Light special-shaped photovoltaic module and processing technology

Abstract

The invention provides a light special-shaped photovoltaic module and a processing technology, and relates to the technical field of solar energy, the light special-shaped photovoltaic module comprises a photovoltaic main body and a flexible frame, the flexible frame is packaged at the edge of the photovoltaic main body, and the photovoltaic main body comprises a front plate, a battery piece and a back plate; packaging adhesive films are laid above the back plate and below the front plate, a metal conductive foil is arranged on the packaging adhesive film of the back plate, the battery piece is laid between the packaging adhesive film of the front plate and the metal conductive foil, and an insulating layer is arranged on the battery piece; the front plate, the battery piece and the back plate are laminated and packaged to form the photovoltaic main body, and the photovoltaic main body is integrally cut after being laminated and packaged, so that the defect that gaps exist when special-shaped assemblies are filled with the square battery piece is overcome, then the edge of the photovoltaic main body is locally packaged through the flexible frame, and the defect that delamination and failure are easy to occur after lamination and integral cutting is solved; and meanwhile, the production process is simplified, the product yield is improved, and the product cost is reduced.

Description

Technical Field

[0001] The invention relates to the field of solar energy technology, and in particular to a lightweight special-shaped photovoltaic component and a processing technology. Background Art

[0002] As a widely used renewable energy source, photovoltaic solar cells have various application scenarios, including centralized power stations, distributed power stations and building integrated photovoltaics (BIPV). In particular, in distributed and BIPV applications, there are high requirements for the appearance design, color and style of photovoltaic modules. These applications require photovoltaic modules to be not only efficient, but also coordinated with architectural aesthetics. Currently, most photovoltaic modules on the market adopt a standard rectangular design. This single shape and style is often difficult to meet the needs of distributed and BIPV projects with special requirements for aesthetics. Therefore, developing diversified photovoltaic module designs to adapt to different architectural styles and personalized needs is an important direction for the future development of the photovoltaic industry.

[0003] At present, a small number of special-shaped photovoltaic modules on the market are all filled with rectangular cells into special-shaped modules, and there are many irregular gaps, which makes the modules not beautiful. The existing patent with patent application number 201510373979.1 is to laminate the battery chips into a whole and then cut them, and then lay the battery front plate and back plate, and finally perform a second cutting to obtain a filled special-shaped battery module. This process requires secondary lamination, which not only increases the energy consumption and material cost of the product, but also leads to the complexity of the process. In particular, adding a lamination process will increase the risk of bubbles, pits and hidden cracks in the module. In addition, since the secondary lamination requires an extra layer of front plate material, this leads to the loss of incident light, thereby reducing the conversion efficiency of the photovoltaic module. Therefore, the present invention proposes a lightweight special-shaped photovoltaic module and a processing technology to solve the problems existing in the prior art. Summary of the invention

[0004] In view of the above problems, the present invention proposes a lightweight special-shaped photovoltaic module and processing technology. The lightweight special-shaped photovoltaic module and processing technology are laminated and packaged into a photovoltaic main body by a front panel, battery cells and a back panel, and the whole is cut after lamination and packaging, which solves the defect of gaps in special-shaped modules filled with square batteries. The edge of the photovoltaic main body is partially packaged by a flexible frame, which solves the defect of easy delamination and failure after lamination and overall cutting, and greatly improves the aesthetics of the module.

[0005] To achieve the purpose of the present invention, the present invention is implemented by the following technical solutions: a lightweight special-shaped photovoltaic module, including a photovoltaic body and a flexible frame, wherein the flexible frame is encapsulated at the edge of the photovoltaic body, and the photovoltaic body includes a front plate, a battery sheet and a back plate;

[0006] The upper part of the back plate and the lower part of the front plate are both covered with packaging films, and a metal conductive foil is provided on the packaging film of the back plate. The battery cell is laid between the packaging film and the metal conductive foil of the front plate, and an insulating layer is provided on the battery cell.

[0007] A further improvement is that the material composition of the front plate is any one of PC plate, PET plate, ETFE plate, FEP plate and PMMA plate.

[0008] A further improvement is that the encapsulating film is any one of EVA, POE, PVB, glue, organic silicone material, and a color film material containing color particles.

[0009] A further improvement is that the solar cell is any one of a PERC cell, a TOPCon cell, a HJT cell, and an XBC cell.

[0010] A further improvement is that the material composition of the back plate is any one of PC board, PET board, ETFE board, FEP board, PMMA board and carbon fiber board.

[0011] A further improvement is that the photovoltaic body is in the shape of a circle, a polygon, a heart shape or a combination of the two, and the material of the flexible frame is in the shape of any one of PC, PET, ETFE, FEP and PMMA.

[0012] A processing technology for a lightweight special-shaped photovoltaic module comprises the following steps:

[0013] S1: Lay a backplane on the carrier, and use tape to fix the carrier and the backplane. The backplane includes a packaging film and a metal conductive foil, and a positioning mark is engraved on the metal conductive foil;

[0014] S2: After the production line transfers the carrier to the next station, the reset device is used to correct the position of the carrier, and then the battery cell is prepared. The battery cell is printed with conductive glue offline and has its own insulation layer;

[0015] S3: Grab the battery cell by the robotic arm, identify the positioning mark of the metal conductive foil, and lay the battery cell on the metal conductive foil;

[0016] S4: Laying the encapsulation film and the front plate on the battery cell, laminating, and cutting once;

[0017] S5: Install, glue and cure the cut special-shaped laminated parts with flexible frames, and use fixtures to fix the flexible frames before the glue is completely cured;

[0018] S6: After curing, install the junction box and inspect before storage.

[0019] A further improvement is that in S1, tempered glass is used as a carrier of the production line, the heat-resistant temperature of the carrier is 200°C-300°C, and the positioning mark on the metal conductive foil is used to cooperate with the camera for positioning.

[0020] A further improvement is that in S2, the battery cell has its own insulating layer, and the insulating layer is an insulating glue or an insulating film.

[0021] A further improvement is that in S3, a camera is integrated on the robot arm to locate the battery cells by identifying the positioning marks of the metal conductive foil.

[0022] The beneficial effects of the present invention are:

[0023] 1. The present invention laminates and packages the front panel, battery cells and back panel into a photovoltaic main body, and cuts the whole body after lamination and packaging, which solves the defect of gaps in square battery cells filling special-shaped components. The edge of the photovoltaic main body is partially encapsulated by a flexible frame, which solves the defect of easy delamination and failure after lamination and overall cutting. The aesthetics of the component is greatly improved, making it more suitable for distributed and BIPV application scenarios. At the same time, it simplifies the production process, improves product yield and reduces product cost.

[0024] 2. The present invention uses a flexible frame to locally encapsulate the edge of the cut photovoltaic body, replacing the existing secondary lamination packaging and secondary cutting process, greatly simplifying the process, improving production efficiency and yield, and reducing costs. The flexible frame local packaging process does not require a second layer of front plate on the front of the component, thereby improving the photoelectric conversion efficiency of the component. The process is compatible with the existing photovoltaic component production line, does not require additional equipment, and has low fixed investment. BRIEF DESCRIPTION OF THE DRAWINGS

[0025] Figure 1 It is a front view of the present invention;

[0026] Figure 2 It is a schematic diagram of the photovoltaic main layered structure of the present invention;

[0027] Figure 3 It is a process flow chart of the present invention. DETAILED DESCRIPTION

[0028] In order to deepen the understanding of the present invention, the present invention will be further described in detail below in conjunction with examples. The examples are only used to explain the present invention and do not constitute a limitation on the protection scope of the present invention.

[0029] Embodiment 1

[0030] according to Figure 1 , 2As shown, this embodiment proposes a lightweight special-shaped photovoltaic module, including a photovoltaic body and a flexible frame, wherein the flexible frame is packaged at the edge of the photovoltaic body, and the photovoltaic body includes a front plate, a battery sheet and a back plate;

[0031] The upper part of the back plate and the lower part of the front plate are both paved with a packaging film, and a metal conductive foil is provided on the packaging film of the back plate. The battery cell is laid between the packaging film and the metal conductive foil of the front plate, and an insulating layer is provided on the battery cell. The front plate, battery cell and back plate are laminated and packaged into a photovoltaic body, and the whole is cut after lamination and packaging, which solves the defect of square battery cells filling special-shaped components with gaps. Then, the edge of the photovoltaic body is partially packaged by a flexible frame, which solves the defect of easy delamination and failure after lamination and overall cutting, greatly improving the aesthetics of the component, making it more suitable for distributed and BIPV application scenarios.

[0032] The material composition of the front plate is any one of PC plate, PET plate, ETFE plate, FEP plate, and PMMA plate. The encapsulation film is any one of EVA, POE, PVB, glue, organic silicone material, and color film material containing color particles. The battery cell is any one of PERC battery, TOPCon battery, HJT battery, and XBC battery. The material composition of the back plate is any one of PC plate, PET plate, ETFE plate, FEP plate, PMMA plate, and carbon fiber plate.

[0033] The photovoltaic body is in the shape of a circle, a polygon, a heart shape, or a combination thereof, to achieve a special-shaped effect that is in harmony with architectural aesthetics; the material of the flexible frame is any one of PC, PET, ETFE, FEP, and PMMA. The use of a flexible frame to partially encapsulate the edge of the cut photovoltaic body replaces the existing secondary lamination encapsulation and secondary cutting process, greatly simplifies the process, improves production efficiency and yield, and reduces costs. The use of a flexible frame partial encapsulation process does not require a second front plate on the front of the component, which improves the photoelectric conversion efficiency of the component. The process is compatible with the existing photovoltaic component production line, does not require additional equipment, and has low fixed investment.

[0034] Embodiment 2

[0035] according to Figure 1 , 2 As shown in FIG. 3 , this embodiment proposes a processing technology for a lightweight special-shaped photovoltaic module, comprising the following steps:

[0036] Lay the backplane on the carrier, use tempered glass as the carrier of the production line, and use tape to fix the carrier and the backplane. The heat-resistant temperature of the carrier is 200℃-300℃. The backplane contains packaging film and metal conductive foil. The metal conductive foil of the backplane is engraved with positioning marks, which can be accurately positioned by the camera. This step is the basis of component production. The positioning mark of the backplane ensures the accurate laying of the battery cells in the subsequent steps.

[0037] After the production line transfers the carrier to the next station, the reset device is first used to correct the position of the carrier to ensure the accuracy of the transfer. Next, the battery cells are laid, and the battery cells used are battery cells printed with conductive glue. The printing of the conductive glue is completed offline, so that the battery cells no longer need the online steel plate printing process of the production line. The battery cells have their own insulating layer (the battery cells are printed with insulating glue or covered with insulating film). This method no longer requires the insulating adhesive layer material in the prior art, so there is no need for the insulating adhesive layer laying process, which further simplifies the component production process.

[0038] The battery cells are grabbed by a robotic arm, which is equipped with a high-precision camera to accurately lay the battery cells by identifying the positioning marks on the metal conductive foil. This automated operation ensures the accurate positioning of the battery cells, further improving the accuracy and efficiency of component production.

[0039] The subsequent steps include laying of packaging film, laying of front panel, lamination and one-time cutting.

[0040] After cutting, the special-shaped laminated parts are installed with flexible frames, glued, and cured. Before the glue is completely cured, the flexible frames need to be fixed with fixtures. During the curing process, the environment should be kept dry and dust-free to avoid affecting the curing effect of the glue.

[0041] After curing, install the junction box and test it for storage. Select the junction box that meets the requirements and check whether its appearance, size and electrical performance meet the requirements. Fix the junction box in the designated position of the photovoltaic module to ensure that the connection between the junction box and the photovoltaic module is firm and reliable. At the same time, check whether the electrical connection inside the junction box is correct to avoid short circuit or open circuit. Perform an appearance inspection on the photovoltaic module to ensure that the flexible frame, junction box and other components are firmly installed without damage or deformation. Use test equipment to test the electrical performance of the photovoltaic module, including open circuit voltage, short circuit current, maximum power point and other parameters. The test results meet the relevant standards and requirements. The photovoltaic modules that have passed the inspection are put into storage and relevant information such as production date, batch number, test results, etc. are recorded. At the same time, the inventory environment is monitored and managed to ensure that the photovoltaic modules are not damaged during storage.

[0042] The present invention laminates and packages the front plate, the battery cell and the back plate into a photovoltaic main body, and cuts the whole body after lamination and packaging, thereby solving the defect of the square battery cell filling the special-shaped component with gaps. Then, the edge of the photovoltaic main body is partially encapsulated by a flexible frame, thereby solving the defect of easy delamination and failure after lamination and overall cutting, greatly improving the aesthetics of the component, making it more suitable for distributed and BIPV application scenarios, and at the same time simplifying the production process, improving the product yield, and reducing the product cost. In addition, the present invention uses a flexible frame to partially encapsulate the edge of the cut photovoltaic main body, replacing the existing secondary lamination packaging and secondary cutting process, greatly simplifying the process, improving production efficiency and yield, and reducing costs. The flexible frame partial encapsulation process does not require a second layer of front plate on the front of the component, thereby improving the photoelectric conversion efficiency of the component. The process is compatible with the existing photovoltaic component production line, does not require additional equipment, and has low fixed investment.

[0043] The above shows and describes the basic principles, main features and advantages of the present invention. It should be understood by those skilled in the art that the present invention is not limited to the above embodiments. The above embodiments and descriptions are only for explaining the principles of the present invention. Without departing from the spirit and scope of the present invention, the present invention may have various changes and improvements, which fall within the scope of the present invention. The scope of protection of the present invention is defined by the attached claims and their equivalents.

Claims

1. A lightweight special-shaped photovoltaic module, comprising a photovoltaic body and a flexible frame, characterized in that: The flexible frame is packaged at the edge of the photovoltaic body, and the photovoltaic body includes a front plate, a battery sheet and a back plate; The upper part of the back plate and the lower part of the front plate are both covered with packaging films, and a metal conductive foil is provided on the packaging film of the back plate. The battery cell is laid between the packaging film and the metal conductive foil of the front plate, and an insulating layer is provided on the battery cell.

2. A lightweight special-shaped photovoltaic module according to claim 1, characterized in that: The material composition of the front plate is any one of PC plate, PET plate, ETFE plate, FEP plate and PMMA plate.

3. A lightweight special-shaped photovoltaic module according to claim 1, characterized in that: The packaging film is any one of EVA, POE, PVB, glue, organic silicone material, and a color film material containing color particles.

4. A lightweight special-shaped photovoltaic module according to claim 1, characterized in that: The battery cell is any one of a PERC battery, a TOPCon battery, a HJT battery, and an XBC battery.

5. The lightweight special-shaped photovoltaic module according to claim 1, characterized in that: The material composition of the back plate is any one of PC plate, PET plate, ETFE plate, FEP plate, PMMA plate and carbon fiber plate.

6. A lightweight special-shaped photovoltaic module according to claim 1, characterized in that: The photovoltaic body has a shape of a circle, a polygon, a heart shape, or a combination of the above, and the flexible frame is made of any one of PC, PET, ETFE, FEP, and PMMA.

7. A processing technology for a lightweight special-shaped photovoltaic module, applied to a lightweight special-shaped photovoltaic module as claimed in any one of claims 1 to 6, characterized in that: The following steps are involved: S1: Lay a backplane on the carrier, and use tape to fix the carrier and the backplane. The backplane includes a packaging film and a metal conductive foil, and a positioning mark is engraved on the metal conductive foil; S2: After the production line transfers the carrier to the next station, the reset device is used to correct the position of the carrier, and then the battery cell is prepared. The battery cell is printed with conductive glue offline and has its own insulation layer; S3: Grab the battery cell by the robotic arm, identify the positioning mark of the metal conductive foil, and lay the battery cell on the metal conductive foil; S4: Laying the encapsulation film and the front plate on the battery cell, laminating, and cutting once; S5: Install, glue and cure the cut special-shaped laminated parts with flexible frames, and use fixtures to fix the flexible frames before the glue is completely cured; S6: After curing, install the junction box and inspect before storage.

8. The processing technology of a lightweight special-shaped photovoltaic module according to claim 7 is characterized in that: In the S1, tempered glass is used as a carrier of the production line, the heat-resistant temperature of the carrier is 200° C.-300° C., and the positioning mark on the metal conductive foil is used to cooperate with the camera for positioning.

9. The processing technology of a lightweight special-shaped photovoltaic module according to claim 7, characterized in that: In S2, the battery cell has its own insulating layer, and the insulating layer is insulating glue or insulating film.

10. The processing technology of a lightweight special-shaped photovoltaic module according to claim 8, characterized in that: In S3, a camera is integrated on the robot arm to locate and lay the battery cells by identifying the positioning mark of the metal conductive foil.

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