WO2011054924A2 - Method for fixing a mounting element to a photovoltaic module - Google Patents

Method for fixing a mounting element to a photovoltaic module Download PDF

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Publication number
WO2011054924A2
WO2011054924A2 PCT/EP2010/066895 EP2010066895W WO2011054924A2 WO 2011054924 A2 WO2011054924 A2 WO 2011054924A2 EP 2010066895 W EP2010066895 W EP 2010066895W WO 2011054924 A2 WO2011054924 A2 WO 2011054924A2
Authority
WO
WIPO (PCT)
Prior art keywords
photovoltaic module
mounting element
adhesive
contact area
mounting
Prior art date
Application number
PCT/EP2010/066895
Other languages
French (fr)
Other versions
WO2011054924A3 (en
Inventor
Andreas Huegli
Alessandro Susani
Silvan Wachter
Jürgen Josef DILLMANN
Original Assignee
Oerlikon Solar Ag, Trübbach
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Oerlikon Solar Ag, Trübbach filed Critical Oerlikon Solar Ag, Trübbach
Priority to CN2010800506526A priority Critical patent/CN102640299A/en
Publication of WO2011054924A2 publication Critical patent/WO2011054924A2/en
Publication of WO2011054924A3 publication Critical patent/WO2011054924A3/en

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Classifications

    • HELECTRICITY
    • H01ELECTRIC ELEMENTS
    • H01LSEMICONDUCTOR DEVICES NOT COVERED BY CLASS H10
    • H01L31/00Semiconductor 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
    • H01L31/18Processes or apparatus specially adapted for the manufacture or treatment of these devices or of parts thereof
    • FMECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F24HEATING; RANGES; VENTILATING
    • F24SSOLAR HEAT COLLECTORS; SOLAR HEAT SYSTEMS
    • F24S25/00Arrangement of stationary mountings or supports for solar heat collector modules
    • F24S25/60Fixation means, e.g. fasteners, specially adapted for supporting solar heat collector modules
    • F24S25/63Fixation means, e.g. fasteners, specially adapted for supporting solar heat collector modules for fixing modules or their peripheral frames to supporting elements
    • F24S25/632Side connectors; Base connectors
    • HELECTRICITY
    • H01ELECTRIC ELEMENTS
    • H01LSEMICONDUCTOR DEVICES NOT COVERED BY CLASS H10
    • H01L31/00Semiconductor 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
    • H01L31/04Semiconductor 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 adapted as photovoltaic [PV] conversion devices
    • H01L31/042PV modules or arrays of single PV cells
    • H01L31/048Encapsulation of modules
    • HELECTRICITY
    • H02GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
    • H02SGENERATION OF ELECTRIC POWER BY CONVERSION OF INFRARED RADIATION, VISIBLE LIGHT OR ULTRAVIOLET LIGHT, e.g. USING PHOTOVOLTAIC [PV] MODULES
    • H02S20/00Supporting structures for PV modules
    • HELECTRICITY
    • H02GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
    • H02SGENERATION OF ELECTRIC POWER BY CONVERSION OF INFRARED RADIATION, VISIBLE LIGHT OR ULTRAVIOLET LIGHT, e.g. USING PHOTOVOLTAIC [PV] MODULES
    • H02S20/00Supporting structures for PV modules
    • H02S20/20Supporting structures directly fixed to an immovable object
    • H02S20/22Supporting structures directly fixed to an immovable object specially adapted for buildings
    • H02S20/23Supporting structures directly fixed to an immovable object specially adapted for buildings specially adapted for roof structures
    • FMECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F24HEATING; RANGES; VENTILATING
    • F24SSOLAR HEAT COLLECTORS; SOLAR HEAT SYSTEMS
    • F24S25/00Arrangement of stationary mountings or supports for solar heat collector modules
    • F24S2025/01Special support components; Methods of use
    • F24S2025/014Methods for installing support elements
    • FMECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F24HEATING; RANGES; VENTILATING
    • F24SSOLAR HEAT COLLECTORS; SOLAR HEAT SYSTEMS
    • F24S25/00Arrangement of stationary mountings or supports for solar heat collector modules
    • F24S25/60Fixation means, e.g. fasteners, specially adapted for supporting solar heat collector modules
    • F24S2025/601Fixation means, e.g. fasteners, specially adapted for supporting solar heat collector modules by bonding, e.g. by using adhesives
    • YGENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y02TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
    • Y02BCLIMATE CHANGE MITIGATION TECHNOLOGIES RELATED TO BUILDINGS, e.g. HOUSING, HOUSE APPLIANCES OR RELATED END-USER APPLICATIONS
    • Y02B10/00Integration of renewable energy sources in buildings
    • Y02B10/10Photovoltaic [PV]
    • YGENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y02TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
    • Y02EREDUCTION OF GREENHOUSE GAS [GHG] EMISSIONS, RELATED TO ENERGY GENERATION, TRANSMISSION OR DISTRIBUTION
    • Y02E10/00Energy generation through renewable energy sources
    • Y02E10/40Solar thermal energy, e.g. solar towers
    • Y02E10/47Mountings or tracking
    • YGENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y02TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
    • Y02EREDUCTION OF GREENHOUSE GAS [GHG] EMISSIONS, RELATED TO ENERGY GENERATION, TRANSMISSION OR DISTRIBUTION
    • Y02E10/00Energy generation through renewable energy sources
    • Y02E10/50Photovoltaic [PV] energy

Definitions

  • the invention relates to a method for fixing a mounting element to a
  • the mounting element being placed at the backside of the photovoltaic module.
  • the invention relates to a method for fixing a mounting element to a photovoltaic module for introducing into industrial processes.
  • Solar cells also known as photovoltaic (PV) cells, are semiconductors that convert electromagnetic energy, such as light or solar radiation, into electricity. Photovoltaic solar energy conversion offers the perspective to provide an environmentally friendly means to generate electricity.
  • a plurality of individual solar cells being arranged on a common base
  • modules often are grouped to larger systems on roofs, building walls or on open grounds, for example, to form a solar power plant.
  • Solar modules may comprise a carrier structure for the photovoltaic active elements or layers and a cover against environmental influences. Both carrier and cover can be made from glass as a widely available and transparent material.
  • Solar modules based on thin film silicon technology as well as crystalline technology need to be fastened to a substructure that provides several basic functions.
  • the substructure may compensate forces coming from wind, rain, and snow. Additionally, it provides an interface to electrical connectors and preferably enables an easy maintenance and trouble free replacement of damaged modules.
  • a variety of fastening needs are required and thus the question of appropriate and cost-saving mounting technologies becomes relevant.
  • photovoltaic module especially due to the fact that manual steps have to be applied, some disadvantages may occur.
  • manual steps are often not reproducible and the yield of the process can be affected due to the fact that manual processes may cause a low throughput. This in turn may be followed by increased labor costs.
  • higher material costs are required in case a manual process is used due to an increased use of material, such as spacer tape, and adhesive, for example.
  • the invention relates to a method for fixing a mounting element to a
  • photovoltaic module the method comprising the steps of:
  • the mounting element is provided in a first feed line, whereas the photovoltaic module (PV module) is provided in a second feed line.
  • a handling device joins the photovoltaic module and the mounting element together.
  • the respective contact areas may be cleaned and an adhesive is applied to the latter.
  • the method according to the invention may thus be controlled in an easy manner by controlling the quantity of the glue, or adhesive, respectively, the adhesive dispensing pattern, quantity of primer, if used, and the placement of the mounting elements. Additionally, the method according to the invention may vary depending on the layout, cycle time and technology used. It thus becomes apparent that the method according to the invention may be adapted to the desired application in a great amount and in an easy manner and may easily be introduced into automated processes such as industrial processes. [0015] Furthermore, the method according to the invention is highly flexible due to the fact that a wide range of sizes as well as configurations of photovoltaic modules can be supported. Additionally, the system for performing the method can easily be upgraded with respect to tact time, future
  • the costs of the method according to the invention may be reduced.
  • the cost of ownership as well as the low manpower cost may contribute to a highly economic process.
  • the method according to the invention may be performed as a semi automatic or fully automatic process allowing a fast tact time and thus a high throughput of photovoltaic modules.
  • the method comprises repeatable process steps leading to minimized material consumption and bonding surface.
  • the stress exerted to the photovoltaic module due to fastening means during its lifetime e.g. more than 25 years, may strongly be reduced.
  • the gluing, or adhesive area provides a small, simple and efficient mounting.
  • the mounting elements are attached to the backside of the photovoltaic module.
  • the backside of the photovoltaic module is the side not being exposed to the sunlight, whereas the front side is exposed to the sunlight.
  • a mounting element according to the invention furthermore is an element used to be directly fixed to the photovoltaic module in order to mount/fix the latter to a substructure. Additional components, e.g. bolts or clamps are not required.
  • a plurality of mounting elements is fixed to the photovoltaic module. This allows an especially secure fixation and thus forms a photovoltaic module with a high durability. It is especially preferred that four mounting elements are fixed to the photovoltaic module, thereby attaching one mounting element substantially to each corner of the photovoltaic module.
  • a primer is applied to the mounting element. This step even more improves the adherence of the mounting element to the photovoltaic module, or its contact area, respectively. Consequently, the durability as well as stability of the so formed photovoltaic module may further be improved.
  • the adhesive comprises a silicone based adhesive (1 K, 2K), a polyurethane based adhesive, an acrylic adhesive, a resin based adhesive, a hotmelt adhesive (e.g. silicone based), a fast curing adhesive, a hotmelt adhesive together with a silicone based adhesive.
  • a silicone based adhesive (1 K, 2K)
  • a polyurethane based adhesive an acrylic adhesive
  • a resin based adhesive e.g. silicone based
  • a hotmelt adhesive e.g. silicone based
  • a fast curing adhesive e.g. silicone based
  • the mounting element is formed of aluminium.
  • a mounting element formed of aluminium EN AW 6060. T66 is suitable for the method according to the invention.
  • aluminium withstands the weather influence when the photovoltaic module is arranged at its intended position thereby further increasing the durability.
  • a mounting element formed of aluminium is very well formable and may thus easily be adapted according to the desired application.
  • the cleaning agents are trapped.
  • the vapours of the cleaning agents are trapped. This allows the method according to the invention to have improved properties with respect to the environmental point of view.
  • the invention furthermore relates to a system for fixing a mounting element to a photovoltaic module, comprising a first feed line for preparing a mounting element, and a second feed line for preparing a photovoltaic module, both feed lines being connected by a handling device for transporting the mounting element to the photovoltaic module.
  • the system according to the invention is thus designed for applying the method according to the invention. It mainly comprises two feed lines, in which the mounting elements and the photovoltaic module are prepared. In detail, they are arranged for the fixation step of the mounting elements to the photovoltaic module.
  • the preparation or arrangement may thus comprise cleaning or applying an adhesive.
  • the latter are connected by a handling device. This means that the objects being prepared on the feed lines, i.e. the mounting elements and the photovoltaic module, are joined together by said handling device.
  • FIG. 1 shows a schematic view of an embodiment of a system for fixing a mounting element to a photovoltaic module for performing the method according to the invention
  • Fig. 2 shows a diagram illustrating an embodiment of the method
  • Fig. 3 shows the backside of a photovoltaic module before fixing the
  • FIG. 4 shows a schematic view of a further embodiment of a system for fixing a mounting element to a photovoltaic module for performing the method according to the invention.
  • Fig. 5 shows a schematic view of a mounting element to be fixed to the photovoltaic module.
  • FIG. 1 shows a schematic view of a system 10 for performing a method of fixing a mounting element 12 to a photovoltaic module 14 according to the invention.
  • the system 10 as well as the method performed thereon provide improvements in the overall manufacturing process for forming photovoltaic modules 14 and are not limited to a specific type of
  • photovoltaic modules 14 The photovoltaic modules 14 with the mounting elements 12 fixed thereto may be used in architectural applications, for example.
  • Preparation of the photovoltaic module 14 and the mounting elements 12 is performed in parallel to optimize the layout, cycle time and process steps.
  • the individual process steps are described down below. It can be a semi automated or fully automated process which preferably is integrated in an industrial process. The critical process steps are controlled and the use of production material is minimized.
  • the system 10 comprises a first feed line 16 for providing and preparing one or a plurality of mounting elements 12 and a second feed line 18 for providing and preparing one or a plurality of photovoltaic modules 14. It is preferred that the mounting element 12 as well as the photovoltaic module 14, is positioned with an accuracy of ⁇ 0,5mm in each process step.
  • the first feed line 16 comprises a conveyer system 20 for transporting the mounting elements 12 in the direction of the arrow 22.
  • the second feed line 18 comprises a conveyer system 24 for transporting the photovoltaic modules 14 in the direction of the arrow 26.
  • the conveyer systems 20, 24 may comprise conveying belts 28, 30 and 32. However, other conveyer systems may be appropriate. They may comprise e.g. a shuttle, robot, or linear axis to transport the photovoltaic module 14 as well as the mounting element 12 to the respective process steps. The speed of the transport may be adjustable.
  • a handling device 34 is provided for transporting the mounting elements 12 in the direction of the arrow 36 and thus to the photovoltaic module 14 to be joined and fixed to the latter.
  • a photovoltaic module 14 is provided and arranged on the second feed line 18.
  • the photovoltaic module 14 is transported by the conveyer system 24 in the direction of the arrow 26, thereby passing several processing stations, or processing steps, respectively.
  • the first processing station may be a cleaning station 38 in which the
  • photovoltaic module 14 is cleaned.
  • the cleaning can be performed manually or preferably by an automated system.
  • contaminations such as polyvinyl butyral (PVB) plasticizer, other organic residuals, such as finger print, fat, oil, rubber, powder, plasticizer from PVB foil, which may be present due to the production of the PVB resin
  • contact area 40 At least the area where the mounting elements 12 are joined to in a later step have to be cleaned. This area is referred to as contact area 40. Consequently, the number of contact areas 40 depends on the number of mounting elements 12 to be joined.
  • the area to be cleaned may thereby comprise 5mm excess in x and y direction (see figure 3), i.e. to every side, of the contact area 40.
  • the cleaning step may comprise cleaning by using a solvent.
  • a solvent for example, acetone, isopropyl alcohol, acetone/alcohol or alike may be used. It is preferred to use the minimum quantity required for removing all
  • the evaporated cleaning agent may preferably be exhausted, or trapped, respectively. Additionally, the usage of cleaning consumables is possible. In detail felt, lint-free cloth, or alike may be used. Further options for cleaning may comprise the usage of atmospheric plasma, corona discharge treatment, or carbon dioxide (CO2, snow, pellets).
  • the cleaning step of the photovoltaic module 14 may be omitted, in case the mounting element 12 is cleaned, as will be apparent down below.
  • the photovoltaic module 14 is conveyed to an adhesive applying station 42 in order to apply an adhesive to the photovoltaic module 14.
  • the adhesive may be dispensed to the backside of the photovoltaic module 14, or its contact areas 40, respectively.
  • any adhesive which may be appropriate for fixing the mounting elements 12 to the photovoltaic module 14, or its contact areas 40, respectively.
  • a silicone based adhesive (1 K, 2K)
  • an adhesive based on polyurethane acrylic adhesives
  • resin based adhesives resin based adhesives
  • hotmelt adhesives e.g. silicone based
  • fast curing adhesive or hotmelt together with silicone based adhesive.
  • an adhesive tape may be attached to the contact area 40.
  • an adhesive system comprising a base material and a catalyst for forming the adhesive.
  • the catalyst and the base material may be mixed in a ratio of 100 parts by weight of base material and 14 parts by weight of catalyst, for example Dow Corning Q3-3636.
  • the adhesive dispensing system may in this case preferably be equipped with gear or piston metering pumps for the base material and the catalyst and furthermore may comprise a static mixer.
  • the geometry of the adhesive bead or a nozzle may have different shapes and should cover the full or at least a part of the gluing surface.
  • the width of the bead preferably is designed to be 50mm at maximum, whereas the height of the bead is designed to be 2-10mm at maximum.
  • the adhesive should be avoided after fixing of the mounting element 12 and furthermore the adhesive should be dispensed in a way that no significant amount of adhesive material is exceeding the mounting element 12 part after mounting of the mounting element 12, i.e. the contact area 40.
  • the adhesive may cover the whole contact area 40, or only a part of it.
  • the quantity of the adhesive, or the thickness of the adhesive tape should not exceed a thickness of 6mm after fixing the mounting element 12.
  • module 14 or its contact areas 40, respectively, may be omitted in case the mounting element 12 is provided with an adhesive or an adhesive tape, like will be described below with respect to figure 4.
  • the mounting elements 12 can be fed to the first feed line 16 manually or preferably in an automatic manner to a starting point 46.
  • the capacity of the first feed line 16 as well as of the second feed line 18 preferably is designed to guarantee continuous production and minimized down times.
  • the process can be used with returnable packaging.
  • the mounting element 12 may be formed of
  • aluminium in particular of aluminium EN AW 6060. T66. It may be plate finished (e.g. blank after extrusion, barrel finishing). Other materials and/or additional surface treatments can be chosen if appropriate.
  • the mounting elements 12 are conveyed to a cleaning station 48.
  • a cleaning agent may comprise a solvent or a slightly abrasive pad on a coarse lint-free cloth or a felt, for example.
  • Further options for cleaning the mounting element 12 may comprise plasma cleaning (in case no primer is needed), corona cleaning, or carbon dioxide cleaning.
  • the cleaning step may be omitted.
  • the mounting element 12 can also be pre-cleaned and prepared for primering.
  • the system has to be flexible to implement other cleaning solutions.
  • the cleaning agent is evaporated. This may be performed in an evaporation step which may last for 1 -20 seconds for example.
  • a primer may be applied to the mounting element 12, or its contact area, respectively.
  • a monomolecular layer of primer may be applied uniformly to the mounting element, e.g. by a spray system or felt application. The usage of a primer may further increase the adherence of the mounting element 12 to the photovoltaic module 14.
  • a drying station 52 may be provided.
  • the primer may be air dried and buffered for about 1 -5min.
  • the drying time is dependent of the film thickness of the primer. Additionally, it is preferred to avoid humidity.
  • a plasma application may be performed.
  • corrosion protection, pyrosil, or a further coating/surface treatment can be applied to the aluminium or other materials.
  • the exhaust gases from the primer and cleaning shall be trapped in order to avoid a contamination of the environment.
  • the mounting elements 12 are fixed, or joined, to the contact areas 40 of the photovoltaic modules 14. This step is performed at the joining station 44.
  • the handling device 34 picks the mounting elements 12 from the conveying system 20 and transports them to the photovoltaic module 14, on the backside of which the mounting elements 12 are joined to the contact areas 40 and fixed thereto due to the provision of the adhesive.
  • the handling device 34 preferably is a device being designed for automatically handling the mounting elements 12.
  • the handling device 34 may be a robot, or a linear axis flipping device.
  • a further possibility may comprise a conveyer shuttle.
  • the speed of the transport preferably is adjustable.
  • contact areas 40 i.e. geometry, shape and/or dimension as well as materials, (e.g. metallic and non-metallic), number, and position, are possible and may vary depending on the dimensions of the photovoltaic module 14 and/or the mounting element 12, the used technologies and configurations.
  • the position of the contact elements 40 is shown in figure 3.
  • the backside 54 of the photovoltaic module 14 is shown together with four contact areas 40 and an electrical contact 56.
  • the exact position of the contact areas 40 may be chosen as shown in the following table 1 :
  • the photovoltaic module 14 may be transported to and arranged at the intended position.
  • the mounting elements 12 may be connected with one or a plurality of further mounting devices, not shown, and attached to the substructure.
  • the mounting devices may be formed as a snap on device, for example.
  • FIG. 4 A further embodiment of the method according to the present invention is schematically shown in figure 4.
  • the method according to figure 4 is to a big extend comparable to the embodiment according to figure 1. Consequently, especially the differences are referred to, whereas the same reference signs refer to the same features.
  • the main difference compared to figure 1 is the step of applying an adhesive.
  • an adhesive is mainly applied to the mounting element 12, whereas no adhesive is applied to the photovoltaic module 14.
  • the element 12 with a cavity 58 may be used as is shown in figure 5.
  • the cavity 58 may be filled with the adhesive.
  • the geometry of the mounting element 12 may thus allow filling the adhesive into the cavity 58 while the mounting element 12 is positioned upon the photovoltaic module 14, thereby forming a film 60 of adhesive.
  • the adhesive dispensing station and the joining station 44 may be combined in one station 58.

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Abstract

The invention relates to a method for fixing a mounting element (12) to a photovoltaic module (14), the method comprising the steps of: providing at least on mounting element (12) in a first feed line (16), the mounting element (12) having at least one contact area; providing a photovoltaic module (14) in a second feed line (18) the photovoltaic module (14) having at least one contact area (40); cleaning at least one of the contact area (40) of the photovoltaic module (14) and the contact area of the mounting element (12); applying adhesive to at least one of the contact area (40) of the photovoltaic module (14) and the contact area of the mounting element (12); and fixing the mounting element (12) to the photovoltaic module (14) by transporting the mounting element (12) to the photovoltaic module (14) by a handling device (34) and joining the contact area (40) of the photovoltaic module (14) and the contact area of the mounting element (12) together. The method according to the invention is time saving and cost saving and provides a stable and durable connection of the photovoltaic module.

Description

Description
Method for fixing a mounting element to a photovoltaic module Technical Field
[0001] The invention relates to a method for fixing a mounting element to a
photovoltaic module, the mounting element being placed at the backside of the photovoltaic module. In particular, the invention relates to a method for fixing a mounting element to a photovoltaic module for introducing into industrial processes.
Background Art
[0002] Solar cells, also known as photovoltaic (PV) cells, are semiconductors that convert electromagnetic energy, such as light or solar radiation, into electricity. Photovoltaic solar energy conversion offers the perspective to provide an environmentally friendly means to generate electricity.
However, at the present state, electric energy provided by photovoltaic energy conversion units is still more expensive than electricity provided by conventional power stations. Therefore, the development of more cost-effective means and processes of producing photovoltaic energy conversion units attracted attention in the recent years. Amongst different approaches of producing low-cost solar cells, thin-film silicon solar cells are regarded as an important approach for achieving that goal.
[0003] A plurality of individual solar cells being arranged on a common base
structure and being electrically connected is called a module, solar module or photovoltaic module, respectively. Such modules often are grouped to larger systems on roofs, building walls or on open grounds, for example, to form a solar power plant. Solar modules may comprise a carrier structure for the photovoltaic active elements or layers and a cover against environmental influences. Both carrier and cover can be made from glass as a widely available and transparent material.
[0004] Solar modules based on thin film silicon technology as well as crystalline technology need to be fastened to a substructure that provides several basic functions. In detail, the substructure may compensate forces coming from wind, rain, and snow. Additionally, it provides an interface to electrical connectors and preferably enables an easy maintenance and trouble free replacement of damaged modules. In view of the above, a variety of fastening needs are required and thus the question of appropriate and cost-saving mounting technologies becomes relevant.
[0005] Various module mounting technologies are available today. In order to mount, or fix, respectively, the photovoltaic module to a substructure, all these mounting technologies have in common the requirement of a well designed support structure as well as of tools to mount the photovoltaic module to the mentioned structure. Accordingly, various methods for fixing a mounting element to a photovoltaic module are known depending on the type of mounting element to be used.
[0006] For example, it is known to use fixation points or backrails in order to
"clamp" and or "screw" the module such, that the photovoltaic module can compensate wind and snow loads.
[0007] In case a backrail, or point fasteners are used for mounting the
photovoltaic module to a substructure, manual or automated methods are possible. However, a high number of process steps are required in order to improve the reliability and stability.
[0008] In case clamps are used, only manual methods are possible, which are not introducible in an automated production process of photovoltaic modules, but have to be performed directly during the mounting step. Additionally, a slow and complex installation procedure has to be considered.
[0009] By using the known methods for fixing a mounting element to a
photovoltaic module, especially due to the fact that manual steps have to be applied, some disadvantages may occur. In detail, manual steps are often not reproducible and the yield of the process can be affected due to the fact that manual processes may cause a low throughput. This in turn may be followed by increased labor costs. Additionally, higher material costs are required in case a manual process is used due to an increased use of material, such as spacer tape, and adhesive, for example.
Disclosure of Invention
[0010] It is an object of the invention to provide a method for fixing a mounting element to a photovoltaic module which is time and cost saving and which may be introduced into automated processes.
[001 1] The solution of the object is achieved by a method according to claim 1.
Preferred embodiments are given by the dependent claims.
[0012] The invention relates to a method for fixing a mounting element to a
photovoltaic module, the method comprising the steps of:
- Providing at least on mounting element in a first feed line, the mounting element having at least one contact area;
- Providing a photovoltaic module in a second feed line, the photovoltaic module having at least one contact area;
- Cleaning at least one of the contact area of the photovoltaic module and the contact area of the mounting element;
- Applying adhesive to at least one of the contact area of the photovoltaic module and the contact area and of the mounting element; and
- Fixing the mounting element to the photovoltaic module by transporting the mounting element to the photovoltaic module by a handling device and joining the contact area of the photovoltaic module and the contact area of the mounting element together.
[0013] According to the invention, the mounting element is provided in a first feed line, whereas the photovoltaic module (PV module) is provided in a second feed line. At the downstream part of both feed lines, a handling device joins the photovoltaic module and the mounting element together. To realize an appropriate fixation, the respective contact areas may be cleaned and an adhesive is applied to the latter.
[0014] The method according to the invention may thus be controlled in an easy manner by controlling the quantity of the glue, or adhesive, respectively, the adhesive dispensing pattern, quantity of primer, if used, and the placement of the mounting elements. Additionally, the method according to the invention may vary depending on the layout, cycle time and technology used. It thus becomes apparent that the method according to the invention may be adapted to the desired application in a great amount and in an easy manner and may easily be introduced into automated processes such as industrial processes. [0015] Furthermore, the method according to the invention is highly flexible due to the fact that a wide range of sizes as well as configurations of photovoltaic modules can be supported. Additionally, the system for performing the method can easily be upgraded with respect to tact time, future
technologies, future mounting elements, future photovoltaic modules and thus to different sizes and types of materials used.
[0016] Additionally, the costs of the method according to the invention may be reduced. In detail, the cost of ownership as well as the low manpower cost may contribute to a highly economic process. This is at least partly due to the fact that the method according to the invention may be performed as a semi automatic or fully automatic process allowing a fast tact time and thus a high throughput of photovoltaic modules. Next to that, the method comprises repeatable process steps leading to minimized material consumption and bonding surface.
[0017] According to the invention, it is possible to provide products with a high reliability and quality. For example, the stress exerted to the photovoltaic module due to fastening means during its lifetime, e.g. more than 25 years, may strongly be reduced.
[0018] Apart from that, no spacers are needed, especially compared to the
backrail technique. In contrast thereto, the gluing, or adhesive area provides a small, simple and efficient mounting.
[0019] To enable the formed photovoltaic module to work properly at the intended position, the mounting elements are attached to the backside of the photovoltaic module. According to the invention, the backside of the photovoltaic module is the side not being exposed to the sunlight, whereas the front side is exposed to the sunlight.
[0020] A mounting element according to the invention furthermore is an element used to be directly fixed to the photovoltaic module in order to mount/fix the latter to a substructure. Additional components, e.g. bolts or clamps are not required.
[0021] In a preferred embodiment of the present invention, a plurality of mounting elements is fixed to the photovoltaic module. This allows an especially secure fixation and thus forms a photovoltaic module with a high durability. It is especially preferred that four mounting elements are fixed to the photovoltaic module, thereby attaching one mounting element substantially to each corner of the photovoltaic module.
[0022] In a further preferred embodiment of the present invention, a primer is applied to the mounting element. This step even more improves the adherence of the mounting element to the photovoltaic module, or its contact area, respectively. Consequently, the durability as well as stability of the so formed photovoltaic module may further be improved.
[0023] It is furthermore preferred, that the adhesive comprises a silicone based adhesive (1 K, 2K), a polyurethane based adhesive, an acrylic adhesive, a resin based adhesive, a hotmelt adhesive (e.g. silicone based), a fast curing adhesive, a hotmelt adhesive together with a silicone based adhesive. These adhesives are especially suitable for a durable and stable connection of the mounting element and the photovoltaic module.
[0024] In a further preferred embodiment of the present invention, the mounting element is formed of aluminium. Especially, a mounting element formed of aluminium EN AW 6060. T66 is suitable for the method according to the invention. In particular, aluminium withstands the weather influence when the photovoltaic module is arranged at its intended position thereby further increasing the durability. Additionally, a mounting element formed of aluminium is very well formable and may thus easily be adapted according to the desired application.
[0025] In a further preferred embodiment of the present invention the cleaning agents are trapped. In detail, especially the vapours of the cleaning agents are trapped. This allows the method according to the invention to have improved properties with respect to the environmental point of view.
[0026] With respect to the reaction conditions, it is mostly preferred that the
method is performed at a temperature in the range of≥ 18 to≤ 25°C and/or at a relative humidity in the range of > 40 to≤ 60%. This especially allows achieving a fast and secure adherence effect. Consequently, high tact times together with a stable connection may be realized using the above defined conditions.
[0027] The invention furthermore relates to a system for fixing a mounting element to a photovoltaic module, comprising a first feed line for preparing a mounting element, and a second feed line for preparing a photovoltaic module, both feed lines being connected by a handling device for transporting the mounting element to the photovoltaic module.
[0028] The system according to the invention is thus designed for applying the method according to the invention. It mainly comprises two feed lines, in which the mounting elements and the photovoltaic module are prepared. In detail, they are arranged for the fixation step of the mounting elements to the photovoltaic module. The preparation or arrangement may thus comprise cleaning or applying an adhesive. At the downstream part of the feed lines, the latter are connected by a handling device. This means that the objects being prepared on the feed lines, i.e. the mounting elements and the photovoltaic module, are joined together by said handling device.
Brief Description of Drawings
[0029] These and other aspects of the invention will be apparent from and
elucidated with reference to the embodiments described hereinafter.
[0030] In the drawings:
[0031] Fig. 1 shows a schematic view of an embodiment of a system for fixing a mounting element to a photovoltaic module for performing the method according to the invention;
[0032] Fig. 2 shows a diagram illustrating an embodiment of the method
according to the invention;
[0033] Fig. 3 shows the backside of a photovoltaic module before fixing the
mounting elements thereto;
[0034] Fig. 4 shows a schematic view of a further embodiment of a system for fixing a mounting element to a photovoltaic module for performing the method according to the invention; and
[0035] Fig. 5 shows a schematic view of a mounting element to be fixed to the photovoltaic module.
Detailed Description of Drawings
[0036] Fig. 1 shows a schematic view of a system 10 for performing a method of fixing a mounting element 12 to a photovoltaic module 14 according to the invention. The system 10 as well as the method performed thereon provide improvements in the overall manufacturing process for forming photovoltaic modules 14 and are not limited to a specific type of
photovoltaic modules 14. The photovoltaic modules 14 with the mounting elements 12 fixed thereto may be used in architectural applications, for example.
[0037] Preparation of the photovoltaic module 14 and the mounting elements 12 is performed in parallel to optimize the layout, cycle time and process steps. The individual process steps are described down below. It can be a semi automated or fully automated process which preferably is integrated in an industrial process. The critical process steps are controlled and the use of production material is minimized.
[0038] The system 10 according to the invention comprises a first feed line 16 for providing and preparing one or a plurality of mounting elements 12 and a second feed line 18 for providing and preparing one or a plurality of photovoltaic modules 14. It is preferred that the mounting element 12 as well as the photovoltaic module 14, is positioned with an accuracy of ± 0,5mm in each process step.
[0039] The first feed line 16 comprises a conveyer system 20 for transporting the mounting elements 12 in the direction of the arrow 22. Correspondingly, the second feed line 18 comprises a conveyer system 24 for transporting the photovoltaic modules 14 in the direction of the arrow 26. The conveyer systems 20, 24 may comprise conveying belts 28, 30 and 32. However, other conveyer systems may be appropriate. They may comprise e.g. a shuttle, robot, or linear axis to transport the photovoltaic module 14 as well as the mounting element 12 to the respective process steps. The speed of the transport may be adjustable. At the downstream side of the first feed line 16 as well as of the second feed line 18, a handling device 34 is provided for transporting the mounting elements 12 in the direction of the arrow 36 and thus to the photovoltaic module 14 to be joined and fixed to the latter.
[0040] One embodiment of the method according to the invention, which as well is visualized in figure 2, may be performed as follows.
[0041] A photovoltaic module 14 is provided and arranged on the second feed line 18. The photovoltaic module 14 is transported by the conveyer system 24 in the direction of the arrow 26, thereby passing several processing stations, or processing steps, respectively.
[0042] The first processing station may be a cleaning station 38 in which the
photovoltaic module 14 is cleaned. The cleaning can be performed manually or preferably by an automated system.
[0043] In detail, contaminations such as polyvinyl butyral (PVB) plasticizer, other organic residuals, such as finger print, fat, oil, rubber, powder, plasticizer from PVB foil, which may be present due to the production of the
photovoltaic modules 14, for example, have to be removed from the backside of the solar module 14. At least the area where the mounting elements 12 are joined to in a later step have to be cleaned. This area is referred to as contact area 40. Consequently, the number of contact areas 40 depends on the number of mounting elements 12 to be joined.
According to figure 1 , four contact areas 40 are provided. The area to be cleaned may thereby comprise 5mm excess in x and y direction (see figure 3), i.e. to every side, of the contact area 40.
[0044] The cleaning step may comprise cleaning by using a solvent. For example, acetone, isopropyl alcohol, acetone/alcohol or alike may be used. It is preferred to use the minimum quantity required for removing all
contaminations. Furthermore, the evaporated cleaning agent may preferably be exhausted, or trapped, respectively. Additionally, the usage of cleaning consumables is possible. In detail felt, lint-free cloth, or alike may be used. Further options for cleaning may comprise the usage of atmospheric plasma, corona discharge treatment, or carbon dioxide (CO2, snow, pellets).
[0045] As a result, all contaminations must be removed and no residuals of the cleaning agent should be left on the module, or the contact areas 40, respectively.
[0046] However, even though a cleaning step of the backside of the photovoltaic module 14 like described above is preferred, the cleaning step of the photovoltaic module 14 may be omitted, in case the mounting element 12 is cleaned, as will be apparent down below.
[0047] In a further step, the photovoltaic module 14 is conveyed to an adhesive applying station 42 in order to apply an adhesive to the photovoltaic module 14. In detail, the adhesive may be dispensed to the backside of the photovoltaic module 14, or its contact areas 40, respectively.
[0048] Generally, it is possible to use any adhesive which may be appropriate for fixing the mounting elements 12 to the photovoltaic module 14, or its contact areas 40, respectively. However, it may be preferred to use a silicone based adhesive (1 K, 2K), an adhesive based on polyurethane, acrylic adhesives, resin based adhesives, hotmelt adhesives (e.g. silicone based), fast curing adhesive, or hotmelt together with silicone based adhesive. As an alternative, an adhesive tape may be attached to the contact area 40.
[0049] Additionally, it may be preferred to use an adhesive system comprising a base material and a catalyst for forming the adhesive. The catalyst and the base material may be mixed in a ratio of 100 parts by weight of base material and 14 parts by weight of catalyst, for example Dow Corning Q3-3636. The adhesive dispensing system may in this case preferably be equipped with gear or piston metering pumps for the base material and the catalyst and furthermore may comprise a static mixer.
[0050] The geometry of the adhesive bead or a nozzle may have different shapes and should cover the full or at least a part of the gluing surface. The width of the bead preferably is designed to be 50mm at maximum, whereas the height of the bead is designed to be 2-10mm at maximum.
[0051] As a result of the step of applying an adhesive, air inclusions in the
adhesive should be avoided after fixing of the mounting element 12 and furthermore the adhesive should be dispensed in a way that no significant amount of adhesive material is exceeding the mounting element 12 part after mounting of the mounting element 12, i.e. the contact area 40. The adhesive may cover the whole contact area 40, or only a part of it.
[0052] Additionally, the quantity of the adhesive, or the thickness of the adhesive tape should not exceed a thickness of 6mm after fixing the mounting element 12.
[0053] The step of applying an adhesive to the backside of the photovoltaic
module 14, or its contact areas 40, respectively, may be omitted in case the mounting element 12 is provided with an adhesive or an adhesive tape, like will be described below with respect to figure 4.
[0054] Having applied the adhesive to the backside of the photovoltaic module 14, the latter is conveyed to a joining station 44, in which the mounting elements 12 are joined, or fixed, respectively, to the photovoltaic module 14, as will be apparent down below.
[0055] Referring to the mounting elements 12, they can be fed to the first feed line 16 manually or preferably in an automatic manner to a starting point 46. The capacity of the first feed line 16 as well as of the second feed line 18 preferably is designed to guarantee continuous production and minimized down times. The process can be used with returnable packaging.
[0056] As a preferred example, the mounting element 12 may be formed of
aluminium, in particular of aluminium EN AW 6060. T66. It may be plate finished (e.g. blank after extrusion, barrel finishing). Other materials and/or additional surface treatments can be chosen if appropriate.
[0057] In the following, the mounting elements 12 are conveyed to a cleaning station 48. At the cleaning station, the back surface of the mounting elements 12, or its contact area, respectively, is cleaned with a cleaning agent. The cleaning agent may comprise a solvent or a slightly abrasive pad on a coarse lint-free cloth or a felt, for example. Further options for cleaning the mounting element 12 may comprise plasma cleaning (in case no primer is needed), corona cleaning, or carbon dioxide cleaning.
However, even if a cleaning step is preferred, it has to be noted that in some embodiments, the cleaning step may be omitted. Additionally, the mounting element 12 can also be pre-cleaned and prepared for primering. Generally, it is preferred that the system has to be flexible to implement other cleaning solutions.
[0058] Preferably, the cleaning agent is evaporated. This may be performed in an evaporation step which may last for 1 -20 seconds for example. [0059] In a next step, for example at a primer applying station 50, a primer may be applied to the mounting element 12, or its contact area, respectively. In detail, a monomolecular layer of primer may be applied uniformly to the mounting element, e.g. by a spray system or felt application. The usage of a primer may further increase the adherence of the mounting element 12 to the photovoltaic module 14.
[0060] In case a primer is used, the latter should be evaporated, or dried,
respectively. Consequently, a drying station 52 may be provided.
According to this, the primer may be air dried and buffered for about 1 -5min. The drying time is dependent of the film thickness of the primer. Additionally, it is preferred to avoid humidity.
[0061] Instead of using a primer, a plasma application may be performed. For example, corrosion protection, pyrosil, or a further coating/surface treatment can be applied to the aluminium or other materials.
Consequently, the use of a primer may be discarded.
[0062] Using the 2K- Silicone adhesive, a curing step has to be considered, to guarantee the bonding quality for the further process steps e.g. handling, packaging, and shipping.
[0063] The exhaust gases from the primer and cleaning shall be trapped in order to avoid a contamination of the environment.
[0064] Having provided and prepared the photovoltaic module 14 as well as the mounting element 12, or the plurality of the photovoltaic modules 14 as well as the plurality of the mounting elements 12, respectively, like described above, the mounting elements 12 are fixed, or joined, to the contact areas 40 of the photovoltaic modules 14. This step is performed at the joining station 44.
[0065] Therefore, the handling device 34 picks the mounting elements 12 from the conveying system 20 and transports them to the photovoltaic module 14, on the backside of which the mounting elements 12 are joined to the contact areas 40 and fixed thereto due to the provision of the adhesive. The handling device 34 preferably is a device being designed for automatically handling the mounting elements 12. For example, the handling device 34 may be a robot, or a linear axis flipping device. A further possibility may comprise a conveyer shuttle. The speed of the transport preferably is adjustable.
[0066] Different variations of the contact areas 40, i.e. geometry, shape and/or dimension as well as materials, (e.g. metallic and non-metallic), number, and position, are possible and may vary depending on the dimensions of the photovoltaic module 14 and/or the mounting element 12, the used technologies and configurations. In detail the position of the contact elements 40 is shown in figure 3. In figure 3, the backside 54 of the photovoltaic module 14 is shown together with four contact areas 40 and an electrical contact 56. The exact position of the contact areas 40 may be chosen as shown in the following table 1 :
[0067]
Table 2
Figure imgf000013_0001
Having fixed the mounting elements 12 to the photovoltaic module 14, or its contact areas 40, respectively, the photovoltaic module 14 may be transported to and arranged at the intended position. For example, to fix the photovoltaic module 14 to a surface or a substructure, the mounting elements 12 may be connected with one or a plurality of further mounting devices, not shown, and attached to the substructure. Hence, the mounting devices may be formed as a snap on device, for example.
[0069] A further embodiment of the method according to the present invention is schematically shown in figure 4. Generally, the method according to figure 4 is to a big extend comparable to the embodiment according to figure 1. Consequently, especially the differences are referred to, whereas the same reference signs refer to the same features.
[0070] According to figure 4, the main difference compared to figure 1 is the step of applying an adhesive. In detail, according to figure 4, an adhesive is mainly applied to the mounting element 12, whereas no adhesive is applied to the photovoltaic module 14.
[0071] Depending on the geometry of the mounting element 12, a mounting
element 12 with a cavity 58 may be used as is shown in figure 5. The cavity 58 may be filled with the adhesive. The geometry of the mounting element 12 may thus allow filling the adhesive into the cavity 58 while the mounting element 12 is positioned upon the photovoltaic module 14, thereby forming a film 60 of adhesive. In case a mounting element 12 with cavity 58 is used, the adhesive dispensing station and the joining station 44 may be combined in one station 58.
[0072] It has to be noted that especially according to figures 1 and 4, mostly one station is shown for each process step. However, it is of course possible to combine several steps in one station according to the respective requirements and thus to omit respective stations without leaving the invention as such.
[0073] While the invention has been illustrated and described in detail in the
drawings and foregoing description, such illustration and description are to be considered illustrative or exemplary and not restrictive, the invention is not limited to the disclosed embodiments. Other variations to the disclosed embodiments can be understood and effected by those skilled in the art in practicing the claimed invention, from a study of the drawings, the disclosure, and the appended claims. In the claims, the word "comprising" does not exclude other elements or steps, and the indefinite article "a" or "an" does not exclude a plurality. The mere fact that certain measures are recited in mutually different dependent claims does not indicate that a combination of these measures cannot be used to advantage. Any reference signs in the claims should not be construed as limiting the scope.
Reference signs list
[0074] 10 system
12 mounting element
14 photovoltaic module
16 first feed line
18 second feed line
20 conveyer system
22 arrow
24 conveyer system
26 arrow
28 conveying belts
30 conveying belts
32 conveying belts
34 handling device
36 arrow
38 cleaning station
40 contact area
42 applying station
44 joining station
46 starting point
48 cleaning station
50 applying station
52 drying station
54 backside
56 electrical contact
58 cavity
60 film
62 station

Claims

Claims
1. Method for fixing a mounting element (12) to a photovoltaic module (14), the method comprising the steps of:
- Providing at least on mounting element (12) in a first feed line (16), the mounting element (12) having at least one contact area;
- Providing a photovoltaic module (14) in a second feed line (18) the
photovoltaic module (14) having at least one contact area (40);
- Cleaning at least one of the contact area (40) of the photovoltaic module (14) and the contact area of the mounting element (12);
- Applying adhesive to at least one of the contact area (40) of the photovoltaic module (14) and the contact area of the mounting element (12); and
- Fixing the mounting element (12) to the photovoltaic module (14) by transporting the mounting element (12) to the photovoltaic module (14) by a handling device (34) and joining the contact area (40) of the photovoltaic module (14) and the contact area of the mounting element (12) together.
2. Method according to claim 1 , wherein a plurality of mounting elements (12) is fixed to the photovoltaic module (14).
3. Method according to claim 2, wherein four mounting elements (12) are fixed to the photovoltaic module (14).
4. Method according to any of the preceding claims, wherein a primer is applied to the mounting element (12).
5. Method according to any of the preceding claims, wherein the adhesive
comprises a silicone based adhesive, a polyurethane based adhesive, an acrylic adhesive, a resin based adhesive, a hotmelt adhesive, a fast curing adhesive, a hotmelt adhesive together with a silicone based adhesive.
6. Method according to any of the preceding claims, wherein the mounting
element (12) is formed of aluminium.
7. Method according to any of the preceding claims, wherein the cleaning agents are trapped.
8. Method according to any of the preceding claims, wherein the method is
performed at a temperature in the range of≥ 18 to≤ 25°C.
9. Method according to any of the preceding claims, wherein the method is
performed at a relative humidity in the range of > 40 to≤ 60%.
10. Systenn for fixing a mounting element (12) to a photovoltaic module (14), comprising a first feed line (16) for preparing a mounting element (12), and a second feed line (18) for preparing a photovoltaic module (14), both feed lines (16, 18) being connected by a handling device (38) for transporting the mounting element (12) to the photovoltaic module (14).
PCT/EP2010/066895 2009-11-05 2010-11-05 Method for fixing a mounting element to a photovoltaic module WO2011054924A2 (en)

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