Solar cell module and method for manufacturing such a module

Abstract

A method for manufacturing a solar cell module that includes a solar cell based on a semiconductor substrate with front and rear surfaces, includesfabricating a solar cell from the substrate, anddepositing on at least the rear surface a coating layer.

The deposition step includes applying a coating powder on at least the rear surface, forming an adhered powder layer on said surface.

The method includes after the deposition step: performing a first annealing process on the solar cell module for transforming the adhered powder layer in a pre-annealed coating layer.

Further the method includescreating open contacting areas on the solar cell by removal of the adhered powder layer at locations of contacting areas on the solar cell , wherein the removal precedes the first annealing process, or by masking contacting areas on the solar cell 1, wherein the masking precedes the deposition step.

Claims

1. A method for manufacturing a solar cell module that comprises a solar cell based on a semiconductor substrate with a front surface for capturing radiation and a rear surface, the method comprising: fabricating a solar cell from the semiconductor substrate; depositing on at least one surface of the solar cell a coating layer, the deposition step comprising: applying a coating powder on at least the rear surface, forming an adhered powder layer on said surface; and after the deposition step: performing a first annealing process on the solar cell for transforming the adhered powder layer in a pre-annealed coating layer so as to create a coated solar cell, and wherein the method further comprises either: creating open contacting areas on the solar cell by removal of the adhered powder layer at locations of contacting areas on the solar cell, wherein the removal precedes the first annealing process, or creating open contacting areas on the solar cell by masking contacting areas on the solar cell to prevent coverage by the adhered powder layer and to create open contacting areas on the solar cell, wherein the masking precedes the deposition step or deposition steps.

2. The method according to claim 1, wherein the open contacting areas on the solar cell are free from coating powder.

3. The method according to claim 1, wherein the deposition step additionally comprises applying the coating powder on the front surface, forming an adhered powder layer on said surface.

4. The method according to claim 1, wherein the masking is performed by positioning the solar cell on a clamping tool, with each contacting area of the solar cell being covered by a protrusion of the clamping tool.

5. The method according to claim 4, wherein at least one protrusion of the clamping tool comprises a vacuum nozzle for holding the surface of the contacting area.

6. The method according to claim 1, wherein the first annealing process is conditioned to produce a porous layer as pre-annealed coating layer.

7. The method according to claim 1, wherein the first annealing process is conditioned to produce a dense layer as pre-annealed coating layer.

8. The method according to claim 6, wherein the first annealing process is performed in a vacuum.

9. The method according to claim 6, comprising that the solar cell module is arranged between support layers, preceding the first annealing process, and the first annealing process is performed while the solar cell module is between the support layers.

10. The method according to claim 9, comprising pressing the support layers against the solar cell module.

11. The method according to claim 10, wherein the support layers are provided with a pattern of ribs.

12. The method according to claim 6, comprising the method comprises applying a contacting material in the open contacting areas of the solar cell, by either a dispensing, jetting or a screen printing technique.

13. The method according to claim 12, further comprising for the formation of a solar panel stack by: providing a panel module transparent cover layer: arranging at least one solar cell on the panel module transparent cover layer, such that the contacting surface of the solar cell is facing away from the panel module transparent cover layer; arranging a back-sheet layer on the at least one coated solar cell, the back-sheet layer arranged with a conductive layer pattern with conductive layer pattern contacting areas location-wise corresponding with the contacting areas of the solar cell; exposing the solar panel stack to elevated temperature and pressure in a second annealing process, such that between the solar cell and the back-sheet layer the coating layer as pre-annealed in the first annealing process, melts.

14. The method according to claim 6, further comprising for the formation of a solar panel stack: providing a panel module transparent cover layer:arranging at least one solar cell on the panel module transparent cover layer, such that the contacting surface of the solar cell is facing away from the panel module transparent cover layer; providing a back-sheet layer arranged with a conductive layer pattern with conductive layer contacting areas location-wise corresponding with the contacting areas of the solar cell; arranging contacting material on the conductive layer pattern contacting areas; arranging the back-sheet layer on the at least one coated solar cell with the conductive layer pattern contacting areas corresponding with the contacting areas of the solar cell; exposing the solar panel stack to elevated temperature and pressure in a second annealing process, such that between the solar cell and the back-sheet layer the coating layer as pre-annealed in the first annealing process, melts.

15. The method according to claim 13, wherein the coated solar cell comprises a second pre-annealed coating layer facing towards the panel module transparent cover layer, the second pre-annealed coating layer being melted during said elevated temperature and pressure exposure in the second annealing process.

16. The method according to claim 13, comprising: creating on a surface of the panel module transparent cover layer an adhered powder layer on said surface by using a powder coating technique, exposing the panel module transparent cover layer to a panel module transparent cover annealing process so as to create a cover pre-annealed coating layer on the panel module transparent cover layer, and wherein the arrangement of the panel module transparent cover layer over the at least one coated solar cell comprises arranging the pre-annealed coating layer between the solar cell surface and the panel module transparent cover layer; the pre-annealed coating layer being melted during said elevated temperature and pressure exposure in the second annealing process.

17. The method according to claim 1 wherein the coating powder is applied by electrostatic spraying.

18. The method according to claim 1, wherein the coating powder is applied by an electrostatic printing process or laser printing process.

19. The method according to claim 1, wherein at least the pre-annealed coating layer between the at least one solar cell and the back-sheet layer has a thickness of about 100 m or less.

20. The method according to claim 13, wherein after the exposure to elevated temperature and pressure the contacting material in the contacting areas has a thickness of about 100 m or less.

21. The method according to claim 9, wherein the support layer or support layers consist of a Teflon or a Teflon-compound material.

22. The method according to claim 1, wherein the deposition step is performed using an electrical potential between the powder and the solar cell, and the electrical potential is created by electrostatic charging of the powder.

23. A solar cell module manufactured in accordance with claim 1, comprising a solar cell based on a semiconductor substrate with a rear and front surface, and at least one coating layer, wherein the at least one coating layer is a pre-annealed powder coated layer which has been pre-annealed in a first annealing process and covers at least one of the rear and front surface.

24. The solar cell module according to claim 23, wherein the coating layer consists of thermoplastic material.

25. The solar cell module according to claim 23, wherein the coating layer covers the rear surface and the front surface.

26. The solar cell module according to claim 25, the coating layer comprises a free-standing extended portion extending substantially parallel to the rear surface and to the front surface, around the circumference of the solar cell substrate.

27. The solar cell module according to claim 23, wherein the at least one coating layer has a thickness of 100 m or less.

28. The solar cell module according to claim 23, wherein the at least one coating layer comprises openings at locations corresponding to locations of contacting areas on the solar cell.

29. The solar cell module according to claim 23, wherein the coating layer is in either porous or dense state.

30. A solar panel comprising a panel module transparent cover layer, at least one solar cell, and a back-sheet layer, wherein the solar cell is a coated solar cell manufactured according to claim 1 or a solar cell module according to claim 23; a first encapsulant layer is arranged between the back-sheet layer and the at least one solar cell, and a second encapsulant layer is arranged between the panel module transparent cover layer and the at least one solar cell; the first encapsulant layer being arranged with openings at locations corresponding to locations of contacting areas on the solar cell; contacting pads being arranged in the openings between each contacting area of the at least one solar cell and a corresponding contacting area on the back-sheet layer, wherein at least the first encapsulant layer and the contacting pads have a thickness of 100 m or less.

31. A solar cell or solar panel processing line comprising a first station for powder coating a solar cell, and a second station for annealing the powder coated solar cell to create a coated solar cell with a pre-annealed coating layer on at least one surface of the solar cell, and comprising a third station for selectively removing coating powder from the powder coated solar cell wherein the third station is arranged intermediate the first station and the second station such that in use the solar cell passes the third station before reaching the second station.

32. The solar cell or solar panel processing line according to claim 31, wherein the first station comprises a supporting tool comprising a plurality of pillars and a carrier, in which the pillars extend from the carrier, are arranged to support a solar cell and are positioned at locations corresponding to areas of the solar cell that are to be masked during the deposition of the powder coating on the solar cell.

33. The solar cell or solar panel processing line according to claim 31, wherein the second station comprises a belt furnace, continuous support belts, and a driving mechanism for the support belts; the support belts being arranged in opposing positions for clamping a solar cell module during passage of the solar cell through the belt furnace.

Description

BRIEF DESCRIPTION OF DRAWINGS

[0085] The invention will be explained in more detail below with reference to drawings in which illustrative embodiments of the invention are shown.

[0086] FIG. 1 shows a cross-section of a solar cell module according to a manufacturing step according to an embodiment of the invention;

[0087] FIG. 2a, 2b show a cross-section of the solar cell module during subsequent manufacturing steps;

[0088] FIG. 3 shows a cross-section of the solar cell module during a further manufacturing step according to an embodiment of the invention;

[0089] FIG. 4 shows a cross-section of the solar cell module after a next manufacturing step;

[0090] FIG. 5 shows a cross-section of a solar panel module in accordance with an embodiment of the invention;

[0091] FIG. 6 shows a manufacturing step of a solar cell module according to an embodiment of the invention;

[0092] FIG. 7 shows a cross-section of a solar cell module after the step shown in FIG. 6;

[0093] FIG. 8 shows a top view of the solar cell module of FIG. 7;

[0094] FIG. 9 shows a top view of an arrangement of solar cell modules of FIG. 8;

[0095] FIG. 10 shows a cross-section of a solar cell module and a panel module transparent cover layer in accordance with an embodiment of the invention;

[0096] FIG. 11 shows a cross-section of a solar cell module during a manufacturing step in accordance with an embodiment of the invention;

[0097] FIG. 12 shows a schematic cross-section of a manufacturing step according to an embodiment of the invention.

DETAILED DESCRIPTION OF EMBODIMENTS

[0098] The present invention relates to a method for manufacturing a solar cell module that is based on a semiconductor substrate, for example a solar cell made of a silicon substrate. The solar cell is typically a back contact type solar cell, such as MWT (metal wrap through), EWT (emitter wrap through), HIT (Heterojunction with thin intrinsic layer), IBC (interdigitated back contact). It is however conceivable that in some embodiments the invention also encompasses other solar cell types with front and back contacts.

[0099] FIG. 1 shows a cross-section of a solar cell module 10 according to a manufacturing step according to an embodiment of the invention.

[0100] The solar cell module 10 comprises a solar cell 12 based on a semiconductor substrate as explained above. The solar cell 12 has a front surface F and a rear surface R. In this embodiment the contacting areas 14 of the solar cell are arranged at the rear surface R.

[0101] During this manufacturing step the solar cell 12 is positioned on a support layer 16.

[0102] The rear surface R and the contacting areas 14 are covered by an adhered powder coating layer 20. The adhered powder coating layer 20 has been deposited by exposing the rear surface R (and contacting areas) to particles of a powder under an electric potential between the particles and the rear surface.

[0103] In an embodiment, the electrical potential is created by electrostatic charging of the powder.

[0104] In an alternative embodiment, the coating powder is applied by electrostatic spraying. In yet a further alternative wherein the coating powder is applied by an electrostatic printing process (e.g., a toner and drum based laser printing process).

[0105] In a preferred embodiment, the powder coating consists of thermoplastic material suitable as encapsulant material for a solar panel stack.

[0106] FIG. 2a, 2b show a cross-section of the solar cell module during subsequent manufacturing steps.

[0107] In FIG. 2a, the solar cell module is shown with a nozzle 22 at some distance from the adhered powder coating layer 20. The nozzle is arranged to selectively remove coating powder at predetermined locations such as the contacting areas 14 from the adhered powder coating layer 20. In this manner, open contacting areas 14 substantially free from the coating powder are created.

[0108] In an alternative embodiment, the removal step is replaced by a masking step which prevents coating powder to accumulate at positions on the rear surface that are masked. Masking is done preceding the deposition step.

[0109] In a further embodiment, the masking is performed by positioning the solar cell on a supporting tool (not shown), with each contacting area (or selectively open area) of the solar cell being covered by a pillar of the supporting tool.

[0110] FIG. 2b shows a cross-section of the solar cell module after the removal step with the open contacting areas 14. In the embodiment with a masking step, FIG. 2b shows the solar cell module after removal of the masking tool.

[0111] FIG. 3 shows a cross-section of the solar cell module during a further manufacturing step according to an embodiment of the invention.

[0112] The adhered powder coating layer on the rear surface R is covered by a second support layer 17, and the front surface F is now exposed to powder particles to form an adhered powder coating layer 24 on the front surface F in a similar manner as the powder coating layer 20 on the rear surface R. Next, the adhered powder coating layer 24 is covered by a support layer 18.

[0113] In a subsequent step, the solar cell 12 stacked between the adhered powder coating layers 20, 24 is exposed to elevated temperature to transform the adhered powder coating layers in pre-annealed coating layers 20a, 24a (solidification step).

[0114] The annealing may be done under vacuum conditions.

[0115] The conditions of the annealing and the optional vacuum are configured to either partially or fully melt the powder coating layers to create a pre-annealed coating in a range of a porous pre-annealed coating layer (in a pre-tacking step) to a dense pre-annealed coating layer (in a pre-laminating step), respectively.

[0116] According to an embodiment, the thickness of the pre-annealed coating layers 20a, 24a is 100 m or less. The thickness can be controlled by parameters of the powder coating process and powder parameters such as average grain size and size distribution.

[0117] As a result of the solidification step, the powder coating layers become less brittle and obtain a relatively improved adhesion to the rear and front surfaces of the solar cell 12.

[0118] During the solidification step, the support layers 17, 18 remain positioned to clamp and support the solar cell module 10 (i.e., the solar cell 12 and powder coating layers 20, 24).

[0119] In an embodiment, the support layers consist of Teflon (PTFE) or a Teflon compound, which have excellent lift-off properties for most thermoplastic material and thus can be reused.

[0120] In an embodiment, the surface of one or both of the support layers is provided with a rib pattern, which is transferred into the respective pre-annealed coating layer or layers to create a patterned surface profile on the pre-annealed coating layer(s).

[0121] The skilled in the art will appreciate that the solidification step is carried out in such conditions that prevent the melted powder coating layer 20 to cover the openings at the contacting areas. After the solidification step the openings at the contacting areas remain open.

[0122] FIG. 4 shows a cross-section of the solar cell module after a next manufacturing step.

[0123] After the solidification step, the support layers 17, 18 have been removed. Next, contacting material 26 is applied at the contacting areas 14.

[0124] The contacting material 26 may be dispensed at the location of the contacting areas 14 in the case the pre-annealed coating layers 20a, 24a are porous i.e., formed by the pre-tacking step. In case the pre-annealed coating layers have been created in the pre-laminating step, the contacting material may also be screen printed, stencil printed or jetted.

[0125] The application of the contacting material 26 on the contacting areas of the solar cell module has an advantage that in comparison to application of the contacting material on the back-sheet layer, the application is done over a relatively small area which can be done more accurately without requiring tools that are accurate over substantially the size of back-sheet layer. Moreover, in case of a misaligned print on a solar cell module, only the solar cell module needs replacement while a misaligned print on back-sheet would involve removal of the complete back-sheet.

[0126] FIG. 5 shows a solar panel module 50 in accordance with an embodiment of the invention.

[0127] The solar panel module 50 comprises a stack of a back-sheet layer 52, a patterned conductive layer 54, a plurality of solar cell modules 10 and a panel module transparent cover layer 56.

[0128] The patterned conductive layer 54 is arranged on the back-sheet layer facing towards the solar cell modules 10. The contacting areas 14 on the rear surface R of the solar cells 12 are directed towards the patterned conductive layer 54. On top of the solar cells the panel module transparent cover layer (a glass layer or transparent foil layer) 56 is arranged.

[0129] The solar panel module is manufactured in bottom up direction by providing the back-sheet layer plus patterned conductive layer, arranging a plurality of solar cell modules 10 on the pattern conductive layer such that the locations of the contacting material on the solar cell module are positioned at associated locations on the patterned conductive layer. On top of the solar cell modules 10 the panel module transparent cover layer is arranged.

[0130] According to the invention, the stack does not contain separate encapsulant layers, since the solar cell modules comprise pre-annealed coating layers that provide material for encapsulation. Thus, the invention simplifies the stacking sequence since there is no need for arranging encapsulant layers in the solar panel stack that according to prior art processes would require accurate matching of positions with the patterned conductive layer. Since this step is omitted the stacking requires less time.

[0131] After creating the stack, a lamination process is carried out to fuse the stack, by melting of the material of the pre-annealed coating layers 20a, 24a in a second annealing process. After lamination the solar panel module is cooled down. The pre-annealed coating layers 20a and 24a of the solar cell modules have fused and formed encapsulation 58 between the panel module transparent cover layer and the solar cells, between the solar cells and the back-sheet layer and in between adjacent solar cells.

[0132] If the pre-annealed coating layer(s) 20a, 24a was in a porous state, the porosity allows that application of a vacuum during the lamination process is enhanced, since outgassing through the porous layer improves the degassing step during the lamination process. The porosity in the pre-annealed coating layer comprises channels of interconnected voids that provide flow paths for gas molecules through the pre-annealed coating layer.

[0133] It is noted that if alternatively or additionally the pre-annealed coating layer(s) 20a, 24a was provided with a rib pattern, the rib pattern allows that application of a vacuum during the lamination process is facilitated, by providing channels for degassing the solar panel stack.

[0134] As a result of the use of the pre-annealed coating layers on the solar cells, the thickness of the encapsulation 58 is determined by the initial thickness of the pre-annealed coating layers. The thickness of the encapsulation between solar cell and panel module transparent cover layer or between solar cell and back-sheet layer can be 100 m or less which is relatively thin in comparison with prior art encapsulations in solar panels. The relatively thin encapsulation allows that the required amount of contacting material between a solar cell contact and a contact of the patterned conductive layer is significantly reduced in comparison with the prior art.

[0135] The skilled in the art will appreciate that the creating of the solar panel stack may be done in reversed order, i.e. top down by providing a panel module transparent cover layer; arranging the solar cell modules on the panel module transparent cover layer, the rear surface of the solar cells facing away from the panel module transparent cover layer; and subsequently arranging the patterned conductive layer and back-sheet over the solar cell modules.

[0136] It will be appreciated that additional coating powder may be added between adjacent solar cell modules during or subsequent the step of arranging the solar cell modules in the solar panel stack. If needed, the additional coating powder will provide additional encapsulant material to fill gaps between adjacent solar cell modules.

[0137] FIG. 6 shows a manufacturing step of a solar cell module 11 according to an embodiment of the invention. In this embodiment, after forming the powder coating layer 20 on the rear surface R and after opening the contacting areas at the rear surface, the solar cell module 11 is positioned on the support layer 17, the rear surface facing towards the support layer and the front surface F still free of a powder coating layer facing away.

[0138] Around the solar cell module 11, masking elements 30 are positioned that create circumferential edge around the solar cell module 10.

[0139] Subsequently, a powder coating deposition step is carried out to cover the front surface F with a powder coating layer 24. Additionally, a powder coated layer portion 28 that extends around the circumference of the solar cell 12 is created.

[0140] FIG. 7 shows a cross-section of a solar cell module 11 of FIG. 5 after a solidification step. The extending powder coating layer portions 28 have been transformed into pre-annealed extensions 28a during the solidification step.

[0141] FIG. 8 shows a top view of the solar cell module 11 of FIG. 6 with a central portion where the solar cell 12 is covered by the pre-annealed coating layers 20a, 24a, and a peripheral portion consisting of pre-annealed coating layer material 28a.

[0142] FIG. 9 shows a top view of an arrangement of solar cell modules 11 of FIG. 7 during construction of a solar panel.

[0143] A plurality of solar cell modules 11 with extended pre-annealed coating layers 28a is arranged adjacent to each other with their respective extended pre-annealed coating layers 28a overlapping each other.

[0144] In an embodiment, the solar cell modules 11 are stacked like roof-tiles.

[0145] The use of solar cell modules 11 with extended pre-annealed coating layers 28a in a solar panel has an advantage since the extended pre-annealed coating layers 28a additional material for the encapsulation 58 of the solar panel can serve as additional feed for encapsulating material and may remove the need for adding separate encapsulation material during the creation of the solar panel stack.

[0146] FIG. 10 shows a cross-section of a solar cell module and a panel module transparent cover layer in accordance with an embodiment of the invention.

[0147] In an alternative embodiment, the solar cell modules are provided with a pre-annealed coating layer 20a on only the rear surface R of the solar cell 12, while the front surface are substantially free from a powder coating layer. According to the invention, the panel module transparent cover layer 56 is provided with a pre-annealed coating layer 25a, created by a deposition process with powder coating followed by an annealing step (either pre-tacking or pre-laminating), in a similar manner as for the solar cell module.

[0148] The solar panel stack is created by arranging the front surface of the solar cell modules on the pre-annealed coating layer 25a of the panel module transparent cover layer, subsequently arranging the patterned conductive layer and back-sheet layer over the solar cell modules, and then performing a lamination process on the solar panel stack.

[0149] The pre-annealed coating layer 25a may be arranged to have a surplus thickness which during the panel module lamination step can provides as feed material to fill gaps between adjacent solar cell modules with encapsulant material.

[0150] Alternatively, instead of a powder coated pre-annealed coating layer 25a, an encapsulant layer may be arranged between the panel module transparent cover layer and the solar cell modules.

[0151] Also, as alternative, the front surface of the solar cell modules are covered by a pre-annealed coating layer while at the side of the rear surface a patterned encapsulant layer is provided between the rear surface of the solar cells and the conductive layer pattern on the back-sheet layer.

[0152] FIG. 11 shows a cross-section of a solar cell module during a manufacturing step in accordance with an embodiment of the invention.

[0153] In this embodiment, the solar cell is mounted on a supporting tool 100 comprising a plurality of pillars 105 and a carrier 110. The pillars 105 extend from a carrier 110 and are positioned at locations corresponding to areas of the solar cell that are to be masked during the deposition of the powder coating on the solar cell.

[0154] Preceding the deposition process the solar cell 12 is mounted on the supporting tool 100, and the areas to be masked aligned with the position of the pillars 105. One or more of the pillars can be embodied as a vacuum nozzle to clamp the solar cell on the supporting tool 100.

[0155] The pillars 105 extend from the carrier 110 to have space between the solar cell 12 and the supporting tool.

[0156] Next, a deposition process is performed to deposit coating powder on the solar cell to create an adhered coating layer. Since the solar cell is only covered at the positions to be masked, the deposition process can provide an all-sided deposition of coating powder in a single deposition process.

[0157] In an embodiment, the pillars 105, and optionally the carrier 110, consist of a Teflon or Teflon based compound.

[0158] After the deposition process the solar cell 12 with the adhered coating layer 21 is arranged on the support layers and processed further as described above.

[0159] FIG. 12 shows a schematic cross-section of a manufacturing tool 200 according to an embodiment of the invention.

[0160] The manufacturing tool 200 relates to a pre-tacking or pre-laminating furnace for creating solar cell modules with pre-annealed coating layers 20a, 24a.

[0161] The manufacturing tool 200 comprises a belt furnace 210, continuous support belts 220, 230, and a driving mechanism 240 for the support belts.

[0162] The support belts are arranged in opposing positions for clamping a solar cell module in between them.

[0163] The support belts pass through the belt furnace, in a manner that the adhered coating layers 20, 24 and extended coating layers 28, if present, are transformed in pre-annealed coating layers, in either a pre-tacking or pre-laminating mode.

[0164] The manufacturing tool may be equipped with a powder coating station (not shown) within the path of the support belts.

[0165] In an embodiment, the manufacturing tool 200 is part of a solar cell or solar panel processing line with a first station for powder coating a solar cell, and a second station for annealing the powder coated solar cell to create a coated solar cell with a pre-annealed coating layer on at least one surface of the solar cell.

[0166] According to an embodiment, the solar cell or solar panel processing line is equipped with a third station for selectively removing coating powder from the powder coated solar cell. The third station is arranged intermediate the first station and the second station such that in use the solar cell passes the third station before reaching the second station.

[0167] In an embodiment, the supporting tool as shown in FIG. 11 may be part of the first station of the solar cell or solar panel processing line.

[0168] The invention has been described with reference to some embodiments. Obvious modifications and alterations will occur to the skilled in the art upon reading and understanding the preceding detailed description. It is intended that the invention be construed as including all such modifications and alterations, the scope of the invention being limited only by the appended claims.