CN104395081A - Improved photovoltaic modules for use in vehicle roofs, and/or methods of making the same - Google Patents
Improved photovoltaic modules for use in vehicle roofs, and/or methods of making the same Download PDFInfo
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- CN104395081A CN104395081A CN201380032069.6A CN201380032069A CN104395081A CN 104395081 A CN104395081 A CN 104395081A CN 201380032069 A CN201380032069 A CN 201380032069A CN 104395081 A CN104395081 A CN 104395081A
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- module
- hole
- solar cell
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- glass
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Classifications
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B17/00—Layered products essentially comprising sheet glass, or glass, slag, or like fibres
- B32B17/06—Layered products essentially comprising sheet glass, or glass, slag, or like fibres comprising glass as the main or only constituent of a layer, next to another layer of a specific material
- B32B17/10—Layered products essentially comprising sheet glass, or glass, slag, or like fibres comprising glass as the main or only constituent of a layer, next to another layer of a specific material of synthetic resin
- B32B17/10005—Layered products essentially comprising sheet glass, or glass, slag, or like fibres comprising glass as the main or only constituent of a layer, next to another layer of a specific material of synthetic resin laminated safety glass or glazing
- B32B17/10009—Layered products essentially comprising sheet glass, or glass, slag, or like fibres comprising glass as the main or only constituent of a layer, next to another layer of a specific material of synthetic resin laminated safety glass or glazing characterized by the number, the constitution or treatment of glass sheets
- B32B17/10036—Layered products essentially comprising sheet glass, or glass, slag, or like fibres comprising glass as the main or only constituent of a layer, next to another layer of a specific material of synthetic resin laminated safety glass or glazing characterized by the number, the constitution or treatment of glass sheets comprising two outer glass sheets
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B17/00—Layered products essentially comprising sheet glass, or glass, slag, or like fibres
- B32B17/06—Layered products essentially comprising sheet glass, or glass, slag, or like fibres comprising glass as the main or only constituent of a layer, next to another layer of a specific material
- B32B17/10—Layered products essentially comprising sheet glass, or glass, slag, or like fibres comprising glass as the main or only constituent of a layer, next to another layer of a specific material of synthetic resin
- B32B17/10005—Layered products essentially comprising sheet glass, or glass, slag, or like fibres comprising glass as the main or only constituent of a layer, next to another layer of a specific material of synthetic resin laminated safety glass or glazing
- B32B17/10009—Layered products essentially comprising sheet glass, or glass, slag, or like fibres comprising glass as the main or only constituent of a layer, next to another layer of a specific material of synthetic resin laminated safety glass or glazing characterized by the number, the constitution or treatment of glass sheets
- B32B17/10082—Properties of the bulk of a glass sheet
- B32B17/1011—Properties of the bulk of a glass sheet having predetermined tint or excitation purity
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B17/00—Layered products essentially comprising sheet glass, or glass, slag, or like fibres
- B32B17/06—Layered products essentially comprising sheet glass, or glass, slag, or like fibres comprising glass as the main or only constituent of a layer, next to another layer of a specific material
- B32B17/10—Layered products essentially comprising sheet glass, or glass, slag, or like fibres comprising glass as the main or only constituent of a layer, next to another layer of a specific material of synthetic resin
- B32B17/10005—Layered products essentially comprising sheet glass, or glass, slag, or like fibres comprising glass as the main or only constituent of a layer, next to another layer of a specific material of synthetic resin laminated safety glass or glazing
- B32B17/1055—Layered products essentially comprising sheet glass, or glass, slag, or like fibres comprising glass as the main or only constituent of a layer, next to another layer of a specific material of synthetic resin laminated safety glass or glazing characterized by the resin layer, i.e. interlayer
- B32B17/10761—Layered products essentially comprising sheet glass, or glass, slag, or like fibres comprising glass as the main or only constituent of a layer, next to another layer of a specific material of synthetic resin laminated safety glass or glazing characterized by the resin layer, i.e. interlayer containing vinyl acetal
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B17/00—Layered products essentially comprising sheet glass, or glass, slag, or like fibres
- B32B17/06—Layered products essentially comprising sheet glass, or glass, slag, or like fibres comprising glass as the main or only constituent of a layer, next to another layer of a specific material
- B32B17/10—Layered products essentially comprising sheet glass, or glass, slag, or like fibres comprising glass as the main or only constituent of a layer, next to another layer of a specific material of synthetic resin
- B32B17/10005—Layered products essentially comprising sheet glass, or glass, slag, or like fibres comprising glass as the main or only constituent of a layer, next to another layer of a specific material of synthetic resin laminated safety glass or glazing
- B32B17/1055—Layered products essentially comprising sheet glass, or glass, slag, or like fibres comprising glass as the main or only constituent of a layer, next to another layer of a specific material of synthetic resin laminated safety glass or glazing characterized by the resin layer, i.e. interlayer
- B32B17/10788—Layered products essentially comprising sheet glass, or glass, slag, or like fibres comprising glass as the main or only constituent of a layer, next to another layer of a specific material of synthetic resin laminated safety glass or glazing characterized by the resin layer, i.e. interlayer containing ethylene vinylacetate
-
- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01L—SEMICONDUCTOR DEVICES NOT COVERED BY CLASS H10
- H01L31/00—Semiconductor devices sensitive to infrared radiation, light, electromagnetic radiation of shorter wavelength or corpuscular radiation and specially adapted either for the conversion of the energy of such radiation into electrical energy or for the control of electrical energy by such radiation; Processes or apparatus specially adapted for the manufacture or treatment thereof or of parts thereof; Details thereof
- H01L31/02—Details
- H01L31/02002—Arrangements for conducting electric current to or from the device in operations
- H01L31/02005—Arrangements for conducting electric current to or from the device in operations for device characterised by at least one potential jump barrier or surface barrier
- H01L31/02008—Arrangements for conducting electric current to or from the device in operations for device characterised by at least one potential jump barrier or surface barrier for solar cells or solar cell modules
- H01L31/02013—Arrangements for conducting electric current to or from the device in operations for device characterised by at least one potential jump barrier or surface barrier for solar cells or solar cell modules comprising output lead wires elements
-
- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01L—SEMICONDUCTOR DEVICES NOT COVERED BY CLASS H10
- H01L31/00—Semiconductor devices sensitive to infrared radiation, light, electromagnetic radiation of shorter wavelength or corpuscular radiation and specially adapted either for the conversion of the energy of such radiation into electrical energy or for the control of electrical energy by such radiation; Processes or apparatus specially adapted for the manufacture or treatment thereof or of parts thereof; Details thereof
- H01L31/04—Semiconductor devices sensitive to infrared radiation, light, electromagnetic radiation of shorter wavelength or corpuscular radiation and specially adapted either for the conversion of the energy of such radiation into electrical energy or for the control of electrical energy by such radiation; Processes or apparatus specially adapted for the manufacture or treatment thereof or of parts thereof; Details thereof adapted as photovoltaic [PV] conversion devices
- H01L31/042—PV modules or arrays of single PV cells
- H01L31/048—Encapsulation of modules
- H01L31/0488—Double glass encapsulation, e.g. photovoltaic cells arranged between front and rear glass sheets
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B2457/00—Electrical equipment
- B32B2457/12—Photovoltaic modules
-
- 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
- Y02E10/541—CuInSe2 material PV cells
Abstract
Certain example embodiments relate to techniques for creating improved photovoltaic (PV) modules. In certain example embodiments and first and second glass substrate are provided. A PV array is provided between the first and second glass substrates. The first and second substrates are laminated together with the PV array between the glass substrates. In certain example embodiments the PV module is dimensioned to be similar to an existing roof system (e.g., a sunroof) in a vehicle. In certain example embodiments, holes are provided in a PV module sandwiched between two substrates, the holes being shaped and arranged within the PV module so as to allow light transmission into the vehicle at desired level while still being substantially filled by the laminate or adhesive material used to secure the PV module to the two surrounding substrates.
Description
The application is the U. S. application No.12/926 submitted on October 22nd, 2010, and the part of 058 continues (CIP), and its full content is included into herein as a reference.
The technical field of invention
Exemplary embodiment of the present invention relates to a kind of advanced photovoltaic (PV) module for roof, and/or prepares its method.Particularly, exemplary embodiment of the present invention relates to a kind of PV module for automobile, amusement, boats and ships and/or other vehicles.In the exemplary embodiment, configure hole being sandwiched in the PV module between two substrates, described hole is formed and arranges and puts in PV module, thus makes light enter in vehicle with desired level transmission, and fully insert lamination or jointing material, be used for PV module to be fixed in two substrates of surrounding.
Background of invention and exemplary embodiment general introduction
Photovoltaic (PV) device is known technology (such as, U.S. patent documents Nos.2004/0261841,2006/0180200,2008/0308147; 6,784,361,6,288,325,6,613,603, and 6,123,824, its full content is included into herein as a reference).
The use of many current PV devices is only limitted to relatively-stationary position, such as, on the top being positioned at house or as the part in larger power station.In fact, in some cases, skyscraper is covered effectively by PV battery.In recent years, studying and PV device is being mounted on moveable device, such as automobile or boats and ships.One of them focus be PV device to be mounted on roof and/or car skylight on.In addition, can add solar energy roof, such as, when car is parked in the sun in hot summer, car can run ventilating system.
In exemplary conventional process, as a part for whole manufacture and/or assembling process, the glass for skylight can be installed in vehicle.The size and dimension in skylight can be designed, to meet the bassinet structure and design specification that are provided with skylight.Such as, according to the specification of vehicular manufacturer and/or the shape of car and structure, the skylight of car can be bent or flatten.
Although the design aspect in skylight may be done before general assembly, vehicular manufacturer still needs amendment master-plan to hold skylight.Such as, as everyone knows, as " built-in " structure of car, the interpolation in skylight may require to reduce available whole clear height in compartment.In addition, in some cases, in order to hold skylight, roof may need to be modified (such as, when skylight is positioned at enable possition).Change on bassinet structure may increase the complexity of cost and manufacture sometimes.
Usually, equipment is used for the PV device of means of transport (such as, as skylight annex) the smooth or bending safety glass adding monolithic may be related to, and smooth business PV device is directly attached to or is arranged on (such as, inside skylight) after safety glass.But, this conventional method for PV device being attached to skylight still has problems, such as, add the difficult point in skylight to relate to: assembly not necessarily " is applicable to ", form any necessity or required electrical connection, the size of PV module and/or shape carry out with skylight and/or roof mating, maintain needed for roof structure integrality.
It should be noted that and PV device is added into the gross weight that traditional glass sunroof may increase vehicle.Because weight PV device is connected to vehicle window increases may affect the performance of vehicle.Thus, potential effect interests in PV skylight are provided may to be offseted because the interpolation of PV device makes car weight amount increase.In addition, the overall center of gravity of car may be increased at the additional weight of roof.It may cause safety problem (danger of such as, toppling is larger).
In addition, as mentioned above, because the words do not revised not necessarily " are applicable to ", therefore, the main body revising car may will be needed in the PV device integration newly installed to the structure of car.Such as, when vehicle window is for time open, traditional skylight may be applicable to inserting roof.But when adding PV device, its thickness increased may hinder amended skylight to be contracted in the main body of roof.
Vehicular manufacturer makes skylight and PV device integrate with by design roof and makes up the problems referred to above.But this solution may produce more problem.Such as, the complexity of cost and manufacture may be increased for the additional modifications of vehicle main body.In addition, the main body amendment may carrying out adding for two kinds of structures of existing at least car (such as, a tool skylight and do not have).Further, the PV thickness of detector of interpolation may reduce available clear height in compartment.
In addition, the supplier of PV device may not be general skylight supplier, and the interpolation of PV device may need to increase more installation step and whole manufacture process is more complicated.Be not only between erecting stage and install skylight, vehicular manufacturer may need first to install skylight and then install PV device.It should be noted that this conventional PV installs and may require recombination assembly line.
Installing after sale of PV device may produce additional problem or complexity.For the vehicle manufactured, when PV device (corresponding thickness) is added into vehicle window, market may be needed to customize, comprise roof that structuring is very expensive again.
Therefore, constantly research is a kind of for roof, skylight and/or similar advanced PV technology.In addition, the art needs PV module and the similar products of a kind of advanced person, such as, can effectively install together with the skylight in car or replace the skylight in car.
In the exemplary embodiment, the method for a kind of integrated photovoltaic for the preparation of vehicle (PV) module is provided.There is provided the first low iron glass substrate, described first substrate has the thickness of about 1.5-3.5mm.Second glass substrate is substantially parallel with described first substrate, and described second substrate has the thickness of about 1.5-3.5mm.PV array is configured between the first type surface and the first type surface of the second glass substrate of the first glass substrate.First and second substrates and the PV array layer between it are forced together.According to the size that preset, shape and the weight relevant to vehicle roof, formulate the size of described PV module, shape and Weight structure.
In the exemplary embodiment, a kind of method preparing the integrated PV module of vehicle roof is provided.There is provided first glass substrate with the first thickness, the second glass substrate is substantially parallel with described first substrate and have the second thickness.Compared with described first substrate, described second substrate has higher iron content and lower transmission of visible light.Solar battery group can be inserted between the first and second glass substrates.Described first and second glass substrates are laminated together with solar battery group wherein.
According to exemplary embodiment, provide a kind of method preparing vehicle.The above-mentioned integrated PV module provided is mounted in vehicle.Vehicle can be automobile, truck, tractor, ship, aircraft etc.
In the exemplary embodiment, a kind of integrated PV module being used for replacing existing skylight is provided.The thickness of the first glass substrate is 1.5-3.5mm.Second glass substrate is substantially parallel with described first substrate, and compares the first substrate and have higher iron content and lower transmission of visible light.Solar battery group based on CIGS is configured between the first type surface of the first glass substrate and the first type surface of the second glass substrate, and thin-film solar cells group has connected electrical lead.Described first and second substrates are laminated on together by PVB.Solar battery group is sealed between described first and second substrates by PVB, and electrical lead extends through PVB and passes integrated PV module.Integrated PV module is structurally similar to existing skylight by sizing.
In the exemplary embodiment, PV is battery laminated may provide security and sense of hearing benefit between two glass substrates and two laminated materials.Alternatively, or in addition, the PV module of lamination protects PV battery by UV filter, similar mechanical protection.
In the exemplary embodiment, use CIGS thin film PV battery flexibly that PV module can be made similar or identical with the curvature of the roof assembly of other vehicles or the vehicles to a certain extent in lamination.
In the exemplary embodiment, integrated PV module similarly can be generally used for the top glass of vehicle.Difference is that this PV module contains the electrical connection for PV battery, and the PV battery of PV module can produce the electric power for Vehicular system.
In the exemplary embodiment, comprise glass substrate, PV battery can be similar to the normal glass roof assembly of vehicle in weight with the PV module of lamination.Further, for passenger and vehicle, replace normal glass roof assembly with integrated PV module and security and efficiency benefits can be provided.
In the exemplary embodiment, a kind of method preparing integrated photovoltaic (PV) module of vehicle is provided.First and second glass substrates are provided; There is provided PV module, described PV module has multiple through hole be formed at wherein; Described first and second glass substrates and described PV module layer are wherein forced together.Wherein, during described lamination, due to the size of described through hole, shape and layout, laminated material is by the described multiple through hole at least inserted in described PV module.Described through hole has the selected gross area jointly, thus makes the transmission of visible light through described integrated PV module at least reach selected desired value.
In the exemplary embodiment, provide a kind of method preparing vehicle, integrated photovoltaic (PV) module prepared by said method is provided, and described integrated PV module is mounted in described vehicle.
In the exemplary embodiment, one is provided to prepare the method for photovoltaic (PV) module.Substrate is provided, is formed with multiple solar cell above; Configure latticed conductive material on the substrate; Multiple through hole is formed in described substrate, its pattern is that (a) described through hole has the selected gross area jointly, thus the desired value making the transmission of visible light through integrated PV module reach described PV module to be set up, and (b) described through hole has aspect ratio and location, the laminated material being enough to make to use in the described integrated PV module of preparation flows into wherein, and inserts described through hole.
In the exemplary embodiment, a kind of integrated photovoltaic PV module for vehicle is provided, comprises: the first and second glass substrates; PV module, comprises multiple solar cell separated, and has multiple through hole be formed at wherein, and described PV module is inserted between described first and second glass substrates; With multiple poly-line, to be formed on described substrate and between adjacent solar cell.Wherein, described PV module is laminated to described first and second substrates, and due to the size of described through hole, shape and layout, laminated material is received in the described multiple through hole in described PV module.Described through hole has the selected gross area jointly, thus makes the transmission of visible light through described integrated PV module reach selected desired value.
Feature described herein, aspect, advantage and exemplary embodiment can combine with any suitable combination or sub-portfolio, realize further embodiment.
Brief Description Of Drawings
Below, illustrate in greater detail exemplary embodiment with reference to accompanying drawing, the feature of above and other and advantage will better be understood more completely.
Fig. 1 is the cross-sectional view of the exemplary photovoltaic device illustrated according to an exemplary embodiment;
Fig. 2 a is the cross-sectional view of the composition of the prototype PV module illustrated according to an exemplary embodiment;
Fig. 2 b is the cross-sectional view of the composition of the exemplary PV layer illustrated according to an exemplary embodiment;
Fig. 3 be illustrate according to the bonding of an exemplary embodiment after the cross-sectional view of prototype PV module;
Fig. 4 a is the cross-sectional view of the glass substrate of the exemplary formation illustrated according to an exemplary embodiment;
Fig. 4 b is the cross-sectional view of the glass substrate of the exemplary formation illustrated according to an exemplary embodiment;
Fig. 5 is the cross-sectional view of the prototype PV module illustrated according to an exemplary embodiment;
Fig. 6 a illustrates that, according to an exemplary embodiment, PV module is by the exemplary plane be mounted in roof;
Fig. 6 b, 6c and 6d are the planes of the exemplary geometry of the PV module illustrated according to exemplary embodiment;
Fig. 6 e is the upward view of the prototype PV module illustrated according to exemplary embodiment;
Fig. 7 is the flow chart of the PV module process illustrated for the preparation of top;
Fig. 8 a illustrates according to exemplary embodiment, the schematic cross-sectional view of the assembly in the hole of tool appropriate size before lamination;
Fig. 8 b illustrates in exemplary enforcement, the schematic cross-sectional view of the change that Fig. 8 a embodiment occurs in lamination cycle;
Fig. 9 a be lamination is shown before the schematic cross-sectional view of assembly of opening of the inappropriate size of tool;
Fig. 9 b is the exemplary plot of the consequence of the opening of the inappropriate size illustrated with lamination Fig. 9 a;
Figure 10 a is the top view of the PV module in the hole of the tool appropriate size illustrated according to an exemplary embodiment;
Figure 10 b is the top view of the more general PV module in the hole of the tool appropriate size illustrated according to an exemplary embodiment;
Figure 11 is the chart that aspect ratio and element thickness in the lamination for the success and failure in exemplary rectangular hole are shown;
Figure 12 is the flow chart of the PV module process in the hole of the tool appropriate size for the preparation of vehicle illustrated according to an exemplary embodiment.
Illustrating of exemplary embodiment of the present
Exemplary embodiment relates to a kind of PV module, comprises two glass substrates; Configuration PV layer in-between; And adhesive, glass substrate is bonded in together with PV layer in an integrated PV module.
PV device can be various ways.A field of PV device is thin-film solar cells (TFSC).Such as, TFSC device comprises CIGS (Cu (In, Ga) (Se, S)
2) and CIS (CuInSe
2) solar cell.
From front side or light incident side order backward, the photovoltaic device of CIGS and CIS type can comprise: the front substrate of similar glass material; The front electrode of the transparency conducting layer (such as, transparent conductive oxide) containing similar TCO; Light absorption semiconductive thin film (such as, CIGS and/or CIS film); Back electrode; With the meron of similar glass material.In some cases, between front substrate and front electrode, provide adhesive, and also possible configuration Window layer (such as, be made up of CdS, ZnO or comprise above-mentioned element etc.).Normal light passes front electrode from front side (or the front substrate) incidence of photovoltaic device, and is absorbed by light absorption semiconductive thin film known in the art thus produce photovoltaic electric power.
Layer in TFSC device can be between several millimicrons to several microns.But, be to go wrong TFSC being mounted to use in PV.First, may be harmful at the material (such as, indium, gallium, cadmium) for TFSC battery.Further, some TFSC elements may affect external environment on the contrary.Such as, when exposed to humidity, the element in CIGS may be degenerated, and may cause reduce service life and/or efficiency of solar cell minimizing.Therefore, need one to make TFSC battery exempt to be affected by the external environment, and make the method that external environment (such as, people) affects from TFSC battery.
Be described in detail referring now to accompanying drawing, identical symbol represents identical parts.Fig. 1 comprises transparent front glass substrate 1, selective bonding film 2, the front conductive electrode 3 of single or multiple lift, active semiconductor film 5 containing one or more semiconductor layer (such as CIGS, CIS etc.), the back electrode/reflector 10 of conduction and rear glass substrate 11.In different embodiment of the present invention, the light incident surface 5a of semiconductive thin film 5 can have texture or a texture of not having.Preferably back electrode 10 continuously or basic continous ground through the whole part of glass substrate 11 or essential part, and in some cases, it can be patterned according to required design (such as, strip).Selective bonding film 2 can be comprise based on electric insulating copolymer and/or the sealant containing this polymer, or the adhesive of the material such as similar ethyl vinyl acetate (EVA), polyvinyl butyral resin (PVB).In the exemplary embodiment, the adhesive layer 2 based on polymer has the refractive index (n) of about 1.8-2.2, is more preferably about 1.9-2.1, and such as about 2.0, when being used for during glass after structure uses strengthening internal reflection.Certainly, other layers of non-diagram also can be provided in the devices.Such as, also alternative provides buffering and/or Window layer.
The metal of similar Mo (molybdenum), can be used as photovoltaic device such as CIS solar cell back electrode (afterwards contact) 10.In some cases, Mo can be sputtered after the sodium or sodium calcium silicon being deposited into photovoltaic device on glass substrate 11.Preferably, back electrode (such as, Mo back electrode) 10 has low stress, high conductivity for meron (such as, glass substrate) 11, and good adhesion.In an exemplary embodiment of the present invention, in order to provide this associativity feature, being deposited on the starting stage on substrate 11 at back electrode, oxygen being introduced in the back electrode 10 based on Mo.The back electrode 10 be applied to by oxygen based on Mo can reduce the total stress of back electrode, and improves the adhesiveness of back electrode 10 for soda-lime glass or soda-lime glass substrate 11 simultaneously.But, at some in the splash coating device of width designed by the larger substrate of more than a meter, due to active gases (such as, oxygen) and sputter gas (such as, Ar) pumping speed different between, the well-balanced property of oxygen sometimes in more difficult control last back electrode film.In the embodiment in figure 1, based on the back electrode (may oxidized classification) of Mo by the planar support of meron 11.But in other exemplary embodiments, back electrode can be formed on the grain surface of meron 11.
Fig. 2 a is the cross-sectional view of the composition of the prototype PV module illustrated according to an exemplary embodiment.The PV module 100 with the first glass substrate 102 can be provided, the second glass substrate 108 be configured the downside (such as, sun impact is to the opposite side of PV module 100) of PV module 100.In addition, between the first glass substrate 102 and the second glass substrate 108, more than one functional PV layer 106 is configured.Such as, in the exemplary embodiment, functional PV layer 106 can be supported by the second substrate 108.Can use first and second laminated material 104a, 104b by the first substrate 102 and the second substrate 108 laminated together.Thus, front substrate 1 in Fig. 1 can be the outside substrate 102 in Fig. 2, rear glass substrate 11 then in Fig. 1 can be the second substrate 108 in Fig. 2, and selective adhesive layer 2 can be the first laminated material 104a in Fig. 4, and the functional PV layer 106 in Fig. 2 can comprise the layer 2,3,5,10 in Fig. 1.But, different from the exemplary configuration of Fig. 1, the second laminated material 104b can be provided.In the exemplary embodiment, PV layer 106 can comprise the PV layer (such as, layer 2,3,5 and/or 10) of configuration (such as deposit) on the film of similar thin stainless steel foil or electroconductive polymer coating.Also other substrates and/or material can be used in other embodiments of the invention.
Fig. 2 b is the cross-sectional view of the composition of the exemplary PV layer illustrated according to an exemplary embodiment.PV layer 106 can comprise PV material 114 (such as, CIGS), is configured on substrate 112.Such as, substrate can be stainless steel foil.In the exemplary embodiment, the width of PV layer 106 can be below 1mm, is more preferably below 0.7mm, and is sometimes about 0.5mm.
Laminated material 104a, 104b can be used to the first and second glass substrates 102,108 laminated together, and encapsulate PV layer 106.Laminated material 104a, 104b can be that the similar polyvinyl butyral resin (PVB) of 0.38-0.76mm or the material of ethyl vinyl acetate (EVA) are formed by thickness.In the exemplary embodiment, ultraviolet curing polyurethane liquid also can be used as laminated material.This lamination is done by routine techniques, such as, based on heating and/or pressure lamination, be exposed to ultraviolet radiation (such as, UV curing materials) etc.In the exemplary embodiment, PV layer 106 is clipped in PV can be made to have more flexibility between first and second laminated material 104a, 104b and/or to be applicable to being inserted into various different size and/or shape skylight between substrate and outer substrate.In other embodiments of the invention, first and second laminated material 104a, 104b can be identical or different laminated materials.
PV layer 106 can comprise PV cell arrangements, and it is connected to each other by conductive copper tape.In the exemplary embodiment, PV unit can be singly connect solar cell.Alternatively, PV unit also can be solar cell that is multiple or series connection.The electrical connection of PV unit by conductive adhesive, solder, other etc. come.Two or more ribbon lead 110 can stretch out from one or more edges of PV module 100, such as, be connected with required application (such as, equipment, the deep cycle battery array for storing, the driving battery etc. for hybrid power or electric vehicle of energy grid, similar fan or air-conditioning).Should be understood that in other exemplary embodiments, can be that a ribbon lead extends from PV module.In other exemplary embodiments, also can be two ribbon leads extends along the edge of PV module from a bit.
The thickness of glass substrate can be 1.5-3.5mm, but, the special applications of PV module can be considered for the thickness of glass substrate 102,108 and PV module 100, weight and durability option and different.Such as, the PV module be arranged on sailing boat compares the higher durability of the needs be arranged on car skylight (rejection condition that such as, may occur) at sea.In the exemplary embodiment, the thickness of glass substrate 102 is about 2.0mm, and the thickness of glass substrate 108 can be 1.6mm.
Two glass substrates 102,108 respective major surfaces can comprise printed patterns.This pattern the PV battery frame of PV layer 106 also will can visually can be covered gap and the junction of PV layer.Such as, this pattern can be formed by the preparing ceramic clinker sintered, enamel or other suitable materials, is applied to glass substrate.Such as, the acrylates of a ultraviolet curing or organic substance can be applied to the inner surface of glass substrate.In the exemplary embodiment, these and/or other materials can on the surface of serigraphy needed in desired location, to form required pattern.
Two glass substrates 102,108 can have multi-thickness and color.Preferably provide normalized impedance to carry out light trip to PV layer 106, and the glass of high-transmission rate type come for glass substrate 102.Also high-transmission rate can be used in the exemplary embodiment, the glass of low iron.Such as, United States Patent(USP) Nos. 7,700,870; 7,557,053; 5,030,594, and the open Nos.2006/0169316 of the U.S.; 2006/0249199; 2007/0215205; 2009/0223252; 2010/0122728; 2009/0217978; Be suggested in 2010/0255980, its full content is included into herein as reference.
Exemplary according to an embodiment of the invention soda-lime-silica glass, based on percentage by weight, comprises following basic ingredient:
Table 1: exemplary base glass
Other submembers, comprise the refining aids of multiple routine, and similar SO3, carbon etc. also can be included in parent glass.In the exemplary embodiment, such as, glass described herein by a collection of raw material silica sand, sodium carbonate, dolomite, lime stone, and can use similar sodium sulphate (Na
2sO
4) sulfate and/or Epsom salts (MgSO
4x 7H
2o) and/or gypsum (any combination of about 1:1) be made into as refining agent.In the exemplary embodiment, soda-lime-silica glass described herein comprises the Na of about 10-15% by weight
2the CaO of O and about 6-12%.
Except parent glass (such as, shown in table 1), when preparing the glass according to exemplary embodiment, preparing glass charge comprises can make glass be neutral color (the micro-yellow in exemplary embodiment is illustrated with positive b* value) and/or the material (comprising toner and/or oxidant) with high transmission rate.This material also can be raw material (such as a small amount of iron), or to be added in the parent glass material in batch of material (such as, antimony and/or similar).In an exemplary embodiment of the present invention, the glass of generation can have the transmission of visible light of at least 75%, and be preferably at least 80%, being more preferably at least 85%, is most preferably 90% (being sometimes at least 91%) (Lt D65).
In the exemplary embodiment, except parent glass, glass and/or preparing glass charge can comprise or be formed (percentage by weight formed according to total glass) by with the material shown in following table 2.
Table 2: the exemplary additional materials in glass
In the exemplary embodiment, can by antimony with one or more Sb
2o
3and/or NaSbO
3form be added in preparing glass charge.Also can be Sb (Sb
2o
5).Antimony oxide described herein represents the antimony under any state of oxidation, and is not limited to any specific stoichiometry.
Lower glass redox demonstrates the high oxidation character of glass.Due to antimony (Sb), by antimony trioxide (Sb
2o
3), sodium antimonate (NaSbO
3), sodium pyroantimonate (Sb (Sb
2o
5)), the antimony combination oxidation of sodium or potassium nitrate and/or sodium sulphate form, glass is oxidizing to has lower ferrous content (%FeO).In the exemplary embodiment, by weight, the composition of glass substrate 1 comprises: the antimony oxide being at least equivalent to total ferric oxide twice, is more preferably at least three times, is most preferably the antimony oxide being at least equivalent to total ferric oxide four times.
In the exemplary embodiment, coloured part does not have other colouring agents (trace except potential) substantially.However, it should be understood that, do not departing under object of the present invention and/or target, in other embodiments of the present invention, some other materials (such as, refining aids, melt auxiliary agent, colouring agent and/or impurity) may be present in glass.Such as, in an exemplary embodiment of the present invention, in glass composition, there is no erbium oxide, nickel oxide, cobalt oxide, neodymia, chromium oxide, or one of them, two, three, four or all." there is no " described herein refers to below 2ppm, and is almost low to moderate element or the material of 0ppm.
The sum of iron existed in preparing glass charge and in the glass generated, i.e. coloured part wherein, according to standard convention, with Fe
2o
3form be expressed.But it does not represent that all iron is Fe
2o
3form (as mentioned above).Equally, although the iron of all ferrous state in preparing glass charge or glass may not be the form of FeO, ferrous state (Fe described herein
2+) under the quantity of iron be expressed as FeO.As mentioned above, ferrous state (Fe
2+, FeO) under iron be bluish-green colouring agent, and ferric iron state (Fe
3+) under iron be yellowish green colouring agent, but when realizing neutral or clear color, because stronger colouring agent can bring obvious color to glass, therefore, sometimes ferrous bluish-green colouring agent may be not ideal.
As mentioned above, neutral or substantially clear color and/or high-transmission rate is realized according to the glass of exemplary embodiment of the present invention.In an embodiment, when (being more preferably the thickness of 3-4mm with the thickness of 1-6mm, at this for reference only, thickness is also unrestricted) when measuring, the glass that exemplary embodiment according to the present invention generates has one or more following transmitted light characteristic or color characteristics (Lta is transmission of visible light %).At this, decided by each Ill.D65,10degree Obs with a* and the b* color value in following table.
Table 3: the glass performance of exemplary embodiment
Fig. 3 be illustrate according to the bonding of an exemplary embodiment after the cross-sectional view of prototype PV module.PV module 200 can comprise glass substrate 202,208, and is configured with PV layer 206 between it.The size of PV layer 206 can be less than glass substrate 202,208.After PV module 200 lamination, laminated material 204 can form sealing at the peripheral edge of the first glass substrate 202 and the second glass substrate 208.As shown in Figure 3, laminated material 204 only at the edge of glass substrate 202,208, but, in other embodiments, laminated material can be provided, such as, at least at its peripheral edge along the whole first and/or second substrate 202,208.In the exemplary embodiment, laminated material 204 can contribute to PV layer and external environment are isolated, and it can contribute to the possibility (such as, keeping the drying of PV battery) reducing PV degraded layer.In addition, the PV material of potential danger can be remained in skylight away from external environment (comprising the people in compartment).The ribbon lead 210 of conduction can extend and pass laminated material 204 from PV layer 206.The ribbon lead 210 of this conduction can use (such as fan) to be connected with extra power storage element (such as battery) or the energy.
Fig. 4 a is the cross-sectional view of the glass substrate of the exemplary formation illustrated according to an exemplary embodiment.In the exemplary embodiment, the glass substrate 402,404 used in prototype PV module can be bent.Such as, the skylight of automobile can be slight curvature.Therefore, PV module can replace conventional skylight, crosses the mode being similar to bending skylight and is bent.
Device and method for the sheet glass of thermal bending is the known technology of this area, and at United States Patent(USP) Nos. 5,383,990; 6,240,746; 6,321,570; 6,318,125; 6,158,247; 6,009,726; 4,364,766; 5,443,669; 7,140204; 6,983,104; With 7,082, be illustrated in 260, its full content is included into herein as a reference.
Therefore, glass substrate 402,404 can respectively by thermal flexure.In addition, with reference to Fig. 4 b, the cross-sectional view of the glass substrate of the exemplary formation according to an exemplary embodiment is shown.Glass substrate 406,408 can be become a unit by thermal flexure.The method comparatively economic (such as, disposable thermal has bent two glass substrates) and/or contribute to two glass substrates that curvature basic simlarity is provided.
Fig. 5 be illustrate according to the BENDING PROCESS of an exemplary embodiment after the cross-sectional view of prototype PV module.PV module 500 can comprise as required by sizing and two bending glass substrates 502,504 formed, and PV layer 506.As mentioned above, first and second laminated material 508a, 508b can be used to the first and second substrates 502,504 laminated together, and encapsulate PV layer 506.After bonding, PV module 500 structurally can be similar to an existing sheet glass.In addition configuring ribbon lead 510 impels electric current to be transferred to the outside of PV module 500 from PV layer 506.
Fig. 6 illustrates that, according to an exemplary embodiment, PV module is by the exemplary plane be mounted in roof.PV module 604 can be mounted to the top 602 of car 600.Such as, PV module 604 is installed replaceable or be used for the skylight of replacement standard.The electrical lead 606 be connected with the PV layer of PV module 604 can be exported from PV module.Then electrical lead 606 can be connected with the electronic system of car 600.Alternatively, electrical lead 606 can be connected with special equipment (such as, exhaust fan).
Usual car, when being parked in parking lot the summer of a sweltering heat, may cause the temperature of car inside to raise.Usually, the method for preventing car internal temperature from rising is opend the window the hot-air evacuation in car to outside.But the shortcoming of the method is to be opened by the window of car and shortage security compared with Window closing.Another conventional method provides heat shield on the windshield of car.But the method can reduce produced pyroconductivity, but can not by the heat of generation from car interior shifting to space outerpace.
In this example, the PV module of tool electrical connection can provide independently power supply, comes drive fan, air-conditioning, heater etc.Therefore, electrical lead 606 can be connected (power system-battery or the engine that such as, do not rely on car) with the independent air-conditioning efficiently of car 600.Alternatively or in addition, electrical lead 606 can be connected with power system with the electronics of car 600.When car is not activated and do not discharge the main battery of automobile, it can promote the use of the radio, loudspeaker etc. of car.
In other exemplary embodiments, special reserve battery can be provided.Electrical lead from PV module can directly be connected with reserve battery.PV module can contribute to reserve battery to remain in charged state so that (such as, when the main battery in car is out of order or uses up) can use reserve battery in an emergency situation.Should be understood that other power systems multiple that PV module can be inside and outside with car are electrically connected, such as, for the driving battery system of hybrid power or electric automobile.
In operation, by the mode in similar unloading skylight, PV module 604 is arranged in the top 602 of car 600 and replaces skylight.In the exemplary embodiment, the size (such as, shape, thickness etc.) of PV module 604 can be substantially similar with unloading skylight.It can promote, such as, PV module is used as skylight, thus PV module is retracted by the mode in similar skylight.In the exemplary embodiment, electrical lead 606 can be modified, and connects (such as, so that electric connector upwards extends from skylight and/or is used as a kind of electrical connection track from the framework of car to downward-extension) to provide continuous print.Such as, electrical lead 606 is extensible, when PV module 604 is retracted from roof (such as, similar to the mode in skylight), even if thus make electrical lead in roof, be positioned at different positions, still can be connected.Alternatively, when PV module is positioned at closed position, electrical lead can with the electrical power contacts of outside.In other words, when PV module is closed, electrical lead can with prearranged conductive contact.When PV module is retracted (skylight is opened), electrical lead 606 can be separated with the electronic system of car.In other exemplary embodiments, electrical lead can extend from PV module in identical position.This embodiment can promote the connection (such as, because the interface of PV module is a position) of PV module and external system.Should be understood that and also can implement other technologies, the electrical lead of PV module is used with car and/or other outside electricity and is connected.
Fig. 6 b, 6c and 6d are the planes of the exemplary geometry of the PV module illustrated according to exemplary embodiment.Should be understood that the grid pattern also illustrated shown in these accompanying drawings is only example, in other exemplary embodiment of the present invention, also can use other patterns.
PV module 610 is exemplary 15-string PV assemblies.PV module 610 can have 0.32 square metre region and have about 30 watts (such as, depending on environmental condition) power supply export.
PV module 612 is exemplary 14-string PV assemblies.PV module 612 can have 0.30 square metre region and have about 28 watts (such as, depending on environmental condition) power supply export.
PV module 614 is exemplary 28-string PV assemblies.PV module 614 can have 0.61 square metre region and have about 56 watts (such as, depending on environmental condition) power supply export.。
Fig. 6 e is the upward view of the prototype PV module illustrated according to exemplary embodiment.PV module 650 can have electroconductive binder 652, thus produces electrical connection in solar cells.Electroconductive binder can comprise the adhesive of similar silver epoxy, is equivalent to elargol and adhering and solidifying agent.This epoxy resin can obtain from application technology, such as, 100A and 100B specified.
Electroconductive binder 652 can connect by conductive strip 654.Conductive strip 654 can be made up of copper or other conductive materials (such as, silver etc.).Conductive strip 654 can be connected with ribbon lead 656.According to design requirement, ribbon lead 656 can exit PV module at assigned address from one or more edges of lamination (such as, as shown in Figure 3) and be used as connecing power supply.
Fig. 7 is the flow chart of the PV module process illustrated for the preparation of top.In a step 702, the glass substrate of PV module is provided for.As mentioned above, glass substrate can have different types and quality (such as, the first glass substrate can be the glass of high-transmission rate/low iron type).This glass substrate can be processed thus make substrate have suitable girth and edge treated, carrys out the particular implementation (such as, the design of glass substrate can be depending on its application, such as skylight) for PV module.Further, the specific pattern using above-mentioned pottery to be formed can be added.
Then, in step 704, glass substrate can by hot forming, to meet the use specification of PV module.When glass substrate surface configuration and/or geometrical body meet specific application and close specification, in step 706, the PV layer containing PV battery is inserted between glass substrate.
As mentioned above, thin-film solar cells (such as, CIGS or CIS etc.) can be used in the exemplary embodiment.In the exemplary embodiment, glass substrate can be formed (such as, the curvature of glass substrate can be greater than standard) forcefully.In this exemplary embodiment, the thin-film solar cells of similar CIGS is preferably.However, it should be understood that, also can implement the solar battery technology (such as, crystal silicon solar energy battery) of other types.
In step 708, the PV layer that pressure layer material comes between packaged glass substrate can be applied.The similar material such as polyvinyl butyral resin (PVB) or ethyl vinyl acetate (EVA) can be used in the exemplary embodiment.In the exemplary embodiment, the thickness range of PVB can be 0.1-1.0mm, is more preferably 0.38 or 0.76mm.In the exemplary embodiment, adjustable specific laminated material provides long-term durability and lasting cohesive.Also other laminated materials of apparatus similar adhesive intensity, sealing, durability, optical signature and/or other speciality can be made.Such as, in the exemplary embodiment, a component, two components or multi-component polyurethane can be used.Adhesive (such as, Pressuresensitive Adhesive) can be used in the exemplary embodiment.In step 720, after glass substrate, PV layer and laminated material are combined (such as, directly towards), PV module can be heated and pressure.The application of heating and/or pressure can promote to be sealed in the bonding of two glass substrates PV layer wherein by lamination.Further, in the exemplary embodiment, heating and pressure can make laminated material (such as, PVB) become transparent.Certainly specific laminated material also processes process by other modes, instead of heats and pressure, such as, and UV curing materials.
When two glass substrates and the PV layer that is clipped in the middle combine, it is similar single integrated unit (such as, similar be installed in car in common skylight) structurally.Therefore, in step 712, newly-generated PV module is mounted to roof.In other words, according to size or the design in common skylight, two glass substrates and lamination sealing PV array junctions are in-between synthesized an integrated unit, and be proportionally shapingly substantially similar to common skylight.At this, the process of preparation PV module can make the cost reduction of car assembling process.First, vehicular manufacturer may currently not need the main body revising vehicle to hold the skylight being equipped with PV.The second, in the exemplary embodiment, integrated PV module (such as, the skylight of the integrated PV array of tool) can be provided, vehicular manufacturer by be similar to common skylight is installed mode to install wrapped PV module.The method can be vehicular manufacturer and saves time and money.In addition, in the exemplary embodiment, the thickness of sizing glass substrate and PV array can be less than common skylight.Correspondingly, installation is equipped with the skylight of PV can not reduce available whole clear height in vehicle.In the exemplary embodiment, integrated PV module can have substantially similar to common skylight thickness, thus can be retracted to open skylight.
As known in this technology, conventional skylight is by using the injection molding system of thermoplastic or using the reaction injection molding process of conventional polyurethanes packed.This technology can promote sealing and the installation of glass sunroof.Equally, integrated PV module (such as, PV module 200) is also by using similar or identical technology packed.Correspondingly, such as, existing roof assembly can directly be replaced by the PV module 200 that this technology is packed.In addition, be packaged with the route being beneficial to conductor and connector to come for PV function (such as, electrical lead etc.).
Should be understood that in different embodiment of the present invention, the step shown in Fig. 7 can be performed by different order and/or some steps can not perform.Such as, laminated material can be provided to glass substrate, then by PV battery folder between laminated material and glass substrate.
The specific PV module used in particular vehicle (such as, automobile) may need to meet public use standard.Should be understood that technology described herein can provide to meet and/or more than the requirement of AS-3 laminated material.Such as, in exemplary embodiment by following test: 1) 30ft. drop-dart impact test; 2) 30ft. bead impact test; 3) boiling test in 2 hours; With 4) water smoke contacted two weeks.In addition, other exemplary embodiments meet or by other undesired tests, such as, 1) salt fog contact in two weeks; 2) 1000 hours 85 degree/85%RH expose; 3) shear test of the PV solar cell in PV module; With 4) copper busbar shear test.Therefore, exemplary embodiment can meet and/exceed certain test (such as, security, durability etc.).
Although exemplary embodiment is illustrated use thermal flexure, in other exemplary embodiments, alternatively, or cold bend(ing) in addition also can be used to form glass substrate.
Although exemplary embodiment is illustrated use TFSC, in other exemplary embodiments, also can use the solar cell of other types.Such as crystalline silicon (c-Si) together can use with above-mentioned technology.Non-crystalline silicon (such as, a-Si), microcrystal silicon can be used in other exemplary embodiments, and/or other materials.
In various embodiments, glass substrate can have identical or different composition.Such as, in the exemplary embodiment, the substrate of low iron can be provided to be used as outermost substrate, and relatively provide the material of more cheap type to come for interior substrate.It can provide necessary intensity and thickness, more potential light can be made to enter simultaneously and touch PV layer.Configuring the whole performance that low transmittance glass can not affect module on substrate in the PV layer side of the sun.
Those skilled in the art should be understood that the use of the glass substrate of tool difference composition, and glass substrate may be caused to have different heating coefficients.Such as, time compared with the second glass substrate, the first glass substrate can have relatively low iron percentage.Because the second glass substrate can have higher iron counting, compare the first glass substrate and can heat more quickly (such as, because iron absorbs more heat).Correspondingly, the coefficient of thermal expansion of the first and second glass substrates may be different.Should be understood that when the coefficient of thermal expansion of two kinds of laminated materials is different, because bi-material is with different rate extension and contraction, can not lamination be kept.Therefore, the correct heating attribute identifying two kinds of laminated materials is needed.Such as, when using infrared ray (IR) heat and/or be exposed to IR, the difference of CTE is very important.Different iron-holder means different IR absorptivities.
For solve a method of this problem be adjustment any one or bi-material on heat.Such as, under " normally " condition, when the first glass substrate add ratio of specific heat second glass substrate slow time, can use and heat or heat is removed (such as, passing through heat sink) from the second glass substrate is increased to the first glass substrate.Thus, in the exemplary embodiment, for the difference of the heating coefficient with the second substrate, first (such as, low iron) substrate preferentially can be heated.In the exemplary embodiment, the heating attribute of assembly can be enhanced and optimize, and such as, guarantees that substrate is suitably laminated to another.Exemplary heating attribute can be consider different glass ingredients etc.Also can be adjustment laminated material composition and/or select special laminated material, such as, for above-mentioned difference.
According to the heating attribute considering first and second substrate heterogeneity, lamination step can comprise first and second substrate of heating.Similarly, according to the heating attribute considering first and second substrate heterogeneity, thermal flexure can be carried out to first and second substrate (such as, together or respectively).
The shortcoming be incorporated into by solar cell in the skylight of vehicle is, such as solar cell is not transparent.Certainly, complete transparency can not be expected, because passenger and/or car over-heat inside can be made from the undue heat of whole sunshine.But, when the energy collecting the sun strengthens the electric generation system of vehicle, allow some light to be transferred in vehicle and balance.Not transparent due to most of solar cell or be positioned on transparent substrate, therefore, need a kind of technology replaced, allow the light of predetermined quantity through PV skylight and enter vehicle interior.
Present inventor recognizes the necessity of this balance, and correspondingly have studied and prepare multiple through hole in solar cells and enter to possibility in compartment by making the incident light of fraction.(although other article of commerce have higher or lower transmission of visible light, such as, different vehicles, different vehicles etc.), some business skylights have the transmission of visible light of about 10%.Therefore, when providing PV function, sometimes need to match with percentage transmission.
But, although at least transmissivity can be increased by the through hole of series of rules in theory and quite easily manufactured, but the present inventor finds that solar cell must be clipped between two adhesive layers by the method, is bonded to the inside and outside of sheet glass successively and prepares glass laminates structure.Particularly, the present inventor finds in lamination process, and a solar cell or the set of solar battery group can make in adhesive flow hand-hole with during aperture, and generate non-scattered path by the hole be filled.Therefore, compared with the problem solved with through hole, in fact it can cause more problem, even if through hole is not filled, light is passed wherein, but still can generate irregular outward appearance, such as, when observing from the passenger's angle vehicle.
At this, unexpected discovery, in view of the foregoing and in exemplary enforcement, there is no need to consider that PV skylight lamination and other non-skylight glass laminations (windshield etc.) change lamination process.That is, find at this, in view of the foregoing and in exemplary enforcement, there is no need compared with other non-skylight glass laminations (windshield etc.) as PV skylight lamination customizes adhesive type and temperature, pressure, cycle, and other associated processing conditions.
On the contrary, find at this, the hole dimension of subset, aspect ratio, and the optimum efficiency of spacing tool uniqueness, it can meet the condition in adhesive flow hand-hole, thus adhesive can be filled up or almost fill up opening, thus non-scattered is through opening enter compartment, and when observing from the passenger's angle vehicle, have evenly (more attractive in appearance) outward appearance.
Thus, client's request of preparation displine opening in the PV battery on laminated roof, some openings causing finding in only PV structure make lamination there is no the bubble (usual air, but be sometimes other gases) of delay.Therefore, exemplary embodiment of the present invention considers the geometry in hole, issuable air trapping during reducing manufacture.
Fig. 8 a illustrates according to exemplary embodiment, the schematic cross-sectional view of the assembly in the hole of tool appropriate size before lamination.Should be understood that Fig. 8 a and Fig. 8 b, 9a, 9b do not show in proportion.Such as, glass substrate usual specific viscosity mixture and solar cell thick.Meanwhile, hole may be less than the thickness of glass, and/or shape can be regular or irregular.In the exemplary embodiment, hole can have a key dimension, and is greater than other key dimension.Such as, hole can be groove, can be 1mm or less at minor face, and long limit can be 1mm or longer.
As shown in Figure 8 a, solar cell storehouse 80 is sandwiched between first and second substrate 804a, 804b.Binding material 806 is configured in the one or both sides of solar cell storehouse 802.In solar cell storehouse 802, form a hole 808, increase the transmission of visible light (such as compared with not configuring the situation in hole) entered in vehicle.Although should be understood that a hole shown in Fig. 8 a, also can be provide multiple hole in regular or irregular configuration.
Fig. 8 b illustrates in exemplary enforcement, the schematic cross-sectional view of the change that Fig. 8 a embodiment occurs in lamination cycle.Fig. 8 b illustrate lamination follow bad in, adhesive will cling glass, consistent with its plane, and cling solar cell, consistent with its plane.By the size in choose reasonable hole, adhesive is also by the lax opening also fully or substantially fully inserting hole.Light through adhesive, preferably, does not see the interface of any air-adhesive and/or any textured surface (such as, relevant with the bubble caused by the gas because accumulating etc.).
Fig. 9 a be lamination is shown before the schematic cross-sectional view of assembly of opening 808 ' of the inappropriate size of tool.Fig. 9 b is the exemplary plot of the consequence of the opening of the inappropriate size illustrated with lamination Fig. 9 a.As shown in the example of Fig. 9 b, adhesive 806 is not inserted in opening 808' completely or not in large quantities.Interface 904a, 904b on the contrary along air-adhesive form air pocket 902.According to different situation, the shape of interface 904a and 904b can be level and smooth or irregular, and sometimes can partly contact with each other.Should be understood that the incident light in these features can be height scattering or bending, thus cause invalid Transmission light through the opening in solar cell storehouse 802.Its possibility of result is less-than-ideal outward appearance and/or does not meet target visible light transmission rate.
Figure 10 a is the top view of the PV module in the hole of the tool appropriate size illustrated according to an exemplary embodiment.Be of a size of mm shown in Figure 10 a, but should be understood that other embodiments of the present invention also other sizes applicable.The well-regulated shape of opening tool shown in the example of Figure 10 a and the well-regulated interval of tool.However, it should be understood that, all need in not every exemplary embodiment so.Such as, in different exemplary embodiments, the opening of different size can be formed in one or more regular or irregular interval.Vertical dimension in Figure 10 a illustrates the center line of opening.
As shown in the example of Figure 10 a, PV module comprises region 1002a, the 1002b of two different sizes for support solar cell stack.This region 1002a, 1002b are at least partly by conductor wire 1004, and bus 1006 defines.Should be understood that conductor wire 1004 and/or bus 1006 can comprise silver or any other conductive material.In the example of Figure 10 a, bus 1006 can be given prominence to downwards from the main part of PV module, and in the exemplary embodiment can the positive terminal of indication circuit.Although not shown in the example of Figure 10 a, other bus can project upwards from the opposite side of module and form the negative pole end of circuit.Under certain situation, the bus 1006 as shown in Figure 10 a, bus can be straight line substantially, such as, reduces bus visually or aesthetic impact, allows the larger region covered by solar cell functional layer.In the exemplary embodiment, bus bar can jointly as " collecting line ".But, should be understood that and other also can be adopted to design, collect the energy by other means, may not need thus to use the bus shown in Figure 10 a.
In Figure 10 a example, in the every other row of grid, configure opening.In larger region 1002a, configure two openings 1008a, 1008b, and only configure an opening 1008c in less region 1002b.Each opening 1008 has formed objects and shape.As mentioned above, opening 1008 can be formulated size and shape, to meet target visible light transmission rate.In the exemplary embodiment of Figure 10 a, opening is the channel-shaped with fillet.The external diameter of groove is 23mm, and internal diameter is 1mm.Therefore, opening is about 23 square millimeters in the zone.But opening 1008 minimum range that may correspond between edge of opening and conductive material is further controlled (such as, collecting line, grid etc.).Find at this, such as, the distance of the edge-to-edge of about 1mm is enough to prevent short circuit, otherwise may make module section or can not run completely.The preferably distance of about 2mm, and be more preferably the distance of about 3 millimeters.
In the exemplary embodiment, opening can be concentrated between the grid lines in height dimension.Can flatly be concentrated between the edge of module and contiguous bus 1006 for less region 1002b, opening 1008c.For larger region 1002a, the opposite edges of opening 1008a, 1008b can be equally spaced respectively from its contiguous bus 1006.
As mentioned above, Figure 10 a is illustrated in many-side.Figure 10 b is the top view of the more general PV module in the hole of the tool appropriate size illustrated according to an exemplary embodiment.As shown in the figure, bus is removed, and provides typical or the size of example.It should be understood, of course, that these sizes can be modified in different exemplary embodiments.Similarly, difform opening can be provided in one or more different embodiment.Particularly, as shown in fig. lob, the main distance of opening is the secondary distance of 30mm and opening is 1mm.Opening in periphery and edge are separated by 2.3mm, such as, multiple module can be made to be coupled mutually and/or to be coupled to vehicle etc.The spaced 5mm of adjacent opening, thus there is enough spaces come, for bus or other main electrical connections, to reduce short circuit equally likely possibility.
Figure 11 is the chart that aspect ratio and element thickness in the lamination for the success and failure in exemplary rectangular hole are shown.The length that the figure of Figure 11 indicates exemplary rectangular hole compares wide ratio (with general unit) and cell thickness (such as, mils).The length and width geometry of laminated material (namely representing failure) is not inserted in region the signal more than line in Figure 11, and the length and width geometry of laminated material is inserted in the region signal below line.Different curves, such as shown in Figure 11, the hole of dissimilar geometry can be developed into (such as, square, rectangle, avette, hexagon, and/or the hole of other shapes), laminated material, high pressure or heat treatment cycle and processing conditions (such as temperature, pressure, cycle etc.) etc.The value of boundary curve based on selected materials, can be determined or is calculated in theory by rule of thumb.Different please under condition, boundary line can be bent or be essentially straight line.
Figure 12 is the flow chart of the PV module process in the hole of the tool appropriate size for the preparation of vehicle illustrated according to an exemplary embodiment.As shown in figure 12, in step S1102, determine the geometry in the hole being suitable for target visible light transmission rate and making jointing material flowing wherein.As mentioned above, the size in hole can be considered, aspect ratio, and interval, meet the condition in adhesive flow hand-hole, such as, specific jointing material, PV module thickness etc.In step S1104, one or more hole can be formed in PV module, such as, according to the geometry in selected hole.Hole is formed by any suitable technology.Such as, by laser scribing (such as, use Hitachi through the equipment of U.S.'s mechanics Company, it is modified to meet demand and sets size, position, layout etc., or any other supplier), cutting, perforation and/or any other suitable technology form hole.Glass substrate is provided in step S1106.As mentioned above, this substrate can be bent.In step S1108, by glass substrate with wherein form porose PV module layer and force together.As a part for this process, jointing material flows in hole.Preferably, along with lamination, hole is filled or substantially fills up, thus in the region of access hole, does not have obvious interval and/or do not have other interface.In addition, along with lamination, assembly there is no bubble etc.In step S1110, PV assembly is finally provided to come for installing (such as, as the skylight in vehicle).
In view of above, should be understood that exemplary embodiment relates to a kind of PV module, comprise one or more opening.In some cases, can select and/or adjust the feature of opening to make transmitted light enter to the interior cabin of vehicle, and still make the appearance that the assembly of structure PV module keeps more attractive in appearance simultaneously.In addition, exemplary embodiment considers the constraints such as, with the character of adhesive and lamination process (comprising processing conditions, temperature, pressure, cycle etc.) relevant and option and installment, to guarantee that the light of requirement is successfully transmitted through hole.Such as, the opening size selected by adjustable, makes required jointing material suitably flow in opening.Exemplary embodiment relates to shape and the size of opening subset, thus makes the cross section of the adhesive after lamination substantially even, such as, and specific jointing material and one group of processing conditions.
Such as, the incident light of the whole light transmission of setting 10% is through the opening for connecting configuration, described configuration comprises specific adhesive and lamination cycle and specific solar cell thickness, should understand, when the length in hole with higher rectangular aperture (also can be assumed to be circle) is to wide ratio, then laminated material can not successfully penetrate.On the contrary, when ratio is lower than this value, then opening can be successfully passed through.In the exemplary embodiment, identify the existence on border and as inference, carry out defined range by border, thus realizing the filling of successful opening, then using this information to build the PV assembly for vehicle.
In the exemplary embodiment, one or two substrate can be heat-treated (such as, hot tempering or heat are strengthened).Represent at this " thermal treatment " and " heat treatment " and material is heated to enough temperature, thus realize hot tempering and/or the heat reinforcement of the glass containing this material.This definition comprises: such as, with the temperature of at least 550 degrees Celsius heating coating material in baking oven or smelting furnace, preferably at least 580 degrees Celsius, be more preferably at least 600 degrees Celsius, be even more preferably at least 620 degrees Celsius, be most preferably at least 650 degrees Celsius, and carry out hot tempering and/or heat reinforcement with time enough, in the exemplary embodiment, it can be two minutes to ten minutes.
As used herein term " ... on ", " by ... support " etc., unless explicitly stated otherwise, otherwise should not be interpreted as referring to two elements directly adjacent to each other.In other words, even if there is one or more layer between ground floor and the second layer, ground floor also can be represent to support on the second layer or by the second layer.
In the exemplary embodiment, a kind of method preparing the integrated photovoltaic PV module of vehicle is provided.First and second glass substrates are provided; There is provided PV module, described PV module has multiple through hole be formed at wherein; Described first and second glass substrates and described PV module layer are wherein forced together.Wherein, during described lamination, due to the size of described through hole, shape and layout, laminated material is by the described multiple through hole at least inserted in described PV module.Described through hole has the selected gross area jointly, thus makes the transmission of visible light through described integrated PV module at least reach selected desired value.
Except the feature of previous paragraphs, in the exemplary embodiment, described desired value can be 10%.
Except any one feature in the first two paragraph, in the exemplary embodiment, described PV module can comprise multiple solar cell separated.
Except the feature of previous paragraphs, in the exemplary embodiment, described solar cell can be spaced by latticed conductive material.
Except the feature of previous paragraphs, in the exemplary embodiment, described through hole, is spaced to be enough to prevent the grid lines distance of electrical short.
Except the feature of previous paragraphs, in the exemplary embodiment, described distance can be at least 1mm.
Except any one feature in front four paragraphs, in the exemplary embodiment, described through hole may be located substantially the unit center of described grid.
Except any one feature in the first five paragraph, in the exemplary embodiment, at least some through hole can between adjacent solar cell.
Except any one feature in the first six paragraph, in the exemplary embodiment, at least some through hole can be positioned at the neighboring of described PV module, and compares any solar cell closer to described neighboring.
Except any one feature in the first eight paragraph, in the exemplary embodiment, multiple bus (such as, 3 positive poles and 3 negative poles, or other suitable configurations) can be connected to described PV module.
Except any one feature in front ten paragraphs, in the exemplary embodiment, described through hole is extended respectively and has fillet.
Exemplary embodiment relates to a kind of method preparing vehicle, and described method comprises: provide the integrated photovoltaic PV module prepared by the method for any one in front 11 paragraphs; And described integrated PV module is mounted in described vehicle.
In the exemplary embodiment, a kind of method preparing photovoltaic PV module is provided.Substrate is provided, is formed with multiple solar cell above; Configure latticed conductive material on the substrate; Multiple through hole is formed in described substrate, its pattern is that (a) described through hole has the selected gross area jointly, thus the desired value making the transmission of visible light through integrated PV module reach described PV module to be set up, and (b) described through hole has aspect ratio and location, the laminated material being enough to make to use in the described integrated PV module of preparation flows into wherein, and inserts described through hole.
Except the feature of previous paragraphs, in the exemplary embodiment, described through hole can be formed by laser cutting.
Except any one feature in the first two paragraph, in the exemplary embodiment, the solar cell of described PV module can be the solar cell of CIGS type.
In the exemplary embodiment, a kind of integrated photovoltaic PV module for vehicle is provided, comprises: the first and second glass substrates; PV module, comprises multiple solar cell separated, and has multiple through hole be formed at wherein, and described PV module is inserted between described first and second glass substrates; With multiple poly-line, to be formed on described substrate and between adjacent solar cell.Wherein, described PV module is laminated to described first and second substrates, and due to the size of described through hole, shape and layout, laminated material is received in the described multiple through hole in described PV module.Wherein, described through hole has the selected gross area jointly, thus makes the transmission of visible light through described integrated PV module reach selected desired value.
Except the feature of previous paragraphs, in the exemplary embodiment, described through hole, is spaced to be enough to prevent the grid lines distance of electrical short.
Except any one feature in the first two paragraph, in the exemplary embodiment, described through hole may be located substantially the unit center of described grid.
Except any one feature in first three paragraph, in the exemplary embodiment,
First subset of described through hole is between adjacent solar cell, and the second subset of described through hole is positioned at the neighboring of described PV module, and compares any solar cell closer to described neighboring.
Except any one feature in first three paragraph, in the exemplary embodiment, described laminated material can be PVB.
Except any one feature in front four paragraphs, in the exemplary embodiment, described solar cell can be the solar cell of CIGS type.
Except any one feature in the first six paragraph, in the exemplary embodiment, described second glass substrate has more iron than described first glass substrate.
Exemplary embodiment relates to a kind of skylight, comprises the integrated photovoltaic PV module in the first seven paragraph described in any one.
As mentioned above, although the present invention is illustrated with reference to the most practical and preferred embodiment, but the present invention is not limited to described embodiment, can carry out various amendment and distortion on the contrary in the scope of above-mentioned explanation, amendment will be defined by accompanying right.
Claims (23)
1. prepare a method for the integrated photovoltaic PV module of vehicle, described method comprises:
First and second glass substrates are provided;
There is provided PV module, described PV module has multiple through hole be formed at wherein;
Described first and second glass substrates and described PV module layer are wherein forced together, and
Wherein, during described lamination, due to the size of described through hole, shape and layout, laminated material by the described multiple through hole at least inserted in described PV module, and
Wherein, described through hole has the selected gross area jointly, thus makes the transmission of visible light through described integrated PV module at least reach selected desired value.
2. the method for claim 1, wherein described desired value is 10%.
3. as the method in the claims as described in any one, wherein, described PV module comprises multiple solar cell separated.
4. method as claimed in claim 3, wherein, described solar cell is spaced by latticed conductive material.
5. method as claimed in claim 3, wherein, described through hole, is spaced to be enough to prevent the grid lines distance of electrical short.
6. method as claimed in claim 5, wherein, described distance is at least 1mm.
7. as the method in claim 4-6 as described in any one, wherein, described through hole is positioned at the unit center of described grid.
8. as the method in the claims as described in any one, wherein, at least some through hole is between adjacent solar cell.
9. as the method in the claims as described in any one, wherein, through hole described at least some is positioned at the neighboring of described PV module, and compares any solar cell closer to described neighboring.
10. as the method in the claims as described in any one, comprise further: multiple bus is connected to described PV module.
11. as the method in the claims as described in any one, and wherein, described through hole is extended respectively and has fillet.
12. 1 kinds of methods preparing vehicle, described method comprises:
The integrated photovoltaic PV prepared by the method in the claims described in any one module is provided; And
Described integrated PV module is mounted in described vehicle.
13. 1 kinds of methods preparing photovoltaic PV module, described method comprises:
Substrate is provided, is formed with multiple solar cell above;
Configure latticed conductive material on the substrate;
Multiple through hole is formed in described substrate, its pattern is that (a) described through hole has the selected gross area jointly, thus the desired value making the transmission of visible light through integrated PV module reach described PV module to be set up, and (b) described through hole has aspect ratio and location, the laminated material being enough to make to use in the described integrated PV module of preparation flows into wherein, and inserts described through hole.
14. methods as claimed in claim 13, wherein, described through hole is formed by laser cutting.
15. methods as described in claim 13-14, wherein, the solar cell of described PV module is the solar cell of CIGS type.
16. 1 kinds, for the integrated photovoltaic PV module of vehicle, comprising:
First and second glass substrates;
PV module, comprises multiple solar cell separated, and has multiple through hole be formed at wherein, and described PV module is inserted between described first and second glass substrates; With
Multiple poly-line, to be formed on described substrate and between adjacent solar cell,
Wherein, described PV module is laminated to described first and second substrates, and due to the size of described through hole, shape and layout, laminated material is received in the described multiple through hole in described PV module, and
Wherein, described through hole has the selected gross area jointly, thus makes the transmission of visible light through described integrated PV module reach selected desired value.
17. modules as claimed in claim 16, wherein, described through hole, is spaced by grid lines to be enough to prevent the distance of electrical short.
18. modules as claimed in claim 17, wherein, described through hole is positioned at the unit center of described grid.
19. as the module in claim 16-18 as described in any one, wherein, the first subset of described through hole between adjacent solar cell, and
Second subset of described through hole is positioned at the neighboring of described PV module, and compares any solar cell closer to described neighboring.
20. as the module in claim 16-19 as described in any one, and wherein, described laminated material is PVB.
21. as the module in claim 16-20 as described in any one, and wherein, described solar cell is the solar cell of CIGS type.
22. as the module in claim 16-21 as described in any one, and wherein, described second glass substrate has more iron than described first glass substrate.
23. 1 kinds of skylights, comprise the integrated photovoltaic PV module in claim 16-22 described in any one.
Applications Claiming Priority (3)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| US13/449,623 US8834664B2 (en) | 2010-10-22 | 2012-04-18 | Photovoltaic modules for use in vehicle roofs, and/or methods of making the same |
| US13/449,623 | 2012-04-18 | ||
| PCT/US2013/036685 WO2013158581A1 (en) | 2012-04-18 | 2013-04-16 | Improved photovoltaic modules for use in vehicle roofs, and/or methods of making the same |
Publications (2)
| Publication Number | Publication Date |
|---|---|
| CN104395081A true CN104395081A (en) | 2015-03-04 |
| CN104395081B CN104395081B (en) | 2016-12-07 |
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| Application Number | Title | Priority Date | Filing Date |
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| CN201380032069.6A Expired - Fee Related CN104395081B (en) | 2012-04-18 | 2013-04-16 | The photovoltaic module being modified and/or its preparation method for roof |
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| Country | Link |
|---|---|
| JP (1) | JP6469566B2 (en) |
| CN (1) | CN104395081B (en) |
| DE (1) | DE112013002119T5 (en) |
| WO (1) | WO2013158581A1 (en) |
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| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| WO2020020019A1 (en) * | 2018-07-27 | 2020-01-30 | (Cnbm) Bengbu Design & Research Institute For Glass Industry Co., Ltd | Solar module with patterned cover plate and optical interference layer |
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| WO2017117132A1 (en) * | 2015-12-31 | 2017-07-06 | Sunedison, Inc. | Systems and methods for reducing inactive space in photovoltaic modules |
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Also Published As
| Publication number | Publication date |
|---|---|
| WO2013158581A1 (en) | 2013-10-24 |
| JP2015518661A (en) | 2015-07-02 |
| CN104395081B (en) | 2016-12-07 |
| DE112013002119T5 (en) | 2014-12-31 |
| JP6469566B2 (en) | 2019-02-13 |
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