Classifications

• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
  • B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
  • B23K1/00—Soldering, e.g. brazing, or unsoldering
  • B23K1/005—Soldering by means of radiant energy
  • B23K1/0056—Soldering by means of radiant energy soldering by means of beams, e.g. lasers, E.B.
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
  • B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
  • B23K1/00—Soldering, e.g. brazing, or unsoldering
  • B23K1/0008—Soldering, e.g. brazing, or unsoldering specially adapted for particular articles or work
  • B23K1/0016—Brazing of electronic components
• • 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
  • H01L31/042—PV modules or arrays of single PV cells
  • H01L31/05—Electrical interconnection means between PV cells inside the PV module, e.g. series connection of PV cells
  • H01L31/0504—Electrical interconnection means between PV cells inside the PV module, e.g. series connection of PV cells specially adapted for series or parallel connection of solar cells in a module
  • H01L31/0516—Electrical interconnection means between PV cells inside the PV module, e.g. series connection of PV cells specially adapted for series or parallel connection of solar cells in a module specially adapted for interconnection of back-contact solar cells
• • 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
  • H01L31/18—Processes or apparatus specially adapted for the manufacture or treatment of these devices or of parts thereof
  • H01L31/1876—Particular processes or apparatus for batch treatment of the devices
  • H01L31/188—Apparatus specially adapted for automatic interconnection of solar cells in a module
• • 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

Definitions

• the present invention relates to the assembly of solar panels.
• Solar panels comprise a number of solar cells and a structure to unite these solar cells, to protect them against the rain and other weather influences and to connect them electrically.
• the present invention relates more specifically to the assembly of solar cells comprising a back sheet foil with a number of first contacts, a number of solar cells each with a number of second contacts, to be connected to the first contacts, a front layer and solder paste pads applied to the first contacts or second contacts. Further an encapsulant material is added. During assembly these components are stacked and heated under pressure to form a solar panel. The encapsulant material melts and after solidifying thereof a rigid unit is obtained as is described in US-A-5 972 732. Further electrical connections have to be made between the first and second contacts.
• the present invention proposes a method of the kind referred to above, wherein at least during the soldering the solar panel is compressed in the direction perpendicular to its main plane.
• the forces thus developed will compress the solar panel to such an extend that the forming of bulges is prevented and the quality of the solder joints is improved.
• the solar cells and the front layer are mutually bonded.
• the invention also relates to an apparatus for soldering electrical contacts in a solar panel, the solar panel comprising a back sheet foil with a number of first contacts, a number of solar cells each having a number of second contacts, to be connected to the first contacts, a front layer and solder paste pads applied to the first contacts or to the second contacts, the apparatus comprising means for locally applying heat to the solder paste pads to make the solder melt, a support for locating the solar panel to be soldered and a laser apparatus for heating the solder paste pads to melt these solder paste pads to form a solder joint between the first and the second contacts after solidification, further comprising means for compressing the solar panel in the direction perpendicular to its main plane.
• the forces may be generated by depositing a body with a substantial weight on the solar panel during the soldering process.
• the weight of the body should be sufficient to generate the pressure which is sufficient to compress the solar panel to such an extend that the bulging does not appear.
• This embodiment also provides an apparatus comprising a body with a substantial weight adapted to be located on the solar panel and means for arranging the body on the solar panel and for removing the body from the solar panel.
• the heat for the soldering process is supplied through laser.
• the body should hence have such a configuration that the paths of the laser beams is not hampered. This may be reached by providing an aperture in the body adapted to let the laser beams pass, or by using a body which is transparent for the laser beams.
• the body is substantially flat and it comprises apertures arranged in a pattern coinciding with the pattern of the solder pads.
• the laser beams can pass the body through the apertures.
• clamps are brought into engagement with the solar panel, in such a way that during the soldering process the clamps compress the components of the solar panel in a direction perpendicular to the main plane of the solar panel and that after the soldering process the clamps are removed.
• This embodiment also provides an apparatus comprising clamps adapted to be brought into engagement with the solar panel and means for activating the clamps to compress the components of the solar panel in a direction perpendicular to the main plane of the solar panel.
• This embodiment avoids the problems with the body having a substantial weight. Again these clamping means must be adapted to avoid hampering the laser beams.
• the most promising embodiment provides a method wherein during the soldering a pressure lower than the atmospheric pressure is applied on apertures in a support onto which the solar panel rests during the soldering process.
• the surrounding pressure urges the upper parts of the solar panel to the lower layers so that the layers are pressed together, just as in the preceding embodiments.
• the pressure lower than the atmospheric pressure can be adapted to obtain the required effect, to a minimum of an approximation of a vacuum.
• This last embodiment also provides an apparatus comprising apertures located in the support and by a vacuum pump connected to the apertures.
• the solar panel rests on the support and the lower pressure is applied through the apertures provided in the support.
• the support comprises preferably a material having some resiliency, like a rubber layer having preferably a thickness of around 2mm and a hardness of 90 shore.
• a material having some resiliency like a rubber layer having preferably a thickness of around 2mm and a hardness of 90 shore.
• other materials as support can also be envisaged, like glass, plastic, metal, etc.
• Figure 1 a detailed cross sectional view of a solar panel of the type to which the present invention pertains
• Figure 2 a cross sectional view of a solar panel, wherein a first embodiment is applied
• Figure 3 a cross sectional view of a solar panel, wherein a second embodiment is applied.
• Figure 4 a cross sectional view of a solar panel, wherein a third embodiment is applied.
• Figure 1 depicts a section of a solar panel 1 which has been assembled but which is not yet soldered. It comprises a glass plate 2 on top, under which a solar cell 3 has been arranged. At its underside the solar cell 1 is provided of a number of second solder contacts 4, of which only one has been depicted.
• the solar cell 3 is of the so called back contact type, in particular of the metal wrap through type, so that the contacts of both polarities are present on the back side of the cell 3.
• the lowest layer of the solar panel 1 is a foil 5 of an electrically insulating material, on top of which metal tracks 6 and first solder contacts 7 have been provided.
• a solder pad 8 has been provided on each of the first solder contacts 7, although it is also possible to have the solder pad 8 applied to the second solder contacts 4. Further between the glass plate 2, the foil 5 and in between the solar cells a filling and adhesive material 9 has been provided which unites, after being heated, all parts of the solar panel.
• solder pads 8 which are still solid, need to be melted to form a connection between the first and second solder contacts 7, 4 after solidifying. Therefore use is made of laser beams, not depicted in this figure and which act locally to melt the solder pads. It will be clear that the heating of the solder pads will also heat the parts in the area
• Said body comprises apertures 13, which are each aligned with the locations of the solder connections 8 to be made.
• the apertures are adapted in location and shape to allow the beams 14 of a laser source 15 located above the support 11 to reach the solder pads 8.
• the weight of the body 12 compresses the solar panel 1 to avoid bulging thereof, so that the reliability of the solder connections is assured.
• the solar panels which are produced in large numbers, are supplied on a conveyor, which forms the support. Soldering takes place on a non moving support. As soon as a solar panel has been soldered, it is conveyed further.
• FIG 3 shows an embodiment wherein the solar panel 1 is compressed.
• the solar panel 1 is located onto a support 21, of which the width is smaller than the width of the solar panel 1, so that the solar panel protrudes over the support 21. It is possible that instead of or in addition to protruding in de direction of the width, the solar panel 1 protrudes in the direction of the length over the support.
• the clamps 22 serve to compress the solar panel 1.
• the clamps 22 comprise each a fixed part 23 adapted to contact the lower face of the solar panel 1 and a moveable part 24 connected hinged to the fixed part 23.
• a linear actuator 25 is hinged connected between the fixed part 23 and the moveable part 24 so that actuation of the linear actuator 25 causes the clamp 22 to compress the parts present between the fixed part 23 and the moveable part 24 of the clamp.
• clamps 22 with a hydraulic actuation are foreseen, but the use of clamps having other kinds of actuation, such as pneumatic or electromagnetic are not excluded.
• the drawings show two clamps 22 only, but a skilled man will understand that other numbers of clamps, such as four, six or eight may be used, in dependence of the size of the solar panel 1 and of the clamps.
• the clamps 22 are mounted moveably in substantial horizontal direction in a structure not depicted in the drawings, so that the clamps 22 may be moved from the position depicted in the drawings to a position more sideways of the solar panel 1 to allow the solar panel 1 to be moved into and out of the position depicted in figure 3. Further it will be clear that preceding the soldering action of the solar panel, the clamps will be actuated to compress the solar panel and after the soldering action the clamps will be released.
• FIG. 4 shows an solar panel 1 resting on a support 31, which is preferably made of rubber or of another material with a hardness or another material having a some resiliency and which is provided with a number of apertures 32.
• the apertures 32 are all connected to a vacuum pump 33 via tubing 34.
• the action of this embodiment is such that preceding the soldering of the solar panel 1 located on the support 31, the vacuum pump 33 is actuated to reduce the pressure under the solar panel and to make the ambient pressure compressing the solar panel. After the soldering the vacuum pump is switched off and the tubing connected with the ambient to allow the vacuum to release, making the solar panel ready for the next processing step.

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• Engineering & Computer Science (AREA)
• Physics & Mathematics (AREA)
• Power Engineering (AREA)
• Condensed Matter Physics & Semiconductors (AREA)
• Electromagnetism (AREA)
• General Physics & Mathematics (AREA)
• Computer Hardware Design (AREA)
• Microelectronics & Electronic Packaging (AREA)
• Mechanical Engineering (AREA)
• Life Sciences & Earth Sciences (AREA)
• Sustainable Development (AREA)
• Optics & Photonics (AREA)
• Sustainable Energy (AREA)
• Manufacturing & Machinery (AREA)
• Photovoltaic Devices (AREA)

Applications Claiming Priority (4)

Publications (1)

Family

ID=45874015

Family Applications (1)

Country Status (2)

Cited By (3)

Citations (4)

• 2010
  • 2010-12-03 NL NL2005811A patent/NL2005811C2/en not_active IP Right Cessation
• 2011
  • 2011-09-20 WO PCT/NL2011/050635 patent/WO2012039610A1/en active Application Filing

Patent Citations (4)

Non-Patent Citations (2)

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