A method for manufacturing a photovoltaic module

Abstract

The present application relates to the field of photovoltaic technology, and discloses a photovoltaic module, which comprises a waterproof sealing ring and a front glass, a front adhesive film, a cell layer, a back adhesive film and a back glass which are sequentially stacked from bottom to top and have their centers located on the same straight line and their side edges parallel to each other, and the area of the front glass is large, so that the uncovered part of the back of the front glass forms a ring-shaped part capable of bearing the waterproof sealing ring, the front surface of the waterproof sealing ring is bonded to the back surface of the front glass, and the inner side surface of the waterproof sealing ring is bonded to the outer side surfaces of the front adhesive film, the cell layer, the back adhesive film and the back glass, the waterproof sealing ring is used for preventing the entry of water vapor and preventing the water vapor from entering the adhesive film through the gap, so that the photovoltaic module can be better protected. Furthermore, the present application also provides a manufacturing method of the photovoltaic module, wherein an isolation gasket is laid on the front glass before the front adhesive film, the cell layer, the back adhesive film and the back glass are laid, so that the adhesive film cannot be bonded due to overflow, and the cutting and cleaning of the adhesive film crosslinking product are facilitated.

Description

TECHNICAL FIELD

[0001] The present application relates to the field of photovoltaic technology, in particular to a photovoltaic module manufacturing method. BACKGROUND

[0002] The photovoltaic module is the core part of the solar power generation system and the most important part of the solar power generation system. The photovoltaic module mainly includes nine core components, i.e. photovoltaic cell panel, interconnecting strip, busbar, glass, EVA, backsheet, aluminum alloy, silicone and junction box. For the photovoltaic module with a half-piece component structure, the photovoltaic cell panel is cut in half to reduce the cell working current by half, thereby significantly reducing the electrical loss on the welding strip.

[0003] The existing N-type encapsulation of the photovoltaic module mainly uses front POE (polyolefin elastomer) film + back EVA (ethylene-vinyl acetate copolymer) film for single-glass modules, and front EPE (EVA+POE+EVA three-layer co-extrusion) film + back EPE film or front EPE film + back EVA film for double-glass modules. The main reason is to prevent water vapor from entering to cause EVA hydrolysis and the occurrence of the electrical degradation effect (PID). The cost of POE and EPE is much higher than that of EVA, and the lamination temperature is high (145℃) during production, which is not conducive to energy saving and consumption reduction.

[0004] The prior art discloses a photovoltaic module and a manufacturing method thereof. The manufacturing method comprises the following steps: performing a tempering treatment on a pre-prepared glass; forming a reflective film on the surface of the tempered glass by using a hot transfer printing process or a thermal spraying process to obtain a back glass substrate; obtaining a front glass substrate; sequentially stacking a first adhesive film layer, a cell piece layer, a second adhesive film layer and the back glass substrate on the surface of the front glass substrate to obtain the photovoltaic module, wherein the reflective film faces the second adhesive film layer, and the cell piece layer includes a plurality of double-sided cell pieces. The first adhesive film layer of the patent is an EVA adhesive film layer or a POE adhesive film layer, and the second adhesive film layer is an EVA adhesive film layer or a POE adhesive film layer. The EVA adhesive film is prone to hydrolysis, has a high water vapor transmission rate, and is prone to PID failure problems. SUMMARY

[0005] The present application relates to the field of photovoltaic technology, in particular to a photovoltaic module manufacturing method.

[0006] In order to achieve the above object, the present application provides a photovoltaic module, comprising a waterproof sealing ring and, from bottom to top, a front glass, a front adhesive film, a cell layer, a back adhesive film and a back glass, wherein the front adhesive film, the cell layer, the back adhesive film and the back glass are of the same area and shape, the front glass is of the same shape as the back glass, the area of the front glass is larger than that of the back glass, the centers of the front adhesive film, the cell layer, the back adhesive film and the back glass are located on the same line, and the side edges of the front adhesive film, the cell layer, the back adhesive film and the back glass are parallel to the side edges of the front glass, the waterproof sealing ring is located on the front glass, the waterproof sealing ring is sleeved outside the front adhesive film, the cell layer, the back adhesive film and the back glass, the inner side surfaces of the waterproof sealing ring are bonded to the outer side surfaces of the front adhesive film, the cell layer, the back adhesive film and the back glass, and the front surface of the waterproof sealing ring is bonded to the back surface of the front glass.

[0007] As a preferred solution, the waterproof sealing ring is a high-water-resistance silica gel or a butyl rubber ring.

[0008] As a preferred solution, the front adhesive film and the back adhesive film are both EVA films.

[0009] As a preferred solution, the distance between the edge of the back glass and the edge of the front glass is 1-2 mm, and the thickness of the waterproof sealing ring is equal to the distance between the edge of the back glass and the edge of the front glass.

[0010] As a preferred solution, the front glass, the front adhesive film, the cell layer, the back adhesive film and the back glass are all rectangular.

[0011] The present application also provides a manufacturing method of a photovoltaic module, comprising the following steps:

[0012] S1, manufacturing a front glass, a cell layer and a back glass of the same shape, wherein the area of the cell layer and the back glass is equal, and the area of the front glass is larger than that of the back glass;

[0013] S2, sequentially laying the front glass, a front adhesive film, the cell layer, a back adhesive film and the back glass from bottom to top, so that the centers of the front glass, the cell layer and the back glass are located on the same line, and the side edges of the front glass, the cell layer and the back glass are parallel;

[0014] S3, performing EL detection, and laminating the products without hidden cracks;

[0015] S4, cutting and removing the residual adhesive film crosslinking product along the edge of the back glass;

[0016] S5, cleaning the back surface of the front glass and the side surface of the front adhesive film, the cell sheet layer, the back adhesive film and the back glass;

[0017] S6, coating a waterproof sealing glue along the edge of the back glass to form a waterproof sealing ring which is bonded to the side surface of the front adhesive film, the cell sheet layer, the back adhesive film and the back glass and the back surface of the front glass;

[0018] S7, assembling the components obtained in step S6 with a frame, installing a junction box, then curing, cleaning, power testing, insulation voltage testing, EL testing and finally packaging for storage.

[0019] As a preferred solution, in step S2, before laying the front adhesive film, an isolation gasket is laid on the front glass, the inner circle of the isolation gasket has the same shape and size as the back glass, and the isolation gasket is used to prevent the front adhesive film and the back adhesive film from overflowing to the part where the projection of the front glass and the back glass does not coincide.

[0020] As a preferred solution, the isolation gasket is a high-temperature cloth or a sheet of frame-shaped tooling made of a material that does not bond with the adhesive film.

[0021] As a preferred solution, in step S6, the waterproof sealing glue is high-water-resistance silicone or butyl rubber.

[0022] As a preferred solution, in step S2, the front adhesive film and the back adhesive film are both EVA films.

[0023] Compared with the prior art, the present application has the following advantages:

[0024] The front glass, the front adhesive film, the cell sheet layer, the back adhesive film and the back glass have the same shape, but the area of the front glass is larger, and when laminating, the center of the front glass, the front adhesive film, the cell sheet layer, the back adhesive film and the back glass are located on the same straight line and the sides are parallel, the part of the back surface of the front glass that is not covered forms a ring-shaped waterproof sealing ring, the front surface of the waterproof sealing ring is bonded to the back surface of the front glass, and the inner side surface is bonded to the outer side surface of the front adhesive film, the cell sheet layer, the back adhesive film and the back glass, the waterproof sealing ring is used to prevent the entry of water vapor and prevent water vapor from entering the adhesive film through the gap, which can better protect the photovoltaic module. Moreover, in the manufacturing method of the present application, before laying the front adhesive film, the cell sheet layer, the back adhesive film and the back glass, an isolation gasket is laid on the front glass, which can prevent the adhesive film from bonding with the edge part of the front glass during laying or lamination, make the waterproof sealing ring bond more closely with the front glass, the front adhesive film, the cell sheet layer, the back adhesive film and the back glass, have better waterproof effect, and also facilitate the cutting of the adhesive film crosslinking material and the cleaning before laying the waterproof sealing ring. BRIEF DESCRIPTION OF DRAWINGS

[0025] Figure 1 is a structural schematic diagram of a photovoltaic module of an embodiment of the present application.

[0026] Figure 2 is a flow chart of a method for manufacturing a photovoltaic module of an embodiment of the present application.

[0027] Figure 3 is a flow chart of a production process of the prior art.

[0028] Figure 4 is a flow chart of a production process of a method for manufacturing a photovoltaic module of an embodiment of the present application.

[0029] Figure 5 is a schematic diagram of the layering of components of a method for manufacturing a photovoltaic module of an embodiment of the present application.

[0030] Figure 6 is a schematic diagram of the structure of a spacer ring of a method for manufacturing a photovoltaic module of an embodiment of the present application.

[0031] Figure 7 is a schematic diagram of a first perspective view after lamination of a method for manufacturing a photovoltaic module of an embodiment of the present application.

[0032] Figure 8 is a schematic diagram of a second perspective view after lamination of a method for manufacturing a photovoltaic module of an embodiment of the present application.

[0033] In the figure, 1 is front glass; 2 is front adhesive film; 3 is cell layer; 4 is back adhesive film; 5 is back glass; 6 is waterproof sealing ring; 7 is spacer ring; 8 is residual adhesive film cross-linking product; 9 is frame; 10 is frame adhesive layer. DETAILED DESCRIPTION

[0034] The specific embodiments of the present application will be further described in detail below with reference to the accompanying drawings and examples. The following examples are used to illustrate the present application, but are not used to limit the scope of the present application.

[0035] In the description of the present application, it should be noted that the terms "center", "longitudinal", "lateral", "upper", "lower", "front", "rear", "left", "right", "vertical", "horizontal", "top", "bottom", "inner", "outer", and the like indicate the orientation or positional relationship based on the orientation or positional relationship shown in the drawings, and are only for the convenience of describing the present application and simplifying the description, and therefore cannot be understood as indicating or implying that the devices or elements referred to must have a particular orientation, be constructed and operated in a particular orientation, and therefore cannot be understood as limiting the present application. In addition, the terms "first", "second", "third" are only for descriptive purposes and cannot be understood as indicating or implying relative importance.

[0036] In the description of the present application, it is necessary to point out that unless otherwise explicitly specified and limited, the terms "mounting", "connecting", "connection" should be understood in a broad sense, for example, it can be fixed connection, or detachable connection, or integrally connected; it can be mechanical connection, or electrical connection; it can be directly connected, or indirectly connected through intermediate medium, or the communication inside two elements. For those skilled in the art, the specific meaning of the above terms in the present application can be understood according to the specific circumstances.

[0037] In addition, in the description of the present application, the meaning of "a plurality of" is two or more, unless otherwise specified.

[0038] Embodiment one

[0039] As Figure 1 shown, a photovoltaic module of the preferred embodiment of the present application comprises a waterproof sealing ring 6 and a front glass 1, a front adhesive film 2, a cell piece layer 3, a back adhesive film 4 and a back glass 5 which are sequentially stacked from bottom to top, the area and shape of the front adhesive film 2, the cell piece layer 3, the back adhesive film 4 and the back glass 5 are the same, the shape of the front glass 1 and the back glass 5 are the same, the area of the front glass 1 is larger than that of the back glass 5, the centers of the front glass 1, the front adhesive film 2, the cell piece layer 3, the back adhesive film 4 and the back glass 5 are located on the same straight line, and the side edges of the front adhesive film 2, the cell piece layer 3, the back adhesive film 4 and the back glass 5 are parallel to the side edges of the front glass 1, the waterproof sealing ring 6 is located on the front glass 1, and the waterproof sealing ring 6 is sleeved outside the front adhesive film 2, the cell piece layer 3, the back adhesive film 4 and the back glass 5, the inner side of the waterproof sealing ring 6 is bonded to the outer side of the front adhesive film 2, the cell piece layer 3, the back adhesive film 4 and the back glass 5, and the front of the waterproof sealing ring 6 is bonded to the back of the front glass 1. In this embodiment, the front glass 1, the front adhesive film 2, the cell piece layer 3, the back adhesive film 4 and the back glass 5 have the same shape, but the area of the front glass 1 is large, and when stacking, the centers of the front glass 1, the front adhesive film 2, the cell piece layer 3, the back adhesive film 4 and the back glass 5 are located on the same straight line and the side edges are parallel, the uncovered part of the back of the front glass 1 forms a ring-shaped part which can bear the waterproof sealing ring 6, the front of the waterproof sealing ring 6 is bonded to the back of the front glass 1, and the inner side is bonded to the outer side of the front adhesive film 2, the cell piece layer 3, the back adhesive film 4 and the back glass 5, the waterproof sealing ring 6 is used to prevent the entry of water vapor, so that the water vapor cannot enter the adhesive film through the gap, and the photovoltaic module can be better protected.

[0040] Optionally, the waterproof sealing ring 6 is a high water resistance silicone or butyl rubber ring. In the embodiment, when the front glass 1, the front adhesive film 2, the cell layer 3, the back adhesive film 4 and the back glass 5 are stacked from bottom to top in turn, and the front glass 1 and the cell layer 3 are bonded by the front adhesive film 2, the cell layer 3 and the back glass 5 are bonded by the back adhesive film 4, and the front glass 1, the front adhesive film 2, the cell layer 3, the back adhesive film 4 and the back glass 5 are centrally aligned, the front adhesive film 2, the cell layer 3, the back adhesive film 4 and the back glass 5 form a layer platform, and a waterproof sealing glue layer is coated on the outer periphery of the layer platform to form the waterproof sealing ring 6.

[0041] In addition, the front adhesive film 2 and the back adhesive film 4 of the embodiment are both EVA films. The encapsulation adhesive film adopts EPE or POE, which has high cost, and the lamination temperature of the POE adhesive film is high and the energy consumption is large. Therefore, the embodiment adopts double EVA film encapsulation, which has low cost, the lamination temperature can be reduced from 145℃ to 140℃, and the energy consumption of the laminator is reduced. However, the double EVA adhesive film encapsulation will bring high water vapor transmission rate, and the N-type battery is sensitive to acid. The decomposition of EVA caused by water vapor will produce acetic acid to corrode the grid lines of the battery, resulting in failure of the battery piece. Therefore, the waterproof sealing ring 6 of the embodiment can well solve the above problems. The layer platform structure and sealing mechanism designed in the embodiment can better protect the photovoltaic module and prevent water vapor from entering the EVA layer through the gap. Therefore, the layer platform structure and sealing mechanism designed in the embodiment have good waterproof effect, so that the photovoltaic module can adopt double EVA film, which not only has good waterproof effect, but also reduces cost.

[0042] In the embodiment, the distance between the edge of the back glass 5 and the edge of the front glass 1 is 1-2mm, and the thickness of the waterproof sealing ring 6 is equal to the distance between the edge of the back glass 5 and the edge of the front glass 1.

[0043] Specifically, the front glass 1, the front adhesive film 2, the cell layer 3, the back adhesive film 4 and the back glass 5 are all rectangular. Therefore, the length of the front glass 1 is 1-2mm longer than the length of the front adhesive film 2, the cell layer 3, the back adhesive film 4 and the back glass 5, and the width of the front glass 1 is 1-2mm wider than the width of the front adhesive film 2, the cell layer 3, the back adhesive film 4 and the back glass 5.

[0044] In the embodiment, the photovoltaic module further comprises a frame 9. After the front glass 1, the front adhesive film 2, the cell layer 3, the back adhesive film 4, the back glass 5 and the waterproof sealing ring 6 are bonded, they are inserted into the frame 9, and the side surface of the front glass 1, the waterproof sealing ring 6, the back surface of the waterproof sealing ring 6 and the back glass 5 are bonded to the frame 9 by the frame bonding glue layer 10.

[0045] Embodiment two

[0046] As Figures 2 to 8As shown, the embodiment of the present application preferably a method for manufacturing a photovoltaic module, comprising the following steps:

[0047] S1, manufacturing a front glass 1, a cell layer 3 and a back glass 5 with the same shape, wherein the area of the cell layer 3 and the back glass 5 is equal, and the area of the front glass 1 is larger than that of the back glass 5;

[0048] S2, sequentially laying the front glass 1, a front adhesive film 2, the cell layer 3, a back adhesive film 4 and the back glass 5 from bottom to top, so that the centers of the front glass 1, the cell layer 3 and the back glass 5 are located on the same straight line, and the side edges of the front glass 1, the cell layer 3 and the back glass 5 are parallel;

[0049] S3, performing EL detection, and laminating the product without hidden cracks;

[0050] S4, cutting and removing the residual adhesive film cross-linking material 8 along the edge of the back glass 5;

[0051] S5, cleaning the back of the front glass 1 and the side of the front adhesive film 2, the cell layer 3, the back adhesive film 4 and the back glass 5;

[0052] S6, coating a layer of waterproof sealing glue along the edge of the back glass 5 to form a waterproof sealing ring 6 which is bonded to the side of the front adhesive film 2, the cell layer 3, the back adhesive film 4 and the back glass 5, and the back of the front glass 1;

[0053] S7, assembling the frame 9 and the junction box to the components obtained in step S6, and then performing solidification cleaning, power testing, insulation voltage testing, EL testing, and finally packaging and warehousing.

[0054] Through the above method, the front adhesive film 2, the cell layer 3, the back adhesive film 4 and the back glass 5 of the embodiment form a layer table structure in the center of the front glass 1, and then a circle of waterproof sealing glue is coated around the layer table and on the back of the front glass 1 to form a waterproof sealing ring 6, which can play a waterproof role, so that water vapor cannot contact with EVA, and the purpose of protecting the module is achieved.

[0055] Optionally, in step S6, the waterproof sealing glue is high-water-resistance silicone or butyl glue. In step S2, the front adhesive film 2 and the back adhesive film 4 are both EVA films. The layer table structure is designed, and sealing glue is coated thereon to isolate the adhesive film from air contact, so that water vapor cannot contact and react with the adhesive film, the reliability of the module is improved, and the occurrence of PID effect is weakened. Moreover, the encapsulation adopts double-layer EVA adhesive film encapsulation plus sealing agent edge sealing, which can reduce the cost of adhesive film and reduce the lamination temperature by 3-5℃.

[0056] Embodiment three

[0057] The difference between this embodiment and embodiment two is that, on the basis of embodiment two, the manufacturing method is further described in this embodiment.

[0058] In step S2, before laying the front adhesive film 2, the isolation gasket 7 is laid on the front glass 1. The inner circle shape and size of the isolation gasket 7 are the same as the back glass 5. The isolation gasket 7 is used to prevent the front adhesive film 2 and the back adhesive film 4 from overflowing to the part where the front glass 1 and the back glass 5 do not overlap.

[0059] As shown in Figure 6 , the front glass 1, the front adhesive film 2, the battery piece layer 3, the back adhesive film 4 and the back glass 5 are all rectangular, so the isolation gasket 7 is a rectangular frame. The outer edge contour of the isolation gasket 7 is consistent with the shape and size of the front glass 1, and the inner circle contour is consistent with the shape and size of the back glass 5. In this way, it can be ensured that the adhesive film will not be bonded to the front glass 1 in the part where the back glass 5 and the front glass 1 do not overlap, facilitating the cutting of the adhesive film overflow part in the subsequent process. The residual adhesive film crosslinking product 8 will overflow on the isolation gasket 7 during lamination, so cutting is performed along the edge of the back glass 5, and then the isolation gasket 7 is removed, so that the residual adhesive film crosslinking product 8 can be cleaned up, and preparation is made for the subsequent sealant coating. The isolation gasket 7 of this embodiment is a frame-shaped tool made of high-temperature cloth or a sheet of material that does not adhere to the adhesive film.

[0060] Specifically, as shown in Figure 7 and Figure 8 , in step S3, after lamination, the adhesive film overflows to form a residual adhesive film crosslinking product 8. In step S4, a mechanical knife is used to cut along the edge of the back glass 5, and then the residual adhesive film crosslinking product 8 is taken out together with the isolation gasket 7. The isolation gasket 7 will not adhere to the residue, and the isolation gasket 7 can be reused. After the lamination process is completed, the cutting process is to cut off the residual adhesive film of the layer table structure along the contour of the back glass 5, facilitating the subsequent sealant coating. After cutting is completed, the residual adhesive film is removed and the isolation gasket 7 is removed, and the process enters the sealant coating process. The sealant is coated on the layer table structure around the laminated part along the back glass 5, with a thickness of about 3 mm, a width consistent with the width of the layer table, and a height completely covering the adhesive film layer and the back glass 5, so as to achieve the purpose of air isolation.

[0061] The process flow of the prior art is shown in FIG. 3, and the process flow of this embodiment is shown in FIG. Figure 4The process flow of the embodiment includes slice string welding, front glass 1 feeding, isolation layer laying, front adhesive film 2 cutting and laying, layout, busbar welding, back adhesive film 4 cutting and laying, back plate or back glass 5 laying, front EL detection, laminating, cutting, sealant coating, frame 9 mounting, terminal box mounting, curing and cleaning, power test (I-V test), insulation voltage test, rear EL test, and packaging. Compared with the prior art, the embodiment adds the processes of isolation gasket 7 laying and waterproof sealant coating, reduces the corner cutting process, adds one laying device and one coating device, and reduces one corner cutting machine, thereby reducing the cost of the production line equipment.

[0062] The other steps of the embodiment are the same as those of the second embodiment, which are not described here.

[0063] In summary, the embodiment of the present application provides a photovoltaic module, the shapes of the front glass 1, the front adhesive film 2, the cell piece layer 3, the back adhesive film 4 and the back glass 5 are the same, but the area of the front glass 1 is large, and when laminating, the centers of the front glass 1, the front adhesive film 2, the cell piece layer 3, the back adhesive film 4 and the back glass 5 are located on the same straight line and the side edges are parallel, the uncovered part of the front glass 1 forms a ring-shaped waterproof sealing ring 6, the front surface of the waterproof sealing ring 6 is bonded to the back surface of the front glass 1, the inner side surface is bonded to the outer side surfaces of the front adhesive film 2, the cell piece layer 3, the back adhesive film 4 and the back glass 5, the waterproof sealing ring 6 is used to prevent the entry of water vapor and prevent water vapor from entering the adhesive film through the gap, which can better protect the photovoltaic module. And the embodiment of the present application also provides a manufacturing method of the above photovoltaic module, which uses an isolation gasket 7, which is convenient for cutting residual adhesive film crosslinking material 8, cleaning the layer table structure, and is conducive to the subsequent coating of the waterproof sealing ring 6.

[0064] The above only describes the preferred embodiments of the present application, and it should be noted that those skilled in the art can make several improvements and replacements without departing from the technical principles of the present application, and these improvements and replacements should also be considered as the protection scope of the present application.

Claims

1. A method for manufacturing a photovoltaic module, characterized in that, The method comprises the following steps: S1, manufacturing a front glass (1), a cell sheet layer (3) and a back glass (5) with the same shape, wherein the area of the cell sheet layer (3) and the back glass (5) is equal, and the area of the front glass (1) is larger than that of the back glass (5); S2, sequentially laying the front glass (1), a front adhesive film (2), the cell sheet layer (3), a back adhesive film (4) and the back glass (5) from bottom to top, so that the centers of the front glass (1), the cell sheet layer (3) and the back glass (5) are located on the same straight line, and the side edges of the front glass (1), the cell sheet layer (3) and the back glass (5) are parallel; in step S2, the front adhesive film (2) and the back adhesive film (4) are both EVA films; in step S2, before laying the front adhesive film (2), an isolation gasket (7) is laid on the front glass (1) first, the inner ring of the isolation gasket (7) has the same shape and size as the back glass (5), and the isolation gasket (7) is used to prevent the front adhesive film (2) and the back adhesive film (4) from overflowing to the part where the projections of the front glass (1) and the back glass (5) do not coincide; S3, performing EL detection, and laminating the products without hidden cracks; S4, cutting and removing residual adhesive film cross-linking material (8) along the edge of the back glass (5); S5, cleaning the back of the front glass (1) and the side faces of the front adhesive film (2), the cell sheet layer (3), the back adhesive film (4) and the back glass (5); S6, coating a layer of waterproof sealing glue along the edge of the back glass (5) to form a waterproof sealing ring (6) which is bonded to the side faces of the front adhesive film (2), the cell sheet layer (3), the back adhesive film (4) and the back glass (5), and to the back of the front glass (1); S7, assembling the components obtained in step S6 with a frame (9) and a junction box, then performing solidification cleaning, power testing, insulation voltage testing, EL testing, and finally packaging and warehousing.

2. The method of making a photovoltaic assembly of claim 1, wherein, The isolation gasket (7) is a high-temperature cloth or a sheet frame type tool made of a material which does not bond with the adhesive film.

3. The method of making a photovoltaic assembly of claim 1, wherein, In step S6, the waterproof sealing glue is high-water-resistance silicone or butyl glue.

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