WO2010040775A2 - Module photovoltaïque - Google Patents

Module photovoltaïque Download PDF

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Publication number
WO2010040775A2
WO2010040775A2 PCT/EP2009/063029 EP2009063029W WO2010040775A2 WO 2010040775 A2 WO2010040775 A2 WO 2010040775A2 EP 2009063029 W EP2009063029 W EP 2009063029W WO 2010040775 A2 WO2010040775 A2 WO 2010040775A2
Authority
WO
WIPO (PCT)
Prior art keywords
photovoltaic module
layer
module according
lamination
lamination layer
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Ceased
Application number
PCT/EP2009/063029
Other languages
English (en)
Other versions
WO2010040775A3 (fr
Inventor
Ivan Sinicco
Daniel Lepori
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
TEL Solar Services AG
Original Assignee
Oerlikon Solar IP AG
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Oerlikon Solar IP AG filed Critical Oerlikon Solar IP AG
Publication of WO2010040775A2 publication Critical patent/WO2010040775A2/fr
Publication of WO2010040775A3 publication Critical patent/WO2010040775A3/fr
Anticipated expiration legal-status Critical
Ceased legal-status Critical Current

Links

Classifications

    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B17/00—Layered products essentially comprising sheet glass, or glass, slag, or like fibres
    • B32B17/06—Layered products essentially comprising sheet glass, or glass, slag, or like fibres comprising glass as the main or only constituent of a layer, next to another layer of a specific material
    • B32B17/10—Layered products essentially comprising sheet glass, or glass, slag, or like fibres comprising glass as the main or only constituent of a layer, next to another layer of a specific material of synthetic resin
    • B32B17/10005—Layered products essentially comprising sheet glass, or glass, slag, or like fibres comprising glass as the main or only constituent of a layer, next to another layer of a specific material of synthetic resin laminated safety glass or glazing
    • B32B17/10009—Layered products essentially comprising sheet glass, or glass, slag, or like fibres comprising glass as the main or only constituent of a layer, next to another layer of a specific material of synthetic resin laminated safety glass or glazing characterized by the number, the constitution or treatment of glass sheets
    • B32B17/10036—Layered products essentially comprising sheet glass, or glass, slag, or like fibres comprising glass as the main or only constituent of a layer, next to another layer of a specific material of synthetic resin laminated safety glass or glazing characterized by the number, the constitution or treatment of glass sheets comprising two outer glass sheets
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B17/00—Layered products essentially comprising sheet glass, or glass, slag, or like fibres
    • B32B17/06—Layered products essentially comprising sheet glass, or glass, slag, or like fibres comprising glass as the main or only constituent of a layer, next to another layer of a specific material
    • B32B17/10—Layered products essentially comprising sheet glass, or glass, slag, or like fibres comprising glass as the main or only constituent of a layer, next to another layer of a specific material of synthetic resin
    • B32B17/10005—Layered products essentially comprising sheet glass, or glass, slag, or like fibres comprising glass as the main or only constituent of a layer, next to another layer of a specific material of synthetic resin laminated safety glass or glazing
    • B32B17/10807—Making laminated safety glass or glazing; Apparatus therefor
    • B32B17/10816—Making laminated safety glass or glazing; Apparatus therefor by pressing
    • B32B17/10871—Making laminated safety glass or glazing; Apparatus therefor by pressing in combination with particular heat treatment
    • H—ELECTRICITY
    • H10—SEMICONDUCTOR DEVICES; ELECTRIC SOLID-STATE DEVICES NOT OTHERWISE PROVIDED FOR
    • H10F—INORGANIC SEMICONDUCTOR DEVICES SENSITIVE TO INFRARED RADIATION, LIGHT, ELECTROMAGNETIC RADIATION OF SHORTER WAVELENGTH OR CORPUSCULAR RADIATION
    • H10F19/00—Integrated devices, or assemblies of multiple devices, comprising at least one photovoltaic cell covered by group H10F10/00, e.g. photovoltaic modules
    • H10F19/80—Encapsulations or containers for integrated devices, or assemblies of multiple devices, having photovoltaic cells
    • H—ELECTRICITY
    • H10—SEMICONDUCTOR DEVICES; ELECTRIC SOLID-STATE DEVICES NOT OTHERWISE PROVIDED FOR
    • H10F—INORGANIC SEMICONDUCTOR DEVICES SENSITIVE TO INFRARED RADIATION, LIGHT, ELECTROMAGNETIC RADIATION OF SHORTER WAVELENGTH OR CORPUSCULAR RADIATION
    • H10F77/00—Constructional details of devices covered by this subclass
    • H10F77/40—Optical elements or arrangements
    • H10F77/42—Optical elements or arrangements directly associated or integrated with photovoltaic cells, e.g. light-reflecting means or light-concentrating means
    • H10F77/48—Back surface reflectors [BSR]
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
    • Y02E—REDUCTION OF GREENHOUSE GAS [GHG] EMISSIONS, RELATED TO ENERGY GENERATION, TRANSMISSION OR DISTRIBUTION
    • Y02E10/00—Energy generation through renewable energy sources
    • Y02E10/50—Photovoltaic [PV] energy
    • Y02E10/52—PV systems with concentrators

Definitions

  • the invention relates to a photovoltaic module and a method for manufacturing such a photovoltaic module.
  • Photovoltaic energy is reaching industrial maturity and in order to accelerate this process and allow photovoltaic energy investments amortize earlier, any kind of cost reduction in module production is important.
  • durability and long-term stability against environmental influences of photovoltaic modules also called photovoltaic panels, is a central factor.
  • the invention described hereinafter addresses both aspects with a special view on silicon based thin film photovoltaic modules, but may also be applied for any other type of photovoltaic application needing a durable seal against atmospheric and all other agents affecting the photovoltaic module's life cycle or performance.
  • Photovoltaic devices, photoelectric conversion devices or solar cells are devices which convert light, especially sunlight into direct current (DC) electrical power.
  • DC direct current
  • thin film solar cells are being of interest since they allow using glass, glass ceramics or other rigid or flexible substrates as a base material or a base substrate instead of crystalline or polycrystalline silicon.
  • the solar cell structure i.e. the layer sequence responsible for or capable of the photovoltaic effect is being deposited in thin layers. This deposition may take place under atmospheric or vacuum conditions. Deposition techniques are widely known in the art, such as PVD, CVD, PECVD, APCVD, Hot Wire deposition, all being used and known in semiconductor technology.
  • a silicon based thin-film solar cell generally includes a first electrode, one or more semiconductor thin-film p-i-n or n-i-p based junctions, and a second electrode, which are successively stacked on a substrate.
  • the i-type layer which is a substantially intrinsic semiconductor layer, occupies the most part of the thickness of the thin-film p-i-n junction. Photoelectric conversion occurs primarily in this i-type layer.
  • Thin film cells have been fabricated from microcrystalline, amorphous, compound or semiconductor material, as for instance Si, other than single crystal semiconductor material or other technologies as for instance CIG/CIGS and Cd-Te. All of them can be deposited in situ upon a substrate by chemical vapour deposition, sputtering or other suitable deposition techniques. In use, these cells are assembled in a photovoltaic module which must withstand the rigors of the environment and handling in commerce.
  • a photovoltaic module usually comprises a front cover element also called front side, a photosensitive semiconductor layer also called photovoltaic cell, an adhesive layer, a metallic back reflector and a back cover element also called back side.
  • a photovoltaic module is described.
  • the module comprises front and back sides and edges forming a perimeter and at least one photovoltaic cell capable of converting radiation incident on the front of the module to electrical energy, the module being partially encapsulated in a unitary, reaction-injected molded elastomer which forms a seal against a portion of the front side of the panel bordering the perimeter, and continues around the perimeter and seals against at least a portion of the back side.
  • the back reflector is one of those layers that enhance relative efficiency by 10 % or more and in US 5,008,062 it is a layer on its own.
  • the back reflector is gaining more and more importance.
  • Current metallization back reflector solutions offer good reflection properties but the cost and the time consuming separate processes and equipment required for the scope, do not allow for much cost reduction in this area.
  • the photovoltaic module according to the invention comprises a transparent substrate as a front cover element, a photosensitive semiconductor layer, a lamination layer and a back layer as a back cover element, wherein the lamination layer comprises reflective properties.
  • photovoltaic module refers to a combination of a sheet of transparent material or other lamina forming the front cover element, for example a front glass, an array or group of photovoltaic cells formed as one or more photosensitive semiconductor layers interconnected to provide an output of electrical energy, and a back layer, for example a back glass, comprising different sub layers.
  • the whole structure forms a device capable of transforming incident radiation to electrical current.
  • Such modules traditionally comprise a transparent substrate usually known in the art as front glass, and an active layer which comprises layers of transparent conductors, photovoltaic active material, cell-connecting circuits, metals or reflecting coating which together form an operative photovoltaic module.
  • a sheet of glass or laminated plastic materials like combinations of Tedlar, PET, aluminum film, PVDF, or other rigid material to protect the photovoltaic cell, with the various lamina being bonded together by a dielectric layer for instance plasticized polyvinyl butyryl (PVB) or ethylene vinylacetate (EVA).
  • PVB plasticized polyvinyl butyryl
  • EVA ethylene vinylacetate
  • dielectric layer transparent, the opposite order, with the lamina material facing the sun, covered by a front glass or not, is possible.
  • the lamination layer itself comprises reflective properties so that, according to the inventive solution, a back reflector is not needed any more.
  • the lamination layer is made of a polymer material with a high UV stability, low permeability characteristics, especially regarding moisture, electrical isolation, adhesion and chemical stability. Especially the high UV stability of the lamination layer improves the life cycle of photovoltaic modules essentially.
  • the lamination layer has bonding and reflective characteristics.
  • the lamination layer is preferably a lamination foil which can be easily laminated on the back layer or the front layer comprising the photosensitive semiconductor layer.
  • the color of the lamination layer is white.
  • the lamination layer may have the best possible reflectivity properties with a reflectivity of 1 preferably without any absorption or transmission characteristics.
  • the relative increase of efficiency for an amorphous photovoltaic module with such a lamination layer may be up to 15 %, for amorph/microcrystalline (micromorph) modules up to 45%.
  • the white color may comprise reflective pigments for example metals like Al, Zn, Cr, Ag, Ti or metal oxides like SiO 2 , TiO 2 , BaSO 4 and/or ZrO 2 .
  • the back layer preferably provides high absorption characteristics.
  • Black or other very dark colored paint can be applied on the back side or back layer and preferably on the transparent substrate, for example a front glass, at the perimeter edges where no photovoltaic cell or photosensitive semiconductor layer is present.
  • a black or very dark colored back layer or glass and deposing a butyle paste around the perimeter of the module sticking over a black polymeric laminate in order to improve at the same time the weathering properties of the photovoltaic module using the excellent sealing characteristics of those materials.
  • the lamination layer is preferably a polyolefin based polymer.
  • a polyolefin is a semi-crystalline thermoplastic polymer produced from a simple olefin also called an alkene with the general formula C n H 2n as a monomer.
  • polyethylene is the polyolefin produced by polymerizing the olefin ethylene.
  • polyethylene (PE), polypropylene (PP), polybutylene terephthalate (PBT), polyethylene terephthalate (PET) and polyamid (PA) may be used for the polyolefin based polymer.
  • the permeability to water vapour of such a polyolefin based polymer of the lamination layer is preferably less than 5 g/m 2 per day, most preferred less than 2 g/m 2 per day.
  • the adhesion strength to glass is preferably above 30 N over 15 mm in width.
  • the Pummel test value (Pummel adhesion level) is preferably > 6. The Pummel test is used to determine the adhesion or bonding between the lamination layer and the front cover element or the back cover element. A specimen is cooled if necessary and pummeled with a hammer on the laminated side. Further the resistivity of the polymer is preferably > 10 12 ⁇ , most preferred > 10 14 ⁇ .
  • the damp heat resistance for the lamination layer or foil is preferably > 80 %, most preferred > 90 %, under "85 0 C 85 % RH x 1000 h" standardized test conditions.
  • the heat recycle test resistance of the lamination layer is preferably > 80 %, most preferred > 90 %, after 200 cycles from -40 0 C to 85 °C.
  • the lamination layer is preferably recyclable or nontoxically disposable after the economic life-span of the photovoltaic module, e. g. 20 years, at the end-costumer's site. Further, the lamination layer provides an environmental friendly production. However, polyolefin based polymers have to be treated on the module at temperatures above 150 °C and could therefore compromise the photosensitive semiconductor layer. Therefore a diligent control of the temperature gradient is required, especially in quick and high volume production oriented equipment.
  • the lamination layer at least partially encapsulates the photovoltaic module.
  • the edges of the module have traditionally been smoothed to provide a flush edge surface.
  • the module can be enclosed in a peripheral frame of aluminium, steel, polymer or other rigid frame material. This method of sealing and framing the periphery of the module has been necessary to isolate the solar cell from the environment, and to provide a frame for the mechanical strengthening of the module and to provide a border to permit ease of handling and the attachment of connector boxes and the like for attachment to an external electrical circuit.
  • the lamination layer itself at least partially encapsulate the photovoltaic module, since the lamination layer provides very good bonding and sealing characteristics.
  • the lamination layer preferably is not only arranged between the front cover element and the back cover element but also at least partially surrounds the front cover element and the back cover element. If the lamination layer is additionally white colored the step of providing a back reflector and the manufacturing step of encapsulating and lamination can be simplified into a single one.
  • the lamination layer is a polyolefin based polymer
  • the lamination layer as an encapsulating layer provides good characteristics against permeability, particularly regarding moisture, as well as aging and delamination.
  • the back layer is a float glass.
  • Float glass is a sheet of glass made by floating molten glass on a bed of molten tin. This method gives the sheet uniform thickness and very flat surfaces. The float glass providing industry usually works with a glass width starting at 3200 mm and ending at 3600 mm depending on market and technological factory requirements.
  • a back glass ranging between said at least 3200 mm up to the preferred 3600 mm can exactly encapsulate 3 photovoltaic actively coated front glasses, thus reducing waste of glass producers to a minimum very close to zero.
  • the lamination layer preferably encapsulates at least the internal portion of such connecting means.
  • the lamination layer may further comprise a stiffening structure.
  • the stiffening structure may be for example a metal, fibrous or polymeric sheets or girders, which may be included within the lamination layer or the polymer of the lamination layer.
  • a composite solution is provided adding rigidity to the photovoltaic module.
  • the present invention is directed to a method for manufacturing a photovoltaic module comprising the steps of a) providing a transparent substrate as a front cover element, b) putting a photosensitive semiconductor layer on the transparent substrate, and c) providing a back layer as a back cover element, d) wherein a lamination layer comprising reflective properties is laminated between the transparent substrate with the photosensitive semiconductor layer on it and the back layer.
  • the inventive method preferably comprises a further step e), where the sandwich structure of the front cover element, the semiconductor layer, the lamination layer and the back cover element is evacuated.
  • the front cover element and the back cover element is preferably a glass material.
  • the air filling the space between the front cover element and the back cover element may be removed by the evacuation process.
  • the sandwich may be introduced in a sealable and evacuable enclosure which is operatively connected to vacuum pumps.
  • the duration of the evacuation is preferably ⁇ 30 min, most preferred ⁇ 15 min.
  • step f) comprises a pressing time between 100 s and 400 s, most preferred between 200 s and 300 s.
  • a pressure between 200 mbar and 15 bar, preferably between 2 bar and 7 bar, most preferred between 4,5 bar and 5,5 bar is preferably used.
  • step d) and/or step f) a process temperature between 50 °C and 200 °C, preferably between 140 °C and 160 °C is used.
  • a process temperature between 50 °C and 200 °C, preferably between 140 °C and 160 °C is used.
  • the photovoltaic module is preferably cooled in a further step g).
  • the cooling is advantageously in order to avoid unwanted stresses particularly in the front cover element and the back cover element.
  • the photosensitive semiconductor layer may be protected for damages by this cooling step.
  • the cooling may be performed for example by a cooling gas or air ventilation.
  • the stiffening structure may be for example a metal, metal particles, fibrous or polymeric sheets or girders, which may be included within the lamination layer or the polymer of the lamination layer.
  • a composite solution is provided adding rigidity to the photovoltaic module.
  • Fig. 1 shows a section schematic view of a photovoltaic module according to an embodiment of the invention
  • Fig. 2 shows a top view of three photovoltaic modules according to an embodiment of the invention laminated at one back glass.
  • a foil with properties as described above is to be used as a lamination layer 10 between a front cover element 12, provided as a front glass, and a back cover element 14, provided as a back glass.
  • the method according to the invention requires putting the foil 10 between the front glass 12 with a photosensitive semiconductor layer 16 on it on the front glass 12 or on the back glass 14.
  • the glass-foil-glass arrangement is advantageously introduced in a sealable and evacuable enclosure which is operatively connected to vacuum pumps.
  • An evacuation time of less than 30 min, e. g. 15 min is sufficient to reach an adequate pressure level before the next step in the lamination process, the pressing, can be started.
  • the process temperature for laminating this material with glass shall not exceed 200°C, preferably 160°, in order not to damage the active cell structure. Therefore, in a preferred embodiment the temperature has to be held between 50°C and 180°C, further preferred between 140°C and 160°C during the whole pressing process - depending on the kind of material used. Lowering of the temperature is generally and particularly beneficial to avoid damages of the photovoltaic active cell 16 that is deposited on the front glass 12 and in direct contact with the heated lamination layer 10.
  • the pressing time is chosen to be less than 400 s, for instance 200 s to 300 s at a pressure between 200 mbar and 15 bar depending on the lamination equipment.
  • a so called laminator allows to combine several of the process features described: Evacuation, heating and pressing.
  • Advantageously such a laminator allows the treatment of several such glass-foil-glass arrangements at once, e. g. in a stack.
  • the following parameters are beneficial in such a laminator:
  • a ventilation step pressure adaption to atmospheric level
  • a cooling step is advantageously foreseen in order to avoid unwanted stresses particularly in the glasses 12, 14.
  • Known cooling techniques can be successfully applied such as cooling gas, air ventilation and so on.
  • the foil 10 used is white or whitish.
  • Such a high-reflectivity foil 10, together with a semitransparent back electrode does not need a separately deposited metallic layer in order to reflect not absorbed light back into the active cell for enhancing the photovoltaic semiconductor layer 16 performance. This reflection allows a relative increase of the efficiency up to 15% for a-Si modules end up to 45% for micromorph modules.
  • Using lamination equipment or a suitable autoclave like for float glass applications allows glass widths of more than 3300 mm. As shown in Fig. 2, this way up to three or more photovoltaic modules 18, 20, 22 of standard size, for example with a width of about 1100 mm for each photovoltaic module 18, 20, 22, may be laminated at once on one common back glass 14. This way and with reference to the previously introduced module dimension of 1300 mm x 1100 mm, waste of glass can be completely avoided. According to the invention a single back glass 14 of 3310 mm width can be used without the need to cut the float glass and discard unusable edge strips. In this case a float glass factory product of 3300 mm standard width needs to be cut only in one dimension resulting in drastic glass waste reduction. Taking into account the energy necessary to produce glass, any waste of glass has to be avoided.

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  • Physics & Mathematics (AREA)
  • Thermal Sciences (AREA)
  • Photovoltaic Devices (AREA)

Abstract

La présente invention concerne un module photovoltaïque qui comprend un substrat transparent (12) en tant qu’élément de couverture avant, une couche à semi-conducteur photosensible (16), une couche de stratification (10) et une couche arrière (14) en tant qu’élément de couverture arrière, la couche de stratification (10) comprenant des propriétés réfléchissantes. En outre, la présente invention concerne un procédé de fabrication d’un tel module photovoltaïque.
PCT/EP2009/063029 2008-10-07 2009-10-07 Module photovoltaïque Ceased WO2010040775A2 (fr)

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
US10329308P 2008-10-07 2008-10-07
US61/103,293 2008-10-07

Publications (2)

Publication Number Publication Date
WO2010040775A2 true WO2010040775A2 (fr) 2010-04-15
WO2010040775A3 WO2010040775A3 (fr) 2010-06-24

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ID=41490429

Family Applications (1)

Application Number Title Priority Date Filing Date
PCT/EP2009/063029 Ceased WO2010040775A2 (fr) 2008-10-07 2009-10-07 Module photovoltaïque

Country Status (1)

Country Link
WO (1) WO2010040775A2 (fr)

Cited By (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US9306103B2 (en) 2011-12-22 2016-04-05 E I Du Pont De Nemours And Company Back contact photovoltaic module with integrated circuitry

Family Cites Families (5)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US4401839A (en) * 1981-12-15 1983-08-30 Atlantic Richfield Company Solar panel with hardened foil back layer
AU676330B2 (en) * 1993-06-11 1997-03-06 Isovolta Osterreichische Isolierstoffwerke Aktiengesellschaft Process and device for manufacturing photovoltaic modules
DE4337694A1 (de) * 1993-11-04 1995-05-11 Siemens Solar Gmbh Solarmodul mit verbesserter Lichtausnutzung
JP2915327B2 (ja) * 1995-07-19 1999-07-05 キヤノン株式会社 太陽電池モジュール及びその製造方法
DE102007055733A1 (de) * 2007-12-07 2009-06-10 Kuraray Europe Gmbh Photovoltaikmodule mit reflektierenden Klebefolien

Cited By (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US9306103B2 (en) 2011-12-22 2016-04-05 E I Du Pont De Nemours And Company Back contact photovoltaic module with integrated circuitry

Also Published As

Publication number Publication date
WO2010040775A3 (fr) 2010-06-24

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