Method of manufacturing a photovoltaic module and photovoltaic module

Abstract

This application provides a method for manufacturing a photovoltaic module and a photovoltaic module. The method includes: sequentially stacking a cover plate, a first encapsulating film, solar cells, a second encapsulating film, and a backsheet to form a laminate; edge-wrapping the sides of the laminate using butyl rubber strips; pre-fixing the butyl rubber strips onto the laminate; performing a lamination process on the entire laminate with the butyl rubber strip edges; and bonding the laminate to a frame using butyl rubber strips molten during the lamination process. In this application, butyl rubber strips can be pre-fixed to the sides of the laminate, and the laminate and butyl rubber strips can be laminated together, achieving effective sealing of the sides of the laminate and isolating moisture.

Description

Technical Field

[0001] This application relates to the field of photovoltaic technology, and in particular to a method for preparing a photovoltaic module and a photovoltaic module. Background Technology

[0002] Photovoltaic modules convert solar energy into electrical energy by absorbing sunlight. During the use of photovoltaic modules, external moisture can easily enter the interior of the module. Moisture not only corrodes the solar cells but also affects the adhesion of the encapsulant film, thus impacting the reliability and lifespan of the photovoltaic module.

[0003] Currently, silicone sealant is used to seal and connect the frame and laminate of photovoltaic modules. However, silicone sealant has poor moisture barrier properties. During the use of photovoltaic modules, external moisture can easily penetrate into the interior of the laminate through the silicone sealant, corroding the solar cells and affecting the adhesion performance of the sealant film. Summary of the Invention

[0004] The purpose of this application is to provide a method for manufacturing photovoltaic modules and a photovoltaic module, so as to solve the problem of poor waterproof performance when using silicone sealing connection in photovoltaic modules in the prior art.

[0005] In a first aspect, this application provides a method for manufacturing a photovoltaic module, comprising:

[0006] The cover plate, the first adhesive film, the battery cell, the second adhesive film, and the back sheet are stacked sequentially to form a laminate.

[0007] Butyl rubber strips are used to wrap the edges of the laminate;

[0008] The butyl rubber strip is pre-fixed onto the laminate;

[0009] The laminated part having the butyl rubber strip edge is subjected to lamination treatment;

[0010] The laminate is bonded to the frame using butyl rubber strips molten during the lamination process.

[0011] In one possible implementation, pre-fixing the butyl rubber strip onto the laminate specifically includes:

[0012] The butyl rubber strip is pre-fixed to the cover plate and / or the back plate using adhesive tape.

[0013] In one possible implementation, the tape is a high-temperature tape, and the method further includes: before bonding the laminate to the frame using a butyl rubber strip molten in the lamination process.

[0014] Remove the high-temperature tape.

[0015] In one possible implementation, the tape is a fusible tape.

[0016] In one possible implementation, pre-fixing the butyl rubber strip onto the laminate specifically includes:

[0017] The butyl rubber strip is pre-fixed to the cover plate and / or the back plate by a hot-pressing process, wherein the butyl rubber strip is pre-fixed to the side of the cover plate and / or the back plate by the hot-pressing process.

[0018] Alternatively, the butyl rubber strip can be pre-fixed to the cover plate and / or the back plate by laser welding; the laser welding machine temperature of the laser welding process is between 60℃ and 90℃, and the power is between 1KW and 3KW.

[0019] In one possible implementation, the lamination process of the laminated part having the butyl rubber strip edging specifically includes:

[0020] The laminated part with the butyl rubber strip edge is laminated sequentially through the first and second chambers of the laminator;

[0021] The lamination temperature of the first cavity is between 120°C and 130°C, and the lamination temperature of the second cavity is between 145°C and 155°C.

[0022] The lamination pressure of the first cavity is between -80MPa and -20MPa, and the lamination pressure of the second cavity is between -70MPa and -20MPa.

[0023] The lamination time of the first cavity is between 30s and 180s, and the lamination time of the second cavity is between 30s and 300s.

[0024] In one possible implementation, the step of using butyl rubber strips to wrap the sides of the laminate specifically includes:

[0025] The butyl rubber strip is wrapped around the side of the laminate in the circumferential direction, and at least a portion of the butyl rubber strip covers the portion of the cover plate facing away from the back plate and close to the edge of the laminate, and at least a portion of the butyl rubber strip covers the portion of the back plate facing away from the cover plate and close to the edge of the laminate.

[0026] In one possible implementation, the distance between the outer surface of the portion of butyl rubber strip disposed on the cover plate opposite to the back plate and the outer surface of the portion of butyl rubber strip disposed on the back plate opposite to the cover plate is D1, the thickness of the laminate is D2, and the value of D1 / D2 is greater than 1 and less than or equal to 1.5.

[0027] In one possible implementation, the distance between the outer surface of the portion of the butyl rubber strip disposed on the cover plate opposite to the back plate and the outer surface of the portion of the butyl rubber strip disposed on the back plate opposite to the cover plate is between 6 mm and 12 mm.

[0028] Secondly, embodiments of this application also provide a photovoltaic module, wherein the photovoltaic module is prepared using the photovoltaic module preparation method provided in the first aspect of this application. The photovoltaic module includes a frame and a laminate. The laminate includes a cover plate, a first encapsulant film, a battery cell, a second encapsulant film, and a back sheet stacked sequentially. The sides of the laminate are covered with butyl rubber strips, and the laminate is installed in the frame through the butyl rubber strips.

[0029] The technical solution provided in this application can achieve the following beneficial effects:

[0030] The photovoltaic module manufacturing method and photovoltaic module provided in this application can pre-fix butyl rubber strips on the side of the laminate and enable the laminate and butyl rubber strips to be laminated together, thereby achieving effective sealing of the side of the laminate and isolating moisture.

[0031] It should be understood that the above general description and the following detailed description are merely exemplary and do not limit this application. Attached Figure Description

[0032] Figure 1 This is a flowchart of a photovoltaic module manufacturing method provided in one embodiment of this application;

[0033] Figure 2 This is a schematic diagram of the structure of the laminate provided in the embodiments of this application;

[0034] Figure 3 This is a side view of the assembly of a laminate and a butyl rubber strip in a photovoltaic module according to one embodiment of this application;

[0035] Figure 4 This is a top view of the mating of a laminate and a butyl rubber strip in a photovoltaic module according to an embodiment of this application;

[0036] Figure 5 This is an exploded view of the laminate and butyl rubber strip in a photovoltaic module according to one embodiment of this application;

[0037] Figure 6 A cross-sectional view of a photovoltaic module provided in an embodiment of this application;

[0038] Figure 7 A flowchart illustrating a photovoltaic module fabrication method provided in another embodiment of this application;

[0039] Figure 8A top view of the mating of a laminate and a butyl rubber strip in a photovoltaic module according to another embodiment of this application;

[0040] Figure 9 A side view of the assembly of a laminate and a butyl rubber strip in a photovoltaic module according to another embodiment of this application;

[0041] Figure 10 A flowchart illustrating a photovoltaic module fabrication method provided in another embodiment of this application;

[0042] Figure 11 A flowchart illustrating a photovoltaic module fabrication method provided in another embodiment of this application;

[0043] Figure 12 This is a side view of the laminate and butyl rubber strip in a photovoltaic module according to another embodiment of this application.

[0044] Figure label:

[0045] 1-Laminated components;

[0046] 11-Cover plate;

[0047] 12-First adhesive film;

[0048] 13-Battery Cells;

[0049] 14-Second adhesive film;

[0050] 15-Back panel;

[0051] 1a - First side view;

[0052] 1b - Second side view;

[0053] 2-Butyl rubber strips;

[0054] 21-Part One;

[0055] 22 - Part Two;

[0056] 23-Part Three;

[0057] 3- Tape;

[0058] 100 - Photovoltaic modules;

[0059] 110 - Border;

[0060] 111 - Groove;

[0061] X - Length direction;

[0062] Y-width direction;

[0063] Z - Thickness direction.

[0064] The accompanying drawings, which are incorporated in and form part of this specification, illustrate embodiments consistent with this application and, together with the description, serve to explain the principles of this application. Detailed Implementation

[0065] To make the objectives, technical solutions, and advantages of this application clearer, the following detailed description is provided in conjunction with the accompanying drawings and embodiments. It should be understood that the specific embodiments described herein are merely illustrative and not intended to limit the scope of this application.

[0066] In the description of this application, unless otherwise expressly specified and limited, the terms "first" and "second" are used for descriptive purposes only and should not be construed as indicating or implying relative importance; unless otherwise specified or explained, the term "multiple" refers to two or more; the terms "connected," "fixed," etc., should be interpreted broadly. For example, "connected" can be a fixed connection, a detachable connection, an integral connection, or an electrical connection; it can be a direct connection or an indirect connection through an intermediate medium. Those skilled in the art can understand the specific meaning of the above terms in this application according to the specific circumstances.

[0067] In the description of this specification, it should be understood that the directional terms such as "upper" and "lower" used in the embodiments of this application are used to describe the angles shown in the accompanying drawings and should not be construed as limiting the embodiments of this application. Furthermore, in the context, it should also be understood that when it is mentioned that an element is connected "upper" or "lower" to another element, it can be directly connected to the other element "upper" or "lower," or indirectly connected to the other element "upper" or "lower" through an intermediate element.

[0068] Photovoltaic (PV) modules convert solar energy into electricity by absorbing sunlight. During operation, external moisture can easily penetrate the PV module. This moisture not only corrodes the solar cells but also affects the adhesion of the encapsulant film, thus impacting the module's reliability and lifespan. Currently, silicone sealant is used to seal and connect the frame and laminate of PV modules. However, silicone sealant has poor moisture barrier properties; during use, external moisture can easily seep through the silicone sealant into the laminate, corroding the solar cells and affecting the adhesion of the encapsulant film.

[0069] Figure 1 This is a flowchart of a photovoltaic module manufacturing method provided in one embodiment of this application. Figure 2 This is a schematic diagram of the structure of the laminate provided in the embodiments of this application, such as... Figure 1 and Figure 2 As shown in the figure, this application provides a method for manufacturing photovoltaic modules, which includes the following steps:

[0070] Step S1a: The cover plate 11, the first adhesive film 12, the battery cell 13, the second adhesive film 14, and the back plate 15 are stacked sequentially to form the laminate 1. In specific operation, the cover plate 11 can be placed at the bottom layer, and then the first adhesive film 12, the battery cell 13, the second adhesive film 14, and the back plate 15 can be stacked sequentially on the cover plate 11.

[0071] Both the cover plate 11 and the back plate 15 can be made of glass to allow sunlight to be transmitted to the solar cell 13.

[0072] The solar cell 13 can be a PERC, TOPCon, BC, heterojunction, or perovskite solar cell, or a multi-busbar (MBB) solar cell or an OBB solar cell. Multiple solar cells 13 can be connected in series to form a solar cell string, and multiple solar cell strings can also be configured.

[0073] The materials of the first adhesive film 12 and the second adhesive film 14 can be the same or different. For example, the materials of the first adhesive film 12 and the second adhesive film 14 can both be one of ethylene-ethylene acetate copolymer (EVA), polyolefin elastomer (POE) and EPE (EVA-POE-EVA co-extrusion) materials.

[0074] Step S2a: Use butyl rubber strip 2 to wrap the sides of the laminate 1.

[0075] like Figure 2 As shown, the shape of laminate 1 is typically a cuboid or cube, but it can also be other shapes. This embodiment uses a cuboid as an example to illustrate laminate 1. Laminate 1 has a length direction X, a width direction Y, and a thickness direction Z. The length direction X, width direction Y, and thickness direction Z are mutually perpendicular or approximately perpendicular. "Perpendicular" means the angle between the two directions is 90°, and "approximately perpendicular" means the angle between the two directions can be close to 90°, for example, the angle between the two directions can be a certain angle value within the range of 80° to 100°.

[0076] like Figure 2 As shown, the laminate 1 has two sides, a first side 1a and a second side 1b. The first side 1a is parallel to the plane containing the length direction X and the thickness direction Z of the laminate 1, and the second side 1b is parallel to the plane containing the width direction Y and the thickness direction Z of the laminate 1. When the first side 1a and the second side 1b are exposed, moisture can easily penetrate from the first side 1a and the second side 1b into the space between two adjacent first film layers. For example, moisture can easily penetrate between the first adhesive film 12 and the solar cell 13, or between the second adhesive film 14 and the solar cell 13. This can easily cause the solar cell 13 to be corroded, and at the same time, it can easily reduce the adhesiveness of the adhesive film, resulting in a decrease in the reliability of the photovoltaic module.

[0077] to this end, Figure 3 This is a side view of the mating of the laminate 1 and butyl rubber strip 2 in a photovoltaic module according to an embodiment of this application, as shown. Figure 3 As shown, in this embodiment, after the cover plate 11, the first adhesive film 12, the battery cell 13, the second adhesive film 14 and the back plate 15 are stacked in sequence to form a laminate 1, a butyl rubber strip 2 is used to cover the side of the laminate 1. This allows the butyl rubber strip 2 to seal the gaps between the film layers, preventing moisture from seeping into the interior of the laminate 1 from the gaps between the film layers.

[0078] Among them, compared with silicone in related technologies, butyl rubber strip 2 has high sealing performance, which can prevent water vapor penetration. Butyl rubber strip 2 also has the characteristics of high elongation, good flexibility, pressure resistance and aging resistance.

[0079] In one embodiment, Figure 4 This is a top view of the mating of the laminate 1 and the butyl rubber strip 2 in a photovoltaic module according to an embodiment of this application, as shown. Figure 4 As shown, a continuous butyl rubber strip 2 can be wrapped around the side of the laminate 1, which facilitates the assembly of the butyl rubber strip 2 and the laminate 1.

[0080] In one embodiment, Figure 5 This is an exploded view of the assembly of the laminate 1 and the butyl rubber strip 2 in a photovoltaic module according to an embodiment of this application, as shown below. Figure 5 As shown, four butyl rubber strips 2 can be used. Two of the butyl rubber strips 2 can have a length that is the same as or nearly the same as the length of the laminate 1, allowing them to mate with the side of the laminate 1 in the length direction X. The other two butyl rubber strips 2 can have a length that is the same as or nearly the same as the width of the laminate 1, allowing them to mate with the side of the laminate 1 in the width direction Y. By using four butyl rubber strips 2 to independently mate with each side of the laminate 1, reliable adhesion and fixation of the butyl rubber strips 2 to each side of the laminate 1 can be ensured, preventing the butyl rubber strips 2 from stacking at the corners of the laminate 1.

[0081] Step S3a: Pre-fix the butyl rubber strip 2 onto the laminate 1.

[0082] Before the laminate 1 is fed into the laminator, it is necessary to ensure that the relative position of the butyl rubber strip 2 and the laminate 1 is stable to prevent the butyl rubber strip 2 from falling off. Therefore, tape or similar materials can be used to bond the butyl rubber strip 2 to the laminate 1 to achieve the pre-fixation of the butyl rubber strip 2.

[0083] Step S4a: Perform lamination treatment on the entire laminate 1 with butyl rubber strip 2 as the edge.

[0084] The laminated component 1, with butyl rubber strips 2 edging, can be laminated using a laminator. When edging the laminated component 1, the butyl rubber strips 2 are solid, possessing a stable structural shape, and can cover and position themselves at the corresponding positions on the laminated component 1. After the laminated component 1 with butyl rubber strips 2 edging is fed into the laminator, the high temperature in the laminator melts the first adhesive film 12 and the second adhesive film 14. The molten first adhesive film 12 reliably bonds to the cover plate 11 and the battery cell 13, while the molten second adhesive film 14 reliably bonds to the backplate 15 and the battery cell 13. Simultaneously, the high temperature in the laminator also causes the butyl rubber strips 2 to change from a solid state to a molten state, allowing the molten butyl rubber strips 2 to reliably bond to the sides of the laminated component 1.

[0085] In one embodiment, step S4a specifically includes:

[0086] Step S4a1: The laminate 1 with the butyl rubber strip 2 wrapped around its edges is sequentially passed through the first and second cavities of a laminator for lamination. The laminator can be a dual-cavity laminator, comprising a first cavity and a second cavity. The laminate 1 can be sequentially laminated in the first and second cavities, thereby ensuring that the laminate 1 and the butyl rubber strip 2 are free of air bubbles after lamination, resulting in high processing quality.

[0087] The lamination temperature of the first cavity can be between 120℃ and 130℃, and the lamination temperature of the second cavity can be between 145℃ and 155℃. By making the temperature of the second cavity higher than that of the first cavity, the air bubbles in the laminate 1 and the butyl rubber strip 2 can be almost completely eliminated after passing through the second cavity, thus ensuring the processing quality of the photovoltaic module.

[0088] The lamination pressure in the first chamber can be between -80MPa and -20MPa, and the lamination pressure in the second chamber can be between -70MPa and -20MPa. The negative pressure environment allows the layers in the laminate 1 to adhere more tightly, ensuring the reliability of the bonding between the layers.

[0089] The lamination time for the first cavity can be between 30s and 180s, and the lamination time for the second cavity can be between 30s and 300s. Within these lamination times, the reliability of the connection between the butyl rubber strip 2 and the laminate 1 can be guaranteed.

[0090] In one embodiment, the lamination process can be divided into three stages. In each stage, the laminate 1 can be laminated sequentially through a first cavity and a second cavity. The lamination temperature and pressure in each stage can meet the aforementioned parameter ranges. Regarding the lamination time, in the first and second stages, the lamination time in the first and second cavities can be between 25s and 35s; in the third stage, the lamination time in the first cavity can be between 120s and 180s, and the lamination time in the second cavity can be between 240s and 300s. This ensures that there are no air bubbles in the laminate 1 and the butyl rubber strip 2, and also guarantees the reliability of the bond between the laminate 1 and the butyl rubber strip 2.

[0091] Step S5a: The laminate 1 is bonded to the frame by the butyl rubber strip 2 melted during the lamination process.

[0092] After the lamination step is completed, the laminate 1 with butyl rubber strip 2 can be removed from the laminator. During the short time after being removed from the laminator, the butyl rubber strip 2 can remain in a molten state. Figure 6 A cross-sectional view of the photovoltaic module 100 provided in the embodiments of this application, as shown below. Figure 6 As shown, while the butyl rubber strip 2 remains in a molten state, the laminate 1 can be integrally installed into the frame 110. The main function of the frame 110 of the photovoltaic module 100 is to protect the internal structure of the photovoltaic module 100, improve its mechanical strength and weather resistance, and extend its service life. For example, the frame can be an aluminum alloy frame, a steel frame, a polymer material frame, etc.

[0093] like Figure 6 As shown, the frame 110 may have a groove 111, and the edge portion of the laminate 1 can be engaged in the groove 111 so that the frame 110 can cover the edge portion of the laminate 1. When the edge portion of the laminate 1 is engaged in the groove 111 of the frame 110, the molten butyl rubber strip 2 can adhere to the inner wall of the groove 111. After the butyl rubber strip 2 cures, a reliable connection and fixation between the laminate 1 and the frame 110 can be achieved. Simultaneously, the butyl rubber strip 2 can cover and seal the sides of the laminate 1, effectively isolating moisture.

[0094] In the aforementioned step S3a, there can be various methods for pre-fixing the butyl rubber strip 2, which will be described in different examples of preparation methods below.

[0095] Example 1

[0096] Figure 7 A flowchart of a photovoltaic module fabrication method provided in another embodiment of this application is shown below. Figure 7 As shown, the preparation method provided in this embodiment includes the following steps:

[0097] Step S1b: The cover plate 11, the first adhesive film 12, the battery cell 13, the second adhesive film 14 and the back plate 15 are stacked in sequence to form the laminate 1.

[0098] Step S2b: Use butyl rubber strip 2 to wrap the sides of the laminate 1.

[0099] Step S3b: Use adhesive tape to pre-fix the butyl rubber strip 2 onto the cover plate 11 and / or the back plate 15.

[0100] Step S4b: Perform lamination treatment on the entire laminate 1 with butyl rubber strip 2 as the edge.

[0101] Step S5b: The laminate 1 is bonded to the frame by the butyl rubber strip 2 melted during the lamination process.

[0102] Figure 8 This is a top view of the mating of the laminate 1 and the butyl rubber strip 2 in a photovoltaic module according to another embodiment of this application. Figure 9 This is a side view of the mating of the laminate 1 and butyl rubber strip 2 in a photovoltaic module according to another embodiment of this application, as shown below. Figure 8 and Figure 9 As shown, in step S3b, at least one side of the tape is adhesive. One end of the tape can be adhered to the butyl rubber strip 2, and the other end of the tape can be adhered to the back plate 15 or the cover plate 11. Alternatively, a portion of the tape can be adhered to the back plate 15 and another portion can be adhered to the cover plate 11, thereby reliably positioning the butyl rubber strip 2 on the laminate 1.

[0103] Multiple adhesive tapes can be provided, and these tapes can be bonded to different positions of the butyl rubber strip 2 at intervals. For example, for the butyl rubber strip 2 covering the long side of the laminate 1, 3 to 5 tapes can be evenly distributed at intervals, and for the butyl rubber strip 2 covering the short side of the laminate 1, 2 to 3 tapes can be evenly distributed at intervals. This ensures that the butyl rubber strip 2 covering both the long and short sides of the laminate 1 can be reliably positioned on the laminate 1, preventing it from falling off.

[0104] The width of the adhesive tape needs to meet certain requirements. If the tape is too narrow, it is prone to breakage during the movement of the laminate 1 or during the lamination process, making it difficult to effectively fix the butyl rubber strip 2. If the tape is too wide, it will increase the consumption of tape material and increase manufacturing costs.

[0105] Therefore, in this embodiment, the width of the adhesive tape can be between 30mm and 40mm. For example, the width of the adhesive tape can be 30mm, 32mm, 35mm, 38mm, or 40mm. By keeping the width of the adhesive tape within the above-mentioned size range, both the reliability of fixing the butyl rubber strip 2 and the lower manufacturing cost can be achieved.

[0106] In one embodiment, the tape can be a high-temperature tape, which has high-temperature resistance. During the lamination process of the laminate 1 in the laminator, the high-temperature tape maintains stable structural characteristics and does not melt. After the laminate 1 is removed from the laminator, the molten butyl rubber strip 2 can reliably bond with the laminate 1. Therefore, before assembling the laminate 1 into the frame, the high-temperature tape can be removed to avoid the high-temperature tape blocking the photovoltaic module and reducing the photoelectric conversion efficiency.

[0107] In one embodiment, the tape can be a fusible tape, for example, a reversible hydrogel tape. The fusible tape can melt during the lamination process, thus eliminating the need for removal after lamination. The molten fusible tape can work together with the butyl rubber strip 2 to provide adhesion, simplifying the process.

[0108] Example 2

[0109] Figure 10 A flowchart of a photovoltaic module fabrication method provided in another embodiment of this application is shown below. Figure 10 As shown, the preparation method provided in this embodiment includes the following steps:

[0110] Step S1c: The cover plate 11, the first adhesive film 12, the battery cell 13, the second adhesive film 14 and the back plate 15 are stacked in sequence to form the laminate 1.

[0111] Step S2c: Use butyl rubber strip 2 to wrap the sides of the laminate 1.

[0112] Step S3c: Pre-fix the butyl rubber strip 2 to the cover plate 11 and / or back plate 15 by hot stamping process.

[0113] Step S4c: Perform lamination treatment on the entire laminate 1 with butyl rubber strip 2 as the edge.

[0114] Step S5c: The laminate 1 is bonded to the frame by the butyl rubber strip 2 melted during the lamination process.

[0115] In step S3c, the spot heating method can heat a local area of ​​the butyl rubber strip 2 at a high temperature, so that the heated part of the butyl rubber strip 2 can melt, and the melted part can be bonded and fixed with the laminate 1.

[0116] Therefore, by using spot heating, the butyl rubber strip 2 can be pre-fixed to the laminate 1 without the need for tape, thus simplifying the process.

[0117] Furthermore, it should be noted that in the method of fixing the butyl rubber strip 2 and the laminate 1 with high-temperature tape, the high-temperature tape needs to be removed before the laminate 1 is installed onto the frame. During the process of tearing off the high-temperature tape, a certain amount of molten butyl rubber may be carried away by the high-temperature tape, which will affect the bonding effect of the butyl rubber. At the same time, the molten butyl rubber will also flow due to the pulling of the high-temperature tape. If it flows onto the surface of the cover plate 11 and the back plate 15, it will cause the surface of the cover plate 11 and the back plate 15 to be unclean, which will also affect the propagation of light and thus affect the photoelectric conversion efficiency. In this embodiment, by using spot heating, the above situation is avoided, thereby improving the reliability of the pre-fixation of the butyl rubber strip 2 and the laminate 1.

[0118] In one embodiment, the butyl rubber strip 2 can be pre-fixed to the side of the cover plate 11 and / or the back plate 15 by a hot-spot process. This hot-spot process requires localized high-temperature heating of the butyl rubber strip 2. If the temperature is too high, the excessive heat will be conducted to the laminate 1, causing adverse effects such as localized deformation or burns.

[0119] The photovoltaic module can be a single-glass module or a double-glass module. For a single-glass module, the cover plate 11 is made of glass, and sunlight can be transmitted from the surface of the cover plate 11 to the solar cell 13. For a double-glass module, both the cover plate 11 and the back sheet 15 can be made of glass, and sunlight can be transmitted from the surface of either the cover plate 11 or the back sheet 15 to the solar cell 13. Therefore, the surface of the photovoltaic module in the thickness direction Z is crucial for photoelectric conversion, while the sides of the photovoltaic module need to be installed in the frame and have a smaller impact on photoelectric conversion. Thus, by heating the portion of the butyl rubber strip 2 corresponding to the side of the cover plate 11 and / or the back sheet 15, the impact on the side of the cover plate 11 and / or the back sheet 15 that receives sunlight can be reduced, ensuring high-quality manufacturing of the photovoltaic module.

[0120] Example 3

[0121] Figure 11 A flowchart of a photovoltaic module fabrication method provided in another embodiment of this application is shown below. Figure 11 As shown, the preparation method provided in this embodiment includes the following steps:

[0122] Step S1d: The cover plate 11, the first adhesive film 12, the battery cell 13, the second adhesive film 14 and the back plate 15 are stacked in sequence to form the laminate 1.

[0123] Step S2d: Use butyl rubber strip 2 to wrap the sides of the laminate 1.

[0124] Step S3d: Pre-fix the butyl rubber strip 2 to the cover plate 11 and / or back plate 15 using laser welding.

[0125] Step S4d: Perform lamination treatment on the entire laminate 1 with butyl rubber strip 2 as the edge.

[0126] Step S5d: The laminate 1 is bonded to the frame by the butyl rubber strip 2 melted during the lamination process.

[0127] In step S3d, laser welding continuously heats the butyl rubber strip 2 at high temperatures along the edges of the cover plate 11 and the back plate 15, causing the butyl rubber strip 2 to melt at the positions corresponding to the edges of the cover plate 11 and the back plate 15, thus bonding and fixing it to the edges of the cover plate 11 and the back plate 15. Laser welding is easy to operate and control, has high welding precision, and does not cause waste or contamination of the butyl rubber, making it suitable for mass production.

[0128] The laser welding process uses a laser welding machine with a temperature between 60℃ and 90℃ and a power between 1KW and 3KW. This allows the laser-irradiated areas of the butyl rubber strip 2 to melt while having minimal impact on the areas not irradiated. It also ensures uniform heating of the butyl rubber strip 2 and guarantees the consistency of the connection between the butyl rubber strip 2 and the laminate 1.

[0129] In one embodiment, such as Figure 3 As shown, the butyl rubber strip 2 is wrapped around the side of the laminate 1 in the circumferential direction, and at least a portion of the butyl rubber strip 2 covers the part of the cover plate 11 that is away from the back plate 15 and close to the edge of the laminate 1, and at least a portion of the butyl rubber strip 2 covers the part of the back plate 15 that is away from the cover plate 11 and close to the edge of the laminate 1.

[0130] For ease of explanation, such as Figure 3 As shown, the butyl rubber strip 2 is illustrated by way of example, comprising a first part 21, a second part 22, and a third part 23. The first part 21 is the portion of the butyl rubber strip 2 covering the side of the laminate 1; the second part 22 is the portion of the butyl rubber strip 2 covering the back plate 15 on the side opposite to the cover plate 11; and the third part 23 is the portion of the butyl rubber strip 2 covering the cover plate 11 on the side opposite to the back plate 15.

[0131] The butyl rubber strip 2 can completely cover all sides of the laminate 1 through the first part 21. Simultaneously, the second part 22 and the third part 23 of the butyl rubber strip 2 can extend and correspondingly cover the surfaces of the back plate 15 and the cover plate 11 near their edges. This extends the length between the edge of the butyl rubber strip 2 and the edge of the laminate 1, thus lengthening the path length for moisture penetration. This effectively prevents moisture from penetrating to the sides of the laminate 1 and further penetrating between the layers of the laminate 1. Furthermore, by extending and correspondingly covering the surfaces of the back plate 15 and the cover plate 11 near their edges, the reliability of the connection between the butyl rubber strip 2 and the laminate 1 is ensured, thereby guaranteeing the reliability of the seal on the sides of the laminate 1.

[0132] In one embodiment, such as Figure 3 As shown, the distance between the outer surface of the portion of butyl rubber strip 2 on the side of the cover plate 11 facing away from the back plate 15 and the outer surface of the portion of butyl rubber strip 2 on the side of the back plate 15 facing away from the cover plate 11 is D1, the thickness of the laminate 1 is D2, and the value of D1 / D2 is greater than 1 and less than or equal to 1.5. For example, the value of D1 / D2 can be 1.1, 1.2, 1.3, 1.4, or 1.5. By ensuring that the value of D1 / D2 is within the above range, the reliability of the bonding and fixing between the butyl rubber strip 2 and the laminate 1 can be guaranteed, while avoiding a large Z-axis space above or below the laminate 1 for the butyl rubber strip 2, which is beneficial for achieving a thinner and lighter photovoltaic module.

[0133] In one embodiment, such as Figure 3 As shown, the distance D1 between the outer surface of the portion of the butyl rubber strip 2 disposed on the cover plate 11 facing away from the back plate 15 and the outer surface of the portion of the butyl rubber strip 2 disposed on the back plate 15 facing away from the cover plate 11 can be between 6mm and 12mm. For example, D1 can be 6mm, 7mm, 8mm, 9mm, 10mm, 11mm, or 12mm. By keeping D1 within the above-mentioned range, the reliability of the bonding and fixing between the butyl rubber strip 2 and the laminate 1 can be ensured, while avoiding a large Z-direction space above or below the laminate 1 for the butyl rubber strip 2, which is beneficial for achieving a thinner and lighter photovoltaic module.

[0134] In one embodiment, Figure 12 This is a side view of the mating of the laminate 1 and butyl rubber strip 2 in a photovoltaic module according to another embodiment of this application, as shown below. Figure 12 As shown, the butyl rubber strip 2 can also be set only on the side of the laminate 1, that is, the size of the butyl rubber strip 2 in the thickness direction Z of the laminate 1 is equal to the thickness of the laminate 1, so that it does not occupy the Z-direction space of the laminate 1, which is conducive to realizing the overall thin design of the photovoltaic module.

[0135] This application also provides a photovoltaic module, which is prepared using the preparation method provided in any embodiment of this application. The photovoltaic module includes the aforementioned frame and a laminate 1. The laminate 1 includes a cover plate 11, a first encapsulant film 12, a solar cell 13, a second encapsulant film 14, and a back plate 15 stacked sequentially. The sides of the laminate 1 are covered with butyl rubber strips 2, and the laminate 1 is fixedly installed in the frame by the butyl rubber strips 2.

[0136] In this embodiment, the photovoltaic module prepared by the aforementioned preparation method can achieve sealing of the side of the laminate 1 by butyl rubber strip 2, which can effectively isolate water vapor and prevent water vapor from penetrating into the interior of the laminate 1 and causing problems such as corrosion of the cell 13 and failure of adhesive film viscosity and aging, thereby improving the service life of the photovoltaic module.

[0137] The above description is merely a preferred embodiment of this application and is not intended to limit this application. Various modifications and variations can be made to this application by those skilled in the art. Any modifications, equivalent substitutions, improvements, etc., made within the spirit and principles of this application should be included within the protection scope of this application.

Claims

1. A method for manufacturing a photovoltaic module, characterized in that, include: The cover plate, the first adhesive film, the battery cell, the second adhesive film, and the back sheet are stacked sequentially to form a laminate. Butyl rubber strips are used to wrap the edges of the laminate; The butyl rubber strip is pre-fixed to the cover plate and / or the back plate using adhesive tape; or, the butyl rubber strip is pre-fixed to the cover plate and / or the back plate using a hot-stamping process, wherein the butyl rubber strip is pre-fixed to the side of the cover plate and / or the back plate using the hot-stamping process; or, the butyl rubber strip is pre-fixed to the cover plate and / or the back plate using a laser welding process. The laminated part having the butyl rubber strip edge is subjected to lamination treatment; The laminate is bonded to the frame using butyl rubber strips molten during the lamination process.

2. The photovoltaic module manufacturing method according to claim 1, characterized in that, The tape is a high-temperature tape. Before bonding the laminate to the frame using butyl rubber strips molten during the lamination process, the method further includes: Remove the high-temperature tape.

3. The photovoltaic module manufacturing method according to claim 1, characterized in that, The tape is a fusible tape.

4. The photovoltaic module manufacturing method according to claim 1, characterized in that, The laser welding process uses a laser welding machine with a temperature between 60℃ and 90℃ and a power between 1KW and 3KW.

5. The method for preparing a photovoltaic module according to any one of claims 1-4, characterized in that, The lamination process for the laminated part having the butyl rubber strip edging specifically includes: The laminated part with the butyl rubber strip edge is laminated sequentially through the first and second chambers of the laminator; The lamination temperature of the first cavity is between 120℃ and 130℃, and the lamination temperature of the second cavity is between 145℃ and 155℃. The lamination pressure of the first cavity is between -80MPa and -20MPa, and the lamination pressure of the second cavity is between -70MPa and -20MPa. The lamination time of the first cavity is between 30s and 180s, and the lamination time of the second cavity is between 30s and 300s.

6. The method for preparing a photovoltaic module according to any one of claims 1-4, characterized in that, The step of using butyl rubber strips to wrap the sides of the laminate specifically includes: The butyl rubber strip is wrapped around the side of the laminate in the circumferential direction, and at least a portion of the butyl rubber strip covers the portion of the cover plate facing away from the back plate and close to the edge of the laminate, and at least a portion of the butyl rubber strip covers the portion of the back plate facing away from the cover plate and close to the edge of the laminate.

7. The photovoltaic module manufacturing method according to claim 6, characterized in that, The distance between the outer surface of the portion of butyl rubber strip disposed on the cover plate away from the back plate and the outer surface of the portion of butyl rubber strip disposed on the back plate away from the cover plate is D1, the thickness of the laminate is D2, and the value of D1 / D2 is greater than 1 and less than or equal to 1.

5.

8. The photovoltaic module manufacturing method according to claim 7, characterized in that, The distance between the outer surface of the portion of butyl rubber strip disposed on the cover plate opposite to the back plate and the outer surface of the portion of butyl rubber strip disposed on the back plate opposite to the cover plate is between 6mm and 12mm.

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