Photovoltaic module and method for manufacturing a photovoltaic module

Abstract

An embodiment of the present application provides a photovoltaic module and a method for manufacturing the photovoltaic module. Among them, the photovoltaic module includes: a battery string layer, on one side of the battery string layer, there are at least two busbars for external connection; a first encapsulation layer, the first encapsulation layer is disposed on the side of the battery string layer facing the at least two busbars; a first bonding layer, the first bonding layer is disposed between the battery string layer and the first encapsulation layer to bond the battery string layer and the first encapsulation layer; a water blocking member, the water blocking member is disposed between the first encapsulation layer and the first bonding layer and is disposed close to the busbar; the water blocking member includes a first water blocking sheet and a second water blocking sheet; the first water blocking sheet is disposed close to the first bonding layer, and the second water blocking sheet is disposed close to the first encapsulation layer; the permeability of the second water blocking sheet is less than the permeability of the first water blocking sheet. The photovoltaic module provided by the embodiment of the present application has a highly reliable water blocking performance and is not prone to situations such as hidden cracks, voids, and breakages at the same time.

Description

Technical Field

[0001] This application relates to the technical field of photovoltaic modules, and in particular to a photovoltaic module and a manufacturing method thereof. Background Art

[0002] Photovoltaic cells are sensitive to water vapor. Under the penetration of water vapor, the cells will experience a significant power attenuation and various reliability problems. Therefore, it is necessary to seal the positions where water vapor may penetrate.

[0003] On the backplane glass of a photovoltaic module, there are lead holes through which busbars for connecting cell strings pass. After passing through the lead holes, the busbars are connected to the junction box. Water vapor easily penetrates into the interior of the photovoltaic module through the lead holes, causing water vapor erosion to the cell strings and affecting the luminous efficiency and service life of the module. Summary of the Invention

[0004] Embodiments of this application provide a photovoltaic module and a manufacturing method thereof to solve or alleviate one or more technical problems in the prior art.

[0005] As an aspect of the embodiments of this application, the embodiments provide a photovoltaic module, including:

[0006] A cell string layer, on one side of which there are at least two busbars for external connection;

[0007] A first encapsulation layer, which is disposed on the side of the cell string layer facing the at least two busbars;

[0008] A first bonding layer, which is disposed between the cell string layer and the first encapsulation layer to bond the cell string layer and the first encapsulation layer;

[0009] A water-blocking member, which is disposed between the first encapsulation layer and the first bonding layer and is close to the busbars; the water-blocking member includes a first water-blocking sheet and a second water-blocking sheet; the first water-blocking sheet is close to the first bonding layer, and the second water-blocking sheet is close to the first encapsulation layer; the water permeability of the second water-blocking sheet is less than that of the first water-blocking sheet.

[0010] As another aspect of the embodiments of this application, the embodiments also provide a manufacturing method of a photovoltaic module for manufacturing the photovoltaic module in any of the above embodiments, including:

[0011] Stack the second encapsulation layer, the second bonding layer, and the cell string layer in sequence;

[0012] Stack the first bonding layer above the cell string layer, and the busbars in the cell string layer pass through the first bonding layer;

[0013] Place the first water-blocking sheet above the first bonding layer and close to the bus bar, with the bus bar passing through the first water-blocking sheet;

[0014] Place the second water-blocking sheet on top of the first water-blocking sheet;

[0015] Place the first encapsulation layer on top of the second water-blocking sheet and the first bonding layer, with the first encapsulation layer adhering to the second water-blocking sheet; the bus bar passes through the second water-blocking sheet and the first encapsulation layer;

[0016] Place the above-stacked components in a laminator to perform vacuum pumping and lamination on the components to obtain a photovoltaic module.

[0017] In the embodiments of the present application, two water-blocking sheets with the permeability of the second water-blocking sheet being less than that of the first water-blocking sheet are used for double waterproofing. On the one hand, the second water-blocking sheet with low permeability can cover the first water-blocking sheet with higher permeability to achieve a high-reliability waterproof effect on the outside; on the other hand, inside, a first water-blocking sheet is added between the battery string and the second water-blocking sheet for blocking, which can prevent the second water-blocking sheet from directly contacting the battery string, causing adverse conditions such as hidden cracks, voids, and breakages in the solar cell string. This enables the photovoltaic module to have high-reliability water-blocking performance while ensuring product quality.

[0018] The above summary is only for the purpose of the specification and is not intended to be limiting in any way. In addition to the illustrative aspects, embodiments, and features described above, further aspects, embodiments, and features of the present application will be readily apparent by referring to the drawings and the following detailed description. Description of the Drawings

[0019] In the drawings, unless otherwise specified, the same reference numerals throughout the multiple drawings represent the same or similar components or elements. These drawings are not necessarily drawn to scale. It should be understood that these drawings only depict some embodiments disclosed according to the present application and should not be regarded as limiting the scope of the present application.

[0020] Figure 1 Show a cross-sectional view of a photovoltaic module in a state according to an embodiment of the present application.

[0021] Figure 2 Show a cross-sectional view of a photovoltaic module in another state according to an embodiment of the present application.

[0022] Figure 3 Show a cross-sectional view of a photovoltaic module in yet another state according to an embodiment of the present application.

[0023] Figure 4 Show a structural view of a photovoltaic module according to an embodiment of the present application.

[0024] Figure 5 Shows a top view schematic diagram of a photovoltaic module according to an embodiment of the present application.

[0025] Figure 6 Shows a schematic flow diagram of a method for manufacturing a photovoltaic module according to an embodiment of the present application. Detailed implementation manners

[0026] In the following, only some exemplary embodiments are simply described. As those skilled in the art can recognize, the described embodiments can be modified in various different ways without departing from the spirit or scope of the present application. Therefore, the drawings and the description are considered to be exemplary in nature rather than restrictive.

[0027] Figure 1 Shows a cross-sectional schematic diagram of a photovoltaic module in a state according to an embodiment of the present application. Figure 2 Shows a cross-sectional schematic diagram of a photovoltaic module in another state according to an embodiment of the present application. Figure 3 Shows a cross-sectional schematic diagram of a photovoltaic module in yet another state according to an embodiment of the present application. Figure 4 Shows a structural schematic diagram of a photovoltaic module according to an embodiment of the present application. Figure 5 Shows a top view schematic diagram of a photovoltaic module according to an embodiment of the present application. As Figures 1 to 5 shown, the photovoltaic module includes: a battery string layer 3, a first encapsulation layer 5, a first bonding layer 4, and a water blocking member.

[0028] On one side of the battery string layer 3, there are provided at least two busbars 9 for connection with the outside. The battery string layer 3 can be a battery string composed of silicon crystal batteries. The batteries are connected by welding tapes, and at least two busbars 9 are led out from the welding tapes for connection with an external junction box to realize the function of the photovoltaic module for supplying power to the outside.

[0029] The first encapsulation layer 5 is disposed on the side of the battery string layer 3 facing the at least two busbars 9. The first encapsulation layer 5 can be made of glass material. The first encapsulation layer 5 is used to protect the battery string and prevent the battery string from being washed and invaded by external fluids or media such as wind, rain, and air.

[0030] The first bonding layer 4 is disposed between the battery string layer 3 and the first encapsulation layer 5 to bond the battery string layer 3 and the first encapsulation layer 5. By bonding the battery string layer 3 and the first encapsulation layer 5 with the first bonding layer 4, it is possible to prevent a gap from being formed between the first encapsulation layer 5 and the battery string layer 3, resulting in damage to the battery string layer 3.

[0031] The water blocking member is arranged between the first packaging layer 5 and the first bonding layer 4, and is arranged close to the bus bar 9; the water blocking member includes a first water blocking sheet 7 and a second water blocking sheet 6; the first water blocking sheet 7 is arranged close to the first bonding layer 4, and the second water blocking sheet 6 is arranged close to the first packaging layer 5; the permeability of the second water blocking sheet 6 is less than the permeability of the first water blocking sheet 7.

[0032] The water-blocking member is arranged between the first packaging layer 5 and the first adhesive layer 4. After being melted at high temperature, the water-blocking member is bonded to the first adhesive layer 4, which can prevent water vapor from penetrating into the battery string layer 3 along the bus bar 9, thereby preventing the battery string layer 3 from being corroded by water vapor and affecting its service life.

[0033] In the embodiment of the present application, the water-blocking member includes two layers of water-blocking sheets, and the second water-blocking sheet 6 close to the outside has a lower permeability, which can completely isolate the water vapor from the outside from entering. The permeability requirement of the first water-blocking sheet 7 close to the inside is not high, but the battery string layer 3 and the second water-blocking sheet 6 can be isolated. The first water-blocking sheet 7 can be made of a material that is not easy to crush the battery string layer 3, thereby protecting the battery string layer 3 from damage by the second water-blocking sheet 6. Through the above-mentioned arrangement, the second water-blocking sheet 6 only needs to select a material with the lowest possible permeability, and there is no need to consider whether the battery string layer 3 will be damaged, so that the material selection of the second water-blocking sheet 6 is more, and the low permeability can more thoroughly prevent water vapor from entering the battery string layer 3.

[0034] The embodiment of the present application adopts two layers of water-blocking sheets, the permeability of the second water-blocking sheet 6 is less than that of the first water-blocking sheet 7, for double waterproofing. On the one hand, the second water-blocking sheet 6 with low permeability can cover the first water-blocking sheet 7 with higher permeability, achieving a highly reliable waterproof effect to the outside; on the other hand, the first water-blocking sheet 7 is added between the battery string and the second water-blocking sheet 6 for isolation, which can avoid direct contact between the second water-blocking sheet 6 and the battery string, causing undesirable conditions such as hidden cracks, cavitation, and damage to the solar cell string. This allows the photovoltaic module to have high reliability water-blocking performance while ensuring product quality.

[0035] In one embodiment, the first encapsulation layer 5 includes a first opening 10 for the bus bar 9 to pass through, and the first adhesive layer 4 is provided with a second opening 8 for at least two bus bars 9 to pass through.

[0036] In order to facilitate the passing of the busbar 9 , the first packaging layer 5 is provided with a first opening 10 , and the first adhesive layer 4 is provided with a second opening 8 ; the first opening 10 and the second opening 8 are arranged opposite to each other, and the two may be coaxial.

[0037] When a first opening 10 and a second opening 8 are provided, at least two bus bars 9 can be respectively passed out as close as possible to the edge of the first opening 10 and / or the second opening 8, so that a distance is maintained between at least two bus bars 9 to avoid crossing, so that the flow direction of ions flowing out of at least two bus bars 9 is stable.

[0038] A second opening 8 is provided in the first adhesive layer 4, and a first water-blocking sheet 7 is covered above the second opening 8, so that the bus bar 9 can easily pass through. At the same time, at the position of the bus bar 9, there is more adhesive film that can prevent the second water-blocking sheet 6 from contacting the battery string layer 3, protect the battery string layer 3 from being damaged by the second water-blocking sheet 6, and avoid the occurrence of hidden cracks in the battery string layer 3.

[0039] In one embodiment, the diameter of the second opening 8 is larger than the diameter of the first opening 10; the diameter of the first opening 10 is adapted to the radial size of at least two bus bars 9.

[0040] The radial size of at least two bus bars 9 can be the maximum value of the distances between any two of at least two bus bars 9. Exemplarily, when the number of bus bars 9 is two, the radial size is the distance between the two bus bars 9.

[0041] The diameter of the first opening 10 can be the maximum value of the radial dimensions in the first opening 10. In some exemplary application scenarios, it can be the average value of the radial dimensions in multiple directions of the first opening 10. Similarly, the diameter of the second opening 8 can be understood in the same way as the diameter of the first opening 10.

[0042] In one example, the shape of the first opening 10 is a long strip, and the number of bus bars 9 is two. Then the length of the long side in the long strip is greater than or equal to the distance between the two bus bars 9, and the two bus bars 9 pass through near the two ends of the long strip respectively. In this way, the distance between the two bus bars 9 during the passing-through process can be maximally maintained, and the interaction of electric ions between the two bus bars 9 can be avoided.

[0043] The diameter of the first opening 10 is adapted to the radial size of at least two bus bars 9, which can ensure that the bus bars 9 can easily pass through, and at the same time can avoid the interaction between at least two bus bars 9, resulting in an unstable flow of electric ions.

[0044] In the embodiment of the present application, the diameter of the second opening 8 is larger than the diameter of the first opening 10, which can form a gap between the first adhesive layer 4 and the bus bar 9. Through this gap, during the lamination process, the first water-blocking sheet 7 can fill the gap and isolate the possibility of the first adhesive layer 4 passing along the bus bar 9.

[0045] In one embodiment, the difference in diameter between the first opening 10 and the second opening 8 is 0 - 5 mm.

[0046] In one example, the difference in diameter between the first opening 10 and the second opening 8 can be determined based on the material properties of the first adhesive layer 4 and the material properties of the first water-blocking sheet 7.

[0047] In one example, when the material of the first adhesive layer 4 is the same as that of the first water-blocking sheet 7, the difference in the diameters of the first opening 10 and the second opening 8 can be 0 mm or can be set to be close to 0 mm.

[0048] In one example, when the waterproof property of the material of the first adhesive layer 4 is much lower than that of the first water-blocking sheet 7, or when the permeability of the first adhesive layer 4 is much higher than that of the first water-blocking sheet 7, the difference in the diameters of the first opening 10 and the second opening 8 can be set to be relatively large, for example, 5 mm, so that there is enough first water-blocking sheet 7 to penetrate into the gap during the lamination process to isolate the possibility of the material of the first adhesive layer 4 from passing through.

[0049] In the embodiment of the present application, by setting the second opening 8 to be larger than the first opening 10, the first water-blocking sheet 7 can prevent the material of the first adhesive layer 4 from passing through. When the material of the first adhesive layer 4 passes through, it may pass through the gap of the second water-blocking sheet 6, resulting in water vapor permeating along the first adhesive layer 4 to the battery string layer 3. However, after the first water-blocking sheet 7 melts and fills the gap, only the first water-blocking sheet 7 passes through the gap of the second water-blocking sheet 6. The permeability of the material of the first water-blocking sheet 7 is relatively low compared to that of the first adhesive layer 4, and water vapor is less likely to permeate, thereby further protecting the battery string layer 3 from water vapor erosion and extending the service life of the photovoltaic module.

[0050] In one implementation, before the photovoltaic module is laminated, the height of the water-blocking member is adapted to the height of the first adhesive layer 4, and the ratio of the height of the water-blocking member to the height of the first adhesive layer 4 is 1 / 2 - 1 / 1.

[0051] The water-blocking member is stacked above the first adhesive layer 4, and the water-blocking member is only disposed close to the bus bar 9. The radial dimension of the water-blocking member is much smaller than the dimension of the first adhesive layer 4. And in the position where there is no water-blocking member, during lamination, the first encapsulation layer 5 still needs to contact and bond with the first adhesive layer 4. Therefore, if the height of the water-blocking member is too high, it will be difficult for the first encapsulation layer 5 to bond with the first adhesive layer 4, resulting in voids and affecting the product quality of the photovoltaic module.

[0052] If the height of the water-blocking member is too low, the first opening 10 and the second opening 8 cannot be filled, which will affect the water-blocking effect.

[0053] In the embodiment of the present application, by limiting the ratio of the height of the water-blocking member to the height of the first adhesive layer 4, the water-blocking effect can be ensured while not affecting the product quality of the photovoltaic module.

[0054] In one implementation, before the photovoltaic module is laminated, the height of the water-blocking member is 2 - 5 mm.

[0055] The water-blocking member in the embodiments of the present application includes at least two layers of water-blocking sheets. In the specific implementation process, the height of the first water-blocking sheet 7 and the height of the second water-blocking sheet 6 can be determined respectively based on the defined height of the water-blocking member.

[0056] In some other examples, the water-blocking member may further include multiple layers of water-blocking sheets. In the specific implementation process, the heights of the multiple layers of water-blocking sheets can be determined respectively based on the defined height of the water-blocking member.

[0057] In one implementation manner, before the photovoltaic module is laminated, the height ratio of the first water-blocking sheet 7 to the second water-blocking sheet 6 is 1 / 2 - 1 / 1.

[0058] Based on the different water-blocking effects of the first water-blocking sheet 7 and the second water-blocking sheet 6, according to their different functions, the specific heights of the two can be determined under the condition of the defined height, so as to ensure that the water-blocking member can achieve the water-blocking effect without affecting the product quality of the photovoltaic module.

[0059] In one example, based on the caliber and height of the first opening 10 (i.e., the height of the first encapsulation layer 5), the height of the second water-blocking sheet 6 can be determined to ensure that the second water-blocking sheet 6 can fill the first opening 10.

[0060] It should be noted that the second water-blocking sheet 6 filling the first opening 10 does not mean just filling the first opening 10 exactly, but according to the specific actual situation, after filling the first opening 10, there is a certain overflow amount, so that the second water-blocking sheet 6 overflows the first encapsulation layer 5 and bonds with the first encapsulation layer 5 from the outside of the first encapsulation layer 5, blocking water from the outside of the first encapsulation layer 5 to completely ensure that water vapor will not seep in from the gap between the first encapsulation layer 5 and the second water-blocking sheet 6.

[0061] Based on the height ratio limit between the first water-blocking sheet 7 and the second water-blocking sheet 6, the height of the first water-blocking sheet 7 can be determined. Based on the height limit of the first water-blocking sheet 7, or in combination with the size of the first water-blocking sheet 7 covering the first bonding layer 4, the caliber of the second opening 8 can be determined.

[0062] In one example, before the photovoltaic module is laminated, the volume of the first water-blocking sheet 7 is adapted to the caliber of the second opening 8 to ensure that the first water-blocking sheet 7 can fill the second opening 8.

[0063] In one implementation manner, the first water-blocking sheet 7 covers the second opening 8, and the part of the first water-blocking sheet 7 covering the first bonding layer 4 is the first annular stockpiling area, and the difference between the outer diameter and the inner diameter of the first annular stockpiling area is 3 - 8 mm.

[0064] In the embodiments of the present application, the first water-blocking sheet 7 is disposed above the first adhesive layer 4 by covering the second opening 8 and partially covering the first adhesive layer 4. During the lamination process, the material of the first water-blocking sheet 7 not only fills the second opening 8 but also partially covers the first adhesive layer 4 to ensure isolation between the second water-blocking sheet 6 and the first adhesive layer 4 and prevent the first adhesive layer 4 from piercing through.

[0065] In one example, when the height of the first water-blocking sheet 7 is higher than that of the first adhesive layer 4, a portion of the material of the first water-blocking sheet 7 at a position corresponding to the second opening 8 and higher than the height of the first adhesive layer 4 can also be used as stock material.

[0066] It can be understood that the higher the height of the first water-blocking sheet 7, the more stock material there is. However, the height of the first water-blocking sheet 7 has certain limitations. If the height of the first water-blocking sheet 7 is lower than that of the first adhesive layer 4, the material covering the first adhesive layer 4 needs to be used as a backup to ensure that the material of the first water-blocking sheet 7 can fill the second opening 8.

[0067] The difference between the outer diameter and the inner diameter of the first annular stock material area can be the minimum value of the differences between the outer diameters and the inner diameters in multiple radial directions, or the average value of the differences between the outer diameters and the inner diameters in multiple radial directions.

[0068] Based on the limitation of the difference between the outer diameter and the inner diameter of the first annular stock material area, the amount of stock material can be limited to ensure that the first water-blocking sheet 7 can fill the second opening 8.

[0069] In specific application implementations, the difference between the outer diameter and the inner diameter of the first annular stock material area can be adaptively adjusted according to the height of the first water-blocking sheet 7 and / or in combination with the height of the first adhesive layer 4.

[0070] In one instance, before lamination of the photovoltaic module, the size of the second water-blocking sheet 6 is adapted to the diameter of the first opening 10 to ensure that the second water-blocking sheet 6 can fill the first opening 10.

[0071] In one implementation manner, the portion of the second water-blocking sheet 6 covering the first encapsulation layer 5 is the second annular stock material area, and the difference between the outer diameter and the inner diameter of the second annular stock material area is 2 - 6 mm.

[0072] Similarly to the first water-blocking sheet 7 covering the first adhesive layer 4, through the second annular stock material area, it can be ensured that the second water-blocking sheet 6 can fill the first opening 10.

[0073] In the embodiments of the present application, the shapes of the first opening 10 and the second opening 8 may be different. For example, the first opening 10 is circular and the second opening 8 is square. The shapes of the first water-blocking sheet 7 and the second water-blocking sheet 6 may also be different. For example, the second water-blocking sheet 6 is circular and the first water-blocking sheet 7 is square. The shape of the first water-blocking sheet 7 may be adapted to the shape of the second opening 8; the shape of the second water-blocking sheet 6 may be adapted to the shape of the first opening 10. The shapes of the first opening 10, the second opening 8, the first water-blocking sheet 7, and the second water-blocking sheet 6 may each be any one of a circular shape, a square shape, a regular polygon shape, a triangular shape, a T-shaped, etc., and the embodiments of the present application do not limit this.

[0074] In one embodiment, the water-blocking member further includes a third water-blocking sheet disposed between the first water-blocking sheet 7 and the second water-blocking sheet 6.

[0075] In some specific application scenarios and actual needs, a third water-blocking sheet may be disposed between the first water-blocking sheet 7 and the second water-blocking sheet 6, and the first water-blocking sheet 7, the second water-blocking sheet 6, and the third water-blocking sheet are stacked.

[0076] In one example, among the multiple water-blocking sheets, the permeability of the first water-blocking sheet 7 > the permeability of the third water-blocking sheet > the permeability of the second water-blocking sheet 6.

[0077] It can be understood that the design of the water-blocking member including four or more layers of water-blocking sheets is within the protection scope of the embodiments of the present application.

[0078] The permeability of the third water-blocking sheet may be lower than the permeability of the first water-blocking sheet 7, which can prevent the first water-blocking sheet 7 from passing through the gap of the second water-blocking sheet 6 and penetrating to the outside, so as to further more reliably prevent water vapor from infiltrating.

[0079] In one embodiment, the permeability of the first water-blocking sheet 7 is less than or equal to the permeability of the first adhesive layer 4.

[0080] The permeability of the first water-blocking sheet 7 being less than or equal to the permeability of the first adhesive layer 4 can ensure the water-blocking performance, and the part of the first water-blocking sheet 7 that penetrates through the second water-blocking sheet 6 may have a water-blocking effect equivalent to or better than that of the first adhesive layer 4.

[0081] In one embodiment, the material of the first adhesive layer 4 is at least one of EVA (ethylene-vinyl acetate copolymer), EPE (EVA + POE + EVA, a combination of ethylene-vinyl acetate copolymer and ethylene-a-polyolefin copolymer).

[0082] EVA and EPE are commonly used materials for bonding the battery string layer 3 and the first encapsulation layer 5. Since the first bonding layer 4 is located inside the first encapsulation layer 5 and has a relatively low requirement for water resistance, a suitable material can be selected as the first bonding layer 4 based on cost considerations and / or factors that do not damage the battery string layer 3.

[0083] In one embodiment, the material of the second water-blocking sheet 6 is at least one of POE (ethylene-a-olefin copolymer), EPE, and butyl rubber.

[0084] Comparing the permeabilities of the materials, POE < EPE < EVA. Based on the requirements for permeability in the above embodiments, a material with a lower permeability can be selected as the second water-blocking sheet 6.

[0085] In one example, when the material of the first bonding layer 4 is EVA, the material of the second water-blocking sheet 6 can be selected as POE. The water vapor barrier, high-temperature insulation performance, and high-temperature and high-humidity corrosion resistance of the POE film are all better than those of the EVA material, protecting the battery string layer from damage while improving the water resistance.

[0086] In one embodiment, the material of the second water-blocking sheet 6 is butyl rubber.

[0087] Butyl rubber is a copolymer of isobutene and isoprene and is a type of synthetic rubber.

[0088] The permeability of butyl rubber is lower than any of POE, EPE, and EVA, and it has the best water resistance. Therefore, by selecting the material of the second water-blocking sheet 6 as butyl rubber, the water-blocking effect can be ensured.

[0089] It can be understood that the material of the second water-blocking sheet 6 can also be a material with a lower permeability than that of butyl rubber that can be adopted by those of ordinary skill in the art now or in the future.

[0090] Based on the problem that butyl rubber is prone to extrusion during the lamination process, which may cause the battery string layer 3 to easily appear with hidden cracks and dark cracks, in the embodiments of the present application, the first water-blocking sheet 7 isolates the contact between the butyl rubber and the battery string layer 3, which can protect the battery string layer 3 from the problem of hidden cracks and dark cracks.

[0091] In one embodiment, the material of the first water-blocking sheet 7 is incompatible with the material of the second water-blocking sheet 6.

[0092] The material of the first water-blocking sheet 7 is incompatible with the material of the second water-blocking sheet 6, so that at high temperatures, both are in a viscous flow state. No matter how they are laminated, the second water-blocking sheet 6 will be above the first water-blocking sheet 7, ensuring that the external water blocking is carried out by the second water-blocking sheet 6 with a low permeability, and guaranteeing the water-blocking effect.

[0093] In the embodiment of the present application, the above method is adopted to achieve water blocking, so that the butyl rubber patch used can be reduced to 20*20mm or less, avoiding the position of the battery cell solder strip, and further avoiding the process problem of dark cracks.

[0094] In one embodiment, the photovoltaic module further includes: a second encapsulation layer and a second bonding layer.

[0095] The second encapsulation layer is disposed on the side of the battery string facing away from at least two busbars 9; the second bonding layer is disposed between the battery string layer 3 and the second encapsulation layer to bond the battery string layer 3 and the second encapsulation layer.

[0096] The second encapsulation layer is disposed on the side of the battery string layer 3 facing away from at least two busbars 9. The second encapsulation layer can be made of glass. The second encapsulation layer can have the same material as the first encapsulation layer 5. The second encapsulation layer is used to protect the battery string from being washed and invaded by external fluids or media such as wind, rain, and air.

[0097] In one example, when installing the photovoltaic module, the second encapsulation layer is the side facing the sun, providing a fully enclosed protection for the battery string layer 3. The first encapsulation layer 5 is the side facing away from the sun, and the busbars 9 of the battery string layer 3 are led out from the first encapsulation layer 5 and electrically connected to an external junction box. The first encapsulation layer 5 facing away from the sun can protect the junction box and the busbars 9 from being invaded by rain and sunlight, and improve the service life of the photovoltaic module.

[0098] The second bonding layer is disposed between the battery string layer 3 and the second encapsulation layer to bond the battery string layer 3 and the second encapsulation layer. By bonding the battery string layer 3 and the second encapsulation layer through the second bonding layer, it is possible to prevent a gap from being formed between the second encapsulation layer and the battery string layer 3, resulting in damage to the battery string layer 3.

[0099] For other components of the photovoltaic module in the above embodiment, various technical solutions known to those of ordinary skill in the art now and in the future can be adopted, which will not be described in detail here.

[0100] The embodiment of the present application further provides a manufacturing method of a photovoltaic module, Figure 6 showing a flowchart of a manufacturing method of a photovoltaic module according to an embodiment of the present application. As Figure 6 shown, for manufacturing the photovoltaic module in any implementation aspect of the above embodiment, the manufacturing method includes:

[0101] S610, stacking the second encapsulation layer, the second bonding layer, and the battery string layer in sequence;

[0102] S620, stacking the first bonding layer above the battery string layer, and the busbars in the battery string layer pass through the first bonding layer;

[0103] S630, stack the first water-blocking sheet above the first adhesive layer and close to the bus bar, with the bus bar passing through the first water-blocking sheet;

[0104] S640, stack the second water-blocking sheet above the first water-blocking sheet; the bus bar passes through the second water-blocking sheet; the permeability of the second water-blocking sheet is lower than that of the first water-blocking sheet;

[0105] S650, stack the first encapsulation layer above the second water-blocking sheet and the first adhesive layer, with the first encapsulation layer adhering to the second water-blocking sheet; the bus bar passes through the first encapsulation layer;

[0106] S660, place the stacked above components in a laminator to perform vacuum pumping and lamination on the components to obtain a photovoltaic module.

[0107] In the embodiment of the present application, after sequentially stacking the second encapsulation layer, the second adhesive layer, the battery string layer, the first adhesive layer, the first water-blocking sheet, the second water-blocking sheet, and the first encapsulation layer that constitute any one of the above embodiments, the stacked components are placed in a laminator for lamination to obtain a photovoltaic module. The first water-blocking sheet and the second water-blocking sheet are used to achieve water blocking at the perforation of the bus bar, and the permeability of the second water-blocking sheet is less than that of the first water-blocking sheet. The obtained photovoltaic module has a highly reliable water-blocking performance and is not prone to problems such as hidden cracks, voids, and breakages.

[0108] In one embodiment, before step S620, it further includes: providing a second opening at the first adhesive layer, and the bus bar passes through the second opening to penetrate the first adhesive layer.

[0109] Step S630 includes: covering the first water-blocking sheet on the second opening and covering the first adhesive layer.

[0110] Step S650 includes: providing a first opening at the position of the first encapsulation layer corresponding to the bus bar; stacking the first encapsulation layer on the second water-blocking sheet so that the center of the second water-blocking sheet corresponds to the center of the first opening for stacking.

[0111] In the description of this specification, it should be understood that the orientation or positional relationship indicated by the terms "center", "longitudinal", "transverse", "length", "width", "thickness", "upper", "lower", "front", "rear", "left", "right", "vertical", "horizontal", "top", "bottom", "inner", "outer", "clockwise", "counterclockwise", "axial", "radial", "circumferential", etc. is based on the orientation or positional relationship shown in the drawings. It is only for the convenience of describing the present application and simplifying the description, rather than indicating or implying that the device or element referred to must have a specific orientation, be constructed and operated in a specific orientation, and therefore should not be construed as a limitation to the present application.

[0112] In addition, the terms "first" and "second" are used for descriptive purposes only and should not be construed as indicating or implying relative importance or implicitly specifying the quantity of the indicated technical features. Thus, features defined with "first" and "second" may explicitly or implicitly include one or more of such features. In the description of this application, "a plurality of" means two or more unless specifically defined otherwise.

[0113] In this application, unless otherwise clearly defined and limited, the terms "mounted", "connected", "coupled", "fixed", etc. shall be construed broadly. For example, it may be a fixed connection, a detachable connection, or an integral one; it may be a mechanical connection, an electrical connection, or a communication connection; it may be directly connected, or indirectly connected through an intermediate medium, and it may be the internal communication of two components or the interaction relationship between two components. For those of ordinary skill in the art, the specific meanings of the above terms in this application can be understood according to specific circumstances.

[0114] In this application, unless otherwise clearly defined and limited, the first feature being "on" or "under" the second feature may include the direct contact between the first and second features, or may include the situation where the first and second features are not in direct contact but in contact through additional features therebetween. Moreover, the first feature being "above", "over" and "on top of" the second feature includes that the first feature is directly above and obliquely above the second feature, or merely indicates that the horizontal height of the first feature is higher than that of the second feature. The first feature being "under", "beneath" and "underneath" the second feature includes that the first feature is directly below and obliquely below the second feature, or merely indicates that the horizontal height of the first feature is lower than that of the second feature.

[0115] The above disclosure provides many different embodiments or examples for implementing different structures of this application. To simplify the disclosure of this application, components and settings of specific examples are described above. Of course, they are merely examples and are not intended to limit this application. In addition, this application may repeat reference numerals and / or reference letters in different examples. Such repetition is for the purpose of simplification and clarity and does not itself indicate the relationship between the various embodiments and / or settings discussed.

[0116] The above is only the specific embodiment of this application, but the protection scope of this application is not limited thereto. Any person skilled in the art can easily think of various changes or substitutions within the technical scope disclosed in this application, and these should all be covered by the protection scope of this application. Therefore, the protection scope of this application shall be subject to the protection scope of the claims.

Claims

1. A photovoltaic module, characterized in that, Comprising: A battery string layer, on one side of which there are at least two busbars for external connection. A first encapsulation layer, which is arranged on the side of the battery string layer facing the at least two busbars. A first bonding layer, which is arranged between the battery string layer and the first encapsulation layer to bond the battery string layer and the first encapsulation layer. A water blocking member, which is arranged between the first encapsulation layer and the first bonding layer and is disposed close to the busbar; the water blocking member includes a first water blocking sheet and a second water blocking sheet; the first water blocking sheet is arranged close to the first bonding layer, and the second water blocking sheet is arranged close to the first encapsulation layer; the permeability of the second water blocking sheet is less than that of the first water blocking sheet. Wherein, the first encapsulation layer includes a first opening for the busbar to pass through, and the first bonding layer is provided with a second opening for the at least two busbars to pass through; the diameter of the second opening is larger than that of the first opening, so that a gap is formed between the first bonding layer and the busbar. During the lamination process, the first water blocking sheet fills the gap to isolate the first bonding layer from passing out along the busbar; the diameter of the first opening is adapted to the radial size of the at least two busbars.

2. The photovoltaic module according to claim 1, wherein The difference in diameter between the first opening and the second opening is greater than 0 mm and less than or equal to 5 mm.

3. The photovoltaic module according to claim 1, wherein, Before the photovoltaic module is laminated, the ratio of the height of the water blocking member to the height of the first bonding layer is 1 / 2 - 1 / 1.

4. The photovoltaic module according to claim 1 or 3, characterized in that Before the photovoltaic module is laminated, the height of the water blocking member is 2 - 5 mm.

5. The photovoltaic module according to claim 4, characterized in that, Before the photovoltaic module is laminated, the ratio of the height of the first water blocking sheet to the height of the second water blocking sheet is 1 / 2 - 1 / 1.

6. The photovoltaic module according to claim 1, wherein The first water blocking sheet covers the second opening, and the part of the first water blocking sheet covering the first bonding layer is a first annular stock preparation area, and the difference between the outer diameter and the inner diameter of the first annular stock preparation area is 3 - 8 mm.

7. The photovoltaic module according to claim 1, wherein The part of the second water blocking sheet covering the first encapsulation layer is a second annular stock preparation area, and the difference between the outer diameter and the inner diameter of the second annular stock preparation area is 2 - 6 mm.

8. The photovoltaic module according to claim 1, characterized in that, The water blocking member further includes a third water blocking sheet, which is arranged between the first water blocking sheet and the second water blocking sheet.

9. The photovoltaic module according to claim 1, wherein The permeability of the first water blocking sheet is less than that of the first bonding layer.

10. The photovoltaic module according to claim 1 or 9, characterized in that, The material of the first bonding layer is at least one of EVA and EPE.

11. The photovoltaic module according to claim 10, characterized in that, The material of the second water blocking sheet is at least one of POE, EPE, and butyl rubber.

12. The photovoltaic module according to claim 11, wherein, The material of the second water blocking sheet is butyl rubber.

13. The photovoltaic module according to claim 1, wherein The material of the first water blocking sheet and the material of the second water blocking sheet are incompatible in the high-temperature melting state.

14. The photovoltaic module according to claim 1, wherein Further comprising: A second encapsulation layer, which is arranged on the side of the battery string layer opposite to the at least two busbars. A second bonding layer, which is arranged between the battery string layer and the second encapsulation layer to bond the battery string layer and the second encapsulation layer.

15. A manufacturing method of a photovoltaic module, characterized in that, For manufacturing the photovoltaic module according to any one of claims 1 to 14, comprising: Stacking the second encapsulation layer, the second bonding layer, and the battery string layer in sequence. Place the first adhesive layer above the battery string layer, and the bus bar in the battery string layer penetrates through the first adhesive layer; Place the first water-blocking sheet above the first adhesive layer and close to the position of the bus bar, and the bus bar penetrates through the first water-blocking sheet; Place the second water-blocking sheet above the first water-blocking sheet, and the bus bar penetrates through the second water-blocking sheet; the permeability of the second water-blocking sheet is less than that of the first water-blocking sheet; Place the first encapsulation layer above the second water-blocking sheet and the first adhesive layer, and the first encapsulation layer adheres to the second water-blocking sheet; the bus bar penetrates through the first encapsulation layer; Wherein, the first encapsulation layer includes a first opening for the bus bar to pass through, and the first adhesive layer is provided with a second opening for at least two bus bars to pass through; the diameter of the second opening is larger than that of the first opening, so that a gap is formed between the first adhesive layer and the bus bar. During the lamination process, the first water-blocking sheet fills the gap to isolate the first adhesive layer from passing out along the bus bar; the diameter of the first opening is adapted to the radial size of the at least two bus bars; Place the above stacked components in a laminator to perform vacuum pumping and lamination on the components to obtain a photovoltaic module.

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