High-efficiency waterproof photovoltaic module lamination method and butyl rubber lamination frame thereof

Abstract

The present invention provides a high-efficiency waterproof photovoltaic module lamination method and a butyl rubber lamination frame thereof. The lamination method comprises: S1, feeding front glass into an assembly line; laying precisely cut glass on the glass; connecting battery strings; S2, laying the battery strings on the front adhesive film, laying the precisely cut back adhesive film on the battery strings; finely cutting the back adhesive film; S3, applying adhesive around the front glass; covering the laminated front glass with perforated back glass; S4, injecting adhesive into the back glass holes to complete the sealing of the lead wires; S5, sealing the edges of the laminated photovoltaic module; heating and laminating the photovoltaic module; S6, applying pressure to the heated and laminating photovoltaic module and rapidly cooling it; S7, performing non-destructive testing on the photovoltaic module. The present invention optimizes the lamination tooling structure to address locations prone to glue threading and the causes of glue debonding and delamination, thereby increasing the consistency of the actual effective distance and water-blocking distance at each location after butyl rubber lamination.

Description

Technical Field

[0001] The present invention relates to the field of photovoltaics, and in particular to a high-efficiency waterproof photovoltaic component lamination method and a butyl rubber lamination frame thereof. Background Art

[0002] The development of heterojunction cells, silver-coated copper technology, TOPCON cells (tunneling oxide passivated contact solar cells), and OBB busbar-less technology has led to the emergence of various packaging materials and cell pastes. These new packaging and welding materials have placed new demands on their tolerance to moisture, oxygen, and other factors. For example, OBB busbar-less cells may utilize PVB film (plastic resin film), which has a water absorption rate far exceeding that of conventional packaging materials.

[0003] Furthermore, heterojunction cells require a light-converting adhesive film, but current light-converting agents are susceptible to oxidation. To address this, a layer of butyl adhesive is typically placed around the module for waterproofing. The butyl adhesive module lamination method plays a crucial role in ensuring water-blocking quality.

[0004] However, current butyl lamination methods in the industry suffer from issues such as localized butyl cross-linking, inconsistent effective water-blocking distances across different areas, butyl delamination at edges, and poor adhesion between glass and butyl. These issues cannot be identified through conventional visual inspection, and the industry currently has no effective monitoring methods.

[0005] In view of this, the inventors of the present application have designed a high-efficiency waterproof photovoltaic module lamination method and a butyl rubber lamination frame thereof, in order to overcome the above-mentioned technical problems. Summary of the Invention

[0006] The technical problem to be solved by the present invention is to overcome the defects of the prior art butyl rubber lamination method such as easy glue cross-linking, glue opening, and debonding, and to provide an efficient waterproof photovoltaic module lamination method and a butyl rubber lamination frame thereof.

[0007] The present invention solves the above technical problems through the following technical solutions:

[0008] A high-efficiency waterproof photovoltaic module lamination method is characterized in that the high-efficiency waterproof photovoltaic module lamination method comprises the following steps:

[0009] S1. Glass loading: the front glass flows into the assembly line; film cutting: the precisely cut glass is laid on the glass; battery welding: the battery strings are connected;

[0010] S2. Lamination: Lay the battery string on the front film, and then lay the precisely cut back film on the battery string; back film is precisely cut;

[0011] S3, glue coating, applying adhesive around the front glass; glass bonding, covering the back perforated glass on the laminated front glass;

[0012] S4: Automatically plug the holes, inject glue into the back glass holes, and complete the sealing of the lead wires;

[0013] S5, edge sealing, edge sealing around the laminated photovoltaic modules; lamination, heating and laminating the photovoltaic modules;

[0014] S6, pressurized cooling, heating the laminated photovoltaic modules, applying pressure and rapidly cooling them;

[0015] S7. Perform non-destructive testing on photovoltaic modules to determine whether the adhesive lamination meets the quality standards.

[0016] According to one embodiment of the present invention, the viscose is butyl rubber.

[0017] According to one embodiment of the present invention, step S4 includes: after the back glass is bonded, water-blocking glue is injected into the surrounding and middle of the lead wire through the hole of the back glass by glue injection equipment, so that the glue fully fills the glass hole and forms good contact with the lead wire and the glass.

[0018] According to one embodiment of the present invention, the non-destructive testing method includes radiographic testing, ultrasonic testing and eddy current testing.

[0019] According to one embodiment of the present invention, step S7 includes: the non-destructive testing utilizes the difference in density of various materials to cause the difference in penetrability of radiation, ultrasound or eddy current, thereby forming an image by generating signal difference;

[0020] Image recognition software is then used to compare the contrast differences at various locations in the image, thereby obtaining information on glue sticking, bubbles, and debonding at the edge or middle of the component, thereby determining whether the photovoltaic component meets quality requirements.

[0021] According to one embodiment of the present invention, step S7 further includes:

[0022] S8, framing and junction box installation, installing the junction box and frame for the inspected components;

[0023] S9, curing, curing in a curing room with a certain temperature and humidity; testing and cleaning, cleaning the photovoltaic modules and performing power testing;

[0024] S 10 , packaging, packaging of photovoltaic modules.

[0025] The present invention further provides a butyl rubber laminated frame, characterized in that the butyl rubber laminated frame adopts the above-mentioned high-efficiency waterproof photovoltaic module lamination method, the butyl rubber laminated frame includes at least one set of first edges, at least one set of second edges, and a plurality of corner connectors, the first edges and the second edges are sequentially connected by the corner connectors to form a frame structure;

[0026] The length of the first side is greater than that of the second side, the thickness of the first side is different from the thickness of the second side, and the thickness of the corner connector is gradually changed along the direction of the first side and the second side.

[0027] According to one embodiment of the present invention, the thickness of the second side is 8 mm, and the thickness of the first side is 6 mm.

[0028] According to one embodiment of the present invention, the thickness of the corner connector is 2 mm to 4 mm thicker than the thickness of the first side.

[0029] According to one embodiment of the present invention, the length of the portion where the corner connector is connected to the first side is 300 mm to 800 mm.

[0030] According to one embodiment of the present invention, the length of the portion where the corner connector is connected to the second side is 20 mm to 30 mm.

[0031] According to one embodiment of the present invention, the thickness of the butyl rubber used in the butyl rubber laminated frame is greater than or equal to the sum of the glass deformation depth and the thickness of the adhesive film at the edge of the component.

[0032] The positive progress effect of the present invention is:

[0033] The high-efficiency waterproof photovoltaic module lamination method and lamination frame of the present invention have the following advantages:

[0034] 1. Aiming at the locations prone to glue sticking and the reasons for glue opening and debonding, the lamination tooling structure is optimized to increase the actual effective distance of butyl rubber after lamination and the consistency of water blocking distance at each location.

[0035] 2. For the lamination quality of butyl rubber after lamination, an automatic non-destructive testing method is used to monitor the lamination quality in real time. BRIEF DESCRIPTION OF THE DRAWINGS

[0036] The above and other features, properties and advantages of the present invention will become more apparent through the following description in conjunction with the accompanying drawings and embodiments, in which like reference numerals represent like features throughout, wherein:

[0037] Figure 1 The figure is a flow chart of the high-efficiency waterproof photovoltaic module lamination method of the present invention.

[0038] Figure 2 It is a schematic structural diagram of the butyl rubber laminated frame of the present invention.

[0039] Figure 3 for Figure 1 Enlarged view of part A.

[0040] Figure 4 Schematic diagram of the thickness gradient of the corner connectors in the butyl rubber laminated frame of the present invention.

[0041] Reference numerals

[0042] First side 10

[0043] Second side 20

[0044] Corner connector 30

[0045] The portion 31 of the corner connector connected to the first side

[0046] The portion 32 where the corner connector is connected to the second side DETAILED DESCRIPTION

[0047] In order to make the above-mentioned objects, features and advantages of the present invention more obvious and easy to understand, specific embodiments of the present invention are described in detail below with reference to the accompanying drawings.

[0048] Embodiments of the present invention will now be described in detail with reference to the accompanying drawings. Reference will now be made in detail to preferred embodiments of the present invention, examples of which are illustrated in the accompanying drawings. Wherever possible, the same reference numerals will be used throughout the drawings to represent the same or similar parts.

[0049] Furthermore, although the terms used in the present invention are selected from well-known and commonly used terms, some terms mentioned in the present specification may be selected by the applicant at his or her discretion, and their detailed meanings are explained in the relevant parts of the description herein.

[0050] Furthermore, it is required that the present invention be understood not only by the actual terms used but also by the meanings lying behind each term.

[0051] Figure 1 The figure is a flow chart of the high-efficiency waterproof photovoltaic module lamination method of the present invention.

[0052] like Figure 1 As shown, the present invention discloses a high-efficiency waterproof photovoltaic module lamination method, which uses a non-destructive testing method to identify the adverse conditions of EVA in butyl rubber and measure and monitor the effective water-blocking width.

[0053] The adverse conditions here include EVA glue sticking, debonding, and degumming in butyl rubber.

[0054] Preferably, the non-destructive testing methods include radiographic testing, ultrasonic testing and eddy current testing.

[0055] Preferably, before the non-destructive testing method, the following steps are also included:

[0056] Step S1: glass loading, the front glass flows into the assembly line; film precision cutting, the precisely cut glass is laid on the glass; battery welding, the battery strings are connected.

[0057] Step S2: Laminating: Laying the battery string on the front adhesive film, and then laying the precisely cut back adhesive film on the battery string; the back film is precisely cut.

[0058] Step S3: Glue coating, applying glue around the front glass; and glass bonding, covering the rear perforated glass on the laminated front glass.

[0059] In this case, the viscose may preferably be butyl rubber.

[0060] Step S4: the hole is automatically plugged, and glue is injected into the back glass hole to complete the sealing of the lead wire.

[0061] Preferably, step S4 includes: after the back glass is laminated, injecting water-blocking glue around and in the middle of the lead wire through the hole of the back glass by glue injection equipment, so that the glue fully fills the glass hole and forms good contact with the lead wire and the glass.

[0062] Step S5: edge sealing, sealing the edges of the laminated photovoltaic modules; and lamination, heating and laminating the photovoltaic modules.

[0063] Step S6: Pressurized cooling: heating the laminated photovoltaic modules, applying pressure, and rapidly cooling them.

[0064] Step S7: Perform nondestructive testing on the photovoltaic module to determine whether the adhesive lamination condition meets the quality standard.

[0065] Preferably, the non-destructive testing methods mentioned herein include radiographic testing, ultrasonic testing and eddy current testing.

[0066] The step S7 includes: the non-destructive testing utilizes the density difference of each material to cause the difference in the penetration of radiation, ultrasound or eddy current, thereby forming an image by the signal difference;

[0067] Image recognition software is then used to compare the contrast differences at various locations in the image, thereby obtaining information on glue sticking, bubbles, and debonding at the edge or middle of the component, thereby determining whether the photovoltaic component meets quality requirements.

[0068] More preferably, after the non-destructive testing method, the method further includes:

[0069] Step S8: framing and installing the junction box, installing the junction box and frame on the inspected components.

[0070] Step S9: curing, which is carried out in a curing room with a certain temperature and humidity; testing and cleaning, which is carried out on the photovoltaic modules and power testing.

[0071] Step S 10 , packaging, packaging of photovoltaic modules.

[0072] In addition to edge waterproofing, the junction box mounting holes also require protective treatment, so a new step for hole waterproofing has been added to the process flow. Because butyl adhesive is weaker when heated, a pressurized cooling step is implemented after lamination and curing to prevent the adhesive from delaminating or peeling due to glass rebound.

[0073] Figure 2 It is a schematic structural diagram of the butyl rubber laminated frame of the present invention. Figure 3 for Figure 1 Enlarged view of part A. Figure 4 Schematic diagram of the thickness gradient of the corner connectors in the butyl rubber laminated frame of the present invention.

[0074] like Figures 2 to 4 As shown, the present invention also provides a butyl rubber laminate frame, which adopts the high-efficiency waterproof photovoltaic module lamination method as described above, and the butyl rubber laminate frame includes at least one group of first edges 10, at least one group of second edges 20 and multiple corner connectors 30.

[0075] The first and second sides 10, 20 are connected in sequence by corner connectors 30, forming a frame structure. The length of the first side 10 is greater than that of the second side 20, and the thickness of the first side 10 and the second side 20 are different. The thickness of the corner connectors 30 gradually changes along the direction of the first and second sides 10, 20. This solves the problem of varying degrees of pressure extrusion of the EVA into the butyl rubber due to differences in heat and pressure at different locations in the laminator.

[0076] Preferably, the thickness of the second side 20 can be set to 8 mm, and the thickness of the first side 10 can be set to 6 mm. The thickness of the corner connector 30 is 2 mm to 4 mm thicker than the thickness of the first side 10.

[0077] This structural setting can solve the problem of excessive pressure on the corners caused by excessive pressure on the four corners.

[0078] Further preferably, the length of the portion 31 where the corner connector 30 is connected to the first side 10 can be set to 300mm to 800mm, where the length of the portion 31 where the corner connector 30 is connected to the first side 10 is the length of the portion of the glass that is heated and warped in the wall of the laminator.

[0079] The length of the portion 32 of the corner connector 30 connected to the second side 20 may be set to 20 mm to 30 mm.

[0080] The laminated silicone sheet has a slow transition of pressure at each position, and the uneven pressure caused by the height difference is placed, thereby solving the difference in the degree of pressure extrusion of EVA into butyl rubber due to the difference in heat and pressure conditions at each position of the component in the laminator.

[0081] Due to the deformation of the edges and corners of large-format double-glazed glass, when two pieces of glass are stacked, the edge gap, glass leg curling, and curling control standards are <0.5mm, and the local wave bend control standard is <0.5mm. Therefore, when two pieces of glass are stacked, the edges and local openings will have a glass opening area with a depth of 0.5-1mm compared to the flat area in the middle.

[0082] Since butyl rubber itself has low strength and poor adhesion to glass, stress areas will be formed in these areas due to the high rigidity of the glass after lamination, which will cause tensile stress on the butyl rubber. These areas will easily cause delamination of the butyl rubber inside the adhesive or delamination of the butyl rubber and the glass interface.

[0083] Therefore, to solve the above problem, the butyl rubber layer frame is used, and the thickness of the butyl rubber layer is set to be greater than or equal to the sum of the glass deformation depth and the thickness of the adhesive film at the edge of the component. For example, in this embodiment, the thickness of the butyl rubber layer is 1.5mm, and the thickness of the adhesive film at the edge is about 0.5-0.7mm.

[0084] In summary, the high-efficiency waterproof photovoltaic module lamination method and lamination frame of the present invention have the following advantages:

[0085] 1. Aiming at the locations prone to glue sticking and the reasons for glue opening and debonding, the lamination tooling structure is optimized to increase the actual effective distance of butyl rubber after lamination and the consistency of water blocking distance at each location.

[0086] 2. For the lamination quality of butyl rubber after lamination, an automatic non-destructive testing method is used to monitor the lamination quality in real time.

[0087] For those skilled in the art, the above invention disclosure is intended only as an example and does not constitute a limitation of this application. Although not explicitly stated herein, those skilled in the art may make various modifications, improvements, and amendments to this application. Such modifications, improvements, and amendments are suggested in this application and remain within the spirit and scope of the exemplary embodiments of this application.

[0088] At the same time, this application uses specific terms to describe the embodiments of this application. For example, "one embodiment," "an embodiment," and / or "some embodiments" refer to a certain feature, structure, or characteristic related to at least one embodiment of this application. Therefore, it should be emphasized and noted that "one embodiment," "an embodiment," or "an alternative embodiment" mentioned twice or multiple times in different locations in this specification does not necessarily refer to the same embodiment. In addition, certain features, structures, or characteristics in one or more embodiments of this application may be appropriately combined.

[0089] Similarly, it should be noted that, in order to simplify the description of the present disclosure and thus facilitate understanding of one or more embodiments of the invention, the foregoing descriptions of the embodiments of the present disclosure sometimes combine multiple features into a single embodiment, figure, or description thereof. However, this disclosure method does not mean that the subject matter of the present disclosure requires more features than those recited in the claims. In fact, the features of an embodiment may be fewer than the total features of a single embodiment disclosed above.

[0090] Although specific embodiments of the present invention have been described above, those skilled in the art will appreciate that these are merely illustrative and that the scope of the present invention is defined by the appended claims. Those skilled in the art may make various changes or modifications to these embodiments without departing from the principles and essence of the present invention, and such changes and modifications are intended to fall within the scope of the present invention.

Claims

1. A high-efficiency waterproof photovoltaic module lamination method, characterized in that: The high-efficiency waterproof photovoltaic module lamination method comprises the following steps: S1. Glass loading: the front glass flows into the assembly line; film cutting: the precisely cut glass is laid on the glass; battery welding: the battery strings are connected; S2. Lamination: Lay the battery string on the front film, and then lay the precisely cut back film on the battery string; back film is precisely cut; S3, glue coating, apply adhesive around the front glass; glass bonding, cover the back perforated glass on the laminated front glass; S4, automatic hole plugging, inject glue into the back glass hole to complete the sealing of the lead wire; S5. Edge sealing: edge sealing is performed around the laminated photovoltaic modules; butyl rubber laminating frames are used for lamination, and the photovoltaic modules are heated and bonded; The butyl rubber laminated frame includes at least one set of first sides, at least one set of second sides, and a plurality of corner connectors. The first sides and the second sides are sequentially connected by the corner connectors to form a frame structure. The length of the first side is greater than the length of the second side, and the thickness of the first side is different from the thickness of the second side. The thickness of the corner connector is gradually changed along the direction of the first side and the second side. The thickness of the butyl adhesive used in the butyl adhesive layer frame is greater than or equal to the sum of the glass deformation depth and the thickness of the adhesive film at the edge of the component; S6, pressurized cooling, heating the laminated photovoltaic modules, applying pressure and rapidly cooling them; S7. Perform non-destructive testing on photovoltaic modules to determine whether the adhesive lamination meets the quality standards; The step S7 includes: the non-destructive testing utilizes the density difference of each material to cause the difference in the penetration of radiation, ultrasound or eddy current, thereby forming an image by the signal difference; Then, the contrast differences at various positions of the image are compared to obtain information on whether the adhesive defect is at the edge or middle position of the module, thereby determining whether the photovoltaic module meets the quality requirements.

2. The high-efficiency waterproof photovoltaic module lamination method according to claim 1, characterized in that: The viscose is butyl rubber.

3. The high-efficiency waterproof photovoltaic module lamination method according to claim 1, characterized in that: The step S4 includes: after the back glass is laminated, injecting water-blocking glue around and in the middle of the lead wires through the holes of the back glass using glue injection equipment, so that the glue fully fills the glass holes and forms good contact with the lead wires and the glass.

4. The high-efficiency waterproof photovoltaic module lamination method according to claim 1, characterized in that: The non-destructive testing methods include radiographic testing, ultrasonic testing and eddy current testing.

5. The high-efficiency waterproof photovoltaic module lamination method according to claim 4, characterized in that: In step S7, image recognition software is used to compare the contrast differences of various positions in the image; the undesirable conditions include glue sticking, bubbles, and glue peeling.

6. The high-efficiency waterproof photovoltaic module lamination method according to claim 1, characterized in that: After step S7, the following steps are further included: S8, framing and junction box installation, installing the junction box and frame for the inspected components; S9, curing, curing in a curing room with a certain temperature and humidity; testing and cleaning, cleaning the photovoltaic modules and performing power testing; S 10 , packaging, packaging of photovoltaic modules.

7. The high-efficiency waterproof photovoltaic module lamination method according to claim 1, characterized in that: The thickness of the second side is 8 mm, and the thickness of the first side is 6 mm.

8. The high-efficiency waterproof photovoltaic module lamination method according to claim 1, characterized in that: The thickness of the corner connector is 2 mm to 4 mm thicker than the thickness of the first side.

9. The high-efficiency waterproof photovoltaic module lamination method according to claim 1, characterized in that: The length of the portion where the corner connector is connected to the first side is 300 mm to 800 mm.

10. The high-efficiency waterproof photovoltaic module lamination method according to claim 9, characterized in that: The length of the portion where the corner connector is connected to the second side is 20 mm to 30 mm.

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