METHOD FOR MANUFACTURING A SOLAR CELL MODULE AND SOLAR CELL MODULE

Abstract

The present invention relates to a method for manufacturing a solar cell module by the steps of: providing at least two bifacial solar cells; adjoining arrangement of the solar cells, wherein a gap is provided between the solar cells; providing a diffuse reflector in the gap area. The present invention also relates to such a solar cell module, wherein the diffuse reflector is disposed and configured such that it diffusely reflects the incident light and a portion of the diffusely reflected lights strikes on the solar cell through total reflection at the front boundary layer of the solar cell module.

Claims

1. Method for manufacturing a solar cell module by the following steps: Adjacently arranging at least two bifacial solar cells, wherein a gap is provided between the solar cells; arranging a diffuse reflector with flat surface in the gap area.

2. Method according to claim 1, characterized in that the reflector is attached on the rear-side of the solar cells in the form of an adhesive tape or an adhesive film, before embedding the solar cells.

3. Method according to claim 1, characterized in that the solar cells are laminated between a front surface layer and a back cover, wherein the reflector is attached to an inner side of the back cover, before lamination.

4. Method according to claim 1, characterized in that the solar cells are disposed between two plastic layers, wherein the reflector is provided beforehand in the form of a coloring in the rear-side plastic layer or in the form of an imprint on the rear-side plastic layer and wherein the solar cells along with the reflector are subsequently embedded in the material of the plastic layers by lamination.

5. Method according to claim 1, characterized in that the reflector is attached to the outer side of the back cover of the solar cell module.

6. Method according to claim 3, characterized in that the back cover is provided as rear-side glass.

7. Method according to claim 3, characterized in that the reflector is attached to the back cover in the form of an imprint, an adhesive tape or an adhesive film.

8. Method according to claim 1, characterized in that the reflector is provided or configured linear or grid-shaped.

9. Method according to claim 1, characterized in that the reflector is attached to the rear-side of a rear-side glass of the solar cell module, wherein the rear-side glass is partially surface-treated for attaching the reflector.

10. Method according to claim 9, characterized in that the rear-side glass is coated with a metal for attaching the reflector.

11. Method according to claim 9, characterized in that the rear-side glass is etched or irradiated or ground for attaching the reflector.

12. Method according to claim 9, characterized in that a grid-shaped structure of the reflector is attached to the rear-side glass during the surface treatment by means of a grid-mask or without mask with a controlled nozzle.

13. Solar cell module, particularly manufactured in accordance with a method according to one of the preceding claims, having at least two adjoining bifacial solar cells, wherein a gap is provided between the solar cells and a diffuse reflector with flat surface is disposed and configured in the gap area such that it diffusely reflects light incident in the gap and a portion of the diffusely reflected light strikes on the solar cells through total reflection on a front boundary layer of the solar cell module.

14. Solar cell module according to claim 13, characterized in that the diffuse reflector includes an adhesive tape or an adhesive film with a pigment coating and with an adhesive layer.

15. Solar cell module according to claim 13, characterized in that the diffuse reflector comprises an imprint or an adhesive or a baking varnish, which contains white particle.

16. Solar cell module according to claim 13, characterized in that the diffuse reflector is partially formed with a surface treated back cover of the solar cell module.

17. Solar cell module according to claim 13, characterized in that the diffuse reflector is partially formed with a surface treated rear-side plastic layer of the solar cell module.

Description

SUMMARY OF THE DRAWING

[0034] The present invention is described in more details in the following with the help of exemplary embodiments specified in schematic figures of the drawings. Therefore, it is shown that:

[0035] FIG. 1 shows a schematic cross-sectional representation of a solar cell module according to a first embodiment;

[0036] FIG. 2 shows a schematic cross-sectional representation of a solar cell module according to a second embodiment;

[0037] FIG. 3 shows a schematic cross-sectional representation of a solar cell module according to a third embodiment;

[0038] FIG. 4 shows a schematic cross-sectional representation of a solar cell module according to a fourth embodiment;

[0039] FIG. 5 shows a schematic representation of a top-view on a section of the solar cell module.

[0040] The accompanying figures of the drawing shall show another understanding of the embodiments of the invention. These illustrate the embodiments and are used in connection with the description of the explanation of the principles and concepts of the invention. Other embodiments and many of the advantages mentioned, result in view of the drawings. The elements of the drawings are not necessarily shown to scale with respect to each other.

[0041] In the figures of the drawing, the same, functionally similar and similarly functioning elements, features and componentsunless otherwise specifiedare respectively provided with the same reference numerals.

DESCRIPTION OF EMBODIMENTS

[0042] FIG. 1 shows a schematic cross-sectional representation of a solar cell module 1 according to a first embodiment.

[0043] The solar cell module 1 has two adjoining solar cells 2 in the depicted section of the section plane. A gap 3 is provided between the two solar cells 2. The number of two solar cells is purely as an example. Any higher number of solar cells 2 can also be provided, wherein a gap is respectively provided between two adjoining solar cells. Therefore, the depicted arrangement can safely proceed laterally with further solar cells in the same manner.

[0044] Both the solar cells 2 are embedded in the material of two plastic layers 7, 8. Thus, preferably it could be EVA coatings.

[0045] Further, a front surface layer 5 and back cover 6 close the solar cell module 1 from front and rear, i.e. in the section plane represented upwards and downwards. Therefore, it could

[0046] respectively be a glass layer or a film layer. Further, only the front surface 5 can also be provided as a glass layer and the back cover 6 as a film layer, or vice-versa.

[0047] In the present exemplary embodiment, a diffuser reflector 4 is disposed in the gap area 3 between a rear-side EVA plate 8 and a back cover 6.

[0048] For example, the reflector could be an adhesive tape provided with a white pigment coating. Further, the reflector can also be provided in the form of a coloring in the rear-side plastic layer or in the form of an imprint on the rear-side plastic layer.

[0049] For manufacturing the solar cell module 1, the solar cells 2 are disposed between the plastic layers 7, 8 with the predefined gap 3.

[0050] The reflector 4 is attached on the back cover 6 in case of an adhesive band positioned such that in an assembled state, the reflector 4 is disposed in the gap area 3 between the solar cells 2.

[0051] In case of a coloring in the rear-side plastic layer 8 or an imprint on the rear-side plastic layer 8, the solar cells and the plastic layer are accordingly positioned with each other, so that in an assembled state, the reflector 4 is disposed in the gap area 3 between the solar cells 2.

[0052] Subsequently, the solar cell module 1 is laminated. Therefore, the front surface layer 5 and the back cover 6 are joined to each other via the material of the plastic layers 7, 8, so that the solar cells 2 are embedded therebetween. In case of EVA, this is done at temperatures of about 150 C. Therefore, EVA is initially fluid and crystal clear and then cross-linked three-dimensionally.

[0053] After cooling down, there is a durable bond. Thus, the reflector 4, the front surface layer 5 and the back cover 6 are firmly joined with the material of the plastic layers 7, 8.

[0054] In the solar cell module 1 shown, light striking in the gap 3 from the front surface on the diffuse reflector 4 is diffusely reflected and largely strikes obliquely on the boundary layer of the front surface layer 5 of the solar module 1 with the surrounding air. Therefore, a higher portion of the diffusely reflected light is totally reflected on this boundary layer and can thus be used in the solar cell module 1. A corresponding beam path is marked by an arrow 10 as an example.

[0055] Therefore, the front-side represents a side facing the direct sunlight.

[0056] FIG. 2 shows a schematic cross-sectional representation of a solar cell module 1 according to a second embodiment.

[0057] In contrast to the first embodiment, here, the diffuse reflector 4 is disposed directly on a rear-side of the solar cells 2. Preferably, it could thus also be an adhesive tape or an adhesive film with white pigment coating.

[0058] During the manufacture, the reflector 4 is glued on the rear-side of the solar cells 2, before lamination.

[0059] FIG. 3 shows a schematic cross-sectional representation of a solar cell module 1 according to a third embodiment.

[0060] In this embodiment, the reflector 4 is configured as a rectangular body with a thickness spanning the distance between the back cover 6 and the solar cells 2. Thus, simultaneously it is flush with the back cover 6 and the solar cells 2.

[0061] Therefore, the reflector 4 can also be used here additionally as positioning aid for the solar cells 2, during lamination.

[0062] An additional stage could be provided on the reflector 4 for exact positioning of the solar cells 2.

[0063] For manufacturing, the lower plastic layer 8 is separately provided and the reflector 4 is inlaid therebetween. Subsequently, the solar cells 2 is disposed thereupon and the front plastic layer 7 is provided thereon. During lamination, the reflector 4 can then support the solar cells 2 on the rear-side thereof, so that these remain at the level of the reflector 4 in spite of a pressure applied during lamination.

[0064] Obviously, several reflectors 4 supporting the solar cells can also be respectively provided on the edge of the solar cells 2, particularly surrounding the solar cells 2.

[0065] FIG. 4 shows a schematic cross-sectional representation of a solar cell module 1 according to a fourth embodiment.

[0066] Here, the reflector 4 is provided on the rear-side of the back cover 6. Depending on the distance from the solar cells 2, a portion of the diffusely reflected light can also directly strike on the rear-side of the solar cells 2 in this arrangement. This beam path is marked with an arrow 11 as an example. Another portion of the diffusely reflected light is returned through the gap 3 to the front-side, analogous to the beam path marked in FIG. 1 and can be partially returned there through total reflection to the boundary layer with the air. This beam path is likewise marked here with an arrow 10 as an example.

[0067] In the embodiment shown here, the reflector 4 is preferably attached only after lamination. For example, it can be imprinted on the back cover 6 subsequently. An adhesive tape strip can also be applied outside the rear-side as reflector 4.

[0068] So long as the back cover 6 is a rear-side glass, the reflector 4 is applied by means of a surface treatment of the rear-side glass 6, for example by means of vaporization, etching, irradiation or grinding.

[0069] FIG. 5 shows a schematic representation of a top-view at a section of the solar cell module 1.

[0070] The solar cell module 1 is represented in a corner segment and proceeds downwards and rightwards in the representation, not shown.

[0071] The solar cell module 1 has a surrounding frame 9, which is likewise represented only in the corner segment.

[0072] In the corner segment, four solar cells 2 are uniformly disposed and mutually spaced apart with the same gap 3 respectively. The scheme of this arrangement proceeds preferably over the entire solar cell module.

[0073] Further, the solar cells 2 are also disposed having a gap from the frame 9. A diffuser reflector 4 is respectively provided in all the gaps, which is respectively configured as an adhesive tape in this embodiment.

[0074] The solar cells 2 and the frame 9 are configured rectangular and the solar cells 2 are disposed uniformly and having the same size. Accordingly, the reflectors 4 intersect regularly, so that there is a grid-shaped arrangement.

[0075] Alternative to a grid-shaped arranged adhesive tapes, a correspondingly cut-off adhesive film or a correspondingly applied imprint can also be provided.

[0076] The reflector 4 has a pigment coating with white pigments, for example containing Titanium oxide, Calcium carbonate or Barium sulfate. The pigments can be bonded, for example in an organic matrix. Likewise, it could be a white filled adhesive, for example based on Silicon or Epoxy. Accordingly, the adhesive layer and the pigment coating can also form a common layer.

[0077] Although, the present invention was completely described above with the help of preferred exemplary embodiments, it is not restricted to these, but can be modified in many ways.

[0078] In particular, even different configuration and/or arrangements of the reflector 4 can be combined in a solar cell module 1.

[0079] Further, intersecting reflectors 4 can be configured mutually integrally or overlapping each other. It is also possible that one of the mutually intersecting reflectors 4 is interrupted at the intersection, for example for insulation, if it involves a conductive material.

LIST OF REFERENCE NUMERALS

[0080] 1 Solar cell module [0081] 2 Solar cell [0082] 3 Clearance [0083] 4 Reflector [0084] 5 Front surface layer [0085] 6 Back cover [0086] 7 Plastic layer [0087] 8 Plastic layer [0088] 9 Frame [0089] 10, 11 Beam path