CN106206784A - 可挠式太阳能板模块及其固定结构及其制造方法 - Google Patents
可挠式太阳能板模块及其固定结构及其制造方法 Download PDFInfo
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Abstract
提供一种可挠式太阳能板模块,其具有多个不可挠的太阳能板、多个不可挠的盖板与一可挠式背板。每一不可挠的太阳能板包括一光电组件层及正极配线与负极配线。该多个不可挠的盖板对应至该多个不可挠的太阳能板、位于该多个不可挠的太阳能板的一侧且尺寸大于该多个不可挠的太阳能板。该可挠式背板位于该多个不可挠的太阳能板的另一侧且具有多个孔洞。第一防水胶材设置于相邻的该不可挠的盖板之间并与该可挠式背板相接触。第二防水胶材设置于每一片该不可挠的盖板与该可挠式背板之间并包覆对应的该不可挠的太阳能板的一侧边。该多个不可挠的太阳能板与该可挠式背板贴合,相邻的该不可挠的太阳能板之间的区域为该可挠式太阳能板模块的可挠区。
Description
技术领域
本发明涉及可挠式太阳能板模块、其固定结构及其制造方法。
背景技术
传统的太阳能板模块为了达到较大的发电量,必须要整并多片太阳能板,如此一来不但面积大且耗费固定空间。较新式的太阳能模块虽已具有良好的可挠性、能顺应地形起伏且方便携带,然其制造成本过高且发电量不足。
有鉴于此,业界需要一种发电量大、成本低却又具有可挠性的解决方案。
发明内容
本发明的目的在于提供一种可挠式太阳能板模块,其包括多个不可挠的太阳能板、多个不可挠的盖板、一可挠式背板、第一防水胶材及第二防水胶材。此种可挠式太阳能板模块不但具有大发电量且具有低制造成本的优势。
本发明更提供一种可挠式太阳能板模块的固定结构,其包括上述的可挠式太阳能板模块、位于该可挠式背板中的多个固定孔、多个固定件及第三防水胶材。
本发明又提供一种上述可挠式太阳能板模块的制造方法。
为让本发明的上述目的、特征和优点更能明显易懂,下文将以实施例并配合所附图式,作详细说明如下。需注意的是,所附图式中的各组件仅是示意,并未按照各组件的实际比例进行绘示。
附图说明
图1-3显示根据本发明一实施例的可挠式太阳能板模块的制造方法。
图4显示图3的可挠式太阳能板模块的概略横剖面图。
图4A显示根据本发明的可挠式太阳能板模块的局部放大部,强调挠曲状态即胶材分布。
图5显示根据本发明的可挠式太阳能板模块的固定状态上视图。
图6显示图5的可挠式太阳能板模块的固定状态横剖面图。
具体实施方式
下面将详细地说明本发明的较佳实施例,举凡本中所述的组件、组件子部、结构、材料、配置等皆可不依说明的顺序或所属的实施例而任意搭配成新的实施例,此些实施例当属本发明的范畴。
本发明的实施例及图示众多,为了避免混淆,类似的组件是以相同或相似的标号示之;为避免画面过度复杂及混乱,重复的组件仅标示一处,他处则以此类推。
现参考图1-3及图4,其分别显示根据本发明一实施例的可挠式太阳能板模块1000的制造方法及图3的可挠式太阳能板模块1000的概略横剖面图。首先,如图1所示,准备多个片不可挠的太阳能板100与100’(图1中只显示三片作为示意,可准备更多片)以及多个片比不可挠的太阳能板100与100’略大的玻璃盖板130。如图4所示,每一不可挠的太阳能板100与100’由下至上具有由背玻璃102与光电组件层101所构成的迭层结构。光电组件层101由下而上可包括下电极层、光电转换层、选择性缓冲层及透明上电极层如氧化铟锡(ITO)及/或氧化锌层(ZnO)。下电极与透明上电极层是用于传输由光电转换层所产生的电流。光电转换层用于吸收穿透过透明上电极层与选择性缓冲层的光并将其转换为电流,其可包括由铜(Cu)、铟(In)、镓(Ga)与硒(Se)所构成的半导体材料,或可包括由Ib族元素如铜(Cu)或银(Ag)、IIIb族元素如铝(Al)、镓(Ga)或铟(In)与VIb元素如硫(S)、硒(Se)或碲(Te)所构成的化合物半导体材料。选择性缓冲层系用于在形成透明上电极层时保护光电转换层并协助电传输。不可挠的太阳能板100与100’的结构相同,其相异之处在于配置的位向左右相反,因此后续仅说明其中一者作为代表。每一不可挠的太阳能板100(100’)尚包括设置在两侧电极处的正面正极配线121b(121b’)、正面负极配线111a(111a’)、由正面正极配线121b(121b’)反折至不可挠的太阳能板100(100’)之背面的背面正极配线122b(122b’)及由正面负极配线111a(111a’)反折至不可挠的太阳能板100(100’)的背面的背面负极配线112a(112a’)。在本发明的所有图示中,背面正极配线122b(122b’)与背面负极配线112a(112a’)以虚线呈现,以与正面配线有所区别。又,应注意,在图4及本案的所有图标中,组件并未依比例绘制;例如,正面正极配线121b(121b’)与正面负极配线111a(111a’)的宽度应远小于光电组件层101与背玻璃102的宽度,然为了清楚呈现配线与其它组件之间的电连接关系,在图中特别将其放大。又,在实际的一横剖面中应无法同时见到正极配线121b(121b’)、正面负极配线111a(111a’)与背面正极配线122b(122b’)、背面负极配线112a(112a’)实体相连,但图4为了表达上述者的电连接关系,特以实体相连方式呈现。再者,概图4的目的在于呈现不同组件之间的相对关系,并未显示出每一组件的细部结构;例如,光电组件层101应包括图案化的下电极层、图案化的光电转换层、图案化的选择性缓冲层及图案化的透明上电极层,但为了避免图示过于复杂模糊焦点,仅以未图案化的单层结构来表示光电组件层101。正面正极配线121b(121b’)与不可挠的太阳能板100(100’)的正极电连接,正面负极配线111a(111a’)与不可挠的太阳能板100(100’)的负极电连接。配线例如可由铜箔(Copperfoil)或铜带(Copper ribbon)构成,亦可由其它金属或合金线材构成。每一不可挠的太阳能板100(100’)可包括至少一个太阳能单位组件(unit cell),或者可包括多个彼此串联的太阳能单位组件。玻璃盖板130为不可挠的结构,厚度应尽可能地薄。
接着,如图2所示,将多个片不可挠的太阳能板100与100’平放至一可挠式背板140上,在可挠式背板140与太阳能板100(100’)的背面之间设置第一封装材(未图示)。亦如图2所示,将多个片玻璃盖板130分别放置到每一片不可挠的太阳能板100(100’)上,在玻璃盖板130与不可挠的太阳能板100(100’)的正面之间设置第二封装材(未图示)。第一封装材与第二封装材可相同或不同,其可包括热封装胶材(thermal encapsulant)如乙烯醋酸乙烯酯(Ethylene Vinyl Acetate,EVA)、聚烯烃(polyolefin,PO)、聚乙烯醇缩丁醛(polyvinyl butyral,PVB)等或UV固化胶材(UV curableencapsulant)。每一片不可挠的太阳能板100与相邻之不可挠的太阳能板100’之间应保持适当的距离,意即每一片玻璃盖板130与相邻片玻璃盖板130之间应保护适当的距离d。可挠式背板140可以是高张力的塑料薄片例如聚乙烯(Polyethylene,PE)薄片、聚醯胺(Polyamide,PA)薄片、聚对苯二甲酸乙二酯(Polyethylene terephthalate,PET)薄片、或上述者附加铝箔的薄板。可挠式背板140在对应至每一片不可挠的太阳能板100(100’)的中央区域处有至少一个孔洞(未图示),使每一片不可挠的太阳能板100(100’)的背面的背面正极配线122b(122b’)与背面负极配线112a(112a’)自第一封装材(未图示)与此至少一个孔洞(未图示)穿出以向外连接并彼此连接。以上述的状态,利用真空层压(laminate)法将玻璃盖板130、第二封装材(未图示)、太阳能板100(100’)、第一封装材(未图示)与可挠式背板140贴合固着。
然后,如图3所示并参考图4,在可挠式背板140的末端上固定接线盒150。为了强化接线盒150处的可挠式背板140以避免其受损,可在接线盒150与可挠式背板140之间***强化层141。强化层141的材料可与可挠式背板140相同或不同,且强化层141除了设置于接线盒150与可挠式背板140之间外,尚可选择性地设置于可挠式背板140的***处。如图4所示,使每一片不可挠的太阳能板100(100’)自可挠式背板140的孔洞(未图示)穿出的背面正极配线122b(122b’)经由平贴于可挠式背板140背面的配线151而与相邻的不可挠的太阳能板100’(100)的背面正极配线122b’(122b)电连接,使每一片不可挠的太阳能板100(100’)自可挠式背板140的孔洞(未图示)穿出的背面负极配线112a(112a’)经由平贴于可挠式背板140背面的配线152而与相邻的不可挠的太阳能板100’(100)的背面负极配线112a’(112a)电连接。最靠近接线盒150的不可挠的太阳能板100(100’)的背面正极配线122b(122b’)经由配线151而与接线盒150的正极电连接,其背面负极配线112a(112a’)经由配线152而与接线盒150的负极电连接。以上步骤大致上完成本发明的可挠式太阳能板模块1000的制造。配线151与152可以分别是背面正极配线122b(122b’)本身(其延伸)与背面负极配线112a(112a’)本身(其延伸),也可以是不同的线材。接线盒150更包括正极配线151’与负极配线152’以使可挠式太阳能板模块1000对外电连接。在相邻的玻璃盖板130之间设置第一防水胶材如热塑性聚烯烃(thermalplastic polyolefin,TPO)160与可挠式背板140实体接触并在玻璃盖板130与可挠式背板140之间设置第二防水胶材如丁基胶(butyl rubber)161,以保护太阳能板100’(100)以及其配线不受水气、机械力的影响,同时兼顾玻璃盖板130之间的可挠性,其中第一防水胶材160与第二防水胶材161可以为相同防水胶材或不同的防水胶材。在可挠式背板140的背面配线151与152裸露处可选择性地设置另一层防水材如与可挠式背板相同的一材质或一防水胶材如热塑性聚烯烃170等,以保护配线151与152不受水气、机械力的影响,同时兼顾可挠式背板140的可挠性。
在上述图1-3与4的实施例中,由于可挠式背板140具有可挠性,故只要相邻不可挠的太阳能板100’(100)之间具有充分间隙,便可成就具有多个可折区(图1-3中由距离d所表示之区域)的可挠式太阳能板模块1000。在一较佳实施例中,不可挠的太阳能板100’(100)之间的间隙距离不小于不可挠的太阳能板100(100′)与玻璃盖板130(130′)的厚度总和。除此之外,当不可挠的太阳能板100(100’)的背玻璃102及玻璃盖板130皆足够薄如皆小于或等于2.0mm时,不可挠的太阳能板100(100’)将变得可轻微弯曲(bendable),进一步优化可挠式太阳能板模块1000的可挠性。又,在上述图1-3与4的实施例中,可挠式太阳能板模块1000中的各个不可挠的太阳能板100’(100)以并联方式相互电连接,但应了解,本发明亦可应用至以串联方式电连接的太阳能板。
现参考图4A,其显示根据本发明的可挠式太阳能板模块1000的局部放大图,强调可挠式背板140的挠曲状态暨模块1000中的胶材分布,故省略正面与背面的所有配线。如图4A中所示,当相邻之玻璃盖板130之间具有充分的间隙时,可挠式背板140在相邻之玻璃盖板130之间处于可挠状态,由于真空吸附作用,可挠性基板140在玻璃盖板130边缘处会较靠近玻璃盖板130,但受限于玻璃盖板130、光电组件层101与背玻璃102的厚度,可挠性基板140在玻璃盖板130的中央处会最远离玻璃盖板130。因此在实际应用中,除了图4所示之两相邻玻璃盖板130之间的第一防水胶材160外,亦在玻璃盖板130与可挠式背板140之间设置第二防水胶材161包覆对应的该不可挠的太阳能板的一侧边(如图4A所示)。第二防水胶材161包括与第一防水胶材160相同的材料如热塑性聚烯烃(thermalplastic polyolefin,TPO),或与第一防水胶材160相异的材料如丁基胶(butyl rubber)。又,图4A之组件标号162代表可挠式背板140与太阳能板100或100’(包括背玻璃102与光电组件层101)的背面之间的第一封装材,图4A的组件标号103代表玻璃盖板130与太阳能板100或100’的正面之间的第二封装材。由于太阳能板100或100’四面八方皆受到封装材(第一与第二封装材)及/或防水胶材(160与161)包覆,能避免太阳能板100或100’中的光电组件层101受到水气影响而质变退化,亦能固着太阳能板而省略传统太阳能板模块所需的边框。
现参考图5与图6,其分别显示根据本发明的可挠式太阳能板模块1000的固定状态上视图与固定状态横剖面图。固定本发明的可挠式太阳能板模块1000时,可于太阳能板100与100’之间及/或太阳能板100/100’与接线盒150之间及/或太阳能板100与100’其周边的可挠式背板140(及第一防水胶材160)中设置多个固定孔(图6显示其中一固定孔),利用固定件210贯穿固定孔而将可挠式太阳能板模块1000固定至一固定面如屋顶板或其它支撑架500的上表面。本发明的可挠式太阳能板模块1000借由并联多个太阳能板100与100’可大量发电并且借由其可挠性而能适应各种地形,因此可永久固定于欲装设处。就上述的情境考量,应加强固定的固着性与防水性。为达到此目的,可将第一防水胶材160(或材料相同或不同的第三防水胶材)设置于固定孔内缘与固定件210之间以尽量降低固定件210与固定孔之间的间隙,并可额外地将第一防水胶材160(或材料相同或不同的第三防水胶材)设置于可挠式背板140的背面围绕固定孔以避免水气自固定孔渗入。为了更进一步地增加防水性,可将选择性的防水缓冲垫片181与182分别设置在固定孔上方与固定孔下方,包覆固定孔的上下侧。
为了增加固定的强度及范围,可在可挠式背板140上加装选择性的下压件200。可调整下压件200的左右延伸宽度,使其能够覆于玻璃盖板130上(如图6所示),或使其只局限于太阳能板100与100’之间。亦可调整下压件200的延伸长度,使其长度超过可挠式太阳能板模块1000的宽度(如图5所示),或使其长度远小于可挠式太阳能板模块1000的宽度而以岛状方式分布于太阳能板模块1000中。防水缓冲垫片181的形状与尺寸可与下压件200相同或相异,例如可延伸至玻璃盖板130上、延伸包覆太阳能板100/100’的侧壁或介于相邻的太阳能板100与100’之间。固定件210例如可以是螺丝、铆钉、扣件等。视下压件200的延伸长度而定,一下压件200可具有多个孔洞以搭配多个固定件210(如图5所示),或一下压件200仅具有一个孔洞以搭配单一个固定件210。若欲永久固定可挠式太阳能板模块1000不再拆卸,则在固定前可选择性地在固定面(如屋顶板500的正面或例如地面)上铺设热塑材料,然后再铺设本发明的可挠式太阳能板模块1000,将可挠式太阳能板模块1000直接热塑固着于固定面上。
本发明的可挠式太阳能板模块可大量发电,其可挠式设计能适应各种地形,其高防水性能达到高可靠度的优势。除此之外,本发明的可挠式太阳能板模块容易制造且易固定,能大幅降低成本,极具产业利用价值。
上述实施例仅是为了方便说明而举例,虽遭所属技术领域的技术人员任意进行修改,均不会脱离如权利要求书中所欲保护的范围。
Claims (15)
1.一种可挠式太阳能板模块,其特征在于,包括:
多个不可挠的太阳能板,每一该不可挠的太阳能板包括一光电组件层及正极配线与负极配线;
多个不可挠的盖板,对应至该多个不可挠的太阳能板、位于该多个不可挠的太阳能板的一侧且尺寸大于该多个不可挠的太阳能板;
一可挠式背板,位于该多个不可挠的太阳能板的另一侧且具有多个孔洞,
第一防水胶材,设置于相邻的该不可挠的盖板之间并与该可挠式背板接触;及
第二防水胶材,设置于每一片该不可挠的盖板与该可挠式背板之间并包覆对应的该不可挠的太阳能板的一侧边;
其中该多个不可挠的太阳能板与该可挠式背板贴合,相邻的该不可挠的太阳能板之间的区域为该可挠式太阳能板模块的可挠区。
2.如权利要求1所述的可挠式太阳能板模块,其特征在于,每一片该不可挠的太阳能板的该正极配线与该负极配线借由该可挠式背板的该多个孔洞中的一对外电连接。
3.如权利要求1所述的可挠式太阳能板模块,其特征在于,该第一与第二防水胶材为不同防水胶材。
4.如权利要求1所述的可挠式太阳能板模块,其特征在于,包括:
一接线盒,与该多个不可挠的太阳能板位于该可挠式背板的一相同侧上并与该多个不可挠的太阳能板并联连接;
一强化层,设于该接线盒与该可挠式背板之间。
5.如权利要求1所述的可挠式太阳能板模块,其特征在于,包括:
一封装材,设置于每一该不可挠的太阳能板与每一该不可挠的盖板之间及/或设置于每一该不可挠的太阳能板与该可挠式背板之间,
其中该封装材为热封装胶材或UV固化胶材。
6.如权利要求1所述的可挠式太阳能板模块,其特征在于,两相邻的该不可挠的太阳能板之间的距离不小于一片该不可挠的太阳能板与一片该不可挠的盖板的厚度总和。
7.如权利要求6所述的可挠式太阳能板模块,其特征在于,该不可挠的盖板的厚度小于或等于2.0mm。
8.一种可挠式太阳能板模块之固定结构,其特征在于,包括:
如权利要求1所述的可挠式太阳能板模块;
位于该可挠式背板中的多个固定孔,设置于两相邻的该不可挠的太阳能板之间;
多个固定件,分别贯穿该固定孔而将该可挠式太阳能板模块固定至一固定面;及
第三防水胶材,位于该多个固定孔的内缘与该多个固定件之间。
9.如权利要求8所述的可挠式太阳能板模块之固定结构,其特征在于,包括:
一下压件,位于该可挠式背板上且具有至少一孔用于接受该固定件之至少一者。
10.如权利要求9所述的可挠式太阳能板模块的固定结构,其特征在于,包括:
第一垫片,设于该下压件与该可挠式背板之间;及
第二垫片,设于该可挠式背板与该固定面之间。
11.如权利要求9所述的可挠式太阳能板模块的固定结构,其特征在于,该下压件延伸至该不可挠的盖板上。
12.如权利要求9所述的可挠式太阳能板模块的固定结构,其特征在于,该下压件的长度大于该不可挠的太阳能板的长度。
13.一种可挠式太阳能板模块的制造方法,其特征在于,包括:
提供多个不可挠的太阳能板与多个不可挠的盖板;
将该多个不可挠的太阳能板平放至一可挠式背板的第一侧上,其中相邻的该多个不可挠的太阳能板之间具有一预定距离且该多个不可挠的太阳能板与该可挠式背板之间设有第一封装材;
将多个该不可挠的盖板放置到对应的该多个不可挠的太阳能板上,其中该不可挠的盖板与该不可挠的太阳能板之间设有第二封装材;
真空层压使该多个不可挠的盖板、该第二封装材、该多个不可挠的太阳能板、该第一封装材与该可挠式背板贴合;及
于相邻的该不可挠的盖板之间设置一第一防水胶材与该可挠式背板接触,并于每一片该不可挠之盖板与该可挠式背板之间设置第二防水胶材包覆对应的该不可挠的太阳能板的一侧边。
14.如权利要求13所述的可挠式太阳能板模块之制造方法,其特征在于,该可挠性背板包括多个孔洞且每一该不可挠的太阳能板包括正极配线与负极配线,本方法更包括:
使该正极配线与该负极配线自该可挠性背板的该第一侧经由该多个孔洞到达与该第一侧相对的第二侧。
15.如权利要求14所述的可挠式太阳能板模块的制造方法,其特征在于,于该可挠性背板的该第一侧设置一接线盒并使该多个不可挠的太阳能板与该接线盒电性连接。
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US9831367B2 (en) | 2017-11-28 |
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EP3070747A1 (en) | 2016-09-21 |
US9948232B2 (en) | 2018-04-17 |
TW201635575A (zh) | 2016-10-01 |
US20160276508A1 (en) | 2016-09-22 |
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US20170149376A1 (en) | 2017-05-25 |
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