Photovoltaic (PV) panel production method

Abstract

The invention relates to a photovoltaic (PV) panel production method developed for use in the renewable energy sector, which eliminates the problems of reduced cell options and raw material limitations resulting from the application of electrically conductive adhesives used in panel production.

Description

[0001] PHOTOVOLTAIC (PV) PANEL PRODUCTION METHOD

[0002] Technical Field

[0003] The invention relates to a photovoltaic (PV) panel production method developed for use in the renewable energy sector, which eliminates the problems of reduced cell options and raw material limitations resulting from the application of electrically conductive adhesives used in panel production.

[0004] State of the Art

[0005] Today, solar energy, which is also accepted as an environmentally friendly and sustainable energy source, is increasing with the installation of solar energy systems in both households and businesses becoming more and more common. For this reason, many people and businesses around the world prefer to meet their energy needs with solar energy systems.

[0006] Solar energy is an energy obtained from sun rays and electricity from solar energy is generated using photovoltaic (PV) panels. PV panels are made of a material that can convert the sun rays into electrical energy. Generally, PV panels are made of silicon crystals, and when the sun rays fall on the surface of these crystals, they mobilize the electrons within the crystal. This allows the generation of electric current. Said generated direct current is then converted into alternating current using an inverter device. Alternating current is the same type of electricity used in households and can therefore also be connected to households.

[0007] Solar panels in the present art use a variety of solar cells depending on the desired output of the panel. Solar cells are placed along the panel with space therebetween. They are electrically connected to each other by high-temperature soldering processes using copper bars (strips). The more copper bars are used, the lower the resistance losses and therefore the more efficient the electrical connection. This is one of the reasons why many solar panel manufacturers are on the rise. However, having more bars covering the cells means that there are fewer solar cells exposed to sunlight.

[0008] Shingle solar modules, on the other hand, are solar modules obtained by overlapping the cells cut from the lines where the existing solar cells are connected to each other with copper wires and connecting them to each other with electrically conductive adhesives. In the known state of the art, electrically conductive adhesives are used in the production of shingle PV panels. Since these adhesives are applied to the paths where electric current is transmitted in solar cells, they are applied to very small areas. In novel technology solar cells, these areas are very few, and since electrically conductive adhesives will not be applied to such cells, it causes the raw material used to be limited.

[0009] There is a need to develop new methods in order to eliminate the disadvantages stated above and in the state of the art.

[0010] Summary of the Invention

[0011] The present invention relates to a photovoltaic (PV) panel production method developed for use in the renewable energy sector in order to eliminate the above-mentioned disadvantages and to provide new advantages to the relevant technical field.

[0012] With the invention, PV panel production is achieved without the use of electrically conductive adhesives used in photovoltaic (PV) panel production. The problems of reduced cell options used in panel production and raw material limitation which arise as a result of the use of electrically conductive adhesives used in the present art are eliminated with the invention.

[0013] With the invention, production can be done using any desired cell. In addition, since the adhesives used in the invention are not silver-based, it is ensured that the contribution of the solar panels produced to the carbon footprint is decreased.

[0014] With the process, included in the method of the invention, of mounting (taping) the stacked cells to each other from their back surfaces with tape, the need for expensive welding of adhesives used in the present art is eliminated and production costs are reduced.

[0015] Detailed Description of the Invention

[0016] The example embodiments are described in more detail below with reference to the accompanying descriptions. Furthermore, the embodiments can be established in different forms and should not be interpreted as being limited to the embodiments specified herein. Rather, these example embodiments are provided so that this description will be thorough, and will fully convey the scope to those skilled in the art. The terminology used in this description is intended to be used only to describe specific example embodiments and is not intended to be limiting. As used herein, the context of the forms “one”, “at least”, “preferably” and “and / or” comprise the plural forms unless clearly stated otherwise.

[0017] The invention relates to a photovoltaic (PV) panel production method developed for use in the renewable energy sector / field, which provides production and cost advantages .

[0018] The invention relates to a photovoltaic (PV) panel production method eliminating the problems of reduced cell options and raw material limitations resulting from the application of electrically conductive adhesives used in panel production, and comprising the following process steps:

[0019] - Cutting off solar cells over busbar lines,

[0020] - Stacking the cut cells such that the busbar lines overlap,

[0021] - Mounting the stacked cells to each other from their back surfaces with at least one tape,

[0022] - Cutting at least one ethylene vinyl acetate (EVA) bottom foil, at least one EVA top foil, at least one backsheet foil and at least one frontsheet foil,

[0023] - Forming the layer station of the cut foils such that; cell groups taped to each other are in the middle layer, EVA bottom foil is under the cell groups, EVA top foil is above the cell groups, frontsheet foil is on the top layer, and backsheet foil is on the bottom layer,

[0024] - Compression of the solar module with complete layers with heat and vacuum in the laminator,

[0025] - Shaving the edges of the panels exiting the lamination process,

[0026] - Adhering double-sided tape to the edges of the shaved panels and then mounting the aluminum frame,

[0027] - Mounting the electrical connection box after the frame montage.

[0028] In the invention, at the layer station, the cells are checked for shifting or microcrack formation before the lamination process. In addition, after the mounting of the electrical connection box, it is physically checked whether the panel has suffered any damage in the said montages and lamination process. Then, the electrical output values of said panel are checked and then packaged. The back of the panel is covered with the backsheet foil of the invention and the mechanical durability of the panel is increased.

[0029] The lamination process included in the method of the invention ensures that the layers contained in the panel adhere to each other. This process increases the durability of the panels and provides protection against external factors.

[0030] In the method steps of the invention, the back surfaces of the stacked cells are taped and mounted to each other, thus forming cell groups.

[0031] The tape used in the invention is an insulating tape in an application of the invention, but the application is not limited to this.

[0032] By mounting the solar cells in the invention by taping them with each other, the necessity of using silver-based adhesives of the state of the art is eliminated, and the contribution of the solar panels produced to the carbon footprint is decreased. In addition, said process eliminates the need for expensive resources and saves on production costs.

[0033] Any features described in this description (including appended claims, summary) may be replaced by other alternative features that may have equivalent or similar purposes, unless otherwise stated explicitly. That is, unless otherwise stated explicitly, each feature is only one example of a set of equivalent or similar features.

[0034] The above embodiments are intended only to describe the technical concept and features of the present invention, and the purpose of the present invention is to ensure that those skilled in the art understand the content of the present invention and practice the present invention, and the scope of the present invention is not limited thereto. Equivalent changes or modifications made in accordance with the spirit of the invention are intended to be included in the scope of the invention.

[0035] Industrial Applicability of the Invention

[0036] The invention relates to a photovoltaic (PV) panel production method developed for use in the renewable energy sector, which eliminates the problems of reduced cell options and raw material limitations resulting from the application of electrically conductive adhesives used in panel production, and is industrially applicable. The invention is not limited to the above exemplary embodiments, and the person skilled in the art can readily present other different embodiments of the invention. These should be considered within the protection scope of the invention claimed by the claims.

Claims

CLAIMS1 . A method developed for use in the renewable energy sector, characterized in that it comprises the following steps to produce photovoltaic (PV) panels:- Cutting off solar cells over busbar lines,- Stacking the cut cells such that the busbar lines overlap,- Mounting the stacked cells to each other from their back surfaces with at least one tape,- Cutting at least one ethylene vinyl acetate (EVA) bottom foil, at least one EVA top foil, at least one backsheet foil and at least one frontsheet foil,Forming the layer station of the cut foils such that; cell groups taped to each other are in the middle layer, EVA bottom foil is under the cell groups, EVA top foil is above the cell groups, frontsheet foil is on the top layer, and backsheet foil is on the bottom layer,Compression of the solar module with complete layers with heat and vacuum in the laminator,- Shaving the edges of the panels exiting the lamination process,- Adhering double-sided tape to the edges of the shaved panels and then mounting the aluminum frame,- Mounting the electrical connection box after the frame montage.

2. A panel obtained by a method according to claim 1 .