阅读说明：本技术 一种光伏模块的制造方法 (Manufacturing method of photovoltaic module ) 是由 M·屈内 S·库纳特 M·梅特 于 2019-06-05 设计创作，主要内容包括：一种制造光伏模块的方法,包括：提供(S110)后侧基板(110)；将至少一个光伏电池(130)施加(S120)到后侧基板(110)；在侧向邻近至少一个光伏电池(130)的边缘区域(R)中将可硬化的支撑材料(140)施加(S130)到后侧基板(110)；将玻璃层(120)施加(S140)到光伏电池(130)和支撑材料(140)上；硬化(S150)支撑材料(140)；以及将具有至少一个光伏电池(130)的堆叠的后侧基板(110)与硬化的侧向支撑材料(140)和玻璃层(120)层压(S160)。硬化的支撑材料(140)具有确保在层压(S150)期间在后侧基板(110)与玻璃层(120)之间的最小距离的硬度。(A method of manufacturing a photovoltaic module, comprising: providing (S110) a rear substrate (110); applying (S120) at least one photovoltaic cell (130) to a back side substrate (110); applying (S130) a hardenable support material (140) to the backside substrate (110) in an edge region (R) laterally adjacent to the at least one photovoltaic cell (130); applying (S140) a glass layer (120) onto the photovoltaic cell (130) and the support material (140); hardening (S150) the support material (140); and laminating (S160) the stacked backside substrate (110) with at least one photovoltaic cell (130) with the hardened lateral support material (140) and the glass layer (120). The hardened support material (140) has a hardness that ensures a minimum distance between the backside substrate (110) and the glass layer (120) during lamination (S150).)

1. A method for manufacturing a photovoltaic module, comprising the steps of:

providing (S110) a back side substrate (110) and a glass layer (120);

applying (S120) at least one photovoltaic cell (130) onto the backside substrate (110) or the glass layer (120);

applying (S130) a curable support material (140) onto the backside substrate (110) or the glass layer (120) in an edge region (R) laterally adjacent to the at least one photovoltaic cell (130);

applying (S140) the glass layer (120) or the backside substrate (110) onto a photovoltaic cell (130) and a support material (140);

hardening (S150) the support material (140); and

laminating (S160) the stacked backside substrate (110) with at least one photovoltaic cell (130) with a hardened lateral support material (140) and a glass layer (120);

wherein the hardened support material (140) has a hardness that ensures a minimum distance between the backside substrate (110) and the glass layer (120) during the laminating (S150).

2. The method according to claim 1, wherein the step of hardening (S150) comprises irradiating the hardenable support material (140), in particular with UV radiation.

3. The method according to claim 1, wherein the hardenable support material (140) comprises a self-hardening material, in particular a resin or an acrylate or a silicone, and the hardening (S150) step comprises a temporal sequence such that the laminating (S160) is performed only after hardening of the self-hardening material.

4. The method according to any of the preceding claims, wherein the step of applying (S140) the support material (140) comprises applying a paste in a plurality of areas, in particular in corner areas of the photovoltaic module.

5. The method according to claim 4, wherein the support material (140) is applied in punctiform spots having a spot density and the spot density in the corner regions is greater than in other edge regions (R) of the photovoltaic module.

6. The method according to any of the preceding claims, wherein the backside substrate (110) comprises a further glass layer and prior to the step of laminating (S160) comprises applying an encapsulation material between the glass layer (120) and the further glass layer (120);

and wherein the laminating (S150) comprises at least partially melting the encapsulation material to the support material (140) to achieve tight encapsulation of the at least one photovoltaic cell (130).

7. A method according to claim 6, wherein the encapsulating material comprises ethylene vinyl acetate or silicone or polyvinyl butyral.

8. A photovoltaic module laminate comprising:

a rear substrate (110) and a glass layer (120);

at least one photovoltaic cell (130), the photovoltaic cell (130) being arranged between the backside substrate (110) and the glass layer (120); and

at least one spacer (140) made of a hardenable material, the spacer (140) being formed in an edge region (R) laterally adjacent to the at least one photovoltaic cell (130) between the back side substrate (110) and the glass layer (120) and ensuring a minimum distance between the back side substrate (110) and the glass layer (120) when forming the laminate.

Background

Photovoltaic modules are typically manufactured as laminates, wherein the laminate is formed, for example, from a material stack having a front side glass (light incident side), an encapsulant, a photovoltaic cell and a stable back side film. Furthermore, there are also glass-glass modules with a front glass and a rear glass between which the photovoltaic cells are embedded as a laminate in the sealing material. During the lamination process, so-called angular compression of at least one glass usually occurs.

Fig. 4A and 4B illustrate the problem of angular compression of modules comprising a front side glass 401, a back side substrate 402 (glass substrate or back side film) between which a photovoltaic cell 410 is embedded in an encapsulation material 430. Forces during lamination may cause bending of the front glass 401 and/or the back substrate 402, resulting in a restoring force F.

An example in which the rear substrate 402 is not bent and the front glass 401 on the rear substrate 402 is bent due to a force during lamination is shown in fig. 4A, so that a reset force F is generated after lamination. In fig. 4B, a case where both the front side glass 401 and the back side substrate 402 are bent due to lamination is shown. The reason for this is that rubber pressure pads are formed at the top and bottom in the laminator.

The restoring forces F are at great risk, since they jeopardize the long-term stability of the photovoltaic module. For example, at a distance L from the edge, a cavity 405 may be formed in the embedding material 430 as, for example, the front side glass 401 and/or the back side substrate 402 are pushed upward at the distance L (see fig. 4A). Furthermore, the restoring force F may lead to later delamination. As a result, gaps or cracks may form in the vicinity of the photovoltaic cells 410, which in turn promotes moisture penetration. Eventually-due to variations in laminate thickness-the reliability of the construction process is compromised.

These undesirable tensions occur in particular in the battery-free corner regions of the module, so that there is a particularly high risk of cracks or cavities 405 occurring there. Measurements show that with a normal distance of e.g. 6.5mm between the front side glass 401 and the back side substrate, this distance in the corner regions can be reduced to 5.5mm and along the edges to 6.1 mm. Similarly, the distance L in the edge regions of the long sides may be 60mm, along the short sides may be 70mm, and for the corner regions may be up to 100 mm. Thus, the stress extends deep into the interior of the photovoltaic module.

Heretofore, this problem has been solved by using, for example, a spacer bar near the edge (see DE10050612a1) in order to fixedly set the distance between the front glass and the rear substrate. Thus, angular compression can be avoided in a targeted manner. However, such spacer bars have the disadvantage that they do not always set the correct spacing precisely, since there are always fluctuations in the manufacture. Furthermore, because metals are often used for these known spacer bars (due to their high strength), significant thermal stresses can develop during subsequent use.

Accordingly, there is a need for an improved photovoltaic module laminate that avoids the above-mentioned problems.

Disclosure of Invention

The above object is achieved by a method for manufacturing a photovoltaic module according to claim 1 and a method for a photovoltaic module according to claim 8. The dependent claims relate to advantageous developments of the method according to claim 1.

The present invention relates to a method of manufacturing a photovoltaic module. The method at least comprises the following steps:

-providing a back side substrate (e.g. made of glass);

-applying at least one photovoltaic cell onto the back side substrate;

-applying a hardenable support material onto the backside substrate in an edge region laterally adjacent to at least one photovoltaic cell;

-applying a glass layer on the photovoltaic cell and the support material

-hardening of the support material; and

-laminating the stacked back side substrate, the at least one photovoltaic cell together with the hardened lateral support material and the glass layer.

It is also possible to apply the photovoltaic cell and the support material to the glass layer and then to build up the rear substrate on the photovoltaic cell and the support material.

The hardened support material has a hardness that ensures a minimum spacing between the glass layer and the backside substrate during lamination.

Within the scope of the invention, the laminate is referred to as a pressed and sealed layer stack having at least a back side substrate, a glass layer, one or more photovoltaic cells, one possible encapsulating material and a spacer.

Optionally, the step of hardening comprises irradiation of the hardenable support material, wherein in particular uv or other electromagnetic radiation that accelerates the curing may be used. The hardenable support material is optionally a self-hardening material, wherein in particular a resin (e.g. a 2-component resin) may be used. Since self-curing requires a certain time, in this case, the curing step may be performed in a time sequence in which lamination is performed only after the self-hardening material is hardened.

Optionally, the step of applying the support material comprises applying a paste (or gel or other viscous material) in a plurality of regions, in particular in corner regions of the photovoltaic module. For example, the support material can be applied in spots at a spot density (for example by means of one or more nozzles), whereby the spot density in the corner regions can be selected to be greater than in the other edge regions of the photovoltaic module. The stability of the spacer produced after hardening can be matched to the expected forces. For example, a plurality of regions may be formed in the corner region so that no angular compression occurs. The application and hardening of the embedding material may be done mechanically or automatically, thus eliminating the need for manual insertion and removal of the corner spacers, as compared to conventional methods.

Optionally, a further glass layer can be provided on the rear substrate, so that the photovoltaic module is in particular a glass-glass module.

Furthermore, a sealing material may be applied between the back side substrate and the glass layer prior to the laminating step, wherein the laminating comprises at least partially fusing the sealing material with the support material in order to achieve a tight embedding of the at least one photovoltaic cell. The encapsulating material can have, for example, ethylene vinyl acetate or silicone or polyvinyl butyral.

The invention also relates to a photovoltaic module comprising a back side substrate and a glass layer, at least one photovoltaic cell being arranged between the back side substrate and the glass layer; and a spacer made of a curable material (e.g., a UV curable material or resin). The spacer is configured in the edge region of the at least one photovoltaic cell laterally adjacent to the backside substrate and in front of the glass layer in order to ensure a minimum distance between the backside substrate and the glass layer during lamination.

Embodiments of the present invention therefore solve at least part of the problems described at the outset by forming one or more regions with a special support material in the corner regions and/or edge regions, which are applied, for example, as a paste or in a viscous manner and are hardened before lamination (after the laying of the glass plies). The hardening can be carried out, for example, by irradiation with UV radiation (or other hardening methods). The support material is thus deformed during the production of the module in such a way that it has a thickness that corresponds exactly to the distance between the rear substrate and the glass plate. Exemplary UV curing will fix the distance so that angular compression is avoided in subsequent lamination. The method can be used for various photovoltaic modules and is not limited to a predetermined distance between the opposing back side substrate and the glass sheet.

Other advantages of embodiments include, among others:

the spacer formed can be connected to the encapsulating material in such a way that a tight and stable packaging is achieved and thus a reliable protection against moisture or dirt is obtained.

No adjustment of the workpiece spacing in the laminator is required.

Better space utilization of the process chambers in the laminator.

No adjustment of the transport system is required.

No further work steps need to be performed after lamination.

No optical disadvantages.

In addition, when using a tacky adhesive, the quality of the framing process can be improved.

The embodiments also provide lower process costs.

Drawings

Exemplary embodiments of the present invention will be understood more fully from the detailed description and from the accompanying drawings, which, however, should not be taken to limit the disclosure to the specific embodiments, but are for explanation and understanding only.

Fig. 1 shows a photovoltaic module according to an embodiment of the invention.

Fig. 2A, 2B show further details of the application of the support material according to further embodiments.

Fig. 3 shows a flow diagram of a method for manufacturing a photovoltaic module according to an embodiment of the invention.

Fig. 4A, 4B illustrate a problem in conventional lamination production.

Detailed Description

Fig. 1 shows a photovoltaic module with a rear substrate 110 and a glass layer 120, at least one photovoltaic cell 130, which at least one photovoltaic cell 130 is arranged between the rear substrate 110 and the glass layer 120 and leaves a free edge region R. Spacers 140 are formed in the edge region R laterally adjacent to the at least one photovoltaic cell 130 between the back side substrate 110 and the glass layer 120 to ensure a minimum distance between the back side substrate 110 and the glass layer 120 when forming the laminate. The rear substrate 110 may be, inter alia, another glass layer or a glass plate.

According to an embodiment, the spacers 140 are a hardenable material (support material) which is applied in a viscous or paste-like manner and thus automatically ensures the desired spacing — after hardening. The hardening is performed before laminating the shown stack, for example by uv irradiation. In order to obtain sufficient strength, the support material 140 is selected accordingly.

Fig. 2A and 2B show by way of example the arrangement of the support material 140 along the form of dotted areas 141, 142, 143 of the edges and corners of the example glass plates 110, 120.

The density of the spots 141, 142, 143 of support material 140 may be selected according to the desired force. Thus, for example, in the corner regions 141, a higher density of dot-shaped regions can be purposefully formed in order to be able to withstand higher forces. Along the short sides, areas 143 with a lower density may be formed and along the long sides, areas 142 with the lowest density may be formed. In further embodiments, the density may also be selected differently, wherein the punctiform area is advantageously selected depending on the expected force. The areas 141, 142, 143 need not be point-shaped but may also have other shapes (quadrilateral, triangular, elliptical, linear, etc.). The photovoltaic cell 130 may also be completely or partially surrounded by a support material 140.

Fig. 3 shows a flow diagram of a method for manufacturing a photovoltaic module. The method comprises the following steps:

-S110: providing a back side substrate 110;

-S120: applying at least one photovoltaic cell 130 onto the back side substrate 110;

-S130: applying the hardenable material 140 in laterally adjacent edge regions of at least one photovoltaic cell onto the backside substrate 110;

-S140: applying a glass layer 120 to the photovoltaic cell 130 and the support material 140;

-S150: hardening the support material 140; and

-S160: the stacked backside substrate 110 with at least one photovoltaic cell 130 is laminated with a hardened lateral support material 140 and a glass layer 120.

The process can also be reversed such that the layer stack is formed starting from the glass layer 120.

The support material 140 can be applied in viscous form or in paste form, for example in defined amounts at defined locations by means of a nozzle (see fig. 2B). The support material 140 may be selected in such a form that it can be optically hardened (e.g., using UV radiation), which subsequently results in the support material 140 being shape-stable and acting as a spacer. Thereby preventing the example glass sheets from being pressed together during lamination.

In other embodiments, the support material 140 may be embedded in the encapsulation material. The carrier material 140 is made of a material that is well fused or glued to the encapsulation material, for example, and thus does not constitute a leak-tightness and is furthermore electrically insulating. The support material 140 may, for example, comprise at least one of the following materials: acrylate, (epoxy) resins, silicone resins. Furthermore, the two materials have as much as possible the same coefficient of thermal expansion, in order to keep the thermal stresses low afterwards.

The features of the invention disclosed in the description, the claims and the drawings may be essential for the implementation of the invention both individually and in any combination.

Reference numerals

110 rear substrate (further glass layer)

120 glass layer

130. 410 at least one photovoltaic cell

140 hardenable support material

141. 142, 143 using regions of punctiform supporting material

401 front side glass

402 rear substrate

430 encapsulating material

R edge region