Photovoltaic module with edge creepage area and preparation method thereof

Abstract

The present application discloses a photovoltaic module with an edge creepage area and a preparation method thereof, the method comprising: providing an upper glass, a battery cell, a lower glass, a welding strip, a busbar, and a busbar groove; forming a slot on either end surface of the busbar groove; pasting the battery cell on the upper glass, and pasting the lower glass on the battery cell, one end of the battery cell is connected to the welding strip; bending the welding strip 90 degrees relative to the battery cell, so that a partial structure of the welding strip extends upward along the lower glass and is perpendicular to the battery cell; setting the busbar on the partial structure of the welding strip, and the battery cell is electrically connected to the bus bar on the busbar via the welding strip; inserting the slot of the busbar groove into the partial structure of the welding strip, so that the welding strip and the busbar are sealed in the busbar groove and the partial structure of the busbar groove is set on the lower glass; the photovoltaic module can be connected to an external device via the busbar groove; filling a packaging adhesive layer between the welding strip and the busbar groove where they do not contact the lower glass to complete the preparation of the photovoltaic module.

Description

Technical Field

[0001] The present application relates to the field of photovoltaic technology, and in particular to a photovoltaic module with an edge creepage region and a preparation method thereof. Background Art

[0002] Photovoltaic modules are key equipment for converting solar energy into electrical energy. They mainly include multiple cells, welding ribbons, busbars, and packaging materials (such as glass and backplane). In traditional photovoltaic modules, the current generated by the cells is transmitted to the busbars through welding ribbons, and then the busbars are led to the junction box to form a complete circuit. In order to ensure electrical safety and insulation performance, according to relevant international and domestic standards, the distance from the busbar to the edge of the glass must maintain a certain safety distance. This standard limits the effective layout of cells in the module, resulting in a decrease in the energy density and conversion efficiency of the module.

[0003] In actual engineering applications, the installation area and number of photovoltaic modules are often limited. Due to the distance requirements from the busbar to the edge of the glass, the total power generation under the same area is limited. For photovoltaic modules with junction boxes at the edge, the problem is more prominent. In order to lead out the busbar and weld it to the junction box, it is necessary to drill holes at the edge of the glass, and the hole position must be a certain safe distance away from the edge. This not only increases the manufacturing difficulty, but also further increases the distance from the busbar to the edge of the glass, thereby further reducing the energy density of the battery cell in the module and the conversion efficiency of the module.

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

[0005] The present application provides a photovoltaic module with an edge creepage area and a preparation method thereof, aiming to solve the problem that the installation area and number of photovoltaic modules are often limited in actual engineering applications. Due to the distance requirement from the busbar to the edge of the glass, the total power generation under the same area is limited. For photovoltaic modules with junction boxes at the edge, the problem is more prominent. In order to lead out the busbar and weld it to the junction box, it is necessary to drill holes at the edge of the glass, and the hole position must be a certain safe distance away from the edge. This not only increases the manufacturing difficulty, but also further increases the distance from the busbar to the edge of the glass, thereby further reducing the energy density of the battery cell in the module and the conversion efficiency of the module.

[0006] In a first aspect, the present application provides a method for preparing a photovoltaic module having an edge creepage region, the method comprising:

[0007] Provide upper glass, battery cells, lower glass, welding strips, busbars, and busbars; wherein a slot is formed on any end surface of the busbar;

[0008] Paste the battery cell on the upper glass, and paste the lower glass on the battery cell, and connect one end of the battery cell to the welding ribbon;

[0009] Bend the soldering ribbon 90 degrees relative to the cell, so that part of the soldering ribbon extends upward along the lower glass and is perpendicular to the cell;

[0010] The busbar is arranged on a part of the structure of the welding strip, and the battery cell is electrically connected to the busbar on the busbar via the welding strip, so that an edge creepage area is formed between the welding strip and the battery cell;

[0011] Insert the slot of the busbar into the partial structure of the welding strip, so that the welding strip and the busbar are sealed in the busbar and the partial structure of the busbar is arranged on the lower glass; the photovoltaic module can be connected to the external device through the busbar;

[0012] A packaging adhesive layer is filled between the soldering ribbon and the lower glass where the busbar is not in contact, thereby completing the preparation of a photovoltaic module with an edge creepage area.

[0013] In a second aspect, the present application provides a photovoltaic module having an edge creepage region, comprising:

[0014] Glassing;

[0015] Battery cell, the battery cell is attached to the upper glass;

[0016] Lower glass, which is attached to the battery cell;

[0017] A soldering ribbon, one end of the cell is connected to the soldering ribbon, and the soldering ribbon is bent 90° relative to the cell, so that part of the structure of the soldering ribbon extends upward along the lower glass and is perpendicular to the cell;

[0018] A busbar, wherein the busbar is arranged on a part of the structure of the welding strip, and the battery cell is electrically connected to the busbar on the busbar through the welding strip, so that an edge creepage area is formed between the welding strip and the battery cell;

[0019] A busbar, wherein a slot is formed on any end surface of the busbar, and the slot of the busbar is inserted into a partial structure of the welding strip, so that the welding strip and the busbar are sealed in the busbar and the partial structure of the busbar is arranged on the lower glass;

[0020] The encapsulation adhesive layer is filled between the welding strip and the lower glass where the busbar is not in contact with the lower glass. The photovoltaic module is connected to the external device through the busbar.

[0021] The embodiment of the present application provides a photovoltaic module with an edge creepage area and a preparation method thereof, wherein the photovoltaic module at least includes: an upper glass: an upper protective material of the photovoltaic module. A cell: a key component for photoelectric conversion. A lower glass: a lower protective material of the photovoltaic module. A soldering strip: a conductive material used to connect the cell and the busbar. A busbar: a part that collects the current generated by the cell. A busbar: a structure used to protect the soldering strip and the busbar, with a slot formed on either end face of the busbar. The cell is pasted on the upper glass to ensure a firm bond between the cell and the upper glass. The lower glass is pasted on the cell to ensure a firm bond between the cell and the lower glass. One end of the cell is connected to the soldering strip to ensure that the current generated by the cell can be transmitted through the soldering strip. The soldering strip is bent 90° relative to the cell so that part of the structure of the soldering strip extends upward along the lower glass and is perpendicular to the cell. This step is to reasonably arrange the soldering strip in a limited space and reduce the distance from the busbar to the edge of the glass. The busbar is set on the partial structure of the welding strip, and the battery cell is electrically connected to the busbar on the busbar through the welding strip. In this way, an edge creepage area is formed between the welding strip and the battery cell, which helps to better collect current. Insert the slot of the busbar into the partial structure of the welding strip to ensure that the welding strip and the busbar are sealed in the busbar, and the local structure of the busbar is set on the lower glass. This step not only protects the welding strip and the busbar, but also enables the photovoltaic module to be connected to external equipment. Fill the encapsulation glue layer between the welding strip and the busbar where it does not contact the lower glass to ensure the sealing and insulation of all components, and complete the preparation of the photovoltaic module with an edge creepage area.

[0022] Furthermore, the provided method and photovoltaic module have at least the following beneficial effects:

[0023] 1. Improve energy density: By bending the solder strip 90° and arranging it reasonably, the distance from the bus bar to the edge of the glass is reduced, thereby improving the energy density of the battery cell in the module.

[0024] 2. Increase the total power generation: Under the same installation area, the total power generation is improved due to the increase in energy density. This is of great significance for the limited installation area and quantity in practical engineering applications.

[0025] 3. Simplify the manufacturing process: Due to the bending design of the welding ribbon, there is no need to punch holes on the edge of the glass, which simplifies the manufacturing process and reduces the manufacturing difficulty. Simplifying the manufacturing steps and reducing the need for punching improves the overall manufacturing efficiency.

[0026] 4. Improve the reliability of components: Through the slot design of the busbar and the filling of the encapsulation glue layer, the solder strip and the busbar are well sealed and protected, reducing the intrusion of moisture and dust, and improving the long-term reliability of the component. The filling of the encapsulation glue layer ensures the insulation between the solder strip and the busbar, avoids the risk of short circuit, and improves the safety of the component.

[0027] 5. Optimized structural design: The edge creepage area formed between the solder ribbon and the cell helps to better collect current and optimize the electrical performance of the component. The bending design allows the solder ribbon to be reasonably laid out in a limited space, avoiding unnecessary occupation and improving the overall design compactness of the component.

[0028] 6. Improve electrical performance: By optimizing the layout of the solder strip, the resistance loss of the current transmission path is reduced and the conversion efficiency of the components is improved. Reasonable layout design reduces the accumulation of heat in the welding area and avoids performance degradation caused by local overheating.

[0029] 7. Adapt to various installation requirements: This method is particularly suitable for photovoltaic modules with junction boxes at the edge, solving the problems caused by drilling and safety distance requirements in traditional designs. Through the design of the edge creepage area, the module can more flexibly adapt to different installation requirements and environmental conditions.

[0030] In summary, the present application provides a photovoltaic module with an edge creepage area and a preparation method thereof, which reduces the distance from the busbar to the edge of the glass by optimizing the bending and layout design of the welding strip, thereby improving the energy density and total power generation of the battery cell in the module. At the same time, the manufacturing process is simplified, and the reliability, electrical performance and flexibility of the module are improved. This innovative design method has significant beneficial effects in practical engineering applications, and is particularly suitable for photovoltaic modules with junction boxes at the edge, providing an effective solution for improving the performance of photovoltaic modules and reducing manufacturing costs.

[0031] 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

[0032] 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.

[0033] Figure 1 It is a schematic diagram of the existing photovoltaic module structure;

[0034] Figure 2 It is a schematic diagram of the existing photovoltaic module connection;

[0035] Figure 3 It is a schematic flow chart of the steps of a method for preparing a photovoltaic module with an edge creepage area provided by an embodiment of the present application;

[0036] Figure 4is a top view of a photovoltaic module with an edge creepage area provided by an embodiment of the present application;

[0037] Figure 5 This is a front view of a photovoltaic module with an edge creepage area provided by an embodiment of the present application;

[0038] Figure 6 It is a side view of a photovoltaic module with an edge creepage area provided by an embodiment of the present application;

[0039] Figure 7 It is a schematic flow chart of a method for preparing a photovoltaic module with an edge creepage area provided in one embodiment of the present application;

[0040] Figure 8 This is a connection diagram of a photovoltaic assembly corresponding to an even number of cells provided in one embodiment of the present application;

[0041] Fig. 9 This is a schematic diagram of bus bars corresponding to an even number of battery cells provided in one embodiment of the present application;

[0042] Fig.10 This is a schematic diagram of bus bars corresponding to an odd number of battery cells provided in one embodiment of the present application;

[0043] Fig.11 This is a connection diagram of a photovoltaic module corresponding to an odd number of cells provided in one embodiment of the present application.

[0044] 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

[0045] 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.

[0046] 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.

[0047] 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.

[0048] 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.

[0049] 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.

[0050] 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.

[0051] Photovoltaic modules are key devices that convert solar energy into electrical energy. They mainly include multiple cells, welding strips, bus bars, and packaging materials (such as glass and backplane). In traditional photovoltaic modules, Figure 1 As shown in the figure, the current generated by the cell is transmitted to the busbar through the welding ribbon, and then led to the junction box by the busbar to form a complete circuit. In order to ensure electrical safety and insulation performance, according to relevant international and domestic standards, the distance from the busbar to the edge of the glass must maintain a certain safety distance. This standard limits the effective layout of the cell in the module, resulting in a decrease in the energy density and conversion efficiency of the module.

[0052] In actual engineering applications, the installation area and number of photovoltaic modules are often limited. Due to the distance requirement from the busbar to the edge of the glass, the total power generation under the same area is limited. For photovoltaic modules with junction boxes at the edge, the problem is more prominent. Figure 2 As shown in the figure, in order to lead out the busbars and weld them to the junction box, it is necessary to drill holes on the edge of the glass, and the holes must be at a certain safe distance from the edge. This not only increases the manufacturing difficulty, but also further increases the distance from the busbar to the edge of the glass, thereby further reducing the energy density of the cell in the module and the conversion efficiency of the module.

[0053] Therefore, there is an urgent need for a photovoltaic module to solve at least one of the above problems.

[0054] To solve the above problems, please refer to Figure 3 , Figure 3 is a schematic flow chart of a method for preparing a photovoltaic module with an edge creepage region provided in an embodiment of the present application. The method is used to prepare Figure 4-11 The photovoltaic module corresponding to any of the accompanying drawings.

[0055] Please refer to Figure 3 Specifically, Figure 3 As shown, the provided method for preparing a photovoltaic module with an edge creepage region includes steps S101 to S106. The details are as follows:

[0056] Step S101. Provide upper glass, battery cells, lower glass, solder strips, busbars, and busbars; wherein a slot is formed on any end surface of the busbar.

[0057] Specifically, the upper glass is used as a protective material for photovoltaic modules. Glass with high transparency and good weather resistance is usually used, and the size is determined according to actual needs. Cells are key components for photoelectric conversion. Monocrystalline silicon or multicrystalline silicon cells are usually used. The size and quantity are determined according to the module design. The lower glass is another layer of protective material for photovoltaic modules. Glass with good weather resistance is usually used, and the size matches the upper glass. The welding ribbon is used to connect the conductive material of the cell and the busbar. Materials with good conductivity and high temperature resistance are usually selected. The busbar collects the current generated by the cell, and is usually made of metal materials such as copper or aluminum. The busbar is used to protect the structure of the welding ribbon and the busbar. A slot is formed on either end face of the busbar to facilitate the insertion and sealing of the welding ribbon.

[0058] Exemplarily, some of the parameters provided may be: upper glass: 1600mm × 1000mm × 4mm; cell: monocrystalline silicon cell, size 156mm × 156mm, quantity 60 pieces; lower glass: 1600mm × 1000mm × 4mm; welding strip: copper welding strip, diameter 0.5mm; busbar: copper busbar, thickness 1mm; busbar: plastic busbar, size 1200mm × 100mm, slot width 0.6mm.

[0059] By ensuring that all materials meet the requirements, a reliable foundation is provided for subsequent steps. The slot design on the end face of the busbar facilitates the insertion and sealing of the solder strip, improving the protection and reliability of the component.

[0060] Step S102: Paste the battery cell onto the upper glass, and paste the lower glass onto the battery cell, and connect one end of the battery cell to the welding strip.

[0061] Specifically, the battery cell is pasted on the upper glass by using an adhesive film composed of an adhesive or a conductive adhesive to ensure a firm bond between the battery cell and the upper glass. The lower glass is also pasted on the battery cell through an adhesive film to ensure a firm bond between the battery cell and the lower glass. One end of the battery cell is connected to the welding strip to ensure that the current generated by the battery cell can be transmitted through the welding strip. If the adhesive is an EVA film with a thickness of 0.5 mm, 60 battery cells are pasted on the upper glass in a predetermined arrangement using the EVA film. Then the lower glass is pasted on the upper glass to which the battery cell has been pasted. One end of the battery cell is connected to the copper welding strip by welding. Pasting the battery cell and the lower glass ensures the mechanical strength of the component and reduces damage caused by external factors. The firm connection between the battery cell and the welding strip ensures the reliable transmission of current and improves the electrical performance of the component.

[0062] Step S103: bend the soldering ribbon 90 degrees relative to the battery cell, so that a portion of the soldering ribbon extends upward along the lower glass and is perpendicular to the battery cell.

[0063] Specifically, by using a bending tool or mechanical equipment to bend the soldering ribbon 90° relative to the battery cell, part of the structure of the soldering ribbon extends upward along the lower glass and is perpendicular to the battery cell. The bent part of the soldering ribbon can be reasonably arranged in a limited space to reduce the distance from the bus bar to the edge of the glass. For example, use a bending machine to bend the copper soldering ribbon 90°. Choose to bend at the edge of the battery cell to ensure that part of the structure of the soldering ribbon extends upward along the lower glass. By bending the soldering ribbon, the distance from the bus bar to the edge of the glass is reduced, and the energy density of the battery cell is improved. Reasonable arrangement of the soldering ribbon allows the assembly to arrange more battery cells in a limited installation area, thereby increasing the total power generation.

[0064] Step S104: The busbar is arranged on a part of the structure of the welding strip, and the battery cell is electrically connected to the busbar on the busbar via the welding strip, so that an edge creepage area is formed between the welding strip and the battery cell.

[0065] Specifically, the busbar is placed on the partial structure after the welding strip is bent to ensure the electrical connection between the welding strip and the busbar. An edge creepage area is formed between the welding strip and the battery cell, which helps to better collect the current generated by the battery cell. By welding or other reliable connection methods, ensure that the battery cell is electrically connected to the busbar on the busbar via the welding strip. Place the copper busbar on the bent copper welding strip partial structure. Use welding to electrically connect the welding strip to the busbar on the busbar. The electrical connection between the welding strip and the busbar forms an edge creepage area, which helps to better collect current and reduce resistance loss. The design of the edge creepage area ensures efficient current transfer within the component and improves the conversion efficiency of the component.

[0066] Step S105. Insert the slot of the bus trough into the partial structure of the welding strip, so that the welding strip and the busbar are sealed in the bus trough and the partial structure of the bus trough is arranged on the lower glass; the photovoltaic module can be connected to the external device through the bus trough.

[0067] Specifically, the slot of the busbar is inserted into the bent portion of the solder strip to ensure that the solder strip and the busbar are sealed in the busbar. The partial structure of the busbar is set on the lower glass to provide additional mechanical support and protection. The busbar design enables the photovoltaic module to be connected to external equipment (such as an inverter) to ensure the smooth output of current. For example, a slot with a slot width of 0.6 mm of the plastic busbar is inserted into the bent copper solder strip. Part of the structure of the busbar is set on the lower glass to ensure that the solder strip and the busbar are well protected.

[0068] The sealing design of the busbar protects the solder strip and busbar, reduces the intrusion of the external environment (such as moisture and dust), and prolongs the service life of the component. The local structure of the busbar is set on the lower glass, providing additional mechanical support and enhancing the overall strength of the component. The design of the busbar ensures the reliable connection between the component and the external equipment, and improves the overall reliability of the system.

[0069] Step S106: Fill the area between the soldering ribbon and the busbar where the soldering ribbon is not in contact with the lower glass, thereby completing the preparation of the photovoltaic module with the edge creepage area.

[0070] Specifically, the area where the solder strip and the busbar do not contact the lower glass is filled with encapsulation glue ( Figure 6 and the glue locations in other related drawings) to ensure the sealing and insulation of all components. The encapsulation glue usually uses materials with good insulation and weather resistance, such as EVA film or POE film. After completing the filling of the encapsulation glue layer, the component is finally inspected and tested to ensure the normal operation of all components and complete the preparation of photovoltaic components with edge creepage areas. If EVA film is used, the thickness is 0.5mm. Fill the area where the solder ribbon and the busbar do not contact the lower glass to ensure that the solder ribbon and the busbar are completely sealed. The filling of the encapsulation glue layer ensures the sealing between the solder ribbon and the busbar, prevents the intrusion of moisture and dust, and improves the waterproof and dustproof performance of the component. The encapsulation glue layer provides good insulation performance, avoids the risk of short circuit caused by contact between the solder ribbon and the lower glass, and improves the safety of the component. The filling of the encapsulation glue layer enhances the overall sealing and insulation of the component, and improves the reliability and service life of the component.

[0071] In summary, the present application provides a method for preparing a photovoltaic module with an edge creepage region, and the corresponding principle of the method is as follows: Figure 7As shown in the figure, the method reduces the distance from the busbar to the edge of the glass by optimizing the bending and layout design of the welding ribbon, thereby improving the energy density and total power generation of the battery cell in the module. The specific steps include:

[0072] Material preparation: Ensure that all materials meet the requirements and provide a reliable foundation for subsequent steps. Paste the cell and lower glass: Make the module have good mechanical strength and electrical performance. Bending the welding ribbon: Optimize the layout of the welding ribbon and reduce the distance from the bus bar to the edge of the glass. Busbar setting: Form an edge creepage area, optimize current transfer, and improve conversion efficiency. Busbar insertion: Provide additional mechanical support and protection to ensure reliable connection with external equipment. Filling the encapsulation glue layer: Enhance the sealing and insulation of the module, and improve reliability and safety. This method has significant beneficial effects in actual engineering applications, especially for photovoltaic modules with junction boxes at the edge, and provides an effective solution for improving the performance of photovoltaic modules and reducing manufacturing costs.

[0073] In some embodiments, before completing the preparation of the photovoltaic module with the edge creepage area, it also includes: providing an L-shaped profile; and placing the L-shaped profile in contact with the busbar, the packaging adhesive layer and the upper glass.

[0074] like Figure 5-8 As shown in the figure, the use of L-shaped profiles can significantly enhance the mechanical strength of the edges of photovoltaic modules and prevent damage or deformation caused by stress on the edges during transportation, installation and use. This reinforcement design not only protects the busbar and welding strip, but also improves the structural stability of the entire photovoltaic module. The L-shaped profile is placed in conjunction with the busbar, encapsulation layer and upper glass to further improve the sealing of the edges, prevent moisture and dust from entering the module from the edges, and extend the service life of the module. Enhanced sealing can also reduce performance degradation caused by environmental factors and improve the reliability and stability of the module.

[0075] The L-shaped profile design makes the edges of the photovoltaic module smoother and more regular, which is convenient for alignment and fixing during installation. This design can also reduce the interference with the busbar and welding strip during installation, and improve installation efficiency and quality. By using L-shaped profiles on the edges of photovoltaic modules, the mechanical strength and sealing of the modules are significantly improved, the installation process is simplified, and the reliability and service life of the modules are improved.

[0076] In some embodiments, the thickness of the busbar corresponds to a thickness range of 0.3 mm to 1 mm; the width of the busbar groove is greater than the thickness of the busbar, and the difference between the width of the busbar groove and the thickness of the busbar corresponds to a range of 0.05 mm to 0.15 mm.

[0077] The thickness of the busbar ranges from 0.3mm to 1mm, ensuring that the busbar has good electrical conductivity and mechanical strength, while not increasing the weight and cost of the module due to excessive thickness. The appropriate thickness range can reduce resistance and improve current transmission efficiency, thereby improving the overall conversion efficiency of the photovoltaic module. The width of the busbar is greater than the thickness of the busbar, and the difference between the width and thickness is 0.05mm to 0.15mm. This design ensures that the busbar can be completely sealed by the busbar. The moderate difference range can avoid excessive gaps and reduce the risk of poor sealing, while ensuring that there is an appropriate amount of space in the busbar to prevent damage to the busbar or welding strip due to over-tightening.

[0078] The width design of the busbar ensures the stability and accuracy of the busbar when inserted, reducing deviations and problems during installation. A moderate width difference also helps the busbar to be in closer contact with the cell, improving the reliability of the electrical connection of the entire assembly. The thickness and width of the busbar and busbar are designed within a reasonable range, which can reduce material waste and production costs.

[0079] By optimizing the size design of the busbar and busway, good electrical performance and sealing effect are ensured, the installation reliability and production efficiency are improved, and the cost is reduced.

[0080] In some embodiments, the number of strings corresponding to the battery cells is an even number, and each battery cell is connected to the bus bar on the same bus bar to form the positive electrode and the negative electrode of the battery cell.

[0081] In some embodiments, the number of strings corresponding to the battery cells is an even number, and each battery cell is connected to a bus bar on the same bus bar to form a positive electrode and a negative electrode of the battery cell.

[0082] The number of battery strings is an even number, which means that the battery cells in the module can be divided into multiple pairs of battery strings. Fig. 9 As shown in the figure, the positive and negative electrodes of each cell are connected to the same bus bar to form a complete electrical circuit. One end of each cell is connected to the bus bar through a welding ribbon, so that the current can be effectively transmitted throughout the component. The positive and negative electrodes of the cell are connected to the same bus bar, which simplifies the design and manufacturing process of the electrical connection.

[0083] At the same time, if Figure 8 As shown, in addition to the busbars, the busbars also have diodes integrated on them. The function of these diodes is the same as that of the diodes in the junction box, which can protect the circuit when hot spots occur. This design of the busbar and the busbar slot replaces the function of the junction box, which reduces the distance from the busbar to the edge of the glass, saves the junction box, avoids drilling holes on the edge of the glass, saves the cost of drilling holes in the glass, and increases the power generation per unit area of ​​the photovoltaic module.

[0084] Since the positive and negative electrodes of each cell are connected to the same busbar, the number and complexity of the busbars are reduced, and the design of the electrical connection is simplified. This design makes the electrical layout inside the module more compact and efficient, reduces the number of welding points and conductive paths in the manufacturing process, and reduces production costs and failure rates. Reducing welding points and conductive paths means reducing the potential risk of poor contact and breakage, and improving the reliability and stability of the module. Connecting the positive and negative electrodes of the cell to the same busbar can reduce the resistance during current transmission, improve current transmission efficiency, and thus improve overall conversion efficiency.

[0085] The layout and connection of an even number of cells makes the space inside the module more efficient, reducing unnecessary gaps and waste. This design can increase the filling rate of cells in the module and further improve the energy density and conversion efficiency of the module.

[0086] Exemplarily, a conductive tape is attached to the bus trough, and the conductive tape is connected to an external wire, and is used to lead out the current converged by the bus trough through the conductive tape and the external wire; wherein the height corresponding to the conductive tape is the same as the height of the bus bar in the bus plate. A conductive tape is attached to the bus trough, and the conductive tape is used to lead out the current in the bus trough.

[0087] like Figure 8 As shown in the figure, when there are two photovoltaic modules with an even number of strings, the conductive tape is connected to the external connector to transmit the current to other electrical equipment or the power grid through the external wire. The height of the conductive tape is the same as the height of the busbar in the busbar, ensuring good contact between the conductive tape and the busbar. This height matching design can reduce contact resistance and improve the efficiency and reliability of current transmission.

[0088] Using conductive tape to lead the current out of the busbar simplifies the design of the lead-out part and reduces the complexity and manufacturing difficulty of the lead-out part. The flexible nature of the conductive tape enables it to better adapt to busbars of different shapes and sizes, improving the flexibility and adaptability of manufacturing. The highly matched design of the conductive tape and the busbar ensures good contact between the two and reduces contact resistance. This design improves the stability and reliability of current transmission and reduces the risk of performance degradation and failure due to poor contact.

[0089] Conductive tape not only has a conductive function, but also has a certain sealing performance, which can prevent moisture and dust from entering the component from the lead-out part to a certain extent. This design improves the overall sealing of the component and extends the service life of the component. Using conductive tape instead of the traditional lead-out method can reduce the materials and process complexity required in the manufacturing process. The use of conductive tape can also simplify the installation process, improve production efficiency, and further reduce costs.

[0090] In some embodiments, the number of strings corresponding to the battery cells is an odd number, and each battery cell is connected to the bus bar on two adjacent bus bars to form a positive electrode and a negative electrode of the battery cell respectively.

[0091] like Fig.10 As shown in the figure, the number of battery cells in the string is an odd number, which means that the battery cells in the module cannot be completely connected in pairs, and the positive and negative poles need to be connected through two adjacent bus bars. For example, if the number of strings is 5, the positive pole of the first battery cell is connected to the first bus bar, and the negative pole is connected to the second bus bar; the positive pole of the second battery cell is connected to the second bus bar, and the negative pole is connected to the third bus bar, and so on.

[0092] like Fig.10 As shown, in addition to the busbars, the busbars also have diodes integrated on them. The function of these diodes is the same as that of the diodes in the junction box, which can protect the circuit when hot spots occur. This design of a combination of busbars and busbar troughs replaces the function of the junction box, reduces the distance from the busbar to the edge of the glass, and increases the power generation per unit area of ​​the photovoltaic module. At the same time, it also saves junction boxes, wires, and avoids drilling holes on the edge of the glass. While saving the cost of drilling holes in the glass and the cost of wires, it also reduces the distance between photovoltaic modules, which is conducive to increasing the number of photovoltaic modules installed and increasing the power generation of power stations.

[0093] One end of each cell is connected to a busbar through a welding ribbon to form a positive electrode, and the other end is connected to another adjacent busbar through a welding ribbon to form a negative electrode. This connection method can achieve efficient connection of an odd number of cells and ensure the normal transmission of current in the component.

[0094] The connection of an odd number of cells provides greater flexibility, and the number of cell strings can be adjusted in different application scenarios to meet specific needs. For example, within a limited installation area, the required voltage and current output can be more accurately matched by connecting an odd number of cells. By connecting the positive and negative poles of the cell with two adjacent bus bars, the number and complexity of the bus bars can be reduced, and the efficiency of current transmission can be improved. This design reduces the resistance in the current transmission path, thereby improving the overall conversion efficiency of the component.

[0095] Although the connection method of odd-numbered cells is slightly complicated, the problems that may occur during the manufacturing process can be reduced through reasonable design and process control. For example, the path of the solder strip can be pre-designed during the manufacturing process to ensure the accuracy and reliability of the connection.

[0096] Exemplarily, a conductive tape is affixed in the busbar, and the number of photovoltaic modules is two; inserting the slot of the busbar into the partial structure of the welding tape comprises: pre-bonding the welding tapes of two photovoltaic modules; simultaneously inserting the slot of the busbar into the partial structure of the welding tapes of two photovoltaic modules, the busbars of the two photovoltaic modules are electrically connected via the conductive tape, and the packaging of the two photovoltaic modules is completed; wherein the positive electrode of one photovoltaic module is connected in series with the negative electrode of another photovoltaic module via the conductive tape.

[0097] like Fig.11 As shown, a conductive tape is attached to the confluence groove (the conductive tape is fixed inside the confluence groove in a "Π" shape), and the number of photovoltaic modules is two; the slot of the confluence groove is inserted into the partial structure of the welding tape, including: pre-bonding the welding tapes of two photovoltaic modules; inserting the slot of the confluence groove into the partial structure of the welding tapes of two photovoltaic modules at the same time, the confluence plates of the two photovoltaic modules are electrically connected through the conductive tape, and the packaging of the two photovoltaic modules is completed; wherein the positive electrode of one photovoltaic module is connected in series with the negative electrode of another photovoltaic module through the conductive tape. A conductive tape is attached to the confluence groove, and the conductive tape is used to electrically connect the welding tapes of the two photovoltaic modules. The conductive performance of the conductive tape ensures that the current can be smoothly transmitted between the two photovoltaic modules.

[0098] Before inserting the slot of the busbar into the partial structure of the soldering tape, the soldering tapes of the two photovoltaic modules are pre-laminated to ensure the accuracy and stability of the connection part. Pre-lamination can reduce the difficulty and error rate of alignment during the subsequent insertion process. The slot of the busbar is inserted into the partial structure of the soldering tape of the two photovoltaic modules at the same time, so that the busbars of the two photovoltaic modules are electrically connected through the conductive tape. The partial structure of the busbar is set on the lower glass to complete the encapsulation of the two photovoltaic modules and ensure the sealing and mechanical strength of the connection part. The positive electrode of one photovoltaic module is connected in series with the negative electrode of another photovoltaic module through the conductive tape to form a complete electrical circuit. This series connection method can increase the voltage output of the entire system and is suitable for application scenarios requiring higher voltages. By connecting two photovoltaic modules in series, the voltage output of the system can be significantly increased, which is suitable for power systems or specific applications requiring higher voltages. For example, in long-distance power transmission or high-power applications, high voltage output can reduce losses during transmission and improve energy transmission efficiency. The combined design of the conductive tape and the busbar can ensure the reliability and sealing of the electrical connection between the two photovoltaic modules. This design reduces the risk of poor contact and breakage that may be caused by traditional welding methods, and improves the long-term stability of the system. By pre-bonding the welding ribbons of the two photovoltaic modules, the difficulty and time of alignment in the manufacturing process can be reduced, and production efficiency can be improved. The insertion and packaging process of the busbar is relatively simple, which is convenient for automated production and large-scale manufacturing, and reduces production costs. This design enables two photovoltaic modules to be efficiently connected in a limited space, reducing additional connection components and space requirements. High space utilization efficiency not only improves the energy density of the module, but also reduces the use and waste of materials. By connecting the positive and negative poles of an odd number of cells to two adjacent busbars respectively, a flexible electrical connection method is provided, which improves the efficiency of current transmission and the overall performance of the module.

[0099] In some embodiments, the exposed width of the bus trough is less than or equal to the thickness of the encapsulation layer. The exposed width of the bus trough refers to the width of the portion of the bus trough not covered by the encapsulation layer. In the design, the exposed width of the bus trough needs to be strictly controlled to be less than or equal to the thickness of the encapsulation layer. The encapsulation layer is used to encapsulate components such as battery cells, welding ribbons, and busbars in an integral structure to provide protection and insulation. The thickness of the encapsulation layer needs to be optimized according to actual needs and process parameters to ensure the performance and reliability of the components.

[0100] During the manufacturing process, conductive tape is first applied to the busbar, and then the slot of the busbar is inserted into the partial structure of the solder strip. Ensure that the width of the exposed part of the busbar does not exceed the thickness of the encapsulation layer, and the busbar and other components such as the battery cell are completely wrapped by the encapsulation layer to form a sealed whole.

[0101] Controlling the width of the exposed busbar to be less than or equal to the thickness of the encapsulation adhesive layer can ensure that the busbar is fully wrapped and improve the sealing of the component. Components with good sealing can effectively prevent external impurities such as moisture and dust from entering, extending the service life of the component.

[0102] The busbar is fully wrapped by the encapsulation layer, which can enhance the overall mechanical strength of the component and reduce the damage that may occur during transportation and installation. The improvement of mechanical strength makes the component more robust and able to withstand higher environmental and mechanical stress.

[0103] The width of the exposed part of the busbar is reduced, which can reduce the electrical contact area with the outside world, thereby reducing electrical loss. The reduction of electrical loss improves the power conversion efficiency of the component and increases the output power.

[0104] By controlling the exposed width of the busbar to be less than or equal to the thickness of the encapsulation layer, the sealing and mechanical strength of the photovoltaic module are improved, the power loss is reduced, the appearance design is optimized, and the manufacturing yield is improved. This design improvement can significantly improve the performance and reliability of photovoltaic modules in practical applications, extend the service life of the modules, and enhance the market competitiveness of the products.

[0105] The present application provides a method for preparing a photovoltaic module with an edge creepage area, wherein the photovoltaic module comprises at least: an upper glass: an upper protective material of the photovoltaic module. A cell: a key component for photoelectric conversion. A lower glass: a lower protective material of the photovoltaic module. A soldering strip: a conductive material used to connect the cell and the busbar. A busbar: a part that collects the current generated by the cell. A busbar: a structure used to protect the soldering strip and the busbar, with a slot formed on either end face of the busbar. The cell is pasted on the upper glass to ensure a firm bond between the cell and the upper glass. The lower glass is pasted on the cell to ensure a firm bond between the cell and the lower glass. One end of the cell is connected to the soldering strip to ensure that the current generated by the cell can be transmitted through the soldering strip. The soldering strip is bent 90° relative to the cell so that part of the structure of the soldering strip extends upward along the lower glass and is perpendicular to the cell. This step is to reasonably arrange the soldering strip in a limited space and reduce the distance from the busbar to the edge of the glass. The busbar is set on the partial structure of the welding strip, and the battery cell is electrically connected to the busbar on the busbar through the welding strip. In this way, an edge creepage area is formed between the welding strip and the battery cell, which helps to better collect current. Insert the slot of the busbar into the partial structure of the welding strip to ensure that the welding strip and the busbar are sealed in the busbar, and the local structure of the busbar is set on the lower glass. This step not only protects the welding strip and the busbar, but also enables the photovoltaic module to be connected to external equipment. Fill the encapsulation glue layer between the welding strip and the busbar where it does not contact the lower glass to ensure the sealing and insulation of all components, and complete the preparation of the photovoltaic module with an edge creepage area.

[0106] The method provided thereby has at least the following beneficial effects:

[0107] 1. Improve energy density: By bending the solder strip 90° and arranging it reasonably, the distance from the bus bar to the edge of the glass is reduced, thereby improving the energy density of the battery cell in the module.

[0108] 2. Increase the total power generation: Under the same installation area, the total power generation is improved due to the increase in energy density. This is of great significance for the limited installation area and quantity in practical engineering applications.

[0109] 3. Simplify the manufacturing process: Due to the bending design of the welding ribbon, there is no need to punch holes on the edge of the glass, which simplifies the manufacturing process and reduces the manufacturing difficulty. Simplifying the manufacturing steps and reducing the need for punching improves the overall manufacturing efficiency.

[0110] 4. Improve the reliability of components: Through the slot design of the busbar and the filling of the encapsulation glue layer, the solder strip and the busbar are well sealed and protected, reducing the intrusion of moisture and dust, and improving the long-term reliability of the component. The filling of the encapsulation glue layer ensures the insulation between the solder strip and the busbar, avoids the risk of short circuit, and improves the safety of the component.

[0111] 5. Optimized structural design: The edge creepage area formed between the solder ribbon and the cell helps to better collect current and optimize the electrical performance of the component. The bending design allows the solder ribbon to be reasonably laid out in a limited space, avoiding unnecessary occupation and improving the overall design compactness of the component.

[0112] 6. Improve electrical performance: By optimizing the layout of the solder strip, the resistance loss of the current transmission path is reduced and the conversion efficiency of the components is improved. Reasonable layout design reduces the accumulation of heat in the welding area and avoids performance degradation caused by local overheating.

[0113] 7. Adapt to various installation requirements: This method is particularly suitable for photovoltaic modules with junction boxes at the edge, solving the problems caused by drilling and safety distance requirements in traditional designs. Through the design of the edge creepage area, the module can more flexibly adapt to different installation requirements and environmental conditions.

[0114] In summary, the present application provides a method for preparing a photovoltaic module with an edge creepage area, which reduces the distance from the busbar to the edge of the glass by optimizing the bending and layout design of the welding strip, thereby improving the energy density and total power generation of the battery cell in the module. At the same time, the manufacturing process is simplified, and the reliability, electrical performance and flexibility of the module are improved. This innovative design method has significant beneficial effects in practical engineering applications, and is particularly suitable for photovoltaic modules with junction boxes at the edges, providing an effective solution for improving the performance of photovoltaic modules and reducing manufacturing costs.

[0115] See also Figures 3 to 11 As shown, the present application provides a photovoltaic module with an edge creepage area, including: an upper glass; a battery cell, the battery cell is pasted on the upper glass; a lower glass, the lower glass is pasted on the battery cell; a welding strip, one end of the battery cell is connected to the welding strip, and the welding strip is bent 90° relative to the battery cell so that a partial structure of the welding strip extends upward along the lower glass and is perpendicular to the battery cell; a busbar, the busbar is arranged on the partial structure of the welding strip, and the battery cell is electrically connected to the bus bar on the busbar via the welding strip, so that an edge creepage area is formed between the welding strip and the battery cell; a busbar, a slot is formed on either end face of the busbar, and the slot of the busbar is inserted into the partial structure of the welding strip, so that the welding strip and the busbar are sealed in the busbar and the local structure of the busbar is arranged on the lower glass; an encapsulation adhesive layer, the encapsulation adhesive layer is filled between the welding strip and the busbar where it does not contact the lower glass, and the photovoltaic module is connected to an external device via the busbar.

[0116] 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 connection relationship process of the photovoltaic components and modules described above can refer to the corresponding processes in the embodiments of the photovoltaic component preparation method with edge creepage area described in the above embodiments, and will not be repeated here.

[0117] 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 preparing a photovoltaic module with an edge creepage area, characterized in that: include: Provide an upper glass, a battery cell, a lower glass, a welding strip, a busbar, and a busbar; wherein a slot is formed on any end surface of the busbar; Paste the battery cell on the upper glass, and paste the lower glass on the battery cell, and connect one end of the battery cell to the welding ribbon; The soldering ribbon is bent 90 degrees relative to the battery cell, so that a part of the structure of the soldering ribbon extends upward along the lower glass and is perpendicular to the battery cell; The busbar is arranged on a part of the structure of the welding strip, and the battery cell is electrically connected to the busbar on the busbar via the welding strip, so that an edge creepage area is formed between the welding strip and the battery cell; Insert the slot of the busbar into the partial structure of the welding strip, so that the welding strip and the busbar are sealed in the busbar and the partial structure of the busbar is arranged on the lower glass; the photovoltaic module can be connected to the external device through the busbar; A packaging adhesive layer is filled between the soldering strip and the area where the busbar does not contact the lower glass, thereby completing the preparation of the photovoltaic module with the edge creepage area.

2. The method according to claim 1, characterized in that Before the preparation of the photovoltaic module with the edge creepage area is completed, the method further includes: Provide L-shaped profiles; The L-shaped profile is placed in contact with the busbar, the packaging adhesive layer and the upper glass.

3. The method according to claim 1, characterized in that The thickness of the busbar corresponds to a thickness range of 0.3 mm to 1 mm; the width of the busbar groove is greater than the thickness of the busbar, and the difference between the width of the busbar groove and the thickness of the busbar corresponds to a range of 0.05 mm to 0.15 mm.

4. The method according to claim 1, characterized in that: The number of strings corresponding to the battery cells is an even number, and each battery cell is connected to the bus bar on the same bus bar to form the positive electrode and the negative electrode of the battery cell.

5. The method according to claim 4, characterized in that A conductive tape is attached to the bus trough, and the conductive tape is connected to an external wire for leading out the current converged in the bus trough through the conductive tape and the external wire; wherein the height corresponding to the conductive tape is the same as the height of the bus bar in the bus plate.

6. The method according to claim 1, characterized in that The number of strings corresponding to the battery cells is an odd number, and each battery cell is connected to the bus bar on two adjacent bus bars to form the positive electrode and the negative electrode of the battery cell respectively.

7. The method according to claim 6, characterized in that The conductive tape is affixed in the bus trough, and the number of the photovoltaic modules is two; the slot of the bus trough is inserted into the partial structure of the welding tape, including: Pre-bonding the welding ribbons of the two photovoltaic modules; The slots of the busbar are simultaneously inserted into the partial structures of the welding strips of the two photovoltaic modules, and the busbars of the two photovoltaic modules are electrically connected via the conductive tape to complete the packaging of the two photovoltaic modules; wherein the positive electrode of one photovoltaic module is connected in series with the negative electrode of the other photovoltaic module via the conductive tape.

8. The method according to claim 1, characterized in that The width of the busbar exposed to the outside is less than or equal to the thickness of the packaging glue layer.

9. A photovoltaic module having an edge creepage area, characterized in that: include: Glassing; A battery cell, wherein the battery cell is adhered to the upper glass; A lower glass, wherein the lower glass is adhered to the battery cell; A soldering ribbon, one end of the battery cell is connected to the soldering ribbon, and the soldering ribbon is bent 90° relative to the battery cell, so that a portion of the structure of the soldering ribbon extends upward along the lower glass and is perpendicular to the battery cell; A busbar, wherein the busbar is arranged on a part of the structure of the welding strip, and the battery cell is electrically connected to the busbar on the busbar through the welding strip, so that an edge creepage area is formed between the welding strip and the battery cell; A busbar, wherein a slot is formed on any end surface of the busbar, and the slot of the busbar is inserted into a partial structure of the welding strip, so that the welding strip and the busbar are sealed in the busbar and the partial structure of the busbar is arranged on the lower glass; The encapsulation adhesive layer is filled between the welding strip and the area where the busbar does not contact the lower glass, and the photovoltaic module is connected to an external device via the busbar.

10. The photovoltaic module according to claim 9, characterized in that: Also includes: An L-shaped profile is placed in contact with the busbar, the packaging adhesive layer and the upper glass.

11. The photovoltaic module according to claim 9, characterized in that: Also includes: If the number of strings corresponding to the battery cell is an even number, each battery cell is connected to the bus bar on the same bus bar to form the positive electrode and the negative electrode of the battery cell; If the number of strings corresponding to the battery cells is an odd number, each battery cell is connected to the bus bar on two adjacent bus bars to form the positive electrode and the negative electrode of the battery cell respectively.

12. The photovoltaic module according to claim 11, characterized in that: If the number of strings corresponding to the battery cells is an odd number, a conductive tape is attached to the busbar, and the number of the photovoltaic modules is two; The slots of the busbar are simultaneously inserted into the partial structures of the welding strips of the two photovoltaic modules, and the busbars of the two photovoltaic modules are electrically connected via the conductive tape to complete the packaging of the two photovoltaic modules; wherein the positive electrode of one photovoltaic module is connected in series with the negative electrode of the other photovoltaic module via the conductive tape.

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