• 专利附录
  • 专利说明
  • 权利要求
  • 类似技术
  • 同族专利
  • 引用文献
  • 法律状态
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    • 专利摘要:
    This disclosure describes solar modules with angular polymer, methods for producing solar modules with angular polymer, and methods for laying solar modules with angular polymer. In some examples, a method includes producing a flat polymer sheet comprising one or more photovoltaic cells. The method comprises applying a force to the flat polymer sheet to bend the flat polymer sheet in at least one region, forming an angular polymer sheet from the flat polymer sheet. The method includes mounting the angled polymer sheet on a roof deck (102) such that the photovoltaic cells (108) are angular with respect to the roof deck (102) in the at least one curved area.
    公开号:FR3065837A1
    申请号:FR1853754
    申请日:2018-04-27
    公开日:2018-11-02
    发明作者:David Okawa；Tamir Lance；Gabriela Bunea；Brian Wares；Zachary Judkins
    申请人:SunPower Corp；
    IPC主号:
    专利说明:

    Holder (s): SUNPOWER CORPORATION.
    Extension request (s)
    Agent (s): WOLFGANG NEUBECK - GRUNECKER.
    SOLAR MODULE WITH INCLINED POLYMER.
    FR 3 065 837 - A1 _ This description describes solar modules with angular polymers, methods for the production of solar modules with angular polymers, and methods for installing solar modules with angular polymers. In some examples, a method includes producing a flat polymer sheet comprising one or more photovoltaic cells. The method includes applying force to the flat polymer sheet to curl the flat polymer sheet into at least one area, forming an angular polymer sheet from the flat polymer sheet. The method includes mounting the angular polymer sheet on a roof tray (102) such that the photovoltaic cells (108) are angular with respect to the roof tray (102) according to the at least one curved area.


    i
    SOLAR MODULE WITH INCLINED POLYMER
    The subject described in this specification relates generally to photovoltaic solar systems, and in particular to solar modules with angular polymers.
    Photovoltaic (PV) cells, commonly known as solar cells, are devices for converting solar radiation into electrical energy. PV cells can be assembled into solar modules, which can be used to convert sunlight into electricity. A solar energy system generally comprises several solar modules, shelving or mechanical mounting, one or more inverters and interconnection cabling.
    The object of the present invention is achieved by a method comprising the production of a flat polymer sheet comprising one or more photovoltaic cells; and applying force to the flat polymer sheet to curl the flat polymer sheet into at least one area, forming an angular polymer sheet from the flat polymer sheet.
    The method can also be improved according to various advantageous embodiments.
    According to one embodiment, the method can comprise mounting the angular polymer sheet on a roof plate so that the photovoltaic cells are inclined relative to the roof plate by virtue of the at least one curved zone.
    According to one embodiment, the production of the flat polymer sheet can comprise the formation of at least one layer in the at least one zone comprising a thermoplastic material, and the method can comprise the application of heat to the at least one area before applying force to the flat polymer sheet, and cooling the at least one area before removing the force on the flat polymer sheet.
    According to one embodiment, the method can comprise mounting power electronics on the angular polymer sheet and fixing the wiring on the angular polymer sheet.
    According to one embodiment, the method can comprise stacking the angular polymer sheet with one or more other angular polymer sheets for transport or storage, or both.
    According to one embodiment, the production of the flat polymer sheet may include forming a laminate structure comprising a transparent front sheet, a back sheet and a layer of alternating sections of a rigid polymer and a thermoplastic material.
    According to one embodiment, the production of the flat polymer sheet may comprise the formation of a layer comprising a first section of a rigid polymer, of a first section of a thermoplastic material adjacent to the first section of the rigid polymer , a second section of the rigid polymer adjacent to the first section of the thermoplastic material, a second section of the thermoplastic material adjacent to the second section of the rigid polymer, a third section of the rigid polymer adjacent to the second section of the material thermoplastic, a third section of the thermoplastic material adjacent to the third section of the rigid polymer, and a fourth section of the rigid polymer adjacent to the third section of the thermoplastic material.
    According to one embodiment, the method can include applying heat to the layer; while the layer is hot following the application of heat to the layer, applying force to the flat polymer sheet to curl the flat polymer sheet in the first, second and third sections of the thermoplastic material; cooling the layer before the force is removed; and mounting the angular polymer sheet on a roof tray by securing portions of the sheet under the first section of the rigid polymer and the fourth section of the rigid polymer on the roof tray.
    According to one embodiment, the formation of the flat polymer sheet can comprise the formation of diodes integrated into the laminate inside the flat polymer sheet.
    According to one embodiment, the method may include forming a plurality of holes passing through the angular polymer sheet to allow the wind to pass through the angular polymer sheet.
    The object of the present invention is also achieved by a solar module comprising one or more layers of polymer; and one or more photovoltaic cells on a first zone of the one or more layers of polymer; wherein the one or more layers of polymer are curved in at least a second area outside the first area of the photovoltaic cells.
    The solar module can also be improved according to various advantageous embodiments.
    According to one embodiment, the solar module can comprise a first flat area, a vertical area rising from the first flat area, a downwardly sloping area along a slope moving away from the vertical area and comprising the photovoltaic cells, and a second flat area extending away from the downwardly sloping area.
    According to one embodiment, the solar module can comprise a second vertical zone rising from the second flat zone, a second zone sloping downwards according to a slope moving away from the second vertical zone and comprising a plurality of additional photovoltaic cells, and a third flat area extending away from the second downwardly sloping area.
    According to one embodiment, a first angle between the first flat area and the vertical area can be less than 90 degrees, and a second angle between the vertical area and the downwardly sloping area can be less than 90 degrees.
    According to one embodiment, the solar module can comprise a first flat area, an upwardly sloping area along an upward slope from the first flat area and comprising a first subset of one or more photovoltaic cells, a downwardly sloping area in a downwardly sloping area from the upwardly sloping area and comprising a second subset of one or more photovoltaic cells, and a second flat area extending away from the area in slope down.
    According to one embodiment, the solar module can include power electronics mounted on the second zone.
    According to one embodiment, the solar module can comprise a transparent front sheet, a back sheet, and a layer of alternating sections of a rigid or semi-rigid polymer and of a thermoplastic material.
    According to one embodiment, the solar module can comprise one or more diodes integrated into the laminate in the one or more layers of polymer.
    According to one embodiment, a plurality of holes can be configured through the solar module to allow the wind to pass through the solar module.
    According to one embodiment, the solar module can comprise an articulation connecting the first and second sections of the solar module.
    Figures 1A-G illustrate examples of angular polymer solar modules;
    Figures 2A-D illustrate optional features that can be achieved using angular solar modules;
    FIGS. 3A-B illustrate an example of a solar module with an angular polymer;
    Figures 4A-C illustrate optional features that can be achieved using the solar module of Figures 3A-B;
    FIG. 5 is a flow diagram of an example of a method for manufacturing one or more solar modules with angular polymers;
    to Figure 6 shows the solar module of Figure 1D with holes configured on the sides of the solar module; and
    Figures 7A-C illustrate examples of photovoltaic devices.
    This description describes solar modules with angular polymers, methods for producing solar modules with angular polymers and methods for installing solar modules with angular polymers. Solar modules typically include rigid structural frames and glass encapsulation, for example with a front glass sheet or both front and rear glass sheets. Some solar modules are made from polymers and lack a rigid structural frame and glass encapsulation, using instead, for example, a glassless laminate. In some examples, the angular polymer solar modules described in this description are light in the sense that the panels can be installed on commercial roofs and other roofs with low load requirements. Flat orientation for solar modules can result in poor energy harvesting, and angular polymer solar modules can increase the amount of solar energy harvested by orienting the surfaces of angular polymer solar modules to receive more sunlight.
    In general, the use of polymer solar modules in photovoltaic systems can lead to improved transport and logistics compared to solar modules with rigid structural frames and glass encapsulation due to the lower weight of the modules. In addition, the use of polymer solar modules in PV systems can lead to a reduction in installation time, as a result, for example, of lighter weight, fewer pallets and other savings.
    The use of an angular polymer solar module in PV systems, as described in this specification, can have one or more of the following advantages over conventional solar modules: substantial increases in energy harvesting; improved economy for the product (since solar modules can represent the highest expense in a PV system); the possible use of solar modules for cable management outside the roof terrace; improved normal operating temperatures for solar modules since air can flow above and below the modules; and the possible elimination of shelving systems.
    Figures 1A-F illustrate examples of angular polymer solar modules. FIG. 1A is an isometric view of a solar module 100. FIG. 1B is a top view of the solar module 100 in a flat configuration, that is to say before being made angular. Figure 1C is a side cross-sectional view of the solar module 100 in the flat configuration.
    Referring to Figure 1A, the solar module 100 is mounted on an example roof tray 102 of a building, for example a commercial building with a low load requirement for the roof tray 102, or any other structure appropriate. The roof plate 102, as shown in the example of FIG. 1 A, is flat, that is to say generally parallel to the ground. The solar module 100 can be connected to the roof plate 102 using any suitable method, for example using an adhesive, a tape, a weld, a thermal bond, a mechanical fixing, a ballasting, or a combination of these.
    The solar module 100 comprises a front face 104 and a rear face 106. The front face 104 is generally opposite the roof plate 102. The front face 104 comprises one or more PV cells 108. The PV cells 108 can have any semiconductor structure suitable for generating an electrical voltage from sunlight, for example a front contact, a rear contact, an interdigit rear contact, and the like.
    PV cells 108 are typically encapsulated in transparent or semi-transparent polymer layers, for example as described in more detail below with reference to FIG. 1C. Figure 1A illustrates nine cells in a three by three grid;
    however, in general, any suitable number and orientation of cells can be used. For example, PV cells can be oriented in a single row of cells.
    The solar module 100 is a solar module with polymer in the sense that the solar module 100 comprises one or more rigid layers of polymer which, in operation, provide rigidity and the overall structural shape of the solar module 100. Since the solar module 100 is a solar module with polymer, the solar module 100 does not need to include a metal frame or another frame for the structural support. Although the solar module 100 is formed in the angular shape shown in Figure 1A, the solar module 100 may have some flexibility, for example, so that wind and snow bend rather than break the solar module 100, and so that the solar module 100 does not break during transport and installation operations.
    The solar module 100, as shown in the example of FIG. 1A, comprises seven distinct zones 110, 112, 114, 116, 118, 120 and 122. The first zone 110 is generally parallel to the roof plate 102 and provides a surface for the solar module 100 to be mounted on the roof tray 102. The solar module 100 can be mounted using any suitable type of attachment, for example, by adhesive, mechanical fasteners such as bolts, or by welding.
    The second zone 112 curves away from the roof plate 102 and connects the first zone 110 to the third zone 114. The third zone 114 generally rises upwards and away from the roof plate 102, by example, the third zone 114 can be perpendicular or substantially perpendicular to the roof plate 102. The fourth zone 116 curves from the third zone 114 back towards the roof plate 102, and connects the third zone 114 to the fifth zone 118. The fifth zone 118 comprises the PV cells 108 and is sloping from the fourth zone 116 downwards towards the roof plate 102, for example, the fifth zone 118 can be sloping downwards according to a constant slope. The sixth zone 120 curves upward from the fifth downwardly sloping zone 118 to connect the fifth zone to the seventh zone 122. The seventh zone 122 is generally parallel to the roof plate 102 and provides another zone to mount the solar module 100 on the roof plate 102.
    Since the roof plate 102 is flat, the solar module 100 is angular so that at least part of the solar module 100 comprising the PV cells 108 can be mounted on the roof plate 102 to face a direction receiving the sunlight. For example, if the roof plate 102 is in the northern hemisphere, the solar module 100 can be mounted on the roof plate 102 so that the PV cells 108 are generally oriented upwards towards the south. As shown in FIG. 1A, the fifth zone 118 is sloping at an angle relative to the roof plate 102 and to the first and seventh zones 110 and 122.
    FIG. 1B is a top view of the solar module 100 in a flat configuration, that is to say before being made angular. The solar module 100 can be flat as shown in FIG. 1B after an initial manufacturing step. The solar module 100 can then be formed according to the angular shape shown in FIG. 1A by any suitable method. In some examples, the second, fourth and sixth zones 112, 116 and 120 comprise one or more thermoplastic layers which are heated so that these zones can be curved as described above with reference to FIG. 1A, then cooled so that the overall structure of the solar module 100 is generally rigid.
    Figure 1C is a side cross-sectional view of the solar module 100 in the flat configuration. The solar module 100 includes a number of layers. The layers described below are provided by way of illustration; in general, any suitable structure of PV cells and polymers which provides the solar module 100 with an angular shape can be used.
    In this example, the solar module 100 comprises a transparent UV-stable front sheet 130, a back sheet 132 and a layer of thermoplastic encapsulating agent 134. The back sheet 132 can be, for example, a white back sheet or a back sheet transparent, or a thin glass. In some examples, the backsheet 132 is a patterned backsheet, for example generally opaque with a transparent pattern in areas for exposing the PV cells 108, for example where the PV cells 108 are bifacial.
    The thermoplastic encapsulating agent 134 can be any suitable type of thermoplastic material which becomes flexible above a certain temperature and solidifies on cooling, for example a thermoplastic olefin (TPO). Below the transparent front sheet 130, the solar module 100 includes a thermosetting encapsulating agent 136 on a semiconductor layer 138. The thermosetting encapsulating agent 136 may be useful, for example, to prevent tarnishing and cracking of cells. . The semiconductor layer 138 comprises the PV cells 108, for example one of the other PV chains. Below the semiconductor layer 138 is another layer of thermoplastic encapsulating agent 140.
    Between the two layers of thermoplastic encapsulating agent 134 and 140 is a layer 142 of alternating zones of thermoplastic materials and rigid polymers. Layer 142 comprises sections of rigid polymers 144, 148, 152 and 156 in the first, third, fifth and seventh zones 110, 114, 118 and 122 of the solar module 100. Layer 142 comprises sections of thermoplastic materials 146, 150 , and 154 in the second, fourth and sixth zones 112, 116 and 120 of the solar module 100.
    As a result of the alternating zones of thermoplastic materials and rigid polymers in the layer 142, the solar module 100 can be formed in the form of a flat sheet and then be thermally reformed to curve the second, fourth and sixth zones 112, 116 and 120. During cooling, the solar module 100 then forms the angular shape shown in FIG. 1A. In some examples, flexible metal parts can be incorporated into the laminate (for example, around the edges of the solar module 100) to further control the angular shape of the solar module 100.
    In some examples, the solar module 100 includes diodes integrated into the laminate 124 in the electrical connections of the solar module 100. For example, the solar module 100 can include diodes integrated into the laminate 124 in the third zone 114 of the solar module, which becomes a vertical face when installed on a flat roof plate. The diodes integrated into the laminate 124 can be useful, for example, to minimize a temperature increase near the solar cells 108.
    FIG. 1C illustrates a layer 142 of alternating zones of thermoplastic materials and rigid polymers; however, in some examples, the solar module 100 does not have these alternating zones. For example, the solar module 100 may include layers of uniform thermoplastic materials. In this case, the solar module 100 can be heated and then shaped, for example by pressing the solar module 100 against a mold, then cooled to form the angular shape shown in FIG. 1 A.
    FIGS. 1A-B illustrate the solar module 170 with generally square PV cells 108. In general, the PV cells 108 can have any suitable shape. FIG. 1D illustrates an example of an alternative solar module 170 having a certain number of solar strips in shingles 172, 174 and 176 arranged in the form of shingles with the ends or the long edges of adjacent solar strips overlapping and electrically connected to form, for example, a chain connected in series.
    Adjacent solar cells are conductively bonded to each other in the area in which they overlap with an electrically conductive bonding material. In one example, although only one row of shingle solar strips 172 is shown, multiple shingle solar strips 172 can be used (for example, multiple shingle solar cell strips can be positioned side by side at the same time , for example to increase an output rate or to produce larger PV sheets). In some examples, the strip of shingle solar cells can be connected to another strip of shingle solar cells in parallel.
    Figure 1E is a side view of an example solar module 180 having multiple angular waves 182a-b in a single laminate. Each of the angular waves 182a-b comprises an angular part in relief of laminate with solar cells, for example, as described above with reference to FIGS. 1A-D. The single laminate can be fabricated as a single flat sheet, and then thermally formed. Although the example solar module 180 is illustrated in Figure 1E as having two angular waves 182a-b, in general, the solar module 180 can have any desirable number of angular waves formed in a single laminate structure.
    Figure 1F is a side view of a portion of a solar module 184 having two laminate sections 186a-b joined together by a hinge 188. One or more electrical wires 190 can electrically couple solar cells from the first laminate section 186a to the second section of laminate. 186b. In some examples, each of the laminate sections 186a-b can be an entire angular solar module, for example, as described above with reference to Figures 1A-E.
    In some other examples, the joint 1 is included to implement the angular structure of the solar modules of FIGS. 1A to E, that is to say so that the joint 188 replaces a curved part of the laminated structure ( for example one or more of the second, fourth and sixth zones 112, 116 and 120 illustrated in FIG. 1B). For example, the first laminate section 186a can be the first zone 110, the second laminate section 186b can be the third zone 114, and the joint 188 can replace the second zone 112. In this case, a rigid or semi-stirrup -rigid can be fixed ίο (for example, hung on the side) to the solar module to fix the angular shape of the solar module.
    The joint 188 may include a flexible strip 192. The flexible strip 192 comprises a first sheet 194 fixed to the first section of laminate 186a, a central part 196 which covers a space between the two sections of laminate 186a-b, and a second sheet 198 attached to the second laminate section 186b. The flexible strip 192 allows the two laminate sections 186a-b to move relative to one another, which may be useful, for example, to form an angular solar module or for the storage or transport of solar modules .
    In some examples, the solar modules illustrated in FIGS. 1A to E are dimensioned for installation on a residential or commercial roof. For example, for some residential roof applications, the solar modules have approximately 96 solar cells and are configured, by virtue of the selection of materials and appropriate dimensions, to weigh approximately 8 kg. In another example, for some commercial roof applications, the solar modules have approximately 126 solar cells and are configured, by virtue of the selection of materials and appropriate dimensions, to weigh approximately 10.5 kg. The weight would double for solar modules having two angular waves, for example the solar module 180 in FIG. 1 E.
    The solar modules can be configured so that at each angle, the radius of curvature of the curve between two sections is at least large enough to allow ribbons to cross the curve. For example, the solar modules can be configured so that at the curve between the fourth section 116 and the fifth section 118, the radius of curvature is large enough to allow the ribbons to cross the curve. The minimum radius of curvature can be, for example, 7.5 mm.
    Figure 1G shows two example 160 and 162 forms of angular solar modules. The first shape 160 corresponds to the shape of the solar module 100 of FIG. 1 A. The angle 164 between the first area 110 and the third area 114 is greater than or equal to 90 degrees. The angle 166 between the third zone 114 and the fifth zone 118 is also greater than or equal to 90 degrees. The second shape 162 differs from the first shape 160 in that the angle 164 between the first area 110 and the third area 114 is less than 90 degrees, and the angle 166 between the third area 114 and the fifth area 118 is also less than 90 degrees. Angular solar modules having the second form 162 may be useful, for example, so that the solar module can act as a spring and provide overall flexibility of the solar module.
    Figures 2A-D illustrate optional features which can be achieved using angular solar modules, for example the solar modules of Figures 1A-G. FIG. 2A is a side view of the solar module 100 having a power electronics 202 mounted on the rear face of the solar module 100 and an electrical wiring 204 which passes under the solar module 100. The power electronics 202 and the electrical wiring 204 are kept outside the roof plate 102 in the space under the solar module 100, and is protected from certain environmental elements by the solar module 100. The power electronics 202 may include, for example, a junction box, a microinverter, DC optimizer, or one or more suitable electronic modules.
    Additional spaces under the solar module 100 or at the feet 110 and 122 of the solar module 100 can be used for other components of a PV system in some examples. The solar module 100 can be angular with respect to the roof plate 102 at any suitable angle; for example, the angles 206 and 208 between the roof plate 102 and the solar module can be selected on the basis of a geographic location to improve the recovery of energy from the sun.
    Figure 2B is a side view of a number of solar modules 222, 224 and 226 in a stacked configuration 220. Solar modules 222, 224 and 226 can be stacked, for example for transportation and storage, and then unstacked for the installation. Figure 2C is a side view of the solar module 230 having a bottom structure 232 forming a slot 234 for cable retention, for example a laminate slot formed with the other laminate structures of the solar module 230. In one example, the slot 234 can hold cables, electronics or any component that can enter or can be held by slot 234.
    Figure 2D is a side view of a solar module 240 comprising stiffening elements 242, 244 and 246 inserted or clipped onto the edge of the laminate structure to lock the angles between the laminate sections. The stiffening elements 242, 244 and 246 can be formed of any suitable material which is more rigid than the thermoplastic sections. For example, the stiffening elements 242, 244 and 246 can be metal or plastic rods or bars which cover all or part of the width of the solar module 240.
    Figures 3A-B illustrate an example of a solar module with angular polymer 300. Figure 3A shows an isometric view of the solar module 300. Figure 3B shows a top view of the solar module 300 in a flat configuration, i.e. - say before being made angular.
    The solar module 300 is mounted on a roof plate 102 and in some examples is formed of a laminated structure, for example, as described above with reference to Figure 1C. The solar module 300 comprises one or more PV cells 302 on the first and second angular surfaces 304 and 306. The first and second angular surfaces 304 and 306 are oriented upwards and away from the roof plate 102 in opposite directions, for example so that the solar module 300 is exposed to the sun at various times and seasons. The solar module 300 forms angles in three different zones 308, 310 and 312, for example, using thermoplastic materials in these zones 308, 310 and 312.
    Figures 4A-C illustrate optional features which can be achieved using the solar module 300 of Figures 3A-B. FIG. 4A is a side view of the solar module 300 having a power electronics (for example junction boxes 402 and 404) mounted on the underside of the solar module 300 and an electrical wiring 408 which passes under the solar module 300. FIG. 4B is a bottom view of the solar module 300 in a flat configuration showing the junction boxes 402 and 404 mounted on the underside of the solar module 300. FIG. 4C is a side view of a number of solar modules 422, 424 and 426 in a stacked configuration 420, which may be useful, for example, for transportation and storage.
    The first junction box 402 can serve PV cells on the first angular surface 304 and the second junction box can serve PV cells on the other angular surface 306. The junction boxes 402 and 404 and the electrical wiring 408 are maintained outside the roof tray 102 in the space under the solar module 300 and protected from certain environmental elements by the solar module 300. Additional spaces under the solar module 300 and at the foot of the solar module 300 can be used for other components of a PV system, for example flexible wiring, in some examples. The solar module 300 can be angular with respect to the roof plate 102 at any suitable angle; for example, the angles 406 and 408 between the roof plate
    102 and the solar module can be selected based on geographic location to improve the recovery of energy from the sun.
    FIG. 5 is a flow diagram of an example process 500 for manufacturing one or more solar modules with angular polymers, for example the solar modules 100 and 300 of FIGS. 1A-C and 3A-B. Method 500 can be performed by one or more operators, or by an appropriately programmed robot or automation machine, or both.
    The method 500 includes producing a flat PV sheet (502), forming the flat PV sheet into an angular PV sheet (504) and mounting the angular PV sheet on a roof (506). The flat PV sheet can be a laminated structure. The flat PV sheet is substantially flat, in the sense that the flat PV sheet may not be perfectly flat due, for example, to manufacturing artifacts or certain characteristics which distance from the flat PV sheet or cause a relatively low degree bending of the flat PV sheet.
    For example, method 500 may include laminating a flat PV sheet (for example, as shown in Figure 1C) and then locally reforming thermoplastic polymers by applying heat and then bending forces to give the sheet PV the angular shape. In another example, method 500 includes laminating a flat PV sheet and then using constraining pieces (for example, applying force on the entire sheet against the constraining pieces) to give the PV sheet the shape angular. In another example, the method 500 includes laminating a flat PV sheet, and then attaching the PV sheet to an angular plastic feature to give the PV sheet the angular shape.
    In certain examples, the solar modules 100 and 170 may include wind management characteristics, for example reducing the capacity of the wind to modify the angular structure of the solar modules 100 and 170 or reducing the capacity of the wind to pull the solar modules 100 and 170 off the roof shelf 102, or both. For example, Figure 6 shows the solar module 170 of Figure 1D with holes 602 configured on the sides of the solar module 170 to allow wind to pass through the solar module 170. In one example, the holes 602 may have a circular shape , square, rectangular, polygonal or any other shape allowing the wind to pass through the solar module 170. In certain embodiments, the holes 602 can be slots, for example thin vertical rectangular shapes or positioned horizontally.
    FIGS. 7A-C illustrate example PV devices which can be used as PV cells in the solar modules described in this description. In general, solar modules can include any suitable type of PV device, and Figures 7A-C are provided for illustration purposes.
    Figure 7A is a cross-sectional view of a rear contact solar cell 740 having emitter areas formed above a rear surface of a substrate.
    The solar cell 740 includes a silicon substrate 700 having a light receiving surface 702. A passivation dielectric layer 708 is disposed on the light receiving surface 702 of the silicon substrate 700. An optional intermediate material layer (or layers) 710 is disposed on the dielectric passivation layer 708. An anti-reflection layer (ARC) 719 is disposed on the layer (or layers) of optional intermediate material 710, as shown, or is disposed on the dielectric passivation layer 708.
    On the rear surface of the substrate 700 are formed alternating emitter zones 722 of type P 720 and of type N. In such an embodiment, trenches 721 are arranged between the alternating emitter zones 722 of type P 720 and of type N. More particularly, in one embodiment, first zones of polycrystalline silicon emitter 722 are formed on a first part of a thin dielectric layer 724 and are doped with an impurity of type N. Second zones of polycrystalline silicon emitter 720 are formed on a second part of the thin dielectric layer 724 and are doped with a P-type impurity. In one embodiment, the tunneling dielectric 724 is a layer of silicon oxide having a thickness of about 2 nanometers, or less.
    Conductive contact structures 728/730 are fabricated first by depositing and configuring an insulating layer 726 to have openings, and then forming one or more conductive layers in the openings. In one embodiment, the 728/730 conductive contact structures include metal and are formed by a deposition, lithography and etching approach or, alternatively, a printing or plating process or, alternatively, a sheet or wire adhesion process.
    FIG. 7B represents a solar device in example 750 consisting of solar cells arranged in shingles with the ends of adjacent solar cells overlapping. FIG. 7B is a side view of the solar device 750 which illustrates the orientation of the solar device 750 towards the sun (or another light source such as mirrors facing the sun). The solar device 750 can be called “supercell” or “hypercell” or “array of solar cells”.
    The solar device 750 comprises solar cells 752, 754 and 756 arranged in a shingle fashion with the ends or long edges of adjacent solar cells overlapping and electrically connected to form, for example, a chain connected in series. Each solar cell 102, 104 and 106 may include a semiconductor diode structure and electrical contacts with the semiconductor diode structure. Adjacent solar cells are conductively connected to each other in the area where they overlap by an electrically conductive bonding material which electrically connects the front surface metallization structure of a solar cell to the rear surface metallization structure of the adjacent solar cell.
    For example, consider the first and second solar cells 752 and 754 in the solar device 750. The second solar cell 754 is adjacent to the first solar cell 752 and overlaps the first solar cell 752 in an area 764 where the first and second solar cells 752 and 754 are electrically connected.
    Suitable electrically conductive bonding materials may include, for example, electrically conductive adhesives and electrically conductive adhesive films and adhesive tapes, and common welds. In some examples, the electrically conductive bonding material provides mechanical conformity in the bond between adjacent solar cells which tolerates a stress resulting from the shift between the coefficient of thermal expansion (CTE) of the electrically conductive bonding material and that of the solar cells ( for example, the CTE of silicon).
    Figure 7C is a cross-sectional view of a rear contact solar cell 744 having emitter areas formed in a rear surface of a substrate and having an ARC layer UV cured and thermally annealed on a receiving surface of light from the substrate, in accordance with one embodiment of this disclosure.
    Solar cell 744 includes a silicon substrate 700 having a light receiving surface 702. A passivation dielectric layer 708 is disposed on the light receiving surface of the silicon substrate 700. An optional intermediate material layer (or layers ) 710 is disposed on the dielectric passivation layer 708. An ARC layer 719 is disposed on the layer (or layers) of optional intermediate material 710, as shown, or is disposed on the dielectric passivation layer 708. In a mode of embodiment, the ARC 719 layer is a UV-cured and thermally annealed ARC layer.
    Inside the rear surface of the substrate 700 are formed alternating emitter zones 762 of type P and 760 of type N. More particularly, in one embodiment, the first emitter zones 762 are formed in a first part of substrate 700 and are doped with an N type impurity. The second emitter zones 760 are formed in a second part of substrate 700 and are doped with a P type impurity. The conductive contact structures 768/770 are manufactured first by depositing and configuring an insulating layer to have openings, and then by forming one or more conductive layers in the openings. In one embodiment, the 768/770 conductive contact structures include metal and are formed by a deposition, lithography and etching approach or, alternatively, a printing or plating method or, alternatively, a sheet or wire adhesion process.
    Although specific examples and features have been described above, these examples and features are not intended to limit the scope of this description, even when a single example is described in connection with a particular feature. Examples of features provided in the description are intended to be illustrative rather than restrictive, unless otherwise indicated. The above description is intended to cover such variations, modifications and equivalents, as would be apparent to those skilled in the art having the benefit of this disclosure.
    The scope of the present invention includes any characteristic or combination of characteristics disclosed in this description (explicitly or implicitly), or any generalization of characteristics disclosed, whether or not these characteristics or generalizations mitigate all or part of the problems described in this description.
    权利要求:
    Claims (20)
    [1" id="c-fr-0001]
    1. Process comprising:
    producing a flat polymer sheet comprising one or more photovoltaic cells (108); and forcibly applying the flat polymer sheet to curl the flat polymer sheet into at least one area (110, 112, 114, 116, 118, 120, 122), forming an angular polymer sheet from of the flat polymer sheet.
    [2" id="c-fr-0002]
    2. The method according to claim 1, including mounting the angular polymer sheet on a roof plate (102) so that the photovoltaic cells (108) are inclined relative to the roof plate (102) by virtue of the at least one curved zone (112, 114, 116, 118, 120, 122).
    [3" id="c-fr-0003]
    The method according to claim 1 or 2, wherein the production of the flat polymer sheet comprises forming at least one layer in the at least one area comprising a thermoplastic material, and wherein the method comprises applying heat to the at least one area before applying a force to the flat polymer sheet and cooling the at least one area before removing the force from the flat polymer sheet.
    [4" id="c-fr-0004]
    4. The method according to one of claims 1 to 3, comprising mounting power electronics (202) on the angular polymer sheet and fixing the wiring (204) on the angular polymer sheet.
    [5" id="c-fr-0005]
    5. The method according to one of claims 1 to 4, comprising stacking the angular polymer sheet with one or more other angular polymer sheets for transport or storage, or both.
    [6" id="c-fr-0006]
    The method according to one of claims 1 to 5, wherein the production of the flat polymer sheet includes forming a laminate structure comprising a transparent front sheet (130), a back sheet (132) and a layer of alternating sections of a rigid polymer and a thermoplastic material (142).
    [7" id="c-fr-0007]
    7. The method according to one of claims 1 to 6, wherein the production of the flat polymer sheet comprises the formation of a layer comprising a first section of a rigid polymer, a first section of a material thermoplastic adjacent to the first section of the rigid polymer, a second section of the rigid polymer adjacent to the first section of the thermoplastic material, a second section of the thermoplastic material adjacent to the second section of the rigid polymer, a third section of the rigid polymer adjacent to the second section of the thermoplastic material, a third section of the thermoplastic material adjacent to the third section of the rigid polymer, and a fourth section of the rigid polymer adjacent to the third section of the thermoplastic material.
    [8" id="c-fr-0008]
    8. The method of claim 7, comprising:
    applying heat to the layer;
    while the layer is warm following the application of heat to the layer, applying force to the flat polymer sheet to curl the flat polymer sheet in the first, second and third sections of the thermoplastic material;
    cooling the layer before the force is removed; and mounting the angular polymer sheet on a roof tray by securing portions of the sheet under the first section of the rigid polymer and the fourth section of the rigid polymer on the roof tray.
    [9" id="c-fr-0009]
    9. The method according to claim 1, in which the formation of the flat polymer sheet comprises the formation of diodes integrated into the laminate (124) within the flat polymer sheet.
    [10" id="c-fr-0010]
    10. The method according to one of claims 1 9, comprising the formation of a plurality of holes (602) passing through the angular polymer sheet to allow the wind to pass through the angular polymer sheet.
    [11" id="c-fr-0011]
    11. Solar module including:
    one or more layers of polymer; and one or more photovoltaic cells on a first zone of the one or more layers of polymer;
    wherein the one or more layers of polymer are curved in at least a second area outside the first area of the photovoltaic cells.
    [12" id="c-fr-0012]
    12. The solar module according to claim 11, comprising a first flat area, a vertical area rising from the first flat area, a second area sloping downward along a slope away from the vertical area and the photovoltaic cells, and a second flat area extending away from the downwardly sloping area.
    [13" id="c-fr-0013]
    13. The solar module according to claim 11 or 12, comprising a second vertical zone rising from the second flat zone, a second zone sloping downwards according to a slope moving away from the second vertical zone and comprising a plurality of additional photovoltaic cells, and a third flat area extending away from the second downwardly sloping area.
    [14" id="c-fr-0014]
    14. The solar module according to claim 12, wherein a first angle between the first flat area and the vertical area is less than 90 degrees, and wherein a second angle between the vertical area and the downwardly sloping area is less at 90 degrees.
    [15" id="c-fr-0015]
    15. The solar module according to one of claims 11 14, comprising a first flat area, an upwardly sloping area along an upward slope from the first flat area and comprising a first subset of one or more cells. photovoltaic, a downwardly sloping area in a downward slope from the upwardly sloping area, and comprising a second subset of the one or more photovoltaic cells, and a second flat area extending away from the area sloping down.
    [16" id="c-fr-0016]
    16. The solar module according to one of claims 11 15, comprising power electronics (202) mounted on the second zone.
    [17" id="c-fr-0017]
    17. The solar module according to one of claims 11 16, comprising a transparent front sheet (130), a back sheet (132), and a layer of alternating sections of a rigid or semi-rigid polymer and of a material. thermoplastic (142).
    [18" id="c-fr-0018]
    18. The solar module according to one of claims 11 17, comprising one or more diodes integrated into the laminate (124) in the one or more layers of polymer.
    [19" id="c-fr-0019]
    19. The solar module according to one of claims 11 1, wherein a plurality of holes (602) are configured through the solar module (170) to allow the wind to pass through the solar module (170).
    5
    [0020]
    20. The solar module according to one of claims 11 to 19, comprising a hinge (188) connecting the first (186a) and second (186b) sections of the solar module (184).
    1/15
    2/15 f
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    同族专利:
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    引用文献:
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    法律状态:
    2019-04-25| PLFP| Fee payment|Year of fee payment: 2 |
    2020-04-27| PLFP| Fee payment|Year of fee payment: 3 |
    2021-03-23| PLFP| Fee payment|Year of fee payment: 4 |
    2021-06-25| PLSC| Search report ready|Effective date: 20210625 |
    2021-07-30| TP| Transmission of property|Owner name: MAXEON SOLAR PTE. LTD., SG Effective date: 20210622 |
    优先权:
    申请号 | 申请日 | 专利标题
    US201762491368P| true| 2017-04-28|2017-04-28|
    US62491368|2017-04-28|
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