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EP2399298A1 - Modules photovoltaïques et leur procédé de fabrication - Google Patents

Modules photovoltaïques et leur procédé de fabrication

Info

Publication number
EP2399298A1
EP2399298A1 EP10708794A EP10708794A EP2399298A1 EP 2399298 A1 EP2399298 A1 EP 2399298A1 EP 10708794 A EP10708794 A EP 10708794A EP 10708794 A EP10708794 A EP 10708794A EP 2399298 A1 EP2399298 A1 EP 2399298A1
Authority
EP
European Patent Office
Prior art keywords
resin
cavity
module
photovoltaic
cells
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Withdrawn
Application number
EP10708794A
Other languages
German (de)
English (en)
Inventor
Mario Molina
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Gigi Molina Brevetti Plastici SpA
Original Assignee
Gigi Molina Brevetti Plastici SpA
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 Gigi Molina Brevetti Plastici SpA filed Critical Gigi Molina Brevetti Plastici SpA
Publication of EP2399298A1 publication Critical patent/EP2399298A1/fr
Withdrawn legal-status Critical Current

Links

Classifications

    • H—ELECTRICITY
    • H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
    • H02S—GENERATION OF ELECTRIC POWER BY CONVERSION OF INFRARED RADIATION, VISIBLE LIGHT OR ULTRAVIOLET LIGHT, e.g. USING PHOTOVOLTAIC [PV] MODULES
    • H02S20/00—Supporting structures for PV modules
    • H02S20/20—Supporting structures directly fixed to an immovable object
    • H02S20/22—Supporting structures directly fixed to an immovable object specially adapted for buildings
    • H02S20/23—Supporting structures directly fixed to an immovable object specially adapted for buildings specially adapted for roof structures
    • H02S20/25—Roof tile elements
    • H—ELECTRICITY
    • H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
    • H02S—GENERATION OF ELECTRIC POWER BY CONVERSION OF INFRARED RADIATION, VISIBLE LIGHT OR ULTRAVIOLET LIGHT, e.g. USING PHOTOVOLTAIC [PV] MODULES
    • H02S20/00—Supporting structures for PV modules
    • H02S20/20—Supporting structures directly fixed to an immovable object
    • H02S20/22—Supporting structures directly fixed to an immovable object specially adapted for buildings
    • H02S20/23—Supporting structures directly fixed to an immovable object specially adapted for buildings specially adapted for roof structures
    • H—ELECTRICITY
    • H10—SEMICONDUCTOR DEVICES; ELECTRIC SOLID-STATE DEVICES NOT OTHERWISE PROVIDED FOR
    • H10F—INORGANIC SEMICONDUCTOR DEVICES SENSITIVE TO INFRARED RADIATION, LIGHT, ELECTROMAGNETIC RADIATION OF SHORTER WAVELENGTH OR CORPUSCULAR RADIATION
    • H10F19/00—Integrated devices, or assemblies of multiple devices, comprising at least one photovoltaic cell covered by group H10F10/00, e.g. photovoltaic modules
    • H10F19/80—Encapsulations or containers for integrated devices, or assemblies of multiple devices, having photovoltaic cells
    • H—ELECTRICITY
    • H10—SEMICONDUCTOR DEVICES; ELECTRIC SOLID-STATE DEVICES NOT OTHERWISE PROVIDED FOR
    • H10F—INORGANIC SEMICONDUCTOR DEVICES SENSITIVE TO INFRARED RADIATION, LIGHT, ELECTROMAGNETIC RADIATION OF SHORTER WAVELENGTH OR CORPUSCULAR RADIATION
    • H10F19/00—Integrated devices, or assemblies of multiple devices, comprising at least one photovoltaic cell covered by group H10F10/00, e.g. photovoltaic modules
    • H10F19/80—Encapsulations or containers for integrated devices, or assemblies of multiple devices, having photovoltaic cells
    • H10F19/807—Double-glass encapsulation, e.g. photovoltaic cells arranged between front and rear glass sheets
    • 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
    • Y02B—CLIMATE CHANGE MITIGATION TECHNOLOGIES RELATED TO BUILDINGS, e.g. HOUSING, HOUSE APPLIANCES OR RELATED END-USER APPLICATIONS
    • Y02B10/00—Integration of renewable energy sources in buildings
    • Y02B10/10—Photovoltaic [PV]
    • 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

Definitions

  • the present invention relates in general to the production of solar panels consisting of one or more photovoltaic modules connected to one another and, in particular, a process for the production of photovoltaic modules and the modules thus produced.
  • Background art Currently, the photovoltaic modules most widely marketed are produced using monocrystalline silicon, poly crystalline silicon or amorphous silicon cells. Silicon cells have a very limited thickness, in general of a few microns, and must therefore be placed on a rigid backing and then electrically connected to one another.
  • the conventional production process of a cell type photovoltaic module essentially involves positioning of an encapsulating material on glass, followed by positioning of the cells already connected to one another, and finally positioning of a protective material on the back.
  • the composite thus obtained is subjected to lamination in a press and then mounted in a frame generally made of aluminium.
  • the various layers of the module form a sandwich consisting of:
  • the laminate is placed in a chamber that reaches a temperature of 100°C and in which the vacuum (1 mmHg) is applied for a few minutes.
  • the lamination and polymerization cycles are completed: in fact, heating of the module allows the sheet of EVA to melt around the electric circuits, in order to seal the cells to the lower and upper layers of the module. The temperature is then taken to 160 0 C to complete polymerization of the EVA, and subsequently returned to 100 0 C;
  • one of the major problems of conventional photovoltaic modules is constituted by the excessive weight of the module, in practice due to the weight of the backing structure thereof, which significantly limits possible applications thereof, and to the rigidity of the backing structure caused by the low ductility of glass.
  • An object of the present invention is therefore to propose an improved photovoltaic module having a much lower weight with respect to that of prior art photovoltaic modules and a wider range of applications.
  • Another object of the present invention is to propose a process that allows photovoltaic modules to be produced in shorter times with respect to prior art production processes.
  • a further object of the present invention is to propose a process that allows photovoltaic modules to be produced at lower costs with respect to prior art production processes.
  • the process for the production of photovoltaic modules includes the steps of: i) applying a plurality of photovoltaic cells to a backing fabric comprising glass fibres and electrically connecting the cells to one another; ii) preparing a mould having a shaped cavity and sized in plan to obtain a module having desired dimensions in width and length; iii) applying a layer of transparent gel coat resin in fluid condition to the surfaces of the cavity; iv) placing the backing fabric with the cells attached thereto in the cavity; v) placing a central core on top of the backing fabric; vi) placing a fabric comprising glass fibres on top of the central core; vii) closing the mould by means of an upper mould to seal the cavity; and viii) saturating the cavity with resin until it is completely filled.
  • the backing structure consists of plastic materials, such as resin reinforced with fibres (or fibreglass), and polyurethane or expanded PVC for the central core, i.e. materials that are undoubtedly lighter with respect to those conventionally used, such as glass and aluminium.
  • Saturation of the cavity with filling resin is preferably performed by injection with a low vacuum technique of the RTM LIGHT type. This technique allows gradual diffusion of the resin throughout the inner space of the cavity without damaging the photovoltaic cells, also simultaneously allowing all the air to be removed from the mould cavity.
  • a fabric comprising glass fibres is preferably placed on the central core, in order to give greater strength to the final glass fibre structure also on the back of the module.
  • Suitable fabrics comprising glass fibres are for example those identified by the trademarks ROVICORETM, CONFORMATTM, or in any case fabrics comprising two layers of glass fibres and one intermediate layer made of plastic material or of other materials made of fibres.
  • a further step can also be included to harden the module in an oven, after it has been removed from the mould.
  • This further step can be useful to obtain complete drying of the outer layer of transparent resin coating the module.
  • the transparent resin, or gel coat is a material that allows a high surface hardness to be given to the module.
  • saturation of the cavity with resin can also be performed by means of an infusion technique.
  • the filling resin can also consist of a resin of self-extinguishing type, in order to allow a wider range of applications for the modules obtained according to the present invention in compliance with any safety regulations of various applications.
  • the resin reinforced with fibres is usually a material used for applications that require limited weight but high mechanical strength.
  • the central core can consist of a plastic material such as polyurethane, expanded PVC, or in any case of materials with similar properties.
  • At least one backing fabric comprising glass fibres, on which a plurality of photovoltaic cells electrically connected to one another are applied;
  • a coil can also be incorporated for the circulation of a heat exchange fluid.
  • a heat exchange fluid it is known that the output of photovoltaic cells varies as a function of the temperature and, in particular, the output decreases as the temperature of the cells increases. It may therefore be advantageous to make a heat exchange fluid circulate in the module to remove heat from the photovoltaic cells and utilise the thermal energy of the heated fluid for other uses, for example the production of hot water or the like.
  • the coil is placed in contact with or in proximity of the backing fabric of the cells, on the opposite side with respect to the side on which the cells are attached.
  • FIG. 1 is a perspective view of a photovoltaic module according to the prior art
  • - Fig. 2 is a schematic view showing the typical composition of the photovoltaic module of Fig. 1 ;
  • - Fig. 3 is a partially sectional schematic view showing a mould for implementation of the process according to the present invention;
  • Fig. 5 shows the step to close the mould before saturation with the resin
  • FIG. 6 shows the step of the process according to the invention after saturation with the resin
  • Fig. 7 is a schematic sectional view showing a photovoltaic module according to the present invention after removal thereof from the mould;
  • FIG. 8 is a schematic plan view showing a component of the photovoltaic module according to an alternative embodiment of the present invention.
  • Fig. 9 is a schematic sectional view showing a photovoltaic module including the component represented in Fig. 8;
  • FIG. 10 is a schematic sectional view showing a possible embodiment of a photovoltaic module according to the present invention.
  • FIG. 11 is a schematic sectional view showing a solar panel produced by mutually coupling a plurality of photovoltaic modules such as the one represented in Fig. 10.
  • Figs. 1 and 2 represent by way of example a conventional photovoltaic module 100 including a plurality of photovoltaic cells 110 positioned on a backing structure enclosed by an aluminium frame 130.
  • the conventional module 100 includes a top plate 101 made of high transparency glass, a sealing sheet 102 made of EVA (ethylene vinyl acetate) and then the photovoltaic cells 110 placed on a backing sheet 103 made of MylarTM.
  • another sealing sheet made of EVA and finally a plate 104 which constitutes the back of the module 100, for example made of glass or in an aluminium and Tedlar multilayer composite, are positioned under the cells 110.
  • the sandwich thus produced is then subjected to a lamination step (polymerization of the EVA sheets) and to a compression step to eliminate residual air.
  • a lamination step polymerization of the EVA sheets
  • a compression step to eliminate residual air.
  • the module is enclosed in the aluminium frame 130. It can easily be understood that the weight of a module thus produced is very high, as are the costs of the materials used and the costs for their production.
  • Fig. 3 schematically shows a mould 10 and an upper mould 20 for implementation of the process according to the present invention.
  • express reference will be made to a process in which saturation with resin is performed using the low vacuum (or RTM LIGHT) injection technique, but it should be borne in mind that other similar techniques, for example the infusion technique, can be used, provided that damage to the particularly fragile components, in particular to the photovoltaic cells is avoided.
  • RTM LIGHT low vacuum
  • the mould 10 includes a cavity 11 in which the various components of the photovoltaic module will be placed in succession.
  • the upper mould 20 has a closing portion 21 corresponding in shape and size to the cavity 11 to allow it to be sealed during injection of the resin.
  • the mould 10 and the upper mould 20 can be made of any suitable material, such as aluminium, fibreglass or the like, and can also include a temperature control system to prevent the temperature from dropping below a preset threshold. In fact, is should be borne in mind that below a specific temperature, i.e. 15-16 °C, the process could give somewhat unsatisfactory results as the fluidity of the resin injected could be insufficient to ensure complete and uniform filling of all the empty spaces.
  • the upper mould 20 includes a pair of peripheral seals 22 that allow the mould 10 to be hermetically sealed.
  • a suction connection 23 collects air from the chamber 24 delimited by the seals 22 and by the surfaces of mould and upper mould when these are coupled (Fig. 5), in order to generate a sufficiently high vacuum pressure to maintain the two elements coupled during the subsequent steps of the process.
  • a second suction connection 25 allows a weak vacuum pressure to be generated inside the sealed cavity in order to receive the resin pumped through a connection 26.
  • a reservoir 27 allows the excess resin to be collected at the end of the injection step and confirms that all the empty spaces inside the cavity 11 have been filled.
  • the upper mould 20 is also provided with a plurality of through holes 28 through which the electrical terminals, and any hydraulic terminals, of the module being produced are passed. Appropriate cable clamping devices 29 to constrain the terminals during the steps of the production process can be provided outside the holes 28.
  • a release agent is preferably applied to the walls of the mould 11, in order to facilitate removal of the photovoltaic module from the mould 10 at the end of the process.
  • Fig. 4 shows the first steps of the process for the production of photovoltaic modules according to the present invention.
  • a suitable backing fabric 30 including glass fibres has already been prepared, such as ROVICORETM, CONFORMATTM or the like, on which the photovoltaic cells 40 have been placed and that the necessary electrical connections between these cells have already been made.
  • the central core 60 is preferably produced by a plate made of light plastic material, such as polyurethane or expanded PVC, in order to give properties of high rigidity and strength to the module.
  • the central core 60 generally has a thickness between 0.5 cm and 2 cm, but central cores with greater thicknesses can also be used if it is necessary to satisfy particular requirements of strength in specific installations.
  • a further fabric 70 comprising glass fibres, for example the same fabric of the ROVICORETM, CONFORMATTM type or similar already used for the cell backing, is preferably placed on the core 60.
  • Fig. 5 shows the closing step of the mould 10 on which the upper mould 20 is placed, taking care to pass the terminals 45 for electric connection of the module through the through holes 28 (Fig. 3) and to block the terminals with the cable clamping devices 29.
  • the vacuum pressure generated in the chambers 24 through the suction connection 23 hermetically seals the cavity 11.
  • the vacuum condition that holds the mould closed can, for example, be maintained and released using an appropriate valve 13 positioned on the connection 23 or along the pipe that connects it to the vacuum source.
  • the step to saturate the mould with the resin is then started, using a low vacuum (or RTM LIGHT) technique.
  • a low vacuum or RTM LIGHT
  • the resin substantially "impregnates" all the fabrics with glass fibres and all the spaces not occupied by the components of the module inside the cavity, and the vacuum condition generated inside the cavity also simultaneously ensures that all the air present inside said cavity is evacuated.
  • the process according to the invention includes the use of a low vacuum technique, such as the RTM LIGHT technique, so that the resin flows slowly into all the empty spaces and does not damage the most fragile components, i.e. the photovoltaic cells.
  • a low vacuum technique such as the RTM LIGHT technique
  • vacuum pressures of around -0.5 bar can be used to help the resin to flow in the injection step, i.e. vacuum pressures much lower than those applied, for example, to the connection 23 to maintain the mould closed (from -0.9 to -1.0 bar).
  • the mould 10 is then left closed for a time sufficient to allow the resin to harden and subsequent removal of the module without damage thereto.
  • the module removed from the mould can optionally be subjected to a hardening step in the oven which allows the transparent resin (gel-coat) coating the front wall and the side walls of the module and the filling resin incorporating the components of the module to be given high mechanical strength and surface hardness.
  • a module 80 thus obtained has the configuration represented in Fig. 7, in which the module is overturned with respect to the position inside the mould.
  • the cells 40 are protected frontally by the hardened layer 50 of transparent gel coat, while the filling resin has impregnated the fabrics 30 and 70 containing glass fibres and has also incorporated the central core 60 made of polyurethane or expanded PVC, clamping it between the two fabrics 30 and 70.
  • the module has a thickness generally between around 1 cm and 3 cm, but can also have greater thicknesses for particular applications or installations.
  • an alternative embodiment of the present inventions includes the production of a module 80' in which a coil 61 is incorporated in the central core 60 to allow the circulation of a heat exchange fluid therein.
  • a module 90 such as the one represented in section in Fig. 10 can comprise at the sides thereof shaped portions 91 to allow mutual interlocking between several modules and thus form a single photovoltaic solar panel, such as the one represented in Fig.
  • each module can differ from the number represented herein by way of example, and the module can also take different shapes, as a function of the particular applications.

Landscapes

  • Engineering & Computer Science (AREA)
  • Architecture (AREA)
  • Civil Engineering (AREA)
  • Structural Engineering (AREA)
  • Photovoltaic Devices (AREA)

Abstract

La présente invention porte sur un procédé de fabrication d'un module photovoltaïque dans lequel les cellules photovoltaïques sont incorporées dans une structure en résine renforcée par des fibres (ou fibres de verre). Les cellules sont appliquées sur un tissu comprenant des fibres de verre et positionnées dans la cavité d'un moule, conjointement avec d'autres composants, et la cavité est ensuite saturée par la résine afin d'incorporer tous les composants du module.
EP10708794A 2009-02-17 2010-02-12 Modules photovoltaïques et leur procédé de fabrication Withdrawn EP2399298A1 (fr)

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
ITMI2009A000204A IT1392931B1 (it) 2009-02-17 2009-02-17 Moduli fotovoltaici e procedimento per la loro produzione
PCT/IB2010/000268 WO2010095012A1 (fr) 2009-02-17 2010-02-12 Modules photovoltaïques et leur procédé de fabrication

Publications (1)

Publication Number Publication Date
EP2399298A1 true EP2399298A1 (fr) 2011-12-28

Family

ID=41258327

Family Applications (1)

Application Number Title Priority Date Filing Date
EP10708794A Withdrawn EP2399298A1 (fr) 2009-02-17 2010-02-12 Modules photovoltaïques et leur procédé de fabrication

Country Status (3)

Country Link
EP (1) EP2399298A1 (fr)
IT (1) IT1392931B1 (fr)
WO (1) WO2010095012A1 (fr)

Families Citing this family (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
CN103597607B (zh) * 2010-12-23 2016-09-21 瑞士联邦理工大学，洛桑(Epfl) 光伏元件
GB2580960A (en) * 2019-02-01 2020-08-05 Sunew Filmes Fotovoltaicos Photovoltaic device, photovoltaic device apparatus and method of manufacturing photovoltaic device
EP3712964A1 (fr) * 2019-03-20 2020-09-23 Sono Motors GmbH Procédé de fabrication d'un module photovoltaïque
EP4257889A3 (fr) * 2022-04-08 2024-01-24 Universität Stuttgart Éléments de construction multifonctionnels de surface extérieure, leur fabrication et leur utilisation

Family Cites Families (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
DE2709741A1 (de) * 1977-03-05 1978-09-07 Licentia Gmbh Solarzellenanordnung fuer den terrestrischen bereich
EP1722619A4 (fr) * 2004-03-03 2010-11-24 Bridgestone Corp Materiau pour fenetre de transmission de lumiere a blindage electromagnetique, panneau d'affichage et procede de fabrication d'un module de cellules solaires

Non-Patent Citations (1)

* Cited by examiner, † Cited by third party
Title
See references of WO2010095012A1 *

Also Published As

Publication number Publication date
WO2010095012A1 (fr) 2010-08-26
IT1392931B1 (it) 2012-04-02
ITMI20090204A1 (it) 2010-08-18

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