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WO2017032377A1 - A method for manufacturing a solar cell panel and a solar cell panel manufactured using such a method - Google Patents

A method for manufacturing a solar cell panel and a solar cell panel manufactured using such a method Download PDF

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Publication number
WO2017032377A1
WO2017032377A1 PCT/DK2016/050276 DK2016050276W WO2017032377A1 WO 2017032377 A1 WO2017032377 A1 WO 2017032377A1 DK 2016050276 W DK2016050276 W DK 2016050276W WO 2017032377 A1 WO2017032377 A1 WO 2017032377A1
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WO
WIPO (PCT)
Prior art keywords
casting material
solar cell
transparent
cell panel
front plate
Prior art date
Application number
PCT/DK2016/050276
Other languages
French (fr)
Inventor
Jan Mahler
Original Assignee
Axmetic-Engineering V/ Jan Mahler
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Filing date
Publication date
Application filed by Axmetic-Engineering V/ Jan Mahler filed Critical Axmetic-Engineering V/ Jan Mahler
Publication of WO2017032377A1 publication Critical patent/WO2017032377A1/en

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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
    • H10F19/80—Encapsulations or containers for integrated devices, or assemblies of multiple devices, having photovoltaic cells
    • H—ELECTRICITY
    • H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
    • H02S—GENERATION OF ELECTRIC POWER BY CONVERSION OF INFRARED RADIATION, VISIBLE LIGHT OR ULTRAVIOLET LIGHT, e.g. USING PHOTOVOLTAIC [PV] MODULES
    • H02S40/00—Components or accessories in combination with PV modules, not provided for in groups H02S10/00 - H02S30/00
    • H02S40/40—Thermal components
    • H02S40/42—Cooling means
    • H—ELECTRICITY
    • H10—SEMICONDUCTOR DEVICES; ELECTRIC SOLID-STATE DEVICES NOT OTHERWISE PROVIDED FOR
    • H10F—INORGANIC SEMICONDUCTOR DEVICES SENSITIVE TO INFRARED RADIATION, LIGHT, ELECTROMAGNETIC RADIATION OF SHORTER WAVELENGTH OR CORPUSCULAR RADIATION
    • H10F77/00—Constructional details of devices covered by this subclass
    • H10F77/40—Optical elements or arrangements
    • H10F77/42—Optical elements or arrangements directly associated or integrated with photovoltaic cells, e.g. light-reflecting means or light-concentrating means
    • H10F77/45—Wavelength conversion means, e.g. by using luminescent material, fluorescent concentrators or up-conversion arrangements
    • H—ELECTRICITY
    • H10—SEMICONDUCTOR DEVICES; ELECTRIC SOLID-STATE DEVICES NOT OTHERWISE PROVIDED FOR
    • H10F—INORGANIC SEMICONDUCTOR DEVICES SENSITIVE TO INFRARED RADIATION, LIGHT, ELECTROMAGNETIC RADIATION OF SHORTER WAVELENGTH OR CORPUSCULAR RADIATION
    • H10F77/00—Constructional details of devices covered by this subclass
    • H10F77/40—Optical elements or arrangements
    • H10F77/42—Optical elements or arrangements directly associated or integrated with photovoltaic cells, e.g. light-reflecting means or light-concentrating means
    • H10F77/484—Refractive light-concentrating means, e.g. lenses
    • H—ELECTRICITY
    • H10—SEMICONDUCTOR DEVICES; ELECTRIC SOLID-STATE DEVICES NOT OTHERWISE PROVIDED FOR
    • H10F—INORGANIC SEMICONDUCTOR DEVICES SENSITIVE TO INFRARED RADIATION, LIGHT, ELECTROMAGNETIC RADIATION OF SHORTER WAVELENGTH OR CORPUSCULAR RADIATION
    • H10F77/00—Constructional details of devices covered by this subclass
    • H10F77/60—Arrangements for cooling, heating, ventilating or compensating for temperature fluctuations
    • H10F77/63—Arrangements for cooling directly associated or integrated with photovoltaic cells, e.g. heat sinks directly associated with the photovoltaic cells or integrated Peltier elements for active cooling
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
    • Y02E—REDUCTION OF GREENHOUSE GAS [GHG] EMISSIONS, RELATED TO ENERGY GENERATION, TRANSMISSION OR DISTRIBUTION
    • Y02E10/00—Energy generation through renewable energy sources
    • Y02E10/50—Photovoltaic [PV] energy
    • Y02E10/52—PV systems with concentrators

Definitions

  • the present invention relates to a method for manufacturing a solar ceil panel for producing electrical power from sunlight and to a solar cell panel manufactured using such a method, Background of the invention
  • a solar ceil panel is a photovoltaic component for direct generation of electrical power from sunlight. Key factors in cost-efficient generation of solar power are the efficiency of the solar cells used and the production costs and the life expectancy of the solar cell panels.
  • the typical conventional solar cell panel is composed of a front side made of glass, interconnected soldered solar ceils, an embedding material and a rear side structure.
  • the individual layers of the solar module fulfil the functions described more fully below.
  • the glass front side serves as a protection against mechanical and atmospheric influences. It must exhibit maximum possible transparency in order to minimize, as much as possible, absorption losses in the optical spectral region from 300 nm to 1150 nm because such absorption losses are the direct cause of effi ciency losses of the silicon solar cells conventionally used for power generation.
  • hardened white glass with a thickness of 3 or 4 mm and a low iron content having a transmittance in the visible spectral region from 400 nm to 1.150 nm amounting to 90-91.5 % is used.
  • the reflective loss is typically between 8 and 14 %. Unfortunately, the loss in the region from 300 nm to 400 nm is very high because the radiation at these wavelengths is filtered by the glass.
  • the embedding material serves as the adhesive for the whole module composite.
  • EVA ethylene vinyl acetate
  • EVA melts during a lamination operation at a temperature of about 150 °C, flows into the gaps between the soldered solar cells and is thermally cross-linked. The formation of air bubbles, which lead to reflection losses, is prevented by lamination under vacuum.
  • the rear side protects the solar cells and the embedding material against humidity and oxygen. In addition, it serves as a mechanical protection against scratching, etc., during assembly of the solar cell panel and as electrical insulation.
  • the rear side structure may be made of either glass or, more commonly, a composite film. In general, the variants PVF-PET-PVF or PVF-aluminium-PVF are used. (PVF is an
  • the encapsulation materials used in solar cell panel construction should exhibit good barrier properties against water vapour and oxygen.
  • the solar 20 cells themselves are not attacked by water vapour or oxygen, corrosion of the metal contacts and chemical degradation of the E VA embedding material may take place, A single broken solar cell contact typically results in a complete failure of the module, since normally all the solar cells in a module are electrically interconnected in series.
  • a degradation of the EVA manifests itself in a yellowing of the module, combined with a corresponding reduction in power production due to reduced light absorption and a visual deterioration.
  • solar cell panels In order to achieve competitive production costs for solar power despite the relatively high capital costs, solar cell panels must achieve long operating times. Present-day solar cell panels are therefore designed for a service life of 20 to 30 years. In addition to high stability under atmospheric conditions, there are major requirements for the thermal endurance of the modules, whose temperature during operation may vary cyclically between +80 °C in full sunlight and temperatures below zero. Solar cell panels are subject to comprehensive stability tests (standard tests to IEC 1215), which include atmospheric tests (UV irradiation, damp heat, temperature change), hail tests and high voltage insulation tests.
  • the solar cell panel construction accounts for about 30 % of the overall costs and, thus, represents a relatively high proportion of the production costs for solar ceil panels.
  • This large share of the module manufacture is mainly caused by high material costs (hail-proof 3-4 mm thick iron free front glass, multi-layer film on rear side) and by long process times, i.e. low productivity.
  • the individual layers of the module composite as described above are still assembled and aligned manually.
  • the relatively slow melting of the EVA hot melt adhesive and the lamination of the module composite at approx. 150 °C under vacuum lead to production cycle times of 20-30 minutes per module.
  • the present invention relates to a method for manufacturing a solar cell panel, which method comprises the steps of casting a front plate of the solar cell panel from a first transparent casting material, and using the rear side of the casted front plate as an open mould, into which mould solar cells, cooling fins and electric
  • interconnections are arranged and embedded using a second transparent casting material, thus forming a rear plate of the solar cell panel embedded with the front plate thereof.
  • the method further comprises, before the step of using the casted front plate as an open mould, a step of casting an reinforcement frame for the solar ceil panel from the first transparent casting material, which reinforcement frame is subsequently glued onto the rear side of the front plate along the edges thereof for forming a peripheral wall of the open mould,
  • the reinforcement frame is glued onto the rear side of the front plate using a layer of the second transparent casting material.
  • the layer of the second transparent casting material used as glue is less than 0.5 mm, preferably approximately 0. 1 mm.
  • the casted front plate comprises an reinforcement frame arranged on its rear side along the edges thereof, the reinforcement frame forming a peripheral wall of the open mould.
  • the step of using the casted front plate as an open mould is initiated by covering the rear side of the front plate with a layer of the second casting material.
  • the layer of the second transparent casting material covering the rear side of the front plate is less than 0.5 mm, preferably approximately 0.1 mm.
  • a plurality of solar cells, cooling fins and electric interconnections are placed within the reinforcement frame in the layer of the second transparent casting material and are subsequently covered by a layer of the second transparent casting material, after which the second transparent casting material, now embedding the solar cells, the cooling fins and the connection elements, is hardened.
  • the deposition of the solar cells can take place directly on the rear side of the front plate.
  • the solar cells and the electric interconnections are embedded in and thereby fixed inside the second transparent casting material, it is possible to use solar cells 15 with a thickness of down to 0.12-0.14 mm rather than the normally used thickness of 0.2-0,5 mm, whereby costs and weight can be reduced and a higher efficiency can be obtained.
  • the solar cells have a thickness of 0.165 mm.
  • the cooling fins are mounted onto the solar cells by- means of a heat-conducting paste.
  • the electric interconnections comprises a plurality of copper strips.
  • stiffening ribs 30 and/or fastening elements are placed within the reinforcement frame before the covering layer of the second transparent casting material is added.
  • additional fixing and/or reinforcing elements can, for instance, be formed as recesses, grooves or depressions in the rear side of the front plate for the 5 pl acement, fixing and securing of the sol ar cells and interconnections/cooling
  • one or more of the cooling fins also form
  • one or more of the cooling fins also act as stiffening ribs.
  • the necessary electric connections within the solar cell panel are formed using laser welding through the transparent material.
  • the polyurea/polyurethane hybrid polymer is optically open, it will not block any light, neither the laser.
  • the laser welding is performed using a ring laser welding principle.
  • a preferred process for making the connections is a ring laser welding principle known as SHADOW laser welding. Stepless High Speed Accurate and Discrete One Pulse Welding makes it possible to laser weld, for instance, cobber and silver together.
  • electrical connectors for the solar cell panel are mounted in threaded bores, which are made through the reinforcement frame after the embedding of the solar cells, cooling fins and electric interconnections.
  • an array of multiplier lenses are embedded in the front side panel during the casting thereof.
  • the solar cell panel has an array of sunlight concentrating multiplier lenses on the front side. This increases the efficiency of the solar ceils.
  • the array of lenses has a much larger surface area compared to a flat glass plate.
  • the surface of the lenses are increased up to 71 % more than the surface of a
  • the multiplier lenses are provided with anti- reflection nanostructures.
  • the front plate and/or the rear plate of the solar cell panel are curved in two directions.
  • the first and/or the second casting material comprise nanoparticies that are able to convert ultraviolet light into visible light.
  • the second transparent casting material is softer than the first transparent casting material at normal room temperatures.
  • the first transparent casting material and/or the second transparent casting material are transparent polyurea/poiyurethane hybrid polymers comprising two types of resin, the first resin being a prepolymer of an aliphatic diisocyanate and an amine-terminated poly ether polyol, the second resin being a mixture of compounds containing isocyanate-reactive groups.
  • transparent polyurea/polyurethane hybrid polymer describes a polyurea/polyurethane hybrid polymer, which exhibits a transmission of 91 % or more at wavelengths in the range between 360 nm and 1150 nm. Such a hybrid polymer is advantageous compared to polyurea, which is not transparent, and to polyurethane, which can be transparent but is not optically open for ultraviolet light.
  • polyurea/polyurethane hybrid polymer Compared to glass, polyurea/polyurethane hybrid polymer has the advantage of simpler mechanical workability and simple formability during the production process. This makes it relatively easy to texture the surface, thereby increasing light absorption through surfaces turned obliquely towards the light and, hence, increasing the efficiency of the solar cell panels.
  • the mechanical stability of the module is ensured both by the rear side and by the front side.
  • the main requirement for the front side of the solar cell panel is a high transparency in the visible, ultraviolet and infrared spectral region with wavelengths from 300 nm to about 1500 nm, especially from 320 nm to 1150 nm, in order to guarantee a high photoelectric efficiency of the solar cells.
  • the front and rear sides of the module must both exhibit a generally high stability under atmospheric conditions (e.g., under UV radiation) and protect the embedded solar cells against corrosion by suitable barrier properties (e.g., against water vapour and oxygen).
  • a polyurea/polyurethane hybrid polymer offers high stability under atmospheric conditions, it has the advantage of low material costs, it has a low density and hence a low weight and it has a rapid process ability (approximately 2 minutes) at temperatures as low as about 100 °C. Furthermore, the material is impact-resistant.
  • the first transparent casting material and the second transparent casting material are transparent polyurea/polyurethane hybrid polymers comprising the same two types of resin, only in different mixture proportions.
  • the first transparent casting material is composed of between 70 % and 80 % of the first type of resin and between 20 % and 30 % of the second type of resin, corresponding to a mixture ratio of between 2.33 and 4.00.
  • the second transparent casting material is composed of between 45 % and 55 % of each of the two types of resin,
  • Fig. la illustrates a perspective view of solar cell panel according to an embodiment of the invention as seen from the front side with an enlarged detail view of a part thereof
  • Fig. lb illustrates a perspective view of the same embodiment of the invention as shown in Fig. la as seen from the rear side, also with an enlarged detail view of a part thereof,
  • FIG. 2a illustrates a plane view of the same embodiment of the invention as shown in Figs, a and b as seen from the rear side,
  • Fig. 2 b illustrates a plane view of the same embodiment of the invention as shown in Figs, la and lb as seen from the front side,
  • Fig. 3a is similar to Fig. 2b with the exception that section lines C-C and D-D have been added,
  • Fig. 3b illustrates a cross-section of the solar cell panel along the section line C-C 15 in Fig. 3a with an enlarged detail view of a part thereof
  • Fig. 4a illustrates another cross-section of the same solar cell panel along the section line D-D in Fig. 3a with an enlarged detail view of a part thereof
  • FIG. 4b illustrates the same cross-section as Fig. 4a with an enlarged detail view of another part thereof
  • Fig. 5 illustrates an exploded view of the same embodiment of the solar cell panel as shown in the previous figures.
  • Figs, l a and l b illustrate schematically a preferred embodiment of the invention as seen from the front side and the rear side, respectively. Both of the figures comprise 30 an enlargement of a part thereof In the shown embodiment, the front plate 3
  • Figs. 2a and 2b are side views of the same embodiment of the invention as seen from the rear side and the front side, respectively.
  • Fig. 3a is similar to Fig. 2b with the exception that two section lines (C-C and D-D) are indicated.
  • Fig. 3b is a cross-sectional view along section line C-C of the preferred embodiment of the solar cell panel illustrated in Fig. 3a with an enlarged part thereof.
  • Fig. 4a is a cross-sectional view along section line D-D of the embodiment shown in Fig. 3a, i.e. in a direction perpendicular to the section line C-C used in Fig. 3b, Also Fig. 4a comprises an enlarged part, showing in more detail some of the same elements as Fig. 3b. Fig. 4b illustrates the same cross-section as Fig. 4a, only with an enlarged detail view of another part thereof.
  • the enlarged part of Fig, 4b schematically illustrates the working principle of the multiplier micro lenses 10 and of the quantum dots 3 used in the illustrated embodiment
  • the arrow 1 1 illustrates an incoming ray of sunshine, i.e. a sunbeam.
  • the casting process embeds an array of multiplier micro lenses 10 within the front plate 3.
  • These multiplier micro lenses 10 "amplify" the sunlight by a factor of 2.2 to 2.5. In short, more light is "caught” because the surface is much larger.
  • the rays 1 1 reach the surface of the solar cell panel, a part of the rays 11 are reflected in the surface layer and never reach the solar cells 8.
  • Multiplier micro lenses 10 minimise this problem.
  • the use of multiplier micro lenses 10 can increase the surface area irradiated by the sun by approximately 71 % compared to a flat glass plate.
  • the multiplier micro lenses 0 also causes the solar cell panel to be less sensitive to the incoming angle of the solar radiation. Tests show that the solar cell panel can be placed in an angle compared to the horizontal plane from 5° to 75° and still produce electricity at full efficiency. Existing solar cell panels typically only produce at full efficiency when the angle is between 25° to 45° depending of the time of the year and the physical location in the world. This results in a 50 % increase in electrical production during a day compared to existing technology.
  • the efficiency of the solar cell panel can be increased through so-called
  • incoming rays 11 are deflected by the multiplier micro lenses 10 and are thereby reinforced 12 and reach the solar ceils 8 at a better angle with higher efficiency.
  • ® Light in the ultraviolet or infrared range 17 are dissipated by quantum dots 13 and emitted in a different frequency spectrum, i.e. in another wavelength range, in which solar cells 8 are more reactive.
  • quantum dots 13 When passing the quantum dots 13, ultraviolet sunbeams 17 are shifted to sunbeams 18 with lower energy, while infrared sunbeams 17 are shifted to sunbeams 18 with higher energy.
  • Fig. 5 is an exploded view of a preferred embodiment of the solar cell panel illustrating, apart from the elements shown in the previous figures, different interconnections 2, 7, 16, for instance for the minus pole 2 and for the plus pole 7.
  • the solar cell panel according to the present invention can be produced using the following method:
  • a mixture of a transparent polyurea/polyurethane hybrid polymer is placed in a mould to form the transparent front plate 3 of the panel with the multiplier micro lenses 10 and, optionally, recesses on the rear side thereof for placement of solar cells 8 and electrical connections 2, 7, 9, 16.
  • Another softer mixture of resin is placed on the rear side of the front plate 3, which now acts as a cavity of an open mould.
  • the solar cells 8 are positioned in the mould in such a way that the optically active side faces the hollow of the mould.
  • the rear side is covered with a softer version of the transparent polyurea/polyurethane hybrid polymer with a longer hardening time.
  • a low-pressure or pressure-less casting method is used in order to secure that the fragile soiar cells 8 are not destroyed.
  • the initial components of the reaction system should be devolatilized prior to fabrication.
  • pronounced flow deflections and large pressure jumps are to be avoided during the introduction of the reaction system into the mould. If there are blisters or bobbies in the mixtures, they are removed with gas flames. The gas flame will remove any oxygen from the rear side and "suck" bobbles away.
  • the solar cell panels can be produced by a process, in which the transparent polyurea/polyurethane hybrid polymer rear plate is replaced by a transparent polyurethane compound.
  • the electrical connections are made, preferably by laser welding the interconnections 2, 7, 16 to the solar cells 8. Because the
  • polyurea/polyurethane hybrid polymer is optically open, it will not block any light, neither the laser light used for the welding. 1. Rear plate of solar cell panel

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  • Photovoltaic Devices (AREA)

Abstract

A method for manufacturing a solar cell panel is disclosed, which method comprises the steps of casting a front plate (3) of the solar cell panel from a first transparent casting material, and using the rear side of the casted front plate as an open mould, into which mould solar cells (8), cooling fins (15) and electric interconnections (4, 7, 9, 16) are arranged and embedded using a second transparent casting material, thus forming a rear plate (1) of the solar cell panel embedded with the front plate thereof. Furthermore, a solar cell panel manufactured using such a method is disclosed.

Description

A METHOD FOR MANUFACTURING A SOLAR CELL PANEL
AND A SOLAR CELL PANEL MANUFACTURED USING SUCH A METHOD
Field of the Invention
The present invention relates to a method for manufacturing a solar ceil panel for producing electrical power from sunlight and to a solar cell panel manufactured using such a method, Background of the invention
A solar ceil panel is a photovoltaic component for direct generation of electrical power from sunlight. Key factors in cost-efficient generation of solar power are the efficiency of the solar cells used and the production costs and the life expectancy of the solar cell panels.
The typical conventional solar cell panel is composed of a front side made of glass, interconnected soldered solar ceils, an embedding material and a rear side structure. The individual layers of the solar module fulfil the functions described more fully below.
The glass front side serves as a protection against mechanical and atmospheric influences. It must exhibit maximum possible transparency in order to minimize, as much as possible, absorption losses in the optical spectral region from 300 nm to 1150 nm because such absorption losses are the direct cause of effi ciency losses of the silicon solar cells conventionally used for power generation. Normally, hardened white glass with a thickness of 3 or 4 mm and a low iron content having a transmittance in the visible spectral region from 400 nm to 1.150 nm amounting to 90-91.5 % is used. The reflective loss is typically between 8 and 14 %. Unfortunately, the loss in the region from 300 nm to 400 nm is very high because the radiation at these wavelengths is filtered by the glass.
The embedding material serves as the adhesive for the whole module composite. 5 Generally, EVA (ethylene vinyl acetate) films are used for this purpose. EVA melts during a lamination operation at a temperature of about 150 °C, flows into the gaps between the soldered solar cells and is thermally cross-linked. The formation of air bubbles, which lead to reflection losses, is prevented by lamination under vacuum.
10 The rear side protects the solar cells and the embedding material against humidity and oxygen. In addition, it serves as a mechanical protection against scratching, etc., during assembly of the solar cell panel and as electrical insulation. The rear side structure may be made of either glass or, more commonly, a composite film. In general, the variants PVF-PET-PVF or PVF-aluminium-PVF are used. (PVF is an
15 abbreviation of polyvinyl fluoride and PET is an abbreviation of polyethylene
terephthalate.)
In particular, the encapsulation materials used in solar cell panel construction should exhibit good barrier properties against water vapour and oxygen. Although the solar 20 cells themselves are not attacked by water vapour or oxygen, corrosion of the metal contacts and chemical degradation of the E VA embedding material may take place, A single broken solar cell contact typically results in a complete failure of the module, since normally all the solar cells in a module are electrically interconnected in series.
? 5
A degradation of the EVA manifests itself in a yellowing of the module, combined with a corresponding reduction in power production due to reduced light absorption and a visual deterioration. Today, about 80 % of all solar cell panels are encapsulated on the rear side with one of the composite films described above, and in about 15 % 30 of solar cell panels, glass is used for the front and rear sides. Where a composite film or glass is used for both the front and rear sides, highly transparent casting resins are sometimes used as embedding materials instead of EVA. These highly transparent casting resins cure slowly (over several hours) during production.
In order to achieve competitive production costs for solar power despite the relatively high capital costs, solar cell panels must achieve long operating times. Present-day solar cell panels are therefore designed for a service life of 20 to 30 years. In addition to high stability under atmospheric conditions, there are major requirements for the thermal endurance of the modules, whose temperature during operation may vary cyclically between +80 °C in full sunlight and temperatures below zero. Solar cell panels are subject to comprehensive stability tests (standard tests to IEC 1215), which include atmospheric tests (UV irradiation, damp heat, temperature change), hail tests and high voltage insulation tests.
The solar cell panel construction accounts for about 30 % of the overall costs and, thus, represents a relatively high proportion of the production costs for solar ceil panels. This large share of the module manufacture is mainly caused by high material costs (hail-proof 3-4 mm thick iron free front glass, multi-layer film on rear side) and by long process times, i.e. low productivity. In many cases, the individual layers of the module composite as described above are still assembled and aligned manually. In addition, the relatively slow melting of the EVA hot melt adhesive and the lamination of the module composite at approx. 150 °C under vacuum lead to production cycle times of 20-30 minutes per module.
Due to the relatively thick front glass pane (typically 3.2-4 mm), conventional solar cell panels have a high weight, which makes stable and expensive frames and holding structures necessary. The heat dissipation problem has also not been solved satisfactorily in present-day solar cell panels. Under full sunlight, the modules heat up to a temperature of 80 °C, which leads to a temperature-induced deterioration of the solar cell efficiency and, in the final analysis, to an increase in the price of solar power. Various attempts to reduce the module production costs by using cheaper (i .e. first and foremost, more rapid) production methods have not proven successful to date. In the US patents Nos. 4,830,038 and 5,008,062, rapid foaming around the module rear side of thin-film solar cell panels with poiyurethane foams by the RIM (Reaction Injection Moulding) method is described. Such thin-film solar cells are deposited (e.g. by chemical gas phase deposition) directly onto the rear side of the front glass of the solar module, thereby eliminating the need for an embedding material between the front- and rear sides of the module. Currently, however, only about 10% of all solar cells are manufactured by thin-film technology. The predominant types of solar cells are based on the technology of crystalline silicon wafers. In US patent application No. 2002/0148496 Al, a method of making a solar ceil module with a front side of transparent poiyurethane by the RIM process and an opaque rear side that could be made of different materials is described. Until now, this method has not yet hit the marked due to high material cost of the chosen poiyurethane and because of the difficulties handling the solar cells in the mould.
Brief description of the invention
It is an object of the present invention to provide a method for producing lightweight, impact-resistant solar cell panels, which can be produced by a fully automated method and capture more light. Furthermore, it is an object to provide solar cell panels, which are able to produce more power during a day due to less angle sensitivity. As it will be apparent to one skilled in the art, these and other objects are achieved by the present invention, which relates to a method for manufacturing a solar cell panel, which method comprises the steps of casting a front plate of the solar cell panel from a first transparent casting material, and using the rear side of the casted front plate as an open mould, into which mould solar cells, cooling fins and electric
interconnections are arranged and embedded using a second transparent casting material, thus forming a rear plate of the solar cell panel embedded with the front plate thereof.
In an embodiment of the invention, the method further comprises, before the step of using the casted front plate as an open mould, a step of casting an reinforcement frame for the solar ceil panel from the first transparent casting material, which reinforcement frame is subsequently glued onto the rear side of the front plate along the edges thereof for forming a peripheral wall of the open mould, In an embodiment of the invention, the reinforcement frame is glued onto the rear side of the front plate using a layer of the second transparent casting material.
In an embodiment of the invention, the layer of the second transparent casting material used as glue is less than 0.5 mm, preferably approximately 0. 1 mm.
In an embodiment of the invention, the casted front plate comprises an reinforcement frame arranged on its rear side along the edges thereof, the reinforcement frame forming a peripheral wall of the open mould. In an embodiment of the invention, the step of using the casted front plate as an open mould is initiated by covering the rear side of the front plate with a layer of the second casting material.
In an embodiment of the invention, the layer of the second transparent casting material covering the rear side of the front plate is less than 0.5 mm, preferably approximately 0.1 mm.
In an embodiment of the invention, a plurality of solar cells, cooling fins and electric interconnections are placed within the reinforcement frame in the layer of the second transparent casting material and are subsequently covered by a layer of the second transparent casting material, after which the second transparent casting material, now embedding the solar cells, the cooling fins and the connection elements, is hardened.
Both wafer-type solar cells and thin-film solar cells as well as other types of solar 5 cells, which may be developed in the future, can be used in the solar cell panel of the present invention.
If thin-film solar cells are used, the deposition of the solar cells can take place directly on the rear side of the front plate. The thin-film solar cells on such a
10 substrate are then embedded completely in the second transparent casting material, which ensures protection against mechanical effects and atmospheric influences.
Because the solar cells and the electric interconnections are embedded in and thereby fixed inside the second transparent casting material, it is possible to use solar cells 15 with a thickness of down to 0.12-0.14 mm rather than the normally used thickness of 0.2-0,5 mm, whereby costs and weight can be reduced and a higher efficiency can be obtained. In a preferred embodiment, the solar cells have a thickness of 0.165 mm.
In an embodiment of the invention, before being placed in the layer of the second 20 transparent casting material, the cooling fins are mounted onto the solar cells by- means of a heat-conducting paste.
Efficient cooling of the solar modules leads in general, to an increase in the solar cell efficiency.
? 5
In an embodiment of the invention, the electric interconnections comprises a plurality of copper strips.
In an embodiment of the invention, also light wave switch technology, stiffening ribs 30 and/or fastening elements are placed within the reinforcement frame before the covering layer of the second transparent casting material is added.
Alternatively, additional fixing and/or reinforcing elements can, for instance, be formed as recesses, grooves or depressions in the rear side of the front plate for the 5 pl acement, fixing and securing of the sol ar cells and interconnections/cooling
elements. The use of such additional elements has a mechanically stabilizing function of the solar cell panel already during the casting process.
In an embodiment of the invention, one or more of the cooling fins also form
10 electrical connections between the solar cells.
In an embodiment of the invention, one or more of the cooling fins also act as stiffening ribs.
15 In an embodiment of the invention, after the embedding of the solar cells, cooling fins and electric interconnections into the second transparent casting material, the necessary electric connections within the solar cell panel are formed using laser welding through the transparent material.
20 Because the polyurea/polyurethane hybrid polymer is optically open, it will not block any light, neither the laser.
In an embodiment of the invention, the laser welding is performed using a ring laser welding principle.
? 5
A preferred process for making the connections is a ring laser welding principle known as SHADOW laser welding. Stepless High Speed Accurate and Discrete One Pulse Welding makes it possible to laser weld, for instance, cobber and silver together. In an embodiment of the invention, electrical connectors for the solar cell panel are mounted in threaded bores, which are made through the reinforcement frame after the embedding of the solar cells, cooling fins and electric interconnections. In an embodiment of the invention, an array of multiplier lenses are embedded in the front side panel during the casting thereof.
Preferably, the solar cell panel has an array of sunlight concentrating multiplier lenses on the front side. This increases the efficiency of the solar ceils. The array of lenses has a much larger surface area compared to a flat glass plate. Preferably, the surface of the lenses are increased up to 71 % more than the surface of a
corresponding flat plate. This increases the amount of sunlight captured during a day and ensures 100 % capacity of the solar cell panel at a much longer time of the day. In an embodiment of the invention, the multiplier lenses are provided with anti- reflection nanostructures.
In an embodiment of the invention, the front plate and/or the rear plate of the solar cell panel are curved in two directions.
In an embodiment of the invention, the first and/or the second casting material comprise nanoparticies that are able to convert ultraviolet light into visible light.
In an embodiment of the invention, the second transparent casting material is softer than the first transparent casting material at normal room temperatures.
In an embodiment of the invention, the first transparent casting material and/or the second transparent casting material are transparent polyurea/poiyurethane hybrid polymers comprising two types of resin, the first resin being a prepolymer of an aliphatic diisocyanate and an amine-terminated poly ether polyol, the second resin being a mixture of compounds containing isocyanate-reactive groups. As used herein, the term "transparent polyurea/polyurethane hybrid polymer" describes a polyurea/polyurethane hybrid polymer, which exhibits a transmission of 91 % or more at wavelengths in the range between 360 nm and 1150 nm. Such a hybrid polymer is advantageous compared to polyurea, which is not transparent, and to polyurethane, which can be transparent but is not optically open for ultraviolet light.
Compared to glass, polyurea/polyurethane hybrid polymer has the advantage of simpler mechanical workability and simple formability during the production process. This makes it relatively easy to texture the surface, thereby increasing light absorption through surfaces turned obliquely towards the light and, hence, increasing the efficiency of the solar cell panels. The mechanical stability of the module is ensured both by the rear side and by the front side. The main requirement for the front side of the solar cell panel is a high transparency in the visible, ultraviolet and infrared spectral region with wavelengths from 300 nm to about 1500 nm, especially from 320 nm to 1150 nm, in order to guarantee a high photoelectric efficiency of the solar cells. The front and rear sides of the module must both exhibit a generally high stability under atmospheric conditions (e.g., under UV radiation) and protect the embedded solar cells against corrosion by suitable barrier properties (e.g., against water vapour and oxygen).
In comparison with materials currently used in solar ceil panel constructions, a polyurea/polyurethane hybrid polymer offers high stability under atmospheric conditions, it has the advantage of low material costs, it has a low density and hence a low weight and it has a rapid process ability (approximately 2 minutes) at temperatures as low as about 100 °C. Furthermore, the material is impact-resistant. In an embodiment of the invention, the first transparent casting material and the second transparent casting material are transparent polyurea/polyurethane hybrid polymers comprising the same two types of resin, only in different mixture proportions.
Significant factors affecting the long-term stability of solar cell panels are thermal stress due to changing temperatures and differing coefficients of expansion of the materials used. The stress resulting from these factors is capable of delaminating or even destroying the module composite. This kind of problems can be removed or at least significantly reduced by using the same type of material for the production of the front plate and the rear plate of the solar panel.
In an embodiment of the invention, the first transparent casting material is composed of between 70 % and 80 % of the first type of resin and between 20 % and 30 % of the second type of resin, corresponding to a mixture ratio of between 2.33 and 4.00. In an embodiment of the invention, the second transparent casting material is composed of between 45 % and 55 % of each of the two types of resin,
corresponding to a mixture ratio of between 0.82 and 1.22,
In an aspect of the invention, it relates to a solar cell panel manufactured using the above-described method.
Figures
A few exemplar}- embodiments of the invention are described in the following with references to the figures, of which
Fig. la illustrates a perspective view of solar cell panel according to an embodiment of the invention as seen from the front side with an enlarged detail view of a part thereof, Fig. lb illustrates a perspective view of the same embodiment of the invention as shown in Fig. la as seen from the rear side, also with an enlarged detail view of a part thereof,
5 Fig. 2a illustrates a plane view of the same embodiment of the invention as shown in Figs, a and b as seen from the rear side,
Fig. 2 b illustrates a plane view of the same embodiment of the invention as shown in Figs, la and lb as seen from the front side,
10
Fig. 3a is similar to Fig. 2b with the exception that section lines C-C and D-D have been added,
Fig. 3b illustrates a cross-section of the solar cell panel along the section line C-C 15 in Fig. 3a with an enlarged detail view of a part thereof,
Fig. 4a illustrates another cross-section of the same solar cell panel along the section line D-D in Fig. 3a with an enlarged detail view of a part thereof,
20 Fig. 4b illustrates the same cross-section as Fig. 4a with an enlarged detail view of another part thereof, and
Fig. 5 illustrates an exploded view of the same embodiment of the solar cell panel as shown in the previous figures.
? 5
Detailed description of the invention
Figs, l a and l b illustrate schematically a preferred embodiment of the invention as seen from the front side and the rear side, respectively. Both of the figures comprise 30 an enlargement of a part thereof In the shown embodiment, the front plate 3
comprises 5,625 multiplier micro lenses 10 and the rear plate 1 comprises a grid of cooling fins 15, Electric connectors 5, 6 are arranged in the reinforcement frame, which forms a part of the front piate 3.
Figs. 2a and 2b are side views of the same embodiment of the invention as seen from the rear side and the front side, respectively.
Fig. 3a is similar to Fig. 2b with the exception that two section lines (C-C and D-D) are indicated. Fig. 3b is a cross-sectional view along section line C-C of the preferred embodiment of the solar cell panel illustrated in Fig. 3a with an enlarged part thereof.
In the enlarged part of Fig. 3b, it is seen more clearly how the multiplier micro lenses 10 form part of the front plate 3 and how the solar cells 8 and electric connections 9 are integrated in an interconnection plate 4 with cooling fins 15 in the rear plate 1. Fig. 4a is a cross-sectional view along section line D-D of the embodiment shown in Fig. 3a, i.e. in a direction perpendicular to the section line C-C used in Fig. 3b, Also Fig. 4a comprises an enlarged part, showing in more detail some of the same elements as Fig. 3b. Fig. 4b illustrates the same cross-section as Fig. 4a, only with an enlarged detail view of another part thereof. The enlarged part of Fig, 4b schematically illustrates the working principle of the multiplier micro lenses 10 and of the quantum dots 3 used in the illustrated embodiment, The arrow 1 1 illustrates an incoming ray of sunshine, i.e. a sunbeam. The casting process embeds an array of multiplier micro lenses 10 within the front plate 3. These multiplier micro lenses 10 "amplify" the sunlight by a factor of 2.2 to 2.5. In short, more light is "caught" because the surface is much larger. When the rays 1 1 reach the surface of the solar cell panel, a part of the rays 11 are reflected in the surface layer and never reach the solar cells 8. Multiplier micro lenses 10 minimise this problem. In fact, the use of multiplier micro lenses 10 can increase the surface area irradiated by the sun by approximately 71 % compared to a flat glass plate.
The multiplier micro lenses 0 also causes the solar cell panel to be less sensitive to the incoming angle of the solar radiation. Tests show that the solar cell panel can be placed in an angle compared to the horizontal plane from 5° to 75° and still produce electricity at full efficiency. Existing solar cell panels typically only produce at full efficiency when the angle is between 25° to 45° depending of the time of the year and the physical location in the world. This results in a 50 % increase in electrical production during a day compared to existing technology.
When the sunlight is contracted on a mono or polycrystalline solar cell 8, the power generated is substantially proportional with the square of the light concentration. A power increase from 5.33 W per solar cell using 4 mm glass to 14.61 W per solar cell using a polyurea/polyurethane hybrid polymer has been obtained.
The efficiency of the solar cell panel can be increased through so-called
downconversion, in which a photon with high energy is dissipated by a nanoparticle, a so-called quantum dot 13 , The quantum dot 13 then emits two photons of lower energy to be recorded by the soiar cell 8.
A similar method is called downshifting, which works in much the same way. Here, however, only one photon is emitted and therefore the yield of this method is less than what is obtained using downconversion.
Fig 4b illustrate this schematically:
• Some ultraviolet or infrared sunbeams 19 reach the solar cells 8 directly.
* Other incoming rays 11 are deflected by the multiplier micro lenses 10 and are thereby reinforced 12 and reach the solar ceils 8 at a better angle with higher efficiency. ® Light in the ultraviolet or infrared range 17 are dissipated by quantum dots 13 and emitted in a different frequency spectrum, i.e. in another wavelength range, in which solar cells 8 are more reactive. When passing the quantum dots 13, ultraviolet sunbeams 17 are shifted to sunbeams 18 with lower energy, while infrared sunbeams 17 are shifted to sunbeams 18 with higher energy.
This technology is easily implemented in the present invention, since the quantum dots 13 can easily be mixed with the chemicals when creating the polymer. Since the quantum dots 13 are placed in front of the solar cells 8, some of the shifted photons will be diverted in directions away from the solar ceils 8. This problem, however, is minimised by the multiplier micro lenses 10.
The use of this technology allows for an increase in the efficiency of at least up to 10-12 % and further causes the UVA degradation of the solar cells 8 and the transparent casting materials to be minimized. In addition, the heat impact is lower, since the light energy is converted to electrical power rather than being allocated as heat losses in the solar cells 8. Fig. 5 is an exploded view of a preferred embodiment of the solar cell panel illustrating, apart from the elements shown in the previous figures, different interconnections 2, 7, 16, for instance for the minus pole 2 and for the plus pole 7.
The solar cell panel according to the present invention can be produced using the following method:
A mixture of a transparent polyurea/polyurethane hybrid polymer is placed in a mould to form the transparent front plate 3 of the panel with the multiplier micro lenses 10 and, optionally, recesses on the rear side thereof for placement of solar cells 8 and electrical connections 2, 7, 9, 16. After hardening (approximately 2 min. process time) another softer mixture of resin is placed on the rear side of the front plate 3, which now acts as a cavity of an open mould. The solar cells 8 are positioned in the mould in such a way that the optically active side faces the hollow of the mould. Then the rear side is covered with a softer version of the transparent polyurea/polyurethane hybrid polymer with a longer hardening time.
A low-pressure or pressure-less casting method is used in order to secure that the fragile soiar cells 8 are not destroyed. In order to obtain a blister-free soiar cell cover, the initial components of the reaction system should be devolatilized prior to fabrication. In addition, pronounced flow deflections and large pressure jumps are to be avoided during the introduction of the reaction system into the mould. If there are blisters or bobbies in the mixtures, they are removed with gas flames. The gas flame will remove any oxygen from the rear side and "suck" bobbles away.
In a further embodiment of the present invention, the solar cell panels can be produced by a process, in which the transparent polyurea/polyurethane hybrid polymer rear plate is replaced by a transparent polyurethane compound.
Because the solar cell is integrated in the same material there will only be one optical phase loss due to the change in material. At this time no electrical connections are made.
After the hardening process, the electrical connections are made, preferably by laser welding the interconnections 2, 7, 16 to the solar cells 8. Because the
polyurea/polyurethane hybrid polymer is optically open, it will not block any light, neither the laser light used for the welding. 1. Rear plate of solar cell panel
Δ. Interconnection for minus pole
3. Front plate with micro lenses
4. Interconnection plate with cooling fins
5, Electric connector minus
6, Electric connector plus
7. Interconnection for plus pole
8. Solar cell
9. Connection for connectors
10. Multiplier Micro Lens
11. Incoming ray of sunshine
12. Reinforced sunbeam with better angle
13. Quantum dot
15. Cooling fin
16. Interconnection
17. Ultra violet or infrared sunbeam dissipatt id by quantum dot
18. Shifted sunbeam with lower or higher energy
19. Ultra violet or infrared sunbeam with din set transfer to the ceil

Claims

Claims
1 , A method for manufacturing a solar cell panel, which method comprises the following steps: casting a front plate (3) of the solar cell panel from a first transparent casting material, and using the rear side of the casted front plate as an open mould, into which mould solar cells (8), cooling fins (15) and electric interconnections (4, 7, 9,
16) are arranged and embedded using a second transparent casting material, thus forming a rear plate (1 ) of the solar cell panel embedded with the front plate thereof.
2. The method according to claim 1 further comprising, before the step of using the casted front plate as an open mould, a step of casting an reinforcement frame for the solar cell panel from the first transparent casting material, which reinforcement frame is subsequently glued onto the rear side of the front plate along the edges thereof for forming a peripheral wall of the open mould.
3 , The method according to claim 2, wherein the reinforcement frame is glued onto the rear side of the front plate using a layer of the second transparent casting material,
4. The method according to claim 3, wherein the layer of the second transparent casting material used as glue is less than 0.5 mm, preferably approximately 0.1 mm.
5. The method according to claim 1, wherein the casted front plate comprises an reinforcement frame arranged on its rear side along the edges thereof, the reinforcement frame forming a peripheral wall of the open mould.
6. The method according to any of the preceding claims, wherein the step of using the casted front plate as an open mould is initiated by covering the rear side of the front plate with a layer of the second casting material,
7. The method according to claim 6, wherein the layer of the second transparent casting material covering the rear side of the front plate is less than 0.5 mm, preferably approximately 0, 1 mm,
8. The method according to claim 6 or 7, wherein a plurality of solar cells (8), cooling fins (15) and electric interconnections (4, 7, 9, 16) are placed within the reinforcement frame in the layer of the second transparent casting material and are subsequently covered by a layer of the second transparent casting material, after which the second transparent casting material, now embedding the solar cells, the cooling fins and the connection elements, is hardened.
9, The method according to claim 8, wherein, before being placed in the layer of the second transparent casting material, the cooling fins are mounted onto the solar cells by means of a heat-conducting paste.
10. The method according to claim 8 or 9, wherein the electric interconnections (4,
7, 9, 16) comprises a plurality of copper strips,
1 1. The method according to any of claims 8-10, wherein also light wave switch technology, stiffening ribs and/or fastening elements are placed within the reinforcement frame before the covering layer of the second transparent casting material is added.
12. The method according to any of claims 8-11 , wherein one or more of the cooling fins also form electrical connections between the solar ceils,
13. The method according to any of claims 8-12, wherein one or more of the cooling fins also act as stiffening ribs.
14. The method according to any of the preceding claims, wherein, after the
5 embedding of the solar cells, cooling fins and electric interconnections into the
second transparent casting material, the necessary electric connections within the solar cell panel are formed using laser welding through the transparent material.
15. The method according to claim 14, wherein the laser welding is performed using 10 a ring laser welding principle.
16. The method according to any of the preceding claims, wherein electrical connectors (5, 6) for the solar cell panel are mounted in threaded bores, which are made through the reinforcement frame after the embedding of the solar cells, cooling
15 fins and electric interconnections.
17. The method according to any of the preceding claims, wherein an array of multiplier lenses are embedded in the front side panel during the casting thereof.
20 18. The method according to claim 17, wherein the multiplier lenses are provided with anti-reflection nanostructures.
19. The method according to any of the preceding claims, wherein the front plate and/or the rear plate of the solar cell panel are curved in two directions.
? 5
20. The method according to any of the preceding claims, wherein the first and/or the second casting material comprise nanoparticles that are able to convert ultraviolet light into visible light.
21 . The method according to any of the preceding claims, wherein the second transparent casting material is softer than the first transparent casting material at normal room temperatures.
5 22. The method according to any of the preceding claims, wherein the first
transparent casting material and/or the second transparent casting material are transparent polyurea/polyurethane hybrid polymers comprising two types of resin, the first resin being a prepolymer of an aliphatic diisocyanate and an amine- terminated polyether polyol, the second resin being a mixture of compounds 10 containing i socy anate-reacti ve groups .
23. The method according to claim 22, wherein the first transparent casting material and the second transparent casting material are transparent polyurea/polyurethane hybrid polymers comprising the same two types of resin, only in different mixture
15 proportions.
24. The method according to claim 22 or 23, wherein the first transparent casting material is composed of between 70 % and 80 % of the first type of resin and between 20 % and 30 % of the second type of resin, corresponding to a mixture ratio
20 of between 2.33 and 4.00.
25. The method according to any of claims 22-24, wherein the second transparent casting material is composed of between 45 % and 55 % of each of the two types of resin, corresponding to a mixture ratio of between 0.82 and 1.22.
? 5
26. A solar cell panel manufactured using the method according to any of the preceding claims.
PCT/DK2016/050276 2015-08-27 2016-08-18 A method for manufacturing a solar cell panel and a solar cell panel manufactured using such a method WO2017032377A1 (en)

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