正面的相對兩側形成正面正極配線與正面負極配線並將該正面正極配線與該正面負極配線反折至每一片該太陽能板的背面成為背面正極配線與背面負極配線。將該複數片太陽能板平放至一背板與一蓋板之間並層壓貼合該複數片太陽能板、該背板與該蓋板，其中相鄰之兩片該太陽能板的毗鄰正面電極配線皆為正面正極配線或皆為正面負極配線。
 本發明亦提供一種高效率太陽能板模組，其包含彼此相鄰設置的複數片太陽能板，每一片該太陽能板之一側設有一正極配線而相對的另一側設有一負極配線。相鄰之兩片該太陽能板的毗鄰電極配線係皆為正極配線或皆為負極配線。
 本發明亦提供一種太陽能板模組，其包含一蓋板、一背板、至少一太陽能板、第一封裝材、第二封裝材及第一防水膠材。第一封裝材位於該太陽能板與該背板之間。該第二封裝材位於該太陽能板與該蓋板之間。該第一防水膠材位於該蓋板與該背板延伸突出該太陽能板之外環區域中，位於該蓋板與該背板之間接觸該太陽能板的側邊。
1‧‧‧圖案化之光電轉換層
2‧‧‧圖案化之上電極
3‧‧‧分隔間隙
4‧‧‧圖案化之透明上電極
5‧‧‧選擇性之圖案化緩衝層
6‧‧‧分隔間隙
100‧‧‧太陽能板
100’‧‧‧太陽能板
101‧‧‧正面
102‧‧‧背面
103‧‧‧背玻璃
111a‧‧‧正面負極配線
111a’‧‧‧正面負極配線
112a‧‧‧背面負極配線
112a’‧‧‧背面負極配線
115‧‧‧負極配線
121b‧‧‧正面正極配線
121b’‧‧‧正面正極配線
122b‧‧‧背面正極配線
122b’‧‧‧背面正極配線
125‧‧‧正極配線
130‧‧‧背板
135‧‧‧第一封裝材
140‧‧‧蓋板
145‧‧‧第二封裝材
150‧‧‧接線盒
160‧‧‧外框
161‧‧‧第三封裝材
165‧‧‧第一防水膠材
1000‧‧‧太陽能板模組
1100‧‧‧太陽能板模組
d‧‧‧距離
圖1-5顯示根據本發明一實施例之太陽能板模組的製造方法。
圖6顯示根據本發明另一實施例之太陽能板模組。
圖7顯示根據本發明之太陽能板模組的概略橫剖面圖。
圖8顯示根據本發明之太陽能板模組的封裝材與防水膠材的概略橫
 下面將詳細地說明本發明的較佳實施例，舉凡本文中所述的元件、元件子部、結構、材料、配置等皆可不依說明的順序或所屬的實施例而任意搭配成新的實施例，此些實施例當屬本發明之範疇。
 本發明的實施例及圖示眾多，為了避免混淆，類似的元件係以相同或相似的標號示之；為避免畫面過度複雜及混亂，重覆的元件僅標示一處，他處則以此類推。
 現參考圖1-5及7-8，圖1-5顯示根據本發明一實施例之太陽能板模組的製造方法，圖7顯示根據本發明之太陽能板模組的概略橫剖面圖，圖8顯示根據本發明之太陽能板模組的封裝材與防水膠材的概略橫剖面放大圖。首先，準備複數片如圖1所示之太陽能板100。每一片太陽能板100具有一正面101與一背面102並包含複數以串聯方式彼此連接的太陽能單元(solar cell unit) 10a、10b及10，其中10a與10b代表位於太陽能板100兩端的單元而10代表位於其間的單元。接著參考圖2，太陽能板100較佳地呈矩形故具有長邊與短邊，在太陽能板100之正面101的兩側長邊處設置正面正極配線121b與正面負極配線111a，並將正面正極配線121b與正面負極配線111a反折至太陽能板100之背面102成為背面正極配線122b與背面負極配線112a。在本發明之大部分圖示中，背面正極配線122b與背面負極配線112a係以虛線呈現，以與正面配線有所區別。正面正極配線121b係作為太陽能板100的正極，正面負極配線111a係作為太陽能板100的負極。配線例如可由銅箔(Copper foil)或銅帶(Copper ribbon)構成，亦可由其他金屬或合金線材構成。
 如圖7所示，每一片太陽能板100由下至上具有由背玻璃103、圖案化之下電極層2、圖案化之光電轉換層1、選擇性的圖案化緩衝層5及圖案化之透明上電極層4所構成的圖案化疊層結構。圖7的重點在於表達太陽能板100的細部結構以及其與背板130、蓋板140之間的相對關係，故圖7省略了膠材如封裝材與防水膠材等，上述膠材的說明請參考圖8。下電極層與透明上電極層係用以傳輸由光電轉換層所產生的電流。光電轉換層係用以吸收穿透過透明上電極層與選擇性之緩衝層的光並將其轉換為電流，光電轉換層可包含由銅 (Cu)、銦 (In)、鎵 (Ga)與硒(Se)所構成的半導體材料，或可包含由Ib族元素如銅(Cu)或銀(Ag)、IIIb族元素如鋁(Al)、鎵(Ga)或銦(In)與VIb元素如硫(S)、硒(Se)或碲(Te)所構成的化合物半導體材料。透明上電極層例如是氧化銦錫(ITO)及/或氧化鋅層(ZnO)，下電極層例如是鉬(Mo)。
 背玻璃103為整塊未圖案化的絕緣結構，圖案化之下電極2係形成於其上。圖案化之下電極2彼此之間具有分隔間隙3，分隔間隙3中可填有樹脂或其他絕緣材料以電隔絕不同的下電極2。圖案化之下電極2上形成有相同圖案之圖案化的光電轉換層1與選擇性的圖案化緩衝層5，一圖案化之下電極2係用以串聯電連接相鄰的兩太陽能單元(solar cell unit)10與10或10與10a或10與10b。一圖案化之下電極2亦用以電連接一太陽能單元10a(10b)與一電極配線111a(121b)。在一太陽能單元10(10a/10b)中，相鄰之圖案化的光電轉換層1與選擇性的圖案化緩衝層5之間具有一間隙(不具標號)被形成於上的圖案化上電極4填滿，使上電極4與下電極2電連接(在此例中為實體接觸)；在相鄰的兩太陽能單元(solar cell unit)10與10或10與10a或10與10b之間，為相鄰之圖案化的上電極4、圖案化的光電轉換層1與選擇性的圖案化緩衝層5之間的分隔間隙6，分隔間隙6在後續製程中會被樹脂或其他絕緣材料填滿。在每一太陽能單元10(10a與10b)中，當光穿透圖案化之上電極層4與選擇性緩衝層5而到達圖案化之光電轉換層1時，在圖案化之光電轉換層1中產生電動勢，造成例如自圖案化之上電極層4流向圖案化之下電極2的電流(如圖7之虛線箭頭所示)；在整個太陽能板100中，電流係自正面負極配線111a經由圖案化之下電極2、圖案化之上電極4、圖案化之光電轉換層1.....流至正面正極配線121b。電子的方向係與電流方向相反。應注意，在圖7及本案的其他圖示中元件並未依比例繪製。又，在實際之一橫剖面中應無法同時見到正極配線121b、正面負極配線111a與背面正極配線122b、背面負極配線112a實體相連，但圖7為了表達上述者的電連接關係，特以實體相連方式呈現之。
 接著參考圖3與圖8，將複數片太陽能板100(100’)平放至一背板130上，背板130例如是如圖8所示之軟質背板或硬質背板且背板130的尺寸應足夠大以致於其長度能延伸超過末端兩太陽能板100(100’)且其寬度略大於一太陽能板100(100’)的寬度。軟質背板可以是高張力之塑膠薄片例如聚乙烯(Polyethylene, PE)薄片、聚醯胺(Polyamide, PA)薄片、聚對苯二甲酸乙二酯(Polyethylene terephthalate, PET)薄片、或上述者之組合；硬質背板可以是物理強化玻璃(Tempered glass)、化學強化玻璃(Chemically strengthened glass)或高分子樹脂。背板亦可為上述之組合附加鋁箔之薄板。圖3中僅顯示3片太陽能板，但應瞭解，本發明可應用至更多片太陽能板的情況，較佳地，本發明將大於3片的太陽能板100(100’)平放至一背板130上。太陽能板100’與100之結構相同(太陽能單元相同，但為了簡化版面並未標示；配線相同，故標號方式類似)，其相異之處在於配置的位向左右相反，因此細節不再贅述。根據本發明之太陽能板模組的製造方法，在配置複數片太陽能板100(100’)之相對位置時應注意，相鄰之兩太陽能板100與100’的毗鄰電極必須為電性相同的電極，即一太陽能板100之正極與其一側之另一太陽能100’的正極毗鄰而該太陽能板100的負極與其另一側之另一太陽能板100’的負極毗鄰。當極性相異且距離過近時容易產生漏電現象，然而，本發明之相鄰之兩太陽能板100與100’的毗鄰電極為電性相同的電極(皆為正極或皆為負極)，故可將相鄰之兩太陽能板之毗鄰正面配線之間的距離d縮短至2 mm或更短，較佳地，相鄰之兩太陽能板之毗鄰正面配線之間的距離d係不大於5 mm且不小於1 mm。是以，本發明之太陽能板模組在相同的面積下可配置較多之太陽能板，從而單位面積能產出較高之電力。在確認複數片太陽能板100(100’)在背板130上的配置位置與彼此的相對位置後，如圖8所示將第一封裝材135設置於複數片太陽能板100(100’)與背板130之間。背板130在對應至每一片太陽能板100(100’)之中央區域處(或其他區域處)有至少一個孔洞(未圖示)，使每一片太陽能板100(100’)之背面的背面正極配線122b (122b’)與背面負極配線112a (112a’)自第一封裝材135與此至少一個孔洞(未圖示)穿出以向外連接並彼此連接。該第一封裝材例如是熱封裝膠材(thermal encapsulant)如乙烯醋酸乙烯酯(Ethylene Vinyl Acetate，EVA)、聚烯烴(polyolefin, PO)、聚乙烯醇縮丁醛(polyvinyl butyral , PVB)等、或UV固化膠材(UV curable encapsulant)、或上述者的組合。
 接著參考圖4與圖8。將一蓋板140覆於該複數片太陽能板100(100’)上，並如圖8所示於該複數片太陽能板100(100’)與該蓋板140之間設置第二封裝材145。蓋板140例如是不可撓之玻璃板且蓋板140的尺寸應等於或略小於背板130的尺寸。該第二封裝材145的材質類似於第一封裝材135，兩者的材質可相同或相異。以上述之狀態，利用真空層壓(laminate)法將蓋板140、第二封裝材145、太陽能板100(100’)、第一封裝材135與背板130貼合固著。由於蓋板140與背板130的尺寸足夠大以致於兩者的長度能延伸超過末端兩太陽能板100(100’)且其寬度略大於一太陽能板100(100’)的長度，因此在蓋板140與背板130延伸突出太陽能板100(100’)的外環區域(如後續將述之外框的形狀)中及/或蓋板140與背板130之間無太陽能板100/100’的間隙區域中，可在蓋板140與背板130之間設置第一防水膠材165如熱塑性聚烯烴(thermalplastic polyolefin, TPO)或丁基膠(butyl rubber)接觸太陽能板100(100’)之側邊，以保護太陽能板100’(100)以及其配線不受水氣、機械力的影響。亦即，太陽能板100/100’ 四面八方皆可受到封裝材(第一封裝材135與第二封裝材145)與第一防水膠材165之包覆，避免太陽能板100或100’中的光電換轉層1受到水氣影響而質變退化。
 然後，如圖5所示並參考圖7與圖8，在背板130的背面安裝至少一接線盒150。接線盒150可設置在背板130的背側中央區域中即其中一片太陽能板100/100’的背側，亦可設置在背板130的背側其他區域如圖7所示之最末端之太陽能板100/100’的背側。或者，接線盒150可設置在背板130之背側任何區域。如圖7所示，使太陽能板100(100’)自背板130之至少一孔洞(未圖示)穿出的背面正極配線122b (122b’)與接線盒150的正極電連接，使太陽能板100(100’)自背板130之孔洞(未圖示)穿出的背面負極配線112a (112a’)與接線盒150的負極電連接，並利用配線如每一片太陽能板100(100’)之背面正極與負極配線或額外的配線並聯連接所有的太陽能板100及100’。最後，取決於蓋板140與背板130的尺寸(在圖5之例示中蓋板140之尺寸係略小於背板130之尺寸，但在圖7的例示中蓋板140之尺寸係等於背板130之尺寸)，如圖7與圖8所示在蓋板140或蓋板140與背板130的外圍設置外框160並在外框160與蓋板140或蓋板140與背板130之間設置具有防水性的第三封裝材161。以上步驟大致上完成本發明之可撓式太陽能板模組1000之製造。第三封裝材161例如是壓克力膠帶。接線盒150更可包含一對外的正極配線與一對外的負極配線(未圖示)以使太陽能板模組1000對外電連接。在背板130的背面處可選擇性地設置另一層防水膠材如熱塑性聚烯烴等，以保護接線盒150與背板130背面的配線不受水氣、機械力的影響。
 應瞭解，各個圖示中的強調重點不同，因此各個部件並未依比例繪製。例如，圖8強調在使用可撓式背板130的情況下第一封裝材135、第二封裝材145及第一防水膠材165的分佈，是以，太陽能板100/100’縮小繪製而封裝材、膠材、太陽能板之間的間隙及背板與蓋板之間的距離差異誇大繪製。由於真空層壓時的真空吸附作用，背板130如為軟質背板在無太陽能板100/100’的區域處(如被邊框夾持的外環區域處及太陽能板之間的間隙區域處)會較靠近蓋板140但在有太陽能板100/100’的區域處會較遠離蓋板140。然而，背板130亦可以是硬質背板(圖8未示)，在此情況中背板130與蓋板140之間的距離會大致上維持固定。
 現參考圖6，其顯示根據本發明另一實施例之太陽能板模組1100。太陽能板模組1100的結構係類似於太陽能板模組1000的結構，兩者之差異在於背面正極配線122b(122b’)與背面負極配線112a(112a’)的配置以及背板130背面的正極配線與負極配線。在太陽能板模組1000中，背面正極配線122b(122b’)與背面負極配線112a(112a’)皆由太陽能板100(100’)之長邊的同一端拉出；但太陽能板模組1100中，背面正極配線122b(122b’)與背面負極配線112a(112a’)分別由太陽能板100(100’)之長邊的相對兩端拉出。在太陽能板模組1100中，背板130的背面設有橫跨所有太陽能板100(100’)的正極配線125與負極配線115，正極配線125與接線盒150的正極以及所有太陽能板100(100’)的背面正極配線122b(122b’)連接，負極配線115與接線盒的負極以及所有太陽能100(100’)的背面負極配線112a(112a’)連接。
 圖1-5之實施例皆以太陽能板100與太陽能板100’交錯配置為例說明，但應瞭解，本發明之毗鄰電極為相同電性之電極的概念可應用至其他情境如圖6所示之情境或者所有太陽能板皆為相同位向之太陽能板100的情境。又，圖1-6之實施例皆以太陽能板並聯連接之模組為例說明，但應瞭解，本發明之毗鄰電極為相同電性之電極的概念可應用至太陽能板串聯連接之模組的情境。本發明之相鄰之兩太陽能板的毗鄰電極為電性相同的電極，故可將相鄰之兩太陽能板之間的電極距離縮短至2 mm或更短，以在相同的面積下配置較多之太陽能板，從而提高單位面積產出之電力。圖7之太陽能板的細部結構及圖8之封裝材與膠材配置可適用於圖1-5之實施例及圖1-6之實施例，除此之外，圖8之封裝材與膠材配置亦適用於僅具有單片太陽能板100或100’之太陽能板模組。
 雖然本發明已以較佳實施例揭露如上，然其並非用以限定本發明，任何熟習此技藝者，在不脫離本發明之精神和範圍內，當可作些許之更動與潤飾，因此本發明之保護範圍當視後附之申請專利範圍所界定者為準。
 
100‧‧‧太陽能板
100’‧‧‧太陽能板
111a‧‧‧正面負極配線
111a’‧‧‧正面負極配線
112a‧‧‧背面負極配線
112a’‧‧‧背面負極配線
121b‧‧‧正面正極配線
121b’‧‧‧正面正極配線
122b‧‧‧背面正極配線
122b’‧‧‧背面正極配線
130‧‧‧背板
140‧‧‧蓋板
d‧‧‧距離

Claims (20)

  1. 【第1項】
    一種太陽能板模組，包含：
    彼此相鄰設置的複數片太陽能板，每一片該太陽能板之一側設有一正極配線而相對的另一側設有一負極配線，
    其中相鄰之兩片該太陽能板的毗鄰電極配線係皆為正極配線或皆為負極配線。
  2. 【第2項】
    如申請專利範圍第1項之太陽能板模組，其中每一片該太陽能板包含一背玻璃以及設置於其上之圖案化的光電轉換層。
  3. 【第3項】
    如申請專利範圍第1項之太陽能板模組，其中每一片該太陽能板的該正極配線與該負極配線係位於該太陽能板的正面，且係反折至每一片該太陽能板的背面成為背面正極配線與背面負極配線。
  4. 【第4項】
    如申請專利範圍第3項之太陽能板模組，更包含：
    一蓋板，位於該複數片太陽能板之上方；及
    一背板，位於該複數片太陽能板之下方，
    其中該蓋板、該複數片太陽能板與該背板係層壓貼合。
  5. 【第5項】
    如申請專利範圍第4項之太陽能板模組，更包含：
    第一封裝材，位於該複數片太陽能板與該背板之間；及
    第二封裝材，位於該複數片太陽能板與該蓋板之間，
    其中該第一封裝材或該第二封裝材為乙烯醋酸乙烯酯、聚烯烴、聚乙烯醇縮丁醛或UV固化膠材或上述者的組合。
  6. 【第6項】
    如申請專利範圍第4項之太陽能板模組，其中該背板與該蓋板的尺寸使得兩者的長度係延伸超過該複數片太陽能板之最末端的太陽能板且兩者的寬度係略大於該每一片太陽能板的長度，該太陽能板模組更包含：
    第一防水膠材，位於該蓋板與該背板延伸突出該複數太陽能板之外環區域中，位於該蓋板與該背板之間接觸該複數片太陽能板的側邊。
  7. 【第7項】
    如申請專利範圍第1項之太陽能板模組，其中相鄰之該兩片太陽能板的該毗鄰電極配線之間的距離係不大於5 mm。
  8. 【第8項】
    如申請專利範圍第1項之太陽能板模組，其中相鄰之該兩片太陽能板的該毗鄰電極配線之間的距離係不小於1 mm。
  9. 【第9項】
    一種太陽能板模組的製造方法，包含：
    提供複數片太陽能板；
    於每一片該太陽能板之正面的相對兩側形成正面正極配線與正面負極配線並將該正面正極配線與該正面負極配線反折至每一片該太陽能板的背面成為背面正極配線與背面負極配線；
    將該複數片太陽能板平放至一背板與一蓋板之間並層壓貼合該複數片太陽能板、該背板與該蓋板，其中相鄰之兩片該太陽能板的毗鄰正面電極配線皆為正面正極配線或皆為正面負極配線。
  10. 【第10項】
    如申請專利範圍第9項之太陽能板模組的製造方法，該背板具有複數孔洞，該製造方法更包含：
    設置一接線盒對應至該複數片太陽能板並使每一片該太陽能板之該背面正極配線與該背面負極配線自該複數孔洞之至少一者穿出而與該接線盒電連接。
  11. 【第11項】
    如申請專利範圍第9項之太陽能板模組的製造方法，更包含：
    於該複數片太陽能板與該背板之間設置第一封裝材；及
    於該複數片太陽能板與該蓋板之間設置第二封裝材，
    其中該第一封裝材與該第二封裝材為乙烯醋酸乙烯酯、聚烯烴、聚乙烯醇縮丁醛或UV固化膠材或上述者的組合。。
  12. 【第12項】
    如申請專利範圍第9項之太陽能板模組的製造方法，其中相鄰之兩片該太陽能板的該毗鄰正面電極配線之間的距離係不大於5 mm。
  13. 【第13項】
    如申請專利範圍第9項之太陽能板模組的製造方法，其中相鄰之兩片該太陽能板的該毗鄰正面電極配線之間的距離係不小於1 mm。
  14. 【第14項】
    如申請專利範圍第9項之太陽能板模組的製造方法，更包含：
    於該蓋板與該背板延伸突出該複數太陽能板之外環區域中設置第一防水膠材，該第一防水膠材位於該蓋板與該背板之間接觸該複數片太陽能板的側邊。
  15. 【第15項】
    如申請專利範圍第14項之太陽能板模組的製造方法，更包含：
    於該蓋板與該背板之外緣設置外框並於該外框與該蓋板之間、該外框與該背板之間及該外框與該第一防水膠材之間設置第三封裝材。
  16. 【第16項】
    一種太陽能板模組，包含：
    一蓋板；
    一背板；
    至少一片太陽能板，位於該蓋板與該背板之間，該蓋板與該背板延伸突出該至少一片太陽能板；
    第一封裝材，位於該至少一片太陽能板與該背板之間；
    第二封裝材，位於該至少一片太陽能板與該蓋板之間；及
    第一防水膠材，位於該蓋板與該背板延伸突出該至少一片太陽能板的外環區域中，位於該蓋板與該背板之間接觸該至少一片太陽能板的側邊。
  17. 【第17項】
    如申請專利範圍第16項之太陽能板模組，更包含：
    一外框，位該蓋板與該背板之外緣；及
    第三封裝材，位於該外框與該蓋板之間、該外框與該背板之間及該外框與該第一防水膠材之間。
  18. 【第18項】
    如申請專利範圍第16項之太陽能板模組，該第一封裝材或該第二封裝材為乙烯醋酸乙烯酯、聚烯烴、聚乙烯醇縮丁醛或UV固化膠材或上述者的組合。
  19. 【第19項】
    如申請專利範圍第16項之太陽能板模組，該第一防水膠材為熱塑性聚烯烴或丁基膠。
  20. 【第20項】
    如申請專利範圍第17項之太陽能板模組，該第三封裝材為壓克力膠帶。
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