Solar panel and manufacturing method thereof

Abstract

The invention relates to the technical field of photovoltaic modules, and discloses a solar panel and a manufacturing method thereof.The solar panel comprises a first substrate, a second substrate and a battery string, the first substrate is of a light-transmitting structure, the battery string is arranged between the first substrate and the second substrate which are stacked, and the first substrate and the second substrate are connected through welding and seal the battery string. According to the solar panel provided by the invention, the battery string is mechanically limited through the first substrate and the second substrate, the first substrate and the second substrate are connected through welding, and the battery string is fixed and sealed, so that adhesive film and lamination procedures are omitted, the process energy consumption is reduced, the process time is shortened, the equipment and material cost is reduced, and the service life of the battery string is prolonged.

Description

Technical Field

[0001] The present invention relates to the technical field of photovoltaic components, and in particular to a solar panel and a manufacturing method thereof. Background Art

[0002] In recent years, the photovoltaic industry has developed rapidly, the photoelectric conversion efficiency has continued to improve, and the cost of photovoltaic components has also decreased.

[0003] The structure of photovoltaic modules is usually divided into single glass and double glass. Single glass modules are laminated glass, film, battery cell, film, and backplane in sequence; double glass modules are laminated glass, film, battery cell, film, and glass in sequence; according to the application scenario and installation needs, butyl rubber and other edge sealing and water-blocking materials are selectively set around the inside of the module.

[0004] Photovoltaic modules are formed by film bonding and vacuum lamination, and the stacked materials are vacuum laminated to form a laminate. On the one hand, the number of layers is large, the lamination process is energy-intensive, the process time is long, and the material cost is high; on the other hand, because the edge sealing water-blocking material still has a certain water vapor permeability, the film will generate acidic substances under the influence of heat and water vapor, thus affecting the life of the battery cell.

[0005] Therefore, there is an urgent need for a solar panel and a manufacturing method thereof to solve the above-mentioned technical problems. Summary of the invention

[0006] Based on the above, the purpose of the present invention is:

[0007] 1. Provide a solar panel, mechanically limit the battery string through the first substrate and the second substrate, connect the first substrate and the second substrate and fix and seal the battery string through welding, and eliminate the adhesive film and lamination process, reduce process energy consumption and time, reduce equipment and material costs, and extend the service life of the battery string.

[0008] 2. Provide a method for manufacturing solar panels, mechanically limit the battery string through the built-in limiting structure on the first substrate and / or the second substrate body, connect the first substrate and the second substrate and fix and seal the battery string through welding, and eliminate the adhesive film and lamination process, thereby reducing process energy consumption and time, reducing equipment and material costs, and extending the service life of the battery string.

[0009] To achieve the above object, the present invention adopts the following technical solutions:

[0010] In a first aspect, a solar panel is provided, comprising a first substrate, a second substrate and a battery string, wherein the first substrate is a light-transmitting structure, the battery string is arranged between the stacked first substrate and the second substrate, and the first substrate and the second substrate are connected by welding and the battery string is sealed.

[0011] As an optional technical solution for the solar panel, a first limiting groove is provided on the first substrate, and the battery string is accommodated in the first limiting groove.

[0012] As an optional technical solution for the solar panel, the difference between the depth of the first limiting groove and the thickness of the battery string does not exceed 1 mm.

[0013] As an optional technical solution for solar panels, a first limiting groove is provided on the first substrate, and a second limiting groove is provided on the second substrate. The second limiting groove and the first limiting groove are arranged opposite to each other and are interconnected, and the battery string is accommodated between the first limiting groove and the second limiting groove.

[0014] As an optional technical solution for the solar panel, a first reinforcement area is provided on the first substrate, and a second reinforcement area is correspondingly provided on the second substrate, and the first reinforcement area is connected to the second reinforcement area by welding.

[0015] As an optional technical solution for the solar panel, the battery string is connected to the first substrate or the second substrate by welding.

[0016] As an optional technical solution for the solar panel, the first substrate and / or the second substrate is made of glass or a transparent polymer material.

[0017] As an optional technical solution for the solar panel, a plurality of the first limiting grooves are provided, and the plurality of the first limiting grooves are arranged in parallel and at intervals.

[0018] In a second aspect, a method for manufacturing a solar panel is provided, which is used to manufacture the solar panel as described above, comprising the following steps:

[0019] Processing the first limiting groove on the first substrate; and / or processing the second limiting groove on the second substrate;

[0020] stacking the first substrate, the battery string and the second substrate, and placing the battery string in the first limiting groove and / or the second limiting groove;

[0021] The first substrate and the second substrate are connected by welding, and the battery string is sealed between the first substrate and the second substrate.

[0022] As an optional technical solution of the method for manufacturing a solar panel, processing the first limiting groove on the first substrate specifically includes the following steps:

[0023] A limiting groove is formed on the side of the first substrate facing the battery string by embossing or etching; or at least two first convex strips arranged side by side and spaced apart are fixedly connected on the side of the first substrate facing the battery string, and a first limiting groove adapted to the battery string is formed between adjacent first convex strips; and processing the second limiting groove on the second substrate specifically comprises the following steps:

[0024] A limiting groove is formed on the side of the second substrate facing the battery string by embossing or etching; or at least two second convex strips arranged side by side and spaced apart are fixedly connected on the side of the second substrate facing the battery string, and the second limiting groove adapted to the battery string is formed between adjacent second convex strips.

[0025] As an optional technical solution of the method for manufacturing a solar panel, welding the first substrate and the second substrate specifically comprises the following steps:

[0026] Welding and connecting the first reinforcement area of ​​the first substrate and the second reinforcement area of ​​the second substrate;

[0027] A sealing welding rod is formed by welding along the edges of the first substrate and the second substrate to seal the gap between the first substrate and the second substrate.

[0028] As an optional technical solution of the method for manufacturing a solar panel, welding the first substrate and the second substrate specifically comprises the following steps:

[0029] Along the stacking direction of the first substrate and the second substrate, applying a pressure of a preset force to the welding area to press the first substrate and the second substrate tightly;

[0030] The first substrate and the second substrate are connected by high temperature welding or laser welding.

[0031] The beneficial effects of the present invention are:

[0032] The solar panel provided by the present invention directly connects the first substrate and the second substrate by welding, which, on the one hand, fixes the first substrate and the second substrate, and also fixes the battery string between the two; on the other hand, the battery string is sealed to prevent external water vapor from penetrating between the first substrate and the second substrate and corroding the battery string. The solar panel provided by the present invention directly connects the first substrate and the second substrate by welding, and fixes and seals the battery string, eliminating the need for setting the adhesive film material and the lamination process, reducing the number of lamination layers, reducing process energy consumption and time, reducing equipment and material costs, and preventing the adhesive film from generating acidic substances, with better welding sealing and extending the service life of the battery string.

[0033] The present invention provides a method for manufacturing a solar panel, by setting a first limiting groove and / or a second limiting groove between a first substrate and a second substrate to limit the installation position of a battery string between the first substrate and the second substrate, and then welding and connecting the first substrate and the second substrate, on the one hand, fixing the first substrate and the second substrate, and also fixing the battery string between the two; on the other hand, sealing the battery string to prevent external water vapor from penetrating between the first substrate and the second substrate and corroding the battery string. In summary, the method for manufacturing a solar panel provided by the present invention directly connects and seals the first substrate and the second substrate by welding, and mechanically limits the battery string by the first limiting groove and / or the second limiting groove, eliminating the need for setting the adhesive film material and the lamination process, reducing the number of lamination layers, reducing the process energy consumption and duration, reducing the cost of equipment and materials, and at the same time preventing the adhesive film from generating acidic substances, and achieving better welding sealing, thereby extending the service life of the battery string. BRIEF DESCRIPTION OF THE DRAWINGS

[0034] In order to more clearly illustrate the technical solutions in the embodiments of the present invention, the following briefly introduces the drawings required for use in the description of the embodiments of the present invention. Obviously, the drawings described below are only some embodiments of the present invention. For ordinary technicians in this field, other drawings can be obtained based on the contents of the embodiments of the present invention and these drawings without paying any creative work.

[0035] Figure 1 The stacked structure of the solar panel provided by the present invention is shown in FIG. Figure 1 ;

[0036] Figure 2 is a structural schematic diagram of a first substrate provided by the present invention;

[0037] Figure 3 is a structural schematic diagram of a second substrate provided by the present invention;

[0038] Figure 4 is a cross-sectional schematic diagram of a first substrate provided by the present invention;

[0039] Figure 5 The stacked structure of the solar panel provided by the present invention is shown in FIG. Figure 2 ;

[0040] Figure 6 is a cross-sectional schematic diagram of a second substrate provided by the present invention;

[0041] Figure 7 is a flow chart of the steps of the method for manufacturing a solar panel provided by the present invention;

[0042] Figure 8 is a flowchart of steps for welding a first substrate and a second substrate in two steps;

[0043] Fig. 9It is a flowchart of the specific steps of welding the first substrate and the second substrate.

[0044] In the figure:

[0045] 10. First substrate; 11. First limiting groove; 12. First convex strip; 20. Second substrate; 21. Second limiting groove; 22. Second convex strip; 23. First reinforcement area; 30. Battery string; 40. Sealing welding rod. DETAILED DESCRIPTION

[0046] In order to make the technical problems solved by the present invention, the technical solutions adopted and the technical effects achieved clearer, the technical solutions of the embodiments of the present invention will be further described in detail below in conjunction with the accompanying drawings. Obviously, the described embodiments are only part of the embodiments of the present invention, not all of the embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative work are within the scope of protection of the present invention.

[0047] like Figure 1-Figure 6 As shown, this embodiment provides a solar panel, which includes a first substrate 10, a second substrate 20 and a battery string 30. The first substrate 10, the battery string 30 and the second substrate 20 are stacked in sequence from top to bottom. The first substrate 10 is a light-transmitting structure to allow light to penetrate into the battery string 30. The battery string 30 includes battery cells and battery welding strips.

[0048] Further, such as Figure 1-Figure 6 As shown, the first substrate 10 and the second substrate 20 are connected and sealed by welding to the battery string 30, and the first substrate 10 and the second substrate 20 mechanically limit the battery string 30 through their body structures. Specifically, the solar panel provided in this embodiment directly connects the first substrate 10 and the second substrate 20 by welding, which, on the one hand, fixes the first substrate 10 and the second substrate 20, and also fixes the battery string 30 between the two; on the other hand, the battery string 30 is sealed to prevent external water vapor from penetrating between the first substrate 10 and the second substrate 20 and corroding the battery string 30. The solar panel provided in this embodiment directly connects and seals the first substrate 10 and the second substrate 20 by welding, and fixes and seals the battery string 30, eliminating the need for the setting of the adhesive film material and the lamination process, reducing the number of lamination layers, reducing the process energy consumption and time, reducing the material cost, and at the same time avoiding the generation of acidic substances by the adhesive film, and the welding sealing is better, extending the service life of the battery string 30.

[0049] In this embodiment, if Figure 1-Figure 4As shown, a first limiting groove 11 is provided on the first substrate, and the battery string 30 is limited between the first limiting groove 11 and the second substrate 20. The first limiting groove 11 accommodates the battery string 30 alone, and the depth of the first limiting groove 11 is adapted to the thickness of the battery string 30. The battery string 30 is accommodated and limited by the groove structure, and the battery string 30 is prevented from being subjected to stress during the manufacturing process of the solar panel, thereby further improving stability.

[0050] In the above-mentioned embodiment where the first limiting groove 11 or the second limiting groove 21 accommodates the battery string 30 alone, the difference between the depth of the first limiting groove 11 or the second limiting groove 21 and the thickness of the battery string 30 does not exceed 1 mm. Preferably, the difference between the depth of the first limiting groove 11 or the second limiting groove 21 and the thickness of the battery string 30 does not exceed 0.4 mm.

[0051] In another embodiment, if Figure 5 and Figure 6 As shown, a first limiting groove 11 is provided on the first substrate 10, and a second limiting groove 21 is provided on the second substrate 20. The second limiting groove 21 and the first limiting groove 11 are arranged opposite to each other and are connected to each other. The battery string 30 is accommodated between the first limiting groove 11 and the second limiting groove 21. The first limiting groove 11 and the second limiting groove 21 jointly define the installation position of the battery string 30, and the sum of the depths of the first limiting groove 11 and the second limiting groove 21 is adapted to the thickness of the battery string 30.

[0052] In the above-mentioned embodiment where the first limiting groove 11 and the second limiting groove 21 jointly accommodate the battery string 30, the difference between the sum of the depths of the first limiting groove 11 and the second limiting groove 21 and the thickness of the battery string 30 does not exceed 1 mm. Preferably, the difference between the sum of the depths of the first limiting groove 11 and the second limiting groove 21 and the thickness of the battery string 30 does not exceed 0.4 mm.

[0053] For example, Figure 1-Figure 6 As shown, a plurality of battery strings 30 are provided, and a plurality of first limiting grooves 11 and / or second limiting grooves 21 are correspondingly provided, and correspondingly define the installation positions of the plurality of battery strings 30. In this embodiment, the plurality of first limiting grooves 11 are arranged side by side in the horizontal direction to accommodate the plurality of battery strings 30 arranged side by side.

[0054] Exemplarily, the first limiting groove 11 and the first substrate 10 are integrally formed.

[0055] Exemplarily, the second limiting groove 21 and the second substrate 20 are integrally formed.

[0056] Exemplarily, in this embodiment, the battery string 30 is directly mechanically limited and locked between the first substrate 10 and the second substrate 20 by the first limiting groove 11 and / or the second limiting groove 21 in both the horizontal and vertical directions. In some embodiments, the battery string 30 is also welded to the first substrate 10 or the second substrate 20. Specifically, the battery welding strip in the battery string 30 is connected to the first substrate 10 or the second substrate 20 by laser welding to assist in fixing the battery string 30 and improve the installation stability of the battery string 30.

[0057] For example, Figure 2 As shown, a first reinforcement area (not shown in the figure) is provided on the first substrate 10, and a second reinforcement area 23 is correspondingly provided on the second substrate 20, and the first reinforcement area 23 is connected to the second reinforcement area 23 by welding. Specifically, a plurality of first reinforcement areas and a plurality of second reinforcement areas 23 are provided to increase the welding points between the first substrate 10 and the second substrate 20, thereby improving the connection stability of the first substrate 10 and the second substrate 20.

[0058] For example, Figure 3 As shown, the first reinforcement area and the second reinforcement area 23 can be configured as a long strip structure, or as a disk, a ring, or a dot structure.

[0059] Exemplarily, the first substrate 10 is made of transparent glass or polymer material. In this embodiment, the first substrate 10 is made of glass. In other embodiments of the present invention, the first substrate 10 can also be made of transparent glass, PET (polyethylene terephthalate) or PC (polycarbonate).

[0060] Exemplarily, the second substrate 20 is made of transparent glass or polymer material. In this embodiment, the second substrate 20 is made of glass. In other embodiments of the present invention, the second substrate 20 is made of transparent PET or PC.

[0061] In this embodiment, the first substrate 10 and the second substrate 20 are both made of transparent glass, and the battery string 30 is a double-sided power generation battery string to improve power generation efficiency. Further, the first substrate 10 and the second substrate 20 are connected by laser welding or high temperature heating welding.

[0062] Exemplarily, the thickness of the first substrate 10 and the second substrate 20 are both 1 mm to 5 mm. Preferably, the thickness of the first substrate 10 and the second substrate 20 are both 2 mm to 3.2 mm.

[0063] Exemplarily, the solar panel also includes a frame (not shown in the figure), which is arranged around the periphery of the first substrate 10 and the second substrate 20, and the frame cover is arranged on the periphery of the first substrate 10 and the second substrate 20 to protect the edges and four corners of the first substrate 10 and the second substrate 20.

[0064] like Figure 7-Figure 9 As shown, this embodiment also provides a method for manufacturing the solar panel, which specifically includes the following steps:

[0065] Processing a first limiting groove 11 on the first substrate 10; and / or processing a second limiting groove 21 on the second substrate 20;

[0066] The first substrate 10, the battery string 30 and the second substrate 20 are stacked, and the battery string 30 is placed in the first limiting groove 11 and / or the second limiting groove 21;

[0067] Welding the battery string 30 to the first substrate 10 or the second substrate 20 to assist in fixing the battery string 30;

[0068] Welding and connecting the first substrate 10 and the second substrate 20, and sealing the battery string 30 between the first substrate 10 and the second substrate 20;

[0069] Frames are installed around the first substrate 10 and the second substrate 20 .

[0070] Specifically, the manufacturing method of the solar panel provided in this embodiment sets a first limiting groove 11 and / or a second limiting groove 21 between the first substrate 10 and the second substrate 20 to mechanically limit the installation position of the battery string 30 between the first substrate 10 and the second substrate 20, and then welds the first substrate 10 and the second substrate 20 to connect, so that the assembly of the solar panel can be completed through the lamination and welding processes, eliminating the vacuum lamination and film bonding processes, reducing the number of lamination layers, reducing process energy consumption and time, improving manufacturing efficiency, reducing equipment and material costs, and avoiding the generation of acidic substances by the film, thereby extending the service life of the battery string 30.

[0071] Exemplarily, processing the first limiting groove 11 on the first substrate 10 specifically includes the following steps:

[0072] A limiting groove is formed on the side of the first substrate 10 facing the battery string 30 by embossing or etching; or at least two first convex strips 12 arranged side by side and spaced apart are fixedly connected on the side of the first substrate 10 facing the battery string 30, and a first limiting groove adapted to the battery string 30 is formed between adjacent first convex strips 12.

[0073] Exemplarily, the first protruding strip 12 is connected to the first substrate 10 by welding, bonding or screw connection.

[0074] Exemplarily, processing the second limiting groove 21 on the second substrate 20 specifically includes the following steps:

[0075] A limiting groove is formed on the side of the second substrate 20 facing the battery string 30 by embossing or etching; or at least two second convex strips 22 arranged side by side and spaced apart are fixedly connected on the side of the second substrate 20 facing the battery string 30, and a second limiting groove adapted to the battery string 30 is formed between adjacent second convex strips 22.

[0076] Exemplarily, the second protruding strip 22 is connected to the second substrate 20 by welding, bonding or screw connection.

[0077] For example, Figure 8 As shown, welding the first substrate 10 and the second substrate 20 is performed in two steps, specifically including the following steps:

[0078] The first reinforcing area of ​​the first substrate 10 is connected to the second reinforcing area 23 of the second substrate 20 by welding, so as to assist in fixing the first substrate 10 and the second substrate 20 at multiple points;

[0079] A sealing electrode 40 for sealing a gap between the first substrate 10 and the second substrate 20 is formed by welding along the edges of the first substrate 10 and the second substrate 20 .

[0080] For example, Fig. 9 As shown, the specific operation of welding the first substrate 10 and the second substrate 20 includes the following steps:

[0081] Along the stacking direction of the first substrate 10 and the second substrate 20, a pressure of a preset force is applied to the welding area to press the first substrate 10 and the second substrate 20 tightly to ensure the contact of the welding surface;

[0082] Under the condition that a certain vacuum degree is maintained in the operation area or an inert gas is introduced, the first substrate 10 and the second substrate 20 are connected by high temperature welding or laser welding to avoid air residue between the first substrate 10 and the second substrate 20 .

[0083] Note that the above are only preferred embodiments of the present invention and the technical principles used. Those skilled in the art will understand that the present invention is not limited to the specific embodiments described herein, and that various obvious changes, readjustments and substitutions can be made by those skilled in the art without departing from the scope of protection of the present invention. Therefore, although the present invention has been described in more detail through the above embodiments, the present invention is not limited to the above embodiments, and may include more other equivalent embodiments without departing from the concept of the present invention, and the scope of the present invention is determined by the scope of the appended claims.

Claims

1. A solar panel, comprising a first substrate, a second substrate and a battery string, wherein the first substrate is a light-transmitting structure, and the battery string is arranged between the stacked first substrate and the second substrate, characterized in that: The first substrate and the second substrate are connected by welding to seal the battery string.

2. The solar panel according to claim 1, characterized in that: The first substrate is provided with a first limiting groove, and the battery string is received in the first limiting groove.

3. The solar panel according to claim 2, characterized in that: The difference between the depth of the first limiting groove and the thickness of the battery string does not exceed 1 mm.

4. The solar panel according to claim 1, characterized in that: The first substrate is provided with a first limiting groove, the second substrate is provided with a second limiting groove, the second limiting groove and the first limiting groove are arranged opposite to each other and are connected to each other, and the battery string is accommodated between the first limiting groove and the second limiting groove.

5. The solar panel according to any one of claims 1 to 4, characterized in that: A first reinforcement region is disposed on the first substrate, and a second reinforcement region is correspondingly disposed on the second substrate. The first reinforcement region and the second reinforcement region are connected by welding.

6. The solar panel according to any one of claims 1 to 4, characterized in that: The battery string is connected to the first substrate or the second substrate by welding.

7. The solar panel according to any one of claims 1 to 4, characterized in that: The first substrate and / or the second substrate is made of glass or transparent polymer material.

8. The solar panel according to any one of claims 1 to 4, characterized in that: There are a plurality of the first limiting grooves, and the plurality of the first limiting grooves are arranged in parallel and at intervals.

9. A method for manufacturing a solar panel, characterized in that: The method for manufacturing a solar panel according to any one of claims 1 to 8 comprises the following steps: Processing a first limiting groove on the first substrate; and / or processing a second limiting groove on the second substrate; stacking the first substrate, the battery string and the second substrate, and placing the battery string in the first limiting groove and / or the second limiting groove; The first substrate and the second substrate are connected by welding, and the battery string is sealed between the first substrate and the second substrate.

10. The method for manufacturing a solar panel according to claim 9, characterized in that: Processing the first limiting groove on the first substrate specifically includes the following steps: A limiting groove is formed on the side of the first substrate facing the battery string by embossing or etching; or at least two first convex strips arranged side by side and spaced apart are fixedly connected on the side of the first substrate facing the battery string, and a first limiting groove adapted to the battery string is formed between adjacent first convex strips; Processing the second limiting groove on the second substrate specifically includes the following steps: A limiting groove is formed on the side of the second substrate facing the battery string by embossing or etching; or at least two second convex strips arranged side by side and spaced apart are fixedly connected on the side of the second substrate facing the battery string, and the second limiting groove adapted to the battery string is formed between adjacent second convex strips.

11. The method for manufacturing a solar panel according to claim 9, characterized in that: The welding connection between the first substrate and the second substrate specifically includes the following steps: Welding and connecting the first reinforcement area of ​​the first substrate and the second reinforcement area of ​​the second substrate; A sealing welding rod is formed by welding along the edges of the first substrate and the second substrate to seal the gap between the first substrate and the second substrate.

12. The method for manufacturing a solar panel according to claim 9, characterized in that: The welding connection between the first substrate and the second substrate specifically includes the following steps: Along the stacking direction of the first substrate and the second substrate, applying a pressure of a preset force to the welding area to press the first substrate and the second substrate tightly; The first substrate and the second substrate are connected by high temperature welding or laser welding.

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