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WO2016095952A1 - Covering film for generating photovoltaic electrical energy - Google Patents

Covering film for generating photovoltaic electrical energy Download PDF

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Publication number
WO2016095952A1
WO2016095952A1 PCT/EP2014/077813 EP2014077813W WO2016095952A1 WO 2016095952 A1 WO2016095952 A1 WO 2016095952A1 EP 2014077813 W EP2014077813 W EP 2014077813W WO 2016095952 A1 WO2016095952 A1 WO 2016095952A1
Authority
WO
WIPO (PCT)
Prior art keywords
layer
elements
thin film
intermediate layer
covering film
Prior art date
Application number
PCT/EP2014/077813
Other languages
French (fr)
Inventor
Marcus Leonardus Gerardus Maria VEN VAN DE
Wilhelmus Johannus Franciscus VOCHT DE
Original Assignee
Ven Van De Marcus Leonardus Gerardus Maria
Vocht De Wilhelmus Johannus Franciscus
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Ven Van De Marcus Leonardus Gerardus Maria, Vocht De Wilhelmus Johannus Franciscus filed Critical Ven Van De Marcus Leonardus Gerardus Maria
Priority to PCT/EP2014/077813 priority Critical patent/WO2016095952A1/en
Publication of WO2016095952A1 publication Critical patent/WO2016095952A1/en

Links

Classifications

    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B7/00—Layered products characterised by the relation between layers; Layered products characterised by the relative orientation of features between layers, or by the relative values of a measurable parameter between layers, i.e. products comprising layers having different physical, chemical or physicochemical properties; Layered products characterised by the interconnection of layers
    • B32B7/02—Physical, chemical or physicochemical properties
    • B32B7/023—Optical properties
    • H—ELECTRICITY
    • H10—SEMICONDUCTOR DEVICES; ELECTRIC SOLID-STATE DEVICES NOT OTHERWISE PROVIDED FOR
    • H10F—INORGANIC SEMICONDUCTOR DEVICES SENSITIVE TO INFRARED RADIATION, LIGHT, ELECTROMAGNETIC RADIATION OF SHORTER WAVELENGTH OR CORPUSCULAR RADIATION
    • H10F19/00—Integrated devices, or assemblies of multiple devices, comprising at least one photovoltaic cell covered by group H10F10/00, e.g. photovoltaic modules
    • H10F19/80—Encapsulations or containers for integrated devices, or assemblies of multiple devices, having photovoltaic cells
    • H10F19/804—Materials of encapsulations
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B27/00—Layered products comprising a layer of synthetic resin
    • B32B27/06—Layered products comprising a layer of synthetic resin as the main or only constituent of a layer, which is next to another layer of the same or of a different material
    • B32B27/08—Layered products comprising a layer of synthetic resin as the main or only constituent of a layer, which is next to another layer of the same or of a different material of synthetic resin
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B27/00—Layered products comprising a layer of synthetic resin
    • B32B27/30—Layered products comprising a layer of synthetic resin comprising vinyl (co)polymers; comprising acrylic (co)polymers
    • B32B27/304—Layered products comprising a layer of synthetic resin comprising vinyl (co)polymers; comprising acrylic (co)polymers comprising vinyl halide (co)polymers, e.g. PVC, PVDC, PVF, PVDF
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B27/00—Layered products comprising a layer of synthetic resin
    • B32B27/30—Layered products comprising a layer of synthetic resin comprising vinyl (co)polymers; comprising acrylic (co)polymers
    • B32B27/306—Layered products comprising a layer of synthetic resin comprising vinyl (co)polymers; comprising acrylic (co)polymers comprising vinyl acetate or vinyl alcohol (co)polymers
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B27/00—Layered products comprising a layer of synthetic resin
    • B32B27/36—Layered products comprising a layer of synthetic resin comprising polyesters
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B27/00—Layered products comprising a layer of synthetic resin
    • B32B27/40—Layered products comprising a layer of synthetic resin comprising polyurethanes
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B3/00—Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar shape; Layered products comprising a layer having particular features of form
    • B32B3/02—Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar shape; Layered products comprising a layer having particular features of form characterised by features of form at particular places, e.g. in edge regions
    • B32B3/06—Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar shape; Layered products comprising a layer having particular features of form characterised by features of form at particular places, e.g. in edge regions for securing layers together; for attaching the product to another member, e.g. to a support, or to another product, e.g. groove/tongue, interlocking
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B3/00—Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar shape; Layered products comprising a layer having particular features of form
    • B32B3/26—Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar shape; Layered products comprising a layer having particular features of form characterised by a particular shape of the outline of the cross-section of a continuous layer; characterised by a layer with cavities or internal voids ; characterised by an apertured layer
    • B32B3/263—Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar shape; Layered products comprising a layer having particular features of form characterised by a particular shape of the outline of the cross-section of a continuous layer; characterised by a layer with cavities or internal voids ; characterised by an apertured layer characterised by a layer having non-uniform thickness
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B9/00—Layered products comprising a layer of a particular substance not covered by groups B32B11/00 - B32B29/00
    • B32B9/04—Layered products comprising a layer of a particular substance not covered by groups B32B11/00 - B32B29/00 comprising such particular substance as the main or only constituent of a layer, which is next to another layer of the same or of a different material
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B9/00—Layered products comprising a layer of a particular substance not covered by groups B32B11/00 - B32B29/00
    • B32B9/04—Layered products comprising a layer of a particular substance not covered by groups B32B11/00 - B32B29/00 comprising such particular substance as the main or only constituent of a layer, which is next to another layer of the same or of a different material
    • B32B9/045—Layered products comprising a layer of a particular substance not covered by groups B32B11/00 - B32B29/00 comprising such particular substance as the main or only constituent of a layer, which is next to another layer of the same or of a different material of synthetic resin
    • H—ELECTRICITY
    • H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
    • H02S—GENERATION OF ELECTRIC POWER BY CONVERSION OF INFRARED RADIATION, VISIBLE LIGHT OR ULTRAVIOLET LIGHT, e.g. USING PHOTOVOLTAIC [PV] MODULES
    • H02S20/00—Supporting structures for PV modules
    • H02S20/20—Supporting structures directly fixed to an immovable object
    • H02S20/22—Supporting structures directly fixed to an immovable object specially adapted for buildings
    • H02S20/23—Supporting structures directly fixed to an immovable object specially adapted for buildings specially adapted for roof structures
    • H—ELECTRICITY
    • H10—SEMICONDUCTOR DEVICES; ELECTRIC SOLID-STATE DEVICES NOT OTHERWISE PROVIDED FOR
    • H10F—INORGANIC SEMICONDUCTOR DEVICES SENSITIVE TO INFRARED RADIATION, LIGHT, ELECTROMAGNETIC RADIATION OF SHORTER WAVELENGTH OR CORPUSCULAR RADIATION
    • H10F19/00—Integrated devices, or assemblies of multiple devices, comprising at least one photovoltaic cell covered by group H10F10/00, e.g. photovoltaic modules
    • H10F19/80—Encapsulations or containers for integrated devices, or assemblies of multiple devices, having photovoltaic cells
    • H—ELECTRICITY
    • H10—SEMICONDUCTOR DEVICES; ELECTRIC SOLID-STATE DEVICES NOT OTHERWISE PROVIDED FOR
    • H10F—INORGANIC SEMICONDUCTOR DEVICES SENSITIVE TO INFRARED RADIATION, LIGHT, ELECTROMAGNETIC RADIATION OF SHORTER WAVELENGTH OR CORPUSCULAR RADIATION
    • H10F77/00—Constructional details of devices covered by this subclass
    • H10F77/93—Interconnections
    • H10F77/933—Interconnections for devices having potential barriers
    • H10F77/935—Interconnections for devices having potential barriers for photovoltaic devices or modules
    • H10F77/939—Output lead wires or elements
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2250/00—Layers arrangement
    • B32B2250/44—Number of layers variable across the laminate
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2307/00—Properties of the layers or laminate
    • B32B2307/30—Properties of the layers or laminate having particular thermal properties
    • B32B2307/31—Heat sealable
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2307/00—Properties of the layers or laminate
    • B32B2307/40—Properties of the layers or laminate having particular optical properties
    • B32B2307/42—Polarizing, birefringent, filtering
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2307/00—Properties of the layers or laminate
    • B32B2307/50—Properties of the layers or laminate having particular mechanical properties
    • B32B2307/536—Hardness
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2307/00—Properties of the layers or laminate
    • B32B2307/70—Other properties
    • B32B2307/712—Weather resistant
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2307/00—Properties of the layers or laminate
    • B32B2307/70—Other properties
    • B32B2307/714—Inert, i.e. inert to chemical degradation, corrosion
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2307/00—Properties of the layers or laminate
    • B32B2307/70—Other properties
    • B32B2307/714—Inert, i.e. inert to chemical degradation, corrosion
    • B32B2307/7145—Rot proof, resistant to bacteria, mildew, mould, fungi
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2457/00—Electrical equipment
    • B32B2457/12—Photovoltaic modules
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
    • Y02B—CLIMATE CHANGE MITIGATION TECHNOLOGIES RELATED TO BUILDINGS, e.g. HOUSING, HOUSE APPLIANCES OR RELATED END-USER APPLICATIONS
    • Y02B10/00—Integration of renewable energy sources in buildings
    • Y02B10/10—Photovoltaic [PV]
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
    • Y02E—REDUCTION OF GREENHOUSE GAS [GHG] EMISSIONS, RELATED TO ENERGY GENERATION, TRANSMISSION OR DISTRIBUTION
    • Y02E10/00—Energy generation through renewable energy sources
    • Y02E10/50—Photovoltaic [PV] energy

Definitions

  • Thin film PV elements have a polarity which spatially manifests as a top side having positive polarity and a bottom side negative polarity or vice versa.
  • the thin film PV elements can be laminated on to the intermediate layer with their polarity in two orientations.
  • the thin film PV elements can be laminated on to the intermediate layer with their polarity in two orientations.
  • the method further comprises forming the cover layer from a top layer and at least one under layer, wherein the under layer is laminated on the thin film photovoltaic element.
  • Figure 4 shows a block diagram of a process for manufacturing a covering film according to an embodiment of the invention.
  • Figures 5a - 5b show a cross section in a longitudinal direction of a covering film according to an embodiment of the invention.
  • Figure 5c shows a top view of a covering film according to an embodiment of the invention.
  • Figure 5e shows a cross section of a covering film according to an embodiment of the invention at line B - B' of figure 5c.
  • the layers 101 , 102, 103 and 104 must be securely laminated.
  • the laminating is preferably performed in different steps, starting with the substrate layer 101 and the intermediate layer 103.
  • the choice of material for the intermediate layer 103 and cover layer is preferably a thermoplastic polyurethane, which allows reliable lamination, thereby encapsulating the PV element 102.
  • the intermediate layer 103 can be completely molten.
  • laminating pressure can be applied to layers 101 , 102, 103 and 104 undergoing lamination to provide a tight coupling of the layers. Additionally a vacuum can be applied in each respective step to the layers undergoing lamination to further evacuated any air and moist between the layers.
  • cover layer 104 preferably a multi-layer aliphatic polyurethane film material is used, having at one side facing the PV element 102 and the intermediate layer 103 a hotmelt film ensuring reliable lamination to the PV element 102 and the intermediate layer 103.
  • the top layer of the cover layer 104 facing away from the covering film 100 is preferably composed of a hardened polyurethane film which is weather and microbiologically resistant.
  • This layer preferably also comprises UV resistant material.
  • UV absorbers are ZnO, anti-oxidants, hindered amine light stabilizers (HALS) such as bis (2,2,6,6,-tetramethyl-4-piperidyl) sebacate (commercially available as Tinuvin 770®).
  • HALS hindered amine light stabilizers
  • Fig. 2 shows an arrangement 200 of a covering film for generating photovoltaic electrical energy 100 as roofing, wherein the covering film 100 is positioned on roof elements 201 .
  • Figure 2 shows roof heat insulation elements 202 positioned between the covering film 100 and the roof elements 201 .
  • Such roof insulation elements can for example be manufactured from expanded polyethylene foam.
  • the covering film 100 is provided with two rows of PV elements with a single cover layer 104.
  • Fig.4 shows a block diagram 400 of a method for manufacturing the covering film 100, 300 as described above.
  • a substrate layer 101 is provided.
  • Such substrate layer can be a film which is rolled off from a stock roll and subsequently laminated in a laminating device.
  • the substrate layer has a composition such as PVC as described above.
  • a third step 403 thin film PV elements 102 are laminated on top of the intermediate layer 103.
  • the thin film PV elements have a size and are laminated on the intermediate layer 103 such that around all edges of the thin film PV elements 102 a portion of intermediate layer 103 is left uncovered allowing in a next step 404 the cover layer 104 to be laminated on top of the thin film PV elements 102 and the uncovered intermediate layer 103.
  • a seal is formed between the intermediate layer 103 and the cover layer 104 by the lamination such that the thin film PV elements are fully encapsulated between the respective layers 103, 104.
  • a temperature for the lamination is chosen such that the intermediate layer 103 and the cover layer 104, which both contain thermoplastic polyurethane, can intermingle and bond.
  • the flaps 502 can extend horizontally through the covering film edge 506 in fig. 5b.
  • Interconnection elements 501 and flaps 502 can be manufactured from copper. All interconnections between thin film PV elements 102, i.e. busbars 503a, 503b and interconnection elements 501 are laminated between intermediate layer 103 and cover layer 104 protecting them from oxidation or any other degradation from the environment wherein the covering film is applied.
  • the lamination technique allows a seal between the flaps 502 and the inner parts of the covering film 500.
  • the flaps 502 can be plated as to provide protection against oxidation or any other degradation from the environment.
  • Fig. 5c shows a top view of a covering film 500 having interconnection elements 501 and an interconnection element 504 for interconnecting rows of thin film PV elements (not shown in detail) 506a and 506b.
  • Interconnection element 504 can be a strip made for example from copper.
  • Thin film PV elements have a polarity perpendicular to the plane of the thin film. Electrical current can be extracted from the thin film PV elements by means of the busbars 503a at the top level and 503b at the bottom level of the PV elements.
  • the thin film PV elements in row 506a in have a first polarity with respect to their orientation in the covering film 500.
  • the thin film PV elements in row 506b in have a reverse polarity with respect to their orientation in the covering film 500 and with respect to the polarity of thin film PV elements in row 506a.
  • Fig. 5d shows a cross section of the covering film 500 at line A-A' of figure 5c. Space between interconnection element 501 and intermediate layer 103 can be filled with an additional insulation layer 505. From fig. 5d it is clear that the interconnection element 501 connects busbars 503b at the bottom side of the thin film PV element 102 at opposite sides. Thin film PV elements 507a and 507b correspond with rows 506a and 506b respectively and have reverse polarity relative to each other. Since the polarity is reversed between rows 506a and 506b and consequently elements 507a and 507b, the interconnection element 501 can be connected at the bottom busbars 503b of each thin film PV element 507a, 507b respectively.
  • FIG. 6a shows a schematic representation of the series connection of thin film PV elements 507a, 507b and the connection in two rows 506a, 506b as described above.
  • each PV element 507a in the first row 506a has a polarity 601 a, 601 b
  • each PV element 507b has a reversed polarity 601 b respectively.
  • Arrow 601 a indicates for example that a top side of a corresponding PV element 507a has an electrically negative potential with respect to its bottom side.
  • arrow 601 b indicates for example that a top side of a corresponding PV element 507b has an electrically positive potential with respect to its bottom side.
  • Each PV element in row 506a in figure 6a has the same negative potential 601 a and each PV element in row 506b in figure 6a has the same positive potential 601 b.
  • connection 504 to row 506b can be made at the bottom level of the corresponding PV elements via busbars 503b.
  • connection 504 can be fixed to the intermediate layer 103 as well as the connection elements 501 a and 501 b. In this way a mechanically secure and strong connection 504 can be made between the rows 506a and 506b and via connections 501 a, 501 b with external electrical leads.

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  • Engineering & Computer Science (AREA)
  • Ceramic Engineering (AREA)
  • Architecture (AREA)
  • Civil Engineering (AREA)
  • Structural Engineering (AREA)
  • Photovoltaic Devices (AREA)

Abstract

Covering film for generating photovoltaic electrical energy (100) for, comprising a substrate layer (101), an intermediate layer (103) laminated on top of the substrate layer (101), at least one thin film photovoltaic element (102), having a portion of the intermediate layer (103) surrounding the thin film photovoltaic element (102) uncovered at all edges of the thin film photovoltaic element a cover layer (104), laminated on top of the thin film photovoltaic element (102) and the uncovered intermediate layer (103) surrounding the thin film photovoltaic element (102), and wherein overlapping parts over the intermediate layer (103) and the cover layer (104) have a thermally laminated seal. The intermediate layer (103) comprises a composition of a first thermoplastic polyurethane and a material compatible with a material of the substrate layer (101), and the cover layer (104) comprises a second thermoplastic polyurethane which is compatible with the first thermoplastic polyurethane of the intermediate layer (103).

Description

COVERING FILM FOR GENERATING PHOTOVOLTAIC ELECTRICAL ENERGY
FIELD OF THE INVENTION
The invention relates to a covering film for generating photovoltaic electrical energy and a method for manufacturing the covering film.
BACKGROUND
With the availability of thin film photovoltaic (PV) elements, such as CIGS, amorphous silicon or CdTe, and other PV films, generation of electrical energy in covering films has come within reach. Known solutions such as described in US published patent nr 8375653 show that a PV element can be encapsulated in layers of flexible material. A PV element thus encapsulated can be laminated into a roofing film and applied on to a roof, thus rendering a watertight roof whilst also providing PV electrical energy.
Material used for such purpose can be EFTE, PFE, and other. These materials however need pasting in a vacuum environment and pressing to encapsulate PV film between the EFTE films . Thus complicated machinery is required for manufacturing the encapsulated PV elements.
Furthermore in the process as described of encapsulating PV elements with materials such as EFTE air bubbles as well as small particles, for example dirt, may be encapsulated with the PV elements, negatively affecting performance and appearance of the resulting product.
Furthermore the chosen materials, and especially the seals near the edges of the encapsulation are known for cracks and are thus permeable for water and do not sufficiently prevent deterioration of the PV elements due to water ingress.
It has been suggested to use thermoplastic urethane, however this material is available in many forms and compositions and is not always suitable for continuous use as covering film in combination with PV elements, considering strength, hardness and opacity. For certain applications such as covering of large structures such as swimming pools the known roofing material is unsuitable.
The use thin film PV elements in large surface areas requires special attention with respect to interconnecting the PV elements. Application of covering film with PV energy generation such as in roofing, building facades, swimming pools and the like involve large amounts of electrical energy to be transferred from the covering film. Large electrical currents and/or voltages may occur resulting in overheating of interconnection elements or voltage breakdown within the covering film and/or with the interconnection elements with external electrical leads. Furthermore interconnection means of the PV elements in the covering film with external electrical leads must also be mechanically reliable, as they must withstand mechanical stress due to weather influence and when during use the covering film is regularly applied and removed again.
SUMMARY
It is therefore an object of the invention to provide a solution for any of the above stated problems. The object is achieved in a covering film for generating photovoltaic electrical energy, comprising a substrate layer, an intermediate layer laminated on top of the substrate layer, at least one thin film photovoltaic element, having a portion of the intermediate layer surrounding the thin film photovoltaic element uncovered at all edges of the thin film photovoltaic element a cover layer, laminated on top of the thin film photovoltaic element and the uncovered intermediate layer surrounding the thin film photovoltaic element, and wherein overlapping parts over the intermediate layer and the cover layer have a thermally laminated seal. The intermediate layer has a composition of a first thermoplastic polyurethane and a material compatible with a material of the substrate layer. This allows reliable bonding of the intermediate layer with the substrate layer by the lamination. The cover layer comprises a second thermoplastic polyurethane which is compatible with the first thermoplastic polyurethane of the intermediate layer, which allows reliable bonding of the cover layer with the intermediate layer. Thus the thin film PV elements are securely bonded to the substrate layer and encapsulated between the intermediate layer and the cover layer. The compatibility of materials of these layers enable a perfect seal preventing ingress of any particles or moist from outside of the respective layers.
In an embodiment according to the invention, the substrate layer comprises polyvinylchloride.
Polyvinylchloride allows application of the covering film in for example roofing purposes or swimming pool covering.
In an embodiment according to the invention the cover layer comprises a thermoplastic top layer and at least one thermoplastic under layer laminated on top of each other, the under layer laminated on the thin film photovoltaic element, the top layer being a harder layer than the under layer. This allows the top layer having high weather resistance and microbial and hydrolysis resistance whilst maintaining a reliable bond between cover layer and intermediate layer.
In an embodiment according to the invention, the top layer of the cover layer comprises a UV absorber. This allows extended durability in areas having sunlight with high UV radiation content.
In an embodiment according to the invention, interconnection elements of the thin film PV element are laminated between the intermediate layer and the cover layer. This allows the interconnection elements to be fully separated from the environment wherein the covering film is used, thereby preventing oxidation or any other degradation. Furthermore secure insulation between encapsulated PV elements is achieved.
In a further embodiment according to the invention, the thin film PV elements are connected in two rows, and wherein the thin film PV elements are connected in series having first interconnection elements at one end of the covering film for connecting to external electrical leads, and a second interconnection element for interconnecting the rows of thin film PV elements at an opposite end of the covering film.
This allows external electrical leads to be connected at one single end of the covering film, thus providing easy installation and obviating a need to install long leads when long covering films are used with many PV elements in series. Moreover, connecting the PV elements in series allows a relatively low current and thereby allowing thin interconnections between the PV elements within the covering film while keeping current losses low. The thorough encapsulating in the previous steps provides sufficient insulation between the respective rows of thin film PV elements.
In a further embodiment according to the invention, the thin film PV elements of the respective rows are laminated in opposite polarity, and wherein the interconnection elements are connected to the bottom side of the thin film PV elements between the thin film PV elements and the intermediate layer.
Thin film PV elements have a polarity which spatially manifests as a top side having positive polarity and a bottom side negative polarity or vice versa. As thin film PV elements are generally transparent, the thin film PV elements can be laminated on to the intermediate layer with their polarity in two orientations. Thus it is possible to arrange the thin film PV elements in rows with reverse polarity or on rows wherein the PV element have alternating polarity.
In a further embodiment according to the invention, the interconnection elements are provided with terminal means for connecting external electrical leads.
In a further embodiment according to the invention, the terminal means extend through the covering layer. This allows external electrical leads to be connected on top of the covering film. This can be advantageous when the covering film is for example applied in an aqueous environment such as a swimming pool, where the electrical leads are to be guided from the covering film to a pool side above the water level.
In a further embodiment according to the invention, wherein the terminal means extend through the intermediate layer and the substrate layer. This allows external electrical leads to be connected below the covering film. This for example advantageous in roofing applications where weather has an impact on the top surface of the top surface of the covering film. The covering film can safely be connected below the covering film without influence of weather conditions.
In another aspect of the invention the object is achieved in a method of manufacturing a covering film for generating photovoltaic electrical energy, the method comprising providing a substrate layer, laminating an intermediate layer on the substrate layer, laminating at least one thin film photovoltaic element on the intermediate layer, while leaving a portion of the intermediate layer uncovered at all edges of the elements, laminating a cover layer on top of the thin film photovoltaic elements and the uncovered intermediate layer surrounding the thin film photovoltaic element. The method further comprises forming the intermediate layer from a composition of a first thermoplastic polyurethane and a material compatible with a material of the substrate layer and forming the cover layer from a second thermoplastic polyurethane which is compatible with the first thermoplastic polyurethane of the intermediate layer.
In an embodiment according to the invention the substrate layer is made of polyvinylchloride.
In an embodiment according to the invention, the method further comprises forming the cover layer from a top layer and at least one under layer, wherein the under layer is laminated on the thin film photovoltaic element.
In a further embodiment according to the invention the method comprises providing the top layer with a UV absorber.
In a further embodiment according to the invention the method comprises laminating connection elements between the thin film PV elements between the intermediate layer and the cover layer.
In a further embodiment according to the invention the method comprises laminating terminal means for to the thin film PV elements between the intermediate layer and the cover layer.
In a further embodiment according to the invention the method comprises arranging the thin film PV elements in two rows, connecting the PV elements in series, and connecting the rows of thin film PV elements in series on one end of the covering film, and providing the terminal means at an opposite end of the covering film.
BRIEF DESCRIPTION OF THE DRAWINGS
Figure 1 shows a perspective view of a covering film in accordance with an embodiment of the invention.
Figure 2 shows a perspective view of an application of a covering film according to an embodiment of the invention. Figure 3 shows another application of a covering film according to an embodiment of the invention.
Figure 4 shows a block diagram of a process for manufacturing a covering film according to an embodiment of the invention.
Figures 5a - 5b show a cross section in a longitudinal direction of a covering film according to an embodiment of the invention.
Figure 5c shows a top view of a covering film according to an embodiment of the invention.
Figure 5d shows a cross section of a covering film according to an embodiment of the invention at line A - A' of figure 5c.
Figure 5e shows a cross section of a covering film according to an embodiment of the invention at line B - B' of figure 5c.
Figure 6a and 6b show schematic diagrams of interconnecting PV elements in a covering film according to an embodiment of the invention.
DETAILED DESCRIPTION OF EMBODIMENTS OF THE INVENTION
Figure 1 shows a covering film 100 comprising a substrate layer 101 , at least one photovoltaic (PV) element 102, an intermediate layer 103 between the substrate layer 101 and the at least one PV element. A cover layer 104 is laminated on top of the PV element and intermediate layer 103.
The PV element 102 is laminated on the intermediate layer 103 such around the edges of the PV element 102 the intermediate layer 103 is exposed. In other words the intermediate layer 103 extends beyond the edges of the PV element. Busbars for conducting electrical current from the PV element 102 to connection terminals of the covering film 100 can be provided at opposite edges of the PV element 102. Busbars can be formed by means of conducting tape comprising for example a metal strip and conductive adhesive for contacting the PV elements 102.
In order to obtain a water tight and particle and microbial ingress free covering film, the layers 101 , 102, 103 and 104 must be securely laminated. The laminating is preferably performed in different steps, starting with the substrate layer 101 and the intermediate layer 103. The choice of material for the intermediate layer 103 and cover layer is preferably a thermoplastic polyurethane, which allows reliable lamination, thereby encapsulating the PV element 102. During lamination, the intermediate layer 103 can be completely molten.
As for the substrate layer 101 tough materials are chosen, such as polyvinylchloride (PVC), PET, EFTE, EVA and the like are chosen, a choice of pure thermoplastic polyurethane for the intermediate layer 103 may not provide a reliable lamination between the substrate layer 102 and the intermediate layer 103. It is therefore preferred to use a composite material for the intermediate layer 103. For example in combination with PVC or PET a thermoplastic copolymer hotmelt film having a composition of both polyurethane and polyester can be used. In another example when EVA is used as material for the substrate layer 101 , an EVA-based terpolymer can be used as composition for the intermediate layer 102, thus ensuring reliable lamination between substrate layer 101 and intermediate layer 103, and between the intermediate layer 103 and the cover layer 104.
While laminating pressure can be applied to layers 101 , 102, 103 and 104 undergoing lamination to provide a tight coupling of the layers. Additionally a vacuum can be applied in each respective step to the layers undergoing lamination to further evacuated any air and moist between the layers.
For the cover layer 104 preferably a multi-layer aliphatic polyurethane film material is used, having at one side facing the PV element 102 and the intermediate layer 103 a hotmelt film ensuring reliable lamination to the PV element 102 and the intermediate layer 103. The top layer of the cover layer 104 facing away from the covering film 100 is preferably composed of a hardened polyurethane film which is weather and microbiologically resistant. This layer preferably also comprises UV resistant material. Examples of UV absorbers are ZnO, anti-oxidants, hindered amine light stabilizers (HALS) such as bis (2,2,6,6,-tetramethyl-4-piperidyl) sebacate (commercially available as Tinuvin 770®).
The PV elements 102 can be thin film photovoltaic elements, such as CIGS, amorphous silicon or CdTe PV films and the like. These films can be in an elongated form stretched out over the intermediate layer 103, or subdivided in smaller elements and then laminated on top of the intermediate layer. Arrangements for the thin film PV elements 102 will be set out below.
Fig. 2 shows an arrangement 200 of a covering film for generating photovoltaic electrical energy 100 as roofing, wherein the covering film 100 is positioned on roof elements 201 . Figure 2 shows roof heat insulation elements 202 positioned between the covering film 100 and the roof elements 201 . Such roof insulation elements can for example be manufactured from expanded polyethylene foam. In this example the covering film 100 is provided with two rows of PV elements with a single cover layer 104.
Fig. 3 shows an arrangement 300 of a covering film for generating photovoltaic electrical energy with two rows of film PV elements 102 on a common substrate layer 101 , a common intermediate layer 103 and a common cover layer 104. The cover layer 104 is shown in a cutaway view to reveal the thin film PV elements 102 below it. Per row the PV elements are connected in series using busbars (se figs. 5a - 5e). Each PV elements has a diode connected in parallel between its connections having the same forward conduction direction as a semiconductor element forming the PV element. Both rows are at one end of the covering film 300 (left in figure 3) connected in series, so that both rows provide an aggregate output voltage at the other end (to the right in fig. 3) of the arrangement 300, see also figs. 5a - 5e and the corresponding description.
Fig.4 shows a block diagram 400 of a method for manufacturing the covering film 100, 300 as described above.
In a first step 401 , a substrate layer 101 is provided. Such substrate layer can be a film which is rolled off from a stock roll and subsequently laminated in a laminating device. The substrate layer has a composition such as PVC as described above.
In a second step 402, the intermediate layer 103 is laminated on the substrate layer 101 .
In a third step 403, thin film PV elements 102 are laminated on top of the intermediate layer 103. The thin film PV elements have a size and are laminated on the intermediate layer 103 such that around all edges of the thin film PV elements 102 a portion of intermediate layer 103 is left uncovered allowing in a next step 404 the cover layer 104 to be laminated on top of the thin film PV elements 102 and the uncovered intermediate layer 103. By this step 404 a seal is formed between the intermediate layer 103 and the cover layer 104 by the lamination such that the thin film PV elements are fully encapsulated between the respective layers 103, 104. A temperature for the lamination is chosen such that the intermediate layer 103 and the cover layer 104, which both contain thermoplastic polyurethane, can intermingle and bond.
Fig. 5a and 5b show a cross section in a longitudinal direction d of a covering film 500 having a connection means 501 , 502 for connecting the thin film PV elements 102 to external electrical leads. As described, each thin film PV element has busbars on top 503a and at the bottom 503b at opposite sides in the longitudinal direction d of the covering film 100. The busbars 503a and 503b can be manufactured from copper. Underneath the thin film PV elements are interconnection elements 501 contacting the busbars 503b. Flaps 502 extend substantially vertical from the interconnection elements 501 either through the intermediate layer 103 and substrate layer 101 in fig. 5a and/or through cover layer 104 to provide terminals for interconnection with external electrical leads depending on the application of the covering film. Alternatively the flaps 502 can extend horizontally through the covering film edge 506 in fig. 5b. Interconnection elements 501 and flaps 502 can be manufactured from copper. All interconnections between thin film PV elements 102, i.e. busbars 503a, 503b and interconnection elements 501 are laminated between intermediate layer 103 and cover layer 104 protecting them from oxidation or any other degradation from the environment wherein the covering film is applied. The lamination technique allows a seal between the flaps 502 and the inner parts of the covering film 500. The flaps 502 can be plated as to provide protection against oxidation or any other degradation from the environment.
Fig. 5c shows a top view of a covering film 500 having interconnection elements 501 and an interconnection element 504 for interconnecting rows of thin film PV elements (not shown in detail) 506a and 506b. Interconnection element 504 can be a strip made for example from copper.
Thin film PV elements have a polarity perpendicular to the plane of the thin film. Electrical current can be extracted from the thin film PV elements by means of the busbars 503a at the top level and 503b at the bottom level of the PV elements. In figure 5c the thin film PV elements in row 506a in have a first polarity with respect to their orientation in the covering film 500. The thin film PV elements in row 506b in have a reverse polarity with respect to their orientation in the covering film 500 and with respect to the polarity of thin film PV elements in row 506a.
Fig. 5d shows a cross section of the covering film 500 at line A-A' of figure 5c. Space between interconnection element 501 and intermediate layer 103 can be filled with an additional insulation layer 505. From fig. 5d it is clear that the interconnection element 501 connects busbars 503b at the bottom side of the thin film PV element 102 at opposite sides. Thin film PV elements 507a and 507b correspond with rows 506a and 506b respectively and have reverse polarity relative to each other. Since the polarity is reversed between rows 506a and 506b and consequently elements 507a and 507b, the interconnection element 501 can be connected at the bottom busbars 503b of each thin film PV element 507a, 507b respectively.
Fig. 5e shows a cross section of the covering film 500 at line B - B' in fig. 5c. With the thin film PV elements having reverse polarity in rows 506a and 506b, the corresponding thin film PV elements 507a and 507b at line B - B' can be interconnected by interconnection element 504 by connecting to the bottom busbars 503b of both elements 507a, 507b.
Figure 6a shows a schematic representation of the series connection of thin film PV elements 507a, 507b and the connection in two rows 506a, 506b as described above. In figure 6a, each PV element 507a in the first row 506a has a polarity 601 a, 601 b, whereas in row 506b each PV element 507b has a reversed polarity 601 b respectively. Arrow 601 a indicates for example that a top side of a corresponding PV element 507a has an electrically negative potential with respect to its bottom side. Likewise, arrow 601 b indicates for example that a top side of a corresponding PV element 507b has an electrically positive potential with respect to its bottom side. Each PV element in row 506a in figure 6a has the same negative potential 601 a and each PV element in row 506b in figure 6a has the same positive potential 601 b.
As a consequence, in order to concatenate all PV elements 507a, 507b of the respective rows 506a, 506b in series, the interconnection 503a, 503b between respective PV elements must be from an upper side 503a of a PV element 507a, 507b to a bottom side 503b of an adjacent PV element 507a, 507b. Interconnections are made for example with busbars 503a between the PV elements. At the end of row 506a, a connection is made with row 506b with connection element 504 between busbars 503b at the top of the last PV elements of rows 506a and 506b respectively. Since the interconnection 504 is at the same (top)level with respect to the corresponding PV elements shown on the right in fig. 6a, and the right most PV element 507a in row 506a has a negative polarity 601 a the right most PV element 507b in row 506b has a reversed, positive polarity 601 b.
As shown in figure 6b, the PV elements 507a, 507b are preferably positioned with alternating polarities 601 a, 601 b in each row 506a, 506b. This allows busbars 503a on the top side to connect two adjacent PV elements 507a and, and busbars 503b on the bottom side to connect the next adjacent PV elements 507b, such that the PV elements are connected in series without busbars having to cross from an upper level to a bottom level, resulting in a more secure connection than shown in fig. 6a.
At the end of row 506a, a connection 504 to row 506b can be made at the bottom level of the corresponding PV elements via busbars 503b. Thus connection 504 can be fixed to the intermediate layer 103 as well as the connection elements 501 a and 501 b. In this way a mechanically secure and strong connection 504 can be made between the rows 506a and 506b and via connections 501 a, 501 b with external electrical leads.

Claims

Covering film (100, 300, 500) for generating photovoltaic electrical energy, comprising
a substrate layer (101 );
an intermediate layer (103) laminated on top of the substrate layer
(101 ) ;
at least one thin film photovoltaic element (102), having a portion of the intermediate layer (103) surrounding the thin film photovoltaic element
(102) uncovered at all edges of the thin film photovoltaic element;
- a cover layer (104), laminated on top of the thin film photovoltaic element (102) and the uncovered intermediate layer (103) surrounding the thin film photovoltaic element (102), and wherein overlapping parts over the intermediate layer (103) and the cover layer (104) have a thermally laminated seal;
characterized by
- the intermediate layer (103) comprising a composition of a first thermoplastic polyurethane and a material compatible with a material of the substrate layer (101 );
- the cover layer (104) comprising a second thermoplastic polyurethane which is compatible with the first thermoplastic polyurethane of the intermediate layer (103).
Covering film (100, 300, 500) according to claim 1 , wherein the substrate layer (101 ) is made of polyvinylchloride.
Covering film (100, 300, 500) according to claim 1 or claim 2, wherein the cover layer (104) comprises a thermoplastic top layer and at least one thermoplastic under layer laminated on top of each other, the under layer laminated on the thin film photovoltaic element (102), the top layer being a harder layer than the under layer, the top layer having microbial and hydrolysis resistance.
Covering film (100, 300, 500) according to any of the preceding claim 3, wherein the top layer of the cover layer (104) comprises a UV absorber.
Covering film (300, 500) according to any of the preceding claims, wherein interconnection elements (501 , 503a, 503b) of the thin film PV element are laminated between the intermediate layer (103) and the cover layer (104).
Covering film (300, 500) according to claim 5, wherein the thin film PV elements are connected in two rows (301 a, 301 b, 506a, 506b), and wherein the thin film PV elements are connected in series having first interconnection elements (501 a, 501 b) at one end of the covering film (500) for connecting to external electrical leads, and a second interconnection element 504 for interconnecting the rows (506a, 506b) of thin film PV elements (102) at an opposite end of the covering film (300, 500).
7. Covering film (300, 500) according to claim 6, wherein the thin film PV elements of the respective rows (506a, 506b) are laminated in opposite polarity (601 a, 601 b), and wherein the interconnection elements (501 a, 501 b, 504) are connected to the bottom side (503a, 503b) of the thin film PV elements (102) between the thin film PV elements (102) and the intermediate layer (103).
8. Covering film (300, 500) according to claim 7, wherein the interconnection elements (501 a, 501 b) are provided with terminal means (502) for connecting external electrical leads.
9. Covering film (300, 500) according to claim 8, wherein the terminal means (502) extend through the covering layer (104).
10. Covering film (300, 500) according to claim 8, wherein the terminal means (502) extend through the intermediate layer (103) and the substrate layer (101 ).
1 1 . Method (400) of manufacturing a covering film (100, 300, 500)for generating photovoltaic electrical energy, the method comprising:
- providing (401 ) a substrate layer (101 );
- laminating (402) an intermediate layer (102) on the substrate layer (101 );
- laminating (403) at least one thin film photovoltaic element (102) on the intermediate layer (103), while leaving the intermediate layer (103) uncovered at all edges of the elements (102);
- laminating (404) a cover layer (104) on top of the thin film photovoltaic elements (102) and the uncovered intermediate layer (103) surrounding the thin film photovoltaic element (102);
characterized by
- forming the intermediate layer (103) from a composition of a first thermoplastic polyurethane and a material compatible with a material of the substrate layer (101 );
- forming the cover layer (104) from a second thermoplastic polyurethane which is compatible with the first thermoplastic polyurethane of the intermediate layer (103).
12. Method (400) according to claim 1 1 , wherein the substrate layer (101 ) is made of polyvinylchloride.
13. Method (400) according to claim 1 1 or claim 12, further forming the cover layer (104) from a top layer and at least one under layer, wherein the under layer is laminated on the thin film photovoltaic element.
14. Method (400) according to any of the claims 1 1 - 13, comprising providing the top layer with a UV absorber.
15. Method (400) according to any of the claims 1 1 - 14, further comprising laminating connection elements between the thin film PV elements between the intermediate layer (103) and the cover layer (104).
16. Method according to claim 15, further comprising laminating terminal means (502) for to the thin film PV elements between the intermediate layer (103) and the cover layer (104).
17. Method according to claim 16, further comprising arranging the thin film PV elements in two rows, connecting the PV elements in series, and connecting the rows of thin film PV elements in series on one end of the covering film, and providing the terminal means at an opposite end of the covering film.
PCT/EP2014/077813 2014-12-15 2014-12-15 Covering film for generating photovoltaic electrical energy WO2016095952A1 (en)

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Citations (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
WO2008013837A2 (en) * 2006-07-28 2008-01-31 E. I. Du Pont De Nemours And Company Solar cell encapsulant layers with enhanced stability and adhesion
AT506100A1 (en) * 2007-12-13 2009-06-15 Isovolta PHOTOVOLTAIC MODULE WITH PRIMER LAYER
US8375653B2 (en) 2007-11-06 2013-02-19 Certainteed Corporation Photovoltaic roofing elements including tie layer systems
EP2800149A1 (en) * 2011-12-28 2014-11-05 Mitsubishi Plastics, Inc. Protective material for solar cells

Patent Citations (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
WO2008013837A2 (en) * 2006-07-28 2008-01-31 E. I. Du Pont De Nemours And Company Solar cell encapsulant layers with enhanced stability and adhesion
US8375653B2 (en) 2007-11-06 2013-02-19 Certainteed Corporation Photovoltaic roofing elements including tie layer systems
AT506100A1 (en) * 2007-12-13 2009-06-15 Isovolta PHOTOVOLTAIC MODULE WITH PRIMER LAYER
EP2800149A1 (en) * 2011-12-28 2014-11-05 Mitsubishi Plastics, Inc. Protective material for solar cells

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