DE112022006915T5 - Photovoltaic module and method for producing a photovoltaic module - Google Patents

Abstract

The invention relates to a photovoltaic module comprising a substrate stack and a frame. The substrate stack comprises a cell substrate, wherein at least one photovoltaic cell is arranged on the cell substrate, a backside substrate and a junction box. The cell substrate and the backside substrate are connected to each other with the at least one photovoltaic cell therebetween, and the backside substrate comprises a cut-out portion arranged on an edge of the backside substrate. The junction box has the same shape and size as the cut-out portion of the backside substrate, is arranged within the cut-out portion of the backside substrate and is adhesively connected to the cell substrate on a first surface of the junction box and to the backside substrate on a first side surface of the junction box. The frame is arranged only on a backside of the substrate stack and adhesively connected to it.

Description

The invention relates to a photovoltaic module and a method for producing such a photovoltaic module.

Photovoltaic modules comprise at least one or more photovoltaic cells arranged on a cell substrate, a frame for attaching the photovoltaic module to a base, for example a roof or a wall of a building, and at least one junction box for electrically connecting the photovoltaic cell(s) of one photovoltaic module to the photovoltaic cell(s) of another photovoltaic module or to an electrical output. Photovoltaic modules often comprise further substrates, for example a front substrate arranged on a front side of the cell substrate, i.e. on a side on which light impinges on the photovoltaic cell(s), and/or a back substrate arranged on a back side of the cell substrate, i.e. on a side opposite the front side. Thus, a substrate stack can be formed which comprises the cell substrate and at least one further substrate. The frame may be arranged on a back side of the photovoltaic module, for example on a back side of the substrate stack, in particular on a back side of a back side substrate, or may be arranged at the edge of the photovoltaic module so that it encloses the cell substrate or the substrate stack. There are various ways to incorporate the at least one junction box into the photovoltaic module. If the photovoltaic module is not transparent, the junction box may be arranged on the back side of the photovoltaic module at any location of the lateral extent of the photovoltaic module, for example in the middle of the photovoltaic module (with respect to its lateral extents). However, if the photovoltaic module is transparent, such a junction box would be visible and would therefore disturb the appearance and functionality of the photovoltaic module with respect to its transparency.

WO 2013/080691 A1 describes a solar module with two substrates, namely a cell substrate and a back substrate, with the junction box arranged in a corner of the solar module. To do this, the substrates of the solar module are both cut, i.e. removed, in the respective corner of the solar module and the junction box is attached to the side of both substrates. A U-shaped frame encloses the edges of the substrates and the junction box. Wires protruding from the junction box, which are suitable for connecting the junction box to other junction boxes or an electrical connection, are led through the frame to the side of the solar module or to the front of the solar module.

US 2017/0194900 A1 discloses a similar solar module, but wherein only the backside substrate has a cutout or hole and the junction box is mounted over the cutout or hole so that a conductive line can connect the photovoltaic cells to the junction box. The junction box is nevertheless at least partially disposed on the backside substrate. The frame is again shaped to enclose the substrate stack and surround its edges, but the junction box may not be enclosed by the frame or only a flange base portion of the junction box is enclosed by the frame.

JP 5031698 B2 describes a solar module having a cell substrate and a front substrate, the cell substrate having a cut-out portion at a corner of the solar module. A junction box has a recessed triangular shape on its front side and a square shape on its back side. The recessed shape is a negative of the cut-out of the cell substrate and provides electrical contact to the solar cells on the cell substrate. The front side of the junction box is attached to the back side of the front substrate, while the square part of the junction box is attached to the back side of the cell substrate. Wires for connecting the junction box to other junction boxes or to an electrical terminal extend toward the center of the solar module with respect to their lateral extents. A frame may be provided to clamp the edges of the substrate stack and the junction box.

The state of the art solutions have some drawbacks. For example, if the cell substrate is cut, the active area of the photovoltaic cell(s) is reduced. Feedthroughs for wires to connect the junction box to other solar modules or to an electrical connector only allow the use of special frames adapted to the position of the junction box. If wires are routed to the center of the solar module to avoid feedthroughs through the frame, more space is needed, transparency is reduced and the connection to other solar modules can be complicated. If the junction box is placed on the back of the substrate stack, the thickness of the entire solar module is increased.

It is an object of the invention to provide a photovoltaic module with an alternative arrangement of the junction box which reduces or avoids some of the disadvantages of the prior art. Furthermore, it is an object of the invention to provide a method for producing such a photovoltaic module.

The object is achieved by a photovoltaic module and a method according to the independent claims. Preferred embodiments are specified in the dependent claims.

• - einen Substratstapel, der mindestens ein transparentes Zellsubstrat, mindestens eine auf dem Zellsubstrat angeordnete photovoltaische Zelle, ein Rückseitensubstrat und eine Anschlussdose umfasst, wobei die Anschlussdose einen Anschluss zum elektrischen Kontaktieren der mindestens einen photovoltaischen Zelle und einen Draht oder eine Buchse oder Stecker zum Anschluss an andere Vorrichtungen umfasst, und
• - ein Rahmen,

wobei das Zellsubstrat und das Rückseitensubstrat miteinander verbunden sind, wobei sich die mindestens eine photovoltaische Zelle dazwischen befindet und wobei das Rückseitensubstrat einen ausgeschnittenen Abschnitt umfasst, der an einem Rand des Rückseitensubstrats angeordnet ist.According to the invention, a photovoltaic module comprises at least the following elements:

• - a substrate stack comprising at least one transparent cell substrate, at least one photovoltaic cell arranged on the cell substrate, a backside substrate and a junction box, wherein the junction box comprises a terminal for electrically contacting the at least one photovoltaic cell and a wire or a socket or plug for connection to other devices, and
• - a frame,

wherein the cell substrate and the backside substrate are bonded together with the at least one photovoltaic cell therebetween, and wherein the backside substrate comprises a cut-out portion disposed at an edge of the backside substrate.

According to the invention, the junction box has the same shape and size as the cut-out portion of the back substrate and is arranged within the cut-out portion of the back substrate. The junction box is directly electrically connected to an electrical terminal of the at least one photovoltaic cell via its terminal. The junction box is adhesively connected to the cell substrate on a first surface of the junction box and to the back substrate on a first side surface of the junction box. The wire or the socket or plug is arranged on a second side surface of the junction box, which is different from the first side surface and is arranged on an edge of the substrate stack. Furthermore, according to the invention, the frame is arranged only on a back side of the substrate stack and adhesively connected thereto. That is, the frame is not arranged on an edge or a front side of the substrate stack.

Advantageously, the frame does not make contact with the front of the substrate stack, as is usually the case with clamped frames. Since the frame is not clamped around the edge of the substrate stack, it allows maximizing the active area of the photovoltaic module. Furthermore, the photovoltaic module according to the invention comprises a cell substrate without recesses, so that the entire cell substrate can be used to arrange the at least one photovoltaic cell. Furthermore, the junction box is not visible from the direction in which sunlight enters the photovoltaic module when it is in operation, since the junction box is advantageously hidden under the frame. Such a photovoltaic module is particularly well suited as a building-integrated photovoltaic module. Furthermore, the frame advantageously does not need to have an opening, recess, etc. for the passage of the wire or the socket or plug. Due to the same shape and size of the at least one junction box and the at least one cut-out portion of the rear substrate, the junction box is advantageously arranged within the cut-out portion of the rear substrate. A part of an edge of the junction box, which comprises at least the second side surface of the junction box, forms part of the edge of the substrate stack. The edge of the junction box is understood to mean a plane that surrounds the junction box and delimits it from the environment and comprises the side surfaces of the junction box.

A photovoltaic module according to the invention means any type of photovoltaic module, such as a crystalline or a thin-film photovoltaic module, preferably a thin-film photovoltaic module. A crystalline photovoltaic module comprises at least one crystalline photovoltaic cell arranged on the transparent cell substrate. A thin-film photovoltaic module comprises at least one thin-film photovoltaic cell arranged on the transparent cell substrate. In embodiments, the photovoltaic module is a thin-film photovoltaic module having a plurality of thin-film photovoltaic cells arranged on the transparent cell substrate and electrically connected to one another.

The article "a" or "the" also means "at least one", which means that the photovoltaic module may comprise at least one junction box, wherein the at least one junction box comprises at least one terminal for electrically contacting the at least one photovoltaic cell and at least one wire or at least one socket or plug for connecting to other devices. The same applies to the cut-out portion: It is obvious that the back substrate may comprise at least one cut-out portion or at least one cut-out portion may be formed.

In embodiments, the junction box comprises two wires or a socket and a plug. In further embodiments, the junction box comprises one wire or a socket or a plug. In some embodiments, one junction box per photovoltaic module may be sufficient. In other cases, the photovoltaic module comprises at least two junction boxes. In further embodiments, the photovoltaic module comprises four junction boxes, each of which comprises at least one wire or a socket or a plug.

The at least one wire or the at least one socket or plug is arranged on the second side surface of the junction box, which means that the second side surface of the junction box has at least one opening for the passage of the at least one wire or the at least one socket or plug. Advantageously, no adaptation of the frame, such as forming an opening for the passage of the at least one wire, is required, so that the manufacturing processes of the frame can be simplified.

The frame may be any frame suitable for holding the substrate stack when mounted at a location, for example on a roof or on a building wall. That is, the material, size and shape of the frame can be freely chosen depending on the conditions of use. In embodiments, the frame is made of stainless steel, alloyed metallic materials such as aluminum alloys, plastics or similar materials known in the art and is shaped to run along the perimeter of the back of the substrate stack. In embodiments, the frame has a T-shape or a double-T-shape or a C-shape.

The backside substrate is preferably a transparent substrate, such as a glass substrate. Transparent means that the cell substrate or the backside substrate is transparent to electromagnetic radiation with wavelengths in the visible range as well as to wavelengths absorbed by the at least one photovoltaic cell arranged on the transparent cell substrate. In embodiments, the at least one cut-out section of the backside substrate has a triangular shape, viewed from a direction along the thickness of the substrate stack or the backside substrate. The at least one cut-out section can also have any other shape. In embodiments, the transparent cell substrate and/or the backside substrate are glass substrates.

The front side of the substrate stack faces the sunlight when the photovoltaic module is in operation. The substrate stack also has a back side opposite the front side. The cell substrate of the substrate stack is always closer to the front side of the substrate stack than the back side substrate. In embodiments, the substrate stack may comprise further substrates arranged on the front side of the cell substrate and/or on the back side of the back side substrate.

The cell substrate and the backside substrate each comprise a front side and a back side, wherein the front side of the cell substrate or the backside substrate faces the sunlight when the photovoltaic module is in use and the back side of the cell substrate or the backside substrate faces the front side of the cell substrate or the backside substrate. In embodiments, the backside of the backside substrate is part of the backside of the substrate stack.

In embodiments, the cell substrate and the back substrate have the same shape and size and lie congruently on top of one another. Size is understood to mean the dimensions of the cell substrate or the back substrate along a first and a second in-plane direction, which are perpendicular to one another and each perpendicular to a thickness of the cell substrate or the back substrate. The thickness of the cell substrate or the back substrate means an extension along the direction in which sunlight enters the photovoltaic module. The shape of the cell substrate or the back substrate means a polygonal shape that results from the dimensions of the cell substrate or the back substrate along the first and the second in-plane direction, preferably a square or rectangular shape. In embodiments, an edge of the cell substrate and the edge of the backside substrate, excluding the cut-out portion, form part of the edge of the substrate stack.

The edge of any substrate of the present invention or of the substrate stack is understood to mean a side surface that surrounds the respective substrate or substrate stack perpendicular to the in-plane dimensions of the respective substrate or substrate stack, extends across the thickness of the respective substrate or substrate stack, and delimits the respective substrate or substrate stack from the environment along the first and second in-plane directions.

The cell substrate and the back substrate are connected to the at least one photovoltaic cell in between, for example via an encapsulation encapsulation film, such as a PVB film (polyvinyl butyral), wherein the encapsulation film has at least one cut-out section which is identical in size and shape to the at least one cut-out section of the backside substrate and is arranged on the cell substrate in such a way that the at least one cut-out section of the encapsulation film and the at least one cut-out section of the backside substrate lie congruently on top of one another. In further embodiments, the backside substrate has at least one further cut-out section and the encapsulation film has at least one further cut-out section which is identical in shape and size to the at least one further cut-out section of the backside substrate. In this case, the encapsulation film is arranged on the cell substrate in such a way that the at least one further cut-out section of the encapsulation film and the at least one further cut-out section of the backside substrate also lie congruently on top of one another.

The junction box is adhesively connected to the cell substrate and/or to the at least one photovoltaic cell arranged on the cell substrate on the first surface of the junction box. Furthermore, the junction box is adhesively connected to the back substrate such that the first side surface of the junction box adjoins an edge or side surface of the cut-out portion of the back substrate.

In embodiments, the connection of the at least one junction box may be formed as a solder connection arranged on the first surface of the junction box or in an opening in the first surface of the junction box. In further embodiments, the electrical connection of the at least one photovoltaic cell is arranged on the surface of the cell substrate or of the at least one photovoltaic cell facing the backside substrate. The electrical connection of the at least one photovoltaic cell may be formed on or next to the at least one photovoltaic cell and may be formed as a lateral busbar. Lateral busbars are known and are usually attached to a first and a last cell of the thin-film photovoltaic module and are arranged close to the edge of the cell substrate, wherein the individual series-connected thin-film cells of the thin-film photovoltaic module are arranged next to one another along a first in-plane direction of the transparent cell substrate. A lateral busbar according to the invention is a current-carrying line or strip comprising a conductive material to collect and conduct electrical charge carriers generated within the thin-film photovoltaic module. In further embodiments, the electrical connection of the at least one photovoltaic cell is a connector as is usually used to connect crystalline photovoltaic cells to one another within a photovoltaic module.

The junction box comprises a second junction box surface opposite the first junction box surface. The first and second junction box surfaces are located along the thickness direction of the substrates and the substrate stack, respectively. The junction box further comprises at least the first side surface and the second side surface of the junction box, which are perpendicular to the first surface and the second surface of the junction box, respectively. The first side surface of the junction box faces the substrate stack and the second side surface faces outward and is in direct contact with the environment. In embodiments, the junction box comprises further side surfaces, such as a third side surface, wherein further side surfaces may face the substrate stack or face outward. In embodiments, the junction box has a triangular shape, wherein the third side surface faces outward and the second side surface and the third side surface of the junction box contact each other at a 90 degree angle.

In embodiments, the junction box is made of a polymeric material. In further embodiments, the junction box comprises at least one junction box body. The junction box body comprises at least the first surface and the side surfaces of the junction box. In embodiments, the junction box body may be filled with a potting material that forms the second surface of the junction box. A potting material may be a polymer potting material such as, but not limited to, 2-part silicone compounds, thermosets, epoxies, silicone rubber gels, or similar materials known in the art.

In embodiments, the junction box further comprises a lid disposed and connected to the junction box body and forming at least a portion of the second surface of the junction box. In further embodiments, the junction box body and the lid are shaped to form a snap lock between the junction box body and the lid.

The junction box is arranged on an edge of the substrate stack such that at least one side surface of the junction box is part of an edge of the substrate stack and replaces part of the edge of the backside substrate.

In embodiments, the frame is directly or indirectly connected to the back of the substrate stack. Indirectly means that a spacer can be arranged between the back of the substrate stack and the frame. The spacer can be a polymeric spacer or a spacer made of metals or metallic alloys.

An adhesive bond is a bond that is produced using an adhesive that is applied, for example, as a tape, paste, resin, polymer, glue or thermoplastic laminate and is known from the prior art.

In embodiments, the substrate stack has a square, i.e., quadrangular, shape and the cut-out portion and the junction box are arranged at a corner of the substrate stack. In embodiments, the second side surface and a third side surface of the junction box face outward and form part of the edge of the substrate stack. When the substrate stack has a rectangular shape, the second side surface and the third side surface of the junction box touch at an angle of 90 degrees.

In embodiments, a cutout section and a junction box may be located at some or all four corners of a square substrate stack.

In embodiments, the substrate stack has a rectangular shape and the photovoltaic module comprises four cut-out sections of the back substrate and four junction boxes, each arranged at a corner of the substrate stack. This enables the electrical connection of several photovoltaic modules to form a photovoltaic system. In addition, special photovoltaic module designs, such as submodules, can be realized. A submodule is understood to be a first subset of the at least one photovoltaic cell or a plurality of photovoltaic cells that are electrically connected to one another and form a submodule arranged on the cell substrate. In embodiments, at least two submodules can be arranged on the cell substrate, wherein the submodules are not electrically connected to one another.

In some embodiments, at least one of the four junction boxes may be used as a "dummy junction box" that is electrically connected to a terminal of the at least one photovoltaic cell, but is not electrically connected to other photovoltaic modules or other devices. That is, such a dummy junction box is like a backup junction box that can be used as a replacement in case another junction box used for electrical connection to other photovoltaic modules or devices wears out or breaks.

In embodiments, the substrate stack further comprises a front substrate disposed on and connected to the cell substrate at a surface opposite the surface on which the at least one photovoltaic cell is disposed.

Advantageously, a photovoltaic module with three substrates, preferably transparent substrates such as glass substrates, with increased mechanical stability is obtained.

In embodiments, the front substrate is connected to the cell substrate via an encapsulation film. In further embodiments, the front substrate is a transparent substrate, preferably a glass substrate. In embodiments, the front substrate has the same size and shape as the cell substrate.

In embodiments, the backside of the substrate stack is formed by the backside of the backside substrate and the second surface of the junction box. The frame is then placed on and adhesively bonded to the backside of the backside substrate and the second surface of the junction box opposite the first surface of the junction box.

If the junction box has a height that differs from the thickness of the backside substrate, a step would be present between the second surface of the junction box and the backside of the backside substrate. To compensate for this step, the adhesive on the lower component, which is typically the backside substrate, may be thicker. In other embodiments, a spacer may be provided to compensate for this step and provide a flat surface for adhesively bonding the frame to the backside of the substrate stack.

In embodiments, the substrate stack further comprises an insulating substrate, wherein the insulating substrate is disposed on a surface opposite the surface connected to the cell substrate. , ie the back of the back substrate, is arranged on the back substrate and is adhesively bonded to it. Furthermore, the insulation substrate is arranged on the second surface of the junction box, which is opposite the first surface of the junction box, and is adhesively bonded to it. In both cases, the insulation substrate can be connected to the back substrate or the junction box, not over the entire extent of the back of the back substrate or the second surface of the junction box, but only in some places with a limited lateral extent. A gas- and liquid-tight seal is formed at the edge of the insulation substrate, so that a gas- and liquid-tight insulation space is created between the back substrate and the insulation substrate. The backside of the substrate stack is formed by an insulation substrate backside, which is the surface of the insulation substrate opposite to the surface of the insulation substrate bonded to the backside substrate.

Advantageously, such a photovoltaic module is suitable as a building-integrated photovoltaic module and can, for example, be used instead of a conventional insulating glass window and offers additional functionality for energy generation.

In embodiments, the insulating substrate is a transparent substrate, for example a glass substrate. In further embodiments, the insulating substrate has the same size and shape as the cell substrate.

The insulating substrate has a front side and an opposite back side, the front side facing the back side substrate to which the insulating substrate is adhesively bonded.

The gas- and liquid-tight insulation space between the backside substrate and the insulation substrate is formed by the gas- and liquid-tight seal. A gas- and liquid-tight seal is a sealing material, such as an edge seal, which is commonly used in insulating glass windows. Such an edge seal can be a galvanized, aluminum, stainless steel or polymer edge seal, for example a polymer composite edge seal. The sealant is arranged along the edge of the backside substrate or the insulation substrate to ensure an insulation space between the backside substrate and the insulation substrate. The sealant is adhesively bonded to the backside of the backside substrate and the frontside of the insulation substrate and sealed with another sealing material, such as polysulfide, polyurethane or silicone, at the edge of the substrate stack. In embodiments, the sealant can also be arranged on the second surface of the junction box and adhesively bonded thereto.

In further embodiments, the gas- and liquid-tight insulation space between the backside substrate and the insulation substrate is filled with an inert gas, such as argon.

In embodiments, the photovoltaic module comprises two photovoltaic cells that are not electrically connected to each other via electrical conductors arranged on the cell substrate or arranged between the cell substrate and the backside substrate. Furthermore, the backside substrate comprises at least one further cut-out portion arranged on an edge of the backside substrate at a position corresponding to the position of an electrical terminal of at least one of the two photovoltaic cells that are not electrically connected to each other. The substrate stack further comprises at least one junction box comprising at least one terminal for electrically contacting one of the two photovoltaic cells that are not electrically connected to each other. The at least one junction box has the same shape and size as the further cut-out portion of the backside substrate, is arranged in the further cut-out portion of the backside substrate and is directly electrically connected via its terminal to the electrical terminal of the one of the two photovoltaic cells that are not electrically connected to each other. The at least one junction box is adhesively connected to the cell substrate or at least one of the photovoltaic cells on a first surface of the junction box and to the back substrate on a first side surface of the junction box.

Two photovoltaic cells that are not electrically connected to each other may be at least two photovoltaic cells or at least two subsets of a plurality of electrically connected photovoltaic cells, as described above. That is, a first photovoltaic cell or a first subset of a plurality of photovoltaic cells that are electrically connected to each other forms a first submodule, and a second photovoltaic cell or a second subset of a plurality of photovoltaic cells that are electrically connected to each other forms a second submodule. Although the first submodule and the second submodule are each arranged on the cell substrate, they are not electrically connected to each other. Of course, the photovoltaic module may comprise more than two submodules. modules. In embodiments, the photovoltaic cells, ie the submodules, can be so-called half-cells, preferably crystalline half-cells. Advantageously, such half-cells offer known advantages such as reduced resistance losses, increased power and in particular higher power in partial shading.

The at least one further cut-out portion is preferably arranged at a position other than a corner of the back substrate.

The at least one junction box comprises a second junction box surface opposite the first junction box surface. The first and second junction box surfaces are arranged along the thickness direction of the substrates and the substrate stack, respectively. The second junction box surface may form part of the back side of the substrate stack and may be adhesively bonded to the frame or may be adhesively bonded to an insulating substrate, as described above with respect to the second junction box surface for various embodiments. The at least one junction box further comprises at least the first side surface and a second side surface of the junction box, each perpendicular to the first and second surfaces of the junction box. The first side surface of the junction box faces the back side substrate. The second side surface of the junction box is arranged at the edge of the substrate stack and faces outward and is in direct contact with the environment. Thus, the second side surface of the junction box forms part of the edge of the substrate stack.

In embodiments, the at least one junction box comprises two connections for electrically contacting each of the two submodules and an electrical conductor, e.g. a wire, for electrically connecting the two connections. In this case, the junction box connects the two submodules internally.

In embodiments, the at least one junction box further comprises at least one wire or at least one socket or plug for connection to other devices and arranged on the second side surface of the junction box. In this case, the at least one junction box is designed as a junction box as described above and can be used to electrically connect at least one of the two submodules to other devices.

Of course, the junction box can also comprise more than two connections for electrically contacting more than two submodules and also have more than one electrical conductor or more than two wires or more than two sockets or plugs for connecting to further submodules or devices.

The at least one junction box has the same size and shape as the at least one further cut-out portion of the backside substrate and is arranged within the at least one further cut-out portion of the backside substrate. Thus, an edge of the junction box formed by at least the second side surface of the junction box forms part of the edge of the substrate stack, and the junction box forms part of the substrate stack. In embodiments, the at least one further cut-out portion has a square shape, in particular a rectangular shape or a circular or elliptical shape, viewed from a direction along the thickness of the backside substrate.

In embodiments, the at least one connection of the at least one junction box can be designed as a soldered connection. In further embodiments, the electrical connections of the at least two submodules are arranged on the surface of the cell substrate or the at least one photovoltaic cell, which is directed towards the rear substrate. The electrical connections of the two submodules can be formed on or next to the respective submodule and can be designed as a lateral busbar or connecting plug.

In embodiments, the junction box comprises a box frame with a width in the range of 3 mm to 20 mm. The width means an extension of the box frame perpendicular to the side surfaces of the junction box. In embodiments, the box frame has a width in the range of 10 mm to 20 mm.

The box frame is part of the junction box body and forms the side surfaces of the junction box or the edge of the junction box. Advantageously, a wide box frame improves the adhesive connection between the junction box and the cell substrate or the surface of the photovoltaic cells and between the junction box and the frame or - if present - an insulating substrate, since it increases the size of the first and second surfaces of the junction box. In addition, a wide box frame improves the mechanical stability of the junction box.

In embodiments, the box frame has a width w ₁ in the range from 3 mm to 20 mm, preferably in the range from 10 mm to 20 mm, at least on the side surfaces of the junction box which face outwards and are in direct contact with the environment, ie at least on the second side surface. In further embodiments, the box frame has the width w ₁ also on the first side surface and/or further side surfaces of the junction box.

In further embodiments, the box frame has a width w ₂ at least on the first side surface of the junction box, with which the junction box is adhesively connected to the back substrate, which is smaller than the width w ₁ .

In further embodiments, the box frame is designed as a double-walled box frame. A double-walled box frame according to the invention means a box frame with at least one inner and one outer wall with a distance from each other in the range of 3 mm to 30 mm. The inner wall and the outer wall can have a width or thickness in the range of 2 mm to 10 mm, wherein the thickness of the inner wall can be different or equal to the thickness of the outer wall. The thickness of the inner wall and the outer wall as well as the distance from each other can vary for different side surfaces of the junction box formed by the box frame. The inner wall of the box frame faces the inside of the junction box and the outer wall faces the outside of the junction box and is in direct contact with the rear substrate or the environment. The outer wall forms the side surfaces of the junction box or the edge of the junction box. In further embodiments, the inner and outer walls of the double-walled box frame are connected via at least one cross brace, wherein the at least one cross brace is formed on the inner and/or outer wall of the double-walled frame of the junction box. This advantageously increases the stability of the double-walled frame. In further embodiments, the inner and outer walls of the double-walled box frame of the junction box are connected via several cross braces, whereby several compartments are formed within the distance between the inner and outer walls.

In embodiments, the space between the inner and outer walls of the double-walled box frame or the plurality of compartments may be filled with a potting material, such as a polymeric potting material, such as, but not limited to, 2-component silicone compounds, thermosets, epoxy resins, acrylic and butyl resins, silicone rubber gels, or similar materials known in the art. This may form a first part of the second surface of the junction box. In embodiments, the cover of the junction box is attached to the double-walled box frame via a click lock and forms at least part of the second surface of the junction box. In embodiments, the cover of the junction box is attached to the inner wall of the double-walled frame of the junction box via a click lock and forms a second part of the second surface of the junction box.

Furthermore, any combination of the different embodiments of the box frame is possible, e.g. a solid box frame with the width w ₁ on the first side surface of the junction box and a double-walled box frame with or without cross braces on other, outward-facing side surfaces of the junction box.

The junction box body may further comprise a bottom forming at least a portion of the first surface of the junction box and connected to or integral with the box frame. The bottom may extend over the entire first surface of the junction box except for the terminal of the junction box or may be smaller. The bottom may have a thickness in the range of 0.5 mm to 4 mm, the thickness being measured in the direction of the thickness of the substrate stack.

If present, the at least one junction box may comprise a box frame having the same properties as described above for the box frame of the junction box.

1. a) Bereitstellen eines transparenten Zellsubstrats, wobei mindestens eine photovoltaische Zelle auf dem Zellsubstrat angeordnet ist, eines Rückseitensubstrats, einer Anschlussdose, die einen Anschluss zur elektrischen Kontaktierung der mindestens einen photovoltaischen Zelle und ein Draht oder eine Buchse oder einen Stecker zur Verbindung mit anderen Vorrichtungen umfasst, und eines Rahmens,
2. b) Ausbilden eines ausgeschnittenen Abschnitts an einer Kante des Rückseitensubstrats, wobei der ausgeschnittene Abschnitt die gleiche Form und Größe wie die Anschlussdose hat,
3. c) Verbinden des Zellsubstrats und des Rückseitensubstrats miteinander, so dass die mindestens eine photovoltaische Zelle dazwischen angeordnet ist,
4. d) Aufbringen eines Haftmittels auf eine erste Oberfläche und eine erste Seitenoberfläche der Anschlussdose,
5. e) Platzieren der Anschlussdose in dem ausgeschnittenen Abschnitt des Rückseitensubstrats und auf dem Zellsubstrat, so dass die erste Oberfläche der Anschlussdose auf dem Zellsubstrat angeordnet ist und die erste Seitenoberfläche der Anschlussdose an das Rückseitensubstrat angrenzt und dass der Draht oder die Buchse oder der Stecker auf einer zweiten Seitenoberfläche angeordnet ist, die sich von der ersten Seitenoberfläche unterscheidet und einen Rand des photovoltaischen Moduls bildet, und Bilden einer adhäsiven Verbindung zwischen der ersten Oberfläche der Anschlussdose und dem Zellsubstrat und zwischen der ersten Seitenoberfläche der Anschlussdose und dem Rückseitensubstrat,
6. f) Herstellen eines direkten elektrischen Kontakts zwischen dem Anschluss der Anschlussdose und einem elektrischen Anschluss der mindestens einen photovoltaischen Zelle,
7. g) Aufbringen eines Haftmittels auf eine Rückseite eines Substratstapels, der mindestens das Zellsubstrat, die mindestens eine photovoltaische Zelle, das Rückseitensubstrat und die Anschlussdose umfasst, oder Aufbringen eines Haftmittels auf den Rahmen, und
8. h) Anbringen des Rahmens auf der Rückseite des Substratstapels und Ausbilden einer adhäsiven Verbindung zwischen der Rückseite des Substratstapels und dem Rahmen.

The invention also relates to a method for producing a photovoltaic module, the method comprising at least the following steps:

1. a) providing a transparent cell substrate, wherein at least one photovoltaic cell is arranged on the cell substrate, a back substrate, a junction box comprising a connection for electrically contacting the at least one photovoltaic cell and a wire or a socket or a plug for connection to other devices, and a frame,
2. b) forming a cut-out portion at an edge of the back substrate, the cut-out portion having the same shape and size as the junction box,
3. c) Bonding the cell substrate and the back substrate together so that the minimum at least one photovoltaic cell is arranged between them,
4. d) applying an adhesive to a first surface and a first side surface of the junction box,
5. e) placing the junction box in the cut-out portion of the back substrate and on the cell substrate such that the first surface of the junction box is disposed on the cell substrate and the first side surface of the junction box is adjacent to the back substrate and that the wire or socket or plug is disposed on a second side surface different from the first side surface and forming an edge of the photovoltaic module, and forming an adhesive bond between the first surface of the junction box and the cell substrate and between the first side surface of the junction box and the back substrate,
6. f) establishing a direct electrical contact between the connection of the junction box and an electrical connection of the at least one photovoltaic cell,
7. g) applying an adhesive to a back side of a substrate stack comprising at least the cell substrate, the at least one photovoltaic cell, the back substrate and the junction box, or applying an adhesive to the frame, and
8. h) Attaching the frame to the back of the substrate stack and forming an adhesive bond between the back of the substrate stack and the frame.

Advantageously, such a method enables the easy manufacture of a photovoltaic module with an alternative arrangement of the junction box, thereby reducing or avoiding some of the disadvantages of the prior art.

The photovoltaic module produced by the method according to the invention can be a crystalline photovoltaic module or a thin-film photovoltaic module, preferably a thin-film photovoltaic module, wherein a crystalline photovoltaic module comprises at least one crystalline photovoltaic cell arranged on the transparent cell substrate and a thin-film photovoltaic module comprises at least one thin-film photovoltaic cell arranged on the transparent cell substrate.

In embodiments, the steps are performed in the following order: a), b), c), d), e), f), g) and h).

In embodiments, a glass substrate is provided as a transparent cell substrate in step a). In further embodiments, the backside substrate provided in step a) is a transparent backside substrate, preferably a glass substrate. The cell substrate and the backside substrate have the same shape and size.

In embodiments, the junction box provided in step a) is made of a polymer material. In further embodiments, the junction box provided in step a) comprises at least one junction box body. The junction box body comprises at least the first surface and the side surfaces of the junction box. In embodiments, the junction box further comprises a lid which is arranged and connected to the junction box body and forms at least a part of a second surface of the junction box which is opposite the first surface of the junction box. In further embodiments, the junction box body and the lid are shaped such that a click closure is formed between the junction box body and the lid.

In further embodiments, in step b) at least one cut-out portion is formed on an edge of the backside substrate by a cutting process, for example by a laser cutting process. In preferred embodiments, the at least one cut-out portion is formed on at least one corner of the backside substrate.

In step c), the cell substrate and the backside substrate with the at least one photovoltaic cell arranged therebetween are connected to one another by placing an encapsulation film on the surface of the cell substrate on which the at least one photovoltaic cell is arranged. The encapsulation film has the same shape and size as the cell substrate and comprises at least one cut-out section which is identical in shape and size to the at least one cut-out section of the backside substrate. The encapsulation film is placed on the cell substrate in such a way that the at least one cut-out section of the encapsulation film and the at least one cut-out section of the backside substrate lie congruently on top of one another.

The adhesive in step d) may be applied as a tape, paste, resin, polymer, adhesive or thermoplastic laminate. The adhesive is applied to the first surface of the junction box at least along the perimeter near the edge of the junction box and to the first side surface of the junction box. Alternatively or In addition, in step d), the adhesive may be applied to the back side of the cell substrate and to the edge of the back side substrate, in both cases in the cut-out portion of the back side substrate. This means that the adhesive may be applied in a region of the back side of the cell substrate with or without at least one photovoltaic cell arranged on the encapsulation film or the back side substrate and not covered by it, i.e. the region of the cell substrate on which the at least one cut-out portion of the encapsulation film or the back side substrate is arranged, and on the cut-out edge of the back side substrate.

In embodiments, in step e), an adhesive connection is formed between the first surface of the junction box and the cell substrate or the at least one photovoltaic cell arranged on the cell substrate and between the first side surface of the junction box and the rear substrate, i.e. the edge of the cut-out section of the rear substrate, by a temperature treatment, a radiation treatment or other methods known to the person skilled in the art.

In embodiments, the direct electrical contact between the connection of the junction box and an electrical connection of the at least one photovoltaic cell is established in step f) by means of soldering if the connection of the junction box is designed as a soldered connection. The electrical connection of the at least one photovoltaic cell is arranged on the back of the cell substrate or directly on the photovoltaic cell. The electrical connection of the at least one photovoltaic cell can be designed as a lateral busbar or as a connecting plug.

In embodiments, prior to step g), the junction box body may be filled with a potting material or a cover may be arranged on the junction box, each forming part of the second surface of the junction box.

The adhesive in step g) may be applied as a tape, paste, resin, polymer, adhesive or thermoplastic laminate. The adhesive is applied to the back side of the substrate stack at a position corresponding to the position of the frame in the finished photovoltaic module, e.g. along the perimeter of the substrate stack near the edge of the substrate stack. The substrate stack has a front side facing the sunlight when the photovoltaic module is in use and a back side opposite the front side. In embodiments, the substrate stack may comprise further substrates arranged on the front side and/or the back side of the cell substrate or the back side substrate, respectively. Alternatively or additionally, the adhesive is applied to the frame.

In step h), the frame is placed on the back of the substrate stack, e.g. on the applied adhesive, and an adhesive connection is formed between the back of the substrate stack and the frame by means of a temperature treatment, a radiation treatment or other methods known to those skilled in the art. In embodiments, the frame is placed congruently with the edge of the substrate stack.

In embodiments, the substrate stack has a square shape and the cut-out portion and the junction box are arranged at a corner of the substrate stack.

In embodiments, a cutout section and a junction box may be located at some or all four corners of a square substrate stack.

In embodiments, the substrate stack has a rectangular shape and the photovoltaic module comprises four cut-out portions of the backside substrate and four junction boxes, each arranged at a corner of the substrate stack.

In embodiments, the method further comprises the steps of providing a front substrate and connecting it to the cell substrate at a surface opposite the surface on which the at least one photovoltaic cell is arranged, such that the substrate stack further comprises the front substrate.

In embodiments, the steps of providing a front substrate and connecting it to the cell substrate are carried out after step e).

In embodiments, the front substrate provided may be a transparent substrate, for example a glass substrate. Advantageously, a photovoltaic module is manufactured with three substrates, preferably transparent substrates such as glass substrates.

The front substrate has the same size and shape as the cell substrate and is connected to the cell substrate in such a way that the front substrate and the cell substrate are congruent.

In embodiments, the back side of the substrate stack is formed by the second surface of the junction box being opposite the first surface of the junction box and the back side of the back side substrate, and by forming an adhesive connection between the second surface of the junction box and the frame and between the back side of the back side substrate and the frame in step h).

In embodiments, the second surface of the junction box, as described above, is partially formed by the cover and/or the potting material.

• i) Bereitstellen eines Isolationssubstrats,
• j) Aufbringen eines Haftmittels auf eine zweite Oberfläche der Anschlussdose, die der ersten Oberfläche der Anschlussdose gegenüberliegt, und einer gas- und flüssigkeitsdichten Abdichtung auf eine Rückseite des Rückseitensubstrats oder auf das Isolationssubstrat,
• k) Anbringen des Isolationssubstrats auf der Rückseite des Rückseitensubstrats und auf der zweiten Oberfläche der Anschlussdose und Bilden einer adhäsiven Verbindung zwischen der Rückseite des Rückseitensubstrats und dem Isolationssubstrat und zwischen der zweiten Oberfläche der Anschlussdose und dem Isolationssubstrat und eines gas- und flüssigkeitsdichten Raums zwischen dem Rückseitensubstrat und dem Isolationssubstrat,

wobei die Schritte j) und k) zwischen den Schritten f) und g) durchgeführt werden und wobei der Substratstapel in den Schritten g) und h) auch das Isolationssubstrat umfasst, wobei eine Rückseite des Isolationssubstrats die Rückseite des Substratstapels bildet.In embodiments, the method further comprises the following steps:

• i) providing an insulating substrate,
• j) applying an adhesive to a second surface of the junction box opposite the first surface of the junction box and a gas and liquid tight seal to a back side of the back substrate or to the insulation substrate,
• k) attaching the insulating substrate to the back of the back substrate and to the second surface of the junction box and forming an adhesive bond between the back of the back substrate and the insulating substrate and between the second surface of the junction box and the insulating substrate and a gas and liquid tight space between the back substrate and the insulating substrate,

wherein steps j) and k) are performed between steps f) and g), and wherein the substrate stack in steps g) and h) also comprises the insulating substrate, wherein a back side of the insulating substrate forms the back side of the substrate stack.

Advantageously, this enables the production of a photovoltaic module that is suitable as a building-integrated photovoltaic module and can be used, for example, instead of a conventional insulating glass window and offers additional functionality for energy generation.

In embodiments, the insulating substrate provided in step i) is a transparent substrate, such as a glass substrate. In further embodiments, the insulating substrate provided has the same size and shape as the cell substrate.

In embodiments, an edge seal, which is commonly used in insulating windows, is used as a gas and liquid tight seal. The edge seal is arranged along the peripheral edge of the backside substrate or at corresponding locations of the insulating substrate to ensure an insulating space between the backside substrate and the insulating substrate, and is adhesively bonded to the backside of the backside substrate and the frontside of the insulating substrate. The edge seal may be sealed with another sealing material, such as polysulfide, polyurethane or silicone, at the edge of the substrate stack. In further embodiments, the insulating space between the backside substrate and the insulating substrate is filled with an inert gas, such as argon.

Forming an adhesive bond between the back of the back substrate and the insulation substrate and between the second surface of the junction box and the insulation substrate as well as a gas- and liquid-tight space between the back substrate and the insulation substrate may comprise a temperature treatment, a radiation treatment or other methods known to those skilled in the art.

claim 15

• - Schritt b) umfasst ferner das Bilden eines weiteren ausgeschnittenen Abschnitts an einer Kante des Rückseitensubstrats an einer Position, die der Position eines elektrischen Anschlusses von mindestens einer der zwei photovoltaischen Zellen entspricht, die nicht elektrisch miteinander verbunden sind, wobei der weitere ausgeschnittene Abschnitt die gleiche Größe und Form wie die mindestens eine Verbindungsdose aufweist.
• - Schritt d) umfasst ferner das Aufbringen eines Haftmittels auf eine erste Oberfläche der mindestens einen Verbindungsdose und mindestens auf eine erste Seitenoberfläche der mindestens einen Verbindungsdose.
• - Schritt e) umfasst ferner das Platzieren der mindestens einen Verbindungsdose in dem weiteren ausgeschnittenen Abschnitt des Rückseitensubstrats und auf dem Zellsubstrat, so dass die erste Oberfläche der mindestens einen Verbindungsdose auf dem Zellsubstrat angeordnet ist und die erste Seitenoberfläche der mindestens einen Verbindungsdose an das Rückseitensubstrat angrenzt, und das Bilden einer adhäsiven Verbindung zwischen der ersten Oberfläche der mindestens einen Verbindungsdose und dem Zellsubstrat und zwischen der ersten Seitenoberfläche der mindestens einen Verbindungsdose und dem Rückseitensubstrat.
• - Schritt f) umfasst ferner das Bilden eines direkten elektrischen Kontakts zwischen einem elektrischen Anschluss der mindestens einen Verbindungsdose und einem elektrischen Anschluss einer der beiden photovoltaischen Zellen, die nicht elektrisch miteinander verbunden sind.
• - Der Substratstapel in den Schritten g) und h) umfasst auch die mindestens eine Verbindungsdose.

In embodiments, step a) further comprises providing two photovoltaic cells that are not electrically connected to each other and at least one junction box. The method is then characterized by the following features:

• - Step b) further comprises forming a further cut-out portion on an edge of the backside substrate at a position corresponding to the position of an electrical terminal of at least one of the two photovoltaic cells that are not electrically connected to each other, the further cut-out portion having the same size and shape as the at least one junction box.
• - Step d) further comprises applying an adhesive to a first surface of the at least one junction box and at least to a first side surface of the at least one junction box.
• - Step e) further comprises placing the at least one junction box in the further cut-out portion of the backside substrate and on the cell substrate such that the first surface of the at least one junction box is arranged on the cell substrate and the first side surface of the at least one junction box adjoins the backside substrate, and forming a adhesive connection between the first surface of the at least one junction box and the cell substrate and between the first side surface of the at least one junction box and the rear substrate.
• - Step f) further comprises forming a direct electrical contact between an electrical terminal of the at least one junction box and an electrical terminal of one of the two photovoltaic cells that are not electrically connected to each other.
• - The substrate stack in steps g) and h) also comprises the at least one junction box.

Advantageously, a photovoltaic module can be manufactured consisting of at least two submodules.

The at least two non-electrically connected photovoltaic cells provided in step a) are each arranged on the cell substrate and each form a submodule.

During the joining of the cell substrate and the back substrate in step c), the encapsulation film arranged between the cell substrate and the back substrate has at least one further cut-out section which is identical in shape and size to the at least one further cut-out section of the back substrate. The encapsulation film is placed on the cell substrate in such a way that the at least one further cut-out section of the encapsulation film and the at least one further cut-out section of the back substrate lie congruently on top of one another.

The at least one junction box can electrically connect the at least two submodules to one another or electrically connect at least one of the two submodules to another device if the at least one junction box is designed as a connection box.

Regarding the other properties of the junction box, the same applies as described above regarding the photovoltaic module.

In embodiments, in step d), alternatively or additionally, an adhesive is applied to the back side of the cell substrate and to the edge of the back side substrate, in both cases in the further cut-out section of the back side substrate. That is, the adhesive can be applied in a region of the back side of the cell substrate with or without at least one photovoltaic cell arranged on the encapsulation film or the back side substrate and not covered by it, i.e. the region of the cell substrate on which the at least one further cut-out section of the encapsulation film or the back side substrate is arranged, and on the cut edge of the back side substrate in this further cut-out section.

Placing the at least one junction box in the further cut-out portion of the backside substrate on the cell substrate in step e) also comprises arranging the at least one junction box on the at least one photovoltaic cell arranged on the cell substrate so that the terminal of the junction box and the terminal of the photovoltaic cell can be electrically connected in step f). The at least one junction box forms part of the substrate stack, i.e. the substrate stack comprises the junction box after forming an adhesive connection between the first surface of the junction box and the cell substrate and between the first side surface of the junction box and the backside substrate.

In embodiments, the at least one connection of the at least one junction box can be designed as a soldered connection. In further embodiments, the electrical connection of one of the at least two photovoltaic cells that are not electrically connected to one another is arranged on the surface of the cell substrate on which the photovoltaic cells are arranged. The electrical connection of one of the two photovoltaic cells that are not electrically connected to one another can be designed as a lateral busbar or as a connecting plug.

To realize the invention, it is advantageous to combine the described embodiments and features of the claims as described above. However, the embodiments of the invention described in the above description are examples for illustration and the invention is in no way limited thereto. Any modification, variation and equivalent arrangement as well as combinations of embodiments should be considered as included within the scope of the invention.

implementation examples

• 1A zeigt eine Vorderansicht einer beispielhaften Ausführungsform eines photovoltaischen Moduls, betrachtet entlang einer z-Richtung. Licht tritt in das photovoltaische Modul ein, wenn es in Betrieb ist,
• 1B zeigt eine Rückansicht von 1A, aus der entgegengesetzten Richtung betrachtet,
• 1C zeigt eine Seitenansicht des photovoltaischen Moduls gemäß 1A und 1B, betrachtet entlang einer y-Richtung,
• 1D zeigt eine vergrößerte perspektivische Explosionsansicht des eingekreisten Details von 1C,
• 2A zeigt einen Querschnitt des photovoltaischen Moduls von 1A bis 1D entlang der Linie C-C von 1B,
• 2B zeigt einen Querschnitt einer weiteren Ausführungsform eines photovoltaischen Moduls, betrachtet entlang einer y-Richtung,
• 3 zeigt eine Vorderansicht einer weiteren Ausführungsform eines photovoltaischen Moduls, betrachtet entlang einer z-Richtung, in der Licht in das photovoltaische Modul eintritt, wenn es in Betrieb ist,
• 4 zeigt eine Seitenansicht einer weiteren Ausführungsform eines photovoltaischen Moduls, betrachtet entlang einer y-Richtung,
• 5A zeigt eine Rückansicht einer weiteren Ausführungsform eines photovoltaischen Moduls entlang einer z-Richtung entgegengesetzt zur Richtung, in der Licht in das photovoltaische Modul eintritt, wenn es in Betrieb ist,
• 5B zeigt einen Querschnitt des photovoltaischen Moduls von 5A entlang der Linie A-A' von 5A,
• 6A zeigt eine Vorderansicht einer weiteren Ausführungsform eines photovoltaischen Moduls entlang einer z-Richtung, in der Licht in das photovoltaische Modul eintritt, wenn es in Betrieb ist,
• 6B zeigt einen Querschnitt durch einen Teil des photovoltaischen Moduls von 6A, betrachtet entlang einer y-Richtung,
• 6C zeigt eine Vorderansicht einer weiteren Ausführungsform eines photovoltaischen Moduls entlang einer z-Richtung, in der Licht in das photovoltaische Modul eintritt, wenn es in Betrieb ist,
• 6D zeigt einen Querschnitt durch einen Teil des photovoltaischen Moduls von 6C, betrachtet entlang einer y-Richtung,
• 7A zeigt schematisch eine Ausführungsform einer Anschlussdose in einer Draufsicht,
• 7B zeigt eine weitere Ausführungsform einer Anschlussdose in einer perspektivischen Ansicht,
• 8 zeigt einen Prozessablauf eines Verfahrens zur Herstellung eines photovoltaischen Moduls,
• 9A zeigt einen Teil eines photovoltaischen Moduls, das gemäß dem Prozessablauf in 8 nach Schritt S3 hergestellt wurde,
• 9B zeigt den Teil des photovoltaischen Moduls von 9A vor Schritt S5,
• 9C zeigt den Teil des photovoltaischen Moduls von 9A nach Schritt S8.

The accompanying drawings are included to provide a better understanding of embodiments of the invention and are incorporated in and constitute a part of this specification. The drawings illustrate embodiments of the present invention and together with the Description of the Explanation of Principles Other embodiments of the invention and many of the intended advantages will be readily appreciated as they become better understood by reference to the following detailed description. The elements of the drawings are not necessarily to scale with respect to one another. Like reference numerals indicate corresponding similar parts. Dashed lines refer to components which are not on the surface of the view shown, but are visible due to the transparency of other components or whose position with respect to the visible components is intended to indicate.

• 1A shows a front view of an exemplary embodiment of a photovoltaic module, viewed along a z-direction. Light enters the photovoltaic module when it is in operation,
• 1B shows a rear view of 1A , viewed from the opposite direction,
• 1C shows a side view of the photovoltaic module according to 1A and 1B , viewed along a y-direction,
• 1D shows an enlarged perspective exploded view of the circled detail of 1C ,
• 2A shows a cross-section of the photovoltaic module of 1A to 1D along the line CC from 1B ,
• 2B shows a cross-section of another embodiment of a photovoltaic module, viewed along a y-direction,
• 3 shows a front view of another embodiment of a photovoltaic module, viewed along a z-direction in which light enters the photovoltaic module when it is in operation,
• 4 shows a side view of another embodiment of a photovoltaic module, viewed along a y-direction,
• 5A shows a rear view of another embodiment of a photovoltaic module along a z-direction opposite to the direction in which light enters the photovoltaic module when it is in operation,
• 5B shows a cross-section of the photovoltaic module of 5A along the line AA' from 5A ,
• 6A shows a front view of another embodiment of a photovoltaic module along a z-direction in which light enters the photovoltaic module when it is in operation,
• 6B shows a cross-section through a part of the photovoltaic module of 6A , viewed along a y-direction,
• 6C shows a front view of another embodiment of a photovoltaic module along a z-direction in which light enters the photovoltaic module when it is in operation,
• 6D shows a cross-section through part of the photovoltaic module of 6C , viewed along a y-direction,
• 7A shows schematically an embodiment of a junction box in a plan view,
• 7B shows another embodiment of a junction box in a perspective view,
• 8 shows a process flow of a method for producing a photovoltaic module,
• 9A shows a part of a photovoltaic module that is manufactured according to the process flow in 8 was produced after step S3,
• 9B shows the part of the photovoltaic module of 9A before step S5,
• 9C shows the part of the photovoltaic module of 9A after step S8.

1A shows a front view of a photovoltaic module 100 along a z-direction in which light enters the photovoltaic module 100 when it is in operation. Visible is a transparent cell substrate 11 on which the at least one photovoltaic cell is arranged (the photovoltaic cell is not shown here). A junction box 20 and a frame 30 are indicated by dashed lines. The junction box 20 comprises at least one wire 21 for connection to other devices. The junction box 20 is arranged at a corner of the photovoltaic module 100.

1B shows a corresponding rear view of the photovoltaic module 100 of 1A viewed from an opposite z-direction. Visible are a rear substrate 13 and the frame 30 arranged on the rear substrate 13. Partially visible is the connection box 20 (indicated by partially dashed lines), which is arranged in at least one cut-out section 131 of the rear substrate 13.

1C shows a side view of the photovoltaic module 100 according to 1A and 1B , viewed along a y-direction. The photovoltaic module 100 comprises a substrate stack 10, which comprises at least the transparent cell substrate 11, at least one photoelectric layer arranged on the cell substrate tovoltaic cell 12, the back substrate 13 and the junction box 20. The junction box 20 is arranged in the cut-out portion 131 of the back substrate 13, wherein the cut-out portion 131 is in 1B is shown. Furthermore, the junction box 20 is arranged on an edge 16 of the substrate stack 10. The substrate stack 10 comprises a front side 14 and a back side 15, wherein the back side 15 of the substrate stack 10 is formed by a back side 133 of the back side substrate 13 and a second surface 24 of the junction box 20. Sunlight enters the photovoltaic module 100 from the front side 14 of the substrate stack 10, indicated by arrows. The edge 16 of the substrate stack 10 is part of an edge 101 of the photovoltaic module 100 and is formed by an edge of the cell substrate 11, a second side surface 26 of the junction box 20 and an edge of the back side substrate 13. The cell substrate 11 and the backside substrate 13 are bonded together via an encapsulation film (not shown) with the at least one photovoltaic cell 12 therebetween. The junction box 20 is adhesively bonded to the cell substrate 11 on a first surface 23 of the junction box 20 via an adhesive 40. The junction box 20 is further adhesively bonded to the backside substrate 13 on a first side surface 25 facing the backside substrate 13 via the adhesive 40, the first side surface 25 being adhesively bonded to an edge 132 of the cut-out portion of the backside substrate 13. The junction box 20 includes a terminal 22 for electrically contacting the at least one photovoltaic cell 12 and the wire 21 for connecting to other devices. The junction box 20 is directly electrically contacted via its connection 22 with an electrical connection (not shown) of the at least one photovoltaic cell 12. The wire 21 is arranged on the second side surface 26 of the junction box 20, which faces the environment. The frame 30 is arranged only on the back side 15 of the substrate stack 10 and is adhesively connected to the back side 15 of the substrate stack 10 via the adhesive 40. Although only one adhesive 40 is shown here, which realizes all adhesive connections of the junction box 20 with the cell substrate 11 and the back side substrate 13 and of the frame 30 with the back side substrate 13 and the junction box 20, different adhesives can be used for different adhesive connections.

1D shows an enlarged perspective exploded view of the circled detail of the photovoltaic module 100 of 1C Visible is the cell substrate 11 with the at least one photovoltaic cell 12 arranged on the cell substrate 11 and the backside substrate 13 connected to the cell substrate 11 with the at least one photovoltaic cell 12 therebetween. The backside substrate 13 comprises the cut-out section 131 arranged on an edge of the backside substrate 13. The junction box 20 is arranged in the cut-out section 131, the junction box 20 comprising the wire 21. The frame 30 is arranged only on the backside of the backside substrate 13 and the second surface of the junction box 20 and is adhesively connected to them as described above. As can be seen here, the wire 21 can comprise connecting means such as a socket or a plug.

2A shows a cross-section of the photovoltaic module of 1A to 1D along the line CC from 1B . The in 1C The components shown will not be described again. The junction box 20 includes a junction box body and a cover 28. The cover 28 forms at least a portion of the second surface 24 of the junction box 20. The junction box body includes at least the first surface and the first and second side surfaces of the junction box, as shown in 1C described. The side surfaces of the junction box form a box frame 27. Visible is the direct electrical connection of the connection 22 of the junction box 20 with an electrical connection 121 of the at least one photovoltaic cell 12, which is arranged on a surface of the cell substrate 11.

2B shows a cross section of another embodiment of a photovoltaic module 100, viewed along a y-direction similar to 2A . A special embodiment of the frame 30 is shown. The frame 30 has a recess on the side and at the position of the frame 30 where the frame 30 is arranged on the junction box 20. That is, the junction box 20 is arranged within this recess of the frame 30. This is particularly advantageous when the difference in height (or thickness) of the back substrate 13 and the junction box 20 is large, for example greater than 0.5 mm.

3 shows a front view of a specific embodiment of the photovoltaic module 100, wherein light penetrates the photovoltaic module along a z-direction when it is in operation. Visible are the transparent cell substrate 11 and a plurality of photovoltaic cells arranged on a rear side of the cell substrate 11. For example, the photovoltaic cells can be thin-film cells connected in series. In 3 only the first photovoltaic cell 12a and the last photovoltaic cell 12b in the series connection are designated. For the first photovoltaic cell 12a and the last photovoltaic cell 12b, two electrical terminals 121 are provided each, one terminal 121 being provided at the upper end of the respective photovoltaic cell 12a, 12b and the other terminal 121 being provided at the lower end of the respective photovoltaic cell 12a, 12b with respect to the y-direction. The two terminals 121 of a single photovoltaic cell 12a, 12b may also be connected by a side bus bar. In this specific embodiment, four junction boxes 20a to 20d are provided. Each of the junction boxes 20a to 20d includes a wire 21 for connection to other devices as described above. Each junction box 20a to 20d is arranged in a respective cut-out portion 131a to 131d of the back substrate and at a corner of the photovoltaic module. Each of the terminals 121 of the photovoltaic cells 12a, 12b is connected to a respective electrical terminal (not shown) of a respective junction box 20a to 20d. Providing a junction box at each corner of the photovoltaic module 100 has several advantages. First, the mechanical stability of the entire photovoltaic module 100 is increased because the frame 30 now has the same support point at each corner. In addition, the electrical connection of the photovoltaic module 100 to other devices can be improved due to two electrical terminals on each side. In addition, a junction box on each side, for example junction box 20b and 20c, can be designed as a dummy junction box that is not connected to other devices, but is suitable as a replacement if the respective other junction box on the same side, i.e. junction box 20a or 20d, breaks.

4 shows a side view of another embodiment of a photovoltaic module 100 along a y-direction. The photovoltaic module 100 in this embodiment further comprises a front substrate 17, preferably a transparent glass, which is arranged on a front side of the cell substrate 11 that faces the sunlight incident into the photovoltaic module 100 (indicated by the arrows). The front substrate 17 has the same size and shape as the cell substrate 11 and is adhesively connected to the cell substrate 11 via an encapsulation film. The substrate stack 10 now comprises the cell substrate 11, the at least one photovoltaic cell 12, the rear substrate 13, the junction box 20 and the front substrate 17. A front side of the front substrate 17 forms the front side 14 of the substrate stack. The photovoltaic module 100 of this embodiment is a three-glass photovoltaic module 100 with increased mechanical stability.

5A shows a rear view of another embodiment of a photovoltaic module 100 along a z-direction opposite to the direction in which light enters the photovoltaic module 100 when it is in operation. The photovoltaic module 100 in this embodiment further comprises an insulating substrate 18, preferably a transparent glass. The insulating substrate 18 is arranged on and adhesively bonded to the back substrate, and the frame 30 is arranged on the insulating substrate 18 on the side opposite the back substrate. The photovoltaic module 100 in this embodiment comprises four junction boxes 20a to 20d, each arranged in a cut-out portion 131a to 131d of the back substrate. Further shown is a gasket 50, which is not actually visible since it is hidden under the frame 30, but is shown for better understanding. The seal 50 is arranged on the circumference of the photovoltaic module 100 and is positioned with respect to 5B explained further.

5B shows a cross section of the photovoltaic module 100 of 5A along the line AA' from 5A . That is, the left part of the figure shows a cross section at a position where no junction box is arranged, and the right part of the figure includes a cross section at a position including the junction box 20a. As can be seen, the insulating substrate 18 is arranged on and adhesively bonded to the back substrate 13, preferably a transparent glass back substrate 13, on a surface opposite to the surface of the back substrate 13 that is connected to the cell substrate 11 or the at least one photovoltaic cell 12. The insulating substrate 18 is further arranged on and adhesively bonded to the second surface of the junction box 20a that is opposite to the first surface 23 of the junction box 20a. The substrate stack 10 now comprises the transparent cell substrate 11, the at least one photovoltaic cell 12 arranged on the cell substrate 11, the backside substrate 13, the junction boxes 20a to 20d and the insulation substrate 18. The insulation substrate 18 has the same size and shape as the cell substrate 11 and a backside 182 of the insulation substrate 18 forms the backside 15 of the substrate stack 10. The seal 50 is a gas- and liquid-tight seal formed on the circumference of the insulation substrate 18 so that a gas- and liquid-tight insulation space 181 is formed between the backside substrate 13 and the insulation substrate 18. That is, the seal 50 is formed between the back substrate 13 and the insulation substrate 18 and also between the second surface of each junction box 20a to 20d and the insulation substrate 18. The frame 30 is only on the back side 182 of the insulation substrate 18 and is adhesively connected thereto via an adhesive 40.

6A shows a front view of another embodiment of a photovoltaic module 100 along a z-direction in which light penetrates the photovoltaic module 100 when it is in operation. Visible is the transparent cell substrate 11, which comprises at least two photovoltaic cells 12a, 12b that are not electrically connected to one another via electrical conductors arranged on the cell substrate 11 or arranged between the cell substrate 11 and the rear substrate. In the embodiment shown, each of the at least two photovoltaic cells 12a, 12b means a plurality of photovoltaic cells 12, in particular thin-film photovoltaic cells, that are electrically connected to one another. Therefore, the photovoltaic cells 12a and 12b can also be referred to as a first submodule and a second submodule, wherein the first submodule and the second submodule are not electrically connected to one another and are each arranged on the cell substrate 11. Shown in dashed lines are four junction boxes 20a to 20d, each of which is arranged at a corner of the photovoltaic module 100 and within a respective cut-out portion 131a to 131d of the backside substrate. Accordingly, the backside substrate comprises the four cut-out portions 131a to 131d, which are identical in shape and size to the four junction boxes 20a to 20d. Also shown in dashed lines are two junction boxes 60a and 60b, each of which is arranged at an edge of the photovoltaic module 100. Therefore, the backside substrate comprises two further cut-out portions 134a, 134b, which are identical in size and shape to the junction boxes 60a, 60b. Also shown (although not necessarily visible in the front view) are electrical connections 121 of the photovoltaic cells 12a, 12b. The connection boxes 20a to 20d or the junction boxes 60a, 60b are connected via electrical connections of the connection boxes 20a to 20d or the junction boxes 60a, 60b (in 6A not shown) is directly electrically connected to the electrical terminals 121. In addition, the frame, which is part of the photovoltaic module 100, was 6A omitted for the sake of clarity.

6B shows a cross section through a part of the photovoltaic module 100 of 6A , viewed along a y-direction. The cross section extends along the x-direction within the circled portion of 6A , i.e. through a section of the photovoltaic module 100 in which the further cut-out section 134a and the junction box 60a are arranged. The cell substrate 11 and the rear substrate 13 with the photovoltaic cells 12a, 12b arranged therebetween are visible. The photovoltaic cells or submodules 12a, 12b are not electrically connected to one another via electrical conductors arranged on the cell substrate 11 or between the cell substrate 11 and the rear substrate 13. However, the photovoltaic cells 12a, 12b are electrically connected to one another via an internal connection 601 within the junction box 60a. In this embodiment, the junction box 60a comprises two electrical connections 61 of the junction box 60a, each of which serves to electrically contact the electrical connection 121 of one of the at least two photovoltaic cells 12a, 12b. The junction box 60a is adhesively bonded to the cell substrate 11 via an adhesive 40 at a first surface 62 of the junction box 60a and to the back substrate 13 at a first side surface 63 of the junction box 60a. The first side surface 63 here is any side surface of the junction box 60a that faces the back substrate 13. A side surface of the junction box 60a that does not face the back substrate 13 but the surroundings or outside of the photovoltaic module 100 is referred to as a second side surface of the junction box, which, however, is in 6A and 6B is not referenced by a reference number. The photovoltaic module 100 is shown here without the frame, which is disposed on the backside substrate 13 and on a second surface 64 of the junction box 60a, the second surface 64 being opposite the first surface 62. As described above with respect to the junction boxes, the frame is adhesively connected to the junction box 60a by the adhesive 40.

6C shows a front view of another embodiment of a photovoltaic module 100 similar 6A along a z-direction opposite to the direction in which light enters the photovoltaic module 100 when it is in operation. In contrast to 6A the photovoltaic module 100 comprises four junction boxes 60a to 60d (shown by dashed lines), wherein always two of the four junction boxes 60a to 60d are arranged on the same edge of the backside substrate 13. The backside substrate 13 comprises two further cut-out sections 134a, 134b arranged on an edge of the backside substrate 13. Each of the further cut-out sections 134a, 134b has a size and shape suitable for arranging two of the junction boxes 60a to 60d within the further cut-out section 134a, 134b. In other embodiments, four further cut-out sections may be present, each having a size and shape suitable for arranging one of the junction boxes 60a to 60d within the further cut-out section. In the embodiment shown here, in each of the two further cut-out sections 134a, 134b, the two junction boxes 60a, 60d or 60b, 60c are arranged next to one another in such a way that each junction box 60a to 60d forms part of an edge of the photovoltaic module 100. Each of the junction boxes 60a to 60d comprises at least one wire 21 or at least one socket or plug. That is, each junction box 60a to 60d is shaped like a junction box and serves as such. An electrical connection 602 electrically connects adjacent junction boxes 60a and 60d or 60b and 60c. In other embodiments, the individual junction boxes 60a to 60d can be electrically connected to other devices by wires 21.

6D shows a cross section through a part of the photovoltaic module 100 of 6B , viewed along a y-direction. The cross section extends along the x-direction within the circled portion of 6C , ie through a section of the photovoltaic module 100 in which the further cut-out section 134a and the junction boxes 60a and 60d are arranged. The cell substrate 11 and the rear substrate 13 with the photovoltaic cells 12a, 12b arranged between them are visible. 6D differs from 6B in that the two junction boxes 60a and 60d are arranged in the cut-out section 134a, each junction box 60a, 60d comprising the wire 21 (not shown here) which is internally electrically connected to the electrical connection 61 of the respective junction box 60a or 60d and is suitable for connection to other devices. The two junction boxes 60a, 60d are adhesively connected to the cell substrate 11 and the rear substrate 13 via an adhesive 40, but also to the other junction box 60a, 60d. Here too, the frame is in 6D not shown, although it is present in the photovoltaic module 100.

7A schematically shows an embodiment of a junction box 20 in a plan view of a second surface 24 of the junction box 20. The second surface 24 is the surface of the junction box 20 that is opposite a surface of the junction box 20 that is adhesively bonded to a cell substrate 11. The junction box 20 comprises a wire 21 or at least a socket or plug arranged on a second side surface 26 of the junction box 20 and a box frame 27 of the junction box 20. In this embodiment, the box frame 27 of the junction box 20 has a width w ₁ in the range of 3 mm to 20 mm, preferably 10 mm to 20 mm, at least on the side surfaces of the junction box that face outward and are in direct contact with the environment, for example the second side surface 26 of the junction box 20. Furthermore, the box frame 27 of the junction box 20 has a width w ₂ smaller than w ₁ on a first side surface 25 of the junction box 20, the first side surface 25 being the side surface to which the junction box 20 is adhesively bonded to a back substrate 13. The junction box 20 further includes a cover 28 that closes the junction box 20 at the second surface 24 and is connected to the box frame 27. In other embodiments, the cover 28 may be omitted.

7B shows another embodiment of a junction box 20 in a perspective view of a first side surface 25 and an upper or second surface 24 of the junction box 20. The first side surface 25 is the side surface that faces a rear substrate when the junction box 20 is mounted in a photovoltaic module. The second surface 24 is the surface that is opposite a first surface that is connected to a cell substrate when the junction box is mounted in a photovoltaic module. The junction box 20 in this embodiment comprises a double-walled box frame 27. The double-walled box frame 27 comprises at least one outer wall 271 and one inner wall 272 with a distance from each other in the range of 3 mm to 25 mm. The outer wall 271 is directed outwards and in direct contact with the environment and forms the side surfaces, in particular the first and second side surfaces 25, 26 of the junction box 20 or the edge of the junction box 20. The inner wall 272 of the box frame 27 is directed towards the inside of the junction box 20 and is only formed on the side surfaces of the junction box 20 which, in the assembled state, do not face the rear substrate, i.e. is only formed with respect to the second side surface 26. The inner and outer walls 272, 271 of the double-walled box frame 27 are connected via at least one cross strut 273, wherein the at least one cross strut 273 is formed on the inner and/or outer wall 272, 271 of the double-walled box frame 27 of the junction box 20. In this embodiment, the inner and outer walls 272, 271 of the double-walled can frame 27 are connected via a plurality of cross braces 273, whereby a plurality of compartments 274 are formed within the distance between the inner and outer walls 272, 271. The distance between the inner and outer walls 272, 271 of the double-walled can frame 27 or the plurality of compartments 274 can be filled with a potting material, for example a polymer potting material, for example, but not limited to, 2-component silicone compounds, thermosets, epoxy resins, silicone rubber gels or similar materials known from the prior art. The potting material can form a first part of the second surface 24 of the junction box 20. The junction box 20 in this embodiment further comprises a cover 28 of the junction box 20, which is fastened via a click closure 281 to the outer wall 271 of the double-walled box frame 27 on the first side surface 25 and to the inner wall 272 of the double-walled box frame 27 on the outward-facing side surfaces, ie at least the second side surface 26. The cover 28 forms at least a part of the second surface 24 of the junction box 20, e.g. a second part. In other embodiments, the cover 28 can be attached to all side surfaces of the junction box 20 on the outer wall 271 of the double-walled box frame 27, e.g. by a click closure. In this case, the cover 28 forms the second surface 24 of the junction box.

8 shows an exemplary process flow of a method for producing a photovoltaic module 100. In a first step S1, a transparent cell substrate 11, at least one photovoltaic cell 12 arranged on the cell substrate 11, a backside substrate 13, a junction box 20 comprising a terminal 22 for electrically contacting the at least one photovoltaic cell 12 and a wire 21 or a socket or a plug for connection to other devices, and a frame 30 are provided. In the following step S2, a cut-out section 131 is formed on an edge of the backside substrate 13, the cut-out section 131 having the same shape and size as the junction box 20. Subsequently, in step S3, the cell substrate 11 and the backside substrate 13 are connected to one another, for example by an encapsulation film, so that the at least one photovoltaic cell 12 is arranged therebetween. In step S4, an adhesive 40 is applied to a first surface 23 of the junction box 20 and a first side surface 25 of the junction box 20. In step S5, the junction box 20 is placed in the cut-out portion 131 of the back substrate 13 and on the cell substrate 11 such that the first surface 23 of the junction box 20 is disposed on the cell substrate 11 and the first side surface 25 of the junction box 20 is adjacent to the back substrate 13 and that the wire 21 or the jack or the plug is disposed on a second side surface 26 of the junction box 20. The second side surface 26 differs from the first side surface 25 and forms an edge of the photovoltaic module 100. Furthermore, in step S5, an adhesive connection is established between the first surface 23 of the junction box 20 and the cell substrate 11 and between the first side surface 25 of the junction box 20 and the backside substrate 13. In the following step S6, a direct electrical contact is established between the electrical connection 22 of the junction box 20 and an electrical connection 121 of the at least one photovoltaic cell 12. Subsequently, in step S7, an adhesive 40 is applied to a backside 133 of a substrate stack 10, wherein the substrate stack 10 comprises at least the cell substrate 11, the at least one photovoltaic cell 12, the backside substrate 13 and the junction box 20. In other embodiments, the adhesive 40 is applied to the frame 30. Finally, in step S8, the frame 30 is placed on the back side 133 of the substrate stack 10 and an adhesive connection is formed between the back side 133 of the substrate stack 10 and the frame 30.

9A shows a photovoltaic module 100 which is produced according to the process flow in 8 after step S3. A rear view of the photovoltaic module 100 can be seen, viewed along a z-direction opposite to the direction in which light enters the photovoltaic module 100 when it is in operation. The cell substrate 11 with the at least one photovoltaic cell 12 arranged thereon (shown in dashed lines) and the rear substrate 13 are already connected to one another by an encapsulation film (not shown). The rear substrate 13 has the cut-out section 131 formed in step S2, which has the same size and shape as the junction box 20 provided in step S1. Accordingly, the encapsulation film has a cut-out section which is identical in size and shape to the cut-out section 131 of the backside substrate 13 and is arranged on the cell substrate 11 such that the cut-out section of the encapsulation film and the cut-out section 131 of the backside substrate 13 lie congruently on top of one another. Also visible by a dashed line is a lateral busbar which forms an electrical connection 121 of the at least one photovoltaic cell 12, wherein the electrical connection 121 is arranged in the cut-out section 131 of the backside substrate 13.

9B shows a photovoltaic module 100 which is produced according to the process flow in 8 before step S5. Shown are the photovoltaic module 100 made of 9A and the junction box 20 with an adhesive (not shown) applied to a first surface of the Junction box (not shown) and a first side surface 25 of the junction box 20. The first surface of the junction box 20 faces a second surface 24 of the junction box 20. In step S5, the junction box 20 is placed in the cut-out portion 131 of the back substrate 13 as indicated by the arrow and adhesively bonded on its first surface to the cell substrate 11 and on its first side surface 25 to the back substrate 13.

9C shows a photovoltaic module 100 which is produced according to the process flow in 8 after step S8. Visible is the frame 30, which is adhesively connected to a back of a substrate stack, wherein the substrate stack comprises the cell substrate 11, the back substrate 13, the at least one photovoltaic cell 12 in between and the junction box 20. In this embodiment, the junction box 20 is completely covered by the frame 30 and is therefore not visible.

reference sign

100

Photovoltaic module

101

edge of the photovoltaic module

10

substrate stack

11

cell substrate

12, 12a, 12b

Photovoltaic cell

121

Electrical connection of the photovoltaic cell

13

backside substrate

131, 131a-131d

cut-out section

132

edge of the cut section

133

back of the back substrate

134a, 134b

Another cut-out section

14

front of the substrate stack

15

back of the substrate stack

16

edge of the substrate stack

17

front substrate

18

insulation substrate

181

isolation room

182

back of the insulation substrate

20, 20a-20d

junction box

21

wire

22

Electrical connection of the junction box

23

First surface of the junction box

24

Second surface of the junction box

25

First side surface of the junction box

26

Second side surface of the junction box

27

box frame of the junction box

271

outer wall of a double-walled can frame

272

inner wall of a double-walled can frame

273

cross brace

274

Academic subject

28

cover of the junction box

281

click closure

30

Frame

40

adhesive

50

sealing

60a, 60b

junction box

61

Electrical connection of the junction box

62

First surface of the junction box

63

First side surface of the junction box

64

Second surface of the junction box

601

Internal connection within the junction box

602

Electrical connection of different junction boxes

QUOTES INCLUDED IN THE DESCRIPTION

This list of documents listed by the applicant was generated automatically and is included solely for the better information of the reader. The list is not part of the German patent or utility model application. The DPMA accepts no liability for any errors or omissions.

Cited patent literature

• WO 2013/080691 A1 [0003]
• US 2017/0194900 A1 [0004]
• JP 5031698 B2 [0005]

Claims (15)

Photovoltaic module with at least the following elements: - a substrate stack comprising at least one transparent cell substrate, at least one photovoltaic cell arranged on the cell substrate, a rear substrate and a junction box, wherein the junction box comprises a connection for electrically contacting the at least one photovoltaic cell and a wire or a socket or a plug for connection to other devices, and - a frame, wherein the cell substrate and the rear substrate are connected to one another, wherein the at least one photovoltaic cell is located therebetween and wherein the rear substrate has a cut-out section arranged on an edge of the rear substrate, characterized in that - the junction box has the same shape and size as the cut-out section of the rear substrate, is arranged within the cut-out section of the rear substrate, is directly electrically connected via its connection to an electrical connection of the at least one photovoltaic cell and is connected to the cell substrate on a first surface of the junction box and to the rear substrate on a first side surface the junction box is adhesively connected, and the wire or the socket or the plug is arranged on a second side surface of the junction box which is different from the first side surface and is arranged on an edge of the substrate stack, - the frame is arranged only on a rear side of the substrate stack and is adhesively connected thereto Photovoltaic module according to claim 1 , characterized in that the substrate stack has a square shape and the cut-out portion and the junction box are arranged at a corner of the substrate stack. Photovoltaic module according to claim 1 , characterized in that the substrate stack has a rectangular shape and the photovoltaic module comprises four cut-out sections of the back substrate and four junction boxes, each arranged at a corner of the substrate stack. Photovoltaic module according to one of the Claims 1 until 3 , characterized in that the substrate stack further comprises a front substrate arranged and connected to the cell substrate at a surface opposite the surface on which the at least one photovoltaic cell is arranged. Photovoltaic module according to one of the Claims 1 until 4 , characterized in that the back side of the substrate stack is formed by a back side of the back side substrate and that the frame is further arranged on a second surface of the junction box which is opposite to the first surface of the junction box and is adhesively connected thereto. Photovoltaic module according to one of the Claims 1 until 4 , characterized in that the substrate stack further comprises an insulation substrate, wherein the insulation substrate is arranged on the back substrate on a surface and adhesively bonded thereto which is opposite the surface bonded to the cell substrate, and is arranged on a second surface of the junction box and adhesively bonded thereto which is opposite the first surface of the junction box, and wherein a gas- and liquid-tight seal is formed on the edge of the insulation substrate so that a gas- and liquid-tight insulation space is formed between the back substrate and the insulation substrate, and that the back of the substrate stack is formed by a back of the insulation substrate. Photovoltaic module according to one of the Claims 1 until 6 , characterized in that - the photovoltaic module comprises two photovoltaic cells that are not electrically connected to one another via electrical conductors that are arranged on the cell substrate or between the cell substrate and the rear substrate, - the rear substrate has at least one further cut-out section that is arranged on an edge of the rear substrate at a position that corresponds to the position of an electrical connection of at least one of the two photovoltaic cells that are not electrically connected to one another, and - the substrate stack further comprises at least one junction box that has at least one connection for electrically contacting one of the two photovoltaic cells that are not electrically connected to one another, wherein the at least one junction box has the same shape and size as the further cut-out section of the rear substrate, is arranged in the further cut-out section of the rear substrate and is electrically connected via its connection directly to the electrical connection of one of the two photovoltaic cells that are not electrically connected to one another, and to the cell substrate on a first surface of the junction box and to the rear substrate is adhesively bonded to a first side surface of the junction box. Photovoltaic module according to one of the Claims 1 until 7 , characterized in that the junction box comprises a box frame with a width in the range of 3 mm to 20 mm. A method for producing a photovoltaic module, comprising at least the following steps: a) providing a transparent cell substrate, wherein at least one photovoltaic cell is arranged on the cell substrate, a back substrate, a junction box comprising a terminal for electrically contacting the at least one photovoltaic cell and a wire or a socket or a plug for connection to other devices, and a frame, b) forming a cut-out portion on an edge of the back substrate, wherein the cut-out portion has the same shape and size as the junction box, c) connecting the cell substrate and the back substrate to each other so that the at least one photovoltaic cell is arranged therebetween, d) applying an adhesive to a first surface and a first side surface of the junction box, e) placing the junction box in the cut-out portion of the back substrate and on the cell substrate so that the first surface of the junction box is arranged on the cell substrate and the first side surface of the junction box adjoins the back substrate and that the wire or the socket or the plug is arranged on a second side surface which is different from the first side surface and forms an edge of the photovoltaic module, and forming an adhesive connection between the first surface of the junction box and the cell substrate and between the first side surface of the junction box and the back substrate, f) establishing a direct electrical contact between the terminal of the junction box and an electrical terminal of the at least one photovoltaic cell, g) applying an adhesive to a back side of a substrate stack which comprises at least the cell substrate, the at least one photovoltaic cell, the back substrate and the junction box, or applying an adhesive to the frame, and h) attaching the frame to the back side of the substrate stack and forming an adhesive connection between the back side of the substrate stack and the frame. procedure according to claim 9 , characterized in that the substrate stack has a square shape and the cut-out portion and the junction box are arranged at a corner of the substrate stack. procedure according to claim 9 , characterized in that the substrate stack has a rectangular shape and the photovoltaic module comprises four cut-out sections of the back substrate and four junction boxes, each arranged at a corner of the substrate stack. Method according to one of the Claims 9 until 11 , characterized in that the method further comprises the following steps: providing a front substrate and connecting it to the cell substrate at a surface opposite the surface on which the at least one photovoltaic cell is arranged, so that the substrate stack further comprises the front substrate. Method according to one of the Claims 9 until 12 , characterized in that the back of the substrate stack is formed by a second surface of the junction box, which is opposite the first surface of the junction box, and a back of the back substrate, and that in step h) an adhesive connection is formed between the second surface of the junction box and the frame and between the back of the back substrate and the frame. Method according to one of the Claims 9 until 12 , characterized in that the method further comprises the following steps: i) providing an insulation substrate, j) applying an adhesive to a second surface of the junction box which is opposite the first surface of the junction box, and a gas- and liquid-tight seal to a back side of the back substrate or to the insulation substrate, k) attaching the insulation substrate to the back side of the back substrate and to the second surface of the junction box and forming an adhesive connection between the back side of the back substrate and the insulation substrate and between the second surface of the junction box and the insulation substrate and a gas- and liquid-tight space between the back substrate and the insulation substrate, wherein steps j) and k) are carried out between steps f) and g), and wherein the substrate stack in steps g) and h) also comprises the insulation substrate, wherein a back side of the insulation substrate forms the back side of the substrate stack. Method according to one of the Claims 9 until 14 , characterized in that - step a) further comprises providing two photovoltaic cells that are not electrically connected to one another and at least one junction box, - step b) further comprises forming a further cut-out section on an edge of the backside substrate at a position corresponding to the position of an electrical connection of at least one of the two photovoltaic cells that are not electrically connected to one another, the further cut-out section having the same size and shape as the at least one junction box, - step d) further comprises applying an adhesive to a first surface of the at least one junction box and to a first side surface of the at least one junction box, - step e) further comprises placing the at least one junction box in the further cut-out section of the backside substrate and on the cell substrate so that the first surface of the at least one junction box is arranged on the cell substrate and the first side surface of the at least one junction box adjoins the backside substrate, and forming an adhesive connection between the first surface of the at least one junction box and the cell substrate and between the first side surface of the at least one junction box and the back substrate, - step f) further comprises forming a direct electrical contact between an electrical terminal of the at least one junction box and an electrical terminal of one of the two photovoltaic cells that are not electrically connected to one another, and - the substrate stack in steps g) and h) also comprises the at least one junction box.

Images