Photovoltaic module, manufacturing method thereof, and related device

Abstract

The present application provides a photovoltaic module, a manufacturing method of the photovoltaic module, and related devices. In the photovoltaic module, the front photovoltaic glass layer is a light-transmitting material, and the front photovoltaic glass layer is used to protect the photovoltaic cells and internal structures in the photovoltaic module; the first photovoltaic adhesive film and the second photovoltaic adhesive film are used to bond adjacent component structures; the photovoltaic cells are used to convert light energy into electrical energy; the backplane layer is used to ensure the flatness of the photovoltaic module and provide support for the multi-layer structure; the metal backplane serves as the bottom support and is used to enhance the overall structural strength of the photovoltaic module; the multi-layer structure in the photovoltaic module is obtained by stacking, laminating, and curing and encapsulating, and the lamination time of the multi-layer structure is determined according to the thicknesses of the first photovoltaic adhesive film, the second photovoltaic adhesive film, and the polymer film; the expansion coefficients of the front photovoltaic glass layer and the metal backplane are determined by the co-deformation ability of each component in the photovoltaic module. The embodiments of the present application are beneficial to improving the structural performance of the photovoltaic module itself and can also improve the efficiency in the production process.

Description

Technical Field

[0001] This application relates to the technical field of curtain wall equipment, and particularly to a photovoltaic module, a manufacturing method of the photovoltaic module, and related devices. Background Art

[0002] With the rapid development of the photovoltaic industry, the application scenarios of photovoltaic modules are becoming more and more extensive, and the strength requirements for photovoltaic modules are also getting higher and higher. Photovoltaic equipment refers to devices and systems that directly convert solar energy into electrical energy, usually including components such as solar panels (photovoltaic panels), inverters, controllers, energy storage devices (such as batteries), brackets, and cables. Photovoltaic equipment is widely used in various occasions, from household rooftop installations to large-scale solar power plants, to provide clean and renewable energy.

[0003] In related technologies, for the structure strengthening method of the bonded backplane of the photovoltaic module, a reprocessing method of bonding with silicone structural adhesive is mostly adopted to bond the backplane and the photovoltaic module together. The process of bonding the structural adhesive mostly uses the method of manual glue application, with low efficiency and the curing time of the structural adhesive generally being about seven days, resulting in low efficiency of bonding the backplane and slow production speed of the photovoltaic module.

[0004] Therefore, there is an urgent need to design a brand-new technical solution to solve at least one of the above technical problems. Summary of the Invention

[0005] To solve or improve the above problems, embodiments of this application provide a photovoltaic module, a manufacturing method of the photovoltaic module, and related devices.

[0006] In an embodiment of this application, a photovoltaic module is provided. In the photovoltaic module, the multi-layer structure is stacked from top to bottom in sequence as follows: a front photovoltaic glass layer, a first photovoltaic film, a photovoltaic cell, a second photovoltaic film, a backplane layer, a polymer film, and a metal backplane;

[0007] The front photovoltaic glass layer is a light-transmitting material, and is used to protect the photovoltaic cells and internal structures in the photovoltaic module; the first photovoltaic film and the second photovoltaic film are used to bond adjacent component structures; the photovoltaic cell is used to convert light energy into electrical energy; the backplane layer is used to ensure the flatness of the photovoltaic module and provide support for the multi-layer structure; the polymer film is used to bond adjacent component structures; the metal backplane serves as the bottom support and is used to enhance the overall structural strength of the photovoltaic module;

[0008] The multi-layer structure in the photovoltaic module is obtained by stacking, laminating, and then curing and encapsulating. The lamination time of the multi-layer structure is determined according to the thicknesses of the first photovoltaic film, the second photovoltaic film, and the polymer film;

[0009] The expansion coefficients of the photovoltaic front plate glass layer and the metal back plate are determined by the cooperative deformation ability of the components in the photovoltaic module.

[0010] In another embodiment of the present application, a manufacturing method of a photovoltaic module is provided, characterized in that the photovoltaic module is the photovoltaic module in the above embodiment, and the multi-layer structure in the photovoltaic module is stacked from top to bottom in sequence: a photovoltaic front plate glass layer, a first photovoltaic adhesive film, a photovoltaic cell, a second photovoltaic adhesive film, a back plate layer, a polymer film, and a metal back plate; the method includes:

[0011] Place the photovoltaic front plate glass layer and the first photovoltaic adhesive film on a laminator in a preset order; the photovoltaic front plate glass layer is a light-transmitting material, and the photovoltaic front plate glass layer is used to protect the photovoltaic cells and the internal structure in the photovoltaic module; the first photovoltaic adhesive film and the second photovoltaic adhesive film are used to bond adjacent component structures;

[0012] Place the photovoltaic cell between the first photovoltaic adhesive film and the second photovoltaic adhesive film in a preset order; the photovoltaic cell is used to convert light energy into electrical energy;

[0013] Place the back plate layer under the second photovoltaic adhesive film in a preset order; the back plate layer is used to ensure the flatness of the photovoltaic module and provide support for the multi-layer structure;

[0014] Cover the back plate layer with the polymer film; the polymer film is used to bond adjacent component structures;

[0015] Place the metal back plate at the bottom of the multi-layer structure as the bottom support; the metal back plate is used to enhance the overall structural strength of the photovoltaic module;

[0016] Press the stacked multi-layer structure through high temperature and high pressure by the laminator rollers, so that the first photovoltaic adhesive film, the second photovoltaic adhesive film, and the polymer film are melted and solidified to encapsulate the photovoltaic module;

[0017] Among them, the lamination time of the multi-layer structure is determined according to the thicknesses of the first photovoltaic adhesive film, the second photovoltaic adhesive film, and the polymer film; the expansion coefficients of the photovoltaic front plate glass layer and the metal back plate are determined by the cooperative deformation ability of the components in the photovoltaic module.

[0018] In an embodiment of the present application, a laminated solar cell module is characterized in that the laminated solar cell module at least includes the photovoltaic module in the above embodiment, and the laminated solar cell module is manufactured by using the manufacturing method of the photovoltaic module in the above embodiment.

[0019] In one embodiment of the present application, an electronic device includes:

[0020] at least one processor, a memory, and an input / output unit;

[0021] wherein, the memory is used to store a computer program, and the processor is used to call the computer program stored in the memory to execute the manufacturing method of the photovoltaic module in the above first embodiment.

[0022] In one embodiment of the present application, a computer-readable storage medium is provided, which includes instructions that, when the instructions are run on a computer, cause the computer to execute the manufacturing method of the photovoltaic module in the above first embodiment.

[0023] In the technical solution provided by the embodiments of the present application, in the photovoltaic module, the multi-layer structure is stacked from top to bottom in sequence with: a photovoltaic front plate glass layer, a first photovoltaic adhesive film, a photovoltaic cell, a second photovoltaic adhesive film, a backplane layer, a polymer film, and a metal backplane; the photovoltaic front plate glass layer is a light-transmitting material, and the photovoltaic front plate glass layer is used to protect the photovoltaic cell and the internal structure in the photovoltaic module; the first photovoltaic adhesive film and the second photovoltaic adhesive film are used to bond adjacent component structures; the photovoltaic cell is used to convert light energy into electrical energy; the backplane layer is used to ensure the flatness of the photovoltaic module and provide support for the multi-layer structure; the polymer film is used to bond adjacent component structures; the metal backplane serves as a bottom support and is used to enhance the overall structural strength of the photovoltaic module; the multi-layer structure in the photovoltaic module is obtained by stacking, laminating, and then curing and encapsulating, and the lamination time of the multi-layer structure is determined according to the thicknesses of the first photovoltaic adhesive film, the second photovoltaic adhesive film, and the polymer film; the expansion coefficients of the photovoltaic front plate glass layer and the metal backplane are determined by the cooperative deformation ability of each component in the photovoltaic module.

[0024] In the embodiments of the present application, the front photovoltaic glass layer can protect the photovoltaic cells and the internal structure. The backplane layer can ensure the flatness of the photovoltaic module and provide support for the multi-layer structure. The metal backplane, as the bottom support, can enhance the overall structural strength of the photovoltaic module. The cooperation of each structure ensures the structural stability of the photovoltaic module and proper protection of the internal components. The expansion coefficients of the front photovoltaic glass layer and the metal backplane are determined by the cooperative deformation ability of the components in the photovoltaic module, which helps the photovoltaic module better adapt to changes in factors such as temperature under different environmental conditions, reduces structural problems caused by differences in expansion coefficients, and improves the overall stability. By directly stacking the polymer film and the metal backplane under the back surface of the photovoltaic module, the integrated lamination molding of the metal backplane and the photovoltaic module is realized, which changes the original production method, simplifies the process steps, reduces the operation links, and thus effectively improves the production efficiency of the module. The optimization of the integrated lamination molding process reduces the complexity of manual participation and the amount of manual operation in the production process, which helps to make the production of photovoltaic modules more efficient. Generally speaking, it is beneficial to improve the structural performance of the photovoltaic module itself and also achieve higher efficiency in the production process. BRIEF DESCRIPTION OF THE DRAWINGS

[0025] In order to more clearly illustrate the technical solutions in the embodiments of the present application or the prior art, the following will briefly introduce the drawings required for use in the description of the embodiments or the prior art. Obviously, the following drawings are some embodiments of the present application. For those of ordinary skill in the art, without creative efforts, other drawings can also be obtained based on these drawings.

[0026] Figure 1 It is a schematic structural diagram of a photovoltaic module provided by an embodiment of the present application;

[0027] Figure 2 It is a schematic structural diagram of a photovoltaic module provided by another embodiment of the present application;

[0028] Figure 3 It is a schematic structural diagram of a photovoltaic module provided by still another embodiment of the present application;

[0029] Figure 4 It is a schematic flowchart of the manufacturing method of a photovoltaic module provided by an embodiment of the present application;

[0030] Figure 5 It is a schematic structural diagram of an electronic device provided by an embodiment of the present application. DETAILED DESCRIPTION OF THE EMBODIMENTS

[0031] The present application provides the following embodiments to solve or improve at least some of the above problems. In order to enable those skilled in the art to better understand the solutions of the present application, the technical solutions in the embodiments of the present application will be clearly and completely described below with reference to the drawings in the embodiments of the present application.

[0032] Among some of the features described in the specification, claims, and the above-mentioned drawings of the present application, descriptions such as "first", "second", etc. are used to distinguish different components, parts, modules, devices, etc., and do not represent a sequential order, nor do they limit that "first" and "second" are of different types. In addition, the embodiments described below are only a part of the embodiments of the present application, rather than all embodiments. Based on the embodiments in the present application, all other embodiments obtained by those skilled in the art without creative efforts belong to the scope of protection of the present application.

[0033] To solve the technical problems of low efficiency in bonding the backplane and slow production speed of photovoltaic modules in the related art, in a photovoltaic module provided by an embodiment of the present application, a multi-layer structure is stacked from top to bottom in sequence as follows: a front photovoltaic glass layer, a first photovoltaic adhesive film, a photovoltaic cell, a second photovoltaic adhesive film, a backplane layer, a polymer film, and a metal backplane; the front photovoltaic glass layer is a light-transmitting material, and the front photovoltaic glass layer is used to protect the photovoltaic cells and internal structures in the photovoltaic module; the first photovoltaic adhesive film and the second photovoltaic adhesive film are used to bond adjacent component structures; the photovoltaic cell is used to convert light energy into electrical energy; the backplane layer is used to ensure the flatness of the photovoltaic module and provide support for the multi-layer structure; the polymer film is used to bond adjacent component structures; the metal backplane serves as a bottom support and is used to enhance the overall structural strength of the photovoltaic module; the multi-layer structure in the photovoltaic module is obtained by stacking, laminating, and then curing and encapsulating, and the lamination time of the multi-layer structure is determined according to the thicknesses of the first photovoltaic adhesive film, the second photovoltaic adhesive film, and the polymer film; the expansion coefficients of the front photovoltaic glass layer and the metal backplane are determined by the co-deformation ability of each component in the photovoltaic module.

[0034] In the embodiments of the present application, the front photovoltaic glass layer can protect the photovoltaic cells and the internal structure. The backplane layer can ensure the flatness of the photovoltaic module and provide support for the multi-layer structure. The metal backplane, as the bottom support, can enhance the overall structural strength of the photovoltaic module. The cooperation of each structure ensures the structural stability of the photovoltaic module and proper protection of the internal components. The expansion coefficients of the front photovoltaic glass layer and the metal backplane are determined by the cooperative deformation ability of each component in the photovoltaic module, which helps the photovoltaic module better adapt to changes in factors such as temperature under different environmental conditions, reduces structural problems caused by differences in expansion coefficients, and improves the overall stability. By directly stacking the polymer film and the metal backplane under the back surface of the photovoltaic module, the metal backplane and the photovoltaic module are integrally laminated, changing the original production method, simplifying the process steps, reducing the operation links, and thus effectively improving the production efficiency of the module. The optimization of the integral lamination process reduces the complexity of manual participation and the amount of manual operation during the production process, which helps to make the production of photovoltaic modules more efficient. Generally speaking, it is beneficial to improve the structural performance of the photovoltaic module itself and achieve higher efficiency in the production process.

[0035] Figure 1 The structural schematic diagram of a photovoltaic module provided by an embodiment of the present application is shown. As Figure 1 shown, an embodiment of the present application proposes a photovoltaic module, aiming to control the manufacturing process of the photovoltaic module, which is beneficial to improving the structural performance of the photovoltaic module itself and achieving higher efficiency in the production process. Figure 1 Among them, 1 is the front photovoltaic glass, 2 is the photovoltaic adhesive film, 3 is the photovoltaic cell, 4 is the backplane layer, 5 is the polymer film, and 6 is the metal backplane. Further optionally, the photovoltaic adhesive film includes a first photovoltaic adhesive film and a second photovoltaic adhesive film, and the backplane layer includes backplane glass or a photovoltaic backplane.

[0036] In another example, Figure 2 Among them, 1 is the front photovoltaic glass, 2 is the photovoltaic adhesive film, 3 is the photovoltaic cell, 4 is the backplane layer, 5 is the polymer film, 6 is the metal backplane, 7 is the laminator roller, and 8 is the laminator. The photovoltaic module, the polymer film, and the metal backplane are stacked in the Figure 2 manner and fed into the laminator by the lower roller. The lamination temperature range is 150°C to 180°C, and the lamination time is determined according to the thickness of the photovoltaic adhesive film and the polymer film, and is basically controlled between 10 and 15 minutes. Exemplarily, the backplane layer can be backplane glass or a photovoltaic backplane. Specifically, based on Figure 2 shown, the lamination process flow of the photovoltaic module and the corresponding functions of each step are described:

[0037] Step 1: Place the front photovoltaic glass 1 and the photovoltaic adhesive film 2 on the laminator.

[0038] The front photovoltaic glass plays a role in protecting the internal structure of the photovoltaic module, especially the photovoltaic cells to be placed later. It is the first barrier for the entire module facing the external environment. The photovoltaic encapsulant film here serves as an adhesive material, providing a pasting basis for the photovoltaic cells to be placed later, facilitating better fixation of the cells, forming a tight connection with the front glass, and ensuring the initial stability of the module structure.

[0039] Step Two: Place the photovoltaic cells 3 on the photovoltaic encapsulant film in a certain arrangement order.

[0040] Photovoltaic cells are the core components for the entire photovoltaic module to convert light energy into electrical energy. Placing them in a specific arrangement order can ensure the efficiency of light energy reception and the stability of the power generation performance of the entire module. Placed on the photovoltaic encapsulant film, the cells can be firmly fixed in place by the viscosity of the film, preventing displacement during subsequent operations and use, and ensuring the normal power generation function of the module.

[0041] Step Three: Cover the cells with the backsheet layer 4 and the polymer film 5 to ensure overall flatness.

[0042] The backsheet glass or photovoltaic backsheet can further protect the internal structures such as cells from external factors such as moisture and dust, enhancing the overall sealing and protection of the module. The polymer film here serves as a connecting component. On the one hand, it can better fit the backsheet and cells and other structures, filling possible small gaps to ensure tight bonding between structures. On the other hand, it helps to maintain the flatness of the entire module structure, avoiding local unevenness that may affect subsequent use and aesthetics.

[0043] Step Four: Place the metal backsheet 6 on the last layer as the bottom support.

[0044] The metal backsheet can provide strong bottom support for the entire photovoltaic module, enhancing the overall structural strength of the module, enabling it to better withstand various external forces such as wind force and self-weight during installation and use, preventing the module from deforming or being damaged, and ensuring the long-term stable operation of the module.

[0045] Step Five: Use the laminator roller 7 to laminate the entire module through high temperature and high pressure, and complete curing and encapsulation in the laminator 8.

[0046] With the action of high temperature and high pressure applied by the laminator roller, the photovoltaic encapsulant film and the polymer film can fully exert their viscosity under such conditions, achieving a more firm and tight bond between components. At the same time, the multi-layer structure of the entire module is cured into a whole to complete the encapsulation process, forming a relatively independent, stable and sealed environment inside the module, better protecting key components such as the internal cells, and finally forming a photovoltaic module that can be put into normal use.

[0047] Through this series of steps and corresponding functions, the complete lamination process of photovoltaic modules from the preparation of each component to the final curing and packaging is completed in an orderly manner, and photovoltaic modules with stable performance and reliable structure are manufactured.

[0048] In another example, Figure 3 In the figure, 1 is photovoltaic front plate glass, 2 is photovoltaic adhesive film, 3 is photovoltaic cell sheet, 4 is back plate layer, 5 is polymer film, 6 is corrugated metal back plate, 7 is laminator roller, 8 is laminator, and 9 is high temperature pad.

[0049] When the metal backing plate has metal corrugations, in order to ensure the stability of the assembly during lamination, a high-temperature pad with greater rigidity needs to be placed between the corrugations, which will cause severe deformation during lamination. When the metal backing plate has metal corrugations, the steps of the lamination process and the corresponding functions of each step are explained as follows:

[0050] Step 1: Place the photovoltaic front glass 1 and photovoltaic film 2 on the laminator in the laminating order. As the outermost layer of the photovoltaic module, the photovoltaic front glass protects the internal photovoltaic cells and other components from external physical impact, dust, water vapor and other erosions, and is the first line of defense to ensure the long-term stable operation of the module.

[0051] Photovoltaic adhesive film is a sticky intermediate connecting material that can firmly adhere the subsequently placed photovoltaic cells to the photovoltaic front glass, ensuring that the position of the cells is fixed, laying the foundation for building a stable component structure, and also helping to better combine the components into one during the subsequent lamination process.

[0052] Step 2: Place the photovoltaic cells. The photovoltaic cells 3 are placed on the photovoltaic film 2 in a predetermined arrangement order. The photovoltaic cells are the core components of the entire photovoltaic module to achieve photoelectric conversion. Placing them in a predetermined arrangement order can ensure that they can efficiently and stably convert light energy into electrical energy when receiving light, so that the module has stable power generation performance. Placing them on the photovoltaic film can prevent the cells from moving randomly during operation by relying on the viscosity of the film, ensuring that they are in the correct position in the module, thereby ensuring that the power generation function of the entire module can be performed normally.

[0053] Step 3: Add the backplane layer. Place the backplane layer 4 and the polymer film 5 to ensure that the battery cell and the backplane layer are tightly bonded.

[0054] The backplane glass or photovoltaic backplane is mainly used to provide back protection for internal components such as photovoltaic cells, blocking adverse factors in the external environment (such as moisture, impurities, etc.) from invading the component interior from the back, further enhancing the overall sealing and stability of the component, and extending the service life of the component. The polymer film plays a bonding role, being able to tightly connect the backplane with structures such as the battery cells, filling the tiny gaps that may exist between them, enhancing the integrity of the entire component structure, ensuring close fitting between layers, forming a relatively closed and stable environment inside the component, and helping to ensure that the performance of the component is not interfered by the outside world.

[0055] Step Four: Place the corrugated metal backplane. Place the corrugated metal backplane 6 in the last layer. Its structure is corrugated, which helps to enhance the strength and heat dissipation performance of the backplane.

[0056] In terms of structural strength, the corrugated design endows the metal backplane with higher structural strength, enabling it to better withstand various forces applied to the component from the outside (such as the pulling force during installation, the wind force during use, the self-gravity of the component, etc.), preventing the component from deforming or being damaged, providing reliable bottom support for the entire photovoltaic component, and ensuring the structural stability of the component under different working conditions. In terms of heat dissipation performance, the corrugated structure increases the contact area between the backplane and the air, which is conducive to heat dissipation, can conduct the heat generated by the photovoltaic cells during operation in a timely manner, avoid the component being affected by too high temperature and even causing component damage, help to maintain the component within a suitable working temperature range, and improve the performance and reliability of the component.

[0057] Step Five: Place high-temperature pads. In order to prevent the metal backplane from deforming, place high-temperature pads 9 with relatively large stiffness between the corrugated parts of the corrugated metal backplane.

[0058] These pads play a supporting role during the high-temperature lamination process, preventing the corrugated metal backplane from bending or deforming when heated, and maintaining the flatness of the entire component. In the high-temperature lamination environment, the metal backplane is prone to bending or deforming due to the thermal stress generated by heating. Placing high-temperature pads can provide effective support between the corrugations, resist the influence of this thermal stress, ensure that the corrugated metal backplane maintains its original shape and structure during the lamination process, and then maintain the flatness of the entire component. The flatness of the component is very important for its subsequent installation, use, and the coordinated operation of each component. A flat component is more conducive to ensuring the normal operation of internal components such as battery cells and the overall aesthetics.

[0059] Step Six: Put the above-mentioned component into the laminator 8, and use the laminator rollers 7 to apply appropriate pressure and temperature for curing and encapsulation.

[0060] By applying appropriate pressure and temperature conditions through the rollers of the laminator, the photovoltaic adhesive film and the polymer film can fully exert their adhesiveness in a high-temperature and high-pressure environment, making the bonding between components more firm and tight, achieving the curing of the multi-layer structure of the entire module, and ultimately completing the encapsulation. After encapsulation, a stable and sealed environment is formed inside the module, which can better protect key components such as the internal solar cells from the external environment, thereby manufacturing a photovoltaic module with reliable performance, stable structure, and capable of normal operation.

[0061] Through this series of steps and the functions played by each step, the lamination process of the photovoltaic module with a corrugated metal backsheet is completed from material preparation to final curing and encapsulation, ensuring that the manufactured photovoltaic module meets the usage requirements and has good performance.

[0062] The usage process of this application is divided into the following parts:

[0063] As an optional embodiment, the metal backsheet is a corrugated metal backsheet, and the corrugated metal backsheet is used to bear the pressure generated by wind load, gravity load, and / or seismic action.

[0064] As an optional embodiment, the photovoltaic module further includes high-temperature pads, and the high-temperature pads are evenly filled in the gaps of the corrugated metal backsheet; the high-temperature pads are used to support the shape of the corrugated metal backsheet during the lamination process, preventing the corrugated metal backsheet from deforming due to excessive pressure during the lamination process.

[0065] It can be understood that the main function of the high-temperature pads is to maintain the shape of the corrugated metal backsheet during the lamination process, preventing it from undergoing severe deformation due to excessive pressure during the lamination process. Due to the large undulation of the corrugations, when the laminator applies pressure, the backsheet in the corrugated area may be subjected to uneven pressure distribution, resulting in local excessive deformation. The high-temperature pads provide a stable support surface by filling the gaps between the corrugations, avoiding the collapse or irregular deformation of the corrugated area during the lamination process. The high-temperature pads must have a large stiffness to withstand the high pressure applied during the lamination process and prevent the pads themselves from deforming. The pads with a large rigidity can effectively support the corrugated structure, thus maintaining the shape stability of the metal backsheet during lamination. At the same time, the pads must also have good heat resistance because high temperatures (usually in the range of 150°C - 180°C) are used during the lamination process. Therefore, the pad material should possess heat-resistant characteristics and will not soften or deform in a high-temperature environment. The size of the high-temperature pads needs to precisely match the space between the corrugations. To prevent the pads from sliding or shifting in position during the lamination process, the size of the pads needs to be customized according to the corrugation shape and spacing of the metal backsheet. The pads are usually rectangular or other suitable geometric shapes and can be adjusted according to the specific corrugation spacing and depth to ensure that the pads can completely fill the gap of each corrugation.

[0066] During the lamination process, high-temperature spacers should be evenly distributed between each pair of corrugations to ensure sufficient support in each corrugated area. This can prevent the corrugated area from deforming due to excessive local pressure and ensure the stability of the entire metal backplane surface. The spacers can disperse the pressure during the lamination process and avoid local pressure concentration in certain corrugated areas, which is crucial for improving the uniformity and stability of lamination. During the lamination process, the role of the high-temperature spacers is closely related to other factors (such as lamination temperature, pressure, time, etc.). The rigidity of the spacers ensures that the corrugated area does not deform under high-pressure conditions, and the optimization of temperature and pressure helps the adhesive film to fully soften and bond the photovoltaic module and the metal backplane. By precisely controlling the lamination process, the spacers and other lamination conditions work together to ensure the bonding quality between the photovoltaic module and the backplane.

[0067] In actual production, it is usually necessary to conduct multiple tests to determine the specific shape, size, and material of the high-temperature spacers and adjust the lamination temperature and pressure to achieve the best lamination effect. The material of the spacers may need to be selected and customized according to different types of photovoltaic backplanes (such as different corrugation heights and pitches). As an alternative embodiment, the metal backplane is made of a metal material with a coefficient of linear thermal expansion in the range of 9×10-6 / K to 18×10-6 / K.

[0068] As an alternative embodiment, if the thickness of the first photovoltaic adhesive film and / or the second photovoltaic adhesive film is 1.14 mm and the thickness of the polymer film is 0.3 mm, the lamination time range of the multi-layer structure is 10 minutes to 15 minutes.

[0069] As an alternative embodiment, the lamination temperature range of the multi-layer structure is 150°C to 180°C.

[0070] It should be added here that the control logic of the control device will be introduced in detail in the method embodiments below.

[0071] A manufacturing method of a photovoltaic module provided by an embodiment of the present application. The execution subject of the method in this embodiment can be the photovoltaic module manufacturing device in the above embodiment and is implemented on the basis of the structure of the photovoltaic module embodiment in the above. In the photovoltaic module, the multi-layer structure is stacked from top to bottom in sequence: a photovoltaic front plate glass layer, a first photovoltaic adhesive film, a photovoltaic cell, a second photovoltaic adhesive film, a backplane layer, a polymer film, and a metal backplane. Refer to Figure 4 As shown, the method may include the following steps:

[0072] 101. Place the photovoltaic front glass layer and the first photovoltaic adhesive film on the laminator in a preset order; the photovoltaic front glass layer is a light-transmitting material and is used to protect the photovoltaic cells and the internal structure in the photovoltaic module; the first photovoltaic adhesive film and the second photovoltaic adhesive film are used to bond adjacent component structures;

[0073] 102. Place the photovoltaic cells between the first photovoltaic adhesive film and the second photovoltaic adhesive film in a preset order; the photovoltaic cells are used to convert light energy into electrical energy;

[0074] 103. Place the backplane layer under the second photovoltaic adhesive film in a preset order; the backplane layer is used to ensure the flatness of the photovoltaic module and provide support for the multi-layer structure;

[0075] 104. Cover the backplane layer with the polymer film; the polymer film is used to bond adjacent component structures;

[0076] 105. Place the metal backplane at the bottom of the multi-layer structure as the bottom support; the metal backplane is used to enhance the overall structural strength of the photovoltaic module;

[0077] 106. Through the rollers of the laminator, subject the stacked multi-layer structure to hot pressing treatment under high temperature and high pressure, so that the first photovoltaic adhesive film, the second photovoltaic adhesive film and the polymer film melt and solidify to encapsulate and obtain the photovoltaic module.

[0078] This application provides a manufacturing method of a photovoltaic module. The photovoltaic front glass layer can protect the photovoltaic cells and the internal structure. The backplane layer can ensure the flatness of the photovoltaic module and provide support for the multi-layer structure. The metal backplane as the bottom support can enhance the overall structural strength of the photovoltaic module. The cooperation of each structure ensures the stable structure of the photovoltaic module and proper protection of the internal components. The expansion coefficients of the photovoltaic front glass layer and the metal backplane are determined by the cooperative deformation ability of each component in the photovoltaic module, which helps the photovoltaic module better adapt to changes in factors such as temperature under different environmental conditions, reduce structural problems caused by differences in expansion coefficients, and improve the overall stability. By directly stacking the polymer film and the metal backplane under the back surface of the photovoltaic module, the integrated lamination molding of the metal backplane and the photovoltaic module is realized, which changes the original production method, simplifies the process steps, reduces the operation links, and thus effectively improves the production efficiency of the module. The optimization of the integrated lamination molding process reduces the complexity of manual participation and the amount of manual operation in the production process, and thus helps to make the production efficiency of the photovoltaic module higher in the manufacturing process. Generally speaking, it is beneficial to improve the structural performance of the photovoltaic module itself and also improve the efficiency in the production link.

[0079] Step 101: Place the photovoltaic front panel glass layer and the first photovoltaic adhesive film on the laminator in a preset order. The photovoltaic front panel glass layer serves as the outermost protective structure of the entire photovoltaic module facing the external environment. Utilizing its light transmissivity, it can not only ensure that external light energy can pass through smoothly and irradiate onto the internal photovoltaic cells, but also, relying on its physical properties such as hardness and sealing performance, block adverse factors such as external dust, water vapor, and physical impacts, protecting the internal photovoltaic cells and other structures from damage, and creating good conditions for the long-term stable operation of the photovoltaic module.

[0080] The first photovoltaic adhesive film is essentially a sticky intermediate connecting material. In this step, it is placed below the photovoltaic front panel glass layer, aiming to provide a reliable pasting foundation for the subsequently placed photovoltaic cells. Through the adhesive action of the film, the photovoltaic cells can be tightly bonded to the photovoltaic front panel glass layer. During subsequent operations and the use of the module, it can prevent the cells from shifting and other situations, ensuring the initial stability of the internal structure of the module, and at the same time laying a foundation for the integration between multiple layers of structures.

[0081] Step 102: Place the photovoltaic cells between the first photovoltaic adhesive film and the second photovoltaic adhesive film in a preset order.

[0082] The photovoltaic cells are the core components of the entire photovoltaic module for converting light energy into electrical energy. Placing them in a preset order is based on the design requirements of the photovoltaic module. Different arrangement orders will affect its light energy reception efficiency and the stability of the power generation performance of the entire module. Placed between two layers of photovoltaic adhesive films, relying on the adhesive connection between the first photovoltaic adhesive film and the cells, it can be firmly attached to one side of the front panel glass; while the second photovoltaic adhesive film can be pasted to the cells on the other side, further fixing the position of the cells, and at the same time preparing for the subsequent connection with structures such as the back panel layer, thus ensuring that the cells are in an accurate and stable position inside the module, and ensuring that the module can normally and efficiently convert light energy into electrical energy.

[0083] Step 103: Place the back panel layer below the second photovoltaic adhesive film in a preset order.

[0084] The backplane layer plays a vital supporting and protective role in photovoltaic modules. From the perspective of flatness, by placing it flatly under the second photovoltaic film, it can provide a flat support surface for the entire multi-layer structure, ensuring that each layer maintains overall flatness during subsequent pressing and use, avoiding local unevenness that affects the performance and appearance of the module. From the perspective of structural support, it bears the weight of the upper layers and possible external pressure, providing a solid physical support for the entire multi-layer structure, ensuring that the structure will not easily deform under different installation and use environments, thereby maintaining the relative position relationship between the components inside the module, which is conducive to the normal operation of the module.

[0085] Step 104, covering the backplane layer with the polymer film.

[0086] The polymer film is also a bonding material. When covered on the backplane layer, it can fit closely with the backplane layer, fill the tiny gaps that may exist on the surface of the backplane layer, and enhance the tightness of the connection between the backplane layer and the metal backplane below and the second photovoltaic film above. In the subsequent high-temperature and high-pressure pressing process, the polymer film will better exert its viscosity under the action of heat and pressure, so that the layers can be more firmly bonded, and the entire multi-layer structure will be further integrated into a whole, ensuring a relatively closed and stable environment inside the component, and protecting the performance of the component from interference from external factors.

[0087] Step 105 , placing the metal back plate at the bottom of the multi-layer structure as a bottom support.

[0088] In the metal backplane, the metal material itself has high strength and rigidity. Placing it at the bottom of the multi-layer structure can provide strong bottom support for the entire photovoltaic module. In actual installation and use scenarios, the module may be affected by various forces such as wind, its own gravity, and external forces during installation. With its good structural strength, the metal backplane can effectively resist these external forces, prevent the overall deformation and damage of the module, and ensure the long-term stability of the module, ensuring that the internal components, especially the photovoltaic cells, can continue to work normally in a relatively stable structural environment, thereby maintaining the power generation performance and service life of the entire photovoltaic module.

[0089] Step 106, subjecting the stacked multilayer structure to high temperature and high pressure pressing by rollers of a laminator, so that the first photovoltaic adhesive film, the second photovoltaic adhesive film and the polymer film are melted and solidified, and the photovoltaic module is obtained by encapsulation.

[0090] Under high-temperature conditions, the first photovoltaic film, the second photovoltaic film, and the polymer film will reach their melting points or softening points, thus changing from their original relatively solid state with limited viscosity to a state with good fluidity and stronger viscosity, enabling better filling of the tiny gaps between the layers of the structure and achieving more sufficient and tight contact and bonding between the components. At the same time, the application of high pressure enables the layers to be tightly pressed together under the action of the melted film and polymer film, eliminating gaps such as air between the layers and further enhancing the integrity of the structure. After such high-temperature and high-pressure treatment, as the temperature decreases, the film and polymer film will gradually solidify, firmly fixing the layers of the structure together, ultimately achieving the encapsulation of the entire photovoltaic module, forming a stable, sealed, and integrated whole where all components work together inside the module, ensuring that it can function properly in different external environments, such as performing photoelectric conversion.

[0091] Through this series of steps and corresponding principles, the manufacturing process of the photovoltaic module from component preparation to final encapsulation is completed in an orderly manner, manufacturing a photovoltaic module with a stable structure and reliable performance.

[0092] As an alternative embodiment, assuming that the metal backplane is a corrugated metal backplane, the photovoltaic module further includes high-temperature pads; based on this structure, after placing the metal backplane at the bottom of the multi-layer structure as the bottom support in 105, the arrangement positions of the high-temperature pads can also be determined according to the material properties, shape, and size of the corrugated metal backplane; the arrangement positions at least include: the spacing between the high-temperature pads and the placement depth of the high-temperature pads; based on the arrangement positions, the high-temperature pads are evenly filled into the gaps of the corrugated metal backplane to support the shape of the corrugated metal backplane during lamination, preventing the corrugated metal backplane from deforming due to excessive pressure during lamination.

[0093] During lamination, the corrugated metal backplane will bear a large amount of pressure. Due to its own corrugated shape structure, it is prone to deformation under the action of pressure, such as bending and collapse. By determining the arrangement positions of the high-temperature pads according to the material properties, shape, and size of the corrugated metal backplane and evenly filling the high-temperature pads into its gaps, effective internal support can be provided for the corrugated metal backplane during lamination, resisting the influence of pressure, ensuring that the corrugated metal backplane maintains its original designed shape, avoiding deformation caused by excessive pressure from damaging its structural integrity, and guaranteeing the normal functioning of the structural strength and function of the backplane itself.

[0094] The stable form of the corrugated metal backsheet is crucial for the quality of the entire photovoltaic module. If the backsheet deforms during the lamination process, it will disrupt the flatness and coordination of the multi-layer structure of the entire module, affecting the tightness of the fit and the relative position relationship between components. This may further cause key components such as photovoltaic cells to not be in the best working state, reducing the power generation efficiency and even shortening the service life of the module. The reasonable use of high-temperature pads can prevent this situation from occurring, enabling the module to maintain a good overall structure after manufacturing, and making the components work more smoothly together, thereby improving the overall quality and performance stability of the photovoltaic module.

[0095] This embodiment provides an effective safeguard measure for the lamination process of the photovoltaic module with a corrugated metal backsheet, providing a targeted solution to the possible backsheet deformation problem during the production process. It clarifies the method for determining the arrangement position of the high-temperature pads, making this operation more standardized and operable, helping production personnel to implement the process steps more accurately, reducing production accidents such as product unqualified caused by backsheet deformation, improving the reliability and stability of the entire photovoltaic module production process, ensuring the smooth progress of the production process and the yield rate of the products. In this way, the manufactured photovoltaic modules need to have good structural stability if they are to be applied to various different actual working conditions. Through the effective support of the high-temperature pads for the corrugated metal backsheet, the good structural state of the module is maintained, enabling the module to better cope with different installation angles, external forces such as wind and vibration, as well as environmental factors such as temperature changes during subsequent installation and use. This enhances the adaptability of the photovoltaic module under various different working conditions, extends its service life, and improves its application value.

[0096] Further optionally, in the above steps, determining the arrangement position of the high-temperature pads according to the material properties, shape, and size of the corrugated metal backsheet can be achieved as follows:

[0097] Based on the mechanical strength, yield strength, and elastic modulus information in the material properties, predict the first deformation behavior of the corrugated metal backsheet during the pressing process through a deformation prediction model; the deformation prediction model is trained based on the historical pressing data of multiple corrugated metal backsheets and the corresponding finite element analysis data; determine the initial arrangement position of the high-temperature pads according to the corrugation pitch and size in the shape of the corrugated metal backsheet; based on the configuration parameters during the pressing process, the initial arrangement position, and the mechanical strength, yield strength, and elastic modulus information in the material properties, re-predict the second deformation behavior of the corrugated metal backsheet during the pressing process through the deformation prediction model; based on the first deformation behavior and the second deformation behavior, optimize the initial arrangement position to obtain the target arrangement position.

[0098] In the embodiments of the present application, the deformation prediction model is trained based on the historical pressing data of various corrugated metal backplates and the corresponding finite element analysis data, which endows it with strong scientificity and reference. By inputting the material properties of the corrugated metal backplate to be pressed (such as key information like mechanical strength, yield strength, elastic modulus, etc.), it can relatively accurately predict the first deformation behavior during the pressing process, know in advance the possible deformation conditions of the backplate, provide an accurate basis for taking effective countermeasures subsequently, achieve a forward-looking control of the deformation problem, and help avoid the deformation problem of the backplate caused by blind operation.

[0099] After determining the initial arrangement position of the high-temperature pads, combined with relevant information such as the configuration parameters during the pressing process again, the model is used to re-predict the second deformation behavior of the corrugated metal backplate during the pressing process, and the initial arrangement position is optimized based on the two deformation behaviors before and after to obtain the target arrangement position. This process of multiple predictions and continuous optimization can make the arrangement position of the high-temperature pads more in line with the actual pressing situation requirements, maximize its supporting effect on the corrugated metal backplate, accurately prevent the deformation of the backplate during the pressing process, and ensure the stability of the backplate shape and the integrity of the entire photovoltaic module structure.

[0100] The entire process of determining the arrangement position of the high-temperature pads fully considers various characteristic factors of the corrugated metal backplate. Instead of relying on empirical rough judgments, it obtains the target arrangement position through scientific data and model analysis, making the placement position of the high-temperature pads in the corrugated metal backplate more accurate and reasonable, which helps to execute the process steps more standardly and accurately in actual production and avoid production problems caused by unreasonable arrangements.

[0101] The accurate arrangement position of the high-temperature pads helps to stabilize the production process, reduce adverse situations such as component rework and waste generation caused by the deformation of the corrugated metal backplate, improve the first-pass yield of the product, ensure that the entire photovoltaic module production process can proceed smoothly and stably, enhance the overall reliability and efficiency of the production link, and reduce production costs.

[0102] Since the arrangement position of the high-temperature pads is scientifically optimized, it can effectively prevent the deformation of the corrugated metal backplate during the pressing process, thereby ensuring the flatness and stability of the overall structure of the photovoltaic module. The stable structure helps key components such as photovoltaic cells to be in a good working environment, maintain the cooperative relationship between components, ensure that the module can perform photoelectric conversion work normally and efficiently, and enhance the power generation performance of the module. It avoids problems such as internal stress concentration, component wear, and connection loosening in the module that may be caused by the deformation of the corrugated metal backplate, reduces the potential for component failures during subsequent use, enables the photovoltaic module to maintain good performance during long-term use, extends its service life, and improves the cost performance and market competitiveness of the photovoltaic module.

[0103] In summary, this method for determining the arrangement position of the high-temperature spacer blocks has significant beneficial effects in ensuring the smooth progress of the production process, improving the performance of photovoltaic modules, and extending their service life.

[0104] Further optionally, in the above steps, the step of predicting the first deformation behavior or the second deformation behavior of the corrugated metal backplane during the pressing process by using the deformation prediction model can be implemented as follows:

[0105] Extract the configuration parameters of the pressing process, the initial arrangement position, and the mechanical strength, yield strength, and elastic modulus information in the material properties that are relevant to the pressing process for analysis; construct a corresponding candidate model based on the features to be analyzed; the candidate model includes: a virtual three-dimensional model used to represent different spatial position relationships between the corrugated metal backplane and the high-temperature spacer blocks; perform a pressure distribution analysis on the candidate model to obtain the predicted pressure distribution corresponding to the candidate model; the predicted pressure distribution includes: the pressure distribution conditions borne by the high-temperature spacer blocks under different spatial position relationships; generate the matching first deformation behavior or the second deformation behavior based on the predicted pressure distribution.

[0106] By extracting the configuration parameters of the pressing process, the initial arrangement position, and the features to be analyzed that are relevant to the pressing process in the material properties, the interference of irrelevant information is eliminated, and it is possible to accurately focus on the factors that have a key impact on the deformation behavior of the corrugated metal backplane. This makes the subsequent analysis more targeted, and the model constructed based on these core features can more accurately reflect the actual situation during the pressing process, laying a solid foundation for in-depth understanding of the backplane deformation behavior.

[0107] Constructing the features to be analyzed into a candidate model that includes a virtual three-dimensional model used to represent different spatial position relationships between the corrugated metal backplane and the high-temperature spacer blocks, this model construction method highly conforms to the actual production scenario. It can intuitively present the spatial layout of each component, visualize the abstract physical relationships, and facilitate subsequent detailed analysis of the pressure distribution and other situations from a spatial perspective, which helps to more comprehensively and accurately grasp the complex mechanical relationships during the entire pressing process.

[0108] Performing a pressure distribution analysis on the candidate model can obtain in detail the pressure distribution conditions borne by the high-temperature spacer blocks under different spatial position relationships. This means that it is possible to clearly know how the pressure is transmitted and distributed between the corrugated metal backplane and the high-temperature spacer blocks in various possible layouts, so as to accurately master the pressure conditions faced by each position, providing a key quantitative basis for predicting the deformation behavior of the backplane and avoiding the possible deviations that may occur when relying solely on experience to judge the pressure distribution in the past.

[0109] Generate a matching first deformation behavior or second deformation behavior based on the precise predicted pressure distribution, so that the prediction of the deformation of the corrugated metal backplane is no longer vague and general, but has a solid pressure analysis basis, and can accurately present the deformation trend, degree, etc. of each part of the backplane under specific pressure. This precise prediction helps to take targeted measures in advance to optimize the arrangement of high-temperature pads, etc., and effectively prevent and control the bad deformation of the backplane.

[0110] With the help of the above accurate prediction of the deformation behavior, production personnel can reasonably adjust and optimize the configuration parameters of the pressing process, the initial arrangement position of the high-temperature pads, etc. according to the actual situation, making the production process more scientific and precise, ensuring that the deformation problem of the corrugated metal backplane can be minimized to the greatest extent in actual production, improving the consistency and qualification rate of products, and enhancing the level of the entire photovoltaic module production process.

[0111] Since it can accurately predict and prevent and control the deformation of the corrugated metal backplane, the photovoltaic module can maintain good structural integrity during the manufacturing process. The stable backplane structure helps to maintain the flatness of the entire module, ensure the tight and reasonable cooperation between components, thereby enhancing the power generation performance of the photovoltaic module, reducing the potential failure risk caused by structural deformation at the same time, extending the service life of the module, and enhancing the competitiveness of the photovoltaic module in the market.

[0112] In summary, the implementation steps have significant beneficial effects in improving the accuracy of analysis, grasping the deformation trend, optimizing the production process, and improving the quality of components, providing a strong guarantee for the high-quality production of photovoltaic modules.

[0113] Further optionally, before determining the arrangement position of the high-temperature pads according to the material properties, shape, and size of the corrugated metal backplane in the above steps, the high-temperature resistance performance value and stiffness matching the high-temperature pads can also be determined based on the corrugated material characteristics and high-temperature performance in the material properties; based on the high-temperature resistance performance value and stiffness, select high-temperature pads with a matching material type.

[0114] Specifically, by determining the high-temperature resistance performance value and stiffness matching the high-temperature pads according to the corrugated material characteristics and high-temperature performance in the material properties of the corrugated metal backplane, it can ensure that the performance of the high-temperature pads is adapted to the corrugated metal backplane in the specific environment of high-temperature lamination. Because the lamination process is often accompanied by high temperature and large pressure, only high-temperature pads with high-temperature resistance performance and stiffness meeting the requirements can stably play a role under such harsh conditions, provide reliable support for the corrugated metal backplane, and avoid problems such as melting and deformation due to insufficient performance of the pads themselves, thereby effectively ensuring the morphological stability of the corrugated metal backplane during the lamination process and enhancing the overall support effect.

[0115] Due to factors such as their own materials and design purposes, different corrugated metal backsheets may have different corrugated material characteristics and high-temperature performance requirements. This method of determining the performance parameters of high-temperature pads based on the specific characteristics of the backsheet can achieve personalized customization and matching of high-temperature pads. This enables the high-temperature pads and the corresponding corrugated metal backsheets in each photovoltaic module to achieve the best performance synergy, better meet the production requirements under different working conditions, and improve the adaptability and stability of the entire module in the manufacturing process.

[0116] High-temperature pads with appropriate high-temperature resistance performance values and stiffness can accurately support the corrugated metal backsheet during the lamination process, preventing the backsheet from deforming due to high temperature and high pressure, thereby maintaining the flatness and stability of the overall structure of the photovoltaic module. A stable structure is crucial for the coordinated cooperation among the components inside the photovoltaic module, ensuring that key components such as photovoltaic cells are in a good working environment, helping to improve the power generation performance of the module, and ensuring that the product quality reaches a high level.

[0117] If the high-temperature resistance performance and stiffness of the high-temperature pad do not match, it may not be able to effectively support the backsheet during the lamination process, resulting in backsheet deformation. This will not only affect the immediate production quality of the module but may also cause a series of potential failures during subsequent use, such as loose connections between components and stress concentration damage to components. By accurately selecting a matching high-temperature pad, these potential failure hazards can be reduced at the source, extending the service life of the photovoltaic module, reducing the maintenance cost during use, and improving the reliability and cost-effectiveness of the module.

[0118] Determining and selecting a matching high-temperature pad in advance can avoid the mismatch with the corrugated metal backsheet due to the non-compliance of the high-temperature pad performance requirements during the production process, reducing problems such as product non-conformity and the need for rework caused by this mismatch, making the production process smoother, reducing unnecessary production pauses and resource waste, thereby effectively improving production efficiency and ensuring that the production tasks can be completed on time and with high quality.

[0119] This step provides a clear and scientific basis for the selection of high-temperature pads, helping to standardize the material selection criteria during the production process, enabling production personnel to have rules to follow when selecting high-temperature pads, and selecting appropriate material types according to the established high-temperature resistance performance values and stiffness requirements, improving the accuracy and efficiency of material selection, and further optimizing the entire production process chain of the photovoltaic module.

[0120] In summary, this step has shown significant beneficial effects in multiple aspects such as improving product quality and optimizing the production process by ensuring the performance adaptation between the high-temperature pad and the corrugated metal backsheet, and is of great significance for the efficient and high-quality production of photovoltaic modules.

[0121] The calculation method of the material characteristic parameters of the corrugated metal backplane can refer to the following methods, so that the laminated photovoltaic module can bear wind load, gravity load and seismic action:

[0122] Method 1: Assume that the metal corrugation is calculated according to a profiled steel sheet with a wave crest. In the calculation of a profiled steel sheet with a wave crest (single-span), in the calculation assumption, the vertical frame is designed as a simply supported beam with a single span, which means that the vertical frame is regarded as a beam model with hinged supports at both ends, which can rotate but cannot move horizontally and vertically, to analyze its stress and deformation conditions, and it has to bear wind load, gravity load and seismic action. Wind load is the pressure or suction generated by the external air flow on the structure, gravity load is the force generated by the weight of the vertical frame itself and the supported components, and seismic action is the inertial force transmitted to the structure by the ground motion during an earthquake.

[0123] In terms of calculation parameters, the span Ls of the vertical frame is 1150 mm, which refers to the horizontal distance between the two support points of the vertical frame and affects the calculation of its internal force and deformation; the grid width B1 is 320 mm, which is used to describe the grid size of the structure and has a reference effect on load distribution, etc.; the glass thickness t1 is 7 mm, which is related to the self-weight, strength and stress and deformation characteristics of the glass, etc.; the steel plate thickness t2 is 1.5 mm, which determines the mechanical properties of the steel plate and its cooperation with other components; the specific weight γg1 of the glass is 25600 N / m³, which is the weight of the glass per unit volume and is used to calculate the glass gravity load; the material of the vertical column Q235B hot-rolled indicates the material type and processing technology of the vertical frame, and this material has specific mechanical property indexes for judging the structural safety; in the section characteristics of the vertical frame, the elastic modulus E is 206 GPa, which measures the ability of the material to resist elastic deformation and is used to calculate the deformation of the vertical frame. The cross-sectional area Acs1 is equal to 393.7 mm², which is related to the self-weight of the vertical frame and the calculation of the axial stress intensity. The moment of inertia Ix1 about the x-axis is 11.08 cm 4 and Iy1 about the y-axis is 68.6817 cm 4 , corresponding to different coordinate axis directions respectively, are used to analyze the bending resistance performance of the vertical frame and calculate bending stress, deformation, etc. The section modulus Wx1 about the x-axis is 7.47 cm³ and Wy1 about the y-axis is 22.8939 cm³, which are used to judge whether the bending strength of the vertical frame can meet the design requirements. These parameters describe the key information such as the relevant characteristics, geometric features, material conditions and the types of loads borne by the vertical frame in the corrugated metal structure from different angles, and are the basic basis for structural mechanics analysis and judging the structural safety and rationality.

[0124] Method 2: From the perspective of the reaction force calculation content of the above calculation assumption data, first in the calculation of the weight standard value, in the formula where represents the weight standard value, and its unit is , and It should be the relevant parameters of the standard self-weight values of different parts (such as different components, etc.). is the grid width mentioned above. Here, the weight standard value is comprehensively calculated by multiplying the respective self-weight standard value by the grid width and then multiplying by the coefficient 1.2. The calculated is 0.114029× ; Then, for the calculation of the weight design value, in the formula , is the weight design value, is the partial coefficient related to the gravity load. By multiplying this coefficient by the weight standard value calculated previously , we get which is 0.191568× . For the calculation of the wind line load standard value, in the formula , represents the wind line load standard value, is the parameter related to the wind load standard value. Multiply it by the grid width and then add the weight standard value calculated previously . The calculated is 2.994029× ; In the calculation of the wind + self-weight line load design value, in the formula , is the wind + self-weight line load design value, is the partial coefficient of the wind load. Multiply this coefficient by the wind line load standard value previously and then add the weight design value , we get which is 4.683× ; Finally, in the calculation of the maximum support reaction of the vertical frame under the combined load, in the formulas and , , respectively represent the reactions at different supports. is the span of the vertical frame. Calculate the support reaction by multiplying the wind + self-weight line load design value by half of the span of the vertical frame. The calculated and are both 2.693×kN, and the reaction of the embedded part at the fulcrum is equal to , also 2.693×kN. The calculation of these reactions is based on the given parameters and the corresponding load calculation principles above, comprehensively considering different load conditions such as dead load and wind load, and gradually derived to analyze the stress conditions at the supports and embedded parts of the vertical frame under the corresponding load combinations.

[0125] Method 3: In the calculation of component stiffness, first, the load combination is specified as 1.0 * wind load, which means that the wind load is the main factor considered in this calculation of component stiffness. The deflection control coefficient is set to a250, which is used to control the subsequent calculation of allowable deflection. The specific value of the rigid deflection control is determined by conditional judgment, that is, when the mullion span is less than or equal to 4.5m, it takes 20mm. Since here is 1150mm (less than 4.5m), the value taken is 20mm. This is a given reference value for deflection control. The formula for allowable deflection is , that is, take the smaller value of and , and then take 0.85 times of it to get the specific allowable deflection value of 3.91mm. This value is used to measure the allowable deflection range of the component under force to judge whether the component stiffness meets the requirements. The deflection formula for the steel plate is , where is the standard value of the wind line load, is the mullion span, is the elastic modulus in the mullion section properties, is the moment of inertia of the mullion section. The deflection of the steel plate is calculated to be 2.9873mm. Finally, compare with to obtain as the result, so as to judge whether the deflection of the steel plate is within the allowable range and further evaluate whether the stiffness of the component meets the corresponding requirements. Overall, these parameters and calculations are all centered around judging the stiffness performance of the component under wind load.

[0126] Method 4: In the calculation of component strength, first, the load combination is determined as 1.3 dead load + 1.5 wind load + 1.3×0.5 seismic action. This indicates that when calculating the component strength, the dead load, wind load, and seismic action need to be comprehensively considered, and these loads are combined according to the corresponding coefficients to simulate the actual stress situation. In the maximum stress calculation formula of the tension-bending member, represents the maximum stress of the tension-bending member, is the axial tension, is the cross-sectional area of the component, represents the bending moment borne by the component, is the cross-sectional plastic development coefficient, is the section modulus. Through this formula, the maximum stress generated by the tension-bending member under force is comprehensively calculated. Among them, the axial tension takes the value of 0, and the maximum bending moment Calculated by the formula where is the design value of the wind + self-weight line load, is the vertical frame span. This formula is based on the calculation principle of the bending moment of a simply supported beam under uniformly distributed load in structural mechanics, and the maximum bending moment value is . Then calculate the maximum stress of the steel plate. According to the previous stress calculation formula, substitute the corresponding parameters, that is 、 (the cross-sectional area in the cross-sectional properties of the vertical frame), and Wx1 (the section modulus in the cross-sectional properties of the vertical frame) to calculate, and the maximum stress is obtained as 98.692 Mpa. Finally, compare it with the strength design value f of the material (here, for example, f is 215 Mpa). Since the maximum stress is less than f, it is judged that the component is safe, that is, it shows that under the given load combination, the strength of the component meets the requirements and can normally bear the corresponding acting forces without damage.

[0127] In the embodiment of the present application, the front photovoltaic glass layer can protect the photovoltaic cells and the internal structure. The backplane layer can ensure the flatness of the photovoltaic module and provide support for the multi-layer structure. The metal backplane, as the bottom support, can enhance the overall structural strength of the photovoltaic module. Each structure collaborates to ensure the structural stability of the photovoltaic module and proper protection of the internal components. The expansion coefficients of the front photovoltaic glass layer and the metal backplane are determined by the collaborative deformation ability of each component in the photovoltaic module, which helps the photovoltaic module better adapt to changes in factors such as temperature under different environmental conditions, reduces structural problems caused by differences in expansion coefficients, and improves the overall stability. By directly stacking the polymer film and the metal backplane under the back surface of the photovoltaic module, the metal backplane and the photovoltaic module are integrally laminated, which changes the original production method, simplifies the process steps, reduces the operation links, and thus effectively improves the production efficiency of the module. The process optimization of the integral lamination reduces the complexity of manual participation and the amount of manual operation in the production process, and further helps to make the production efficiency of the photovoltaic module higher in the manufacturing process. Generally speaking, it is beneficial to improve the structural performance of the photovoltaic module itself and also achieve efficiency improvement in the production link.

[0128] Based on the same implementation principle, the embodiment of the present application also provides an electronic device, Figure 5 which is the structural block diagram of the electronic device 300, as shown in Figure 5As shown, the electronic device 300 includes: a processor 301, a memory 302, a communication interface 303, a communication bus 304, and a controller 305; among them, the processor 301, the memory 302, and the communication interface 303 complete communication with each other through the communication bus 304; the memory 302 is used to store computer programs; the processor 301 is used to execute the programs stored in the memory 302 to implement corresponding processing functions; the communication bus 304 is used for communication between the electronic device 300 and other devices; the controller 305 is used to implement the manufacturing method of the photovoltaic module described in the above method embodiments.

[0129] In the embodiment of the present application, the communication bus 304 may be a Peripheral Component Interconnect (PCI) bus or an Extended Industry Standard Architecture (EISA) bus, etc. The communication bus 304 may be divided into an address bus, a data bus, a control bus, etc., and the specific form is not limited. For the convenience of representation, Figure 5 only a thick line is used to represent it in the figure, but it does not mean that there is only one bus or one type of bus.

[0130] The memory 302 may include a Random Access Memory (RAM), or may also include a non-volatile memory, such as at least one disk memory. Optionally, the memory may also be at least one storage device located far from the aforementioned processor 301.

[0131] The processor 301 may be a general-purpose processor, including a Central Processing Unit (CPU), a Network Processor (NP), etc.; it may also be a Digital Signal Processor (DSP), an Application Specific Integrated Circuit (ASIC), a Field-Programmable Gate Array (FPGA), or other programmable logic devices, discrete gate or transistor logic devices, discrete hardware components, and the specific form may be determined according to actual requirements.

[0132] Accordingly, an embodiment of the present application further provides a computer-readable storage medium storing a computer program, and when the computer program is executed, it can implement the steps executable by the electronic device in the above method embodiment. Finally, it should be noted that: the above embodiments are only used to illustrate the technical solutions of the present application, and are not intended to limit them; although the present application has been described in detail with reference to the foregoing embodiments, those of ordinary skill in the art should understand that: they can still modify the technical solutions described in the foregoing embodiments, or perform equivalent replacements for some of the technical features; and these modifications or replacements do not cause the essence of the corresponding technical solutions to deviate from the spirit and scope of the technical solutions of the embodiments of the present application.

Claims

1. A photovoltaic module, characterized in that, In the photovoltaic module, the multi-layer structure is stacked from top to bottom in sequence with: a front photovoltaic glass layer, a first photovoltaic film, photovoltaic cells, a second photovoltaic film, a backplane layer, a polymer film, and a metal backplane; The front photovoltaic glass layer is a light-transmitting material, and the front photovoltaic glass layer is used to protect the photovoltaic cells and internal structures in the photovoltaic module; the first photovoltaic film and the second photovoltaic film are used to bond adjacent component structures; the photovoltaic cells are used to convert light energy into electrical energy; the backplane layer is used to ensure the flatness of the photovoltaic module and provide support for the multi-layer structure; the polymer film is used to bond adjacent component structures; the metal backplane serves as a bottom support and is used to enhance the overall structural strength of the photovoltaic module; The multi-layer structure in the photovoltaic module is obtained by stacking, laminating, and then curing and encapsulating. The lamination time of the multi-layer structure is determined according to the thicknesses of the first photovoltaic film, the second photovoltaic film, and the polymer film; The expansion coefficients of the front photovoltaic glass layer and the metal backplane are determined by the co-deformation ability of each component in the photovoltaic module; The metal backplane is a corrugated metal backplane, and the corrugated metal backplane is used to bear the pressure generated by wind loads, gravity loads, and / or seismic actions; The photovoltaic module further includes high-temperature pads, and the high-temperature pads are evenly filled in the voids of the corrugated metal backplane; the high-temperature pads are used to support the shape of the corrugated metal backplane during the lamination process and prevent the corrugated metal backplane from deforming due to excessive pressure during the lamination process.

2. The photovoltaic module according to claim 1, characterized in that, The metal backplane uses a metal material with a linear thermal expansion coefficient in the range of 9×10 -6 / K to 18×10 -6 / K.

3. The photovoltaic module according to claim 1, characterized in that, If the thickness of the first photovoltaic film and / or the second photovoltaic film is 1.14 mm and the thickness of the polymer film is 0.3 mm, then the lamination time range of the multi-layer structure is 10 minutes to 15 minutes.

4. The photovoltaic module according to claim 1, characterized in that The lamination temperature range of the multi-layer structure is 150°C to 180°C.

5. A manufacturing method of a photovoltaic module, characterized in that, The photovoltaic module is the photovoltaic module according to any one of claims 1 to 4. In the photovoltaic module, the multi-layer structure is stacked from top to bottom in sequence with: a front photovoltaic glass layer, a first photovoltaic film, photovoltaic cells, a second photovoltaic film, a backplane layer, a polymer film, and a metal backplane; The method includes: Place the front photovoltaic glass layer and the first photovoltaic film on the laminator in a preset order; the front photovoltaic glass layer is a light-transmitting material, and the front photovoltaic glass layer is used to protect the photovoltaic cells and internal structures in the photovoltaic module; the first photovoltaic film and the second photovoltaic film are used to bond adjacent component structures; Place the photovoltaic cells between the first photovoltaic film and the second photovoltaic film in a preset order; the photovoltaic cells are used to convert light energy into electrical energy; Place the backplane layer under the second photovoltaic film in a preset order; the backplane layer is used to ensure the flatness of the photovoltaic module and provide support for the multi-layer structure; Cover the backplane layer with the polymer film; the polymer film is used to bond adjacent component structures; Place the metal backplane at the bottom of the multi-layer structure as a bottom support; the metal backplane is used to enhance the overall structural strength of the photovoltaic module; The stacked multilayer structure is subjected to high temperature and high pressure pressing by rollers of a laminator, so that the first photovoltaic adhesive film, the second photovoltaic adhesive film and the polymer film are melted and solidified, and the photovoltaic module is obtained by encapsulation; The lamination time of the multilayer structure is determined by the thickness of the first photovoltaic adhesive film, the second photovoltaic adhesive film and the polymer film; the expansion coefficient of the photovoltaic front plate glass layer and the metal back plate is determined by the cooperative deformation ability of each component in the photovoltaic module; Wherein, the metal back plate is a corrugated metal back plate, and the photovoltaic module further includes a high temperature pad; After placing the metal back plate at the bottom of the multi-layer structure as a bottom support, the method further includes: Determine the arrangement position of the high temperature pads according to the material properties, shape and size of the corrugated metal back plate; the arrangement position at least includes: the spacing between the high temperature pads and the placement depth of the high temperature pads; The high temperature pads are uniformly filled into the gaps of the corrugated metal backing plate based on the arrangement positions, so as to support the shape of the corrugated metal backing plate during the lamination process by the high temperature pads, thereby preventing the corrugated metal backing plate from being deformed due to excessive pressure during the lamination process; Wherein, determining the arrangement position of the high temperature pads according to the material properties, shape and size of the corrugated metal back plate includes: According to the mechanical strength, yield strength and elastic mold information in the material properties, the first deformation behavior of the corrugated metal backboard during the pressing process is predicted by a deformation prediction model; the deformation prediction model is trained based on historical pressing data of various corrugated metal backboards and corresponding finite element analysis data; Determining the initial arrangement position of the high temperature pads according to the corrugation spacing and size of the corrugated metal back plate; Based on the pressing process configuration parameters, the initial arrangement position, and the mechanical strength, yield strength, and elastic mold information in the material properties, re-predicting the second deformation behavior of the corrugated metal backboard during the pressing process through the deformation prediction model; Based on the first deformation behavior and the second deformation behavior, the initial arrangement position is optimized to obtain a target arrangement position.

6. The method according to claim 5, wherein Predicting the first deformation behavior of the corrugated metal backboard during the pressing process by a deformation prediction model includes: Extracting the features to be analyzed related to the pressing process from the mechanical strength, yield strength, and elastic mold information in the material properties; Constructing a corresponding candidate model for the feature to be analyzed; the candidate model includes: a virtual three-dimensional model for representing different spatial position relationships between the corrugated metal back plate and the high-temperature pad; Performing pressure distribution analysis on the candidate model to obtain a predicted pressure distribution corresponding to the candidate model; the predicted pressure distribution includes: pressure distribution of the high temperature pad under different spatial position relationships; The matched first deformation behavior is generated based on the predicted pressure distribution.

7. The method according to claim 5, wherein Before determining the arrangement position of the high temperature pads according to the material properties, shape and size of the corrugated metal back plate, the method further includes: Based on the corrugated material characteristics and high-temperature performance among the material properties, determine the high-temperature resistance performance value and stiffness that match the high-temperature spacer block. Based on the high-temperature resistance performance value and stiffness, select a high-temperature spacer block with a matching material type.

8. A laminated solar cell module, characterized in that, The laminated solar cell module includes at least the photovoltaic module according to any one of claims 1 to 4, and the laminated solar cell module is manufactured by using the manufacturing method of the photovoltaic module according to any one of claims 5 to 7.

9. A non-transitory computer-readable storage medium, characterized in that, The storage medium stores a computer software program, and when the computer software program is executed by a processor, it implements the manufacturing method of the photovoltaic module according to any one of claims 5 to 7.

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