Lamination method based on linkage between laminator and autoclave

Abstract

The present application provides a lamination method based on the linkage of a laminator and an autoclave, which belongs to the field of photovoltaics. The method comprises: providing a laminated photovoltaic module and performing an electroluminescence test, obtaining an electroluminescence test result corresponding to the photovoltaic module, and confirming whether the photovoltaic module includes a battery string with a preset defect; the preset defect includes at least one or more of cracks, short circuits, black cores and cold solder joints; if it is confirmed according to the electroluminescence test result that the photovoltaic module passes the electroluminescence test, placing the photovoltaic module in a lamination chamber of a laminator for pre-lamination, so that the photovoltaic module produces gluing; placing the pre-laminated photovoltaic module in a vertical direction on a preset support frame; the vertical direction is a direction perpendicular to the battery arrangement direction of the photovoltaic module; pushing the support frame into a preset autoclave, and the autoclave pressurizes and heats the photovoltaic module in turn according to preset parameters corresponding to multiple preset stages to complete the packaging of the photovoltaic module.

Description

Technical Field

[0001] The invention belongs to the field of photovoltaics, and in particular relates to a lamination method based on the linkage of a laminator and an autoclave. Background Art

[0002] In the current production process of Building Integrated Photovoltaic (BIPV) modules, the lamination process is a key link, but it is also a major bottleneck. The maximum module area that a traditional laminator can process at one time is 2.7 meters × 5.4 meters = 14.58 square meters. The cavity size of the laminator limits the number of modules processed each time, and the different types of film and glass thickness make the lamination time fluctuate between 40 minutes and 60 minutes. In this case, the lamination process becomes the bottleneck of the entire production line, seriously affecting the overall production efficiency and resulting in low production capacity.

[0003] At the same time, traditional laminators have obvious deficiencies in temperature distribution and pressure control. Due to uneven temperature distribution, components are prone to problems such as insufficient gluing and falling off during the lamination process, affecting the stability and consistency of the components. In addition, the pressure provided by the laminator is relatively small, and it cannot effectively ensure the tightness of the components under high temperature and high pressure, which further reduces the production quality. These problems are particularly obvious in mass production, and it is difficult to meet high-standard technical requirements.

[0004] Therefore, a lamination method is urgently needed to solve at least one of the above problems. Summary of the invention

[0005] The present application provides a lamination method based on the linkage of a laminator and an autoclave, aiming to solve the obvious deficiencies of traditional laminators in temperature distribution and pressure control. Due to the uneven temperature distribution, the components are prone to problems such as insufficient gluing and falling off during the lamination process, affecting the stability and consistency of the components. In addition, the pressure provided by the laminator is relatively small, and the tightness of the components under high temperature and high pressure cannot be effectively guaranteed, thereby further reducing the production quality. These problems are particularly obvious in mass production, and it is difficult to meet high-standard technical requirements.

[0006] In a first aspect, the present application provides a lamination method based on the linkage of a laminator and an autoclave, the method comprising:

[0007] Providing laminated photovoltaic modules;

[0008] Performing electroluminescence detection on the photovoltaic module, obtaining the electroluminescence detection result corresponding to the photovoltaic module, and confirming whether the photovoltaic module includes a battery string with a preset defect; the preset defect includes at least one or more of cracks, short circuits, black cores and cold solder joints;

[0009] If the photovoltaic module passes the electroluminescence test according to the electroluminescence test result, the photovoltaic module is placed in a lamination chamber of a laminator for pre-lamination, so that the photovoltaic module is glued;

[0010] Placing the pre-laminated photovoltaic module on a preset support frame in a vertical direction; wherein the vertical direction is a direction perpendicular to the battery arrangement direction of the photovoltaic module;

[0011] The support frame is pushed into a preset autoclave, and the autoclave pressurizes and heats the photovoltaic components in turn according to preset parameters corresponding to multiple preset stages to complete the packaging of the photovoltaic components; the multiple preset stages include at least a preheating stage, a first heating stage, a second heating stage and a cooling stage.

[0012] In some embodiments, before providing the laminated photovoltaic module, it also includes: providing a front glass panel, a first adhesive film, a battery string, a bus bar, a second adhesive film and a back glass panel; in a lamination room with a preset environment, laying the first adhesive film on the front glass panel; laying the battery string on the first adhesive film, and welding the bus bar to the battery string; laying the second adhesive film and the back glass on the battery string and the bus bar in sequence to complete the lamination of the photovoltaic module.

[0013] Exemplarily, the glass widths corresponding to the front glass and the back glass are the same; before completing the lamination of the photovoltaic module, it also includes: trimming the first adhesive film and the second adhesive film so that the film widths corresponding to the trimmed first adhesive film and the second adhesive film are greater than the glass width, and the difference between the film width and the glass width is within a preset width range, and the preset width range is 10 mm to 20 mm.

[0014] Exemplarily, the preset environment corresponding to the lamination chamber includes a preset temperature range and a preset humidity range, the preset temperature range is 18° C. to 24° C., and the preset humidity range is 18% RH to 28% RH.

[0015] In some embodiments, the electroluminescence detection of the photovoltaic component includes: providing an electroluminescence detection device; the electroluminescence detection device includes a high-voltage power supply and a CCD acquisition module; fixing the photovoltaic component on a preset detection table after cleaning; the detection table is located in a darkroom environment; connecting the high-voltage power supply to the photovoltaic component; controlling the photovoltaic component to emit visible light or near-infrared light according to preset electroluminescence parameters through the high-voltage power supply; the electroluminescence parameters include at least voltage, current and exposure time; when the photovoltaic component emits visible light or near-infrared light, the CCD acquisition module collects the luminescence image information corresponding to the photovoltaic component; and completing the electroluminescence detection of the photovoltaic component according to the luminescence image information.

[0016] Exemplarily, completing the electroluminescence detection of the photovoltaic component according to the luminescent image information includes: inputting the luminescent image information into a preset multi-scale filter, the multi-scale filter outputting multi-scale features corresponding to the luminescent image information; the multi-scale filter includes any one of a Gaussian pyramid filter or a multi-scale Laplacian filter; performing semantic segmentation and instance segmentation on the luminescent image information according to the multi-scale features, and obtaining a semantic segmentation map and defect mask information corresponding to the luminescent image information; the semantic segmentation map includes multiple pixel defect type identifiers; performing edge detection on the luminescent image information to obtain edge detection information corresponding to the luminescent image information; completing the electroluminescence detection of the photovoltaic component according to the semantic segmentation map, edge detection information and the defect mask information.

[0017] Exemplarily, if the preset defects include cracks, short circuits, black cores and cold solder joints; the electroluminescence detection of the photovoltaic module is completed according to the semantic segmentation map, edge detection information and the defect mask information, including: determining whether the luminescent image includes continuous edge breaks according to the edge detection information and the semantic segmentation map, so as to determine whether the luminescent image includes the cracks; determining the current distribution information corresponding to the luminescent image according to the semantic segmentation map, and determining whether the luminescent image includes a current abnormality area based on the thermal map technology and the current distribution information, so as to determine whether the luminescent image includes the short circuit; obtaining the brightness information and contrast information corresponding to the luminescent image according to the defect mask information and the semantic segmentation map, and determining whether the luminescent image includes the black core according to the brightness information and contrast information; obtaining the welding point morphology and welding point brightness information corresponding to the luminescent image according to the defect mask information and the edge detection information, so as to determine whether the luminescent image includes the cold solder joint; the welding point morphology corresponding to the cold solder joint is discontinuous and the brightness is uneven.

[0018] In some embodiments, placing the photovoltaic components into a lamination chamber of a laminator for pre-lamination also includes: controlling the laminator to pre-laminate the photovoltaic components in the lamination chamber according to preset lamination parameters to exclude air in the photovoltaic components and prevent the photovoltaic components from cracking when subjected to high pressure; wherein the preset lamination parameters include lamination temperature, vacuum time and lamination pressure.

[0019] Exemplarily, the lamination temperature corresponds to a range of 140° C. to 150° C., the vacuuming time corresponds to a range of 9 min to 11 min, and the lamination pressure corresponds to a range of -80 Kpa to -60 Kpa; wherein, during the pre-lamination process, the lamination temperature increases with time.

[0020] In some embodiments, the support frame is an A-type support frame, and the top of the A-type support frame is formed as a component accommodating area; placing the pre-laminated photovoltaic component in a vertical direction on a preset support frame includes: placing the photovoltaic component in a vertical direction in the component accommodating area of ​​the A-type support frame, and the component accommodating area fixes the photovoltaic component on the A-type support frame.

[0021] In some embodiments, the target temperature and target pressure corresponding to the preheating stage are respectively lower than the target temperature and target pressure of the first heating stage, the target temperature and target pressure of the first heating stage are respectively lower than the target temperature and target pressure of the second heating stage, and the autoclave stops heating and pressurizing the photovoltaic module during the cooling stage until the temperature inside the autoclave is lower than the door opening temperature of the autoclave.

[0022] Exemplarily, the temperature range corresponding to the preheating stage is 40°C to 50°C; the temperature range corresponding to the first heating stage is 115°C to 125°C, the pressure range is 0.7Mpa to 0.9Mpa, and the time range is 25min to 35min; the temperature corresponding to the second heating stage is 135°C to 145°C, the pressure range is 1.1Mpa to 1.2Mpa, and the time range is 25min to 35min.

[0023] In some embodiments, the autoclave pressurizes and heats the photovoltaic module according to preset parameters corresponding to multiple preset stages in sequence, including: obtaining a target temperature and a target pressure corresponding to each of the preset stages; obtaining a stage duration corresponding to each of the preset stages; determining a switching moment corresponding to each of the stages according to each of the stage durations; determining a dynamic adjustment temperature of the autoclave according to the switching moment and the target temperature corresponding to each of the preset stages; determining a dynamic adjustment pressure of the autoclave according to the switching moment and the target pressure corresponding to each of the preset stages; and completing pressurization and heating of the autoclave according to the dynamic adjustment temperature and the dynamic adjustment pressure.

[0024] Exemplarily, determining the dynamic adjustment temperature of the autoclave according to the switching moment and target temperature corresponding to each of the preset stages includes: obtaining the temperature feedback coefficient and temperature time constant corresponding to each of the preset stages; obtaining the real-time temperature of the autoclave according to a temperature sensor preset in the autoclave; determining the dynamic adjustment temperature according to the real-time temperature, the switching moment corresponding to each of the preset stages, the temperature feedback coefficient, the temperature time constant and the target temperature; the expression of the dynamic adjustment temperature includes:

[0025]

[0026] Among them, the following: For the dynamic temperature adjustment, is the current time corresponding to the heating and pressurizing in the autoclave, is the real-time temperature, is the initial temperature corresponding to the photovoltaic module, , , are the target temperature, temperature time constant, and temperature feedback coefficient corresponding to the preheating stage, respectively. The switching time corresponding to the preheating stage is 0. , , and are the target temperature, temperature time constant, switching time and temperature feedback coefficient corresponding to the first heating stage, respectively. , , and are the target temperature, temperature time constant, switching time and temperature feedback coefficient corresponding to the second heating stage, respectively. , , and They are respectively the target temperature, temperature time constant, switching time and temperature feedback coefficient corresponding to the temperature reduction and heating stages.

[0027] Exemplarily, determining the dynamic adjustment pressure of the autoclave according to the switching moment and target pressure corresponding to each of the preset stages includes: obtaining the pressure feedback coefficient and pressure time constant corresponding to each of the preset stages; obtaining the real-time pressure of the autoclave according to the pressure sensor preset in the autoclave; determining the dynamic adjustment pressure according to the real-time pressure, the switching moment corresponding to each of the preset stages, the pressure feedback coefficient, the pressure time constant and the target pressure; the expression of the dynamic adjustment pressure includes:

[0028]

[0029] Among them, the following: For the dynamically adjusted pressure, is the current time corresponding to the heating and pressurizing in the autoclave, is the real-time pressure, is the initial pressure corresponding to the photovoltaic module, , , are the target pressure, pressure time constant, and pressure feedback coefficient corresponding to the preheating stage, respectively. The switching time corresponding to the preheating stage is 0. , , and are the target pressure, pressure time constant, switching time and pressure feedback coefficient corresponding to the first heating stage, respectively. , , and are the target pressure, pressure time constant, switching time and pressure feedback coefficient corresponding to the second temperature rise stage, respectively, , , and They are respectively the target pressure, pressure time constant, switching time and pressure feedback coefficient corresponding to the temperature reduction and heating stages.

[0030] The lamination method based on the linkage of a laminator and an autoclave provided in the embodiment of the present application is intended to improve the lamination quality and production efficiency of photovoltaic modules. First, multiple layers of materials (such as battery cells, backplanes, PVB films, etc.) are stacked together to form a photovoltaic module to be laminated. Then, the laminated photovoltaic module is subjected to electroluminescence (EL) detection to obtain the test results. The test results are used to confirm whether there are battery strings with preset defects in the photovoltaic module, which include cracks, short circuits, black cores, and cold solder joints. Then, if the photovoltaic module passes the electroluminescence test, the next step is entered; otherwise, it needs to be repaired or scrapped. Further, the photovoltaic module that has passed the test is placed in a lamination chamber of the laminator for pre-lamination. The purpose of pre-lamination is to make the photovoltaic module initially produce gluing phenomenon and ensure the initial bonding between the layers of materials. Furthermore, the pre-laminated photovoltaic module is placed on a preset support frame in a vertical direction. The vertical direction refers to the direction perpendicular to the battery arrangement direction of the photovoltaic module, which can reduce the material displacement and deformation caused by gravity during the lamination process. Finally, the support frame with the photovoltaic modules is pushed into the preset autoclave. The autoclave pressurizes and heats the photovoltaic modules in turn according to the parameters of multiple preset stages to complete the final packaging. The multiple preset stages include the preheating stage, the first heating stage, the second heating stage and the cooling stage. The temperature and pressure parameters of each stage are precisely designed to ensure the efficiency and reliability of the packaging process.

[0031] The solution provided thereby has at least the following beneficial effects:

[0032] 1. Uniform temperature distribution: Traditional laminators have uneven temperature distribution, which leads to insufficient gluing, shedding, etc. This method uses pressure heating in an autoclave to ensure uniform temperature distribution of photovoltaic modules during the entire packaging process, thereby improving the gluing quality of the modules.

[0033] 2. Improved pressure control: Traditional laminators provide low pressure, making it difficult to ensure the tightness of components under high temperature and high pressure. This method uses an autoclave for pressurized heating, which can provide higher pressure, effectively improve the tightness of components, and ensure packaging quality.

[0034] 3. Reduce the occurrence of defects: Through electroluminescence testing, preset defects in photovoltaic modules, such as cracks, short circuits, black cores and cold solder joints, can be discovered and dealt with in advance, thereby reducing the risk of these problems occurring during the lamination process.

[0035] 4. Improve production efficiency: The traditional laminator has deficiencies in temperature and pressure control, resulting in a low yield rate in the production process. This method can significantly improve production efficiency and reduce rework or scrap caused by quality problems through the linkage of the laminator and the autoclave.

[0036] 5. Meet high-standard technical requirements: In mass production, traditional laminators are difficult to meet high-standard technical requirements. This method can ensure that each photovoltaic module meets consistent high-quality standards during the encapsulation process through multi-stage pressurization and heating and precise parameter control, thereby meeting the market demand for high-tech requirements.

[0037] 6. Reduce material displacement and deformation: Placing the pre-laminated photovoltaic modules vertically on the support frame can reduce material displacement and deformation caused by gravity and further improve the stability of the package.

[0038] In summary, the lamination method based on the linkage of a laminator and an autoclave provided in the present application significantly improves the temperature distribution and pressure control of photovoltaic modules during the lamination process through multi-stage pressurization heating and pre-lamination, reduces the occurrence of defects, improves production efficiency and packaging quality, and meets high-standard technical requirements.

[0039] 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

[0040] 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.

[0041] Figure 1 It is a schematic flow chart of steps of a lamination method based on linkage of a laminator and an autoclave provided in one embodiment of the present application;

[0042] Figure 2 is a schematic diagram of a laminator provided in one embodiment of the present application;

[0043] Figure 3 is a schematic diagram of an autoclave provided in one embodiment of the present application;

[0044] Figure 4 Schematic diagram of an A-type support frame provided in one embodiment of the present application.

[0045] 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

[0046] 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.

[0047] 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.

[0048] 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.

[0049] 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.

[0050] 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.

[0051] 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.

[0052] In the current production process of Building Integrated Photovoltaic (BIPV) modules, the lamination process is a key link, but it is also a major bottleneck. The maximum module area that a traditional laminator can process at one time is 2.7 meters × 5.4 meters = 14.58 square meters. The cavity size of the laminator limits the number of modules processed each time, and the different types of film and glass thickness make the lamination time fluctuate between 40 minutes and 60 minutes. In this case, the lamination process becomes the bottleneck of the entire production line, seriously affecting the overall production efficiency and resulting in low production capacity.

[0053] At the same time, traditional laminators have obvious deficiencies in temperature distribution and pressure control. Due to uneven temperature distribution, components are prone to problems such as insufficient gluing and falling off during the lamination process, affecting the stability and consistency of the components. In addition, the pressure provided by the laminator is relatively small, and it cannot effectively ensure the tightness of the components under high temperature and high pressure, which further reduces the production quality. These problems are particularly obvious in mass production, and it is difficult to meet high-standard technical requirements.

[0054] Therefore, a lamination method is urgently needed to solve at least one of the above problems.

[0055] To solve the above problems, please refer to Figure 1 , Figure 1 It is a schematic flow chart of a lamination method based on the linkage of a laminator and an autoclave provided in one embodiment of the present application.

[0056] Specifically, Figure 1 As shown, the provided lamination method based on the linkage of a laminator and an autoclave includes steps S101 to S105. The details are as follows:

[0057] Step S101: providing a laminated photovoltaic module.

[0058] Specifically, in this step, the laminated photovoltaic modules need to be prepared first. The lamination process of photovoltaic modules usually includes stacking photovoltaic cell strings, PVB, backboards, glass and other materials in a certain order and structure. The laminated photovoltaic modules should meet certain size and shape requirements to ensure their stability and reliability in the subsequent lamination process. Such as material preparation: prepare photovoltaic cell strings, PVB film, backboard and tempered glass. Lamination order: place the backboard, PVB film, photovoltaic cell string, PVB film, and tempered glass in sequence from bottom to top. Size inspection: ensure that the size of the laminated module meets the regulations, such as a width of 1000mm and a length of 1600mm. Ensure the consistency and position accuracy of each layer of material through standardization of the lamination process. Reduce the scrap rate in the subsequent lamination process by checking the materials and lamination order in advance.

[0059] Step S102. Perform electroluminescence detection on the photovoltaic module to obtain the electroluminescence detection result corresponding to the photovoltaic module, which is used to confirm whether the photovoltaic module includes a battery string with preset defects; the preset defects include at least one or more of cracks, short circuits, black cores and cold solder joints.

[0060] Specifically, in this step, electroluminescence (EL) detection equipment is used to detect the laminated photovoltaic modules. EL detection can identify various defects in photovoltaic cell strings, such as cracks, short circuits, black cores and cold solder joints. The test results will be used to confirm whether the photovoltaic modules meet the requirements of subsequent lamination. For example, a detection device with a high-resolution camera and an EL light source is used. The photovoltaic module is placed on the inspection table, photons are excited by the EL light source, and the high-resolution camera captures and analyzes the image. The image is automatically analyzed by the software to identify and mark defects such as cracks, short circuits, black cores and cold solder joints. By identifying defects before lamination, subsequent processing time and materials are avoided. Ensure that only qualified components enter the subsequent process to improve the quality of the final product.

[0061] Step S103: If it is confirmed according to the electroluminescence test result that the photovoltaic module has passed the electroluminescence test, the photovoltaic module is placed in a lamination chamber of a laminator for pre-lamination, so that the photovoltaic module is glued.

[0062] Specifically, photovoltaic modules that have been confirmed to be free of defects through EL testing will be placed in the laminating chamber of the laminator for pre-lamination. The purpose of pre-lamination is to make the PVB and other materials in the module initially bonded to form a certain initial tightness, in preparation for subsequent autoclave treatment. For example, the pre-lamination temperature is 95°C, the pressure is 0.5MPa, and the time is 5 minutes. Place the photovoltaic module flatly in the laminating chamber of the laminator to ensure that the module is not indented or deformed. Use PLC (Programmable Logic Controller) to control the heating and pressurization process of the laminator to ensure stable parameters. Pre-lamination can initially bond PVB and other materials, reducing the time and energy consumption of subsequent autoclave treatment. Ensure that the relative positions of the layers of materials in the module are fixed before entering the autoclave to prevent displacement. At the same time, if Figure 2 As shown, after the work of the laminating chamber 1 is completed, the laminating machine does not enter the laminating chamber 2 for lamination as in the prior art because the present application improves the laminating efficiency by reducing the laminating time, and the pre-lamination is only for exhausting air, so the second chamber is not needed.

[0063] Step S104: Place the pre-laminated photovoltaic module in a vertical direction on a preset support frame; wherein the vertical direction is a direction perpendicular to the battery arrangement direction of the photovoltaic module.

[0064] Specifically, the pre-laminated photovoltaic modules need to be placed in a vertical direction on a preset support frame. The vertical direction refers to the direction perpendicular to the arrangement direction of the photovoltaic cells. This placement can ensure that the modules are evenly heated and compressed in the autoclave, and avoid sagging or deformation of the materials due to gravity. The support frame should have enough support points to ensure that the modules are stably placed in the vertical direction. The operator gently places the pre-laminated modules on the support frame, ensuring that all four corners of the modules are supported. After placement, check whether the modules are stable to prevent them from tipping over. Vertical placement can ensure that the modules are evenly heated in the autoclave, avoiding local temperatures that are too high or too low. Reduce the sagging and deformation of materials caused by gravity and improve the flatness of the modules.

[0065] Step S105. Push the support frame into a preset autoclave, and the autoclave pressurizes and heats the photovoltaic components in turn according to preset parameters corresponding to multiple preset stages to complete the packaging of the photovoltaic components; the multiple preset stages include at least a preheating stage, a first heating stage, a second heating stage, and a cooling stage.

[0066] Specifically, in this step, the support frame is pushed into Figure 3 In the autoclave shown, the autoclave will be pressurized and heated according to multiple preset stages to complete the encapsulation of photovoltaic modules. These stages generally include a preheating stage, a first heating stage, a second heating stage, and a cooling stage. For example, in the preheating stage: the temperature of the autoclave rises from 0°C to 45°C, the pressure is 0, and the duration is 15 minutes. The first heating stage: the temperature rises from 45°C to 100°C, the corresponding range of the pressure rise is 0.5 to 1.0MPa, and the duration is 30 minutes. The second heating stage: the temperature rises from 100°C to 140°C, and the pressure is maintained at 1.2MPa, and the duration is 30 minutes. Cooling stage: the temperature drops to 45°C, the pressure drops to 0.2MPa, and the autoclave is opened after the pressure reaches 0.

[0067] The uniform pressure provided by the autoclave can ensure the tightness of the components at high temperatures and improve the packaging quality. Through multi-stage heating, the temperature distribution inside the component is ensured to be uniform to avoid local overheating or overcooling. Reasonable multi-stage parameter settings can shorten the time of the entire packaging process and improve production efficiency. Through strict temperature and pressure control, the scrap rate caused by improper process is reduced to ensure the stability and consistency of the product.

[0068] In summary, the lamination method based on the linkage of laminator and autoclave effectively solves the shortcomings of traditional laminators in temperature distribution and pressure control through electroluminescence detection, pre-lamination, vertical support and multi-stage pressurization and heating, and improves the packaging quality and production efficiency of photovoltaic modules. This method is particularly suitable for high-standard mass production and can significantly improve the stability and consistency of products.

[0069] In some embodiments, before providing the laminated photovoltaic module, it also includes: providing a front glass panel, a first adhesive film, a battery string, a bus bar, a second adhesive film and a back glass panel; in a lamination room with a preset environment, laying the first adhesive film on the front glass panel; laying the battery string on the first adhesive film, and welding the bus bar to the battery string; laying the second adhesive film and the back glass on the battery string and the bus bar in sequence to complete the lamination of the photovoltaic module.

[0070] Performing the lamination operation in a lamination room with a preset environment can ensure the stability of environmental conditions (such as temperature, humidity, etc.), thereby improving the accuracy of lamination. By laying the front glass, first adhesive film, battery string, bus bar, second adhesive film and back glass in sequence, the precise alignment between the layers of material is ensured to reduce lamination problems caused by material offset. The front glass, first adhesive film, battery string, bus bar, second adhesive film and back glass are provided, and these materials undergo strict quality inspection before lamination to ensure that they meet production standards. High-quality materials are the basis for producing high-quality photovoltaic modules, and the detailed description in Example 1 helps to ensure that all materials are in optimal condition.

[0071] During the lamination process, the busbars are welded to the battery strings to ensure the reliability and stability of the electrical connection. By performing the welding operation in a preset environment, solder joint defects (such as cold solder joints, short circuits, etc.) can be reduced and the electrical performance of the components can be improved. By laying the second adhesive film and the backplane glass on the battery string and the busbar in sequence, a compact and stable package is formed. This lamination method ensures that in the subsequent lamination and packaging process, each layer of material can be evenly stressed, reducing the generation of internal stress and improving the tightness of the package.

[0072] Completing the lamination steps in advance can significantly reduce the processing time in the laminator and autoclave, improving overall production efficiency. Accurate lamination operations can reduce rework caused by material problems and further improve production efficiency. Operating in a lamination room with a preset environment can reduce the entry of external dust and pollutants and ensure the surface cleanliness of the photovoltaic module. A clean surface is conducive to improving the gluing effect and reducing the problems of insufficient gluing and shedding.

[0073] In summary, by performing precise lamination operations in a lamination room with a preset environment, the quality of materials and the reliability of electrical connections are ensured, the packaging structure is optimized, and surface contamination is reduced, thereby significantly improving the lamination efficiency and yield rate of photovoltaic modules. These meticulous preliminary preparations lay a solid foundation for subsequent lamination and packaging, further ensuring the high quality and consistency of the final product.

[0074] Exemplarily, the glass widths corresponding to the front glass and the back glass are the same; before completing the lamination of the photovoltaic module, it also includes: trimming the first adhesive film and the second adhesive film so that the film widths corresponding to the trimmed first adhesive film and the second adhesive film are greater than the glass width, and the difference between the film width and the glass width is within a preset width range, and the preset width range is 10 mm to 20 mm.

[0075] By trimming the first and second adhesive films so that their corresponding adhesive film widths are greater than the glass width, it is possible to ensure that the adhesive film has appropriate coverage at the edge of the photovoltaic module. This trimming method can prevent problems such as bubbles and debonding caused by insufficient coverage of the edge of the adhesive film during the lamination process, and improve the tightness and reliability of the package. The difference between the width of the adhesive film and the glass is within the preset width range (10mm to 20mm), which can ensure that the edge of the photovoltaic module is effectively sealed and protected. Proper edge sealing helps prevent the intrusion of moisture and external contaminants and extend the service life of the photovoltaic module. It can also avoid material waste caused by excessive width of the adhesive film, while ensuring that the width of the adhesive film is sufficient to cover the edge of the glass to achieve the best packaging effect. Reasonable use of materials not only reduces production costs, but also improves production efficiency. The appropriate edge width of the adhesive film can improve the appearance of the photovoltaic module, making its surface smooth and without overflowing glue.

[0076] Exemplarily, the preset environment corresponding to the lamination chamber includes a preset temperature range and a preset humidity range, the preset temperature range is 18° C. to 24° C., and the preset humidity range is 18% RH to 28% RH.

[0077] Lamination operations within the preset temperature range (18°C to 24°C) and the preset humidity range (18%RH to 28%RH) ensure that the physical and chemical properties of the material are stable. Stable material properties help improve the accuracy of lamination and the quality of subsequent lamination.

[0078] In some embodiments, the electroluminescence detection of the photovoltaic component includes: providing an electroluminescence detection device; the electroluminescence detection device includes a high-voltage power supply and a CCD acquisition module; fixing the photovoltaic component on a preset detection table after cleaning; the detection table is located in a darkroom environment; connecting the high-voltage power supply to the photovoltaic component; controlling the photovoltaic component to emit visible light or near-infrared light according to preset electroluminescence parameters through the high-voltage power supply; the electroluminescence parameters include at least voltage, current and exposure time; when the photovoltaic component emits visible light or near-infrared light, the CCD acquisition module collects the luminescence image information corresponding to the photovoltaic component; and completing the electroluminescence detection of the photovoltaic component according to the luminescence image information.

[0079] Setting the test bench in a darkroom environment can avoid interference from external light and ensure the accuracy and clarity of the collected luminous image information. Cleaning the photovoltaic modules before testing can remove dust and pollutants on the surface, ensure that the image collection results are not affected by pollution, and improve the accuracy of the test.

[0080] By controlling the photovoltaic modules to emit visible light or near-infrared light according to preset electroluminescent parameters through a high-voltage power supply, defects inside the photovoltaic modules can be accurately detected. Electroluminescent parameters include voltage, current and exposure time. Precise control of these parameters can ensure the consistency and reliability of the detection results and avoid misjudgment due to parameter changes.

[0081] By using the CCD acquisition module to collect the luminous image information of the photovoltaic module, the module can be fully inspected, especially when detecting defects such as cracks, short circuits, black cores and cold solder joints, the clarity and resolution of the image information are very important. The angle and position of the CCD acquisition module can be adjusted to ensure comprehensive inspection of the photovoltaic module from multiple angles, improving the comprehensiveness and accuracy of the inspection.

[0082] Through the luminous image information, it is possible to visually confirm whether there are cell strings with preset defects in the photovoltaic module, and timely discover and deal with these problems to avoid quality problems caused by defects in the subsequent lamination process. Discovering and dealing with defects in advance can reduce rework and scrap caused by quality problems and improve production efficiency and yield rate.

[0083] The use of electroluminescent detection equipment can realize automated detection, reduce manual intervention, and improve detection speed and efficiency. Automated equipment can perform batch detection, significantly improve the detection processing capacity, and meet the needs of large-scale production.

[0084] The luminescent image information collected by the CCD acquisition module can be recorded and stored, which is convenient for subsequent data analysis and quality tracking. Through the analysis of luminescent image information, different types of defects can be classified and counted, providing a scientific basis for process improvement. At the same time, electroluminescence detection is a preventive detection method that can detect potential problems before lamination and reduce risks in the subsequent packaging process. Ensuring the quality of photovoltaic modules through detection can improve the final lamination and packaging tightness, and enhance the overall quality and stability of the product.

[0085] This embodiment provides a specific electroluminescence detection method to ensure the accuracy of the detection environment, the precision and comprehensiveness of the detection process. This method can detect and deal with defects in photovoltaic modules in advance, reduce rework and scrap, and improve detection efficiency and production quality. In particular, through the darkroom environment and cleaning treatment, as well as the use of high-voltage power supply and CCD acquisition module, the reliability and consistency of the detection results are ensured, providing a solid guarantee for subsequent lamination and packaging.

[0086] Exemplarily, completing the electroluminescence detection of the photovoltaic component according to the luminescent image information includes: inputting the luminescent image information into a preset multi-scale filter, the multi-scale filter outputting multi-scale features corresponding to the luminescent image information; the multi-scale filter includes any one of a Gaussian pyramid filter or a multi-scale Laplacian filter; performing semantic segmentation and instance segmentation on the luminescent image information according to the multi-scale features, and obtaining a semantic segmentation map and defect mask information corresponding to the luminescent image information; the semantic segmentation map includes multiple pixel defect type identifiers; performing edge detection on the luminescent image information to obtain edge detection information corresponding to the luminescent image information; completing the electroluminescence detection of the photovoltaic component according to the semantic segmentation map, edge detection information and the defect mask information.

[0087] By inputting the luminous image information into the preset multi-scale filter, the multi-scale features of the image can be extracted, thereby improving the accuracy and reliability of image processing. The Gaussian pyramid filter or multi-scale Laplacian filter can effectively process the detail information in the image, reduce noise interference, and enhance the contrast and clarity of the image.

[0088] By performing semantic segmentation on the luminescent image information, different pixel areas in the image can be classified into different defect types and a semantic segmentation map can be generated. Instance segmentation can further distinguish defects of different instances and generate defect mask information, which helps to accurately locate and analyze individual defects. By performing edge detection on the luminescent image information, edge information in the image can be obtained, which helps to find edge defects such as slivers. Edge detection information can be combined with semantic segmentation maps and defect mask information to provide more comprehensive defect detection results. By combining multi-scale features, semantic segmentation maps, edge detection information, and defect mask information, more reliable defect detection can be achieved. Multi-feature fusion can reduce the misjudgment rate of single feature detection and improve the accuracy of detection results.

[0089] It should be noted that, in some embodiments, if the preset defects include cracks, short circuits, black cores and cold solder joints; the electroluminescence detection of the photovoltaic module is completed according to the semantic segmentation map, edge detection information and the defect mask information, including: determining whether the luminescent image includes continuous edge breaks according to the edge detection information and the semantic segmentation map, so as to determine whether the luminescent image includes the cracks; determining the current distribution information corresponding to the luminescent image according to the semantic segmentation map, and determining whether the luminescent image includes a current abnormality area based on the thermal map technology and the current distribution information, so as to determine whether the luminescent image includes the short circuit; obtaining the brightness information and contrast information corresponding to the luminescent image according to the defect mask information and the semantic segmentation map, and determining whether the luminescent image includes the black core according to the brightness information and contrast information; obtaining the welding point morphology and welding point brightness information corresponding to the luminescent image according to the defect mask information and the edge detection information, so as to determine whether the luminescent image includes the cold solder joint; the welding point morphology corresponding to the cold solder joint is discontinuous and the brightness is uneven.

[0090] By combining edge detection information and semantic segmentation maps, it is possible to detect whether there are continuous edge breaks in the luminous image, thereby determining whether there are splinters. This method can locate the location of the splinters with high precision, facilitating subsequent repair and processing.

[0091] By using the semantic segmentation map to determine the current distribution information corresponding to the luminescent image, the abnormal current area can be identified. Based on the heat map technology and current distribution information, the area of ​​abnormal current can be intuitively displayed to determine whether there is a short circuit. This method can accurately determine the location and severity of the short circuit and provide guidance for repair.

[0092] By obtaining the brightness and contrast information of the luminous image through the defect mask information and the semantic segmentation map, it is possible to determine whether there is a black heart. This method can effectively identify areas with abnormal brightness and contrast and improve the accuracy of black heart detection.

[0093] By obtaining the solder joint morphology and solder joint brightness information corresponding to the luminous image through defect mask information and edge detection information, it is possible to determine whether there is a cold solder joint. The solder joint morphology corresponding to a cold solder joint is discontinuous and the brightness is uneven. This method can intuitively identify cold solder joints and improve the reliability of detection.

[0094] By accurately locating and classifying defects such as cracks, short circuits, black cores and cold solder joints, problems can be discovered and handled in a timely manner, improving the production quality of photovoltaic modules. Detailed defect detection results can provide a scientific basis for process improvement and further improve product reliability and performance.

[0095] By targeting specific defects such as cracks, short circuits, black cores and cold solder joints, and through comprehensive analysis of multiple image features, accurate defect determination and positioning are achieved, ensuring the quality and reliability of photovoltaic modules. The combination of these two methods jointly improves the production quality and detection efficiency of photovoltaic modules.

[0096] In some embodiments, placing the photovoltaic components into a lamination chamber of a laminator for pre-lamination also includes: controlling the laminator to pre-laminate the photovoltaic components in the lamination chamber according to preset lamination parameters to exclude air in the photovoltaic components and prevent the photovoltaic components from cracking when subjected to high pressure; wherein the preset lamination parameters include lamination temperature, vacuum time and lamination pressure.

[0097] By controlling the vacuuming time, the air inside the PV module can be effectively removed and the formation of bubbles can be reduced. The presence of bubbles can affect the packaging quality of the PV module, resulting in insufficient bonding between the cell and the glass, and reducing the reliability and performance of the module. Vacuuming during the pre-lamination process can significantly reduce this problem.

[0098] By properly setting the lamination temperature and lamination pressure, the photovoltaic modules can be prevented from being subjected to excessive mechanical stress and resulting in cracks during the high-pressure lamination process. Appropriate lamination temperature and pressure can ensure that the materials inside the module gradually adapt to the high-pressure environment during the pre-lamination process, reducing the risk of cracks caused by sudden high pressure.

[0099] The use of preset lamination parameters (including lamination temperature, vacuum time and lamination pressure) can ensure the consistency of each pre-lamination process. The use of preset parameters reduces the subjective judgment and operation errors of operators and improves the standardization of production.

[0100] At the same time, the pre-lamination process can better release the bubbles between the film and the glass by gradually increasing the pressure, ensuring that there is no air residue inside the laminated component. Gradually increasing the pressure and properly controlling the temperature, pressure and vacuum time can improve the tightness between the layers of material inside the component and reduce stratification and debonding.

[0101] By controlling the preset lamination parameters (lamination temperature, vacuum time and lamination pressure) during the pre-lamination process, the air inside the photovoltaic module is effectively removed and cracks are avoided. This process not only improves the packaging quality and reduces internal defects, but also optimizes the production process and saves time and resources. The consistency and reliability of pre-lamination also help to improve the overall production yield and finished product rate of photovoltaic modules, thereby improving the market competitiveness of products and user satisfaction.

[0102] Exemplarily, the lamination temperature corresponds to a range of 140° C. to 150° C., the vacuuming time corresponds to a range of 9 min to 11 min, and the lamination pressure corresponds to a range of -80 Kpa to -60 Kpa; wherein, during the pre-lamination process, the lamination temperature increases with time.

[0103] The lamination temperature is set in the range of 140℃ to 150℃, which can ensure effective fusion between the adhesive film and the glass, avoiding insufficient bonding due to too low a temperature or material damage due to too high a temperature. During the pre-lamination process, the lamination temperature increases over time, which can gradually increase the temperature so that the material gradually adapts to the heating process, reduces the impact of thermal stress on the components, and further reduces the risk of cracking.

[0104] The vacuuming time is set between 9 minutes and 11 minutes, which can ensure that the air in the component is fully evacuated and reduce the formation of bubbles. Appropriate vacuuming time can ensure the thoroughness of bubble removal and avoid the negative impact of bubbles on component performance and reliability.

[0105] The lamination pressure is set in the range of -80 Kpa to -60 Kpa. This pressure range can ensure that the components are subjected to appropriate negative pressure during the pre-lamination process, promoting close fit between materials. Reasonable lamination pressure can avoid damage to components caused by excessive mechanical stress, especially in the process of increasing temperature, negative pressure can better protect components from damage. By setting a specific temperature, time and pressure range, the pre-lamination process can be standardized, the error of human operation can be reduced, and the parameters of each pre-lamination can be ensured to be consistent.

[0106] By specifically setting the lamination temperature, vacuum time and lamination pressure range during the pre-lamination process, and noting that the temperature increases over time, an accurate and reliable pre-lamination method is achieved. This method can significantly reduce air bubbles and crack defects in photovoltaic modules, improve the electrical and mechanical properties of the modules, and extend their service life. At the same time, the standardization and optimization of parameters also improves production efficiency and yield, providing a solid guarantee for subsequent formal lamination and packaging.

[0107] In some embodiments, Figure 4 As shown, the support frame is an A-type support frame, and the top of the A-type support frame is formed as a component accommodating area; the pre-laminated photovoltaic components are placed vertically on a preset support frame, including: placing the photovoltaic components vertically in the component accommodating area of ​​the A-type support frame, and the component accommodating area fixes the photovoltaic components on the A-type support frame.

[0108] The A-type support frame has a stable structure and can firmly fix the photovoltaic modules. The top of the A-type support frame is formed as a module accommodation area. This design allows the photovoltaic modules to be accurately placed and fixed, reducing movement or slipping during transportation and handling.

[0109] Placing PV panels vertically on A-type support racks can significantly optimize space utilization, especially when the space in the production workshop is limited, so that storage and operation space can be used more effectively. The vertical placement method reduces the horizontal footprint of the panels and improves the overall space utilization of the workshop.

[0110] The design of the module housing area can ensure that the photovoltaic modules remain stable when placed vertically, reducing the risk of damage caused by improper placement or handling. Vertical placement can reduce the pressure and friction on the module surface, avoid surface scratches or damage, and improve the appearance quality and overall performance of the module.

[0111] By using the A-type support frame and the component accommodation area, the pre-laminated photovoltaic components are fixed on the support frame in a vertical direction. This method not only improves the fixing stability of the components, optimizes the space utilization, reduces the risk of damage to the components during transportation and storage, but also improves the convenience of operation and the accuracy of detection. In addition, the standardized operation process reduces the impact of human factors, improves production efficiency and yield, reduces storage and maintenance costs, and provides reliable guarantees for the production of photovoltaic components.

[0112] In some embodiments, the target temperature and target pressure corresponding to the preheating stage are respectively lower than the target temperature and target pressure of the first heating stage, the target temperature and target pressure of the first heating stage are respectively lower than the target temperature and target pressure of the second heating stage, and the autoclave stops heating and pressurizing the photovoltaic module during the cooling stage until the temperature inside the autoclave is lower than the door opening temperature of the autoclave.

[0113] The target temperature and target pressure in the preheating stage are relatively low. This stage can slowly preheat the photovoltaic modules to gradually adapt them to the temperature and pressure environment, reducing thermal and mechanical stress caused by sudden changes. The temperature and pressure in the first heating stage gradually increase, which helps to further integrate the materials in the module and remove more air. The target temperature and pressure in the second heating stage are higher, which further ensures the tightness between the materials and improves the overall performance and reliability of the module. In the cooling stage, the autoclave stops heating and pressurizing the photovoltaic modules until the temperature drops below the door opening temperature. This process ensures that the modules gradually adapt to the environment during the cooling process and avoids internal stress and damage caused by sudden cooling.

[0114] The gradual change of temperature and pressure can reduce the internal stress of the component caused by sudden changes during the lamination process, preventing cracking and delamination. The gradual heating and pressurization gives the materials in the component more time to adapt to the changes in temperature and pressure, reducing the risk of material damage and improving the adaptability and bonding quality of the material.

[0115] Temperature control at different stages can ensure that each layer of material fuses at the appropriate temperature, improving the lamination effect and consistency. Gradually increasing pressure can better promote the close fit between materials, eliminate bubbles, and improve the tightness and reliability of components.

[0116] The gradual change of temperature and pressure settings can reduce abnormal situations caused by sudden changes and improve the stability and efficiency of the production process. By precisely controlling the temperature and pressure at each stage, the yield of components can be significantly improved and the scrap rate can be reduced.

[0117] Exemplarily, the temperature range corresponding to the preheating stage is 40°C to 50°C; the temperature range corresponding to the first heating stage is 115°C to 125°C, the pressure range is 0.7Mpa to 0.9Mpa, and the time range is 25min to 35min; the temperature corresponding to the second heating stage is 135°C to 145°C, the pressure range is 1.1Mpa to 1.2Mpa, and the time range is 25min to 35min.

[0118] The lower temperature range in the preheating stage can slowly preheat the photovoltaic module, allowing its internal materials to gradually adapt to temperature changes and reduce initial thermal stress. Low-temperature preheating helps protect the module from damage caused by sudden thermal stress during the high temperature stage and avoids uneven expansion and contraction of the internal materials of the module.

[0119] The higher temperature and moderate pressure in the first heating stage help the film and glass in the component to further fuse, remove more air and reduce the formation of bubbles. Moderate pressure can promote close fit between materials, improve tightness and reduce delamination.

[0120] The higher temperature and higher pressure in the second heating stage can ensure that the materials in the component achieve the best fusion and sealing effect, further improving the reliability and performance of the component. High temperature and high pressure can promote the final bonding between the film and the glass, ensuring the stability and durability of the component in long-term use.

[0121] The autoclave stops heating and pressurizing the PV module during the cooling stage until the temperature drops below the door opening temperature. Gradual cooling can prevent thermal shock caused by sudden cooling of the module, reduce internal stress and the risk of cracking. The gradual cooling process helps the internal materials of the module to evenly return to normal temperature, improving the overall stability and reliability of the module.

[0122] In some embodiments, the autoclave pressurizes and heats the photovoltaic module according to preset parameters corresponding to multiple preset stages in sequence, including: obtaining a target temperature and a target pressure corresponding to each of the preset stages; obtaining a stage duration corresponding to each of the preset stages; determining a switching moment corresponding to each of the stages according to each of the stage durations; determining a dynamic adjustment temperature of the autoclave according to the switching moment and the target temperature corresponding to each of the preset stages; determining a dynamic adjustment pressure of the autoclave according to the switching moment and the target pressure corresponding to each of the preset stages; and completing pressurization and heating of the autoclave according to the dynamic adjustment temperature and the dynamic adjustment pressure.

[0123] The target temperature and target pressure are low, which can gradually preheat the photovoltaic modules to adapt them to the temperature and pressure environment and reduce the initial thermal and mechanical stress. The target temperature and target pressure in the first heating stage gradually increase, which helps the materials in the module to further fuse, exclude more air and reduce the formation of bubbles. The target temperature and target pressure in the second heating stage reach a higher level to ensure the best fusion and tightness between the materials and improve the reliability and performance of the module. The autoclave stops heating and pressurizing until the temperature drops below the door opening temperature to avoid thermal shock and internal stress caused by sudden cooling.

[0124] The gradual change of temperature and pressure can reduce the internal stress of the component caused by sudden changes during the lamination process, preventing cracking and delamination. Gradual heating and pressurization give the materials in the component more time to adapt to the changes in temperature and pressure, reducing the risk of material damage.

[0125] Temperature control at different stages can ensure that each layer of material fuses at the appropriate temperature, improving the lamination effect and consistency. Gradually increasing pressure can better promote the close fit between materials, eliminate bubbles, and improve the tightness and reliability of components.

[0126] Exemplarily, determining the dynamic adjustment temperature of the autoclave according to the switching moment and target temperature corresponding to each of the preset stages includes: obtaining the temperature feedback coefficient and temperature time constant corresponding to each of the preset stages; obtaining the real-time temperature of the autoclave according to a temperature sensor preset in the autoclave; determining the dynamic adjustment temperature according to the real-time temperature, the switching moment corresponding to each of the preset stages, the temperature feedback coefficient, the temperature time constant and the target temperature; the expression of the dynamic adjustment temperature includes:

[0127]

[0128] Among them, the following: For the dynamic temperature adjustment, is the current time corresponding to the heating and pressurizing in the autoclave, is the real-time temperature, is the initial temperature corresponding to the photovoltaic module, , , are the target temperature, temperature time constant, and temperature feedback coefficient corresponding to the preheating stage, respectively. The switching time corresponding to the preheating stage is 0. , , and are the target temperature, temperature time constant, switching time and temperature feedback coefficient corresponding to the first heating stage, respectively. , , and are the target temperature, temperature time constant, switching time and temperature feedback coefficient corresponding to the second heating stage, respectively. , , and They are respectively the target temperature, temperature time constant, switching time and temperature feedback coefficient corresponding to the temperature reduction and heating stages.

[0129] By obtaining the temperature feedback coefficient and temperature time constant of each preset stage, the temperature of the autoclave can be adjusted more accurately. The temperature sensor in the autoclave is used to obtain the real-time temperature to ensure the real-time and accuracy of temperature control. The temperature of the autoclave is dynamically adjusted according to the real-time temperature, switching time, temperature feedback coefficient, temperature time constant and target temperature to ensure accurate temperature control at each stage.

[0130] Through real-time feedback and dynamic adjustment, temperature fluctuations can be effectively reduced, ensuring the temperature stability of photovoltaic modules during the lamination process and avoiding changes in material properties caused by temperature fluctuations. Accurate temperature control can prevent overheating or overcooling of modules during the lamination process and ensure that the materials are fused within the optimal temperature range.

[0131] The introduction of temperature feedback coefficient and time constant can make the temperature change process smoother and reduce the impact of temperature mutation on the thermal stress of components. In the preheating stage, by dynamically adjusting the temperature, the components can gradually adapt to the high temperature environment and improve the preheating effect.

[0132] Exemplarily, determining the dynamic adjustment pressure of the autoclave according to the switching moment and target pressure corresponding to each of the preset stages includes: obtaining the pressure feedback coefficient and pressure time constant corresponding to each of the preset stages; obtaining the real-time pressure of the autoclave according to the pressure sensor preset in the autoclave; determining the dynamic adjustment pressure according to the real-time pressure, the switching moment corresponding to each of the preset stages, the pressure feedback coefficient, the pressure time constant and the target pressure; the expression of the dynamic adjustment pressure includes:

[0133]

[0134] Among them, the following: For the dynamically adjusted pressure, is the current time corresponding to the heating and pressurizing in the autoclave, is the real-time pressure, is the initial pressure corresponding to the photovoltaic module, , , are the target pressure, pressure time constant, and pressure feedback coefficient corresponding to the preheating stage, respectively. The switching time corresponding to the preheating stage is 0. , , and are the target pressure, pressure time constant, switching time and pressure feedback coefficient corresponding to the first heating stage, respectively. , , and are the target pressure, pressure time constant, switching time and pressure feedback coefficient corresponding to the second temperature rise stage, respectively, , , and They are respectively the target pressure, pressure time constant, switching time and pressure feedback coefficient corresponding to the temperature reduction and heating stages.

[0135] By obtaining the pressure feedback coefficient and pressure time constant of each preset stage, the pressure of the autoclave can be adjusted more accurately. The real-time pressure is obtained by the pressure sensor in the autoclave to ensure the real-time and accuracy of pressure control. According to the real-time pressure, switching time, pressure feedback coefficient, pressure time constant and target pressure, the pressure of the autoclave is dynamically adjusted to ensure accurate pressure control at each stage.

[0136] Through real-time feedback and dynamic adjustment, pressure fluctuations can be effectively reduced, ensuring the pressure stability of photovoltaic modules during the lamination process and avoiding changes in material properties caused by pressure fluctuations. Accurate pressure control can prevent overpressure or underpressure in the lamination process and ensure that the materials are bonded and fused within the optimal pressure range.

[0137] The introduction of pressure feedback coefficient and time constant can make the pressure change process smoother and reduce the impact of sudden pressure changes on the mechanical stress of components. In the first and second heating stages, by dynamically adjusting the pressure, the close fit between materials can be better promoted, improving the tightness and reliability of components.

[0138] The lamination method based on the linkage of a laminator and an autoclave provided in the embodiment of the present application is intended to improve the lamination quality and production efficiency of photovoltaic modules. First, multiple layers of materials (such as battery cells, backplanes, PVB films, etc.) are stacked together to form a photovoltaic module to be laminated. Then, the laminated photovoltaic module is subjected to electroluminescence (EL) detection to obtain the test results. The test results are used to confirm whether there are battery strings with preset defects in the photovoltaic module, which include cracks, short circuits, black cores, and cold solder joints. Then, if the photovoltaic module passes the electroluminescence test, the next step is entered; otherwise, it needs to be repaired or scrapped. Further, the photovoltaic module that has passed the test is placed in a lamination chamber of the laminator for pre-lamination. The purpose of pre-lamination is to make the photovoltaic module initially produce gluing phenomenon and ensure the initial bonding between the layers of materials. Furthermore, the pre-laminated photovoltaic module is placed on a preset support frame in a vertical direction. The vertical direction refers to the direction perpendicular to the battery arrangement direction of the photovoltaic module, which can reduce the material displacement and deformation caused by gravity during the lamination process. Finally, the support frame with the photovoltaic modules is pushed into the preset autoclave. The autoclave pressurizes and heats the photovoltaic modules in turn according to the parameters of multiple preset stages to complete the final packaging. The multiple preset stages include the preheating stage, the first heating stage, the second heating stage and the cooling stage. The temperature and pressure parameters of each stage are precisely designed to ensure the efficiency and reliability of the packaging process.

[0139] The solution provided thereby has at least the following beneficial effects:

[0140] 1. Uniform temperature distribution: Traditional laminators have uneven temperature distribution, which leads to insufficient gluing, shedding, etc. This method uses pressure heating in an autoclave to ensure uniform temperature distribution of photovoltaic modules during the entire packaging process, thereby improving the gluing quality of the modules.

[0141] 2. Improved pressure control: Traditional laminators provide low pressure, making it difficult to ensure the tightness of components under high temperature and high pressure. This method uses an autoclave for pressurized heating, which can provide higher pressure, effectively improve the tightness of components, and ensure packaging quality.

[0142] 3. Reduce the occurrence of defects: Through electroluminescence testing, preset defects in photovoltaic modules, such as cracks, short circuits, black cores and cold solder joints, can be discovered and dealt with in advance, thereby reducing the risk of these problems occurring during the lamination process.

[0143] 4. Improve production efficiency: The traditional laminator has deficiencies in temperature and pressure control, resulting in a low yield rate in the production process. This method can significantly improve production efficiency and reduce rework or scrap caused by quality problems through the linkage of the laminator and the autoclave.

[0144] 5. Meet high-standard technical requirements: In mass production, traditional laminators are difficult to meet high-standard technical requirements. This method can ensure that each photovoltaic module meets consistent high-quality standards during the encapsulation process through multi-stage pressurization and heating and precise parameter control, thereby meeting the market demand for high-tech requirements.

[0145] 6. Reduce material displacement and deformation: Placing the pre-laminated photovoltaic modules vertically on the support frame can reduce material displacement and deformation caused by gravity and further improve the stability of the package.

[0146] In summary, the lamination method based on the linkage of a laminator and an autoclave provided in the present application significantly improves the temperature distribution and pressure control of photovoltaic modules during the lamination process through multi-stage pressurization heating and pre-lamination, reduces the occurrence of defects, improves production efficiency and packaging quality, and meets high-standard technical requirements.

[0147] 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 lamination method based on the linkage of a laminator and an autoclave, characterized in that: The method comprises: Providing laminated photovoltaic modules; Performing electroluminescence detection on the photovoltaic module to obtain electroluminescence detection results corresponding to the photovoltaic module, so as to confirm whether the photovoltaic module includes a battery string with preset defects; the preset defects include at least one or more of cracks, short circuits, black cores and cold solder joints; If it is confirmed according to the electroluminescence test result that the photovoltaic assembly passes the electroluminescence test, placing the photovoltaic assembly into a lamination chamber of a laminator for pre-lamination, so that the photovoltaic assembly is glued; Placing the pre-laminated photovoltaic module on a preset support frame in a vertical direction; wherein the vertical direction is a direction perpendicular to the battery arrangement direction of the photovoltaic module; The support frame is pushed into a preset autoclave, and the autoclave pressurizes and heats the photovoltaic assembly according to preset parameters corresponding to a plurality of preset stages, including: obtaining a target temperature and a target pressure corresponding to each of the preset stages; obtaining a stage duration corresponding to each of the preset stages; determining a switching moment corresponding to each of the stages according to each of the stage durations; determining a dynamic adjustment temperature of the autoclave according to the switching moment and the target temperature corresponding to each of the preset stages, including: obtaining a temperature feedback coefficient and a temperature time constant corresponding to each of the preset stages; obtaining a real-time temperature of the autoclave according to a temperature sensor preset in the autoclave; determining a dynamic adjustment temperature of the autoclave according to the real-time temperature, the switching moment corresponding to each of the preset stages, and the temperature feedback coefficient and the temperature time constant ... determining a dynamic adjustment temperature of the autoclave according to the real-time temperature, the switching moment corresponding to each of the preset stages, and the temperature feedback coefficient and the temperature time constant; determining a dynamic adjustment temperature of the autoclave according to the target temperature and the temperature feedback coefficient and the temperature time constant; determining a dynamic adjustment temperature of the autoclave according to the target temperature and the temperature feedback coefficient and the temperature time constant; determining a dynamic adjustment temperature of the autoclave according to the target temperature and the temperature feedback coefficient and the temperature time constant; determining a dynamic adjustment temperature of the autoclave according to the target temperature and the temperature feedback coefficient and the temperature time constant; determining a dynamic adjustment temperature of the autoclave according to the target temperature and the temperature feedback coefficient and the temperature feedback coefficient and the temperature time constant; determining a dynamic adjustment temperature of the autoclave according to the target temperature and the real-time temperature, the switching moment corresponding to each of the preset stages, and the temperature feedback coefficient and the temperature time constant; determining a dynamic adjustment temperature of the autoclave according to the target temperature and the real-time temperature, the switching moment corresponding to each of the preset The method comprises the steps of: determining the dynamic adjustment temperature according to the switching moment and target pressure corresponding to each of the preset stages; determining the dynamic adjustment pressure of the autoclave according to the switching moment and target pressure corresponding to each of the preset stages, including: obtaining the pressure feedback coefficient and pressure time constant corresponding to each of the preset stages; obtaining the real-time pressure of the autoclave according to the pressure sensor preset in the autoclave; determining the dynamic adjustment pressure according to the real-time pressure, the switching moment corresponding to each of the preset stages, the pressure feedback coefficient, the pressure time constant and the target pressure; completing pressurizing and heating the autoclave according to the dynamic adjustment temperature and the dynamic adjustment pressure; completing the packaging of the photovoltaic module; and the plurality of preset stages at least include a preheating stage, a first heating stage, a second heating stage and a cooling stage.

2. The method according to claim 1, characterized in that Before providing laminated photovoltaic modules, it also includes: Providing front glass, first adhesive film, battery string, bus bar, second adhesive film and back glass; In a lamination room with a preset environment, laying the first adhesive film on the front glass plate; Laying the battery string on the first adhesive film, and welding the bus bar to the battery string; The second adhesive film and back plate glass are sequentially laid on the battery string and the bus bar to complete the lamination of the photovoltaic module.

3. The method according to claim 2, characterized in that The front glass and the back glass have the same glass width; Before completing the lamination of the photovoltaic module, the method further comprises: The first adhesive film and the second adhesive film are trimmed so that the adhesive film widths corresponding to the trimmed first adhesive film and the second adhesive film are greater than the glass width, and the difference between the adhesive film width and the glass width is within a preset width range, and the preset width range is 10 mm to 20 mm.

4. The method according to claim 2, characterized in that: The preset environment corresponding to the lamination chamber includes a preset temperature range and a preset humidity range, the preset temperature range is 18° C. to 24° C., and the preset humidity range is 18% RH to 28% RH.

5. The method according to claim 1, characterized in that The electroluminescence detection of the photovoltaic module comprises: Providing an electroluminescent detection device; the electroluminescent detection device comprises a high voltage power supply and a CCD acquisition module; Fixing the photovoltaic module on a preset testing platform after cleaning; the testing platform is located in a darkroom environment; Connecting the high voltage power supply to the photovoltaic module; Controlling the photovoltaic module to emit visible light or near-infrared light according to preset electroluminescent parameters through the high-voltage power supply; the electroluminescent parameters at least include voltage, current and exposure time; When the photovoltaic component emits visible light or near-infrared light, the CCD acquisition module acquires luminous image information corresponding to the photovoltaic component; The electroluminescence detection of the photovoltaic component is completed according to the luminescent image information.

6. The method according to claim 5, characterized in that The step of completing the electroluminescence detection of the photovoltaic module according to the luminescent image information includes: Inputting the luminous image information into a preset multi-scale filter, wherein the multi-scale filter outputs multi-scale features corresponding to the luminous image information; the multi-scale filter includes any one of a Gaussian pyramid filter and a multi-scale Laplacian filter; According to the multi-scale features, semantic segmentation and instance segmentation are respectively performed on the luminescent image information, and a semantic segmentation map and defect mask information corresponding to the luminescent image information are respectively obtained; the semantic segmentation map includes a plurality of pixel defect type identifiers; Performing edge detection on the luminous image information to obtain edge detection information corresponding to the luminous image information; The electroluminescence detection of the photovoltaic module is completed according to the semantic segmentation map, the edge detection information and the defect mask information.

7. The method according to claim 6, characterized in that If the preset defects include cracks, short circuits, black cores and cold solder joints; the electroluminescence detection of the photovoltaic module is completed according to the semantic segmentation map, the edge detection information and the defect mask information, including: determining whether the luminous image includes continuous edge breaks according to the edge detection information and the semantic segmentation map, so as to determine whether the luminous image includes the split; Determine the current distribution information corresponding to the luminescent image according to the semantic segmentation map, and determine whether the luminescent image includes a current abnormal area based on the heat map technology and the current distribution information, so as to determine whether the luminescent image includes the short circuit; Acquire brightness information and contrast information corresponding to the luminous image according to the defect mask information and the semantic segmentation map, and determine whether the luminous image includes the black center according to the brightness information and the contrast information; The welding point morphology and welding point brightness information corresponding to the luminous image are obtained according to the defect mask information and the edge detection information to determine whether the luminous image includes the cold solder joint; the welding point morphology corresponding to the cold solder joint is discontinuous and the brightness is uneven.

8. The method according to claim 1, characterized in that: The step of placing the photovoltaic module into a lamination chamber of a laminator for pre-lamination further comprises: Controlling the laminator to pre-laminate the photovoltaic module in the lamination chamber according to preset lamination parameters to remove air from the photovoltaic module and prevent the photovoltaic module from cracking when subjected to high pressure; Wherein, the preset lamination parameters include lamination temperature, vacuuming time and lamination pressure.

9. The method according to claim 8, characterized in that The lamination temperature corresponds to a range of 140° C. to 150° C., the vacuuming time corresponds to a range of 9 min to 11 min, and the lamination pressure corresponds to a range of -80 Kpa to -60 Kpa; wherein, during the pre-lamination process, the lamination temperature increases with time.

10. The method according to claim 1, characterized in that The support frame is an A-type support frame, and the top of the A-type support frame is formed as a component accommodating area; the pre-laminated photovoltaic components are placed on the preset support frame in a vertical direction, including: The photovoltaic component is placed in a component accommodating area of ​​the A-type support frame in a vertical direction, and the component accommodating area fixes the photovoltaic component on the A-type support frame.

11. The method according to claim 1, characterized in that: The target temperature and target pressure corresponding to the preheating stage are respectively lower than the target temperature and target pressure of the first heating stage, the target temperature and target pressure of the first heating stage are respectively lower than the target temperature and target pressure of the second heating stage, and the autoclave stops heating and pressurizing the photovoltaic module during the cooling stage until the temperature inside the autoclave is lower than the door opening temperature of the autoclave.

12. The method according to claim 11, characterized in that The temperature range corresponding to the preheating stage is 40°C to 50°C; The first heating stage corresponds to a temperature range of 115°C to 125°C, a pressure range of 0.7Mpa to 0.9Mpa, and a time range of 25min to 35min; The second heating stage corresponds to a temperature of 135° C. to 145° C., a pressure range of 1.1 MPa to 1.2 MPa, and a time range of 25 min to 35 min.

13. The method according to claim 1, characterized in that The expression for dynamically adjusting the temperature includes: Among them, the following: For the dynamic temperature adjustment, is the current time corresponding to the heating and pressurizing in the autoclave, is the real-time temperature, is the initial temperature corresponding to the photovoltaic module, , , are the target temperature, temperature time constant, and temperature feedback coefficient corresponding to the preheating stage, respectively. The switching time corresponding to the preheating stage is 0. , , and are the target temperature, temperature time constant, switching time and temperature feedback coefficient corresponding to the first heating stage, respectively. , , and are the target temperature, temperature time constant, switching time and temperature feedback coefficient corresponding to the second heating stage, respectively. , , and are respectively the target temperature, temperature time constant, switching time and temperature feedback coefficient corresponding to the cooling stage.

14. The method according to claim 1, characterized in that The expression for dynamically adjusting the pressure includes: Among them, the following: For the dynamically adjusted pressure, is the current time corresponding to the heating and pressurizing in the autoclave, is the real-time pressure, is the initial pressure corresponding to the photovoltaic module, , , are the target pressure, pressure time constant, and pressure feedback coefficient corresponding to the preheating stage, respectively. The switching time corresponding to the preheating stage is 0. , , and are the target pressure, pressure time constant, switching time and pressure feedback coefficient corresponding to the first heating stage, respectively. , , and are the target pressure, pressure time constant, switching time and pressure feedback coefficient corresponding to the second temperature rise stage, respectively, , , and are respectively the target pressure, pressure time constant, switching time and pressure feedback coefficient corresponding to the cooling stage.

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