Method for producing photovoltaic thin film module

• US 20030029493A1
• Filed: 09/09/2002
• Published: 02/13/2003
• Est. Priority Date: 03/09/2000
• Status: Abandoned Application

• Current Assignee: Isovolta Osterreichische Isolierstoffwerke AG
• Original Assignee: Isovolta Osterreichische Isolierstoffwerke AG
• Inventors: Plessing, Albert
• Application Number:
  US10/221,028
• Publication Number:
  US 20030029493A1
• Time in Patent Office: Days
• US Class Current: 136/251
• CPC Class Codes: B32B 27/08 of synthetic resin
• CPC Class Codes: B32B 37/20 involving the assembly of continuous webs only
• CPC Class Codes: B32B 37/22 involving the assembly of both discrete and continuous layers
• CPC Class Codes: B32B 38/0036 Heat treatment for heating or cooling of layers during lamination B32B37/06, B32B37/08
• CPC Class Codes: H01L 31/048 Encapsulation of modules
• CPC Class Codes: H01L 31/18 Processes or apparatus specially adapted for the manufacture or treatment of these devices or of parts thereof
• CPC Class Codes: Y02E 10/50 Photovoltaic [PV] energy

Abstract

The invention relates to a method for producing a photovoltaic thin film module (1) which is provided with a thin film solar cell system (2) that is mounted on carrier materials (3) and is covered with a compound (4) on at least one side of the surface, whereby said compound consists of an encapsulating material and is provided with a sealing layer (5) on the side of the surface thereof, said side being arranged on the thin film solar cell system (2). According to a covering method, the encapsulating material (4) and the thin film solar cell system (2), together with the carrier (3), are guided along one another and are pressed under pressure and at an increased temperature in such a way that a weather-proof, photovoltaic thin film module in the form of a compound (1) is designed. According to a method that can be carried out easily, a photovoltaic thin film module that is resistant to UV light, water vapour and other effects of the weather is provided. The photovoltaic module can additionally be provided with flexible characteristics by selecting the carrier material in such a way that said material is configured in the form of plastic foils or plastic foil compounds for instance.

Claims

1. Process for producing a photovoltaic thin film module (1, 10) which has a thin film solar cell system (2) which has been applied to carrier materials (3, 11) and which is optionally jacketed on both sides by encapsulation material composites (4, 4′

), characterized in that in a lamination step the material web for the encapsulation material composite (4, 4′

) consisting of a protective layer (8, 9) and a sealing layer is brought near another material web for the thin film solar cell system (2) and its carrier material (3, 11) in a lamination station such that the sealing layer (5) adjoins the thin film solar cell system (2) and that by increased pressure and optionally increased temperature a composite in the form of a photovoltaic module (1, 10) is formed.

2. Process as claimed in claim 1, wherein lamination is done using one or more calender roller pairs (17, 21).

3. Process as claimed in claim 1 or 2, wherein the photovoltaic thin film module (1, 10) which has been formed is additionally hardened.

4. Process as claimed in one of claims 1 to 3, wherein the carrier material for the thin film solar cell system (2) is a flexible carrier material (11).

5. Process as claimed in claim 4, wherein the flexible carrier material (11) is one based on plastic films or plastic film composites.

6. Process as claimed in claim 4, wherein the flexible carrier material (11) is one based on metal foils or steel strips.

7. Process as claimed in one of claims 1 to 3, wherein the carrier material for the thin film solar cell system (2) is a stiff carrier material (3).

8. Process as claimed in claim 7, wherein the stiff carrier material (3) is glass.

9. Process as claimed in one of claims 1 to 8, wherein in the encapsulation material (4, 4′

) there is a barrier layer (9) which consists of a weathering layer (8), an inorganic oxide layer (7) and a carrier layer (6) which is intended for the inorganic oxide layer (7).

10. Process as claimed in claim 9, wherein plastic films or film composites based on polyethylene naphthenate (PEN) or a coextrudate of polyethylene terephthalate (PETP) and polyethylene naphthenate (PEN) are used in the carrier layer (6).

11. Process as claimed in claim 9 or 10, wherein in the barrier layer (9) an inorganic oxide layer (7) consisting of aluminum or silicon in a thickness of 30 to 200 nm is used.

12. Process as claimed in one of claims 1 to 11, wherein the sealing layer (5) is formed from hot melt materials, such as polyamide or thermoplastic elastomers and/or ionomers.