Method for interconnecting solar cell arrays, solar module and device for electrical interconnecting solar cell arrays

Abstract

The invention relates to improvements in the technical field of the manufacture of solar modules (1). For this purpose, in particular a method for interconnecting solar cell arrays (2) consisting of crystalline solar cells (3) is proposed, in which at least one transverse connector (4, 9) made of an electrically conductive tape (5, 7) is used for the interconnecting.

Description

Technical Field

[0001] The invention relates to a method for interconnecting a solar array consisting of crystalline solar cells, a solar module having such a solar array and a device for interconnecting a solar array consisting of crystalline solar cells. Background Art

[0002] Until now, the interconnection of crystalline solar arrays has been achieved using copper ribbons, which have to be soldered after being laid in order to produce an electrical connection to the solar cells. If a solar array comprises a large number of solar cell strings to be interconnected, a correspondingly large number of soldered connections must be made, which can be associated with a relatively high level of effort. In addition, when soldering the copper ribbons, heat can enter the solar cells, which can lead to stresses and possibly damage the solar cells. Summary of the invention

[0003] The object of the present invention is therefore to provide a method for interconnecting a solar cell array consisting of crystalline solar cells, a solar module having such a solar cell array and a device for electrically interconnecting a solar cell array consisting of crystalline solar cells, which facilitate efficient and therefore economical and at the same time protective interconnection of the solar cell arrays and thus simplify the production of the solar modules.

[0004] In order to achieve the above object, a method for interconnecting a solar array consisting of crystalline solar cells is first proposed, which method has the apparatus and features of the independent claims for this method. Therefore, in order to achieve the above object, a method for interconnecting a solar array consisting of crystalline solar cells is proposed, wherein at least one transverse connector made of an electrically conductive tape is used for interconnecting the solar array.

[0005] By using conductive tape to provide a transverse connector for interconnecting solar arrays, it is possible to dispense with the relatively complex soldering of contact points to copper tapes, which have hitherto been used as transverse connectors for interconnection. In the simplest case, the at least one transverse connector can be a strip of conductive tape. Such a strip can simply be pulled from a roll in the required length and cut to length. This can significantly simplify the provision and application of the transverse connector.

[0006] The interconnection by means of the transverse connector made of the conductive adhesive tape can be carried out without inputting heat into the solar cells of the solar array. This protects the solar array during the interconnection and reduces scrap during the production of solar modules.

[0007] Another advantage of the method according to the invention is that a transverse connector made of an electrically conductive adhesive tape can be applied significantly faster than a copper tape which has to be soldered on a large number of individual contact points and also requires less mechanical effort. This facilitates the economical implementation of the method and thus facilitates efficient production of solar modules.

[0008] In one embodiment of the method, it is provided that at least one transverse connector made of an electrically conductive adhesive tape is glued to a row of solar cells. This can be done in particular in such a way that the transverse connector extends within the row without contacting adjacent rows. In this way, short circuits of adjacent rows are avoided.

[0009] In one embodiment of the method, it is provided that at least one transverse connector made of a conductive tape is glued to the sun-facing side of a row of the solar array. It is also possible to glue at least one transverse connector made of a conductive tape to the back side of a row facing away from the sun-facing side.

[0010] In one embodiment of the method, at least one transverse connector, such as an initial transverse connector explained in more detail below, is glued to the sun-facing side of a row of solar cells of the solar array. Then, at least one further transverse connector can be glued to the back side of one of the rows of solar cells of the solar array, for example an edge row. The transverse connector made of conductive tape glued to the back side of the row does not cover the photovoltaic active area of ​​the solar cell row on the sun-facing side of the solar array.

[0011] In a particularly advantageous embodiment of the method, a transverse connector made of a preferably double-sided electrically conductive adhesive tape is bonded as a preliminary transverse connector to a carrier structure for the solar array. For example, a plastic film, preferably an EVA (polyethylene-polyvinyl acetate copolymer) film or a PCB (circuit board) film can be used as a carrier structure for the solar array. After the preliminary transverse connector has been bonded to the carrier structure, the solar array, in particular with the edge-side solar cell rows, can be laid onto the preliminary transverse connector and the preliminary transverse connector can be bonded to a row of the solar array.

[0012] In this embodiment of the method, it is particularly advantageous if the initial transverse connector is made of a double-sided conductive tape. The double-sided conductive tape can first be glued to the carrier structure and thus fixed to the carrier structure. It is then no longer necessary to clamp the initial transverse connector separately in order to keep it in position on the carrier structure.

[0013] If the solar array is subsequently laid onto a carrier structure, the initial transconnector remains in position because it adheres to the carrier structure. On its side facing away from the carrier structure, the initial transconnector made of double-sided adhesive tape also has an adhesive surface, which can then be used to connect the initial transconnector to a row of the solar array. The use of such an initial transconnector can be particularly advantageous, in particular for automated implementation of the method.

[0014] In one embodiment of the method, two or more transverse connectors made of conductive tape are attached to solar cells in different rows. In particular, if two or more transverse connectors made of conductive tape are attached to solar cells in different rows of a solar cell array, the solar cell array can be divided into individual segments with the aid of the transverse connectors.

[0015] By means of a corresponding bypass circuit (for example, when a bypass diode is used), the solar cell array can provide satisfactory power even in partial shading. If one segment of the solar cell array is shaded, the shaded segment can be bypassed by the bypass circuit. The power of the remaining solar cells other than the shaded segment of the solar cell array can continue to generate electricity without being excessively affected by the shaded segment.

[0016] Preferably, at least two transverse connectors are glued to different rows at a distance from each other of at least one row, preferably a plurality of rows of solar cells. The distance between two transverse connectors then determines the size of the segment of the solar array defined by the transverse connectors.

[0017] Typically, there are gaps between adjacent solar cells in a row. When using transverse connectors made of conductive tape, the transverse connectors can be visible through these gaps between adjacent solar cells in a row. This can affect the appearance of the solar cell array. In order to avoid affecting the appearance of the solar cell array in this way, the gaps between adjacent solar cells in a row can be covered with a covering element, such as a covering strip, in particular a covering adhesive strip. To this end, a covering element can be placed over the gaps between adjacent solar cells. By covering the gaps, the gaps can be visually bridged and / or closed. Preferably, a covering element is placed over the gaps between adjacent solar cells in a row, and then a transverse connector made of conductive tape is adhered to the row. The transverse connector is then adhered to the solar cells in the row above the covering element.

[0018] By visually closing these gaps with covering elements, such as covering strips, preferably covering rubber strips, it is possible to avoid that the transverse connectors can be seen through the gaps between adjacent solar cells on the sun-facing side of the solar array. Preferably, the covering element can have a color that corresponds to the color of the solar cells of the solar array. It is also advantageous in this case if a row-oriented dimension of the covering element that can be measured transversely or perpendicularly to the row is larger than a dimension of the transverse connector that can be measured in the same direction. This ensures that the transverse connector can be covered by the covering element without being visible through the gaps between adjacent solar cells.

[0019] In order not to reduce the photovoltaically active area of ​​the solar cells, it is expedient to apply the cover element to the rear side of the solar cell array which faces away from the sun-facing side of the solar cell array.

[0020] In order to connect the transverse connector to the terminal box, the transverse connector can be electrically connected to the longitudinal connector. Preferably, the longitudinal connector is also made of an electrically conductive adhesive tape. The longitudinal connector can then be glued to the transverse connector to be connected to the terminal box without much effort. Thus, like the one or more transverse connectors, the longitudinal connector can also be a strip of electrically conductive adhesive tape in a very simple case. Such a strip can simply be pulled from a roll and cut to length in the required length. This can significantly simplify the provision and use of the longitudinal connector when implementing the method.

[0021] The two transverse connectors can be connected via their longitudinal connectors, for example, to a junction box. The transverse and longitudinal connectors can be part of a bypass circuit, by means of which, in the event of shading, some rows of solar elements of the solar array can be bypassed in order not to affect the power of the remaining solar cells of the solar array, which are located outside the segment of the solar array defined by the two transverse connectors.

[0022] The bypass diode may be part of the bypass circuit described above. When the resistance is increased by shading of a row in a segment of the solar array defined by two transverse connectors, the bypass circuit may function and cause current to flow through the remaining solar cells of the solar array beside the solar cells of the shaded segment.

[0023] In one embodiment of the method, at least one transverse connector is bonded to a row of the solar array in such a way that it has a projection beyond the row end of the row. The transverse connector can then be connected to the longitudinal connectors in the region of its projection.

[0024] In a preferred embodiment of the method, which facilitates the particularly space-saving interconnection of solar arrays, at least one longitudinal connector can be placed, in particular glued, on a row of the solar array in an orientation transversely or perpendicular to the row of the solar array. This is preferably done on the back side of the solar array, which faces away from the sun-facing side of the solar array.

[0025] The longitudinal connectors can also be placed, in particular adhesively bonded, on a carrier structure adjacent to the solar cells of the solar array transversely or perpendicularly to the row orientation of the solar array.

[0026] In particular, if at least one longitudinal connector is to be placed, in particular glued, on the row in an orientation transversely or perpendicularly to the row of the solar array, it is advantageous to first place, in particular glue, an electrical insulator, in particular an insulating tape, on the row transversely or perpendicularly between two transverse connectors. The longitudinal connectors can then be placed, in particular glued, on the electrical insulator and the transverse connectors. With the aid of the electrical insulator, it can be prevented that the longitudinal connectors short-circuit the rows of the solar array. The insulating tape can be, for example, an insulating tape made of EPE. The insulating tape can be easily glued and can therefore be fastened to the solar array without much effort.

[0027] The solar cells of the solar cell array may preferably be arranged in a shingled matrix.

[0028] In order to achieve this object, a solar module with a solar array consisting of crystalline solar cells is also proposed, which has the features of the independent claim for such a solar module. Therefore, in order to achieve this object, in particular a solar module with a solar array consisting of crystalline solar cells is proposed, which solar arrays are interconnected by means of at least one transverse connector made of an electrically conductive adhesive tape.

[0029] In one embodiment of the solar module, at least one transverse connector made of an electrically conductive adhesive tape can be glued to a row of solar cells. This is preferably done without contacting the solar cells of an adjacent row.

[0030] At least one transverse connector for interconnecting solar modules can be made of a conductive double-sided tape and can be glued as an initial transverse connector to a carrier structure of a solar module for a solar array and / or to the sun-facing side of a solar array, as described above in conjunction with the method.

[0031] The solar cells of the solar array can be arranged in a shingled matrix arrangement. In such a shingled matrix arrangement, the voltage build-up takes place in a direction transverse to or perpendicular to the row orientation of the rows of solar cells. A voltage level can exist within a row of solar cells in the shingled matrix arrangement. The transverse connectors applied to the row within a row can thus contact the solar cells across which the voltage level exists. This facilitates the segmentation of the solar array as already explained above.

[0032] The voltage build-up then takes place in the rows of the solar array transversely or perpendicularly to the row orientation. Voltage levels can exist within a row of solar cells in a solar array. Thus, the rows of solar cells in a shingled matrix arrangement can be distinguished from conventional solar cell strings. In a solar cell string, the solar cells are arranged and interconnected to one another in such a way that the voltage build-up takes place in the longitudinal extension direction of the string. In contrast, in a shingled matrix arrangement, the voltage build-up does not take place in the longitudinal extension direction of the rows of solar cells.

[0033] For connection to the junction box of the solar module, at least one transverse connector made of conductive tape can be connected to a longitudinal connector. Such a longitudinal connector can also preferably be made of conductive tape. This facilitates a simple electrical connection between the longitudinal connector and the transverse connector.

[0034] The longitudinal connectors can extend transversely or vertically on a solar cell row arranged between two transverse connectors. In one embodiment of the solar module, the longitudinal connectors can also be arranged adjacent to the solar cell array, for example on a carrier structure of the solar module for the solar cell array and can optionally also extend transversely or vertically to the row orientation of the solar cell rows of the solar cell array.

[0035] An insulator can be arranged between the longitudinal connector and the solar cell row. As an insulator, for example, an insulating tape, preferably an insulating adhesive tape, can be glued to the solar cell. With the aid of the insulator, a short circuit that could occur when the longitudinal connector is in direct contact with the solar cell can be avoided. The insulator can be made of EPE (polyethylene foam).

[0036] The interspaces between adjacent solar cells of a row to which the transverse connector made of the conductive tape is bonded can be covered with a covering element, in particular with a covering strip or with a covering adhesive strip. The transverse connector is then arranged behind the covering element and is not visible through the interspace. The interspace is then visually closed by the covering element. In order to be able to cover the transverse connector with the covering element, it is advantageous if the covering element has a width that is measurable transversely or perpendicularly to the longitudinal extension of the transverse connector and is at least as large as the width of the transverse connector that is measurable in the same direction.

[0037] The cover element is preferably arranged on the rear side of the solar array, which rear side faces away from the sun-facing side of the solar array.

[0038] The two transverse connectors can be connected to each other via longitudinal connectors and a junction box and / or a bypass circuit, for example with a bypass diode. The bypass circuit can be used to bypass the solar cell located between the two transverse connectors in the event of shading, so as not to affect the power of the remaining solar cells of the solar module.

[0039] At least one transverse connector made of conductive tape can be arranged on the sun-facing side of the solar cell array of the solar module. At least one transverse connector made of conductive tape and / or a longitudinal connector made of conductive tape, in particular, is arranged on the back side of the solar cell array, which faces away from the sun-facing side of the solar cell array.

[0040] The transverse connector and the longitudinal connector may be adhesive strips formed by conductive tape. The initial transverse connector may be adhesive strips formed by conductive double-sided tape.

[0041] In order to achieve this object, a device for electrically interconnecting a solar array made of crystalline solar cells is also proposed, which has the means and features of the independent claim for such a device. The device is designed to carry out the claimed method and has at least one cross-connector applicator, which is designed to apply an electrically conductive adhesive tape as a cross-connector to the rows of the solar array.

[0042] In one embodiment of the device, it is provided that the device has at least one covering element applicator which is provided for applying, in particular adhesively bonding, the covering element to the interspaces between adjacent solar cells of a row of the solar array.

[0043] The device can have at least one longitudinal connector applicator which is provided for applying, in particular for adhesively bonding, the longitudinal connector.

[0044] Furthermore, the device can have at least one insulation applicator for applying, in particular for adhering, an electrical insulator, preferably an electrical insulating tape.

[0045] In one embodiment of the device, the transverse connector applicator has a feed roller. A reserve of conductive tape can be wound on the feed roller for providing the transverse connector. The transverse connector applicator can also have an application element, in particular an application roller, and / or a pressing element. With the aid of the application roller, the conductive tape unrolled from the feed roller can be pasted on the surface of a row of solar cells and thus the conductive tape can be applied to a row of solar cells as a transverse connector. With the aid of a pressing element (which can be configured as a pressing roller, for example), the pasted transverse connector made of the conductive tape can be pressed onto the surface of the solar cell after its application. This can improve the adhesion of the transverse connector. In this case, it can be advantageous that the pressing element is arranged downstream of the application element in the application direction of the transverse connector.

[0046] Similarly, the device may also comprise a supply roller with a covering element for a covering element applicator, a supply roller with a longitudinal connector for a longitudinal connector applicator and a supply roller with an insulator, in particular with an insulating tape or an insulating adhesive tape, for an insulator applicator.

[0047] The covering element applicator, the longitudinal connector applicator and / or the insulator applicator can have an application element, such as an application roller, and / or a pressing element, in particular a pressing roller, which is preferably located downstream of the respective application element in the application direction. In this way, the respective structure, which is preferably configured as a rubber strip, i.e., for example, the covering element, the insulator and / or the longitudinal connector can first be applied to its target surface by means of the respective application element and then pressed onto the surface to which it is adhered by means of the downstream pressing element.

[0048] In order to prevent the solar cell from being overloaded when applying transverse connectors, longitudinal connectors, covering elements and / or insulators, the device can be configured for pressure monitoring. Preferably, the device preferably has at least one pressure sensor for at least one transverse connector applicator, at least one covering element applicator, at least one insulator applicator and / or at least one longitudinal connector applicator, respectively, by means of which the pressure acting on the solar cell can be monitored when applying transverse connectors, covering elements, insulators and / or longitudinal connectors. If the maximum allowable pressure is exceeded, the device can reduce the pressure and avoid damage to the solar cell by at least one corresponding control unit. Each of the aforementioned applicators can have a corresponding control unit respectively. However, the device can also have a central control unit, which can perform the above-mentioned pressure control or pressure regulation on the applicator.

[0049] The invention is explained in more detail below with reference to exemplary embodiments, but the invention is not limited to these exemplary embodiments. Further exemplary embodiments result from the combination of features of one or more claims and / or the combination of one or more features of the exemplary embodiments. BRIEF DESCRIPTION OF THE DRAWINGS

[0050] The attached pictures are as follows:

[0051] Figure 1 A perspective view showing a first embodiment of a solar module having a carrier structure comprising a glass pane and a plastic film applied to the glass pane, and having a solar array applied to the plastic film, wherein three different rows of the solar array are bonded to transverse connectors made of an electrically conductive adhesive tape for interconnecting the solar array;

[0052] Figure 2 A perspective view of another embodiment of a solar module is shown, wherein the solar cell arrays of the solar module are interconnected by means of two transverse connectors made of conductive tape;

[0053] Figure 3 and 4 A further embodiment of a solar module is shown, in which three transverse connectors and a total of three longitudinal connectors made of conductive tape are respectively adhered to interconnect the solar arrays;

[0054] Figure 5 A single view of a glass pane is shown, which is used as part of a carrier structure as in the solar module shown in the previous figures;

[0055] Figure 6 A single view of a plastic film is shown, which, as in the solar module shown in the previous figure, is used as part of a carrier structure, said plastic film being placed Figure 5 On the glass plate shown in ;

[0056] Figure 7 A carrier structure for a solar cell array is shown, the carrier structure comprising a glass plate and a plastic film, wherein a transverse connector made of a double-sided conductive tape serving as an initial transverse connector is adhered to the plastic film;

[0057] Figure 8 Show Figure 7 , the carrier structure having an initial transverse connector and a shingled matrix solar cell array, the shingled matrix solar cell array being laid with its first row of solar cells onto the initial transverse connector;

[0058] Fig. 9 Show Figure 8 The solar cell array shown in , wherein the gaps between the solar cells of the row are visually closed by a covering element, to which the transverse connectors are subsequently to be glued;

[0059] Fig.10 Show Fig. 9 The solar cell array shown in , which has two additional transverse connectors made of conductive tape attached to the back side of the solar cell array;

[0060] Fig.11 Show Fig.10 The solar cell array shown in , wherein the insulator is in the form of an insulating tape pasted between two transverse connectors spaced apart from each other by a plurality of rows of solar cells;

[0061] Fig.12 Show Fig.11 The solar cell array shown in , wherein each transverse connector is connected to a longitudinal connector, and the longitudinal connector is a strip made of a conductive tape, which is adhered to the transverse connector on one hand and to the electrical insulator on the other hand;

[0062] Fig.13 Show Fig.12 The solar cell array shown in , which has a junction box connected to the transverse connector;

[0063] Fig.14 A solar cell array is shown which is divided into three segments by an initial transverse connector made of conductive tape and three further transverse connectors, which has two junction boxes in which a bypass diode is arranged in each case, and a planar diode as a bypass diode on the middle segment of the three segments, which planar diode can be laminated onto a finished solar module;

[0064] Fig.15 A cross-sectional side view of a portion of a solar module with an array of interconnected solar cells is shown for illustrating its layer structure;

[0065] Fig.16 A perspective view showing a transverse connector applicator of an apparatus for interconnecting solar arrays during application of an initial transverse connector made of a conductive tape;

[0066] Fig.17 A perspective view of a covering element applicator of the device is shown, which is provided for bridging and thereby closing the gaps between adjacent solar cells by adhesively bonding covering elements, so that a transverse connector arranged behind them is no longer visible through the gaps;

[0067] Fig.18 A perspective view showing a transverse connector applicator of the device, which is arranged for applying transverse connectors made of an electrically conductive tape to rows of solar cells;

[0068] Fig.19A perspective view showing an insulator applicator of the device, which is provided for applying an electrical insulator, ie an electrically insulating tape, to a solar cell between transverse connectors;

[0069] Fig. 20 A perspective view showing a longitudinal connector applicator of the device, the longitudinal connector applicator being configured for applying a longitudinal connector;

[0070] Fig.21 An embodiment of an apparatus for interconnecting solar arrays is shown in which a transconnector applicator is disposed on a robot of the apparatus; and

[0071] Fig. 22 Another embodiment of an apparatus for interconnecting solar arrays is shown in which different applicators are suspended from a gantry of the apparatus. DETAILED DESCRIPTION

[0072] Figures 1 to 15 At least some parts of a solar module are shown, which are designated as a whole by reference numeral 1. The solar modules 1 each have a solar array 2 consisting of crystalline solar cells 3, ie solar cell shingles. The solar arrays 2 are interconnected by means of transverse connectors 4, 9 made of conductive adhesive tape.

[0073] Figures 1 to 15 It is shown that transverse connectors 4, 9 made of conductive tape 5, 7 are respectively glued to a row 6 of solar cells 3, without contacting the solar cells 3 of the adjacent row. In each of the solar modules 1 shown, at least one transverse connector 4 made of conductive double-sided tape 7 is glued to a carrier structure 8 of the solar module 1 for the solar cell array 2, and the solar cell array 2 is then laid onto the transverse connector 4 made of conductive double-sided tape 7. The transverse connector 4 made of conductive double-sided tape 7 can also be referred to as the initial transverse connector 9. The initial transverse connector 9 is Figure 7 1 is shown on a carrier structure 8 of a solar module 1 before the solar array 2 is laid onto the carrier structure 8 and thus onto an initial cross-connector 9 made of double-sided adhesive tape 7 .

[0074] The figures also show that the solar cells 3 of the solar cell array 2 are arranged in a so-called shingled matrix arrangement. Here, two adjacent rows 6 of solar cells 3 are arranged offset from each other on the one hand and one row 6 overlaps the adjacent row 6 on the other hand. In this way, the solar cell array 2 acquires a wall-like structure, which facilitates the formation of multiple current paths within the solar cell array 2 due to the offset and overlap of the solar cells 3 of adjacent rows 6.

[0075] In this context, it should be noted that the voltage build-up takes place in this case transversely or perpendicularly to the orientation of the row 6 of the solar array 2 over the row 6 of the solar array 2. A voltage level then exists within a row 6 of solar cells 3 of the solar array 2. In contrast, the voltage build-up takes place in conventional solar cell strings along their longitudinal extension. Conventional solar cell strings can therefore be distinguished from rows of solar cells 3, as can be seen in the illustrated solar array 2.

[0076] The transverse connectors 4 , 9 made of conductive adhesive tape 5 , 7 are each connected to a longitudinal connector 10 likewise made of conductive adhesive tape 5 for connection to a terminal box of the respective solar module 1 . Figures 1 to 4 Different arrangements of transverse connectors 4 , 9 and longitudinal connectors 10 are shown for interconnecting solar arrays 2 of solar modules 1 .

[0077] In all of the solar modules 1 shown, the longitudinal connectors 10 extend perpendicularly to the row orientation of the rows 6 of solar cells 3. Figures 1 to 3 In the solar module 1 shown in FIG. 1 , the longitudinal connectors 10 extend perpendicularly to the row orientation of the rows 6 over the individual rows 6 of solar cells 3 .

[0078] exist Figure 4 In the exemplary embodiment of the solar module 1 shown, the longitudinal connectors 10 are applied to the carrier structure 8 of the solar module 1 for the solar array 2 adjacent to the solar array 2, but still extend perpendicularly to the rows 6 of solar cells 3 of the solar array 2. Figures 1 to 3 In the solar module 1 shown in FIG. 1 , the longitudinal connectors 10 extend perpendicularly to the rows 6 on the rows 6 of solar cells 3 , which are arranged between two transverse connectors 4 , 9 .

[0079] An insulator 11 in the form of an insulating tape, i.e. an insulating adhesive tape, is arranged between the longitudinal connectors 10 and the solar cell rows 6. The insulator 11 is glued onto the solar cell 3. The insulator 11 is made of EPE insulating tape and prevents the longitudinal connectors 10 from short-circuiting the solar cell 3.

[0080] Figures 1 to 4It is also shown that the gaps 12 between adjacent solar cells 3 of a row 6 bonded to the transverse connectors 4 made of conductive tape 5 are visually closed by a covering element 13 in the form of a covering adhesive strip. The covering element 13 is arranged on the back side 14 of the solar array 2, which faces away from the sun-facing side 15 of the solar array 2. The covering element 13 is wider than the transverse connectors 4, 9 and prevents the transverse connectors 4 made of conductive tape 5 from being visible on the sun-facing side 15 of the solar array 2 and affecting the overall visual impression of the solar module 1. In this case, it is advantageous if the covering element 13 has a color similar to or even the same as the solar cells 3 of the solar array 2.

[0081] The two transverse connectors 4, 9 are connected to each other via longitudinal connectors 10 and a junction box 16, which can be arranged, for example, at one of the positions denoted by reference numeral 160. The junction box can include or form a bypass circuit with a bypass diode 38, which allows bypassing the solar cell 3 located between the two transverse connectors 4, 9 in the event of shading. The transverse connectors 4, 9 can be used to divide the solar cell array 2 into segments 19, 20.

[0082] If one of the segments 19, 20 is shaded or partially shaded, the shaded segment 19, 20 can be bypassed by a bypass circuit with a bypass diode 38. In the case of shading, the resistance of the solar cell 3 located in the shaded segment 19, 20 increases, so that the bypass diode 38 is connected and releases the current path passing by the shaded segment 19, 20. In this way, the shaded segment 19, 20 is temporarily bypassed, so that the power of the non-shaded segment 19, 20 of the solar cell array 2 is not affected.

[0083] The figures show that there is a distance of several rows 6 of solar cells 3 between two transverse connectors 4, 9 made of conductive tapes 5, 7. At least one transverse connector, namely the initial transverse connector 9 made of conductive double-sided tape 7, is arranged on the sun-facing side 15 of the solar array 2. The remaining transverse connectors 4 made of conductive tape 5 and the longitudinal connectors 10 are arranged on the back side 14 of the solar array 2, which faces away from the sun-facing side 15 of the solar array 2.

[0084] The interconnection of the solar cell arrays 2 of the solar module 1 shown in the figures can be carried out according to the method described below for interconnecting solar cell arrays 2 consisting of crystalline solar cells 3 .

[0085] Here, transverse connectors 4, 9 made of conductive tape 5, 7 are used to interconnect the solar arrays 2. The transverse connectors 4, 9 made of conductive tape are respectively glued to a row 6 of solar cells 3. The transverse connectors 4, 9 are glued to the rows 6 of solar cells 3 in such a way that they extend within their respective row 6 without touching or overlapping the solar cells 3 of adjacent rows.

[0086] One transverse connector, namely the initial transverse connector 9 made of conductive tape 7, is glued to the sun-facing side 15 of one row 6. The remaining transverse connectors 4 made of conductive tape 5 are glued to the back side 14 of the row 6 of solar cells 3 facing away from the sun-facing side 15. Before the solar array 2 is positioned on the carrier structure 8, the transverse connector denoted by the reference numeral 9 is glued as the initial transverse connector to the carrier structure 8 of the solar module 1 for the solar array 2. The initial transverse connector 9 is made of double-sided conductive tape 7, so that the initial transverse connector 9 can be glued according to the Figure 7 It is adhered to the carrier structure 8 itself and provides an adhesive surface on its free surface, which is used for connection to the solar cells 3 of the first row 6 of the solar cell array 2 .

[0087] The carrier structure 8 of the solar module 1 shown in the figures comprises Figure 5 The glass plate 17 and Figure 6 The plastic film 18 shown in FIG. 1 , i.e., an EVA film or a PCB film, is used. The initial transverse connector 9 is glued to the plastic film 18 of the carrier structure 8. The solar array 2 is then laid with the sun-facing side 15 of an edge row 6 of solar cells 3 on the initial transverse connector 9 and the initial transverse connector 9 is glued to the edge row 6 of the solar array 2.

[0088] Transverse connectors 4, 9 made of conductive adhesive tapes 5, 7 are glued to different rows 6 of solar cells 3 of the solar array 2 in order to divide the solar array 2 into individual segments 19 and 20. The transverse connectors 4, 9 are glued to the rows 6 of the solar array 2 at a distance from one another by a plurality of rows 6 of solar cells 3.

[0089] Before gluing transverse connector 4 to row 6, Fig. 9 First, the gaps 12 between adjacent solar cells 3 of a row 6 to which the transverse connectors 4 are to be attached are visually closed with a covering element 13, i.e. a covering adhesive strip. The transverse connectors 4 are then attached to the rows 6 and the already attached covering elements 13. The transverse connectors 4 are then covered by the covering elements 13 and are no longer visible through the gaps 12 when viewed from the sun-facing side 15 of the solar array 2.

[0090] Like the transverse connector 4 , the cover element 13 is also glued onto the back side 14 of the solar array 2 .

[0091] The transverse connectors 4, 9 are electrically connected to a longitudinal connector 10 for connection to the terminal box. Like the transverse connector 4, the longitudinal connector 10 is also made of an electrically conductive adhesive tape 5.

[0092] exist Figure 4 In the solar module 1 of FIG. 1 , the transverse connectors 4 , 9 are glued to the row 6 and the support structure 8 with a projection beyond the row ends 21 of the row 6 . The respectively projecting section of the transverse connectors 4 , 9 is then used for connection to the longitudinal connectors 10 .

[0093] The longitudinal connectors 10 are placed perpendicularly to the row orientation of the rows 6 of the solar array 2 , ie glued to the rows 6 or glued next to the solar array 2 to a carrier structure 8 for the solar modules 1 of the solar array 2 .

[0094] Before placing the longitudinal connectors 10 on the solar cells 3, first an insulator 11 made of insulating tape is glued to the row 6 between two transverse connectors 4, 9, perpendicular to the row orientation of the row 6. The longitudinal connectors 10 are then glued to the insulator 11 and the transverse connectors 4, 9.

[0095] In the embodiment of the solar module 1 shown in the figures, the solar cells 3 of the solar cell array 2 are arranged in a shingled matrix.

[0096] according to Figures 5 to 12 First, a glass plate 17 is provided as part of a carrier structure 8. Then, Figure 6 The plastic film 18 shown in FIG. 1 is applied to the glass pane 17 .

[0097] according to Figure 7 In one working step, the plastic film 18 is first bonded to the initial transverse connector 9 made of the conductive double-sided adhesive tape 7. Figure 8 , the solar cell array 2 is then laid onto the plastic film 18 serving as a carrier structure 8, wherein the edge rows 6 of the solar cell array 2 are laid with their sun-facing sides 15 onto the initial transverse connectors 9 and the initial transverse connectors 9 are glued to the edge rows 6 of the solar cell array 2.

[0098] according to Fig. 9 , a covering element 13 in the form of a covering glue strip is subsequently applied in order to visually close the gaps 12 between adjacent solar cells 3 of a row 6 to which the transverse connector 4 is to be glued.

[0099] according to Fig.10, then, in addition to the initial transconnector 9, further transconnectors 4 are glued to the rows 6 with the visually closed gaps 12. The transconnectors 4 are then no longer visible from the sun-facing side 15 of the solar array 2, since they are arranged behind the solar cells 3 and the cover element 13.

[0100] In the next method step, the insulator 11 is adhesively bonded in the form of a strip of insulating tape to the row 6 of solar elements 3 located between the two transverse connectors 4 , 9 on the back side 14 of the solar array 2 .

[0101] In this case, the insulator 11 is oriented perpendicularly to the row orientation of the row 6. Finally, Fig.12 The solar cell array 2 is shown interconnected after application of the longitudinal connector 10. The junction box 16 can be connected to the longitudinal connector 10 at the location indicated by the reference numeral 160.

[0102] Fig.13 Show Fig.12 The solar cell array 2 shown in FIG. 1 has a structure arranged Fig.12 The junction box 16 is located at a position indicated by reference numeral 160 in FIG. The junction box 16 is electrically connected to the transverse connectors 4, 9 via the longitudinal connectors 10. The junction box 16 includes a bypass diode 38, by means of which the bypass circuit described above can be realized when one of the two segments 19 and 20 of the solar array 2 is partially shaded.

[0103] Fig.14 A further embodiment of a solar array 2 which is interconnected by means of a total of four transverse connectors 4 , 9 is shown.

[0104] The solar array 2 is divided into a total of three solar cell 3 segments 19 , 20 and 35 by means of a transconnector 4 bonded to the carrier structure 8 as an initial transconnector 9 and three further transconnectors 4 bonded to the back side 14 of the solar array 2 or to the solar cell rows 6 .

[0105] The first section 19 and the third section 35 are each assigned a terminal box 16 . The terminal boxes 16 are connected to the transverse connectors 4 , 9 or 4 via longitudinal connectors 10 .

[0106] The two transverse connectors 4 defining the second or middle section 20 of the solar array 2 are connected to a planar diode 34, which serves as a bypass diode, via a longitudinal connector 10. Due to its small structural height, the planar diode 34 can be laminated into the finished solar module 1 after applying a rear plastic film 36, which can be an EVA plastic film or a PCB plastic film, and optionally a rear carrier layer 37.

[0107] Fig.15 1 shows a cross section through a solar module 1 having an interconnected solar array 2 as shown in different embodiments in the previous figures. Fig.15 The layer structure of the solar module 1 is clearly shown.

[0108] On the sun-facing side 15 of the solar array 2 a carrier structure 8 for the solar modules 1 of the solar array 2 can be seen, which carrier structure comprises a glass plate 17 and a plastic film 18. The solar array 2 consisting of the rows 6 of crystalline solar cells 3 is laid onto the plastic film 18.

[0109] Fig.15 The middle row 6 of solar cells 3 of the part of the solar cell array 2 shown in FIG. 1 is bonded to a transverse connector 4 made of a conductive tape 5 on its back side 14. Thus, Fig.15 The solar array 2 shown in FIG. 1 is divided into at least two segments 19 and 20. The back side 14 of the solar array 2 is covered with a back plastic film 36, such as an EVA film or also a PCB film. A back carrier layer 37 is applied to the back plastic film 36. The interconnected solar array 2 is then laminated between the two plastic films 18 and 36 in the finished solar module 1.

[0110] Figures 16 to 22 A detail of a device, designated as a whole by reference numeral 22, for electrically interconnecting a solar array 2 consisting of crystalline solar cells 3 is shown. The device 22 is provided for carrying out the method described above and has a plurality of transverse connector applicators 23, which are provided for applying electrically conductive adhesive tapes 5, 7 as transverse connectors 4, 9 to the rows 6 of the solar array 2 and / or to the carrier structure 8 of the solar array 2.

[0111] Fig.16 A cross-connector applicator 23 is shown, which is provided for bonding an electrically conductive double-sided adhesive tape 7 as an initial cross-connector 9 to a carrier structure 8 for a solar array 2 .

[0112] Fig.18 Cross-connector applicators 23 are shown, which are provided for attaching conductive adhesive tapes 5 as further cross-connectors 4 to rows 6 of solar array 2 .

[0113] The device 22 also has a covering element applicator 24. These covering element applicators are Fig.17 1 and is provided for adhesively bonding a covering element 13 to the interspaces 12 between adjacent solar cells 3 of a row 6 of solar cells 3 .

[0114] Fig.19An insulation applicator 26 of the device 22 is shown, which is provided for applying an electrical insulator 11 made of an insulating tape. Fig.19 The insulator applicator 26 is shown after the insulator 11 has been applied.

[0115] The apparatus 22 also includes at least one longitudinal connector applicator 25, Fig. 20 2 shows a longitudinal connector applicator before applying a longitudinal connector 10. The longitudinal connector applicator 25 is provided for adhesively bonding the longitudinal connector 10 to the solar array 2 and / or to a carrier structure 8 for the solar array 2.

[0116] All the above-mentioned applicators 23, 24, 25 and 26 are constructed similarly. Each applicator 23, 24, 25 and 26 of the device 22 has a supply roller 27, an application element 28 (i.e., the application roller) and a pressure element 29 (i.e., the pressure roller located downstream of the application element 28 in the application direction).

[0117] The adhesive tape used as either the transverse connector 4, the initial transverse connector 9, the longitudinal connector 10 or the insulator 11 can be unwound from a supply roll 27 and applied by means of corresponding application elements 28. After the application of the adhesive tape, the adhesive tape is pressed onto the surfaces to be bonded by means of downstream pressing elements 29. This increases the adhesive effect of the adhesive tape on the respective surfaces.

[0118] The corresponding adhesive tapes 4, 9, 10, 11 and 13 can be pre-wound on the corresponding supply rolls according to the required length. But the device 22 can also have a cutting device for cutting the adhesive tapes 4, 9, 10, 11 and 13 to a fixed length for each applicator 23, 24, 25 and 26 respectively.

[0119] Furthermore, the device 22 is provided for pressure monitoring of the transverse connector applicator 23 , the covering element applicator 24 , the longitudinal connector applicator 25 and the insulator applicator 26 in order to protect the solar cells 3 and prevent them from being damaged when applying the adhesive tapes 4 , 9 , 10 , 11 and 13 .

[0120] The device 22 has at least one pressure sensor 30 for each transverse connector applicator 23, for each covering element applicator 24, for each longitudinal connector applicator 25 and for each insulator applicator 26, by means of which the pressure applied to the solar cell 3 when applying the transverse connectors 4, 9, covering elements 13, insulators 11 and / or longitudinal connectors 10 can be monitored.

[0121] The control unit 31 of the applicators 23, 24, 25 and 26 of the device 22 is provided for regulating and reducing the pressure of the applicators 23, 24, 25 and 26 during application if a maximum permissible pressure is exceeded during application.

[0122] Fig.21 The apparatus 22 is shown with a transverse connector applicator 23 on a robot 32 . Fig. 22 The apparatus 22 is shown with a gantry 33 on which the transverse connector applicator 23 and the insulator applicator 26 are arranged.

[0123] The invention relates to improvements in the technical field of solar module production. In particular, a method for interconnecting a solar cell array 2 made of crystalline solar cells 3 is proposed, wherein at least one transverse connector 4 , 9 made of an electrically conductive adhesive tape 5 , 7 is used for interconnection.

[0124] Reference numerals list

[0125] 1 Solar Module

[0126] 2 Solar Arrays

[0127] 3. Solar Cells

[0128] 4 Horizontal connector

[0129] 5. Conductive tape

[0130] 6 Solar cell rows in a solar cell array

[0131] 7. Conductive double-sided tape

[0132] 8 Carrier structure

[0133] 9 Initial Transverse Connectors

[0134] 10 Vertical connector

[0135] 11Insulators and insulating tapes

[0136] 12 Gap

[0137] 13 Covering elements

[0138] 14 Back

[0139] 15 Sunny side

[0140] 16 Junction Box

[0141] 160 Junction Box Location

[0142] 17 Glass Plate

[0143] 18 Plastic film

[0144] 19 The first segment of the solar array

[0145] 20 Second segment of solar array

[0146] 21 row end

[0147] 22 equipment

[0148] 23 Transverse Connector Applicator

[0149] 24 Covering element applicator

[0150] 25 Longitudinal Connector Applicator

[0151] 26 Insulation applicator

[0152] 27 Feed Roller

[0153] 28 coating element

[0154] 29 Clamping element

[0155] 30 Pressure Sensor

[0156] 31Control unit

[0157] 32 Robot

[0158] 33 gantry

[0159] 34 Planar diode

[0160] 35 The third segment of the solar array

[0161] 36 Plastic film on the back

[0162] 37 Carrier layer on the back

[0163] 38 bypass diodes.

Claims

1. A method for interconnecting a solar cell array (2) consisting of crystalline solar cells (3), wherein: At least one transverse connector (4, 9) made of an electrically conductive adhesive tape (5, 7) is used for interconnecting the solar arrays (2).

2. The method according to the preceding claim, wherein: At least one transverse connector (4, 9) made of an electrically conductive tape is adhered to a row (6) of solar cells (3), in particular such that the transverse connector (4, 9) extends within the row (6) without contacting adjacent rows.

3. A method according to any one of the preceding claims, wherein: At least one transverse connector (4, 9) made of an electrically conductive adhesive tape (5, 7) is glued to the sun-facing side (15) of a row (6) or to the back side (14) of a row (6) facing away from the sun-facing side (15).

4. A method according to any one of the preceding claims, wherein: A transverse connector (4, 9) made of an electrically conductive tape, preferably a double-sided electrically conductive tape (7), is bonded as an initial transverse connector (9) to a carrier structure (8) for a solar cell array (2), for example to a plastic film (18), preferably an EVA film or a PCB film, and then the solar cell array (2), in particular the row (6) of solar cells (3) on the edge side, is laid on the initial transverse connector (9) and the initial transverse connector (9) is bonded to the row (6) of the solar cell array (2).

5. A method according to any one of the preceding claims, wherein: At least two or more transverse connectors (4, 9) made of conductive tape (5, 7) are bonded to solar cells (3) of different rows (6), preferably at least two transverse connectors (4, 9) are bonded to at least one row (6) of solar cells (3) at a distance from one another.

6. A method according to any one of the preceding claims, wherein: A covering element (13), such as a covering strip, in particular a covering adhesive strip, is placed in the gap (12) between adjacent solar cells (3) in a row (6), and then a transverse connector (4, 9) made of an electrically conductive tape (5, 7) is glued to the row (6), preferably the covering element (13) is applied to the back side (14) of the solar cell array (2), which is facing away from the sun-facing side (15) of the solar cell array (2).

7. A method according to any one of the preceding claims, wherein: The transverse connector (4, 9) is electrically connected to a longitudinal connector (10) for connection to a junction box.

8. A method according to the preceding claim, wherein: As the longitudinal connector (10), a strip made of an electrically conductive adhesive tape (5) is used.

9. A method according to any one of the preceding claims, wherein: At least one transverse connector (4, 9) is glued to a row (6) with a projection beyond the row end (21) of the row (6).

10. A method according to any one of the preceding claims, wherein: At least one longitudinal connector (10) is placed, in particular glued, on the row (6) in a manner transversely or perpendicularly to the row orientation of the solar cell array (2), or the longitudinal connector (10) is placed, in particular glued, on a supporting structure (8) adjacent to the solar cells (3) of the solar cell array (2) in a manner transversely or perpendicularly to the row orientation of the solar cell array (2).

11. A method according to any one of the preceding claims, wherein: An electrical insulator (11), in particular an insulating strip, is placed, in particular glued, on the row (6) between two transverse connectors (4, 9) in a manner transversely or perpendicular to the row orientation of the row (6), and then at least one longitudinal connector (10) is placed, in particular glued, on the electrical insulator (11) and / or the transverse connectors (4, 9).

12. A method according to any one of the preceding claims, wherein: The solar cells (3) of the solar cell array (2) are arranged in a shingled matrix.

13. A solar module (1) comprising a solar array (2) consisting of crystalline solar cells (3), the solar array (2) being interconnected by means of at least one transverse connector (4) made of an electrically conductive adhesive tape.

14. The solar module (1) according to the preceding claim, wherein: At least one transverse connector (4) made of an electrically conductive adhesive tape (5) is glued to a row (6) of solar cells (3), preferably without contacting adjacent rows.

15. The solar module (1) according to any one of the preceding claims, wherein: At least one transverse connector (4) is made of an electrically conductive double-sided adhesive tape (7) and / or the solar cells (3) of the solar cell array (2) are arranged in a shingled matrix, in particular a voltage is established in a row (6) of the solar cell array (2) that is oriented transversely or perpendicularly to the row (6) and / or a voltage level exists within a row (6) of solar cells (3) of the solar cell array (2).

16. The solar module (1) according to any one of the preceding claims, wherein: At least one transverse connector (4, 9) made of an electrically conductive adhesive tape (5, 7) is connected to a longitudinal connector (10) made of an electrically conductive adhesive tape (5), in particular for connection to a junction box of a solar module (1).

17. The solar module (1) according to the preceding claim, wherein: The longitudinal connector (10) extends transversely or perpendicularly to the row orientation of the row (6) over a row (6) of solar cells (3), in particular arranged between two transverse connectors (4, 9).

18. The solar module (1) according to the preceding claim, wherein: An insulator (11), in particular an insulating tape, is arranged between the longitudinal connector (10) and the row (6) of solar cells (3), said insulator being in particular adhesively bonded to the solar cells (3).

19. The solar module (1) according to any one of the preceding claims, wherein: The gaps (12) between adjacent solar cells (3) of a row (6) bonded to transverse connectors (4, 9) made of conductive tape (5, 7) are covered with a covering element (13), in particular a covering strip or a covering adhesive strip, in particular the covering element (13) is arranged on the back side (14) of the solar cell array (2), the back side facing away from the sun-facing side (15) of the solar cell array (2).

20. The solar module (1) according to any one of the preceding claims, wherein: The two transverse connectors (4, 9) are connected to one another via longitudinal connectors (10) and a terminal box and / or a bypass circuit, for example with a bypass diode (38).

21. The solar module (1) according to any one of the preceding claims, wherein: Between two transverse connectors (4, 9) made of conductive tape (5, 7) there is a distance corresponding to at least one row (6) of solar cells (3).

22. The solar module (1) according to any one of the preceding claims, wherein: At least one transverse connector (5, 9) made of a conductive tape (7) is arranged on the sun-facing side (15) of the solar cell array (2), and / or at least one transverse connector (4) and / or longitudinal connector (10) made of a conductive tape (5) is arranged on the back side (14) of the solar cell array (2), the back side facing away from the sun-facing side (15) of the solar cell array (2).

23. A device (22) for electrically interconnecting a solar cell array (2), wherein: The device (22) is configured to carry out the method according to any of the preceding claims and has at least one cross-connector applicator (23) which is configured to adhere electrically conductive adhesive tapes (5, 7) as cross-connectors (4, 9) to rows (6) of a solar array (2) and / or to a carrier structure (8) for the solar array (2).

24. The device (22) according to the preceding claim, wherein The device (22) has at least one covering element applicator (24) which is provided for applying, in particular adhesively bonding, a covering element (13) to the gaps (12) between adjacent solar cells (3) of a row (6) of a solar cell array (2).

25. The device (22) according to any one of the preceding claims, wherein The device (22) has at least one longitudinal connector applicator which is provided for applying, in particular for adhesively bonding, the longitudinal connector (10).

26. The device (22) according to any one of the preceding claims, wherein The device (22) has at least one insulation applicator (25) for applying, in particular for adhesively bonding, an electrical insulator (11), in particular an insulating tape.

27. The device (22) according to any one of the preceding claims, wherein The transverse connector applicator (23), the covering element applicator (24), the longitudinal connector applicator (25) and / or the insulator applicator (26) have a feed roller (27), an application element (28), in particular an application roller, and / or a pressure element (29), in particular a pressure roller, preferably the pressure roller being located downstream of the application element (28) in the application direction.

28. The device (22) according to any one of the preceding claims, wherein The device (22) is configured to monitor the pressure of a transverse connector applicator (23), a covering element applicator (24), a longitudinal connector applicator (25) and / or an insulator applicator (26). Preferably, the device (22) has at least one pressure sensor (30) for at least one transverse connector applicator (23), at least one covering element applicator (24), at least one longitudinal connector applicator (25) and / or at least one insulator applicator (26), respectively, by means of which the pressure acting on the solar cell (3) when applying the transverse connector (4, 9), the covering element (13), the insulator (11) and / or the longitudinal connector (10) can be monitored.

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