Packaging material film and manufacturing method thereof, solar cell module and manufacturing method thereof

Abstract

The present disclosure provides an encapsulation material film, a method for manufacturing the same, and a solar cell module and a method for manufacturing the same. The encapsulation material film is configured for use in a solar cell module, wherein the solar cell module includes multiple solder ribbons. The encapsulation material film includes a first region, the orthographic projection of the first region on the surface of the solar cell module at least partially overlapping with the orthographic projection of at least one of the multiple solder ribbons, and the thickness of the first region differs from the thickness of other regions of the encapsulation material film. A solar cell module employing this encapsulation material film can reduce the amount of encapsulation material used and provide sufficient protection for the solder ribbons.

Description

Technical Field

[0001] Embodiments of the present disclosure relate to an encapsulation material film and a method for manufacturing the same, a solar cell module and a method for manufacturing the same. Background Art

[0002] As the industry continues to develop and crystalline silicon manufacturing capacity continues to improve, the power and efficiency of photovoltaic modules are increasing, and the cost of photovoltaic power generation is gradually decreasing. However, as the proportion of photovoltaic modules in system costs gradually decreases, downstream demand for more efficient and longer-lasting modules is becoming increasingly strong.

[0003] Existing double-glass modules can effectively utilize incident light from both the front and back sides, thereby significantly improving power generation efficiency. However, double-glass modules have rigid connections on both sides, and a large amount of encapsulation film is used. How to reduce the amount of film used and improve reliability is an urgent problem that needs to be solved. Summary of the Invention

[0004] The embodiments of the present disclosure provide a packaging material film and a manufacturing method thereof, a solar cell module and a manufacturing method thereof, which can reduce the amount of packaging material used in the battery module, for example, the back side, reduce the thickness of the battery module, reduce the distance between the battery backboard material and the battery cell, and improve the reliability of the module and the anti-PID (Potential Induced Degradation) performance.

[0005] In a first aspect, an embodiment of the present disclosure provides a packaging material film configured for use in a solar cell assembly, wherein the solar cell assembly includes a plurality of welding ribbons, wherein the packaging material film includes: a first region, the orthographic projection of the first region on the surface where the solar cell assembly is located at least partially overlaps with the orthographic projection of at least one of the plurality of welding ribbons, wherein the film thickness of the first region is different from the film thickness of other regions of the packaging material film.

[0006] In a second aspect, an embodiment of the present disclosure provides a solar cell assembly, comprising: a cell string comprising a plurality of cell sheets connected to each other; a packaging material layer, arranged on at least one side of the cell string and formed by the packaging material film according to the first aspect; and a plurality of welding ribbons, arranged on at least one side of the cell string between the cell string and the packaging material layer.

[0007] In a third aspect, an embodiment of the present disclosure provides a method for manufacturing a solar cell assembly, wherein the solar cell assembly is as described in any of the second aspects, and the manufacturing method includes: providing the cell string; arranging multiple welding ribbons on at least one side of the cell string; arranging a packaging material film on the multiple welding ribbons, wherein a first area of the packaging material film is aligned with at least one of the multiple welding ribbons; arranging a backplane material on the packaging material film; and laminating using a laminator to make a laminate, wherein the packaging material film is formed into a packaging material layer, wherein the film thickness of the first area is different from the film thickness of other areas of the packaging material film.

[0008] In a fourth aspect, an embodiment of the present disclosure provides a method for manufacturing a packaging material film as described in any of the first aspects, comprising: making the packaging material into a material film; processing the material film so that the material film is formed into the packaging material film, wherein the packaging material film is constructed for a solar cell module, the solar cell module includes a plurality of welding strips, wherein the packaging material film includes: a first region, the orthographic projection of the first region on the surface where the solar cell module is located at least partially overlaps with the orthographic projection of at least one of the plurality of welding strips, wherein the film thickness of the first region is different from the film thickness of other regions of the packaging material film. BRIEF DESCRIPTION OF THE DRAWINGS

[0009] In order to more clearly illustrate the technical solutions of the embodiments of the present invention, the drawings of the embodiments will be briefly introduced below. Obviously, the drawings in the following description only relate to some embodiments of the present invention, but are not intended to limit the present invention.

[0010] Figure 1A is a plan view of a packaging material film according to an embodiment of the present disclosure;

[0011] Figure 1B It is along Figure 1A A partial cross-sectional view of the packaging material film taken along line AA';

[0012] Figure 2A is a plan view of another exemplary packaging material film;

[0013] Figure 2B It is along Figure 2A A cross-sectional view of the packaging material film taken along line BB' in FIG.

[0014] Figure 3A is a plan view of another example packaging material film;

[0015] Figure 3B It is along Figure 3A A cross-sectional view of the packaging material film taken along line CC' in FIG.

[0016] Figure 4Ais a cross-sectional view of a solar cell module before lamination;

[0017] Figure 4B is a cross-sectional view of a laminated solar cell module; and

[0018] Figure 5 is a schematic diagram of a method for manufacturing a packaging material film. DETAILED DESCRIPTION

[0019] To make the purpose, technical solutions, and advantages of the embodiments of the present invention more clear, the technical solutions of the embodiments of the present invention will be clearly and completely described below in conjunction with the accompanying drawings of the embodiments of the present invention. Obviously, the described embodiments are part of the embodiments of the present invention, not all of the embodiments. Based on the described embodiments of the present invention, all other embodiments obtained by ordinary technicians in this field without creative work are within the scope of protection of the present invention.

[0020] Unless otherwise defined, the technical or scientific terms used herein shall have the ordinary meaning understood by persons of ordinary skill in the art to which the invention pertains. The terms "first", "second" and similar terms used in this disclosure do not indicate any order, quantity or importance, but are merely used to distinguish between different components. Similarly, terms such as "one", "an" or "the" do not indicate a quantity limitation, but rather indicate the presence of at least one. Terms such as "include" or "comprise" mean that the elements or objects preceding the term encompass the elements or objects listed following the term and their equivalents, without excluding other elements or objects. Terms such as "connect" or "connected" are not limited to physical or mechanical connections, but may include electrical connections, whether direct or indirect. Terms such as "upper", "lower", "left", and "right" are only used to indicate relative positional relationships. When the absolute position of the object being described changes, the relative positional relationship may also change accordingly.

[0021] For single-glass or double-glass solar cell modules, the presence of sodium ions in the glass poses a significant challenge to the module's resistance to PID (Potential Induced Degradation). When PID occurs in a module, the module suffers severe power loss. The causes of PID are numerous and the mechanism is complex, but one of the most important conditions is water vapor. Furthermore, the back surfaces of P-type crystalline silicon cells, which currently have the largest market share, are all field-passivated. AlxOx is electronegative and has an attractive effect on Na+, so the current main P-type crystalline silicon double-glass modules experience even more severe degradation when PID occurs, with some power degradation reaching as high as 50%. Therefore, reducing the impact of water vapor infiltration and sodium ions on modules, especially on the back cells, is an important and ongoing research issue for photovoltaic modules.

[0022] An embodiment of the present disclosure provides a packaging material film and a solar cell module using the packaging material film, wherein the orthographic projection of the first region of the packaging material film on the surface where the solar cell module is located at least partially overlaps with the orthographic projection of at least one of the multiple welding strips, wherein the film thickness of the first region is different from the film thickness of other regions of the packaging material film, for example, the film thickness of the first region is greater than the film thickness of other regions of the packaging material film. In this way, when the packaging material film is used to manufacture solar cell modules, the first area with thicker packaging material is directly opposite to the welding ribbon, so that when the solar cell modules are subsequently laminated, since the packaging material above the welding ribbon is thicker, the packaging material in this area will not flow out of the space between the welding ribbon and the back panel material due to pressure and temperature. At the same time, other areas, such as areas with thinner packaging material or hollow areas, will also have packaging material due to the flow of packaging material around them, so that at the end of lamination, the packaging material can be ensured to remain between the back panel and the welding ribbon, wrapping the back side of the welding ribbon away from the battery cell, that is, the side facing the back panel material, thereby ensuring that the welding ribbon and the back panel material, especially the glass back panel, are filled with flexible packaging material, which fully protects the welding ribbon, improves the yield of the battery cell and avoids defects such as breakage of the welding ribbon of the battery cell and damage to the battery cell. In addition, the packaging material will flow to other areas, so that it can be completely distributed between the battery string and the back panel and / or front panel material, and completely encapsulate the charged body, such as the battery string. Furthermore, since the encapsulation film is also filled between the soldering ribbon protruding from the surface of the cell and the backsheet material, there is encapsulation film everywhere between the backsheet material and the cell, allowing the backsheet material to be firmly attached to the cell. This allows the encapsulation material to connect the frontsheet material, cell strings, and backsheet material of the module to form a whole. Furthermore, using an encapsulation film with uneven thickness, or even hollowed-out, can reduce the amount of backsheet material used, reduce the distance between the backsheet material and the cell, and improve the backside energy conversion efficiency of the cell.

[0023] The packaging material film and the manufacturing method thereof, the solar cell module and the manufacturing method thereof according to the embodiments of the present disclosure will be exemplarily described below with reference to the accompanying drawings.

[0024] Figure 1A shows a plan view of a packaging material film 5, Figure 1B Shown along Figure 1A The partial cross-sectional view of the packaging material film 5 taken along the line AA' in FIG. 5 is for simplicity of illustration. Figure 1B The entire cross-sectional view of the packaging material film 5 is not shown, but other regions have the same structure. The packaging material film is configured to be used for a solar cell module, which includes multiple welding strips, such as Figure 1A and Figure 1B As shown, the packaging material film 5 includes a first area 5a, the orthographic projection of the first area 5a on the surface where the solar cell assembly is located at least partially overlaps with the orthographic projection of at least one of the multiple welding strips, and the thickness D1 of the packaging material film in the first area 5a is different from the thickness D2 of the packaging material film in other areas. For example, the thickness D1 of the packaging material film in the first area 5a is greater than the thickness D2 of the packaging material film in other areas.

[0025] For example, the thickness D2 of the packaging material film in other areas may be zero. Figure 2A and Figure 2B The packaging material film 5 is shown in a hollow shape, wherein Figure 2B It is along Figure 2A A cross-sectional view of the encapsulation material film 5 taken along line BB' shows that the encapsulation material film 5 is in a hollow grid shape. The area corresponding to the soldering ribbon is a first area 5a, and the remaining areas are hollow shapes 5b. The hollow grid shape of the encapsulation material film 5 is formed by interconnected first areas 5a. The first areas 5a form the skeleton of the hollow grid shape, and the remaining areas 5b are the hollow areas of the hollow grid shape of the encapsulation material film. Figure 2B The plan view of the hollow pattern formed in the hollow area is a circular hole shape. The hollow pattern can also be a strip, square or oval shape, etc. The embodiments of the present disclosure are not limited to this, and technicians in this field can choose according to needs.

[0026] For example, the solar cell assembly includes a cell string and a plurality of welding ribbons arranged on the cell string, wherein the cell string includes a plurality of cell sheets, and the orthographic projection of the first area 5a of the packaging material film on the surface where the solar cell assembly is located, that is, the orthographic projection on the surface where the cell string is located, at least partially overlaps with the orthographic projection of at least one of the plurality of welding ribbons.

[0027] For example, the orthographic projection of the first region 5a on the surface where the cell string of the solar cell module is located at least partially overlapping with the orthographic projection of at least one of the multiple welding ribbons may include the orthographic projection of the first region 5a on the surface where the cell string is located partially overlapping with one, two, or all of the multiple welding ribbons, and the embodiments of the present disclosure are not limited to this. The orthographic projection of the first region 5a on the surface where the cell string is located at least partially overlapping with the orthographic projection of the welding ribbon may mean that the orthographic projection of the first region and the orthographic projection of the welding ribbon partially overlap or completely overlap, and complete overlap may mean that they completely overlap or that the orthographic projection of the welding ribbon falls within the orthographic projection range of the first region.

[0028] For example, when the film thickness D2 of the other regions is not zero, the packaging material film of the first region may be two layers of packaging material, while the packaging material of the other regions may be one layer of packaging material. That is, the packaging material film of the first region may be formed by adding a film backing strip in the region corresponding to the soldering tape on the entire layer of packaging material, so that the film thickness of the first region is greater than that of the other regions. However, the embodiments of the present disclosure are not limited to this.

[0029] Furthermore, Figure 3A shows a plan view of another example packaging material film 5, Figure 3B Shown along Figure 3A The cross-sectional view of the packaging material film 5 taken along the line CC' in FIG. Figure 3A and Figure 3B As shown, the orthographic projection of the first area 5a of the encapsulation material film 3 on the surface where the solar cell is located can also at least partially overlap with the orthographic projection of the gap between the cells in the solar cell on the surface where the solar cell is located, for example, completely overlap, partially overlap, or the orthographic projection of the gap between the cells is within the orthographic projection range of the first area. Figure 3A and Figure 3B As can be seen, the first region 5a is also provided in the gaps between the longitudinal cells 19, that is, the gaps between the cells arranged parallel to the extending direction of the solder strips, and the first region 5a is also provided in the gaps between the transverse cells, that is, the gaps between the cells arranged perpendicular to the extending direction of the solder strips. Figure 3B , Figure 3B The first region 5a corresponding to the gaps between the horizontal cells is also shown to be thicker, that is, thicker than other regions. This is merely an example, and those skilled in the art will appreciate that the first region corresponding to the gaps between the vertical cells can also be thicker than other regions, thereby improving adhesion between the backsheet and frontsheet and enhancing cell stability.

[0030] Figure 3A and Figure 3BIn the figure, the first region corresponding to the gap between the cells is shown to be thicker than the first region corresponding to the soldering tape. In the gap between the cells, the distance between the backsheet material and the frontsheet material is large, requiring more encapsulation material to fill the gap, thereby better bonding the frontsheet, backsheet, and cells, and improving the stability of the cell. However, it should be clear to those skilled in the art that the thickness of the first region corresponding to the gap between the cells can also be equal to the thickness of the first region corresponding to the soldering tape, which can still achieve the effect of better bonding the frontsheet, backsheet material, and cells. However, showing the first region corresponding to the gap between the cells as thicker than the first region corresponding to the soldering tape can further improve the fixation effect of the solar cell module and enhance its stability.

[0031] Furthermore, the first region of the encapsulation material film may also correspond to the peripheral region of the battery string. The film thickness of the first region corresponding to the peripheral region may be equal to or greater than the film thickness of the first region corresponding to the gaps between battery cells, and may be equal to or greater than the thickness of the first region corresponding to the soldering ribbon. The embodiments of the present disclosure are not limited to this, and those skilled in the art may make selections as needed.

[0032] Figure 1B and Figure 3B In the figure, five welding strips are provided corresponding to a column of longitudinal battery cells. These are all examples and are only used to illustrate the technical solution of the present disclosure, and are not intended to limit the present disclosure. In actual situations, technicians in this field can select the corresponding number of welding strips as needed.

[0033] For example, in the encapsulation material film 5, the thickness of the first region 5a can be 0.4 mm to 0.6 mm, and the thickness of the other regions can be 0 mm to 0.3 mm, for example, 0.1 mm or 0.2 mm. The thickness of the first region corresponding to the solder ribbon, the gap between the cells, and the peripheral area of the solar cell module can be selected from 0.4 mm to 0.6 mm.

[0034] Alternatively, the film thickness in the first region may have a uniform thickness, or may have a non-uniform thickness, but the film thickness of each region in the first region is greater than the film thickness in other regions, which is not limited in the embodiments of the present disclosure.

[0035] For example, in an embodiment of the present disclosure, the encapsulation material film may be formed of an encapsulation material, and the encapsulation material may include one or more of ethylene-vinyl acetate copolymer (EVA), polyolefin elastomer (POE), and polyvinyl butyral (PVB). For example, the encapsulation material may be ethylene-vinyl acetate copolymer (EVA), polyolefin elastomer (POE), or polyvinyl butyral (PVB), or may be a mixture of any two of the three, or a mixture of the three.

[0036] For example, the polyolefin elastomer can be one or more of ethylene and butene, pentene, hexene or octene copolymers. When the encapsulating material is ethylene-vinyl acetate copolymer (EVA), the EVA material with different vinyl acetate (VA) contents can be adopted. When the encapsulating material is a polyolefin elastomer, the copolymer of ethylene and butene, pentene, hexene or octene or the copolymer with butene, pentene, hexene or octene of different ethylene contents can be adopted. A mixture of the two is adopted in EVA, POE and PVB of different relative contents, or a mixture of three different in content. When the encapsulating material film comprises the encapsulating material having the same component or composition and different in content, it can be considered as different encapsulating materials. For example, when the encapsulation material is ethylene-vinyl acetate copolymer, when the components are the same but the VA content is different, they can be considered as different encapsulation materials; when the encapsulation material is a mixture of polymer materials, when the composition is the same but the content is different, for example, when the encapsulation material includes a mixture of EVA and POE, if the EVA content is different, they can be considered as different encapsulation materials. These two examples are just given. For other situations, those skilled in the art can infer, and they will not be elaborated here.

[0037] Alternatively, the packaging material may include a co-extruded material of ethylene-vinyl acetate copolymer, polyolefin elastomer and ethylene-vinyl acetate copolymer (EPE). For example, the packaging material film includes three layers, that is, POE is sandwiched between two layers of EVA and formed by a co-extruder. The main purpose of adding POE in the middle is to reduce the PID phenomenon of the component. It should be clear to those skilled in the art that the thickness of each of the three layers can be changed according to the type of battery and component. For example, the bulk density of each layer of the packaging material film formed by the three-layer co-extruded material can be 140g / m 2 / 200g / m 2 / 140g / m 2 , the bulk density is 480g / m 2 For adhesive films, the bulk density is usually used to control the thickness.

[0038] For example, the packaging material film may include the same polymer material or the same polymer material mixture, that is, the first region 5a and the other regions include the same polymer material, that is, a polymer material with the same components and the same content, or the same polymer material mixture, that is, a mixture of polymer materials with the same composition and the same content of each component; or, the packaging material in the first region 5a and the packaging material in other regions are polymer materials with the same components and different contents; or the packaging material film includes a polymer material mixture, and the mixture of the first region and the other regions can be the same composition but different in at least one component content, or different in both composition and content, which will not be listed here.

[0039] Alternatively, the first region 5a and the other regions may include the same polymer material or the same polymer material mixture. For example, the packaging material film may be ethylene-vinyl acetate copolymer (EVA), polyolefin elastomer (POE), polyvinyl butyral (PVB), a mixture of EVA and POE, a mixture of EVA and PVB, a mixture of POE and PVB, or a mixture of the three. However, the packaging material components or compositions of all regions are the same and the content is the same, for example, EVA with the same VA content, a mixture of EVA and POE with the same EVA and POE content, etc., which will not be listed one by one here.

[0040] For example, the first region 5a and the other regions may comprise different polymer materials or different polymer material mixtures. For example, the first region 5a and the other regions may use polymer materials with the same components but different contents. When the first region 5a and the other regions are EVA, the VA content of the EVA in the first region 3a and the other regions may be different. The same is true for other materials, which will not be listed here one by one.

[0041] The encapsulation material film of the disclosed embodiment is configured for use with solar cells. By forming the encapsulation material film so that the thickness of the first region corresponding to the soldering ribbon is different from the thickness of other regions, for example, greater than the thickness of other regions, the encapsulation material film can be used to reduce the distance between the backsheet and the cells while reducing the amount of encapsulation material used, and the soldering ribbon is fully protected, ensuring a sufficient bond between the backsheet, the cells, and the soldering ribbon. Furthermore, the first region can also correspond to the gap between the cells and / or the peripheral area of the solar cell module, thereby further improving the bonding strength between the backsheet, front sheet, and cells, and enhancing the performance and stability of the battery.

[0042] On the other hand, the embodiments of the present disclosure further provide a solar cell module comprising any of the above-mentioned packaging material films, such as Figure 4A and Figure 4B As shown, Figure 4Ashows a cross-sectional view of a solar cell module before lamination, Figure 4B A cross-sectional view of the laminated solar cell module, that is, the finally formed solar cell module is shown. Figure 4A and Figure 4B The packaging material film used is Figure 3A and Figure 3B The packaging material films shown are similar to those of other examples and will not be listed here for the sake of brevity. Figure 4A and Figure 4B As shown, the solar cell assembly 100 includes: a cell string 1, including a plurality of cell sheets 19 connected to each other; a packaging material layer 51, arranged on at least one side of the cell string, and formed by any packaging material film 5 as described above; a plurality of welding strips 11, arranged between the cell string 1 and the packaging material layer 51 on at least one side of the cell string 1, wherein the packaging material film 5 includes a first region 5a, the orthographic projection of the first region on the surface where the cell string 1 is located at least partially overlaps with the orthographic projection of at least one of the plurality of welding strips, and the film thickness of the first region 5a is different from, for example, greater than, the film thickness of other regions 5b.

[0043] For example, the orthographic projection of the first region 5a on the surface where the battery string 1 is located at least partially overlaps with the orthographic projection of at least one of the multiple welding strips, which may include the orthographic projection of the first region 5a on the surface where the battery string 1 is located at least partially overlapping with one, two, or all of the multiple welding strips. The embodiments of the present disclosure are not limited to this. The orthographic projection of the first region 5a on the surface where the battery string 1 is located at least partially overlaps with the orthographic projection of the welding strip, which may include the orthographic projection of the first region completely overlapping with the orthographic projection of the welding strip, the orthographic projection of the welding strip falling within the orthographic projection range of the first region, or the orthographic projection of the first region partially overlapping with the orthographic projection of the welding strip. The embodiments of the present disclosure are not limited to this, and those skilled in the art may make selections as needed.

[0044] Figure 4B A cross-sectional view of the solar cell assembly after lamination is shown. As can be seen from the figure, there is a packaging material layer 51 between the welding ribbon and the back panel material 7 after lamination. Therefore, for the solar cell assembly using the packaging material film of the embodiment of the present disclosure, no matter which situation it is possible to reduce the amount of packaging material used while ensuring that the packaging material film after lamination can wrap the back side of the welding ribbon away from the battery cell, that is, the side facing the back panel material, and fully protect the welding ribbon.

[0045] For example, when the orthographic projection of the welding ribbon completely falls within the orthographic projection range of the first area, the welding ribbon can be completely wrapped by the thicker packaging material film, and the welding ribbon can be well protected to avoid damage. There is no area between the backplane material and the battery cell where the welding ribbon directly contacts the backplane material. The packaging material film is completely set between the two, and the two are well bonded, thereby further improving the performance of the solar cell.

[0046] For the sake of brevity, the materials of the packaging material film will not be specifically described here. For details, please refer to the above examples. Here, only the solar cell module including the packaging material film and the situation when the packaging material film is set in the solar cell module are described.

[0047] Figure 4A In the embodiment, the gaps between the battery cells are also provided with a first region having a relatively thick thickness. Figure 4B In the solar cell assembly after lamination, the space between the back sheet material 7 and the front sheet material 3 is also fully filled with packaging material, so that the back sheet, the front sheet and the battery cells can be well fixed.

[0048] For example, in the solar cell assembly of the embodiment of the present disclosure, the packaging material film 5 and the multiple welding strips 11 can be arranged on the back of the cell string 1, and the solar cell assembly also includes: a backboard material, which is arranged on the side of the packaging material film away from the welding strips.

[0049] For example, the back plate material may be an inorganic or organic material, such as glass or PTFE cloth.

[0050] Figure 4A and Figure 4B In the solar cell module shown in FIG, the encapsulation material film 5 is provided on the back of the cell string, and the back sheet material is shown as glass. Before lamination, as shown in FIG. Figure 4A As shown, the encapsulation material film 5 is disposed between the cell string 1, the solder ribbon 11, and the backsheet material 7. The first region 5a of the encapsulation material film is aligned with at least one solder ribbon 11, for example, aligned with all solder ribbons 11. This alignment can be achieved by aligning the center of a solder ribbon 11 with the center of the first region 5a, or by aligning at least a portion of the orthographic projection of the solder ribbon 11 on the surface of the cell string 1 with the first region 5a. For example, the orthographic projection of the first region 5a can completely overlap the orthographic projection of the solder ribbon, or the orthographic projections of the first region 5a and the first region 5a can partially overlap.

[0051] It should be noted that it can be Figure 3B The upper side of the packaging material film contacts the welding strip 11, which can also be Figure 3B The lower side of the packaging material film in the contact soldering strip 11.

[0052] For example, the center of the soldering ribbon 11 can be aligned with the center of the first region 5a, and the orthographic projection area of the first region 5a is greater than or equal to the orthographic projection area of the soldering ribbon, so that the back of the soldering ribbon can be completely protected by the packaging material film after lamination, while reducing the film thickness and reducing the possibility of damage to the soldering ribbon, thereby improving battery performance.

[0053] During the lamination process of the solar cell module, the packaging material film becomes molten through pressurization and heating. However, for the first area 5a, since a thicker packaging material film is provided corresponding to the welding ribbon, although the packaging material will flow away from this area during lamination, due to its thickness, after lamination, the space between the welding ribbon and the backboard material can also be guaranteed to be filled with soft packaging material, thereby protecting the battery cells from damage during the module manufacturing process and the welding ribbon from breakage and other damages; in addition, since the packaging material film flows out to other areas, there is packaging material everywhere between the backboard material and the battery string, and the packaging material between the welding ribbon and the backboard material will not flow out completely and the welding ribbon will directly contact the backboard material. This can also ensure that there is packaging material to connect the battery string and the backboard material, thereby forming a whole, thereby improving the performance of the solar cell module.

[0054] Furthermore, the solar cell assembly 100 may further include an encapsulation material layer 4, a soldering ribbon 11, and a front plate material 3 located on the front side of the cell string 1. For example, the front plate material 3 may be glass.

[0055] For example, the packaging material layer 4 located on the front side can use a packaging material film with uniform thickness, or can be consistent with the packaging material film used on the back side. For example, such a packaging material film is used: the area corresponding to at least one welding strip is thicker and / or the area corresponding to the gap between the battery cells is thicker and / or the area corresponding to the peripheral area of the solar cell module is thicker. Technicians in this field can make choices as needed.

[0056] Figure 4B The figure shows a case where the front panel material is glass and the back panel material is glass, that is, a double-glass module. The solar cell module of the embodiment of the present disclosure can also be a case where the front panel material is glass and the back panel material is polytetrafluoroethylene fabric, that is, a single-glass module. For the sake of simplicity, the example of a single-glass module is not shown.

[0057] Alternatively, in a solar cell module, the packaging material film and the multiple welding ribbons are arranged on the back and front sides of the cell string, and the solar cell module further includes: a back panel material, which is arranged on the back side of the packaging material film away from the welding ribbons; and a front panel material, which is arranged on the front side of the packaging material film away from the welding ribbons, wherein the back panel material and the front panel material are glass.

[0058] It should be noted here that since the packaging material film will flow during the lamination process, combined with Figure 4A and Figure 4B as well as Figure 3A and Figure 3B Before lamination, the first area corresponding to the solder ribbon is thickened. During the lamination process, the packaging material in the first area will flow. After lamination, the packaging film will become thinner. In this way, the first area corresponding to the solder ribbon may be thicker or thinner than other areas after lamination. However, in any case, after lamination, the solder ribbon will be protected by the film and will not directly contact the backplane material.

[0059] In actual situations, those skilled in the art may set the thickness of the first region according to needs and the conditions of the packaging material. For example, the thickness of the first region may be between 0.4 mm and 0.6 mm, and the embodiments of the present disclosure are not limited thereto.

[0060] For example, Figure 4B After lamination, the packaging material films on the front and back of the cell will flow together where there are gaps, forming a Figure 4B Furthermore, for Figure 4A and Figure 4B The double-glass component shown in the figure is sealed with double layers around the solar cell component to protect the packaging material inside the component and ensure that the component can maintain the light transmittance and insulation of the packaging material after various aging. Figure 4B As shown, a sealing material 6 is provided between the back panel and the front panel materials of the double-glass component, and a sealant 8 is provided around the periphery of the solar cell component and on the outside of the back panel material and the front panel material, and a frame 9 is further provided, thereby completing the production of the solar cell component.

[0061] Furthermore, the solar cell assembly may also include a desiccant 13 located between the sealing material and the sealant in a direction parallel to the surface of the solar cell assembly, thereby further preventing water vapor from penetrating from all sides of the assembly and damaging the solar cell assembly, thereby improving the stability and performance of the solar cell assembly.

[0062] For the solar cell module of the embodiment of the present disclosure, since a thicker packaging material film is used to form a packaging material layer in at least the area corresponding to the welding strip, it is possible to reduce the amount of packaging material used, for example, reduce the amount of back packaging material used, ensure that the welding strip can be wrapped by flexible material during lamination, prevent the welding strip from being damaged, and enhance the bonding strength between the back plate and the battery cell. It is also possible to reduce the distance between the back plate and the battery cell and / or the distance between the front plate and the battery cell, thereby improving the stability of the battery module.

[0063] On the other hand, the embodiments of the present disclosure further provide a method for manufacturing the packaging material film as described above. Figure 5 Shown, including:

[0064] forming the packaging material into a material film;

[0065] The material film is processed so that the material film is formed into any packaging material film as described above, wherein the packaging material film is constructed for a solar cell module, the solar cell module includes a plurality of welding strips, wherein the packaging material film includes: a first region, the orthographic projection of the first region on the surface where the solar cell module is located at least partially overlaps with the orthographic projection of at least one of the plurality of welding strips, and the film thickness of the first region is different from the film thickness of other regions of the packaging material film.

[0066] For example, the film thickness of the first region is greater than the film thickness of other regions of the packaging material film.

[0067] The specific features of the packaging material film can be found in any of the above embodiments, and for the sake of brevity, they will not be described here in detail.

[0068] For example, processing the material film may include: forming a photoresist material on the material film; exposing the photoresist material using a mask plate, the pattern of the mask plate corresponds to other areas of the packaging material film; exposing and developing the photoresist material to form the photoresist pattern, the retained area of the photoresist pattern corresponds to the first area; etching the material film to remove at least a portion of the material film in the other areas.

[0069] For example, forming the packaging material into a film includes: forming a first film using the packaging material; and forming a film strip on a localized area of the first film to form the film, wherein the localized area corresponds to the first area. Thus, the packaging material film in the first area is formed into two layers, while the packaging material film in the other areas remains a single layer. This results in a film thickness in the first area being greater than that in the other areas.

[0070] When the encapsulating material film includes a mixture of polymer materials, the use of the encapsulating material to form the first material film can be: the encapsulating materials are mixed to form the first material film. The encapsulating materials can refer to the materials described in the corresponding embodiments of the encapsulating material film above, and for the sake of brevity, they will not be described here. For example, when the encapsulating material film includes a mixture of polymer materials, it can be a material film made by mixing two or three of ethylene-vinyl acetate copolymer (EVA), polyolefin elastomer (POE) or polyvinyl butyral (PVB). When the encapsulating material film includes a three-layer co-extruded material (EPE) of ethylene-vinyl acetate copolymer, polyolefin elastomer and ethylene-vinyl acetate copolymer, three rows of co-extrusion dies can be used to extrude the three materials at different times to form a material film including EPE co-extruded material.

[0071] For example, when the packaging material film is a three-layer co-extruded material, such as an EPE co-extruded material, the process of making the packaging material into a material film may include: using a co-extrusion device to make the material film, including: using four to six rows of co-extrusion dies, and loading EVA, POE and PVB into the first to third rows of co-extrusion dies respectively, and for the fourth to sixth rows of co-extrusion dies, only the die corresponding to the first area can be opened so that only the packaging material corresponding to the first area is further set. For example, the fourth to sixth rows of co-extrusion dies can be loaded with EVA, POE and PVB respectively, or the fourth row, the fourth row and the fifth row, or the fourth to sixth rows of co-extrusion dies can be loaded with any packaging material. Those skilled in the art can choose to use one, two or all of the fourth to sixth rows of co-extrusion dies according to the thickness difference between the first area and other areas, and the materials loaded in the fourth to sixth rows can also be selected as needed. During manufacturing, only the die corresponding to the first area can be opened. The embodiments of the present disclosure are not limited to this.

[0072] For example, making the packaging material into a material film may include: using a co-extrusion device to form the material film, and at least two rows of co-extrusion dies may be used, at least one row of which is used to form a first layer of packaging material, and at least one row of co-extrusion dies is used to form a second layer of packaging material. When forming the second layer of packaging material, only the co-extrusion die corresponding to the first area may be opened.

[0073] For example, the width of the co-extrusion die can correspond to the welding strip, so that the material extruded therefrom corresponds to the first area corresponding to the welding strip. When each co-extrusion die is relatively narrow, multiple co-extrusion dies can correspond to the area corresponding to a welding strip. Those skilled in the art can select as needed.

[0074] For example, processing the material film so that the material film is formed into any packaging material film as described above may include: cooling the material film, for example, cooling the material film using a casting roller, shaping it after an embossing process, and then trimming and winding it.

[0075] The material film can be cooled immediately after the packaging material is extruded from the co-extrusion device using the co-extrusion die head. For example, when forming a multi-layer co-extruded material, one layer of material can be extruded first, and then a second layer of material can be extruded on the first layer of material after a predetermined time, and then the next layer of material can be extruded after a predetermined time. Here, the predetermined time must be greater than zero and shorter than the cooling time of the material. That is, the next layer of material is applied before the lower layer of material is completely cooled and solidified, so that the upper and lower layers can be separated and have sufficient bonding strength. Of course, for this layered co-extruded material, those skilled in the art can also adopt other methods, and the embodiments of the present disclosure are not limited to this.

[0076] On the other hand, an embodiment of the present disclosure also provides a method for manufacturing the solar cell assembly as described above, the manufacturing method comprising: providing the cell string; arranging a plurality of welding ribbons on at least one side of the cell string; arranging a packaging material film on the plurality of welding ribbons, wherein a first area of the packaging material film is aligned with at least one of the plurality of welding ribbons; arranging a backplane material on the packaging material film; and laminating using a laminator to make a laminate, wherein the packaging material film is formed into a packaging material layer, wherein the film thickness of the first area of the packaging material film is different from the film thickness of other areas of the packaging material film.

[0077] It should be noted that the packaging material film here is the packaging material film described in the above embodiment obtained by the above manufacturing method. For the sake of brevity, the same parts as the above embodiment will not be described here in detail. For details, please refer to the above embodiment.

[0078] For example, the manufacturing method may further include: edge trimming inspection, applying a sealing material 6 , a sealant 8 , and further providing a frame 9 .

[0079] For example, laminating using a laminator to produce a laminate may include: when the lamination temperature is 145° C., vacuuming the laminator for 8 minutes and laminating for 10 minutes.

[0080] For example, lamination using a laminator can also be performed in steps. The pressure of the first lamination can be 0 to 300 mbar, and the pressure of the second lamination can be 300 to 1000 mbar. By performing step-by-step lamination, the pressure of each lamination can be appropriately reduced, thereby reducing the hidden crack rate of the battery assembly.

[0081] For example, providing the battery string may include: using a string welding machine to make a battery string with 12 half-cell batteries in each string.

[0082] For example, an exemplary manufacturing method may include: making a battery string with 12 half-cell batteries in each string using a string welding machine according to the design; laying the front panel material glass and the front packaging material; using a busbar or other conductor to connect the battery strings in series or in parallel according to the circuit requirements, and setting the lead wires; laying the back packaging material film so that the first area is at least aligned with the welding ribbon of the battery string; laying the back panel material, inspecting and testing it; entering the laminator for lamination to make a laminated part; performing subsequent steps such as edge trimming inspection, applying sealing material and sealant, installing the frame and junction box, etc. to make a solar cell module.

[0083] For example, another exemplary manufacturing method may include: making a battery string according to the design; laying the front panel material glass and the front packaging material EVA / POE / EVA co-extruded material; using a busbar or other conductor to connect the battery strings in series or in parallel according to the circuit requirements, and setting the lead wires; laying the back packaging material film, such as a packaging material film formed by EVA / POE / EVA co-extruded material, and the first area of the packaging material film is aligned with at least the welding area in the battery string; laying the sealing material all around, laying the back panel glass, and inspecting and testing; entering the laminator for lamination to make a laminated part, and the lamination process can be: lamination temperature 145°C; edge trimming inspection, installing desiccant around the laminated component; applying sealant, installing a frame and a junction box, etc., to make a solar cell module.

[0084] Alternatively, placing the encapsulation material film on the plurality of welding ribbons may further include aligning the first region with gaps between the plurality of cells included in the solar cell assembly. Alternatively, placing the encapsulation material film on the plurality of welding ribbons may further include aligning the first region with a peripheral region of the solar cell assembly. This provides better protection for the solar cell assembly and stabilizes cell performance.

[0085] The encapsulation material film and its manufacturing method, the solar cell module and its manufacturing method provided by the embodiments of the present disclosure have the following beneficial effects:

[0086] 1. The soldering tape corresponds to the first area of the packaging material film, thereby reducing the amount of packaging material used and ensuring that the packaging film can wrap the back of the soldering tape away from the battery cell after lamination, fully protecting the soldering tape and reducing the distance between the backsheet material and the battery cell, thereby achieving a better bond between the backsheet material and the battery cell;

[0087] 2. The first region where the encapsulation material film is thicker may also correspond to the gaps between the battery cells and / or around the battery cells, thereby better bonding the front and rear plates to the battery cells and improving battery stability;

[0088] 3. Double-layer sealing is used for the battery components, and desiccant is added between the double-layer seals to further prevent water vapor from penetrating from all sides of the components and damaging the solar cell components, thereby improving the stability and performance of the solar cell components.

[0089] While various embodiments of the present invention have been described above, the foregoing description is intended to be illustrative, non-exhaustive, and not limited to the disclosed embodiments. Many modifications and variations will be apparent to those skilled in the art without departing from the scope and spirit of the described embodiments. The terminology used herein is selected to best explain the principles of the embodiments, their practical applications, or technological improvements in the marketplace, or to enable others skilled in the art to understand the embodiments disclosed herein. The scope of the present invention is defined by the appended claims.

[0090] While various embodiments of the present invention have been described above, the foregoing description is intended to be illustrative, non-exhaustive, and not limited to the disclosed embodiments. Many modifications and variations will be apparent to those skilled in the art without departing from the scope and spirit of the described embodiments. The terminology used herein is selected to best explain the principles of the embodiments, their practical applications, or technological improvements in the marketplace, or to enable others skilled in the art to understand the embodiments disclosed herein. The scope of the present invention is defined by the appended claims.

Claims

1. A packaging material film, configured to be used for a solar cell module, wherein the solar cell module comprises a plurality of welding ribbons, wherein the packaging material film comprises: a first region, wherein an orthographic projection of the first region on the surface where the solar cell assembly is located at least partially overlaps with an orthographic projection of at least one of the plurality of welding ribbons; The film thickness of the first region is greater than the film thickness of other regions of the packaging material film, The solar cell assembly includes a plurality of cells, and the orthographic projection of the first region on the surface where the solar cell assembly is located at least partially overlaps with the orthographic projection of the gaps between the cells. wherein the orthographic projection of the first area on the surface where the solar cell assembly is located at least partially overlaps with the orthographic projection of the peripheral area of the solar cell assembly, The thickness of the first area that at least partially overlaps with the orthographic projection of the gap between the battery cells and the thickness of the first area that at least partially overlaps with the orthographic projection of the peripheral area of the solar cell assembly are greater than the thickness of the first area that at least partially overlaps with the orthographic projection of at least one of the multiple welding strips. 2 . The packaging material film according to claim 1 , wherein the film thickness of the other regions is zero, and the packaging material film is in a hollow grid shape. 3 . The encapsulation material film according to claim 1 , wherein the encapsulation material film in the first region comprises two layers of encapsulation material, and the encapsulation material film in the other regions comprises one layer of encapsulation material. 4 . The packaging material film according to claim 2 , wherein the hollow pattern of the packaging material film is in the shape of a circular hole, a strip, a square or an ellipse.

5. The encapsulation material film according to any one of claims 1 to 4, wherein the encapsulation material film comprises an encapsulation material, and the encapsulation material comprises one or more of ethylene-vinyl acetate copolymer (EVA), polyolefin elastomer (POE) and polyvinyl butyral (PVB). 6 . The encapsulating material film according to claim 5 , wherein the encapsulating material comprises a co-extruded material (EPE) of ethylene-vinyl acetate copolymer, polyolefin elastomer and ethylene-vinyl acetate copolymer. 7 . The packaging material film according to claim 5 , wherein the polyolefin elastomer is one or more of ethylene-butene, ethylene-pentene, ethylene-hexene and ethylene-octene copolymers. 8 . The packaging material film according to claim 1 , wherein the film thickness in the first region is non-uniform, and the film thickness of each region in the first region is greater than the film thickness of the other regions. 9 . The packaging material film according to claim 1 , wherein the film thickness of the first region is 0.4 mm to 0.6 mm, and the film thickness of the other regions is 0.1 mm to 0.3 mm.

10. A solar cell assembly comprising: A battery string, comprising a plurality of battery cells connected to each other; an encapsulation material layer, provided on at least one side of the battery string, and formed of an encapsulation material film according to any one of claims 1 to 9; A plurality of welding ribbons are arranged between the battery string and the packaging material layer on at least one side of the battery string.

11. The solar cell assembly according to claim 10, wherein the packaging material layer and the plurality of welding ribbons are arranged on the back side of the cell string. The solar cell further comprises: The back plate material is arranged on a side of the packaging material layer away from the welding strip. 12 . The solar cell module according to claim 11 , wherein the back sheet material is an inorganic or organic material. 13 . The solar cell module according to claim 12 , wherein the back sheet material is glass or polytetrafluoroethylene (PTFE) cloth.

14. The solar cell assembly according to claim 10, wherein the encapsulation material layer and the plurality of welding ribbons are arranged on the back and front sides of the cell string. The solar cell assembly further comprises: A back plate material is provided on the back side of the packaging material layer away from the welding strip; The front plate material is arranged on the front side of the packaging material layer away from the welding strip, wherein the back plate material and the front plate material are glass.

15. The solar cell assembly according to claim 14, further comprising: A sealing material is located between the back plate material and the front plate material; a sealant, disposed on the outer sides of the backsheet material and the frontsheet material in the peripheral area of the solar cell assembly; The desiccant is located between the sealing material and the sealant in a direction parallel to the surface where the solar cell assembly is located.

16. A method for manufacturing a solar cell module, wherein the solar cell module is as claimed in any one of claims 10 to 15, the method comprising: providing the battery string; Disposing a plurality of welding ribbons on at least one side of the battery string; disposing a film of encapsulation material on the plurality of solder ribbons, wherein a first region of the film of encapsulation material is aligned with at least one of the plurality of solder ribbons; Disposing a backplane material on the packaging material film; Laminating is performed using a laminator to produce a laminate, wherein the packaging material film is formed into a packaging material layer, The film thickness of the first region is greater than the film thickness of other regions of the packaging material film, The step of providing a packaging material film on the plurality of welding strips further comprises: The first region is aligned with the gaps between the plurality of cells included in the solar cell assembly. The step of providing a packaging material film on the plurality of welding strips further comprises: aligning the first region with the peripheral region of the solar cell assembly, The thickness of the first area that at least partially overlaps with the orthographic projection of the gap between the battery cells and the thickness of the first area that at least partially overlaps with the orthographic projection of the peripheral area of the solar cell assembly are greater than the thickness of the first area that at least partially overlaps with the orthographic projection of at least one of the multiple welding strips.

17. A method for manufacturing the packaging material film according to claim 1, comprising: forming the packaging material into a material film; processing the material film so that the material film is formed into the packaging material film, The packaging material film is configured to be used for a solar cell assembly, the solar cell assembly comprising a plurality of welding strips, the packaging material film comprising: a first region, the orthographic projection of the first region on the surface where the solar cell assembly is located at least partially overlapping with the orthographic projection of at least one of the plurality of welding strips, The film thickness of the first region is greater than the film thickness of other regions of the packaging material film, The solar cell assembly includes a plurality of cells, and the orthographic projection of the first region on the surface where the solar cell assembly is located at least partially overlaps with the orthographic projection of the gaps between the cells. wherein the orthographic projection of the first area on the surface where the solar cell assembly is located at least partially overlaps with the orthographic projection of the peripheral area of the solar cell assembly, The thickness of the first area that at least partially overlaps with the orthographic projection of the gap between the battery cells and the thickness of the first area that at least partially overlaps with the orthographic projection of the peripheral area of the solar cell assembly are greater than the thickness of the first area that at least partially overlaps with the orthographic projection of at least one of the multiple welding strips.

18. The manufacturing method according to claim 17, wherein the processing of the material film comprises: forming a photoresist material on the material film; exposing the photoresist material using a mask, wherein the pattern of the mask corresponds to other areas of the packaging material film; exposing and developing the photoresist material to form a photoresist pattern, wherein a reserved area of the photoresist pattern corresponds to the first area; The material film is etched to remove at least a portion of the material film in the other region.

19. The manufacturing method according to claim 17, wherein forming the packaging material into a material film comprises: forming a first material film using a packaging material; forming a film strip on a local area of the first material film to form the material film, The local area corresponds to the first area.

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