Photovoltaic module and manufacturing method thereof

Abstract

The invention provides a photovoltaic module and a manufacturing method thereof. The photovoltaic module comprises a conductive backboard and a battery layer. The battery layer comprises a plurality of battery strings, and each battery string comprises a plurality of battery pieces. The conductive backboard comprises a conductive layer and an insulating layer located between the conductive layer and the battery layer. The insulating layer is provided with a plurality of via holes and comprises an insulating film and a first gap film, the insulating film is provided with a battery region and a first gap region, the battery region corresponds to one battery piece, and the first gap region corresponds to a gap region between adjacent battery strings. The first gap film is arranged along the first gap area and at least partially covers the battery area, and at least part of the via hole penetrates through the first gap film and the corresponding battery area, so that the hole in the insulating layer is not blocked by the first gap film, the effect of preventing the inter-string gap from leaking light is achieved, and the fitting precision requirement of the first gap film is reduced. The strength of the via hole on the first gap film is enhanced, so that the via hole is not easy to deform, and the reliability of electric connection in the photovoltaic module is improved.

Description

Technical Field

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

[0002] In the photovoltaic field, in order to improve the appearance of photovoltaic modules and increase the efficiency of modules, appearance tape (also called gap film) is usually attached to the cell gaps on the glass surface (between strings / between cells) to improve the color difference and light absorption effect of the module surface.

[0003] The manufacturing method of existing photovoltaic modules is generally to first open holes in the insulating film, and then attach the appearance tape to the gap between the battery strings and the battery cells. As the power requirements of photovoltaic modules increase, the width of the gap between the battery strings and the battery cells is getting smaller and smaller, and the hole spacing is getting smaller and smaller. The conventional process has higher and higher requirements for the tolerance and attachment accuracy of the appearance tape itself. In addition, because directly drilling holes in the insulating film will reduce the strength of the insulating film, the holes on the insulating film are prone to deformation after the photovoltaic module is laminated, which affects the transmission of current during use. Summary of the invention

[0004] The present application provides a photovoltaic module and a method for manufacturing the same, in order to solve the technical problems that the gap film has high lamination accuracy requirements and the holes on the insulating film are prone to deformation after the photovoltaic module is laminated.

[0005] According to one aspect of the present application, a photovoltaic module is provided, which includes a conductive backplane and a battery layer arranged in a stacked manner. The battery layer includes a plurality of battery strings arranged at intervals, and each of the battery strings includes a plurality of battery cells. The conductive backplane includes a conductive layer, and an insulating layer located between the conductive layer and the battery layer. The insulating layer is provided with a plurality of vias and includes an insulating film and a first gap film, the insulating film having a plurality of battery areas and at least one first gap area, each of the battery areas corresponds to one of the battery cells, and each of the first gap areas corresponds to a gap area between adjacent battery strings. The first gap film is arranged along the first gap area and at least partially covers the battery area, and at least part of the vias penetrate the first gap film and the corresponding battery area.

[0006] In an optional solution of the present application, the via hole set through the first gap film is a closed hole or a non-closed hole with a gap.

[0007] In an optional solution of the present application, the via hole set through the first gap membrane is a circular hole, a square hole or a long strip hole.

[0008] In an optional solution of the present application, on both sides of the first gap area, the spacing between adjacent vias on adjacent battery areas is D2, the width of the first gap film is d2, wherein d2 / D2 is 50% to 150%. Preferably, d2 / D2 is 100% to 150%.

[0009] In an optional solution of the present application, the first gap film includes a first adhesive layer and a second adhesive layer stacked, the first adhesive layer is bonded to the insulating film, and the second adhesive layer is bonded to the battery cell. The melting point of the first adhesive layer is lower than that of the second adhesive layer.

[0010] In an optional solution of the present application, the bonding width between the second bonding layer and the battery cell is greater than 0.3 mm.

[0011] In an optional solution of the present application, the plurality of battery cells are arranged at intervals, the insulating film further has a second gap region, the second gap region corresponds to the gap region between adjacent battery cells. The insulating layer further includes a second gap film, the second gap film is arranged along the second gap region.

[0012] In an optional solution of the present application, the via hole is not provided on the second gap film and the second gap area.

[0013] In an optional solution of the present application, on both sides of the second gap area, the spacing between adjacent vias on adjacent battery areas is D1, and the width of the second gap film is d1, wherein d1 / D1 is 0% to 100%. Preferably, d1 / D1 is 10% to 50%.

[0014] In an optional solution of the present application, part of the second gap film covers the first gap film.

[0015] According to another aspect of the present application, a method for manufacturing a photovoltaic module is provided, which includes manufacturing an insulating layer, manufacturing a conductive backplane, and manufacturing a photovoltaic module.

[0016] The method of making an insulating layer includes: providing an insulating film, and defining a battery area and a first gap area on the insulating film; setting a first gap film on the insulating film along the first gap area; and drilling holes in the battery area of ​​the insulating film and the first gap film.

[0017] The manufacturing of the conductive backplane includes: providing a conductive layer, and disposing the conductive layer on a side of the insulating layer away from the first gap film 22 .

[0018] The method for manufacturing a photovoltaic module comprises: arranging a plurality of battery strings of a battery layer on the conductive backplane, and making each battery sheet in the battery string correspond to one of the battery areas, and making the gap area between adjacent battery strings correspond to one of the first gap areas.

[0019] In an optional solution of the present application, before drilling holes in the battery area of ​​the insulating film and the first gap film, the manufacturing of the insulating layer further includes: determining a second gap area on the insulating film; and setting a second gap film on the insulating film along the second gap area.

[0020] In an optional solution of the present application, the method of punching holes in the battery area of ​​the insulating film and the first gap film is punching.

[0021] In an optional solution of the present application, after drilling holes in the battery area of ​​the insulating film and the first gap film, the manufacturing of the insulating layer further includes: determining a second gap area on the insulating film; and setting a second gap film on the insulating film along the second gap area.

[0022] In an optional scheme of the present application, the method of drilling holes in the battery area of ​​the insulating film and the first gap film is laser drilling. After laser drilling and before setting the second gap film on the insulating film, the manufacturing of the insulating layer also includes: using a scraper to remove waste on the surface of the insulating film and the first gap film.

[0023] In an optional solution of the present application, the manufacturing of the photovoltaic module further includes: when arranging multiple battery strings of the battery layer on the conductive backplane, the gap area between adjacent battery sheets in the battery string corresponds to one of the second gap areas.

[0024] In summary, the photovoltaic module and the manufacturing method thereof provided in the present application have at least the following beneficial effects:

[0025] Since the vias on the first gap membrane also penetrate the battery area of ​​the insulating film, the inner wall of the vias on the first gap membrane is equivalent to a double-layer structure, which enhances the strength of the vias on the first gap membrane. Therefore, after the photovoltaic module is laminarized, the holes on the first gap membrane are not easily deformed, so that the current in the battery cell can be transmitted to the conductive layer of the conductive backplane through the vias T on the first gap membrane, thereby improving the electrical connection reliability in the photovoltaic module and ensuring the transmission of current during the use of the photovoltaic module.

[0026] Furthermore, since at least part of the via holes on the insulating layer penetrate the first gap film and the corresponding battery area setting of the insulating film at the same time, no matter whether the first gap film deviates from the first gap area setting of the insulating film, the holes on the insulating layer will not be blocked by the first gap film. This not only prevents light leakage from the gaps between strings, but also reduces the bonding accuracy requirements of the first gap film on the insulating film and improves the yield of the insulating layer.

[0027] In addition, since the holes on the insulating layer are not blocked by the first gap membrane, the via holes on the first gap membrane can also play a positioning role when the battery cells are laid out, and are used to align and position the battery cells, thereby improving the subsequent battery cell layout positioning accuracy, thereby improving the electrical connection reliability between the electrical interconnection structure on the battery cell and the conductive layer, and avoiding the problem of electrical connection failure caused by deformation of the holes in this area. BRIEF DESCRIPTION OF THE DRAWINGS

[0028] In order to more clearly illustrate the specific implementation of the present application or the technical solutions in the prior art, the following briefly introduces the drawings required for use in the specific implementation or the prior art description. Obviously, the drawings described below are some implementations of the present application. For those skilled in the art, other drawings can be obtained based on these drawings without creative work.

[0029] Figure 1 A schematic diagram of a portion of the structure of a photovoltaic module provided in an embodiment of the present application;

[0030] Figure 2 A schematic diagram of the structure of an insulating layer provided in one embodiment of the present application;

[0031] Figure 3 for Figure 2 Schematic diagram of the structure of the insulating film;

[0032] Figure 4 A schematic diagram of the structure of an insulating layer provided in another embodiment of the present application;

[0033] Figure 5 A schematic diagram of the structure of an insulating layer provided in yet another embodiment of the present application;

[0034] Figure 6 for Figure 5 An enlarged view of the circled part in ;

[0035] Figure 7 for Figure 6 The local cross-section along line AA in ;

[0036] Figure 8 for Figure 6 A local cross-sectional view along line BB in ;

[0037] Fig. 9 A schematic diagram of the basic process of the method for manufacturing a photovoltaic module provided in an embodiment of the present application;

[0038] Fig.10 A schematic diagram of a process for manufacturing a photovoltaic module provided in a specific embodiment of the present application;

[0039] Fig.11 It is a schematic diagram of a process of manufacturing a photovoltaic module provided in another specific embodiment of the present application.

[0040] The reference numerals are as follows:

[0041] 100. Conductive back plate;

[0042] 10. Conductive layer; 20. Insulating layer; 21. Insulating film; 211. Battery region; 212. First gap region; 213. Second gap region; 22. First gap film; 23. Second gap film; 30. Substrate;

[0043] 200, battery layer; 210, battery cell;

[0044] T. Via. DETAILED DESCRIPTION

[0045] In order to make the above and other features and advantages of the present application more clear, the present invention is further described below in conjunction with the accompanying drawings. It should be understood that the specific embodiments given herein are for the purpose of explaining to those skilled in the art and are only exemplary and not restrictive.

[0046] In the description of this application, if there is a feature defined as "first" or "second" for descriptive purposes only, it cannot be understood as indicating or implying relative importance or implicitly indicating the number of the indicated technical features. Features defined as "first" or "second" may explicitly or implicitly include at least one of the defined features. If the description of "plurality" appears, the general meaning is to include at least two, such as two, three, etc., unless otherwise clearly and specifically defined.

[0047] In this application, unless otherwise clearly specified and limited, the terms such as "installed", "connected", "connected", "fixed" and so on should be understood in a broad sense. For example, it can be a fixed connection, a detachable connection, or an integrated connection; it can be a mechanical connection or an electrical connection, it can be a direct connection, or it can be an indirect connection through an intermediate medium, it can be the internal connection of two elements or the interaction relationship between two elements. For those skilled in the art, the specific meanings of the above terms in this application can be understood according to the specific circumstances.

[0048] In the description of the present application, if the terms "one embodiment", "some embodiments", "example", "specific example", or "some examples" appear, it means that the specific features, structures, materials or characteristics described in conjunction with the embodiment or example are included in at least one embodiment or example of the present application. In this specification, the schematic representations of the above terms do not necessarily refer to the same embodiment or example. Moreover, the specific features, structures, materials or characteristics described may be combined in any one or more embodiments or examples in a suitable manner. In addition, those skilled in the art may combine and combine the different embodiments or examples described in this specification and the features of the different embodiments or examples, without contradiction.

[0049] Figure 1 A schematic diagram of a portion of the structure of a photovoltaic module provided in an embodiment of the present application.

[0050] Reference Figure 1 The photovoltaic module provided in the present application at least includes a conductive back sheet 100 and a battery layer 200 which are stacked.

[0051] The conductive backplane 100 includes a conductive layer 10 and an insulating layer 20 located between the conductive layer 10 and the battery layer 200. The insulating layer 20 acts as an insulator between the conductive layer 10 and the battery layer 200. The conductive layer 10 can be directly integrated with the insulating layer 20 in a composite manner to form an integrated conductive backplane structure, which is convenient for direct use and can achieve the purpose of saving processes. Specifically, the conductive layer 10 can be a metal foil, such as a copper foil.

[0052] Furthermore, in order to encapsulate the raw and auxiliary materials of the components, protect the components, and isolate the busbars (or busbars), the conductive backplane 100 may also include a substrate 30. The substrate 30 may be a single-layer structure or a multi-layer composite structure. During the use of the photovoltaic module, the substrate 30 is in direct contact with the external environment, and it may be made of a material that is resistant to aging, insulation, and moisture.

[0053] The battery layer 200 includes a plurality of battery strings, which are spaced apart on a side of the insulating layer 20 away from the conductive layer 10. Two battery strings can be connected via a busbar (or busbar), and the plurality of battery strings can be connected in series, in parallel, or in series and parallel combination to realize current convergence output via a busbar (or busbar).

[0054] Each battery string includes a plurality of battery cells 210, and the plurality of battery cells 210 are connected in series through the conductive layer 10 to form a battery string. According to actual conditions, the plurality of battery cells 210 can be arranged at intervals or partially overlapped.

[0055] Figure 2This is a schematic diagram of the structure of an insulating layer provided in an embodiment of the present application. Figure 3 for Figure 2 Schematic diagram of the structure of the insulating film.

[0056] Reference Figure 2 and Figure 3 The insulating layer 20 is provided with a plurality of vias T, and the vias T are used to set conductive materials, so that the electrical interconnection structure on the battery cell 210 can be electrically connected to the conductive layer 10 through the conductive filler in the vias T, thereby connecting the plurality of battery cells 210 in each battery string in series through the conductive layer 10. The electrical interconnection structure can be a main grid or a thin grid on the battery cell, or a thickened section of the grid line itself, or a separately provided electrical connection portion, i.e., a PAD point, and other structures that can have an electrical connection function, which are not limited here.

[0057] Specifically, the insulating layer 20 includes an insulating film 21 and a first gap film 22 disposed on the side of the insulating film 21 facing the battery cell 210. The insulating film 21 has a plurality of battery regions 211 and at least one first gap region 212, each battery region 211 corresponds to a battery cell 210 and is located between the corresponding battery cell 210 and the conductive layer 10, and each first gap region 212 corresponds to a gap region between adjacent battery strings and is located between the gap region between the adjacent battery strings and the conductive layer 10. The first gap film 22 is disposed along the first gap region 212 and at least partially covers the battery region 211.

[0058] The gap region between adjacent battery strings is called an inter-string gap. After the battery layer 200 and the conductive backplane 100 are stacked, at least a portion of the first gap film 22 is located in the gap region between adjacent battery strings to prevent light leakage from the inter-string gap.

[0059] The number of battery areas 211 depends on the number of battery cells 210 in the photovoltaic module, and the number of first gap areas 212 depends on the number of battery strings in the photovoltaic module. Therefore, the positions and numbers of battery areas 211 and first gap areas 212 can be predetermined on the insulating film 21 according to the number of battery cells 210 in the photovoltaic module, the number of battery strings formed by the battery cells 210, and the spatial arrangement of the battery strings, and then the first gap film 22 can be set (such as by pasting) on ​​the insulating film 21 based on the first gap areas 212.

[0060] At least part of the vias T on the insulating layer 20 are arranged through the first gap film 22 and the battery area 211, that is, the part of the vias T is formed by simultaneously penetrating the first gap film 22 and the corresponding battery area 211. For example, part of the vias T on the insulating layer 20 is arranged through the first gap film 22 and the battery area 211 (that is, the part of the vias T is formed by simultaneously penetrating the first gap film 22 and the corresponding battery area 211), and part of the vias T is arranged through the battery area 211 (that is, the part of the vias T is formed only by penetrating the corresponding battery area 211). In other words, all the vias T are located on the battery area 211, only part of the vias T are simultaneously located on the first gap film 22, and no vias T are arranged in the first gap area 212.

[0061] Since the via T on the first gap film 22 is set to penetrate the battery area 211 of the insulating film 21 at the same time, the inner wall of the via T on the first gap film 22 is equivalent to having a double-layer structure, which enhances the strength of the via T on the first gap film 22. Therefore, after the photovoltaic module is laminarized, the hole on the first gap film 22 is not easy to deform, so that the current in the battery cell 210 can be transmitted to the conductive layer 10 of the conductive backplane 100 through the via T on the first gap film 22, thereby improving the electrical connection reliability in the photovoltaic module and further ensuring the transmission of current during the use of the photovoltaic module.

[0062] Furthermore, since at least part of the vias T on the insulating layer 20 penetrate the first gap film 22 and the corresponding battery area 211 of the insulating film 21 at the same time, no matter whether the first gap film 22 deviates from the first gap area 212 of the insulating film 21, the holes on the insulating layer 20 will not be blocked by the first gap film 22, thereby not only preventing light leakage from the gaps between strings, but also reducing the requirements for the fitting accuracy of the first gap film 22 on the insulating film 21 and improving the yield of the insulating layer 20.

[0063] In addition, since the holes on the insulating layer 20 are not blocked by the first gap membrane 22, the vias T on the first gap membrane 22 can also play a positioning role when the battery cells are laid out, and are used to align and position the battery cells 210, thereby improving the subsequent battery cell layout positioning accuracy, thereby improving the electrical connection reliability between the electrical interconnection structure on the battery cell 210 and the conductive layer 10, and avoiding the problem of electrical connection failure caused by deformation of the holes in this area.

[0064] Figure 4 A schematic structural diagram of an insulating layer provided in another embodiment of the present application.

[0065] Reference Figure 2 and Figure 4The vias T provided in the corresponding battery area 211 that penetrate the first gap film 22 and the insulating film 21 can be circular holes, square holes or long holes. Similarly, the vias T provided in the battery area 211 that penetrate only the insulating film 21 can also be circular holes, square holes or long holes.

[0066] The via hole T provided in the corresponding battery area 211 penetrating the first gap film 22 and the insulating film 21 may be a closed hole or a non-closed hole with a gap.

[0067] Here, a "closed hole" refers to a closed structure formed by connecting the ends of the cross-sectional profile of the hole. For example, the via T can be a closed circular hole (such as Figure 2 As shown), closed square holes or closed long strip holes (as shown Figure 4 shown).

[0068] "Non-closed hole with a notch" means that the ends of the cross-sectional profile of the hole are spaced apart and surrounded by a non-closed structure with a notch (also called an opening). For example, the via T can be a circular hole with a notch, a square hole with a notch, or a long strip hole with a notch.

[0069] It can be understood that the “circular hole with a notch” mentioned here refers to a circular hole that is missing a part and thus forms an approximately circular shape, rather than an absolutely circular hole.

[0070] In some embodiments, the first gap film 22 includes a first adhesive layer and a second adhesive layer stacked together, the first adhesive layer is bonded to the insulating film 21, and the second adhesive layer is bonded to the battery cell 210. In particular, since the first adhesive layer and the second adhesive layer are usually fixed by heating and melting, in order to avoid the second adhesive layer from melting in advance during the bonding process between the first adhesive layer and the insulating film 21, the melting point of the first adhesive layer needs to be lower than the melting point of the second adhesive layer.

[0071] The second adhesive layer is used to bond with the battery cell 210 . To prevent the first gap film 22 from warping after the second adhesive layer is bonded with the battery cell 210 , the bonding width between the second adhesive layer and the battery cell 210 is greater than 0.3 mm.

[0072] Such an arrangement can ensure that the second adhesive layer and the battery cell 210 have a sufficient bonding area, thereby ensuring the bonding strength between the two, thereby preventing the first gap film 22 from warping during use.

[0073] Reference Figure 2 and Figure 4, the multiple battery cells 210 in the battery string are arranged at intervals, and the insulating film 21 also has a second gap area 213, which corresponds to the gap area between adjacent battery cells 210 and is located between the gap area between the adjacent battery cells 210 and the conductive layer 10. The insulating layer 20 also includes a second gap film 23, which is arranged along the second gap area 213 and attached to the second gap area 213 and corresponds to the gap area between adjacent battery cells 210, and the second gap film 23 and the second gap area 213 are not provided with a via T.

[0074] The gap between adjacent battery cells 210 is called an inter-cell gap. After the battery layer 200 and the conductive backplane 100 are stacked, the second gap film 23 is entirely located in the gap region between adjacent battery strings to prevent light leakage from the inter-cell gap.

[0075] It should be noted that the first gap film 22 and the second gap film 23 can be a transparent film layer or a colored film layer, which can be selected according to the specific component. Furthermore, the first gap film 22 and the second gap film 23 can be a colored appearance tape or a reflective film, thereby achieving the purpose of beautifying the photovoltaic component, increasing the utilization rate of light and the power of the component. Of course, the first gap film 22 and the second gap film 23 can also be a composite structure of a colored appearance tape and a reflective film. This application does not specifically limit the materials and structures of the first gap film 22 and the second gap film 23.

[0076] Figure 5 A schematic structural diagram of an insulating layer provided in yet another embodiment of the present application.

[0077] Reference Figure 5 In the arrangement direction of the plurality of cells 210 in the cell string, the edge of the first gap film 22 can be aligned with the edge of the insulating film 21. This arrangement can increase the aesthetics of the photovoltaic module and prevent light leakage. Of course, in order to prevent the first gap film 22 and the insulating film 21 from wrinkling at the edge and generating bubbles, as well as to save film materials, in the arrangement direction of the plurality of cells 210 in the cell string, the edge of the insulating film 21 can also be arranged beyond the edge of the first gap film 22, such as Figure 2 and Figure 3As shown, that is, in the arrangement direction of the multiple battery cells 210 in the battery string, the edge of the first gap film 22 has a certain distance from the edge of the insulating film 21. Further, the first gap film 22 can be an appearance tape, and the distance between the edge of the first gap film 22 and the edge of the insulating film 21 can be set to be less than 15mm. At this time, the distance between the two can be covered by the frame of the photovoltaic module. Such a setting can save film materials and ensure aesthetics at the same time; further, the first gap film 22 can be a reflective film, and the distance between the edge of the first gap film 22 and the edge of the insulating film 21 can be set to be less than 100mm. Such a setting can save film materials, prevent the first gap film 22 and the insulating film 21 from wrinkling at the edge and avoid the generation of bubbles. At the same time, the reflective film can reflect the light passing through the gap of the battery string back for secondary use, so as to achieve the purpose of improving the efficiency of the photovoltaic module. Similarly, the second gap film 23 can also have the same design as the first gap 22 according to actual needs, that is, the edge of the second gap film 23 can be aligned with the edge of the insulating film 21, or the edge of the insulating film 21 can also exceed the edge of the second gap film 23, which will not be repeated here.

[0078] Furthermore, in order to prevent light leakage around the edges of the photovoltaic module, the insulating layer 20 may further include an edge film (not shown), which is disposed on the edges around the insulating film 21. Based on the provision of the edge film, the aesthetics of the photovoltaic module is further improved, which is particularly suitable for frameless photovoltaic module products.

[0079] Figure 6 for Figure 5 The enlarged image of the circled part in Figure 7 for Figure 6 The local section view along line AA in Figure 8 for Figure 6 A local cross-sectional view along line BB in FIG.

[0080] Reference Figure 6 , on both sides of the first gap area 212, the spacing between adjacent vias T on adjacent battery areas 211 is D2, the width of the first gap film 22 is d2, wherein d2 / D2 is 50% to 150%. For example, d2 / D2 can be 50%, 60%, 70%, 80%, 90%, 100%, 110%, 120%, 130%, 140%, 150%, etc.

[0081] By setting the value of d2 / D2 within the above range, the film material of the first gap film 22 can be saved. Regardless of whether the first gap film 22 is precisely attached to the first gap area 212 of the insulating film 21 or is skewed, the first gap film 22 can simultaneously prevent light leakage between the gaps between strings. On both sides of the first gap area 212, the edge vias of the battery area 211 close to the first gap area 212 correspond to the edge electrical interconnection structure on the battery cell 210, and the edge electrical interconnection structure on the battery cell 210 has a certain distance from the corresponding side of the battery cell 210. Therefore, the spacing D2 between adjacent vias T on adjacent battery areas 211 is greater than the corresponding string spacing (the string spacing is the spacing between the sides of the battery cells 210 in two adjacent battery strings). When d2 / D2 is set to 50% at the minimum, it can ensure that the width of d2 is greater than the string spacing, avoiding light leakage and saving film materials to the greatest extent. If it is less than 50%, light leakage may occur. When d2 / D2 is set to 150% at the maximum, the width d2 of the first gap film 22 is greater than the spacing D2 between adjacent vias T, and D2 is greater than the string spacing. Therefore, the width d2 of the first gap film 22 is much greater than the string spacing. With this setting, even if the first gap film 22 is attached to the insulating film 21 and there is a large skew, it can better prevent light leakage between the gaps between the strings. However, the ratio of the two should not be too large, otherwise the cost of the film material will increase.

[0082] Preferably, d2 / D2 is 100% to 150%. For example, d2 / D2 can be 100%, 105%, 110%, 115%, 120%, 125%, 130%, 135%, 140%, 145%, 150%, etc. By setting the value of d2 / D2 within the above range, the film material of the first gap film 22 can be saved to the greatest extent, while ensuring that the first gap film 22 can prevent light leakage between the gaps between strings. When d2 / D2 is set to be greater than or equal to 100%, at this time, according to the control accuracy of the process during actual bonding, closed holes, or non-closed holes with gaps, or both may appear on the first gap membrane 22 (in the case of skewed bonding). At this time, a large number of vias T can pass through the edges of the first gap membrane 22 and the battery area 211 at the same time, so that the inner wall of the via T on the first gap membrane 22 is equivalent to having a double-layer structure, which enhances the strength of the via T on the first gap membrane 22 and is not easy to deform. The via T on the first gap membrane 22 can play a positioning role in the layout of the battery cells, and is used to align and position the battery cells 210, thereby improving the subsequent battery cell layout positioning accuracy, thereby improving the electrical connection reliability between the electrical interconnection structure on the battery cell 210 and the conductive layer 10, and avoiding the problem of electrical connection failure due to deformation of the holes in this area. When d2 / D2 is set to be less than or equal to 150%, even if the first gap film 22 is skewed when attached to the insulating film 21, it can be ensured that the via (T) set through the first gap film (22) is a closed hole. The closed hole structure is more stable and not easy to deform, which greatly improves the electrical connection reliability between the electrical interconnection structure on the battery cell 210 and the conductive layer 10.

[0083] Exemplarily, the first gap membrane 22 completely covers the first gap area 212 and is partially set beyond the first gap area 212, and the portions exceeding the first gap area 212 on both sides respectively cover the portions of the battery area 211 corresponding to the adjacent battery strings, so as to set two rows of vias T on the first gap membrane 22, and D2 is the spacing between the two rows of vias T.

[0084] Reference Figure 6 , on both sides of the second gap region 213, the spacing between adjacent vias T on adjacent battery regions 211 is D1, the width of the second gap film 23 is d1, wherein d1 / D1 is 0% to 100%. For example, d1 / D1 can be 10%, 20%, 30%, 40%, 50%, 60%, 70%, 80%, 90%, 100%, etc.

[0085] By setting the value of d1 / D1 within the above range, the film material of the second gap film 23 can be saved. Regardless of whether the second gap film 23 is precisely attached to the second gap area 213 of the insulating film 21 or is skewed, the second gap film 23 can simultaneously prevent light leakage between the sheets. On both sides of the second gap area 213, the edge vias of the battery area 211 close to the second gap area 213 correspond to the end electrical interconnection structure on the battery sheet 210, and the end electrical interconnection structure on the battery sheet 210 has a large distance from the corresponding side of the battery sheet 210. Therefore, the distance D1 between adjacent vias T on adjacent battery areas 211 is relatively large and much larger than the corresponding sheet spacing (the sheet spacing is the spacing between the sides of two adjacent battery sheets 210). According to actual process requirements, the inter-cell spacing can be a negative spacing, zero, or a positive spacing. Therefore, when multiple battery cells 210 are spaced apart, that is, when the inter-cell spacing is greater than 0, the range of d1 / D1 is greater than 0, which can prevent light leakage between the cells. When d1 / D1 is 100% at maximum, the width d1 of the second gap film 23 is much larger than the inter-cell spacing. With this arrangement, even if the second gap film 23 is attached to the insulating film 21 and there is a large skew, light leakage between the cells can be better prevented.

[0086] Preferably, d1 / D1 is 10% to 50%. For example, d1 / D1 can be 10%, 15%, 20%, 25%, 30%, 35%, 40%, 45%, 50%, etc. Setting the value of d1 / D1 within the above range can save the film material of the second gap film 23 to the greatest extent, while ensuring that the second gap film 23 can prevent light leakage between the sheets. When d1 / D1 is set to a minimum of 10%, under the condition of good fitting accuracy, it can ensure that the width of d1 is greater than the sheet spacing, avoid light leakage, and save film material to the greatest extent; when d1 / D1 is a maximum of 50%, even in the case of skewness in the fitting, since the width of the second gap area 213 is much greater than the sheet spacing, it can better prevent light leakage between the sheets, while saving film material to the greatest extent.

[0087] Reference Figure 7 and Figure 8 , the second gap film 23 is partially covered on the first gap film 22. That is, the first gap film 22 is attached to the insulating film 21 before the second gap film 23.

[0088] Specifically, the insulating film 21 may be a rectangular structure, the first gap film 22 extends along the long side of the insulating film 21, and the second gap film 23 extends along the short side of the insulating film 21. During the bonding process, considering the feeding direction, the cost of the incoming materials, the flatness, and the matching of the equipment, the short side of the insulating film 21 is usually selected for feeding, so that it is convenient to bond the first gap film 22 along the long side of the insulating film 21; and after the first gap film 22 is bonded, the second gap film 23 is bonded along the short side of the insulating film 21, so that part of the second gap film 23 is covered on the first gap film 22, thereby improving the overall bonding efficiency of the first gap film 22 and the second gap film 23.

[0089] The photovoltaic module provided in the present application also includes a glass plate (not shown), which is arranged on the side of the multiple battery strings away from the insulating layer 20. The glass plate is laminated together with the multiple battery strings and the conductive backplane 100 through a packaging film to form the photovoltaic module of the present application.

[0090] It should be noted that the photovoltaic module provided in the present application is not limited to the above structure, and it may also include a frame arranged on the side of the glass plate away from the battery string, etc. Of course, other structures may also be provided, and the present application does not make specific limitations.

[0091] Fig. 9 A schematic diagram of the basic process flow of the method for manufacturing a photovoltaic module provided in an embodiment of the present application.

[0092] Reference Fig. 9 The method for manufacturing a photovoltaic module provided in the embodiment of the present application includes S1-S3.

[0093] S1, manufacturing an insulating layer 20. The manufacturing of the insulating layer 20 specifically includes: providing an insulating film 21, and defining a battery area 211 and a first gap area 212 on the insulating film 21; disposing a first gap film 22 on the insulating film 21 along the first gap area 212; and drilling holes in the battery area 211 and the first gap film 22 of the insulating film 21.

[0094] “Determining the battery area 211 and the first gap area 212 on the insulating film 21” means that according to the design of the component product (such as: version, battery cell / string arrangement and electrical interconnection, etc.), the structure, parameters and other requirements of the insulating film 21, the battery area 211 and the first gap area 212 can be defined by equipment or system, and the battery area 211 and the first gap area 212 can also be divided on the insulating film 21.

[0095] Specifically, along the first gap region 212, the first gap film 22 can be attached to the first gap region 212 of the insulating film 21 by means of heat-compression bonding. After attachment, the first gap region 212 can be completely covered by the first gap film 22, or partially covered by the first gap film 22, and only the portion of the battery region 211 close to the first gap region 212 is covered by the first gap film 22.

[0096] S2, manufacturing a conductive backplane 100. The manufacturing of the conductive backplane 100 specifically includes: providing a conductive layer 10, and arranging the conductive layer 10 on a side of the insulating layer 20 away from the first gap film 22.

[0097] S3, making a photovoltaic module. The making of the photovoltaic module specifically includes: arranging a plurality of battery strings of the battery layer on the conductive backplane 100, and making each battery cell 210 in the battery string correspond to a battery area 211, and making the gap area between adjacent battery strings correspond to a first gap area 212.

[0098] In the manufacturing method of the photovoltaic module in this embodiment, an integrated insulating layer 20 is obtained by first laminating the first gap film 22 on the first gap area 212 of the insulating film 21 and then punching holes on the insulating film 21 and the first gap film 22. This improves the yield of the insulating layer 20 and avoids the problem of gap film blockage caused by punching holes after laminating the film.

[0099] After punching, since the via T on the first gap area 212 is arranged to penetrate the first gap film 22 and the battery area 211 of the insulating film 21, the inner wall of the via T on the first gap film 22 is equivalent to a double-layer structure, which enhances the strength of the via T on the first gap film 22. Therefore, after the lamination of the photovoltaic module, the via T on the first gap film 22 is not easy to deform, thereby improving the reliability of the electrical connection in the photovoltaic module, and further ensuring the transmission of current during the use of the photovoltaic module.

[0100] Fig.10 It is a schematic diagram of the process of manufacturing a photovoltaic module provided in a specific embodiment of the present application.

[0101] Reference Fig.10 The method for manufacturing a photovoltaic module provided in the embodiment of the present application includes S110-S160.

[0102] S110 , providing an insulating film 21 , and defining a battery region 211 , a first gap region 212 , and a second gap region 213 on the insulating film 21 .

[0103] “Determining the battery area 211, the first gap area 212, and the second gap area 213 on the insulating film 21” means that according to the design of the component product (such as: version, battery cell / string arrangement and electrical interconnection, etc.), the structure, parameters and other requirements of the insulating film 21, the battery area 211, the first gap area 212, and the second gap area 213 can be defined by equipment or system, and the battery area 211, the first gap area 212, and the second gap area 213 can also be divided on the insulating film 21.

[0104] S120, disposing the first gap film 22 on the insulating film 21 along the first gap region 212. For example, the first gap film 22 may be attached to the first gap region 212 of the insulating film 21 by thermal compression bonding.

[0105] Specifically, after lamination, the first gap region 212 may be completely covered by the first gap film 22 or partially covered by the first gap film 22 , while only the portion of the battery region 211 close to the first gap region 212 is covered by the first gap film 22 .

[0106] S130 , performing laser drilling on the battery region 211 of the insulating film 21 and the first gap film 22 .

[0107] After the first gap film 22 is attached to the first gap area 212 of the insulating film 21, the insulating film 21 with the first gap film 22 is moved as a whole to the equipment corresponding to the hole opening process for processing of the via T, so that the via T close to the first gap area 212 can penetrate the first gap film 22 and the corresponding battery area 211 of the insulating film 21 attached to the first gap film 22, while the via T at other positions is only set to penetrate the battery area 211 of the insulating film 21.

[0108] Since the punching process is performed after the first gap film 22 is bonded to the first gap area 212 of the insulating film 21, regardless of whether the first gap film 22 is precisely bonded to the first gap area 212 of the insulating film 21 or is skewed, the vias T on the first gap film 22 are all set to penetrate the first gap film 22 and the corresponding battery area 211 of the insulating film 21. This not only improves the structural strength of the vias T near the first gap area 212, but also the holes on the insulating layer 20 are not blocked by the first gap film 22, which not only reduces the bonding accuracy requirements of the first gap film 22 on the insulating film 21, but also helps to improve the yield of the insulating layer 20.

[0109] S140 , disposing a second gap film 23 on the insulating film 21 along the second gap region 213 to obtain the insulating layer 20 .

[0110] After the drilling process is performed on the insulating film 21 and the first gap film 22 , the second gap film 23 is attached to the second gap area 213 of the insulating film 21 to obtain an integrated insulating layer 20 , which facilitates the subsequent laying of the insulating layer 20 as a whole on the conductive layer 10 .

[0111] S150 , providing a conductive layer 10 , and disposing the conductive layer 10 on a side of the insulating layer 20 away from the first gap film 22 , to obtain a conductive backplane 100 .

[0112] S160, multiple battery strings of the battery layer are arranged on the conductive backplane 100, and each battery cell 210 in the battery string corresponds to a battery area 211, the gap area between adjacent battery strings (i.e., the gap between strings) corresponds to a first gap area 212, and the gap area between adjacent battery cells 210 (i.e., the gap between cells) corresponds to a second gap area 213, so as to prepare the photovoltaic module of the present application.

[0113] Among them, in a state where multiple battery strings are not connected, based on the positions of the first gap area 212 and the second gap area 213, multiple battery strings and multiple battery cells 210 in each battery string can be set at corresponding positions on the insulating layer 20, and then electrically connected to the conductive layer 10 through the conductive material in the via T on the insulating layer 20, so as to connect the multiple battery cells 210 in each battery string in series, and connect the multiple battery strings in series, in parallel, or in series and in parallel. In addition, after the multiple battery strings in the battery layer are set on the conductive backplane 100, the photovoltaic module of the present application can be laminated to obtain the final photovoltaic module product.

[0114] Therefore, in the manufacturing method of the photovoltaic module in this embodiment, an integrated integrated insulating layer 20 is obtained by first setting the first gap film 22 on the first gap area 212 of the insulating film 21, then punching holes on the insulating film 21 and the first gap film 22, and finally setting the second gap film 23 on the second gap area 213 of the insulating film 21. This improves the yield of the insulating layer 20 and avoids the problem of gap film blockage caused by punching holes after film pasting.

[0115] Moreover, after punching, since the via T on the first gap area 212 is arranged to penetrate the first gap film 22 and the battery area 211 of the insulating film 21, the inner wall of the via T on the first gap film 22 is equivalent to having a double-layer structure, which enhances the strength of the via T on the first gap film 22. Therefore, after the lamination of the photovoltaic module, the hole on the first gap film 22 is not easy to deform, thereby improving the reliability of the electrical connection in the photovoltaic module, and further ensuring the transmission of current during the use of the photovoltaic module.

[0116] Furthermore, after laser drilling and before disposing the second gap film 23 on the second gap region 213 of the insulating film 21 , the photovoltaic module manufacturing method of the present application further includes: removing waste on the surface of the insulating film 21 and the first gap film 22 by using a scraper.

[0117] Since laser drilling on the battery area 211 of the insulating film 21 and the first gap film 22 will generate waste materials such as hair scraps, and the waste materials will remain on the surface of the insulating film 21 and the first gap film 22, the present application uses a scraper to remove the waste materials on the surface of the insulating film 21 and the first gap film 22 after laser drilling and before setting the second gap film 23 on the second gap area 213 of the insulating film 21, which can ensure that the second gap film 23 will not be scratched when removing the waste materials, thereby improving the yield of the insulating layer 20. At the same time, since the laser + scraper process is simple and the process cost is low, it helps to reduce the preparation cost of photovoltaic modules.

[0118] Fig.11 It is a schematic diagram of a process of manufacturing a photovoltaic module provided in another specific embodiment of the present application.

[0119] Reference Fig.11 The method for manufacturing a photovoltaic module provided in the embodiment of the present application includes S210-S260.

[0120] S210 , providing an insulating film 21 , and defining a battery region 211 , a first gap region 212 , and a second gap region 213 on the insulating film 21 .

[0121] S220 , a first gap film 22 is disposed on the insulating film 21 along the first gap region 212 .

[0122] S230 , a second gap film 23 is disposed on the insulating film 21 along the second gap region 213 .

[0123] S240 , punching and punching are performed on the battery area 211 of the insulating film 21 and the first gap film 22 to obtain the insulating layer 20 .

[0124] S250 , providing a conductive layer 10 , and disposing the conductive layer 10 on a side of the insulating layer 20 away from the first gap film 22 , to obtain a conductive backplane 100 .

[0125] S260, multiple battery strings of the battery layer are arranged on the conductive backplane 100, and each battery cell 210 in the battery string corresponds to a battery area 211, the gap area between adjacent battery strings 30 corresponds to a first gap area 212, and the gap area between adjacent battery cells 210 corresponds to a second gap area 213, so as to prepare the photovoltaic module of the present application.

[0126] In the manufacturing method of the photovoltaic module in this embodiment, an integrated integrated insulating layer 20 is obtained by first setting a first gap film 22 on the first gap area 212 of the insulating film 21, then setting a second gap film 23 on the second gap area 213 of the insulating film 21, and finally punching and punching on the battery area 211 of the insulating film 21 and the first gap film 22. This improves the yield of the insulating layer 20 and avoids the problem of gap film blockage caused by punching after film pasting.

[0127] Moreover, after punching, since the via T close to the first gap area 212 passes through the first gap film 22 and the battery area 211 of the insulating film 21, the inner wall of the via T on the first gap film 22 is equivalent to having a double-layer structure, which enhances the strength of the via T on the first gap film 22. Therefore, after the lamination of the photovoltaic module, the hole on the first gap film 22 is not easy to deform, thereby improving the reliability of the electrical connection in the photovoltaic module, and further ensuring the transmission of current during the use of the photovoltaic module.

[0128] In addition, since punching is performed by punching, the purpose of removing waste can be achieved directly while punching, thus eliminating the need for additional waste removal processes, which helps to improve the preparation efficiency of photovoltaic modules.

[0129] Although the embodiments of the present application have been shown and described above, it can be understood that the above embodiments are exemplary and cannot be understood as limitations on the present application. Those skilled in the art can change, modify, replace and modify the above embodiments within the scope of the present application.

Claims

1. A photovoltaic module, characterized in that: It comprises a conductive back plate (100) and a battery layer (200) which are stacked; The battery layer (200) comprises a plurality of battery strings arranged at intervals, and each of the battery strings comprises a plurality of battery cells (210); The conductive backplane (100) comprises a conductive layer (10), and an insulating layer (20) located between the conductive layer (10) and the battery layer (200); The insulating layer (20) is provided with a plurality of via holes (T) and comprises an insulating film (21) and a first gap film (22), the insulating film (21) having a plurality of battery regions (211) and at least one first gap region (212), each of the battery regions (211) corresponding to one of the battery cells (31), and each of the first gap regions (212) corresponding to a gap region between adjacent battery strings; The first gap film (22) is arranged along the first gap area (212) and at least partially covers the battery area (211), and at least part of the vias (T) are arranged through the first gap film (22) and the corresponding battery area (211).

2. The photovoltaic module according to claim 1, characterized in that: The via hole (T) arranged through the first gap film (22) is a closed hole or a non-closed hole with a gap.

3. The photovoltaic module according to claim 1, characterized in that: The via hole (T) arranged through the first gap film (22) is a circular hole, a square hole or a long strip hole.

4. The photovoltaic module according to claim 1, characterized in that: On both sides of the first gap region (212), the spacing between adjacent vias (T) on adjacent battery regions (211) is D2, the width of the first gap film (22) is d2, wherein d2 / D2 is 50% to 150%; Preferably, d2 / D2 is 100% to 150%.

5. The photovoltaic module according to claim 1, characterized in that: The first gap film (22) comprises a first adhesive layer and a second adhesive layer which are stacked, the first adhesive layer being bonded to the insulating film (21), and the second adhesive layer being bonded to the battery cell (210); The melting point of the first adhesive layer is lower than the melting point of the second adhesive layer.

6. The photovoltaic module according to claim 5, characterized in that: The bonding width between the second bonding layer and the battery cell (210) is greater than 0.3 mm.

7. The photovoltaic module according to any one of claims 1 to 6, characterized in that: The plurality of battery cells (210) are arranged at intervals, the insulating film (21) further comprises a second gap region (213), and the second gap region (213) corresponds to a gap region between adjacent battery cells (31); The insulating layer (20) further comprises a second gap film (23), wherein the second gap film (23) is arranged along the second gap region (213).

8. The photovoltaic module according to claim 7, characterized in that: The via hole (T) is not provided on the second gap film (23) and the second gap area (213).

9. The photovoltaic module according to claim 7, characterized in that: On both sides of the second gap region (213), the spacing between adjacent vias (T) on adjacent battery regions (211) is D1, and the width of the second gap film (23) is d1, wherein d1 / D1 is 0% to 100%; Preferably, d1 / D1 is 10% to 50%.

10. The photovoltaic module according to claim 7, characterized in that: Part of the second gap film (23) covers the first gap film (22).

11. A method for manufacturing a photovoltaic module, characterized in that: include: Manufacturing an insulating layer (20), comprising: providing an insulating film (21), and determining a battery area (211) and a first gap area (212) on the insulating film (21); arranging a first gap film (22) on the insulating film (21) along the first gap area (212); and drilling holes in the battery area (211) of the insulating film (21) and the first gap film (22); Manufacturing a conductive backplane (100), comprising: providing a conductive layer (10), and arranging the conductive layer (10) on a side of the insulating layer (20) away from the first gap film (22); The photovoltaic module is manufactured, comprising: arranging a plurality of battery strings of a battery layer on the conductive back plate (100), and making each battery sheet (210) in the battery string correspond to one of the battery areas (211), and making the gap area between adjacent battery strings correspond to one of the first gap areas (212).

12. The method for manufacturing a photovoltaic module according to claim 11, characterized in that: Before drilling holes in the battery area (211) of the insulating film (21) and the first gap film (22), the manufacturing of the insulating layer (20) further includes: Defining a second gap region (213) on the insulating film (21); A second gap film (23) is provided on the insulating film (21) along the second gap region (213).

13. The method for manufacturing a photovoltaic module according to claim 12, characterized in that: The method of punching holes in the battery area (211) of the insulating film (21) and the first gap film (22) is punching.

14. The method for manufacturing a photovoltaic module according to claim 11, characterized in that: After drilling holes in the battery area (211) of the insulating film (21) and the first gap film (22), the manufacturing of the insulating layer (20) further includes: Defining a second gap region (213) on the insulating film (21); A second gap film (23) is provided on the insulating film (21) along the second gap region (213).

15. The method for manufacturing a photovoltaic module according to claim 14, characterized in that: The method of drilling holes in the battery area (211) of the insulating film (21) and the first gap film (22) is laser drilling; After laser drilling and before providing a second gap film (23) on the insulating film (21), the manufacturing of the insulating layer (20) further comprises: using a scraper to remove waste materials on the surface of the insulating film (21) and the first gap film (22).

16. The method for manufacturing a photovoltaic module according to claim 12 or 14, characterized in that: The manufacturing of the photovoltaic module also includes: when arranging a plurality of battery strings of the battery layer on the conductive back plate (100), the gap area between adjacent battery sheets (210) in the battery string corresponds to one of the second gap areas (213).

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