Photovoltaic module and preparation method thereof

Abstract

The invention discloses a photovoltaic module and a preparation method thereof, and relates to the technical field of solar cell manufacturing, and the method specifically comprises a laminated part, a frame arranged on one side of the laminated part, a first packaging adhesive film and a second packaging adhesive film. Wherein a first extension section is arranged on one side of the cover plate of the laminated piece, and the extension section is close to the frame; the first packaging adhesive film is arranged below the first extension section and extends to a lower edge area of the back plate included by the laminated piece; one or more drainage holes are formed in the side face of the frame. And filling a second packaging adhesive film between the closed area and the laminated piece aiming at the closed area without the drain hole in the frame. According to the embodiment, accumulated water can be drained, and meanwhile, the side, close to the frame, of the back plate is effectively protected, so that water vapor cannot permeate into the laminated structure of the back plate in the drainage process, and the layering problem of the photovoltaic module is avoided.

Description

Technical Field

[0001] The present invention relates to the technical field of solar cell manufacturing, and in particular to a photovoltaic module and a preparation method thereof. Background Art

[0002] Existing photovoltaic modules usually include a laminate containing solar cells and a support frame installed around the laminate. The laminate is installed on the roof of a house or other installation area at a suitable angle using the support frame to maximize the sunlight received. However, since the laminate is a sheet structure with a whole surface, as the installation time increases, water and dust are likely to accumulate on the surface of the laminate.

[0003] In the prior art, in order to solve the problem of water and dust accumulation, a hole design is made on the side of the supporting frame so that water can flow out from one side of the laminate. However, during the flow of water, it is still difficult to avoid the problem of water vapor penetration at the edge of the laminate. Since the back sheet of the existing photovoltaic module is usually a stacked structure obtained by bonding multiple functional layers, water vapor will penetrate into the middle of the stacked gap of the back sheet, causing the photovoltaic module to have a delamination problem, thereby reducing the service life of the photovoltaic module. Summary of the invention

[0004] In view of this, an embodiment of the present invention provides a photovoltaic module and a preparation method thereof, which facilitates the drainage of accumulated water by setting one or more drainage holes on the side of the frame. At the same time, a first extension section is set on the cover plate, and a first packaging film is used to encapsulate the area below the first extension section to the lower edge of the back plate, which effectively protects the side of the back plate close to the frame, so that water vapor cannot penetrate into the stacked structure of the back plate during the drainage process, thereby avoiding the delamination problem of the photovoltaic module.

[0005] In order to solve the above technical problems, the present invention provides the following technical solutions:

[0006] In a first aspect, the present invention provides a photovoltaic module, comprising: a laminate, a frame arranged on one side of the laminate, a first encapsulation film and a second encapsulation film; wherein a first extension section is arranged on one side of a cover plate included in the laminate, and the extension section is close to the frame; the first encapsulation film is arranged below the first extension section and extends to the lower edge area of ​​a back plate included in the laminate; one or more drainage holes are arranged on the side of the frame; for a closed area in the frame where the drainage hole is not arranged, the second encapsulation film is filled between the closed area and the laminate.

[0007] Optionally, a second extension section is provided on a side of the back plate close to the frame; and a groove for inserting the second extension section is provided on a side of the first extension section facing the back plate.

[0008] Optionally, in the case where there are multiple drainage holes, the first extension sections are arranged at intervals on a side of the cover plate close to the frame, and the first extension section, the second extension section and the drainage holes are arranged correspondingly.

[0009] Optionally, in the case where there are multiple drainage holes, the first extension section is arranged through a side of the cover plate close to the frame, and the first packaging film is arranged corresponding to the drainage holes.

[0010] Optionally, the back plate is made of a bendable flexible material, and the second extension section is inserted into the groove after being bent toward one side of the cover plate.

[0011] Optionally, the laminate also includes: a front adhesive film, a battery array and a rear adhesive film arranged between the cover plate and the back plate; wherein the front adhesive film, the battery array and the rear adhesive film correspond to the area on the cover plate except the first extension segment, and / or correspond to the area on the back plate except the second extension segment.

[0012] Optionally, the material of the first encapsulation film includes at least one of the following: EVA film, POE film, EVA / POE laminated film, EVA / POE / EVA laminated film or POE / EVA / POE laminated film; and / or, the material of the second encapsulation film includes at least one of the following: EVA film, POE film, EVA / POE laminated film, EVA / POE / EVA laminated film or POE / EVA / POE laminated film.

[0013] In a second aspect, the present invention provides a method for preparing a photovoltaic module, comprising:

[0014] Step 1, coating a first sealant on a laminate to form a first sealant film; wherein the first sealant is coated below a first extension section on a cover plate included in the laminate and extends to a lower edge region of a back plate included in the laminate;

[0015] Step 2, installing the frame on one side of the laminate coated with the first sealant;

[0016] Step 3: corresponding to the closed area in the frame where the drainage hole is not provided, a second sealant is poured between the closed area and the laminate to form a second sealant film.

[0017] In a third aspect, the present invention provides a photovoltaic power station, comprising:

[0018] The technical solution of the first aspect of the above invention has the following advantages or beneficial effects: by providing one or more drainage holes on the side of the frame, it is convenient to drain the accumulated water. At the same time, by providing a first extension section on the cover plate and using a first packaging film to encapsulate the area below the first extension section to the lower edge of the back plate, the side of the back plate close to the frame is effectively protected, so that water vapor cannot penetrate into the stacked structure of the back plate during the drainage process, thereby avoiding the delamination problem of the photovoltaic module. BRIEF DESCRIPTION OF THE DRAWINGS

[0019] The accompanying drawings are used to better understand the present invention and do not constitute an improper limitation of the present invention.

[0020] Figure 1 It is a schematic diagram of the structure of a photovoltaic module in the prior art;

[0021] Figure 2 is a schematic cross-sectional structure diagram of a photovoltaic module with a drainage hole area provided on a frame according to an embodiment of the present invention;

[0022] Figure 3 is a schematic diagram of the cross-sectional structure of a photovoltaic module according to an embodiment of the present invention with respect to an area where no drainage holes are provided on the frame;

[0023] Figure 4 is a schematic structural diagram of a frame in a photovoltaic module according to an embodiment of the present invention;

[0024] Figure 5 is a schematic structural diagram of each stacked component before preparing a laminate according to an embodiment of the present invention;

[0025] Figure 6 is a schematic diagram of the overall structure of a laminate according to an embodiment of the present invention;

[0026] Figure 7 is a top view of a cover plate according to an embodiment of the present invention;

[0027] Figure 8 is a bottom view of a stack according to an embodiment of the present invention from the direction of a back plate;

[0028] Fig. 9 It is a schematic diagram of the main process of a method for preparing a photovoltaic module provided in an embodiment of the present invention;

[0029] Fig.10 is a schematic diagram of a structure in which a frame is installed on one side of a laminate obtained after step S902 according to an embodiment of the present invention;

[0030] Fig.11 It is a schematic diagram of the main process of preparing a laminate according to an embodiment of the present invention.

[0031] The reference numerals are as follows:

[0032] 1-laminate; 11-cover plate; 111-first extension section; 112-groove; 12-back plate; 121-second extension section; 13-front film; 14-battery array; 15-rear film; 2-frame; 21-drainage hole; 22-enclosed area; 3-first encapsulation film; 4-second encapsulation film; 100-encapsulation film. DETAILED DESCRIPTION

[0033] A solar cell is a photoelectric semiconductor sheet that uses sunlight to generate electricity directly. It is also called a "solar chip" or "photovoltaic cell". As long as it is illuminated by light that meets certain illumination conditions, it can instantly output voltage and generate current in the presence of a circuit. In physics, it is called solar photovoltaic (PV), or photovoltaic for short. In order to conveniently and clearly describe the method for preparing a solar cell and the solar cell of the present invention, the following exemplary embodiments of the present invention are described in conjunction with the accompanying drawings, which include various details of the embodiments of the present invention to facilitate understanding, and they should be considered as merely exemplary. Therefore, those of ordinary skill in the art should recognize that various changes and modifications can be made to the embodiments described herein without departing from the scope and spirit of the present invention. Similarly, for the sake of clarity and conciseness, the description of well-known functions and structures is omitted in the following description.

[0034] For existing photovoltaic modules, Figure 1 As an example, a specific description is given to explain the technical problem to be solved by the embodiment of the present invention. It can be understood that the stacking member 1 is usually surrounded by a frame 2, but in order to maximize the exposure to sunlight, the stacking member 1 is often tilted at a certain angle, that is, there is a side with a lower horizontal height in the stacking member 1. As the installation time increases, water and dust will accumulate on one side of the upper surface of the stacking member 1, and the accumulated rainwater and dust will flow to the side of the stacking member 1 with a lower horizontal height due to gravity. Figure 1 Side shown. Figure 1 It can be seen that in order to prevent dust and rain from entering the stack 1, the prior art fills the packaging film 100 between the frame 2 and the stack 1 to protect the side of the stack 1. However, as time goes by, water vapor will still penetrate along the packaging film to the side of the stack 1, causing the stack 1 to have edge water vapor penetration problems, thereby affecting the service life of the photovoltaic module. Therefore, in order to reduce the penetration of water vapor as much as possible, the embodiment of the present invention provides a photovoltaic module with a new structure.

[0035] Figure 2 and Figure 3 The cross-sectional schematic diagram of different regions of the photovoltaic module provided by the embodiment of the present invention is shown to illustrate the setting positions of the first encapsulation film 3 and the second encapsulation film 4, wherein: Figure 2 It is a schematic diagram of the cross-sectional structure of the area where the drainage hole 21 is set on the frame 2. Figure 3 It is a schematic cross-sectional structure diagram of a closed area 22 on the frame 2 where no drainage hole 21 is provided. Figure 4 A schematic structural diagram of a frame 2 in a photovoltaic module provided in an embodiment of the present invention is shown.

[0036] like Figures 2 to 4 As shown, the photovoltaic module provided by the embodiment of the present invention includes: a laminate 1, a frame 2 arranged on one side of the laminate 1, a first packaging film 3 and a second packaging film 4; wherein, a first extension section 111 is arranged on one side of the cover plate 11 included in the laminate 1, and the extension section 111 is close to the frame 2; the first packaging film 3 is arranged below the first extension section 111 and extends to the lower edge area of ​​the back plate 12 included in the laminate 1; one or more drainage holes 21 are arranged on the side of the frame 2; for the closed area 22 in the frame 2 where the drainage hole 21 is not arranged, the second packaging film 4 is filled between the closed area 22 and the laminate 1.

[0037] Specifically, in Figure 2 and Figure 3 The left side of laminate 1 is Figure 1 In order to illustrate the specific structure of the photovoltaic module of the embodiment of the present invention, Figure 2 and Figure 3 It is shown as horizontal placement, which does not represent the actual state after installation. It should be noted that in order to solve the problem of water vapor penetrating from the side to the inside of the laminate 1 in the prior art, the embodiment of the present invention has different designs for the area where the drainage hole 21 is set and the area where the drainage hole 21 is not set, specifically including:

[0038] (1) For the area where the drainage hole 21 is set

[0039] Since there will be a gap between the laminate 1 and the frame 2 after the frame 2 is installed, rainwater can flow to the drainage hole 21 through the gap between the laminate 1 and the frame 2, so that rainwater can flow out. In the embodiment of the present invention, a first extension section 111 is arranged on the side of the cover plate 11 close to the frame 2, and a first encapsulation film 3 that can extend all the way to the lower edge area of ​​the back plate 12 is arranged below the first extension section 111. In other words, in order to protect the back plate 12 of the stacked structure from being corroded by water vapor, the embodiment of the present invention uses the extended first extension section 111 and the first encapsulation film 3 to encapsulate the side of the back plate 12, so that water vapor cannot directly contact the side of the back plate 12, effectively protecting the back plate 12. At the same time, the first encapsulation film 3 in the embodiment of the present invention simultaneously encapsulates the ends of other stacked structures located between the cover plate 11 and the back plate 12 in the laminate 1, reducing the risk of water vapor penetrating into other components in the laminate 1, and effectively improving the service life of the photovoltaic module.

[0040] (2) For areas where drainage holes 21 are not provided

[0041] Since the drain holes 21 are provided on the frame 2, most of the rainwater will flow to the drain holes 21. Therefore, the water vapor in the area without the drain holes 21 will be much less than that in the area with the drain holes 21. Therefore, the embodiment of the present invention uses the second packaging film 4 to fill the gap between the closed area 22 and the laminate 1, that is, only the gap in the area of ​​the drain holes 21 is retained, so that the water flow can flow out quickly and in a directional manner, and will not flow through the closed area 22, thereby protecting the partial area of ​​the laminate 1 corresponding to the closed area.

[0042] Through the above arrangement, it can be seen that the embodiment of the present invention uses the second packaging film 4 to achieve directional outflow of rainwater, reduce unnecessary flow paths, and protect part of the laminate 1 structure. At the same time, the first packaging film 3 is used to provide additional protection for another part of the laminate 1 structure through which rainwater flows, effectively achieving waterproof and dustproof properties of the photovoltaic module.

[0043] In an optional embodiment, the present invention also improves the structure of the back plate 12, which can cooperate with the cover plate 11 to better achieve the waterproof and dustproof effect. Specifically, the photovoltaic module provided by the present invention is provided with a second extension section 121 on the side of the back plate 12 close to the frame 2; and a groove 112 for inserting the second extension section 121 is provided on the side of the first extension section 111 facing the back plate 12. Figure 5 and Figure 6 Take the above structure as an example to illustrate, where: Figure 5 It is a schematic diagram of the structure of each stacked component before preparing the laminate 1, Figure 6 FIG. 1 is a schematic diagram of the overall structure of the laminate 1. Figure 5 and Figure 6As shown, the first extension section 111 and the second extension section 121 are arranged on the same side of the stack 1, and the groove 112 on the first extension section 111 matches the outer contour of the back plate 12, so that the second extension section 121 can be inserted into the groove 112 of the cover plate 11 after being bent upward. In a further optional embodiment, the depth of the groove 112 is the same as the length of the second extension section 121, so that the back plate 12 can be just inserted into the groove 112 of the cover plate 11.

[0044] In an optional embodiment, the second extension section 121 may be inserted into the groove 112 on the first extension section 111, as shown in FIG. Figure 5 As shown, the back plate 12 is made of a bendable flexible material, and the second extension section 121 is inserted into the groove 112 after being bent toward one side of the cover plate 11 .

[0045] In addition to the cover plate 11 and the back plate 12 in the laminate 1, in an optional embodiment, as Figure 5 and Figure 6 As shown, the present invention also includes: a front film 13, a battery array 14 and a rear film 15 arranged between the cover plate 11 and the back plate 12; wherein the front film 13, the battery array 14 and the rear film 15 correspond to the area on the cover plate 11 excluding the first extension section 111, and / or correspond to the area on the back plate 12 excluding the second extension section 121. That is to say, the first extension section 111 and the second extension section 112 in the embodiment of the present invention are compared with the length of the front film 13, the battery array 14 and the rear film 15, that is, the length of the cover plate 11 and the back plate 12 is longer than that of the front film 13, the battery array 14 and the rear film 15, which is different from the structure in the prior art where the cover plate 11, the back plate 12, the front film 13, the battery array 14 and the rear film 15 are stacked with the same length. It is understandable that because only one side of the laminate 1 has a lower horizontal height, there is a problem of water and dust accumulation. Therefore, the embodiment of the present invention only makes structural improvements on the side with the lower horizontal height. The other side can also be set to a symmetrical structure according to actual needs. The present invention does not make specific limitations on this.

[0046] In an optional embodiment, in view of the situation where there are multiple drainage holes 21, the embodiment of the present invention also provides two different structures of the cover plate 11. Specifically, in an optional embodiment, the first extension section 111 is arranged at intervals on the side of the cover plate 11 close to the frame 2, and the first extension section 111, the second extension section 121 and the drainage hole 21 are arranged correspondingly. The top view structure of this cover plate 11 can be as follows: Figure 7As shown, the first extension section 111, the second extension section 121, and the corresponding first packaging film 3 are only provided in the area where the drainage hole 21 is provided, while the first extension section 111 and the second extension section 121 are not provided in the area where the drainage hole is not provided, and the cover plate 11, the back plate 12, and other structures in the stack 1 are still stacked. In another optional embodiment, as Figure 7 As shown, the first extension section 111 is disposed through the side of the cover plate 11 close to the frame 2, and the first packaging film 3 is disposed corresponding to the drainage hole 21. Figure 8 It is a bottom view of the stack 1 from the direction of the back plate 12. It can be seen that under this arrangement, the second extension section 121 on the back plate 12 can also be set through, that is, the side surface of one end of the back plate 12 set with the second extension section 121 is fully inserted into the first extension section 111 of the cover plate 11, and only the first packaging film 3 is set corresponding to the drainage hole 21. Compared with the previous embodiment, the through arrangement of the first extension section 111 and the second extension section 121 can better protect other stacked structures in the stack 1, but the material consumption of the cover plate 11 and the back plate 12 will be relatively increased.

[0047] The materials of the first encapsulation film 3 and the second encapsulation film 4 may be the same or different. In an optional embodiment, the material of the first encapsulation film 3 includes at least one of the following: EVA film, POE film, EVA / POE laminated film, EVA / POE / EVA laminated film or POE / EVA / POE laminated film; the material of the second encapsulation film 4 includes at least one of the following: EVA film, POE film, EVA / POE laminated film, EVA / POE / EVA laminated film or POE / EVA / POE laminated film.

[0048] Regarding the material of the front adhesive film 13 and the back adhesive film 15, in an optional embodiment, the front adhesive film 13 and the back adhesive film 15 can be at least one of EVA adhesive film, POE adhesive film, EVA / POE laminated film, EVA / POE / EVA laminated film or POE / EVA / POE laminated film.

[0049] For the material of the cover plate 11, in an optional embodiment, it is at least one of tempered photovoltaic glass or semi-tempered glass. For the back plate 12, in an optional embodiment, the back plate 12 includes a multi-layer structure, and the multi-layer structure includes at least an insulating functional layer and a weather-resistant functional layer. Among them, the insulating functional layer is polyethylene terephthalate (PET), modified polyethylene terephthalate (PET) or a multi-layer film structure containing polyethylene terephthalate (PET), and the weather-resistant functional layer is a PVF film layer, a PVDF film layer or an ETFE film layer.

[0050] In a further optional embodiment, a commonly used frame structure is provided on the other side edges of the laminate 1, and a second packaging film 4 is also filled between the frame and the laminate 1 to prevent rainwater and dust from entering the other sides of the laminate 1, thereby achieving all-round protection for the laminate 1 and improving the overall performance of the photovoltaic module.

[0051] In summary, the photovoltaic module provided by the embodiment of the present invention is conducive to the drainage of accumulated water by providing one or more drainage holes on the side of the frame. At the same time, by providing a first extension section on the cover plate and using a first packaging film to encapsulate the area below the first extension section to the lower edge of the back plate, the side of the back plate close to the frame is effectively protected, so that water vapor cannot penetrate into the stacked structure of the back plate during the drainage process, thereby avoiding the delamination problem of the photovoltaic module.

[0052] Fig. 9 A method for preparing a photovoltaic module provided by an embodiment of the present invention is shown, and the method may include the following steps:

[0053] Step S901, coating a first sealant on the laminate to form a first sealant film; wherein the first sealant is coated below the first extension section on the cover plate included in the laminate and extends to the lower edge area of ​​the back plate included in the laminate;

[0054] Step S902, installing the frame on one side of the laminate coated with the first sealant;

[0055] Step S903 , corresponding to the closed area in the frame where no drainage hole is provided, a second sealant is poured between the closed area and the laminate to form a second sealant film.

[0056] In an optional embodiment, in order to save the consumption of the first sealant as much as possible, the first sealant in step S901 is only applied to the position corresponding to the setting of the drainage hole, and is not applied to the area where the drainage hole is not set.

[0057] Fig.10 The schematic diagram of the structure after the frame is installed on one side of the laminate after step S902 is shown. In an optional embodiment, other frames are also provided on other sides of the laminate, so step S902 also includes: installing other frames around the laminate, combining and fixing with the frame, so as to fix the laminate inside the frame.

[0058] In an optional embodiment, before step S901, a specific process of preparing the laminate may be further included, such as Fig.11 As shown, including:

[0059] Step S1101, pre-bending the back plate to obtain a second extension section facing the cover plate;

[0060] Step S1102, sequentially stacking a back plate having a second extension section, a rear adhesive film, a battery array, a front adhesive film, and a cover plate, and inserting the second extension section into the groove of the first extension section;

[0061] Step S1103, laminating through a single lamination process to obtain a laminated part.

[0062] In summary, the method for preparing a photovoltaic module provided by an embodiment of the present invention is conducive to the drainage of accumulated water by setting one or more drainage holes on the side of the frame. At the same time, by setting a first extension section on the cover plate and using a first packaging film to encapsulate the area below the first extension section to the lower edge of the back plate, the side of the back plate close to the frame is effectively protected, so that water vapor cannot penetrate into the stacked structure of the back plate during the drainage process, thereby avoiding the delamination problem of the photovoltaic module.

[0063] The introduction provided in the above steps is only used to help understand the structure, method and core idea of ​​the present invention. For ordinary technicians in this technical field, without departing from the principle of the present invention, several improvements and modifications can be made to the present invention, and these improvements and modifications also belong to the scope of protection of the claims of the present invention.

Claims

1. A photovoltaic module, characterized in that: include: A laminate (1), a frame (2) arranged on one side of the laminate (1), a first packaging film (3) and a second packaging film (4); wherein: A first extension section (111) is provided on one side of the cover plate (11) included in the laminate (1), and the extension section (111) is close to the frame (2); The first packaging adhesive film (3) is arranged below the first extension section (111) and extends to the lower edge region of the back plate (12) included in the laminate (1); One or more drainage holes (21) are provided on the side of the frame (2); For the closed area (22) in the frame (2) where the drainage hole (21) is not provided, the second packaging adhesive film (4) is filled between the closed area (22) and the laminate (1).

2. The photovoltaic module according to claim 1, characterized in that: A second extension section (121) is provided on a side of the back plate (12) close to the frame (2); A groove (112) for inserting the second extension section (121) is provided on a side of the first extension section (111) facing the back plate (12).

3. The photovoltaic module according to claim 2, characterized in that: In the case where there are multiple drainage holes (21), the first extension sections (111) are arranged at intervals on a side of the cover plate (11) close to the frame (2), and the first extension section (111), the second extension section (121) and the drainage holes (21) are arranged correspondingly.

4. The photovoltaic module according to claim 2, characterized in that: In the case where there are multiple drainage holes (21), the first extension section (111) is arranged to penetrate a side of the cover plate (11) close to the frame (2), and the first packaging film (3) is arranged corresponding to the drainage holes (21).

5. The photovoltaic module according to claim 2, characterized in that: The back plate (12) is made of a bendable flexible material, and the second extension section (121) is inserted into the groove (112) after being bent toward one side of the cover plate (11).

6. The photovoltaic module according to claim 2, characterized in that: The laminate (1) further comprises: a front adhesive film (13), a battery array (14) and a rear adhesive film (15) arranged between the cover plate (11) and the back plate (12); The front adhesive film (13), the battery array (14) and the rear adhesive film (15) correspond to an area on the cover plate (11) excluding the first extension section (111), and / or correspond to an area on the back plate (12) excluding the second extension section (121).

7. The photovoltaic module according to claim 1, characterized in that: The material of the first packaging film (3) includes at least one of the following: EVA film, POE film, EVA / POE laminated film, EVA / POE / EVA laminated film or POE / EVA / POE laminated film; and / or, The material of the second packaging film (4) includes at least one of the following: EVA film, POE film, EVA / POE laminated film, EVA / POE / EVA laminated film or POE / EVA / POE laminated film.

8. A method for preparing a photovoltaic module, characterized in that: include: Step 1, coating a first sealant on a laminate to form a first sealant film; wherein the first sealant is coated below a first extension section on a cover plate included in the laminate and extends to a lower edge region of a back plate included in the laminate; Step 2, installing the frame on one side of the laminate coated with the first sealant; Step 3: corresponding to the closed area in the frame where the drainage hole is not provided, a second sealant is poured between the closed area and the laminate to form a second sealant film.

9. The preparation method according to claim 8, characterized in that: Before step 1, also include: Step 01, pre-bending the back plate to obtain a second extension section facing the cover plate; Step 02, sequentially stacking a back plate having a second extension section, a rear adhesive film, a battery array, a front adhesive film and a cover plate, and inserting the second extension section into the groove of the first extension section; Step 03, laminating through a single lamination process to obtain the laminated part.

10. A photovoltaic power station, characterized in that: include: A plurality of photovoltaic modules as claimed in any one of claims 1 to 7.

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