TWI595677B - 防裂太陽能電池模組與其製造方法 - Google Patents

防裂太陽能電池模組與其製造方法 Download PDF

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TWI595677B
TWI595677B TW102142364A TW102142364A TWI595677B TW I595677 B TWI595677 B TW I595677B TW 102142364 A TW102142364 A TW 102142364A TW 102142364 A TW102142364 A TW 102142364A TW I595677 B TWI595677 B TW I595677B
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seal
cell module
polyolefin
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成德 金
尼可拉斯 伯納特
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太陽電子公司
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Description

防裂太陽能電池模組與其製造方法
文中所描述標的之實施例大體上係關於太陽能電池模組。更特定地，標的之實施例係關於太陽能電池模組結構與製造製程。
太陽能電池為用於轉換太陽輻射為電能之被廣泛知悉之裝置。太陽能電池有在正常運作期間面向太陽以收集太陽輻射之前側與相對於前側之背側。衝擊於太陽能電池上之太陽輻射創造可被用以產生能量給外在電路，如負載，之電荷。
太陽能電池可被串聯且被封裝在一起以形成太陽能電池模組。封裝提供對太陽能電池之環境保護。在於例如居家、商業結構或光伏打發電廠中之現場操作之前，太陽能電池可能在輸送、安裝或保養期間遭受粗糙的處置。本發明之實施例關於有防止裂痕產生於太陽能電池上之特徵之太陽能電池模組。
在一實施例中，防裂太陽能電池模組包含裝載於框架上之保護封裝。保護封裝包含保護性地密封太陽能電池之聚烯烴密封物。聚烯 烴於骨架或支鏈中具有少於5重量百分比之氧和氮。換句話說，在聚烯烴之分子結構之任何位置中，氧和氮之總和重量百分比皆少於5。聚烯烴同時具有在聚烯烴之任何熱處理(例如壓合)前，經動力學分析(DMA)測量，於攝氏90度下少於10000帕秒(Pa second)之複數黏度。保護封裝包含頂蓋、密封物與背板。太陽能電池模組允許以較少在太陽能電池之表面上產生裂痕之風險運送、安裝與保養。
本發明之此些與其他特徵經由閱讀包含所附圖式與發明專利申請範圍之整份揭露，將對技術領域中一般技術人員來說是清楚明顯的。
100、150‧‧‧太陽能電池模組
101、151-1、151-2、151-3、151-4‧‧‧太陽能電池
102‧‧‧框架
103‧‧‧前部
104‧‧‧背部
251‧‧‧透明頂蓋
252、252-1、252-2‧‧‧密封物
253‧‧‧背板
254‧‧‧連接器
301、302、303‧‧‧步驟
標的之更充分的了解可透過參閱詳細之描述與發明專利申請範圍結合下列圖式考量而推知，其中所有圖式中相似之圖式符號標示相似元件。圖式並不照比例繪製。
第1圖為顯示有蕨裂(fern cracks)之範例太陽能電池模組之部分之俯視示意圖。
第2圖為顯示根據本發明之實施例之太陽能電池模組之透視圖。
第3圖至第5圖為描繪根據本發明之實施例之製造太陽能電池模組之方法之剖面示意圖。
第6圖為顯示根據本發明之實施例之製造太陽能電池模組之方法之流程圖。
在此揭露中，提供許多具體細節，如部件、材料與方法之範例，以提供本發明之實施例之完全了解。然而，此領域之一般技術人員將認識到，本發明可無一或多個具體細節地實行。在其他例中，不顯示或描述眾所皆知之細節以避免模糊本發明之態樣。
第1圖為顯示有蕨裂之範例太陽能電池模組150之部分之俯視示意圖。太陽能電池模組150包含裝載於框架152上之複數個太陽能電池151(也就是說，151-1、151-2、151-3、151-4等等)。有許多太陽能電池151於太陽能電池模組150中，但為了說明之清楚性只顯示於左上角中的一些太陽能電池。
大體而言，太陽能電池從其來源，例如倉庫或工廠，被運送到將安裝並運作太陽能電池模組之工作地點。太陽能電池模組在運送期間被裝載或卸載時可能遭受粗糙的處置。在工作地點，太陽能電池模組於安裝前或安裝期間與保養期間可能遭受更粗糙的處置。舉例來說，在安裝前，太陽能電池模組可能被放在可能被安裝者或其他工人踩過之地板上。一些安裝者也可能忽略標準處理指示。
在第1圖之範例中，一些太陽能電池151有蕨裂152。蕨裂152可能透過粗糙的處置與在現場中反覆之機械壓力而造成。蕨裂152被如此命名係因為他們通常，並非必要，分叉並擴展於受損之太陽能電池151表面上。在第1圖之範例中，太陽能電池151-1、151-2與151-4(但沒有太陽能電池151-3)有蕨裂152。蕨裂152可引起熱太陽電池以及可導致功率損耗。
參閱第2圖，其顯示根據本發明之實施例之太陽能電池模組100之透視圖。太陽能電池100為所謂的「地面太陽能電池模組」其被設計用於固定應用，例如在屋頂上或透過光伏打發電廠。在第2圖之範例中，太陽能電池模組100包含連接器太陽能電池101之陣列。為了說明之清楚性，僅有一些太陽能電池101被標示於第2圖中。在第2圖之範例中，太陽能電池101包含背側接觸太陽能電池。在背側接觸太陽能電池中，所有擴散區域與結合於擴散區域之金屬接點形成於太陽能電池之背側上。也就是說，P型與N型擴散區兩者與結合於其之金屬接點在太陽能電池之背側上。在其他實施例中，太陽能電池101包含其中一個極性之擴散區(例如N型擴散區)於太陽能電池之前側，以及相對極性之擴散區(例如P型擴散區)於太陽能電池之背側之前接觸太陽能電池。
可見於第2圖中的為太陽能電池101之前側。太陽能電池101之前側也被稱為「太陽側」因為其於正常運作期間面向太陽。太陽能電池101之背側相對於前側。框架102提供機械支撐予太陽能電池101。太陽能電池模組100之前部103與太陽能電池101之前側於同側上並可見於第2圖中。太陽能電池模組100之背部104於前部103下。太陽能電池模組100之背部104與太陽能電池101之背側於同側上。
第3至5圖為描繪根據本發明之實施例之製造太陽能電池模組之方法之剖面示意圖。
第3圖為顯示根據本發明之實施例之太陽能電池模組100之部件之爆炸圖。太陽能電池模組可包含透明頂蓋251、密封物252之薄板、太陽能電池101、連接器254以及背板253。於前部103之密封物252之薄板被標記為「252-1」以及於後部104之密封物252之薄板被標記為「252-2」。透明頂蓋251與前側之密封物252-1用作為前側封裝部件， 以及背側之密封物252-2與背板253用作為背側封裝部件。在第3圖之範例中，透明頂蓋251為前側封裝部件之最外部以及背板253為背側封裝部件之最外部。
透明頂蓋251與密封物252包含光學透明材料。為前部103上之最頂層之透明頂蓋251，保護太陽能電池101免於環境之傷害。太陽能電池模組100安裝於現場中以致使於正常操作期間透明頂蓋251面向太陽。太陽能電池101之前側以透明頂蓋251之方式面向太陽。在第3圖之範例中，透明頂蓋251包含玻璃(例如3.2mm厚，鈉鈣玻璃)。
密封物252保護性地密封太陽能電池101。本發明者發現蕨裂與所使用密封物之種類之間有所關連。在材料層級，本發明者也發現密封物之黏性對於控制蕨裂程度或嚴重性上是關鍵的。需要處理這些在密封物之特性，而非太陽能電池本身中未被預期到之發現以減輕太陽能電池上之蕨裂。在本發明之實施例中，密封物252之特性被最佳化以減少太陽能電池101上蕨裂之發生。
在一實施例中，密封物252包含聚烯烴。適合的聚烯烴之範例包含聚乙烯、高密度聚乙烯、低密度聚乙烯、線性低密度聚乙烯以及聚丙烯。在一實施例中，為了提防蕨裂，密封物252包含於骨架或支鏈中具有少於5重量百分比之氧與氮之聚烯烴。換句話說，在聚烯烴之分子結構之任何位置中，氧和氮之總和重量百分比皆少於5。在一實施例中，聚烯烴進一步具有在堆疊或任何熱處理前，經動力學分析(DMA)測量，於攝氏90度少於10000Pa-s之複數黏度。密封物252之聚烯烴之體積電阻率經ASTM D257測試於1kV、10分鐘充電(electrification)與攝氏60度下測量，較佳地為至少1015Ohm-cm。如同眾所皆知的，ASTM D257為先前以美國材料和試驗協會(American Society of Testing and Materials)為 人所知悉之ASTM國際標準組織(ASTM International)制定之標準。
連接器254可包含用於電性地互連太陽能電池101之金屬。在第3圖之範例中，太陽能電池101包含串聯之背側接觸太陽能電池，以及連接器254電性地連結太陽能電池101之背側上之相對應之P型與N型擴散區。太陽能電池101也可包含串聯之前接觸太陽能電池，在此情況下，連接器254將連接於太陽能電池之後側與前側上之擴散區。
太陽能電池101之背側面向背板253。背板253可為對太陽能電池模組100之其他部件提供環境保護之任何材料之單層或多層。舉例來說，含氟聚合物(flouropolymer)、聚偏氟乙烯(polyvinylidene fluoride)、聚四氟乙烯(polytetrafluoroethylene)、聚丙烯(polypropylene)、聚苯硫(polyphenylene sulfide)、聚酯(polyester)、聚碳酸酯(polycarbonate)或聚伸苯醚(polyphenylene oxide)被使用為背板之單層或為多層之部分。背板253於背部104上。
在一實施例中，透明頂蓋251、於前側上之密封物252-1、透過連接器254電性地連結之太陽能電池101、於背側上之密封物252-2、以及背板253一同形成以創造保護封裝。前述部件依第3圖之堆疊順序形成在一起，繪示於第4圖中。更特定地，太陽能電池101安置於密封物252-1與252-2間，背板253安置於密封物252-2下，以及透明頂蓋251安置於密封物252-1上。剛剛提到之部件，舉例來說，透過真空壓合隨後被擠壓並加熱在一起。壓合製程一同融化密封物252-1之薄板與密封物252-2之薄板以密封太陽能電池101。在第4圖中，密封物252-1與密封物252-2簡單地被標示為「252」以指示其已被一同融化。
第5圖顯示裝載於框架102上之第4圖之保護封裝。被密封於密封物252中，太陽能電池101與框架102電性隔離。
討論於下之表1、2及3顯示以上揭露之密封物在防止蕨裂上之效用。
表1顯示各種聚烯烴密封物(樣本1、樣本2、樣本3與樣本4)於不同溫度下經動力學分析以1/s剪率測量之複數黏性。表1以帕秒顯示複數黏性。黏性於密封物之任何熱處理前測量，在此範例中是在壓合前。
如表1中所示，標示為「樣本3」與「樣本4」之聚烯烴密封物有於攝氏90度時少於10000Pa-s之複數黏性。樣本3與4有根據本發明之實施例之密封物之特性。標示為「樣本1」與「樣本2」之聚烯烴密封物有於攝氏90度時大於10000Pa-s之複數黏性，以及因此沒有防蕨裂之特性。
表2顯示當使用上面提到之聚烯烴密封物之樣本時於太陽能電池上產生蕨裂之相對可能性。更特定地，如表2中所提到的，本發明者實行之研究指出被樣本1密封之太陽能電池產生裂縫之可能性相較於被樣本3密封之太陽能電池為四倍。相似地，被樣本2密封之太陽能電池產生裂縫之可能性相較於被樣本3密封之太陽能電池為三倍。
表3顯示被樣本2、樣本3與樣本4密封之太陽能電池在一人踩上太陽能電池模組之壓力測試中之相對功率劣化。壓力測試模擬在現場中之安裝或清潔過程期間之踩踏。在第一次測試中，重85kg之人踩上所有太陽能電池之模組。在第二次測試中，重120kg之人踩上所有太陽能電池之模組。
如同表3中所示，被樣本2密封之太陽能電池展示遠高於被樣本3或樣本4其中之一密封之太陽能電池之功率劣化。當較重之人踏上太陽能電池模組時，太陽能電池相對功率劣化之差異上升。
第6圖顯示根據本發明之實施例之製造太陽能電池模組之方法之流程圖。第6圖之方法包含提供用於太陽能電池模組之密封物(步驟301)。在一實施例中，密封物包含聚烯烴，其於骨架或支鏈中具有少於5重量百分比之氧與氮，以及具有在壓合或任何熱處理前，經動力學分析測量，於攝氏90度少於10000帕秒之複數黏度。聚烯烴密封物經ASTM D257測試，於1kV、10分鐘充電與攝氏60度下測量，也可具有至少1015Ohm-cm之體積電阻率。
要被包含於太陽能電池模組中之太陽能電池被保護性地封裝於密封物中(步驟302)。在一實施例中，太陽能電池安置於密封物之薄板間(例如底板與頂板)，背板安置於密封物之底板下，以及透明頂蓋安置於密封物之頂板上。透明頂蓋、被密封物之薄板三明治夾層之太陽能電池與背板接著透過例如真空壓合擠壓並加熱在一起，舉例來說。所得之保護 封裝接著裝載於框架上(步驟303)。所製造之太陽能電池模組為防蕨裂，降低於運送、安裝與保養期間容納於其中之太陽能電池受損之機會。
已揭露防裂太陽能電池模組與其製造方法。雖然已提供本發明之特定實施例，其要被了解的是此些實施例僅用於說明之目的而非限制。許多其他之實施例對於閱讀本揭露之此領域中一般技術人員來說為顯而易見的。
100‧‧‧太陽能電池模組
101‧‧‧太陽能電池
102‧‧‧框架
103‧‧‧前部
104‧‧‧背部
251‧‧‧透明頂蓋
252‧‧‧密封物
253‧‧‧背板

Claims (18)

  1. 一種太陽能電池模組，其包含：複數個太陽能電池；一密封物，其密封該複數個太陽能電池，該密封物包含一聚烯烴，其於骨架(backbone)或支鏈中具有少於5重量百分比之氧與氮，該聚烯烴具有在該密封物之任何熱處理前，經動力學分析測量，於攝氏90度下少於10000Pa-s之複數黏度，其中該聚烯烴包含聚乙烯；一透明頂蓋，位於該太陽能電池模組之一前部上，該前部在正常運作期間面向太陽；以及一背板，位於該太陽能電池模組之一背部。
  2. 如申請專利範圍第1項所述之太陽能電池模組，其中該聚烯烴經ASTM D257測試於1kV、10分鐘充電(electrification)與攝氏60度下測量，係具有至少1015Ohm-cm之體積電阻率。
  3. 如申請專利範圍第1項所述之太陽能電池模組，其更進一步包含：一框架，以及其中該透明頂蓋、密封該複數個太陽能電池之該密封物與該背板裝載於該框架上。
  4. 如申請專利範圍第3項所述之太陽能電池模組，其中該複數個太陽能電池與該框架電性隔離。
  5. 如申請專利範圍第1項所述之太陽能電池模組，其中該複數個太陽能電池包含背側接觸太陽能電池。
  6. 如申請專利範圍第1項所述之太陽能電池模組，其中該聚烯烴包含聚丙烯。
  7. 一種製造太陽能電池模組之方法，該方法包含：提供用於一太陽能電池模組之一密封物，該密封物包含之一聚烯烴，其於骨架(backbone)或支鏈中具有少於5重量百分比之氧與氮，以及具有在保護性地封裝複數個太陽能電池於該密封物中以創造一保護封裝前，經動力學分析測量，於攝氏90度少於10000帕秒之複數黏度，其中該聚烯烴包含聚乙烯；保護性地封裝該複數個太陽能電池於該密封物中以創造該保護封裝；裝載該保護封裝於一框架上。
  8. 如申請專利範圍第7項所述之方法，其中該聚烯烴經ASTM D257測試於1kV、10分鐘充電與攝氏60度下測量，係具有至少1015Ohm-cm之體積電阻率。
  9. 如申請專利範圍第7項所述之方法，其中該複數個太陽能電池包含背側接觸太陽能電池。
  10. 如申請專利範圍第7項所述之方法，其中該聚烯烴包含聚乙烯。
  11. 如申請專利範圍第7項所述之方法，其中該聚烯烴包含聚丙烯。
  12. 如申請專利範圍第7項所述之方法，其中保護性地封裝該複數個太陽能電池於該密封物中以創造該保護封裝係包含： 安置該複數個太陽能電池於該密封物之一頂板與一底板間，一背板在該密封物之該底板下，以及一透明頂蓋於該密封物之該頂板上；擠壓並加熱該密封物之該頂板與該底板、該透明頂蓋與該背板在一起。
  13. 如申請專利範圍第12項所述之方法，其中該密封物之該頂板與該底板、該透明頂蓋與該背板透過真空壓合被擠壓並加熱在一起。
  14. 一種太陽能電池模組，其包含：複數個太陽能電池；一保護封裝，其包含密封該複數個太陽能電池之一密封物，該密封物包含具有少於5重量百分比之氧與氮於骨架(backbone)或支鏈中之一聚烯烴，其中該聚烯烴包含聚乙烯；以及一框架，該保護封裝裝載於其上。
  15. 如申請專利範圍第14項所述之太陽能電池模組，其中該聚烯烴具有在該密封物之任何熱處理前，經動力學分析測量，於攝氏90度下少於10000Pa-s之複數黏度。
  16. 如申請專利範圍第14項所述之太陽能電池模組，其中該聚烯烴經ASTM D257測試於1kV、10分鐘充電(electrification)與攝氏60度下測量，係具有至少1015Ohm-cm之體積電阻率。
  17. 如申請專利範圍第14項所述之太陽能電池模組，其中該保護封裝包含： 一透明頂蓋；該密封物，密封該複數個太陽能電池；以及一背板。
  18. 如申請專利範圍第14項所述之太陽能電池模組，其中該聚烯烴包含聚丙烯。
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