DE102009051397A1 - Process for pretreating a photovoltaic module for bonding to a mounting device - Google Patents

Abstract

A method of pre-treating a photovoltaic module for bonding with a mounting device provides for providing a photovoltaic module (30) having a surface (O30) of a glass material and providing a mixture (100) containing a gas (110) or a Plasma (120) contains. On a region (B1, B2) of the surface (O30) of the photovoltaic module (30), a flow of the mixture (100) is generated. The area (B1, B2) of the surface (O30) of the photovoltaic module becomes when the flow of the mixture (100) to the surface (O30) of the photovoltaic module by reaction of the gas (110) or the plasma (120) with one on the surface (O30) of the photovoltaic module deposited material (400).

Description

The invention relates to a method for pretreating a photovoltaic module, on the surface of which a mounting device can be fastened by an adhesive connection.

A photovoltaic module generally has a photosensitive layer. The photosensitive layer converts light energy of radiation incident on the photosensitive layer into electrical energy. To protect the photosensitive layer from external damage, the photosensitive layer may be disposed between glass sheets. For mounting such a photovoltaic module on a substrate, such as a roof, a mounting device can be mounted on one of the glass surfaces. The mounting device may comprise a metallic carrier system. Such a mounting device may, for example, be glued to the surface of one of the glass panes. In order to ensure a secure hold between the glass pane and the mounting device in the adhesive bond, the glass surface must be cleaned before applying the adhesive. Furthermore, it must be ensured that there is no moisture infiltration in the region of the bond between the glass pane and the mounting device, since otherwise there is a risk that the mounting device will detach from the glass pane.

To clean the glass surface, for example, a solution of isopropanol or an isopropyl alcohol solution can be applied manually to the surface of a glass pane of the photovoltaic module. In order to prevent the ingress of moisture at the adhesive bond between the glass pane and the mounting device, a primer may additionally be applied. Primer systems are currently both solvent-based and as silane glass primer. The solvent-based systems are generally very dilute adhesives. During the processing of such solvent-based adhesion promoters, flash-off times must be maintained after application. Furthermore, the solvents used generally have environmentally hazardous substances.

When using silane primers, one difficulty is to apply a very thin layer of the silane primer to the glass substrate. In the case of an automated application, such an extremely thin application of an isopropanol solution with a mixed silane primer poses a great challenge. Manual application of the adhesion promoter, however, is very time-consuming, since after application of the adhesion promoter, the glass surfaces must be wiped dry again.

The object of the present invention is to provide a method for pretreating a photovoltaic module for bonding with a mounting device, wherein the treatment of the glass surface can be done as quickly as possible and after the pretreatment of the glass surface a secure hold of the adhesive bond between the glass and the mounting device is guaranteed ,

According to one embodiment of a method for pretreating a photovoltaic module for bonding to a mounting device, it is provided that a photovoltaic module is provided which has a surface of a material made of glass, and further a mixture is provided which contains a gas or a plasma , A flow of the mixture is generated on a portion of the surface of the photovoltaic module. The area of the surface of the photovoltaic module is cleaned by impinging the flow of the mixture on the surface of the photovoltaic module by reaction of the gas or the plasma with a material deposited on the surface of the photovoltaic module.

As the plasma, for example, an atmospheric plasma can be used. When using a mixture of the gas, the gas can be ignited in a flaming device. The glass surface is cleaned by the action of the plasma on the surface of a glass pane of the photovoltaic module or by the flame treatment of the surface of the glass pane of the photovoltaic module with the ignited gas mixture. In addition to cleaning, the surface tension and wettability of the glass sheet are increased, thereby improving the adhesive properties of the glass material.

The flame of the ignited gas mixture has a temperature between 700 ° C and 1000 ° C, preferably of about 800 ° C, on. If a plasma mixture is used for cleaning, the plasma acts at a temperature of 150 ° C to 200 ° C on the surface of a glass pane of the photovoltaic module. Due to the action of the flame or the plasma occurs locally only a small change in temperature on the surface of the glass. This small temperature change induces only low thermal stresses in the glass, which can avoid stress fractures in the glass. Furthermore, a driving speed of at least 10 m per minute, with which a flaming device or a plasma source and the glass surface of the photovoltaic module are moved relative to each other ensures that no temperature increase occurs in the glass, possibly would cause a breakage of the material. Due to the short processing time thus stress fractures of the glass material can be prevented or almost completely excluded.

When a silicon-containing compound is added to the gas or plasma as additive, the cleaned glass surface is coated with a thin silicon-containing layer. As a result, the glass surface is sealed, so that a moisture infiltration between the glass surface and an adhesive that can be applied for bonding a mounting device on the coated glass, prevented.

In the method for pretreating a photovoltaic module for bonding with a mounting device, the cleaning and the pretreatment of the surfaces is carried out in terms of process technology in a single step.

The invention will be explained in more detail below with reference to figures showing exemplary embodiments of the present invention. Show it:

1 an embodiment of a photovoltaic module with a photosensitive layer arranged between glass panes,

2 an embodiment of a method for producing a photovoltaic module, in which a mounting device is attached to the module,

3 an embodiment of a photovoltaic module with a mounted on a surface of the photovoltaic module mounting device,

4 an embodiment of a device for pretreating a photovoltaic module for bonding a mounting device to a surface of the photovoltaic module,

5 a further embodiment of a device for pretreating a photovoltaic module for bonding a mounting device to a surface of the photovoltaic module,

6 an embodiment of a photovoltaic module with a mounted on a glass seal sealing coating.

1 shows a photovoltaic module, which is a photosensitive layer 36 having. At the in 1 embodiment shown, the photosensitive layer 36 a partial layer 36a and a sub-layer 36b on. The sub-layer 36a For example, it may comprise microcrystalline silicon which is sensitive to light radiation in the high frequency visible region as well as parts of the infrared region. The sub-layer arranged underneath 36b may contain amorphous silicon which is photosensitive to low frequency light of the visible spectrum. Upon impact of light rays on the photosensitive layer 36 arise free charge carriers, causing contact surfaces 34 and 35 a tension arises. To protect against external damage is the photosensitive layer structure 36 with the contact surfaces 34 and 35 between glass panes 31 and 32 arranged. For gluing the glass panes is a foil 33 between the contact surface 35 and the glass pane 31 intended.

2 shows a schematic representation of a manufacturing method for manufacturing a photovoltaic module, the in 1 may have shown layer structure. During the procedure, the individual layers of the in 1 laminated layer structure of the photovoltaic module laminated together, then cleaned, sealed and then glued to a mounting device.

In one step 1 become the individual layers of the photovoltaic module 30 initially prelaminated, which can be done for example by means of a roll laminator. In step 2 the final lamination takes place. For this purpose, several photovoltaic modules are stacked with the respective prelaminated layers on a holding device and finally laminated in an autoclave by the action of pressure and temperature.

After the assembly of the photovoltaic module is firmly pressed, a mounting device, with which the photovoltaic module can be mounted on a substrate surface, can be attached to one of the glass panes. To do this, a surface O30a or O30b of one of the glass panes must first be in one step 3 getting cleaned. To ensure a secure hold of the mounting device to the glass, is in step 3 in addition to cleaning the surface of the glass sheet sealed. In step 4 Then, the application of an adhesive and the bonding of the mounting device with the glass surface of the module.

3 shows a top O30 on one of the glass panes 31 . 32 of the photovoltaic module 30 , At areas B1 and B2 of the photovoltaic module is the mounting device 200 appropriate. This is between the surface O30 of the glass 31 respectively 32 an adhesive layer 300 applied. The mounting device can thus be fixed by an adhesive bond on the glass sheets.

4 shows an embodiment of a device for pretreating a photovoltaic module 30 before the adhesive layer 300 for bonding the photovoltaic module with the mounting device the surface of one of the glass panes of the photovoltaic module is attached. The photovoltaic module 30 is on transport wheels 40 stored. On the surface O30, the photovoltaic module has an impurity 400 on. At the pollution 400 For example, they may be residuals of material deposited on the surface of the glass in an autoclave during the lamination process. These impurities may contain carbon compounds. The contaminants may further include organic deposits resulting from outgassing of polyvinyl butyral which is a constituent of the film 33 Photovoltaic module has arisen during lamination in the Autoclave.

Above the photovoltaic module 30 is at the in 4 shown embodiment of the device for cleaning and sealing the surface O30a of the glass sheet 31 a flaming device 10 intended. The flaming device 10 is on a guide rail 50 attached. The guide rail 50 is over a bracket 60 on a surface 70 , For example, a wall or ceiling, attached. In a container 90 is a mixture of a gas 110 and an additive added to the gas 130 contain. The mixture 100 from the gas and the additive can via a supply line 80 the flaming device 10 be supplied.

To clean and seal the glass surface O30a of the photovoltaic module generates the Beflammeinrichtung 10 a flow of the mixture 100 towards the surface O30a of the photovoltaic module. The flaming device 10 and the photovoltaic module 30 are arranged to each other such that not the entire surface O30a of the photovoltaic module, but only in 3 shown areas B1 and B2 are flamed. As gas 110 For example, natural gas or town gas can be used for flaming. The flameproofing device can be set in such a way that when the gas mixture is ignited a temperature between 700 ° C. and 1000 ° C. is generated.

By the flames become the impurities 400 from the glass surface O30a burned to form volatile reaction products. The reaction products may be from the surface of the glass sheet 31 be sucked off. Since a temperature change at the areas B1 and B2 is small, excessive strains that could cause the glass to break can not be induced in the glass.

As an additive 130 can the combustion gas 110 For example, organosilicon compounds are admixed. This is done during the flaming next to the cleaning of the surface of the glass 31 in addition a coating of the cleaned surface of the glass sheet. When organosilicon precursors as additives 130 in the gas mixture 100 are used, a silicization of the glass surface occurs. The silicate layer deposited on the glass surface may, for example, have a thickness between 10 nm and 30 nm. The organosilicon compounds may contain, for example, hexamethyldisilazane or hexamethyldisiloxane.

To cover the entire areas B1 and B2 along the surface of the glass 30 To clean and coat, is the photovoltaic module 30 along the rigidly mounted flaming device 10 emotional. In another variant, the Beflammeinrichtung 10 along the guide rail 50 over the photovoltaic module 30 emotional. For cleaning and applying a passivation layer on the surface of the glass pane, the Beflammeinrichtung and the photovoltaic module 30 for example, be moved against each other at a speed of 10 m per minute.

At a driving speed of 10 m per minute and higher, the surface of a glass pane of the photovoltaic module can be cleaned reliably and the cleaned glass surface can be coated with a passivation layer having a layer thickness of 20 nm. Through the silicate layer, the cleaned glass surface is sealed. As a result, a moisture infiltration of an adhesive layer, which is applied to the coating for bonding a mounting device with the photovoltaic module, can be largely prevented. Due to the high driving speed in conjunction with the temperature of the flame in the range between 700 ° C and 1000 ° C and the only local exposure of the flames on the areas of the glass surface, where the mounting device is glued to the photovoltaic module, excessive heating of the entire Glass pane to be prevented. As a result, stress fractures in the glass material due to the effect of heat can be almost eliminated.

5 shows a further embodiment of a device for cleaning and sealing the surface O30a of the glass sheet 31 of the photovoltaic module 30 , The photovoltaic module 30 is on transport wheels 40 stored. At the surface O30a, the photovoltaic module has impurities 400 on, for example, occurred during the lamination process. The impurities 400 may be particles containing carbon compounds.

At a distance above the photovoltaic module 30 is a plasma source 20 on a guide rail 50 attached. The guide rail 50 is over a bracket 60 on a surface 70 . For example, on a wall or on a ceiling held. In a container 90 there is a mixture 100 from a plasma 120 and an additive 130 , The plasma may be, for example, an atmospheric plasma. Such an atmospheric plasma can be generated by ionizing air by a strong electric field. As additives (precursor) 130 For example, silicon-containing compounds which are, for example, gaseous can be admixed with the plasma. Hexamethyldisiloxane or hexamethyldisilazane can be used as additives, for example. The plasma mixture is delivered via a supply line 80 the plasma source 20 fed.

To clean and seal the surface O30a of the photovoltaic module is from the plasma source 20 a flow of the mixture from the plasma 120 and the silicon-containing precursor 130 directed towards the surface O30a of the photovoltaic module. When the photovoltaic module is placed on a cathode, due to the applied electric field positive ions are accelerated from the plasma toward the surface of the photovoltaic module. Upon impact, ions release atoms and molecules of impurities by direct momentum transfer 400 from the surface O30a of the photovoltaic module.

Furthermore, the excited oxygen and the oxygen ions cause a chemical reaction on the surface of a glass pane of the photovoltaic module to be cleaned, by means of which the glass pane is cleaned of the impurities. In the case of carbon contaminants, the excited oxygen and oxygen ions may form carbon dioxide and water upon reaction with hydrocarbon. Thus, hydrocarbons are converted into volatile in the temperature range or the adhesive strength not adversely affecting chemical compounds. The chemical compounds can thus be volatile and evaporate from the surface or remain as chemically passive components on the surface and therefore have no influence on the adhesive strength.

As a result of the silicon-containing additives, in addition to the cleaning action by the plasma, deposition of a passivation layer occurs on the surface O30a of a glass cover of the photovoltaic module. In the case of silicon-containing additives, a silicon-containing coating is formed on the surface of the glass sheets. The coating seals the cleaned glass surface.

For cleaning and sealing areas B1 and B2 on the surface of the glass pane 31 can the photovoltaic module 30 relative to the plasma source 20 to be moved. In another embodiment, the plasma source 20 along the guide rail 50 postponed. To clean the glass surface and apply the sealant layer, the plasma source and photovoltaic module can be moved relative to each other at speeds of 10 meters per minute and higher.

The plasma is conducted at a temperature of 150 ° C to 200 ° C locally to the areas B1 and B2, where the bonding is provided with the mounting device. As a result, the glass is heated locally only at the areas B1 and B2. The selected temperature of the plasma and the travel speeds of at least 10 m per minute prevent local overheating of the glass material. Thus, stress fractures in the glass material can be prevented.

6 shows a section of the photovoltaic module of 1 in which the glass pane 31 cleaned by the flame treatment or the plasma treatment and with a coating 37 provided for sealing the surface. When using silicon-containing precursors in the gas or plasma mixture may be on the surface of the glass 31 a silicate layer 37 be deposited, by which a moisture infiltration of the applied to the silicate layer adhesive layer can be almost completely prevented. Due to the pretreatment of the glass surface, small contact angles or large surface tensions occur on the glass surface. As a result, the surface is well wettable, so when applying the adhesive layer 300 a reliable bond with the mounting device 200 , which has, for example, a construction made of a metal.

LIST OF REFERENCE NUMBERS

1, 2, 3, 4

steps

10

Beflammeinrichtung

20

plasma source

30

photovoltaic module

31, 32

glass panes

33

foil

34, 35

contact surfaces

36

Photosensitive layer

37

coating

40

transport device

50

guide rail

60

bracket

70

underground

80

feed pipe

90

container

100

Gas / plasma mixture

110

gas

120

plasma

130

Additive (precursor)

200

mounter

300

adhesive layer

400

pollution

Claims (12)

A method of pretreating a photovoltaic module for bonding with a mounting device, comprising the following steps: - providing a photovoltaic module ( 30 ) having a surface (O30) of a glass material, - providing a mixture ( 100 ), which is a gas ( 110 ) or a plasma ( 120 ), - generating a flow of the mixture ( 100 ) to a region (B1, B2) of the surface (O30) of the photovoltaic module ( 30 ), - cleaning of the area (B1, B2) of the surface (O30) of the photovoltaic module by reaction of the gas ( 110 ) or plasma ( 120 ) with a deposited on the surface (O30) of the photovoltaic module material ( 400 ) upon impingement of the flow of the mixture ( 100 ) on the surface (O30) of the photovoltaic module. Process according to claim 1, comprising: admixing an additive ( 130 ) to the gas ( 110 ) or the plasma ( 120 ), - coating the area (B1, B2) of the surface (O30) of the photovoltaic module with a layer ( 37 by depositing a compound containing the additive on the surface (O30) of the photovoltaic module upon impingement of the flow of the mixture ( 100 ) on the surface (O30) of the photovoltaic module. Method according to one of claims 1 or 2, wherein the gas ( 110 ) or the plasma ( 120 ) is mixed with an organic compound containing silicon. Method according to one of claims 1 to 3, wherein the gas ( 110 ) or the plasma ( 120 ) Hexamethyldisilazane or hexamethyldisiloxane is mixed. Method according to one of claims 2 to 4, wherein the coating of the area (B1, B2) of the surface (O30) of the photovoltaic module takes place such that the layer ( 37 ) is deposited on the region (B1, B2) of the surface of the photovoltaic module with a layer thickness between 10 nm and 30 nm. Method according to one of claims 1 to 5, wherein the region (B1, B2) of the surface (O30) of the photovoltaic module ( 30 ) with a silicate layer ( 37 ) is coated. Method according to one of claims 1 to 5, wherein for generating the flow of the mixture ( 100 ) from the plasma ( 120 ) a plasma source ( 20 ) providing an atmospheric plasma. Method according to one of claims 1 to 6, comprising: flaming the region (B1, B2) of the surface (O30) of the photovoltaic module by igniting the mixture ( 100 ), which is the gas ( 110 ) contains. The method of claim 8, wherein the ignited mixture comprises the admixed additive ( 130 ) contains. Method according to one of Claims 8 or 9, - in which, in order to produce a flame treatment for flame-proofing the area (B1, B2) of the surface of the photovoltaic module, a flameproofing device ( 10 ) for igniting the mixture ( 100 ) from the gas ( 110 ), wherein - of the flaming device ( 10 ) upon ignition of the mixture ( 100 ) from the gas ( 110 ) a flame with a temperature between 700 ° C and 1000 ° C is generated. Method according to one of claims 7 to 10, wherein during the generation of the flow of the mixture ( 100 ) on the area (B1, B2) of the surface (O30) of the photovoltaic module, the photovoltaic module ( 30 ) relative to the flame-treatment device ( 10 ) or relative to the plasma source ( 20 ) is moved at a speed, whereby the area (B1, B2) of the surface (O30) of the photovoltaic module upon impact of the flow of the mixture ( 100 ) is heated to the range (B1, B2) to a temperature of less than 110 ° C. Method according to one of claims 1 to 11, comprising: gluing the mounting device ( 200 ) on the area (B1, B2) of the surface (O30) of the photovoltaic module after coating the area (B1, B2) with the layer ( 37 ).

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