Method for cross-connecting a solar cell array, solar module and device for electrical cross-connection of solar cell arrays

Abstract

The invention relates to improvements in the technical field of solar panel (1) manufacturing. To this end, inter alia, a method is proposed for cross-connecting a solar cell array (2) of crystalline solar cells (3), in which at least one cross-connector (4,9) of electrically conductive adhesive tape (5,7) is used for cross-connection.

Description

[0001] Method for cross-connecting a solar cell arrangement, solar module and device for electrical cross-connecting of solar cell arrangements

[0002] The invention relates to a method for cross-connecting a solar cell arrangement made of crystalline solar cells, a solar module with such a solar cell arrangement and a device for cross-connecting solar cell arrangements made of crystalline solar cells.

[0003] The cross-connection of crystalline solar cell arrays is currently achieved using copper strips, which must be soldered after installation to establish an electrical connection to the solar cells. If the solar cell arrays comprise multiple strings of solar cells that are to be cross-connected, a correspondingly high number of soldered connections must be created, which can be relatively complex. Soldering the copper strips can also cause heat to enter the solar cells, which can lead to stress and possibly damage to the solar cells.

[0004] The object of the invention is therefore to provide a method for cross-connecting a solar cell arrangement made of crystalline solar cells, a solar module with such a solar cell arrangement and a device for electrically cross-connecting solar cell arrangements made of crystalline solar cells, which promote an efficient and thus economical and at the same time gentle cross-connection of solar cell arrangements and thereby simplify the production of solar modules.

[0005] To solve the problem, a method for cross-connecting a solar cell array made of crystalline solar cells is proposed, which method has the means and features of the independent claim directed to such a method. To solve the problem, a method for cross-connecting a solar cell array made of crystalline solar cells is proposed, in which at least one cross-connector made of electrically conductive adhesive tape is used for cross-connecting the solar cell array.

[0006] By using an electrically conductive adhesive tape to provide a cross-connector for the cross-connection of the solar cell array, the comparatively complex soldering of contact points to copper strips, which were previously used as cross-connectors for cross-connection, can be eliminated. In the simplest case, the at least one cross-connector can be an adhesive strip made of electrically conductive adhesive tape. Such an adhesive strip can simply be pulled off a roll and cut to the required length. This can significantly simplify the provision and application of the cross-connectors.

[0007] Cross-connection using a cross-connector made of electrically conductive adhesive tape can be achieved without introducing heat into the solar cells of the solar cell array. This protects the solar cell array during cross-connection and reduces waste during solar module production.

[0008] A further advantage of the method according to the invention is that a cross-connector made of electrically conductive adhesive tape can be applied considerably more quickly and requires less mechanical effort than a copper strip, which must be soldered at a large number of individual contact points. This promotes the economical implementation of the method and thus the efficient production of solar modules.

[0009] In one embodiment of the method, at least one cross-connector made of electrically conductive adhesive tape is bonded to a row of solar cells. This can be done, in particular, such that the cross-connector runs within the row without contacting neighboring rows. This prevents a short circuit between neighboring rows.

[0010] In one embodiment of the method, at least one cross-connector made of electrically conductive adhesive tape is bonded to the sunny side of a row of a solar cell array. It is also possible to bond at least one cross-connector made of electrically conductive adhesive tape to the rear side of a row facing away from the sunny side.

[0011] In one embodiment of the method, at least one cross-connector, for example an initial cross-connector explained in more detail below, is bonded to a sunny side of a row of solar cells in the solar cell array. At least one further cross-connector can then be bonded to a rear side of one of the rows, for example to an edge-side row of solar cells in the solar cell array. The cross-connector made of an electrically conductive adhesive tape bonded to a rear side of a row does not conceal any photovoltaically effective area of ​​the row of solar cells on a sunny side of the solar cell array.

[0012] In a particularly advantageous embodiment of the method, a cross-connector made of a preferably double-sided, electrically conductive adhesive tape is bonded as an initial cross-connector to a support structure for the solar cell array. A plastic film, preferably an EVA film or a PCB film, can be used as the support structure for the solar cell array. After the initial cross-connector has been bonded to the support structure, the solar cell array, in particular with a row of solar cells at the edge, can be placed onto the initial cross-connector, and the initial cross-connector can be bonded to a row of the solar cell array.

[0013] In this embodiment of the method, it is particularly advantageous if the initial cross-connector consists of a double-sided, electrically conductive adhesive tape. The double-sided, electrically conductive adhesive tape can first be bonded to the support structure and thus fixed to the support structure. The initial cross-connector then no longer needs to be clamped separately to maintain its position on the support structure.

[0014] If the solar cell array is subsequently placed on the support structure, the initial cross-connector maintains its position because it adheres to the support structure. On its side facing away from the support structure, the initial cross-connector, made of double-sided adhesive tape, also has an adhesive surface, which can then be used to connect the initial cross-connector to a row of the solar cell array. The use of such an initial cross-connector can be particularly advantageous for the automated implementation of the process.

[0015] In one embodiment of the method, two or more cross-connectors made of electrically conductive adhesive tape are bonded to different rows of solar cells. In particular, if more than two cross-connectors made of electrically conductive adhesive tape are bonded to different rows of solar cells of the solar cell array, the solar cell array can be divided into individual segments using the cross-connectors. By means of a corresponding electrical bypass circuit, for example using bypass diodes, the

[0016] A solar cell array can still deliver satisfactory performance even when partially shaded. If a segment of the solar cell array is protected, the shaded segment can be bypassed via the bypass circuit. The output of the remaining solar cells outside the shaded segment of the solar cell array can then continue to generate electricity without undue interference from the shaded segment.

[0017] Preferably, at least two cross-connectors are bonded to different rows at a distance of at least one row, preferably several rows of solar cells, from each other. The distance between two cross-connectors then determines the size of a segment of the solar cell array defined by the cross-connectors.

[0018] There are usually gaps between adjacent solar cells in a row. When cross connectors made of electrically conductive adhesive tape are used, the cross connectors can be visible through these gaps between adjacent solar cells in a row. This can impair the appearance of the solar cell arrangement. To avoid such an impairment of the appearance of the solar cell arrangement, gaps between adjacent solar cells in a row can be covered by cover elements, for example by cover strips, in particular by adhesive cover strips. For this purpose, the cover elements can be placed over the gaps between adjacent solar cells. By covering the gaps, the gaps can be optically bridged and / or closed.Preferably, the cover elements are placed over the gaps between adjacent solar cells in a row before a cross-connector made of electrically conductive adhesive tape is bonded to the row. The cross-connector is then bonded over the cover elements to the solar cells in the row.

[0019] The cover elements, for example cover strips, preferably adhesive cover strips, and the optical closing of these gaps make it possible to prevent the cross-connector from being visible through the gaps between adjacent solar cells on the sunny side of the solar cell array. The cover elements can preferably have a color that matches the color of the solar cells in the solar cell array. In this context, it is also advantageous if the cover elements have a dimension that can be measured transversely or at right angles to the row alignment of the rows and that is larger than a dimension of the cross-connector that can be measured in the same direction. This ensures that the cross-connectors can be covered with the cover elements without being visible through the gaps between adjacent solar cells.

[0020] In order not to reduce the photovoltaically effective area of ​​the solar cells, it is expedient to apply the cover elements to a rear side of the solar cell arrangement which is facing away from a sunny side of the solar cell arrangement.

[0021] To connect a cross-connector to a junction box, the cross-connector can be electrically connected to a longitudinal connector. The longitudinal connector is preferably also made of an electrically conductive adhesive tape. The longitudinal connector can then be easily bonded to the cross-connector that is to be connected to a junction box. In the simplest case, the longitudinal connector, like the cross-connector(s), can therefore also be an adhesive strip made of electrically conductive adhesive tape. Such an adhesive strip can simply be pulled off a roll and cut to the required length. This can considerably simplify the provision and application of longitudinal connectors when carrying out the process.

[0022] Two cross connectors can be connected to a junction box, for example, via their longitudinal connectors. The cross connectors and the longitudinal connectors can be part of a bypass circuit, which can be used to bypass the rows of solar elements in the solar cell array in the event of shading, so as not to impair the performance of the remaining solar cells in the solar cell array that are located outside a segment of the solar cell array defined by the two cross connectors.

[0023] A bypass diode can be part of the aforementioned bypass circuit. If the electrical resistance increases due to shading of the cells in the segment of the solar cell array defined by the two cross connectors, the bypass circuit can become active and conduct current past the solar cells in the shaded segment and through the remaining solar cells in the solar cell array.

[0024] In one embodiment of the method, at least one cross connector is bonded to a row of the solar cell array in such a way that it projects beyond one end of the row. In its projecting area, the cross connector can then be connected to a longitudinal connector.

[0025] In a preferred embodiment of the method, which promotes a particularly space-saving cross-connection of the solar cell array, at least one longitudinal connector can be placed, in particular glued, across the rows of the solar cell array, transversely or at right angles to a row alignment of the solar cell array. This is preferably done on a rear side of the solar cell array, which faces away from the sun-exposed side of the solar cell array.

[0026] It is also possible to place, in particular to glue, a longitudinal connector transversely or at right angles to a row alignment of the solar cell array onto a support structure adjacent to the solar cells of the solar cell array.

[0027] Particularly when at least one longitudinal connector is to be laid, in particular glued, across the rows between two cross-connectors at right angles or transversely to the row alignment of the solar cell array, it is advantageous to first lay, in particular glue, an electrical insulator, in particular an insulation tape, transversely or perpendicularly across the rows between two cross-connectors. The longitudinal connector can then be laid, in particular glued, onto the electrical insulator and a cross-connector. The electrical insulator can be used to prevent the longitudinal connector from short-circuiting rows of the solar cell array. The insulation tape can be an adhesive insulation tape made, for example, from EPE. An adhesive insulation tape can be glued on easily and can therefore be attached to the solar cell array without great effort.

[0028] The solar cells of the solar cell arrangement can preferably be arranged in a shingle matrix arrangement.

[0029] To achieve this objective, a solar module with a solar cell arrangement made of crystalline solar cells is also proposed, which has the features of the independent claim directed to such a solar module. In particular, to achieve this objective, a solar module with a solar cell arrangement made of crystalline solar cells is proposed, wherein the solar cell arrangement is cross-connected to at least one cross-connector made of electrically conductive adhesive tape.

[0030] In one embodiment of the solar module, at least one cross-connector made of electrically conductive adhesive tape can be bonded to a row of solar cells. This is preferably done without contacting neighboring rows of solar cells.

[0031] At least one cross-connector used for cross-connecting the solar module can consist of an electrically conductive, double-sided adhesive tape. This cross-connector can, as previously explained in connection with the method, be bonded as an initial cross-connector to a support structure of the solar module for the solar cell array and / or to a sunny side of the solar cell array.

[0032] The solar cells of the solar cell array can be arranged in a shingle-matrix configuration. In such a shingle-matrix configuration, the voltage builds up in a direction transverse or perpendicular to the row direction of the individual solar cell rows. Within a row of solar cells in the shingle-matrix configuration, an electrical voltage level can be present. The cross-connectors applied to the rows within a row can thus contact solar cells to which a voltage level is present. This facilitates the previously explained segmentation of the solar cell array.

[0033] The electrical voltage builds up across the rows of the solar cell array at right angles or perpendicular to the alignment of the rows. An electrical voltage level can be present within a row of solar cells in the solar cell array. This distinguishes a row of solar cells in a shingle matrix arrangement from a conventional string of solar cells. In a string of solar cells, the solar cells are arranged and interconnected in such a way that the voltage builds up in the longitudinal direction of the string. In contrast, in a shingle matrix arrangement, no electrical voltage builds up in the longitudinal direction of a row of solar cells.

[0034] For connection to a junction box of the solar module, at least one cross-connector made of electrically conductive adhesive tape can be connected to a longitudinal connector. Such a longitudinal connector can preferably also be made of electrically conductive adhesive tape. This facilitates easy establishment of an electrical connection between the longitudinal connector and the cross-connector.

[0035] The longitudinal connector can run transversely or at right angles across rows of solar cells arranged between two transverse connectors. In one embodiment of the solar module, a longitudinal connector can also be arranged adjacent to the solar cell array, for example, on a support structure of the solar module for the solar cell array, and optionally also run transversely or at right angles to the row direction of the rows of solar cells in the solar cell array.

[0036] An insulator can be arranged between the longitudinal connector and the rows of solar cells. The insulator can be, for example, an insulation tape, preferably an adhesive insulation tape, bonded to the solar cells. The insulator can prevent a short circuit that could occur if the longitudinal connector came into direct contact with the solar cells. The insulator can be made of EPE.

[0037] Gaps between adjacent solar cells of a row covered with a cross-connector made of electrically conductive adhesive tape can be covered with cover elements, in particular with cover strips or with cover adhesive strips. The cross-connector is then arranged behind the cover elements and is not visible through the gaps. The gaps are then visually closed by the cover elements. In order to be able to cover the cross-connectors with the cover elements, it is advantageous if the cover elements have a width that can be measured transversely or at right angles to the longitudinal extent of the cross-connector and that is at least as large as the width of the cross-connector that can be measured in the same direction.

[0038] The cover elements are preferably arranged on a rear side of the solar cell arrangement which faces away from a sun-facing side of the solar cell arrangement.

[0039] Two cross-connectors can be connected via longitudinal connectors and a junction box and / or a bypass circuit, for example, with a bypass diode. A bypass circuit makes it possible to bypass the solar cells located between two cross-connectors in the event of shading, so as not to impair the performance of the remaining solar cells of the solar module.

[0040] At least one cross-connector made of electrically conductive adhesive tape can be arranged on a sunny side of the solar cell arrangement of the solar module. It is also possible for at least one cross-connector made of electrically conductive adhesive tape and / or one longitudinal connector, in particular made of electrically conductive adhesive tape, to be arranged on a rear side of the solar cell arrangement that faces away from a sunny side of the solar cell arrangement.

[0041] The previously mentioned cross-connectors and longitudinal connectors can be adhesive strips made of electrically conductive adhesive tape. The previously mentioned initial cross-connectors can be adhesive strips made of electrically conductive, double-sided adhesive tape.

[0042] To achieve this objective, a device for electrically interconnecting a solar cell array composed of crystalline solar cells is also proposed, comprising the means and features of the independent claim directed to such a device. The device is configured to carry out the claimed method and comprises at least one cross-connector applicator configured to adhere electrically conductive adhesive tape as a cross-connector to rows of a solar cell array.

[0043] In one embodiment of the device, it is provided that it has at least one cover element applicator which is designed to apply, in particular to adhere, cover elements to gaps between adjacent solar cells of a row of a solar cell arrangement.

[0044] The device may comprise at least one longitudinal connector applicator which is designed to apply, in particular to glue, longitudinal connectors.

[0045] The device may further comprise at least one insulation applicator for applying, in particular for gluing, electrical insulators, preferably electrical insulation tape.

[0046] In one embodiment of the device, the cross-connector applicator has a supply roll. A supply of electrically conductive adhesive tape for providing cross-connectors can be wound on the supply roll. The cross-connector applicator can further have an application element, in particular an application roller, and / or a pressing element. With the aid of the application roller, it is possible to apply the electrically conductive

[0047] Adhesive tape, which has been unrolled from a supply roll, is stuck onto a surface of solar cells in a row and the electrically conductive adhesive tape is thereby applied to the solar cells in a row as a cross-connector. With the help of the pressing element, which can be designed as a pressing roller, for example, it is possible to press the glued-on cross-connector made of electrically conductive adhesive tape onto the surface of the solar cells after it has been applied. This can improve the adhesion of the cross-connectors. In this context, it can be advantageous if the pressing element is arranged downstream of the application element in the direction of application of the cross-connectors.

[0048] In an analogous manner, the device can also comprise a supply roll with cover elements for the cover element applicator, a supply roll with longitudinal connectors for the longitudinal connector applicator and a supply roll with insulators, in particular with insulation tape or insulation adhesive tape, for the insulation applicator.

[0049] The cover element applicator, the longitudinal connector applicator and / or the insulation applicator can have application elements, for example application rollers, and / or pressing elements, in particular pressing rollers, which are preferably arranged downstream of the respective application element in the application direction. In this way, it is possible to first apply the respective structure, preferably designed as an adhesive strip, for example the cover elements, the insulators and / or the longitudinal connectors, to their target surface using the respective application element and then to press them onto the surface to which they have been adhered using the downstream pressing element. In order to protect the solar cells from overloading during application of the cross connectors, longitudinal connectors, cover elements and / or insulators, the device can be configured for pressure monitoring.The device preferably has at least one pressure sensor for at least one cross-connector applicator, for at least one cover element applicator, for at least one insulation applicator and / or for at least one longitudinal connector applicator, preferably in each case, with which the pressure acting on the solar cells during application of the cross-connectors, cover elements, insulators and / or longitudinal connectors can be monitored. If a permissible maximum pressure is exceeded, the device can reduce the pressure and prevent damage to the solar cells by means of at least one corresponding control unit. Each of the aforementioned applicators can each have a corresponding control unit. However, the device can also have a central control unit which can carry out the previously explained pressure control or pressure regulation of the applicators.

[0050] The invention is explained in more detail below using exemplary embodiments, but is not limited to these exemplary embodiments. Further exemplary embodiments result from the combination of the features of individual or multiple claims with one another and / or from the combination of individual or multiple features of the exemplary embodiments.

[0051] It shows :

[0052] Figure 1 is a perspective view of a first embodiment of a solar module with a support structure comprising a glass pane and a plastic film applied to the glass pane, and with a solar cell arrangement applied to the plastic film, wherein for the cross-connection of the solar cell arrangement, three different rows of the solar cell arrangement are bonded with cross-connectors made of electrically conductive adhesive tape,

[0053] Figure 2 is a perspective view of a further embodiment of a solar module in which the solar cell arrangement of the solar module is cross-connected with two cross-connectors made of electrically conductive adhesive tape,

[0054] Figures 3 and 4 show further embodiments of solar modules, wherein three cross connectors and a total of three longitudinal connectors made of electrically conductive adhesive tape are glued on for cross-connecting the solar cell arrangements,

[0055] Figure 5 is a detailed view of a glass pane as used as part of the support structure in the solar modules shown in the previous figures,

[0056] Figure 6 is a detail view of a plastic film as used in the solar modules shown in the previous figures as part of the support structure, wherein the plastic film is placed on the glass pane shown in Figure 5,

[0057] Figure 7 shows a support structure for a solar cell arrangement, which consists of a glass pane and a plastic film, wherein a cross-connector serving as an initial cross-connector made of a double-sided, electrically conductive adhesive tape is glued onto the plastic film,

[0058] Figure 8 shows the support structure shown in Figure 7 with the initial cross-connector and a shingle matrix solar cell arrangement, which is placed with its first row of solar cells on the initial cross-connector,

[0059] Figure 9 shows the solar cell arrangement shown in Figure 8, wherein gaps between solar cells of the rows are optically closed by means of cover elements, to which cross connectors are subsequently to be glued,

[0060] Figure 10 shows the solar cell arrangement shown in Figure 9 with two further cross-connectors made of electrically conductive adhesive tape glued to a back side of the solar cell arrangement,

[0061] Figure 11 shows the solar cell arrangement shown in Figure 10, wherein an insulator in the form of an insulation tape is glued between two cross-connectors spaced apart by several rows of solar cells,

[0062] Figure 12 shows the solar cell arrangement shown in Figure 11, wherein each of the cross connectors is connected to a respective longitudinal connector, and wherein the longitudinal connectors are adhesive strips of electrically conductive adhesive tape, which are glued on the one hand to the cross connectors and on the other hand to the electrical insulators,

[0063] Figure 13 shows the solar cell arrangement shown in Figure 12 with junction boxes connected to the cross connectors,

[0064] Figure 14 shows a solar cell arrangement divided into three segments by an initial cross-connector and three further cross-connectors made of electrically conductive adhesive tape, with two junction boxes, in each of which a bypass diode is arranged, and with a flat diode as a bypass diode on a middle of the three segments, which can be laminated on the finished solar module,

[0065] Figure 15 is a sectional side view with a section of a solar module with a cross-connected solar cell arrangement to illustrate its layer structure,

[0066] Figure 16 is a perspective view of a cross-connector applicator of a device for cross-connecting solar cell arrays during the application of an initial cross-connector made of electrically conductive adhesive tape,

[0067] Figure 17 is a perspective view of cover element applicators of the device, which are designed to bridge gaps between adjacent solar cells by gluing cover elements on and thereby close them, so that a cross-connector arranged behind them is no longer visible through the gaps,

[0068] Figure 18 is a perspective view of cross-connector applicators of the device, which are designed to bond cross-connectors made of electrically conductive adhesive tape to rows of solar cells,

[0069] Figure 19 is a perspective view of an insulation applicator of the device, which is designed for bonding electrical insulators, namely electrical insulation adhesive tapes, to solar cells between cross-connectors,

[0070] Figure 20 is a perspective view of a longitudinal connector applicator of the device, which is designed for gluing longitudinal connectors,

[0071] Figure 21 shows an embodiment of a device for cross-connecting solar cell arrangements, in which a cross-connector applicator is arranged on a robot of the device, and

[0072] Figure 22 shows a further embodiment of a device for cross-connecting solar cell arrangements, in which different applicators are suspended from a portal of the device.

[0073] Figures 1-15 show at least parts of solar modules designated as a whole by 1. The solar modules 1 each have a solar cell array 2 made of crystalline solar cells 3, namely solar cell shingles. The solar cell arrays 2 are cross-connected by cross connectors 4, 9 made of electrically conductive adhesive tape.

[0074] Figures 1-15 show that the cross-connectors 4, 9 made of electrically conductive adhesive tape 5, 7 are each glued to a row 6 of solar cells 3 without contacting adjacent rows of solar cells 3. In each solar module 1 shown, there is at least one cross-connector 4 made of electrically conductive, double-sided adhesive tape 7, which is glued to a support structure 8 of the solar module 1 for the solar cell arrangement 2 before the solar cell arrangement 2 is placed on the cross-connector 4 made of double-sided adhesive tape 7. The cross-connector 4 made of electrically conductive, double-sided adhesive tape 7 can also be referred to as an initial cross-connector 9. The initial cross-connector 9 is shown in Figure 7 on the support structure 8 of a solar module 1, even before the solar cell arrangement 2 has been placed on the support structure 8 and thus on the initial cross-connector 9 made of double-sided adhesive tape 7.

[0075] The figures further illustrate that the solar cells 3 of the solar cell arrays 2 are arranged in a so-called shingle matrix arrangement. Two adjacent rows 6 of solar cells 3 are offset from one another, while one row 6 overlaps the adjacent row 6. In this way, the solar cell arrays 2 are given a brickwork-like structure, which, due to the offset and overlap of the solar cells 3 of adjacent rows 6, promotes the formation of a plurality of current paths within the solar cell arrays 2.

[0076] In this context, it is worth mentioning that an electrical voltage buildup occurs across the rows 6 of the solar cell arrays 2 at right angles or transversely to an alignment of the rows 6 of the solar cell arrays 2. An electrical voltage level is then present within a row 6 of solar cells 3 of the solar cell arrays 2. In comparison, the voltage buildup in a conventional string of solar elements occurs in the direction of its longitudinal extent. A conventional string of solar cells is therefore to be distinguished from a row of solar cells 3, as can be found in the solar cell arrays 2 shown.

[0077] The cross connectors 4, 9 made of electrically conductive adhesive tape 5, 7 are each connected to a longitudinal connector 10, which also consists of electrically conductive adhesive tape 5, for connection to a junction box of the respective solar module 1. Figures 1 to 4 show different possibilities for arranging cross connectors 4, 9 and longitudinal connectors 10 for interconnecting the solar cell arrays 2 of the solar module 1.

[0078] In all solar modules 1 shown, the longitudinal connectors 10 run at right angles to a row alignment of the rows 6 of solar cells 3. In the solar modules 1 shown in Figures 1-3, the longitudinal connectors 10 run at right angles to a row alignment of the rows 6 across rows 6 of solar cells 3.

[0079] In the exemplary embodiment of a solar module 1 shown in Figure 4, the longitudinal connectors 10 are applied adjacent to the solar cell arrangement 2 on the support structure 8 of the solar module 1 for the solar cell arrangement 2, but nevertheless run at right angles to the rows 6 of solar cells 3 of the solar cell arrangement 2. In the solar modules 1 shown in Figures 1-3, the longitudinal connectors 10 run at right angles to the rows 6 over the rows 6 of solar cells 3, which are arranged between two transverse connectors 4, 9.

[0080] An insulator 11 in the form of an insulation tape, namely an adhesive insulation tape, is arranged between the longitudinal connectors 10 and the rows 6 of solar cells 3. The insulators 11 are glued to the solar cells 3. The insulators 11 consist of an EPE insulation tape and prevent the longitudinal connectors 10 from short-circuiting the solar cells 3.

[0081] Figures 1-4 further show that gaps 12 between adjacent solar cells 3 of a row 6 to which a cross-connector 4 made of electrically conductive adhesive tape 5 is attached are optically closed with cover elements 13 in the form of adhesive cover strips. The cover elements 13 are arranged on a rear side 14 of the solar cell arrays 2, which rear side faces away from a sun-exposed side 15 of the solar cell arrays 2. The cover elements 13 are wider than the cross-connectors 4, 9 and prevent the cross-connectors 4 made of electrically conductive adhesive tape 5 from being visible on the sun-exposed side 15 of the solar cell arrays 2 and from impairing the overall visual impression of the solar modules 1. In this context, it is advantageous if the cover elements 13 have a similar or even the same color as the solar cells 3 of the solar cell arrays 2.

[0082] Two cross-connectors 4, 9 are connected to one another via longitudinal connectors 10 and a junction box 16, which can be arranged, for example, at one of the positions designated 160. The junction box can contain or form a bypass circuit with a bypass diode 38, which allows the solar cells 3 located between two cross-connectors 4, 9 to be bypassed in the event of shading. With the aid of the cross-connectors 4, 9, the solar cell arrangements 2 can be divided into segments 19, 20.

[0083] Should one of the segments 19, 20 become shaded or partially shaded, it is possible to bypass the shaded segment(s) 19, 20 via a bypass circuit with a bypass diode 38. In the event of shading, the electrical resistance of the solar cells 3 located in the shaded segment 19, 20 may increase, causing the bypass diode 38 to switch and open a current path past the shaded segment 19, 20. In this way, the shaded segment 19, 20 is temporarily bypassed so as not to impair the performance of unshaded segments 19, 20 of the solar cell arrangement 2.

[0084] The figures show that there is a distance of several rows 6 of solar cells 3 between two cross-connectors 4, 9 made of electrically conductive adhesive tape 5, 7. At least one cross-connector, namely the initial cross-connector 9 made of electrically conductive, double-sided adhesive tape 7, is arranged on the sunny side 15 of the solar cell arrays 2. The remaining cross-connectors 4 made of electrically conductive adhesive tape 5 and also the longitudinal connectors 10 are arranged on the rear side 14 of the solar cell arrays 2, which is facing away from the sunny side 15 of the solar cell arrays 2.

[0085] The cross-connection of the solar cell arrangements 2 of the solar modules 1 shown in the figures can be carried out according to the method described below for cross-connecting a solar cell arrangement 2 made of crystalline solar cells 3.

[0086] Cross connectors 4, 9 made of electrically conductive adhesive tape 5, 7 are used for cross-connecting the solar cell array 2. The cross connectors 4, 9 made of electrically conductive adhesive tape are each glued to a row 6 of solar cells 3. The cross connectors 4, 9 are glued to the rows 6 of solar cells 3 in such a way that they run within their respective row 6 without contacting or overlapping adjacent rows of solar cells 3.

[0087] A cross-connector, namely the initial cross-connector 9 made of electrically conductive adhesive tape 7, is glued to a sunny side 15 of a row 6. The remaining cross-connectors 4 made of electrically conductive adhesive tape 5 are glued to a rear side 14 of rows 6 of solar cells 3, said rear side facing away from the sunny side 15. The cross-connector designated 9 is glued as an initial cross-connector onto the support structure 8 of the solar module 1 for the solar cell arrangement 2, before the solar cell arrangement 2 is positioned on the support structure 8. This initial cross-connector 9 consists of double-sided, electrically conductive adhesive tape 7, so that the initial cross-connector 9 can adhere to the support structure 8 itself according to Figure 7 and provides an adhesive surface on its free surface which can be used to connect to a first row 6 of solar cells 3 of the solar cell arrangement 2.

[0088] The support structure 8 of the solar module 1 shown in the figures consists of a glass plate 17, which is shown in Figure 5, and of a plastic film 18, namely an EVA film or a PCB film, which is shown in Figure 6. The initial cross connector 9 is glued onto the plastic film 18 of the support structure 8. The solar cell arrangement 2 is then placed with the sunny side 15 of an edge row 6 of solar cells 3 onto the initial cross connector 9 and the initial cross connector 9 is glued onto the edge row 6 of the solar cell arrangement 2.

[0089] The cross connectors 4, 9 made of electrically conductive adhesive tape 5, 7 are glued to different rows 6 of solar cells 3 of the solar cell array 2 in order to divide the solar cell array 2 into individual segments 19 and 20. The cross connectors 4, 9 are glued to the rows 6 of the solar cell array 2 at a distance of several rows 6 of solar cells 3 from one another.

[0090] Before the cross connectors 4 are glued onto the rows 6, according to Figure 9, gaps 12 between adjacent solar cells 3 of a row 6, to which a cross connector 4 is to be glued, are first optically closed by cover elements 13, namely by adhesive cover strips. Subsequently, the cross connectors 4 are glued onto the rows 6 and the already glued cover elements 13. The cross connectors 4 are then concealed by the cover elements 13 and, viewed from a sunny side 15 of the solar cell arrangement 2, are no longer visible through the gaps 12. Like the cross connectors 4, the cover elements 13 are also glued to the back 14 of the solar cell arrangement 2.

[0091] The cross connectors 4, 9 are each electrically connected to a longitudinal connector 10 for connection to a junction box. Like the cross connectors 4, the longitudinal connectors 10 also consist of electrically conductive adhesive tape 5.

[0092] In the solar module 1 of Figure 4, the cross connectors 4, 9 are glued to the rows 6 and the support structure 8 with a projection beyond a row end 21 of the rows 6. The respective projecting section of the cross connectors 4, 9 is then used to connect to the longitudinal connectors 10.

[0093] The longitudinal connectors 10 are placed at right angles to a row alignment of the rows 6 of the solar cell arrays 2 either over the rows 6 , namely glued , or glued next to the solar cell arrays 2 onto the support structures 8 of the solar modules 1 for the solar cell arrays 2 .

[0094] Before the longitudinal connectors 10 are placed over the solar cells 3, insulators 11, consisting of insulating adhesive tape, are first glued perpendicular to the row alignment of the rows 6 onto the rows 6 between two cross connectors 4, 9. The longitudinal connectors 10 are then glued onto the insulators 11 and the cross connectors 4, 9.

[0095] In the embodiments of solar modules 1 shown in the figures, the solar cells 3 of the solar cell arrangements 2 are arranged in a shingle matrix arrangement.

[0096] The method explained above is illustrated with reference to Figures 5 to 12. First, a glass pane 17 is prepared as part of the support structure 8. Subsequently, the plastic film 18 shown in Figure 6 can be applied to the glass pane 17.

[0097] According to Figure 7, the plastic film 18 is first bonded in one step to the initial cross-connector 9, which consists of electrically conductive, double-sided adhesive tape 7. According to Figure 8, the solar cell array 2 is then placed on the plastic film 18 serving as the support structure 8, with an edge-side row 6 of the solar cell array 2 being placed with its sunny side 15 on the initial cross-connector 9, and the initial cross-connector 9 being bonded to the edge-side row 6 of the solar cell arrays 2.

[0098] According to Figure 9, the cover elements 13 are then applied in the form of adhesive cover strips in order to optically close gaps 12 between adjacent solar cells 3 of a row 6 to which a cross connector 4 is to be glued.

[0099] According to Figure 10, in addition to the initial cross-connector 9, further cross-connectors 4 are then glued onto the rows 6 with the optically closed gaps 12. The cross-connectors 4 are then no longer visible from the sunny side 15 of the solar cell array 2, since they are arranged behind the solar cells 3 and the cover elements 13.

[0100] In a subsequent process step, the insulators 11 in the form of strips of insulating adhesive tape are glued to the rows 6 of solar elements 3 located between two cross connectors 4, 9 on the back 14 of the solar cell arrangement 2.

[0101] The insulators 11 are perpendicular to a

[0102] Line alignment of the rows 6 aligned. Figure 12 finally shows the cross-connected solar cell arrangement 2 after the application of the longitudinal connectors 10. At the positions designated 160, junction boxes 16 can be connected to the longitudinal connectors 10.

[0103] Figure 13 shows the solar cell arrangement 2 depicted in Figure 12, with junction boxes 16 arranged at the positions designated 160 in Figure 12. The junction boxes 16 are electrically connected to the cross connectors 4, 9 via the longitudinal connectors 10. The junction boxes 16 contain bypass diodes 38, with which the previously explained bypass circuit can be implemented in the event of partial shading of one of the two segments 19 and 20 of the solar cell arrangement 2.

[0104] Figure 14 shows a further embodiment of a solar cell arrangement 2 cross-connected with a total of four cross connectors 4, 9.

[0105] By means of a cross-connector 4, which was glued to the support structure 8 as an initial cross-connector 9, and three further cross-connectors 4, which are glued to a rear side 14 of the solar cell arrangement 2 or the rows 6 of solar cells 3, this solar cell arrangement 2 is divided into a total of three segments 19, 20 and 35 of solar cells 3.

[0106] A junction box 16 is assigned to each of the first segments 19 and 35. The junction boxes 16 are connected to the cross connectors 4, 9 and 4, respectively, via longitudinal connectors 10.

[0107] The two cross connectors 4, which delimit the second or middle segment 20 of the solar cell array 2, are connected via longitudinal connectors 10 to a flat diode 34, which functions as a bypass diode. Due to its low overall height, this flat diode 34 can be laminated onto 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.

[0108] Figure 15 shows a cross-section through a solar module 1 having a cross-connected solar cell arrangement 2, as shown in various embodiments in the previous figures. Figure 15 clearly illustrates the layered structure of the solar module 1.

[0109] On the sunny side 15 of the solar cell arrangement 2, the support structure 8 of the solar module 1 for the solar cell arrangement

[0110] 2 from the glass pane 17 and the plastic film 18. The solar cell arrangement 2 from rows 6 of crystalline solar cells is applied to the plastic film 18.

[0111] 3 hung up .

[0112] A middle row 6 of solar cells 3 of the section of the solar cell arrangement 2 shown in Figure 15 has a cross-connector 4 made of electrically conductive adhesive tape 5 glued to its rear side 14. The solar cell arrangement 2 shown in Figure 15 is thus divided into at least two segments 19 and 20. The rear side 14 of the solar cell arrangement 2 is covered with a rear plastic film 36, for example an EVA film or a PCB film. A rear carrier layer 37 is applied to the rear plastic film 36. The cross-connected solar cell arrangement 2 is then laminated between the two plastic films 18 and 36 in the finished solar module 1.

[0113] Figures 16-22 show details of a device, designated as a whole by 22, for electrically interconnecting solar cell arrays 2 made of crystalline solar cells 3. The device 22 is designed to carry out the method explained above and has a plurality of cross-connector applicators 23 which are designed to adhere electrically conductive adhesive tape 5, 7 as cross-connectors 4, 9 to rows 6 of solar cell arrays 2 and / or to support structures 8 for solar cell arrays 2.

[0114] Figure 16 shows a cross-connector applicator 23 which is designed to adhere electrically conductive, double-sided adhesive tape 7 as an initial cross-connector 9 to support structures 8 for solar cell arrangements 2.

[0115] Figure 18 shows cross-connector applicators 23 which are designed to adhere electrically conductive adhesive tape 5 as additional cross-connectors 4 to rows 6 of solar cell arrays 2.

[0116] The device 22 further comprises cover element applicators 24. These are shown in Figure 17 and are designed to adhere cover elements 13 to gaps 12 between adjacent solar cells 3 of a row 6 of solar cells 3.

[0117] Figure 19 shows an insulation applicator 26 of the device 22, which is configured for applying electrical insulators 11 made of insulation adhesive tape. Figure 19 shows the insulation applicator 26 after application of the insulators 11.

[0118] The device 22 also has at least one longitudinal connector applicator 25, which is shown in Figure 20 prior to the application of longitudinal connectors 10. The longitudinal connector applicator 25 is designed for adhesively bonding longitudinal connectors 10 to the solar cell arrays 2 and / or to support structures 8 for the solar cell arrays 2. All of the previously mentioned applicators 23, 24, 25, and 26 are constructed in a comparable manner. Each of the applicators 23, 24, 25, and 26 of the device 22 has a supply roll 27, an application element 28, namely an application roll, and a pressing element 29, namely a pressing roll arranged downstream of the application element 28 in the application direction.

[0119] The adhesive tapes used as cross connectors 4, initial cross connectors 9, longitudinal connectors 10, or insulators 11 can be unrolled from the supply roll 27 and applied using the respective application element 28. After application, the adhesive tapes are then pressed onto the surfaces to be bonded by the downstream pressing element 29. This increases the adhesive strength of the adhesive tapes to the respective surface.

[0120] The respective adhesive tapes 4, 9, 10, 11, and 13 can be pre-cut to the required length on the respective supply roll. However, it is also possible for the device 22 to have a cutting device for each applicator 23, 24, 25, and 26 for cutting the adhesive tapes 4, 9, 10, 11, and 13 to length.

[0121] The device 22 is further configured to monitor the pressure of the transverse connector applicators 23, the cover element applicator 24, the longitudinal connector applicator 25 and the insulation applicator 26 in order to protect the solar cells 3 from damage during the application of the adhesive tapes 4, 9, 10, 11 and 13.

[0122] The device 22 has at least one pressure sensor 30 for each cross-connector applicator 23, for each cover element applicator 24, for each longitudinal connector applicator 25 and for each insulation applicator 26, with which the pressure applied to the solar cells 3 during the application of the cross-connectors

[0123] 4,9, the cover elements 13, insulators 11 and / or

[0124] The pressure exerted on the longitudinal connector 10 can be monitored.

[0125] Control units 31 of the applicators 23, 24, 25 and 26 of the device 22 are designed to regulate and reduce the pressure of the applicators 23, 24, 25 and 26 during application if a permissible maximum pressure is exceeded during application.

[0126] Figure 21 shows a device 22 with a cross-connector applicator 23 on a robot 32. Figure 22 shows a device 22 with a portal 33 on which cross-connector applicators 23 and an insulation applicator 26 are arranged.

[0127] The invention relates to improvements in the technical field of solar module production. Among other things, a method for cross-connecting a solar cell array 2 composed of crystalline solar cells 3 is proposed, in which at least one cross-connector 4, 9 made of electrically conductive adhesive tape 5, 7 is used for the cross-connection.

[0128] / List of reference symbols List of reference symbols

[0129] 1 solar module

[0130] 2 Solar cell arrangement

[0131] 3 solar cells

[0132] 4 cross connectors

[0133] 5 electrically conductive adhesive tape

[0134] 6 row of solar cells in 2

[0135] 7 electrically conductive, double-sided adhesive tape

[0136] 8 Support structure

[0137] 9 Initial cross connectors

[0138] 10 longitudinal connectors

[0139] 11 I insulator, I insulation tape

[0140] 12 gap

[0141] 13 Cover element

[0142] 14 Back

[0143] 15 Sunny side

[0144] 16 junction box

[0145] 160 Position of a junction box

[0146] 17 Glass pane

[0147] 18 plastic film

[0148] 19 first segment of 2

[0149] 20 second segment of 2

[0150] 21 End of line

[0151] 22 Device

[0152] 23 Cross connector applicator

[0153] 24 Cover element applicator

[0154] 25 Longitudinal connector applicator

[0155] 26 I isolation applicator

[0156] 27 supply roll

[0157] 28 Application element

[0158] 29 Pressure element

[0159] 30 pressure sensor

[0160] 31 Control unit

[0161] 32 Robot 33 Portal

[0162] 34 flat diode

[0163] 35 third segment of 2

[0164] 36 backing plastic film 37 backing layer

[0165] 38 Bypass diode

[0166] / Claims

Claims

Claims: A method for cross-connecting a solar cell arrangement (2) made of crystalline solar cells (3), wherein at least one cross-connector (4, 9) made of electrically conductive adhesive tape (5, 7) is used for cross-connecting the solar cell arrangement (2). A method according to the preceding claim, wherein at least one cross-connector (4, 9) made of electrically conductive adhesive tape is adhered to a row (6) of solar cells (3), in particular such that the cross-connector (4, 9) runs within the row (6) without contacting adjacent rows. A method according to any of the preceding claims, wherein at least one cross-connector (4, 9) made of electrically conductive adhesive tape (5, 7) is adhered to a sun-facing side (15) of a row (6) or to a rear side (14) of a row (6) facing away from the sun-facing side (15).Method according to one of the preceding claims, wherein a cross connector (4, 9) made of, preferably double-sided, electrically conductive adhesive tape (7) is applied as an initial cross connector (9) to a support structure (8) for the solar cell arrangement (2), for example to a plastic film (18), preferably to an EVA film or a PCB film, after which the solar cell arrangement (2), in particular with an edge-side row (6) of solar cells (3), is placed on the initial cross connector (9) and the initial cross connector (9) is thereby applied to the row (6) of the solar cell arrangement (2). A method according to any one of the preceding claims, wherein at least two or more cross connectors (4, 9) made of electrically conductive adhesive tape (5, 7) are adhered to different rows (6) of solar cells (3), preferably wherein at least two cross connectors (4, 9) are adhered to the rows (6) at a distance of at least one row (6) of solar cells (3) from each other. A method according to any one of the preceding claims, wherein cover elements (13), for example cover strips, in particular cover adhesive strips, are placed over gaps (12) between adjacent solar cells (3) of a row (6) before a cross connector (4, 9) made of electrically conductive adhesive tape (5, 7) is adhered to the row (6), preferably wherein the cover elements (13) are applied to a rear side (14) of the solar cell arrangement (2) that faces away from a sun-exposed side (15) of the solar cell arrangement (2).A method according to any one of the preceding claims, wherein a transverse connector (4, 9) for connection to a junction box is electrically connected to a longitudinal connector (10). A method according to the preceding claim, wherein an adhesive strip made of electrically conductive adhesive tape (5) is used as the longitudinal connector (10). A method according to any one of the preceding claims, wherein at least one transverse connector (4, 9) is adhered to a row (6) with a projection extending over a row end (21) of a row (6). A method according to any one of the preceding claims, wherein at least one longitudinal connector (10) extends transversely or perpendicularly to a row orientation of the solar cell arrangement (2) over the... A method according to any of the preceding claims, wherein an electrical insulator (11), in particular an insulating tape, is applied transversely or perpendicularly to a row orientation of the rows (6) onto the rows (6) between two transverse connectors (4, 9), wherein at least one longitudinal connector (10) is applied, in particular glued, onto the electrical insulator (11) and / or a transverse connector (4, 9). A method according to any of the preceding claims, wherein the solar cells (3) of the solar cell arrangement (2) are arranged in a shingle matrix arrangement.Solar module (1) with a solar cell arrangement (2) of crystalline solar cells (3), wherein the solar cell arrangement (2) is cross-connected by at least one cross-connector (4) made of electrically conductive adhesive tape. Solar module (1) according to the preceding claim, wherein at least one cross-connector (4) made of electrically conductive adhesive tape (5) is adhered to a row (6) of solar cells (3), preferably without contacting adjacent rows. Solar module (1) according to any of the preceding claims, wherein at least one cross-connector (4) consists of electrically conductive, double-sided adhesive tape (7) and / or wherein the. Solar cells (3) of the solar cell arrangement (2) are arranged in a shingle matrix arrangement, in particular wherein an electrical voltage build-up occurs transversely or perpendicularly to an orientation of the rows (6) across rows (6) of the solar cell arrangement (2) and / or wherein an electrical voltage level is present within a row (6) of solar cells (3) of the solar cell arrangement (2). Solar module (1) according to one of the preceding claims, wherein at least one transverse connector (4, 9) made of electrically conductive adhesive tape (5, 7), in particular for connection to a junction box of the solar module (1), is connected to a longitudinal connector (10), in particular made of electrically conductive adhesive tape (5). Solar module (1) according to the preceding claim, wherein the longitudinal connector (10) extends transversely or perpendicularly to a row orientation of the rows (6) across rows (6) of solar cells (3), in particular those arranged between two transverse connectors (4, 9).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 rows (6) of solar cells (3), and is in particular glued onto the solar cells (3). Solar module (1) according to any of the preceding claims, wherein gaps (12) between adjacent solar cells (3) of a row (6) covered with a transverse connector (4, 9) made of electrically conductive adhesive tape (5, 7) with cover elements (13), in particular with cover strips or with. Cover strips are covered, in particular wherein the cover elements (13) are on a back (14) of the solar cell arrangement (2) are arranged which are one The solar cell arrangement (2) is oriented away from the sun side (15). A solar module (1) according to one of the preceding claims, wherein two cross connectors (4, 9) are connected to each other via longitudinal connectors (10) and a junction box and / or a bypass circuit, for example with a bypass diode (38). A solar module (1) according to one of the preceding claims, wherein there is a distance of at least one row (6) of solar cells (3) between two cross connectors (4, 9) made of electrically conductive adhesive tape (5, 7). Solar module (1) according to one of the preceding claims, wherein at least one cross connector (5, 9) made of electrically conductive adhesive tape (7) is arranged on a sun side (15) of the solar cell arrangement (2), and / or wherein at least one cross connector (4) made of electrically conductive adhesive tape (5) and / or a longitudinal connector (10) is / are arranged on a rear side (14) of the solar cell arrangement (2) which faces away from a sun side (15) of the solar cell arrangement (2).Device (22) for electrical cross-connection of solar cell arrangements (2) , wherein the device (22) is configured for carrying out the method according to one of the preceding claims and has at least one cross-connector applicator (23) which is configured for applying electrically conductive adhesive tape (5,7) as a cross-connector (4,9) to rows (6) of solar cell arrangements (2) and / or to support structures (8) for solar cell arrangements (2). Device (22) according to the preceding claim, wherein the device (22) includes at least one cover element applicator (24) comprising a device (22) that is configured for applying, in particular adhering, cover elements (13) to gaps (12) between adjacent solar cells (3) of a row (6) of solar cell arrangements (2). Device (22) according to one of the preceding claims, wherein the device (22) comprises at least one longitudinal connector applicator configured for applying, in particular adhering, longitudinal connectors (10). Device (22) according to one of the preceding claims, wherein the device (22) comprises at least one insulation applicator (25) for applying, in particular adhering, electrical insulators (11), in particular insulating tape.Device (22) according to one of the preceding claims, wherein the transverse connector applicator (23), the cover element applicator (24), the longitudinal connector applicator (25) and / or the insulation applicator (26) comprises a supply roller (27), an application element (28), in particular an application roller, and / or a pressure element (29), in particular a pressure roller, preferably located downstream of the application element (28) in the application direction. Device (22) according to one of the preceding claims, wherein the device (22) is configured for pressure monitoring of the transverse connector applicator (23), the cover element applicator (24), the longitudinal connector applicator (25) and / or the insulation applicator (26), preferably wherein the device (22) is configured for at least one transverse connector applicator (23), for at least one. Cover element applicator (24) , for at least one longitudinal connector applicator (25) and / or for at least one insulation applicator (26), preferably each, at least one pressure sensor (30) with which the pressure is applied to the solar cells (3) during the application of the transverse connectors (4,9). The pressure acting on the cover elements (13), insulators (11) and / or longitudinal connectors (10) can be monitored. / Summary

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