A photovoltaic module and a method of manufacturing the same

Abstract

The application discloses a photovoltaic module and a preparation method thereof. The photovoltaic module can include a junction box, a cover plate, a front encapsulation adhesive film, a cell array, a back encapsulation adhesive film and a back plate which are arranged in a stack. The cell array includes a vertically placed middle busbar and cell strings which are arranged on both sides of the middle busbar and are electrically connected with the middle busbar. The back plate includes a first slot structure corresponding to the middle busbar and a first connecting line lead-out hole arranged on the first slot structure. The middle busbar is embedded in the first slot structure. One end of the middle busbar extends out of the first slot structure from the first connecting line lead-out hole and is electrically connected with the junction box. The photovoltaic module provided by the scheme can avoid the middle busbar from generating pressure on the cell piece and reduce the risk of hidden cracks.

Description

Technical Field

[0001] This invention relates to a photovoltaic module and its manufacturing method. Background Technology

[0002] High-density photovoltaic modules are increasingly favored by the market because they have a smaller module area, which can save the amount of main materials required for the module (such as frames, cover plates, encapsulants and backsheets) as well as the amount of power station components such as brackets, land and cables.

[0003] Currently, the main methods to increase the density and reduce the size of photovoltaic modules are to reduce the spacing between solar cells and to stack busbars on top of the cells. On the one hand, the production process of photovoltaic modules with busbars stacked on top of the cells requires significant changes to the existing photovoltaic module production process and is quite cumbersome. On the other hand, stacking busbars on top of the cells puts additional pressure on the cells, making the photovoltaic modules more susceptible to microcracks. Summary of the Invention

[0004] In view of this, the present invention provides a photovoltaic module and a method for manufacturing the same. The photovoltaic module can be manufactured using existing photovoltaic module manufacturing processes without changing the existing photovoltaic module manufacturing processes, and the operation is relatively simple. Moreover, the photovoltaic module provided by the embodiments of the present invention avoids the pressure of the busbar on the solar cells, thereby reducing the risk of microcracks in the photovoltaic module.

[0005] To solve the above-mentioned technical problems, the present invention provides the following technical solution:

[0006] In a first aspect, the present invention provides a photovoltaic module, comprising: a junction box, a cover plate, a front encapsulation film, a cell array, a back encapsulation film, and a back sheet, wherein...

[0007] The battery array includes: a vertically placed central busbar and battery strings disposed on both sides of the central busbar and electrically connected to the central busbar;

[0008] The back plate includes a first groove structure corresponding to the intermediate busbar and a first connecting wire lead-out hole disposed on the first groove structure.

[0009] The intermediate busbar is embedded within the first groove-shaped structure;

[0010] One end of the intermediate busbar extends from the first connecting wire outlet hole into the first groove-shaped structure and is electrically connected to the junction box.

[0011] In a second aspect, embodiments of the present invention provide a method for preparing a photovoltaic module according to the first aspect embodiment, comprising:

[0012] Step 1: Lay out the cover plate, front sealing film, arranged battery strings, vertically placed middle busbar and edge busbar in sequence;

[0013] Step 2: Establish electrical connections between the intermediate busbar and the edge busbar and the battery string;

[0014] Step 3: Sequentially stack and cover the battery string with a back sealing film and a back plate, wherein the intermediate busbar is embedded in the first groove structure included in the back plate, and one end of the intermediate busbar extends out of the first groove structure from the first connecting wire lead-out hole included in the back plate to form a stacked component, wherein the first groove structure is a protruding structure relative to the outer side of the back plate.

[0015] Step 4: Laminate the laminated components;

[0016] Step 5: Assemble the mounting slot of the junction box onto the raised structure, and slide the junction box in one direction to make the electrical connection part of the junction box contact one end of the corresponding intermediate busbar extending out of the first slot structure, and weld it.

[0017] The technical solution of the first aspect of the above invention has the following advantages or beneficial effects:

[0018] In the photovoltaic module provided by the embodiments of the present invention, the battery strings on both sides are connected by a vertically placed intermediate busbar, and the first groove structure set in the back plate cooperates with the intermediate busbar to ensure the sealed encapsulation of the photovoltaic module. Compared with the design of laminating the intermediate busbar to the edge of the battery cell to reduce the size of the photovoltaic module, the photovoltaic module provided by the embodiments of the present invention can be manufactured using the existing photovoltaic module manufacturing process without changing the existing photovoltaic module manufacturing process, and the operation is relatively simple. Moreover, the photovoltaic module provided by the embodiments of the present invention avoids the busbar from putting pressure on the battery cell, reducing the risk of microcracks in the photovoltaic module. Attached Figure Description

[0019] Figure 1 This is a schematic diagram of a first cross-sectional structure of a photovoltaic module according to an embodiment of the present invention;

[0020] Figure 2 This corresponds to the embodiments of the present invention. Figure 1 The image shows an exploded view of part of the photovoltaic module structure.

[0021] Figure 3 This is a schematic diagram of a second cross-sectional structure of a photovoltaic module according to an embodiment of the present invention;

[0022] Figure 4 This corresponds to the embodiments of the present invention. Figure 3 The image shows an exploded view of part of the photovoltaic module structure.

[0023] Figure 5 This is a schematic diagram of a third cross-sectional structure of a photovoltaic module according to an embodiment of the present invention;

[0024] Figure 6 This corresponds to the embodiments of the present invention. Figure 5 The image shows an exploded view of part of the photovoltaic module structure.

[0025] Figure 7 This is a schematic diagram of the fourth cross-sectional structure of a photovoltaic module according to an embodiment of the present invention;

[0026] Figure 8 This corresponds to the embodiments of the present invention. Figure 7 The image shows an exploded view of part of the photovoltaic module structure.

[0027] Figure 9 This is a schematic diagram of a fifth cross-sectional structure of a photovoltaic module according to an embodiment of the present invention;

[0028] Figure 10 This corresponds to the embodiments of the present invention. Figure 9 The image shows an exploded view of part of the photovoltaic module structure.

[0029] Figure 11 This is a schematic diagram of a sixth cross-sectional structure of a photovoltaic module according to an embodiment of the present invention;

[0030] Figure 12 This corresponds to the embodiments of the present invention. Figure 8 A schematic diagram of the three-dimensional structure of a photovoltaic module;

[0031] Figure 13 This is a three-dimensional structural diagram of a junction box applied to a photovoltaic module according to an embodiment of the present invention;

[0032] Figure 14 This is a schematic diagram of the contact surface between the junction box and the photovoltaic module according to an embodiment of the present invention;

[0033] Figure 15 This is a side view showing the relative relationship between the junction box and the busbar according to an embodiment of the present invention;

[0034] Figure 16 This is a side view of a junction box according to an embodiment of the present invention;

[0035] Figure 17 This is a schematic diagram of the side cross-sectional structure of the junction box according to an embodiment of the present invention;

[0036] Figure 18 This is a schematic diagram of the routing of the busbar lead-out portion connected to the same junction box according to an embodiment of the present invention;

[0037] Figure 19 This is a schematic diagram of the main process of a photovoltaic module manufacturing method according to an embodiment of the present invention;

[0038] Figure 20 This is a schematic diagram of the structural changes corresponding to step S1902 in the method for preparing a photovoltaic module according to an embodiment of the present invention;

[0039] Figure 21 This is a schematic diagram of the lamination tooling structure according to an embodiment of the present invention.

[0040] The attached figures are labeled as follows:

[0041] 10-Cover plate; 20-Front encapsulation film; 30-Battery array; 31-Intermediate busbar; 32-Battery string; 33-Edge busbar; 40-Back encapsulation film; 41-Second groove structure; 42-Fourth groove structure; 44-Second transparent conductive film layer; 50-Back plate; 51-First groove structure; 52-First connecting wire lead-out hole; 53-Third groove structure; 60-Junction box; 61-Mounting groove; 62-Electrical connection part; 63-Busbar connection groove; 64-Separated part; 65-Through hole; 66-Housing; 100-Lamination tooling. Detailed Implementation

[0042] The layered arrangement involved in the embodiments of the present invention generally refers to one structure being stacked on top of or below another structure, and the structure may be in direct or indirect contact with the main surface of the other structure. Direct contact generally means that the one structure is directly formed, grown, or deposited on the upper or lower surface of the other structure; indirect contact generally means that other functional layers are formed between the one structure and the other structure.

[0043] In the embodiments of this invention, the upper surface or front side of a structure generally refers to a surface or a portion thereof that faces sunlight or is upward during the use of the solar cell; the lower surface or back side of a structure generally refers to a surface or a portion thereof that faces away from sunlight or is downward during the use of the solar cell. The upper and lower surfaces, or the front and back sides, of a structure are opposite to each other.

[0044] In the embodiments of this invention, the terms "first," "second," "third," and "fourth," etc., are used to distinguish different structures or components or different positions of the same structure, and are not intended to limit the number or order of structures or components. For example, the first groove structure and the second groove structure in the embodiments of this invention are generally used to distinguish groove structures located in different positions and / or with certain structural differences. As another example, the first connecting wire lead-out hole and the second connecting wire lead-out hole are used to distinguish connecting wire lead-out holes located in different positions.

[0045] To address the limitations of existing photovoltaic modules in terms of busbars for increasing module density and reducing form factor, this invention provides a novel photovoltaic module structure, a junction box for the photovoltaic module, and a method for manufacturing the photovoltaic module.

[0046] in, Figures 1 to 7 as well as Figures 9 to 11 This diagram shows a cross-sectional view of a portion of the structure of a photovoltaic module provided in an embodiment of the present invention. Figure 8 and Figure 12 A three-dimensional structural schematic diagram of a photovoltaic module provided in an embodiment of the present invention is shown; Figures 13 to 17 A partial structural schematic diagram of the junction box provided in an embodiment of the present invention is shown; Figure 18 This diagram illustrates the relative relationship between the two busbar leads connected to the same junction box, as provided in an embodiment of the present invention.

[0047] like Figures 1 to 12 As shown, an embodiment of the present invention provides a photovoltaic module. The photovoltaic module may include:

[0048] The junction box 60, and the stacked cover plate 10, front sealing film 20, battery array 30, back sealing film 40, and back plate 50, wherein,

[0049] The battery array 30 includes: a vertically placed central busbar 31 and battery strings 32 disposed on both sides of the central busbar 31 and electrically connected to the central busbar 31;

[0050] The backplate 50 includes a first groove structure 51 corresponding to the intermediate busbar 31 and a first connecting wire lead-out hole 52 disposed on the first groove structure 51;

[0051] The intermediate busbar 31 is embedded in the first groove-shaped structure 51;

[0052] One end of the intermediate busbar 31 extends from the first connecting wire lead-out hole 52 into the first groove structure 51 and is electrically connected to the junction box 60.

[0053] The intermediate busbar 31 is generally a cuboid or approximately cuboid structure. A vertically placed intermediate busbar 31 typically refers to two opposing first surfaces (which include the long side and have a smaller area) that face the cover plate 10 and the back plate 50, respectively. The two opposing second surfaces (which include the long side and have the largest area, i.e., the two largest main surfaces) correspond to the battery strings 32 located on either side of the intermediate busbar 31. The intermediate busbar 31 can be a conventional intermediate busbar 31 (in the prior art, the two largest main surfaces (i.e., the second surfaces) of the intermediate busbar 31 generally correspond to the cover plate 10 and the back plate 50, while the two opposing first surfaces correspond to the battery strings 32 located on either side of the intermediate busbar 31). However, in the case where the intermediate busbar 31 used in the prior art is directly selected in the embodiment of the present invention, compared with the prior art, the two main surface positions of the vertically placed intermediate busbar 31 are rotated by 90 degrees or 270 degrees.

[0054] The use of the vertically placed intermediate busbar 31 greatly reduces the area occupied by the intermediate busbar 31 on the front encapsulation film 20, thereby reducing the spacing between the battery strings 32 located on both sides of the intermediate busbar 31, reducing the area of ​​the photovoltaic module, and increasing the density of the photovoltaic module.

[0055] In addition, by selecting a busbar of existing size as the intermediate busbar 31, the current collection capacity of the intermediate busbar 31 is guaranteed, while the manufacturing process does not require major changes, making the manufacturing process universal and not increasing the cost of photovoltaic modules.

[0056] In addition, the photovoltaic module provided in this embodiment of the invention is a novel structure. Compared with the design of pressing the middle busbar 31 onto the edge of the cell to reduce the size of the photovoltaic module, the photovoltaic module provided in this embodiment of the invention can be manufactured using the existing photovoltaic module manufacturing process without changing the existing photovoltaic module manufacturing process. The operation is relatively simple. Moreover, the photovoltaic module provided in this embodiment of the invention avoids the busbar from putting pressure on the cell, reducing the risk of microcracks in the photovoltaic module.

[0057] Specifically, regarding the aforementioned intermediate busbar 31, in the thickness direction of the photovoltaic module, the thickness of the intermediate busbar 31 is greater than the thickness of the battery string 32; the width of the intermediate busbar 31 in the extension direction of the battery string 32 is less than or equal to the thickness of the battery cells in the battery string 32, thereby reducing the spacing between the battery strings 32 disposed on both sides of the intermediate busbar 31. In other words, in the photovoltaic module provided in this embodiment of the invention, the battery strings 32 on both sides are connected by a vertically placed intermediate busbar 31, and the width of the intermediate busbar 31 in the extension direction of the battery string 32 is less than or equal to the thickness of the battery cells in the battery string 32. The intermediate busbar 31 is embedded in the first groove structure 51 of the back plate 50, thereby reducing the spacing between the battery strings 32 disposed on both sides of the intermediate busbar 31, thus reducing the area of ​​the photovoltaic module. In addition, by designing that the thickness of the intermediate busbar 31 is greater than the thickness of the battery string 32 in the thickness direction of the photovoltaic module, the current collection capacity of the intermediate busbar 31 can be guaranteed.

[0058] In this structure, the edge cells of the battery string 32 near the central busbar 31 are welded to the corresponding side of the central busbar 31 via interconnecting strips. In other words, the edge cells near the central busbar 31 are electrically connected to the second surface of the central busbar 31 via interconnecting strips, ensuring sufficient contact between the interconnecting strips and the central busbar 31. Furthermore, this structure allows the central busbar 31 to be held stable when vertically positioned by the battery strings 32 located on both sides of it.

[0059] To accommodate the vertically placed intermediate busbar 31, this embodiment of the invention provides back-encapsulating films 40 and backsheets 50 with various structures. These back-encapsulating films 40 and backsheets 50, in conjunction with the vertically placed intermediate busbar 31, yield photovoltaic modules with various structures. Figures 1 to 12 The photovoltaic module shown is only a partial example of its structure. It is worth noting that any other photovoltaic module based on the embodiments of the present invention, and... Figures 1 to 12 Photovoltaic modules obtained by deforming the photovoltaic module structure shown are also within the scope of protection of this application.

[0060] The main difference between the various backplate 50 structures lies in the relative relationship between the first groove structure and the main surface of the backplate 50. Specifically, this embodiment of the invention provides two backplate 50 structures that match the vertically placed intermediate busbar 31.

[0061] Among them, such as Figures 1 to 4 , Figure 9 and Figure 10As shown, the first type of backplate 50 structure includes a first groove-shaped structure 51 confined within the backplate 50. This first type of backplate 50 structure can be obtained by directly slotting an existing backplate. The side of the first type of backplate 50 structure away from the battery array 30 is a planar structure. Based on this, the thickness of the first type of backplate 50 structure provided in this embodiment of the invention is generally 5 to 9 mm. For example, the thickness of the first type of backplate 50 structure can be 5 mm, 6 mm, 7 mm, 8 mm, 9 mm, etc. In addition, in order to ensure the waterproofness of the first type of backplate 50 structure, the thickness of the side of the first groove-shaped structure 51 away from the intermediate busbar 31 is generally not less than 0.5 mm.

[0062] Among them, such as Figures 5 to 8 , Figure 11 and Figure 12 As shown, the second type of backsheet 50 structure includes a first groove structure 51, which is a protrusion on one side of the main surface relative to the thickness direction of the backsheet 50. The opening of this protrusion structure is located on the other side of the thickness direction of the backsheet 50. Wherein, in this backsheet 50 applied to a photovoltaic module, the side of the backsheet 50 with the protrusion structure in the thickness direction is the outer side of the backsheet 50. For this second type of backsheet 50 structure, the thickness of other areas of the backsheet 50, except for the area where the first groove structure 51 is located, can be a conventional thickness.

[0063] In this context, the outer side of a structure generally refers to the side of the structure away from the cell array 30 in the thickness direction of the photovoltaic module.

[0064] Furthermore, regardless of whether it is the first groove structure 51 of the first type of backplate 50 structure or the first groove structure 51 of the second type of backplate 50 structure, the two ends of the first groove structure 51 can be open or closed, and the user can choose according to the requirements. In addition, the groove dimensions (groove width, groove length, groove height) of the first groove structure 51 can be controlled according to the requirements.

[0065] Furthermore, the back sealing film 40 can also have two structures that match the vertically placed intermediate busbar 31. For example, Figure 2 and Figure 6 As shown, the first type of back-sealing film 40 structure can be a planar back-sealing film 40 disposed on both sides of the vertically placed intermediate busbar 31. For example... Figure 4 and Figure 8 As shown, the second type of back-sealing film 40 structure may have a second groove structure 41 provided in the middle region of the back-sealing film 40, wherein the second groove structure 41 is a protruding structure relative to the outer side of the back-sealing film 40. The second groove structure 41 is used to accommodate a portion of the middle busbar 31.

[0066] The two backplate 50 structures that cooperate with the vertically placed intermediate busbar 31 and the two back sealing film 40 structures that cooperate with the vertically placed intermediate busbar 31 can be combined arbitrarily.

[0067] Specifically, the first combination structure of the backplate 50 and the back sealing film 40 is as follows: Figure 1 and Figure 2 As shown. The first combined structure is a combination of the first backplate 50 structure and the first back-encapsulating film 40 structure. In this first combined structure, the intermediate busbar 31 is directly embedded in the first groove structure 51 of the backplate 50. During the lamination process, the back-encapsulating film 40, which is disposed on both sides of the intermediate busbar 31, can flow into the gap between the side of the intermediate busbar 31 and the side of the first groove structure 51 to achieve the purpose of sealing the battery string 32 in the battery array 30. In addition, by the back-encapsulating film 40 flowing into the gap between the side of the intermediate busbar 31 and the side of the first groove structure 51, the intermediate busbar 31 can be further stabilized, ensuring that the relative position of the battery string 32 and the intermediate busbar 31 is relatively stable, thereby ensuring that the battery string 32 and the intermediate busbar 31 form a stable electrical connection.

[0068] Specifically, the second combination structure of the backplate 50 and the back sealing film 40 is as follows: Figure 3 and Figure 4 As shown. The second combined structure is a combination of the first backplate 50 structure and the second back-encapsulating film 40 structure. In this second combined structure, the intermediate busbar 31 is embedded in the second groove structure 41 of the second back-encapsulating film 40 structure. Then, the protruding portion of the intermediate busbar 31 and the second groove structure 41 is embedded in the first groove structure 51 of the backplate 50. During the lamination process, the second groove structure 41 partially isolates the first groove structure 51 from the intermediate busbar 31, avoiding damage to the intermediate busbar 31 during the lamination process and enabling better sealing of the battery array 30.

[0069] Specifically, the third combination structure of the backplate 50 and the back sealing film 40 is as follows: Figure 5 and Figure 6 As shown. The third combined structure is a combination of the second backplate 50 structure and the first back-encapsulating film 40 structure. Regarding the second backplate 50 structure: the first grooved structure 51 is a raised structure relative to the outer side of the backplate 50; correspondingly, the first connecting wire lead-out holes 52 are respectively located on both sides of the raised structure. Regarding this third combined structure, during the lamination process, the back-encapsulating film 40 located on both sides of the intermediate busbar 31 is cast between the side of the first grooved structure 51 and the side of the intermediate busbar 31 to achieve the purpose of sealing the battery string 32.

[0070] Specifically, the fourth combination structure of the backplate 50 and the back sealing film 40 is as follows: Figure 7 and Figure 8 As shown. The fourth combination structure is a combination of the second backplate 50 structure and the second back-encapsulating film 40 structure. Regarding the second backplate 50 structure: the first groove-shaped structure 51 is a raised structure relative to the outer side of the backplate 50; the first connecting wire lead-out holes 52 are respectively located on both sides of the raised structure. Correspondingly, as... Figure 7 and Figure 8 As shown, the second type of back sealing film 40 structure includes a second groove structure 41 corresponding to the intermediate busbar 31 and a second connection wire lead-out hole (not shown in the figure) provided on the second groove structure 41 corresponding to the first connection wire lead-out hole 52. For this fourth combination structure, the back sealing film 40 enters between the first groove structure 51 and the intermediate busbar 31 to better seal the battery array 30.

[0071] In the four combined structures described above, the portion of the back sealing film 40 corresponding to the intermediate busbar 31 is embedded within the first groove structure 51. The difference lies in the following: in the second and fourth combined structures, the second groove structure 41 included in the back sealing film 40 completely fills the space between the first groove structure 51 and the intermediate busbar 31 to achieve the purpose of sealing the battery array 30. In the first and third combined structures, the back sealing film 40 only partially fills the gap between the side of the first groove structure 51 and the side of the intermediate busbar 31, cooperating with the intermediate busbar 31 to achieve the purpose of sealing the battery string 32.

[0072] Understandably, for the first and third combined structures described above, the width of the first groove structure 51 is basically the same as the thickness of the intermediate busbar 31; the depth of the first groove structure 51 is basically the same as the value obtained by subtracting the thickness of the battery cell and the thickness of the back sealing film 40 from the width of the intermediate busbar 31. For the second and fourth combined structures described above, the width and depth of the first groove structure 51 must be able to accommodate the intermediate busbar 31 and the second groove structure 41. The specific dimensions of the first groove structure 51 can be adjusted according to the designed dimensions of the second groove structure 41 and the intermediate busbar 31.

[0073] In other words, in the second and fourth combinational structures mentioned above, such as Figure 3 , Figure 4 , Figure 7 and Figure 8As shown, the back-sealing adhesive film 40 includes a second groove structure 41 corresponding to the intermediate busbar 31 and a second connecting wire lead-out hole (not shown in the figure) disposed on the second groove structure 41 corresponding to the first connecting wire lead-out hole 52; the second groove structure 41 is embedded in the first groove structure 51; the intermediate busbar 31 is embedded in the second groove structure 41; one end of the intermediate busbar 31 extends from the second connecting wire lead-out hole and the first connecting wire lead-out hole 52 out of the first groove structure 51.

[0074] Furthermore, in the structure of the photovoltaic module provided in this embodiment of the invention, the cell array 30 further includes: a vertically placed edge busbar 33 connected in series with the cell string 32; as shown Figures 9 to 11 As shown, the backsheet 50 also includes a third groove structure 53 corresponding to the edge busbar 33, wherein the edge busbar 33 is embedded in the third groove structure 53. That is to say, compared with the edge busbars of existing photovoltaic modules, the edge busbar 33 in the photovoltaic module provided in this embodiment of the invention can also be placed vertically.

[0075] Based on the aforementioned vertically placed edge confluence zone 33, such as Figures 9 to 11 As shown, in the thickness direction of the photovoltaic module, the thickness of the edge busbar 33 is greater than the thickness of the cell string 32; the width of the edge busbar 33 in the extension direction of the cell string 32 is less than or equal to the thickness of the cell in the cell string 32; the edge busbar 33 is embedded in the third groove structure 53. Making the thickness of the edge busbar 33 greater than the thickness of the cell string 32 (i.e., the thickness of the cell in the cell string 32) better seals the photovoltaic module. During subsequent use of the photovoltaic module, it can better prevent rainwater from entering the photovoltaic module from the side. Even if the amount of encapsulating film at the edge of the photovoltaic module is relatively small or aging occurs, this design of the edge busbar 33 can still effectively prevent moisture erosion.

[0076] The vertically placed edge busbar 33 can be obtained by rotating the placement direction of the edge busbar used in the prior art by 90 degrees or 270 degrees. Alternatively, the dimensions of the edge busbar 33 in the thickness direction of the photovoltaic module and the dimensions in the extension direction of the cell string 32 can be redesigned.

[0077] Understandably, for the structure of the battery array 30 including the vertically placed edge busbar 33 and the backplate 50 including the third groove structure 53, the third groove structure 53 corresponding to the edge busbar 33 in the backplate 50 can be applied to the four combined structures formed by the backplate 50 and the back encapsulation film 40 in the above embodiments to form a new photovoltaic module structure. Figure 9 and Figure 10 This is merely an illustrative example of the application of the third groove-shaped structure 53 corresponding to the edge busbar 33 to the above-mentioned... Figure 1 and Figure 2 The photovoltaic module with a new structure is formed after the first combination structure shown; Figure 11 An exemplary illustration shows the application of the third groove structure 53 to the above. Figure 5 and Figure 6 The third combination structure shown creates a new photovoltaic module structure. Based on this, those skilled in the art can understand how to apply this third groove structure 53 to the second and fourth combination structures, which will not be elaborated further here.

[0078] Furthermore, in order to better meet the mutual coordination of the third groove structure 53 of the aforementioned edge busbar 33 structure, back sealing film 40, and backsheet 50 structure, and to facilitate the control of photovoltaic module assembly, lamination, and other processes, such as... Figures 9 to 11 As shown, the back-sealing film 40 includes a fourth groove structure 42 corresponding to the edge busbar 33; the fourth groove structure 42 is embedded within the third groove structure 53; the edge busbar 33 is embedded within the fourth groove structure 42. Through the design of this fourth groove structure 42, in conjunction with the edge busbar 33, on the one hand, the fourth groove structure 42 can stabilize the edge busbar 33; on the other hand, the fourth groove structure 42 can better encapsulate the edge of the photovoltaic module, preventing moisture from intruding from the edge of the photovoltaic module.

[0079] It is worth noting that the inner bottom surface (i.e. the side facing the busbar) of the first groove structure 51, the second groove structure 41, the third groove structure 53 and the fourth groove structure 42 are shaped to match the shape of the backlight surface of the busbar.

[0080] For photovoltaic modules that include the first type of backsheet 50 structure, the junction box 60 can be a directly selected existing junction box.

[0081] Furthermore, in order to meet the requirements of the second type of backsheet 50 structure (i.e., a backsheet 50 structure with a protruding structure on the outer side) and to enable the junction box to better fit the backsheet 50, the photovoltaic module provided in this embodiment of the invention, such as... Figures 12 to 17 As shown, the junction box 60 included in the photovoltaic module may include: a mounting groove 61 that mates with the protruding structure, an electrical connection portion 62 disposed on both sides of the mounting groove 61, and a diode module (not shown in the figure) electrically connected to the electrical connection portion 62.

[0082] The mounting groove 61 fits into the protruding structure;

[0083] For two adjacent intermediate busbars 31 connected to the same junction box 60,

[0084] One end of a middle busbar 31 is electrically connected to an electrical connection part 62 on one side of the mounting groove;

[0085] One end of the other intermediate busbar 31 is electrically connected to the electrical connection part 62 on the other side of the mounting groove.

[0086] In addition to two electrical connection portions 62, the junction box 60 also includes a diode module. The two electrical connection portions 62 are electrically connected to the positive and negative terminals of the diode module, respectively. The two electrical connection portions 62 can be electrode connection pieces disposed on the junction box 60, and these electrode connection pieces can be connected to one end of the busbar 31 by soldering. Furthermore, the two electrical connection portions 62 are two electrode connection pieces, located on opposite sides of the protruding structure and parallel to each other.

[0087] The mounting groove 61 fits into the raised structure, so that... Figure 14 The main surface of the junction box 60 shown is attached to the backlight surface of the back panel to ensure the stability of the junction box 60 and to achieve the purpose of sealing the junction box 60.

[0088] For two adjacent intermediate busbars 31 connected to the same junction box 60, the two ends of the first groove structure 51 extend in the same direction and are consistent with the extension direction of the first groove structure 51 of the protruding structure.

[0089] like Figure 18 As shown, for two adjacent intermediate busbars 31 connected to the same junction box 60, one end of the first intermediate busbar 31 extending from the first groove structure 51 is bent towards the other end (i.e., one end of the first intermediate busbar 31 extending from the first groove structure 51 is folded back); one end of the second intermediate busbar 31 extending from the first groove structure 51 extends towards the direction of the first intermediate busbar 31. By ensuring that the photovoltaic module extension portions of the two adjacent intermediate busbars 31 connected to the same junction box 60 all face the same side, subsequent installation of the junction box 60 can be achieved by first snapping the junction box 60 onto the protruding structure, and then sliding the junction box 60 in one direction to make contact between the intermediate busbar 31 and the electrical connection portion 62 of the junction box 60, facilitating the installation of the intermediate busbar 31 into the junction box 60.

[0090] In cases where the photovoltaic modules extending from the two adjacent intermediate busbars 31 connected to the same junction box 60 are all facing the same side, after the junction box 60 is installed onto the raised structure, the photovoltaic modules extending from the two adjacent intermediate busbars 31 can be located inside the housing of the junction box 60.

[0091] For example, targeting Figure 18 The structure shown depicts two adjacent intermediate busbars 31. The junction box 60 can be initially mounted on the raised structure, wherein the two electrical connection portions of the junction box 60 are located... Figure 18The right side of the two adjacent intermediate busbars 31 shown can subsequently slide along direction D on the protruding structure so that the intermediate busbar 31 is installed into the junction box 60, the intermediate busbar 31 contacts the electrical connection part 61, and then a stable electrical connection is formed between the intermediate busbar 31 and the electrical connection part 61 directly by soldering.

[0092] Additionally, the junction box 60 includes two busbar inlets 64 (not shown in the figure) located at one end of the housing, wherein one busbar inlet 64 corresponds to one electrical connection 61, and the other busbar inlet 64 corresponds to another electrical connection 61. One end of the first groove-shaped structure 51 extending from the intermediate busbar 32 contacts the corresponding electrical connection 61 through the busbar inlet 64. With this structure, the junction box 60 can be directly installed on the portion of the protruding structure not occupied by the busbar, and subsequently, by sliding the junction box 60 on the protruding structure, the intermediate busbar 32 passes through the busbar inlet 64 and contacts the electrical connection 61.

[0093] Furthermore, such as Figures 15 to 17 As shown, the junction box 60 further includes: busbar connection slots 63 respectively disposed on both sides of the mounting slot 61, wherein,

[0094] Electrical connection part 62 is disposed in busbar connection groove 63;

[0095] One end of the first groove-shaped structure 51 extending from the intermediate busbar 31 is embedded in the busbar connecting groove 63.

[0096] By setting the busbar connection slot 63, during the movement of the junction box 60, it is convenient to guide the intermediate busbar 31 to move relative to the junction box 60 along the busbar connection slot 63, ensuring that the intermediate busbar 31 is installed accurately, and facilitating the subsequent stabilization of the intermediate busbar 31 in the busbar connection slot 63, avoiding displacement after the intermediate busbar 31 has formed a stable electrical connection with the junction box 60.

[0097] Furthermore, such as Figures 13 to 17 As shown, the junction box 60 further includes two separate parts 64. The diode module included in the junction box 60 is disposed in one separate part 64, and the diode module is electrically connected to two electrical connection parts 62. The two separate parts 64 are detachably connected and form a mounting groove 61. The two electrical connection parts 62 are respectively disposed in the two separate parts 64. This design of the two separate parts 64 facilitates the installation of the junction box 60. Furthermore, if the diode module malfunctions, it can be replaced directly by replacing a new separate part 64, facilitating subsequent maintenance of the junction box 60.

[0098] The detachable connection of the two separate parts 64 means that the two separate parts 64 can be connected by means of disassembly, such as threaded screws or expansion screws.

[0099] Furthermore, such as Figure 14 As shown, the junction box 60 further includes two through holes 65 located at both ends of the junction box 60 housing. The two through holes 65 correspond to the mounting groove 61, and the line connecting the two through holes 65 is aligned with the extending direction of the mounting groove 61. The through holes 65 allow the junction box 60 housing to be securely fitted onto the protruding structure, thus better stabilizing the junction box 60.

[0100] Furthermore, such as Figure 14 As shown, the junction box 60 may further include a housing 66 disposed around the two separate portions 64, wherein the housing 66 is used to hold sealant. This is to better secure the junction box 60 and to better seal the junction box 60.

[0101] Furthermore, the junction box further includes a sealing cover (not shown in the figure), wherein the sealing cover fits onto the housing 66 to seal the two separate parts 64 within the space enclosed by the housing 66 and the sealing cover 67, thereby further sealing the junction box 60.

[0102] The photovoltaic module provided in this embodiment of the invention has a more stable connection between the interconnect strip and the intermediate bus strip, as well as between the junction box and the intermediate bus strip, resulting in higher photoelectric conversion efficiency and better reliability.

[0103] In addition, the photovoltaic modules provided in this embodiment of the invention are consistent in all their components, and the welding point between the interconnecting strip and the intermediate busbar is located on the side, making the photovoltaic modules more aesthetically pleasing.

[0104] Furthermore, embodiments of the present invention provide a method for preparing the above-mentioned photovoltaic module, such as... Figure 19 As shown, the preparation method may include the following steps:

[0105] Step S1901: Sequentially lay out the cover plate 10, the front sealing film 20, the arranged battery strings 32, the vertically placed middle busbar 31 and the edge busbar 33;

[0106] In this step, a cover plate 10 is first laid, a pre-sealing film 20 is laid on the cover plate 10, and then battery strings 32, vertically placed central busbars 31, and edge busbars 33 are laid on the pre-sealing film 20. The laying order of the battery strings 32, the vertically placed central busbars 31, and the edge busbars 33 can be as follows: first, the battery strings 32 are laid, and then the central busbars 31 and edge busbars 33 are laid according to the position of the battery strings 32.

[0107] Step S1902: Establish electrical connections between the intermediate busbar 31 and the edge busbar 33 and the battery string 32;

[0108] In this battery string, the interconnecting strips of the edge battery cells corresponding to the laying position of the intermediate busbar 31 are in a bent state; accordingly, this step may include: welding the bent interconnecting strips of the edge battery cells to the side of the intermediate busbar 31.

[0109] Specifically, such as Figure 20 As shown, the battery string 32 is first laid on the front encapsulation film 20. Then, the interconnecting strips in the battery string 32 corresponding to the intermediate busbar 31 are bent to form a bent state. Next, the intermediate busbar 31 is placed vertically between the bent interconnecting strips. Finally, the bent interconnecting strips are soldered to the side of the intermediate busbar 31 corresponding to the interconnecting strip. This side has a relatively large area, which allows the interconnecting strip to form a stable electrical connection with the intermediate busbar 31.

[0110] In addition, since the edge bus 33 is a vertically placed structure, the edge interconnecting strip is bent, and then the edge bus 33 is placed vertically. Finally, the interconnecting strip is welded to the side of the vertically placed edge bus 33 corresponding to the interconnecting strip, so as to ensure that the interconnecting strip and the edge bus 33 form a stable electrical connection.

[0111] Step S1903: Sequentially stack and cover the back sealing film 40 and the back plate 50 on the battery string 32, wherein the intermediate busbar 31 is embedded in the first groove structure 51 included in the back plate 50, and one end of the intermediate busbar 31 extends out of the first groove structure 51 from the first connecting wire lead-out hole 52 included in the back plate 50 to form a stacked component.

[0112] For the back sealing film 40 Figure 2 and Figure 6 As shown in the structure, the intermediate busbar 31 can be directly led out from the first connecting wire lead-out hole 52, or the busbar lead-out wire can be electrically connected to the intermediate busbar 31 through the first connecting wire lead-out hole 52.

[0113] In the case where the back packaging film 40 includes a second groove structure 41, a second connecting wire lead-out hole corresponding to the first connecting wire lead-out hole 52 is provided on the second groove structure 41. Then, the intermediate bus 31 can be led out from the first connecting wire lead-out hole 52 and the second connecting wire lead-out hole, or the lead wire of the intermediate bus 31 can be electrically connected to the intermediate bus 31 through the first connecting wire lead-out hole 52 and the second connecting wire lead-out hole.

[0114] Step S1904: Laminate the laminated parts.

[0115] against Figures 1 to 4 , Figure 9 and Figure 10 The structure shown indicates that the lamination tooling used in this step can be directly used from existing lamination tooling. For... Figures 5 to 8 and Figure 11The structure shown, the lamination tooling used in this step is as follows: Figure 20 The laminating fixture 100 shown includes grooves that match the raised structures to prevent damage to the photovoltaic modules during the lamination process.

[0116] As can be seen from the above steps, compared with the existing photovoltaic module manufacturing methods, the photovoltaic module manufacturing method of the present invention requires less modification. The photovoltaic module manufacturing provided by the present invention can be achieved by simply adjusting the existing photovoltaic module manufacturing process. This allows the photovoltaic module provided by the present invention to be manufactured based on existing processes, avoiding various cumbersome operations, making the manufacturing cost controllable, and suitable for large-scale promotion.

[0117] In addition, compared with existing photovoltaic module manufacturing methods, the improvements in the embodiments of the present invention are relatively simple, easy to implement, convenient for mass production, and conducive to the commercialization of photovoltaic modules.

[0118] Furthermore, the first groove structure 51 is a raised structure on the outer side of the back plate 50; the above preparation method also includes: assembling the mounting groove 61 of the junction box 60 onto the raised structure, and by sliding the junction box 60 in one direction, making the electrical connection part 62 of the junction box 60 contact one end of the corresponding intermediate busbar 31 extending out of the first groove structure 51, and welding it.

[0119] Furthermore, embodiments of the present invention also provide, as... Figures 12 to 17 The junction box shown is intended for use with the photovoltaic modules provided in the above embodiments; that is, the junction box is part of the photovoltaic modules. Alternatively, the junction box can also be sold or purchased separately as an independent structure for use in the photovoltaic modules, other equipment, or other components. The structure of the junction box has been described in detail in the above embodiments and will not be repeated here. The above description is only for the purpose of helping to understand the method, structure, and core ideas of the present invention. For those skilled in the art, various improvements and modifications can be made to the present invention without departing from the principles of the invention, and these improvements and modifications also fall within the scope of protection of the claims of the present invention.

Claims

1. A photovoltaic module, characterized in that, include: A junction box (60), a cover plate (10), a front sealing film (20), a battery array (30), a back sealing film (40), and a back plate (50) stacked together, wherein, The battery array (30) includes: a vertically placed central busbar (31) and battery strings (32) disposed on both sides of the central busbar (31) and electrically connected to the central busbar (31); The back plate (50) includes a first groove structure (51) corresponding to the intermediate busbar (31) and a first connecting wire lead-out hole (52) disposed on the first groove structure (51); The intermediate busbar (31) is embedded in the first groove structure (51); One end of the intermediate busbar (31) extends from the first connecting wire lead-out hole (52) out of the first groove structure (51) and is electrically connected to the junction box (60).

2. The photovoltaic module according to claim 1, characterized in that, The back sealing film (40) includes a second groove structure (41) corresponding to the intermediate busbar (31) and a second connection wire lead-out hole provided on the second groove structure (41) corresponding to the first connection wire lead-out hole (52); The second groove structure (41) is embedded in the first groove structure (51); The intermediate busbar (31) is embedded in the second groove structure (41); One end of the intermediate busbar (31) extends from the second connecting line lead-out hole and the first connecting line lead-out hole (52) to form the first groove structure (51).

3. The photovoltaic module according to claim 1 or 2, characterized in that, The first groove structure (51) is a raised structure on the outer side relative to the back plate (50); The first connecting wire lead-out hole (52) is located on both sides of the protrusion structure.

4. The photovoltaic module according to claim 3, characterized in that, The junction box (60) includes: a mounting groove (61) that mates with the protruding structure, an electrical connection portion (62) disposed on both sides of the mounting groove (61), and a diode module electrically connected to the electrical connection portion (62); The mounting groove (61) is fitted into the protruding structure; For two adjacent intermediate busbars (31) connecting the same junction box (60), One end of the intermediate busbar (31) is electrically connected to the electrical connection part (62) on one side of the mounting groove; One end of the other intermediate busbar (31) is electrically connected to the electrical connection part (62) on the other side of the mounting groove.

5. The photovoltaic module according to claim 4, characterized in that, For two adjacent intermediate busbars (31) connecting the same junction box (60), the two ends of the first groove structure (51) extend in the same direction and are consistent with the extension direction of the first groove structure (51) of the protruding structure.

6. The photovoltaic module according to claim 4, characterized in that, The junction box (60) further includes: busbar connection slots (63) respectively disposed on both sides of the mounting slot (61), wherein, The electrical connection part (62) is disposed in the busbar connection groove (63); One end of the first groove structure (51) extending from the intermediate busbar (31) is embedded in the busbar connecting groove (63).

7. The photovoltaic module according to claim 4, characterized in that, The junction box (60) further includes: two separate parts (64), wherein, The junction box (60) includes a diode module disposed in one of the split parts (64), and the diode module is electrically connected to the two electrical connection parts (62); The two separate parts (64) are detachably connected and surround the mounting groove (61); The two electrical connection portions (62) are respectively disposed in the two separate portions (64).

8. The photovoltaic module according to any one of claims 1, 2, and 4 to 7, characterized in that, The battery array (30) further includes: a vertically placed edge busbar (33) connected in series with the battery string; the back plate (50) further includes a third groove structure (53) corresponding to the edge busbar (33); wherein the edge busbar (33) is embedded in the third groove structure (53); or, The battery array (30) further includes: a vertically placed edge busbar (33) connected in series with the battery string; the back plate (50) further includes a third groove structure (53) corresponding to the edge busbar (33); the back sealing film (40) includes a fourth groove structure (42) corresponding to the edge busbar (33); wherein the fourth groove structure (42) is embedded in the third groove structure (53), and the edge busbar (33) is embedded in the fourth groove structure (42).

9. The method for preparing a photovoltaic module according to any one of claims 1 to 8, characterized in that, include: Step 1: Sequentially lay out the cover plate (10), the front sealing film (20), the arranged battery strings (32), the vertically placed middle busbar (31) and the edge busbar (33); Step 2: Establish electrical connections between the intermediate busbar (31) and the edge busbar (33) and the battery string (32); Step 3: Sequentially stack and cover the battery string (32) with back sealing film (40) and back plate (50), wherein the intermediate busbar (31) is embedded in the first groove structure (51) included in the back plate (50), and one end of the intermediate busbar (31) extends out of the first connecting wire lead-out hole (52) included in the back plate (50) to form a stacked component, and the first groove structure (51) is a protruding structure relative to the outer side of the back plate (50); Step 4: Laminate the laminated components; Step 5: Assemble the mounting groove (61) of the junction box (60) onto the protruding structure, and slide the junction box (60) in one direction to make the electrical connection part (62) of the junction box (60) contact one end of the corresponding intermediate busbar (31) extending out of the first groove structure (51), and weld it.

10. The method for preparing a photovoltaic module according to claim 9, characterized in that, The interconnecting strips of the edge cells in the battery string corresponding to the laying position of the intermediate busbar (31) are in a bent state; Step 2 includes welding the folded interconnecting strip of the edge battery cell to the side of the intermediate busbar (31).

Images