WO2012069995A2 - Methods and apparatus for applying a connection agent to atleast a connector for connection atleast a solar cell - Google Patents

Methods and apparatus for applying a connection agent to atleast a connector for connection atleast a solar cell Download PDF

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Publication number
WO2012069995A2
WO2012069995A2 PCT/IB2011/055242 IB2011055242W WO2012069995A2 WO 2012069995 A2 WO2012069995 A2 WO 2012069995A2 IB 2011055242 W IB2011055242 W IB 2011055242W WO 2012069995 A2 WO2012069995 A2 WO 2012069995A2
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WO
WIPO (PCT)
Prior art keywords
connection
atleast
connector
agent
stream
Prior art date
Application number
PCT/IB2011/055242
Other languages
French (fr)
Other versions
WO2012069995A3 (en
WO2012069995A4 (en
Inventor
Joachim Ufheil
Original Assignee
Somont Gmbh
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Filing date
Publication date
Application filed by Somont Gmbh filed Critical Somont Gmbh
Publication of WO2012069995A2 publication Critical patent/WO2012069995A2/en
Publication of WO2012069995A3 publication Critical patent/WO2012069995A3/en
Publication of WO2012069995A4 publication Critical patent/WO2012069995A4/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
    • H01L31/1876Particular processes or apparatus for batch treatment of the devices
    • H01L31/188Apparatus specially adapted for automatic interconnection of solar cells in a module
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B05SPRAYING OR ATOMISING IN GENERAL; APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
    • B05BSPRAYING APPARATUS; ATOMISING APPARATUS; NOZZLES
    • B05B12/00Arrangements for controlling delivery; Arrangements for controlling the spray area
    • B05B12/16Arrangements for controlling delivery; Arrangements for controlling the spray area for controlling the spray area
    • B05B12/18Arrangements for controlling delivery; Arrangements for controlling the spray area for controlling the spray area using fluids, e.g. gas streams
    • 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
    • H01L31/05Electrical interconnection means between PV cells inside the PV module, e.g. series connection of PV cells
    • H01L31/0504Electrical 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
    • 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 present invention relates generally to connecting photovoltaic (PV) devices, and more particularly, to methods and apparatus for applying a connection agent to atleast a connector or contact for connection of atleast a solar cell without the use of Volatile Organic Compounds (VOCs) in a fast, robust, cost effective, secure, and environmental friendly manner.
  • PV photovoltaic
  • VOCs Volatile Organic Compounds
  • first wafers are manufactured.
  • the surface of the wafer is etched with a chemical process to reduce the depth of the defects and then the wafer is structured to improve its optical properties.
  • a p-n junction is made by doping the silicon with appropriate contaminations and then an anti-reflex layer is applied.
  • electrical conductors for example, fingers and bus bars, are deposited on top of the cells and are fired in a furnace.
  • cells are tested to evaluate their proprieties. Now the wafer has become a solar cell that incorporated in a solar module.
  • the solar cells are interconnected with connectors such as ribbons by soldering.
  • connectors normally exist of a flat copper body which is coated with a solder. To perform the soldering between the solar cells and the connector flux is necessary.
  • the ribbon or cell is normally moistened by immersion bath coating or spraying the flux directly onto the surface followed by application of heat through a drying station to evaporate the Isopropanol to leave back the adipic acid. In the former case a lot of flux is lost because the ribbon is also fluxed where it is not needed.
  • No-Clean Fluxes are low solid - less than 5% fluxes. They are completely non- halide, give excellent wetting on surface mounted components, and leave no visible flux residue after soldering. Normally no further cleaning is required. Main problems by using a liquid non clean flux on the base of Isopropanol are safety and environment regulations.
  • the active component of the flux may include the Adipic acid which is a very cheap non-toxic acid that is even used in food. If Adipic acid is used, it is preferably heated to 152°C to 160°C.
  • the general purpose of the present invention is to provide an improved combination of convenience and utility, to include the advantages of the prior art, and to overcome the drawbacks inherent in the prior art.
  • the present invention provides effective means to perform the soldering between the solar cells and the ribbon without using Volatile Organic Compounds (VOCs) in a fast, robust, cost effective, secure, and environmental friendly manner.
  • VOCs Volatile Organic Compounds
  • the present invention provides a method for applying atleast a connection agent to atleast a connector for connecting atleast a solar cell.
  • the method comprises the steps of: heating atleast the connection agent, transporting the connection agent with atleast a stream of gas, and depositing the connection agent to atleast the connector.
  • the steam of gas includes atleast one of gas, air, mixture of gasses or any combination thereof.
  • the stream of gas may be filled with one of a gaseous agent or an agent in form of aerosols or any combination thereof.
  • the method further comprises the step of: dispersing the connection agent in the gaseous stream.
  • the present invention provides a method for applying a connection agent to atleast a connector for connecting atleast a solar cell.
  • the method comprises the steps of: dispensing the connection agent in an atmosphere and depositing the connection agent to atleast one connector.
  • the method may further comprise the step of moving the connector thru the atmosphere for deposition of the connection agent on the connector.
  • the atmosphere may also be one of a gaseous stream and an aerosol or any combinations thereof.
  • the method for applying a connection agent to atleast the connector for connecting atleast the solar cell comprises the steps of: creating a gaseous stream; creating a connection stream; and depositing the connection stream at the connector, wherein the connection stream is created by dispersing the connection agent in the gaseous stream.
  • multiple wires may be passed thru atleast a stream. If the stream is used, means may be provided for collecting an agent/material that does not stick to the connector. The thus collected material may be used again in the inventive method of the present invention.
  • the connection stream impinges on the connector outside the atmosphere. With atmosphere a body of gas, air or a mixture of gasses is meant. The atmosphere is most likely held in a partially closed container.
  • the present invention provides an apparatus for applying a connection agent to atleast a connector for connecting atleast the solar cell.
  • the apparatus comprises: means for dispensing the connection agent in an atmosphere; and means for depositing the connection agent to the connector.
  • the apparatus further comprises any one of means for moving the connector thru the atmosphere for deposition of the connection agent on the connector, means for creating a connection stream, means for depositing desired amount of the connection stream on the connector.
  • the connection stream is created by dispersing the connection agent in the gaseous stream.
  • FIG. 1A and IB illustrate a method for applying a connection agent to atleast a connector for connection atleast a solar cell, according to an exemplary embodiment of the present invention.
  • FIG. 2 illustrates an apparatus for applying a connection agent to atleast the connector for connecting atleast the solar cell, according to an exemplary embodiment of the present invention;
  • FIGS. 3 and 4 illustrate schematic setups of connection agent condensation, according to an exemplary embodiment of the present invention
  • FIG. 5 illustrates an heating system, according to an exemplary embodiment of the present invention
  • FIGS. 6A and 6B illustrate an opening adapted to drawn an agent from a reservoir, according to an exemplary embodiment of the present invention
  • FIG. 7A illustrates a nozzle surrounded by a second concentric nozzle for hot air/gas, according to an exemplary embodiment of the present invention.
  • FIG 7B and 7C illustrate means adapted to recollect the agent from the air around the nozzle, according to an exemplary embodiment of the present invention.
  • the terms 'a', 'an', 'atleast' do not denote a limitation of quantity, but rather denote the presence of at least one of the referenced item, the term 'a plurality' denotes the presence of more than one referenced items.
  • the PV device includes atleast any one of an individual waver, a solar cell being manufactured, a solar cell (also referred to as 'cell') or any combination thereof.
  • the terms 'flux agent', 'flux', 'gaseous flux', agent, 'connection agent' and 'active component' may also be used herein interchangeably.
  • the terms 'connector', 'ribbon' may also be used herein interchangeably and denote the conductor used for conduction electrical power away from the cells.
  • the terms 'cell contact' and 'bus bar' may also be used herein interchangeably and denote the conductor used for conduction electrical power on the solar cell.
  • Solar cells may be of any technology such as thin film, crystalline, hetero junction, Hetero junction with intrinsic thin layer (HIT) etc.
  • connection agent is an active component which is capable of being melted, evaporated, sublimated, and suspended in the atmosphere.
  • the connection agent is also capable of atleast partially deoxidizing a surface of the connector or contact.
  • the connection agent includes atleast one of a dry powder, a gaseous active component, and a liquefied active component or any combination thereof.
  • the inventive method for applying a connection agent to atleast a connector for connecting atleast a solar cell comprising the steps of dispensing the connection agent in an atmosphere; and depositing the connection agent to the connector, wherein the atmosphere is filled with one of a gaseous agent or an agent in form of aerosols or any combination thereof. Filled may mean that the agent is suspended in the atmosphere.
  • the present invention provides improved methods and apparatus for applying a connection agent to atleast the connector for connecting atleast the solar cell.
  • the apparatus of the present invention may be mass produced inexpensively and provides user an easy, robust, efficient, secure, cost effective, environment friendly and productive way of connection or soldering PV devices.
  • FIGS. 1A and IB together which illustrate a method 100 for applying atleast a connection agent to atleast a connector for connecting atleast a solar cell, according to an exemplary embodiment of the present invention.
  • the method 100 comprises the steps of: heating atleast the connection agent 22 at a step 111, transporting the connection agent 22 with atleast a stream of gas 30 at a step 122, and depositing the connection agent 22 to atleast the connector at a step 133.
  • the steam of gas 30 includes atleast one of gas, air, mixture of gasses or any combination thereof.
  • the stream of gas 30 may be filled with one of a gaseous agent or an agent in form of aerosols or any combination thereof.
  • the method 100 further comprises the step of: dispersing the connection agent 22 in the gaseous stream.
  • connection agent 22 may be a liquid or solid active component.
  • the apparatus 200 comprises: means 210 for dispensing the connection agent 22 in an atmosphere and means 220 for depositing the connection agent 22 to the connector,
  • the apparatus 200 may further comprise any one of means for moving the connector thru the atmosphere for deposition of the connection agent 22 on the connector, means for creating a connection stream 20, means for depositing desired amount of the connection stream 20 on the connector.
  • the connection stream 20 may be created by dispersing the connection agent 22 in a gas stream 30.
  • the goal of the present invention may be achieved by using only the active component of the connection agent 22 which may be a dry powder at room temperature.
  • the gas -stream 30 (also referred to as 'transport stream') may be directed over the melting or melted powder 22 and then to a nozzle 16.
  • the saturated air / airborne active component may be sprayed onto a ribbon where it is directly deposited (Physical Vapour depositing).
  • the relative low temperature (room temperature) of the ribbon or cell makes the active component condensate on it.
  • an atmosphere may be created above a body or level of the active component 22.
  • the atmosphere may be one of a gas stream 30 or vapour (also referred to as 'active gaseous component'), aerosols or any combination thereof.
  • the atmosphere of gaseous active component 30 may be created by melting the active component 22.
  • the vapour pressure of a material is an indication of a liquid's evaporation rate when the material is still in its condensed state. The higher the vapour pressure of the material for example, the connection agent 22, the more of it will be in gaseous form.
  • the present invention is capable of using materials with a high vapour pressure so that the material vaporizes quickly as the stream of air 18 may remove the vapour that was previously formed.
  • aerosols solid and fluid particles or a combination thereof are meant that are suspended in an atmosphere.
  • the vapour pressure is dependent of the temperature of the material, therefore the vapour pressure increases with the temperature.
  • the active component 22 may become fluid and thus release more damp or the active component 22 may remain solid. If the active component 22 remains solid, then the active component 22 may be sublimated.
  • the setup 300 and 400 comprises atleast a container 12 for retaining an active component 22, atleast a gas connection for providing an air stream 18, and atleast a nozzle 16.
  • the container 12 may be a pump or a heatable and chemically resistant box.
  • the container 12 may have a heater 14.
  • the gas stream 30 and the atmosphere may be mixed using a ventilator or the like.
  • the inlet for the gas stream 30 may be placed such that the gas has to travel thru the atmosphere and preferable disturb the atmosphere as to create turbulence.
  • the air stream 18 may lead directly into the active liquid component 22.
  • any one of the air stream 18 and the component parts the air steam 18 touches may be heated to facilitate the vaporisation and keep the active component 22 above a certain temperature in the remaining apparatus (also referred to as 'system').
  • the air stream 18 in and to the nozzle 16 may be needed to prevent the active component 22 from condensing in the nozzle 16 or the conduct to the active component 22 from clogging the system.
  • the Air stream 18, may be a dry air with no contamination of oil, may be used to keep the system clean. Further, dry air with no contamination of oil, may be preferably keep the system clean.
  • the holder or container 12 of the active component may be replaceable.
  • the active component When the machine is first started up, the active component may be evaporated partially so that enough of the material is transported in the Air stream 18.
  • a small container 12 may be used for retaining the active component because one large container for the active component 12 is not practical as all material (may enough for a week, month or year) would have to be heated.
  • a local heating may be adapted to heat the active component 22.
  • the local heating may be done by any one of EM radiation (IR, laser), ultra sound, electrical fields or any other energy carrier the active component 22 is receptive to.
  • an over night heating may also be adapted to heat the active component 22.
  • the active component 22 may be kept at a minimum temperature when not used so that the machine may be started faster.
  • a concentration sensor may be adapted for monitoring the concentration of the active component 22 in the atmosphere or stream 30.
  • the concentration of the active component may be monitored inline, e.g. with a flow through controller and a quartz micro balance.
  • the speed of the system may be set according to the measured concentration and temperatures so that it runs as fast as possible while guaranteeing that enough flux is deposited.
  • the concentration sensor may be an optical sensor, a gas concentration sensor or a sensor based on any other physical property. In order to facilitate the condensation of the flux, i.e., active component 22, on the target the letter may be cooled or at least prevented from being heated.
  • a temperature sensor may be adapted for monitoring the temperature of the active component 22.
  • the temperature of the active component 22 may be monitored in such a way that it is ensured that enough material vaporizes.
  • a direction sensor may be adapted for monitoring atleast one of a direction, speed, concentration of the stream coming from the nozzle 16.
  • the direction sensor may be an optical sensor which is capable of determining amount of the connection agent 22 on to the connector.
  • the speed of connector may be set or controlled as to deposit right amount of connection agent 22 on to the connector. In the latter case, measuring means may be used to control the amount deposited on the connector. Alternatively the control may be manual.
  • an a dimension and design of opening of the nozzle may be adapted to make the cross section of the connection stream equal or smaller than a dimension of the target connector or cell contact so that basically all of the material is deposited on the desired area.
  • the active component 22 may include atleast any of Succinic-, Glutaric-, Pimelio, Suberic-, Suberic-, Lactic-, citric-, steraic-, cyclohexanecaerboxylic acid, an acid with the right physical and chemical properties or any combination thereof.
  • the active component 22 is an acid which is capable of partially deoxidizing bus bar and the surface of the ribbon or contact.
  • the melting point is preferably approximately 70°C, 50 °C or 30 °C lower than the melting point of the used solder and accordingly even lower than the soldering temperature used. Due to this the liquid active component 22 may facilitate the heat transfer from the solder head to the solder. Moreover, since the active component 22 melts before the solder, it is liquefied, forming a thermal bridge between the soldering head and the ribbon or bus bar. Also the transport of the dissolved oxides away from the ribbon or bus bar is facilitated.
  • Vapour pressure of the liquid active component 22 is preferably as high as possible to guarantee a high concentration of the active component in the airstream 18 to decrease the average time needed to cover the cell ribbon with the active component 22.
  • an appropriate gas such as (dried) air or an inert gas to avoid the formation of an inert layer on the cell ribbon.
  • unfluxed ribbon 60 and fluxed ribbon 62 are illustrated, according to an exemplary embodiment of the present invention.
  • the unfluxed ribbon 60 may run thru a cavity filled with the active component 22 (gaseous flux).
  • One side or a first side of the ribbon may be covered, for example, by wall of the container, to prevent flux or the connection agent 22 on the first side.
  • the ribbon may also be turned and/or kept clean with an 'air' flow. This way as the nozzles 16 may be needed accordingly the clogging of the nozzles 16 may be prevented.
  • the ribbon may be cut before or after fluxing
  • FIG. 5 illustrates a heating system 500, according to an exemplary embodiment of the present invention.
  • the heating system 500 comprises atleast an inner chamber 52 for receiving the active agent and atleast an outer heating chamber 54.
  • a heated medium such as air, gas or a fluid flows thru the outer heating chamber 54 thus heating the agent/material without coming in contact with it.
  • the outer heating chamber 54 may be provided with some isolation material 56 so that the heat-flow to the ambient air is reduced.
  • the small arrows 58 in the outer heating chamber 54 show the direction of the air flows thru the out heating chamber 54.
  • FIGS. 6A and 6B which illustrate an opening 602 (FIG. 6A) of the heating system 500.
  • the opening 602 is adapted to draw an agent/material from a reservoir, according to an exemplary embodiment of the present invention.
  • the opening 602 is the nozzle 16 (FIG. 6B).
  • the air 18 or some other gas coming in from the left (As shown in FIG. 6B) is not primarily used for heating the agent 22, even though it may be warm to prevent cooling the agent 22.
  • the air 18 flows thru the two ducts: one running down to the chamber for the agent 22 and one going straight on.
  • the venture principle is used to pull the fluid agent 22 upwards.
  • the air flowing over the vertical duct takes with it some fluid agent and transports it out of the nozzle 16.
  • means are adapted to protect the gas containing the agent 22 against ambient air.
  • FIG. 7A which illustrates the nozzle 16 (also referred to as a 'first nozzle') surrounded by a second nozzle means 16' for hot air/gas, according to an exemplary embodiment of the present invention.
  • the second nozzle means 16' may be adapted near the first nozzle 16 and may be a second concentric nozzle.
  • the gas containing the agent 22 (arrows in the middle) leave the nozzle 16 at high temperature. In order to protect this gas, locally an atmosphere of hot air/gas may be created that shields the agent 22 from cooling down.
  • This protective curtain 21 comes from a second opening 16' that is placed concentric around the nozzle 16 for the agent 22.
  • the first nozzle 16 and the second nozzle means 16' are capable of focusing a beam with the agent 22, so that the agent 22 can be applied more precisely.
  • the complete ambient air is heated so that the ambient air does not cool down the agent too much.
  • FIG 7B and 7C illustrate means adapted to recollect the agent 22 from the air
  • the operations discussed herein may be implemented through computing devices such as hardware, software, firmware, or combinations thereof, which may be provided as a computer program product, e.g., including a machine-readable or computer-readable medium having stored thereon instructions or software procedures used to program a computer to perform a process discussed herein.
  • the machine -readable medium may include a storage device.
  • the operation of components of the apparatus 200 of FIG. 2-7B may be controlled by such machine-readable medium.

Abstract

Methods and apparatus for applying a connection agent to atleast a connector for connecting at least a solar cell. The method comprise the steps of heating atleast a connection agent, transporting the connection agent with atleast a stream of gas, and depositing the connection agent to atleast a connector.

Description

METHODS AND APPARATUS FOR APPLYING A CONNECTION AGENT TO ATLEAST A CONNECTOR FOR CONNECTION ATLEAST A SOLAR CELL
FIELD OF THE INVENTION
[001] The present invention relates generally to connecting photovoltaic (PV) devices, and more particularly, to methods and apparatus for applying a connection agent to atleast a connector or contact for connection of atleast a solar cell without the use of Volatile Organic Compounds (VOCs) in a fast, robust, cost effective, secure, and environmental friendly manner.
BACKGROUND OF THE INVENTION
[002] For the production of solar cells, first wafers are manufactured. The surface of the wafer is etched with a chemical process to reduce the depth of the defects and then the wafer is structured to improve its optical properties. A p-n junction is made by doping the silicon with appropriate contaminations and then an anti-reflex layer is applied. Once this has been done, electrical conductors, for example, fingers and bus bars, are deposited on top of the cells and are fired in a furnace. At the end of the production line, cells are tested to evaluate their proprieties. Now the wafer has become a solar cell that incorporated in a solar module.
[003] For the production of solar modules consisting of crystalline solar cells, in at first step the solar cells are interconnected with connectors such as ribbons by soldering. These connectors normally exist of a flat copper body which is coated with a solder. To perform the soldering between the solar cells and the connector flux is necessary.
[004] Prior art disclose different techniques to perform the soldering between the solar cells and the ribbon. Many such techniques are too complex for reliable operation and are not capable of effectively perform the soldering between the solar cells and the ribbon. For example, in solar industries liquid non clean fluxes are widely used. These fluxes consist of Isopropanol as solvent and 0.5 - 2.5 weight per cent of adipic acid which is the active Component. Adipic acid activates the surface by etching off oxide layers and to remove them. Isopropanol is used to permit a homogeny coating of the adipic acid onto the cell or ribbon. The ribbon or cell is normally moistened by immersion bath coating or spraying the flux directly onto the surface followed by application of heat through a drying station to evaporate the Isopropanol to leave back the adipic acid. In the former case a lot of flux is lost because the ribbon is also fluxed where it is not needed.
[005] No-Clean Fluxes are low solid - less than 5% fluxes. They are completely non- halide, give excellent wetting on surface mounted components, and leave no visible flux residue after soldering. Normally no further cleaning is required. Main problems by using a liquid non clean flux on the base of Isopropanol are safety and environment regulations.
[006] In a machine which fluxes with an immersion bath need storage of approximately 50 litres flux. With several machines in a factory floor the limit of flammable liquids is rapidly reached. During the operation of the machine, the Isopropanol is evaporated and sucked off. As the emissions of Volatile Organic Compounds (VOC) are regulated, full production of several machines could excess the allowed limit. Up to now no satisfying solutions were found upon these problems. Furthermore a dry tunnel is needed, making the stringer more expensive.
[007] Since most part of the cost for flux is Isopropanol which makes out more than
95% of the flux. Leaving Isopropanol out also saves costs. The active component of the flux may include the Adipic acid which is a very cheap non-toxic acid that is even used in food. If Adipic acid is used, it is preferably heated to 152°C to 160°C.
[008] Therefore, there exists need for improved means capable of overcoming disadvantages inherent in conventional ways to perform the soldering between the solar cells and the ribbon and providing effective means to perform the soldering between the solar cells and the ribbon without using Volatile Organic Compounds (VOCs) in a fast, robust, cost effective, secure, and environmental friendly manner.
SUMMARY OF THE INVENTION
[009] In view of the foregoing disadvantages inherent in the prior arts, the general purpose of the present invention is to provide an improved combination of convenience and utility, to include the advantages of the prior art, and to overcome the drawbacks inherent in the prior art.
[0010] In one aspect, the present invention provides effective means to perform the soldering between the solar cells and the ribbon without using Volatile Organic Compounds (VOCs) in a fast, robust, cost effective, secure, and environmental friendly manner.
[0011] In another aspect, the present invention provides a method for applying atleast a connection agent to atleast a connector for connecting atleast a solar cell. The method comprises the steps of: heating atleast the connection agent, transporting the connection agent with atleast a stream of gas, and depositing the connection agent to atleast the connector. The steam of gas includes atleast one of gas, air, mixture of gasses or any combination thereof. The stream of gas may be filled with one of a gaseous agent or an agent in form of aerosols or any combination thereof. The method further comprises the step of: dispersing the connection agent in the gaseous stream.
[0012] In another aspect, the present invention provides a method for applying a connection agent to atleast a connector for connecting atleast a solar cell. The method comprises the steps of: dispensing the connection agent in an atmosphere and depositing the connection agent to atleast one connector. The method may further comprise the step of moving the connector thru the atmosphere for deposition of the connection agent on the connector. The atmosphere may also be one of a gaseous stream and an aerosol or any combinations thereof.
[0013] In another aspect of the present invention, the method for applying a connection agent to atleast the connector for connecting atleast the solar cell comprises the steps of: creating a gaseous stream; creating a connection stream; and depositing the connection stream at the connector, wherein the connection stream is created by dispersing the connection agent in the gaseous stream.
[0014] In another aspect of the present invention, for connecting very thin connectors, multiple wires may be passed thru atleast a stream. If the stream is used, means may be provided for collecting an agent/material that does not stick to the connector. The thus collected material may be used again in the inventive method of the present invention. The connection stream impinges on the connector outside the atmosphere. With atmosphere a body of gas, air or a mixture of gasses is meant. The atmosphere is most likely held in a partially closed container.
[0015] In another aspect, the present invention provides an apparatus for applying a connection agent to atleast a connector for connecting atleast the solar cell. The apparatus comprises: means for dispensing the connection agent in an atmosphere; and means for depositing the connection agent to the connector. The apparatus further comprises any one of means for moving the connector thru the atmosphere for deposition of the connection agent on the connector, means for creating a connection stream, means for depositing desired amount of the connection stream on the connector. The connection stream is created by dispersing the connection agent in the gaseous stream.
[0016] These together with other objects of the invention, along with the various features of novelty that characterize the invention, are pointed out with particularity in the claims annexed hereto and forming a part of this disclosure. For a better understanding of the invention, its operating advantages and the specific objects attained by its uses, reference should be had to the accompanying drawings and descriptive matter in which there are illustrated exemplary embodiments of the invention.
BRIEF DESCRIPTION OF THE DRAWINGS
[0017] For a better understanding of the nature of the present invention, reference should be made in the detailed description taken in conjunction with the accompanying drawings in which:
[0018] FIG. 1A and IB illustrate a method for applying a connection agent to atleast a connector for connection atleast a solar cell, according to an exemplary embodiment of the present invention. [0019] FIG. 2 illustrates an apparatus for applying a connection agent to atleast the connector for connecting atleast the solar cell, according to an exemplary embodiment of the present invention;
[0020] FIGS. 3 and 4 illustrate schematic setups of connection agent condensation, according to an exemplary embodiment of the present invention;
[0021] FIG. 5 illustrates an heating system, according to an exemplary embodiment of the present invention;
[0022] FIGS. 6A and 6B illustrate an opening adapted to drawn an agent from a reservoir, according to an exemplary embodiment of the present invention;
[0023] FIG. 7A illustrates a nozzle surrounded by a second concentric nozzle for hot air/gas, according to an exemplary embodiment of the present invention; and
[0024] FIG 7B and 7C illustrate means adapted to recollect the agent from the air around the nozzle, according to an exemplary embodiment of the present invention.
[0025] Like reference numerals refer to like parts throughout the several views of the drawings.
DETAILED DESCRIPTION OF THE INVENTION
[0026] The exemplary embodiments described herein detail for illustrative purposes are subject to many variations and structure and design. It should be emphasized, however that the present invention is not limited to a particular methods and apparatus to perform the soldering (herein after referred to as 'connection') between atleast a solar cells and a ribbon as shown and described. Rather, the principles of the present invention can be used with a variety of PV device connection, soldering configurations and structural arrangements. It is understood that various omissions, substitutions of equivalents are contemplated as circumstances may suggest or render expedient, but the present invention is intended to cover the application or implementation without departing from the spirit or scope of the it's claims.
[0027] In the following detail description, for purposes of explanation, numerous specific details are set forth in order to provide a thorough understanding of the present invention. It will be apparent, however, to one skilled in the art that the present invention may be practiced without these specific details.
[0028] As used herein, the terms 'a', 'an', 'atleast' do not denote a limitation of quantity, but rather denote the presence of at least one of the referenced item, the term 'a plurality' denotes the presence of more than one referenced items.
[0029] The PV device includes atleast any one of an individual waver, a solar cell being manufactured, a solar cell (also referred to as 'cell') or any combination thereof. The terms 'flux agent', 'flux', 'gaseous flux', agent, 'connection agent' and 'active component' may also be used herein interchangeably. The terms 'connector', 'ribbon' may also be used herein interchangeably and denote the conductor used for conduction electrical power away from the cells. The terms 'cell contact' and 'bus bar' may also be used herein interchangeably and denote the conductor used for conduction electrical power on the solar cell. Solar cells may be of any technology such as thin film, crystalline, hetero junction, Hetero junction with intrinsic thin layer (HIT) etc.
[0030] The connection agent is an active component which is capable of being melted, evaporated, sublimated, and suspended in the atmosphere. The connection agent is also capable of atleast partially deoxidizing a surface of the connector or contact. The connection agent includes atleast one of a dry powder, a gaseous active component, and a liquefied active component or any combination thereof. The inventive method for applying a connection agent to atleast a connector for connecting atleast a solar cell, comprising the steps of dispensing the connection agent in an atmosphere; and depositing the connection agent to the connector, wherein the atmosphere is filled with one of a gaseous agent or an agent in form of aerosols or any combination thereof. Filled may mean that the agent is suspended in the atmosphere. It does not necessarily mean that no more agent could be suspended in the atmosphere, e.g. while it reached its vapour pressure. [0031] In an exemplary embodiment, the present invention provides improved methods and apparatus for applying a connection agent to atleast the connector for connecting atleast the solar cell. The apparatus of the present invention may be mass produced inexpensively and provides user an easy, robust, efficient, secure, cost effective, environment friendly and productive way of connection or soldering PV devices.
[0032] Referring to FIGS. 1A and IB together which illustrate a method 100 for applying atleast a connection agent to atleast a connector for connecting atleast a solar cell, according to an exemplary embodiment of the present invention. The method 100 comprises the steps of: heating atleast the connection agent 22 at a step 111, transporting the connection agent 22 with atleast a stream of gas 30 at a step 122, and depositing the connection agent 22 to atleast the connector at a step 133. The steam of gas 30 includes atleast one of gas, air, mixture of gasses or any combination thereof. The stream of gas 30 may be filled with one of a gaseous agent or an agent in form of aerosols or any combination thereof. The method 100 further comprises the step of: dispersing the connection agent 22 in the gaseous stream.
[0033] Referring to FIG. 2 which illustrates an apparatus 200 for applying a connection agent 22 to atleast a connector for connection atleast the solar cell, according to an exemplary embodiment of the present invention. The connection agent 22 may be a liquid or solid active component. The apparatus 200 comprises: means 210 for dispensing the connection agent 22 in an atmosphere and means 220 for depositing the connection agent 22 to the connector, The apparatus 200 may further comprise any one of means for moving the connector thru the atmosphere for deposition of the connection agent 22 on the connector, means for creating a connection stream 20, means for depositing desired amount of the connection stream 20 on the connector. The connection stream 20 may be created by dispersing the connection agent 22 in a gas stream 30.
[0034] According to an exemplary embodiment, the goal of the present invention may be achieved by using only the active component of the connection agent 22 which may be a dry powder at room temperature. By heating up the powder 22 the principle of an air brush may be applied. The gas -stream 30 (also referred to as 'transport stream') may be directed over the melting or melted powder 22 and then to a nozzle 16. At the nozzle 16, the saturated air / airborne active component may be sprayed onto a ribbon where it is directly deposited (Physical Vapour depositing). The relative low temperature (room temperature) of the ribbon or cell makes the active component condensate on it.
[0035] According to an exemplary embodiment of the present invention, an atmosphere may be created above a body or level of the active component 22. The atmosphere may be one of a gas stream 30 or vapour (also referred to as 'active gaseous component'), aerosols or any combination thereof. The atmosphere of gaseous active component 30 may be created by melting the active component 22. The vapour pressure of a material is an indication of a liquid's evaporation rate when the material is still in its condensed state. The higher the vapour pressure of the material for example, the connection agent 22, the more of it will be in gaseous form. The present invention is capable of using materials with a high vapour pressure so that the material vaporizes quickly as the stream of air 18 may remove the vapour that was previously formed. With aerosols, solid and fluid particles or a combination thereof are meant that are suspended in an atmosphere.
[0036] The vapour pressure is dependent of the temperature of the material, therefore the vapour pressure increases with the temperature. By increasing the temperature, the active component 22 may become fluid and thus release more damp or the active component 22 may remain solid. If the active component 22 remains solid, then the active component 22 may be sublimated.
[0037] Referring to FIGS. 3 and 4 which illustrate schematic setups 300 and 400 of flux condensation, according to exemplary embodiments of the present invention. The setup 300 and 400 comprises atleast a container 12 for retaining an active component 22, atleast a gas connection for providing an air stream 18, and atleast a nozzle 16. The container 12 may be a pump or a heatable and chemically resistant box. The container 12 may have a heater 14.
[0038] The gas stream 30 and the atmosphere may be mixed using a ventilator or the like. The inlet for the gas stream 30 may be placed such that the gas has to travel thru the atmosphere and preferable disturb the atmosphere as to create turbulence. [0039] According to an exemplary embodiment of the present invention, to increase the amount of the active component 22 in the airstream 18, i.e., dispersion of particles in air stream 18, the air stream 18 may lead directly into the active liquid component 22.
[0040] According to an exemplary embodiment of the present invention atleast any one of the air stream 18 and the component parts the air steam 18 touches, may be heated to facilitate the vaporisation and keep the active component 22 above a certain temperature in the remaining apparatus (also referred to as 'system'). Also the air stream 18 in and to the nozzle 16 may be needed to prevent the active component 22 from condensing in the nozzle 16 or the conduct to the active component 22 from clogging the system. Preferably the Air stream 18, may be a dry air with no contamination of oil, may be used to keep the system clean. Further, dry air with no contamination of oil, may be preferably keep the system clean.
[0041] According to an exemplary embodiment of the present invention, the holder or container 12 of the active component may be replaceable. When the machine is first started up, the active component may be evaporated partially so that enough of the material is transported in the Air stream 18. Preferably, a small container 12 may be used for retaining the active component because one large container for the active component 12 is not practical as all material (may enough for a week, month or year) would have to be heated.
[0042] According to an exemplary embodiment of the present invention, a local heating may be adapted to heat the active component 22. By heating the active component 22 locally, for example, the top surface of the material, enough vaporization may be achieved in a relatively short time. The local heating may be done by any one of EM radiation (IR, laser), ultra sound, electrical fields or any other energy carrier the active component 22 is receptive to.
[0043] According to an exemplary embodiment of the present invention, an over night heating may also be adapted to heat the active component 22. The active component 22 may be kept at a minimum temperature when not used so that the machine may be started faster. [0044] According to an exemplary embodiment of the present invention, a concentration sensor may be adapted for monitoring the concentration of the active component 22 in the atmosphere or stream 30. The concentration of the active component may be monitored inline, e.g. with a flow through controller and a quartz micro balance. The speed of the system may be set according to the measured concentration and temperatures so that it runs as fast as possible while guaranteeing that enough flux is deposited. The concentration sensor may be an optical sensor, a gas concentration sensor or a sensor based on any other physical property. In order to facilitate the condensation of the flux, i.e., active component 22, on the target the letter may be cooled or at least prevented from being heated.
[0045] According to an exemplary embodiment of the present invention, a temperature sensor may be adapted for monitoring the temperature of the active component 22. The temperature of the active component 22 may be monitored in such a way that it is ensured that enough material vaporizes.
[0046] According to an exemplary embodiment of the present invention, a direction sensor may be adapted for monitoring atleast one of a direction, speed, concentration of the stream coming from the nozzle 16. The direction sensor may be an optical sensor which is capable of determining amount of the connection agent 22 on to the connector. The speed of connector may be set or controlled as to deposit right amount of connection agent 22 on to the connector. In the latter case, measuring means may be used to control the amount deposited on the connector. Alternatively the control may be manual.
[0047] According to an exemplary embodiment of the present invention, an a dimension and design of opening of the nozzle may be adapted to make the cross section of the connection stream equal or smaller than a dimension of the target connector or cell contact so that basically all of the material is deposited on the desired area. As stated above, it may also be desirable that the cross-section of the stream is wider than the target, say a ribbon. In that case the design and dimension of the nozzle 16 may is adapted accordingly.
[0048] Although Adipic acid is the most common active component in non clean fluxes, many other chemicals are possible, According to an exemplary embodiment of the present invention, the active component 22 may include atleast any of Succinic-, Glutaric-, Pimelio, Suberic-, Suberic-, Lactic-, citric-, steraic-, cyclohexanecaerboxylic acid, an acid with the right physical and chemical properties or any combination thereof.
[0049] The active component 22 is an acid which is capable of partially deoxidizing bus bar and the surface of the ribbon or contact.
[0050] According to an exemplary embodiment of the present invention, the melting point is preferably approximately 70°C, 50 °C or 30 °C lower than the melting point of the used solder and accordingly even lower than the soldering temperature used. Due to this the liquid active component 22 may facilitate the heat transfer from the solder head to the solder. Moreover, since the active component 22 melts before the solder, it is liquefied, forming a thermal bridge between the soldering head and the ribbon or bus bar. Also the transport of the dissolved oxides away from the ribbon or bus bar is facilitated.
[0051] Vapour pressure of the liquid active component 22 is preferably as high as possible to guarantee a high concentration of the active component in the airstream 18 to decrease the average time needed to cover the cell ribbon with the active component 22.
[0052] As air stream 18 an appropriate gas may be used such as (dried) air or an inert gas to avoid the formation of an inert layer on the cell ribbon.
[0053] Referring to FIG. 4 wherein unfluxed ribbon 60 and fluxed ribbon 62 are illustrated, according to an exemplary embodiment of the present invention. The unfluxed ribbon 60 may run thru a cavity filled with the active component 22 (gaseous flux). One side or a first side of the ribbon may be covered, for example, by wall of the container, to prevent flux or the connection agent 22 on the first side. The ribbon may also be turned and/or kept clean with an 'air' flow. This way as the nozzles 16 may be needed accordingly the clogging of the nozzles 16 may be prevented. The ribbon may be cut before or after fluxing
[0054] Referring to FIG. 5 which illustrates a heating system 500, according to an exemplary embodiment of the present invention. The heating system 500 comprises atleast an inner chamber 52 for receiving the active agent and atleast an outer heating chamber 54. A heated medium such as air, gas or a fluid flows thru the outer heating chamber 54 thus heating the agent/material without coming in contact with it. The outer heating chamber 54 may be provided with some isolation material 56 so that the heat-flow to the ambient air is reduced. The small arrows 58 in the outer heating chamber 54 show the direction of the air flows thru the out heating chamber 54.
[0055] Referring to FIGS. 6A and 6B which illustrate an opening 602 (FIG. 6A) of the heating system 500. The opening 602 is adapted to draw an agent/material from a reservoir, according to an exemplary embodiment of the present invention. The opening 602 is the nozzle 16 (FIG. 6B).
[0056] The air 18 or some other gas coming in from the left (As shown in FIG. 6B) is not primarily used for heating the agent 22, even though it may be warm to prevent cooling the agent 22. The air 18 flows thru the two ducts: one running down to the chamber for the agent 22 and one going straight on. The venture principle is used to pull the fluid agent 22 upwards. The air flowing over the vertical duct takes with it some fluid agent and transports it out of the nozzle 16.
[0057] According to an exemplary embodiment of the present invention, means are adapted to protect the gas containing the agent 22 against ambient air. Referring to FIG. 7A which illustrates the nozzle 16 (also referred to as a 'first nozzle') surrounded by a second nozzle means 16' for hot air/gas, according to an exemplary embodiment of the present invention. The second nozzle means 16' may be adapted near the first nozzle 16 and may be a second concentric nozzle. The gas containing the agent 22 (arrows in the middle) leave the nozzle 16 at high temperature. In order to protect this gas, locally an atmosphere of hot air/gas may be created that shields the agent 22 from cooling down. This protective curtain 21 (dashed arrows) comes from a second opening 16' that is placed concentric around the nozzle 16 for the agent 22. The first nozzle 16 and the second nozzle means 16' are capable of focusing a beam with the agent 22, so that the agent 22 can be applied more precisely. In an alternative embodiment, the complete ambient air is heated so that the ambient air does not cool down the agent too much.
[0058] FIG 7B and 7C illustrate means adapted to recollect the agent 22 from the air
(represented by two clouds CI and C2) around the nozzle 16, according to an exemplary embodiment of the present invention. This may be another concentric duct. These means may also be provided in any other way, probably taking into account the effect gravity has on the agent 22. The means may also be situated behind the ribbon/connector to be fluxed.
[0059] In various exemplary embodiments of the present invention, the operations discussed herein, e.g., with reference to FIGS. 1- 7B, may be implemented through computing devices such as hardware, software, firmware, or combinations thereof, which may be provided as a computer program product, e.g., including a machine-readable or computer-readable medium having stored thereon instructions or software procedures used to program a computer to perform a process discussed herein. The machine -readable medium may include a storage device. For example, the operation of components of the apparatus 200 of FIG. 2-7B may be controlled by such machine-readable medium.
[0060] In other instances, well-known methods, procedures, components, and circuits have not been described herein so as not to obscure the particular embodiments of the present invention. Further, various aspects of embodiments of the present invention may be performed using various means, such as integrated semiconductor circuits, computer-readable instructions organized into one or more programs, or some combination of hardware and software.
[0061] Although a particular exemplary embodiment of the invention has been disclosed in detail for illustrative purposes, it will be recognized to those skilled in the art that variations or modifications of the disclosed invention, including the rearrangement in the configurations of the parts, changes in sizes and dimensions, variances in terms of shape may be possible. Accordingly, the invention is intended to embrace all such alternatives, modifications and variations as may fall within the spirit and scope of the present invention.
[0062] The foregoing descriptions of specific embodiments of the present invention have been presented for purposes of illustration and description. They are not intended to be exhaustive or to limit the invention to the precise forms disclosed, and obviously many modifications and variations are possible in light of the above teaching. The embodiments were chosen and described in order to best explain the principles of the invention and its practical application, to thereby enable others skilled in the art to best utilize the invention and various embodiments with various modifications as are suited to the particular use contemplated. It is understood that various omissions, substitutions of equivalents are contemplated as circumstance may suggest or render expedient, but is intended to cover the application or implementation without departing from the spirit or scope of the claims of the present invention.

Claims

CLAIMS: We Claim
1. A method for applying a connection agent to atleast a connector for connecting atleast a solar cell, comprising the steps of:
heating atleast a connection agent;
transporting the connection agent with atleast a stream of gas; and
depositing the connection agent to atleast a connector,
wherein the stream of gas is filled with one of a gaseous agent or an agent in form of aerosols or any combination thereof.
2. The method of claim 1 , further comprising the step of dispensing the connection agent in an atmosphere;
3. The method of claim 1-2, further comprising the step of moving the connector thru the atmosphere for deposition of the connection agent on the connector.
4. The method of claim 1-3, further comprising the steps of:
creating atleast a connection stream from the atmosphere; and
depositing the connection stream on the connector.
5. The method of claim 1-4, wherein the connector includes one of a solar cell, cell connector, a bus bar of the solar cell or any combination thereof.
6. The method of claim 1-5, further comprising the step of creating a damp of the connection agent by heating the connection agent.
7. The method of claim 1-6, wherein atleast one of speed of the connector and the connection stream is controlled by depositing right amount of connection agent on the connector.
8. An apparatus for applying a connection agent to atleast a connector for connecting atleast a solar cell, comprising: means for dispensing the connection agent in an atmosphere; and means for depositing the connection agent onto the connector.
9. The apparatus of claim 8, further comprising any one of means for moving the connector thru the atmosphere, means for creating a connection stream, means for depositing desired amount of the connection stream on to the connector or any combination thereof, wherein the connection stream is created by dispersing the connection agent in an atmosphere.
10. The apparatus of claim 8-9, further comprising atleast one of a container for accommodating the connection agent, an air connection for creating a jet of the gaseous mixture, and a nozzle for depositing the connection stream to the connector or any combination thereof.
11. The apparatus of claim 8-10, wherein atleast a concentration sensor is adapted for monitoring the concentration of the connection agent.
12. The apparatus of claim 8-11, wherein atleast a temperature sensor is adapted for monitoring the temperature of the connection agent, gas stream, connecting stream, atmosphere or any combination thereof.
13. The apparatus of claim 8-12, wherein a dimension of an opening of the nozzle is adapted to make the cross section of the connection stream equal or smaller than a dimension of the target connector or cell contact.
14. The apparatus of claim 8-13, wherein atleast a sensor is adapted for monitoring atleast one of a size of the connection stream, an amount of the connection stream, position and amount of connection agent on the connector or any combination thereof.
15. The apparatus of claim 8-14, wherein second nozzle means are provided near the first nozzle to create an atmosphere of hot air or gas to shields the agent from cooling down in ambient air.
PCT/IB2011/055242 2010-11-23 2011-11-22 Methods and apparatus for applying a connection agent to atleast a connector for connection atleast a solar cell WO2012069995A2 (en)

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EP2837459A1 (en) 2013-08-17 2015-02-18 Somont GmbH Systems and methods for applying particles in a gas flow to a workpiece
WO2015025234A1 (en) 2013-08-17 2015-02-26 Somont Gmbh Systems and methods for applying particles in a gas flow to a workpiece
EP3157065A1 (en) * 2015-10-12 2017-04-19 LG Electronics Inc. Apparatus and method for attaching interconnector of solar cell panel
JP2017076794A (en) * 2015-10-12 2017-04-20 エルジー エレクトロニクス インコーポレイティド Apparatus and method for attaching interconnector of solar cell panel
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EP3540791A1 (en) * 2018-03-08 2019-09-18 LG Electronics Inc. Flux coating device and method for solar cell panel, and apparatus for attaching interconnector of solar cell panel
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