WO2004038814A1 - Process for assembly of photovoltaic modules - Google Patents

Process for assembly of photovoltaic modules Download PDF

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Publication number
WO2004038814A1
WO2004038814A1 PCT/EP2003/011794 EP0311794W WO2004038814A1 WO 2004038814 A1 WO2004038814 A1 WO 2004038814A1 EP 0311794 W EP0311794 W EP 0311794W WO 2004038814 A1 WO2004038814 A1 WO 2004038814A1
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WO
WIPO (PCT)
Prior art keywords
cells
conducting
process according
cell
conducting element
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Application number
PCT/EP2003/011794
Other languages
French (fr)
Inventor
Giacomo Manenti
Original Assignee
Suntech S.R.L.
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Suntech S.R.L. filed Critical Suntech S.R.L.
Priority to AU2003274074A priority Critical patent/AU2003274074A1/en
Priority to EP03758055A priority patent/EP1556903A1/en
Publication of WO2004038814A1 publication Critical patent/WO2004038814A1/en

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Classifications

    • 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
    • H01L31/18—Processes or apparatus specially adapted for the manufacture or treatment of these devices or of parts thereof
    • H01L31/1876—Particular processes or apparatus for batch treatment of the devices
    • 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
    • H01L31/05—Electrical interconnection means between PV cells inside the PV module, e.g. series connection of PV cells
    • H01L31/0504—Electrical interconnection means between PV cells inside the PV module, e.g. series connection of PV cells specially adapted for series or parallel connection of solar cells in a module
    • H01L31/0512—Electrical interconnection means between PV cells inside the PV module, e.g. series connection of PV cells specially adapted for series or parallel connection of solar cells in a module made of a particular material or composition of materials
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
    • Y02E—REDUCTION OF GREENHOUSE GAS [GHG] EMISSIONS, RELATED TO ENERGY GENERATION, TRANSMISSION OR DISTRIBUTION
    • Y02E10/00—Energy generation through renewable energy sources
    • Y02E10/50—Photovoltaic [PV] energy
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
    • Y02P—CLIMATE CHANGE MITIGATION TECHNOLOGIES IN THE PRODUCTION OR PROCESSING OF GOODS
    • Y02P70/00—Climate change mitigation technologies in the production process for final industrial or consumer products
    • Y02P70/50—Manufacturing or production processes characterised by the final manufactured product

Definitions

  • the present invention concerns a process for assembly of photovoltaic modules, comprising a plurality of interconnected solar cells.
  • Photovoltaic modules commonly consist of a series of solar cells (in general thin slices of appropriately doped mono or polycrystalline silicon) arranged on a surface and interconnected in series or parallel according to requirements.
  • the slices of silicon have two opposite parallel faces, one doped p and one doped n, the latter obtained, in general, by diffusion of an appropriate doping agent (such as phosphorous) through one face of a p doped slice.
  • an appropriate doping agent such as phosphorous
  • a grille is created for collection of the current consisting of thin conductors called fingers which must have an extension over the surface as widespread as possible, for optimal collection of the current generated, but at the same time be compatible with the need to leave as much surface as possible exposed to receive the light radiation;
  • the fingers can be created on the surface by deposition and partial diffusion of materials such as mixtures of aluminium and silver, by means of known techniques (like deposition of compounds containing said materials by masking and heating).
  • the same method is used to create thicker collectors, called bus bars, connected to the fingers, and to which the contacts can be soldered, for example appropriately tin-plated copper strips for connecting the cells to other cells or to the electrical circuits of which they form part.
  • a layer of aluminium is deposited and partially diffused throughout said surface, as described above.
  • silver can also be introduced in order to facilitate the soldering.
  • the face that will receive the radiation will from now on be called front of the cell and the opposite face back.
  • the cells provided with copper strips can be connected in series, soldering the strip applied to the bus bar of the front of one cell to the back of another.
  • rows, or strings are formed which are then arranged on a panel, made of plastic for example.
  • Several strings are then connected in series or parallel, thus constituting the photovoltaic module, which is then appropriately sealed, for example by means of a sheet of glass (with suitable physical characteristics such as transparency to certain wavelengths), having a layer of suitable material such as a film of ethylene vinyl acetate (EVA).
  • EVA ethylene vinyl acetate
  • Assembly of a photovoltaic module therefore, involves various soldering phases which must be performed in subsequent steps, such as application of the copper strips to the cells by soldering (operation also called tipping), soldering between them and connection between the strings to form the circuits.
  • soldering operation also called tipping
  • These steps, as well as the formation of strings and their arrangement on the panel, are time-expensive and difficult, and involve serious risk of breakage of the cells. This is also due to the fact that these operations are not suited to automated procedures and are generally performed manually by an operator, or only the soldering operations are partially automated in a limited number of points in formation of the strings; in any case, the process is inefficient and is labour-intensive. Assembly costs are therefore high and become progressively more relevant as technology allows obtaining cells at increasingly lower costs.
  • the steps can be performed in the above order or in another order if necessary.
  • positioning of the cells on said panel can be simultaneous with connection of the conducting element to the back.
  • the fixing step is performed under heat, simultaneously for all the cells; in this step the conducting glue hardens, if required by the type of glue used; again, this process is performed hot.
  • the conducting element can be a conducting adhesive tape or a strip of material appropriately fixed to the back of the cells with soldering paste or conducting glue applied in-between.
  • the process also provides for hot application of a film of suitable material on the panel on which the cells are arranged.
  • the material can be EVA and it can advantageously be applied simultaneously with the fixing step.
  • the film can be applied together with a sheet of transparent material, for example glass, which will close the panel at the front.
  • the deposition of conducting glue or soldering paste on at least part of the front of the cells, in general on the bus bars, can be performed on a conveyor belt from which the cells are withdrawn preferably by a robotised arm and deposited on the panel; according to a particular aspect of the invention, the panel can be previously provided with a series of conducting bases, made of copper for example, at least one per cell. These bases can be obtained by various techniques commonly employed in printed circuit technology.
  • the conducting glue can, in certain cases, be the adhesive already present on the conducting tape, as manufactured; this applies, for example, in the case of double- sided conducting tape. LIST OF FIGURES The present invention will now be illustrated by a detailed description of preferred but not exclusive forms of embodiment, provided simply as an example, with the help of the attached figures in which:
  • Figure 1 schematically represents a cell to which a conducting element is applied in a process according to the present invention.
  • Figure 2 schematically represents an overhead view of a portion of panel constituting the back of a module produced according to the process of the present invention.
  • Figure 3 schematically represents a view of two adjacent cells positioned in a module produced according to the process of the present invention.
  • Figures 4 and 5 schematically show a view of two possible alternatives of a step of the process according to the invention.
  • FIG 6 schematically represents another view (lateral and in section) of the step of the process of Figure 4.
  • an adhesive conducting tape 3 (for example, tape 3M 1138), which will constitute the conducting element, is applied to the back 2 of the solar cells 1 (preferably complete with contact structures such as fingers, bus bars and conducting material on the back, as commonly produced).
  • the tape 3 is preferably applied so that an adequate portion 4 protrudes at the side of the ' cell as shown in figure 1. This can be done while the cell is conveniently positioned on a conveyor belt and the tape can be automatically applied.
  • the adhesive tape can be applied through a transverse groove of the belt leaving the portion of the back of the cell free for application of the tape, or the cell can be positioned with a part protruding from one side of the conveyor belt, where the tape 3 can be applied, while the cell is retained by appropriate devices on the conveyor belt such as another roller, for example.
  • the cell can be positioned with the back facing upwards for application of the adhesive tape and then overturned, for example by a mechanical arm, for the subsequent phases.
  • the tape can be deposited, for example, by means of an automatic dispenser and cut automatically to form elements of the required length for the next cell connection.
  • the next operation consists in the application of conducting glue (for example Loctite 3880) or soldering paste (for example LT 30 Multicore) (unless a two-sided conducting tape is used) on part 5 of the front of the cell 1 , in general on the bus bar 5.
  • the glue can be applied by means of an automatic dispenser above the conveyor belt, for example in the form of strips 7 or spheres, or in any other suitable form.
  • Figure 2 shows a portion of panel 8 on which the cells will be positioned, said panel constituting the rear part of the photovoltaic module.
  • the panel is made of suitable material (for example Tedlar, PET, PEN, GHE, Capton, glass or other) and may feature a series of bases 9, preferably in the shape of a cell and produced by means of appropriate techniques, those commonly used in the production of printed circuits.
  • the cells can be aligned in various ways, for example parallel rows 11 , 11 ' on which the strings of cells will be formed.
  • On each base 9 a cell 1 will be positioned, after an adequate amount of glue (indicated by 10 in figure 3) or soldering paste has been applied on the base by means of stencil technology or with a dispenser, for example.
  • the glue will be preferably hardened or the soldering, by means of the soldering paste, will be performed in the fixing step.
  • the cells 1 ', 1 " will be positioned on the bases 9 in sequence so that two adjacent cells are connected by the tape 3 in series, i.e. the front of one to the back of the other.
  • cell 1 ' is positioned first; cell 1" will be positioned so that the free portion 4 of the tape 3 covers with the end 12 the part of cell 1' on which the glue or paste has been applied (in general the bus bar).
  • Some bases 9' can be provided with contacts 13 to which the bus bars of the cells positioned at one end of a string are connected, for example by means of conducting tape or strips of conducting material, to permit connection with other strings or for connection to the circuits outside the module.
  • Other collectors 14 can be provided on the panel 8 to connect the bus bars to the external circuits in the same way.
  • Different solutions from the one described can be used, such as herringbone arrangement or, if necessary, instead of on the opposite side as shown in figure 3, some cells can have the tape on the side adjacent to the bus bar so that two nearby strings can be directly connected; it is nevertheless preferable to have equal cells prepared in the same way, especially in an automated process.
  • the adhesive tape 3 can be replaced by an element made of other material, such as a copper strip.
  • lamination is performed, i.e. hot application of a film, for example of EVA, on the whole panel.
  • a film for example of EVA
  • the application is performed preferably under heat, by means of suitable heating devices, preferably at a temperature that also causes hardening of the conducting glue or soldering via the soldering paste; for example, heating can be performed in an oven under vacuum, a technique commonly used for lamination.
  • suitable heating devices preferably at a temperature that also causes hardening of the conducting glue or soldering via the soldering paste; for example, heating can be performed in an oven under vacuum, a technique commonly used for lamination.
  • the materials will be preferably chosen so that the lamination, the soldering or hardening take place together, at the same temperature, thus, the fixing step and the film application are performed simultaneously.
  • the solar cells used are generally made of mono or polycrystalline silicon and preferably have a thickness of between 100 and 500 ⁇ m.
  • the conducting element for example a conducting tape or a copper sheet, can completely cover the back of the cell; it can be applied while the cell is on a conveyor belt with the back facing upwards, if necessary after application of conducting glue or soldering paste; the soldering or hardening takes place immediately afterwards, for example on the conveyor belt by means of a heated surface. The cell is then overturned and the subsequent steps are the same as those already seen. An adequate portion of the conducting element still protrudes at the side of the cell to permit connection between different cells. In this case it is not necessary for the panel 8 to be provided with the bases for application of the cells which, equipped with conducting element, can be positioned directly on the panel, if found necessary, by means of ordinary adhesive.
  • the conducting element can be a pre-punched sheet of copper or conducting material, i.e. in which cuts of suitable shape have been made, in order to form tabs 15, attached to the sheet, which will then constitute the connection with the front of the other cells (or with the panel collectors) and will be appropriately folded before the sheet is applied to the cell.
  • the punching can also be performed on the bases 9" (see figures 4, 5 and 6) made of copper (or suitable material) provided on the panel. In this case the tabs must be raised before application of the cell.
  • conducting glue or soldering paste is deposited on the base before raising of the tab, which is then folded on the front (in general on the bus bars) of the adjacent cell 1 , which has advantageously been positioned before.
  • Raising and folding can be performed by a robotised arm, for example provided with suction cups.
  • the process can be fully or partly automated, also reducing the risk of errors and breakage and permitting rational arrangement of the cells in the modules, with the possibility of reducing unused spaces between the cells and increasing efficiency per module surface unit. Furthermore, the process can be used with cells like those commonly available on the market, and does not require modifications in the manufacturing procedures.
  • the invention also concerns a photovoltaic module comprising a series of photovoltaic cells connected in series by means of conducting elements fixed to the front of said cells by means of conducting glue or soldering paste.

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  • Engineering & Computer Science (AREA)
  • Physics & Mathematics (AREA)
  • Condensed Matter Physics & Semiconductors (AREA)
  • Electromagnetism (AREA)
  • General Physics & Mathematics (AREA)
  • Computer Hardware Design (AREA)
  • Microelectronics & Electronic Packaging (AREA)
  • Power Engineering (AREA)
  • Manufacturing & Machinery (AREA)
  • Life Sciences & Earth Sciences (AREA)
  • Sustainable Development (AREA)
  • Photovoltaic Devices (AREA)

Abstract

Process for assembly of a photovoltaic module comprising a series of photovoltaic cells (1, 1') and electrical terminals, said process comprising the following steps: connection of a conducting element (3, 9',9',15) to the back (2), of the cells; deposition of conducting glue or soldering paste (7) on at least part (5) of the front (6) of the cells; positioning of the cells on a panel (8) of suitable material; connection to the front of the cells of the conducting element connected to the back of another cell or to an electrical terminal; fixing, by hardening of the conducting glue or soldering by means of the soldering paste; hot application of a film of EVA and a sheet of glass to cover the panel, simultaneously with the fixing.

Description

PROCESS FOR ASSEMBLY OF PHOTOVOLTAIC MODULES
FIELD OF THE INVENTION
The present invention concerns a process for assembly of photovoltaic modules, comprising a plurality of interconnected solar cells. PRIOR ART
Photovoltaic modules commonly consist of a series of solar cells (in general thin slices of appropriately doped mono or polycrystalline silicon) arranged on a surface and interconnected in series or parallel according to requirements. The slices of silicon have two opposite parallel faces, one doped p and one doped n, the latter obtained, in general, by diffusion of an appropriate doping agent (such as phosphorous) through one face of a p doped slice. To collect the current produced by the cells, the two faces are provided with appropriate conducting structures. On the n doped face, which is commonly the one exposed to the radiation that must be converted into electrical energy, after deposition of a suitable anti-reflecting material, a grille is created for collection of the current consisting of thin conductors called fingers which must have an extension over the surface as widespread as possible, for optimal collection of the current generated, but at the same time be compatible with the need to leave as much surface as possible exposed to receive the light radiation; the fingers can be created on the surface by deposition and partial diffusion of materials such as mixtures of aluminium and silver, by means of known techniques (like deposition of compounds containing said materials by masking and heating). The same method is used to create thicker collectors, called bus bars, connected to the fingers, and to which the contacts can be soldered, for example appropriately tin-plated copper strips for connecting the cells to other cells or to the electrical circuits of which they form part.
As regards the face (doped p) not exposed to the radiation, a layer of aluminium is deposited and partially diffused throughout said surface, as described above. In certain areas, to which the contacts will be soldered, silver can also be introduced in order to facilitate the soldering.
The face that will receive the radiation will from now on be called front of the cell and the opposite face back. Several variations exist as regards the cell structure, both in terms of materials to be used and of geometry of the contacts and of the conducting parts. The cells provided with copper strips can be connected in series, soldering the strip applied to the bus bar of the front of one cell to the back of another. In this way rows, or strings, are formed which are then arranged on a panel, made of plastic for example. Several strings are then connected in series or parallel, thus constituting the photovoltaic module, which is then appropriately sealed, for example by means of a sheet of glass (with suitable physical characteristics such as transparency to certain wavelengths), having a layer of suitable material such as a film of ethylene vinyl acetate (EVA). By means of heating the film is applied directly over the cells arranged on the panel as described above; this step is also called lamination.
Assembly of a photovoltaic module, therefore, involves various soldering phases which must be performed in subsequent steps, such as application of the copper strips to the cells by soldering (operation also called tipping), soldering between them and connection between the strings to form the circuits. These steps, as well as the formation of strings and their arrangement on the panel, are time-expensive and difficult, and involve serious risk of breakage of the cells. This is also due to the fact that these operations are not suited to automated procedures and are generally performed manually by an operator, or only the soldering operations are partially automated in a limited number of points in formation of the strings; in any case, the process is inefficient and is labour-intensive. Assembly costs are therefore high and become progressively more relevant as technology allows obtaining cells at increasingly lower costs. An assembly process more widely or completely subject to automation is therefore desirable, capable of reducing manufacturing times and risks of breakage in order to reduce the costs of the photovoltaic modules. It is also desirable to reduce the number of subsequent operations, for example by combining the various connection and soldering steps. Furthermore, a widely automated process would make it easier to optimise arrangement of the cells on the panel, thus reducing unused spaces and increasing the overall efficiency of the module. SUMMARY The problems illustrated above have now been solved by a process for assembly of a photovoltaic module comprising a series of photovoltaic cells and electrical terminals, said process comprising the following steps:
- connection of a conducting element to the back of the cells; - deposition of conducting glue or soldering paste on at least part of the front of the cells;
- positioning of the cells on a panel made of suitable material;
- connection to the front of the cells of a conducting element connected to the back of another cell or to an electrical terminal; - fixing of the conducting element to the front of the cells, by means of said conducting glue or by soldering with said soldering paste.
The steps can be performed in the above order or in another order if necessary. As will be seen, positioning of the cells on said panel can be simultaneous with connection of the conducting element to the back. Advantageously, the fixing step is performed under heat, simultaneously for all the cells; in this step the conducting glue hardens, if required by the type of glue used; again, this process is performed hot.
The conducting element can be a conducting adhesive tape or a strip of material appropriately fixed to the back of the cells with soldering paste or conducting glue applied in-between.
Preferably the process also provides for hot application of a film of suitable material on the panel on which the cells are arranged. The material can be EVA and it can advantageously be applied simultaneously with the fixing step. The film can be applied together with a sheet of transparent material, for example glass, which will close the panel at the front.
The deposition of conducting glue or soldering paste on at least part of the front of the cells, in general on the bus bars, can be performed on a conveyor belt from which the cells are withdrawn preferably by a robotised arm and deposited on the panel; according to a particular aspect of the invention, the panel can be previously provided with a series of conducting bases, made of copper for example, at least one per cell. These bases can be obtained by various techniques commonly employed in printed circuit technology. The conducting glue can, in certain cases, be the adhesive already present on the conducting tape, as manufactured; this applies, for example, in the case of double- sided conducting tape. LIST OF FIGURES The present invention will now be illustrated by a detailed description of preferred but not exclusive forms of embodiment, provided simply as an example, with the help of the attached figures in which:
Figure 1 schematically represents a cell to which a conducting element is applied in a process according to the present invention. Figure 2 schematically represents an overhead view of a portion of panel constituting the back of a module produced according to the process of the present invention.
Figure 3 schematically represents a view of two adjacent cells positioned in a module produced according to the process of the present invention. Figures 4 and 5 schematically show a view of two possible alternatives of a step of the process according to the invention.
Figure 6 schematically represents another view (lateral and in section) of the step of the process of Figure 4. DETAILED DESCRIPTION According to a possible aspect of the invention, an adhesive conducting tape 3 (for example, tape 3M 1138), which will constitute the conducting element, is applied to the back 2 of the solar cells 1 (preferably complete with contact structures such as fingers, bus bars and conducting material on the back, as commonly produced). The tape 3 is preferably applied so that an adequate portion 4 protrudes at the side of the 'cell as shown in figure 1. This can be done while the cell is conveniently positioned on a conveyor belt and the tape can be automatically applied. If the back of the cell is underneath, the adhesive tape can be applied through a transverse groove of the belt leaving the portion of the back of the cell free for application of the tape, or the cell can be positioned with a part protruding from one side of the conveyor belt, where the tape 3 can be applied, while the cell is retained by appropriate devices on the conveyor belt such as another roller, for example. Alternatively the cell can be positioned with the back facing upwards for application of the adhesive tape and then overturned, for example by a mechanical arm, for the subsequent phases. The tape can be deposited, for example, by means of an automatic dispenser and cut automatically to form elements of the required length for the next cell connection. The next operation consists in the application of conducting glue (for example Loctite 3880) or soldering paste (for example LT 30 Multicore) (unless a two-sided conducting tape is used) on part 5 of the front of the cell 1 , in general on the bus bar 5. The glue can be applied by means of an automatic dispenser above the conveyor belt, for example in the form of strips 7 or spheres, or in any other suitable form. Figure 2 shows a portion of panel 8 on which the cells will be positioned, said panel constituting the rear part of the photovoltaic module. The panel is made of suitable material (for example Tedlar, PET, PEN, GHE, Capton, glass or other) and may feature a series of bases 9, preferably in the shape of a cell and produced by means of appropriate techniques, those commonly used in the production of printed circuits. The cells can be aligned in various ways, for example parallel rows 11 , 11 ' on which the strings of cells will be formed. On each base 9 a cell 1 will be positioned, after an adequate amount of glue (indicated by 10 in figure 3) or soldering paste has been applied on the base by means of stencil technology or with a dispenser, for example. The glue will be preferably hardened or the soldering, by means of the soldering paste, will be performed in the fixing step. With reference to figure 3, according to a preferred aspect, the cells 1 ', 1 " will be positioned on the bases 9 in sequence so that two adjacent cells are connected by the tape 3 in series, i.e. the front of one to the back of the other. For example, cell 1 ' is positioned first; cell 1" will be positioned so that the free portion 4 of the tape 3 covers with the end 12 the part of cell 1' on which the glue or paste has been applied (in general the bus bar). Some bases 9' (see figure 3) can be provided with contacts 13 to which the bus bars of the cells positioned at one end of a string are connected, for example by means of conducting tape or strips of conducting material, to permit connection with other strings or for connection to the circuits outside the module. Other collectors 14 can be provided on the panel 8 to connect the bus bars to the external circuits in the same way. Different solutions from the one described can be used, such as herringbone arrangement or, if necessary, instead of on the opposite side as shown in figure 3, some cells can have the tape on the side adjacent to the bus bar so that two nearby strings can be directly connected; it is nevertheless preferable to have equal cells prepared in the same way, especially in an automated process. The adhesive tape 3 can be replaced by an element made of other material, such as a copper strip.
Once all the cells have been positioned on the panel and all the connections have been made, according to a preferred aspect of the invention, lamination is performed, i.e. hot application of a film, for example of EVA, on the whole panel. In general a sheet of glass can be applied with the film. The application is performed preferably under heat, by means of suitable heating devices, preferably at a temperature that also causes hardening of the conducting glue or soldering via the soldering paste; for example, heating can be performed in an oven under vacuum, a technique commonly used for lamination. The materials will be preferably chosen so that the lamination, the soldering or hardening take place together, at the same temperature, thus, the fixing step and the film application are performed simultaneously.
The solar cells used are generally made of mono or polycrystalline silicon and preferably have a thickness of between 100 and 500 μm. According to a further aspect of the invention, the conducting element, for example a conducting tape or a copper sheet, can completely cover the back of the cell; it can be applied while the cell is on a conveyor belt with the back facing upwards, if necessary after application of conducting glue or soldering paste; the soldering or hardening takes place immediately afterwards, for example on the conveyor belt by means of a heated surface. The cell is then overturned and the subsequent steps are the same as those already seen. An adequate portion of the conducting element still protrudes at the side of the cell to permit connection between different cells. In this case it is not necessary for the panel 8 to be provided with the bases for application of the cells which, equipped with conducting element, can be positioned directly on the panel, if found necessary, by means of ordinary adhesive.
According to a possible variation the conducting element can be a pre-punched sheet of copper or conducting material, i.e. in which cuts of suitable shape have been made, in order to form tabs 15, attached to the sheet, which will then constitute the connection with the front of the other cells (or with the panel collectors) and will be appropriately folded before the sheet is applied to the cell. The punching can also be performed on the bases 9" (see figures 4, 5 and 6) made of copper (or suitable material) provided on the panel. In this case the tabs must be raised before application of the cell. According to a particular aspect of the invention, conducting glue or soldering paste is deposited on the base before raising of the tab, which is then folded on the front (in general on the bus bars) of the adjacent cell 1 , which has advantageously been positioned before. Raising and folding can be performed by a robotised arm, for example provided with suction cups.
It is easy to see that the soldering or hardening operations involve fewer steps, and can even consist of one single step together with the lamination. This considerably reduces production times and costs. Furthermore, the process can be fully or partly automated, also reducing the risk of errors and breakage and permitting rational arrangement of the cells in the modules, with the possibility of reducing unused spaces between the cells and increasing efficiency per module surface unit. Furthermore, the process can be used with cells like those commonly available on the market, and does not require modifications in the manufacturing procedures.
The invention also concerns a photovoltaic module comprising a series of photovoltaic cells connected in series by means of conducting elements fixed to the front of said cells by means of conducting glue or soldering paste. Many variations and process sequences are possible apart from those illustrated, in addition to optimisation of said processes resulting from the use of cells of different shapes and sizes with respect to the standard in force, while remaining within the scope of the invention.

Claims

1. Process for assembly of a photovoltaic module comprising a series of photovoltaic cells (1 , 1 ') and electrical terminals, said process comprising the following steps: - connection of a conducting element (3, 9',9",15) to the back (2) of the cells;
- deposition of conducting glue or soldering paste (7) on at least part (5) of the front (6) of the cells;
- positioning of the cells on a panel (8) of suitable material;
- connection to the front of the cells of the conducting element connected to the back of another cell or to an electrical terminal;
- fixing of the conducting element to the front of the cells, by means of said conducting glue or by soldering with said soldering paste.
2. Process according to claim 1 in which the conducting element is a conducting adhesive tape (3).
3. Process according to claim 1 in which the conducting element is applied to the back of the cell by means of conducting glue or soldering paste.
4. Process according to any of the previous claims in which the panel (8) features a series of bases (9, 9', 9") which are made of conducting material and have the same shape of the cells, on which bases the cells are positioned after deposition of conducting glue or soldering paste on the bases.
5. Process according to any of the previous claims comprising a step involving hot application of a film on the panel on which the cells have been arranged.
6. Process according to claim 5 in which said film is made of EVA and its hot application is simultaneous with the fixing, which is performed by means of the heat.
7. Process according to claim 1 in which said conducting element totally covers the back of the cell to which it is applied.
8. Process according to claim 2 in which the conducting adhesive tape (3) is applied while the cell is on a conveyor belt.
9. Process according to any of the previous claims in which the conducting glue or soldering paste is deposited on the front of the cells by an automatic dispenser while the cell is on a conveyor belt.
10. Process according to any of the previous claims in which the cells are deposited on the panel by means of a robotised arm.
11. Process according to any of the previous claims in which the panel is made of a material chosen from Tedlar, PET, PEN, Capton, GHE or glass.
12. Process according to any of the previous claims in which, in the case of two adjacent cells, to be connected in series by a conducting element, the first to be deposited is cell (1') which will be connected to said conducting element at the front and then cell (1"), connected to said conducting element at the back.
13. Process according to claim 1 in which a pre-punched copper sheet is applied to the back of the cells in order to obtain a tab (15) which is folded before application to the cell, said tab being connected to the front of another cell.
14. Process according to any of the previous claims in which said cells are slices of mono or polycrystalline silicon and have a thickness between 100 and 500 μm.
15. Photovoltaic module comprising a series of photovoltaic cells (1 , 1 ', 1 ") connected in series by means of conducting elements (3) fixed to the front (6) of said cells by means of conducting glue or soldering paste (7).
16. Module according to claim 15 in which said conducting element is a conducting adhesive tape.
PCT/EP2003/011794 2002-10-25 2003-10-24 Process for assembly of photovoltaic modules WO2004038814A1 (en)

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AU2003274074A AU2003274074A1 (en) 2002-10-25 2003-10-24 Process for assembly of photovoltaic modules
EP03758055A EP1556903A1 (en) 2002-10-25 2003-10-24 Process for assembly of photovoltaic modules

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IT002276A ITMI20022276A1 (en) 2002-10-25 2002-10-25 ASSEMBLY PROCESS OF PHOTOVOLTAIC MODULES

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CN101931019A (en) * 2010-08-30 2010-12-29 江苏润达光伏科技有限公司 Low-stress solar assembly and manufacture method thereof
CN102332483A (en) * 2011-08-01 2012-01-25 常州天合光能有限公司 Connection mode of solar battery cells
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JP2014229754A (en) * 2013-05-22 2014-12-08 三菱電機株式会社 Method for manufacturing solar cell module and solar cell module
JP2017143311A (en) * 2017-05-17 2017-08-17 三菱電機株式会社 Method of manufacturing solar battery module
CN108574021A (en) * 2018-05-26 2018-09-25 宁夏小牛自动化设备有限公司 Convergent belt composition backing device and confluence tape welding machine and undertaking absorption welding method
CN110193685A (en) * 2019-06-03 2019-09-03 无锡奥特维科技股份有限公司 A kind of cell piece string welding machine and cell piece series welding method
CN110193685B (en) * 2019-06-03 2024-04-30 无锡奥特维科技股份有限公司 Battery piece series welding machine and battery piece series welding method

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DE102006021804A1 (en) * 2006-05-09 2007-11-15 International Solar Energy Research Center Konstanz E.V. Solar cell module and method for the production of solar cell modules
WO2012016103A3 (en) * 2010-07-30 2012-03-15 Dow Global Technologies Llc System and automated assembly method for the production of interconnected thin-film solar cell modules
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CN101931019A (en) * 2010-08-30 2010-12-29 江苏润达光伏科技有限公司 Low-stress solar assembly and manufacture method thereof
CN101931019B (en) * 2010-08-30 2012-07-11 江苏润达光伏科技有限公司 Low-stress solar assembly and manufacture method thereof
CN102332483A (en) * 2011-08-01 2012-01-25 常州天合光能有限公司 Connection mode of solar battery cells
JP2014229754A (en) * 2013-05-22 2014-12-08 三菱電機株式会社 Method for manufacturing solar cell module and solar cell module
JP2017143311A (en) * 2017-05-17 2017-08-17 三菱電機株式会社 Method of manufacturing solar battery module
CN108574021A (en) * 2018-05-26 2018-09-25 宁夏小牛自动化设备有限公司 Convergent belt composition backing device and confluence tape welding machine and undertaking absorption welding method
CN108574021B (en) * 2018-05-26 2023-12-01 宁夏小牛自动化设备股份有限公司 Bus bar welding backing plate device, bus bar welding machine and receiving and adsorbing welding method
CN110193685A (en) * 2019-06-03 2019-09-03 无锡奥特维科技股份有限公司 A kind of cell piece string welding machine and cell piece series welding method
CN110193685B (en) * 2019-06-03 2024-04-30 无锡奥特维科技股份有限公司 Battery piece series welding machine and battery piece series welding method

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EP1556903A1 (en) 2005-07-27
ITMI20022276A1 (en) 2004-04-26

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