WO2016065948A1 - Unite de cellule solaire, fil conducteur, reseau, module de cellule et leur procede de fabrication - Google Patents

Unite de cellule solaire, fil conducteur, reseau, module de cellule et leur procede de fabrication Download PDF

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Publication number
WO2016065948A1
WO2016065948A1 PCT/CN2015/084098 CN2015084098W WO2016065948A1 WO 2016065948 A1 WO2016065948 A1 WO 2016065948A1 CN 2015084098 W CN2015084098 W CN 2015084098W WO 2016065948 A1 WO2016065948 A1 WO 2016065948A1
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Prior art keywords
cell
solar cell
metal wire
cells
row
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PCT/CN2015/084098
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English (en)
Inventor
Zhiqiang Zhao
Zhanfeng Jiang
Long He
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Byd Company Limited
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Publication date
Priority claimed from CN201510218535.0A external-priority patent/CN106206813A/zh
Application filed by Byd Company Limited filed Critical Byd Company Limited
Publication of WO2016065948A1 publication Critical patent/WO2016065948A1/fr

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    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01L—SEMICONDUCTOR DEVICES NOT COVERED BY CLASS H10
    • H01L31/00—Semiconductor devices sensitive to infrared radiation, light, electromagnetic radiation of shorter wavelength or corpuscular radiation and specially adapted either for the conversion of the energy of such radiation into electrical energy or for the control of electrical energy by such radiation; Processes or apparatus specially adapted for the manufacture or treatment thereof or of parts thereof; Details thereof
    • H01L31/04—Semiconductor devices sensitive to infrared radiation, light, electromagnetic radiation of shorter wavelength or corpuscular radiation and specially adapted either for the conversion of the energy of such radiation into electrical energy or for the control of electrical energy by such radiation; Processes or apparatus specially adapted for the manufacture or treatment thereof or of parts thereof; Details thereof adapted as photovoltaic [PV] conversion devices
    • H01L31/042—PV modules or arrays of single PV cells
    • H01L31/05—Electrical interconnection means between PV cells inside the PV module, e.g. series connection of PV cells
    • H01L31/0504—Electrical interconnection means between PV cells inside the PV module, e.g. series connection of PV cells specially adapted for series or parallel connection of solar cells in a module
    • H01L31/0508—Electrical interconnection means between PV cells inside the PV module, e.g. series connection of PV cells specially adapted for series or parallel connection of solar cells in a module the interconnection means having a particular shape
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01L—SEMICONDUCTOR DEVICES NOT COVERED BY CLASS H10
    • H01L31/00—Semiconductor devices sensitive to infrared radiation, light, electromagnetic radiation of shorter wavelength or corpuscular radiation and specially adapted either for the conversion of the energy of such radiation into electrical energy or for the control of electrical energy by such radiation; Processes or apparatus specially adapted for the manufacture or treatment thereof or of parts thereof; Details thereof
    • H01L31/04—Semiconductor devices sensitive to infrared radiation, light, electromagnetic radiation of shorter wavelength or corpuscular radiation and specially adapted either for the conversion of the energy of such radiation into electrical energy or for the control of electrical energy by such radiation; Processes or apparatus specially adapted for the manufacture or treatment thereof or of parts thereof; Details thereof adapted as photovoltaic [PV] conversion devices
    • H01L31/042—PV modules or arrays of single PV cells
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01L—SEMICONDUCTOR DEVICES NOT COVERED BY CLASS H10
    • H01L31/00—Semiconductor devices sensitive to infrared radiation, light, electromagnetic radiation of shorter wavelength or corpuscular radiation and specially adapted either for the conversion of the energy of such radiation into electrical energy or for the control of electrical energy by such radiation; Processes or apparatus specially adapted for the manufacture or treatment thereof or of parts thereof; Details thereof
    • H01L31/04—Semiconductor devices sensitive to infrared radiation, light, electromagnetic radiation of shorter wavelength or corpuscular radiation and specially adapted either for the conversion of the energy of such radiation into electrical energy or for the control of electrical energy by such radiation; Processes or apparatus specially adapted for the manufacture or treatment thereof or of parts thereof; Details thereof adapted as photovoltaic [PV] conversion devices
    • H01L31/042—PV modules or arrays of single PV cells
    • H01L31/048—Encapsulation of modules
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
    • Y02E—REDUCTION OF GREENHOUSE GAS [GHG] EMISSIONS, RELATED TO ENERGY GENERATION, TRANSMISSION OR DISTRIBUTION
    • Y02E10/00—Energy generation through renewable energy sources
    • Y02E10/50—Photovoltaic [PV] energy

Definitions

  • the present disclosure relates to a field of solar cells, and more particularly, to a conductive wire of a solar cell unit, a solar cell unit, a solar cell array, a solar cell module and a manufacturing method thereof.
  • a solar cell module is one of the most important components of a solar power generation device. Sunlight irradiates to a cell from its front surface and is converted to electricity within the cell.
  • the cell includes a cell substrate and conductive wires and secondary grid lines disposed on the front surface of the cell substrate.
  • the conductive wires and secondary grid lines cover part of the front surface of the cell, which block part of the sunlight, and then the part of sunlight irradiating to the conductive wires and the secondary grid lines cannot be converted into electric energy.
  • the conductive wires and the secondary grid lines need to be designed as fine as possible in order for the solar cell module to receive more sunlight.
  • the conductive wires and the secondary grid lines serve to conduct current, and in terms of resistivity, the finer the conductive wires and the secondary grid lines are, the smaller the cross section area thereof is, which causes greater loss of electricity due to increased resistivity. Therefore, the conductive wires and the secondary grid lines shall be designed to get a balance between light blocking and electric conduction, and to take the cost into consideration.
  • the front surface of the solar cell is usually provided with the primary grid lines and the secondary grid lines to output the current generated by the photoelectric effect or chemistry effect.
  • solar cell manufacturers conducted extensive researches on how to increase the number of the primary grid lines. In prior art, the number of primary grid lines has been successfully increased from two to three, or even five.
  • the primary grid lines are formed by printing the paste containing expensive silver, so the manufacturing cost is very high, and the increase of the silver primary grid lines absolutely causes an increase in cost.
  • the current silver primary grid line has a great width (for example, up to over 2mm) , such that the increase of the silver primary grid lines will enlarge the shading area, and make the photoelectric conversion efficiency low.
  • the silver primary grid lines printed on the cells are replaced with metal wires, such as copper wires which serve as the primary grid lines to output the current. Since the silver primary grid lines are no longer used, the cost can be reduced considerably; the diameter of the copper wire is relatively small, so the shading area can be decreased. Thus, the number of the primary grid lines can be further increased up to 10, and the cell of this kind may be called a cell without primary grid lines, in which the metal wire replaces the silver primary grid lines and welding strips in the traditional solar cell.
  • the inventor of the present disclosure finds if a cell is manufacture in this way that multiple parallel metal wires are drawn simultaneously, cut off, and then welded to the cell simultaneously, due to limitations of sophistication of equipment and process, for example, the influence of stress, the solar cell is bent to some extent when disposed at a free state, so the metal wire needs to remain strained to flatten the cell (a test proves that the minimum strain is at least 2N for a copper wire with a diameter of 0.2mm) .
  • each metal wire needs to be provided with clips or similar equipment at the two ends thereof, and the equipment occupies certain space, but the space in the cell is limited.
  • the above technical solution can further increase the number of the metal wires, but the transparent film may affect the light absorption, which causes kind of shading, and thus lowers the photoelectric conversion efficiency.
  • the above technical solution cannot connect the metal wires with the secondary grid lines by the welding process, because the melting temperature of the transparent film must be higher than the welding temperature (usually around 140°C) , otherwise the transparent film will melt in the process of welding, which may lose the function of fixing the metal wires, and then the metal wires drift, resulting in poor welding effects.
  • the encapsulating material at present is EVA whose melting point is 70°C to 80°C, much lower than the welding temperature. If the welding process is employed, as said above, the melting temperature of the transparent film must be higher than the welding temperature, which is higher than the melting point of the encapsulating material. Thus, in the encapsulating process, the encapsulating material (EVA) will melt at the encapsulating temperature, but the transparent film will not, such that the melting encapsulating material cannot penetrate the solid transparent film to completely seal the cells. Hence, the sealing effect is poor, and the actual product tends to fail. In terms of encapsulating, the melting temperature of the transparent film needs to be lower than the welding temperature, which is an evident paradox.
  • the technical solution of fixing the metal wires via the transparent film cannot adopt the welding process to weld the metal wires with the secondary grid lines, or the metal wires are merely in contact with the secondary grid lines on the cells, i.e. the metal wires are only placed on the secondary grid lines.
  • the connection strength of the metal wires and the secondary grid lines is so low that the metal wires tend to separate from the secondary grid lines in the laminating process or in use, which causes bad contact, low efficiency of the cells, or even failure thereof. Consequently, the product in this technical solution is not promoted and commercialized. There is no fairly mature solar cell without primary grid lines.
  • the present disclosure seeks to solve at least one of the problems existing in the related art to at least some extent.
  • the solar cell with multiple primary grid lines provided in the present disclosure can be commercialized for mass production, and easy to manufacture with simple equipment, especially in low cost.
  • the present disclosure provides a conductive wire of a solar cell unit, and the conductive wire is easy to manufacture in low cost, and can improve the photoelectric conversion efficiency.
  • the present disclosure further provides a solar cell unit that is easy to manufacture in low cost, and improves the photoelectric conversion efficiency.
  • the present disclosure further provides a solar cell array that is easy to manufacture in low cost, and improves the photoelectric conversion efficiency.
  • the present disclosure further provides a solar cell module with the above solar cell array, and the solar cell module is easy to manufacture in low cost, and improves the photoelectric conversion efficiency.
  • the present disclosure further provides a method for manufacturing the solar cell module.
  • a conductive wire of a solar cell unit is constituted by a metal wire whose height is H, and whose width is W, a ratio of the height H and the width W being greater than 1:1.
  • the conductive wire according to embodiments of the present disclosure is constituted by the metal wire whose height-width ratio is greater than 1, which can make full use of the space in the thickness direction of the cell, i.e. the space in the direction of the height of the conductive wires, so as to increase the cross section of the conductive wires.
  • the conductive cross section can be enlarged with the same shading area.
  • the solar cell unit according to the embodiments of the present disclosure has larger conductive cross section of the conductive wires, so as to improve the performance of the cell.
  • a solar cell unit includes a cell which consists of a cell substrate and a secondary grid line disposed on a front surface of the cell substrate; a conductive wire disposed on the front surface of the cell substrate, intersected and connected with the secondary grid line, and the conductive wire is a conductive wire for a solar cell unit according to the above embodiments.
  • a solar cell array includes a plurality of solar cell units which are the solar cell units according to the above embodiments, and cells of the adjacent cell units are connected by the metal wire.
  • a solar cell module includes an upper cover plate, a front adhesive layer, a cell array, a back adhesive layer and a lower cover plate superposed in sequence, the cell array being a solar cell array according to the above embodiments.
  • a method for manufacturing a solar cell module includes: providing a solar cell array according to the above embodiments; superposing an upper cover plate, a front adhesive layer, the solar cell, a back adhesive layer and a lower cover plate in sequence, in which a front surface of the solar cell unit faces the front adhesive layer, a back surface thereof facing the back adhesive layer, and laminating them to obtain the solar cell module.
  • Fig. 1 is a plan view of a solar cell array according to an embodiment of the present disclosure
  • Fig. 2 is a longitudinal sectional view of a solar cell array according to an embodiment of the present disclosure
  • Fig. 3 is a transverse sectional view of a solar cell array according to embodiments of the present disclosure
  • Fig. 4 is a schematic diagram of a metal wire for forming a conductive wire according to embodiments of the present disclosure
  • Fig. 5 is a plan view of a solar cell array according to another embodiment of the present disclosure.
  • Fig. 6 is a plan view of a solar cell array according to another embodiment of the present disclosure.
  • Fig. 7 is a schematic diagram of a metal wire extending reciprocally according to embodiments of the present disclosure.
  • Fig. 8 is a schematic diagram of two cells of a solar cell array according to embodiments of the present disclosure.
  • Fig. 9 is a sectional view of a solar cell array formed by connecting, by a metal wire, the two cells according to Fig. 8;
  • Fig. 10 is a schematic diagram of a solar cell module according to embodiments of the present disclosure.
  • Fig. 11 is a sectional view of part of the solar cell module according to Fig. 10.
  • a cell unit includes a cell 31 and conductive wires 32, so the conductive wires 32 can be called the conductive wires 32 of the cell unit.
  • a cell 31 includes a cell substrate 311, a secondary grid line 312 disposed on a front surface (the surface on which light is incident) of the cell substrate 311, a back electric field 313 disposed on a back surface of the cell substrate 311, and a back electrode 314 disposed on the back electric field 313.
  • the secondary grid line 312 can be called the secondary grid line 312 of the cell 31, the back electric field 313 called the back electric field 313 of the cell 31, and the back electrode 314 called the back electrode 314 of the cell 31.
  • a cell substrate 311 can be an intermediate product obtained by subjecting, for example, a silicon chip to processes of felting, diffusing, edge etching and silicon nitride layer depositing.
  • the cell substrate 311 in the present disclosure is not limited to be formed by the silicon chip.
  • the cell 31 comprises a silicon chip, some processing layers on a surface of the silicon chip, a secondary grid line on a shiny surface (namely a front surface) , and a back electric field 313 and a back electrode 314 on a shady surface (namely a back surface) , or includes other equivalent solar cells of other types without any front electrode.
  • the cell unit, the cell 31 and the cell substrate 311 are used to illustrate the present disclosure, but shall not be construed to limit the present disclosure.
  • a solar cell array 30 is arranged by a plurality of cells, i.e. by a plurality of cells 31 connected by a conductive wire 32.
  • a metal wire S constitutes the conductive wire 32 of the cell, and extends between surfaces of the adjacent cells 31, which shall be understood in a broad sense that the metal wire S may extend between surfaces of the adjacent cells 31, or may be connected with a secondary grid line 312 of the cell 31, or may be connected with a secondary grid line 312 of a first cell 31 and a back electrode 314 of a second cell 31 adjacent to the first cell 31, or a part of the metal wire S is connected with the secondary grid line 312 and the other part of the metal wire S is connected with a back electrode 314 of the cell 31.
  • the metal wire S can extend between front surfaces of adjacent cells 31, or extend between a front surface of a first cell 31 and a back surface of a second cell 31 adjacent to the first cell 31.
  • the conductive wire 32 may include a front conductive wire 32A extending on the front surface of the cell 31 and electrically connected with the secondary grid lien 312 of the cell 31, and a back conductive wire 32B extending on the back surface of the cell 31 and electrically connected with the back electrode 314 of the cell 31.
  • Part of the metal wire S between the adjacent cells 31 can be called a connection conductive wire.
  • orientation terms such as “upper” and “lower” usually refer to the orientation “upper” or “lower” as shown in the drawings under discussion, unless specified otherwise; “front surface” refers to a surface of the solar cell module facing the light in practical application (for example, when the module is in operation) , i.e. a shiny surface on which light is incident, while “back surface” refers to a surface of the solar cell module back to the light in practical application.
  • the conductive wires 32 of the solar cell unit according to the embodiments of the present disclosure are constituted by a metal wire whose height is H, and whose width is W, a ratio of the height H and the width W being greater than 1: 1.
  • the conductive wires 32 disposed on the cell 31 for example.
  • the ratio between the height H in the direction from up to down and the width W in the direction from left to right is greater than 1: 1.
  • the melting connection is employed, for example, welding connection
  • part of the conductive wires may melt to be electrically connected with the secondary grid lines, such that the ratio of the height H and the width W of the conductive wires welded may be smaller than 1: 1.
  • the present disclosure refers to the ratio of the height and the width of the metal wire before welding, rather than the ratio of the height and the width of the conductive wires welded.
  • the conductive wires 32 have a height-width ratio of greater than 1, such that the conductive wires 32 can make full use of the space in the direction of the height thereof, so as to increase the cross section of the conductive wires.
  • the conductive cross section can be enlarged with the same shading area of a single conductive wire.
  • the shading area (i.e. the cross section) of the single conductive wire is identical, the shading area of the conductive wires in the present disclosure is smaller, so more conductive wires can be adopted, to increase the conductive cross section of the conductive wire overall, so as to improve the performance of the cell.
  • the ratio of the height H and the width W is smaller than 6: 1. More preferably, the ratio of the height H and the width W ranges from 1.5: 1 to 3: 1. In some specific embodiments of the present disclosure, the width W ranges from 0.04mm to 0.2mm. Preferably, the width W ranges from 0.08mm to 0.2mm.
  • the height H ranges from 0.15mm to 0.8mm. Further, the height H ranges from 0.2mm to 0.5mm.
  • the conductive cross section of the conductive wires 32 with the cell 31 can be configured to be larger, so as to further improve the performance of the cell.
  • the conductive wires 32 are a copper wire coated with a connection material 322, i.e. the conductive wires 32 are constituted by the metal wire 321 and the connection material 322 coating the metal wire 321.
  • connection material 322 is a welding layer.
  • welding layer is an alloy layer.
  • connection material 322 is a conductive adhesive.
  • the metal wire 321 is coated with the connection material 322, such as a conductive adhesive or a welding layer, so as to facilitate electric connection of the metal wire 321 and the cell 31, and avoid affecting the photoelectric conversion efficiency due to the drifting of the metal wire during the connection process.
  • the electric connection of the metal wire 321 and the cell 31 can be conducted when or before the solar cell module is laminated. Preferably, they are connected before laminating.
  • the metal wire has a rectangular cross section. Further, a lead angle is disposed on two upper angles of the rectangle.
  • the metal wire of this structure can reflect the light to the cell, which further improves light intensity on the cell, so as to improve photoelectric conversion efficiency.
  • the solar cell unit includes a cell 31 and conductive wires 32.
  • the cell 31 consists of a cell substrate 311 and secondary grid lines 312 disposed on a front surface of the cell substrate 311; the conductive wires 32 are disposed on the front surface of the cell substrate 311, intersected and connected with the secondary grid lines 312, and the conductive wires 32 are the conductive wires 32of the solar cell unit according to the above embodiments.
  • the solar cell unit according to the present disclosure is mainly formed with the cell 31 and conductive wires 32; the cell 31 is mainly constituted by the cell substrate 311 and secondary grid lines 312.
  • the conductive cross section area of the conductive wires 32 and the cell 31 is relatively large, so as to improve the performance of the cell.
  • the solar cell array 30 will be described according to the embodiments of the present disclosure.
  • the solar cell array 30 includes a plurality of solar cell units which are the solar cell units according to the above embodiment, cells 31 of adjacent cell units being connected by the metal wire, i.e. the conductive wires 32.
  • the solar cell array 30 according to the embodiment of the present disclosure has the corresponding technical effect, i.e. having good conductivity and high photoelectric conversion efficiency.
  • the conductive wires are constituted by the metal wire S which extends reciprocally between a surface of a first cell 31 and a surface of a second cell 31 adjacent to the first cell 31.
  • the cell unit is formed by the cell 31 and the conductive wires 32 constituted by the metal wire S which extends on the surface of the cell 31.
  • the solar cell array 30 according to the embodiments of the present disclosure are formed with a plurality of cell unit units; the conductive wires 32 of the plurality of cell units are formed by the metal wire 321 which extends reciprocally between the surfaces of the cells 31.
  • the metal wire S extends reciprocally between a surface of a first cell 31 and a surface of a second cell 31 adjacent to the first cell 31.
  • the metal wire S may extend reciprocally between a front surface of a first cell 31 and a back surface of a second cell 31 adjacent to the first cell 31; the metal wire S may extend from a surface of the first cell 31 through surfaces of a predetermined number of middle cells 31 to a surface of the last cell 31, and then extends back from the surface of the last cell 31 through the surfaces of a predetermined number of middle cells 31 to the surface of the first cell 31, extending reciprocally like this.
  • the metal wire S can extend on front surfaces of two cells, such that the metal wire S constitutes a front conductive wire 32A of two cells connected in series.
  • a first metal wire S extends reciprocally on a front surface of a cell 31, and a second metal wire S extends reciprocally on a back surface of the cell 31, such that the first metal wire S constitutes a front conductive wire 32A, and the second metal wire S constitutes a back conductive wire 32B.
  • the metal wire S can extend reciprocally between a front surface of a first cell 31 and a back surface of a second cell 31 adjacent to the first cell 31, such that part of the metal wire S which extends on the front surface of the first cell 31 constitutes a front conductive wire 32A, and part thereof which extends on the back surface of the second cell 31 constitutes a back conductive wire 32B.
  • the conductive wire 32 can be understood as the front conductive wire 32A, the back conductive wire 32B, or the combination thereof.
  • the term “extending reciprocally” can be understood as that the metal wire 321 extends reciprocally once to form to two conductive wires 32 which form a U-shape or V-shape structure by the metal wire 321 extending reciprocally, yet the present disclosure is not limited to the above.
  • a plurality of conductive wires 32 of the cell units are constituted by the metal wire 321 which extends reciprocally; and the adjacent cells 31 are connected by the conductive wires 32.
  • the conductive wires 32 of the cell units in the present disclosure are used to output the current, and are not necessarily printed by expensive silver paste, and can be manufactured in a simple manner without using a solder strip to connect the cells. It is easy and convenient to connect the metal wire 321 with the secondary grid line and the back electrode, so that the cost of the cells is reduced considerably.
  • the conductive wires 32 are constituted by the metal wire 321 which extends reciprocally, the width of the conductive wires 32 (i.e. the width of projection of the metal wire on the cell) is much smaller than that of the current primary grid lines printed by silver paste, thereby decreasing the shading area. Further, the number of the conductive wires 32 can be adjusted easily, and thus the resistance of the conductive wires 32 is reduced, compared with the conductive wires made of the silver paste, and the efficiency of photoelectric conversion is improved. Since the metal wire 321 extends reciprocally to form the conductive wires, when the cell array 30 is used to manufacture the solar cell module 100, the metal wire 321 is easier to control accurately and will not tend to shift, i.e. the metal wire is not easy to “drift” , which will not affect but further improve the photoelectric conversion efficiency.
  • the solar cell array 30 according to the embodiments of the present disclosure has low cost and high photoelectric conversion efficiency.
  • the solar cell array 30 according to a specific embodiment of the present disclosure is illustrated with reference to Fig. 1 to Fig. 3.
  • two cell units in the solar cell array 30 are shown.
  • it shows two cells bodies 31 connected with each other via the conductive wire 32 constituted by the metal wire S.
  • the cell 31 comprises a cell substrate 311, a secondary grid line 312 (afront secondary grid line 312A) disposed on a front surface of the cell substrate 311, a back electric field 313 disposed on a back surface of the cell substrate 311, and a back electrode 314 disposed on the back electric field 313.
  • the back electrode 314 may be a back electrode of a traditional cell, for example, printed by the silver paste, or may be a back secondary grid line 312B similar to the secondary grid line on the front surface of the cell substrate, or may be multiple discrete welding portions, unless specified otherwise.
  • the secondary grid line refers to the secondary grid line 312 on the front surface of the cell substrate 311, unless specified otherwise.
  • the metal wire extends reciprocally between a front surface of a first cell 31 and a back surface of a second cell 31.
  • the solar cell array in the embodiment includes two cells 31A, 31B (called a first cell 31A and a second cell 31B respectively for convenience of description) .
  • the metal wire S extends reciprocally between the front surface of the first cell 31A (ashiny surface, i.e. an upper surface in Fig. 2) and the back surface of the second cell 31B, such that the metal wire S constitutes a front conductive wire of the first cell 31A and a back conductive wire of the second cell 31B.
  • the metal wire S is electrically connected with the secondary grid line of the first cell 31A (for example, being welded or bounded by a conductive adhesive) , and electrically connected with the back electrode of the second cell 31B.
  • back electrodes 314 are disposed on the back surface of the cell substrate 311, and the metal wire is welded with the back electrodes 314.
  • front secondary grid lines 312A are disposed on the front surface of the cell substrate 311, and back electrodes 314 are disposed on the back surface thereof.
  • the conductive wires 32 are welded with the front secondary grid lines 312A; when the conductive wires 32 are located on the back surface of the cell substrate 311, the conductive wires 32 are welded with the back electrodes 314 on the back surface of the cell substrate 311.
  • the metal wire S extends reciprocally between the first cell 31A and the second cell 31B for 1o to 60 times.
  • the metal wire extends reciprocally for 12 times to form 24 conductive wires, and there is only one metal wire.
  • a single metal wire extends reciprocally for 12 times to form 24 conductive wires, and the distance of the adjacent conductive wires can range from 2.5mm to 15mm.
  • the number of the conductive wires is increased, compared with the traditional cell, such that the distance between the secondary grid line and the conductive wire which the current runs through is decreased, so as to reduce the resistance and improve the photoelectric conversion efficiency.
  • the adjacent conductive wires form a U-shape structure, for convenience of winding the metal wire.
  • the present disclosure is not limited to the above.
  • the adjacent conductive wires form a V-shape structure.
  • the metal wire is a copper wire, yet the present disclosure is not limited thereto.
  • the metal wire 321 may be an aluminum wire.
  • the metal wire 321 has a circular cross section, such that more sunlight can reach the cell substrate to further improve the photoelectric conversion efficiency.
  • the metal wire 321 is coated with a connection material layer 322, such as a conductive adhesive layer or a welding layer.
  • the metal wire is welded with the secondary grid line and/or the back electrode by the welding layer, such that it is convenient to electrically connect the metal wire with the secondary grid line and/or the back electrode, and to avoid drifting of the metal wire in the connection process so as to guarantee the photoelectric conversion efficiency.
  • the electrical connection of the metal wire with the cell can be conducted when or before the solar cell module is laminated, and preference is given to the latter.
  • the metal wire preferably, before the metal wire contact the cell, the metal wire extends under strain, i.e. straightening the metal wire. After the metal wire is connected with the secondary grid line and the back electrode of the cell, the strain of the metal wire can be released, so as to further avoid the drifting of the conductive wire when the solar cell module is manufacture, and to guarantee the photoelectric conversion efficiency.
  • Fig. 5 is a schematic diagram of a solar cell array according to another embodiment of the present disclosure.
  • the metal wire extends reciprocally between the front surfaces of the first cell 31A and the front surface of the second cell 31B, such that the metal wire constitutes front conductive wires of the first cell 31A and the second cell 31B.
  • the first cell 31A and the second cell are connected in parallel.
  • the back electrode of the first cell 31A and the back electrode of the second cell 31B can be connected via a back conductive wire constituted by another metal wire which extends reciprocally.
  • the back electrode of the first cell 31A and the back electrode of the second cell 31B can be connected in a traditional manner.
  • the solar cell array 30 according to another embodiment of the present disclosure is illustrated with reference to Fig. 6.
  • the solar cell array 30 comprises n ⁇ m cells 31.
  • the column number and the row number can be different. For convenience of description, in Fig.
  • the cells 31 in one row are called a first cell 31, a second cell 31, a third cell 31, a fourth cell 31, a fifth cell 31, and a sixth cell 31 sequentially; in a direction from up to down, the columns of the cells 31 are called a first column of cells 31, a second column of cells 31, a third column of cells 31, a fourth column of cells 31, a fifth column of cells 31, and a sixth column of cells 31 sequentially.
  • the metal wire In a row of the cells, the metal wire extends reciprocally between a surface of a first cell 31 and a surface of a second cell 31 adjacent to the first cell 31; in two adjacent rows of cells 31, the metal wire extends reciprocally between a surface of a cell 31 in a a th row and a surface of a cell in a (a+1) th row, and m-1 ⁇ a ⁇ 1.
  • the metal wire in a row of the cells 31, the metal wire extends reciprocally between a front surface of a first cell 31 and a back surface of a second cell 31 adjacent to the first cell 31, so as to connect the cells in one row in series.
  • the metal wire extends reciprocally between a front surface of a cell 31 at an end of the a th row and a back surface of a cell 31 at an end of the (a+1) th row, to connect the two adjacent rows of cells 31 in series.
  • the metal wire extends reciprocally between the surface of the cell 31 at an end of the a th row and the surface of the cell 31 at an end of the (a+1) th row, the end of the a th row and the end of the (a+1) th row located at the same side of the matrix form, as shown in Fig. 6, located at the right side thereof.
  • a first metal wire extends reciprocally between a front surface of a first cell 31 and a back surface of the second cell 31;
  • a second metal wire extends reciprocally between a front surface of the second cell 31 and a back surface of a third cell 31;
  • a third metal wire extends reciprocally between a front surface of the third cell 31 and a back surface of a fourth cell 31;
  • a fourth metal wire extends reciprocally between a front surface of the fourth cell 31 and a back surface of a fifth cell 31;
  • a fifth metal wire extends reciprocally between a front surface of the fifth cell 31 and a back surface of a sixth cell 31.
  • a sixth metal wire extends reciprocally between a front surface of the sixth cell 31 in the first row and a back surface of a sixth cell 31 in the second row, such that the first row and the second row are connected in series.
  • a seventh metal wire extends reciprocally between a front surface of the sixth cell 31 in the second row and a back surface of a fifth cell 31 in the second row;
  • a eighth metal wire extends reciprocally between a front surface of the fifth cell 31 in the second row and a back surface of a fourth cell 31 in the second row, until a eleventh metal wire extends reciprocally between a front surface of a second cell 31 in the second row and a back surface of a first cell 31 in the second row, and then a twelfth metal wire extends reciprocally between a front surface of the first cell 31 in the second row and a back surface of a first cell 31 in the third row, such that the second row and the third row are connected in series.
  • a bus bar is disposed at the left side of the first cell 31 in the first row and the left side of the first cell 31 in the sixth row respectively; a first bus bar is connected with a conductive wire extending from the left side of the first cell 31 in the first row, and a second bus bar is connected with a conductive wire extending from the left side of the first cell 31 in the sixth row.
  • the cells in the embodiments of the present disclosure are connected in series by the conductive wires –the first row, the second row, the third row, the fourth row, the fifth row and the sixth row are connected in series by the conductive wires.
  • the second and third row, and the fourth and fifth rows can be connected in parallel with a diode respectively to avoid light spot effect.
  • the diode can be connected in a manner commonly known to those skilled in the art, for example, by a bus bar.
  • the present disclosure is not limited to the above.
  • the first and second rows can be connected in series, the third and fourth rows connected in series, the fifth and sixth rows connected in series, and meanwhile the second and third rows are connected in parallel, the fourth and fifth connected in parallel.
  • a bus bar can be disposed at the left or right side of corresponding rows respectively.
  • the cells 31 in the same row can be connected in parallel.
  • a metal wire extends reciprocally from a front surface of a first cell 31 in a first row through the front surfaces of the cells 31 in the second row to the sixth row.
  • adjacent cells 31 can be connected by a single metal wire that extends reciprocally for several times, which is easier to manufacture in lower cost.
  • the metal wire is coated with a welding layer.
  • the ratio of the thickness of the welding layer and the diameter of the metal wire is (0.02-0.5) : 1.
  • the ratio of the thickness of the welding layer and the diameter of the conductive wire 32 is (0.02-0.5) : 1.
  • the conductive wires 32 consist of a metal wire and a welding layer coating the metal wire.
  • the welding layer may coat the metal wire completely or partially.
  • the alloy layer is, preferably, formed at a position where the welding layer is welded with the secondary grid lines 312 of the cell 31.
  • the welding layer can coat the periphery of the metal wire in a circular manner.
  • the thickness of the welding layer can fall into a relatively wide range.
  • the welding layer has a thickness of 1 to 100 ⁇ m, more preferably, 1 to 30 ⁇ m.
  • the alloy with a low melting point for forming the welding layer may be a conventional alloy with a low melting point which can be 100 to 220°C.
  • the alloy with the low melting point contains Sn, and at least one of Bi, In, Ag, Sb, Pb and Zn, more preferably, containing Sn, Bi, and at least one of In, Ag, Sb, Pb and Zn.
  • the alloy may be at least one of Sn-Bi alloy, In-Sn alloy, Sn-Pb alloy, Sn-Bi-Pb alloy, Sn-Bi-Ag alloy, In-Sn-Cu alloy, Sn-Bi-Cu alloy and Sn-Bi-Zn alloy.
  • the alloy is Bi-Sn-Pb alloy, for example, containing 40 weight percent of Sn, 55 weight percent of Bi, and 5 weight percent of Pb (i.e. Sn40%-Bi55%-Pb5%) .
  • the thickness of the welding layer can be 0.001 to 0.06mm.
  • the conductive wire 32 may have a cross section of 0.01 to 0.5mm 2 .
  • the metal wire can be conventional in the art, for example, a copper wire.
  • the secondary grid line 312 has a width of 40 to 80 ⁇ m and a thickness of 5 to 20 ⁇ m; there are 50 to 120 secondary grid lines 312, and the distance between adjacent secondary grid lines 312 ranges from 0.5 to 3mm.
  • the solar cell module 100 according to embodiments of the present disclosure is illustrated with reference to Fig. 10 and Fig. 11.
  • the solar cell module 100 includes an upper cover plate 10, a front adhesive layer 20, the cell array 30, a back adhesive layer 40 and a lower cover plate 50 superposed sequentially along a direction from up to down.
  • the front adhesive layer 20 and the back adhesive layer 40 are adhesive layers commonly used in the art.
  • the front adhesive layer 20 and the back adhesive layer 40 are polyethylene-octene elastomer (POE) and/or ethylene-vinyl acetate copolymer (EVA) .
  • POE polyethylene-octene elastomer
  • EVA ethylene-vinyl acetate copolymer
  • the upper cover plate 10 and the lower cover plate 50 can be selected and determined by conventional technical means in the art.
  • the upper cover plate 10 and the lower cover plate 50 can be transparent plates respectively, for example, glass plates.
  • the conductive wire can be first bounded or welded with the secondary grid lines and the back electrode of the cell 31, and then superposed and laminated.
  • the solar module 100 includes an upper cover plate 10, a front adhesive layer 20, the cell array 30, a back adhesive layer 40 and a lower cover plate 50.
  • the cell array 30 includes a plurality of cells 31, and adjacent cells 31 are connected by the plurality of conductive wires 32.
  • the conductive wires 32 are constituted by the metal wire S which extends reciprocally between surfaces of adjacent cells.
  • the conductive wires 32 are welded with the secondary grid lines.
  • the front adhesive layer 20 contacts with the conductive wires 32 directly and fills between the adjacent conductive wires 32.
  • the solar cell module 100 includes an upper cover plate 10, a front adhesive layer 20, the cell array 30, a back adhesive layer 40 and a lower cover plate 50 superposed sequentially along a direction from up to down.
  • the cell array 30 includes a plurality of cells 31 and conductive wires 32 for connecting the plurality of cells 31.
  • the conductive wires are constituted by the metal wire S which extends reciprocally between surfaces of two adjacent cells 31.
  • the conductive wires 32 are electrically connected with the cells 31, in which the front adhesive layer 20 on the cells 31 contacts with the conductive wires 32 directly and fills between the adjacent conductive wires 32, such that the front adhesive layer 20 can fix the conductive wires 32, and separate the conductive wires 32 from air and moisture from the outside world, so as to prevent the conductive wires 32 from oxidation and to guarantee the photoelectric conversion efficiency.
  • the conductive wires 32 constituted by the metal wire S which extends reciprocally replace traditional primary grid lines and solder strips, so as to reduce the cost.
  • the metal wire S extends reciprocally to decrease the number of free ends of the metal wire S and to save the space for arranging the metal wire S, i.e. without being limited by the space.
  • the number of the conductive wires 32 constituted by the metal wire which extends reciprocally may be increased considerably, which is easy to manufacture, and thus is suitable for mass production.
  • the front adhesive layer 20 contacts with the conductive wires 32 directly and fills between the adjacent conductive wires 32, which can effectively isolate the conductive wires from air and moisture to prevent the conductive wires 32 from oxidation to guarantee the photoelectric conversion efficiency.
  • the metal wire S extends reciprocally between a front surface of a first cell and a back surface of a second cell adjacent to the first cell; the front adhesive layer 20 contacts with the conductive wires on the front surface of the first cell 31 directly and fills between the adjacent conductive wires 32 on the front surface of the first cell 31; the back adhesive layer 40 contacts with the conductive wires 32 on the back surface of the second cell 31 directly and fills between the adjacent conductive wires 32 on the back surface of the second cell 31.
  • the two adjacent cells 31 are connected by the metal wire S.
  • the front surface of the first cell 31 is connected with the metal wire S
  • the back surface of the second cell 31 is connected with the metal wire S.
  • the front adhesive layer 20 on the first cell 31 whose front surface is connected with the metal wire S is in direct contact with the metal wire S on the front surface of the first cell 31 and fills between the adjacent conductive wires 32.
  • the back adhesive layer 40 on the second cell 31 whose back surface is connected with the metal wire S is in direct contact with the metal wire S on the back surface of the second cell 31 and fills between the adjacent conductive wires 32 (as shown in Fig. 2) .
  • the solar cell module 100 not only the front adhesive layer 20 can separate the conductive wires 32 on the front surfaces of part of the cells 31 from the outside world, but also the back adhesive layer 40 can separate the conductive wires 32 on the back surfaces of part of the cells 31 from the outside world, so as to further guarantee the photoelectric conversion efficiency of the solar cell module 100.
  • the solar cell module has a series resistance of 380 to 440m ⁇ per 60 cells.
  • the present disclosure is not limited to 60 cells, and there may be 30 cells, 72 cells, etc.
  • the series resistance of the solar cell module is 456 to 528m ⁇ , and the electrical performance of the cells is better.
  • the solar cell module has an open-circuit voltage of 37.5-38.5V per 60 cells.
  • the present disclosure is not limited to 60 cells, and there may be 30 cells, 72 cells, etc.
  • the short-circuit current is 8.9 to 9.4A, and has nothing to do with the number of the cells.
  • the solar cell module has a fill factor of 0.79 to 0.82, which is independent from the dimension and number of the cells, and can affect the electrical performance of the cells.
  • the solar cell module has a working voltage of 31.5-32V per 60 cells.
  • the present disclosure is not limited to 60 cells, and there may be 30 cells, 72 cells, etc.
  • the working current is 8.4 to 8.6A, and has nothing to do with the number of the cells.
  • the solar cell module has a conversion efficiency of 16.5-17.4%, and a power of 265-280W per 60 cells.
  • a method for manufacturing the solar cell module 100 according to the embodiments of the present disclosure will be illustrated with respect to Fig. 7 to Fig. 9.
  • the method according to the embodiments of the present disclosure includes the following steps:
  • the method includes the steps of preparing a solar array 30, superposing the upper cover plate 10, the front adhesive layer 20, the cell array 30, the back adhesive layer 40 and the lower cover plate 50 in sequence, and laminating them to obtain the solar cell module 100. It can be understood that the method further includes other steps, for example, sealing the gap between the upper cover plate 10 and the lower cover plate 50 by a sealant, and fixing the above components together by a U-shape frame, which are known to those skilled in the art, and thus will be not described in detail herein.
  • the method includes a step of forming a plurality of conductive wires by a metal wire which extends reciprocally surfaces of cells 31 and is electrically connected with the surfaces of cells 31, such that the adjacent cells 31 are connected by the plurality of conductive wires to constitute a cell array 30.
  • the metal wire extends reciprocally for 12 times under strain.
  • a first cell 31A and a second cell 31B are prepared.
  • a front surface of the first cell 31A is connected with a metal wire
  • a back surface of the second cell 31B is connected with the metal wire, such that the cell array 30 is formed.
  • Fig. 9 shows two cells 31.
  • the metal wire which extends reciprocally connects the front surface of the first cell 31 and the back surface of the second cell 31 adjacent to the first cell 31, i.e. connecting a secondary grid line of the first cell 31 with a back electrode of the second cell 31 by the metal wire.
  • the metal wire extends reciprocally under strain from two clips at two ends thereof.
  • the metal wire can be winded only with the help of two clips, which saves the clips considerably and then reduces the assembling space.
  • the adjacent cells are connected in series.
  • the adjacent cells can be connected in parallel by the metal wire based on practical requirements.
  • the cell array 30 obtained is superposed with the upper cover plate 10, the front adhesive layer 20, the back adhesive layer 40 and the lower cover plate 50 in sequence, in which a front surface of the cell 31 faces the front adhesive layer 20, a back surface thereof facing the back adhesive layer 40, and laminating them to obtain the solar cell module 100.
  • the metal wire can be bounded or welded with the cell 31 when or before they are laminated.
  • the front adhesive layer 20 is disposed in direct contact with the conductive wires 32. In the process of laminating, the front adhesive layer 20 melts and fills the gaps between adjacent conductive wires 32.
  • the back adhesive layer 40 is disposed in direct contact with the conductive wires 32. In the process of laminating, the back adhesive layer 40 melts and fills the gaps between adjacent conductive wires 32.
  • Example 1 is used to illustrate the solar cell module 100 according to the present disclosure and the manufacturing method thereof.
  • a copper wire is attached to an alloy layer of Sn40%-Bi55%-Pb5% (melting point: 125°C) , in which the copper wire has a rectangular cross section; the ratio of the width and the height of the copper wire is 1: 2; and the area of the cross section is 0.04mm 2 ; and the alloy layer has a thickness of 16 ⁇ m.
  • the conductive wires are obtained.
  • a POE adhesive layer in 1630 ⁇ 980 ⁇ 0.5mm are provided (melting point: 65°C) , and a glass plate in 1633 ⁇ 985 ⁇ 3mm and a polycrystalline silicon cell 31 in 156 ⁇ 156 ⁇ 0.21mm are provided correspondingly.
  • the cell 31 has 91 secondary grid lines (silver, 60 ⁇ m in width, 9 ⁇ m in thickness) , each of which substantially runs through the cell 31 in a longitudinal direction, and the distance between the adjacent secondary grid lines is 1.7mm.
  • the cell 31 has five back electrodes (tin, 1.5mm in width, 10 ⁇ m in thickness) on its back surface. Each back electrode substantially runs through the cell 31 in a longitudinal direction, and the distance between the adjacent back electrodes is 31mm.
  • 60 cells 31 are arranged in a matrix form (six rows and ten columns) .
  • the metal wire extends reciprocally between a front surface of a first cell 31 and a back surface of a second cell under strain.
  • the metal wire extends reciprocally under strain from two clips at two ends thereof, so as to form 15 parallel conductive wires.
  • the metal wire extends reciprocally under strain from two clips at two ends thereof, so as to form 15 parallel conductive wires.
  • the secondary grid lines of the first cell 31 are welded with the conductive wires and the back electrodes of the second cell 31 are welded with the conductive wires at a welding temperature of 160°C.
  • the distance between parallel adjacent conductive wires is 9.9mm. 10 cells are connected in series into a row, and six rows of the cells of such kind are connected in series into a cell array via the bus bar.
  • an upper glass plate, an upper POE adhesive layer, multiple cells arranged in a matrix form and welded with the metal wire, a lower POE adhesive layer and a lower glass plate are superposed sequentially from up to down, in which the shiny surface of the cell 31 faces the front adhesive layer 20, such that the front adhesive layer 20 contacts with the conductive wires 32 directly; and the shady surface of the cell 31 faces the back adhesive layer 40, and finally they are laminated in a laminator, in which the front adhesive layer 20 fills between adjacent conductive wires 32.
  • a solar cell module A1 is obtained.
  • the difference of Comparison example 1 and Example 1 lies in that the copper wire has a height of 0.1mm and a width of 0.2mm. In such a way, a solar cell module D1 is obtained.
  • Example 2 The difference of Example 2 and Example 1 lies in that the ratio of the height and the width of the copper wire is 4: 1, the height being 0.6mm and the width being 0.15mm. In such a way, a solar cell module A2 is obtained.
  • Example 3 The difference of Example 3 and Example 1 lies in that the ratio of the height and the width of the copper wire is 6: 1, the height being 0.9mm and the width being 0.15mm. In such a way, a solar cell module A3 is obtained.
  • the solar cell module according to the embodiments of the present disclosure can obtain relatively high photoelectric conversion efficiency.
  • first and second are used herein for purposes of description and are not intended to indicate or imply relative importance or significance or to imply the number of indicated technical features.
  • the feature defined with “first” and “second” may comprise one or more of this feature.
  • “a plurality of” means two or more than two, unless specified otherwise.
  • a structure in which a first feature is “on” or “below” a second feature may include an embodiment in which the first feature is in direct contact with the second feature, and may also include an embodiment in which the first feature and the second feature are not in direct contact with each other, but are contacted via an additional feature formed therebetween.
  • a first feature “on, ” “above, ” or “on top of” a second feature may include an embodiment in which the first feature is right or obliquely “on, ” “above, ” or “on top of” the second feature, or just means that the first feature is at a height higher than that of the second feature; while a first feature “below, ” “under, ” or “on bottom of” a second feature may include an embodiment in which the first feature is right or obliquely “below, ” “under, ” or “on bottom of” the second feature, or just means that the first feature is at a height lower than that of the second feature.

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

Abstract

La présente invention concerne un fil conducteur (32) d'une unité de cellule solaire, une unité de cellule solaire, un réseau de cellules solaires (30), un module de cellule solaire (100) et leur procédé de fabrication. Le fil conducteur (32) est constitué par un fil métallique dont la hauteur est H, et dont la largeur est W, un rapport de la hauteur H et la largeur W étant de 1:1 à 6:1
PCT/CN2015/084098 2014-10-31 2015-07-15 Unite de cellule solaire, fil conducteur, reseau, module de cellule et leur procede de fabrication WO2016065948A1 (fr)

Applications Claiming Priority (22)

Application Number Priority Date Filing Date Title
CN201410606607.4 2014-10-31
CN201410606607 2014-10-31
CN201410608576.6 2014-10-31
CN201410608577.0 2014-10-31
CN201410608469 2014-10-31
CN201410608580.2 2014-10-31
CN201410608580 2014-10-31
CN201410608576 2014-10-31
CN201410608469.3 2014-10-31
CN201410606601.7 2014-10-31
CN201410606675 2014-10-31
CN201410606601 2014-10-31
CN201410606700 2014-10-31
CN201410608579 2014-10-31
CN201410606700.5 2014-10-31
CN201410608577 2014-10-31
CN201410606675.0 2014-10-31
CN201410608579.X 2014-10-31
CN201510085666.6 2015-02-17
CN201510085666 2015-02-17
CN201510218535.0 2015-04-03
CN201510218535.0A CN106206813A (zh) 2014-10-31 2015-04-30 太阳能电池单元、导电线、阵列、电池组件及其制备方法

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Citations (5)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
JPS59172779A (ja) * 1983-03-23 1984-09-29 Toshiba Corp 太陽電池
CN102479857A (zh) * 2010-11-29 2012-05-30 比亚迪股份有限公司 太阳能电池组件边框及太阳能电池组件
CN202871835U (zh) * 2012-10-25 2013-04-10 阿特斯(中国)投资有限公司 一种太阳能电池组件
CN103137791A (zh) * 2013-03-13 2013-06-05 中国科学院上海微系统与信息技术研究所 湿法沉积和低温热处理相结合制备异质结太阳电池方法
US20130160825A1 (en) * 2011-12-22 2013-06-27 E I Du Pont De Nemours And Company Back contact photovoltaic module with glass back-sheet

Patent Citations (5)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
JPS59172779A (ja) * 1983-03-23 1984-09-29 Toshiba Corp 太陽電池
CN102479857A (zh) * 2010-11-29 2012-05-30 比亚迪股份有限公司 太阳能电池组件边框及太阳能电池组件
US20130160825A1 (en) * 2011-12-22 2013-06-27 E I Du Pont De Nemours And Company Back contact photovoltaic module with glass back-sheet
CN202871835U (zh) * 2012-10-25 2013-04-10 阿特斯(中国)投资有限公司 一种太阳能电池组件
CN103137791A (zh) * 2013-03-13 2013-06-05 中国科学院上海微系统与信息技术研究所 湿法沉积和低温热处理相结合制备异质结太阳电池方法

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