Laminating machine for manufacturing photovoltaic module and manufacturing method of photovoltaic module

Abstract

The invention provides a laminating machine for manufacturing a photovoltaic module and a manufacturing method of the photovoltaic module, and the laminating machine for manufacturing the photovoltaic module comprises a housing which is provided with a sealed cavity; the platform is arranged in the closed cavity; the crimping assembly is arranged in the closed cavity, the crimping assembly comprises a pre-crosslinking crimping part and a connecting crimping part arranged on the periphery of the pre-crosslinking crimping part in a surrounding manner, a first heater is arranged on the pre-crosslinking crimping part, a second heater is arranged on the connecting crimping part, and the first heater and the second heater are independently controlled; the gas injection structure is communicated with the closed cavity so as to inject functional gas into the closed cavity; the air exhaust structure is communicated with the closed cavity so as to exhaust air in the closed cavity. According to the technical scheme, the problems that in the prior art, recycling operation of the photovoltaic module is tedious, and the cost is high can be effectively solved.

Description

Technical Field

[0001] The present invention relates to the technical field of photovoltaic manufacturing, and in particular to a laminator for manufacturing photovoltaic modules and a method for manufacturing photovoltaic modules. Background Art

[0002] In the related art, a photovoltaic module generally includes a solar panel, two adhesive layers respectively arranged on both sides of the solar panel, and two support plates respectively arranged on the side of the two adhesive layers away from the solar panel, wherein at least one support plate is a transparent plate.

[0003] When photovoltaic modules are recycled, the main thing recycled is the solar panels. However, since the solar panels are connected to the support plates with adhesive layers on both sides, it is difficult to separate the solar panels from the support plates. After the two are separated, the adhesive layer will also adhere to the solar panels, and it is necessary to use chemical reagents or high temperature to remove the adhesive layer on the surface of the solar panels. The above processing methods are cumbersome and costly. Summary of the invention

[0004] The main purpose of the present invention is to provide a laminator for manufacturing photovoltaic modules and a method for manufacturing photovoltaic modules, so as to solve the problem of complicated and high cost of recycling photovoltaic modules in the related art.

[0005] In order to achieve the above-mentioned purpose, according to one aspect of the present invention, there is provided a laminator for manufacturing photovoltaic modules, comprising: a shell having a closed cavity; a platform arranged in the closed cavity; a crimping assembly arranged in the closed cavity, the crimping assembly comprising a pre-cross-linked crimping piece and a connecting crimping piece arranged around the periphery of the pre-cross-linked crimping piece, a first heater is arranged on the pre-cross-linked crimping piece, a second heater is arranged on the connecting crimping piece, and the first heater and the second heater are independently controlled; a gas injection structure connected to the closed cavity to fill the closed cavity with functional gas; and an exhaust structure connected to the closed cavity to exhaust the gas in the closed cavity.

[0006] Furthermore, the air injection structure includes an air pump, an air inflation pipe connected between the air pump and the shell, and a first control valve arranged on the air inflation pipe; and / or, the air extraction structure includes an air extraction pump, an air extraction pipe connected between the air extraction pump and the shell, and a second control valve arranged on the air extraction pipe.

[0007] Furthermore, the laminator also includes a lifting mechanism movably arranged on the shell and extending into the closed cavity, and the lifting mechanism can drive the crimping assembly to rise and fall; and / or, the platform includes a carrying plate and a conveyor belt wrapped around the outer periphery of the carrying plate.

[0008] According to another aspect of the present invention, a method for manufacturing a photovoltaic module is provided, wherein the photovoltaic module is manufactured using the above-mentioned laminator, and the manufacturing method comprises:

[0009] Treating the first encapsulation layer by a first heater to obtain a first pre-crosslinked encapsulation layer, wherein the first pre-crosslinked encapsulation layer has a first pre-crosslinked region and a first original region, wherein a degree of crosslinking in the first pre-crosslinked region is greater than a degree of crosslinking in the first original region;

[0010] The second encapsulation layer is treated by the first heater to obtain a second pre-crosslinked encapsulation layer, wherein the second pre-crosslinked encapsulation layer has a second pre-crosslinked region and a second original region, wherein the crosslinking degree of the second pre-crosslinked region is greater than the crosslinking degree of the second original region, the second pre-crosslinked region is arranged correspondingly to the first pre-crosslinked region, and the second original region is arranged correspondingly to the first original region;

[0011] Placing the battery plate between the first pre-crosslinked packaging layer and the second pre-crosslinked packaging layer so that the battery plate is located within the first pre-crosslinked region and the second pre-crosslinked region to obtain a laminated structure;

[0012] The first original region of the first pre-crosslinked encapsulation layer and the second original region of the second pre-crosslinked encapsulation layer are treated by a second heater, so that the first original region and the second original region are crosslinked and connected together.

[0013] Furthermore, between the step of placing the solar panel between the first pre-crosslinked encapsulation layer and the second pre-crosslinked encapsulation layer so that the solar panel is located in the first pre-crosslinked region and the second pre-crosslinked region to obtain a laminated structure and the step of treating the first original region of the first pre-crosslinked encapsulation layer and the second original region of the second pre-crosslinked encapsulation layer by a second heater so that the first original region and the second original region are crosslinked and connected together, the manufacturing method further includes:

[0014] The closed cavity is evacuated by means of an exhaust structure;

[0015] Functional gas is injected into the closed cavity through the gas injection structure.

[0016] Further, the step of treating the first encapsulation layer by a first heater to obtain a first pre-cross-linked encapsulation layer includes:

[0017] Placing a first support plate on the platform and placing a packaging film on the first support plate to obtain a first packaging layer;

[0018] Setting anti-stick high temperature cloth on the packaging film;

[0019] The anti-adhesion high temperature cloth is pressed down by the pre-crosslinking crimping piece and the area of ​​the packaging film corresponding to the anti-adhesion high temperature cloth is heated to form a first pre-crosslinking area.

[0020] Furthermore, in the step of injecting the functional gas into the closed cavity through the gas injection structure: the gas injection pressure is between 0.8 standard atmospheric pressure and 1.2 standard atmospheric pressure.

[0021] According to another aspect of the present invention, a method for manufacturing a photovoltaic module is provided, wherein the photovoltaic module is manufactured using the above-mentioned laminator, and the manufacturing method comprises:

[0022] placing a second support plate on the platform;

[0023] Placing a first support ring on the second support plate, wherein the outer side wall of the first support ring is located on the inner side of the outer side wall of the second support plate;

[0024] placing a solar panel assembly on the first support ring;

[0025] Placing a second support ring on the battery panel assembly, the second support ring being arranged corresponding to the first support ring;

[0026] Placing a third support plate on the second support ring, wherein the outer side wall of the second support ring is located on the inner side of the outer side wall of the third support plate;

[0027] A packaging glue is arranged between the second support plate and the third support plate, and the packaging glue is located outside the first support ring, the battery plate assembly and the second support ring;

[0028] The packaging glue is processed by the second heater so that the packaging glue is cross-linked to form a packaging glue ring connected to the second support plate, the third support plate, the first support ring, the battery panel assembly and the second support ring.

[0029] Furthermore, between the step of providing a packaging glue between the second support plate and the third support plate, the packaging glue being located outside the first support ring, the battery panel assembly and the second support ring, and the step of treating the packaging glue by a second heater so that the packaging glue is cross-linked to form a packaging glue ring connected to the second support plate, the third support plate, the first support ring, the battery panel assembly and the second support ring, the manufacturing method further includes:

[0030] The closed cavity is evacuated by means of an exhaust structure;

[0031] Functional gas is injected into the closed cavity through the gas injection structure.

[0032] Further, the first support ring includes a ring body, a first packaging glue layer arranged on a first side of the ring body, and a second packaging glue layer arranged on a second side of the ring body; and / or, the battery panel assembly includes a battery body, a first back plate arranged on a first side of the battery body, and a second back plate arranged on a second side of the battery body, and at least one of the first back plate and the second back plate is a transparent plate.

[0033] The technical solution of the present invention is applied, and the shell has a closed cavity, and the closed cavity forms a manufacturing space for manufacturing photovoltaic modules by lamination. The platform is located in the closed cavity and is used to carry the raw materials or semi-finished products and finished products of the photovoltaic modules. The crimping assembly is arranged in the closed cavity and located above the platform. The crimping assembly can press down the raw materials or semi-finished products of the photovoltaic modules to achieve the lamination of the photovoltaic modules to form the finished photovoltaic modules. Among them, the crimping assembly includes a pre-crosslinking crimping part and a connecting crimping part arranged around the periphery of the pre-crosslinking crimping part. The pre-crosslinking crimping part can perform pre-crosslinking treatment on a part of the packaging film used for bonding, so that this part of the packaging film can be cross-linked first, so that it loses its bonding ability or has a lower bonding ability, and then this part of the packaging film does not bond with the battery panel or has a lower adhesion with the battery panel. When the photovoltaic module is recycled, it is convenient to separate the various parts of the photovoltaic module and there is no adhesive glue left on the surface of the battery panel or only a small amount of adhesive glue remains, thereby reducing the cost of recycling the battery panel. The connecting crimping piece is arranged around the periphery of the pre-cross-linking crimping piece, and is used to realize the sealing package of the peripheral part of the photovoltaic module, so as to ensure the sealing performance of the finished photovoltaic module. In addition, the laminator of this embodiment also includes a gas injection structure and a vacuum structure. The gas in the closed cavity is first extracted by the vacuum structure, and then the functional gas is filled into the closed cavity by the gas injection structure. The functional gas can play a corresponding function, thereby ensuring the performance of the photovoltaic module. Therefore, the technical solution of the present application can effectively solve the problem of cumbersome and high cost of recycling photovoltaic modules in the related art. BRIEF DESCRIPTION OF THE DRAWINGS

[0034] The drawings constituting a part of the present application are used to provide a further understanding of the present invention. The exemplary embodiments of the present invention and their descriptions are used to explain the present invention and do not constitute an improper limitation of the present invention. In the drawings:

[0035] Figure 1 A simplified structural diagram of an embodiment of a laminator according to the present invention is shown;

[0036] Figure 2 Shows Figure 1 A bottom view schematic diagram of a crimping assembly of a laminator;

[0037] Figure 3 A flow chart showing a first embodiment of a manufacturing method according to the present invention;

[0038] Figure 4 Shown according to Figure 3 A simplified structural diagram of a photovoltaic module manufactured by the manufacturing method;

[0039] Figure 5 A flow chart showing a second embodiment of a manufacturing method according to the present invention;

[0040] Figure 6 Shown according to Figure 5 A simplified structural diagram of a photovoltaic module manufactured by the manufacturing method.

[0041] The above drawings include the following reference numerals:

[0042] 10. Shell; 11. Sealed cavity;

[0043] 20. Platform; 21. Loading plate; 22. Conveyor belt;

[0044] 30. crimping assembly; 31. pre-crosslinking crimping piece; 311. first heater; 312. first pressing plate; 32. connecting crimping piece; 321. second heater; 322. second pressing plate;

[0045] 40. gas injection structure; 41. gas pump; 42. gas filling pipe; 43. first control valve;

[0046] 50. Air extraction structure; 51. Air extraction pump; 52. Air extraction pipe; 53. Second control valve;

[0047] 60. Lifting mechanism;

[0048] 70. Pressure gauge;

[0049] 1. Battery panel; 2. First support plate; 3. Second support plate; 4. First support ring; 5. Battery panel assembly; 501. Battery body; 502. First back plate; 503. Second back plate; 6. Second support ring; 7. Third support plate; 8. Packaging rubber ring; 901. First pre-cross-linking area; 902. Second pre-cross-linking area. DETAILED DESCRIPTION

[0050] The following will be combined with the drawings in the embodiments of the present invention to clearly and completely describe the technical solutions in the embodiments of the present invention. Obviously, the described embodiments are only part of the embodiments of the present invention, rather than all the embodiments. The following description of at least one exemplary embodiment is actually only illustrative and is by no means intended to limit the present invention and its application or use. Based on the embodiments of the present invention, all other embodiments obtained by ordinary technicians in this field without creative work are within the scope of protection of the present invention.

[0051] It should be noted that the terms used herein are only for describing specific embodiments and are not intended to limit the exemplary embodiments according to the present application. As used herein, unless the context clearly indicates otherwise, the singular form is also intended to include the plural form. In addition, it should be understood that when the terms "comprise" and / or "include" are used in this specification, it indicates the presence of features, steps, operations, devices, components and / or combinations thereof.

[0052] Unless otherwise specifically stated, the relative arrangement, numerical expressions and numerical values ​​of the parts and steps set forth in these embodiments do not limit the scope of the present invention. Meanwhile, it should be understood that, for ease of description, the sizes of the various parts shown in the accompanying drawings are not drawn according to the actual proportional relationship. The technology, method and equipment known to those of ordinary skill in the relevant art may not be discussed in detail, but in appropriate cases, the technology, method and equipment should be considered as a part of the specification. In all examples shown and discussed here, any specific value should be interpreted as being merely exemplary, rather than as a limitation. Therefore, other examples of exemplary embodiments may have different values. It should be noted that similar reference numerals and letters represent similar items in the following drawings, and therefore, once a certain item is defined in an accompanying drawing, it does not need to be further discussed in subsequent drawings.

[0053] like Figure 1 and Figure 2 As shown, the present application provides a laminator for manufacturing photovoltaic modules, and an embodiment of the laminator of the present application includes: a housing 10, a platform 20, a crimping assembly 30, a gas injection structure 40 and a gas extraction structure 50. The housing 10 has a closed cavity 11; the platform 20 is arranged in the closed cavity 11; the crimping assembly 30 is arranged in the closed cavity 11, and the crimping assembly 30 includes a pre-cross-linked crimping part 31 and a connecting crimping part 32 arranged around the periphery of the pre-cross-linked crimping part 31, a first heater 311 is arranged on the pre-cross-linked crimping part 31, and a second heater 321 is arranged on the connecting crimping part 32, and the first heater 311 and the second heater 321 are independently controlled; the gas injection structure 40 is connected to the closed cavity 11 to fill the closed cavity 11 with functional gas; the gas extraction structure 50 is connected to the closed cavity 11 to extract the gas in the closed cavity 11.

[0054] The technical solution of this embodiment is applied, and the shell 10 has a closed cavity 11, and the closed cavity 11 forms a manufacturing space for manufacturing photovoltaic modules by lamination. The platform 20 is located in the closed cavity 11 and is used to carry the raw materials for manufacturing photovoltaic modules or the semi-finished products and finished products of photovoltaic modules. The crimping assembly 30 is arranged in the closed cavity 11 and is located above the platform 20. The crimping assembly 30 can press down the raw materials or semi-finished products of photovoltaic modules to achieve lamination of photovoltaic modules to form finished photovoltaic modules. Among them, the crimping assembly 30 includes a pre-crosslinked crimping piece 31 and a connecting crimping piece 32 arranged around the periphery of the pre-crosslinked crimping piece 31. The pre-crosslinked crimping piece 31 can perform pre-crosslinking treatment on a partial area of ​​the packaging film used for bonding, so that this part of the packaging film can be cross-linked first, so that it loses its bonding ability or has a lower bonding ability, thereby making this part of the packaging film not bonded to the battery panel or having a lower adhesion to the battery panel. When the photovoltaic modules are recycled, it is easy to separate the various parts of the photovoltaic modules and no adhesive or only a small amount of adhesive remains on the surface of the solar panel, thereby reducing the cost of recycling the solar panel. The connecting crimping piece 32 is arranged around the periphery of the pre-cross-linking crimping piece 31, and is used to achieve the sealed packaging of the peripheral part of the photovoltaic module to ensure the sealing performance of the finished photovoltaic module. In addition, the laminator of this embodiment also includes a gas injection structure 40 and a vacuum structure 50. The gas in the closed cavity 11 is first extracted through the vacuum structure 50 and then the functional gas is filled into the closed cavity 11 through the gas injection structure 40. The functional gas can play a corresponding function, thereby ensuring the performance of the photovoltaic module. Therefore, the technical solution of this embodiment can effectively solve the problem of cumbersome and high cost of recycling photovoltaic modules in the related art.

[0055] Among them, the functional gas can be an inert gas that acts as a protective gas or ionized hydrogen that acts as a passivation gas, and production personnel can select specific functional gases according to needs.

[0056] like Figure 1 As shown, the housing 10 includes an upper shell and a lower shell spliced ​​to each other, and a closed cavity 11 is formed between the upper shell and the lower shell.

[0057] like Figure 1 As shown, the gas injection structure 40 includes an air pump 41, an air filling pipe 42 connected between the air pump 41 and the housing 10, and a first control valve 43 disposed on the air filling pipe 42. The air pump 41 can fill the closed cavity 11 with functional gas through the air filling pipe 42, and the first control valve 43 is disposed on the air filling pipe 42, which can control the opening and closing of the air filling passage and the amount of functional gas filled per unit time.

[0058] like Figure 1As shown, the air extraction structure 50 includes an air extraction pump 51, an air extraction pipe 52 connected between the air extraction pump 51 and the housing 10, and a second control valve 53 arranged on the air extraction pipe 52. The air extraction pump 51 can extract the gas in the closed cavity 11 through the air extraction pipe 52, so that the closed cavity 11 is in a vacuum state, and then the functional gas is filled into the closed cavity 11 through the gas injection structure 40 to ensure the purity of the functional gas in the closed cavity 11, thereby ensuring the purity of the functional gas inside the photovoltaic module. The second control valve 53 is arranged on the air extraction pipe 52, which can control the on and off of the air extraction passage and the amount of gas extracted per unit time.

[0059] like Figure 1 As shown, the laminator further includes a lifting mechanism 60 movably disposed on the housing 10 and extending into the closed chamber 11, and the lifting mechanism 60 can drive the crimping assembly 30 to be lifted and lowered. Specifically, the lifting mechanism 60 includes a driving motor disposed above the housing 10 and a connecting rod connected between the driving motor and the crimping assembly 30, and the driving motor drives the crimping assembly 30 to be lifted and lowered through the connecting rod, so as to facilitate placing the raw materials of the pressed photovoltaic assembly or the semi-finished products of the photovoltaic assembly on the platform 20 and pressing the crimping assembly 30 downward to manufacture the photovoltaic assembly.

[0060] Specifically, in this embodiment, the lifting mechanism 60 drives the pre-cross-linking crimping piece 31 and the connecting crimping piece 32 to move up and down synchronously. Since the first heater 311 and the second heater 321 are independently controlled, when pre-cross-linking treatment is performed on a partial area of ​​the packaging film, only the first heater 311 needs to be started; when sealing and packaging the peripheral part of the photovoltaic module, only the second heater 321 needs to be started.

[0061] like Figure 1 As shown, the pre-crosslinking crimping piece 31 includes a first pressing plate 312 and a first heater 311 disposed above the first pressing plate 312 , and the connecting crimping piece 32 includes a second pressing plate 322 and a second heater 321 disposed above the second pressing plate 322 .

[0062] like Figure 1 As shown, in this embodiment, the lifting mechanism 60 drives the pre-cross-linked crimping part 31 and the connecting crimping part 32 to move synchronously. In an embodiment not shown in the figure, the lifting mechanism can also drive the pre-cross-linked crimping part and the connecting crimping part to move independently, that is, the lifting mechanism includes at least two drive motors.

[0063] like Figure 2As shown, in this embodiment, the pre-cross-linked crimping piece 31 is a rectangular structure, the connecting crimping piece 32 is an annular structure wound around the periphery of the pre-cross-linked crimping piece 31, and the battery panel 1 is located within the range of the pre-cross-linked crimping piece 31, wherein the battery panel 1 includes a plurality of battery cells arranged in series or in parallel, each battery cell has a gap between them, and the functional gas can be filled into the gap between the battery cells. In an embodiment not shown in the figure, the pre-cross-linked crimping piece may also include a plurality of pre-cross-linked sub-pressing plates corresponding to the plurality of battery cells one by one, and the connecting crimping piece includes an internal connecting press plate corresponding to the gap between the single cells and the single cells, and an annular press plate wound around the plurality of pre-cross-linked sub-pressing plates and the periphery of the internal connecting press plate, so that the connection strength inside the photovoltaic module and the easy disassembly of the photovoltaic module during the recycling process can be taken into account.

[0064] like Figure 1 As shown, the platform 20 includes a carrier plate 21 and a conveyor belt 22 wound around the outer periphery of the carrier plate 21. The conveyor belt 22 is arranged around the carrier plate 21, and the platform 20 also includes a roller structure arranged at both ends of the carrier plate 21, and the conveyor belt 22 is sleeved on the roller structure. When the roller structure rotates, the conveyor belt 22 is driven to rotate, so as to transport the raw materials of the photovoltaic module or the semi-finished products of the photovoltaic module to the position corresponding to the crimping assembly 30.

[0065] like Figures 3 to 6 As shown, the present application also provides a method for manufacturing a photovoltaic module, using the above-mentioned laminator to manufacture the photovoltaic module, wherein: Figure 3 shows a flow chart of a manufacturing method according to a first embodiment of the present application, Figure 4 A simplified structural diagram of a photovoltaic module obtained according to the manufacturing method of the first embodiment is shown; Figure 5 shows a flow chart of a manufacturing method according to a second embodiment of the present application, Figure 6 A simplified structural diagram of a photovoltaic module obtained according to the manufacturing method of the second embodiment is shown.

[0066] like Figure 3 As shown, the first embodiment of the manufacturing method of the present application includes:

[0067] Step S110: treating the first encapsulation layer by the first heater 311 to obtain a first pre-crosslinked encapsulation layer, wherein the first pre-crosslinked encapsulation layer has a first pre-crosslinked region 901 and a first original region, wherein the crosslinking degree of the first pre-crosslinked region 901 is greater than the crosslinking degree of the first original region;

[0068] Step S120: treating the second encapsulation layer by the first heater 311 to obtain a second pre-crosslinked encapsulation layer, wherein the second pre-crosslinked encapsulation layer has a second pre-crosslinked region 902 and a second original region, wherein the crosslinking degree of the second pre-crosslinked region 902 is greater than the crosslinking degree of the second original region, the second pre-crosslinked region 902 is arranged correspondingly to the first pre-crosslinked region 901, and the second original region is arranged correspondingly to the first original region;

[0069] Step S130: placing the solar panel 1 between the first pre-crosslinking encapsulation layer and the second pre-crosslinking encapsulation layer, so that the solar panel 1 is located in the first pre-crosslinking area 901 and the second pre-crosslinking area 902, to obtain a laminated structure;

[0070] Step S140: treating the first original region of the first pre-cross-linked encapsulation layer and the second original region of the second pre-cross-linked encapsulation layer by the second heater 321 so that the first original region and the second original region are cross-linked and connected together.

[0071] By applying the technical solution of this embodiment, the first encapsulation layer and the second encapsulation layer are firstly treated by the first heater 311, so that a part of the first encapsulation layer is cross-linked to obtain a first pre-cross-linked region 901, and a part of the second encapsulation layer is cross-linked to obtain a second pre-cross-linked region 902, and the first pre-cross-linked region 901 and the second pre-cross-linked region 902 lose viscosity or have only low viscosity, wherein the first pre-cross-linked region 901 is located in the middle of the first pre-cross-linked encapsulation layer and the shape of the first pre-cross-linked region 901 is the same as the shape of the pre-cross-linked crimping piece 31, and the second pre-cross-linked region 902 is located in the middle of the second pre-cross-linked encapsulation layer and the shape of the second pre-cross-linked region 902 is the same as the shape of the pre-cross-linked crimping piece 31; then the solar panel 1 is placed between the first pre-cross-linked encapsulation layer and the second pre-cross-linked encapsulation layer, and the solar panel 1 is cross-linked to the first pre-cross-linked region 901. 01 and the second pre-cross-linking area 902 are arranged correspondingly, the solar panel 1 will not be bonded to the first pre-cross-linking area 901 and the second pre-cross-linking area 902 or the bonding force between the solar panel 1 and the first pre-cross-linking area 901 and the second pre-cross-linking area 902 is small, which is convenient for decomposing the photovoltaic module during recycling of the photovoltaic module and for separating the solar panel 1 separately; then the first original area of ​​the first pre-cross-linking encapsulation layer and the second original area of ​​the second pre-cross-linking encapsulation layer are treated by the second heater 321, so that the first original area and the second original area are cross-linked and connected together, and since the connecting crimping piece 32 is arranged around the periphery of the pre-cross-linking crimping piece 31, the bonding connection between the first pre-cross-linking encapsulation layer and the second pre-cross-linking encapsulation layer and the sealing of the periphery of the photovoltaic module are realized, thereby ensuring the overall connection strength of the photovoltaic module and the internal sealing effect.

[0072] In this embodiment, between the step of placing the solar panel 1 between the first pre-crosslinked packaging layer and the second pre-crosslinked packaging layer so that the solar panel 1 is located in the first pre-crosslinked area 901 and the second pre-crosslinked area 902 to obtain a laminated structure and the step of processing the first original area of ​​the first pre-crosslinked packaging layer and the second original area of ​​the second pre-crosslinked packaging layer by the second heater 321 so that the first original area and the second original area are crosslinked and connected together (i.e., between step S130 and step S140), the control method further includes:

[0073] The closed cavity 11 is evacuated by the evacuation structure 50;

[0074] Functional gas is injected into the sealed cavity 11 through the gas injection structure 40 .

[0075] The air in the closed cavity 11 is first extracted through the exhaust structure 50, and then the functional gas is injected into the closed cavity 11 through the gas injection structure 40, so that the closed cavity 11 is filled with the functional gas, and then the parts of the encapsulated photovoltaic module without a physical structure (such as the gaps between battery cells) can be filled with the functional gas, while ensuring the purity of the functional gas inside the photovoltaic module.

[0076] Further, the first encapsulation layer is treated by the first heater 311 to obtain the first pre-crosslinked encapsulation layer, including:

[0077] Step S111: placing a first support plate 2 on the platform 20 and placing a packaging film on the first support plate 2 to obtain a first packaging layer;

[0078] Step S112: placing an anti-sticking high-temperature cloth on the packaging film;

[0079] Step S113 : pressing down the anti-adhesion high temperature cloth through the pre-crosslinking crimping member 31 and heating the area of ​​the packaging film corresponding to the anti-adhesion high temperature cloth to form a first pre-crosslinking area 901 .

[0080] The first support plate 2 may be a transparent support plate (e.g., a glass plate) or an opaque support back plate, and the packaging film may be a film structure such as an EVA film, a POE film, or an EPE film. An anti-sticking high-temperature cloth is arranged on the packaging film, and the pre-cross-linking crimping member 31 is made to press down the anti-sticking high-temperature cloth and heat the corresponding area on the packaging film to form a first pre-cross-linking area 901. The anti-sticking high-temperature cloth can then be removed, so that the surface of the first pre-cross-linking area 901 forms a solidified non-stick surface or has only a low viscosity after being heated again.

[0081] Among them, step S111 and step S112 can also be performed outside the laminator, that is, first put the packaging mold on the first support plate 2, then set the anti-sticking high-temperature cloth on the packaging mold, and then place the layer structure formed by the three on the platform 20.

[0082] It should be noted that the steps of obtaining the second pre-crosslinked encapsulation layer are the same as the steps of obtaining the first pre-crosslinked encapsulation layer, which will not be repeated here. The second encapsulation layer also includes a support plate and an encapsulation film arranged on the support plate. At least one of the first support plate 2 and the support plate of the second encapsulation layer is a transparent support plate.

[0083] In step S130, placing the solar panel 1 between the first pre-crosslinked encapsulation layer and the second pre-crosslinked encapsulation layer refers to:

[0084] placing the encapsulation film of one of the first pre-crosslinked encapsulation layer and the second pre-crosslinked encapsulation layer facing upward;

[0085] Placing the solar panel 1 in the pre-cross-linked area of ​​the pre-cross-linked encapsulation layer;

[0086] The other of the first pre-crosslinked encapsulation layer and the second pre-crosslinked encapsulation layer is placed with the encapsulation film facing downward.

[0087] It should be noted that step S130 may be performed outside the laminator, and then the stacked structure is placed on the platform 20 ; step S130 may also be performed directly on the platform 20 .

[0088] In this embodiment, in the step of injecting functional gas into the closed cavity 11 through the gas injection structure 40: the gas injection pressure is between 0.8 standard atmospheric pressure and 1.2 standard atmospheric pressure. It should be noted that the "gas injection pressure" here refers to the pressure reached by the closed cavity 11, that is, the gas injection is stopped when the pressure in the closed cavity 11 reaches the gas injection pressure. The gas injection pressure is controlled within the above range so that the air pressure in the cavity inside the encapsulated photovoltaic module is equivalent to the external atmospheric pressure, so as to avoid the pressure difference between the inside and outside of the photovoltaic module, which may cause the first support plate 2 to be damaged by the air pressure.

[0089] like Figure 1 As shown, in order to facilitate the control of the gas injection pressure, the laminator further includes a pressure gauge 70 which is arranged on the shell 10 and extends into the closed cavity 11 .

[0090] Specifically, in this embodiment, the first support plate 2 is a photovoltaic glass of 2384mm×1134mm, and the packaging film is an EVA film, the size of the EVA film is equal to or slightly larger than the size of the photovoltaic glass; the size of the platform 20 is 3m×1.5m; the size of the first pressing plate 312 of the pre-cross-linked crimping part 31 is 2360mm×1110mm. When performing step S110, only the first heater 311 is turned on to heat the first pressing plate 312, and the second heater 321 does not work.

[0091] In step S1113, the first heater 311 heats the temperature of the first pressing plate 312 to between 50°C and 150°C, and the first pressing plate 312 is pressed down for a time between 7min and 13min. By controlling the temperature and time within the above range, the cross-linking degree of the first pre-cross-linking area 901 can be ensured while reducing energy consumption. When performing step S140, the second heater 321 works and the first heater 311 does not work.

[0092] After step S140 is completed, the laminated photovoltaic module is taken out from the laminator and steps such as frame installation, junction box installation, and curing are performed.

[0093] like Figure 5 and Figure 6 As shown, the second embodiment of the manufacturing method of the present application includes:

[0094] Step S210: placing a second support plate 3 on the platform 20;

[0095] Step S220: placing the first support ring 4 on the second support plate 3, with the outer side wall of the first support ring 4 being located on the inner side of the outer side wall of the second support plate 3;

[0096] Step S230: placing the solar panel assembly 5 on the first support ring 4;

[0097] Step S240: placing a second support ring 6 on the battery panel assembly 5, wherein the second support ring 6 is arranged corresponding to the first support ring 4;

[0098] Step S250: placing the third support plate 7 on the second support ring 6, with the outer side wall of the second support ring 6 being located on the inner side of the outer side wall of the third support plate 7;

[0099] Step S260: placing a packaging glue between the second support plate 3 and the third support plate 7, wherein the packaging glue is located outside the first support ring 4, the battery panel assembly 5 and the second support ring 6;

[0100] Step S270: The packaging glue is treated by the second heater 321 so that the packaging glue is cross-linked to form a packaging glue ring 8 connected to the second support plate 3, the third support plate 7, the first support ring 4, the battery panel assembly 5 and the second support ring 6.

[0101] By applying the technical solution of this embodiment, by setting the first support ring 4 between the battery panel assembly 5 and the second support plate 3, and setting the second support ring 6 between the battery panel assembly 5 and the third support plate 7, the battery panel assembly 5 and the second support plate 3 are arranged at intervals, and the battery panel assembly 5 and the third support plate 7 are arranged at intervals. The surface of the battery panel assembly 5 corresponding to the inside of the first support ring 4 and the second support ring 6 does not need to be provided with adhesive glue, so that when the photovoltaic assembly is subsequently recycled, there is no adhesive glue left on the surface of the battery panel assembly 5 or only a small amount of adhesive glue remains, thereby reducing the recycling cost of the battery panel assembly 5. The packaging glue is located on the outside of the first support ring 4, the battery panel assembly 5, and the second support ring 6. After the packaging glue is treated by the second heater 321, the packaging glue is cross-linked and forms a packaging glue ring 8 connected to the second support plate 3, the third support plate 7, the first support ring 4, the battery panel assembly 5, and the second support ring 6, thereby realizing the sealing packaging of the periphery of the photovoltaic assembly. Specifically, the packaging glue has fluidity and viscosity after heating, and can achieve bonding of the second support plate 3, the third support plate 7, the first support ring 4, the battery panel assembly 5, and the second support ring 6.

[0102] The packaging glue may be EVA glue, POE glue or EPE glue.

[0103] In this embodiment, between the step (step S260) of providing a packaging glue between the second support plate 3 and the third support plate 7, wherein the packaging glue is located outside the first support ring 4, the battery panel assembly 5, and the second support ring 6, and the step (step S270) of treating the packaging glue by the second heater 321 so that the packaging glue is cross-linked to form a packaging glue ring 8 connected to the second support plate 3, the third support plate 7, the first support ring 4, the battery panel assembly 5, and the second support ring 6, the manufacturing method further includes:

[0104] The closed cavity 11 is evacuated by the evacuation structure 50;

[0105] Functional gas is injected into the sealed cavity 11 through the gas injection structure 40 .

[0106] The air in the closed cavity 11 is first extracted through the exhaust structure 50, and then the functional gas is injected into the closed cavity 11 through the gas injection structure 40, so that the closed cavity 11 is filled with the functional gas, and then the parts of the encapsulated photovoltaic module without a solid structure (such as the gaps between battery cells, the intervals between the battery panel assembly 5 and the second support plate 3 and the third support plate 7) can be filled with the functional gas, while ensuring the purity of the functional gas inside the photovoltaic module.

[0107] Specifically, the first support ring 4 includes a ring body, a first encapsulation adhesive layer arranged on the first side of the ring body, and a second encapsulation adhesive layer arranged on the second side of the ring body. When the encapsulation adhesive is heated by the second heater 321, the first encapsulation adhesive layer and the second encapsulation interlayer are also heated, and then a cross-linking reaction occurs, so that the ring body is firmly connected to the solar panel assembly 5 and the second support plate 3, thereby ensuring the connection stability of the internal structure of the encapsulated photovoltaic assembly. Among them, the first encapsulation adhesive layer and the second encapsulation adhesive layer can be EVA glue, POE glue or EPE glue, etc. The structural composition of the second support ring 6 is similar to that of the first support ring 4, which will not be repeated here.

[0108] like Figure 6 As shown, the battery panel assembly 5 includes a battery body 501, a first back plate 502 arranged on a first side of the battery body 501, and a second back plate 503 arranged on a second side of the battery body 501, and at least one of the first back plate 502 and the second back plate 503 is a transparent plate. The battery body 501 includes a plurality of battery cells arranged in series or in parallel. Since the second support plate 3 and the third support plate 7 are arranged at intervals from the battery panel assembly 5, the second support plate 3 and the third support plate 7 cannot directly support the battery cells. By arranging the first back plate 502 and the second back plate 503, it is possible to support the plurality of battery cells.

[0109] Specifically, at least one of the first back plate 502 and the second back plate 503 is a transparent plate, and the supporting plate corresponding to the transparent plate (the second supporting plate 3 or the third supporting plate 7 ) is also a transparent plate to form a light path.

[0110] like Figure 6 As shown, the packaging glue will have fluidity after being heated, and will fill the annular space formed by the second support plate 3, the third support plate 7, the first support ring 4, the battery plate assembly 5 and the second support ring 6. The first back plate 502 and the second back plate 503 both protrude outward from the battery body 501. Since there is a gap at the circumferential edges of the first back plate 502 and the second back plate 503, the packaging glue after being heated will also flow into the gap.

[0111] In the description of the present invention, it is necessary to understand that the directions or positional relationships indicated by directional words such as "front, back, up, down, left, right", "lateral, vertical, perpendicular, horizontal" and "top, bottom" are usually based on the directions or positional relationships shown in the drawings. They are only for the convenience of describing the present invention and simplifying the description. Unless otherwise specified, these directional words do not indicate or imply that the devices or elements referred to must have a specific direction or be constructed and operated in a specific direction. Therefore, they cannot be understood as limiting the scope of protection of the present invention. The directional words "inside and outside" refer to the inside and outside relative to the contours of each component itself.

[0112] For ease of description, spatially relative terms such as "above", "above", "on the upper surface of", "above", etc. may be used here to describe the spatial positional relationship between a device or feature and other devices or features as shown in the figure. It should be understood that spatially relative terms are intended to include different orientations of the device in use or operation in addition to the orientation described in the figure. For example, if the device in the accompanying drawings is inverted, the device described as "above other devices or structures" or "above other devices or structures" will be positioned as "below other devices or structures" or "below other devices or structures". Thus, the exemplary term "above" can include both "above" and "below". The device can also be positioned in other different ways (rotated 90 degrees or in other orientations), and the spatially relative descriptions used here are interpreted accordingly.

[0113] In addition, it should be noted that the use of terms such as "first" and "second" to limit components is only for the convenience of distinguishing the corresponding components. If not otherwise stated, the above terms have no special meaning and therefore cannot be understood as limiting the scope of protection of the present invention.

[0114] The above description is only a preferred embodiment of the present invention and is not intended to limit the present invention. For those skilled in the art, the present invention may have various modifications and variations. Any modification, equivalent replacement, improvement, etc. made within the spirit and principle of the present invention shall be included in the protection scope of the present invention.

Claims

1. A laminator for manufacturing photovoltaic modules, characterized in that: include: A housing (10) having a sealed cavity (11); A platform (20) is arranged in the sealed chamber (11); A crimping assembly (30) is arranged in the sealed cavity (11), the crimping assembly (30) comprising a pre-crosslinked crimping piece (31) and a connecting crimping piece (32) arranged around the periphery of the pre-crosslinked crimping piece (31), the pre-crosslinked crimping piece (31) is provided with a first heater (311), the connecting crimping piece (32) is provided with a second heater (321), and the first heater (311) and the second heater (321) are independently controlled; A gas injection structure (40) communicated with the sealed cavity (11) to inject functional gas into the sealed cavity (11); The gas extraction structure (50) is in communication with the sealed cavity (11) so as to extract the gas in the sealed cavity (11).

2. The laminating machine according to claim 1, characterized in that The gas injection structure (40) comprises an air pump (41), an air filling pipe (42) connected between the air pump (41) and the housing (10), and a first control valve (43) arranged on the air filling pipe (42); and / or, The air extraction structure (50) comprises an air extraction pump (51), an air extraction pipe (52) connected between the air extraction pump (51) and the housing (10), and a second control valve (53) arranged on the air extraction pipe (52).

3. The laminating machine according to claim 1, characterized in that The laminator further comprises a lifting mechanism (60) movably arranged on the housing (10) and extending into the closed chamber (11), wherein the lifting mechanism (60) can drive the crimping assembly (30) to move up and down; and / or, The platform (20) comprises a carrying plate (21) and a conveyor belt (22) arranged around the outer periphery of the carrying plate (21).

4. A method for manufacturing a photovoltaic module, characterized in that: A photovoltaic module is manufactured using a laminator according to any one of claims 1 to 3, the manufacturing method comprising: Treating the first encapsulation layer with a first heater (311) to obtain a first pre-crosslinked encapsulation layer, wherein the first pre-crosslinked encapsulation layer has a first pre-crosslinked region (901) and a first original region, wherein the crosslinking degree of the first pre-crosslinked region (901) is greater than the crosslinking degree of the first original region; The second encapsulation layer is treated by the first heater (311) to obtain a second pre-crosslinked encapsulation layer, wherein the second pre-crosslinked encapsulation layer has a second pre-crosslinked region (902) and a second original region, wherein the crosslinking degree of the second pre-crosslinked region (902) is greater than the crosslinking degree of the second original region, the second pre-crosslinked region (902) is arranged corresponding to the first pre-crosslinked region (901), and the second original region is arranged corresponding to the first original region; Placing a solar panel (1) between the first pre-crosslinked encapsulation layer and the second pre-crosslinked encapsulation layer, so that the solar panel (1) is located in the first pre-crosslinked region (901) and the second pre-crosslinked region (902), thereby obtaining a laminated structure; The first original region of the first pre-crosslinked encapsulation layer and the second original region of the second pre-crosslinked encapsulation layer are treated by a second heater (321), so that the first original region and the second original region are crosslinked and connected together.

5. The manufacturing method according to claim 4, characterized in that: Between the step of placing the solar panel (1) between the first pre-crosslinked encapsulation layer and the second pre-crosslinked encapsulation layer so that the solar panel (1) is located in the first pre-crosslinked region (901) and the second pre-crosslinked region (902) to obtain a laminated structure and the step of treating the first original region of the first pre-crosslinked encapsulation layer and the second original region of the second pre-crosslinked encapsulation layer by a second heater (321) so that the first original region and the second original region are crosslinked and connected together, the manufacturing method further comprises: The closed cavity (11) is subjected to a vacuum treatment by means of a vacuuming structure (50); Functional gas is injected into the sealed cavity (11) through the gas injection structure (40).

6. The manufacturing method according to claim 5, characterized in that: The step of treating the first encapsulation layer by a first heater (311) to obtain a first pre-crosslinked encapsulation layer comprises: Placing a first support plate (2) on a platform (20) and placing a packaging film on the first support plate (2) to obtain the first packaging layer; Arranging an anti-stick high temperature cloth on the packaging film; The anti-adhesion high temperature cloth is pressed down by a pre-crosslinking crimping piece (31) and the area of ​​the packaging film corresponding to the anti-adhesion high temperature cloth is heated to form the first pre-crosslinking area (901).

7. The manufacturing method according to claim 5 or 6, characterized in that: In the step of injecting functional gas into the closed cavity (11) through the gas injection structure (40), the gas injection pressure is between 0.8 standard atmospheric pressure and 1.2 standard atmospheric pressure.

8. A method for manufacturing a photovoltaic module, characterized in that: A photovoltaic module is manufactured using a laminator according to any one of claims 1 to 3, the manufacturing method comprising: Placing a second support plate (3) on the platform (20); A first supporting ring (4) is placed on the second supporting plate (3), wherein the outer side wall of the first supporting ring (4) is located on the inner side of the outer side wall of the second supporting plate (3); Placing a solar panel assembly (5) on the first supporting ring (4); A second support ring (6) is placed on the battery panel assembly (5), wherein the second support ring (6) is arranged corresponding to the first support ring (4); A third support plate (7) is placed on the second support ring (6), wherein the outer side wall of the second support ring (6) is located on the inner side of the outer side wall of the third support plate (7); A packaging glue is arranged between the second support plate (3) and the third support plate (7), and the packaging glue is located on the outer sides of the first support ring (4), the battery plate assembly (5) and the second support ring (6); The packaging glue is treated by a second heater (321) so that the packaging glue is cross-linked to form a packaging glue ring (8) connected to the second support plate (3), the third support plate (7), the first support ring (4), the battery plate assembly (5) and the second support ring (6).

9. The manufacturing method according to claim 8, characterized in that: Between the step of arranging a packaging glue between the second support plate (3) and the third support plate (7), wherein the packaging glue is located outside the first support ring (4), the battery panel assembly (5) and the second support ring (6), and the step of treating the packaging glue by a second heater (321) so that the packaging glue is cross-linked to form a packaging glue ring (8) connected to the second support plate (3), the third support plate (7), the first support ring (4), the battery panel assembly (5) and the second support ring (6), the manufacturing method further comprises: The closed cavity (11) is subjected to a vacuum treatment by means of a vacuuming structure (50); Functional gas is injected into the sealed cavity (11) through the gas injection structure (40).

10. The manufacturing method according to claim 8 or 9, characterized in that: The first supporting ring (4) comprises a ring body, a first packaging glue layer arranged on a first side of the ring body, and a second packaging glue layer arranged on a second side of the ring body; and / or, The battery panel assembly (5) comprises a battery body (501), a first back plate (502) arranged on a first side of the battery body (501), and a second back plate (503) arranged on a second side of the battery body (501), wherein at least one of the first back plate (502) and the second back plate (503) is a transparent plate.

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