Solar module

Abstract

The present invention relates to a solar module having a front-side transparent protective element, a rear-side protective element, an encapsulation material, and at least one photovoltaically active element which is electrically connected to at least one electrical line element. The problem addressed by the invention is that of simplifying a solar module and the production thereof. The solar module according to the invention also has, at least on one edge, a support element which is at least partly embedded between the front-side protective element and the rear-side protective element, the support element supporting at least one portion of the line element.

Description

[0001] solar module

[0002] The present invention relates to a solar module comprising a front-side transparent protective element, a rear-side protective element, an encapsulation material, and at least one photovoltaically active element electrically connected to at least one electrical conduction element. The invention also includes a method for manufacturing such a solar module.

[0003] Photovoltaic solar modules, also called solar modules, are used to harness solar energy by converting it into electrical energy. A solar module typically comprises various components connected to one another in a laminate. This solar module laminate, also called a laminate, consists in particular of a front protective element, in particular a glass pane, an interconnection of semiconductor solar cells, in particular based on crystalline silicon solar wafers, a rear protective element, in particular a rear film or a rear glass pane, and encapsulation materials, which each establish a connection between the photovoltaically active element and the front protective element as well as the rear protective element. However, it can also comprise additional films and components.The solar module may also contain additional sealing elements to insulate the active elements of the solar module against external environmental influences, such as moisture, ammonia, and other aggressive gases or liquids. The solar module may also include electrical interconnection elements located in the laminate, such as electrical wiring elements and / or bridging elements.

[0004] There are both frameless and framed solar modules. The frame of solar modules protects the solar laminate, or the mechanically sensitive solar laminate panel, during transport and installation.

[0005] In the production of solar modules and solar module laminates, there are several process steps that are very difficult to automate. These steps specifically include the electrical connection of solar cell strings via electrical connectors or wiring elements, as well as the routing of the electrical wiring elements from the laminate. The object of the invention, however, is to simplify a solar module and its production.

[0006] The invention achieves this object by means of a solar module as specified above, which further comprises, at least on one edge, a carrier element which is at least partially embedded between the front-side protective element and the rear-side protective element, wherein the carrier element carries at least a portion of the conducting element. A feature of this solar module is the carrier element which is at least partially embedded in the solar module laminate. This carrier element carries one or more electrical conducting elements during the production of the solar module laminate. The carrier element can have both mechanical protection and / or fastening functions, serve as a spacer between the front-side protective element and the rear-side protective element, simplify the electrical connection of the solar module, and overall result in a simpler and more cost-effective construction of the solar module.The manufacturing process of the solar module with the support element and other module components is also simplified.

[0007] The support element(s) are made of an electrically insulating material. Suitable materials include, for example, plastics that remain mechanically stable at typical solar module lamination temperatures in the range of 80–180°C. The specific temperatures used depend on the processing temperatures of the individual components. For HJT and Smartwire solar modules, typical temperatures are in the range of 130°C to 160°C; for other solar modules, different temperatures may be required. In particular, in some embodiments, the support elements are made of thermosets or fiber-reinforced plastics.

[0008] The solar module laminate may comprise at least one front-side protective element, a rear-side protective element, a front-side encapsulation material, a rear-side encapsulation material, at least one photovoltaically active element, and electrical connecting or conducting elements.

[0009] The solar module laminate can be viewed in XYZ space, with one long edge of the solar module laminate pointing along the X-direction, a second long edge of the solar module perpendicular to the first long edge pointing in the Y-direction, and the surface normal of the solar module laminate pointing in the Z-direction. The support element can have a flat, plate-like shape, at least in certain areas of the solar module laminate.

[0010] The support element may have a T-shaped or an L-shaped cross-section when viewed in a YZ plane and / or in an XZ plane.

[0011] The support element may extend beyond the edge of at least one of the front or rear protective elements.

[0012] The support element can be assembled from individual segments or consist of a single piece. The support element(s) have an extended, plate-like shape in an XY plane within the laminate. Parts of the support element can lie outside the laminate and protrude beyond one of the front or rear protective elements. In an XZ or YZ sectional view, the support element can have a T- or L-shape, respectively.

[0013] The support element can also have a connecting support element that connects a support element portion located on a first module side to a support element portion located on a second module side. Instead of a large support element with various support element portions arranged at the edges of the solar module laminate and with at least one connecting support element that connects the support element portions, several support elements and connecting support elements can also be installed in the solar module laminate, wherein the support elements and the connecting support elements can be constructed similarly or identically; the different designations "support elements" and "connecting support elements" are primarily associated with the different arrangement positions at the edge or in the center of the solar module laminate.

[0014] The solar module laminate can have a sealing element between the front-side protective element and the support element in an edge region of the solar module and / or a sealing element between the rear-side protective element and the support element. The sealing element can, for example, be an inserted butyl surface seal.

[0015] The solar module can also have an external connecting element between the support element and at least one of the front or rear protective elements. The external connecting element can serve as a seal and be made of a low-hardness plastic with good adhesion properties. The external connecting element can also serve to compensate for various shape tolerances of the front protective element, the rear protective element, and the support element.

[0016] The carrier element can be mechanically or materially bonded to the front and / or rear protective element, at least within the solar module laminate, by the encapsulation material. The term "mechanical" can also include an adhesive bond.

[0017] In addition to the electrical conduction or connection element, the support element can also carry at least one electrical component. The electrical component can be an electrical bridging element. These bridging elements, also known as bypass elements, can be switching diodes or semiconductor circuits that bridge less illuminated solar cells in the solar module.

[0018] The support element can also carry an electrical connection element that serves to connect at least one electrical line element to an external connecting cable. The electrical connection element can be designed to establish a pluggable electrical connection or a non-separable connection between the at least one line element and a connecting cable.

[0019] In some embodiments, the carrier element has structures located in regions between the front-side protective element and the rear-side protective element. These structures can have a first height in a first region in the Z direction, which approximately corresponds to the distance between the two protective elements, and a second height in a second region located between the protective elements, wherein the second height is less than the first height. The thicker first region can serve as a spacer and as a mechanically stable connection region. In addition, the regions with a lower height can form channels that support the evacuation of the laminate stack and facilitate the flow of encapsulation material around them during the lamination process.

[0020] The invention also includes a manufacturing process for a solar module laminate, comprising the following process steps: a) providing a transparent front-side protective element, b) positioning a first encapsulation element made of encapsulation material on the front-side protective element, c) placing at least one carrier element with a connected or applied conductive element on the front-side protective element and / or the encapsulation material, d) positioning at least one photovoltaically active element on the front-side encapsulation material, e) establishing an electrical connection between at least one conductive element and electrical cell contact connectors of the at least one photovoltaically active element, f) positioning a second encapsulation element made of encapsulation material on the stack, g) positioning a rear-side protective element on the stack,h) Laminating the stack produced in steps ag in a laminating machine.

[0021] In this case, steps c and d can be combined in that the at least one conducting element is already positioned on the carrier element before it is placed on the protective element and / or the encapsulation material.

[0022] Likewise, in an alternative process sequence, steps c and d can be performed in reverse order. This means that at least one photovoltaically active element can be applied first, followed by the carrier element in a directly subsequent step.

[0023] The manufacture of the solar module laminate may further include applying a sealing element between the front-side protective element and the support element and / or the back-side protective element and the support element.

[0024] The at least one sealing element can also be introduced into the laminate by attaching the sealing element or sealing elements to the carrier element before the carrier element is placed on it.

[0025] The manufacture of the solar module or the solar module laminate may further include applying an external connecting element between the carrier element and the front-side protective element and / or the back-side protective element.

[0026] Embodiments of the invention will be described below with reference to the following figures: Fig. 1 shows schematically a solar module, lying in an XY plane, with a support element that is positioned along a long edge of the solar module.

[0027] Fig. 2 shows a solar module lying in an XY plane, with two support elements, each positioned along the two long edges of the solar module.

[0028] Fig. 3 shows an arrangement of support elements in which the two support elements are arranged along the two short edges of a solar module.

[0029] Fig. 4 shows an arrangement of two support elements which are arranged in several parts along two opposite edges and which are connected to each other by a connecting support element.

[0030] Fig. 5 shows a solar module in an XZ or a YZ sectional view with a flat support element that is flush with the front protective element 3 and the rear protective element 4 at the edge of the solar module laminate.

[0031] Fig. 6 shows a solar module in an XZ or YZ sectional view with a T-shaped support element.

[0032] Fig. 7 shows a solar module in an XZ or YZ sectional view with an L-shaped support element.

[0033] Fig. 8 shows a solar module in an XZ or a YZ sectional view with a connecting element 9 between the support element 2 and the front-side protective element 3 and the rear-side protective element 4.

[0034] Fig. 9 shows a solar module in an XZ or a YZ sectional view with an outer connecting element 9 which connects the support element 2 with the front-side protective element 3 and the rear-side protective element 4 in a clamp-like manner.

[0035] Fig. 10 shows a solar module in an XZ or YZ sectional view with a detailed view of a two-part connecting element 9, which includes a clamp-like element 9' and an adhesive element 9".

[0036] Fig. 11 shows a section of a partial view of a solar module 1 and a variant of a support element 2 integrated in the solar module. Fig. 12 shows a section of a partial view of a solar module 1 and a variant of a support element 1 integrated in the solar module, wherein in this section an electrical line element leads to an electrical plug contact.

[0037] Figure 1 schematically shows a solar module 1 having a single support element 2. The support element 2 is arranged, for example, on one of the edges, here on a long edge of a rectangular solar module 1. In this exemplary embodiment, the support element 2 extends along the entire edge of the solar module 1. In exemplary embodiments not shown, the support element 2 is shorter and extends only over a partial area. The dimensions of the support element 2 in the XY plane are shown enlarged in relation to the size of the solar module for better visibility. In various exemplary embodiments, the support element has a width in the range of 5-30 mm in the X direction.

[0038] Figures 2 and 3 each show a solar module 1, each having a support element 2a, 2b along two opposite edges of the solar module 1. In the solar module 1 of Fig. 2, the support elements 2a, 2b are arranged on the longer sides of the solar module 1, while in Fig. 3 they are arranged on the shorter sides. In further embodiments not shown, support elements 2 are arranged on all edges of the solar module laminate.

[0039] Figure 4 shows a solar module 1 in which two support elements 2a, 2b are arranged parallel along two opposite edges, and in which a connecting support element 2c is arranged perpendicular to the support elements 2a, 2b and connects them to one another. The connecting support element 2c extends over a strip in the central region of the solar module 1. In the embodiment shown in Figure 4, the support elements 2a, 2b and the connecting support element 2c are individual elements.

[0040] The support elements 2a, 2b, 2c shown in Figure 4 can also be joined together to form a single support element or manufactured as such. In a similar solar module (not shown), a one-piece H-shaped support element is used, which has support element portions 2a, 2b, 2c. In other variants (not shown), support elements 2a, 2b and at least one connecting support element 2c are arranged at different positions on the solar module.

[0041] The central arrangement of the connecting support element 2c shown in Figure 4 is particularly advantageous in the event that one or more electrical line elements 8 for the parallel and / or serial connection of two electrically similar module halves are carried thereon. Other connection variants can be implemented more favorably if the line elements 8 and the support element 2 carrying them are arranged at one module end or, in further variants, in at least one intermediate position. In further variants not shown, support elements 2 are attached to all four edges of the solar module 1. In yet further variants, support elements 2 are attached at more than one position crossing the solar module 1. In further variants not shown, support elements 2 are attached to all four edges of the solar module 1 and additionally at at least one position crossing the solar module 1.

[0042] Figure 5 shows an exemplary embodiment of a carrier element 2 in a flat, plate-like design. The carrier element terminates at the edge of the solar module 1 with the front-side protective element 3 and the rear-side protective element 4. It carries an electrical conduction element 8 and is connected to the protective elements 3, 4 in one partial area by the front and rear encapsulation material 5. Furthermore, the carrier element 2 is connected to the protective elements 3, 4 in another partial area by means of sealing elements 7, here butyl seals. This enables improved protection of the photovoltaic elements 6 against environmental influences such as moisture outside the solar module. The solar module laminate of the solar module 1, which is shown in detail in Fig. 5, is used in various exemplary embodiments either directly as a frameless solar module or, after attaching a frame, as a framed solar module.

[0043] As an alternative to the embodiment shown in Figure 5, the carrier element can have a recess relative to the front and / or rear protective element 3, 4 or can protrude beyond at least one of the protective elements 3, 4.

[0044] Figure 6 shows a variant of a solar module 1, wherein the support element 2 has a T-shaped cross-section in an XZ or YZ sectional view. The first support element part 2' of the support element 2, pointing in the X or Y direction, is arranged at least partially between the front and rear protective elements 3, 4, and the second support element part 2, extending perpendicularly thereto in the Z direction, 1' of the support element 2 is arranged outside the front and rear protective elements. The outer, second support element part 2", the roof of the T, is located laterally outside the solar module laminate and can be regarded as a simple frame and edge protection for the solar module thus produced. The support element 2 advantageously adjoins the surfaces of the front and rear protective elements 3, 4, forming a plane. The solar module 1 constructed in this way has improved self-cleaning properties compared to conventional solar modules and is more cost-effective.

[0045] Figure 7 shows a further variant of a solar module 1 according to the invention, wherein the support element 2 has an L-shape in an XZ or YZ sectional view. The leg of the support element 2 pointing in the X or Y direction is arranged as the first support element part 2', at least partially between the front and rear protective elements 3, 4. The leg of the support element 2 extending perpendicularly thereto in the Z direction is arranged as the second support element part 2" outside the front or rear protective elements 3, 4. In the example shown, the leg of the second support element part 2" of the support element 2 points in the direction of the front protective element 3. In a version not shown, the second support element part 2" points in the direction of the rear protective element 4.

[0046] Figure 8 shows an XZ or YZ sectional view of a T-shaped support element 2, which is mechanically and materially connected to the front and rear protective elements by means of a connecting element 9. The connecting element 9 establishes an adhesive connection between the support element 2. The connecting element 9 can also enhance or replace the sealing function of the sealing element 7. In the illustrated embodiment, the connecting element 9 is made of silicone adhesive; in other embodiments not shown, the material for forming the connecting element 9 is selected from the material classes of silicones, butyl rubbers, and thermoplastics.

[0047] Figure 9 shows an alternative connecting element 9, which at least partially encloses the support element 2 in its part projecting beyond the protective elements 3, 4 as a profile- and clamp-like connecting element 9 and mechanically connects it to the protective elements 3, 4. The profile-like connecting element 9 is made of aluminum here; in other examples not shown, it is made of a plastic or steel profile, for example.

[0048] Figure 10 further shows that the connecting element 9 can consist of two parts, a clamp-like profile 9' and an adhesive and sealing element 9". The adhesive element 9" connects the profile 9' to the carrier element 2 and / or at least one of the front or rear protective elements 3, 4.

[0049] Figure 11 shows a design variant of a solar module 1 in a three-dimensional view. For the sake of clarity, the front-side protective element and the encapsulation material have been omitted from this view. The illustration shows a carrier element 2 having island structures 2"' within the laminate stack. These island structures 2"', or the valleys between them with a lower height, support the evacuation of the laminate stack and also enable the encapsulation material 5 to flow around the carrier element 2 during the lamination process. These island structures 2"' are shown in Figure 11 only on the side facing the front-side protective element. In various embodiments, the island structures 2"' are also present on the side facing the rear-side protective element 4.

[0050] Figure 12 schematically shows a section of a solar module 1, which contains a contact element 12 connected to and integrated into the carrier element 2. The contact element 12 contains an electrical plug contact 11, which is electrically connected to the conductor element 8. The contact element 12, with the plug contact 11, enables an electrical cable to be attached to the solar module.

[0051] In an alternative solution not shown, instead of a plug contact 11, a connecting cable is directly connected to a contact element 12 and the electrical line element 8.

[0052] In a further variant not shown, a contact element 12 which is electrically connected to the conducting element 8 and is carried by the carrier element 2 is provided, which is accessible through an opening in the rear encapsulation element 5 and an opening in the rear protective element 4 for interconnection in the manufacturing process.

[0053] Reference symbol

[0054] 1: Solar module

[0055] 2, 2a, 2b: Support elements

[0056] 2c Connecting support element

[0057] 2', 2": support element parts

[0058] 2"' island structure

[0059] 3: front protective element

[0060] 4: rear protective element

[0061] 5: Encapsulation material

[0062] 6: photovoltaically active element

[0063] 7: Sealing element

[0064] 8: Line element

[0065] 9, 9', 9": Connecting elements 10: electrical cell contact connectors

[0066] 11: electrical plug contact

[0067] 12: Contact element

Claims

Patent claims 1. Solar module (1) comprising a front-side transparent protective element (3), a rear-side protective element (4), an encapsulation material (5), at least one photovoltaically active element (6) which is electrically connected to at least one electrical conducting element (8), characterized in that the solar module (1) further comprises, at least on one edge, a carrier element (2) which is at least partially embedded between the front-side protective element (3) and the rear-side protective element (4), wherein the carrier element (2) carries at least a section of the conducting element (8).

2. Solar module according to claim 1, wherein the support element (2) has a flat plate-like shape.

3. Solar module according to claim 1, wherein the carrier element (2) projects beyond the edge of the front-side protective element (3) and / or the rear-side protective element (4).

4. Solar module (1) according to claim 1 or 3, wherein the support element (2) has a T-shaped or an L-shaped shape in a YZ plane sectional view and / or in an XZ plane sectional view.

5. Solar module (1) according to at least one of claims 1 to 4, wherein the support element (2) has a connecting support element (2c) which connects a support element part (2a) of the support element (2) arranged on a first module side to a support element part (2b) on a second, parallel opposite module side.

6. Solar module (1) according to at least one of claims 1 to 5, in which a sealing element (7) is arranged at least in an edge region of the solar module between the carrier element (2) and the front-side protective element (3) and / or the rear-side protective element (4).

7. Solar module (1) according to at least one of claims 1 to 6, in which the carrier element (2) is mechanically or materially connected to at least one of the protective elements (3, 4) at the edge region via a connecting element (9).

8. Solar module (1) according to at least one of claims 1-7, in which the carrier element (2) is at least partially connected to the front-side protective element (3) and / or the rear-side protective element (4) by the encapsulation material (5).

9. Solar module (1) according to at least one of claims 1-8, in which the carrier element (2) carries at least one electrical component in addition to the at least one conducting element (8).

10. Solar module (1) according to at least one of claims 1-9, in which the carrier element (2) carries an electrical contact element (12), characterized in that the contact element (12) is connected to at least one electrical conduction element (8).

11. Solar module (1) according to at least one of claims 1-10, in which the carrier element (2) has a first height in the direction of the front-side protective element (3) and / or in the direction of the rear-side protective element (4) in the Z direction in a first region located between the protective elements (3, 4), and a second height in a second region located between the protective elements, wherein the second height is less than the first height.

12. Manufacturing method of a solar module (1) comprising the following process steps: a) providing a transparent front-side protective element (3), b) positioning a first encapsulation element made of encapsulation material (5) on the front-side protective element, c) placing at least one carrier element (2) with a connected or applied line element (8) on the front-side protective element and / or the encapsulation material (5), d) positioning at least one photovoltaically active element (6) on the encapsulation material (5), e) establishing an electrical connection between at least one conducting element (8) and electrical cell contact connectors (10) of the at least one photovoltaically active element (6), f) positioning a second encapsulation element made of encapsulation material (5) on the layer stack, g) positioning a rear protective element (4) on the layer stack, h) laminating the layer stack produced in steps ag in a laminating system.

13. Manufacturing method according to claim 12, characterized in that when placing the carrier element (2) a sealing element (7) is applied between the front protective element (3) and the carrier element (2) and / or between the carrier element (2) and the rear protective element (4).

14. Manufacturing method according to claim 12 or 13, characterized in that before or after the lamination of the layer stack, an outer connecting element (9) is attached, which creates a connection between the carrier element (2) and the front-side protective element (3) and / or rear-side protective element (4).

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