[go: up one dir, main page]

WO1994022172A1 - Panneaux solaires et procede de fabrication correspondant - Google Patents

Panneaux solaires et procede de fabrication correspondant Download PDF

Info

Publication number
WO1994022172A1
WO1994022172A1 PCT/US1994/003081 US9403081W WO9422172A1 WO 1994022172 A1 WO1994022172 A1 WO 1994022172A1 US 9403081 W US9403081 W US 9403081W WO 9422172 A1 WO9422172 A1 WO 9422172A1
Authority
WO
WIPO (PCT)
Prior art keywords
solar cells
solar
solar panel
cells
backing layer
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Ceased
Application number
PCT/US1994/003081
Other languages
English (en)
Inventor
John Victor Sagrati, Jr.
John Carl Solenberger
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
EIDP Inc
Original Assignee
EI Du Pont de Nemours and Co
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by EI Du Pont de Nemours and Co filed Critical EI Du Pont de Nemours and Co
Publication of WO1994022172A1 publication Critical patent/WO1994022172A1/fr
Anticipated expiration legal-status Critical
Ceased legal-status Critical Current

Links

Classifications

    • H—ELECTRICITY
    • H10—SEMICONDUCTOR DEVICES; ELECTRIC SOLID-STATE DEVICES NOT OTHERWISE PROVIDED FOR
    • H10F—INORGANIC SEMICONDUCTOR DEVICES SENSITIVE TO INFRARED RADIATION, LIGHT, ELECTROMAGNETIC RADIATION OF SHORTER WAVELENGTH OR CORPUSCULAR RADIATION
    • H10F19/00—Integrated devices, or assemblies of multiple devices, comprising at least one photovoltaic cell covered by group H10F10/00, e.g. photovoltaic modules
    • H10F19/90—Structures for connecting between photovoltaic cells, e.g. interconnections or insulating spacers
    • H10F19/902—Structures for connecting between photovoltaic cells, e.g. interconnections or insulating spacers for series or parallel connection of photovoltaic cells
    • H10F19/904—Structures for connecting between photovoltaic cells, e.g. interconnections or insulating spacers for series or parallel connection of photovoltaic cells characterised by the shapes of the structures
    • D—TEXTILES; PAPER
    • D21—PAPER-MAKING; PRODUCTION OF CELLULOSE
    • D21H—PULP COMPOSITIONS; PREPARATION THEREOF NOT COVERED BY SUBCLASSES D21C OR D21D; IMPREGNATING OR COATING OF PAPER; TREATMENT OF FINISHED PAPER NOT COVERED BY CLASS B31 OR SUBCLASS D21G; PAPER NOT OTHERWISE PROVIDED FOR
    • D21H13/00—Pulp or paper, comprising synthetic cellulose or non-cellulose fibres or web-forming material
    • D21H13/10—Organic non-cellulose fibres
    • D21H13/20—Organic non-cellulose fibres from macromolecular compounds obtained otherwise than by reactions only involving carbon-to-carbon unsaturated bonds
    • D21H13/24—Polyesters
    • D—TEXTILES; PAPER
    • D21—PAPER-MAKING; PRODUCTION OF CELLULOSE
    • D21H—PULP COMPOSITIONS; PREPARATION THEREOF NOT COVERED BY SUBCLASSES D21C OR D21D; IMPREGNATING OR COATING OF PAPER; TREATMENT OF FINISHED PAPER NOT COVERED BY CLASS B31 OR SUBCLASS D21G; PAPER NOT OTHERWISE PROVIDED FOR
    • D21H13/00—Pulp or paper, comprising synthetic cellulose or non-cellulose fibres or web-forming material
    • D21H13/36—Inorganic fibres or flakes
    • D21H13/38—Inorganic fibres or flakes siliceous
    • D21H13/40—Inorganic fibres or flakes siliceous vitreous, e.g. mineral wool, glass fibres
    • D—TEXTILES; PAPER
    • D21—PAPER-MAKING; PRODUCTION OF CELLULOSE
    • D21H—PULP COMPOSITIONS; PREPARATION THEREOF NOT COVERED BY SUBCLASSES D21C OR D21D; IMPREGNATING OR COATING OF PAPER; TREATMENT OF FINISHED PAPER NOT COVERED BY CLASS B31 OR SUBCLASS D21G; PAPER NOT OTHERWISE PROVIDED FOR
    • D21H17/00—Non-fibrous material added to the pulp, characterised by its constitution; Paper-impregnating material characterised by its constitution
    • D21H17/63—Inorganic compounds
    • D21H17/67—Water-insoluble compounds, e.g. fillers, pigments
    • H—ELECTRICITY
    • H10—SEMICONDUCTOR DEVICES; ELECTRIC SOLID-STATE DEVICES NOT OTHERWISE PROVIDED FOR
    • H10F—INORGANIC SEMICONDUCTOR DEVICES SENSITIVE TO INFRARED RADIATION, LIGHT, ELECTROMAGNETIC RADIATION OF SHORTER WAVELENGTH OR CORPUSCULAR RADIATION
    • H10F19/00—Integrated devices, or assemblies of multiple devices, comprising at least one photovoltaic cell covered by group H10F10/00, e.g. photovoltaic modules
    • H10F19/80—Encapsulations or containers for integrated devices, or assemblies of multiple devices, having photovoltaic cells
    • H—ELECTRICITY
    • H10—SEMICONDUCTOR DEVICES; ELECTRIC SOLID-STATE DEVICES NOT OTHERWISE PROVIDED FOR
    • H10F—INORGANIC SEMICONDUCTOR DEVICES SENSITIVE TO INFRARED RADIATION, LIGHT, ELECTROMAGNETIC RADIATION OF SHORTER WAVELENGTH OR CORPUSCULAR RADIATION
    • H10F71/00—Manufacture or treatment of devices covered by this subclass
    • H10F71/137—Batch treatment of the devices
    • D—TEXTILES; PAPER
    • D21—PAPER-MAKING; PRODUCTION OF CELLULOSE
    • D21H—PULP COMPOSITIONS; PREPARATION THEREOF NOT COVERED BY SUBCLASSES D21C OR D21D; IMPREGNATING OR COATING OF PAPER; TREATMENT OF FINISHED PAPER NOT COVERED BY CLASS B31 OR SUBCLASS D21G; PAPER NOT OTHERWISE PROVIDED FOR
    • D21H13/00—Pulp or paper, comprising synthetic cellulose or non-cellulose fibres or web-forming material
    • D21H13/10—Organic non-cellulose fibres
    • D21H13/12—Organic non-cellulose fibres from macromolecular compounds obtained by reactions only involving carbon-to-carbon unsaturated bonds
    • D21H13/14—Polyalkenes, e.g. polystyrene polyethylene
    • D—TEXTILES; PAPER
    • D21—PAPER-MAKING; PRODUCTION OF CELLULOSE
    • D21H—PULP COMPOSITIONS; PREPARATION THEREOF NOT COVERED BY SUBCLASSES D21C OR D21D; IMPREGNATING OR COATING OF PAPER; TREATMENT OF FINISHED PAPER NOT COVERED BY CLASS B31 OR SUBCLASS D21G; PAPER NOT OTHERWISE PROVIDED FOR
    • D21H13/00—Pulp or paper, comprising synthetic cellulose or non-cellulose fibres or web-forming material
    • D21H13/10—Organic non-cellulose fibres
    • D21H13/20—Organic non-cellulose fibres from macromolecular compounds obtained otherwise than by reactions only involving carbon-to-carbon unsaturated bonds
    • D21H13/26—Polyamides; Polyimides
    • D—TEXTILES; PAPER
    • D21—PAPER-MAKING; PRODUCTION OF CELLULOSE
    • D21H—PULP COMPOSITIONS; PREPARATION THEREOF NOT COVERED BY SUBCLASSES D21C OR D21D; IMPREGNATING OR COATING OF PAPER; TREATMENT OF FINISHED PAPER NOT COVERED BY CLASS B31 OR SUBCLASS D21G; PAPER NOT OTHERWISE PROVIDED FOR
    • D21H13/00—Pulp or paper, comprising synthetic cellulose or non-cellulose fibres or web-forming material
    • D21H13/36—Inorganic fibres or flakes
    • D21H13/46—Non-siliceous fibres, e.g. from metal oxides
    • D21H13/48—Metal or metallised fibres
    • D—TEXTILES; PAPER
    • D21—PAPER-MAKING; PRODUCTION OF CELLULOSE
    • D21H—PULP COMPOSITIONS; PREPARATION THEREOF NOT COVERED BY SUBCLASSES D21C OR D21D; IMPREGNATING OR COATING OF PAPER; TREATMENT OF FINISHED PAPER NOT COVERED BY CLASS B31 OR SUBCLASS D21G; PAPER NOT OTHERWISE PROVIDED FOR
    • D21H13/00—Pulp or paper, comprising synthetic cellulose or non-cellulose fibres or web-forming material
    • D21H13/36—Inorganic fibres or flakes
    • D21H13/46—Non-siliceous fibres, e.g. from metal oxides
    • D21H13/50—Carbon fibres
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
    • Y02E—REDUCTION OF GREENHOUSE GAS [GHG] EMISSIONS, RELATED TO ENERGY GENERATION, TRANSMISSION OR DISTRIBUTION
    • Y02E10/00—Energy generation through renewable energy sources
    • Y02E10/50—Photovoltaic [PV] energy
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
    • Y02P—CLIMATE CHANGE MITIGATION TECHNOLOGIES IN THE PRODUCTION OR PROCESSING OF GOODS
    • Y02P70/00—Climate change mitigation technologies in the production process for final industrial or consumer products
    • Y02P70/50—Manufacturing or production processes characterised by the final manufactured product

Definitions

  • This invention relates to solar panels, particularly those comprising a plurality of photovoltaic cells, and to a direct compression molding process for the manufacture thereof, whereby the solar panel can be made to conform to the shape required by the end use.
  • Solar panels useful for converting radiant energy directly into electrical energy commonly consist of a plurality of photovoltaic cells or wafers fixed to a suitable support and covered by a transparent protective material.
  • Each cell on the support contains electrodes for the transport of the current resulting from the incident radiation and is conductively interconnected with the other cells on the support so that the current generated by the individual cells can be collected and available to perform work.
  • heterojunction and Schottky barrier devices typically fall into two categories, i.e., heterojunction and Schottky barrier devices.
  • Typical heterojunction devices include epitaxially grown Ga ⁇ - x Al x As-GaAs, ZnSe-GaAs, GaP-Si and ZnS-Si devices.
  • Schottky barrier devices are the simplest types to prepare in that they only require an ohmbic contact on the back of the device and a transparent conductive material on the front. Examples include transparent conductive In2 ⁇ 3 or Sn ⁇ 2 glass on Si and GaAs substrates.
  • Various types of photovoltaic cells based on amorphous silicon alloys prepared in accordance with U.S. Patent No. 4,226,898, are disclosed in U.S. Patent No. 4,443,652.
  • U.S. Patent No. 3,780,424 discloses a silicon solar cell array in which a series of solar cells are provided with grid systems connected to bus bars for the collection and distribution of electric current. The solar panels disclosed therein are formed by supporting the cells on a polyimide substrate via a layer of adhesive material and covering the cells with protective transparent cover.
  • U.S. Patent No. 3,368,596 discloses a solar cell modular assembly in which silicon photovoltaic cells are fused between two sheets of fluorinated ethylene/propylene copolymer. The solar cells in the modular assembly are provided with negative grids and collectors.
  • U.S. Patent No. 3,849,880 discloses a method of fabricating a solar cell array in which individual solar cells are positioned on preprinted areas of a substrate by an adhesive. Electrical interconnectors must be carefully slid into place and welded.
  • U.S. Patent 4,084,985 involves photoetching a pattern of collector grid systems with appropriate interconnections and bus bar tabs into a plastic or glass sheet. The etched regions are then filled with a first thin conductive metal film followed by a layer of a mixed metal oxide, such as InAsO x or InSnO x . The resulting multiplicity of solar cells are then bonded between the protective plastic or glass sheet at the sites of the collector grid systems and a back electrode substrate by conductive metal filled epoxy to complete the fabrication of the solar panel.
  • Patent 4,443,652 involves utilizing an electrically conductive strip to interconnect small area segments (electrically isolated semiconductor bodies) of each large area (collection of small area segments) to provide a first electrode of the large area photovoltaic cell and access to the substrate from the layered surface of each large area cell to provide the second electrode of that cell.
  • a feature of the present invention is its adaptability to coatings and the like. An advantage of the present invention is that it does not require glass plating,' metal support, or in some cases adhesives. Another advantage of the present invention is that the coefficient of thermal expansion may be controlled to avoid damage during thermocycling.
  • thermoplastic substrate secured to the solar cells upon the second supported surface
  • the process comprises:
  • Figure 1 is an exploded view of a conventional design for a solar panel.
  • FIG. 2 is an exploded view of a solar panel according to the invention including solar cells with conductive grids which are placed into slots in the backing layer and connected by electrodes.
  • FIG. 3 is an exploded view of a solar panel according to the invention including solar cells with conductive grids placed into a web impregnated with thermoplastic material and connected by electrodes .
  • Figure 4 is an exploded view of a solar panel according to the invention and illustrating that the transparent cover can be applied to the solar cells without adhesive.
  • Figure 5 is an exploded view of a solar panel according to the invention and illustrating that a conductive material can be applied to the solar cells and conductive grids to establish electrical interconnectivity.
  • Figure 6A is a side view of a roll press apparatus utilized to make the present solar panels according to a process of the invention.
  • Figure 6B is a side view of a roll press apparatus utilized to make the present solar panels according to another process of the invention.
  • Figures 7A and 7B are top and exploded side views of a solar panel according to the invention, including layers of thermoplastic material.
  • Figures 8A and 8B are top and exploded side views of a solar panel according to the invention and having a unique design configuration.
  • Figure 9 is a side view of a solar panel according to the invention illustrating an embodiment providing enhanced light trapping by molded geometry of the backing layer.
  • Figure 10 is a side view of a solar panel according to the invention illustrating an embodiment providing snap-in cell mounting.
  • the invention relates to a process for preparing solar panels by direct compression molding thermoplastic preform sheets, preferably fiber reinforced.
  • Compression molding with fiber reinforcing thermoplastic preform sheets has advantages over other plastic molding techniques in that relatively large thin flat sheets, layered or homogeneous, can be cost effectively manufactured within close physical tolerances.
  • Photovoltaic cells such as those described above, are available in a wide variety of forms, any of which are useful in producing the solar panels in accordance with this invention.
  • the cells can most conveniently be purchased with a conductive grid already applied to the top of the cell and, optionally with a conductive coating on the bottom of the cell.
  • Solar sub-modules also available commercially, are electrically interconnected collections of cells on a support. A plurality of such sub-modules may be arranged and electrically interconnected to form arrays. For purposes of the present invention it is to be understood that all of these configurations of solar cells are considered as within the scope thereof.
  • SUBST1TUTESHEET(RULE26) modules can be electrically interconnected in the solar panel, such electrodes must be applied to the cells in some way.
  • the electrodes can be applied by conventional techniques to each individual cell or individual sub- module or array prior to placement onto the backing layer in accordance with this invention.
  • the electrodes can also be applied by placing them in the side of the transparent layer adjacent to the solar cells, sub- modules or arrays, positioned relative to the solar cells, solar sub-modules or arrays to provide electrical interconnectivity. Then, when the transparent layer is placed on top of the backing containing the cells, sub- modules or arrays, the electrical interconnectivity can be accomplished in one step coincident with the compression step, i.e., the application of heat and pressure.
  • Typical solar cells useful in the practice of this invention include silicon-based material, such as single crystalline, polycrystalline cast ingot amorphous silicon ribbon or sheet (including polycrystalline thin film) , III-V semiconductor and other non-silicon based materials.
  • Solar sub-modules useful in the practice of this invention are typically direct deposit, laser- scribed, transparent surface electrode products.
  • the backing layer used in accordance with this ⁇ invention must contain a thermoplastic or resin useful in compression molding.
  • thermoplastic resins useful in the practice of this invention include polyethylene, polypropylene, polyesters, copolyesters, thermoset (ABS) , polyamides including Nylon 6, 66, 11, 12, 612, and J2, "high temperature” Nylons (such as Nylon 46), polyetheretherketone (PEEK), polyether- ketoneketone (PEKK) , polymethylphenylene, polyarylates, polyimides, polyvinylidene fluoride and other thermo ⁇ plastic fluoropolymers, and thermoplastic liquid crystalline polymers. Additionally, these resins may be used in blends or alloys thereof according to techniques readily appreciated by those skilled in the art.
  • thermoset resins useful in the practice of this invention include those containing unsaturated polyesters, and the like. Additionally, these resins may be used in blends or alloys thereof according to techniques readily appreciated by those skilled in the art.
  • the backing layer can also contain other materials, such as high modulus reinforcing fibers, depending on the strength, coefficient of thermal expansion, flexibility and durability desired.
  • the incorporation of the reinforcing fibers by any of a variety of techniques known to those skilled in the art imparts a desired coefficient of thermal expansion to the substrate. By varying parameters such as the fiber type or orientation on filler material, desirable coefficients can be achieved.
  • the backing layer preferably contains reinforcing material for rigidity and/or conduction. Conductive materials are necessary when the solar cells or sub- modules to be placed on the backing layer do not contain wiring or other forms of interconnection and/or conduction. Non-conductive materials include glass or other non-conductive reinforcements of random in-plane discrete variety, such as those described in U.S.
  • Conductive materials may consist of carbon fiber or particle, graphite fiber or particle, metal fiber or particles, metallized particles or fibers, conductive plastics, or other conductive reinforcements or fillers of random in-plane discrete variety, or woven or aligned reinforced sheet intimately impregnated with thermo ⁇ plastic resin.
  • the solar cells or sub-modules can be placed onto the backing layer in a wide variety of ways . If the thermoplastic resin chosen has sufficient adhesion to hold the cells or sub-modules in place on the backing layer, no further processing is necessary prior to applying a transparent covering layer. If adhesion is not sufficient, a plurality of slots can be molded in the backing layer in a predetermined pattern, the size of the slots sufficient to accommodate an individual solar cell or solar sub-module. The individual solar cells or solar sub-modules can then be placed into the slots in the backing layer. The cells or sub-modules can be manually or robotically placed in the slots.
  • a conductive layer must be applied to each cell or sub-module or to the backing layer per 2S. prior to insertion of the cells in the slots. If a solar panel delivering very high current a-c low voltage is desired, the conductive material can be deposited on the entire surface of the backing layer prior to placement of the cells or sub-modules thereon/therein. However, it is more common for one to want high voltage, so the conductive material should be applied so that the it is positioned under each solar cell or sub-module.
  • the transparent covering material which may or may not contain electrodes or other conductive material or agent embedded therein, can be any durable rigid or flexible material.
  • the transparent covering material can conveniently be applied by simple coating, e.g., spin casting, spraying, etc., of solutions of organic or inorganic materials or blends thereof.
  • the transparent covering material can also be in the form of a film, which may or may not require an adhesive. The film can simply be placed on the surface of the backing layer containing the solar cells or sub-modules and fused to the backing layer under the conditions of temperature and pressure employed in the compression molding process. If the application of the transparent material occurs following compression molding of the solar cells or sub-modules to the backing layer, then the temperature and pressure are chosen in accordance with adhesive requirements.
  • FIG. 1 A traditional manufacturing process is represented generally at 10 in Figure 1.
  • Commercially available solar cells 12 are equipped with a conductive surface grid and soldered together in a series of wiring 14. After which, sheets of adhesive film 16 such as ethyl vinyl acetate are applied to the top of the cells.
  • a transparent glass or plastic film 18 such as Tefzel® fluoropolymer modified copolymer of ethylene and tetrafluoroethylene (a trademark of E. I. du Pont de Nemours and Company) .
  • Sheets of adhesive 20 are applied to the back of the cells 12 followed by a backing film 22 such as Tedlar® polyvinyl fluoride film (a trademark of the E. I. du Pont de Nemours and Company) .
  • Tedlar® polyvinyl fluoride film a trademark of the E. I. du Pont de Nemours and Company
  • the resulting sandwich is compressed and cured to form a bond between the cells, the cover and the backing material.
  • the resulting solar sub-module is then placed in a rigid frame 24 after which electrical connections are added.
  • Figure 2 One of the embodiments of the practice of this invention is shown in Figure 2.
  • Commercially available solar cells 12 are equipped with a conductive grid, 26.
  • An electrode (as wiring 14) , is applied to each of the solar cells 12.
  • the resulting solar cells 12 are then placed into a backing layer 28 containing molded slots 32 optionally having a conductive material 34 in each slot 32 which is fabricated by conventional molding techniques from a thermoplastic resin and deposition.
  • An adhesive 36 is applied to bond the solar cell 12 to the backing layer 28.
  • a transparent covering material 38 typically in the form of a plastic sheet is bonded to the top of the sandwich by a clear adhesive film 40, such as ethylene vinyl acetate film and adhered thereto by application of temperature and pressure. Note that while the covering material 38 and adhesive 40 are depicted in cross-hatch for purposes of illustration, in actuality these components are transparent.
  • FIG. 3 A second embodiment of the practice of this invention is shown in Figure 3 generally at 50.
  • Commercially available solar cells 12 are equipped with a conductive grid 26.
  • An electrode (as wiring 14) is applied to each of the solar cells 12.
  • the resulting solar cells 12 are then placed onto a backing layer 28 comprising a web impregnated with thermoplastic material.
  • the backing layer 28 and solar cells 12 are then compression molded to form a composite.
  • a transparent covering material 38 typically in the form of a plastic sheet is bonded to the top of the sandwich by a clear adhesive film 40, such as ethylene vinyl acetate film and adhered thereto by application of temperature and pressure.
  • FIG 4 A third embodiment of the practice of this invention is shown in Figure 4, generally at 60.
  • Commercially available solar cells 12 are equipped with a conductive grid 26.
  • An electrode (as wiring 14) is applied to each of the solar cells 12.
  • the resulting solar cells 12 are then placed onto a backing layer 28 comprising a web impregnated with thermoplastic material 44.
  • the backing layer 28 and solar cells 12 are then compression molded to form a composite.
  • a transparent covering material 38 is applied to the surface of the compression molded solar cells 12 and backing layer 28 by spraying or other coating or casting means.
  • FIG. 1 A fourth embodiment of the practice of this invention is shown in Figure 5 generally at 70.
  • FIG. 1 A cross sectional view of a variation on the * general embodiments of the invention shown in Figures 2, 3, 4 and 5 is shown in Figure 9.
  • backing layer 28 contains molded slots 90, the sides of which are angled away from the top of solar cell 12 so that additional light can be trapped for activation of the cells.
  • the molded slots 90 are depicted with four sides 91 each, and further the molded slots 90 are normal to the plane of the backing layer 28.
  • one or more sides 91 form an obtuse angle relative to the interface of the backing layer 28 and solar cell 12.
  • two opposed sides 91 are angled.
  • Most preferably all sides 91 are angled. It is to be readily appreciated by one skilled in the art that any configuration of sides may impart this effect so long as the appropriate amount of reflection is achieved. Flat sides may not even be required, as for example a circular cell with conical sides. Such modifications to suit design criteria are contemplated as within the scope of the invention herein.
  • the reflectivity of the sides of the molded slot can be further enhanced, if desired, by applying a reflective material or coating 91 to the angled sides of the molded slot 90 prior to applying transparent covering material 38.
  • FIG. 10 A cross sectional view of another variation on the general embodiments of the invention shown in Figures 2 , 3, 4, 5 and 9 is shown in Figure 10.
  • This embodiment contemplates the separate manufacture of the module backing layer 28 containing molded slots 32 and snap unit 100 containing solar cell 12.
  • the molded slot 32 is sized and configured in such a way as to allow for friction fit or other snap-fitting mechanism (possibly detachable) for snap unit 100.
  • Snap unit 100 comprises a cell backing layer 101 containing wiring 14 and connector leads 102. It is readily appreciated by those skilled in the art that such a mechanism can be selected from a wide variety of technologies. Depending on the needs of the user, a snap fit mechanism may for example be selected which is detachable.
  • the backing layer 101 is a thermoplastic substrate secured to said solar cells. It must have a coefficient of thermal expansion which is not very different from that of the backing layer 28 which has the molded slots. If the coefficient of thermal expansion were too different, the snap unit would either loosen up or get too tight and cause pop-up.
  • Embedded within the cell backing layer 101 is solar cell 12 containing conductive grid 26 and conductive material 34.
  • the snap unit 100 is covered by a transparent covering material 38.
  • the snap unit 100 including the solar cell 12 and affiliated components as depicted in the figure can be manufactured separate from the module backing layer 28 and snapped into the module backing layer 28 in such a way that wiring 14 connects to wire connectors 102 upon contact with wire connectors 103. This embodiment allows for individual solar cells to be replaced by simply snapping out the old unit and snapping in a new unit, rather than having to replace the entire solar module or panel.
  • the compression molding may be accomplished through a roller-press represented generally at 80 and 90 in Figures 6A and 6B, respectively.
  • the solar cells 12 which may or may not be partially electrically interconnected (as with back electrodes 52) , are fed into a roll press 44 with the backing layer 28 and a surface layer 56 comprising a web impregnated with thermoplastic material.
  • Sufficient pressure is supplied by the roll press 44 to form the composite/- Heat is optionally supplied to enhance consolidation of the material, by any of a wide variety of means known to those skilled in the art.
  • the roll press 44 may be designed to provide necessary heat.
  • a conductive material 42 is then applied to the surface of the solar cells 12 by a first applicator 46 to complete the electrical interconnection.
  • a transparent covering material 38 is then applied to the surface of the compression molded solar cells 12 and backing layer 28 by spraying or other coating or casting means via a second applicator 48.
  • the solar cells 12 may be supplied with top and bottom electrodes 5 .
  • a pincher 58 which acts to bond the top and bottom electrodes 54 may supply heat and pressure.
  • the cells are fed into a roll press 44 together with the backing layer 28 comprising a web impregnated with thermoplastic material and a surface layer 56 also comprising a web impregnated with thermoplastic material. Sufficient heat and pressure are supplied by the roll press to form the composite.
  • a conductive material 42 as in Figure 6A may then be applied to the surface of the solar cells 12 to complete the electrical interconnection if necessary.
  • a transparent covering material 38 is then applied to the surface of the compression molded solar cells and backing layer by spraying or other coating or casting means via applicator 48.
  • a solar cell mounted in one face of a high modulus fiber reinforced thermoplastic polyethylene terephthalate composite plaque (as depicted in Figures 7A and 7B) was formed by first placing the solar cell in a steel tool lying face down against one surface of the tool, then placing a layered assembly of high modulus fiber reinforced thermoplastic impregnated preform sheet materials in a tool to cover the solar cell, and finally molding the preform layers with heat and pressure to form a consolidated plaque with a solar cell imbedded in one surface. It was observed that the solar cell withstood the temperature and pressure required to melt consolidate the reinforced thermoplastic sheets without loss of photovoltaic efficiency and without cracking. It was further observed that electrically conductive metallic or filled thermoplastic sheets material layers can be employed to conduct current from the back of the solar cell to complete the electrical circuit to potentially interconnect with additional cells.
  • Molding was accomplished using a steel picture frame molding tool, consisting of two 17.8 cm by 17.8 cm blocks of 5.1 cm thick which fit in close tolerance inside a steel frame also 5.1 cm thick and 25.4 cm square. A layered preform was captured inside the tool between the two steel blocks and the tool was placed in a heated platten press, whereby heat and pressure were applied to mold the preform.
  • the preform for the plaque was built up from 17.8 cm by 17.8 cm square layers of composite sheet materials in the following manner: first a layer of 5 mil Du Pont Kapton® polyimide film (a trademark of E. I. du Pont de Nemours and Company) (not shown) was placed on the bottom of the mold to act as a release layer after molding. Next, a 10 cm square solar cell 26 was * centered, collector side down, on the Kapton® polyimide film. Then a layer of a 25% 1.27 cm glass fiber reinforced polyethylene terephthalate moldable composite sheet 62 having a basis weight of 500 grams per square meter was placed on the back of the solar cell.
  • Du Pont Kapton® polyimide film a trademark of E. I. du Pont de Nemours and Company
  • This layer had an 8 cm centered square hole 64 cut in it to reveal the conductive coated side of the solar cell through the hole .
  • a layer of lightweight aluminum expanded metal screen 66 (as shown, copper screen) having a basis weight of 10 grams per square meter and a 50 mesh pattern was layered on the preform.
  • a composite sheet 62 was placed on the metal screen 66.
  • layers (as shown, four) of Essee® 500 (a trademark of E. I. du Pont de Nemours and Company) moldable composite sheet 68 having a basis weight of 500 grams per square meter, where each sheet is composed of 10% 2.54 cm fiber glass dispersed randomly in plane, 40% conductive carbon particles and 50% polyethylene terephthalate.
  • Four additional layers of a commercially available glass/polyethylene terephthalate moldable composite sheet 72 were then added.
  • a final layer of Kapton® polyimide film (not shown) was added to the top of the preform as a release film.
  • the resulting preform was placed in the square plaque tool, which in turn was placed in an MTP-14 programmable press.
  • the tool temperature was raised to 280°C under a pressure of 3.45 x 10 +5 Pascals.
  • the pressure was increased to 3.45 x 10 +6 Pascals and held at those conditions for ten minutes.
  • the plaque was removed from the mold.
  • the solar cell 26 was observed to be imbedded in the plaque with the upper surface flush with the plaque surface without flash covering the solar cell 26.
  • the conductive composite sheet 68 was observed to be captured between the upper and lower glass/polyethylene terephthalate layers to form an electrically conductive layer.
  • the solar cell was observed to provide a current between the collector grid on the cell surface and the layer of conductive plastic visible at the edge of the plaque between the two non-conductive layers.
  • Example 2 The procedure of Example 1 was followed except that the third layer (the metal screen 66) was in the form of a cross of 2 mil thick aluminum foil as shown in Figures 8A and 8B and the four layers of electrically conductive Essee® 500 moldable composite sheet 68 were replaced with four layers of a commercially available glass/polyethylene terephthalate moldable composite sheet 71. Using a high intensity lamp and a volt/ohm meter the solar cell 26 was observed to produce a current between the collector grid on the cell surface and the aluminum foil layer contacted near the edge of the plaque through a hole in the upper conductive composite sheet layer.
  • the third layer the metal screen 66
  • the metal screen 66 was in the form of a cross of 2 mil thick aluminum foil as shown in Figures 8A and 8B and the four layers of electrically conductive Essee® 500 moldable composite sheet 68 were replaced with four layers of a commercially available glass/polyethylene terephthalate moldable composite sheet 71.
  • the solar cell 26 was observed to produce

Landscapes

  • Chemical & Material Sciences (AREA)
  • Inorganic Chemistry (AREA)
  • Chemical Kinetics & Catalysis (AREA)
  • Photovoltaic Devices (AREA)

Abstract

L'invention se rapporte à des panneaux solaires, tels que notamment des panneaux comprenant plusieurs cellules voltaïques, ainsi qu'à un procédé de moulage par compression pour la fabrication de tels panneaux, dans lequel le panneau solaire peut être fabriqué de façon à s'adapter à la forme requise par l'usage final.
PCT/US1994/003081 1993-03-24 1994-03-22 Panneaux solaires et procede de fabrication correspondant Ceased WO1994022172A1 (fr)

Applications Claiming Priority (4)

Application Number Priority Date Filing Date Title
US3659693A 1993-03-24 1993-03-24
US08/036,596 1993-03-24
US10232293A 1993-08-10 1993-08-10
US08/102,322 1993-08-10

Publications (1)

Publication Number Publication Date
WO1994022172A1 true WO1994022172A1 (fr) 1994-09-29

Family

ID=26713314

Family Applications (1)

Application Number Title Priority Date Filing Date
PCT/US1994/003081 Ceased WO1994022172A1 (fr) 1993-03-24 1994-03-22 Panneaux solaires et procede de fabrication correspondant

Country Status (1)

Country Link
WO (1) WO1994022172A1 (fr)

Cited By (17)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US5516704A (en) * 1994-04-01 1996-05-14 Fuji Electric Co., Ltd. Method and an apparatus for manufacturing thin-film photoelectric conversion modules
EP1732140A1 (fr) * 2005-06-06 2006-12-13 Alcan Technology & Management Ltd. Substrat flexible et avec des cellules photovoltaiques son procéde de fabrication
WO2008093120A3 (fr) * 2007-02-02 2008-12-31 G24 Innovations Ltd Revêtements protecteurs
EP2123420A2 (fr) 2008-05-21 2009-11-25 Tesa AG Procédé d'encapsulage de composants optoélectroniques
NL2001727C2 (nl) * 2008-06-26 2009-12-29 Eurotron B V Werkwijze voor het vervaardigen van een zonnepaneel, alsmede halffabrikaat daarvoor.
EP2275471A1 (fr) 2009-06-18 2011-01-19 Ems-Patent Ag Monofeuille dorsale de module photovoltaïque, son procédé de fabrication et son utilisation dans la production de modules photovoltaïques
NL2003936C2 (nl) * 2009-12-10 2011-06-14 Eurotron B V Werkwijze en inrichting voor het vervaardigen van zonnepaneel onder gebruikmaking van een drager.
WO2011131346A2 (fr) 2010-04-21 2011-10-27 Muehlbauer Ag Procédé et dispositif de fabrication d'un module solaire comprenant des cellules solaires en couches minces souples et module solaire comprenant des cellules solaires en couches minces souples
EP2422976A1 (fr) 2010-07-30 2012-02-29 Ems-Patent Ag Feuille arrière multicouche pour module photovoltaïque ainsi que sa fabrication et son utilisation dans la production de modules photovoltaïques
WO2012088098A3 (fr) * 2010-12-20 2013-05-16 Solar Machines Incorporated Encapsulation monocellule et architecture de module a format adaptable pour la production d'énergie photovoltaïque et leur procédé de construction
DE102012003455A1 (de) 2012-02-22 2013-08-22 Mühlbauer Ag Verfahren und Vorrichtung zur Herstellung eines Solarmoduls und ein Solarmodul mit flexiblen Dünnschicht-Solarzellen
WO2013124438A2 (fr) 2012-02-22 2013-08-29 Muehlbauer Ag Procédé et dispositif de production d'un module solaire et module solaire muni de cellules solaires flexibles à couche mince
US20140326401A1 (en) * 2007-06-28 2014-11-06 Certainteed Corporation Photovoltaic Roofing Tiles And Methods For Making Them
US20150075604A1 (en) * 2012-03-21 2015-03-19 Sharp Kabushiki Kaisha Thin-film compound photovoltaic cell and method for manufacturing same
WO2015168075A1 (fr) 2014-04-29 2015-11-05 E. I. Du Pont De Nemours And Company Cellules photovoltaïques dotées d'une feuille de support améliorée
WO2015168068A1 (fr) 2014-04-29 2015-11-05 E. I. Du Pont De Nemours And Company Cellules photovoltaïques à feuille arrière multicouche améliorée
WO2015168073A1 (fr) 2014-04-29 2015-11-05 E. I. Du Pont De Nemours And Company Modules de cellule solaire présentant une feuille support améliorée

Citations (13)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US3780424A (en) * 1970-10-26 1973-12-25 Nasa Method of making silicon solar cell array
US3849880A (en) * 1969-12-12 1974-11-26 Communications Satellite Corp Solar cell array
US4067764A (en) * 1977-03-15 1978-01-10 Sierracin Corporation Method of manufacture of solar cell panel
US4084985A (en) * 1977-04-25 1978-04-18 The United States Of America As Represented By The Administrator Of The National Aeronautics And Space Administration Method for producing solar energy panels by automation
EP0002816A1 (fr) * 1977-12-22 1979-07-11 Hubertus Sarfert Dispositif à cellules solaires destiné à produire de l'énergie électrique, générateur solaire se composant d'une pluralité de ces dispositifs ainsi que leur méthode de réalisation
GB2042802A (en) * 1979-02-14 1980-09-24 Ferranti Ltd Encapsulation of semiconductor devices
US4226898A (en) * 1978-03-16 1980-10-07 Energy Conversion Devices, Inc. Amorphous semiconductors equivalent to crystalline semiconductors produced by a glow discharge process
WO1982003728A1 (fr) * 1978-05-19 1982-10-28 Pierre Dubois Panneau de cellules solaires et son procede de fabrication
US4443652A (en) * 1982-11-09 1984-04-17 Energy Conversion Devices, Inc. Electrically interconnected large area photovoltaic cells and method of producing said cells
JPS6214477A (ja) * 1985-07-12 1987-01-23 Teijin Ltd 太陽電池モジユ−ル
JPS6314480A (ja) * 1986-07-04 1988-01-21 Sharp Corp 太陽電池モジユ−ルの製造方法
EP0325369A2 (fr) * 1988-01-20 1989-07-26 Siemens Solar Industries L.P. Module photovoltaique
US5134016A (en) * 1990-10-31 1992-07-28 E. I. Du Pont De Nemours And Company Fiber reinforced porous sheets

Patent Citations (13)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US3849880A (en) * 1969-12-12 1974-11-26 Communications Satellite Corp Solar cell array
US3780424A (en) * 1970-10-26 1973-12-25 Nasa Method of making silicon solar cell array
US4067764A (en) * 1977-03-15 1978-01-10 Sierracin Corporation Method of manufacture of solar cell panel
US4084985A (en) * 1977-04-25 1978-04-18 The United States Of America As Represented By The Administrator Of The National Aeronautics And Space Administration Method for producing solar energy panels by automation
EP0002816A1 (fr) * 1977-12-22 1979-07-11 Hubertus Sarfert Dispositif à cellules solaires destiné à produire de l'énergie électrique, générateur solaire se composant d'une pluralité de ces dispositifs ainsi que leur méthode de réalisation
US4226898A (en) * 1978-03-16 1980-10-07 Energy Conversion Devices, Inc. Amorphous semiconductors equivalent to crystalline semiconductors produced by a glow discharge process
WO1982003728A1 (fr) * 1978-05-19 1982-10-28 Pierre Dubois Panneau de cellules solaires et son procede de fabrication
GB2042802A (en) * 1979-02-14 1980-09-24 Ferranti Ltd Encapsulation of semiconductor devices
US4443652A (en) * 1982-11-09 1984-04-17 Energy Conversion Devices, Inc. Electrically interconnected large area photovoltaic cells and method of producing said cells
JPS6214477A (ja) * 1985-07-12 1987-01-23 Teijin Ltd 太陽電池モジユ−ル
JPS6314480A (ja) * 1986-07-04 1988-01-21 Sharp Corp 太陽電池モジユ−ルの製造方法
EP0325369A2 (fr) * 1988-01-20 1989-07-26 Siemens Solar Industries L.P. Module photovoltaique
US5134016A (en) * 1990-10-31 1992-07-28 E. I. Du Pont De Nemours And Company Fiber reinforced porous sheets

Non-Patent Citations (2)

* Cited by examiner, † Cited by third party
Title
PATENT ABSTRACTS OF JAPAN vol. 011, no. 182 (E - 515) 11 June 1987 (1987-06-11) *
PATENT ABSTRACTS OF JAPAN vol. 012, no. 217 (E - 624) 21 June 1988 (1988-06-21) *

Cited By (29)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US5516704A (en) * 1994-04-01 1996-05-14 Fuji Electric Co., Ltd. Method and an apparatus for manufacturing thin-film photoelectric conversion modules
EP1732140A1 (fr) * 2005-06-06 2006-12-13 Alcan Technology & Management Ltd. Substrat flexible et avec des cellules photovoltaiques son procéde de fabrication
WO2008093120A3 (fr) * 2007-02-02 2008-12-31 G24 Innovations Ltd Revêtements protecteurs
US20140326401A1 (en) * 2007-06-28 2014-11-06 Certainteed Corporation Photovoltaic Roofing Tiles And Methods For Making Them
EP2123420A2 (fr) 2008-05-21 2009-11-25 Tesa AG Procédé d'encapsulage de composants optoélectroniques
DE102008024551A1 (de) 2008-05-21 2009-11-26 Tesa Se Verfahren zur Verkapselung von optoelektronischen Bauteilen
US7976750B2 (en) 2008-05-21 2011-07-12 Tesa Se Method of encapsulating optoelectronic components
NL2001727C2 (nl) * 2008-06-26 2009-12-29 Eurotron B V Werkwijze voor het vervaardigen van een zonnepaneel, alsmede halffabrikaat daarvoor.
EP2139050A3 (fr) * 2008-06-26 2010-02-17 Eurotron B.V. Procédé de production d'un panneau solaire et semi-produit
EP2275471A1 (fr) 2009-06-18 2011-01-19 Ems-Patent Ag Monofeuille dorsale de module photovoltaïque, son procédé de fabrication et son utilisation dans la production de modules photovoltaïques
EP2275471B2 (fr) † 2009-06-18 2015-12-09 Ems-Patent Ag Monofeuille dorsale de module photovoltaïque, son procédé de fabrication et son utilisation dans la production de modules photovoltaïques
NL2003936C2 (nl) * 2009-12-10 2011-06-14 Eurotron B V Werkwijze en inrichting voor het vervaardigen van zonnepaneel onder gebruikmaking van een drager.
EP3422421A1 (fr) * 2009-12-10 2019-01-02 Eurotron B.V. Procédé et dispositif de fabrication d'un panneau solaire à l'aide d'un support
WO2011071373A1 (fr) * 2009-12-10 2011-06-16 Eurotron B.V. Procédé et dispositif de production d'un panneau solaire à l'aide d'un support
US8753915B2 (en) 2009-12-10 2014-06-17 Eurotron B.V. Method and device for producing a solar panel using a carrier
DE102010015740A1 (de) 2010-04-21 2011-10-27 Mühlbauer Ag Verfahren und Vorrichtung zur Herstellung eines Solarmoduls und ein Solarmodul mit flexiblen Dünnschicht-Solarzellen
WO2011131345A1 (fr) 2010-04-21 2011-10-27 Muehlbauer Ag Procédé et dispositif de fabrication d'un module solaire comprenant des cellules solaires en couches minces souples et module solaire comprenant des cellules solaires en couches minces souples
WO2011131346A2 (fr) 2010-04-21 2011-10-27 Muehlbauer Ag Procédé et dispositif de fabrication d'un module solaire comprenant des cellules solaires en couches minces souples et module solaire comprenant des cellules solaires en couches minces souples
US8796064B2 (en) 2010-04-21 2014-08-05 Muehlbauer Ag Method and device for producing a solar module comprising flexible thin-film solar cells, and solar module comprising flexible thin-film solar cells
EP2422976A1 (fr) 2010-07-30 2012-02-29 Ems-Patent Ag Feuille arrière multicouche pour module photovoltaïque ainsi que sa fabrication et son utilisation dans la production de modules photovoltaïques
WO2012088098A3 (fr) * 2010-12-20 2013-05-16 Solar Machines Incorporated Encapsulation monocellule et architecture de module a format adaptable pour la production d'énergie photovoltaïque et leur procédé de construction
WO2013124438A2 (fr) 2012-02-22 2013-08-29 Muehlbauer Ag Procédé et dispositif de production d'un module solaire et module solaire muni de cellules solaires flexibles à couche mince
DE102012003455A1 (de) 2012-02-22 2013-08-22 Mühlbauer Ag Verfahren und Vorrichtung zur Herstellung eines Solarmoduls und ein Solarmodul mit flexiblen Dünnschicht-Solarzellen
US20150075604A1 (en) * 2012-03-21 2015-03-19 Sharp Kabushiki Kaisha Thin-film compound photovoltaic cell and method for manufacturing same
WO2015168075A1 (fr) 2014-04-29 2015-11-05 E. I. Du Pont De Nemours And Company Cellules photovoltaïques dotées d'une feuille de support améliorée
WO2015168068A1 (fr) 2014-04-29 2015-11-05 E. I. Du Pont De Nemours And Company Cellules photovoltaïques à feuille arrière multicouche améliorée
WO2015168073A1 (fr) 2014-04-29 2015-11-05 E. I. Du Pont De Nemours And Company Modules de cellule solaire présentant une feuille support améliorée
US9978898B2 (en) 2014-04-29 2018-05-22 E. I. Du Pont De Nemours And Company Photovoltaic cells with improved multilayer backsheet
US10597533B2 (en) 2014-04-29 2020-03-24 Performance Materials Na, Inc. Solar cell modules with improved backsheet

Similar Documents

Publication Publication Date Title
WO1994022172A1 (fr) Panneaux solaires et procede de fabrication correspondant
US6239352B1 (en) Substrate and collector grid structures for electrically interconnecting photovoltaic arrays and process of manufacture of such arrays
TWI390747B (zh) 使用單石模組組合技術製造的光伏打模組
CN1082727C (zh) 太阳能电池组件及其制造方法
JP2014502033A (ja) 太陽電池の相互接続、そのモジュール、パネル及び方法
US5973258A (en) Photovoltaic device
EP2020688B1 (fr) Connection entre cellules solaires dans un module utilisant le bonding par thermo-compression et un tel module
US8110737B2 (en) Collector grid, electrode structures and interrconnect structures for photovoltaic arrays and methods of manufacture
US8222513B2 (en) Collector grid, electrode structures and interconnect structures for photovoltaic arrays and methods of manufacture
KR101476478B1 (ko) 태양 전지 모듈의 제조 방법
WO2020187792A1 (fr) Procédé de fabrication de module photovoltaïque
EP0860886A2 (fr) Module de cellules solaires
EP0877427A2 (fr) Module de cellules solaires et méthode de fabrication
WO1996009650A1 (fr) Systeme de collecte de courant pour cellules photovoltaiques
WO2009078936A2 (fr) Dispositifs photovoltaïques protégés contre l'environnement
US9306103B2 (en) Back contact photovoltaic module with integrated circuitry
IL278537B1 (en) A flexible and lightweight photovoltaic module that includes a front layer made of polymer and a back layer made of composite material
EP4111588A1 (fr) Dispositif photovoltaïque hybride comportant des segments plans rigides et des segments flexibles non plans
KR102019310B1 (ko) 태양 전지 모듈 및 그의 제조 방법
US20160181969A1 (en) Photovoltaic Power Farm Structure and Installation
US11043606B2 (en) Solar cell edge interconnects
JPH06510631A (ja) 改良された太陽電池の積層装置
CN102386334A (zh) 一种太阳能电池光伏建筑组件及制造方法
EP2735378A1 (fr) Procédé de fabrication d'un module solaire avec agent d'encapsulation et appareil pour l'effectuer
US20210367088A1 (en) Photovoltaic building element

Legal Events

Date Code Title Description
AK Designated states

Kind code of ref document: A1

Designated state(s): JP

AL Designated countries for regional patents

Kind code of ref document: A1

Designated state(s): AT BE CH DE DK ES FR GB GR IE IT LU MC NL PT SE

DFPE Request for preliminary examination filed prior to expiration of 19th month from priority date (pct application filed before 20040101)
121 Ep: the epo has been informed by wipo that ep was designated in this application
122 Ep: pct application non-entry in european phase