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WO2023279167A1 - Solar cell structure - Google Patents

Solar cell structure Download PDF

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Publication number
WO2023279167A1
WO2023279167A1 PCT/AU2022/050715 AU2022050715W WO2023279167A1 WO 2023279167 A1 WO2023279167 A1 WO 2023279167A1 AU 2022050715 W AU2022050715 W AU 2022050715W WO 2023279167 A1 WO2023279167 A1 WO 2023279167A1
Authority
WO
WIPO (PCT)
Prior art keywords
solar cell
adhesive strip
elongate conductor
elongate
adhesive
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Ceased
Application number
PCT/AU2022/050715
Other languages
French (fr)
Inventor
Yang Li
Ning SONG
Pei-Chieh Hsiao
Carolin ROEMER
Alison Joan Lennon
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.)
NewSouth Innovations Pty Ltd
Original Assignee
NewSouth Innovations Pty Ltd
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
Priority claimed from AU2021902116A external-priority patent/AU2021902116A0/en
Application filed by NewSouth Innovations Pty Ltd filed Critical NewSouth Innovations Pty Ltd
Priority to EP22836408.9A priority Critical patent/EP4367724A4/en
Priority to CN202280057924.8A priority patent/CN117916896A/en
Publication of WO2023279167A1 publication Critical patent/WO2023279167A1/en
Anticipated expiration legal-status Critical
Ceased legal-status Critical Current

Links

Classifications

    • H—ELECTRICITY
    • H10—SEMICONDUCTOR DEVICES; ELECTRIC SOLID-STATE DEVICES NOT OTHERWISE PROVIDED FOR
    • H10F—INORGANIC SEMICONDUCTOR DEVICES SENSITIVE TO INFRARED RADIATION, LIGHT, ELECTROMAGNETIC RADIATION OF SHORTER WAVELENGTH OR CORPUSCULAR RADIATION
    • H10F19/00—Integrated devices, or assemblies of multiple devices, comprising at least one photovoltaic cell covered by group H10F10/00, e.g. photovoltaic modules
    • H10F19/90—Structures for connecting between photovoltaic cells, e.g. interconnections or insulating spacers
    • H10F19/902—Structures for connecting between photovoltaic cells, e.g. interconnections or insulating spacers for series or parallel connection of photovoltaic cells
    • H—ELECTRICITY
    • H10—SEMICONDUCTOR DEVICES; ELECTRIC SOLID-STATE DEVICES NOT OTHERWISE PROVIDED FOR
    • H10F—INORGANIC SEMICONDUCTOR DEVICES SENSITIVE TO INFRARED RADIATION, LIGHT, ELECTROMAGNETIC RADIATION OF SHORTER WAVELENGTH OR CORPUSCULAR RADIATION
    • H10F19/00—Integrated devices, or assemblies of multiple devices, comprising at least one photovoltaic cell covered by group H10F10/00, e.g. photovoltaic modules
    • H10F19/90—Structures for connecting between photovoltaic cells, e.g. interconnections or insulating spacers
    • H10F19/902—Structures for connecting between photovoltaic cells, e.g. interconnections or insulating spacers for series or parallel connection of photovoltaic cells
    • H10F19/904—Structures for connecting between photovoltaic cells, e.g. interconnections or insulating spacers for series or parallel connection of photovoltaic cells characterised by the shapes of the structures
    • 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
    • H10F10/00—Individual photovoltaic cells, e.g. solar 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
    • H—ELECTRICITY
    • H10—SEMICONDUCTOR DEVICES; ELECTRIC SOLID-STATE DEVICES NOT OTHERWISE PROVIDED FOR
    • H10F—INORGANIC SEMICONDUCTOR DEVICES SENSITIVE TO INFRARED RADIATION, LIGHT, ELECTROMAGNETIC RADIATION OF SHORTER WAVELENGTH OR CORPUSCULAR RADIATION
    • H10F19/00—Integrated devices, or assemblies of multiple devices, comprising at least one photovoltaic cell covered by group H10F10/00, e.g. photovoltaic modules
    • H10F19/90—Structures for connecting between photovoltaic cells, e.g. interconnections or insulating spacers
    • H—ELECTRICITY
    • H10—SEMICONDUCTOR DEVICES; ELECTRIC SOLID-STATE DEVICES NOT OTHERWISE PROVIDED FOR
    • H10F—INORGANIC SEMICONDUCTOR DEVICES SENSITIVE TO INFRARED RADIATION, LIGHT, ELECTROMAGNETIC RADIATION OF SHORTER WAVELENGTH OR CORPUSCULAR RADIATION
    • H10F77/00—Constructional details of devices covered by this subclass
    • H10F77/20—Electrodes
    • H10F77/206—Electrodes for devices having potential barriers
    • H10F77/211—Electrodes for devices having potential barriers for photovoltaic cells

Definitions

  • the present disclosure relates to solar cell structure and particularly to solar cell structure including multiple solar cells that are interconnected in series.
  • Solar cell modules are structures that commonly include a plurality of solar cells that are electrically connected together in series and held within at least one encapsulant layer bounded on either side by protective transparent layers such as glass layers.
  • the plurality of solar cells are commonly conductively connected using elongate conductors coated in solder.
  • the high temperatures typically required to melt the solder can introduce thermomechanical stress to the solar cells which prevents the use of thin solar cells which may otherwise crack or fracture under the thermomechanical stress.
  • some high efficiency solar cells such as heterojunction and perovskite/silicon tandem type cells require low temperature manufacturing processes.
  • the at least one adhesive strip may extend along and cover at least 50%, at least 60%, at least 70%, at least 80%, at least 90%, or up to 100% of a length of the at least one elongate conductor that contacts the first and/or second solar cell.
  • a width of the at least one adhesive strip may be less than 500%, 400%, 300%, or 200% of the width of the at least one elongate conductor.
  • the at least one adhesive strip may form a seal between the at least one elongate conductor and the at least one encapsulant layer.
  • the first and second solar cells may be: overlapped, arranged adjacent with no gap between the solar cells, or spaced apart.
  • the at least one adhesive strip may be transparent, translucent and/or comprise or act as a light scattering film.
  • the at least one elongate conductor may have one of the following cross sections: circular, elliptical, triangular, quadrilateral, and polygonal.
  • the at least one elongate conductor may comprise a light diverting ribbon and/or a light scattering ribbon.
  • the at least one adhesive strip may comprises tape, and wherein the tape may comprise pressure sensitive tape or heat active tape.
  • the at least one adhesive strip may comprise at least one double sided adhesive portion and/or at least one single sided adhesive portion.
  • a method of forming a solar cell structure comprising: connecting at least one elongate conductor to a first surface of a first solar cell and a second surface of a second solar cell, wherein at least one elongate adhesive strip extends along and covers at least a portion of the at least one elongate conductor and secures the portion of the at least one elongate conductor to the first surface of the first solar cell and/or the second surface of the second solar cell; and introducing, prior to, during, or after, the connecting, at least one encapsulant layer that at least partially encapsulates the first and second solar cells, the at least one elongate conductor, and the at least one adhesive strip.
  • the at least one elongate conductor may comprise at least one first elongate conductor and at least one second elongate conductor and the at least one adhesive strip may comprise at least one first adhesive strip and at least one second adhesive strip
  • the introducing may comprise introducing at least a first encapsulant layer and a second encapsulant layer
  • the connecting may comprise: attaching a first portion of the at least one first elongate conductor to the first encapsulant layer using a double sided adhesive portion of the at least one first adhesive strip; attaching the first surface of the first solar cell to the first encapsulant layer using the double sided adhesive portion of the at least one first adhesive strip, such that the first portion of the at least one first elongate conductor that is attached to the first encapsulant layer is attached to at least the first surface of the first solar cell; attaching a first portion of the at least one second elongate conductor to the second encapsulant layer using a double sided adhesive portion of the at least
  • the introducing may comprise introducing at least a first encapsulant layer and a second encapsulant layer
  • the connecting may comprise: attaching a first portion of the at least one elongate conductor to the first encapsulant layer using a first double sided adhesive portion of the at least one adhesive strip; attaching a second portion of the at least one elongate conductor to the second encapsulant layer using a second double sided adhesive portion of the at least one adhesive strip; attaching the first surface of the first solar cell to the first portion of the at least one elongate conductor that is attached to the first encapsulant layer using the first double sided adhesive portion of the at least one adhesive strip; and attaching the second surface of the second solar cell to the second portion of the at least one elongate conductor that is attached to the second encapsulant layer using the second double sided adhesive portion of the at least one adhesive strip.
  • Figure 2 shows a perspective view of the elongate conductors and the elongate adhesive strips shown in Figure 1;
  • Figure 3 shows a sectional view of the solar cell structure generally as shown in Figure 1 with the first solar cell and the second solar cell being spaced apart;
  • Figure 4 shows a sectional view of the solar cell structure shown generally as shown in Figure 1 with the first solar cell and the second solar cell being overlapped;
  • Figure 5a shows a schematic of an elongate conductor with a circular cross section, and a transparent elongate adhesive strip, according to an embodiment of the present disclosure
  • Figure 5b shows a schematic of an elongate conductor with a triangular cross section, and a transparent elongate adhesive strip, according to an embodiment of the present disclosure
  • Figure 5e shows a schematic of an elongate conductor with a rectangular cross section, and a grooved elongate adhesive strip, according to an embodiment of the present disclosure
  • Figure 5f shows a schematic of an elongate conductor with a rectangular cross section, and a partially transparent and partially grooved elongate adhesive strip, according to an embodiment of the present disclosure
  • Figure 6 shows a flow chart of a method of forming a solar cell structure according to an embodiment of the present disclosure, the method comprising connecting at least one elongate conductor to a first surface of a first solar cell and/or a second surface of a second solar cell and introducing at least one encapsulant layer;
  • Figure 7 illustrates a connecting approach, according to an embodiment of the present disclosure, that may be used in the method of Figure 6;
  • Figure 8a illustrates an introducing approach, according to an embodiment of the present disclosure, that may be used in the method of Figure 6;
  • Figure 8b illustrates the introducing approach shown in Figure 8a after a lamination has been performed
  • Figure 9 and 10 illustrate a connecting approach, according to an embodiment of the present disclosure, that may be used in the method of Figure 6;
  • Figures 11 and 12 illustrate a connecting approach, according to an embodiment of the present disclosure, that may be used in the method of Figure 6;
  • Figures 17 and 18 illustrate introducing and connecting approaches, according to an embodiment of the present disclosure, that may be used in the method of Figure 6;
  • a solar cell structure 10 includes a first solar cell 12 having a front surface 14 and a rear surface 16 and a second solar cell 18 having a front surface 20 and a rear surface 22.
  • the solar cell structure 10 further comprises at least one elongate conductor, and more specifically, in this embodiment, a plurality of elongate conductors 24, electrically connecting the front surface 14 of the first solar cell 12 to the rear surface 22 of the second solar cell 18.
  • the plurality of elongate conductors 24 are positioned side by side and are spaced apart from each other.
  • the solar cell structure 10 further comprises at least one elongate adhesive strip, and more specifically, in this embodiment, a plurality, of elongate adhesive strips 26, each extending along and covering at least a portion 32, 34 of a respective one of the elongate conductors 24 and securing that portion 32, 34 of the elongate conductors 24 to the front surface 14 of the first solar cell 12 and/or the rear surface 22 of the second solar cell 18.
  • the solar cell structure 10 further comprises at least one encapsulant layer 30 ( Figures 8a and 8b) that at least partially encapsulates the first and second solar cells 12, 18, the elongate conductors 24 and the adhesive strips 26.
  • Encapsulant material used in embodiments of the present disclosure may comprise ethylene vinyl acetate (EVA), polyolefin (POE), thermoplastic olefin (TPO) and/or silicone, for example.
  • Conductive material used in the at least one elongate conductor 24 in embodiments of the present disclosure may comprise metal such as copper, albeit a variety of different metals may be used, for example, nickel, silver, gold and/or tin, and it will be understood that the at least one elongate conductor 24 may instead or additionally comprise one or more conductive polymers.
  • the metal may be coated with low melting temperature solder, for example SnBi, SnBiAg, SnPbBi, Snln, SnBilnAg, etc.
  • the elongate conductors 24 can be electrically connected to the solar cells 12, 18 using metal contacts (not shown) such as pads or tabs, and which locate at least partially between the elongate conductors 24 and the solar cells 12, 18.
  • the metal contacts may comprise any suitable metal, for example, copper, nickel, silver, gold and/or tin, and it will be understood that the contacts may instead or additionally comprise one or more conductive polymers.
  • the at least partial encapsulation of the first and second solar cells 12, 18 may be achieved using a lamination process in which heat and pressure are applied.
  • the low temperature solder can be coated on all surfaces of metal of the elongate conductors 24 at a thickness of between 5 to 50 pm, or between 10 to 20 pm, for example.
  • the metal of the elongate conductor 24 e.g., copper
  • a reflective material such as silver or aluminium
  • the lamination or encapsulation can be performed at a temperature in the range of 135°C to 160°C, or 140°C and 150°C, for example, and performed for atotal time of between 10 minutes to 18 minutes, or between 12 minutes to 15 minutes, for example.
  • the solder on the elongate conductors 24 softens and flows to form an electrical connection with the tabs on the solar cells 12, 18.
  • pressure may also be uniformly applied to the surface/s 14, 16, 20, 22 of the solar cell structure 10. The magnitude of the pressure may be between approximately 20 to 120 kPa, for example, and may be applied in one or more phases, for example from 60kPa to 40kPa and then to 20 kPa.
  • the at least one adhesive strip 26 extends along and covers a first portion 32 of each elongate conductor 24 to secure the first portion 32 to the front surface 14 of the first solar cell 12, and extends along and covers a second portion 34 of each elongate conductor 24 to secure the second portion 34 to the rear surface 22 of the second solar cell 18.
  • the at least one adhesive strip 26 may act to secure the first and second portions 32, 34 to the respective solar cell surfaces until solder is melted to form a complete electrical connection between the elongate conductor 24 and the solar cells 12, 18.
  • the at least one adhesive strip 26 comprises a first adhesive strip and a second adhesive strip, the first adhesive strip extending along, covering and securing the first portion 32 of the at least one elongate conductor 24 and the second adhesive strip extending along, covering and securing the second portion 34 of the at least one elongate conductor 24.
  • first solar cell 12 and the second solar cell 18 may employ a single elongate adhesive strip 26 extending along and covering both the first and second portions 32, 34 of the elongate conductor 24.
  • the single elongate adhesive strip 26 may be twisted to be able to adhere to both the front surface 14 of the first solar cell 12 and/or the rear surface 22 of the second solar cell 18, or the single elongate adhesive strip 26 may comprise a double sided adhesive portion or the single elongate adhesive strip 26 may comprise a single sided adhesive portion arranged on opposing ends and sides of the single adhesive strip 26.
  • the at least one adhesive strip 26 may only secure a portion 32, 34 of the at least one elongate conductor 24 to the front surface 14 of the first solar cell 12 or the rear surface 22 of the second solar cell 18, with another portion of the at least one elongate conductor 24 being unsecured to the other of the front surface 14 of the first solar cell 12 or the rear surface 22 of the second solar cell 18.
  • Figure 2 shows a first set 36 of elongate adhesive strips 26 attached to a front side 38 of the first portion 32 and a second set 40 of elongate adhesive strips 26 attached to a rear side 42 of the second portion 34.
  • a width of the adhesive strip 26 may be greater than a width of the elongate conductor 24.
  • a width 44 of the adhesive strip 26 may be less than 500%, 400%, 300%, or 200% of the width 46 of the elongate conductor 24.
  • the adhesive strip 26 may extend along and cover a substantial portion of the elongate conductor. For example it may extend along and cover at least 50%, at least 60%, at least 70%, at least 80%, at least 90%, or up to 100% of a length of the elongate conductor 24 that contacts the first 12 and/or second solar cell 18, to allow for a secure adhesion. It should be noted that the angles and relative sizes of different components of the structure in the figures of the present disclosure are provided for illustrative purposes and are not necessarily to scale. [0051] As shown in Figure 8b, which will be described in greater detail below, each adhesive strip 26 can form a seal between each elongate conductor 24 and the at least one encapsulant layer 30.
  • the seal is advantageous to inhibit encapsulant from flowing underneath the elongate conductors 24 and therefore reducing electrical contact between the elongate conductors 24 and the first 12 and/or second 18 solar cell.
  • This may be particularly advantageous in embodiments whereby the at least one encapsulant layer 30 is formed from melting an encapsulant material after each elongate conductor 24 has been secured to the first 12 and/or second 18 solar cell by the adhesive strip 26.
  • the seal formed by the adhesive strip 26 may also be advantageous, e.g. when using solder and under a low temperature manufacturing and laminating process, by constraining the flowing of the solder material laterally along the tabs of the solar cells 12, 18 when the solar cell structure 10 is heated and the solder begins to melt. This may provide a more homogeneous re-distribution of the solder and reduce the probability of void formation in either of the solder or the structure 10 after the at least one encapsulant layer 30 has been applied and the structure 10 has been laminated.
  • Figure 3 shows a sectional view of an embodiment of the solar cell structure 10 with the first and second solar cells 12, 18 being spaced apart with the at least one elongate conductor 24 having an angled or curved portion 48 in order to traverse from the front surface 14 of the first solar cell 12 to the rear surface 22 of the second solar cell 18.
  • FIG 4 shows a sectional view of an embodiment of the solar cell structure 10 with the first and second solar cells 12, 18 overlapping with the at least one elongate conductor 24 having a substantially linear portion 50 in order to traverse from the front surface 14 of the first solar cell 12 to the rear surface 22 of the second solar cell 18. It will be understood that the solar cells 12, 18 may also be arranged adjacent each other with no gap between the solar cells 12, 18.
  • Figures 5a-5f show various embodiments of the elongate conductors 24 and the elongate adhesive strips 26.
  • Embodiments of the elongate conductors 24 include those with cross sections that are a circular ( Figure 5a), triangular (Figure 5b), rectangular ( Figures 5d-5f) and polygonal, in particular, grooved ( Figure 5c).
  • the circular cross section is optionally the cross section of a wire conductor
  • the triangular cross section is optionally the cross section of a light diverting ribbon conductor
  • the rectangular cross sections are optionally the cross sections of flat ribbon conductors
  • the grooved cross section is optionally the cross section of a light scattering ribbon conductor.
  • the elongate conductor 24 may have other suitable cross sections such as an elliptical or square cross section.
  • Embodiments of the elongate adhesive strips 26 include those that are at least partly transparent (or translucent) ( Figures 5a-5d), light scattering due to the inclusion of a grooved cross section ( Figure 5e), and a combination of transparent (or translucent) and light scattering (Figure 5f).
  • the adhesive strip 26 shown in Figures 5e and 5f may be patterned to act as a light scattering film.
  • the at least one adhesive strip 26 comprises an adhesive film or an adhesive tape, for example pressure sensitive tape or heat active tape. It will be understood that the at least one adhesive strip 26 may have a double sided adhesive portion and/or a single sided adhesive portion.
  • the adhesive tape and the adhesive film may be usable as an adhesive tape or film at room temperature or otherwise and may be comprise any suitable material, for example, thermoplastics including ethylene- vinyl acetate, plastics, foams, foils, and the like.
  • a method 100 of forming a solar cell structure such as the solar cell structure 10 described above, according to an embodiment of the present disclosure, is illustrated in Figure 6.
  • the method 100 includes connecting 102 at least one elongate conductor 24 to a first surface 14 of a first solar cell 12 and a second surface 22 of a second solar cell 18.
  • At least one elongate adhesive strip 26 extends along and covers at least a portion 32, 34 of the at least one elongate conductor 24 and secures the portion 32, 34 of the at least one elongate conductor 24 to the first surface 14 of the first solar cell 12 and/or the second surface 22 of the second solar cell 18.
  • the method 100 further comprises introducing 104, prior to, during, or after, the connecting 102, at least one encapsulant layer 30 that at least partially encapsulates the first and second solar cells 12, 18, the at least one elongate conductor 24, and the at least one adhesive strip 26.
  • the at least one encapsulant layer may be introduced entirely after the connection of the at least one elongate conductor to the solar cells, whereas in other embodiments that the at least one encapsulant layer may introduced prior to or during the process of connection of the at least one elongate conductor to the solar cells.
  • first surface of the first solar cell may be a front surface of the first solar cell and the second surface of the first solar cell may be a rear surface of the second solar cell or, alternatively, the first surface of the first solar cell may be a rear surface of the first solar cell and the second surface of the first solar cell may be a front surface of the second solar cell.
  • first surface of the first solar cell may be a front surface of the first solar cell and the second surface of the first solar cell may be a front surface of the second solar cell.
  • the particular order in which the elongate conductor is attached to the front surface of one cell and the rear surface of the other cell is not limited.
  • Figure 7 shows that, in some embodiments, the connecting 102 includes attaching the at least one adhesive strip 26 to the first portion 32 and to the second portion 34 of the at least one elongate conductor 24.
  • the connecting 102 further includes securing the first portion 32 of the at least one elongate conductor 24 to the first surface 14 of the first solar cell 12 using the at least one adhesive strip 26.
  • the connecting 102 further comprises placing the second solar cell 18 over the second portion 34 of the at least one elongate conductor 24, and securing the second surface 22 of the second solar cell to the second portion 34 of the at least one elongate conductor 24 using the at least one adhesive strip 26.
  • the connecting 102 is performed, for example, by laying down the first solar cell 12 on a substrate 52, the elongate adhesive strips 26 then being attached to the first surface 14 of the first solar cell 12.
  • the second solar cell 18 is then laid down on the substrate 52 to attach the second surface 22 of the second solar cell 18 to the elongate adhesive strips 26. This process can be repeated to interconnect multiple solar cells as shown in Figure 7.
  • Figure 8a shows a sectional view of solar cell structure according to the present disclosure in which at least one encapsulant layer, and specifically two encapsulant layers 30 in this example, are introduced.
  • Figure 8a also shows protective layers 31 (e.g. one or more glass layers 31) which are formed or positioned outside of the encapsulant layers 30 to protect the solar cell structure 10.
  • protective layers 31 e.g. one or more glass layers 31
  • adhesive strips 26 are attached to the surfaces 14, 16 of the first solar cell 12 and along and over portions of respective elongate conductors 24 such that they seal or provide a protective barrier between elongate conductors 24 and the encapsulant layers 30.
  • Figure 8b shows the encapsulant layers 30 once they are melted and set after lamination, whereupon the elongate adhesive strips 26 further conform to the shape of the conductors 24.
  • the seal provided by the adhesive strips 26 is beneficial to inhibit melted encapsulant material from flowing underneath the conductors 24 whereupon it might provide a complete or partial barrier between electrical contact of the elongate conductors 24 and the solar cell 12. Further, the seal provides a barrier to inhibit solder from flowing laterally outwards from the elongate conductors 24 and onto the solar cells 12, 18.
  • the connecting 102 includes securing the first portion 32 of the at least one elongate conductor 24 to the first surface 14 of the first solar cell 12 using the at least one adhesive strip 26.
  • the connecting 102 further includes inverting the first solar cell 12 with the first portion 32 of the at least one elongate conductor 24 secured to the first surface 14 of the first solar cell 12 as shown in Figure 10.
  • the connecting 102 further includes attaching the second portion 34 of the at least one elongate conductor 24 to the second surface 22 of the second solar cell 18 using the at least one adhesive strip 26 ( Figure 10).
  • each solar cell can have the first portion 32 of the at least one elongate conductor 24 secured to its first surface prior to inverting/tuming/flipping/rotating the cell to attach the second portion 34 of the at least one elongate conductor 24 to its second surface as shown in Figures 9 and 10.
  • the at least one adhesive strip 26 comprises at least one first adhesive strip 54 and at least one second adhesive strip 56
  • the connecting 102 comprises (see Figure 11) positioning the first solar cell 12 under the first portion 32 of the at least one elongate conductor 24 and positioning the second solar cell 18 over the second portion 34 of the at least one elongate conductor 24.
  • the connecting 102 further comprises securing the first portion 32 of the at least one elongate conductor 24 to the first surface 14 of the first solar cell 12 using the at least one first adhesive strip 54, the at least one first adhesive strip also extending to and securing to the first surface 20 of the second solar cell 18.
  • the connecting 102 further includes inverting the first and second solar cells 12, 18 with the first portion 32 of the at least one elongate conductor 24 secured to the first surface 14 of the first solar cell 12 and the at least one first adhesive strip 54 extending to and securing to the first surface 20 of the second solar cell 18 ( Figure 12).
  • the connecting 102 further comprises securing the second portion 34 of the at least one elongate conductor 24 to the second surface 22 of the second solar cell 18 using the at least one second adhesive strip 56, the at least one second adhesive strip 56 also extending to and securing to the second surface 16 of the first solar cell 12.
  • longer elongate adhesive strips 54, 56 may be used to secure the elongate conductors 24 to the first and second surfaces of the cells when interconnecting multiple cells, thereby further securing the interconnection between the solar cells and reducing the time taken to form the solar cell structure 10 due to a reduction in the number of elongate adhesive strips 26 required ( Figure 12).
  • the at least one elongate conductor 24 comprises at least one first elongate conductor 58 and at least one second elongate conductor 60 and the at least one adhesive strip 26 comprises at least one first adhesive strip 54 and at least one second adhesive strip 56.
  • the introducing 104 comprises introducing at least a first encapsulant layer 62 and a second encapsulant layer 64.
  • the connecting 102 comprises attaching the first portion 32 of the at least one first elongate conductor 58 to the first encapsulant layer 62 using a double sided adhesive portion of the at least one first adhesive strip 54 ( Figure 13).
  • the connecting 102 further comprises attaching the first surface 14 of the first solar cell 12 (and optionally the first surface 20 of the second solar cell 18) to the first encapsulant layer 62 using the double sided adhesive portion of the at least one first adhesive strip 54, such that the first portion 32 of the at least one first elongate conductor 58 that is attached to the first encapsulant layer 62 is attached to at least the first surface 14 of the first solar cell 12 ( Figure 14).
  • the connecting 102 further comprises attaching the first portion 32 of the at least one second elongate conductor 60 to the second encapsulant layer 64 using a double sided adhesive portion of the at least one second adhesive strip 56.
  • the connecting 102 further comprises attaching the second surface 22 of the second solar cell 18 (and optionally the second surface 16 of the first solar cell 12) to the second encapsulant layer 64 using the double sided adhesive portion of the at least one second adhesive strip 56, such that the first portion 32 of the at least one second elongate conductor 60 that is attached to the second encapsulant layer 64 is attached to at least the second surface 22 of the second solar cell 18 ( Figure 15).
  • the connecting 102 further comprises connecting the at least one first elongate conductor 58 to the at least one second elongate conductor 60 ( Figure 16).
  • an enlarged end section 66 is provided on the at least one second elongate conductor 60 in order to connect the at least one second elongate conductor 60 to the at least one first elongate conductor 58 via a gap 68 provided between the first solar cell 12 and the second solar cell 18. It will be understood that one or both of the at least one first elongate conductor 58 and the at least one second elongate conductor 60 may comprise the enlarged end section 66.
  • the embodiment of the method 100 shown in Figures 13-16 allows for a full sized first and second encapsulant layers 62, 64 to be formed or set prior to attaching the at least one first or second elongate conductors 58, 60.
  • the first and second encapsulant layers 62, 64 act as a substrate upon which the at least one first or second elongate conductors 58, 60 are attached.
  • the introducing 104 comprises introducing at least the first encapsulant layer 62 and the second encapsulant layer 64.
  • the connecting 102 comprises attaching the first portion 32 of the at least one elongate conductor 24 to the first encapsulant layer 62 using a first double sided adhesive portion of the at least one adhesive strip 26.
  • the connecting 102 further includes attaching the second portion 34 of the at least one elongate conductor 24 to the second encapsulant layer 64 using a second double sided adhesive portion of the at least one adhesive strip 26.
  • the connecting 102 further comprises attaching the first surface 14 of the first solar cell 12 to the first portion 32 of the at least one elongate conductor 24 that is attached to the first encapsulant layer 62 using the first double sided adhesive portion of the at least one adhesive strip 26.
  • the connecting 102 further comprises attaching the second surface 22 of the second solar cell 18 to the second portion 34 of the at least one elongate conductor 24 that is attached to the second encapsulant layer 64 using the second double sided adhesive portion of the at least one adhesive strip 26.
  • the at least one encapsulant layer 30, 62, 64 is introduced, formed and/or set prior to attaching the at least one elongate conductor 24 to the first and/or second solar cell 12, 18 using the at least one elongate adhesive strip 26. Further, these embodiments allow for solar cells as well as half solar cells to be interconnected by forming a stack 70 as shown in Figure 18 and a more complete stack 70a, at least with regards the centre solar cell 12, as shown in Figure 19.
  • the elongate adhesive strips 26 secure the portion 32, 34 of the elongate conductors 24 to the first surface 14 of the first solar cell 12 and/or to the second surface 22 of the second solar cell 18.
  • This process of interconnecting solar cells can be repeated for multiple solar cells in order to form a solar panel or solar array, with each cell being interconnected via attaching the at least one elongate conductor 24 using the elongate adhesive strips 26.
  • At least one encapsulant layer 30, 62, 64 is provided that at least partially encapsulates the first and second solar cells 12, 18, the at least one elongate conductor 24 and the at least one adhesive strip 26.
  • the at least one adhesive strip 26 may be shaped, and/or applied or attached to the first surface 14 of the first solar cell 12 and/or to the second surface 22 of the second solar cell 18, such that the at least one adhesive strip 26 forms a seal between the at least one encapsulant layer 30 and the at least one elongate conductor 24.
  • the at least one elongate adhesive strip 26 may be used to secure the at least one elongate conductor 24 to the solar cells 12, 18 prior to applying heat and/or pressure to melt solder and the at least one encapsulant layer 30 at low temperatures, e.g., during a low temperature manufacturing process such as lamination.
  • the low temperature process may reduce thermomechanical stress in the solar cell and allow for thinner solar cells to be interconnected and solar cells of different varieties such as some high efficiency solar cells such as heterojunction and perovskite/silicon tandem type cells.
  • the at least one elongate adhesive strip 26 may maintain orientation and inhibit movement or sliding of the at least one elongate conductor 24 while the at least one encapsulant layer 30 is being introduced and/or set and while the solder is melting due to heat and/or pressure that is being applied to the solar cell structure 10 during lamination. It will be understood that the application of pressure to the solar cell structure 10 may compact solder and/or the encapsulant material which may remove voids in the solder and/or the encapsulant material.
  • the seal that the at least one elongate adhesive strip 26 may provide between the at least one elongate conductor 24 and the at least one encapsulant layer 30 may inhibit faults from occurring in solar cells due to encapsulant material flowing between the at least one elongate conductor 24 and the solar cells 12, 18, e.g. to impinge on electrical contacts and/or busbars, etc. of the solar cells 12, 18.
  • the seal may also inhibit faults from occurring due to solder flowing out from the at least one elongate conductor 24 onto the solar cells 12, 18 and/or voids forming within the solder which can weaken the bond between the at least one conductor 24 and the solar cells 12, 18.
  • efficiencies may be achieved in manufacturing, including when using single elongate adhesive strips to secure multiple discrete elongate conductors.

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Abstract

A Solar cell structure, and a method of forming the solar cell structure, are disclosed. The solar cell structuring includes: a first solar cell having a front surface and a rear surface; a second solar cell having a front surface and a rear surface; at least one elongate conductor electrically connecting the front surface of the first solar cell to the rear surface of the second solar cell; at least one elongate adhesive strip extending along and covering at least a portion of the at least one elongate conductor and securing the portion of the at least one elongate conductor to the front surface of the first solar cell and/or the rear surface of the second solar cell; and at least one encapsulant layer that at least partially encapsulates the first and second solar cells, the at least one elongate conductor and the at least one adhesive strip.

Description

Solar cell structure
Cross-Reference to Related Application
[0001] This application claims priority to Australian provisional patent application no. 2021902116, filed on 9 July 2021, the entire content of which is incorporated herein by reference.
Technical Field
[0002] The present disclosure relates to solar cell structure and particularly to solar cell structure including multiple solar cells that are interconnected in series.
Background
[0003] Solar cell modules are structures that commonly include a plurality of solar cells that are electrically connected together in series and held within at least one encapsulant layer bounded on either side by protective transparent layers such as glass layers.
[0004] The plurality of solar cells are commonly conductively connected using elongate conductors coated in solder. However, the high temperatures typically required to melt the solder can introduce thermomechanical stress to the solar cells which prevents the use of thin solar cells which may otherwise crack or fracture under the thermomechanical stress. Further, some high efficiency solar cells such as heterojunction and perovskite/silicon tandem type cells require low temperature manufacturing processes.
[0005] Accordingly, it can be desirable to use low temperature processes that use low- temperature solder to create a bond between the conductors and the solar cell. In these processes, the at least one encapsulant layer can be formed to laminate the solar cells at the same time that the low-temperature solder is being melted to form the conductive connection or bond, since the low -temperature solder has a melting point lower than the lamination temperature.
[0006] Any discussion of documents, acts, materials, devices, articles or the like which has been included in the present specification is not to be taken as an admission that any or all of these matters form part of the prior art base or were common general knowledge in the field relevant to the present disclosure as it existed before the priority date of each of the appended claims.
Summary
[0007] In an aspect of the present disclosure, there is provided a solar cell structure, comprising: a first solar cell having a front surface and a rear surface; a second solar cell having a front surface and a rear surface; at least one elongate conductor electrically connecting the front surface of the first solar cell to the rear surface of the second solar cell; at least one elongate adhesive strip extending along and covering at least a portion of the at least one elongate conductor and securing the portion of the at least one elongate conductor to the front surface of the first solar cell and/or the rear surface of the second solar cell; and at least one encapsulant layer that at least partially encapsulates the first and second solar cells, the at least one elongate conductor and the at least one adhesive strip. The at least one adhesive strip may comprise a first adhesive strip and a second adhesive strip, the first adhesive strip extending along and covering the first portion of the at least one elongate conductor and the second adhesive strip extending along and covering the second portion of the at least one elongate conductor. The at least one elongate conductor may comprise at least two discrete elongate conductors that are side by side, and the at least one adhesive strip may comprises at least two discrete adhesive strips, each of the at least two discrete adhesive strips extending along and covering a respective one of the at least two discrete elongate conductors.
[0008] The at least one adhesive strip may extend along and cover at least 50%, at least 60%, at least 70%, at least 80%, at least 90%, or up to 100% of a length of the at least one elongate conductor that contacts the first and/or second solar cell. A width of the at least one adhesive strip may be less than 500%, 400%, 300%, or 200% of the width of the at least one elongate conductor.
[0009] The at least one adhesive strip may form a seal between the at least one elongate conductor and the at least one encapsulant layer. The first and second solar cells may be: overlapped, arranged adjacent with no gap between the solar cells, or spaced apart. The at least one adhesive strip may be transparent, translucent and/or comprise or act as a light scattering film. The at least one elongate conductor may have one of the following cross sections: circular, elliptical, triangular, quadrilateral, and polygonal. [0010] The at least one elongate conductor may comprise a light diverting ribbon and/or a light scattering ribbon. The at least one adhesive strip may comprises tape, and wherein the tape may comprise pressure sensitive tape or heat active tape. The at least one adhesive strip may comprise at least one double sided adhesive portion and/or at least one single sided adhesive portion.
[0011] In another aspect of the present disclosure, there is provided a method of forming the solar cell structure discussed above.
[0012] In yet another aspect of the present disclosure, there is provided a method of forming a solar cell structure, the method comprising: connecting at least one elongate conductor to a first surface of a first solar cell and a second surface of a second solar cell, wherein at least one elongate adhesive strip extends along and covers at least a portion of the at least one elongate conductor and secures the portion of the at least one elongate conductor to the first surface of the first solar cell and/or the second surface of the second solar cell; and introducing, prior to, during, or after, the connecting, at least one encapsulant layer that at least partially encapsulates the first and second solar cells, the at least one elongate conductor, and the at least one adhesive strip.
[0013] In some embodiments, the connecting may comprise: attaching the at least one adhesive strip to a first portion and to a second portion of the at least one elongate conductor; securing the first portion of the at least one elongate conductor to the first surface of the first solar cell using the at least one adhesive strip; and securing the second portion of the at least one elongate conductor to the second surface of the second solar cell using the at least one adhesive strip.
[0014] In some embodiments, the connecting may comprise: securing a first portion of the at least one elongate conductor to the first surface of the first solar cell using the at least one adhesive strip; inverting the first solar cell with the first portion of the at least one elongate conductor secured to the first surface of the first solar cell; after the inverting, securing a second portion of the at least one elongate conductor to the second surface of the second solar cell using the at least one adhesive strip.
[0015] In some embodiments, the at least one adhesive strip may comprise at least one first adhesive strip and at least one second adhesive strip and the connecting may comprise: positioning the first solar cell under a first portion of the at least one elongate conductor; positioning the second solar cell over a second portion of the at least one elongate conductor; securing the first portion of the at least one elongate conductor to the first surface of the first solar cell using the at least one first adhesive strip, the at least one first adhesive strip also extending to and securing to a first surface of the second solar cell; inverting the first and second solar cells with the first portion of the at least one elongate conductor secured to the first surface of the first solar cell and the at least one first adhesive strip extending to and securing to the first surface of the second solar cell; and securing the second portion of the at least one elongate conductor to the second surface of the second solar cell using the at least one second adhesive strip, the at least one second adhesive strip also extending to and securing to a second surface of the first solar cell.
[0016] In some embodiments, the at least one elongate conductor may comprise at least one first elongate conductor and at least one second elongate conductor and the at least one adhesive strip may comprise at least one first adhesive strip and at least one second adhesive strip, the introducing may comprise introducing at least a first encapsulant layer and a second encapsulant layer, and the connecting may comprise: attaching a first portion of the at least one first elongate conductor to the first encapsulant layer using a double sided adhesive portion of the at least one first adhesive strip; attaching the first surface of the first solar cell to the first encapsulant layer using the double sided adhesive portion of the at least one first adhesive strip, such that the first portion of the at least one first elongate conductor that is attached to the first encapsulant layer is attached to at least the first surface of the first solar cell; attaching a first portion of the at least one second elongate conductor to the second encapsulant layer using a double sided adhesive portion of the at least one second adhesive strip; attaching a second surface of the second solar cell to the second encapsulant layer using the double sided adhesive portion of the at least one second adhesive strip, such that the first portion of the at least one second elongate conductor that is attached to the second encapsulant layer is attached to at least the second surface of the second solar cell; and connecting the at least one first elongate conductor to the at least one second elongate conductor.
[0017] In some embodiments, the introducing may comprise introducing at least a first encapsulant layer and a second encapsulant layer, and the connecting may comprise: attaching a first portion of the at least one elongate conductor to the first encapsulant layer using a first double sided adhesive portion of the at least one adhesive strip; attaching a second portion of the at least one elongate conductor to the second encapsulant layer using a second double sided adhesive portion of the at least one adhesive strip; attaching the first surface of the first solar cell to the first portion of the at least one elongate conductor that is attached to the first encapsulant layer using the first double sided adhesive portion of the at least one adhesive strip; and attaching the second surface of the second solar cell to the second portion of the at least one elongate conductor that is attached to the second encapsulant layer using the second double sided adhesive portion of the at least one adhesive strip.
[0018] Throughout this specification the word "comprise", or variations such as "comprises" or "comprising", will be understood to imply the inclusion of a stated element, integer or step, or group of elements, integers or steps, but not the exclusion of any other element, integer or step, or group of elements, integers or steps.
Brief Description of Drawings
[0019] Embodiments of the disclosure will now be described by way of example only with reference to the accompanying drawings in which:
[0020] Figure 1 shows a perspective view of a solar cell structure, comprising elongate conductors electrically connecting a first solar cell and a second solar cell, and elongate adhesive strips securing the elongate conductors, according to an embodiment of the present disclosure;
[0021] Figure 2 shows a perspective view of the elongate conductors and the elongate adhesive strips shown in Figure 1;
[0022] Figure 3 shows a sectional view of the solar cell structure generally as shown in Figure 1 with the first solar cell and the second solar cell being spaced apart;
[0023] Figure 4 shows a sectional view of the solar cell structure shown generally as shown in Figure 1 with the first solar cell and the second solar cell being overlapped;
[0024] Figure 5a shows a schematic of an elongate conductor with a circular cross section, and a transparent elongate adhesive strip, according to an embodiment of the present disclosure;
[0025] Figure 5b shows a schematic of an elongate conductor with a triangular cross section, and a transparent elongate adhesive strip, according to an embodiment of the present disclosure;
[0026] Figure 5c shows a schematic of an elongate conductor with a polygonal or grooved cross section, and a transparent elongate adhesive strip, according to an embodiment of the present disclosure; [0027] Figure 5d shows a schematic of an elongate conductor with a rectangular cross section, and a transparent elongate adhesive strip, according to an embodiment of the present disclosure ;
[0028] Figure 5e shows a schematic of an elongate conductor with a rectangular cross section, and a grooved elongate adhesive strip, according to an embodiment of the present disclosure;
[0029] Figure 5f shows a schematic of an elongate conductor with a rectangular cross section, and a partially transparent and partially grooved elongate adhesive strip, according to an embodiment of the present disclosure;
[0030] Figure 6 shows a flow chart of a method of forming a solar cell structure according to an embodiment of the present disclosure, the method comprising connecting at least one elongate conductor to a first surface of a first solar cell and/or a second surface of a second solar cell and introducing at least one encapsulant layer;
[0031] Figure 7 illustrates a connecting approach, according to an embodiment of the present disclosure, that may be used in the method of Figure 6;
[0032] Figure 8a illustrates an introducing approach, according to an embodiment of the present disclosure, that may be used in the method of Figure 6;
[0033] Figure 8b illustrates the introducing approach shown in Figure 8a after a lamination has been performed;
[0034] Figure 9 and 10 illustrate a connecting approach, according to an embodiment of the present disclosure, that may be used in the method of Figure 6;
[0035] Figures 11 and 12 illustrate a connecting approach, according to an embodiment of the present disclosure, that may be used in the method of Figure 6;
[0036] Figures 13 to 16 illustrate introducing and connecting approaches, according to an embodiment of the present disclosure, that may be used in the method of Figure 6;
[0037] Figures 17 and 18 illustrate introducing and connecting approaches, according to an embodiment of the present disclosure, that may be used in the method of Figure 6; and
[0038] Figure 19 illustrates a stack that may be formed, according to an embodiment of the present disclosure, based on the introducing and connecting approaches of Figures 17 and 18. Detailed Description of Exemplary Embodiments
[0039] With reference to Figure 1, a solar cell structure 10 according to an embodiment of the present disclosure includes a first solar cell 12 having a front surface 14 and a rear surface 16 and a second solar cell 18 having a front surface 20 and a rear surface 22. The solar cell structure 10 further comprises at least one elongate conductor, and more specifically, in this embodiment, a plurality of elongate conductors 24, electrically connecting the front surface 14 of the first solar cell 12 to the rear surface 22 of the second solar cell 18. The plurality of elongate conductors 24 are positioned side by side and are spaced apart from each other. The solar cell structure 10 further comprises at least one elongate adhesive strip, and more specifically, in this embodiment, a plurality, of elongate adhesive strips 26, each extending along and covering at least a portion 32, 34 of a respective one of the elongate conductors 24 and securing that portion 32, 34 of the elongate conductors 24 to the front surface 14 of the first solar cell 12 and/or the rear surface 22 of the second solar cell 18. The solar cell structure 10 further comprises at least one encapsulant layer 30 (Figures 8a and 8b) that at least partially encapsulates the first and second solar cells 12, 18, the elongate conductors 24 and the adhesive strips 26.
[0040] Encapsulant material used in embodiments of the present disclosure may comprise ethylene vinyl acetate (EVA), polyolefin (POE), thermoplastic olefin (TPO) and/or silicone, for example. Conductive material used in the at least one elongate conductor 24 in embodiments of the present disclosure may comprise metal such as copper, albeit a variety of different metals may be used, for example, nickel, silver, gold and/or tin, and it will be understood that the at least one elongate conductor 24 may instead or additionally comprise one or more conductive polymers. The metal may be coated with low melting temperature solder, for example SnBi, SnBiAg, SnPbBi, Snln, SnBilnAg, etc. The elongate conductors 24 can be electrically connected to the solar cells 12, 18 using metal contacts (not shown) such as pads or tabs, and which locate at least partially between the elongate conductors 24 and the solar cells 12, 18. The metal contacts may comprise any suitable metal, for example, copper, nickel, silver, gold and/or tin, and it will be understood that the contacts may instead or additionally comprise one or more conductive polymers. The at least partial encapsulation of the first and second solar cells 12, 18 may be achieved using a lamination process in which heat and pressure are applied. During this process, in addition to the at least one encapsulant layer 30 melting to at least partially encapsulate the solar cells 12, 18, the low -temperature solder may be melted to form the conductive connection between the elongate conductors 24 and the solar cells 12, 18.
[0041] The low temperature solder can be coated on all surfaces of metal of the elongate conductors 24 at a thickness of between 5 to 50 pm, or between 10 to 20 pm, for example. In some embodiments, the metal of the elongate conductor 24 (e.g., copper) can be coated on all surfaces with a reflective material such as silver or aluminium, and the low temperature solder is then coated only on the surface of the elongate conductor 24 comprising the reflective material.
[0042] The lamination or encapsulation can be performed at a temperature in the range of 135°C to 160°C, or 140°C and 150°C, for example, and performed for atotal time of between 10 minutes to 18 minutes, or between 12 minutes to 15 minutes, for example. During lamination, the solder on the elongate conductors 24 softens and flows to form an electrical connection with the tabs on the solar cells 12, 18. During lamination or encapsulation, pressure may also be uniformly applied to the surface/s 14, 16, 20, 22 of the solar cell structure 10. The magnitude of the pressure may be between approximately 20 to 120 kPa, for example, and may be applied in one or more phases, for example from 60kPa to 40kPa and then to 20 kPa.
[0043] The terms “front” and “rear” are used herein to indicate the sides of elements of the solar cell structure that face generally towards the sun and generally away from the sun, respectively, when in use.
[0044] As shown in Figure 1, the at least one adhesive strip 26 extends along and covers a first portion 32 of each elongate conductor 24 to secure the first portion 32 to the front surface 14 of the first solar cell 12, and extends along and covers a second portion 34 of each elongate conductor 24 to secure the second portion 34 to the rear surface 22 of the second solar cell 18. The at least one adhesive strip 26 may act to secure the first and second portions 32, 34 to the respective solar cell surfaces until solder is melted to form a complete electrical connection between the elongate conductor 24 and the solar cells 12, 18.
[0045] In particular, in this embodiment the at least one adhesive strip 26 comprises a first adhesive strip and a second adhesive strip, the first adhesive strip extending along, covering and securing the first portion 32 of the at least one elongate conductor 24 and the second adhesive strip extending along, covering and securing the second portion 34 of the at least one elongate conductor 24. [0046] It will be understood by the person skilled in the art, however, that the first solar cell 12 and the second solar cell 18 may employ a single elongate adhesive strip 26 extending along and covering both the first and second portions 32, 34 of the elongate conductor 24. For example, the single elongate adhesive strip 26 may be twisted to be able to adhere to both the front surface 14 of the first solar cell 12 and/or the rear surface 22 of the second solar cell 18, or the single elongate adhesive strip 26 may comprise a double sided adhesive portion or the single elongate adhesive strip 26 may comprise a single sided adhesive portion arranged on opposing ends and sides of the single adhesive strip 26.
[0047] It will be further understood that in alternative embodiments the at least one adhesive strip 26 may only secure a portion 32, 34 of the at least one elongate conductor 24 to the front surface 14 of the first solar cell 12 or the rear surface 22 of the second solar cell 18, with another portion of the at least one elongate conductor 24 being unsecured to the other of the front surface 14 of the first solar cell 12 or the rear surface 22 of the second solar cell 18.
[0048] The configuration of the elongate conductors 24 and the elongate adhesive strips 26 of the present embodiment are shown in more detail in Figure 2. Figure 2 shows a first set 36 of elongate adhesive strips 26 attached to a front side 38 of the first portion 32 and a second set 40 of elongate adhesive strips 26 attached to a rear side 42 of the second portion 34.
[0049] In order for each adhesive strip 26 to cover each elongate conductor 24 and attach each elongate conductor 24 to the first and/or second solar cells 12, 18, a width of the adhesive strip 26 may be greater than a width of the elongate conductor 24. However, to reduce an amount of material required, and/or to reduce an amount of any undesirable shading that might be caused by the adhesive strip 26, a width 44 of the adhesive strip 26 may be less than 500%, 400%, 300%, or 200% of the width 46 of the elongate conductor 24.
[0050] It will be understood that the adhesive strip 26 may extend along and cover a substantial portion of the elongate conductor. For example it may extend along and cover at least 50%, at least 60%, at least 70%, at least 80%, at least 90%, or up to 100% of a length of the elongate conductor 24 that contacts the first 12 and/or second solar cell 18, to allow for a secure adhesion. It should be noted that the angles and relative sizes of different components of the structure in the figures of the present disclosure are provided for illustrative purposes and are not necessarily to scale. [0051] As shown in Figure 8b, which will be described in greater detail below, each adhesive strip 26 can form a seal between each elongate conductor 24 and the at least one encapsulant layer 30. The seal is advantageous to inhibit encapsulant from flowing underneath the elongate conductors 24 and therefore reducing electrical contact between the elongate conductors 24 and the first 12 and/or second 18 solar cell. This may be particularly advantageous in embodiments whereby the at least one encapsulant layer 30 is formed from melting an encapsulant material after each elongate conductor 24 has been secured to the first 12 and/or second 18 solar cell by the adhesive strip 26.
[0052] The seal formed by the adhesive strip 26 may also be advantageous, e.g. when using solder and under a low temperature manufacturing and laminating process, by constraining the flowing of the solder material laterally along the tabs of the solar cells 12, 18 when the solar cell structure 10 is heated and the solder begins to melt. This may provide a more homogeneous re-distribution of the solder and reduce the probability of void formation in either of the solder or the structure 10 after the at least one encapsulant layer 30 has been applied and the structure 10 has been laminated.
[0053] Figure 3 shows a sectional view of an embodiment of the solar cell structure 10 with the first and second solar cells 12, 18 being spaced apart with the at least one elongate conductor 24 having an angled or curved portion 48 in order to traverse from the front surface 14 of the first solar cell 12 to the rear surface 22 of the second solar cell 18.
[0054] Figure 4 shows a sectional view of an embodiment of the solar cell structure 10 with the first and second solar cells 12, 18 overlapping with the at least one elongate conductor 24 having a substantially linear portion 50 in order to traverse from the front surface 14 of the first solar cell 12 to the rear surface 22 of the second solar cell 18. It will be understood that the solar cells 12, 18 may also be arranged adjacent each other with no gap between the solar cells 12, 18.
[0055] Figures 5a-5f show various embodiments of the elongate conductors 24 and the elongate adhesive strips 26. Embodiments of the elongate conductors 24 include those with cross sections that are a circular (Figure 5a), triangular (Figure 5b), rectangular (Figures 5d-5f) and polygonal, in particular, grooved (Figure 5c). The circular cross section is optionally the cross section of a wire conductor, the triangular cross section is optionally the cross section of a light diverting ribbon conductor, the rectangular cross sections are optionally the cross sections of flat ribbon conductors, and the grooved cross section is optionally the cross section of a light scattering ribbon conductor. It will be understood by the person skilled in the art that the elongate conductor 24 may have other suitable cross sections such as an elliptical or square cross section.
[0056] Embodiments of the elongate adhesive strips 26 include those that are at least partly transparent (or translucent) (Figures 5a-5d), light scattering due to the inclusion of a grooved cross section (Figure 5e), and a combination of transparent (or translucent) and light scattering (Figure 5f). The adhesive strip 26 shown in Figures 5e and 5f may be patterned to act as a light scattering film. In some embodiments, the at least one adhesive strip 26 comprises an adhesive film or an adhesive tape, for example pressure sensitive tape or heat active tape. It will be understood that the at least one adhesive strip 26 may have a double sided adhesive portion and/or a single sided adhesive portion. It will also be understood that the adhesive tape and the adhesive film may be usable as an adhesive tape or film at room temperature or otherwise and may be comprise any suitable material, for example, thermoplastics including ethylene- vinyl acetate, plastics, foams, foils, and the like.
[0057] A method 100 of forming a solar cell structure, such as the solar cell structure 10 described above, according to an embodiment of the present disclosure, is illustrated in Figure 6. The method 100 includes connecting 102 at least one elongate conductor 24 to a first surface 14 of a first solar cell 12 and a second surface 22 of a second solar cell 18.
[0058] As a part of the connecting 102, at least one elongate adhesive strip 26 extends along and covers at least a portion 32, 34 of the at least one elongate conductor 24 and secures the portion 32, 34 of the at least one elongate conductor 24 to the first surface 14 of the first solar cell 12 and/or the second surface 22 of the second solar cell 18.
The method 100 further comprises introducing 104, prior to, during, or after, the connecting 102, at least one encapsulant layer 30 that at least partially encapsulates the first and second solar cells 12, 18, the at least one elongate conductor 24, and the at least one adhesive strip 26.
[0059] Some example connecting and introducing approaches used in the method 100, according to different embodiments of the present disclosure, are now discussed with reference to Figures 7-18. It will be recognized from these discussions that, in some embodiments, the at least one encapsulant layer may be introduced entirely after the connection of the at least one elongate conductor to the solar cells, whereas in other embodiments that the at least one encapsulant layer may introduced prior to or during the process of connection of the at least one elongate conductor to the solar cells. Further, it will be recognized that the first surface of the first solar cell may be a front surface of the first solar cell and the second surface of the first solar cell may be a rear surface of the second solar cell or, alternatively, the first surface of the first solar cell may be a rear surface of the first solar cell and the second surface of the first solar cell may be a front surface of the second solar cell. In this regard, the particular order in which the elongate conductor is attached to the front surface of one cell and the rear surface of the other cell is not limited.
[0060] Figure 7 shows that, in some embodiments, the connecting 102 includes attaching the at least one adhesive strip 26 to the first portion 32 and to the second portion 34 of the at least one elongate conductor 24. The connecting 102 further includes securing the first portion 32 of the at least one elongate conductor 24 to the first surface 14 of the first solar cell 12 using the at least one adhesive strip 26. The connecting 102 further comprises placing the second solar cell 18 over the second portion 34 of the at least one elongate conductor 24, and securing the second surface 22 of the second solar cell to the second portion 34 of the at least one elongate conductor 24 using the at least one adhesive strip 26.
[0061] In some embodiments, the connecting 102 is performed, for example, by laying down the first solar cell 12 on a substrate 52, the elongate adhesive strips 26 then being attached to the first surface 14 of the first solar cell 12. The second solar cell 18 is then laid down on the substrate 52 to attach the second surface 22 of the second solar cell 18 to the elongate adhesive strips 26. This process can be repeated to interconnect multiple solar cells as shown in Figure 7.
[0062] Figure 8a shows a sectional view of solar cell structure according to the present disclosure in which at least one encapsulant layer, and specifically two encapsulant layers 30 in this example, are introduced. Figure 8a also shows protective layers 31 (e.g. one or more glass layers 31) which are formed or positioned outside of the encapsulant layers 30 to protect the solar cell structure 10.
[0063] In this embodiment, adhesive strips 26 are attached to the surfaces 14, 16 of the first solar cell 12 and along and over portions of respective elongate conductors 24 such that they seal or provide a protective barrier between elongate conductors 24 and the encapsulant layers 30. Figure 8b shows the encapsulant layers 30 once they are melted and set after lamination, whereupon the elongate adhesive strips 26 further conform to the shape of the conductors 24. The seal provided by the adhesive strips 26 is beneficial to inhibit melted encapsulant material from flowing underneath the conductors 24 whereupon it might provide a complete or partial barrier between electrical contact of the elongate conductors 24 and the solar cell 12. Further, the seal provides a barrier to inhibit solder from flowing laterally outwards from the elongate conductors 24 and onto the solar cells 12, 18.
[0064] In some embodiments, with reference to Figure 9, the connecting 102 includes securing the first portion 32 of the at least one elongate conductor 24 to the first surface 14 of the first solar cell 12 using the at least one adhesive strip 26. The connecting 102 further includes inverting the first solar cell 12 with the first portion 32 of the at least one elongate conductor 24 secured to the first surface 14 of the first solar cell 12 as shown in Figure 10. After the inverting, the connecting 102 further includes attaching the second portion 34 of the at least one elongate conductor 24 to the second surface 22 of the second solar cell 18 using the at least one adhesive strip 26 (Figure 10).
[0065] For multiple solar cells, each solar cell can have the first portion 32 of the at least one elongate conductor 24 secured to its first surface prior to inverting/tuming/flipping/rotating the cell to attach the second portion 34 of the at least one elongate conductor 24 to its second surface as shown in Figures 9 and 10.
[0066] In some embodiments, with reference to Figures 11 and 12, the at least one adhesive strip 26 comprises at least one first adhesive strip 54 and at least one second adhesive strip 56, and the connecting 102 comprises (see Figure 11) positioning the first solar cell 12 under the first portion 32 of the at least one elongate conductor 24 and positioning the second solar cell 18 over the second portion 34 of the at least one elongate conductor 24. The connecting 102 further comprises securing the first portion 32 of the at least one elongate conductor 24 to the first surface 14 of the first solar cell 12 using the at least one first adhesive strip 54, the at least one first adhesive strip also extending to and securing to the first surface 20 of the second solar cell 18. The connecting 102 further includes inverting the first and second solar cells 12, 18 with the first portion 32 of the at least one elongate conductor 24 secured to the first surface 14 of the first solar cell 12 and the at least one first adhesive strip 54 extending to and securing to the first surface 20 of the second solar cell 18 (Figure 12). The connecting 102 further comprises securing the second portion 34 of the at least one elongate conductor 24 to the second surface 22 of the second solar cell 18 using the at least one second adhesive strip 56, the at least one second adhesive strip 56 also extending to and securing to the second surface 16 of the first solar cell 12.
[0067] Accordingly, longer elongate adhesive strips 54, 56 may be used to secure the elongate conductors 24 to the first and second surfaces of the cells when interconnecting multiple cells, thereby further securing the interconnection between the solar cells and reducing the time taken to form the solar cell structure 10 due to a reduction in the number of elongate adhesive strips 26 required (Figure 12).
[0068] In some embodiments, with reference to Figures 13 to 15, the at least one elongate conductor 24 comprises at least one first elongate conductor 58 and at least one second elongate conductor 60 and the at least one adhesive strip 26 comprises at least one first adhesive strip 54 and at least one second adhesive strip 56. The introducing 104 comprises introducing at least a first encapsulant layer 62 and a second encapsulant layer 64. The connecting 102 comprises attaching the first portion 32 of the at least one first elongate conductor 58 to the first encapsulant layer 62 using a double sided adhesive portion of the at least one first adhesive strip 54 (Figure 13).
The connecting 102 further comprises attaching the first surface 14 of the first solar cell 12 (and optionally the first surface 20 of the second solar cell 18) to the first encapsulant layer 62 using the double sided adhesive portion of the at least one first adhesive strip 54, such that the first portion 32 of the at least one first elongate conductor 58 that is attached to the first encapsulant layer 62 is attached to at least the first surface 14 of the first solar cell 12 (Figure 14). The connecting 102 further comprises attaching the first portion 32 of the at least one second elongate conductor 60 to the second encapsulant layer 64 using a double sided adhesive portion of the at least one second adhesive strip 56. The connecting 102 further comprises attaching the second surface 22 of the second solar cell 18 (and optionally the second surface 16 of the first solar cell 12) to the second encapsulant layer 64 using the double sided adhesive portion of the at least one second adhesive strip 56, such that the first portion 32 of the at least one second elongate conductor 60 that is attached to the second encapsulant layer 64 is attached to at least the second surface 22 of the second solar cell 18 (Figure 15). The connecting 102 further comprises connecting the at least one first elongate conductor 58 to the at least one second elongate conductor 60 (Figure 16).
[0069] In particular, as shown in Figure 16, an enlarged end section 66 is provided on the at least one second elongate conductor 60 in order to connect the at least one second elongate conductor 60 to the at least one first elongate conductor 58 via a gap 68 provided between the first solar cell 12 and the second solar cell 18. It will be understood that one or both of the at least one first elongate conductor 58 and the at least one second elongate conductor 60 may comprise the enlarged end section 66.
[0070] The embodiment of the method 100 shown in Figures 13-16 allows for a full sized first and second encapsulant layers 62, 64 to be formed or set prior to attaching the at least one first or second elongate conductors 58, 60. In this way, the first and second encapsulant layers 62, 64 act as a substrate upon which the at least one first or second elongate conductors 58, 60 are attached.
[0071] In some embodiments, with reference to Figure 17, the introducing 104 comprises introducing at least the first encapsulant layer 62 and the second encapsulant layer 64. The connecting 102 comprises attaching the first portion 32 of the at least one elongate conductor 24 to the first encapsulant layer 62 using a first double sided adhesive portion of the at least one adhesive strip 26. The connecting 102 further includes attaching the second portion 34 of the at least one elongate conductor 24 to the second encapsulant layer 64 using a second double sided adhesive portion of the at least one adhesive strip 26. With further reference to Figure 18, the connecting 102 further comprises attaching the first surface 14 of the first solar cell 12 to the first portion 32 of the at least one elongate conductor 24 that is attached to the first encapsulant layer 62 using the first double sided adhesive portion of the at least one adhesive strip 26. The connecting 102 further comprises attaching the second surface 22 of the second solar cell 18 to the second portion 34 of the at least one elongate conductor 24 that is attached to the second encapsulant layer 64 using the second double sided adhesive portion of the at least one adhesive strip 26.
[0072] In embodiments as discussed with reference to Figures 17-18, the at least one encapsulant layer 30, 62, 64 is introduced, formed and/or set prior to attaching the at least one elongate conductor 24 to the first and/or second solar cell 12, 18 using the at least one elongate adhesive strip 26. Further, these embodiments allow for solar cells as well as half solar cells to be interconnected by forming a stack 70 as shown in Figure 18 and a more complete stack 70a, at least with regards the centre solar cell 12, as shown in Figure 19.
[0073] In use, the elongate adhesive strips 26 secure the portion 32, 34 of the elongate conductors 24 to the first surface 14 of the first solar cell 12 and/or to the second surface 22 of the second solar cell 18. This process of interconnecting solar cells can be repeated for multiple solar cells in order to form a solar panel or solar array, with each cell being interconnected via attaching the at least one elongate conductor 24 using the elongate adhesive strips 26. At least one encapsulant layer 30, 62, 64 is provided that at least partially encapsulates the first and second solar cells 12, 18, the at least one elongate conductor 24 and the at least one adhesive strip 26. The at least one adhesive strip 26 may be shaped, and/or applied or attached to the first surface 14 of the first solar cell 12 and/or to the second surface 22 of the second solar cell 18, such that the at least one adhesive strip 26 forms a seal between the at least one encapsulant layer 30 and the at least one elongate conductor 24.
[0074] In embodiments of the present disclosure, the at least one elongate adhesive strip 26 may be used to secure the at least one elongate conductor 24 to the solar cells 12, 18 prior to applying heat and/or pressure to melt solder and the at least one encapsulant layer 30 at low temperatures, e.g., during a low temperature manufacturing process such as lamination. The low temperature process may reduce thermomechanical stress in the solar cell and allow for thinner solar cells to be interconnected and solar cells of different varieties such as some high efficiency solar cells such as heterojunction and perovskite/silicon tandem type cells. Further, the at least one elongate adhesive strip 26 may maintain orientation and inhibit movement or sliding of the at least one elongate conductor 24 while the at least one encapsulant layer 30 is being introduced and/or set and while the solder is melting due to heat and/or pressure that is being applied to the solar cell structure 10 during lamination. It will be understood that the application of pressure to the solar cell structure 10 may compact solder and/or the encapsulant material which may remove voids in the solder and/or the encapsulant material.
[0075] Furthermore, the seal that the at least one elongate adhesive strip 26 may provide between the at least one elongate conductor 24 and the at least one encapsulant layer 30 may inhibit faults from occurring in solar cells due to encapsulant material flowing between the at least one elongate conductor 24 and the solar cells 12, 18, e.g. to impinge on electrical contacts and/or busbars, etc. of the solar cells 12, 18. The seal may also inhibit faults from occurring due to solder flowing out from the at least one elongate conductor 24 onto the solar cells 12, 18 and/or voids forming within the solder which can weaken the bond between the at least one conductor 24 and the solar cells 12, 18. Further, efficiencies may be achieved in manufacturing, including when using single elongate adhesive strips to secure multiple discrete elongate conductors.
[0076] It will be appreciated by persons skilled in the art that numerous variations and/or modifications may be made to the above-described embodiments, without departing from the broad general scope of the present disclosure. The present embodiments are, therefore, to be considered in all respects as illustrative and not restrictive.

Claims

CLAIMS:
1. Solar cell structure, comprising: a first solar cell having a front surface and a rear surface; a second solar cell having a front surface and a rear surface; at least one elongate conductor electrically connecting the front surface of the first solar cell to the rear surface of the second solar cell; at least one elongate adhesive strip extending along and covering at least a portion of the at least one elongate conductor and securing the portion of the at least one elongate conductor to the front surface of the first solar cell and/or the rear surface of the second solar cell; and at least one encapsulant layer that at least partially encapsulates the first and second solar cells, the at least one elongate conductor and the at least one adhesive strip.
2. The solar cell structure of claim 1, wherein the at least one adhesive strip extends along and covers a first portion of the at least one elongate conductor to secure the first portion to the front surface of the first solar cell, and extends along and covers a second portion of the at least one elongate conductor to secure the second portion to the rear surface of the second solar cell.
3. The solar cell structure of claim 2, wherein the at least one adhesive strip comprises a first adhesive strip and a second adhesive strip, the first adhesive strip extending along and covering the first portion of the at least one elongate conductor and the second adhesive strip extending along and covering the second portion of the at least one elongate conductor.
4. The solar cell structure of claim 2 or 3, wherein the at least one elongate conductor comprises at least two discrete elongate conductors that are side by side, and wherein the at least one adhesive strip comprises at least two discrete adhesive strips, each of the at least two discrete adhesive strips extending along and covering a respective one of the at least two discrete elongate conductors.
5. The solar cell structure of any one of the preceding claims, wherein the at least one adhesive strip extends along and covers at least 50%, at least 60%, at least 70%, at least 80%, at least 90%, or up to 100% of a length of the at least one elongate conductor that contacts the first and/or second solar cell.
6. The solar cell structure of any one of the preceding claims, wherein a width of the at least one adhesive strip is less than 500%, 400%, 300%, or 200% of a width of the at least one elongate conductor.
7. The solar cell structure of any one of the preceding claims, wherein the at least one adhesive strip forms a seal between the at least one elongate conductor and the at least one encapsulant layer.
8. The solar cell structure of any one of the preceding claims, wherein the first and second solar cells are: overlapped, arranged adjacent with no gap between the solar cells, or spaced apart.
9. The solar cell structure of any one of the preceding claims, wherein the at least one adhesive strip is transparent and/or comprises light scattering film.
10. The solar cell structure of any one of the preceding claims, wherein the at least one elongate conductor has one of the following cross sections: circular, elliptical, triangular, quadrilateral, and polygonal.
11. The solar cell structure of any one of the preceding claims, wherein the at least one elongate conductor comprises a light diverting ribbon and/or a light scattering ribbon.
12. The solar cell structure of any one of the preceding claims, wherein the at least one adhesive strip comprises tape, and wherein the tape comprises pressure sensitive tape or heat active tape.
13. The solar cell structure of any one of the preceding claims, wherein the at least one adhesive strip comprises at least one double sided adhesive portion and/or at least one single sided adhesive portion.
14. A method of forming the solar cell structure of any one of the preceding claims.
15. A method of forming a solar cell structure, the method comprising: connecting at least one elongate conductor to a first surface of a first solar cell and a second surface of a second solar cell, wherein at least one elongate adhesive strip extends along and covers at least a portion of the at least one elongate conductor and secures the portion of the at least one elongate conductor to the first surface of the first solar cell and/or the second surface of the second solar cell; and introducing, prior to, during, or after, the connecting, at least one encapsulant layer that at least partially encapsulates the first and second solar cells, the at least one elongate conductor, and the at least one adhesive strip.
16. The method of claim 15, wherein the connecting comprises: attaching the at least one adhesive strip to a first portion and to a second portion of the at least one elongate conductor; securing the first portion of the at least one elongate conductor to the first surface of the first solar cell using the at least one adhesive strip; and securing the second portion of the at least one elongate conductor to the second surface of the second solar cell using the at least one adhesive strip.
17. The method of claim 15, wherein the connecting comprises: securing a first portion of the at least one elongate conductor to the first surface of the first solar cell using the at least one adhesive strip; inverting the first solar cell with the first portion of the at least one elongate conductor secured to the first surface of the first solar cell; after the inverting, securing a second portion of the at least one elongate conductor to the second surface of the second solar cell using the at least one adhesive strip.
18. The method of claim 15, wherein the at least one adhesive strip comprises at least one first adhesive strip and at least one second adhesive strip, and wherein the connecting comprises: positioning the first solar cell under a first portion of the at least one elongate conductor; positioning the second solar cell over a second portion of the at least one elongate conductor; securing the first portion of the at least one elongate conductor to the first surface of the first solar cell using the at least one first adhesive strip, the at least one first adhesive strip also extending to and securing to a first surface of the second solar cell; inverting the first and second solar cells with the first portion of the at least one elongate conductor secured to the first surface of the first solar cell and the at least one first adhesive strip extending to and securing to the first surface of the second solar cell; and securing the second portion of the at least one elongate conductor to the second surface of the second solar cell using the at least one second adhesive strip, the at least one second adhesive strip also extending to and securing to a second surface of the first solar cell.
19. The method of claim 15, wherein the at least one elongate conductor comprises at least one first elongate conductor and at least one second elongate conductor and the at least one adhesive strip comprises at least one first adhesive strip and at least one second adhesive strip, wherein the introducing comprises introducing at least a first encapsulant layer and a second encapsulant layer, and wherein the connecting comprises: attaching a first portion of the at least one first elongate conductor to the first encapsulant layer using a double sided adhesive portion of the at least one first adhesive strip; attaching the first surface of the first solar cell to the first encapsulant layer using the double sided adhesive portion of the at least one first adhesive strip, such that the first portion of the at least one first elongate conductor that is attached to the first encapsulant layer is attached to at least the first surface of the first solar cell; attaching a first portion of the at least one second elongate conductor to the second encapsulant layer using a double sided adhesive portion of the at least one second adhesive strip; attaching a second surface of the second solar cell to the second encapsulant layer using the double sided adhesive portion of the at least one second adhesive strip, such that the first portion of the at least one second elongate conductor that is attached to the second encapsulant layer is attached to at least the second surface of the second solar cell; and connecting the at least one first elongate conductor to the at least one second elongate conductor.
20. The method of claim 15, wherein the introducing comprises introducing at least a first encapsulant layer and a second encapsulant layer, and wherein the connecting comprises: attaching a first portion of the at least one elongate conductor to the first encapsulant layer using a first double sided adhesive portion of the at least one adhesive strip; attaching a second portion of the at least one elongate conductor to the second encapsulant layer using a second double sided adhesive portion of the at least one adhesive strip; attaching the first surface of the first solar cell to the first portion of the at least one elongate conductor that is attached to the first encapsulant layer using the first double sided adhesive portion of the at least one adhesive strip; and attaching the second surface of the second solar cell to the second portion of the at least one elongate conductor that is attached to the second encapsulant layer using the second double sided adhesive portion of the at least one adhesive strip.
PCT/AU2022/050715 2021-07-09 2022-07-08 Solar cell structure Ceased WO2023279167A1 (en)

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