Solar Cell Lamination

Abstract

The present invention relates to a solar cell sheet comprising a first and a second substrate, which first and second substrates are flexible and suitable for roll to roll printing, and the solar cell sheet further comprises one or more self-contained solar cell units, wherein each self-contained solar cell unit comprises one or more solar cell modules, and each solar cell module comprises a plurality of serially connected solar cells, wherein each of the solar cell modules comprises: a first substrate portion of the first flexible substrate and a second substrate portion of the second substrate, a plurality of first electrodes and a plurality of second electrodes arranged between the first and second substrate portions; and at least one organic active layer arranged between the plurality of first electrodes and the plurality of second electrodes; wherein, a continuous or discontinuous portion of a first adhesive material encircles each of the solar cell units. The present invention further relates to a method for producing the solar cell sheet comprising one or more self-contained solar cell units.

Claims

1. A method for producing a solar cell sheet, said solar cell sheet comprising two or more self-contained solar cell units, wherein each self-contained solar cell unit comprises one or more solar cell modules, said method comprising: providing a first and a second flexible substrate portion suitable for roll to roll deposition; for each solar cell module: providing a first set of electrodes on a predetermined portion said first substrate, providing a second set of electrodes on a predetermined portion of said second substrate, providing a first organic active layer on one of said first and second sets of electrodes, and optionally a second organic active layer on the other of said first and second sets of electrodes, providing a layer of adhesive material on at least one of said first and second substrate, which layer of adhesive material is continuous or discontinuous and encircles each one of said one or more solar cell units; laminating by means of heat and pressure said first and said second substrate portions together in a roll-to-roll process such that the layer of adhesive material adheres the first and second substrates to each other, and for each solar cell module: the active layer is arranged spatially between and in electrical contact with said plurality of first electrodes and said plurality of second electrodes; separating at least one of the solar cell units from the other solar cell units or the rest of the sheet.

2. The method according to claim 1 wherein the step of separating at least one of the solar cell units is performed by means of cutting.

3. The method according to claim 1 wherein said step of separating at least one of the solar cell units from the other solar cell units is at least partly performed by cutting in between two neighboring lines of adhesive material.

4. The method according to claim 1, wherein the layer of said adhesive material is conductive or non-conductive.

5. The method according to claim 1, wherein said step of providing a layer of adhesive material on at least one of said first and second substrate comprises the step of providing an adhesive layer which at least partly forms an outer and an inner line.

6. The method according to claim 5, wherein one of said outer and inner lines is more hydrophobic compared to the other.

7. The method according to claim 6, wherein said inner line is more hydrophobic compared to said outer line and said outer line has a higher oxygen permeability compared to said inner line.

8. The method according to claim 6, wherein said outer line is more hydrophobic compared to said inner line and said inner line has a higher oxygen permeability compared to said outer line.

9. The method according to claim 1, wherein said layer of adhesive material after drying has a width of at least 10 nm and/or at most 1 mm in a direction parallel with said substrate.

10. The method according to claim 1, wherein said layer of adhesive material after drying has a width of at most 1 mm in a direction parallel with said substrate.

11. The method according to claim 1, wherein the method further comprises providing each one of said at least one solar cell modules with a plurality of discontinuous portions of an adhesive non-conductive material spatially arranged within said solar cell module.

12. The method according to claim 2, wherein said step of providing a layer of adhesive material on at least one of said first and second substrate comprises the step of providing an adhesive layer which at least partly forms an outer and an inner line.

13. The method according to claim 2, wherein said layer of adhesive material after drying has a width of at least 10 nm and/or at most 1 mm in a direction parallel with said substrate.

14. The method according to claim 2, wherein said layer of adhesive material after drying has a width of at most 1 mm in a direction parallel with said substrate.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0080] The above objects, as well as additional objects, features and advantages of the present invention, will be more fully appreciated by reference to the following illustrative and non-limiting detailed description of embodiments of the present invention, when taken in conjunction with the accompanying drawings, wherein:

[0081] FIG. 1a shows a schematic and cross-sectional top view of a solar cell sheet with solar cell units in accordance with at least one embodiment of the present invention;

[0082] FIGS. 1b-1f show a schematic and top cross-sectional view of one of the solar cell units in FIG. 1a in accordance with at least one embodiment of the present invention;

[0083] FIG. 2 shows a schematic and top cross-sectional view of top and bottom parts of the solar cell units in FIG. 1a in accordance with at least one embodiment of the present invention;

[0084] FIGS. 3a-3d show a schematic and top cross-sectional view of a plurality of solar cell units in accordance with at least one embodiment of the present invention;

[0085] FIG. 4 shows a schematic and top cross-sectional view of various adhesive material layouts in accordance with at least one embodiment of the present invention;

[0086] FIGS. 5a-5d show a schematic and top and side cross-sectional views of a plurality of solar cells in accordance with at least one embodiment of the present invention;

DETAILED DESCRIPTION OF THE DRAWINGS

[0087] In the present detailed description, embodiments of the present invention will be discussed with the accompanying figures. It should be noted that this by no means limits the scope of the invention, which is also applicable in other circumstances for instance with other types or variants of methods for laminating a solar cell module or other types or variants of solar cell module than the embodiments shown in the appended drawings. Further, that specific features are mentioned in connection to an embodiment of the invention does not mean that those components cannot be used to an advantage together with other embodiments of the invention.

[0088] The following description will use terms such as “top”, “bottom”, “outer” etc. These terms generally refer to the views and orientations as shown in the drawings. The terms are used for the reader's convenience only and shall not be limiting.

[0089] FIG. 1a schematically shows a solar cell module 6, comprising a first set of electrode stripes 52 arranged on a first substrate and a second set of electrode stripes arranged on a second substrate, wherein the stripes in each set are separated from each other by gaps 54. Moreover, the electrodes are sandwiched between the first and second substrates, and an active layer is sandwiched between the first and second set of electrodes. Additionally, the solar cell module comprises a first and a second electrode or busbar 57a, 57b for extracting the generated energy.

[0090] FIG. 1b illustrates one example of a solar cell module encircled and delimited by adhesive material adhesive material 5, which may be a conductive adhesive or a non-conductive adhesive material that encircles/delimits the area of the solar cell unit 4. The adhesive material 5 divides the substrate in an inner part 4a and an outer part 4b. The inner part 4a comprises at least one solar cell module 6 as shown in FIG. 1b.

[0091] In FIG. 5b-5d, the solar cell module 6 comprises a first flexible substrate portion 10 on which a plurality of first electrodes 52 is arranged as well as a first continuous or discontinuous active layer 53. The first substrate portion 10 may be transparent or semi-transparent. The first substrate portion 10 as well as the first plurality of electrodes 52 are suitable for roll-to-roll processing methods, e.g. roll-to-roll printing, roll-to-roll coating and roll-to-roll lamination.

[0092] The plurality of first electrodes 52 are provided as substantially parallel stripes on the first substrate portion 10. The plurality of first electrodes 52 extends along the substrate in the z-direction. In other words, the longest extension of the stripes will here be in the z-direction. As shown in FIG. 5a, the longest extension of the first substrate portion 10 and the plurality of first electrodes 52 is here the same direction. The plurality of first electrodes 52 is arranged such that they are spatially separated from each other in a x-direction, which separation forms a plurality of gaps 54 between said first electrodes 52. In an alternative embodiment, the longest extension of the stripes may be in a direction transverse or orthogonal to the longest extension of the substrate. In more detail, when the longest extension of the substrate is in the z direction, the longest direction of the plurality of first electrodes 52 may be in the x-direction or in any direction between x and z.

[0093] The solar cell module 6 may further comprise a second flexible substrate portion 20 having the same configuration as described in relation to the first substrate unless otherwise is stated. In other words, there may be a plurality of second electrodes 522 and a second continuous or discontinuous active layer 53.

[0094] The solar cell module 6 may further comprise a first and second contacting electrode 56a, 56b optionally comprising a respective first and a second busbar 57a, 57b or contacting points.

[0095] It shall be noted that the thickness of the different layers, e.g. the first and the second active layer 53, or the plurality of first 52 or second 52 electrodes have not been drawn to scale.

[0096] Alternatively, the solar cell modules 6 may be arranged as described in EP 3 364 474 A1.

[0097] In a different example as shown in FIG. 1c, a solar cell unit 4 may comprise more than one solar cell modules 6.

[0098] According to another example, shown in FIG. 1d and FIG. 1e, the solar cell unit further comprises another type of component 102 such as a logic circuit or a flat PCB. The component is optionally attached at contact points 101, and connected to the solar cells by means of electronic conductors 100a, and may also comprise further electrodes 100b for connection to other devices. In FIG. 1d the solar cell unit is shown without adhesive applied on top, and in FIG. 1e the solar cell unit is shown before lamination to the second substrate when the adhesive has been applied (where preferably at least the part covering the electronic conductors is non-conductive).

[0099] FIG. 2 shows one example of forming the solar cell units 4 on the solar cell sheet 1, wherein the solar cell modules 6 are arranged on the bottom substrate 2 and the top substrate 3 is provided with the adhesive material 5.

[0100] In the arrangement in the example, the adhesive material 5 is applied on the bottom substrate 2 in stripes 7 continuously extending in the z direction and further with intersecting continuous portions 8 extending in the x direction. In more detail, the intersection where the extensions of the adhesive material extending in x and z directions meet, creates the delimited inner area 4a of the solar cell units in a ladder-like appearance. By laminating the top and bottom substrates 2,3 together while aligning the adhesive portions 5 on the respective substrates, the completed solar cell sheet is created.

[0101] According to one embodiment the adhesive material is printed close to (within 10 nm to 1 mm from the solar cell) or even on top of the solar cell module, as a minimization of gaps at the inner surface may facilitate the reduction of air pocket in the finished product.

[0102] According to another embodiment each solar cell unit 4 may be delimited individually by the adhesive material as shown in FIG. 3a. In this embodiment each solar cell unit 4 is defined by an adhesive border line 32 encircling a respective one of the solar cell units, which border lines create gaps 31 between two adjacent solar cell units 4 and may facilitate cutting the solar cell units 4 apart while maintaining the adhesive properties of the adhesive. Additionally, it may reduce the amount of adhesive material required for adhering the solar cell substrates 1. Further, as shown in FIG. 3b and FIG. 3c, the solar cell sheet 1 may comprise a single solar cell unit 33 e.g. extending fully or substantially throughout the whole area of the solar cell sheet 1. The single solar cell unit 33 may comprise a plurality of solar cell modules 6, as shown in FIG. 3b or may comprise a single solar cell module 6 extending throughout the entire unit as shown in FIG. 3c. The solar cell modules 6 within each solar cell unit 4, 33 may be connected to the contacting electrodes or busbar contacting points individually, or be electrically connected in series or in parallel to form an expanded network of solar cell modules.

[0103] To produce the solar cell sheets 1, the adhesive layer may be applied on both the bottom substrate 2 and the top substrate 3 or on only one of the substrates. The adhesive material 5 may be provided in any geometrical shape or contour, where a circular, triangular, or rectangular shape are basic examples. As shown in FIG. 4, the adhesive material 5 may be applied in a continuous manner e.g. in a continuous line 41, in a broken line 42 or in any other layout 43 which will be desired for the fabrication process. The adhesive layers maybe applied on the substrates as individual portions 43 arranged with a determined separation gap in respect to each other as seen in FIG. 4. It is advantageous however, that after the adhesion or lamination step of the bottom 2 and top 3 substrates, the adhesive material 5 applied in any of the above-mentioned manners forms a continuous boundary 44 delimiting the solar cell units 4. The delimiting boundary 44 serves as a barrier between the inner part 4a and outer part 4b of the solar cell modules 4, and may serve to maintain the isolation between the solar cell units and the outside environment. For example, the humidity conditions inside the units may be configured to be kept at a certain level in respect to the ambient humidity. In addition, the barrier protects the units from outside pollutants such as dust particles or atmospheric particulate matters such as smog, soot, etc. which may enter and destroy the solar cell modules 6. In other words, the adhesive layer in addition to improving the mechanical stability of the solar cell sheets 1 acts as a protective barrier which shields the solar cell units 4 from the outside environment.

[0104] According to one example the boundary 44 comprises a first line encircling and/or delimiting the solar cell unit. In addition to this first line the boundary also comprises a second line encircling and/or delimiting the solar cell unit, which second line is preferably arranged close to said first line. According to one embodiment each one of the lines only partly encircles the solar cell unit, but together they fully encircle the solar cell unit. According to another embodiment one or both of the lines fully encircles the solar cell unit. The first and the second lines may be of the same or different adhesive materials. One of the lines may e.g. consist of a hydrophobic adhesive material designed to decrease the passage of moister there through; and the other of the lines may e.g. consist of an adhesive material with low oxygen permeability designed to decrease the passage of oxygen there through. A line may also comprise interleaved or alternating portions of hydrophobic adhesive material and adhesive material with low oxygen permeability along the extension of the line.

[0105] This second line may partly or fully encircle the solar cell unit, whereas the first line fully encircles the solar cell unit.

[0106] In another exemplary embodiment as shown in the top cross-sectional view of a solar cell module in FIG. 5a, the solar cell modules 6 may include individual portions 51 of the adhesive material arranged within each solar cell module. Such portions maybe arranged in various spatial distribution on the substrate portions 10, 20. For example, in FIG. 5b, a cross-sectional side view of the same solar cell module 6 of FIG. 5a with five solar cells on the bottom substrate portion is depicted. In this embodiment, the portions 51 of adhesive material are placed within the gaps 54 created between adjacent electrodes 52, 522. The discontinuous adhesive material in this example is a non-conductive material. As mentioned earlier, the solar cell modules 6 may or may not optionally include a continuous or discontinuous active layer 53 on the second substrate portion. In this example the active layer 53 is only provided on the first substrate portion 10.

[0107] In another example embodiment shown in FIG. 5c-d, the active layer 53 maybe discontinuous and the first and second electrodes may be connected via electric conductors 55 placed within the gaps 54 of adjacent electrodes on the first 10 and the second 20 substrate portions. In this case the adhesive material may be placed on the first 531 and/or a second active layer (not shown) of the first 10 and the second 20 substrate portions. Optionally, the adhesive material is transparent within the working wavelength of the solar cells so as not to affect the functionality of the module.

[0108] In yet another example shown in FIG. 5d, in the same solar cell module 6 of FIG. 5c, the discontinuous portions 51 of the adhesive material may be placed within the gaps 54 between the contacting electrodes 56a, 66b, the gaps 54 between the first active layer and busbar contacting points 57a, 57b or the gaps 54 between the contacting electrodes 56a, 66b and busbar contacting points 57a, 57b.

[0109] The skilled person realizes that a number of modifications of the embodiments described herein are possible without departing from the scope of the invention, which is defined in the appended claims. For instance, the stripes of the plurality of the adhesive materials used may be applied on the substrates in any other positions as well as geometrical shape and arrangements than explained in the examples above. Further, other components of the solar cell units such as first and second electrodes may for example be of any other curvature than the one shown in the figures. They may also be deposited such that their longest extension being in any direction between the x- and z-directions. Hence, they need not be neither parallel nor perpendicular to the longest extension of the substrate. The skilled person also realizes that other conducting or semiconducting materials can be used as either electrodes or in the active layers of the solar cell module.