Method for manufacturing solar cell module, solar cell module and junction box

Abstract

Examples disclose a method of manufacturing a solar cell assembly (1800), the method comprising: arranging a solar cell, a connection line (1431) having a contact portion in electrical contact with a solar cell contact of the solar cell, and a collection portion of an interconnector spanning the connection line (1431) and in electrical contact with the connection line (1431) between a front-side encapsulation layer (1471) and a back-side encapsulation layer (1472); laminating to obtain a solar cell module laminated structure comprising a front side encapsulation layer (1471), a solar cell and a rear side encapsulation layer (1472); a junction box (1880, 24000, 26000, 27000, 28000, 29000) is arranged on the solar cell module laminated structure, a rear side encapsulation layer (1772) is arranged between the front side encapsulation layer (1771) and the junction box (1880, 24000, 26000, 27000, 28000, 29000), and the junction box (1880, 24000, 26000, 27000, 28000, 29000) comprises a shell and a conductor (1881); and contactless material bonding a conductor (1881) to the end (17411) of the interconnector. Other examples disclose a solar electronic assembly (1800).

Description

Technical Field

[0001] The present disclosure relates to a solar cell module and a method for manufacturing the solar cell module. The solar cell module may also be referred to as a photovoltaic module. Background Art

[0002] WO2015 / 001413A1 discloses a solar cell module, sometimes also referred to as a photovoltaic module, which includes a plurality of solar cell strings, wherein each solar cell string includes a plurality of solar cells connected in series. The solar cells are arranged between a front side encapsulation layer and a back side encapsulation layer.

[0003] In addition, WO2011 / 011855A1 proposes a method for connecting a plurality of back-contact solar cells, in particular interdigitated back contact (IBC) solar cells, in particular, a plurality of solar cells can be connected in series through a plurality of parallel connection lines to form a solar cell string.

[0004] According to WO2019 / 191689A1, a solar cell may have a wire metallization that connects the solar cells in a string. The ends of the metallization wire include a busbar and / or an interconnector. The busbar or interconnector is folded over the footprint of the solar cell. Insulation features may be added to isolate the folded portion of the metallization wire from another metallization wire on the solar cell. The metallization wire may allow the manufacture of an interconnector or busbar folded behind the cell to reduce the overall solar cell module size, thereby improving the efficiency of the solar cell module.

[0005] Solar modules must be able to be connected to electrical devices. To date, electrical cables have to be connected to the solar modules. Sometimes, the solar modules also include bypass diodes. Typically, the terminals for connecting the electrical cables and the bypass diodes are accommodated in one or more junction boxes arranged on the rear side of the solar module. The conductors arranged in the junction boxes must be electrically connected to the busbars and / or interconnectors, preferably after the lamination process, in which the solar cells have been encapsulated between the front glass and the rear glass or back sheet. There is a need to simplify the connection. Summary of the invention

[0006] Said need has been solved by the subject matter of the independent claims. Advantageous embodiments are described in the dependent claims.

[0007] According to a first aspect, an example discloses a method for manufacturing a solar cell module, wherein the method comprises: arranging solar cells between a front-side encapsulation layer and a rear-side encapsulation layer, a connecting wire having a contact portion electrically contacting a solar cell contact of the solar cell, and a collecting portion of an interconnector spanning the connecting wire and electrically contacting the connecting wire, wherein an end of the interconnector passes through an opening of the rear-side encapsulation layer; laminating to obtain a solar cell module laminate structure comprising a front-side encapsulation layer, a solar cell and the rear-side encapsulation layer; providing a junction box on the solar cell module laminate structure so that the rear-side encapsulation layer is arranged between the front-side encapsulation layer and the junction box, wherein the junction box comprises a shell and a conductor; and bonding the conductor non-contact material to the end of the interconnector.

[0008] According to some examples, the solar cell contact having the first polarity may be disposed on a different side of the solar cell than the solar cell contact having the second polarity. Other examples may require that the solar cell contact having the first polarity and the solar cell contact having the second polarity be disposed on the same side of the solar cell. The solar cell may include an IBC solar cell.

[0009] In some examples, the connection wire may have an approximately circular cross section. In other examples, the connection wire may have an elongated cross section. The connection wire may correspond to a strip wire commonly used for contacting solar cell contacts. Each solar cell may include its own plurality of connection wires. In some examples, the connection wire may correspond to the Smartwire Connection Technology (SWCT) described, for example, in DE 10 2020 109600 A1. TM ) wires used in connection technology. At least two solar cells can share multiple connection wires. Multiple connection wires can be used to electrically connect solar cells in series or in parallel.

[0010] In some examples, the conductor portion is encapsulated within the housing.

[0011] Other examples may require that the conductors are surrounded by the housing and the solar module laminate after the junction box has been arranged on the solar module laminate.

[0012] The junction box is bonded to the solar cell module laminate structure by glue and / or tape, and in particular, before the conductor is bonded to the end of the interconnector, the junction box is bonded to the solar cell module laminate structure by glue and / or tape. This can be beneficial to maintain the position of the junction box relative to the solar cell panel laminate during the process of bonding the conductor to the end of the interconnector.

[0013] The contactless material bonding may include at least one of: induction brazing, induction welding, and laser welding. The electromagnetic energy required for these processes may be applied through the housing of the junction box. For example, the housing of the junction box may be transparent to the wavelength used for laser welding, so that the laser beam is only absorbed by the ends of the conductors and / or interconnects to establish the bond.

[0014] The conductor may be elastic. Due to the elasticity, when the junction box is arranged on the rear side of the solar module laminate structure, the conductor can be pressed onto the end of the interconnector and establish mechanical contact, thereby allowing material bonding of the conductor to the end.

[0015] The housing of the junction box may be coverless. Thus, all components (eg bridging elements, cables, conductors) may be (at least partially) enclosed in the housing.

[0016] In some examples, the method may include folding back the ends of the interconnector. Other examples may require that, before folding back the ends of the interconnector, the ends are passed through a through hole of a rear glass and / or a back sheet of the solar cell module.

[0017] The method may further include arranging a back sheet and / or a rear glass on a side of the interconnector opposite to the first solar cell such that the groove of the back sheet and / or the rear glass accommodates the folded-back portion.

[0018] The example proposes laminating the solar cell modules after the ends of the interconnectors have been folded back.

[0019] The method may comprise covering the side of the end portion opposite to the solar cell, in particular with an adhesive film, before laminating the solar cell module.

[0020] An example of the method further includes removing an insulating material on a side of the folded-back portion opposite to the collecting portion before the bonding.

[0021] According to a second aspect, an example discloses a solar cell assembly, comprising: a solar cell assembly laminate structure, comprising a solar cell, a connecting wire having a contact portion electrically contacting a solar cell contact of the solar cell, and a collecting portion of an interconnector spanning the connecting wire and electrically contacting the connecting wire, wherein the solar cell, the connecting wire and the collecting portion are arranged between a front-side encapsulation layer and a rear-side packaging layer, wherein an end of the interconnector passes through an opening in the rear-side encapsulation layer; a junction box on the solar cell assembly laminate structure, wherein the rear-side encapsulation layer is arranged between the front-side packaging layer and the junction box, wherein the junction box comprises a shell and a conductor, wherein the conductor material is bonded to the end of the interconnector.

[0022] The contact interface between the conductor and the end portion may be arranged on a plane parallel to the solar cell. The specific plane parallel to the reference plane may correspond to a specific plane arranged at a certain distance from the reference plane and / or a specific plane arranged within the reference plane.

[0023] In an example, the conductor is materially bonded to the end portion. The conductor can be soldered to the end portion. The conductor can also be welded to the end portion, in particular resistance welding or laser welding.

[0024] In an example, the end portion may be a folded back portion. This may improve the aesthetic appearance of the front side of the solar cell assembly as seen from the front side of the solar cell assembly, as will be further described below.

[0025] The collecting portion of the interconnector may be arranged between the folded-back portion and the first solar cell.

[0026] In an example of a solar cell module, the interconnector may pass through a through hole of a rear glass and / or a back sheet of the solar cell module, wherein the rear glass and / or the back sheet is arranged between the collecting portion and the folded back portion of the interconnector.

[0027] The end portion is received in a groove of the back sheet and / or rear glass of the solar cell module.

[0028] Some examples may require that the conductor be bonded to the end of the interconnect opposite the solar cell.

[0029] The conductors can be connected to bridge elements, in particular diodes and / or semiconductor switches and / or transistors. Alternatively or additionally, the conductors can also be connected to terminals, wherein the terminals are used to connect the solar cell assembly to an electrical cable. BRIEF DESCRIPTION OF THE DRAWINGS

[0030] Examples of the proposed solar cell module are described with reference to the following drawings:

[0031] Figure 1 A solar cell assembly is shown;

[0032] Figure 2 A string of solar cells is shown;

[0033] Figure 3 A portion of a solar cell unit is shown;

[0034] Figure 4 A portion of a solar cell assembly is shown;

[0035] Figure 5 A portion of a solar cell assembly is shown;

[0036] Figure 6A partially fabricated solar cell module is shown;

[0037] Figure 7 A partially fabricated solar cell module is shown;

[0038] Figure 8 A partially fabricated solar cell module is shown;

[0039] Fig. 9 A partially fabricated solar cell module is shown;

[0040] Fig.10 A partially fabricated solar cell module is shown;

[0041] Fig.11 A partially fabricated solar cell module is shown;

[0042] Fig.12 A partially fabricated solar cell module is shown;

[0043] Fig.13 A partially fabricated solar cell module is shown;

[0044] Fig.14 A partially fabricated solar cell module is shown;

[0045] Fig.15 A partially fabricated solar cell module is shown;

[0046] Fig.16 A partially fabricated solar cell module is shown;

[0047] Fig.17 A partially fabricated solar cell module is shown;

[0048] Fig.18 A partially fabricated solar cell module is shown;

[0049] Fig.19 A partially fabricated solar cell module is shown;

[0050] Fig. 20 A solar cell assembly is shown;

[0051] Fig.21 A string of solar cells is shown;

[0052] Fig. 22 shows a partially fabricated solar cell module; and

[0053] Fig.23 A partially fabricated solar cell module is shown.

[0054] Fig.24 is a perspective view of the junction box.

[0055] Fig.25 yes Fig.24 Schematic side view of the junction box.

[0056] Fig.26 is a schematic side view of a junction box.

[0057] Fig. 27 is a schematic side view of a junction box.

[0058] Fig.28 is a schematic side view of a junction box.

[0059] Fig.29 is a schematic side view of a junction box. DETAILED DESCRIPTION

[0060] Figure 1 A solar cell assembly 100 is shown. Specifically, Figure 1 The circuit of the solar cell module 100 and the arrangement of the solar cells 101, ..., 116, etc. of the solar cell module 100 as viewed from the front side of the solar cell module 100 are schematically shown.

[0061] The solar cell assembly 100 includes a first solar cell unit 161 and a corresponding second solar cell unit 162. The first solar cell unit 161 and the second solar cell unit 162 are electrically connected in parallel. The first solar cell unit 161 includes three similar solar cell sub-units 163, 164, 165 connected in series. Generally, the first solar cell unit 161 may also include fewer or more sub-units connected in series.

[0062] The first solar cell subunit includes a first solar cell string including solar cells 101, ..., 103 and a second solar cell string including solar cells 104, ... 106. Each solar cell string may include two or more solar cells.

[0063] The first solar cell string may be electrically connected in series with the second solar cell string via the interconnector 145. In particular, the first solar cell string and the second solar cell string may share the same interconnector 145. The first bridge element 151 is electrically connected in parallel with the solar cell sub-unit 163. Similarly, the second bridge element 152 is electrically connected in parallel with the solar cell sub-units of the second solar cell unit 162. For the other solar cell sub-units 164, 165, ... in the solar cell unit 161 and the solar cell sub-units in the second solar cell unit 162, other bridge elements may be provided. Figure 1The bridge elements shown in the figure are diodes 151 and 152. Diodes 151 and 152 can also be called bypass diodes. However, different bridge elements, such as active switches, can also be used as an alternative or supplement. When the solar cells 101, ..., 103, 104, ..., 106 of the solar cell subunit 163 are not illuminated, the bridge element 151 allows current to pass through the solar cell unit 161. Next, the role of the bypass diode (or more generally referred to as a bridge element) is explained. Each solar cell generates electricity by converting sunlight into electrical energy. However, sometimes the solar cell string may be shaded (for example, by leaves, dust, dirt, bird droppings, etc.), and the shade will reduce its power output. In the reference scenario without a bridge element, the shaded solar cell string must carry the same current as the unshaded solar cell string. This may cause "hot spots", that is, when the unshaded solar cell string pushes current through the shaded solar cell string, the temperature rise area that appears in the shaded solar cell string. This may cause thermal stress and damage, or even destroy the cell. The bypass diode can mitigate this effect. Under normal (balanced) conditions, the diode is reverse biased, meaning that it does not conduct electricity. However, if the solar cell string becomes shaded, and the voltage drop across the shaded cell causes the string voltage to become negative, the bypass diode becomes forward biased and begins to conduct electricity. This essentially "bypasses" the shaded solar cell string, allowing current to bypass rather than flow through the solar cell string, hence the term "bypass diode." This can increase the efficiency of the solar cell assembly 100. The bridge element 151 is electrically connected to the interconnectors 141, 142 of the solar cells 101, 106, and the bridge element 152 is electrically connected to the interconnectors 143, 144 of the solar cells 111, 116. Providing separate bridge elements for the solar cell sub-cells 163, 164, 165 in the solar cell unit 161 and the solar cell sub-cells in the solar cell unit 162 can increase the efficiency of the solar cell assembly 100 compared to known solar cell assemblies in which two parallel electrically connected solar cell sub-cells share one or more common bridge elements.

[0064] Figure 2 Further shown is a first solar cell string consisting of solar cells 101, 102 and 103. The solar cell string is shown from the back side of the solar cell assembly 100. The solar cells 101, 102, 103 include solar cell contacts 221 having a first polarity (e.g., negative or positive) and solar cell contacts 222 having a second polarity (e.g., positive or negative), respectively.

[0065] The solar cell string includes a first group of multiple parallel connecting lines 231 and a second group of multiple parallel connecting lines 232, wherein the first group of multiple parallel connecting lines 231 has a contact portion that electrically contacts the solar cell contact point 221 with a first polarity of the solar cell 101, and the second group of multiple parallel connecting lines 232 electrically contacts the solar cell contact point 222 with a second polarity of the solar cell 101.

[0066] The interconnector 141 is provided with a collecting portion spanning across the first plurality of parallel connection lines 231 and in electrical contact with the first plurality of parallel connection lines 231 .

[0067] The second plurality of parallel connection lines 232 are in electrical contact with the solar cell contacts of the solar cell 102 having the first polarity. Thus, the second plurality of parallel connection lines 232 connect the solar cell 101 and the solar cell 102 in series. Similarly, more sets of parallel connection lines 233, 234 connect the solar cell 102 and the solar cell 103 in series and connect the solar cell 103 to the interconnector 145.

[0068] Figure 3 A portion of the solar cell unit 161 is shown. The portion of the solar cell unit 161 is shown from the rear side of the solar cell module 100. Figure 3 Three solar cell strings are shown, which are respectively composed of solar cells 101, 102, 103, solar cells 104, 105, 106 and solar cells 107, 108, 109. The solar cell strings are connected in series. Before this, solar cells 103 and 104 share the same interconnector 145, and solar cells 106 and 107 share the same interconnector 142.

[0069] like Figures 1 to 3 As shown, interconnectors 141, 142, 143, 144, 145, 146, ... can be arranged on the side of the solar cell. Therefore, most of the front surface of the solar cell assembly 100 will be occupied by the interconnectors and cannot be used to collect light.

[0070] like Figure 4 As shown, the connection line 431 can be bent, and the interconnectors 441, 443 can be arranged on the rear side of the solar cell assembly 400. Therefore, the solar cells 401, 411 (corresponding to Figure 1 The solar cells 101, 111 shown in FIG. 4 can be arranged closer together. Typically, the connecting wire 431 is arranged on the foil segment 471 before being soldered to the contacts of the solar cells 401, 411. Figure 4 As shown, a buffer bar 472 may be provided between the foil segment 471 and the interconnector 441. The interconnector 441 is provided between the bent portion of the connection line 431 and the buffer bar 472.

[0071] Figure 5 A portion of a solar cell assembly 500 similar to the solar cell assembly 400 is shown. Elements 501, 571, 572, 541, 531, 543, 511 correspond to Figure 4 Components 401 , 471 , 472 , 441 , 431 , 443 , 411 are shown in FIG. 4 . Different from the solar cell assembly 400 , the bent portion of the connection line 531 is disposed between the interconnector 541 and the buffer strip 572 .

[0072] The solar cells and their connection components of a solar cell module may have to be protected from environmental damage to avoid performance degradation and damage. Usually, they are encapsulated in a laminate structure. However, some electrical connections must pass through the laminate structure in order to connect the solar cell module to the cable. In some cases, bridging elements need to be arranged outside the laminate structure. The connection components are usually arranged in a junction box arranged on the rear side of the solar cell module.

[0073] Figure 6 A partially fabricated solar cell assembly 600 is shown, corresponding to Figure 4 The solar cell assembly 400 shown in . A front side encapsulation layer 674 and a front glass 673 are provided on the front side of the solar cells 401, 409. The front glass can also be made of any transparent material, such as transparent plastic. The connecting wire 431 is connected to the interconnector 441. Similarly, the connecting wire connects the solar cell 409 to the interconnector 442. The interconnector 441 includes a collecting portion 4411 and an end portion 4412 for collecting current from a plurality of parallel connecting wires 431. The end portion 4412 is at a certain angle to the collecting portion 4411. The angle can correspond to approximately 90 degrees. The end portion 4412 can be bent before the interconnector 441 is connected to the connecting wire 431.

[0074] like Figure 7 As shown, the end portion 4412 may be folded back so that the end portion 4412 is arranged in parallel with the collecting portion 4411. In this case, the end portion 4412 may also be referred to as a folded back portion.

[0075] according to Figure 8, on the rear side of the partially manufactured solar cell module 800, a rear side encapsulation layer 875 and a back sheet 876 may be provided. Grooves such as groove 877 are provided on the rear side encapsulation layer 875 and the back sheet 876. The folded back portion 4412 of the interconnector 441 is accommodated in the groove 877. Heat and pressure may then be applied from the front and rear sides. This may soften or melt the encapsulation material so that the encapsulation material can flow into the cavity of the stacked layers. This process may also be referred to as lamination, and the lamination may be performed in a laminator (not shown). Since the folded back portion 4412 is accommodated in the groove 877, the front and rear sides of the partially manufactured solar cell assembly 800 are substantially flat, which facilitates lamination.

[0076] like Fig. 9 As shown, a junction box 980 can be connected to the back side of a laminated, partially manufactured solar cell assembly 900. The junction box 980 includes a conductor 981. The conductor 981 can be part of a bridge element of the solar cell assembly 900, in particular, the bridge element can be a bypass diode. The conductor 981 is electrically connected to the interconnector 441, and in some examples is preferably materially bonded (German: stoffschlussig verbunden) to the interconnector 441. The contact / bonding interface between the conductor 981 and the end 4412 of the interconnector 441 is substantially arranged in a plane between the conductor 981 and the solar cell 401 and parallel to the solar cell 401.

[0077] The arrangement of the bonding interface facilitates the bonding process. In particular, the bonding location is easily accessible to a bonding machine (e.g., a welding device or welding apparatus). For example, a single translation movement of the bonding machine in a single direction (e.g., from bottom to top) may be sufficient to complete the bonding process.

[0078] The method also avoids bending the interconnect 441 multiple times, thereby avoiding weakening the interconnect 441 .

[0079] Furthermore, the method is also advantageous for automated installation of the junction box 980 .

[0080] Compared to existing junction boxes, the junction box proposed in the examples presented here can be particularly flat. This can enable the solar cell assembly to be used as a roof tile. Moreover, less potting material may be required to fill the junction box after the electrical connection is established, thereby saving costs. In addition, the time required to fill the junction box with potting material is also reduced.

[0081] Fig. 9In the example shown, the bonding is achieved by resistance welding using electrode 991. Resistance welding has the advantage that the interconnector 441 and the conductor 981 are only heated locally. Therefore, the risk of other components of the solar cell module being damaged by heat or having reduced performance is reduced. Moreover, electrode 991 can be used to press the conductor onto the interconnector 441. During the bonding process, no other measures are required to fix the position of these components.

[0082] However, the bonding can also be achieved by brazing. In particular, induction brazing can be used. Brazing can be performed at lower temperatures than welding, further reducing the risk of damaging any components of the solar module.

[0083] about Figures 6 to 9 In the example described, the end 4412 of the interconnect 441 is a folded back portion. However, it is also conceivable to use a completely flat interconnect 441, i.e., the interconnect 441 has the collecting portion and the end arranged in a single layer. This can reduce the complexity involved in bending the interconnect 441.

[0084] The use of the folded back portion may have the advantage that the bonding interface is hidden behind the collecting portion of the interconnector. Therefore, the color change due to welding is not visible on the front side of the solar cell module, thereby improving the aesthetic appearance of the solar cell module.

[0085] Fig.10 A partially fabricated solar cell assembly 1000 is shown. In the solar cells 1001 and 1009 (which may correspond to Figure 4 The front side of the solar cells 401 and 409 shown in FIG. 1 is provided with a front glass 1073 and a front side encapsulation layer 1074. The interconnector 1041 includes a collecting portion 10411 and an angled end portion 10412, the collecting portion 10411 being electrically connected to a connection line 1031 electrically connected to the solar cell 1001. The angled end portion 10412 passes through a through hole 1077 provided in a rear side encapsulation layer 1075 and a rear glass 1076.

[0086] like Fig.11 As shown, the end portion 10412 can be folded back so that the back glass 1076 is arranged between the collecting portion 10411 and the folded back portion 10412 of the interconnector 1041. During the lamination process, an adhesive tape 1178 covering the folded back portion 10412 can be provided. This can help prevent any insulating material from covering the portion of the surface of the folded back portion 10412 to be electrically connected in subsequent process steps. Although not specifically described, such an adhesive tape can also be used to cover the folded back portion 10412 during the lamination process. Figure 8 The folded back portion 4412 is shown. Fig. 9 similar, Fig.12It shows that during the manufacturing process of the solar cell module 1200 , the conductor 1281 of the junction box 1280 is connected to the folded portion 10412 using the electrode 1291 .

[0087] Fig.13 Another solar cell module 1300 is shown having a front glass 1373, a front side encapsulation layer 1374, a back side encapsulation layer 1375, and a back glass 1376. Fig. 9 and Fig.12 Unlike the solar cell assembly in FIG. 1 , the collecting portion 13411 is not arranged behind the solar cell 1301, but is arranged on the side of the solar cell 1301, which is different from the solar cell assembly in FIG. Figure 3 The interconnect 141 shown in FIG. Fig.13 The electrode 1391 for contact resistance welding and the edge of the solar cell module 1300 are shown. The junction box 1380 includes a conductor 1381, and the conductor 1381 is connected to the terminal. The terminal can be used to connect the electrical cable 1382 to the solar cell module 1300. In this way, the current collected by the collecting portion 13411 of the interconnector 1341 and conducted through the folded portion 13412 thereof can flow through the electrical cable 1382. Fig.13 In the example, the junction box 1380 only includes a terminal connected to the conductor 1381. However, in other examples, the junction box may include such a terminal for connecting an electrical cable and an additional bridging element. The conductor of the junction box can thus connect the terminal and the bridging element.

[0088] Fig.14 1 shows a portion of a solar cell module, specifically, a portion of a solar cell module laminate structure 1400, wherein interconnectors 1441, 1443 are laterally disposed between solar cells 1401, 1411. Interconnectors 1441, 1443 and solar cells 1401, 1411 may correspond to Figures 1 to 3 The interconnectors 141 , 143 and the solar cells 101 , 111 are shown in FIG.

[0089] Solar cells 1401, 1411 and their connections may need to be protected from the environment to avoid performance degradation and damage. Typically, they are packaged in Fig.14 In the illustrated solar cell module laminate structure 1400 , a solar cell 1401 including a solar cell contact 1421 having a first polarity and a solar cell contact having a second polarity, and a plurality of parallel connection lines 1431 having contact portions electrically contacting the solar cell contact 1421 having the first polarity are arranged between a front side encapsulation layer 1471 and a back side encapsulation layer 1472 .

[0090] The back plate 1473 is disposed on the side of the rear encapsulation layer 1472 opposite to the solar cell 1401. The front glass 1474 may be disposed on the side of the front encapsulation layer 1471 opposite to the solar cell 1401. Generally, when the solar cell module is installed in a certain position, substantially only the front glass 1474 of the solar cell module is visible to the user. The cover strip 1475 is disposed laterally between the solar cells 1401, 1411, and vertically between the interconnectors 1441, 1443 and the front encapsulation layer 1471. The cover strip 1475 may shield the portion of the solar cell module between the solar cells 1401, 1411, so that a person cannot observe through the front glass 1474. In this way, the aesthetic appearance of the solar cell module may be improved.

[0091] Some ends of some interconnectors may have to pass through the laminate structure to electrically connect the solar cell module to the cable and further to the electrical device. In some cases, a bridging element may also need to be provided outside the laminate structure.

[0092] In this way, Fig.15 As indicated in , the end 14411 of the interconnector 1441 passes through the openings of the rear side packaging layer 1472 and the back plate 1473 .

[0093] Fig.16 The same portion of the solar cell module laminate structure 1400 is shown in a view rotated 90 degrees. The ends 14411 , 14421 of the interconnectors 1441 , 1442 both pass through the backside encapsulation layer 1472 .

[0094] like Fig.17 As shown, the ends 14411 , 14421 of the interconnectors 1441 , 1442 are folded back to obtain folded back portions 17411 , 17421 .

[0095] The back plate 1473 may include a conductive material, such as a metal plate. The insulating mask 1477 may help ensure a sufficient non-conductive distance between the cut edge of the back plate 1473 and the interconnectors 1441 and / or 1442. The insulating mask 1477 may also help avoid short circuits of the interconnectors 1441, 1442. The ends 14411, 14421 pass through an opening of the insulating mask 1477 that is smaller than an opening of the back plate 1473.

[0096] Lamination may involve applying heat and / or pressure to the stacked layers for a certain period of time. The heat and / or pressure may melt the front encapsulation layer 1471 and / or the back encapsulation layer 1472 so that the material of the front encapsulation layer 1471 and / or the back encapsulation layer 1472 may flow into the remaining gaps in the stacked layers. Moreover, lamination may help to bond between the elements of the stacked layers.

[0097] like Fig.17 As shown, the solar cell 1411, the connection wire 1431 having a contact portion electrically contacting the solar cell contact of the solar cell, and the collecting portion 14412 of the interconnector 1441 electrically contacting the connection wire 1431 are arranged between the front side encapsulation layer 1471 and the back side encapsulation layer 1472. The end portion 14411 / 17411 passes through the opening of the back side encapsulation layer 1472.

[0098] Fig.18 A portion of a solar cell assembly 1800 is shown. Fig.17 The illustrated solar cell assembly laminate structure 1700 is provided with a junction box 1880 such that the rear encapsulation layer 1472 is arranged between the front encapsulation layer 1471 and the junction box 1880. The junction box includes a housing and a conductor 1881. The conductor 1881 is materially bonded to the end 17411 of the interconnector 1441 in a non-contact manner. The bridge element 1851, specifically a bypass diode, can be encapsulated in the junction box 1880, i.e., arranged in a corresponding cavity formed in the housing of the junction box 1880. A protrusion is arranged on the plate-like base, and a cavity is formed in the protrusion. The bypass diode is offset from the bonding position of the conductor 1881.

[0099] The conductor 1881 may be partially encapsulated in the housing of the junction box 1880. In some examples, after the junction box 1880 is arranged on the solar cell module laminate structure 1700, the conductor 1881 may be surrounded by the housing of the junction box 1880 and the solar cell module laminate structure 1700. The conductor 1881 is arranged in a groove 1889 formed at the surface of the housing facing the laminate structure.

[0100] The junction box 1880 can be bonded to the solar cell module laminate structure by glue and / or tape. In particular, the junction box 1880 can be bonded to the solar cell module laminate structure by glue and / or tape before the conductor 1881 is connected to the end / folded back portion 17411 of the interconnector.

[0101] The non-contact contact material bonding may include at least one of induction brazing, induction welding, laser welding and / or electron beam welding. These processes may involve transmitting an electromagnetic field through the housing of the junction box 1880. The conductor 1881 may be elastic. Thus, after the junction box 1880 is bonded to the solar cell module laminate structure 1700 by glue and / or tape, and before material bonding, the elastic force may press the conductor 1881 against the end or folded back portion 17411.

[0102] The housing of the junction box 1880 can be coverless. In particular, the bridging elements and / or electrical cables used to connect the solar cell assembly to the grid can be completely encapsulated in the housing of the junction box 1880. After the junction box 1880 is connected to the solar cell assembly laminate structure, there can be no gaps in the junction box 1880 that must be filled with potting material. In this way, omitting the potting step can reduce the complexity of the manufacturing process. In addition, omitting the potting material can save costs.

[0103] You can also Fig.12 , 13 The conductors 1281, 1381 of the junction boxes 1280, 1380 shown are non-contact materially bonded to the corresponding interconnectors 1041, 1341. Fig.18 The illustrated junction box 1880 replaces the junction boxes 1280 , 1380 .

[0104] Fig.19 Another portion of solar cell assembly 1800 is shown. Solar cell assembly 1800 may include another junction box 1980 including conductors 1981 connected to cables 1982. Element 1977 may be connected to Fig.18 Corresponding to element 1477 shown in .

[0105] Fig. 20 A solar cell assembly 2000 is shown. Specifically, Fig. 20 The circuit of the solar cell module 2000 and the arrangement of solar cells 2001 , . . . , 2016 , etc., viewed from the front side of the solar cell module 2000 are schematically illustrated.

[0106] The solar cell assembly 2000 includes a first solar cell unit 2061 and a corresponding second solar cell unit 2062. The first solar cell unit 2061 and the second solar cell unit 2062 are electrically connected in parallel. The first solar cell unit 2061 includes three similar solar cell subunits 2063, 2064, 2065 connected in series. Generally, the first solar cell unit 2061 may also include fewer or more subunits connected in series.

[0107] The first solar cell subunit 2063 includes a first solar cell string including solar cells 2001, ..., 2003 and a second solar cell string including solar cells 2004, ..., 2006. Each solar cell string may include two or more solar cells.

[0108] The first solar cell string may be electrically connected in series to the second solar cell string using the interconnector 2045. In particular, the first solar cell string and the second solar cell string may share the same interconnector 2045. The bridge element 2051 may be electrically connected in parallel to the solar cell subunit 2063 and the corresponding solar cell subunit of the second solar cell unit 2062. Other bridge elements may also be provided for the other solar cell subunits 2064, 2065, ... of the solar cell unit 2061 and the corresponding solar cell subunit of the solar cell unit 2062. Fig. 20 The bridge element shown in is a diode. The diode may be referred to as a bypass diode. However, a different bridge element, such as an active switch, may be used as an alternative or in addition. The bridge element 2051 may allow current to pass through the solar cell unit 2061 when the solar cells 2001, ... 2003, 2004, ... 2006 and / or the solar cells 2011, ... 2013, 2014, ... 2016 of the solar cell subunit 2063 are not illuminated. This may increase the efficiency of the solar cell assembly 2000.

[0109] The bridge element 2051 is electrically connected to the interconnectors 2041 , 2042 of the solar cells 2001 , 2006 .

[0110] Fig.21 Shows Fig. 20 The solar cell assembly 2000 shown includes a first solar cell string including solar cells 2001, 2002, and 2003. The solar cell string is shown from the rear side of the solar cell assembly 2000. The solar cells 2001, 2002, and 2003 include solar cell contacts 2121 having a first polarity (e.g., positive or negative) and solar cell contacts having a second polarity (e.g., negative or positive). The solar cell contacts having the second polarity are arranged at Fig.21 The rear sides of solar cells 2001, 2002, 2003 are shown.

[0111] The solar cell string includes a plurality of parallel connection lines 2131 having contact portions that electrically contact the solar cell contacts 2121 of the solar cell 2001 having a first polarity and the solar cell contacts of the solar cell 2002 having a second polarity.

[0112] The interconnector 2041 is configured to have a collecting portion that spans across and electrically contacts the plurality of parallel connection lines 2132 .

[0113] Fig. 22FIG. 2 shows a portion of a solar cell module, specifically a portion of a solar cell module laminate structure 2200, wherein an interconnector 2241 is laterally disposed between solar cells 2201 and 2211. The interconnector 2241 and the solar cells 2201 and 2211 may correspond to Fig. 20 and 21 The interconnector 2041 and solar cells 2001, 2011 are shown in FIG.

[0114] Solar cells 2201, 2211 and their connecting components may need to be protected from environmental damage to avoid performance degradation and damage. Typically, they are encapsulated in a solar cell module laminate structure 2200, such as Fig. 22 A solar cell 2201 including solar cell contacts 2221 with a first polarity and solar cell contacts with a second polarity, and a plurality of parallel connection lines 2231 having contact portions electrically contacting the solar cell contacts 2221 with the first polarity are arranged between a front side encapsulation layer 2271 and a rear side encapsulation layer 2272.

[0115] The back plate 2273 is disposed on the side of the rear encapsulation layer 2272 opposite to the solar cell 2201. The front glass 2274 is disposed on the side of the front encapsulation layer 2271 opposite to the solar cell 2201. Generally, when the solar cell module is installed in a certain position, substantially only the front glass 2274 of the solar cell module is visible to the user. The cover strip 2275 is disposed laterally between the solar cells 2201, 2211, and vertically between the interconnectors 2241, 2242 and the front encapsulation layer 2271. The cover strip 2275 can shield the portion between the solar cells 2201, 2211 of the solar cell module, so that a person cannot observe through the front glass 2274. In this way, the aesthetic appearance of the solar cell module can be improved. An insulating mask 2277 corresponding to the insulating mask 1477 can also be provided.

[0116] Some ends of some interconnectors may have to pass through the laminate structure in order to electrically connect the solar cell module to the cable and further to the grid. In some examples, a bridge element may also be provided outside the solar cell module laminate structure.

[0117] Therefore, if Fig. 22 As shown, the end 22411 of the interconnect 2241 passes through the opening in the backside encapsulation layer 2272 and the opening in the backplane 2273.

[0118] Fig.23 The same portion of the solar cell module laminate structure 2100 is shown in a 90 degree rotated view. Fig. 20 The interconnects 2041, 2042) shown in FIG. 2 pass through the backside packaging layer 2272.

[0119] The ends 22411 , 22421 of both interconnectors 2241 , 2242 may be folded back at a later stage to obtain folded back portions.

[0120] Fig.24 24000 according to various examples. For example, the junction box 24000 can implement the junction box 1880 (see Fig.18 ).

[0121] The junction box 24000 has a housing 24001 with a plate-like base 24005. The plate-like base 24005 has a relatively small thickness 24004 between the upper side or surface 24002 and the lower side or surface 24003, for example not more than 10 mm or not more than 5 mm; this relatively small thickness 24004 facilitates contactless material bonding at bonding locations 24021, 24022. For example, an electromagnetic field can be transmitted through the plate-like base 24005 of the housing 24001 at the bonding locations 24021, 24022. For example, induction brazing can be achieved by positioning a transmitter coil from the upper side 24002 at the bonding locations 24021, 24022 of the upper surface 24002. The transmitter coil can thus be pushed from the upper side 24002 to the plate-like base 24005 and used to connect the conductors arranged on the lower side 24003 below the bonding locations 24021, 24022 (at Fig.24 In another example, laser welding is possible when the housing 24001 is made of a material transparent to the laser wavelength. The laser beam can be incident from the upper surface 24002 and penetrate the housing 24001 at the bonding locations 24021, 24022.

[0122] The figure also shows raised portions 24011, 24012, and corresponding cavities are defined in the raised portions. Electrical couplers, diodes or other electrical components can be arranged in the cavities. These cavities are completely encapsulated by the housing, and there is no cover for opening the cavities. For example, the raised portions 24011, 24012 can be bonded to the plate-like base 24005 by glue. For example, waterproof gel can be filled in the cavities.

[0123] Fig.25 yes Fig.24 A schematic side view of junction box 24000 is shown along line AB.

[0124] The dotted lines in the figure show cavities 25091, 25092 formed in the protrusions 24011, 24012 extending from the upper side 24002 of the plate-like base 24005. The cavities 25091, 25092 have electrical components arranged therein, such as cables or couplers ( Fig.25 The dotted line in the figure) is biased relative to the bonding position and the conductors 25081 and 25082, thereby reducing the heat influx into the cavities 25091 and 25092 during material bonding, thereby avoiding damage to the electrical components.

[0125] The figure also shows a groove 25150 formed on the lower surface 24003 of the plate-like base 24005 (see Fig.18 : groove 1889). Flanges (not shown) may surround groove 25150 so that once junction box 24000 is attached to the solar cell module laminate structure, groove 25150 may be isolated from the surroundings / environment by these flanges, the corresponding surfaces of the solar cell module laminate structure and the lower surface 24003 of junction box 24000.

[0126] The figure also shows conductors 25081, 25082 arranged below the coupling positions 24021, 24022 and located at the lower surface 24003 of the plate-like base 24005 of the housing 24001. The conductors 25081, 25082 are arranged in the groove 25150.

[0127] Specifically, when the junction box 24000 is not attached to the outer surface of the solar cell module laminate structure, the conductors 25081, 25082 extend away from the lower surface 24003, thereby extending out of the groove 25150 (e.g., Fig.25 ). This is because of the elasticity of the conductors 25081, 25082, which here refers to the elasticity caused by the shape of the conductors 25081, 25082 formed as leaf springs. Once the junction box 25000 is attached to the solar cell module laminate structure, the conductors 25081, 25082 will engage / press against the ends of the interconnectors and be pushed back into the grooves 25150. The depth of the grooves 25150 is equal to or greater than the thickness of the conductors 25081, 2502, so that the conductors 25081, 25082 can be completely accommodated in the grooves 25150. This makes it possible to seal the contact area between the conductors 25081, 25082 and the ends of one or more interconnectors by the grooves 25150.

[0128] Fig.26 The junction box 2600 is Fig.25 As shown in Fig.24The present invention is a modification of the junction box 24000. Specifically, the junction box 26000 includes another cavity 26095 arranged between the conductors 25081 and 25082 and formed in another protrusion 26015. For example, a bypass diode can be arranged in the cavity 26095.

[0129] Fig. 27 and Fig.28 The junction boxes 27000 and 28000 shown are further variations of the junction boxes 2400 and 26000, respectively. This illustrates the flexibility in the design of the cavity / protrusion arrangement. Furthermore, a sequence of protrusions and cavities and conductors comprising more than two conductors and more than two or even three cavities / protrusions may also be provided (see Fig.29 Junction box 29000 in the case.

[0130] All the examples described herein have the advantage of avoiding bending of the connector end portions after lamination. This can greatly simplify the installation process of the junction box.

[0131] In the case where the solar cell assembly includes a front glass and a back sheet, the ends of the interconnects may no longer need to be led out of the laminated structure. Instead, the angled ends of the interconnects may be folded back before lamination, in particular before the rear encapsulation layer and the back sheet are arranged behind the solar cell. The grooves in the back sheet and the rear encapsulation layer may be arranged to enable contact with the folded back portion. Preferably, the grooves are large enough to accommodate the folded back portion of the interconnect. This can help keep the thickness of the laminated structure consistent with when there is no folded back portion.

[0132] The solar cell modules described herein can use the design and size of the junction box. In particular, the solar cell modules including the front glass and the back sheet and the solar cell modules including the front glass and the back glass can use the same junction box.

[0133] The proposed method for manufacturing a solar cell module may have a higher process reliability. Passing the angled ends of the interconnectors through the openings of the junction box and / or the backsheet may be prone to errors. If errors occur, complex subsequent processes may be required and / or the yield of the solar cell module may be reduced. The positioning of the junction box relative to the ends is not so critical as proposed here.

Claims

1. A method for manufacturing a solar cell module (1800), The method comprises: Arranged between the front side encapsulation layer (1471) and the back side encapsulation layer (1472) Solar cells; A connecting wire (1431) having a contact portion that is in electrical contact with a solar cell contact of the solar cell; and a collecting portion of the interconnector spanning the connection line (1431) and in electrical contact with the connection line (1431), laminating to obtain a solar cell assembly laminate structure, wherein the solar cell assembly laminate structure comprises the front side encapsulation layer (1471), the solar cell and the back side encapsulation layer (1472), A junction box (1880, 24000, 26000, 27000, 28000, 29000) is arranged on the solar cell assembly laminate structure, so that the rear side packaging layer (1772) is arranged between the front side packaging layer (1771) and the junction box (1880, 24000, 26000, 27000, 28000, 29000), The junction box (1880, 24000, 26000, 27000, 28000, 29000) comprises a housing and a conductor (1881), and bonding the conductor (1881) to the end (17411) of the interconnector in a non-contact material manner, The housing has no cover.

2. The method according to claim 1, Wherein the conductor (1881) is partially encapsulated within the housing.

3. The method according to claim 2, After the junction box (1880, 24000, 26000, 27000, 28000, 29000) is arranged on the solar cell component laminate structure, the conductor (1881) is surrounded by the shell and the solar cell component laminate structure.

4. The method according to any one of claims 1 to 3, The junction box (1880, 24000, 26000, 27000, 28000, 29000) is bonded to the laminated structure of the solar cell module by glue and / or tape, in particular, before the conductor (1881) is bonded to the end (17411) of the interconnector, it is bonded to the laminated structure of the solar cell module by glue and / or tape.

5. The method according to any one of claims 1 to 4, Wherein the non-contact material bonding comprises at least one of the following: Induction brazing; Induction welding; Laser welding; and / or Electron beam welding.

6. The method according to any one of the preceding claims, Wherein the conductor (1881) is elastic.

7. The method according to any one of the preceding claims, The housing comprises a bridging element, and the conductor is connected to the bridging element (1851).

8. The method according to any one of the preceding claims, The method further comprises folding back the end portion (17411) of the interconnector to obtain a folded back portion of the interconnector.

9. The method according to claim 8, The method further comprises Before folding back the end of the interconnector, the end is passed through a through hole of the rear glass and / or back sheet (1473) of the solar cell module (1806).

10. The method according to claim 9, The method further comprises A back sheet (1473) and / or a rear glass is arranged on a side of the interconnector opposite to the solar cell, so that the groove of the back sheet and / or the rear glass accommodates the folded back portion (17411) of the interconnector.

11. A solar cell assembly (1800), comprising: A solar cell module laminate structure comprising: Solar cells; a connecting wire (1431) having a contact portion that is in electrical contact with a solar cell contact of the solar cell; and a collecting portion (14412) of the interconnector spanning the connection line and in electrical contact with the connection line, The solar cell, the connecting wire (1431) and the collecting part are arranged between the front side packaging layer (1471) and the back side packaging layer (1472), A junction box (1880, 24000, 26000, 27000, 28000, 29000) is located on the solar cell module laminate structure, wherein the rear side encapsulation layer (1472) is arranged between the front side packaging layer (1471) and the junction box (1880, 24000, 26000, 27000, 28000, 29000), The junction box (1880, 24000, 26000, 27000, 28000, 29000) comprises a shell and a conductor (1881), wherein the conductor (1881) material is bonded to the end portion (17411) of the interconnector, wherein the conductor (1881) is isolated from the surrounding environment by the housing and the solar cell laminate structure, The housing has no cover.

12. The solar cell module according to claim 11, The contact interface between the conductor (1881) and the end (17411) is arranged on a plane parallel to the solar cell.

13. The solar cell module according to claim 11 or 12, Wherein the end portion (17411) is a folded back portion.

14. The solar cell module according to any one of claims 10 to 13, wherein the interconnector passes through a through hole of the rear glass and / or back sheet (1472) of the solar cell module (1800), and The rear glass and / or back plate (1472) is arranged between the collecting portion (14412) and the folded back portion (17411) of the interconnector.

15. The solar cell module according to any one of claims 10 to 13, The end portion is received in a groove of the back plate and / or rear glass of the solar cell module.

16. The solar cell module according to any one of claims 10 to 15, The conductor (1881) is electrically connected to the bridge element (1851), specifically, to the diode.

17. The solar cell module according to any one of claims 10 to 16, The conductor (1981) is electrically connected to the cable (1982).

18. Junction boxes (1880, 24000, 26000, 27000, 28000, 29000) for connection to the solar cell module laminate structure, The junction box comprises a housing and one or more conductors. wherein each of the one or more conductors is arranged to be bonded to an end material of a corresponding interconnector in the solar cell module laminate structure, The housing has no cover.

19. The junction box (1880, 24000, 26000, 27000, 28000, 29000) according to claim 18, wherein one or more cavities (25091, 25092) are defined in the housing (24001), One or more electrical connectors or diodes are arranged in the one or more cavities.

20. The junction box (1880, 24000, 26000, 27000, 28000, 29000) according to claim 19, Wherein the one or more cavities (25091, 25092) are completely enclosed by the shell.

21. The junction box (1880, 24000, 26000, 27000, 28000, 29000) according to claim 19 or 20, Wherein the one or more cavities (25091, 25092) are arranged to be biased relative to the one or more conductors.

22. The junction box according to any one of claims 18 to 21, The housing (24001) comprises a plate-shaped base (24005), The one or more conductors (25081, 25082) are at least partially arranged in one or more grooves (25150) formed in the plate-like base (24005) of the housing (24001).

23. The junction box (1880, 24000, 26000, 27000, 28000, 29000) according to claim 22, wherein the one or more grooves (25150) are formed on the lower side (24003) of the plate-like base (24005), One or more cavities (25091, 25092) are defined in the housing (24001), in, The raised portions (24011, 24012) defining the one or more cavities (25091, 25092) extend from an upper side (24002) of the plate-like base (24005) opposite to the lower side (24003).

24. The junction box (1880, 24000, 26000, 27000, 28000, 29000) according to claim 22 or 23, Wherein the thickness extension (24004) of the plate-like base (24005) between the upper side (24002) and the lower side (24003) is not greater than 5 mm.

25. The junction box (1880, 24000, 26000, 27000, 28000, 29000) according to any one of claims 18 to 24, Wherein one or more conductors (25081, 25082) are elastic.

26. The junction box (1880, 24000, 26000, 27000, 28000, 29000) according to any one of claims 18 to 25, wherein the one or more conductors (25081, 25082) are provided with The shape induces elasticity to compress the interconnector of the laminated structure of the solar cell module.

27. The junction box (1880, 24000, 26000, 27000, 28000, 29000) according to any one of claims 18 to 26, The one or more conductors (25081, 25082) extend away from the housing to engage with and contact the interconnector of the solar cell module laminate structure.

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