Method for manufacturing a deformable photovoltaic unit, method for manufacturing a deformable photovoltaic array, deformable photovoltaic unit, deformable photovoltaic array, and deformable photovoltaic module

Abstract

The invention relates to a method for manufacturing a deformable photovoltaic unit (10), the method comprising: providing a photovoltaic unit (10) comprising a carrier structure (12) with an electrically conductive contacting structure (14), and with a deformable first carrier layer (22), wherein the first carrier layer (22) is arranged at a first contacting portion (16) of the contacting structure (14), and at least one planar solar cell (26) having a first side (28) and an opposite second side (30), wherein the first side (28) of the at least one solar cell (26) is connected to the first carrier layer (22) in such a way that the first contacting portion (16) extends between the first carrier layer (22) and the at least one solar cell (26), and the second side (30) of the at least one solar cell (26) remains free; and applying a breaking force to the photovoltaic unit (10) such that the at least one solar cell (26) fractures into fragments (34), wherein the fragments (34) remain connected to the first carrier layer (22).

Description

[0001] Title: Method for producing a deformable photovoltaic unit, method for producing a deformable photovoltaic array, deformable photovoltaic unit, deformable photovoltaic array, deformable photovoltaic module

[0002] Description

[0003] The invention relates to a method for producing a deformable photovoltaic unit. Furthermore, the present invention relates to a method for producing a deformable photovoltaic array. Furthermore, the present invention relates to a deformable photovoltaic unit, a deformable photovoltaic array, and a deformable photovoltaic module.

[0004] Solar cells are typically rigid, flat structures. Photovoltaic units or photovoltaic modules with such typical solar cells are well suited for installation on flat surfaces, such as roofs or flat terrain. However, use on uneven surfaces or surfaces with changing shapes (e.g., water) is only possible to a limited extent due to the rigid nature of typical solar cells. Furthermore, the existing photovoltaic units are not suitable, or only partially suitable, for flexible applications.

[0005] In order to facilitate use on uneven surfaces, it is known to prepare solar cells in such a way that they can be shaped into a curved form. For example, AT 506 129 A1 describes a method in this regard in which a flat crystalline solar cell is first embedded between two deformable layers to create a laminate. The two layers enclose the solar cell so that a first of the layers is arranged on a first side of the solar cell and a second of the layers is arranged on a second side of the solar cell facing away from the first side. The laminate is then curved into a desired shape, breaking the solar cell into fragments which, however, remain electrically connected to one another. However, there is a desire to be able to not only shape photovoltaic units into a curved form, but also to design the photovoltaic units so that they can be flexibly and permanently deformed.In addition, there is a need for improvement regarding the mechanical robustness of such photovoltaic units.

[0006] The invention addresses the problem of providing a photovoltaic unit in a simple and scalable manner that is flexibly deformable and also mechanically robust.

[0007] This object is achieved according to the invention by a method having the features of claim 1, by a method having the features of claim 17, by a photovoltaic unit having the features of claim 19, by a photovoltaic array having the features of claim 23 and by a photovoltaic module having the features of claim 24.

[0008] The method according to the invention for producing a deformable photovoltaic unit comprises providing a photovoltaic unit that is initially rigid or non-deformable. The provided photovoltaic unit comprises a support structure and at least one planar solar cell. The support structure has an electrically conductive contacting structure and a deformable first support layer, in particular a support film. The first support layer is arranged on a first contacting section of the contacting structure. The at least one planar solar cell has a first side and an opposite second side. The first side of the at least one solar cell is connected to the first support layer in such a way that the first contacting section extends between the first support layer and the at least one solar cell, and that the second side of the at least one solar cell is free, i.e. in particular is not covered.Due to the presence of the flat solar cell, the photovoltaic unit is initially rigid or non-deformable.

[0009] The method according to the invention for producing a deformable photovoltaic unit further comprises applying a breaking force to the provided photovoltaic unit, i.e., the non-deformable or rigid photovoltaic unit, acting on the at least one solar cell such that the at least one solar cell is broken into fragments. The breaking of the solar cell into fragments occurs such that the fragments remain bonded to the first carrier layer, in particular by a material bond. Applying the breaking force to the provided photovoltaic unit can comprise bending the photovoltaic unit about an axis of the solar cell. By breaking the solar cell into fragments, a deformable, in particular flexibly bendable, photovoltaic unit is obtained.Because the second side of the solar cell is exposed, i.e., uncovered, during the breaking process, the process can be carried out with particularly gentle material handling, as overstretching of the carrier layer can be avoided. When breaking two opposing carrier layers, small bending radii, which are advantageous for subsequent flexibility, can lead to cracks forming in at least one of the layers, which can negatively impact the durability of the photovoltaic unit. A deformable photovoltaic unit manufactured according to the process according to the invention is particularly robust and durable.

[0010] Surprisingly, it has been shown that the bond between the first side of the solar cell and the first carrier layer is sufficient to hold the solar cell fragments to the first carrier layer during and after breakage. As explained in detail below, the proposed method also makes it particularly easy to connect photovoltaic units produced in this way to form a string, thus obtaining photovoltaic arrays with a plurality of photovoltaic units.

[0011] Preferably, the effective direction of the breaking force runs from the first side of the solar cell towards the free second side of the solar cell.

[0012] The contacting structure is preferably formed by a plurality of electrically conductive metal wires. The metal wires preferably run parallel to one another. However, the contacting structure can also be formed by a mesh of metal wires. The contacting structure can be self-supporting. This means that the contacting structure can be handled as such independently of the first carrier layer. However, the carrier structure can also be formed from metal wires that can be handled independently of one another and are held together by the first carrier layer. The first carrier layer is preferably a polymeric carrier layer. This means that the first carrier layer is made of a polymeric material. The first carrier layer and the first contacting section are preferably bonded to one another, particularly preferably by thermal lamination.

[0013] The first side and the second side of the solar cell lie opposite one another and thus face away from one another. The first side of the solar cell is preferably a front side of the solar cell. The opposite second side is preferably a back side of the solar cell. By arranging the solar cell on the first carrier layer, the solar cell, in particular the first side, is electrically connected to the first contacting section extending between the first carrier layer and the solar cell. The first carrier layer and the first side of the solar cell are preferably bonded to one another, particularly preferably by thermal lamination. The first contacting section is enclosed between the first carrier layer and the solar cell. The second side of the solar cell is free or not covered. There is therefore no deformable carrier layer or other deformable layer on the second side.

[0014] The provided photovoltaic unit may comprise a single planar solar cell, i.e., only one planar solar cell. Alternatively, the provided photovoltaic unit may also comprise several planar solar cells, in particular those that are electrically connected to one another.

[0015] The sides of the fragments connected to the carrier layer are referred to below as the first sides of the fragments. The opposite free sides of the fragments are referred to as the second sides.

[0016] The provision of the initially rigid or non-deformable photovoltaic unit, i.e. method step a., comprises in particular the material-to-material connection of the first carrier layer to the first contacting section by lamination and / or the material-to-material connection of the first carrier layer to the at least one solar cell by lamination. It is preferred if the first carrier layer, the first contacting section and the at least one solar cell are material-to-material connected to one another in a common lamination process. Such a procedure is particularly time-efficient. Alternatively, however, it is also possible for the first carrier layer to be material-to-material connected to the first contacting section in a first lamination process and for the first carrier layer to be material-to-material connected to the solar cell in a subsequent second lamination process.Carrying out two consecutive lamination processes offers the advantage of facilitating the desired positioning of the elements involved.

[0017] The photovoltaic unit is preferably subjected to the breaking force in such a way that the fragments or at least a large part of the fragments after the solar cell has broken are

[0018] The contact structure remains electrically connected. The solar cell is broken in such a way that no electrically isolated and therefore inactive fragments are created, which could impair the efficiency of the photovoltaic unit or photovoltaic module.

[0019] In an advantageous embodiment, the photovoltaic unit is conveyed along a breaking structure to break the solar cell, in particular such that the breaking structure applies the breaking force to the photovoltaic unit. This procedure enables a time-efficient integration of the breaking of the solar cell into the production process. If, for example, the solar cells of several photovoltaic units are to be broken one after the other, a continuous production process can be achieved by conveying them along the breaking structure. Preferably, the several photovoltaic units are continuously conveyed along the breaking structure by a conveyor device, with the breaking structure applying the breaking force to each photovoltaic unit.

[0020] The crushing structure is preferably elongated, with the longitudinal center axis of the crushing structure oriented perpendicular to a conveying direction along which the photovoltaic unit is conveyed along the crushing structure. The crushing structure can be a stationary crushing structure. For example, the crushing structure is a stationary crushing edge. However, the crushing structure can also be rotatably mounted. For example, the crushing structure can also be a rotatably mounted crushing roller.

[0021] In particular, conveying the photovoltaic unit along the crushing structure may comprise bending the photovoltaic unit around the crushing structure.

[0022] In some preferred embodiments, it is provided that the photovoltaic unit is conveyed multiple times along the same breaking structure, wherein the photovoltaic unit is rotated in a second breaking process relative to a previously performed first breaking process with respect to a conveying direction. Carrying out multiple breaking processes makes it possible to break the solar cell in a mosaic-like manner. This promotes later deformability of the photovoltaic unit after breaking. If the photovoltaic unit is conveyed along the breaking structure in the first breaking process, the solar cell is broken into fragments, wherein the course of the breaking edges of the fragments is determined, for example, by the orientation of the photovoltaic unit and by the orientation of the breaking structure.If the photovoltaic unit is rotated relative to the conveying direction in the subsequent second crushing process compared to the first crushing process, the fracture edges generated in the second crushing process are aligned at an angle to the fracture edges generated in the first crushing process. Preferably, the photovoltaic unit is in the second

[0023] Crushing process rotated by an angle of 90° compared to the first crushing process.

[0024] In some preferred embodiments, it is provided that the photovoltaic unit is conveyed along a first crushing structure in a first crushing process, that the photovoltaic unit is conveyed along a second crushing structure in a second crushing process, and that the photovoltaic unit is rotated in the second crushing process relative to the first crushing process with respect to a conveying direction. This procedure also allows the solar cell to be crushed in a mosaic manner, as explained above. The use of two different crushing structures, i.e. the first crushing structure and the second crushing structure, has the advantage that a particularly continuous production process can be achieved. The photovoltaic unit does not have to be fed to the same crushing structure multiple times. Preferably, the photovoltaic unit is rotated by an angle of 90° in the second crushing process relative to the first crushing process.

[0025] In some preferred embodiments, weakening lines are formed in the solar cell to create predetermined breaking points for the solar cell to break. By creating weakening lines, a controlled breaking of the solar cell into fragments can be achieved. The fracture edges run essentially along the weakening lines. The weakening lines are preferably created on the second side of the solar cell.

[0026] Preferably, the weakening lines are created by scribing the solar cell with a laser. A laser enables the precise creation of weakening lines in the solar cell. Furthermore, the laser creates the weakening lines without contact, so the solar cell does not need to be fixed or otherwise secured for the formation of the weakening lines. Alternatively, the weakening lines can also be created mechanically, for example, by scribing with one or more needles, by grinding, or by milling.

[0027] In some preferred embodiments, it is preferably provided that the provision of the photovoltaic unit comprises the materially bonding of the first carrier layer to the first side of the solar cell, and that the lines of weakness are formed subsequent to the materially bonding of the first carrier layer to the first side of the solar cell. Because the second side of the solar cell is free, the lines of weakness can still be formed in the solar cell even after bonding to the first carrier layer, namely on the second side. The formation of the lines of weakness subsequent to the bonding to the first carrier layer has the advantage that the positioning and course of the lines of weakness can be adapted to the actual arrangement of the solar cell, in particular to the actual arrangement of the solar cell relative to the metal wires of the contacting structure.This ensures that fragments that are electrically insulated from the contact structure are avoided when the solar cell breaks.

[0028] In some preferred embodiments, the solar cell is broken into fragments in such a way that adjacent fragments are separated from each other by a gap. Adjacent fragments can thus be spaced apart from each other by a gap.

[0029] According to an advantageous development, after applying the breaking force to the photovoltaic unit, a filler material can be introduced into at least a portion of the gap, preferably into all gaps. In this respect, a filler material can be introduced at least between some fragments. The filler material can be introduced such that the gap is only partially filled. The filler material can be introduced such that the gap is completely filled. The filler material can be introduced such that the filler material overflows.

[0030] The filler material is preferably an electrically insulating material. This reduces the risk of electrical short circuits. For example, when solar cells break, splinters or other contaminants may remain in the gaps, leading to unwanted electrical connections between the opposite polarity (first and second sides) of the fragments. The filler material can neutralize such splinters or residues, which has a positive effect on the product's electrical performance. Furthermore, this process can reduce scrap and thus increase productivity.

[0031] The filler material can be designed in different ways. In some preferred embodiments, the filler material can be a curable material that, starting from a low-viscosity initial configuration, can be converted into a higher-viscosity final configuration by curing. Introducing the filler material into the gap can then, in particular, comprise applying the filler material in the low-viscosity configuration and subsequent curing. Curing can, for example, comprise applying heat, IR radiation, and / or UV radiation. Curing can also comprise aging for a predetermined aging time. Preferably, the filler material is electrically insulating, at least in the final configuration. Such a method has proven particularly effective in addressing the problems described above.It has been found that by applying the filling material in the low-viscosity initial configuration, any splinters or contaminants can be effectively flushed out of the gaps and - should any residues remain in the gaps afterwards - these can be embedded in an electrically insulating matrix after curing and thus rendered harmless.

[0032] In particular, the filler material in the initial configuration can be a two-component material. For example, the filler material can be a two-component polyurethane adhesive. The filler material can also be a light-curing adhesive.

[0033] The filling material can also be provided in the form of an ink or a paste.

[0034] The filling material can be applied in a variety of ways. For example, it can be applied using a spraying process, pyrolysis, or inkjet printing.

[0035] It is particularly advantageous if the filler material is selectively introduced into a respective gap. In particular, the filler material can be introduced into a gap using a dosing device designed to selectively introduce the filler material into the gap. Such a method is material-efficient and also reduces the risk of active surfaces of the solar cell becoming contaminated by filler material.

[0036] In a preferred embodiment, the dosing device can have a fluid guide device and a fluid conveying device. The fluid guide device, in particular, has or consists of a capillary. The capillary is preferably dimensioned such that an outer diameter of the capillary in a discharge region of the capillary is equal to or less than an opening width of a gap. Such a method has proven to be particularly resource-efficient and promotes rapid and targeted application of the filler material into the gap. In an advantageous further development, the dosing device can have a positioning device designed to drive a relative movement of the substrate (photovoltaic unit) and the fluid guide device, in particular the capillary. In particular, the positioning device can be configured to guide the capillary along the fracture edges.

[0037] In an advantageous further development, the method can include cleaning the fracture edges or gaps after breaking the solar cell, i.e., after applying the breaking force to the solar cell, and before inserting the filler material. Cleaning can be performed, for example, using compressed air. Alternatively or additionally, cleaning can include CO2 snow jet cleaning. In this way, the aforementioned risk of electrical short circuits can be further reduced and the adhesive strength of the filler material can be increased.

[0038] In some preferred embodiments, a deformable, in particular polymeric, cover layer, in particular a cover film, is arranged on the second sides of the fragments of the solar cell and is materially bonded to the fragments. The fragments are then arranged between the first carrier layer and the cover layer. The first carrier layer and the cover layer together enclose the fragments and hold the fragments securely together. This facilitates handling of the photovoltaic unit, so that the photovoltaic unit can be used as part of a photovoltaic module or as a stand-alone photovoltaic unit. Preferably, the cover layer is bonded to the second sides of the fragments by lamination. The cover film is arranged in particular after the optional introduction of the filler material.

[0039] Within the scope of a preferred development, the contacting structure can have a second contacting section that projects laterally beyond the at least one solar cell. In particular, a deformable, in particular polymeric, second carrier layer, in particular a second carrier film, can then be arranged on the second contacting section. The second carrier layer is preferably arranged next to the solar cell, i.e., on the same side of the contacting structure as the solar cell. The second carrier layer can be arranged on the contacting structure before the solar cell is broken. Preferably, the second carrier layer is integrally bonded to the second contacting section by lamination. A joint lamination process can be carried out in which the first carrier layer is integrally bonded to the first contacting section of the solar cell, and the second carrier layer is integrally bonded to the second contacting section.

[0040] An embodiment of the method described above, in which photovoltaic units with a laterally projecting second contacting section are obtained, makes it possible to connect several of these photovoltaic units in a simple and efficient manner to form a deformable photovoltaic row, in particular in the form of a string.

[0041] The invention also relates to such a method for producing a deformable photovoltaic array having a plurality of deformable photovoltaic units. The method comprises: i. producing a plurality of deformable photovoltaic units by the method according to the invention for producing a deformable photovoltaic unit, wherein the contacting structure of a respective photovoltaic unit has a second contacting section that projects laterally beyond the at least one solar cell and on which a deformable, in particular polymeric, second carrier layer is arranged, and ii. electrically connecting the fragments of a first photovoltaic unit of the photovoltaic units to the second contacting section of a second photovoltaic unit of the photovoltaic units.

[0042] This results in a series connection of the fragments of the first photovoltaic unit with the fragments of the second photovoltaic unit. In particular, a string-like photovoltaic array can be obtained from a plurality of photovoltaic units.

[0043] Preferably, in step ii., the second sides of the fragments of the first photovoltaic unit are connected, in particular materially, to the second carrier layer of the second photovoltaic unit in such a way that the second contacting section of the second photovoltaic unit extends between the second carrier layer of the second photovoltaic unit and the fragments of the first photovoltaic unit. The second carrier layer of the second photovoltaic unit thus forms a cover layer for the second sides of the fragments of the first photovoltaic unit. The electrical connection of the fragments of the first photovoltaic unit to the second contacting section of the second photovoltaic unit and the connection of the fragments of the first photovoltaic unit to the second carrier layer of the second photovoltaic unit therefore take place in a common connecting process, in particular in a common lamination process.This enables time-efficient production of the deformable photovoltaic array.

[0044] According to a further aspect, a method for producing a deformable photovoltaic array having a plurality of deformable photovoltaic units is proposed, comprising: i. producing a plurality of deformable photovoltaic units (10), each comprising:

[0045] - Providing a photovoltaic unit (10) comprising

[0046] 1. a carrier structure (12) with an electrically conductive contacting structure (14) and with a deformable, in particular polymeric, first carrier layer (22), in particular a first carrier film, wherein the first carrier layer (22) is arranged on a first contacting section (16) of the contacting structure (14), and

[0047] 2. at least one planar solar cell (26) having a first side (28) and an opposite second side (30), wherein the first side (28) of the at least one solar cell (26) is connected to the first carrier layer (22) in such a way, in particular by a material fit, that the first contacting section (16) extends between the first carrier layer (22) and the at least one solar cell (26) and that the second side (30) of the at least one solar cell (26) is free, wherein the contacting structure has a second contacting section that projects laterally beyond the at least one solar cell, ii. applying a breaking force to the photovoltaic unit (10) in such a way that the at least one solar cell (26) is broken into fragments (34), wherein the fragments (34) remain connected to the first carrier layer (22), in particular by a material fit. iii.Electrically connecting the fragments (34) of a first photovoltaic unit (10a) of the photovoltaic units (10) to the second contacting section (18) of a second photovoltaic unit (10b) of the photovoltaic units (10).

[0048] In the further aspect, a deformable, in particular polymeric, second carrier layer is preferably arranged on the second contacting section. Preferably, in step iii, the second sides of the fragments of the first photovoltaic unit are then connected, in particular by a material bond, to the second carrier layer of the second photovoltaic unit in such a way that the second contacting section of the second photovoltaic unit extends between the second carrier layer of the second photovoltaic unit and the fragments of the first photovoltaic unit.

[0049] The optional features and advantages mentioned above in connection with the method for producing a deformable photovoltaic unit can also be used to design the method according to the further aspect.

[0050] The deformable photovoltaic unit according to the invention comprises a support structure with an electrically conductive contact structure and with a deformable, in particular polymeric, first support layer, in particular a first support film, wherein the first support layer is arranged on a first contact section of the contact structure. The contact structure can be formed by a plurality of metal wires, in particular running parallel.

[0051] The deformable photovoltaic unit according to the invention further comprises fragments of at least one planar solar cell, wherein the fragments each have a first side and an opposite second side, wherein the first sides of the fragments are connected to the first carrier layer, in particular by a material bond, wherein the first contacting section extends between the fragments and the first carrier layer, and wherein the second sides of the fragments are free, i.e. not covered.

[0052] With regard to the advantages achievable with the deformable photovoltaic unit, reference is made to the relevant explanations regarding the method for producing deformable photovoltaic units. The features described in connection with the method for producing deformable photovoltaic units can be used to further develop the deformable photovoltaic unit.

[0053] In some preferred embodiments of the deformable photovoltaic unit, it is provided that the contacting structure has a second contacting section that projects laterally beyond the fragments, wherein a deformable, in particular polymeric, second carrier layer, in particular a second carrier film, is arranged on the second contacting section. The second carrier layer is preferably arranged on the same side of the contacting structure as the fragments of the at least one solar cell. Such a design of the deformable photovoltaic unit facilitates the combination of several similar photovoltaic units to form a string-shaped photovoltaic array. Preferably, the first contacting section is formed by first longitudinal sections of the parallel metal wires and the second contacting section by second longitudinal sections of the parallel metal wires.

[0054] The invention also relates to a deformable photovoltaic array. The photovoltaic array comprises at least two deformable photovoltaic units according to the invention, wherein the contacting structure of the photovoltaic units has a second contacting section that protrudes laterally beyond the fragments, and wherein a deformable, in particular polymeric, second carrier layer, in particular a second carrier film, is arranged on the second contacting section. The fragments of a first photovoltaic unit of the photovoltaic units are electrically connected to the second contacting section of a second photovoltaic unit of the photovoltaic units.

[0055] Preferably, the second sides of the fragments of the first photovoltaic unit are connected, in particular by a material bond, to the second carrier layer of the second photovoltaic unit such that the second contacting section of the second photovoltaic unit extends between the second carrier layer of the second photovoltaic unit and the fragments of the first photovoltaic unit. The second carrier layer of the second photovoltaic unit thus forms a covering layer for the second sides of the fragments of the first photovoltaic unit. The second sides of the fragments of the first photovoltaic unit are therefore no longer exposed in the photovoltaic array, but are covered by the second carrier layer.

[0056] According to yet another aspect, there is proposed a deformable photovoltaic array comprising:

[0057] - at least two deformable photovoltaic units, each comprising:

[0058] - a carrier structure with an electrically conductive contacting structure (14), and with a deformable, in particular polymeric, first carrier layer (22), in particular a first carrier film, wherein the first carrier layer (22) is arranged on a first contacting section (16) of the contacting structure (14), and

[0059] - fragments (34) of at least one planar solar cell (26), wherein the fragments (34) each have a first side (52) and an opposite second side (54), wherein the first sides (52) of the fragments (34) are connected to the first carrier layer (22), in particular by a material bond, wherein the first contacting section (16) extends between the fragments (34) and the first carrier layer (22), and wherein the second sides (54) of the fragments (34) are free, wherein the contacting structure (14) has a second contacting section (18) which projects laterally beyond the fragments (34), and wherein a deformable, in particular polymeric, second carrier layer (24), in particular a second carrier film, is arranged on the second contacting section (18),

[0060] - wherein the fragments (34) of a first photovoltaic unit (10a) of the photovoltaic units (10) are electrically connected to the second contacting section (18) of a second photovoltaic unit (10b) of the photovoltaic units (10).

[0061] The invention also relates to a deformable photovoltaic module. The photovoltaic module comprises at least two deformable photovoltaic rows according to the invention, which are arranged next to one another. The photovoltaic rows are electrically connected to one another by at least one common connection device, in particular a busbar. By arranging two or more photovoltaic rows next to one another, a flat photovoltaic module of a desired size can be realized. The number of photovoltaic rows and the number of photovoltaic units in the rows allow the photovoltaic module to be scaled virtually as desired. The photovoltaic module is deformable and can therefore be formed into a shape that requires little space, which facilitates transport of the photovoltaic module. For example, the photovoltaic module can be rolled up into a roll.

[0062] The invention is described in more detail below with reference to the figures.

[0063] Figure 1 is a side view of individual parts of a photovoltaic unit prior to assembly; Figure 2 is a side view of a photovoltaic unit comprising the individual parts shown in Figure 1;

[0064] Figure 3 is a plan view of the photovoltaic unit shown in Figure 2;

[0065] Figure 4 is a plan view of the photovoltaic unit after the formation of weakening lines in a solar cell of the photovoltaic unit;

[0066] Figure 5 shows a breaking device for breaking the solar cell of the photovoltaic unit into fragments;

[0067] Figure 6 is a side view of the photovoltaic unit after breaking the solar cell into fragments;

[0068] Figure 7 is a plan view of the photovoltaic unit shown in Figure 6;

[0069] Figure 8 shows a photovoltaic array with several photovoltaic units;

[0070] Figure 9 shows a photovoltaic module with several photovoltaic rows;

[0071] Figure 10 is a schematic diagram illustrating a method for introducing filling material; and

[0072] Figure 11 further schematic representation to explain a method for introducing filling material.

[0073] In the following description and in the figures, the same reference symbols are used for identical or corresponding features.

[0074] Figures 1 to 7 show various aspects of a method for producing a deformable photovoltaic unit 10.

[0075] With reference to Figures 1 to 3, the method provides that a photovoltaic unit 10 is first provided, which is still rigid or non-deformable at this point in time.

[0076] The photovoltaic unit 10 comprises a support structure 12. The support structure 12 comprises an electrically conductive contact structure 14 with a first contact section 16 and a second contact section 18. The contact structure 14 is formed in this case by a plurality of parallel metal wires 20, as can be seen in Figure 3. The first contact section 16 and the second contact section 18 are arranged one behind the other with respect to the longitudinal extent of the metal wires 20. The metal wires 20 thus extend through the first contact section 16 and the second contact section 18.

[0077] As an alternative to the parallel metal wires 20, the contacting structure 14 can also comprise a mesh of metal wires.

[0078] The carrier structure 12 also comprises a deformable first carrier layer 22. The first carrier layer 22 is arranged on the first contacting section 16 and is integrally connected to the first contacting section 16. Preferably, the first carrier layer 22 is a polymeric carrier layer 22. Preferably, the first carrier layer 22 is film-shaped, i.e., as a carrier film.

[0079] In the illustrated embodiment, the carrier structure 12 additionally comprises a deformable second carrier layer 24. The second carrier layer 24 is arranged on the second contacting section 18. As can be seen in the figures, the first carrier layer 22 and the second carrier layer 24 are arranged on a respective opposite side of the contacting structure 14. With reference to the arrangement shown in the figures, the first carrier layer 22 is arranged on the underside of the contacting structure 14. The second carrier layer 24 is arranged on the top side of the contacting structure 14. Preferably, the second carrier layer 24 is a polymeric carrier layer 24. Preferably, the second carrier layer 24 is in the form of a film, i.e., as a carrier film.

[0080] The photovoltaic unit 10 also comprises at least one planar solar cell 26, in this case precisely one planar solar cell 26. The solar cell 26 is rigid or non-deformable. This property of the solar cell 26 means that the photovoltaic unit 10 itself is also rigid or non-deformable. The solar cell 26 has a first side 28 and an opposite second side 30.

[0081] The first side 28 of the solar cell 26 is connected to the first carrier layer 22 in such a way that the first contacting section 16 extends between the first carrier layer 22 and the solar cell 26. The metal wires 20 of the contacting structure 14 are thus in contact with the first side 28 of the solar cell 26 in the region of the first contacting section 16, so that the metal wires 20 are electrically connected to the first side 28 of the solar cell 26. The second carrier layer 24 is arranged on the same side of the contacting structure 14 as the solar cell 26, i.e., next to the solar cell 26. The second side 30 of the solar cell 26 is free or unoccupied. Thus, there is no carrier layer or the like on the second side 30 of the solar cell 26.

[0082] The provision of the photovoltaic unit 10 shown in Figures 2 and 3 preferably includes the material-to-material connection of the individual parts shown in Figure 1 by lamination. Particularly preferably, the individual parts shown in Figure 1, i.e., the first carrier layer 22, the second carrier layer 24, the contacting structure 14, and the solar cell 26, are material-to-material connection in a single lamination process. However, the individual parts can also be material-to-material connection in successive lamination processes. For example, in a first lamination process, the first carrier layer 22 and the second carrier layer 24 are each material-to-material connection to the contacting structure 14. In a subsequent second lamination process, the first carrier layer 22 and the solar cell 26 are material-to-material connection.

[0083] With reference to Figure 4, weakening lines 32 are then formed in the solar cell 26 to create predetermined breaking points 33 for subsequent breaking of the solar cell 26. In the present case, the weakening lines 32 are formed in the free second side 30 of the solar cell 26. Preferably, the weakening lines 32 are formed in the solar cell 26 by scribing with a laser. Alternatively, the weakening lines 32 can also be formed mechanically in the second side 30, for example by scribing with a needle. It is also possible to form the weakening lines 32 in the solar cell 26 before the first carrier layer 22 is connected to the solar cell 26.

[0084] In the illustrated embodiment, a plurality of first weakening lines 32a are formed in the solar cell 26, running perpendicular to the metal wires 20. Furthermore, a plurality of second weakening lines 32b are formed in the solar cell 26, running parallel to the metal wires 20. This makes it possible to fracture the solar cell 26 in a mosaic-like manner, as explained in more detail below. The weakening lines 32a and 32b form a checkerboard pattern on the second side 30 of the solar cell 26.

[0085] Figure 5 shows a breaking device 36 for breaking the solar cell 26 into fragments 34. The

[0086] Crushing device 36 comprises a conveyor device 38. In the present case, the conveyor device 38 comprises a first belt conveyor 40 with a first conveyor belt 42 and a second belt conveyor 44 with a second conveyor belt 46 opposite the first belt conveyor 40. The photovoltaic unit 10 can be arranged between the first conveyor belt 42 and the second conveyor belt 46 and can be conveyed by the belt conveyors 40 and 44 in a conveying direction 48.

[0087] The crushing device 36 also comprises a preferably stationary crushing structure 50. The crushing structure 50 is elongated and extends perpendicular to the conveying direction 48 or perpendicular to the image plane of Figure 5. The crushing structure 50 is arranged such that the conveying direction 48 behind the crushing structure 50 is angled relative to the conveying direction 48 in front of the crushing structure 50.

[0088] If the photovoltaic unit 10 is conveyed by the conveyor device 38 along the breaking structure 50, the angled course of the conveying direction 48 causes the photovoltaic unit 10 to be pressed against the breaking structure 50. As a result, the breaking structure 50 applies a breaking force to the photovoltaic unit 10, in particular the solar cell 26, such that the solar cell 26 is broken into fragments 34 along at least some of the weakening lines 32. The fragments 34 remain connected to the first carrier layer 22.

[0089] Preferably, the photovoltaic unit 10 is arranged during the breaking process such that, as the photovoltaic unit 10 is conveyed along the breaking structure 50, the first side 28 of the solar cell 26 faces the breaking structure 50. This results in the first carrier layer 22 being bent away from the solar cell 26 when the solar cell 26 is broken. Accordingly, undesirable stretching of the first carrier layer 22 is avoided.

[0090] Depending on the orientation of the weakening lines 32, the solar cell 26 will not be broken along all weakening lines 32 in one breaking process. For example, if the first weakening lines 32a and the second weakening lines 32b are present, the solar cell 26 will be broken only along the weakening lines 32 that are oriented perpendicularly or substantially perpendicularly to the conveying direction 48.

[0091] In order to protect the solar cell 26 both along the first weakening lines 32a and along the second

[0092] In order to break the weakening lines 32b, a first breaking process and a second breaking process are preferably carried out one after the other, wherein the solar cell 26 is rotated in the second breaking process relative to the conveying direction 48, preferably by 90°.

[0093] The two crushing processes can be carried out using the same crushing structure 50. In this case, the solar cell 26 or the photovoltaic unit 10 is conveyed multiple times along the same crushing structure 50.

[0094] However, the two crushing processes can also be performed using a different crushing structure. In this case, the solar cell 26 or the photovoltaic unit 10 is conveyed along a first crushing structure in the first crushing process and along a second crushing structure in the second crushing process. This has the advantage that the photovoltaic unit 10 does not have to be fed to the same crushing device multiple times. This allows the production process to be optimized.

[0095] Figures 6 and 7 show the photovoltaic unit 10 following the breaking of the solar cell 26 into fragments 34. The fragments 34 each have a first side 52 and an opposite second side 54. As can be seen, the first sides 52 of the fragments 34 are connected to the first carrier layer 22. Each of the fragments 34 is also electrically connected to the contacting structure 14. The second sides 54 of the fragments 34 are exposed after breaking.

[0096] By breaking the solar cell 26 into fragments 34, the photovoltaic unit 10 becomes deformable in the area of ​​the solar cell 26. Thus, a deformable photovoltaic unit 10 is obtained.

[0097] Several such deformable photovoltaic units 10 can be combined to form a photovoltaic array 58. Figure 8 shows, by way of example, such a photovoltaic array 58, which has a first deformable photovoltaic unit 10a and a second deformable photovoltaic unit 10b.

[0098] To produce the photovoltaic array 58, the second carrier layer 24 of the second photovoltaic unit 10b is arranged on the free second sides 54 of the fragments 34 of the first photovoltaic unit 10a. Such an arrangement of the photovoltaic units 10a and 10b is also referred to as a shingled arrangement. The second carrier layer 24 of the second photovoltaic unit 10b is then connected to the fragments 34 of the first photovoltaic unit 10a such that the second contacting section 18 of the second photovoltaic unit 10b extends between the second carrier layer 24 of the second photovoltaic unit 10b and the fragments 34 of the first photovoltaic unit 10a.

[0099] The fragments 34 of the first photovoltaic unit 10 are thereby electrically connected to the contact structure 14 of the second photovoltaic unit 10b. The fragments 34 of the first photovoltaic unit 10a are then connected in series with the fragments 34 of the second photovoltaic unit 10b, thus forming a string-shaped photovoltaic array 58.

[0100] In the photovoltaic array 58 shown in Figure 8, only two photovoltaic units 10 are present. However, the photovoltaic array 58 can also have a larger number of photovoltaic units 10 connected in series. In the photovoltaic array 58 shown in Figure 8, the second carrier layer 24 of the first photovoltaic unit 10a is nonfunctional. The second carrier layer 24 can therefore also be removed in the finished photovoltaic array 58, in particular together with the second contacting section 18 arranged thereon.

[0101] Figure 9 shows a deformable photovoltaic module 60 having a plurality of deformable photovoltaic rows 58 arranged side by side.

[0102] The photovoltaic module 60 has an electrically conductive first connection device 62 that is electrically connected to the photovoltaic rows 58. Preferably, the first connection device 62 is a busbar. The first connection device 62 is arranged at a first end portion of the photovoltaic rows 58 and extends perpendicular to the longitudinal extent of the photovoltaic rows 58 along the photovoltaic rows 58.

[0103] The photovoltaic module 60 also includes an electrically conductive second connection device 64 that is electrically connected to the photovoltaic rows 58. Preferably, the second connection device 64 is a busbar. The second connection device 64 is arranged at a second end portion of the photovoltaic rows 58 and extends perpendicular to the longitudinal extent of the photovoltaic rows 58 along the photovoltaic rows 58. As mentioned above, the solar cells 26 are preferably fractured such that adjacent fragments are spaced apart from one another by a gap 66 (see Fig. 7 and Fig. 10).

[0104] Within the scope of an advantageous development of the method, a filling material 68 can be introduced into at least a portion, in particular into all, of these gaps 66.

[0105] Figures 10 and 11 show an exemplary method for introducing such a film material 68 into the gap 66. In the specific example, the filling material 68 is introduced by means of a dosing device 70 which is designed to selectively introduce the filling material 68 into the gap 66.

[0106] By way of example and preferably, the dosing device 70 comprises a capillary 72. The capillary 72 serves as a dispenser. As shown by way of example in Figures 10 and 11, the capillary 72 is preferably designed such that an outer diameter of the capillary 72 is smaller than an opening width 76 of the gap 66, at least in a downstream discharge region 74 of the capillary 72.

Claims

Patent claims 1. A method for producing a deformable photovoltaic unit (10), comprising: - Providing a photovoltaic unit (10) comprising a carrier structure (12) with an electrically conductive contacting structure (14) and with a deformable, in particular polymeric, first carrier layer (22), in particular a first carrier film, wherein the first carrier layer (22) is arranged on a first contacting section (16) of the contacting structure (14), and at least one planar solar cell (26) with a first side (28) and an opposite second side (30), wherein the first side (28) of the at least one solar cell (26) is connected to the first carrier layer (22), in particular by a material bond, in such a way that the first contacting section (16) extends between the first carrier layer (22) and the at least one solar cell (26) and that the second side (30) of the at least one solar cell (26) is free, - applying a breaking force to the photovoltaic unit (10) such that the at least one solar cell (26) is broken into fragments (34), wherein the fragments (34) remain connected to the first carrier layer (22), in particular in a materially bonded manner.

2. The method according to claim 1, wherein the photovoltaic unit (10) is subjected to the breaking force in such a way that the fragments (34) remain electrically connected to the contacting structure (14) after the solar cell (26) has broken.

3. Method according to claim 1 or 2, wherein the photovoltaic unit (10) for breaking the solar cell (26) is conveyed along a, in particular stationary, breaking structure (50), in particular a breaking edge or breaking roller, in such a way that the breaking structure (50) applies the breaking force to the photovoltaic unit (10), in particular the solar cell (26).

4. Method according to the preceding claim, wherein the photovoltaic unit (10) is conveyed several times along the same crushing structure (50), wherein the photovoltaic unit (10) is rotated in a second crushing process relative to a previously carried out first crushing process with respect to a conveying direction (48), in particular by an angle of 90°.

5. The method according to claim 3, wherein the photovoltaic unit (10) is conveyed along a first crushing structure in a first crushing process, wherein the photovoltaic unit (10) is conveyed along a second crushing structure in a second crushing process, and wherein the photovoltaic unit (10) is rotated in the second crushing process with respect to a conveying direction (48) relative to the first crushing process, in particular by an angle of 90°.

6. Method according to one of the preceding claims, wherein lines of weakness (32) are formed in the solar cell (26) in order to produce predetermined breaking points (33) for breaking the solar cell (26).

7. Method according to the preceding claim, wherein the weakening lines (32) are formed by scribing the solar cell (26) with a laser.

8. The method according to one of claims 6 or 7, wherein the provision of the photovoltaic unit (10) comprises the material-to-material connection of the first carrier layer (22) to the first side (28) of the solar cell (26), and wherein the lines of weakness (32) are formed subsequent to the material-to-material connection of the first carrier layer (22) to the first side (28) of the solar cell (26).

9. Method according to one of the preceding claims, wherein adjacent fragments (34) are separated from one another by a gap (66), wherein a filling material (68) is introduced into at least a portion of the gap (66).

10. The method according to the preceding claim, wherein the filling material (68) is an electrically insulating material.

11. The method according to claim 9 or 10, wherein the filler material (68) is a curable material which, starting from a low-viscosity initial configuration, can be converted into a higher-viscosity configuration by curing, wherein the introduction of the filler material into the gap comprises applying the filler material in the low-viscosity initial configuration and subsequently curing to obtain the final configuration.

12. The method according to any one of claims 9 to 11, wherein the filling material (68) is introduced into a gap (66) by means of a dosing device (70) which is designed to selectively introduce the filling material (68) into the gap (66).

13. Method according to the preceding claim, wherein the dosing device (70) has a capillary (72) whose outer diameter is smaller than an opening width (76) of the gap (66) at least in a discharge region (74) of the capillary (72).

14. Method according to one of claims 9 to 13, wherein before the introduction of the filling material (68) the gap (66) is cleaned, in particular by means of compressed air and / or CC snow.

15. Method according to one of the preceding claims, wherein a deformable, in particular polymeric, cover layer, in particular cover film, is arranged on the second sides (54) of the fragments (34) of the solar cell (26) facing away from the first carrier layer (22) and is connected to the fragments (34), in particular by a material bond.

16. The method according to any one of the preceding claims, wherein the contacting structure (14) has a second contacting section (18) which projects laterally beyond the at least one solar cell (26), and wherein a deformable, in particular polymeric, second carrier layer (24), in particular a second carrier film, is or will be arranged on the second contacting section (18).

17. A method for producing a deformable photovoltaic array (58) having a plurality of deformable photovoltaic units (10), comprising: i. producing a plurality of deformable photovoltaic units (10) by a method according to claim 16, and ii. electrically connecting the fragments (34) of a first photovoltaic unit (10a) of the photovoltaic units (10) to the second contacting section (18) of a second photovoltaic unit (10b) of the photovoltaic units (10).

18. The method according to claim 17, wherein in step ii. the second sides (54) of the fragments (34) of the first photovoltaic unit (10a) are connected to the second carrier layer (24) of the second photovoltaic unit (10b) in such a way, in particular by a material bond, that the second contacting section (18) of the second photovoltaic unit (10b) extends between the second carrier layer (24) of the second photovoltaic unit (10b) and the fragments (34) of the first photovoltaic unit (10a).

19. A deformable photovoltaic unit (10), in particular produced by a method according to one of claims 1 to 16, comprising a carrier structure (12) with an electrically conductive contacting structure (14), and with a deformable, in particular polymeric, first carrier layer (22), in particular a first carrier film, wherein the first carrier layer (22) is arranged on a first contacting section (16) of the contacting structure (14), and fragments (34) of at least one planar solar cell (26), wherein the fragments (34) each have a first side (52) and an opposite second side (54), wherein the first sides (52) of the fragments (34) are connected to the first carrier layer (22), in particular by a material fit, wherein the first contacting section (16) extends between the fragments (34) and the first carrier layer (22), and wherein the second sides (54) of the fragments (34) are free.

20. Deformable photovoltaic unit (10) according to the preceding claim, wherein adjacent fragments (34) are separated from one another by a gap (66), wherein a filling material (68) is introduced into at least a portion of the gap (66).

21. A deformable photovoltaic unit (10) according to the preceding claim, wherein the filler material (68) is an electrically insulating material.

22. Deformable photovoltaic unit (10) according to one of claims 19 to 21, wherein the contacting structure (14) has a second contacting section (18) which projects laterally beyond the fragments (34), and wherein a deformable, in particular polymeric, second carrier layer (24), in particular a second carrier film, is arranged on the second contacting section (18).

23. Deformable photovoltaic array (58), comprising: - at least two deformable photovoltaic units (10) according to claim 22, - wherein the fragments (34) of a first photovoltaic unit (10a) of the photovoltaic units (10) are electrically connected to the second contacting section (18) of a second photovoltaic unit (10b) of the photovoltaic units (10).

24. Deformable photovoltaic module (60), comprising: - at least two deformable photovoltaic arrays (58) according to claim 23, - wherein the photovoltaic rows (58) are arranged next to one another, and wherein the photovoltaic rows (58) are electrically connected to one another by at least one common connection device (62, 64), in particular a busbar.

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