EP2443667A2 - A process for manufacturing photovoltaic panels - Google Patents

A process for manufacturing photovoltaic panels

Info

Publication number
EP2443667A2
EP2443667A2 EP09787755A EP09787755A EP2443667A2 EP 2443667 A2 EP2443667 A2 EP 2443667A2 EP 09787755 A EP09787755 A EP 09787755A EP 09787755 A EP09787755 A EP 09787755A EP 2443667 A2 EP2443667 A2 EP 2443667A2
Authority
EP
European Patent Office
Prior art keywords
backsheet
bussing
zones
layer
uncovered
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Withdrawn
Application number
EP09787755A
Other languages
German (de)
French (fr)
Inventor
Franco Stefani
Attilio Russo
Gianluca Aiazzi
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.)
System SpA
Original Assignee
System Photonics SpA
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by System Photonics SpA filed Critical System Photonics SpA
Publication of EP2443667A2 publication Critical patent/EP2443667A2/en
Withdrawn legal-status Critical Current

Links

Classifications

    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01L—SEMICONDUCTOR DEVICES NOT COVERED BY CLASS H10
    • H01L31/00—Semiconductor devices sensitive to infrared radiation, light, electromagnetic radiation of shorter wavelength or corpuscular radiation and specially adapted either for the conversion of the energy of such radiation into electrical energy or for the control of electrical energy by such radiation; Processes or apparatus specially adapted for the manufacture or treatment thereof or of parts thereof; Details thereof
    • H01L31/04—Semiconductor devices sensitive to infrared radiation, light, electromagnetic radiation of shorter wavelength or corpuscular radiation and specially adapted either for the conversion of the energy of such radiation into electrical energy or for the control of electrical energy by such radiation; Processes or apparatus specially adapted for the manufacture or treatment thereof or of parts thereof; Details thereof adapted as photovoltaic [PV] conversion devices
    • H01L31/042—PV modules or arrays of single PV cells
    • H01L31/048—Encapsulation of modules
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01L—SEMICONDUCTOR DEVICES NOT COVERED BY CLASS H10
    • H01L31/00—Semiconductor devices sensitive to infrared radiation, light, electromagnetic radiation of shorter wavelength or corpuscular radiation and specially adapted either for the conversion of the energy of such radiation into electrical energy or for the control of electrical energy by such radiation; Processes or apparatus specially adapted for the manufacture or treatment thereof or of parts thereof; Details thereof
    • H01L31/02—Details
    • H01L31/02002—Arrangements for conducting electric current to or from the device in operations
    • H01L31/02005—Arrangements for conducting electric current to or from the device in operations for device characterised by at least one potential jump barrier or surface barrier
    • H01L31/02008—Arrangements for conducting electric current to or from the device in operations for device characterised by at least one potential jump barrier or surface barrier for solar cells or solar cell modules
    • H01L31/0201—Arrangements for conducting electric current to or from the device in operations for device characterised by at least one potential jump barrier or surface barrier for solar cells or solar cell modules comprising specially adapted module bus-bar structures
    • H—ELECTRICITY
    • H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
    • H02S—GENERATION OF ELECTRIC POWER BY CONVERSION OF INFRARED RADIATION, VISIBLE LIGHT OR ULTRAVIOLET LIGHT, e.g. USING PHOTOVOLTAIC [PV] MODULES
    • H02S40/00—Components or accessories in combination with PV modules, not provided for in groups H02S10/00 - H02S30/00
    • H02S40/30—Electrical components
    • H02S40/34—Electrical components comprising specially adapted electrical connection means to be structurally associated with the PV module, e.g. junction boxes
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
    • Y02E—REDUCTION OF GREENHOUSE GAS [GHG] EMISSIONS, RELATED TO ENERGY GENERATION, TRANSMISSION OR DISTRIBUTION
    • Y02E10/00—Energy generation through renewable energy sources
    • Y02E10/50—Photovoltaic [PV] energy

Definitions

  • the invention relates to a process for manufacturing photovoltaic panels.
  • a common characteristic of the usual production processes for photovoltaic panels is that a considerable amount of manual work is necessary, especially in the stage of setting up the electrical connections of the tab ribbon of the strings of photovoltaic cells inserted in the panel.
  • the most widely-used panels are not able to guarantee a waterproofing function in order to be used in covers, cannot be trodden upon and have to be fixed to specially-predisposed structures usually constituted by aluminium beams and steel brackets.
  • attempts have been made to obviate the problem of realising panels that are adaptable to the various shapes of roofs by manufacturing small modules that can be coupled with various existing roof- tile systems.
  • the known solutions do not enable good exploitation of the surface available.
  • traditional panels normally exhibit only two rear-portion (known as the backs heet) colours: white or black.
  • the present invention is aimed at obviating the limitations of the prior art and in particular to overcome the drawbacks relating to the panel manufacturing methods of the prior art, according to what is set out in the claims.
  • An advantage of the present invention consists in using particularly efficient materials for realising the backsheet. Disclosure of Invention
  • figure 1 is a schematic exploded view of a photovoltaic panel obtained with the invention
  • figure 2 is a schematic lateral view in section of a photovoltaic panel obtained with the invention.
  • FIG. 1 schematically illustrate the structure of a photovoltaic panel obtained using the process, described herein below, for manufacturing photovoltaic panels, which comprises the following stages, in order: predisposing a ceramic support or backsheet 1 which is located on a rest 2; making through-holes 10 in the backsheet, which through-holes 10 are predisposed for the passage of electrical conductors; meticulous cleaning of the ceramic support or backsheet 1 using cleaning and drying means therefor; realising an electrical circuit or bussing 3 by superposition thereof on an upwards-facing surface of the backsheet 1, which bussing 3 is made solid to the upper surface of the backsheet 1 ; covering, if necessary, the bussing 3 with a layer of insulating material 4 superposed such as not to cover predetermined points or zones 30 for a subsequent electrical connection, leaving the points or zones 30 accessible or open for the said connection; laying or arranging a first layer of wrapping 5 over the whole surface of the backsheet 1 ; the laying not including the zones exhibiting the predetermined points 30 left uncovered or accessible
  • the ceramic support, or backsheet 1 is a slim sheet, preferably 3 mm or less and is subjected to careful cleaning, at least washing and drying using known means.
  • the covering of the bussing 3 with a first layer of insulating material 4, superposed such as not to cover predetermined points or zones 30 in order for a subsequent electrical connection to be made, is done with a layer of insulating material which masks and/or hides the bussing 3.
  • a particular advantage of the invention consists in using a ceramic support, or backsheet 1, made of ceramic material. It is preferably made of a ceramic material provided with good heat conductivity characteristics, such as vitrified stoneware, which come in the form of a slim sheet in comparison to usual tiles formed by powder sintering and subsequent firing. The thickness of the support is usually 3mm or less.
  • a considerable advantage of the present invention is that it enables a completely automated work cycle to be established, in particular including the realisation of the electrical connections of the tab ribbons. - A -
  • a photovoltaic panel which comprises, superposed in reverse order to the final installed presentation order: a ceramic support, or backs heet 1, which affords through-holes 10 predisposed for passage of electrical conductors; an electrical circuit, or bussing 3, which is superposed on a surface of the backsheet 1 and is made solid to the surface; a layer of insulating material 4 superposed such as to cover the bussing 3, leaving predetermined points or zones 30 accessible or uncovered for subsequent electrical connection thereof; a first layer of wrapping 5 arranged on the whole surface of the preceding layers located on the backsheet 1, with exclusion of the predetermined parts or zones 30 left accessible or uncovered for the electrical connections; a layer of strings of photovoltaic cells 8 arranged such that there is a correspondence by superposing of the relative tab ribbons 60 with the predetermined points or zones 30 previously left accessible or uncovered for the electrical connections, where the tab ribbons 60 are welded to the bussing 3 at the predetermined uncovered points or zones 30; a second layer of continuous
  • the layers and/or the components are solidly and stably joined together by vacuum hot-pressing or lamination.
  • the bussing 3 is electrically connected via the through-holes 10 to junction boxes 9.
  • the invention provides a considerable speeding-up of the production process, together with high product quality, with the product exhibiting characteristics which enable, among other things, easy connecting-up to the junction boxes.

Landscapes

  • Engineering & Computer Science (AREA)
  • Microelectronics & Electronic Packaging (AREA)
  • Physics & Mathematics (AREA)
  • Condensed Matter Physics & Semiconductors (AREA)
  • Electromagnetism (AREA)
  • General Physics & Mathematics (AREA)
  • Computer Hardware Design (AREA)
  • Power Engineering (AREA)
  • Sustainable Development (AREA)
  • Sustainable Energy (AREA)
  • Life Sciences & Earth Sciences (AREA)
  • Photovoltaic Devices (AREA)
  • Roof Covering Using Slabs Or Stiff Sheets (AREA)

Abstract

A process for manufacturing photovoltaic panels, comprising: predisposing a ceramic support or backsheet (1) which is located on a rest (2); making through-holes (10) in the backsheet, predisposed for the passage of electrical conductors; meticulous cleaning of the ceramic support or backsheet (1); realising an electrical circuit or bussing (3) by superposition thereof on an upwards - facing surface of the backsheet (1); covering the bussing (3) with a layer of insulating material (4) superposed such as not to cover predetermined points or zones (30) for a subsequent electrical connection; laying or arranging a first layer of wrapping (5) over the whole surface of the backsheet (1); the laying not including the zones exhibiting the predetermined points (30) laying strings of photovoltaic cells (6) such that tab ribbons (60) thereof overlap with the points or zones (30) previously arranged and left accessible or uncovered, for electric connection thereto; welding the tab ribbons (60) to the bussing (3) laying a second layer of continuous wrapping (7); superposing a protective layer of frontsheet (8); vacuum hot-pressing; cooling down to ambient temperature; electrically connecting the bussing (3) to junction boxes (9) via the through-holes (10).

Description

Description A Process for Manufacturing Photovoltaic Panels.
Technical Field
The invention relates to a process for manufacturing photovoltaic panels. Background Art
A common characteristic of the usual production processes for photovoltaic panels is that a considerable amount of manual work is necessary, especially in the stage of setting up the electrical connections of the tab ribbon of the strings of photovoltaic cells inserted in the panel. Further, the most widely-used panels are not able to guarantee a waterproofing function in order to be used in covers, cannot be trodden upon and have to be fixed to specially-predisposed structures usually constituted by aluminium beams and steel brackets. In some cases attempts have been made to obviate the problem of realising panels that are adaptable to the various shapes of roofs by manufacturing small modules that can be coupled with various existing roof- tile systems. In all cases the known solutions do not enable good exploitation of the surface available. Furthermore, traditional panels normally exhibit only two rear-portion (known as the backs heet) colours: white or black.
The present invention is aimed at obviating the limitations of the prior art and in particular to overcome the drawbacks relating to the panel manufacturing methods of the prior art, according to what is set out in the claims.
An advantage of the present invention consists in using particularly efficient materials for realising the backsheet. Disclosure of Invention
Further characteristics and advantages of the present invention will better emerge from the detailed description of a preferred though not exclusive embodiment of the present invention, illustrated with the aid of the non- limiting figures of the drawings, in which: figure 1 is a schematic exploded view of a photovoltaic panel obtained with the invention; figure 2 is a schematic lateral view in section of a photovoltaic panel obtained with the invention. The figures schematically illustrate the structure of a photovoltaic panel obtained using the process, described herein below, for manufacturing photovoltaic panels, which comprises the following stages, in order: predisposing a ceramic support or backsheet 1 which is located on a rest 2; making through-holes 10 in the backsheet, which through-holes 10 are predisposed for the passage of electrical conductors; meticulous cleaning of the ceramic support or backsheet 1 using cleaning and drying means therefor; realising an electrical circuit or bussing 3 by superposition thereof on an upwards-facing surface of the backsheet 1, which bussing 3 is made solid to the upper surface of the backsheet 1 ; covering, if necessary, the bussing 3 with a layer of insulating material 4 superposed such as not to cover predetermined points or zones 30 for a subsequent electrical connection, leaving the points or zones 30 accessible or open for the said connection; laying or arranging a first layer of wrapping 5 over the whole surface of the backsheet 1 ; the laying not including the zones exhibiting the predetermined points 30 left uncovered or accessible for electrical connections; laying strings of photovoltaic cells 6 such that tab ribbons 60 thereof overlap with the points or zones 30 previously arranged and left accessible or uncovered, for electric connection thereto; welding the tab ribbons 60 to the bussing 3 at the predetermined points or zones 30; laying a second layer of continuous wrapping 7; superposing a protective layer of frontsheet 8; vacuum hot-pressing or laminating the above-described sandwich of materials; cooling down to ambient temperature; electrically connecting the bussing 3 to junction boxes 9 via the through- holes 10.
The ceramic support, or backsheet 1, is a slim sheet, preferably 3 mm or less and is subjected to careful cleaning, at least washing and drying using known means.
The covering of the bussing 3 with a first layer of insulating material 4, superposed such as not to cover predetermined points or zones 30 in order for a subsequent electrical connection to be made, is done with a layer of insulating material which masks and/or hides the bussing 3. A particular advantage of the invention consists in using a ceramic support, or backsheet 1, made of ceramic material. It is preferably made of a ceramic material provided with good heat conductivity characteristics, such as vitrified stoneware, which come in the form of a slim sheet in comparison to usual tiles formed by powder sintering and subsequent firing. The thickness of the support is usually 3mm or less.
A considerable advantage of the present invention is that it enables a completely automated work cycle to be established, in particular including the realisation of the electrical connections of the tab ribbons. - A -
With the described process, a photovoltaic panel is obtained which comprises, superposed in reverse order to the final installed presentation order: a ceramic support, or backs heet 1, which affords through-holes 10 predisposed for passage of electrical conductors; an electrical circuit, or bussing 3, which is superposed on a surface of the backsheet 1 and is made solid to the surface; a layer of insulating material 4 superposed such as to cover the bussing 3, leaving predetermined points or zones 30 accessible or uncovered for subsequent electrical connection thereof; a first layer of wrapping 5 arranged on the whole surface of the preceding layers located on the backsheet 1, with exclusion of the predetermined parts or zones 30 left accessible or uncovered for the electrical connections; a layer of strings of photovoltaic cells 8 arranged such that there is a correspondence by superposing of the relative tab ribbons 60 with the predetermined points or zones 30 previously left accessible or uncovered for the electrical connections, where the tab ribbons 60 are welded to the bussing 3 at the predetermined uncovered points or zones 30; a second layer of continuous wrapping 7; a layer of protective material or frontsheet 8.
The layers and/or the components are solidly and stably joined together by vacuum hot-pressing or lamination.
The bussing 3 is electrically connected via the through-holes 10 to junction boxes 9. The invention provides a considerable speeding-up of the production process, together with high product quality, with the product exhibiting characteristics which enable, among other things, easy connecting-up to the junction boxes.

Claims

Claims.
1). A process for manufacturing photovoltaic panels, characterised in that it comprises: predisposing a ceramic support or backsheet (1) which is located on a rest
(2); making through-holes (10) in the backsheet, which through-holes (10) are predisposed for the passage of electrical conductors; meticulous cleaning of the ceramic support or backsheet (1) using cleaning and drying means therefor; realising an electrical circuit or bussing (3) by superposition thereof on an upwards-facing surface of the backsheet (1), which bussing (3) is made solid to the upper surface of the backsheet (1); covering, if necessary, the bussing
(3) with a layer of insulating material
(4) superposed such as not to cover predetermined points or zones (30) for a subsequent electrical connection, leaving the points or zones (30) accessible or open for the said connection; laying or arranging a first layer of wrapping (5) over the whole surface of the backsheet (1); the laying not including the zones exhibiting the predetermined points (30) left uncovered or accessible for electrical connections; laying strings of photovoltaic cells (6) such that tab ribbons (60) thereof overlap with the points or zones (30) previously arranged and left accessible or uncovered, for electric connection thereto; welding the tab ribbons (60) to the bussing (3) at the predetermined points or zones (30); laying a second layer of continuous wrapping (7); superposing a protective layer of frontsheet (8); vacuum hot-pressing or laminating the above-described sandwich of materials; cooling down to ambient temperature; electrically connecting the bussing (3) to junction boxes (9) via the through- holes (10).
2). The process for manufacturing photovoltaic panels of claim 1, characterised in that the backsheet (1) is a slab and is slim, preferably having a thickness of 3mm or less.
3). The process for manufacturing photovoltaic panels of claim 1, characterised in that the backsheet (1) is subjected to the meticulous cleaning at least by means of washing and drying thereof.
4). The process for manufacturing photovoltaic panels of claim 3, characterised in that covering of the bussing (3) with a first layer of insulating material (4) which is laid such as not to cover predetermined points or zones (30), leaving the said points or zones (30) accessible or uncovered for a subsequent electrical connection thereof, is realised with the first layer of insulating material (4) which masks and/or hides the bussing (3).
5). The process for manufacturing photovoltaic panels of claim 3, characterised in that the backsheet (1) is made of a ceramic material.
6). The process for manufacturing photovoltaic panels of claim 3, characterised in that the backsheet (1) is made of a ceramic material having good heat conductivity, preferably vitrified stoneware.
7). The process for manufacturing photovoltaic panels of claim 6, characterised in that the backsheet (1) is made of a ceramic material having good heat conductivity characteristics, preferably vitrified stoneware, which is in a form of a slab having a thickness of 3mm or less. 8). A photovoltaic panel, characterised in that it comprises, superposed in order going from a bottom of the panel to a top thereof: a ceramic support, or backsheet (1), which affords through-holes (10) predisposed for passage of electrical conductors; an electrical circuit, or bussing (3), which is superposed on a surface of the backsheet (1) and is made solid to the surface; a layer of insulating material (4) superposed such as to cover the bussing
(3), leaving predetermined points or zones (30) accessible or uncovered for subsequent electrical connection thereof; a first layer of wrapping (5) arranged on the whole surface of the preceding layers located on the backsheet (1), with exclusion of the predetermined parts or zones (30) left accessible or uncovered for the electrical connections; a layer of strings of photovoltaic cells (8) arranged such that there is a correspondence by superposing of the relative tab ribbons (60) with the predetermined points or zones (30) previously left accessible or uncovered for the electrical connections, where the tab ribbons (60) are welded to the bussing (3) at the predetermined uncovered points or zones (30); a second layer of continuous wrapping (7); a layer of protective material or frontsheet (8); the layers and/or the components being solidly and stably joined together by vacuum hot-pressing or lamination; the bussing (3) being electrically connected via the through-holes (10) to junction boxes (9).
EP09787755A 2009-06-17 2009-06-17 A process for manufacturing photovoltaic panels Withdrawn EP2443667A2 (en)

Applications Claiming Priority (1)

Application Number Priority Date Filing Date Title
PCT/IT2009/000265 WO2010146607A2 (en) 2009-06-17 2009-06-17 A process for manufacturing photovoltaic panels

Publications (1)

Publication Number Publication Date
EP2443667A2 true EP2443667A2 (en) 2012-04-25

Family

ID=43356832

Family Applications (1)

Application Number Title Priority Date Filing Date
EP09787755A Withdrawn EP2443667A2 (en) 2009-06-17 2009-06-17 A process for manufacturing photovoltaic panels

Country Status (2)

Country Link
EP (1) EP2443667A2 (en)
WO (1) WO2010146607A2 (en)

Families Citing this family (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
TWI440196B (en) 2011-07-12 2014-06-01 Au Optronics Corp Back contact solar module and electrode soldering method therefor
CN102244148B (en) * 2011-07-18 2013-04-24 索日新能源股份有限公司 Welding method of tandem type solar silicon wafer group and special shelf thereof
US9444004B1 (en) * 2014-05-02 2016-09-13 Deployable Space Systems, Inc. System and method for producing modular photovoltaic panel assemblies for space solar arrays
IT201800009389A1 (en) * 2018-10-12 2020-04-12 Vismunda Srl "ASSEMBLY METHOD AND BIVALENT COMBINED STATION, FOR PHOTOVOLTAIC PANELS"

Family Cites Families (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US5972732A (en) * 1997-12-19 1999-10-26 Sandia Corporation Method of monolithic module assembly
JP3579623B2 (en) * 1999-09-29 2004-10-20 シャープ株式会社 Solar cell module
EP1909334A1 (en) * 2006-10-06 2008-04-09 Schreiner Group GmbH & Co. KG Method and composite foil for contacting and sealing a solar module
AU2007352245A1 (en) * 2007-04-26 2008-11-06 System S.P.A. A photovoltaic module or panel with a ceramic support slab

Non-Patent Citations (1)

* Cited by examiner, † Cited by third party
Title
See references of WO2010146607A3 *

Also Published As

Publication number Publication date
WO2010146607A2 (en) 2010-12-23
WO2010146607A3 (en) 2011-12-08

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