Photovoltaic module, method for manufacturing photovoltaic module and related device

Abstract

The invention provides a photovoltaic module, a manufacturing method of the photovoltaic module and a related device. A photovoltaic front plate glass layer in the photovoltaic module is made of a light-transmitting material, and the photovoltaic front plate glass layer is used for protecting photovoltaic cells and an internal structure in the photovoltaic module; the first photovoltaic adhesive film and the second photovoltaic adhesive film are used for bonding adjacent assembly structures; the photovoltaic battery piece is used for converting light energy into electric energy; the back plate layer is used for ensuring the flatness of the photovoltaic module and providing support for the multi-layer structure; the metal back plate serves as a bottom support and is used for enhancing the overall structural strength of the photovoltaic module; a multi-layer structure in the photovoltaic module is obtained by stacking, laminating, curing and packaging, and the laminating time of the multi-layer structure is determined according to the thicknesses of the first photovoltaic adhesive film, the second photovoltaic adhesive film and the polymeric film; the expansion coefficient of the photovoltaic front plate glass layer and the metal back plate is determined by the cooperative deformation capability of each component in the photovoltaic module. According to the embodiment of the invention, the structural performance of the photovoltaic module can be improved, and the efficiency can be improved in the production link.

Description

Technical Field

[0001] The present application relates to the technical field of curtain wall equipment, and in particular to a photovoltaic module, a method for manufacturing a photovoltaic module, and related devices. Background Art

[0002] With the proposal of the "dual carbon strategy" and the rapid development of the photovoltaic industry, the application scenarios of photovoltaic modules are becoming more and more extensive, and the strength requirements of photovoltaic modules are becoming higher and higher. Photovoltaic equipment refers to devices and systems that directly convert sunlight energy into electrical energy, usually including solar panels (photovoltaic panels), inverters, controllers, energy storage devices (such as batteries), brackets and cables and other components. Photovoltaic equipment is widely used in various occasions, from home rooftop installations to large-scale solar power stations, to provide clean and renewable energy.

[0003] In the related art, the structural reinforcement method of bonding the back sheet of photovoltaic modules is mostly to use the reprocessing method of bonding with silicone structural adhesive to bond the back sheet and photovoltaic modules together. The bonding process of structural adhesive is mostly done by hand-coating, which is inefficient and the curing time of structural adhesive is generally about seven days, resulting in low efficiency of bonding the back sheet and slow production speed of photovoltaic modules.

[0004] Therefore, it is urgent to design a new technical solution to solve at least one of the above technical problems. Summary of the invention

[0005] In order to solve or improve the above-mentioned problems, the embodiments of the present application provide a photovoltaic module, a method for manufacturing a photovoltaic module, and related devices.

[0006] In one embodiment of the present application, a photovoltaic module is provided, wherein a multilayer structure is stacked in order from top to bottom: a photovoltaic front plate glass layer, a first photovoltaic adhesive film, a photovoltaic cell sheet, a second photovoltaic adhesive film, a back plate layer, a polymer film, and a metal back plate;

[0007] The photovoltaic front panel glass layer is a light-transmitting material, and the photovoltaic front panel glass layer is used to protect the photovoltaic cells and internal structures in the photovoltaic module; the first photovoltaic adhesive film and the second photovoltaic adhesive film are used to bond adjacent module structures; the photovoltaic cells are used to convert light energy into electrical energy; the back panel layer is used to ensure the flatness of the photovoltaic module and provide support for the multi-layer structure; the polymer film is used to bond adjacent module structures; the metal back panel serves as a bottom support to enhance the overall structural strength of the photovoltaic module;

[0008] The multi-layer structure in the photovoltaic module is obtained by stacking, laminating, curing and packaging, and the lamination time of the multi-layer structure is determined according to the thickness of the first photovoltaic adhesive film, the second photovoltaic adhesive film and the polymer film;

[0009] The expansion coefficients of the photovoltaic front plate glass layer and the metal back plate are determined by the cooperative deformation capabilities of the components in the photovoltaic module.

[0010] In another embodiment of the present application, a method for manufacturing a photovoltaic module is provided, wherein the photovoltaic module is the photovoltaic module in the above embodiment, and the multilayer structure in the photovoltaic module is stacked in sequence from top to bottom: a photovoltaic front plate glass layer, a first photovoltaic adhesive film, a photovoltaic cell sheet, a second photovoltaic adhesive film, a back plate layer, a polymer film, and a metal back plate; the method comprises:

[0011] Placing the photovoltaic front panel glass layer and the first photovoltaic adhesive film on a laminator in a preset order; the photovoltaic front panel glass layer is a light-transmitting material, and the photovoltaic front panel glass layer is used to protect the photovoltaic cells and internal structure in the photovoltaic module; the first photovoltaic adhesive film and the second photovoltaic adhesive film are used to bond adjacent module structures;

[0012] Placing the photovoltaic cell sheet between the first photovoltaic adhesive film and the second photovoltaic adhesive film in a preset order; the photovoltaic cell sheet is used to convert light energy into electrical energy;

[0013] Placing the backing layer under the second photovoltaic adhesive film in a preset order; the backing layer is used to ensure the flatness of the photovoltaic module and provide support for the multi-layer structure;

[0014] The back plate layer is covered with the polymer film; the polymer film is used to bond adjacent component structures;

[0015] The metal back plate is placed at the bottom of the multi-layer structure as a bottom support; the metal back plate is used to enhance the overall structural strength of the photovoltaic module;

[0016] The stacked multilayer structure is subjected to high temperature and high pressure pressing by rollers of a laminator, so that the first photovoltaic adhesive film, the second photovoltaic adhesive film and the polymer film are melted and solidified, and the photovoltaic module is obtained by encapsulation;

[0017] Among them, the lamination time of the multilayer structure is determined according to the thickness of the first photovoltaic adhesive film, the second photovoltaic adhesive film and the polymer film; the expansion coefficient of the photovoltaic front panel glass layer and the metal back panel is determined by the coordinated deformation ability of each component in the photovoltaic module.

[0018] In one embodiment of the present application, a laminated solar cell assembly is provided, characterized in that the laminated solar cell assembly at least includes the photovoltaic assembly in the above embodiment, and the laminated solar cell assembly is manufactured using the manufacturing method of the photovoltaic assembly in the above embodiment.

[0019] In one embodiment of the present application, an electronic device includes:

[0020] at least one processor, memory, and input-output unit;

[0021] The memory is used to store a computer program, and the processor is used to call the computer program stored in the memory to execute the method for manufacturing a photovoltaic module in the first embodiment.

[0022] In one embodiment of the present application, a computer-readable storage medium is provided, which includes instructions. When the instructions are executed on a computer, the computer executes the method for manufacturing a photovoltaic module in the first embodiment.

[0023] In the technical solution provided in the embodiment of the present application, the multi-layer structure in the photovoltaic module is stacked in sequence from top to bottom: a photovoltaic front panel glass layer, a first photovoltaic film, a photovoltaic cell, a second photovoltaic film, a back panel layer, a polymer film, and a metal back panel; the photovoltaic front panel glass layer is a light-transmitting material, and the photovoltaic front panel glass layer is used to protect the photovoltaic cell and the internal structure in the photovoltaic module; the first photovoltaic film and the second photovoltaic film are used to bond adjacent module structures; the photovoltaic cell is used to convert light energy into electrical energy; the back panel layer is used to ensure the flatness of the photovoltaic module and provide support for the multi-layer structure; the polymer film is used to bond adjacent module structures; the metal back panel serves as a bottom support to enhance the overall structural strength of the photovoltaic module; the multi-layer structure in the photovoltaic module is obtained by stacking, laminating, curing and packaging, and the lamination time of the multi-layer structure is determined according to the thickness of the first photovoltaic film, the second photovoltaic film and the polymer film; the expansion coefficient of the photovoltaic front panel glass layer and the metal back panel is determined by the collaborative deformation ability of each component in the photovoltaic module.

[0024] In the embodiment of the present application, the photovoltaic front panel glass layer can protect the photovoltaic cell and internal structure, the back panel layer can ensure the flatness of the photovoltaic module and provide support for the multi-layer structure, and the metal back panel as the bottom support can enhance the overall structural strength of the photovoltaic module. The various structures work together to ensure that the photovoltaic module structure is stable and the internal components are properly protected. The expansion coefficient of the photovoltaic front panel glass layer and the metal back panel is determined by the cooperative deformation ability of each component in the photovoltaic module, which helps the photovoltaic module to better adapt to changes in factors such as temperature under different environmental conditions, reduce structural problems caused by differences in expansion coefficients, and improve overall stability. By stacking the polymer film and the metal back panel directly under the photovoltaic back panel surface, the metal back panel and the photovoltaic module are laminated and formed in one piece, which changes the original production method, simplifies the process steps, and reduces the operation links, thereby effectively improving the production efficiency of the module. The process optimization of integrated lamination reduces the complexity of manual participation and the amount of manual operation in the production process, which helps to make the photovoltaic module more efficient in the production and manufacturing process. Overall, it is beneficial to improve the structural performance of the photovoltaic module itself and improve efficiency in the production process. BRIEF DESCRIPTION OF THE DRAWINGS

[0025] In order to more clearly illustrate the embodiments of the present application or the technical solutions in the prior art, a brief introduction will be given below to the drawings required for use in the embodiments or the description of the prior art. Obviously, the drawings described below are some embodiments of the present application. For ordinary technicians in this field, other drawings can be obtained based on these drawings without paying any creative work.

[0026] Figure 1 A schematic diagram of the structure of a photovoltaic module is provided for one embodiment of the present application;

[0027] Figure 2 A schematic diagram of the structure of a photovoltaic module is provided for another embodiment of the present application;

[0028] Figure 3 A schematic diagram of the structure of a photovoltaic module is provided for another embodiment of the present application;

[0029] Figure 4 A schematic diagram of a process for manufacturing a photovoltaic module provided in one embodiment of the present application;

[0030] Figure 5 A schematic diagram of the structure of an electronic device provided in one embodiment of the present application. DETAILED DESCRIPTION

[0031] The present application provides the following embodiments to solve or improve at least some of the above problems. In order to enable people in the technical field to better understand the present application, the technical solutions in the embodiments of the present application will be clearly and completely described below in conjunction with the drawings in the embodiments of the present application.

[0032] In some features described in the specification, claims and the above-mentioned drawings of this application, descriptions such as "first" and "second" are used to distinguish different components, parts, modules, devices, etc., and do not represent the order of precedence, nor do they limit "first" and "second" to be different types. In addition, the embodiments described below are only some embodiments of the present application, not all embodiments. Based on the embodiments in this application, all other embodiments obtained by those skilled in the art without making creative work are within the scope of protection of this application.

[0033] In order to solve the technical problems of low efficiency of bonding backplanes and slow production speed of photovoltaic modules in related technologies, a multilayer structure in a photovoltaic module provided in an embodiment of the present application is stacked from top to bottom in sequence: a photovoltaic front panel glass layer, a first photovoltaic adhesive film, a photovoltaic cell, a second photovoltaic adhesive film, a back panel layer, a polymer film, and a metal back panel; the photovoltaic front panel glass layer is a light-transmitting material, and the photovoltaic front panel glass layer is used to protect the photovoltaic cell and the internal structure in the photovoltaic module; the first photovoltaic adhesive film and the second photovoltaic adhesive film are used to bond adjacent module structures; the photovoltaic cell is used to convert light energy into electrical energy; the back panel layer is used to ensure the flatness of the photovoltaic module and provide support for the multilayer structure; the polymer film is used to bond adjacent module structures; the metal back panel serves as a bottom support to enhance the overall structural strength of the photovoltaic module; the multilayer structure in the photovoltaic module is obtained by curing and packaging after stacking and lamination, and the lamination time of the multilayer structure is determined according to the thickness of the first photovoltaic adhesive film, the second photovoltaic adhesive film and the polymer film; the expansion coefficient of the photovoltaic front panel glass layer and the metal back panel is determined by the cooperative deformation ability of each component in the photovoltaic module.

[0034] In the embodiment of the present application, the photovoltaic front panel glass layer can protect the photovoltaic cell and internal structure, the back panel layer can ensure the flatness of the photovoltaic module and provide support for the multi-layer structure, and the metal back panel as the bottom support can enhance the overall structural strength of the photovoltaic module. The various structures work together to ensure that the photovoltaic module structure is stable and the internal components are properly protected. The expansion coefficient of the photovoltaic front panel glass layer and the metal back panel is determined by the cooperative deformation ability of each component in the photovoltaic module, which helps the photovoltaic module to better adapt to changes in factors such as temperature under different environmental conditions, reduce structural problems caused by differences in expansion coefficients, and improve overall stability. By stacking the polymer film and the metal back panel directly under the photovoltaic back panel surface, the metal back panel and the photovoltaic module are laminated and formed in one piece, which changes the original production method, simplifies the process steps, and reduces the operation links, thereby effectively improving the production efficiency of the module. The process optimization of integrated lamination reduces the complexity of manual participation and the amount of manual operation in the production process, which helps to make the photovoltaic module more efficient in the production and manufacturing process. Overall, it is beneficial to improve the structural performance of the photovoltaic module itself and improve efficiency in the production process.

[0035] Figure 1 FIG. 1 shows a schematic diagram of the structure of a photovoltaic module provided by an embodiment of the present application. Figure 1 As shown, an embodiment of the present application proposes a photovoltaic module, which aims to control the manufacturing process of the photovoltaic module, which is beneficial to improving the structural performance of the photovoltaic module itself and achieving efficiency improvement in the production process. Figure 1 In the figure, 1 is photovoltaic front panel glass, 2 is photovoltaic adhesive film, 3 is photovoltaic cell sheet, 4 is back panel layer, 5 is polymer film, and 6 is metal back panel. Further optionally, the photovoltaic adhesive film includes a first photovoltaic adhesive film and a second photovoltaic adhesive film, and the back panel layer includes back panel glass or photovoltaic back panel.

[0036] In another example, Figure 2 In the figure, 1 is the photovoltaic front glass, 2 is the photovoltaic adhesive film, 3 is the photovoltaic cell sheet, 4 is the backplane layer, 5 is the polymer film, 6 is the metal backplane, 7 is the laminator roller, and 8 is the laminator. Figure 2 The backplane layer can be stacked in a manner and fed into a laminator by a lower roller. The lamination temperature ranges from 150°C to 180°C. The lamination time is determined by the thickness of the photovoltaic film and the polymer film and is basically controlled between 10 and 15 minutes. For example, the backplane layer can be a backplane glass or a photovoltaic backplane. Specifically, based on Figure 2 As shown in the figure, the lamination process of photovoltaic modules and the corresponding functions of each step are explained:

[0037] Step 1: Place the photovoltaic front panel glass 1 and the photovoltaic adhesive film 2 on a laminator.

[0038] The photovoltaic front glass protects the internal structure of the photovoltaic module, especially the photovoltaic cells to be placed later. It is the first barrier for the entire module facing the external environment. The photovoltaic film serves as an adhesive material here, providing a bonding basis for the photovoltaic cells to be placed later, facilitating better fixation of the cells, forming a tight connection with the front glass, and ensuring the initial stability of the module structure.

[0039] Step 2: The photovoltaic cells 3 are placed on the photovoltaic film in a certain arrangement order.

[0040] Photovoltaic cells are the core components of the entire photovoltaic module to achieve the conversion of light energy into electrical energy. Placing them in a specific arrangement order can ensure the efficiency of receiving light energy and the stability of the power generation performance of the entire module. When placed on the photovoltaic film, the stickiness of the film can firmly fix the cells in the corresponding position to prevent them from shifting during subsequent operations and use, ensuring that the module can perform its power generation function normally.

[0041] Step 3: Cover the backplane layer 4 and the polymer film 5 on the battery cell to ensure the overall flatness.

[0042] The backplane glass or photovoltaic backplane can further protect the internal structures such as the battery cells from external factors such as moisture and dust, and enhance the overall sealing and protection of the component. The polymer film is used as a connecting component. On the one hand, it can better fit the backplane and battery cells and other structures, fill in the possible tiny gaps, and ensure the close combination of the structures. On the other hand, it helps to maintain the flatness of the entire component structure to avoid local unevenness that affects subsequent use and aesthetics.

[0043] Step 4: Place a metal back plate 6 on the last layer as a bottom support.

[0044] The metal backplane can provide strong bottom support for the entire photovoltaic module, enhance the overall structural strength of the module, and enable it to better withstand various external forces such as wind force and deadweight during installation and use, prevent deformation and damage of the module, and ensure the long-term stable operation of the module.

[0045] Step 5: Use the laminator roller 7 to laminate the entire assembly at high temperature and high pressure, and complete the curing and packaging in the laminator 8.

[0046] With the help of high temperature and high pressure applied by the laminator roller, the photovoltaic adhesive film and polymer film can give full play to their viscosity under such conditions, achieving a stronger and tighter bond between the components. At the same time, the multi-layer structure of the entire component is solidified as a whole, completing the packaging process, so that a relatively independent, stable and sealed environment is formed inside the component, which better protects the internal battery cells and other key components, and finally forms a photovoltaic component that can be put into normal use.

[0047] Through this series of steps and corresponding functions, the complete lamination process of photovoltaic modules from the preparation of each component to the final curing and packaging is completed in an orderly manner, and photovoltaic modules with stable performance and reliable structure are manufactured.

[0048] In another example, Figure 3 In the figure, 1 is photovoltaic front plate glass, 2 is photovoltaic adhesive film, 3 is photovoltaic cell sheet, 4 is back plate layer, 5 is polymer film, 6 is corrugated metal back plate, 7 is laminator roller, 8 is laminator, and 9 is high temperature pad.

[0049] When the metal backing plate has metal corrugations, in order to ensure the stability of the assembly during lamination, a high-temperature pad with greater rigidity needs to be placed between the corrugations, which will cause severe deformation during lamination. When the metal backing plate has metal corrugations, the steps of the lamination process and the corresponding functions of each step are explained as follows:

[0050] Step 1: Place the photovoltaic front glass 1 and photovoltaic film 2 on the laminator in the laminating order. As the outermost layer of the photovoltaic module, the photovoltaic front glass protects the internal photovoltaic cells and other components from external physical impact, dust, water vapor and other erosions, and is the first line of defense to ensure the long-term stable operation of the module.

[0051] Photovoltaic adhesive film is a sticky intermediate connecting material that can firmly adhere the subsequently placed photovoltaic cells to the photovoltaic front glass, ensuring that the position of the cells is fixed, laying the foundation for building a stable component structure, and also helping to better combine the components into one during the subsequent lamination process.

[0052] Step 2: Place the photovoltaic cells. The photovoltaic cells 3 are placed on the photovoltaic film 2 in a predetermined arrangement order. The photovoltaic cells are the core components of the entire photovoltaic module to achieve photoelectric conversion. Placing them in a predetermined arrangement order can ensure that they can efficiently and stably convert light energy into electrical energy when receiving light, so that the module has stable power generation performance. Placing them on the photovoltaic film can prevent the cells from moving randomly during operation by relying on the viscosity of the film, ensuring that they are in the correct position in the module, thereby ensuring that the power generation function of the entire module can be performed normally.

[0053] Step 3: Add the backplane layer. Place the backplane layer 4 and the polymer film 5 to ensure that the battery cell and the backplane layer are tightly bonded.

[0054] Backplane glass or photovoltaic backplane is mainly used to provide back protection for internal components such as photovoltaic cells, blocking adverse factors in the external environment (such as moisture, impurities, etc.) from invading the interior of the module from the back, further improving the overall sealing and stability of the module, and extending the service life of the module. The polymer film plays a bonding role, which can tightly connect the backplane and the cell structure, fill the tiny gaps that may exist between them, enhance the integrity of the entire module structure, ensure that the layers fit tightly, and form a relatively closed and stable environment inside the module, which helps to ensure that the performance of the module is not disturbed by the outside world.

[0055] Step 4: Place the corrugated metal back plate. The corrugated metal back plate 6 is placed on the last layer. Its structure is in a corrugated shape, which helps to improve the strength and heat dissipation performance of the back plate.

[0056] In terms of structural strength, the corrugated design gives the metal backplane a higher structural strength, enabling it to better withstand various forces applied to the components by the outside world (such as tension during installation, wind force during use, and the component's own gravity, etc.), preventing the components from being deformed or damaged, and providing reliable bottom support for the entire photovoltaic component, ensuring the structural stability of the component under different working conditions. In terms of heat dissipation performance, the corrugated structure increases the contact area between the backplane and the air, which is conducive to the dissipation of heat. It can promptly conduct away the heat generated by the photovoltaic cells during operation, avoiding the components from affecting the power generation efficiency or even causing component damage due to excessive temperature, and helping to maintain the components in a suitable operating temperature range, improving the performance and reliability of the components.

[0057] Step 5: Placement of high temperature pads: In order to prevent the metal back plate from deforming, high temperature pads 9 with greater rigidity are placed between the corrugated parts of the corrugated metal back plate.

[0058] These pads play a supporting role during the high-temperature lamination process, preventing the corrugated metal backsheet from bending or deforming when heated, and maintaining the flatness of the entire component. In a high-temperature lamination environment, the metal backsheet is prone to bending or deforming due to thermal stress caused by heat. Placing high-temperature pads can provide effective support between the corrugations to resist the influence of such thermal stress, ensuring that the corrugated metal backsheet maintains its original shape and structure during the lamination process, thereby maintaining the flatness of the entire component. The flatness of the component is very important for its subsequent installation, use, and the coordinated function of various components. A flat component is more conducive to ensuring the normal operation of internal components such as battery cells and the overall aesthetics.

[0059] Step 6: Place the above components into a laminator 8 and use the laminator roller 7 to apply appropriate pressure and temperature for curing and packaging.

[0060] The laminator roller applies appropriate pressure and temperature conditions to enable the photovoltaic film and polymer film to fully exert their viscosity under high temperature and high pressure, making the bonding between the components more firm and tight, achieving the solidification of the multi-layer structure of the entire component, and finally completing the encapsulation. The encapsulated component forms a stable and sealed environment inside, which can better protect the key components such as the internal battery cells from the influence of the external environment, thereby manufacturing a photovoltaic component with reliable performance, stable structure and normal use.

[0061] Through this series of steps and the role played by each step, the lamination process of photovoltaic modules with metal corrugated backsheets is completed from material preparation to final curing and packaging, ensuring that the manufactured photovoltaic modules meet the use requirements and have good performance.

[0062] The application process is divided into the following parts:

[0063] As an optional embodiment, the metal back plate is a corrugated metal back plate, and the corrugated metal back plate is used to bear the pressure generated by wind load, gravity load and / or earthquake action.

[0064] As an optional embodiment, the photovoltaic module also includes a high-temperature pad, which is evenly filled in the gaps of the corrugated metal backboard; the high-temperature pad is used to support the shape of the corrugated metal backboard during the lamination process to prevent the corrugated metal backboard from being deformed due to excessive pressure during the lamination process.

[0065] It is understood that the main function of the high temperature pad is to maintain the shape of the corrugated metal backing during the lamination process and prevent it from being severely deformed due to excessive pressure during the lamination process. Due to the large fluctuations of the corrugation, when the laminator applies pressure, the backing in the corrugated area may be subjected to uneven pressure distribution, resulting in local excessive deformation. The high temperature pad provides a stable support surface by filling the gaps between the corrugations to prevent the corrugated area from collapsing or irregular deformation during the lamination process. The high temperature pad must have a large rigidity to withstand the high pressure applied during the lamination process and prevent the pad itself from deforming. The rigid pad can effectively support the corrugated structure, thereby maintaining the shape of the metal backing during lamination. At the same time, the pad must also have good high temperature resistance because high temperatures (usually in the range of 150°C~180°C) are used during the lamination process. Therefore, the pad material should have the characteristics of high temperature resistance and will not soften or deform in a high temperature environment. The size of the high temperature pad needs to accurately match the space between the corrugations. In order to avoid the spacer from sliding or shifting during the lamination process, the size of the spacer needs to be customized according to the corrugation shape and spacing of the metal backing. The spacer is usually rectangular or other suitable geometric shape, which can be adjusted according to the specific corrugation spacing and depth to ensure that the spacer can completely fill the gap of each corrugation.

[0066] During the lamination process, the high temperature pads should be evenly distributed between each pair of corrugations to ensure that each corrugated area has sufficient support. This can prevent the corrugated area from being deformed due to excessive local pressure and ensure the stability of the entire metal backplane surface. The pads can disperse the pressure during the lamination process and avoid local pressure concentration in certain corrugated areas, which is crucial to improving the uniformity and stability of the lamination. During the lamination process, the role of the high temperature pads is closely related to other factors (such as lamination temperature, pressure, time, etc.). The rigidity of the pads ensures that the corrugated area does not deform under high pressure conditions, and the optimization of temperature and pressure helps the adhesive film fully soften and bond the photovoltaic module to the metal backplane. Through precise control of the lamination process, the pads work together with other lamination conditions to ensure the bonding quality between the photovoltaic module and the backplane.

[0067] In actual production, it is usually necessary to conduct multiple tests to determine the specific shape, size and material of the high-temperature pad, and adjust the lamination temperature and pressure to achieve the best lamination effect. The material of the pad may need to be selected and customized according to different photovoltaic backsheet types (such as different corrugation heights and spacing). As an optional embodiment, the metal backsheet uses a metal material with a temperature linear expansion coefficient ranging from 9×10-6 / K to 18×10-6 / K.

[0068] As an optional embodiment, if the thickness of the first photovoltaic adhesive film and / or the second photovoltaic adhesive film is 1.14 mm, and the thickness of the polymer film is 0.3 mm, the lamination time of the multilayer structure ranges from 10 minutes to 15 minutes.

[0069] As an optional embodiment, the lamination temperature range of the multilayer structure is 150°C to 180°C.

[0070] It should be added here that the control logic of the control device will be introduced in detail in the method embodiment below.

[0071] An embodiment of the present application provides a method for manufacturing a photovoltaic module. The method described in this embodiment can be performed by the photovoltaic module manufacturing device in the above embodiment, which is implemented on the basis of the structure of the above photovoltaic module embodiment. The multi-layer structure in the photovoltaic module is stacked from top to bottom: a photovoltaic front glass layer, a first photovoltaic adhesive film, a photovoltaic cell sheet, a second photovoltaic adhesive film, a back plate layer, a polymer film, and a metal back plate. See Figure 4 As shown, the method may include the following steps:

[0072] 101. Place the photovoltaic front panel glass layer and the first photovoltaic adhesive film on a laminator in a preset order; the photovoltaic front panel glass layer is a light-transmitting material, and the photovoltaic front panel glass layer is used to protect the photovoltaic cells and internal structure in the photovoltaic module; the first photovoltaic adhesive film and the second photovoltaic adhesive film are used to bond adjacent module structures;

[0073] 102. Place the photovoltaic cell sheet between the first photovoltaic adhesive film and the second photovoltaic adhesive film according to a preset order; the photovoltaic cell sheet is used to convert light energy into electrical energy;

[0074] 103. Place the back plate layer under the second photovoltaic adhesive film according to a preset order; the back plate layer is used to ensure the flatness of the photovoltaic module and provide support for the multi-layer structure;

[0075] 104. Covering the backplane layer with the polymer film; the polymer film is used to bond adjacent component structures;

[0076] 105. Place the metal back plate at the bottom of the multi-layer structure as a bottom support; the metal back plate is used to enhance the overall structural strength of the photovoltaic module;

[0077] 106. The stacked multilayer structure is subjected to high-temperature and high-pressure pressing by rollers of a laminator so that the first photovoltaic adhesive film, the second photovoltaic adhesive film and the polymer film are melted and solidified, and the photovoltaic module is obtained by encapsulation.

[0078] The present application provides a method for manufacturing a photovoltaic module, wherein the photovoltaic front panel glass layer can protect the photovoltaic cell and internal structure, the back panel layer can ensure the flatness of the photovoltaic module and provide support for the multi-layer structure, and the metal back panel as the bottom support can enhance the overall structural strength of the photovoltaic module, and each structure cooperates to ensure that the photovoltaic module structure is stable and the internal components are properly protected. The expansion coefficient of the photovoltaic front panel glass layer and the metal back panel is determined by the cooperative deformation ability of each component in the photovoltaic module, which helps the photovoltaic module to better adapt to changes in factors such as temperature under different environmental conditions, reduce structural problems caused by differences in expansion coefficients, and improve overall stability. By stacking the polymer film and the metal back panel directly under the photovoltaic back panel surface, the metal back panel and the photovoltaic module are laminated and formed as one, which changes the original production method, simplifies the process steps, reduces the operation links, and effectively improves the production efficiency of the module. The process optimization of the integrated lamination reduces the complexity of manual participation and the amount of manual operation in the production process, which helps to make the photovoltaic module more efficient in the production and manufacturing links. Overall, it is beneficial to improve the structural performance of the photovoltaic module itself and improve efficiency in the production link.

[0079] Step 101, placing the photovoltaic front panel glass layer and the first photovoltaic adhesive film on a laminator according to a preset order. The photovoltaic front panel glass layer is the outermost protective structure of the entire photovoltaic module facing the external environment. By utilizing its light transmittance, it can not only ensure that the external light can smoothly pass through and illuminate the internal photovoltaic cells, but also rely on its own physical properties, such as hardness and sealing, to block external dust, water vapor, physical impact and other adverse factors, protect the internal photovoltaic cells and other structures from damage, and create good conditions for the long-term stable operation of the photovoltaic module.

[0080] The first photovoltaic adhesive film is essentially a sticky intermediate connecting material. In this step, it is placed under the photovoltaic front panel glass layer to provide a reliable bonding foundation for the photovoltaic cells to be placed later. The adhesive effect of the adhesive film can tightly bond the photovoltaic cells to the photovoltaic front panel glass layer, preventing the cells from shifting during subsequent operations and the use of the components, ensuring the initial stability of the internal structure of the component, and also laying the foundation for the integration of the multi-layer structure.

[0081] Step 102: placing the photovoltaic cells between the first photovoltaic adhesive film and the second photovoltaic adhesive film according to a preset order.

[0082] Photovoltaic cells are the core components of the entire photovoltaic module to achieve the conversion of light energy into electrical energy. They are placed in a preset order based on the design requirements of the photovoltaic module. Different arrangement orders will affect their efficiency in receiving light energy and the stability of the power generation performance of the entire module. They are placed between two layers of photovoltaic films. Relying on the adhesive connection between the first photovoltaic film and the cell, they can be firmly attached to one side of the front glass. The second photovoltaic film can be attached to the cell on the other side to further fix the position of the cell. At the same time, it also prepares for the subsequent connection with the backplane layer and other structures, so as to ensure that the cell is in an accurate and stable position inside the module, thereby ensuring that the module can normally and efficiently convert light energy into electrical energy.

[0083] Step 103: placing the backplane layer under the second photovoltaic adhesive film according to a preset order.

[0084] The backplane layer plays a vital supporting and protective role in photovoltaic modules. From the perspective of flatness, by placing it flatly under the second photovoltaic film, it can provide a flat support surface for the entire multi-layer structure, ensuring that each layer maintains overall flatness during subsequent pressing and use, avoiding local unevenness that affects the performance and appearance of the module. From the perspective of structural support, it bears the weight of the upper layers and possible external pressure, providing a solid physical support for the entire multi-layer structure, ensuring that the structure will not easily deform under different installation and use environments, thereby maintaining the relative position relationship between the components inside the module, which is conducive to the normal operation of the module.

[0085] Step 104, covering the backplane layer with the polymer film.

[0086] The polymer film is also a bonding material. When covered on the backplane layer, it can fit closely with the backplane layer, fill the tiny gaps that may exist on the surface of the backplane layer, and enhance the tightness of the connection between the backplane layer and the metal backplane below and the second photovoltaic film above. In the subsequent high-temperature and high-pressure pressing process, the polymer film will better exert its viscosity under the action of heat and pressure, so that the layers can be more firmly bonded, and the entire multi-layer structure will be further integrated into a whole, ensuring a relatively closed and stable environment inside the component, and protecting the performance of the component from interference from external factors.

[0087] Step 105 , placing the metal back plate at the bottom of the multi-layer structure as a bottom support.

[0088] In the metal backplane, the metal material itself has high strength and rigidity. Placing it at the bottom of the multi-layer structure can provide strong bottom support for the entire photovoltaic module. In actual installation and use scenarios, the module may be affected by various forces such as wind, its own gravity, and external forces during installation. With its good structural strength, the metal backplane can effectively resist these external forces, prevent the overall deformation and damage of the module, and ensure the long-term stability of the module, ensuring that the internal components, especially the photovoltaic cells, can continue to work normally in a relatively stable structural environment, thereby maintaining the power generation performance and service life of the entire photovoltaic module.

[0089] Step 106, subjecting the stacked multilayer structure to high temperature and high pressure pressing by rollers of a laminator, so that the first photovoltaic adhesive film, the second photovoltaic adhesive film and the polymer film are melted and solidified, and the photovoltaic module is obtained by encapsulation.

[0090] Under high temperature conditions, the first photovoltaic film, the second photovoltaic film and the polymer film will reach their melting point or softening point, thus changing from a relatively solid state with limited viscosity to a state with good fluidity and stronger viscosity, which can better fill the tiny gaps between the layers of the structure, so that the components can achieve more complete and close contact and bonding. At the same time, the application of high pressure allows the layers to be tightly pressed together under the action of the melted film and polymer film, eliminating gaps such as air between the layers, and further enhancing the integrity of the structure. After such high temperature and high pressure treatment, as the temperature decreases, the film and polymer film will gradually solidify, firmly fixing the layers of the structure together, and finally realizing the encapsulation of the entire photovoltaic module, so that the inside of the module forms a stable, sealed whole with coordinated work of various components, ensuring that it can normally perform functions such as photoelectric conversion under different external environments.

[0091] Through this series of steps and corresponding principles, the manufacturing process of photovoltaic modules from the preparation of various components to the final packaging is completed in an orderly manner, and photovoltaic modules with stable structure and reliable performance are manufactured.

[0092] As an optional embodiment, assuming that the metal backboard is a corrugated metal backboard, and the photovoltaic module also includes a high-temperature pad; based on this structure, after the metal backboard is placed at the bottom of the multi-layer structure as a bottom support in 105, the arrangement position of the high-temperature pad can also be determined according to the material properties, shape, and size of the corrugated metal backboard; the arrangement position includes at least: the spacing between the high-temperature pads, and the placement depth of the high-temperature pads; based on the arrangement position, the high-temperature pads are evenly filled into the gaps of the corrugated metal backboard to support the shape of the corrugated metal backboard during the lamination process through the high-temperature pads, thereby preventing the corrugated metal backboard from being deformed due to excessive pressure during the lamination process.

[0093] During the lamination process, the corrugated metal backboard will be subjected to great pressure. Due to its corrugated shape, it is easy to deform under pressure, such as bending and collapse. By determining the arrangement of the high-temperature pads according to the material properties, shape, and size of the corrugated metal backboard, and evenly filling the high-temperature pads into its gaps, it can provide effective internal support for the corrugated metal backboard during lamination, resist the impact of pressure, ensure that the corrugated metal backboard maintains the original design, avoid deformation caused by excessive pressure that damages its structural integrity, and ensure the structural strength and normal function of the backboard itself.

[0094] The stability of the corrugated metal backsheet is crucial to the quality of the entire photovoltaic module. If the backsheet is deformed during the lamination process, it will break the flatness and coordination of the multi-layer structure of the entire module, affect the tightness of the fit between the components and the relative position relationship, and may cause key components such as photovoltaic cells to not be in the best working state, reduce power generation efficiency, and even shorten the service life of the module. The rational use of high-temperature pads can prevent this from happening, so that the module can maintain a good overall structure after manufacturing, and the various components can work more smoothly together, thereby improving the overall quality and performance stability of the photovoltaic module.

[0095] This embodiment provides an effective safeguard for the lamination process of photovoltaic modules with corrugated metal backboards, so that there is a targeted solution to the problem of backboard deformation that may occur during the production process. The arrangement position determination method of the high-temperature pads is clarified, making this operation more standardized and operable, helping production personnel to implement process steps more accurately, reducing production accidents such as unqualified products caused by backboard deformation, improving the reliability and stability of the entire photovoltaic module production process, and ensuring the smooth progress of the production process and the yield rate of the product. In this way, if the manufactured photovoltaic modules are to be applied to various actual working conditions, they need to have good structural stability. Through the effective support of the corrugated metal backboard by the high-temperature pads, the good structural state of the module is maintained, so that during the subsequent installation and use of the module, whether facing different installation angles, external forces such as wind and vibration, or under the influence of environmental factors such as temperature changes, it can better cope with it with a stable structure, enhancing the adaptability of photovoltaic modules under various working conditions, extending its service life, and improving its application value.

[0096] Further optionally, in the above steps, the arrangement position of the high temperature pads is determined according to the material properties, shape and size of the corrugated metal back plate, which can be implemented as follows:

[0097] According to the mechanical strength, yield strength, and elastic mold information in the material properties, the first deformation behavior of the corrugated metal backboard during the pressing process is predicted by a deformation prediction model; the deformation prediction model is trained based on the historical pressing data of various corrugated metal backboards and the corresponding finite element analysis data; according to the corrugation spacing and size in the shape of the corrugated metal backboard, the initial arrangement position of the high-temperature pad is determined; based on the pressing process configuration parameters, the initial arrangement position, and the mechanical strength, yield strength, and elastic mold information in the material properties, the second deformation behavior of the corrugated metal backboard during the pressing process is re-predicted by the deformation prediction model; based on the first deformation behavior and the second deformation behavior, the initial arrangement position is optimized to obtain the target arrangement position.

[0098] In the embodiment of the present application, the deformation prediction model is trained based on the historical pressing data of various corrugated metal backboards and the corresponding finite element analysis data, which makes it highly scientific and referenceable. By inputting the material properties of the corrugated metal backboard to be pressed (such as key information such as mechanical strength, yield strength, elastic modulus, etc.), it is possible to more accurately predict its first deformation behavior during the pressing process, and know in advance the possible deformation of the backboard, which provides an accurate basis for taking effective countermeasures in the future, realizes forward-looking control of deformation problems, and helps to avoid the deformation of the backboard caused by blind operation.

[0099] After determining the initial arrangement position of the high-temperature pads, the model is used to re-predict the second deformation behavior of the corrugated metal backsheet during the pressing process in combination with the configuration parameters of the pressing process and other related information, and the initial arrangement position is optimized based on the two deformation behaviors to obtain the target arrangement position. This process of multiple predictions and continuous optimization can make the arrangement position of the high-temperature pads more in line with the actual pressing situation, maximize its supporting role for the corrugated metal backsheet, accurately prevent and control the deformation of the backsheet during the pressing process, and ensure the stability of the backsheet shape and the integrity of the entire photovoltaic module structure.

[0100] The entire process of determining the layout of the high-temperature pads fully considers the various characteristics of the corrugated metal backboard. It no longer relies on empirical and rough judgments, but instead uses scientific data and model analysis to derive the target layout position, making the placement of the high-temperature pads in the corrugated metal backboard more accurate and reasonable, which helps to perform the process steps more standardized and accurately in actual production, and avoid production problems caused by unreasonable layout.

[0101] The precise arrangement of high-temperature pads helps stabilize the production process, reduce adverse conditions such as component rework and scrap caused by deformation of the corrugated metal backplane, improve the one-time pass rate of the product, ensure the smooth and stable production process of the entire photovoltaic module, improve the overall reliability and efficiency of the production process, and reduce production costs.

[0102] Since the arrangement of high-temperature pads has been scientifically optimized, it can effectively prevent the corrugated metal backboard from deforming during the pressing process, thereby ensuring the flatness and stability of the overall structure of the photovoltaic module. The stable structure helps key components such as photovoltaic cells to be in a good working environment, maintain the coordinated relationship between the components, ensure that the components can perform photoelectric conversion work normally and efficiently, and improve the power generation performance of the components. It avoids problems such as internal stress concentration, component wear, loose connections, etc. caused by the deformation of the corrugated metal backboard, reduces the hidden dangers of failure of the components in the subsequent use, and enables the photovoltaic modules to maintain a good performance state during long-term use, prolongs its service life, and improves the cost-effectiveness and market competitiveness of photovoltaic modules.

[0103] In summary, this method of determining the arrangement position of high-temperature pads has significant beneficial effects, whether in ensuring the smooth progress of the production process or in improving the performance of photovoltaic modules and extending their service life.

[0104] Further optionally, in the above steps, the step of predicting the first deformation behavior or the second deformation behavior of the corrugated metal backboard during the pressing process by using the deformation prediction model can be implemented as follows:

[0105] Extract the pressing process configuration parameters, the initial arrangement position, and the mechanical strength, yield strength, and elastic mold information in the material properties that are related to the pressing process. Construct a corresponding candidate model for the features to be analyzed. The candidate model includes: a virtual three-dimensional model for representing different spatial position relationships between the corrugated metal backboard and the high-temperature pad. Perform pressure distribution analysis on the candidate model to obtain a predicted pressure distribution corresponding to the candidate model. The predicted pressure distribution includes: the pressure distribution of the high-temperature pad under different spatial position relationships. Generate a matching first deformation behavior or second deformation behavior based on the predicted pressure distribution.

[0106] By extracting the pressing process configuration parameters, initial arrangement positions, and features to be analyzed in material properties related to the pressing process, the interference of irrelevant information is eliminated, and the factors that have a key impact on the deformation behavior of the corrugated metal backboard can be accurately focused. This makes the subsequent analysis more targeted, and the model built based on these core features can more accurately reflect the actual situation in the pressing process, laying a solid foundation for a deep understanding of the deformation behavior of the backboard.

[0107] The features to be analyzed are constructed into candidate models including virtual three-dimensional models for representing different spatial position relationships between the corrugated metal backing plate and the high-temperature pad. This model construction method is highly consistent with the actual production scenario. It can intuitively present the spatial layout between the components, visualize the abstract physical relationship, facilitate the subsequent detailed analysis of pressure distribution and other conditions from a spatial perspective, and help to more comprehensively and accurately grasp the complex mechanical relationship in the entire pressing process.

[0108] Performing pressure distribution analysis on the candidate model can obtain detailed pressure distribution of the high temperature pad in different spatial positions. This means that it is clear how the pressure is transmitted and distributed on the corrugated metal backing and the high temperature pad in various possible layouts, so as to accurately grasp the pressure conditions faced by each position, providing a key quantitative basis for predicting the deformation behavior of the backing, and avoiding the deviation that may occur in the past when relying solely on experience to judge the pressure distribution.

[0109] Based on the accurate predicted pressure distribution, the matching first deformation behavior or second deformation behavior is generated, so that the prediction of the deformation of the corrugated metal backboard is no longer vague and general, but has a solid pressure analysis foundation, which can accurately present the deformation trend and degree of each part of the backboard under the specific pressure. This accurate prediction helps to take targeted measures in advance to optimize the arrangement of high-temperature pads, etc., and effectively prevent and control the adverse deformation of the backboard.

[0110] With the help of the above-mentioned accurate deformation behavior prediction, production personnel can reasonably adjust and optimize the pressing process configuration parameters, the initial arrangement position of the high-temperature pads, etc. according to the actual situation, so as to make the production process more scientific and accurate, and ensure that the deformation problem of the corrugated metal backboard can be minimized in actual production, improve the consistency and qualification rate of products, and improve the level of the entire photovoltaic module production process.

[0111] The ability to accurately predict and prevent the deformation of corrugated metal backsheets allows photovoltaic modules to maintain good structural integrity during the manufacturing process. A stable backsheet structure helps maintain the flatness of the entire module, ensuring close and reasonable coordination between components, thereby improving the power generation performance of photovoltaic modules, while reducing the potential risk of failure caused by structural deformation, extending the service life of modules, and enhancing the competitiveness of photovoltaic modules in the market.

[0112] In summary, this implementation step has significant beneficial effects in improving the accuracy of analysis, grasping deformation trends, optimizing production processes, and improving component quality, providing a strong guarantee for the high-quality production of photovoltaic modules.

[0113] Further optionally, before determining the arrangement position of the high-temperature pad according to the material properties, shape and size of the corrugated metal backboard in the above steps, the high-temperature resistance performance value and stiffness matching the high-temperature pad can be determined based on the corrugated material characteristics and high-temperature performance in the material properties; based on the high-temperature resistance performance value and stiffness, a high-temperature pad with matching material type is selected.

[0114] Specifically, by determining the high temperature resistance performance value and stiffness of the high temperature pad according to the corrugated material characteristics and high temperature performance in the material properties of the corrugated metal backboard, it can be ensured that the performance of the high temperature pad in the specific environment of high temperature lamination is compatible with the corrugated metal backboard. Because the lamination process is often accompanied by high temperatures and high pressures, only high temperature pads that meet the requirements of high temperature resistance and stiffness can play a stable role under such harsh conditions, provide reliable support for the corrugated metal backboard, and avoid melting, deformation and other problems due to insufficient performance of the pad itself, thereby effectively ensuring the stability of the shape of the corrugated metal backboard during the lamination process and improving the overall support effect.

[0115] Different corrugated metal backsheets may have different corrugated material properties and high-temperature performance requirements due to their own materials, design purposes and other factors. This method of determining the performance parameters of high-temperature pads based on specific backsheet characteristics can achieve personalized customization and matching of high-temperature pads. This allows the high-temperature pads in each photovoltaic module to achieve the best performance synergy with the corresponding corrugated metal backsheet, better respond to production needs under different working conditions, and improve the adaptability and stability of the entire module in the manufacturing process.

[0116] High-temperature pads with appropriate high-temperature resistance values ​​and rigidity can accurately support the corrugated metal backsheet during the lamination process, preventing the backsheet from deforming due to high temperature and high pressure, thereby maintaining the flatness and stability of the overall structure of the photovoltaic module. A stable structure is essential for the coordination between the various components inside the photovoltaic module, which can ensure that key components such as photovoltaic cells are in a good working environment, help improve the power generation performance of the module, and ensure that the product quality reaches a high level.

[0117] If the high temperature pads do not match the high temperature resistance and rigidity, the backsheet may not be effectively supported during the lamination process, resulting in deformation of the backsheet, which will not only affect the immediate production quality of the module, but may also cause a series of potential failures in subsequent use, such as loose connections between components, stress concentration and damage to components, etc. By accurately selecting matching high temperature pads, these potential failures can be reduced from the source, the service life of photovoltaic modules can be extended, the maintenance cost during use can be reduced, and the reliability and cost performance of the modules can be improved.

[0118] Determining and selecting matching high-temperature pads in advance can avoid the mismatch between the high-temperature pads and the corrugated metal backboard due to the performance of the high-temperature pads not meeting the requirements during the production process, reduce problems such as product failure and the need for rework caused by such mismatches, make the production process smoother, reduce unnecessary production pauses and waste of resources, thereby effectively improving production efficiency and ensuring that production tasks can be completed on time and with high quality.

[0119] This step provides a clear and scientific basis for the selection of high-temperature spacers, helps to standardize the material selection criteria in the production process, and enables production personnel to follow rules when selecting high-temperature spacers. They can select the appropriate material type according to the established high-temperature performance values ​​and stiffness requirements, thereby improving the accuracy and efficiency of material selection and further optimizing the entire photovoltaic module production process chain.

[0120] In summary, this step has shown significant beneficial effects in improving product quality, optimizing production processes, and other aspects by ensuring the performance compatibility of high-temperature pads and corrugated metal backsheets, and is of great significance to the efficient and high-quality production of photovoltaic modules.

[0121] The calculation method of the material characteristic parameters of the corrugated metal backsheet can refer to the following methods, so that the laminated photovoltaic modules can bear wind loads, gravity loads and earthquake effects:

[0122] Method 1: Assume that the metal corrugated sheet is calculated as a corrugated steel plate. In the calculation of a corrugated steel plate (single span), the calculation assumes that the vertical frame is designed as a single-span simply supported beam, which means that the vertical frame is regarded as a beam model with hinged supports at both ends, which can rotate but cannot move horizontally and vertically to analyze its stress and deformation. It has to bear wind load, gravity load and earthquake action. Wind load is the pressure or suction generated by the flow of external air on the structure, gravity load is the force generated by the weight of the vertical frame itself and the supported components, and earthquake action is the inertial force transmitted to the structure by the ground movement when an earthquake occurs.

[0123] In terms of calculation parameters, the vertical frame span Ls is 1150mm, which refers to the horizontal distance between the two ends of the vertical frame, affecting its internal force and deformation calculation; the grid width B1 is 320mm, which is used to describe the size of the structural grid and has a reference for load distribution; the glass thickness t1 is 7mm, which is related to the weight, strength and stress deformation characteristics of the glass itself; the steel plate thickness t2 is 1.5mm, which determines the mechanical properties of the steel plate and its coordination with other components; the glass weight γg1 is 25600・N / m³, which is the weight of the unit volume of glass and is used to calculate the glass gravity load; the column material Q235B hot-rolled indicates the material type and processing technology used in the vertical frame. The material has specific mechanical performance indicators for judging the safety of the structure; in the vertical frame cross-sectional characteristics, the elastic modulus E is 206.GPa, which measures the material's ability to resist elastic deformation and is used to calculate the deformation of the vertical frame. The cross-sectional area Acs1 is equal to 393.7mm², which involves the calculation of the vertical frame's deadweight and axial force strength, and the cross-sectional moment of inertia Ix1 is 11.08cm 4 , Iy1 is 68.6817cm 4 , corresponding to different coordinate axis directions, are used to analyze the bending performance of the vertical frame and calculate bending stress, deformation, etc. The section resistance moment Wx1 is 7.47cm³ and Wy1 is 22.8939cm³, which is used to determine whether the bending strength of the vertical frame can meet the design requirements. These parameters describe the key information such as the relevant characteristics, geometric features, material conditions and load types of the vertical frame in the metal corrugated structure from different angles, and are the basic basis for structural mechanics analysis and judgment of structural safety and rationality.

[0124] Method 2: Based on the above calculation assumptions, the reaction force calculation content is as follows: First, in the calculation of the weight standard value, the formula inside, Indicates the standard value of weight, its unit is , and It should be the relevant parameters of the standard value of the deadweight of different parts (such as different components, etc.). is the grid width mentioned above. Here, the weight standard value is calculated by multiplying the weight standard value by the grid width and then multiplying it by the coefficient \(1.2\). =0.114029× ; Then calculate the weight design value, the formula middle, is the design weight value, It is the partial factor related to gravity load, which is calculated by adding this factor to the weight standard value Multiply them together and you get =0.191568× For the calculation of the standard value of wind line load, the formula inside, Indicates the standard value of wind line load, It is a parameter related to the standard value of wind load, which is combined with the grid width Multiply and add the weight standard value calculated previously , calculated is 2.994029× ; In the calculation of the design value of wind + self-weight linear load, the formula inside, is the design value of wind + self-weight linear load, It is the partial factor of wind load, which is multiplied by the standard value of wind line load mentioned above. Plus the weight design value , we can conclude is 4.683× ; Finally, in the calculation of the maximum support reaction of the vertical frame under the combined load, the formula and inside, , Represent the reaction forces at different supports, is the vertical frame span, which is designed by wind + self-weight linear load Multiply by half the vertical frame span to calculate the support reaction. and are both 2.693×kN, and the reaction force of the embedded parts at the fulcrum is and Equal, also 2.693×kN. The calculation of these reaction forces is based on the previously given parameters and the corresponding load calculation principles, and is gradually derived by comprehensively considering different load conditions such as constant load and wind load. It is used to analyze the stress conditions of the vertical frame at the supports and embedded parts under the corresponding load combination.

[0125] Method 3: In the calculation of component stiffness, the load combination is first clearly defined as 1.0 * wind load, which means that the calculation of component stiffness mainly considers the wind load. The deflection control coefficient is set to a250, which plays a control role in the subsequent calculation of allowable deflection. The rigid deflection control here determines the specific value through conditional judgment, that is, when the vertical frame span is When it is less than or equal to 4.5m, take 20mm, because here It is 1150mm (less than 4.5m), so the value is is 20mm, this It is the reference value for a given deflection control. The calculation formula is , that is, take and The smaller value of the two, and then taking 0.85 times it, the specific allowable deflection value is 3.91mm. This value is used to measure the deflection range allowed by the component under stress to determine whether the component stiffness meets the requirements. The deflection calculation formula of the steel plate is ,in is the standard value of wind line load, is the vertical frame span, is the elastic modulus in the vertical frame section properties, is the moment of inertia of the vertical frame section, and the deflection of the steel plate is calculated by this formula is 2.9873mm, and finally compared and , we can conclude The results are used to determine whether the deflection of the steel plate is within the allowable range, and then to evaluate whether the stiffness of the component meets the corresponding requirements. All these parameters and calculations are centered around judging the stiffness performance of the component under wind load.

[0126] Method 4: In the calculation of component strength, the load combination is first determined as 1.3 dead load + 1.5 wind load + 1.30.5 earthquake action, which means that when calculating the strength of a component, it is necessary to comprehensively consider the dead load, wind load and earthquake action, and combine these loads according to the corresponding coefficients to simulate the actual stress conditions. inside, represents the maximum stress of the tension-bending member, is the axial tension, is the cross-sectional area of ​​the component, is the bending moment on the member, is the cross-section plastic development coefficient, is the section resistance moment, and this formula is used to comprehensively calculate the maximum stress generated by the tension-bending member under load. The value is 0, the maximum bending moment By formula Calculate here is the design value of wind + self-weight linear load, is the vertical frame span. The formula is based on the calculation principle of bending moment when a simply supported beam is subjected to uniformly distributed load in structural mechanics, and the maximum bending moment value is Then calculate the maximum stress of the steel plate, according to the previous stress calculation formula, substitute the corresponding parameters, that is, , (Cross-sectional area in the vertical frame section properties), And Wx1 (section resistance moment in the vertical frame section characteristics) are used to calculate, and the maximum stress is obtained to be 98.692Mpa. Finally, it is compared with the strength design value f of the material (for example, f is 215Mpa here). Because the maximum stress is less than f, it is judged that the component is safe, which means that under the given load combination, the strength of the component meets the requirements and can normally withstand the corresponding force without damage.

[0127] In the embodiment of the present application, the photovoltaic front panel glass layer can protect the photovoltaic cell and internal structure, the back panel layer can ensure the flatness of the photovoltaic module and provide support for the multi-layer structure, and the metal back panel as the bottom support can enhance the overall structural strength of the photovoltaic module. The structures work together to ensure that the photovoltaic module is stable and the internal components are properly protected. The expansion coefficient of the photovoltaic front panel glass layer and the metal back panel is determined by the cooperative deformation ability of each component in the photovoltaic module, which helps the photovoltaic module to better adapt to changes in factors such as temperature under different environmental conditions, reduce structural problems caused by differences in expansion coefficients, and improve overall stability. By stacking the polymer film and the metal back panel directly under the photovoltaic back panel surface, the metal back panel and the photovoltaic module are laminated and formed in one piece, which changes the original production method, simplifies the process steps, and reduces the operation links, thereby effectively improving the production efficiency of the module. The process optimization of integrated lamination reduces the complexity of manual participation and the amount of manual operation in the production process, which helps to make the photovoltaic module more efficient in the production and manufacturing process. Overall, it is beneficial to improve the structural performance of the photovoltaic module itself and improve efficiency in the production process.

[0128] Based on the same implementation principle, the embodiment of the present application also provides an electronic device, Figure 5 is a structural block diagram of the electronic device 300, such as Figure 5As shown, the electronic device 300 includes: a processor 301, a memory 302, a communication interface 303, a communication bus 304 and a controller 305; wherein the processor 301, the memory 302, and the communication interface 303 communicate with each other via the communication bus 304; the memory 302 is used to store computer programs; the processor 301 is used to execute the programs stored in the memory 302 to implement corresponding processing functions; the communication bus 304 is used for communication between the electronic device 300 and other devices; and the controller 305 is used to implement the manufacturing method of the photovoltaic module described in the above method embodiment.

[0129] In the embodiment of the present application, the communication bus 304 may be a Peripheral Component Interconnect (PCI) bus or an Extended Industry Standard Architecture (EISA) bus, etc. The communication bus 304 may be divided into an address bus, a data bus, a control bus, etc., and the specific form is not limited. For ease of representation, Figure 5 Only one thick line is used in the diagram, but this does not mean that there is only one bus or only one type of bus.

[0130] The memory 302 may include a random access memory (RAM) or a non-volatile memory (non-volatile memory), such as at least one disk memory. Optionally, the memory may also be at least one storage device located far away from the processor 301 .

[0131] The processor 301 can be a general-purpose processor, including a central processing unit (CPU), a network processor (NP), etc.; it can also be a digital signal processor (DSP), an application specific integrated circuit (ASIC), a field-programmable gate array (FPGA) or other editable logic devices, discrete gate or transistor logic devices, discrete hardware components, and the specific form can be determined according to actual needs.

[0132] Accordingly, the embodiment of the present application also provides a computer-readable storage medium storing a computer program, which, when executed, can implement the steps that can be performed by the electronic device in the above method embodiment. Finally, it should be noted that the above embodiments are only used to illustrate the technical solution of the present application, rather than to limit it; although the present application is described in detail with reference to the above embodiments, a person of ordinary skill in the art should understand that the technical solutions described in the above embodiments can still be modified, or some of the technical features can be replaced by equivalents; and these modifications or replacements do not deviate the essence of the corresponding technical solution from the spirit and scope of the technical solutions of the embodiments of the present application.

Claims

1. A photovoltaic module, characterized in that: The multilayer structure in the photovoltaic module is stacked in order from top to bottom: a photovoltaic front plate glass layer, a first photovoltaic adhesive film, a photovoltaic cell sheet, a second photovoltaic adhesive film, a back plate layer, a polymer film, and a metal back plate; The photovoltaic front panel glass layer is a light-transmitting material, and the photovoltaic front panel glass layer is used to protect the photovoltaic cells and internal structures in the photovoltaic module; the first photovoltaic adhesive film and the second photovoltaic adhesive film are used to bond adjacent module structures; the photovoltaic cells are used to convert light energy into electrical energy; the back panel layer is used to ensure the flatness of the photovoltaic module and provide support for the multi-layer structure; the polymer film is used to bond adjacent module structures; the metal back panel serves as a bottom support to enhance the overall structural strength of the photovoltaic module; The multi-layer structure in the photovoltaic module is obtained by stacking, laminating, curing and packaging, and the lamination time of the multi-layer structure is determined according to the thickness of the first photovoltaic adhesive film, the second photovoltaic adhesive film and the polymer film; The expansion coefficients of the photovoltaic front glass layer and the metal back plate are determined by the cooperative deformation capabilities of the components in the photovoltaic module; The metal back plate is a corrugated metal back plate, and the corrugated metal back plate is used to bear the pressure generated by wind load, gravity load and / or earthquake action; The photovoltaic module also includes a high-temperature pad, which is evenly filled in the gaps of the corrugated metal backboard; the high-temperature pad is used to support the shape of the corrugated metal backboard during the lamination process to prevent the corrugated metal backboard from being deformed due to excessive pressure during the lamination process.

2. The photovoltaic module according to claim 1, characterized in that: The metal back plate has a temperature linear expansion coefficient in the range of 9×10 -6 / K to 18×10 -6 / K between the metal materials.

3. The photovoltaic module according to claim 1, characterized in that: If the thickness of the first photovoltaic adhesive film and / or the second photovoltaic adhesive film is 1.14 mm, and the thickness of the polymer film is 0.3 mm, the lamination time of the multilayer structure is in the range of 10 minutes to 15 minutes.

4. The photovoltaic module according to claim 1, characterized in that: The lamination temperature of the multilayer structure ranges from 150°C to 180°C.

5. A method for manufacturing a photovoltaic module, characterized in that: The photovoltaic module is a photovoltaic module according to any one of claims 1 to 4, wherein the multilayer structure in the photovoltaic module is stacked in order from top to bottom: a photovoltaic front plate glass layer, a first photovoltaic adhesive film, a photovoltaic cell sheet, a second photovoltaic adhesive film, a back plate layer, a polymer film, and a metal back plate; the method comprises: Placing the photovoltaic front panel glass layer and the first photovoltaic adhesive film on a laminator in a preset order; the photovoltaic front panel glass layer is a light-transmitting material, and the photovoltaic front panel glass layer is used to protect the photovoltaic cells and internal structure in the photovoltaic module; the first photovoltaic adhesive film and the second photovoltaic adhesive film are used to bond adjacent module structures; Placing the photovoltaic cell sheet between the first photovoltaic adhesive film and the second photovoltaic adhesive film in a preset order; the photovoltaic cell sheet is used to convert light energy into electrical energy; Placing the backing layer under the second photovoltaic adhesive film in a preset order; the backing layer is used to ensure the flatness of the photovoltaic module and provide support for the multi-layer structure; The back plate layer is covered with the polymer film; the polymer film is used to bond adjacent component structures; The metal back plate is placed at the bottom of the multi-layer structure as a bottom support; the metal back plate is used to enhance the overall structural strength of the photovoltaic module; The stacked multilayer structure is subjected to high temperature and high pressure pressing by rollers of a laminator, so that the first photovoltaic adhesive film, the second photovoltaic adhesive film and the polymer film are melted and solidified, and the photovoltaic module is obtained by encapsulation; The lamination time of the multilayer structure is determined by the thickness of the first photovoltaic adhesive film, the second photovoltaic adhesive film and the polymer film; the expansion coefficient of the photovoltaic front plate glass layer and the metal back plate is determined by the cooperative deformation ability of each component in the photovoltaic module; Wherein, the metal back plate is a corrugated metal back plate, and the photovoltaic module further includes a high temperature pad; After placing the metal back plate at the bottom of the multi-layer structure as a bottom support, the method further includes: Determine the arrangement position of the high temperature pads according to the material properties, shape and size of the corrugated metal back plate; the arrangement position at least includes: the spacing between the high temperature pads and the placement depth of the high temperature pads; Based on the arrangement position, the high-temperature pads are evenly filled into the gaps of the corrugated metal backboard, so that the high-temperature pads support the shape of the corrugated metal backboard during the lamination process, thereby preventing the corrugated metal backboard from being deformed due to excessive pressure during the lamination process.

6. The method according to claim 5, characterized in that The step of determining the arrangement position of the high temperature pads according to the material properties, shape, and size of the corrugated metal back plate includes: According to the mechanical strength, yield strength and elastic mold information in the material properties, the first deformation behavior of the corrugated metal backboard during the pressing process is predicted by a deformation prediction model; the deformation prediction model is trained based on historical pressing data of various corrugated metal backboards and corresponding finite element analysis data; Determining the initial arrangement position of the high temperature pads according to the corrugation spacing and size of the corrugated metal back plate; Based on the pressing process configuration parameters, the initial arrangement position, and the mechanical strength, yield strength, and elastic mold information in the material properties, re-predicting the second deformation behavior of the corrugated metal backboard during the pressing process through the deformation prediction model; Based on the first deformation behavior and the second deformation behavior, the initial arrangement position is optimized to obtain a target arrangement position.

7. The method according to claim 6, characterized in that Predicting the first deformation behavior of the corrugated metal backboard during the pressing process by a deformation prediction model includes: Extracting the features to be analyzed related to the pressing process from the mechanical strength, yield strength, and elastic mold information in the material properties; Constructing a corresponding candidate model for the feature to be analyzed; the candidate model includes: a virtual three-dimensional model for representing different spatial position relationships between the corrugated metal back plate and the high-temperature pad; Performing pressure distribution analysis on the candidate model to obtain a predicted pressure distribution corresponding to the candidate model; the predicted pressure distribution includes: pressure distribution of the high temperature pad under different spatial position relationships; The matched first deformation behavior is generated based on the predicted pressure distribution.

8. The method according to claim 6, characterized in that Before determining the arrangement position of the high temperature pads according to the material properties, shape and size of the corrugated metal back plate, the method further includes: Based on the corrugated material characteristics and high temperature performance in the material properties, determining the high temperature resistance performance value and stiffness matched by the high temperature pad; Based on the high temperature resistance performance value and stiffness, a high temperature pad with a matching material type is selected.

9. A laminated solar cell module, characterized in that: The laminated solar cell assembly at least comprises the photovoltaic assembly described in any one of claims 1 to 4, and the laminated solar cell assembly is manufactured by the method for manufacturing the photovoltaic assembly described in any one of claims 5 to 8.

10. A non-transitory computer-readable storage medium, characterized in that: The storage medium stores a computer software program, and when the computer software program is executed by a processor, the method for manufacturing a photovoltaic module according to any one of claims 5 to 8 is implemented.

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