Photovoltaic module laminating method and photovoltaic module

Abstract

The invention discloses a photovoltaic module laminating method and a photovoltaic module, and the photovoltaic module laminating method comprises the steps: placing a laminated frameless photovoltaic module into a cavity of a laminating machine, and carrying out the lamination at a first pressure; after lamination is finished, whether material blockage occurs is judged, and if yes, discharging is not conducted, and pressure maintaining is conducted through second pressure; if not, discharging; wherein the second pressure is smaller than the first pressure. The second pressure during pressure maintaining is smaller than the first pressure during lamination, the pressure applied to the glass edge of the frameless photovoltaic module is reduced, the purpose of relieving inward movement (inward shrinkage) of the battery strings on the edge is achieved, and the parallel-series problem during lamination of the frameless photovoltaic module is solved.

Description

Technical Field

[0001] The present invention relates to the photovoltaic field, and in particular to a photovoltaic component lamination method and a photovoltaic component. Background Art

[0002] Solar photovoltaic modules, also known as solar panels, are the core of solar power generation systems. Their function is to convert solar energy into electrical energy, or to store it in batteries, or to drive loads. Single solar cells cannot be used directly as power sources. To use them as power sources, several single cells must be connected in series or parallel and tightly packaged into modules. The packaging into modules must be laminated, so the lamination process is a key step in module production and is indispensable.

[0003] Currently, the most advanced lamination process method is frameless lamination + stewing pot pressure holding; frameless lamination means that the edge press frame is eliminated during the component lamination process, and the components are directly put into the laminator cavity for the lamination process; stewing pot pressure holding means that when blockage occurs and the components in the lamination cavity cannot be discharged in time, the lamination cavity will continue to maintain the lamination pressure without opening the lid, that is, the pressure holding pressure will continue to maintain the maximum set pressure of the lamination, which can eliminate the problem of recoil bubbles when the stewing pot lid is opened for double-glass component lamination.

[0004] Advantages of frameless lamination process: The placement and removal of edge press frames require human intervention. Eliminating the edge press frames can not only directly eliminate the lamination manpower configuration and reduce manufacturing costs, but also the laminator component feeding can be directly started continuously without the need for personnel tracking and confirmation, ensuring maximum production capacity release.

[0005] Disadvantages of frameless lamination process: In the frameless lamination process, the adhesive sheet will directly exert pressure on the edge of the component glass. When a hot pot occurs, the outer battery strings will move inward and cause parallel connection problems, affecting the quality of the component products.

[0006] In view of this, it is necessary to provide an improved photovoltaic module lamination method and photovoltaic module to solve the above technical problems. Summary of the invention

[0007] The present invention aims to solve at least one of the technical problems existing in the prior art and provide a photovoltaic module lamination method and a photovoltaic module.

[0008] In order to achieve one of the above-mentioned invention objects, the present invention adopts the following technical solution:

[0009] A photovoltaic module lamination method comprises the following steps:

[0010] placing the stacked frameless photovoltaic modules into a chamber of a laminator and laminating them at a first pressure;

[0011] After lamination is completed, determine whether there is material blockage, if so, do not discharge the material and maintain the pressure at the second pressure; if not, discharge the material;

[0012] Wherein, the second pressure is lower than the first pressure.

[0013] Furthermore, the first pressure is -25Kpa to -35Kpa, and the second pressure is -50Kpa to -80Kpa.

[0014] Furthermore, the chamber of the laminator includes an upper chamber and a lower chamber separated by a rubber plate. The frameless photovoltaic module is placed in the lower chamber, the lower chamber is evacuated to a vacuum state and the evacuation is continued, and gas is filled into the upper chamber to a first pressure so that the rubber plate applies pressure to the frameless photovoltaic module.

[0015] Furthermore, filling the upper chamber with gas is divided into three stages: the first stage: the pressure is -65Kpa~-75Kpa, and the time is 55s~65s; the second stage: the pressure is -45Kpa~-55Kpa, and the time is 55s~65s; the third stage: the pressure is -25Kpa~-35Kpa, and the time is 55s~65s, wherein the pressure of the third stage is the first pressure.

[0016] Furthermore, if material blockage occurs, the first pressure is first released, and then the second pressure is applied to maintain the pressure.

[0017] Furthermore, the gas in the upper chamber is first released to a vacuum, and the evacuation of the lower chamber is stopped simultaneously; then the lower chamber is evacuated, and the upper chamber is filled with gas to the second pressure.

[0018] Furthermore, if there is material blockage, the pressure of the upper chamber is reduced from the first pressure to the second pressure.

[0019] Furthermore, during the lamination and pressure holding stages, the heating temperature of the heating plate is 120°C to 150°C.

[0020] Furthermore, after the blocking material is cleared, the cover is opened and the material is discharged.

[0021] The present invention also provides a photovoltaic module obtained by laminating using the photovoltaic module laminating method.

[0022] The beneficial effect of the present invention is that in the photovoltaic module lamination method of the present invention, the second pressure is less than the first pressure, that is, the pressure during pressure holding is less than the pressure during lamination, thereby reducing the pressure applied by the rubber sheet to the glass edge of the frameless photovoltaic module, so as to achieve the purpose of slowing down the inward movement (shrinkage) of the battery string at the edge, and solve the problem of parallel string when laminating frameless photovoltaic modules. BRIEF DESCRIPTION OF THE DRAWINGS

[0023] Figure 1 It is a structural schematic diagram of a laminator;

[0024] Figure 2 Schematic diagram of the force exerted by the adhesive sheet on the photovoltaic module during the lamination process, (a) is a framed photovoltaic module, and (b) is a frameless photovoltaic module;

[0025] Figure 3 The figure is a flow chart of a photovoltaic module lamination method according to a preferred embodiment of the present invention.

[0026] Among them, 100-laminator, 1-base, 2-upper cover, 3-rubber plate, 4-upper chamber, 5-lower chamber, 6-edge pressing frame. DETAILED DESCRIPTION

[0027] The present invention will be described in detail below in conjunction with the specific embodiments shown in the accompanying drawings. However, these embodiments do not limit the present invention, and any structural, methodological, or functional changes made by a person skilled in the art based on these embodiments are all within the scope of protection of the present invention.

[0028] In the various drawings of the present invention, for the convenience of illustration, some sizes of structures or parts are exaggerated relative to other structures or parts, and thus, they are only used to illustrate the basic structure of the subject matter of the present invention.

[0029] like Figure 1 As shown, a laminator 100 for laminating photovoltaic modules M is shown. The laminator 100 mainly includes a base 1, an upper cover 2 covering the base 1, an exhaust component (not shown), and an inflation component (not shown).

[0030] The base 1 is used to place the photovoltaic module M to be laminated, and a heating component is provided on the base 1 to heat the photovoltaic module M, melt the adhesive film and cross-link it, and bond the photovoltaic cells, glass, etc. together.

[0031] The upper cover 2 forms a chamber with the base 1. Specifically, a rubber plate 3 is provided inside the upper cover 2, and the rubber plate 3 and the top of the upper cover 2 form an upper chamber 4, and when the upper cover 2 is buckled on the base 1, a lower chamber 5 is formed between the rubber plate 3 and the base 1, that is, the rubber plate 3 divides the chamber of the laminator 100 into a closed upper chamber 4 and a lower chamber 5.

[0032] The exhaust assembly includes a first exhaust assembly connected to the upper chamber 4 and a second exhaust assembly connected to the lower chamber 5, and the charging assembly is connected to the upper chamber 4 to charge the upper chamber 4 with gas of a predetermined pressure. The rubber sheet 3 is formed of a high temperature resistant and ductile deformable soft material, and can be deformed under the pressure of the upper chamber 4 and the lower chamber 5 to apply pressure to the photovoltaic module M below.

[0033] During lamination, the photovoltaic module M is placed on the base 1 and the upper cover 2 is buckled. At this time, the photovoltaic module M is located in the lower chamber 5. The lower chamber 5 is evacuated to a vacuum state (-100Kpa) by the second vacuum assembly and the evacuation is continued; the heating assembly is started to heat the photovoltaic module M; and the upper chamber 4 is inflated by the air pump, so that the rubber sheet 3 is deformed and bulges downward to apply pressure to the photovoltaic module M below.

[0034] The inventors have found that: Figure 2 As shown in (a), for a photovoltaic module M with a frame, the edge pressing frame 6 is usually about 1 mm higher than the module. Therefore, when the pressure applied after the adhesive sheet 3 is deformed during the lamination process, it will be blocked by the edge pressing frame 6, and the pressure will not be directly applied to the edge of the photovoltaic module M. The problem of parallel connection will not occur for a long time. Figure 2 As shown in (b), for the frameless photovoltaic module M', the rubber sheet 3 is deformed when the upper chamber 4 is inflated during the lamination process, which directly applies pressure F to the edge of the frameless photovoltaic module M'. The pressure F applied at the edge is decomposed into a force component F1 that directly applies force to the inside of the module and a downward force component F2. Under the action of the force component F1, the battery strings at the edge may move inward and become parallel.

[0035] The present invention provides a photovoltaic module lamination method, which mainly prevents the battery strings of the frameless photovoltaic module M' from being paralleled by improving the pressure-maintaining process during the material-blocking stewing pot.

[0036] The photovoltaic module lamination method of the present invention comprises the following steps:

[0037] Putting the stacked frameless photovoltaic modules M' into a laminator 100 and laminating them at a first pressure;

[0038] After lamination is completed, determine whether there is material blockage. If so, do not discharge the material and maintain the pressure at the second pressure; if not, discharge the material.

[0039] The stacked frameless photovoltaic module M' includes a back plate, a back film, a battery string, a front film, and a cover plate, but does not include an edge frame 6. In a single-sided photovoltaic module, the back plate is opaque and the cover plate is tempered glass; in a double-sided photovoltaic module, both the back plate and the cover plate are tempered glass.

[0040] The frameless photovoltaic module M' is placed in the lower chamber 5 of the laminator 100, and the lower chamber 5 is evacuated into a vacuum state (-100Kpa) by the second vacuum assembly and the vacuum is continuously evacuated; gas is filled into the upper chamber 4 to a first pressure by an air pump, and the rubber sheet 3 bends downward under the first pressure to apply pressure to the frameless photovoltaic module M' in the lower chamber 5 to achieve lamination.

[0041] Preferably, filling the upper chamber 4 with gas is divided into three stages: the first stage: the pressure is -65Kpa to -75Kpa, and the time is 55s to 65s; the second stage: the pressure is -45Kpa to -55Kpa, and the time is 55s to 65s; the third stage: the pressure is -25Kpa to -35Kpa, and the time is 55s to 65s.

[0042] The pressure is increased step by step in stages, which can prevent the movement of the adhesive film and further prevent the movement of the battery cell. The first pressure in this article refers to the pressure at the end of lamination, that is, the pressure in the third stage.

[0043] In a specific embodiment, in the first stage, the pressure is -70 Kpa and the time is 60 s; in the second stage, the pressure is -50 Kpa and the time is 60 s; in the third stage, the pressure is -30 Kpa and the time is 60 s.

[0044] After lamination, if material blocking occurs, a simmering pot is required to maintain pressure. The second pressure of the present invention is less than the first pressure, that is, the pressure during pressure maintenance is less than the pressure during lamination, which reduces the pressure applied by the adhesive sheet 3 to the glass edge of the frameless photovoltaic module M', so as to achieve the purpose of slowing down the inward movement (inward contraction) of the battery string at the edge, and solves the problem of parallel connection during lamination of the frameless photovoltaic module M'.

[0045] Preferably, the holding pressure setting value can be edited independently, and the second pressure is -50Kpa to -80Kpa, preferably -50Kpa. Under this pressure, the film can be prevented from bubbling and the edge battery string can be prevented from moving inward.

[0046] In one embodiment, if the material is blocked, the first pressure is first released, and then the second pressure is applied to maintain the pressure. Specifically, the upper chamber 4 is first depressurized to vacuum, and then filled with gas to the second pressure, interrupting the continuous pressure of the final stage of lamination and the pressure of the pressure maintenance stage, so that the pressure maintenance pressure intervenes alone, that is, the pressure of the final stage of lamination will not continue to the pressure maintenance stage, effectively ensuring that the battery strings at the edge do not move inward.

[0047] Furthermore, when the gas in the upper chamber 4 is released to a vacuum, the evacuation of the lower chamber 5 is stopped simultaneously; then the lower chamber 5 is evacuated, and the upper chamber 4 is filled with gas to the second pressure.

[0048] In another embodiment, when blocking, the first pressure is directly reduced to the second pressure for pressure maintenance, which also interrupts the high pressure in the last stage of lamination and continues to the pressure maintenance stage, and reduces one inflation to avoid film flow.

[0049] In addition, during the lamination and pressure holding stages, the heating temperature of the heating plate is controlled at 120° C. to 150° C. to ensure that the adhesive film is melted and cross-linked, and the layers are bonded together.

[0050] Furthermore, the photovoltaic module lamination method further comprises: after the blocking material is removed, the cover is opened and the material is discharged.

[0051] If the pressure maintenance reaches the preset time and the blockage is not removed, the blockage needs to be removed manually in time to avoid the pressure maintenance time being too long. In this embodiment, the preset time is 30 minutes to 2 hours.

[0052] The photovoltaic module lamination method of the present invention is described in detail below using a specific embodiment.

[0053] Process ①: Laying down frameless photovoltaic modules M';

[0054] Process ②: The frameless photovoltaic module M' enters the lower chamber 5 for lamination operation, the first stage: the pressure is -70Kpa, the time is 60s; the second stage: the pressure is -50Kpa, the time is 60s; the third stage: the pressure is -30Kpa, the time is 60s;

[0055] Process ③: After the component lamination is completed, the material is not discharged, the lid is not opened, and the material is blocked and stewed in the pot;

[0056] Process ④: The holding pressure is intervened separately, and the holding pressure range is set to -50Kpa. Specifically, after the lamination is completed → the cover is not opened, the upper chamber 4 is evacuated to a vacuum state, and the lower chamber 5 stops evacuating → the upper chamber 4 is inflated and pressurized to the second pressure value again, and the lower chamber 5 is evacuated → the holding pressure operation is performed according to the second pressure.

[0057] process ⑤ : After the pressure maintenance is completed, the cover is opened after inflation, and the components in the laminator 100 are discharged.

[0058] In this embodiment, the pressure holding test is continued for 0.5 h without any parallel connection phenomenon.

[0059] In summary, compared with the method of maintaining pressure with maximum pressure in the prior art, the second pressure of the present invention is less than the first pressure, that is, the pressure during pressure maintenance is less than the pressure during lamination, thereby reducing the pressure applied by the rubber sheet 3 on the glass edge of the frameless photovoltaic module M', so as to achieve the purpose of slowing down the inward movement (shrinkage) of the battery string at the edge, and solve the problem of parallel connection during lamination of the frameless photovoltaic module M'.

[0060] It should be understood that although this specification is described according to implementation modes, not every implementation mode contains only one independent technical solution. This description of the specification is only for the sake of clarity. Those skilled in the art should regard the specification as a whole. The technical solutions in each implementation mode may also be appropriately combined to form other implementation modes that can be understood by those skilled in the art.

[0061] The series of detailed descriptions listed above are only specific descriptions of feasible implementation methods of the present invention. They are not intended to limit the scope of protection of the present invention. Any equivalent implementation methods or changes that do not deviate from the technical spirit of the present invention should be included in the scope of protection of the present invention.

Claims

1. A photovoltaic module lamination method, characterized in that: The steps include: placing the stacked frameless photovoltaic modules into a chamber of a laminator and laminating them at a first pressure; After lamination is completed, determine whether there is material blockage, if so, do not discharge the material and maintain the pressure at the second pressure; if not, discharge the material; Wherein, the second pressure is lower than the first pressure.

2. The photovoltaic module lamination method according to claim 1, characterized in that: The first pressure is -25Kpa to -35Kpa, and the second pressure is -50Kpa to -80Kpa.

3. The photovoltaic module lamination method according to claim 1, characterized in that: The chamber of the laminator includes an upper chamber and a lower chamber separated by a rubber plate. The frameless photovoltaic module is placed in the lower chamber, the lower chamber 5 is evacuated to a vacuum state and the evacuation is continued, and gas is filled into the upper chamber to a first pressure so that the rubber plate applies pressure to the frameless photovoltaic module.

4. The photovoltaic module lamination method according to claim 3, characterized in that: Filling the upper chamber with gas is divided into three stages: the first stage: the pressure is -65Kpa~-75Kpa, and the time is 55s~65s; the second stage: the pressure is -45Kpa~-55Kpa, and the time is 55s~65s; the third stage: the pressure is -25Kpa~-35Kpa, and the time is 55s~65s, wherein the pressure of the third stage is the first pressure.

5. The photovoltaic module lamination method according to claim 3 or 4, characterized in that: If material blockage occurs, the first pressure is first released, and then the second pressure is applied to maintain the pressure.

6. The photovoltaic module lamination method according to claim 5, characterized in that: First, the gas in the upper chamber is released to a vacuum, and the vacuuming of the lower chamber is stopped simultaneously; then, the lower chamber is vacuumed, and the upper chamber is filled with gas to the second pressure.

7. The photovoltaic module lamination method according to claim 3 or 4, characterized in that: If the material is blocked, the pressure of the upper chamber is reduced from the first pressure to the second pressure.

8. The photovoltaic module lamination method according to claim 7, characterized in that: During the lamination and holding stages, the heating temperature of the heating plate is 120°C to 150°C.

9. The photovoltaic module lamination method according to claim 1, characterized in that: After the blockage is cleared, open the cover and discharge the material.

10. A photovoltaic module, characterized in that: Obtained by lamination by the photovoltaic module lamination method according to any one of claims 1 to 9.

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