WO2011128757A1 - Photovoltaic cell for integrated building applications and method manufacturing this cell - Google Patents

Photovoltaic cell for integrated building applications and method manufacturing this cell Download PDF

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Publication number
WO2011128757A1
WO2011128757A1 PCT/IB2011/000807 IB2011000807W WO2011128757A1 WO 2011128757 A1 WO2011128757 A1 WO 2011128757A1 IB 2011000807 W IB2011000807 W IB 2011000807W WO 2011128757 A1 WO2011128757 A1 WO 2011128757A1
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WO
WIPO (PCT)
Prior art keywords
tile
face
cell
active structure
photovoltaic
Prior art date
Application number
PCT/IB2011/000807
Other languages
French (fr)
Other versions
WO2011128757A8 (en
Inventor
Federico Caporale
Fabio Di Fonzo
Marco Di Stanislao
Maurizio Masi
Maura Tonini
Original Assignee
Industria E Innovazione S.P.A.
Politecnico Di Milano
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.)
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Publication date
Application filed by Industria E Innovazione S.P.A., Politecnico Di Milano filed Critical Industria E Innovazione S.P.A.
Priority to EP11724445.9A priority Critical patent/EP2559070B8/en
Publication of WO2011128757A1 publication Critical patent/WO2011128757A1/en
Publication of WO2011128757A8 publication Critical patent/WO2011128757A8/en

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Classifications

    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01L—SEMICONDUCTOR DEVICES NOT COVERED BY CLASS H10
    • H01L31/00—Semiconductor devices sensitive to infrared radiation, light, electromagnetic radiation of shorter wavelength or corpuscular radiation and specially adapted either for the conversion of the energy of such radiation into electrical energy or for the control of electrical energy by such radiation; Processes or apparatus specially adapted for the manufacture or treatment thereof or of parts thereof; Details thereof
    • H01L31/04—Semiconductor devices sensitive to infrared radiation, light, electromagnetic radiation of shorter wavelength or corpuscular radiation and specially adapted either for the conversion of the energy of such radiation into electrical energy or for the control of electrical energy by such radiation; Processes or apparatus specially adapted for the manufacture or treatment thereof or of parts thereof; Details thereof adapted as photovoltaic [PV] conversion devices
    • H01L31/054—Optical elements directly associated or integrated with the PV cell, e.g. light-reflecting means or light-concentrating means
    • H01L31/0547—Optical elements directly associated or integrated with the PV cell, e.g. light-reflecting means or light-concentrating means comprising light concentrating means of the reflecting type, e.g. parabolic mirrors, concentrators using total internal reflection
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01L—SEMICONDUCTOR DEVICES NOT COVERED BY CLASS H10
    • H01L31/00—Semiconductor devices sensitive to infrared radiation, light, electromagnetic radiation of shorter wavelength or corpuscular radiation and specially adapted either for the conversion of the energy of such radiation into electrical energy or for the control of electrical energy by such radiation; Processes or apparatus specially adapted for the manufacture or treatment thereof or of parts thereof; Details thereof
    • H01L31/04—Semiconductor devices sensitive to infrared radiation, light, electromagnetic radiation of shorter wavelength or corpuscular radiation and specially adapted either for the conversion of the energy of such radiation into electrical energy or for the control of electrical energy by such radiation; Processes or apparatus specially adapted for the manufacture or treatment thereof or of parts thereof; Details thereof adapted as photovoltaic [PV] conversion devices
    • H01L31/042—PV modules or arrays of single PV cells
    • H01L31/048—Encapsulation of modules
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01L—SEMICONDUCTOR DEVICES NOT COVERED BY CLASS H10
    • H01L31/00—Semiconductor devices sensitive to infrared radiation, light, electromagnetic radiation of shorter wavelength or corpuscular radiation and specially adapted either for the conversion of the energy of such radiation into electrical energy or for the control of electrical energy by such radiation; Processes or apparatus specially adapted for the manufacture or treatment thereof or of parts thereof; Details thereof
    • H01L31/04—Semiconductor devices sensitive to infrared radiation, light, electromagnetic radiation of shorter wavelength or corpuscular radiation and specially adapted either for the conversion of the energy of such radiation into electrical energy or for the control of electrical energy by such radiation; Processes or apparatus specially adapted for the manufacture or treatment thereof or of parts thereof; Details thereof adapted as photovoltaic [PV] conversion devices
    • H01L31/054—Optical elements directly associated or integrated with the PV cell, e.g. light-reflecting means or light-concentrating means
    • H01L31/0543—Optical elements directly associated or integrated with the PV cell, e.g. light-reflecting means or light-concentrating means comprising light concentrating means of the refractive type, e.g. lenses
    • H—ELECTRICITY
    • H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
    • H02S—GENERATION OF ELECTRIC POWER BY CONVERSION OF INFRARED RADIATION, VISIBLE LIGHT OR ULTRAVIOLET LIGHT, e.g. USING PHOTOVOLTAIC [PV] MODULES
    • H02S20/00—Supporting structures for PV modules
    • H02S20/20—Supporting structures directly fixed to an immovable object
    • H02S20/22—Supporting structures directly fixed to an immovable object specially adapted for buildings
    • H—ELECTRICITY
    • H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
    • H02S—GENERATION OF ELECTRIC POWER BY CONVERSION OF INFRARED RADIATION, VISIBLE LIGHT OR ULTRAVIOLET LIGHT, e.g. USING PHOTOVOLTAIC [PV] MODULES
    • H02S20/00—Supporting structures for PV modules
    • H02S20/20—Supporting structures directly fixed to an immovable object
    • H02S20/22—Supporting structures directly fixed to an immovable object specially adapted for buildings
    • H02S20/26—Building materials integrated with PV modules, e.g. façade elements
    • Y—GENERAL 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
    • Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
    • Y02B—CLIMATE CHANGE MITIGATION TECHNOLOGIES RELATED TO BUILDINGS, e.g. HOUSING, HOUSE APPLIANCES OR RELATED END-USER APPLICATIONS
    • Y02B10/00—Integration of renewable energy sources in buildings
    • Y02B10/10—Photovoltaic [PV]
    • Y—GENERAL 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
    • Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
    • Y02E—REDUCTION OF GREENHOUSE GAS [GHG] EMISSIONS, RELATED TO ENERGY GENERATION, TRANSMISSION OR DISTRIBUTION
    • Y02E10/00—Energy generation through renewable energy sources
    • Y02E10/50—Photovoltaic [PV] energy
    • Y02E10/52—PV systems with concentrators

Definitions

  • the present invention relates to a photovoltaic cell, in particular for integrated building applications, and a method for manufacturing this cell .
  • the cell of the invention is particularly indicated for being used as a building element for making building structures, especially for making vertical walls.
  • a field of application of great interest for photovoltaic cells and panels is that of so-called Building Integrated Photovoltaics (BIPV) ; in these applications, the photovoltaic panels are destined to substitute traditional building elements such as roofs, facades and so forth, with an evident synergetic effect and considerable savings from the building construction standpoint.
  • BIPV Building Integrated Photovoltaics
  • two different problems limit the diffusion of these solutions: low energy efficiency and a generally unsatisfying aesthetic effect.
  • One object of the present invention is therefore that of providing a photovoltaic cell that is devoid of the drawbacks of the known art pointed out herein; in particular, an object of the invention is that of providing a photovoltaic cell that can be used in integrated building applications, especially for making vertical walls for buildings and other architectural structures, while being relatively inexpensive and simple to make, efficient from the energy standpoint and with a satisfactory aesthetic appearance.
  • the present invention is therefore relative to a photovoltaic cell as defined in basic terms in the attached claim 1 and a method for manufacturing photovoltaic cells as defined in claim 9.
  • the invention also regards the use of a photovoltaic cell in a building panel for making building structures, especially for making vertical walls, as defined in claim 10.
  • the invention also regards the use of a special support element as a substrate for photovoltaic cells, in particular multilayer thin film or photoelectrochemical photovoltaic cells, as defined in claim 11.
  • the present invention actually provides a new support element for making various types of photovoltaic cells with a multilayer structure, for example, various types of thin film cells and photoelectrochemical cells or Graetzel cells; the support element is composed of a tile made of glass, in particular of moulded glass (i.e. obtained via a molten glass moulding operation), or another transparent material, in particular a transparent polymeric material, having opportunely shaped surfaces for confining sunlight inside the tile .
  • Various multilayer structures can be applied to the support element to form different types of photovoltaic cells, in particular thin film cells (for example, a-Si:H, micromorph silicon, Cd-Te, CIS/CIGS, and so on) and photoelectrochemical cells (so-called DSSC, "Dye Sensitized Solar Cells", or Graetzel cells) .
  • thin film cells for example, a-Si:H, micromorph silicon, Cd-Te, CIS/CIGS, and so on
  • photoelectrochemical cells so-called DSSC, "Dye Sensitized Solar Cells", or Graetzel cells
  • the cells in accordance with the invention differ with respect to some known solutions (in which a separately made optical element is mounted on an ordinary cell to function as a lens to focus rays on the active element) due to the fact that the active structure of the cell is constructed directly on the already opportunely shaped substrate (tile) .
  • both the support element and the photovoltaic cell as a whole are relatively simple and economical to manufacture.
  • the photovoltaic cell of the invention can be used as a building element with high efficiency, even and especially for making vertical walls; the cell of the invention can also be made in various shapes, sizes and colours, so as to create walls having different aesthetic- architectural effects.
  • FIG. 1 is an schematic view, in longitudinal section and out of scale, of a portion of a photovoltaic cell in accordance with a first embodiment of the invention.
  • FIG. 2 is a schematic view, in longitudinal section and out of scale, of a portion of a photovoltaic cell in accordance with a second embodiment of the invention.
  • a photovoltaic cell in particular a multilayer thin film cell, is indicated as a whole by reference numeral 1.
  • the cell 1 comprises a support element 2 and a multilayer active structure 3, carried by the support element 2 and formed by a plurality of functional layers that, as a whole, are able to convert light energy into electrical energy via the photovoltaic effect.
  • the support element 2 consists of a tile 5 made of glass (or another transparent material , in particular a polymeric material) and that is basically prismatic, for example having a quadrangular (rectangular or square) plan shape; the tile 5 has two larger opposite faces 6, 7, arranged on opposite sides of a central plane P, and a perimeter edge 8 that connects the two faces 6 , 7.
  • the face 6 is destined to face directly to the sun and therefore constitutes an outer face of the tile 5; the other face 7 constitutes an inner face of the tile 5.
  • the tile 5 is advantageously composed of a monolithic piece made of moulded glass, i.e. obtained by the pressure moulding of molten glass.
  • pressure moulding of molten glass is a mechanical process of plastic deformation carried out by hot dynamic action exerted by a press on molten glass in order to make the glass fill a cavity between two metal dies; in pressure moulding, an opportune quantity of molten glass having suitable temperature and plasticity characteristics is introduced into a hot metal die, into which a counter die is then immersed that, by exerting pressure, forces the glass to occupy the space between the die and the counter die, thereby determining the thickness and shape of the object to be made,
  • a tile or piece made "of moulded glass” is a manufactured item made by a pressure moulding operation on molten glass.
  • the tile 5 can be made by moulding (injection moulding in particular) another transparent material, in particular a transparent polymeric material, for example, polymethyl methacrylate (PMMA) , polycarbonate (PC) , ethylene tetrafluorethylene (ETFE) , polyethylene terephthalate (PET) , polyethylene naphthalate (PEN) and so forth.
  • a transparent polymeric material for example, polymethyl methacrylate (PMMA) , polycarbonate (PC) , ethylene tetrafluorethylene (ETFE) , polyethylene terephthalate (PET) , polyethylene naphthalate (PEN) and so forth.
  • PMMA polymethyl methacrylate
  • PC polycarbonate
  • ETFE ethylene tetrafluorethylene
  • PET polyethylene terephthalate
  • PEN polyethylene naphthalate
  • the two faces 6, 7 have opportunely shaped surfaces for confining sunlight inside the tile 5; in particular, the faces 6, 7 are shaped to confine and trap the light incident on the outer face 6 inside the tile 5 and avoid or limit light leaving through the faces 6, 7, giving rise to multiple total reflections .
  • the faces 6, 7 are shaped such that the active structure 3 has high conversion efficiency in the conditions of use of the cell 1 and therefore, in particular, when the support element 2 and therefore the cell 1 as a whole are arranged vertically (plane P vertical, such as on a vertical wall of a building for example) .
  • the cell 1 is destined to form a building panel for making building structures, in particular for making vertical walls; in this preferred application, the cell 1 is therefore installed substantially vertically, that is to say with plane P substantially vertically, and the faces 6, 7 are shaped in consequence.
  • the faces 6, 7 have respective series of projections 10 defining light orientation patterns.
  • the projections 10 and the patterns they define are shaped such that, in use, sunlight incident on the outer face 6 is confined inside the tile 5 and, consequently, such that the energy conversion efficiency of the cell 1 is optimized.
  • the outer face 6 is shaped so as give the active structure 3 an optimal orientation with respect to the sun, also according to the place of installation; the projections 10 of the outer face 6 are therefore also designed, if necessary, according to the latitude or, in any case, the location where the cell 1 will be installed.
  • each face 6, 7 has a crested surface and shows a succession of crests and grooves.
  • each face 6, 7 has a substantially saw-toothed lateral profile.
  • the projections 10 are ridges that extend longitudinally along their respective axes; in particular, the projections 10 are essentially prismatic ridges and extend along respective straight axes that are parallel to each other and to the central plane P and, in use, are substantially horizontal.
  • the projections 10 of each face 6, 7 are arranged parallel to each other with a set pitch that is preferably constant.
  • Each projection 10 has a pair of lateral sides 12 converging to a free extremity 13 or apex that, preferably, consists of an edge.
  • the projections 10 are substantially V-shaped and have a substantially triangular cross-section.
  • the production method chosen for making the tile 5 enables recurring profiles composed of elements even of quite complex geometry, such as a scalene triangle for example, to be obtained.
  • the geometry of the projections 10 can easily be adapted to the specific latitude where it is planned to use the cell 1.
  • the patterns formed by the projections 10 on the faces 6, 7 can be the same, similar or different, as they are formed by projections 10 that have the same or different shapes, sizes and/or layout on the two faces 6, 7.
  • the projections 10 of the inner face 7 can be arranged with the same or a different pitch, in particular a lower one, with respect to the projections 10 of the outer face 6; advantageously, the projections 10 of the inner face 7 are offset with respect to the projections 10 of the outer face 6, as shown in Figure 1, for the purpose of optimizing light entrapment inside the tile 5 through multiple total reflections .
  • the inner face 7 is microstructured, i.e. it has uniformly distributed incisions of micrometric dimensions (less than a millimetre) , in order to diffuse light inside tile 5 and therefore onto the active structure 3.
  • the support element 2 constitutes a substrate on which the active structure 3 is arranged, which is specifically arranged on the inner face 7 of the tile 5, namely on the opposite face to the face that is destined, in use, to face the sun.
  • the active structure 3 can be of any known type, for example, a multilayer thin film structure.
  • the active structure 3 includes at least one active layer 15 for the conversion of light rays into electrical current (i.e. possessing the photovoltaic effect), arranged between a front conductive layer 16, made of transparent conductive oxide for example, and a back conductive layer 17, made of a metallic material or transparent conductive oxide for example; the conductive layers 16 and 17 are arranged on opposite sides of the active layer 15 and, optionally, the active structure 3 can include one or more barrier layers .
  • a plurality of longitudinally elongated conductive elements 18 are positioned along respective projections 10 of the inner face 7 and precisely on the free extremities 13 (apexes or edges) of these projections. These conductive elements 18 serve to collect the charge generated by the active structure 3.
  • the conductive elements 18 are advantageously embedded in the front conductive layer 16 and completely buried therein, on the side facing the tile 5. However, it is understood that, depending on the applications, the conductive elements 18 can be arranged in other positions, for example, on tips, depressions or even on the lateral surfaces of the profile not directly exposed to the sun.
  • the active structure 3 can be closed/sealed by an opportune coating 19 formed, for example, by a metalized layer and/or a polymeric layer.
  • the cell 1 is made by a manufacturing process that basically comprises the steps of:
  • the tile 5 is made through the pressure moulding of molten glass, namely by hot plastic deformation exerted by a press on a mass of molten glass in a mould; the molten glass is introduced into a cavity between two dies (die and counter die) that define the shape of the tile to be made.
  • the tile is made, in any case, by hot moulding in a die and, advantageously, by injection moulding.
  • the faces 6, 7 are made in the desired shape (hence provided with projections 10) directly in the moulding step.
  • a die having two opposite moulding faces shaped to make the respective faces 6, 7 is used; the moulding surface that forms the inner face 7 may possibly be embossed or machined to create the microstructured surface of the face 7.
  • the depositing step of the active structure 3 includes, for example, the steps of:
  • the coating 19 for covering the active structure 3 on the side opposite to the support element 2 is applied.
  • the cell 1 comprises two tiles 5 coupled to each other and an active structure 3 inserted between the two tiles 5.
  • Each tile 5 is advantageously provided with a plurality of contact elements 18, arranged on the projections 10 of the inner faces 7 of both tiles 5 and buried in respective conductive layers.
  • the perimeter edges 8 of the tiles 5 are shaped so as to realize a shape coupling or geometric coupling or a mechanical joint .
  • the perimeter edges 8 of the two tiles 5 are then advantageously joined to each other and sealed, by heat treatment for example, in order to seal the active structure 3 inside them.
  • This processing enables hermetic and almost everlasting sealing of the cell 1 to be achieved.
  • This solution is particularly indicated in the case of photoelectrochemical cells (Graetzel cells or dye-sensitized solar cells, DSSC) , as the sealing avoids the problem once and for all of electrolyte leakage from the inside of the cell and consequent rapid deterioration.
  • the active structure 3 includes (as in a typical Graetzel cell) two electrodes separated by a matrix, in titanium dioxide for example, which contains a liquid active substance (typically a colouring agent) and an electrolytic solution.
  • a liquid active substance typically a colouring agent

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  • Engineering & Computer Science (AREA)
  • Physics & Mathematics (AREA)
  • Condensed Matter Physics & Semiconductors (AREA)
  • Electromagnetism (AREA)
  • General Physics & Mathematics (AREA)
  • Computer Hardware Design (AREA)
  • Microelectronics & Electronic Packaging (AREA)
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Abstract

A photovoltaic cell (1), for integrated building applications in particular, comprises at least a support element (2) and an active structure (3) arranged on the support element (2) and capable of converting light energy into electrical energy by photovoltaic effect; the support element (2) is a tile (5) of glass or a moulded polymeric material, which extends between two opposite faces (6, 7) provided with respective series of projections (10) defining light orientation patterns for confining the light incident on a first face (6) inside the tile (5) and onto the active structure (3).

Description

PHOTOVOLTAIC CELL FOR INTEGRATED BUILDING APPLICATIONS AND METHOD FOR MANUFACTURING THIS CELL
TECHNICAL FIELD
The present invention relates to a photovoltaic cell, in particular for integrated building applications, and a method for manufacturing this cell .
The cell of the invention is particularly indicated for being used as a building element for making building structures, especially for making vertical walls.
BACKGROUND ART
A field of application of great interest for photovoltaic cells and panels is that of so-called Building Integrated Photovoltaics (BIPV) ; in these applications, the photovoltaic panels are destined to substitute traditional building elements such as roofs, facades and so forth, with an evident synergetic effect and considerable savings from the building construction standpoint. However, two different problems limit the diffusion of these solutions: low energy efficiency and a generally unsatisfying aesthetic effect.
Low efficiency particularly afflicts photovoltaic panels installed on vertical walls, due to the significant loss of reflection caused by unfavourable orientation with respect to the sun. Solutions exist in which traditional panels are mounted at an optimal angle, but are limited to shadings and can in no way substitute building sheathing.
Given the architectural context, it becomes evident that the aesthetic rendering of a BIPV facade is of fundamental importance. The solutions currently available on the market are basically limited to three types of solar panels: single- crystal silicon, polycrystalline silicon and amorphous silicon. Of these, only the latter can be made in a uniform and semitransparent manner on large surfaces, and so might find an application in architecture; in any case, the choice of colours with these products remains very limited.
In conclusion, there is not a photovoltaic cell or panel available at the moment that can be used in architecture, especially for vertical surfaces, and which at the same time is adequately efficient from the energy standpoint and satisfactory from the aesthetic-architectural viewpoint (as well as being manufacturable with relatively moderate costs) .
DISCLOSURE OF INVENTION
One object of the present invention is therefore that of providing a photovoltaic cell that is devoid of the drawbacks of the known art pointed out herein; in particular, an object of the invention is that of providing a photovoltaic cell that can be used in integrated building applications, especially for making vertical walls for buildings and other architectural structures, while being relatively inexpensive and simple to make, efficient from the energy standpoint and with a satisfactory aesthetic appearance.
The present invention is therefore relative to a photovoltaic cell as defined in basic terms in the attached claim 1 and a method for manufacturing photovoltaic cells as defined in claim 9.
The invention also regards the use of a photovoltaic cell in a building panel for making building structures, especially for making vertical walls, as defined in claim 10.
The invention also regards the use of a special support element as a substrate for photovoltaic cells, in particular multilayer thin film or photoelectrochemical photovoltaic cells, as defined in claim 11. The present invention actually provides a new support element for making various types of photovoltaic cells with a multilayer structure, for example, various types of thin film cells and photoelectrochemical cells or Graetzel cells; the support element is composed of a tile made of glass, in particular of moulded glass (i.e. obtained via a molten glass moulding operation), or another transparent material, in particular a transparent polymeric material, having opportunely shaped surfaces for confining sunlight inside the tile .
Various multilayer structures can be applied to the support element to form different types of photovoltaic cells, in particular thin film cells (for example, a-Si:H, micromorph silicon, Cd-Te, CIS/CIGS, and so on) and photoelectrochemical cells (so-called DSSC, "Dye Sensitized Solar Cells", or Graetzel cells) .
As is known, unlike polycrystalline or single-crystal silicon cells, these cells are made by the successive depositing of various functional layers .
The cells in accordance with the invention differ with respect to some known solutions (in which a separately made optical element is mounted on an ordinary cell to function as a lens to focus rays on the active element) due to the fact that the active structure of the cell is constructed directly on the already opportunely shaped substrate (tile) .
In accordance with the invention, both the support element and the photovoltaic cell as a whole are relatively simple and economical to manufacture.
Thanks to the particular structure and geometry of the support element, the photovoltaic cell of the invention, however made, can be used as a building element with high efficiency, even and especially for making vertical walls; the cell of the invention can also be made in various shapes, sizes and colours, so as to create walls having different aesthetic- architectural effects.
BRIEF DESCRIPTION OF THE DRAWINGS
Further characteristics and advantages of the present invention shall become apparent from the description of the following non-limitative embodiments, with reference to the attached drawings, where:
- Figure 1 is an schematic view, in longitudinal section and out of scale, of a portion of a photovoltaic cell in accordance with a first embodiment of the invention, and
- Figure 2 is a schematic view, in longitudinal section and out of scale, of a portion of a photovoltaic cell in accordance with a second embodiment of the invention.
BEST MODE FOR CARRRYING OUT THE INVENTION
In Figure 1, a photovoltaic cell, in particular a multilayer thin film cell, is indicated as a whole by reference numeral 1.
The cell 1 comprises a support element 2 and a multilayer active structure 3, carried by the support element 2 and formed by a plurality of functional layers that, as a whole, are able to convert light energy into electrical energy via the photovoltaic effect.
The support element 2 consists of a tile 5 made of glass (or another transparent material , in particular a polymeric material) and that is basically prismatic, for example having a quadrangular (rectangular or square) plan shape; the tile 5 has two larger opposite faces 6, 7, arranged on opposite sides of a central plane P, and a perimeter edge 8 that connects the two faces 6 , 7. In use, the face 6 is destined to face directly to the sun and therefore constitutes an outer face of the tile 5; the other face 7 constitutes an inner face of the tile 5.
The tile 5 is advantageously composed of a monolithic piece made of moulded glass, i.e. obtained by the pressure moulding of molten glass.
Here and hereafter, the following meanings are intended:
- "pressure moulding of molten glass" is a mechanical process of plastic deformation carried out by hot dynamic action exerted by a press on molten glass in order to make the glass fill a cavity between two metal dies; in pressure moulding, an opportune quantity of molten glass having suitable temperature and plasticity characteristics is introduced into a hot metal die, into which a counter die is then immersed that, by exerting pressure, forces the glass to occupy the space between the die and the counter die, thereby determining the thickness and shape of the object to be made,
- a tile or piece made "of moulded glass" is a manufactured item made by a pressure moulding operation on molten glass.
Alternatively, the tile 5 can be made by moulding (injection moulding in particular) another transparent material, in particular a transparent polymeric material, for example, polymethyl methacrylate (PMMA) , polycarbonate (PC) , ethylene tetrafluorethylene (ETFE) , polyethylene terephthalate (PET) , polyethylene naphthalate (PEN) and so forth.
The two faces 6, 7 have opportunely shaped surfaces for confining sunlight inside the tile 5; in particular, the faces 6, 7 are shaped to confine and trap the light incident on the outer face 6 inside the tile 5 and avoid or limit light leaving through the faces 6, 7, giving rise to multiple total reflections . In other terms, the faces 6, 7 are shaped such that the active structure 3 has high conversion efficiency in the conditions of use of the cell 1 and therefore, in particular, when the support element 2 and therefore the cell 1 as a whole are arranged vertically (plane P vertical, such as on a vertical wall of a building for example) .
In fact, in accordance with a preferred embodiment of the invention, the cell 1 is destined to form a building panel for making building structures, in particular for making vertical walls; in this preferred application, the cell 1 is therefore installed substantially vertically, that is to say with plane P substantially vertically, and the faces 6, 7 are shaped in consequence.
In particular, the faces 6, 7 have respective series of projections 10 defining light orientation patterns.
The projections 10 and the patterns they define are shaped such that, in use, sunlight incident on the outer face 6 is confined inside the tile 5 and, consequently, such that the energy conversion efficiency of the cell 1 is optimized.
In particular, the outer face 6 is shaped so as give the active structure 3 an optimal orientation with respect to the sun, also according to the place of installation; the projections 10 of the outer face 6 are therefore also designed, if necessary, according to the latitude or, in any case, the location where the cell 1 will be installed.
In particular, each face 6, 7 has a crested surface and shows a succession of crests and grooves.
Preferably, each face 6, 7 has a substantially saw-toothed lateral profile. The projections 10 are ridges that extend longitudinally along their respective axes; in particular, the projections 10 are essentially prismatic ridges and extend along respective straight axes that are parallel to each other and to the central plane P and, in use, are substantially horizontal.
The projections 10 of each face 6, 7 are arranged parallel to each other with a set pitch that is preferably constant.
Each projection 10 has a pair of lateral sides 12 converging to a free extremity 13 or apex that, preferably, consists of an edge.
In the example shown in Figure 1, the projections 10 are substantially V-shaped and have a substantially triangular cross-section.
The production method chosen for making the tile 5 enables recurring profiles composed of elements even of quite complex geometry, such as a scalene triangle for example, to be obtained. In consequence, the geometry of the projections 10 can easily be adapted to the specific latitude where it is planned to use the cell 1.
The patterns formed by the projections 10 on the faces 6, 7 can be the same, similar or different, as they are formed by projections 10 that have the same or different shapes, sizes and/or layout on the two faces 6, 7.
For example, the projections 10 of the inner face 7 can be arranged with the same or a different pitch, in particular a lower one, with respect to the projections 10 of the outer face 6; advantageously, the projections 10 of the inner face 7 are offset with respect to the projections 10 of the outer face 6, as shown in Figure 1, for the purpose of optimizing light entrapment inside the tile 5 through multiple total reflections .
Advantageously, but not necessarily, the inner face 7 is microstructured, i.e. it has uniformly distributed incisions of micrometric dimensions (less than a millimetre) , in order to diffuse light inside tile 5 and therefore onto the active structure 3.
The support element 2 constitutes a substrate on which the active structure 3 is arranged, which is specifically arranged on the inner face 7 of the tile 5, namely on the opposite face to the face that is destined, in use, to face the sun.
The active structure 3 can be of any known type, for example, a multilayer thin film structure.
In general, the active structure 3 includes at least one active layer 15 for the conversion of light rays into electrical current (i.e. possessing the photovoltaic effect), arranged between a front conductive layer 16, made of transparent conductive oxide for example, and a back conductive layer 17, made of a metallic material or transparent conductive oxide for example; the conductive layers 16 and 17 are arranged on opposite sides of the active layer 15 and, optionally, the active structure 3 can include one or more barrier layers .
In the preferred embodiment shown in Figure 1, a plurality of longitudinally elongated conductive elements 18 are positioned along respective projections 10 of the inner face 7 and precisely on the free extremities 13 (apexes or edges) of these projections. These conductive elements 18 serve to collect the charge generated by the active structure 3. The conductive elements 18 are advantageously embedded in the front conductive layer 16 and completely buried therein, on the side facing the tile 5. However, it is understood that, depending on the applications, the conductive elements 18 can be arranged in other positions, for example, on tips, depressions or even on the lateral surfaces of the profile not directly exposed to the sun.
At the back (i.e. on the side opposite to the support element 2), the active structure 3 can be closed/sealed by an opportune coating 19 formed, for example, by a metalized layer and/or a polymeric layer.
The cell 1 is made by a manufacturing process that basically comprises the steps of:
- moulding the tile 5 by the moulding of molten glass or a polymeric material, and
- depositing the active structure 3 on face 7 of the tile.
As previously pointed out, the tile 5 is made through the pressure moulding of molten glass, namely by hot plastic deformation exerted by a press on a mass of molten glass in a mould; the molten glass is introduced into a cavity between two dies (die and counter die) that define the shape of the tile to be made.
If a polymeric material is used, the tile is made, in any case, by hot moulding in a die and, advantageously, by injection moulding.
The faces 6, 7 are made in the desired shape (hence provided with projections 10) directly in the moulding step. A die having two opposite moulding faces shaped to make the respective faces 6, 7 is used; the moulding surface that forms the inner face 7 may possibly be embossed or machined to create the microstructured surface of the face 7.
In turn, the depositing step of the active structure 3 includes, for example, the steps of:
- applying the contact elements 18 on the projections 10 of face 7,
- depositing the front conductive layer 16 so as to embed the contact elements 18, and
- depositing the other layers of the active structure 3 in succession, for example, the active layer 15 and the back conductive layer 17.
Lastly, and optionally, the coating 19 for covering the active structure 3 on the side opposite to the support element 2 is applied.
In the embodiment in Figure 2, in which details that are the same or similar to those already described are indicated with the same reference numerals, the cell 1 comprises two tiles 5 coupled to each other and an active structure 3 inserted between the two tiles 5.
Each tile 5 is advantageously provided with a plurality of contact elements 18, arranged on the projections 10 of the inner faces 7 of both tiles 5 and buried in respective conductive layers. One or more active layers and possibly other functional layers, for example barrier layers to form the active structure 3, are included between the conductive layers .
The perimeter edges 8 of the tiles 5 are shaped so as to realize a shape coupling or geometric coupling or a mechanical joint .
The perimeter edges 8 of the two tiles 5 are then advantageously joined to each other and sealed, by heat treatment for example, in order to seal the active structure 3 inside them. This processing enables hermetic and almost everlasting sealing of the cell 1 to be achieved. This solution is particularly indicated in the case of photoelectrochemical cells (Graetzel cells or dye-sensitized solar cells, DSSC) , as the sealing avoids the problem once and for all of electrolyte leakage from the inside of the cell and consequent rapid deterioration.
In this case, the active structure 3 includes (as in a typical Graetzel cell) two electrodes separated by a matrix, in titanium dioxide for example, which contains a liquid active substance (typically a colouring agent) and an electrolytic solution.
It is further understood that what is described and shown herein is susceptible to modifications and variants without departing from the scope of the invention, as defined in the attached claims .

Claims

1. A photovoltaic cell (1), in particular for building integrated photovoltaic applications, comprising at least a support element (2) and an active structure (3) arranged on the support element (2) and capable of converting light energy into electrical energy by photovoltaic effect, the support element (2) being a tile (5) of a transparent material that extends between a first face (6) that, in use, constitutes an outer face of the cell directly facing the sun, and a second face (7) , opposite to the first face (6) and that, in use, constitutes an inner face of the cell (1) , both of said opposite faces (6, 7) being provided with respective series of projections (10) defining light orientation patterns for confining the light incident on first face (6) inside the tile (5) and onto the active structure (3), the tile (5) being formed by a monolithic piece made of moulded glass or a moulded polymeric material and obtained by pressure moulding of molten glass or by moulding a polymeric material.
2. The cell according to claim 1, wherein one or both faces (6, 7) of the tile (5) have a substantially saw-toothed profile.
3. The cell according to claim 1 or 2, wherein the second face (7) is microstructured for diffusing the light inside the tile (5) and onto the active structure (3) .
4. The cell according to one of the preceding claims, wherein a plurality of longitudinally elongated conductive elements (18) are positioned along respective projections (10) of the second face (7) , for example, on the top edges of said projections, and are embedded in a front conductive layer (16) and completely buried therein, on the side opposite to the tile (5) .
5. The cell according to one of the preceding claims, wherein the active structure (3) is closed/sealed at the back, i.e. on the side opposite to the support element (2), by a coating (19), for example formed by a metalized layer and/or a polymeric layer.
6. The cell according to one of the preceding claims, comprising two tiles (5) coupled to each other and having respective faces (7) facing each other, with the active structure (3) interposed between the two tiles (5) .
7. The cell according to claim 6, wherein the two tiles (5) have respective perimeter edges (8) shaped so as to realize a shape coupling or geometric coupling or a mechanical oint .
8. The cell according to claim 7, wherein the perimeter edges (8) of the two tiles (5) are joined to one another and sealed, for example by heat treatment, in order to seal the active structure (3) inside them.
9. A method for manufacturing a photovoltaic cell (1) , in particular for building integrated photovoltaic applications, comprising the steps of:
- moulding a tile (5) of glass or a transparent polymeric material by the pressure moulding of molten glass or by moulding a transparent polymeric material, providing directly in the moulding step two opposite faces (6, 7) of the tile (5) with respective series of projections (10) defining light orientation patterns for confining the light incident on a first face (6) inside the tile (5), and
- depositing on a second face (7) of the tile (5), opposite to the first face (6), an active structure (3) capable of converting light energy into electrical energy by photovoltaic effect .
10. A building panel for making building structures, in particular for making vertical walls, characterized by- comprising a photovoltaic cell according to any one of claims 1 to 8.
11. Use of a tile (5) as a support element for photovoltaic cells, in particular multilayer thin film or photoelectrochemical photovoltaic cells, said tile (5) being made of a transparent material and extending between two opposite faces (6, 7) provided with respective series of projections (10) defining light orientation patterns for confining the light incident on a first face (6) inside the tile (5) , the tile (5) being formed by a monolithic piece made of moulded glass or a moulded polymeric material and obtained by pressure moulding of molten glass or a polymeric material in a mould.
PCT/IB2011/000807 2010-04-12 2011-04-12 Photovoltaic cell for integrated building applications and method manufacturing this cell WO2011128757A1 (en)

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EP2559070B1 (en) 2015-10-07
IT1399376B1 (en) 2013-04-16
EP2559070B8 (en) 2015-12-09
ITMI20100614A1 (en) 2011-10-13
WO2011128757A8 (en) 2012-05-18

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