WO2012127397A1

WO2012127397A1 - Methods and system for producing atleast a photovoltaic device with atleast a protective member

Info

Publication number: WO2012127397A1
Application number: PCT/IB2012/051290
Authority: WO
Inventors: André RICHTER
Original assignee: Somont Gmbh
Priority date: 2011-03-18
Filing date: 2012-03-17
Publication date: 2012-09-27
Also published as: EP2686887A1

Abstract

Disclosed are methods and system for contacting atleast a connector to atleast a photovoltaic device. The method comprises the steps of: applying selectively atleast the protective member for atleast partially covering the photovoltaic device; leaving open atleast a contact area on atleast the photovoltaic device; placing atleast an electrical conduct on atleast said contact area; and applying atleast a coupling material to atleast said open contact area as to couple atleast the electrical conduct with atleast the photovoltaic device. The system comprises: means for selectively applying atleast the protective member for atleast partially covering the photovoltaic device; means for placing atleast an electrical conduct on atleast an open contact area of the photovoltaic device not covered by the protective member; and means for coupling atleast the electrical conduct with atleast the photovoltaic device by applying coupling material to atleast the open contact area of the photovoltaic device.

Description

METHODS AND SYSTEM FOR PRODUCING ATLEAST A PHOTOVOLTAIC DEVICE WITH

ATLEAST A PROTECTIVE MEMBER

FIELD OF THE INVENTION

[001] The present invention relates generally to manufacturing and connecting solar cells, and, more particularly to methods and system for producing solar cells with a protective member to improve handling and transporting of solar cells in further processing in a cost effective, secure, environmentally safe, and efficient manner.

BACKGROUND OF THE INVENTION

[002] Solar cells are semiconductor devices which transform light in electrical power. The solar cell consists of an active material such as silicon and can have a sensitive area that is at least partially covered by an antireflective coating or transparent conductive member. Fingers are used for collecting the electrons set free by sun light. All electrons are gathered by a bus bar guiding the electrons to a load attached to the solar cell.

[003] A plurality of solar cells may be connected to form a solar module. Nowadays, the bus bar of a first solar cell is normally connected to a back contact of a second solar cell by a connector. Newer technologies are available where the front-face or the back-face of adjacent cells have different polarities and thus the interconnection is done in one plane. Depending on the technology of the solar cell, it may be possible to omit the bus bar and contact the connector directly to the solar cell.

[004] Normally solar cells are shipped in stacks. In order to make sure that the solar cells do not damage each other, intermediate sheets of papers may be inserted between them. Further, touching the surface of the cell would normally leave a finger print with acids that over the years may attack the surface of the solar cell.

[005] Presently no protective member is used to protect the photovoltaic device. Further, it may be desirable to apply protective members (also referred to as 'protective layer') to one or two sides of the solar cell for secure transportation of the solar cells.

[006] Such arrangements may be not convenient, cost effective, secure, and environment friendly for handling and transporting of solar cells in further processing. Accordingly, improved means are needed to overcome such problems.

[007] German patent document number DE102010014555.6 discloses use of electro plating for interconnecting solar cells. However, this document fails to recognize that modern cells have active regions that are electrically conductive, meaning that the active region would be plated as well, covering the active region and blocking the light needed for production of electrical energy. It therefore does not describe how this may be prevented from happening. [008] The features of afore cited prior arts discloses complex methods for handling and transporting of solar cells in further processing; thereby, necessitating the need for a new technique which is simple and reliable in operation.

[009] Accordingly, there exists a need of means for effectively handling and transporting the solar cells in further processing, which solves the problems in the prior art with simple technologies process and prevent solar cells from getting damaged and damaged cells being used down stream in the manufacturing process in a cost effective, environmentally safe, and secure manner.

SUMMARY OF THE INVENTION

[0010] 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 therein.

[001 1] In one aspect, the present invention provides a method for producing atleast a photovoltaic device with atleast a protective member. The method comprises the steps of: applying selectively atleast a protective member for atleast partially covering the photovoltaic device, leaving open atleast a contact area on atleast the photovoltaic device, placing atleast an electrical conduct on atleast the open contact area, applying atleast a coupling material to atleast the open contact area of the photovoltaic device as to couple atleast the electrical conduct with atleast the photovoltaic device. The coupling material may be applied by means of atleast one of soldering, plating, chemical vapour dispositioning, physical vapour dispositioning, plasma dispositioning or any combination thereof. Said plating may be any kind of plating including but not limiting to electroplating and chemical plating. The coupling material may be a solder paste, metallic such as layers deposited by plating or vapour or plasma dispositioning, a glue, a polymer, preferably curable or any combination thereof. The protective member is an electrical insulator, for example, a polymer or an oxidation layer, which is attached to a light sensitive surface of the photovoltaic device. In an embodiment of the present invention, one or more layers of the protective member may be applied to the light sensitive surface of the photovoltaic device. With protective is meant any layer that protects the cell electrically, mechanically or chemically.

[0012] In another aspect, the present invention provides a system for producing atleast a photovoltaic device with atleast a protective member. The system comprises means for selectively applying atleast the protective member for atleast partially covering the photovoltaic device, means for placing atleast and electrical conduct on atleast an open contact area of the photovoltaic device not covered by the protective member, and means for coupling atleast the electrical conduct with atleast the photovoltaic device by applying coupling material to atleast said open contact area of the photovoltaic device.

[0013] In yet another aspect, the present invention provides a photovoltaic device having atleast a protective member adapted to extending beyond atleast a border of the photovoltaic devices. The protective member is capable of: protecting the borders of atleast the photovoltaic devices, facilitating the placing of the photovoltaic devices in the matrix wherein multiple protective members may even fit like pieces of a puzzle and may fill the gaps between the photovoltaic devices so that no additional adhesive member may be needed at all. [0014] In yet another aspect of the present invention, the surface of the photovoltaic device is covered with an additional protective member, making handling and transporting less critical. For example touching the surface of the photovoltaic device is now no longer a problem. Also, the protective member may be larger than the photovoltaic device itself, thereby protecting brittle edges of the photovoltaic device or prevent in case of existing micro-cracks the growth of these cracks. When applied on both sides, the protective member may reinforce the wafer.

[0015] In yet another aspect of the present invention, a method for forming atleast a photovoltaic module, comprises atleast a step of any of the method 100, wherein the protective member is left completely or at least substantial parts thereof on the photovoltaic device especially that part that interfaces with the photovoltaic device before the members of the photovoltaic module are joined and part of the protective member left on the photovoltaic device becomes part of the photovoltaic module.

[0016] In yet another aspect of the present invention, the inventive protective layer may be used to shield the photovoltaic device from (electro-)chemical processes during manufacturing of the solar module.

[0017] 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

[0018] The advantages and features of the present invention will become better understood with reference to the following more detailed description taken in conjunction with the accompanying drawings in which:

[0019] FIGS. 1A and IB illustrate a conventional crystalline photovoltaic device; [0020] FIG. 1C illustrates a schematic diagram of the conventional photovoltaic device; [0021] FIG. ID illustrates a conventional solar string ;

[0022] FIG. IE illustrates a view of the conventional crystalline photovoltaic device;

[0023] FIG. IF illustrates a housing wherein the photovoltaic devices are placed on, according to state of the art;

[0024] FIGS. 2 A and 2B illustrate a a contact area on the photovoltaic device, according to the state of the art;

[0025] FIGS. 3A and 3B illustrate a wire placed on the photovoltaic device, according to an exemplary embodiment of the present invention; [0026] FIGS 4A and 4B illustrate a photovoltaic device with a protective member and a electrical conduct, according to an exemplary embodiment of the present invention;

[0027] FIGS. 5A and 5B illustrate a curvature of the photovoltaic device, according to an exemplary embodiment of the present invention;

[0028] FIG. 6 illustrates a top view of the photovoltaic device, according to an exemplary embodiment of the present invention;

[0029] FIG. 6B illustrates a cross sectional view of the photovoltaic device, according to an exemplary embodiment of the present invention;

[0030] FIG. 7A illustrates two photovoltaic devices with the protective member ready for electroplating, according to an exemplary embodiment of the present invention;

[0031] FIG. 7B illustrates a lay-up of two photovoltaic devices with the protective member before lamination, according to an exemplary embodiment of the present invention;

[0032] FIG. 7C illustrates a lay-up of two photovoltaic devices with the protective member after lamination, according to an exemplary embodiment of the present invention;

[0033] FIG. 8 illustrates a flow graph of a method for contacting atleast a electrical conduct to atleast a photovoltaic device, according to an exemplary embodiment of the present invention; and

[0034] FIG. 9 illustrates a system for applying atleast a protective member to atleast a photovoltaic device, according to an exemplary embodiment of the present invention;

[0035] Like reference numerals refer to like parts throughout the several views of the drawings. DETAILED DESCRIPTION OF THE DRAWINGS

[0036] 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 particular system for applying atleast a protective member to atleast a photovoltaic device or methods for contacting atleast a electrical conduct to atleast a photovoltaic device as shown and described. Rather, the principles of the present invention can be used with a variety of photovoltaic device contacting, for example, soldering, plasma connection, welding, etc., and electroplating methods 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 its claims.

[0037] In the following 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.

[0038] As used herein, the term 'plurality' refers to the presence of more than one of the referenced item and the terms 'a', 'an', and 'atleast' do not denote a limitation of quantity, but rather denote the presence of atleast one of the referenced item. The term 'device' also includes 'engine' or 'machine' or 'system' or 'apparatus'.

[0039] The terms 'photovoltaic device', 'solar cell', 'photovoltaic cell', and 'cell' may also be used herein interchangeably and may also denote part of such devices. The photovoltaic device may be of any technology such as thin film, crystalline, multi junction, Hetero-junction with Intrinsic Thin member, etc. The photovoltaic device also includes interconnected solar cells (strings) wafer in any stage of becoming a photovoltaic device such and thin film module. A plurality of photovoltaic device may form a matrix. Further, a solar module may be made with photovoltaic devices with a protective member such that the protective member may be suited for being part of the solar module.

[0040] In case of thin film technology, different active regions, e.g. made on a single sub-strate or superstrate plate or active regions on different sub-strate or superstrate, may be connected in the inventive manner. The protective member according to the present invention may such that when processing the module no additional adhesive member is needed. If, for example, the cover is made from EVA, only a second glass plate or a back sheet may be added on top of the protective member and laminated there to. The protective member is a transparent electrical insulator, for example, a polymer or an oxidation layer, which is attached to a light sensitive surface of the photovoltaic device to provide mechanical protection to the sensitive surface.

[0041] The terms 'electrical conduct', 'connector' and 'ribbon', may also be used herein interchangeably. The terms 'contact area', 'contact', finger, vias and 'bus bar' may also be used herein interchangeably to refer to the same thing, i.e., the area where the electrical conduct is connected to the photovoltaic device. The contact area may be provided with a coating, preferably a metal coating or may be formed by any member of the solar cell, for example, an anti-reflective coating such as an ITO layer.

[0042] In an exemplary embodiment, the present invention provides system and method for producing photovoltaic device with a protective member adapted to improve handling, transporting and further processing of photovoltaic devices. The system of the present invention may be mass produced inexpensively and provides users an easy, robust, efficient, secure, cost effective, environment friendly and productive way of applying atleast the protective member to atleast the photovoltaic device or methods for contacting atleast the electrical conduct to atleast the photovoltaic device.

[0043] In an exemplary embodiment, the present invention provides means to cover the photovoltaic device with an electrical isolation member to prevent (electro)plating of the surface of the photovoltaic device so that the photovoltaic device may: remain receptive to sun light, may be inert to the galvanic solution as not to be damaged under its influences, and not be covered with a metallic member, rendering the photovoltaic device effective. [0044] The present invention is not limited to electro-plating and any other kind of plating including but not limiting electroless or chemical plating may also be used as well. The reaction may then be activated by laser, temperature, e-beam, alpha- beta, gamma ray or any other suitable radiation.

[0045] In an exemplary embodiment of the present invention, the surface of the photovoltaic device is covered with an additional protective member, making handling and transporting less critical. For example touching the surface of the photovoltaic device is now no longer a problem. Also, the protective member may be larger than the photovoltaic device itself, thereby protecting brittle edges of the photovoltaic device. The protective member may be applied on all sides, for example, front side, back side, and edges, of the photovoltaic device to secure the photovoltaic device from scratches, shock, chemicals etc.

[0046] Referring to FIG. 1A which illustrates a conventional crystalline soar cell 10 that may be used according to the present invention. Generally, the photovoltaic device 10 consists of two members 11 and 13 of an active material, e.g., silicon, and may have a sensitive area that is atleast partially covered by an antireflective coating 18 (also referred to as 'ARC') or transparent conductive member 18 (also referred to as 'TCO'). A plurality of fingers 12 are used for collecting the electrons set free by sun light 15 (as shown in FIG. 1A). All electrons are gathered by atleast a contact area 14 (also referred to as 'bus bar') guiding the electrons to a load 17 attached to the photovoltaic device 10. The photovoltaic device 10 may be a back contact photovoltaic device 10 wherein all contacts are on the back side of the photovoltaic device 10. Only fingers 12 extend on the front side of the photovoltaic device 10 for collecting electrons.

[0047] Referring to FIG IB which illustrates the conventional photovoltaic device 10, wherein a pluralityy of vias 19 thru the photovoltaic device 10 are denoted by white dots that may be used according to the present invention

[0048] Referring to FIG. 1C which illustrates a schematic diagram of the conventional photovoltaic device 10. The photovoltaic device 10 has a top surface with a plurality of doped silicon wafers called fingers 12 and two bus bars 14 connected across the fingers 12 to collect the electric charge generated. A metallization member may be applied usually to the whole bottom surface. The bus bars 14 at the top surface of the photovoltaic device 10 and the metalized member 16 on the bottom surface photovoltaic device 10 acts as two terminals of the photovoltaic device 10 to establish electrical contacts with other electrical members in an electric circuit.

[0049] Referring to FIG. ID which illustrates a conventional solar string 20 which may be used to form matrices of a solar module, according to the state of the art and may use cells according to the present invention. In order to get higher power, a number of photovoltaic devices 10a, 10b, 10c, ... are interconnected and assembled in the solar modules. The solar modules consist of several photovoltaic devices 10a, 10b and 10c, which are electrically and mechanically connected in series. In the solar module, the topside metallization of the photovoltaic device 10a may be linked to backside metallization of the next photovoltaic device 10b, using electrical conducts 22 called ribbons. These electrical conducts 22 usually are soldered on the contact areas or contacts 14 of the photovoltaic devices 10a, 10b and 10c in order to minimize contact resistivity and to get a uniform electrical contact over the whole contact area 14. [0050] FIG. IE illustrates a view of a conventional photovoltaic device 10a, 10b that may be used according to the present invention, wherein the contacts 16 on the sunny side run around the photovoltaic device 10a, 10b. The contacts 16 bring the electrical current to contact area 14 on the back side of the photovoltaic device 10.

[0051] The surface of the photovoltaic device 10 is normally covered with the ARC member 18, for example, SiN_x member, as shown in the FIG. IE. The ARC member 18 may be anti reflective coating member. Typically the ARC member 18 is an electric insulation, but it must not be very dense and the galvanisation may damage it as well. Since ARC members 18 must have a very exact thickness, it may not dissolve during electroplating. The ARC members 18 may have pinholes, which are not fully protected by further processing and therefore undesired plating or other treatment at this areas may occur.

[0052] Beside the non-conductive members, there are conductive members as well, like the TCO members 18 which support the current flow to the fingers 12. The TCO member 18 may for example, be made of atleast one of tin-doped indium-oxide (ITO), aluminium-doped zinc-oxide (AZO) and indium- doped cadmium-oxide. The TCO members 18 may have additional functions, for example, the TCO member 18: may be part of the anti reflection member 18, may be used for passivation and for protective of the surface of the photovoltaic device 10. Passivation members may form dangling bonds on a silicon surface or a defective position (e.g., dislocation, grain boundary, or point defect), so as to effectively reduce the recombination rate of the electron-hole pairs on the silicon surface and defective position, thereby improving the lifetime of a few carriers and improving the efficiency of the photovoltaic device 10.

[0053] Referring to FIG. IF which illustrates a housing or base 21 adapted to retain the photovoltaic devices 10a, 10b, 10c, 10d,..., wherein the contact area 14 may be adapted as part of the housing 21.

[0054] Referring to FIGS. 2A and 2B which illustrate a contact area 14 on the photovoltaic device 10, according to state of the art. The contact area 14 is normally connected to the back contact of a second photovoltaic device 10b (as shown in FIG. ID) by a electrical conduct 22 which is an electrical conductor. In an exemplary embodiment, depending on the technology of the photovoltaic device 10, the present invention is capable of omitting the contact area 14 (bus bar) by providing means for a contact of the electrical conduct 22 directly to the photovoltaic device 10.

[0055] Referring to FIGS. 3 A and 3B which illustrate a system 60 to omit a metallic structure such as a bus bar of the photovoltaic device 10 and facilitate a contact of the electrical conduct 22 directly to the photovoltaic device 10, according to an exemplary embodiment of the present invention.

[0056] The system 60 includes means for plating such as electro plating (also referred to as 'galvanizing') and chemical plating. The wire 6 may be placed on the photovoltaic device 10. The wire 6 may, e.g., be made of copper or any other conductive material and may have a coating on it facilitating the plating. The coating may set free the materials used for the plating. The wire 6 may have any shape like round, rectangle, triangle, flat (e.g. like a printed circuit board) or be part of a sheet with conductors which is best suited for the purpose. Usual and because of cost reasons, normally the round wires 6 are used. [0057] The photovoltaic device 10 with the wire 6 held thereon and anodes are placed in an electrolyte. The wire 6 and the photovoltaic device 10 may be the target for galvanization, so they may be used as cathode. Because the photovoltaic device 10 may be partially or fully placed in a galvanic medium (not shown) for galvanization, the electrical contacting is easier done thru the wire 6 sticking out of the galvanic medium. This may be referred to as a stack made of wire 6 and the photovoltaic device 10. By applying a voltage to atleast one of the wires 6 and the photovoltaic device 10 stack, a protective member 90 which may be a member of a conductive material, e.g., metallic zinc or cupper, may be deposited on the wire 6 and the photovoltaic device 10, wherein the wire 6 may also becomes cathode, because of being electrically connected to the photovoltaic device 10.

[0058] Clearly the surface of the photovoltaic device 10 that must not be electroplated and remain receptive to sun light 15 (as shown in FIG. 1A) must: be inert to the galvanic solution as not to be damaged under its influences, not be covered with a metallic member, rendering the photovoltaic device 10 effective. These objectives of the present invention may be met by covering the photovoltaic device 10 with an electrical isolation member 90 according to the present invention (also referred to as 'protective member'), as shown in FIGS. 3A -7C.

[0059] The present invention is not limited to electro plating and electroless or chemical plating may also be used as well. The reaction is then activated by laser, temperature, e-beam, alpha- beta, gamma ray or plasma beam.

[0060] The present invention provides a protective member 90 that may remain on the photovoltaic device 10, thereby overcoming the drawback of removing the protective member 90 normally with great efforts, possibly damaging the photovoltaic device 10.

[0061] Leaving the protective member 90 may shorten the production by one production step. The removal of the protective member 90 may be relatively dangerous to the photovoltaic device 10 because chemicals used for removal of the protective member 90 may impair the surface and mechanical stresses (pealing off, heat treatment) may lead to breakage of the photovoltaic device 10.

[0062] According to an exemplary embodiment, a positive by-product of the present invention is that the surface of the photovoltaic device 10 may be now covered with an additional protective member, making handling and transporting of the photovoltaic device 10 less critical. For example touching the surface of the photovoltaic device 10 would normally leave a finger print with acids that over the years may attack the surface of the photovoltaic device 10. The present invention overcomes this problem. Also, the protective member 90 may be larger than the photovoltaic device 10 itself, thereby protecting its brittle edges.

[0063] Referring to FIGS. 4A and 4B which illustrate a photovoltaic device 10 with the protective member 90, according to an exemplary embodiment of the present invention. The electrical conducts 22 connected to a photovoltaic device 10 may be positioned or be kept in position by a position member 95 (as shown in FIGS 6 A and 6B) on the surface of the photovoltaic device 10 formed by the protective member 90. In this embodiment, the protective member 90 may be made thick enough to restrict the electrical conducts 22 from moving sideward. Also the protective member 90 shapes the coupling material 85 deposited by the plating. The coupling material 85 may at the end of the processing only extend in the contact areas that are left open in the protective layer 90. Coupling material 85 that extends over the edge of the contact areas that are left open may be removed to prevent unnecessary covering of the active area.

[0064] Referring to FIGS. 5A and 5B which illustrate a curvature 88 of the photovoltaic device 10, according to an exemplary embodiment of the present invention. After being completely manufactured, photovoltaic devices 10 may have a light convex shape. This is an effect of a non-symmetrical build up of the photovoltaic device 10, for example, generally a top surface of the photovoltaic device is having coatings, fingers 12 and contact areas 14 (bus bars), whereas the back surface of the photovoltaic device 10 is having only one contact covering the complete back surface. As shown in the FIG. 5A, an upper edge of the photovoltaic device 10 is not a straight line because the upper edge is having a curvature 88. The curvature 88 may not be a result of the photovoltaic device 10 bending under gravity. The highly brittle and non flexible photovoltaic device 10 really is curved.

[0065] Referring to FIGS. 6A which illustrates a top view of the photovoltaic device 10, according to an exemplary embodiment of the present invention. As the curvature 88 of the photovoltaic device 10 makes that the electrical conducts 22 are not easily held against the surface of photovoltaic device 10, therefore the protective member 90 and the position member 95 may be used to locally pressing or holding the electrical conduct 22 to the photovoltaic device 10 to restrict a movement of the electrical conduct 22. The movement of the electrical conduct may include atleast one of sideward, upward, and downward movement. In the upward and downward movement, the electrical conduct 22 may be respectively moving towards (near) and away from the photovoltaic device 10.

[0066] According to an exemplary embodiment of the present invention, the protective member 90 may not or may only be partially removed before the coupling material is applied during further processing of the photovoltaic device 10 or wafer. The protective member 90 may be made thick enough as to protect the sensitive region of the photovoltaic device 10 in further processing.

[0067] According to an exemplary embodiment of the present invention, the protective member 90 may be selectively applied to the photovoltaic device 10 in atleast one of the forms liquid, solid, gaseous or any combination thereof, by atleast one of screen printing, casting, moulding, chemical vapour dispositioning, physical vapour dispositioning, plasma dispositioning, plating, spraying, dipping or any combination thereof. The liquid form includes any one of inkjet printing and screen printing. The solid form includes any one of a sheet, powder moulding or any combination thereof

[0068] According to an exemplary embodiment of the present invention, the protective member 90 may be transparent. The protective member 90 may be adapted as transparent as possible in case the protected member is applied to a sunny side of the photovoltaic device 10 or the protective member 90 may be atleast partially transparent to radiation used by the photovoltaic device 10. Transparency of the protective member 90 may also be obtained after further processing of the photovoltaic device 10, for example, after lamination of the solar module, where molecules of a polymer cover, e.g., EVA, may react (cross-link) as to become transparent, also using up additives in to the polymer cover. If the protective member is applied to the back side of the photovoltaic device 10, then it may possess completely different properties, for example, may be water resistant e.g., PET, Polyvinylfluorid (Tedlar), etc., may be white or mirroring as to reflect light not converted into electrical power and not transparent.

[0069] According to an exemplary embodiment of the present invention, the protective member 90 may form the top member of the photovoltaic device 10 (as shown in FIG. 6A). In such case, the protective member 90 is capable of bonding to materials used for forming the solar module.

[0070] According to an exemplary embodiment of the present invention, the protective member 90 may be an intermediate member. An additional top member (not shown) may be applied to the photovoltaic device 10, for example, after the plating, to improve adhesion to the other materials of the module or improve optical properties.

[0071 ] According to an exemplary embodiment of the present invention, the protective member 90 may have anti-reflex properties and may be part of the anti reflex member that may consist of a buildup of multiple members/layers. The interference of these members may cause the anti reflective property. Therefore, the additional top member may be needed to obtain the desired interference. Further, the top member better adheres to the other materials used in the module. A further use of the top member may be to protect the coupling material deposited on the photovoltaic device 10 or the electrical conduct 22. The top member may also be used to even out the height differences, making lamination easier because less air is trapped in the lay-up.

[0072] If the protective member 90 may have anti-reflex properties and may be part of the anti reflex member then the protective member 90 may not necessarily have to be the top member of the photovoltaic device 10. Preferably the protective member 90 may be made of such material that when the photovoltaic device 10 is part of a solar module. The protective member 90 may have the same function as the encapsulant used in for the photovoltaic module and may have about the same optical properties.

[0073] According to an exemplary embodiment of the present invention, the protective member 90 may be a plastic or polymer member. The protective member 90 may be made of a plastic such that the protective member 90 may bind to materials used for forming the solar module. Such materials may be any one of EVA (Ethylene-vinyl acetate), a silicon based plastic, polyvinyl butyral, ionomer, epoxide, TPU (thermoplastic polyurethane or thermoplastic elastomers in general) or any combination thereof. Fibres may be added to the protective plastics. Additional light conversion chemicals (like up- or down conversion) may be added to the plastics to get additional effects.

[0074] Referring to FIG. 6B which illustrates a side view of the photovoltaic device 10 (as shown in FIG. 6A), according to an exemplary embodiment of the present invention.

[0075] FIG. 7A illustrates two photovoltaic devices 10 with the protective member 90 ready for electroplating, according to an exemplary embodiment of the present invention.

[0076] FIG. 7B illustrates a lay-up of two photovoltaic devices 10 the protective member 90 before lamination, according to an exemplary embodiment of the present invention. [0077] FIG. 7C illustrates a lay-up of two photovoltaic devices 10 with the protective member 90 after lamination, according to an exemplary embodiment of the present invention.

[0078] The present invention provides atleast a photovoltaic device 10 having atleast a protective member 90 adapted to extending beyond atleast a border of the photovoltaic devices 10 (As shown in FIG. 7A). The protective member 90 is capable of protecting the borders of atleast the photovoltaic devices 10, facilitating the placing of the photovoltaic devices 10 in the matrix 20 (as shown in FIG. IF) wherein multiple protective members 90 may even fit like pieces of a puzzle and may fill the gaps between the photovoltaic device 10 (as shown in FIG. 7B) so that no additional adhesive member may be needed at all.

[0079] After laminating, protective members 90 are touching, forming a complete encapsulation of all photovoltaic devices 10 (as shown in FIG. 7C). This lay-up, for example, may contain a glass plate 70 and a back sheet 80. The protruding portions 75 of the protective member 90 may be thicker as to compensate for the fact that there is no photovoltaic device 10. The back side of the photovoltaic devices 10 may also be provided with the protective member 90.

[0080] In this way the step of placing additive members, such as EVA or silicon may be omitted completely. The interconnected photovoltaic devices 10 are protected and may be handled faster with out the risk of being damaged. Preferably, the matrix is placed on the glass plate 70 as soon as possible to that the glass plate 70 may be used as a carrier. To facilitate evacuation of the lay-up, channels or protruding element may be provided on the protecting member 90 that lay on the glass plate 70, enabling air from flowing out of the lay-up.

[0081] Referring to FIG. 8 which illustrates a flow graph of a method 100 for producing atleast a photovoltaic device 10 with atleast a protective member 90, according to an exemplary embodiment of the present invention. The method 100 comprises the steps of: applying selectively atleast a protective member 90 for atleast partially covering the photovoltaic device 10 at a step 110, leaving open atleast a contact area on atleast the photovoltaic device 10 at a step 120; placing atleast an electrical conduct 22 on atleast the open contact area 14 on atleast the photovoltaic device 10 at a step 130, and applying atleast a coupling material to atleast said open contact area of the photovoltaic device 10 to couple atleast the electrical conduct 22 with atleast the photovoltaic device 10 at a step 140. The step 120 of leaving open atleast the contact area on atleast the photovoltaic device 10 includes opening the protective member 90 applied to in atleast the contact area on atleast the photovoltaic device 10. The coupling material may be used for coupling atleast the electrical conduct 22 with atleast the photovoltaic device 10 at a step 230. The coupling material may be applied by means of atleast one of soldering, plating, chemical vapour dispositioning, physical vapour dispositioning, plasma dispositioning or any combination thereof. Said plating may be any kind of plating including but not limiting to electroplating and chemical plating. The coupling material may be a solder paste, metallic such as layers deposited by plating or vapour or plasma dispositioning, a glue, a polymer, preferably curable or any combination thereof. The protective member 90 is an electrical insulator, for example, a polymer or an oxidation layer, which is attached to a light sensitive surface of the photovoltaic device 10. In an embodiment of the present invention, one or more layers of the protective member 90 may be applied to the light sensitive surface of the photovoltaic device. The term 'protective layer' includes any layer that protects the photovoltaic device 10 electrically, mechanically or chemically. The coupling material 85 may also be used for conducting current on the photovoltaic device 10, e.g., to form bus bars and fingers on the photovoltaic device 10.

[0082] The electrical conduct 22 may be including but not limiting to an electrical conductor used to transport current over the photovoltaic device 10 and a connector to transport current off the photovoltaic device 10. With this additional step, the protective member 90 may protect the photovoltaic device 10 during coupling of the electrical conduct, especially the protective member 90 may prevent atleast the coupling material from being deposited on the photovoltaic device 10 itself, preferably the protective member 90 may prevent the coupling material from covering the active region of the photovoltaic device 10 in regions where the covering is not desired.

[0083] According to an exemplary embodiment of the present invention, the protective member 90 is applied to the photovoltaic device 10 and atleast partially removed. The protective member 90 may be removed by atleast one of laser scribing, Ion beam, Lithographic, cutting, milling and etching techniques. Alternatively wires or ropes may be covered by the protective member 90 and are pulled off to tear the protective member 90 and thus form unprotected areas. The protective member 90 may be applied to the complete photovoltaic device 10, one or two sided, using inkjet printing, screen printing or immersing. The protective member 90 may be made of a molten or dissolved plastic.

[0084] In one exemplary embodiment of the present invention, the protective member 90 may be opened by firstly printing a solvent, for example, liquid, in powder or in any other form, which may be used to solve the protective member 90. This approach may reduce the amount of protective member 90 at this particular area and the protective member 90 may be washed out easily. The liquid solvent may also be applied to the surface of the photovoltaic device 10 and the protective member 90 may be applied over it. The solvent weakens the protective member 90 locally, making it possible to remove protective member 90 there. In both cases the protective member 90 may be a polymer cover layer.

[0085] In another exemplary embodiment of the present invention, the full area of the photovoltaic device 10 may be covered with the protective member 90 and thereafter drying or curing may be performed. After this the protective member 90 may be opened with a heat iron. This heat iron may be structured/ configured in a manner such that the full photovoltaic device 10 may be processed in one step.

[0086] In the above described cases, the protective member 90 may be structured and must be aligned with atleast a conductive element, e.g. a wire, to connect the photovoltaic device 10.

[0087] Most of galvanic systems can be operated in cathodic reductive way (e.g. metal deposition) or in oxidative way. To reverse the voltage- if the photovoltaic device 10 gets anodic and has no metal at the surface, it will generate Oxygen or other oxidic compounds depending of the nature of the solution and the material of the photovoltaic device 10. The oxidic film may establish a protective, non-conductive layer. Anodic over voltage- a high voltage may create lots of different reaction at the anode, i.e., at the surface of the photovoltaic device 10. For example in an acid Cu-electrolyte, the reaction will generate Cu(I)20 and Cu(II)0. These films typically have bad conductance and can function as protective layer. Bathes containing tin, silver etc., are not suitable for this, because of the conductive properties of SnO and AgO. Organic compounds in the bath may support this mode as well: in the reverse voltage approach negative ions or negative parts of long organic carbon chains may cover the very first surface layer of the photovoltaic device 10. Due to the regular alignment of these chains, a protective layer 90 is establishes and reactions between the chains, like hydrogen bonding, take place. This layer or a simple oxide layer may act as protective layer 90.

[0088] Another way to provide the protective layer 90 therefore is to oxidize the photovoltaic device 10 (thus forming a non conductive layer at wireless areas. Said wireless areas include areas where no vias, fingers, bus bars or the like are present for picking up electrical current. The main advantage of this approach is that the oxidization of the photovoltaic device 10 may be done in the galvanic bath and an auto alignment of the protective member 90 is achieved such that the protective member 90 is exactly at wireless areas. If one wire will be insulated by the oxide layer then it is advantageous that the wire will be the source. In the galvanic plating mode, an overvoltage will occur exactly at this place, so a very thin oxide layer may be destroyed and normal galvanic deposition may take place. This may be supported by a very short positive (galvanic plating mode) pulse.

[0089] The over voltage or reverse voltage are only allowed to be applied for a short or very short time. In the short time, the area overall will be covered in the same way. The area where the wires lay direct at the surface of the photovoltaic device 10, there will be no or less oxidation between wire and the photovoltaic device 10. Because of the higher voltage direct after starting the galvanic deposition at this place, the oxidic compound is removed at this area. The galvanic condition has to be selected in a way that the protective film is not destroyed or at least performs its desired function long enough.

[0090] According to an exemplary embodiment, the present invention provides a method for forming atleast a solar module. The method comprises atleast the steps of the method 100, wherein the protective member 90 left completely or at least substantial parts thereof on the photovoltaic device 10 especially that part that interfaces with the photovoltaic device 10 before a plurality of members of the photovoltaic module are joined and part of the protective member left on the photovoltaic device becomes part of the solar module. The member includes photovoltaic device, EVA, glass, back sheet. The term joined or joining include atleast one of lamination, moulding, curtain coating or any combination thereof.

[0091] Referring to FIG. 9 which illustrates a system 200 for producing atleast a photovoltaic device 10, according to an exemplary embodiment of the present invention. The system 200 comprises means 210 for selectively applying atleast the protective member 90 for atleast partially covering the photovoltaic device 10, means 220 for placing atleast an electrical conduct to the photovoltaic device 10, means for placing atleast an electrical conduct on atleast an open contact area of the photovoltaic device 10 not covered by the protective member 90, and means 230 for coupling atleast the electrical conduct 22 with atleast the photovoltaic device 10 by applying coupling material to atleast the open contact area of the photovoltaic device 10. The term 'selectively applying' may mean applying the protective member 90 and selectively removing parts of the protective member 90 or applying the protective member 90 in a structured way, leaving out certain areas. The system 200 may also be used when atleast one of bus bars, fingers, coatings or any combination thereof, may be applied to the photovoltaic device 10 by means of electroplating. The means 210 for selectively applying the protective member 90 are capable of partially or completely covering the covering the photovoltaic device 10 and then partially removing the protective member 90. The complete covering of the photovoltaic device 10 may be done by dipping the photovoltaic device 10 in a material for the protective member 90 that is molten, dissolved or simply a fluid at that stage of the process. [0092] The protective member 90 includes atleast an electrically isolating coating between atleast a contact area 14 on the photovoltaic device 10. The coupling of the electrical conduct 22 with the photovoltaic device 10 may include joining the electrical conduct 22 with atleast a contact area 14 of the photovoltaic device 10 by plating atleast a metal on atleast one of the electrical conduct 22 and the contact area 14.

[0093] According to an exemplary embodiment of the present invention, the method 100 for contacting atleast the electrical conduct to atleast the photovoltaic device 10 further comprising atleast a step selected from the steps: holding the electrical conduct 22 on atleast the contact area on atleast the photovoltaic device 10, placing atleast one of the photovoltaic device 10 and the electrical conduct 22 in a medium for plating including a galvanic medium; placing atleast an anode in the galvanic medium and using atleast the electrical conduct 22 as a cathode; applying atleast the protective member 90 as to facilitate atleast one of the positioning of the electrical conduct 22 in the medium for plating and holding the electrical conduct 22 into a desired place in the in the medium for plating; holding (not removing) the protective member 90 with the photovoltaic device 10 so that during transportation and further treatment, such as lamination, of the photovoltaic device 10, the protective member 90 stays on the photovoltaic device 10 and even becomes part of the end product made of the photovoltaic device 10; and generating atleast one of a flow and underpressure in the galvanic medium to press the electrical conduct 22 onto the photovoltaic device 10.

[0094] According to an exemplary embodiment, the present invention provides a photovoltaic device 10 having atleast a protective member 90. The protective member 90 may includes atleast one of EVA (Ethylene-vinyl acetate), a silicon based plastic, polyvinyl butyral, ionomer, epoxy, thermoplastic polyurethane, thermoplastic elastomers or any combination thereof. The plastic may be enforced by fibres.

[0095] The method 100 for contacting atleast the electrical conduct 22 to atleast the photovoltaic device 10 further comprising the step of interconnecting a plurality of photovoltaic devices 10a, 10b, 10c,...10η into atleast one of strings 20 and matrices.

[0096] The method 100 for contacting atleast the electrical conduct 22 to atleast the photovoltaic device 10 further comprising the step of forming atleast an electrically conductive structure of the photovoltaic device 10. The electrically conductive structure may includes atleast one of fingers 12, bus bars 14, vias 19 for back contacting photovoltaic devices 10 or any combination thereof.

[0097] The protective member 90 may be a solved protective member. A material of the protective member 90 may be applied to the photovoltaic device 10 in atleast any one of the manners including but not limiting to solving the material of the protective member 90 in a solvent being applied to the photovoltaic device 10, melting the material of the protective member 90 over the photovoltaic device 10, fluiding the material of the protective member 90 that has to be hardened, for example by curing. The degree of curing may be kept low to improve binding to other materials, e.g., EVA, in the solar module. The curing of the protective member 90 may be controlled by atleast one of heat, UV radiation, chemical agents.

[0098] According to an exemplary embodiment of the present invention, the protective member 90 may also be applied by any other means including but not limiting to chemical vapour dispositioning and physical vapour dispositioning. [0099] According to an exemplary embodiment of the present invention, in case if solvent is present in the protective member 90 then the solvent may be removed by applying any one of heat, an air stream, an agent that reacts with the solvent or any combination thereof.

[00100] According to an exemplary embodiment of the present invention, the electrical conducts 22 may extend parallel or perpendicular to atleast one of the fingers 12 and contact areas 14. In the case of the electrical conducts 22 extending parallel to atleast one of the fingers 12 and contact areas 14, atleast one electrical conduct 22 ideally extend over any one of finger 12 and contact area 14 and is connected there to without covering the active surface of the photovoltaic device 10.

[00101] According to an exemplary embodiment of the present invention, if no fingers 12 or contact area 14 may be present on the photovoltaic device 10, then the conductive surface of the photovoltaic device 10 may be used as cathode.

[00102] In various exemplary embodiments of the present invention, the operations discussed herein, e.g., with reference to FIGS. 1 to 9, 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 method 100 and the systems 60, 200 may be controlled by such machine-readable medium.

[00103] 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.

[00104] 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.

[00105] 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 What is claimed is:

1. A method for producing atleast a photovoltaic device with atleast a protective member, comprising the steps of:

applying selectively atleast the protective member for atleast partially covering the photovoltaic device; leaving open atleast a contact area on atleast the photovoltaic device;

placing atleast an electrical conduct on atleast said contact area; and

applying atleast a coupling material to atleast said open contact area as to couple atleast the electrical conduct with atleast the photovoltaic device.

2. The method according to the previous claims wherein the coupling material is applied by means of atleast one of soldering, plating, chemical vapour dispositioning, physical vapour dispositioning, plasma dispositioning or any combination thereof.

3. The method according to the previous claims further comprising atleast one of the steps of:

holding the electrical conduct on atleast the contact area on atleast the photovoltaic device;

placing atleast one of the photovoltaic device and the electrical conduct in a medium for plating;

applying protective member as to hold the electrical conduct in a desired place; and

pressing the electrical conduct onto the photovoltaic device.

4. The method according to the previous claims, wherein the protective member is applied to the photovoltaic device by atleast one of screen printing, casting, moulding, chemical vapour dispositioning, physical vapour dispositioning, plasma dispositioning, plating, spraying, dipping or any combination thereof.

5. The method according to the previous claims, wherein an additional top member is applied to the photovoltaic device after the application of the coupling material.

6. The method according to the previous claims, wherein the step of leaving open atleast the contact area on atleast the photovoltaic device includes opening the protective member applied thereto in atleast the contact area on atleast the photovoltaic device.

7. The method according to the previous claims, wherein the protective member is opened by printing a solvent.

8. The method according to the previous claims further comprising the steps of: applying the liquid solvent on the photovoltaic device; and applying the protective member over the applied liquid solvent.

9. The method according to the previous claims further comprising atleast one of the steps of: covering full area of the photovoltaic device with the protective member; drying the protective member; curing the protective member; and opening the protective member with a heat iron, wherein preferably the heat iron is adapted in a manner such that the full photovoltaic device is processed in one step.

10. The method according to the previous claims further comprising the step of applying atleast one of a reverse voltage, and an over voltage to generate atleast a oxidic film which is capable of establishing the protective member in form of a non-conductive protective layer.

11. A system for producing atleast a photovoltaic device with atleast a protective member, comprising: means for selectively applying atleast the protective member for atleast partially covering the photovoltaic device;

means for placing atleast an electrical conduct on atleast an open contact area of the photovoltaic device not covered by the protective member; and

means for coupling atleast the electrical conduct with atleast the photovoltaic device by applying coupling material to atleast the open contact area of the photovoltaic device.

12. The system according to the previous claims, wherein atleast one of the electrical conduct and a conductive surface of the photovoltaic device is adapted as a cathode.

13. A photovoltaic device established according to atleast one of the method and with the system of the previous claims.

14. A method for forming atleast a photovoltaic module, comprising the steps of any of the previous method claims, wherein the protective member is left completely or at least substantial parts thereof on the photovoltaic device especially that part that interfaces with the photovoltaic device before the members of the photovoltaic module are joined and part of the protective member left on the photovoltaic device becomes part of the photovoltaic module.

15. A method for interconnecting at least two photovoltaic devices, consisting of applying a method of one of the previous claims to said at least two photovoltaic devices, wherein an electrical conduct is capable of electrically connecting said at least two photovoltaic devices.