A high-strength and lightweight photovoltaic module and its manufacturing method

Abstract

This application provides a high-strength, lightweight photovoltaic module and its manufacturing method. The method includes: providing a power generation unit, including a power generation chip, a first panel, a first backplate, and a junction box. The power generation chip includes opposing first and second end faces, and the first backplate includes opposing third and fourth end faces. The first panel is bonded to the first end face, the second end face is bonded to the third end face, and the junction box is bonded to the fourth end face. A support unit is provided, including a structural reinforcing core, a second panel, and a second backplate. The structural reinforcing core includes opposing fifth and sixth end faces, and the second backplate includes opposing seventh and eighth end faces, with a receiving area formed on the eighth end face. The structural reinforcing core is composed of multiple hollow parts with preset contour shapes connected together. The second panel is bonded to the fifth end face, and the sixth end face is bonded to the seventh end face. The fourth end face is bonded to the eighth end face to bond the power generation unit and the support unit. After bonding, the junction box is placed in the receiving area.

Description

Technical Field

[0001] The invention belongs to the technical field of photovoltaics, and in particular relates to a high-strength and lightweight photovoltaic component and a manufacturing method thereof. Background Art

[0002] As the global demand for renewable energy continues to increase, photovoltaic power generation systems are increasingly being used in high-rise buildings and in harsh climate conditions. However, traditional photovoltaic modules have encountered many challenges in their application in high-rise buildings or areas with high wind pressure. Traditional photovoltaic modules are mainly composed of transparent panels, power generation chips, backplanes, etc., and their structural strength and weight are the main bottlenecks limiting their application in these special environments.

[0003] In high-rise buildings or areas with high wind pressure, photovoltaic modules need to withstand higher wind pressure. According to industry standards, if they need to withstand wind pressures above 6kPa, traditional photovoltaic modules usually need to be equipped with two layers of 10mm thick glass, which makes the weight of the module reach 50kg / m². This high weight not only increases the burden on the building structure, but may also lead to insufficient use strength of the module, further affecting its safety and stability. In addition, the increase in module weight may lead to a significant increase in transportation and installation costs, thus affecting the economic efficiency of the overall system.

[0004] Therefore, there is an urgent need for a high-strength and lightweight photovoltaic module to solve at least one of the above problems. Summary of the invention

[0005] The present application provides a high-strength and lightweight photovoltaic module and its manufacturing method, aiming to solve the problem that photovoltaic modules need to withstand higher wind pressure in high buildings or areas with high wind pressure. According to industry standards, if they need to withstand wind pressures above 6kPa, traditional photovoltaic modules usually need to be configured with two layers of 10mm thick glass, so that the weight of the module reaches 50kg / m². This high weight not only increases the burden on the building structure, but may also lead to insufficient strength of the module, further affecting its safety and stability. In addition, the increase in the weight of the module may lead to a significant increase in transportation and installation costs, thereby affecting the economy of the overall system.

[0006] In a first aspect, the present application provides a method for manufacturing a high-strength and lightweight photovoltaic module, the method comprising:

[0007] A power generation unit is provided, the power generation unit comprising a power generation chip, a first panel, a first back panel and a junction box, the power generation chip comprising a first end face and a second end face arranged oppositely, the first back panel comprising a third end face and a fourth end face arranged oppositely;

[0008] The first panel is bonded to the first end surface, the second end surface is bonded to the third end surface, and the junction box is bonded to the fourth end surface;

[0009] A support unit is provided, the support unit comprising a structural reinforcement core, a second panel and a second back panel, the structural reinforcement core comprising a fifth end face and a sixth end face arranged opposite to each other, the second back panel comprising a seventh end face and an eighth end face arranged opposite to each other, and an accommodation area is formed on the eighth end face; the structural reinforcement core is formed by connecting a plurality of hollow pieces with preset contour shapes;

[0010] Bonding the second panel to the fifth end surface, and bonding the sixth end surface to the seventh end surface respectively;

[0011] The fourth end face is bonded to the eighth end face to bond the power generation unit and the support unit, and after bonding, the junction box is placed in the accommodating area.

[0012] In some embodiments, the transmittance of the first panel is greater than a preset transmittance; the power generation unit also includes a first adhesive layer, a second adhesive layer and a third adhesive layer; the first panel is bonded to the first end face, the second end face is bonded to the third end face, and the junction box is bonded to the fourth end face, respectively, including: setting the first adhesive layer between the first panel and the first end face, and the first panel is bonded to the first end face via the first adhesive layer; setting the second adhesive layer between the first panel and the first end face, and the second end face is bonded to the third end face via the second adhesive layer; setting the third adhesive layer between the junction box and the fourth end face, and the junction box is bonded to the third end face via the third adhesive layer.

[0013] Exemplarily, the first panel is cross-linked with the first end face by pressurizing and heating via the first adhesive layer, and the second end face is cross-linked with the third end face by pressurizing and heating via the second adhesive layer; and / or, the junction box is cured and bonded with the third end face via the third adhesive layer.

[0014] It should be noted that, in some embodiments, the pressurized heating cross-linking includes a first working section, a second working section and a cooling section. The pressurization pressure range of the first working section is 65kpa to 110kpa, the pressurization temperature range is 105℃ to 165℃, and the pressurization time range is 550s to 700s; the pressurization pressure range of the second working section is 70 kpa to 110kpa, the pressurization temperature range is 120℃ to 155℃, and the heating time range is 150s to 300s; the cooling section adopts an air cooling process, and the cooling time range is 250s to 350s; and / or the time range for the curing bonding of the third bonding layer and the third end face is 3h to 9h.

[0015] Exemplarily, the material of the first bonding layer and / or the material of the second bonding layer is any one of ethylene-vinyl acetate copolymer, polyvinyl butyral, sulfonamide plasticized polycarbonate, polyolefin elastomer and expanded polyethylene; and / or, the third bonding layer is any one of silicone glue, silicone sealant, epoxy potting glue.

[0016] In some embodiments, the support unit also includes a fourth adhesive layer and a fifth adhesive layer; the second panel is bonded to the fifth end face, and the sixth end face is bonded to the seventh end face, respectively, including: setting the fourth adhesive layer between the second panel and the fifth end face, and the second panel is bonded to the fifth end face via the fourth adhesive layer; setting the fifth adhesive layer between the sixth end face and the seventh end face, and the sixth end face is bonded to the seventh end face via the fifth adhesive layer.

[0017] Exemplarily, the fourth adhesive layer and / or the fifth adhesive layer is any one of a room temperature curing adhesive or a thermoplastic adhesive film; if the fourth adhesive layer and / or the fifth adhesive layer is a room temperature curing adhesive, the curing temperature range of the room temperature curing adhesive is 25°C to 30°C, and the curing time range is 24h to 72h; if the fourth adhesive layer and / or the fifth adhesive layer is a thermoplastic adhesive film, the curing pressure range of the thermoplastic adhesive film is 65 kPa to 110 kPa, the curing temperature range is 105°C to 165°C, and the curing time range is 450s to 600s.

[0018] In some embodiments, the support unit also includes: a sixth bonding layer; bonding the fourth end face to the eighth end face, including: setting the sixth bonding layer between the fourth end face and the eighth end face to bond the power generation unit and the support unit; wherein the tensile shear strength of the sixth bonding layer is within a preset tensile strength range, the peak load of the sixth bonding layer is within a preset load range, and the tensile bonding strength is within a preset bonding strength range.

[0019] Exemplarily, the preset tensile strength range is 2 MPa to 19 MPa; and / or, the preset load range is 625 N to 7680 N; and / or, the preset bonding strength range is 1.35 MPa to 12.8 MPa.

[0020] Exemplarily, the material of the sixth bonding layer is any one of polyurethane glue, epoxy resin glue, acrylic glue, isocyanate glue, silicone structural glue, ethylene-vinyl acetate copolymer, polyvinyl butyral and sulfonamide plasticized polycarbonate.

[0021] In some embodiments, the number of sides corresponding to the preset contour shape of the hollow piece is a preset number of sides, an air chamber is formed inside the hollow piece, and the thermal conductivity of the air chamber is greater than the preset thermal conductivity.

[0022] Exemplarily, the preset number of sides is 6, the side length of the hollow member corresponds to a side length range of 4 mm to 6 mm, the thickness of the hollow member corresponds to a thickness range of 0.04 mm to 0.08 mm; and / or, the preset thermal conductivity is 0.02 W / (m·k).

[0023] Exemplarily, the power generation power of the power generation chip is the target power, and the number, side length and thickness of the hollow parts in the structural reinforcement core are determined according to the target power, the preset number of sides and the thermal conductivity of the air chamber, so that the weight and surface area of ​​the structural reinforcement core are respectively less than the preset weight and preset surface area.

[0024] In a second aspect, the present application provides a high-strength and lightweight photovoltaic module, comprising:

[0025] A power generation unit, the power generation unit comprises a power generation chip, a first panel, a first back panel and a junction box, the power generation chip comprises a first end face and a second end face which are arranged oppositely, the first back panel comprises a third end face and a fourth end face which are arranged oppositely, the first panel is bonded to the first end face, the second end face is bonded to the third end face, and the junction box is bonded to the fourth end face;

[0026] A support unit, the support unit comprises a structural reinforcement core, a second panel and a second back panel, the structural reinforcement core comprises a fifth end face and a sixth end face that are oppositely arranged, the second back panel comprises a seventh end face and an eighth end face that are oppositely arranged, the second panel is bonded to the fifth end face, the sixth end face is bonded to the seventh end face, an accommodation area is formed on the eighth end face, the fourth end face is bonded to the eighth end face to bond the power generation unit and the support unit, and the junction box is placed in the accommodation area;

[0027] Among them, the structural reinforcement core is composed of multiple hollow parts with preset contour shapes, so as to reduce the mass of the supporting unit and improve the heat dissipation efficiency of the high-strength and lightweight photovoltaic modules.

[0028] The present application provides a high-strength and lightweight photovoltaic module and a manufacturing method thereof. The high-strength and lightweight photovoltaic module is mainly composed of two parts: a power generation unit and a support unit: the power generation unit includes: a power generation chip: including a first end face and a second end face. A first panel: bonded to the first end face of the power generation chip. A first back plate: bonded to the second end face of the power generation chip. A junction box: bonded to the fourth end face of the first back plate. The support unit includes: a structural reinforcement core: composed of a plurality of hollow pieces with preset contour shapes, which is used to reduce the mass of the support unit and improve the heat dissipation efficiency. A second panel: bonded to the fifth end face of the structural reinforcement core. A second back plate: including a seventh end face and an eighth end face that are relatively arranged, and bonded to the sixth end face of the structural reinforcement core. An accommodation area: formed on the eighth end face of the second back plate, for placing a junction box.

[0029] The manufacturing process of the power generation unit includes: bonding the second end face of the power generation chip to the third end face of the first back plate. Bonding the junction box to the fourth end face of the first back plate. The manufacturing process of the support unit includes: bonding the second panel to the fifth end face of the structural reinforcement core. Bonding the sixth end face of the structural reinforcement core to the seventh end face of the second back plate. Finally, bonding the fourth end face of the first back plate of the power generation unit to the eighth end face of the second back plate of the support unit, so that the junction box is placed in the accommodation area of ​​the support unit.

[0030] The provided components and methods have at least the following beneficial effects

[0031] 1. Weight reduction: By using a structural reinforcement core composed of hollow parts, the overall weight of the photovoltaic module is significantly reduced. Traditional modules require two layers of 10mm thick glass and weigh 50kg / m², while the weight of the module in this method is greatly reduced, reducing the burden on the building structure and reducing transportation and installation costs.

[0032] 2. Enhanced structural strength: The design of the structural reinforcement core enables photovoltaic modules to withstand higher wind pressure (above 6kPa) in high-rise buildings or areas with high wind pressure. The reinforcement core formed by connecting hollow parts not only improves the rigidity of the module, but also enhances its ability to resist wind pressure, ensuring the safety and stability of the module.

[0033] 3. Optimize installation and transportation: Due to the reduction in component weight, installation and transportation are more convenient, further improving the economy of the system. This is especially important in high-rise buildings and areas with high wind pressure, because these areas have higher installation requirements and correspondingly higher costs.

[0034] 4. Improve the use strength: The components of this method are not only light in weight, but also have high structural strength, which avoids the problem of insufficient use strength due to increased weight and extends the service life of the components.

[0035] 5. Reduce material costs: Using hollow parts as reinforcing cores reduces the need for thick glass, thereby reducing material costs. At the same time, the design of hollow parts also optimizes the overall manufacturing cost of the component.

[0036] In summary, the high-strength and lightweight photovoltaic module manufacturing method of the present application not only solves the problems faced by traditional modules in high buildings or areas with high wind pressure, but also significantly improves the economy and safety of the system.

[0037] It should be understood that the foregoing general description and the following detailed description are exemplary and explanatory only and are not restrictive of the present application. BRIEF DESCRIPTION OF THE DRAWINGS

[0038] In order to more clearly illustrate the technical solutions of the embodiments of the present application, the drawings required for use in the description of the embodiments will be briefly introduced below. Obviously, the drawings described below are some embodiments of the present application. For ordinary technicians in this field, other drawings can be obtained based on these drawings without paying any creative work.

[0039] Figure 1 This is a schematic flow chart of the steps of a high-strength and lightweight photovoltaic module and a method for manufacturing the same provided in one embodiment of the present application;

[0040] Figure 2 is a schematic diagram of a power generation unit of the present application;

[0041] Figure 3 It is a schematic diagram of a support unit provided in one embodiment of the present application.

[0042] It should be understood that the foregoing general description and the following detailed description are exemplary and explanatory only and are not restrictive of the present application. DETAILED DESCRIPTION

[0043] The following will be combined with the drawings in the embodiments of the present application to clearly and completely describe the technical solutions in the embodiments of the present application. Obviously, the described embodiments are part of the embodiments of the present application, not all of the embodiments. Based on the embodiments in the present application, all other embodiments obtained by ordinary technicians in this field without creative work are within the scope of protection of this application.

[0044] The flowcharts shown in the accompanying drawings are only examples and do not necessarily include all the contents and operations / steps, nor must they be executed in the order described. For example, some operations / steps may also be decomposed, combined or partially merged, so the actual execution order may change according to actual conditions.

[0045] It should be understood that, in order to facilitate the clear description of the technical solutions of the embodiments of the present invention, in the embodiments of the present invention, the words "first", "second", etc. are used to distinguish the same items or similar items with substantially the same functions and effects. Those skilled in the art can understand that the words "first", "second", etc. do not limit the quantity and execution order, and the words "first", "second", etc. do not necessarily limit the difference.

[0046] It should be understood that the terms used in this application specification are only for the purpose of describing specific embodiments and are not intended to limit the application. As used in this application specification and the appended claims, unless the context clearly indicates otherwise, the singular forms "a", "an" and "the" are intended to include plural forms.

[0047] It should also be understood that the term “and / or” used in the specification and appended claims refers to and includes any and all possible combinations of one or more of the associated listed items.

[0048] In conjunction with the accompanying drawings, some embodiments of the present application are described in detail below. In the absence of conflict, the following embodiments and features in the embodiments can be combined with each other.

[0049] As the global demand for renewable energy continues to increase, photovoltaic power generation systems are increasingly being used in high-rise buildings and in harsh climate conditions. However, traditional photovoltaic modules have encountered many challenges in their application in high-rise buildings or areas with high wind pressure. Traditional photovoltaic modules are mainly composed of transparent panels, power generation chips, backplanes, etc., and their structural strength and weight are the main bottlenecks limiting their application in these special environments.

[0050] In high-rise buildings or areas with high wind pressure, photovoltaic modules need to withstand higher wind pressure. According to industry standards, if they need to withstand wind pressures above 6kPa, traditional photovoltaic modules usually need to be equipped with two layers of 10mm thick glass, which makes the weight of the module reach 50kg / m². This high weight not only increases the burden on the building structure, but may also lead to insufficient use strength of the module, further affecting its safety and stability. In addition, the increase in module weight may lead to a significant increase in transportation and installation costs, thus affecting the economic efficiency of the overall system.

[0051] Therefore, there is an urgent need for a high-strength and lightweight photovoltaic module to solve at least one of the above problems.

[0052] To solve the above problems, please refer to Figure 1 , Figure 1 It is a schematic flow chart of a method for manufacturing a high-strength and lightweight photovoltaic module provided in one embodiment of the present application.

[0053] Specifically, Figure 1 As shown, the method for manufacturing a high-strength and light-weight photovoltaic module includes steps S101 to S105. The power generation unit 1 of the prepared photovoltaic module is as follows Figure 2 As shown, the support unit 2 is as shown in Figure 3 The corresponding steps are described as follows:

[0054] Step S101. Provide a power generation unit, the power generation unit comprising a power generation chip, a first panel, a first back panel and a junction box, the power generation chip comprising a first end face and a second end face oppositely disposed, the first back panel comprising a third end face and a fourth end face oppositely disposed.

[0055] Specifically, the power generation chip 13: is usually made of polycrystalline silicon or monocrystalline silicon, and is responsible for converting solar energy into electrical energy. The first panel 11 is usually transparent glass with a thickness of about 2-3 mm, which is used to protect the power generation chip 13 and allow sunlight to pass through. The first backplane 15 is usually a composite material backplane with a thickness of about 0.4-0.5 mm, which is used to protect the back of the power generation chip 13 and provide a certain mechanical strength. The junction box 17 includes an electrical connector and a protective device for collecting and transmitting the electrical energy generated by the power generation chip 13. The first end face in the chip structure is the side in contact with the first panel 11. The second end face is the side in contact with the first backplane 15. The third end face in the backplane structure is the side in contact with the second end face of the power generation chip 13. The fourth end face is the side in contact with the junction box 17. The various parts of the power generation unit 1 can be produced and tested independently, which improves manufacturing efficiency and quality control. The overall structure of the power generation unit 1 is relatively simple, which is convenient for subsequent assembly steps.

[0056] Exemplarily, the power generation chip 13 uses a monocrystalline silicon photovoltaic chip with a size of 156mm x 156mm and a thickness of 0.2mm. The first panel 11 uses a 3mm thick tempered glass. The first backplane 15 uses a 0.5mm thick composite material backplane. A small junction box 17 is used, with a size of 60mm x 40mm x 20mm, including a connector and a protection diode.

[0057] Step S102: respectively bond the first panel to the first end surface, bond the second end surface to the third end surface, and bond the junction box to the fourth end surface.

[0058] Specifically, a transparent EVA film (ethylene-vinyl acetate copolymer) is used to bond the first panel 11 to the first end face of the power generation chip 13 through a lamination process. An adhesive material (such as an EVA film or a PVB film) is used to bond the second end face of the power generation chip 13 to the third end face of the first back plate 15 through a lamination process. A thermally conductive adhesive or a dedicated junction box 17 fixing adhesive is used to bond the junction box 17 to the fourth end face of the first back plate 15. Through bonding, the power generation chip 13 is sealed between the first panel 11 and the first back plate 15, effectively protecting the chip from the external environment (such as moisture, dust), and extending the service life. The bonding process ensures the stable connection of the various parts of the power generation unit 1 and improves the stability of the structure. The junction box 17 is bonded to the fourth end face of the first back plate 15, which is convenient for subsequent electrical connection and maintenance.

[0059] Exemplarily, EVA film: 0.5mm thick, used to bond the first panel 11 and the power generation chip 13, the lamination temperature is 150°C, the pressure is 1.5 atmospheres, and the lamination time is 10 minutes. PVB film: 0.38mm thick, used to bond the power generation chip 13 and the first backplane 15, the lamination temperature is 120°C, the pressure is 1.0 atmospheres, and the lamination time is 8 minutes. Junction box 17 fixing glue: use thermal conductive silicone, 1mm thick, 5g glue amount, bonding temperature is 60°C, and curing time is 30 minutes.

[0060] Step S103. Provide a support unit, the support unit includes a structural reinforcement core, a second panel and a second back panel, the structural reinforcement core includes a fifth end face and a sixth end face arranged opposite to each other, the second back panel includes a seventh end face and an eighth end face arranged opposite to each other, and a accommodating area is formed on the eighth end face; the structural reinforcement core is composed of a plurality of hollow pieces with preset contour shapes connected together.

[0061] Specifically, the structural reinforcement core 23 is composed of a plurality of hollow pieces of preset contour shapes, providing structural strength and rigidity. The second panel 21 is usually a lightweight material, such as a composite material or a high-strength plastic, with a thickness of about 0.5-1.0 mm. The second back plate 25 is usually a composite material back plate with a thickness of about 0.5-1.0 mm, and a receiving area is formed on the eighth end surface. The fifth end surface in the reinforcement core structure is the side in contact with the second panel 21. The sixth end surface is the side in contact with the second back plate 25. The seventh end surface in the back plate structure is the side in contact with the sixth end surface of the structural reinforcement core 23. The eighth end surface is the side in contact with the fourth end surface of the first back plate 15 of the power generation unit 1, and a receiving area is formed on the eighth end surface for placing the junction box 17. The structural reinforcement core 23 is composed of a plurality of hollow pieces, which significantly improves the rigidity and wind pressure resistance of the component, so that it can be stably used in high buildings or high wind pressure areas. The design of the hollow piece greatly reduces the weight of the support unit 2, reduces the burden on the building structure, and also reduces the transportation and installation costs. The various parts of the support unit 2 can be produced and tested independently, further improving manufacturing efficiency and quality control.

[0062] Exemplarily, the structural reinforcement core 23: uses multiple groups of aluminum alloy hollow pieces, each group of hollow pieces has a rectangular cross section, a length of 1500mm, a width of 100mm, and a height of 20mm. The hollow pieces are connected by bonding or welding. The second panel 21: uses a 1.0mm thick polycarbonate composite panel. The second back plate 25: uses a 0.8mm thick composite back plate, and the eighth end surface forms a 70mm x 50mm accommodating area.

[0063] Step S104: Bond the second panel to the fifth end surface, and bond the sixth end surface to the seventh end surface respectively.

[0064] Specifically, a structural adhesive (such as epoxy adhesive) is used to bond the second panel 21 to the fifth end face of the structural reinforcement core 23 through a bonding process. A structural adhesive is used to bond the sixth end face of the structural reinforcement core 23 to the seventh end face of the second back plate 25 through a bonding process. Through bonding, the various parts of the support unit 2 are sealed between the second panel 21 and the second back plate 25, effectively preventing the external environment from damaging the structural reinforcement core 23. The bonding process ensures the stable connection of the various parts of the support unit 2 and improves the stability of the overall structure. The bonded support unit 2 is more rigid and can better withstand external pressure, especially wind pressure.

[0065] For example, epoxy adhesive: use two-component epoxy structural adhesive with a mixing ratio of 1:1, a thickness of 1mm, an application amount of 100g per square meter, a bonding temperature of room temperature (25°C), and a curing time of 24 hours. Adhesive tool: use a roller or a manual roller to ensure that the bonding surface is flat and free of bubbles.

[0066] Step S105: Bond the fourth end surface to the eighth end surface to bond the power generation unit and the support unit. After bonding, the junction box is placed in the accommodating area.

[0067] Specifically, a structural adhesive (such as polyurethane adhesive) is used to bond the fourth end face of the first back plate 15 of the power generation unit 1 to the eighth end face of the second back plate 25 of the support unit 2 through a bonding process. After bonding, the junction box 17 is placed in the accommodation area of ​​the support unit 2 to ensure that the junction box 17 is in close contact with the eighth end face of the second back plate 25. The bonding of the power generation unit 1 and the support unit 2 makes the assembly a whole, thereby improving the integration and overall performance of the assembly. The junction box 17 is placed in the accommodation area to protect the junction box 17 from the influence of the external environment and improve the safety of the electrical connection. Through a reasonable bonding design, the weight distribution of the assembly is ensured to be uniform, which further improves the stability and safety of the assembly in high buildings or areas with high wind pressure. The overall structure of the assembly simplifies the installation process, makes the installation more convenient and quick, and reduces the installation cost.

[0068] Exemplary, polyurethane glue: use a single-component polyurethane structural glue with a thickness of 1 mm, an application amount of 50 g per square meter, a bonding temperature of room temperature (25°C), and a curing time of 6 hours. Bonding tool: use a press or a manual press tool to ensure that the bonding surfaces are in close contact without gaps. Placement of the junction box 17: use a positioning fixture to accurately place the junction box 17 in the accommodation area, ensuring that the junction box 17 is in close contact with the eighth end face of the second backplane 25 to prevent unstable electrical connection due to looseness.

[0069] In summary, through the above detailed steps and technical contents, the high-strength and lightweight photovoltaic modules of the present application not only significantly improve the structural strength and wind pressure resistance, but also effectively reduce the weight, reduce the manufacturing and installation costs, and improve the economy and safety of the system. The specific examples show the material selection and process parameters in each step, further ensuring the high performance and reliability of the modules.

[0070] In some embodiments, the transmittance of the first panel 11 is greater than a preset transmittance; the power generation unit 1 also includes a first adhesive layer 12, a second adhesive layer 14 and a third adhesive layer 16; the first panel 11 is bonded to the first end face, the second end face is bonded to the third end face, and the junction box 17 is bonded to the fourth end face, including: the first adhesive layer 12 is set between the first panel 11 and the first end face, and the first panel 11 is bonded to the first end face via the first adhesive layer 12; the second adhesive layer 14 is set between the first panel 11 and the first end face, and the second end face is bonded to the third end face via the second adhesive layer 14; the third adhesive layer 16 is set between the junction box 17 and the fourth end face, and the junction box 17 is bonded to the third end face via the third adhesive layer 16.

[0071] In this embodiment, a specific requirement for the light transmittance of the first panel 11 is added, requiring its light transmittance to be greater than a preset light transmittance, which ensures that the photovoltaic module can maintain a high light energy transmittance while maintaining high strength, thereby improving its power generation efficiency.

[0072] The light transmittance of the first panel 11 is greater than the preset light transmittance, which means that more solar energy can be irradiated onto the photovoltaic cells through the panel, thereby increasing the power generation efficiency of the photovoltaic module, which is critical to improving the overall efficiency of the photovoltaic system.

[0073] During the bonding process, a first bonding layer 12, a second bonding layer 14 and a third bonding layer 16 are used. The provision of these bonding layers not only enhances the structural connection strength of the assembly, but also ensures tight bonding between the components, further improving the overall strength and stability of the assembly.

[0074] In the specific bonding process, the adhesive layer is provided to ensure a firm connection between the first panel 11 and the first end face, the second end face and the third end face, and the junction box 17 and the fourth end face. This not only improves the mechanical properties of the assembly, but also ensures the safety and maintainability of important components such as the junction box 17.

[0075] Exemplarily, the first panel 11 is pressurized and heated to crosslink with the first end face via the first adhesive layer 12 , and the second end face is pressurized and heated to crosslink with the third end face via the second adhesive layer 14 ; and / or, the junction box 17 is cured and bonded to the third end face via the third adhesive layer 16 .

[0076] By applying pressure and heat during the bonding process, chemical reactions and physical cross-linking between the bonding layer and the respective connection surfaces can be promoted, thus greatly improving the quality and durability of the bond. This ensures the stability and durability of the components under various environmental conditions.

[0077] The pressurized heating cross-linking process enables the adhesive material to form a tighter and stronger connection at the bonding interface, thereby enhancing the overall structural stability of the component. This is crucial for the performance of the component under high wind pressure or other extreme environmental conditions. Although the pressurized heating treatment increases the complexity of the manufacturing process, by optimizing the process parameters and equipment configuration, an efficient production process can be achieved, production time and cost can be reduced, and overall production efficiency can be improved. Through pressurized heating treatment, the enhanced bonding quality and structural stability enable the components to better adapt to various complex installation and use environments, including tall buildings or areas with high wind pressure. This greatly improves the adaptability and application range of the components.

[0078] It should be noted that, in some embodiments, the pressurized heating cross-linking includes a first working section, a second working section and a cooling section. The pressurization pressure range of the first working section is 65kpa to 110kpa, the pressurization temperature range is 105℃ to 165℃, and the pressurization time range is 550s to 700s; the pressurization pressure range of the second working section is 70 kpa to 110kpa, the pressurization temperature range is 120℃ to 155℃, and the heating time range is 150s to 300s; the cooling section adopts an air cooling process, and the cooling time range is 250s to 350s; and / or, the time range for the third bonding layer 16 to be cured and bonded to the third end face is 3h to 9h.

[0079] The pressing pressure range of the first working stage is 65kPa to 110kPa, the pressing temperature range is 105℃ to 165℃, and the pressing time range is 550s to 700s. At this stage, the bonding material is initially cross-linked to form a stable initial bonding structure, which is very important for ensuring the initial bonding strength and uniformity.

[0080] The second working stage has a pressurization pressure range of 70kPa to 110kPa, a pressurization temperature range of 120℃ to 155℃, and a heating time range of 150s to 300s. This stage further deepens the cross-linking of the bonding material, improves the durability and stability of the bonding, and ensures that the components will not become loose or fail during long-term use.

[0081] The cooling stage uses air cooling, and the cooling time ranges from 250s to 350s. This stage of cooling can prevent the bonding material from deforming or stress concentration at high temperatures, ensuring that the final shape of the component is stable and free of internal stress.

[0082] By optimizing the two pressurized and heated working sections, it is possible to ensure that the adhesive material forms a uniform and tight cross-linked network between the connecting surfaces, thereby greatly improving the mechanical properties of the components and enabling them to maintain structural stability under high wind pressure conditions.

[0083] By precisely controlling the pressurization pressure, temperature and time at each stage, an efficient production process can be achieved, production time can be reduced, and production efficiency can be improved. At the same time, the air cooling process in the cooling section also avoids the long cooling time of the traditional cooling method, further shortening the production cycle. The optimized pressurized heating cross-linking process can improve the weather resistance and anti-aging properties of the bonding material, making the components more reliable in long-term outdoor use and extending the service life of the components. 16 The time range for the third bonding layer 16 to cure and bond with the third end face is 3 hours to 9 hours. This longer curing time ensures the stable installation of the junction box 17 on the fourth end face, improving safety and maintainability.

[0084] Exemplarily, the material of the first bonding layer 12 and / or the material of the second bonding layer 14 is any one of ethylene-vinyl acetate copolymer, polyvinyl butyral, sulfonamide plasticized polycarbonate, polyolefin elastomer and expanded polyethylene; and / or, the third bonding layer 16 is any one of silicone glue, silicone sealant, epoxy potting glue.

[0085] The first adhesive layer 12 and the second adhesive layer 14 can be selected from ethylene-vinyl acetate copolymer (EVA), polyvinyl butyral (PVB), sulfonamide plasticized polycarbonate (SPC), polyolefin elastomer (POE) or expanded polyethylene (EPE). These materials have good light transmittance and mechanical strength, and can effectively protect photovoltaic cells while maintaining high light transmittance to ensure high power generation efficiency of the components. EVA: It has good light transmittance and weather resistance, low cost, and is a commonly used photovoltaic component encapsulation material. PVB: It has excellent bonding strength and mechanical properties, and can better resist external shock and vibration. SPC: It has good stability and transparency at high temperatures and is suitable for applications in high temperature environments. POE: It has excellent anti-PID (potential induced degradation) performance and weather resistance, which can improve the long-term reliability of the components. EPE: It is lightweight and has good buffering properties, which can reduce damage to the components during transportation and installation.

[0086] The third bonding layer 16 can be made of silicone glue, silicone sealant or epoxy potting glue. These materials have excellent waterproof and sealing properties, which can ensure the safety and stability of the junction box 17 in outdoor environments. Silicone glue: has good weather resistance and chemical resistance, and can effectively prevent the erosion of moisture and chemicals. Silicone sealant: has excellent temperature resistance and elasticity, and is suitable for various temperature and humidity conditions. Epoxy potting glue: has high mechanical strength and chemical resistance, and can provide long-term protection and sealing effects.

[0087] The selection of these high-performance adhesive materials can significantly improve the durability and reliability of the modules and extend their service life. Especially in high wind pressure and harsh environments, the high strength and weather resistance of the materials are crucial to the stability and safety of the modules. The selection of these materials not only meets industry standards, but is also compatible with existing production processes and equipment, reducing the complexity and cost of process adjustments. For example, EVA and PVB are currently commonly used materials in the manufacture of photovoltaic modules, and the equipment and technology are very mature. By selecting different adhesive materials, they can be optimized according to specific environmental conditions (such as temperature, humidity, wind pressure, etc.), so that the modules can perform well in various environments.

[0088] In some embodiments, the support unit 2 also includes a fourth adhesive layer 22 and a fifth adhesive layer 24; the second panel 21 is bonded to the fifth end face, and the sixth end face is bonded to the seventh end face, respectively, including: the fourth adhesive layer 22 is set between the second panel 21 and the fifth end face, and the second panel 21 is bonded to the fifth end face via the fourth adhesive layer 22; the fifth adhesive layer 24 is set between the sixth end face and the seventh end face, and the sixth end face is bonded to the seventh end face via the fifth adhesive layer 24.

[0089] The fourth adhesive layer 22 and the fifth adhesive layer 24 can ensure a strong bond between the second panel 21, the structural reinforcement core 23 and the second back plate 25, further enhancing the overall structural stability of the support unit 2. This helps the photovoltaic module maintain structural integrity under high wind pressure and other extreme environmental conditions, and improves its safety and reliability.

[0090] The added adhesive layer can provide more bonding points and a larger bonding area, thereby improving the bonding strength between the components. This is very important for ensuring that the assembly will not loosen or detach during long-term use. The use of the fourth adhesive layer 22 and the fifth adhesive layer 24 can optimize the mechanical properties of the assembly, especially in the support unit 2 part. This helps to reduce the risk of damage to the assembly during transportation and installation and improve its service life. The selection and use of the adhesive layer can ensure the bonding quality between the components, reduce defects in the manufacturing process, and improve the overall manufacturing quality of the assembly.

[0091] Exemplarily, the fourth adhesive layer 22 and / or the fifth adhesive layer 24 is any one of a room temperature curing adhesive or a thermoplastic adhesive film; if the fourth adhesive layer 22 and / or the fifth adhesive layer 24 is a room temperature curing adhesive, the curing temperature range of the room temperature curing adhesive is 25°C to 30°C, and the curing time range is 24h to 72h; if the fourth adhesive layer 22 and / or the fifth adhesive layer 24 is a thermoplastic adhesive film, the curing pressure range of the thermoplastic adhesive film is 65 kPa to 110 kPa, the curing temperature range is 105°C to 165°C, and the curing time range is 450s to 600s.

[0092] The curing temperature range of room temperature curing adhesive is 25℃ to 30℃, and the curing time range is 24 hours to 72 hours. Room temperature curing adhesive can be cured at room temperature and is suitable for scenarios where there is no high-temperature equipment or manufacturing needs to be carried out at room temperature. This reduces the dependence on special equipment and reduces manufacturing costs. The curing process of room temperature curing adhesive under natural conditions is relatively slow, which can ensure the uniform distribution of bonding materials at the bonding interface and improve the bonding quality. The use of room temperature curing adhesive avoids the thermal stress caused by high temperature heating and helps reduce the risk of deformation of components during the manufacturing process.

[0093] The curing pressure range of thermoplastic film is 65kPa to 110kPa, the curing temperature range is 105℃ to 165℃, and the curing time range is 450 seconds to 600 seconds. Thermoplastic film can cure quickly under high temperature and high pressure, which greatly shortens the manufacturing time and improves production efficiency. Thermoplastic film can form high bonding strength under high temperature and high pressure to ensure that the components remain stable during long-term use. Thermoplastic film has good adaptability and can form a strong bond on the surfaces of different materials, improving the reliability and stability of the components. Under high temperature and high pressure, thermoplastic film can better fill the microscopic gaps and bubbles on the connection surface, ensure the flatness and airtightness of the bonding interface, and prevent the intrusion of moisture and air.

[0094] In some embodiments, the support unit 2 also includes: a sixth bonding layer; bonding the fourth end face to the eighth end face, including: setting the sixth bonding layer between the fourth end face and the eighth end face to bond the power generation unit 1 and the support unit 2; wherein the tensile shear strength of the sixth bonding layer is within a preset tensile strength range, the peak load of the sixth bonding layer is within a preset load range, and the tensile bonding strength is within a preset bonding strength range.

[0095] The tensile shear strength of the sixth bonding layer is within the preset tensile strength range, which can ensure that the power generation unit 1 and the support unit 2 will not be easily separated when subjected to lateral shear force, thereby improving the overall strength of the component. The peak load of the sixth bonding layer is within the preset load range, which can ensure that the bonding layer can withstand a large vertical load without failure, thereby ensuring the structural stability and safety of the component. The tensile bonding strength of the sixth bonding layer is within the preset bonding strength range, which can ensure that the bonding layer will not split or fall off when subjected to longitudinal tensile force, thereby further improving the durability of the component.

[0096] By setting the tensile shear strength, peak load and tensile bonding strength of the bonding layer, it is possible to ensure that the performance of the bonding layer is stable under various environmental conditions, extend the service life of the component and improve its reliability. The presence of the sixth bonding layer not only strengthens the connection between the power generation unit 1 and the support unit 2, but also optimizes the mechanical properties of the entire component, so that it can better maintain structural integrity when subjected to various external forces. The high performance of the bonding layer ensures the safety performance of the component under extreme environmental conditions, especially under high wind pressure and severe weather conditions, and can effectively prevent loosening or separation between components and protect the internal photovoltaic cells from damage.

[0097] Exemplarily, the preset tensile strength range is 2 MPa to 19 MPa; and / or, the preset load range is 625 N to 7680 N; and / or, the preset bonding strength range is 1.35 MPa to 12.8 MPa.

[0098] The preset tensile strength range corresponds to 2MPa to 19MPa. The tensile strength within this range ensures that the bonding layer has sufficient strength when subjected to lateral shear force to prevent separation between components. The preset load range corresponds to 625N to 7680N. The peak load within this range ensures that the bonding layer will not fail when subjected to large vertical loads, ensuring the structural stability and safety of the component. The preset bonding strength range corresponds to 1.35MPa to 12.8MPa. The tensile bonding strength within this range ensures that the bonding layer will not split or fall off when subjected to longitudinal tensile force, further improving the durability and reliability of the component.

[0099] By setting a specific parameter range, you can select bonding materials with different properties to suit different application environments and needs. For example, in areas with high wind pressure, you can choose materials with higher tensile shear strength and peak load; in areas with high humidity or high temperature, you can choose materials with higher tensile bond strength. By setting a clear parameter range, you can ensure that products produced in different batches have stable bonding properties and improve the consistency and stability of product quality.

[0100] Exemplarily, the material of the sixth bonding layer is any one of polyurethane glue, epoxy resin glue, acrylic glue, isocyanate glue, silicone structural glue, ethylene-vinyl acetate copolymer, polyvinyl butyral and sulfonamide plasticized polycarbonate.

[0101] Polyurethane glue: It has excellent weather resistance and flexibility, can maintain good bonding performance under various environmental conditions, and is suitable for long-term outdoor use. Epoxy resin glue: It has high bonding strength and good chemical resistance, can provide long-term protection and bonding effects, and is suitable for scenes requiring high mechanical strength. Acrylic glue: It has good transparency and weather resistance, and is suitable for photovoltaic modules that require high light transmittance. Isocyanate glue: It has excellent bonding strength and weather resistance, and is suitable for applications that require high strength and high stability. Silicone structural adhesive: It has good weather resistance and temperature resistance, and is suitable for photovoltaic modules under extreme environmental conditions. EVA: It has good light transmittance and weather resistance, and is low in cost. It is a commonly used photovoltaic module encapsulation material. PVB: It has excellent bonding strength and mechanical properties, and can better resist external shock and vibration. SPC: It has good stability and transparency at high temperatures, and is suitable for applications in high temperature environments.

[0102] The selection of different adhesive materials can be optimized according to specific application requirements. For example, the selection of polyurethane adhesive and silicone structural adhesive can improve the weather resistance and long-term stability of the components; the selection of EVA and PVB can improve the light transmittance and mechanical strength. By selecting high-performance adhesive materials, it can be ensured that the connection between the power generation unit 1 and the support unit 2 is more reliable and safe, reducing the risk of damage during transportation, installation and use. These material selections not only meet industry standards, but also can adapt to different manufacturing conditions. For example, acrylic adhesive is suitable for room temperature curing, while epoxy resin adhesive and EVA are suitable for high temperature and pressure curing, which provides flexibility for different manufacturing processes.

[0103] In some embodiments, the number of sides corresponding to the preset contour shape corresponding to the hollow piece is a preset number of sides, and an air chamber is formed inside the hollow piece, and the thermal conductivity of the air chamber is greater than the preset thermal conductivity. The design of the hollow piece can significantly reduce the weight of the structural reinforcement core 23 by reducing the use of materials. This is very beneficial for the transportation and installation of large photovoltaic modules, and can reduce transportation costs and installation difficulties. The air chamber formed inside the hollow piece has a lower thermal conductivity, which can effectively reduce heat transfer and improve the thermal management performance of the component. This helps to keep the photovoltaic cell within a suitable operating temperature range, improve power generation efficiency and extend service life. The preset contour shape and number of sides of the hollow piece can ensure that it reduces material use and optimizes mechanical properties while providing sufficient support strength. This helps to reduce the overall weight while ensuring structural stability.

[0104] Exemplarily, the preset number of sides is 6, the side length of the hollow member corresponds to a side length range of 4 mm to 6 mm, the thickness of the hollow member corresponds to a thickness range of 0.04 mm to 0.08 mm; and / or, the preset thermal conductivity is 0.02 W / (m·k).

[0105] The hexagonal hollow member design can provide better mechanical properties and structural stability, while reducing the amount of material used, thereby reducing weight. The side length range of 4mm to 6mm can balance the size of the hollow member, ensuring that it will not be too large or too small while providing sufficient support, affecting the stability of the overall structure and the manufacturing process. The thickness range of 0.04mm to 0.08mm can ensure that the hollow member remains lightweight while providing the necessary mechanical strength, reducing the amount of material used. The thermal conductivity of the air chamber is less than 0.02W / (m·k), which can effectively reduce the heat transfer from the photovoltaic cell to the support unit 2 and improve the thermal management efficiency. This helps to keep the photovoltaic cell within a suitable operating temperature range and improve the power generation efficiency.

[0106] Exemplarily, the power generation power of the power generation chip 13 is the target power, and the number, side length and thickness of the hollow parts in the structural reinforcement core 23 are determined according to the target power, the preset number of sides and the thermal conductivity of the air chamber, so that the weight and surface area of ​​the structural reinforcement core 23 are respectively less than the preset weight and the preset surface area.

[0107] By determining the number, side length and thickness of the hollow pieces in the structural reinforcement core 23 according to the target power, the preset number of sides and the thermal conductivity of the air chamber, it is possible to ensure that the photovoltaic module has optimized thermal management and structural performance while achieving the expected power generation. By adjusting the number, side length and thickness of the hollow pieces, it is possible to ensure that the weight and surface area of ​​the structural reinforcement core 23 are less than the preset weight and preset surface area, respectively. This not only reduces the weight of the module, but also reduces the use of materials and reduces manufacturing costs.

[0108] The optimized hollow component design can ensure that the component is lightweight while dissipating heat efficiently, so that the component can still maintain good thermal management performance at high power output. By precisely controlling the number, side length and thickness of the hollow components, the weight can be reduced to the maximum extent while ensuring the structural strength, thereby improving the overall performance and economy of the component.

[0109] The present application provides a method for manufacturing a high-strength and lightweight photovoltaic module. The high-strength and lightweight photovoltaic module is mainly composed of two parts: a power generation unit and a support unit: the power generation unit includes: a power generation chip: including a first end face and a second end face. A first panel: bonded to the first end face of the power generation chip. A first back plate: bonded to the second end face of the power generation chip. A junction box: bonded to the fourth end face of the first back plate. The support unit includes: a structural reinforcement core: composed of a plurality of hollow pieces with preset contour shapes, used to reduce the mass of the support unit and improve the heat dissipation efficiency. A second panel: bonded to the fifth end face of the structural reinforcement core. A second back plate: including a seventh end face and an eighth end face that are relatively arranged, and bonded to the sixth end face of the structural reinforcement core. An accommodation area: formed on the eighth end face of the second back plate, for placing a junction box.

[0110] The manufacturing process of the power generation unit includes: bonding the second end face of the power generation chip to the third end face of the first back plate. Bonding the junction box to the fourth end face of the first back plate. The manufacturing process of the support unit includes: bonding the second panel to the fifth end face of the structural reinforcement core. Bonding the sixth end face of the structural reinforcement core to the seventh end face of the second back plate. Finally, bonding the fourth end face of the first back plate of the power generation unit to the eighth end face of the second back plate of the support unit, so that the junction box is placed in the accommodation area of ​​the support unit.

[0111] The provided components and methods have at least the following beneficial effects

[0112] 1. Weight reduction: By using a structural reinforcement core composed of hollow parts, the overall weight of the photovoltaic module is significantly reduced. Traditional modules require two layers of 10mm thick glass and weigh 50kg / m², while the weight of the module in this method is greatly reduced, reducing the burden on the building structure and reducing transportation and installation costs.

[0113] 2. Enhanced structural strength: The design of the structural reinforcement core enables photovoltaic modules to withstand higher wind pressure (above 6kPa) in high-rise buildings or areas with high wind pressure. The reinforcement core formed by connecting hollow parts not only improves the rigidity of the module, but also enhances its ability to resist wind pressure, ensuring the safety and stability of the module.

[0114] 3. Optimize installation and transportation: Due to the reduction in component weight, installation and transportation are more convenient, further improving the economy of the system. This is especially important in high-rise buildings and areas with high wind pressure, because these areas have higher installation requirements and correspondingly higher costs.

[0115] 4. Improve the use strength: The components of this method are not only light in weight, but also have high structural strength, which avoids the problem of insufficient use strength due to increased weight and extends the service life of the components.

[0116] 5. Reduce material costs: Using hollow parts as reinforcing cores reduces the need for thick glass, thereby reducing material costs. At the same time, the design of hollow parts also optimizes the overall manufacturing cost of the component.

[0117] In summary, the high-strength and lightweight photovoltaic module manufacturing method of the present application not only solves the problems faced by traditional modules in high buildings or areas with high wind pressure, but also significantly improves the economy and safety of the system.

[0118] like Figure 2 and Figure 3As shown, the present application provides a high-strength and lightweight photovoltaic module, including: a power generation unit 1, the power generation unit 1 includes a power generation chip 13, a first panel 11, a first back plate 15 and a junction box 17, the power generation chip 13 includes a first end face and a second end face arranged oppositely, the first back plate 15 includes a third end face and a fourth end face arranged oppositely, the first panel 11 is bonded to the first end face, the second end face is bonded to the third end face, and the junction box 17 is bonded to the fourth end face; a support unit 2, the support unit 2 includes a structural reinforcement core 23, a second panel 21 and a second back plate 25 The structural reinforcement core 23 includes a fifth end face and a sixth end face that are relatively arranged, the second back plate 25 includes a seventh end face and an eighth end face that are relatively arranged, the second panel 21 is bonded to the fifth end face, the sixth end face is bonded to the seventh end face, an accommodating area is formed on the eighth end face, the fourth end face is bonded to the eighth end face, so as to bond the power generation unit 1 and the support unit 2, and the junction box 17 is placed in the accommodating area; wherein, the structural reinforcement core 23 is composed of a plurality of hollow pieces with preset contour shapes connected to reduce the mass of the support unit 2 and improve the heat dissipation efficiency of the high-strength and lightweight photovoltaic module.

[0119] The high-strength and lightweight photovoltaic module is mainly composed of two parts: the power generation unit 1 and the support unit 2: the power generation unit 1 includes: the power generation chip 13: including the first end face and the second end face. The first panel 11: bonded to the first end face of the power generation chip 13. The first back plate 15: bonded to the second end face of the power generation chip 13. The junction box 17: bonded to the fourth end face of the first back plate 15. The support unit 2 includes: the structural reinforcement core 23: composed of a plurality of hollow pieces with preset contour shapes, used to reduce the mass of the support unit 2 and improve the heat dissipation efficiency. The second panel 21: bonded to the fifth end face of the structural reinforcement core 23. The second back plate 25: including the seventh end face and the eighth end face arranged oppositely, and bonded to the sixth end face of the structural reinforcement core 23. The accommodation area: formed on the eighth end face of the second back plate 25, for placing the junction box 17.

[0120] The manufacturing process of the power generation unit 1 includes: bonding the second end face of the power generation chip 13 to the third end face of the first back plate 15. Bonding the junction box 17 to the fourth end face of the first back plate 15. The manufacturing process of the support unit 2 includes: bonding the second panel 21 to the fifth end face of the structural reinforcement core 23. Bonding the sixth end face of the structural reinforcement core 23 to the seventh end face of the second back plate 25. Finally, bonding the fourth end face of the first back plate 15 of the power generation unit 1 to the eighth end face of the second back plate 25 of the support unit 2, so that the junction box 17 is placed in the accommodation area of ​​the support unit 2.

[0121] The power generation unit 1 is composed of a power generation chip 13, a first panel 11, a first back plate 15 and a junction box 17. The power generation chip 13 is the core part of the photovoltaic module and is responsible for converting light energy into electrical energy. The first panel 11 and the first back plate 15 are respectively bonded to the two opposite end surfaces of the power generation chip 13 to play a role of protection and support. The junction box 17 is bonded to the fourth end surface of the first back plate 15 to connect and manage the electricity generated by the power generation chip 13.

[0122] The support unit 2 is composed of a structural reinforcement core 23, a second panel 21 and a second back plate 25. The structural reinforcement core 23 is composed of a plurality of hollow pieces with preset contour shapes. The design of these hollow pieces not only reduces the overall mass of the support unit 2, but also improves the heat dissipation efficiency of the photovoltaic module. The second panel 21 and the second back plate 25 are respectively bonded to the fifth end face and the seventh end face of the structural reinforcement core 23, further enhancing the overall structural strength and stability.

[0123] By using a plurality of hollow members with preset contour shapes as the structural reinforcement core 23, the amount of material used is greatly reduced, thereby reducing the overall mass of the photovoltaic module. The design of the hollow member increases air circulation, helps dissipate heat, and improves the performance and life of the photovoltaic module in a high temperature environment.

[0124] The bonding design of the first panel 11, the first back panel 15, the second panel 21 and the second back panel 25, as well as the supporting function of the structural reinforcement core 23, ensure the stability and durability of the photovoltaic module in various environments. The junction box 17 is placed in the accommodation area of ​​the support unit 2, making the overall structure more compact and convenient for installation and maintenance.

[0125] For example, the parameters of the actual high-strength and lightweight photovoltaic assembly provided in this application may be:

[0126] Power generation chip 13: adopts high-efficiency monocrystalline silicon photovoltaic cells, with a size of 156mm x 156mm.

[0127] The first panel 11 is made of transparent anti-ultraviolet glass with a thickness of about 2 mm.

[0128] The first back plate 15 is made of a composite material with strong weather resistance and has a thickness of about 1 mm.

[0129] Junction box 17: It has built-in lightning protection, moisture-proof and dust-proof functions, and its dimensions are 100mm x 50mm x 20mm.

[0130] The structural reinforcement core 23 is composed of a plurality of hexagonal hollow parts connected together, each of which has a wall thickness of 0.5 mm and a height of 10 mm.

[0131] The second panel 21 is made of a lightweight aluminum alloy material and has a thickness of about 1.5 mm.

[0132] The second back plate 25 is made of corrosion-resistant stainless steel and has a thickness of about 1 mm.

[0133] Accommodating area: A groove with a size of 100 mm x 50 mm x 30 mm is opened on the eighth end surface of the second back plate 25 for accommodating the junction box 17 .

[0134] The lightweight design reduces the amount of material used, thereby reducing production costs. At the same time, the efficient heat dissipation performance extends the service life of the components and reduces the cost of maintenance and replacement. By optimizing the heat dissipation design, the power generation efficiency of photovoltaic modules in high temperature environments has been improved, thereby increasing the overall energy output. The design of the structural reinforcement core 23 improves the wind and pressure resistance of the components, allowing them to maintain stable operation in harsh natural environments. The lightweight and compact design makes photovoltaic modules easier to transport and install, reducing construction time and costs. The use of lightweight materials reduces dependence on heavy machinery and transportation tools, thereby reducing carbon emissions and better meeting the requirements of green energy.

[0135] In summary, the provided high-strength and lightweight photovoltaic modules have significant advantages in many aspects and can be widely used in various solar power generation systems, especially in scenarios where weight and heat dissipation performance need to be considered.

[0136] It should be noted that technicians in the relevant field can clearly understand that for the convenience and simplicity of description, the specific structure and parameters of the high-strength and lightweight photovoltaic components described above can refer to the corresponding processes in the embodiments of the method for manufacturing high-strength and lightweight photovoltaic components described in the above embodiments, and will not be repeated here.

[0137] The above is only a specific implementation of the present application, but the protection scope of the present application is not limited thereto. Any technician familiar with the technical field can easily think of various equivalent modifications or replacements within the technical scope disclosed in the present application, and these modifications or replacements should be included in the protection scope of the present application. Therefore, the protection scope of the present application shall be based on the protection scope of the claims.

Claims

1. A method for manufacturing a high-strength and lightweight photovoltaic module, characterized in that: include: A power generation unit is provided, the power generation unit comprising a power generation chip, a first panel, a first back panel and a junction box, the power generation chip comprising a first end face and a second end face arranged oppositely, the first back panel comprising a third end face and a fourth end face arranged oppositely; Respectively bonding the first panel to the first end surface, bonding the second end surface to the third end surface, and bonding the junction box to the fourth end surface; A support unit is provided, the support unit comprising a structural reinforcement core, a second panel and a second back panel, the structural reinforcement core comprising a fifth end face and a sixth end face arranged oppositely, the second back panel comprising a seventh end face and an eighth end face arranged oppositely, and a receiving area is formed on the eighth end face; the structural reinforcement core is formed by connecting a plurality of hollow pieces with preset contour shapes; the number of sides corresponding to the preset contour shapes of the hollow pieces is a preset number of sides, an air chamber is formed inside the hollow piece, and the thermal conductivity of the air chamber is greater than the preset thermal conductivity; The preset number of sides is 6, the side length of the hollow member corresponds to a side length range of 4 mm to 6 mm, the thickness of the hollow member corresponds to a thickness range of 0.04 mm to 0.08 mm, the preset thermal conductivity is 0.02 W / (m·k), the power generation power of the power generation chip is the target power, and the number, side length and thickness of the hollow members in the structural reinforcement core are determined according to the target power, the preset number of sides and the thermal conductivity of the air chamber, so that the weight and surface area of ​​the structural reinforcement core are respectively less than the preset weight and the preset surface area; respectively bonding the second panel to the fifth end surface, and bonding the sixth end surface to the seventh end surface; The fourth end surface is bonded to the eighth end surface to bond the power generation unit and the support unit, and after bonding, the junction box is placed in the accommodating area.

2. The method according to claim 1, characterized in that The light transmittance of the first panel is greater than a preset light transmittance; the power generation unit further comprises a first adhesive layer, a second adhesive layer and a third adhesive layer; the first panel is respectively bonded to the first end surface, the second end surface is bonded to the third end surface, and the junction box is bonded to the fourth end surface, comprising: The first adhesive layer is disposed between the first panel and the first end surface, and the first panel is bonded to the first end surface via the first adhesive layer; The second adhesive layer is disposed between the power generation chip and the first back plate, and the second end surface is bonded to the third end surface via the second adhesive layer; The third adhesive layer is disposed between the junction box and the fourth end surface, and the junction box is bonded to the third end surface via the third adhesive layer.

3. The method according to claim 2, characterized in that The first panel is cross-linked with the first end face by pressurizing and heating via the first adhesive layer, and the second end face is cross-linked with the third end face by pressurizing and heating via the second adhesive layer; and / or, The junction box is cured and bonded to the third end surface via the third adhesive layer.

4. The method according to claim 3, characterized in that The pressurized heating cross-linking includes a first working section, a second working section and a cooling section, wherein the pressurization pressure range of the first working section is 65 kPa to 110 kPa, the pressurization temperature range is 105°C to 165°C, and the pressurization time range is 550s to 700s; the pressurization pressure range of the second working section is 70 kPa to 110 kPa, the pressurization temperature range is 120°C to 155°C, and the heating time range is 150s to 300s; the cooling section adopts an air cooling process, and the cooling time range is 250s to 350s; and / or, The time range for curing and bonding the third adhesive layer and the third end face is 3 hours to 9 hours.

5. The method according to claim 1, characterized in that: The supporting unit further includes a fourth adhesive layer and a fifth adhesive layer; and the second panel is bonded to the fifth end surface and the sixth end surface is bonded to the seventh end surface respectively, including: The fourth adhesive layer is arranged between the second panel and the fifth end surface, and the second panel is bonded to the fifth end surface via the fourth adhesive layer; The fifth adhesive layer is disposed between the sixth end face and the seventh end face, and the sixth end face is bonded to the seventh end face via the fifth adhesive layer.

6. The method according to claim 5, characterized in that The fourth adhesive layer and / or the fifth adhesive layer is any one of a room temperature curing adhesive or a thermoplastic adhesive film; If the fourth adhesive layer and / or the fifth adhesive layer is a room temperature curing adhesive, the curing temperature of the room temperature curing adhesive is in the range of 25° C. to 30° C., and the curing time is in the range of 24 h to 72 h; If the fourth adhesive layer and / or the fifth adhesive layer is a thermoplastic film, the curing pressure of the thermoplastic film is in a range of 65 kpa to 110 kpa, the curing temperature is in a range of 105° C. to 165° C., and the curing time is in a range of 450 s to 600 s.

7. The method according to claim 1, characterized in that The supporting unit further includes: a sixth bonding layer; and bonding the fourth end surface to the eighth end surface includes: Disposing the sixth bonding layer between the fourth end surface and the eighth end surface to bond the power generation unit and the support unit; The tensile shear strength of the sixth bonding layer is within a preset tensile strength range, the peak load of the sixth bonding layer is within a preset load range, and the tensile bonding strength is within a preset bonding strength range.

8. The method according to claim 7, characterized in that The preset tensile strength range is 2MPa to 19MPa; and / or, The preset load range is 625N to 7680N; and / or, The preset bonding strength range is 1.35 MPa to 12.8 MPa.

9. A high-strength and lightweight photovoltaic module, characterized in that: include: A power generation unit, the power generation unit comprising a power generation chip, a first panel, a first back panel and a junction box, the power generation chip comprising a first end face and a second end face arranged oppositely, the first back panel comprising a third end face and a fourth end face arranged oppositely, the first panel is bonded to the first end face, the second end face is bonded to the third end face, and the junction box is bonded to the fourth end face; A support unit, the support unit comprising a structural reinforcement core, a second panel and a second back panel, the structural reinforcement core comprising a fifth end face and a sixth end face arranged oppositely, the second back panel comprising a seventh end face and an eighth end face arranged oppositely, the second panel is bonded to the fifth end face, the sixth end face is bonded to the seventh end face, an accommodation area is formed on the eighth end face, the fourth end face is bonded to the eighth end face to bond the power generation unit and the support unit, and the junction box is placed in the accommodation area; The structural reinforcement core is composed of a plurality of hollow pieces with preset contour shapes, so as to reduce the mass of the support unit and improve the heat dissipation efficiency of the high-strength and lightweight photovoltaic module; the number of sides corresponding to the preset contour shape corresponding to the hollow piece is a preset number of sides, an air chamber is formed inside the hollow piece, and the thermal conductivity of the air chamber is greater than the preset thermal conductivity; The preset number of sides is 6, the side length of the hollow part corresponds to a side length range of 4 mm to 6 mm, the thickness of the hollow part corresponds to a thickness range of 0.04 mm to 0.08 mm, the preset thermal conductivity is 0.02 W / (m·k), the power generation power of the power generation chip is the target power, and the number, side length and thickness of the hollow parts in the structural reinforcement core are determined according to the target power, the preset number of sides and the thermal conductivity of the air chamber, so that the weight and surface area of ​​the structural reinforcement core are respectively less than the preset weight and the preset surface area.

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