Manufacturing method of curved glass photovoltaic module

Abstract

The invention discloses a method for manufacturing a curved glass photovoltaic module, which comprises the following steps of: S1, manufacturing a pre-pressed piece: sequentially laying a first release film and a first laminated layer, placing a plurality of photovoltaic cell strings, then covering a second laminated layer and a second release film on a cell piece, and then pre-pressing and laminating to obtain a pre-pressed piece; melting the first laminated layer and the second laminated layer into an integrated adhesive film layer, and tearing off the first release film and the second release film after lamination is completed to obtain a pre-pressed part; s2, laminating: placing front plate curved glass, then placing the pre-pressing piece in the step S1, enabling the pre-pressing piece to be naturally bent under the gravity of the pre-pressing piece to fit the shape of the front plate curved glass, and finally placing a back plate to obtain a laminated piece; s3, transferring the laminated part in the step S2 into a vacuum bag, sealing, and pre-vacuumizing; and S4, transferring the vacuum bag which is pre-vacuumized in the step S3 into laminated glass equipment for final lamination, and trimming to obtain a finished curved glass photovoltaic module. The method is high in yield and production efficiency.

Description

Technical Field

[0001] The present invention specifically relates to a manufacturing method of a curved glass photovoltaic module, belonging to the technical field of manufacturing solar photovoltaic cell modules. Background Art

[0002] Due to the specific curved shape, the curved glass photovoltaic module can be combined with building facades, automobile bodies, etc., and installed on the outer surfaces of buildings or automobiles, which is both beautiful and can generate electricity. Most of the curved glass photovoltaic modules in the prior art adopt CIGS battery technology. CIGS batteries belong to flexible photovoltaic batteries and have a certain degree of bendability. However, their photoelectric conversion efficiency is relatively low; crystalline silicon solar cells have a high photoelectric conversion efficiency, but they are fragile, the bendable curvature is limited to a certain extent, and multiple solar cells need to be connected in series and parallel with solder tapes. During the production process, the distance between adjacent strings is prone to shift, which is not easy to control and the yield is not high. Even CIGS batteries have the problem of displacement; at the same time, the curved glass photovoltaic module cannot be laminated by a conventional flat laminator, and the production efficiency is not high. Summary of the Invention

[0003] Aiming at the problems existing in the prior art, the present invention provides a manufacturing method of a curved glass photovoltaic module.

[0004] The technical solution of the present invention is as follows: A manufacturing method of a curved glass photovoltaic module includes the following steps: S1. Manufacturing a pre-pressed part: Horizontally place a support flat plate on a platform, lay a first release film on the support flat plate, lay a first interlayer on the first release film, place a plurality of photovoltaic cell strings on the first interlayer. Each cell string includes a plurality of photovoltaic cells connected in series by soldering. Then, connect the cell strings in series or parallel by soldering with solder tapes according to the design scheme. Next, cover the solar cells with a second interlayer, lay a second release film on the second interlayer, and then transfer the support flat plate and the objects carried thereon to a conventional flat laminator for pre-pressing and laminating, so that the first interlayer and the second interlayer are melted into an integrated adhesive film layer, and the adhesive film layer wraps the solar cells. After the lamination is completed, tear off the first release film and the second release film to obtain the pre-pressed part; S2. Laminating: Place the front plate curved glass with its concave surface facing up, then place the pre-pressed part in S1 with the light-receiving surface of the solar cells facing down. The pre-pressed part naturally bends under its own gravity to fit the shape of the front plate curved glass, and finally place the back plate to obtain a laminated part; S3. Transfer the laminated part in S2 into a vacuum bag, seal it, and pre-evacuate the air; S4, transfer the vacuum bag after pre-vacuuming in S3 to the laminated glass equipment, continue to evacuate and heat the vacuum bag, so that the integrated adhesive film layer of the pre-pressed part can bond the front curved glass and the back plate into a whole, finally cool down, break the vacuum, take out the laminate from the vacuum bag, trim and install the junction box to obtain the finished curved glass photovoltaic module.

[0005] Furthermore, in the lamination process of S2, the following steps can also be adopted: placing the front panel curved glass with its concave surface facing upward, then placing the third interlayer, then placing the pre-pressed part in S1, then placing the fourth interlayer, and finally placing the back panel to obtain a laminated part; wherein the first interlayer, the second interlayer, the third interlayer, and the fourth interlayer are made of the same material, and the material can be EVA or PVB.

[0006] Furthermore, in S3, air guide nets are laid on the upper and lower surfaces of the laminate in the vacuum bag, respectively.

[0007] Furthermore, the back panel is also curved glass, and the curvature direction and size of the back panel are consistent with those of the front panel.

[0008] Furthermore, the photovoltaic cell in S1 is a crystalline silicon cell, and the type of the crystalline silicon cell is preferably a back contact cell, and the light-receiving surface of the back contact cell faces the front curved glass.

[0009] Furthermore, the laminated glass equipment in S3 is a normal pressure oven, which includes a box body and a vacuum system. A track is provided in the box body, on which multiple glass trolleys can be placed, and multiple vacuum bags are placed flat on the glass trolleys. The vacuum system can vacuum each vacuum bag individually or simultaneously.

[0010] Furthermore, the laminated glass equipment in S3 is an autoclave, which includes an autoclave body and a vacuum system. A track is arranged in the autoclave body, and a plurality of glass racks can be placed on the track.

[0011] Furthermore, the glass frame vehicle includes a base frame, wheels are provided under the base frame, the wheels can roll along the track, a vertical frame is provided in the middle of the base frame, a plurality of rows of transverse through holes are provided on the vertical frame, each through hole allows a support rod to be inserted, a plurality of support rods are passed through each row of transverse through holes, the support rods are symmetrically distributed about the vertical frame, the vacuum bag is suspended by two support rods at adjacent intervals at the same height, and the spacing between adjacent support rods can be adjusted according to the size of the glass.

[0012] Beneficial effects: In the present invention, a flat laminator is used to encapsulate and fix photovoltaic cells in an adhesive film layer in advance to form a pre-pressed component. In this way, the distance between the cells will not produce significant displacement during subsequent processes such as sheet combination, bending, and movement. At the same time, the flexible adhesive film layer encapsulates and protects the cells in advance, significantly improving the subsequent bending performance of the cells, significantly reducing the breakage rate of crystalline silicon cells, and significantly improving the yield rate of the curved glass photovoltaic module. Finally, through the laminating process design of a vacuum bag, a laminated glass device, and a glass carrier truck, hundreds of photovoltaic modules can be produced each time, greatly improving the production efficiency. Description of the Drawings

[0013] Figure 1 It is a schematic diagram of an oven system.

[0014] Figure 2 It is a three-dimensional schematic diagram of a glass carrier truck.

[0015] Figure 3 It is a front view of a glass carrier truck.

[0016] Figure 4 It is a schematic diagram of a support rod supporting a vacuum bag containing a laminated component.

[0017] Figure 5 It is a schematic diagram of a vacuum pumping system.

[0018] Figure 6 It is a schematic diagram of a conventional cell.

[0019] Figure 7 It is a schematic diagram of the back of a back-contact cell.

[0020] Figure 8 It is a schematic diagram of an autoclave system.

[0021] Figure 9 It is a schematic diagram of the cell layout in the photovoltaic module of Embodiment 1.

[0022] Figure 10 It is a schematic diagram of the cell and diode layout in the photovoltaic module of Embodiment 2.

[0023] Figure 11 It is a circuit diagram of the photovoltaic module of Embodiment 2.

[0024] Figure 12 It is a schematic diagram of a diode string structure.

[0025] Figure 13 It is a schematic diagram of the cell and diode layout in the photovoltaic module of Embodiment 3.

[0026] Figure 14 It is a circuit diagram of the photovoltaic module of Embodiment 3.

[0027] Figure 15It is a schematic diagram of the layout of solar cells and diodes in the photovoltaic module of Example 4.

[0028] Figure 16 It is the circuit diagram of the photovoltaic module of Example 4.

[0029] Figure 17 It is the schematic diagram of the back side of the photovoltaic module of Example 5.

[0030] Figure 18 It is the schematic diagram of the front side of the photovoltaic module of Example 5.

[0031] Markings in the figure: 1 box body, 2 vacuum pumping system, 3 glass carrier, 4 vacuum bag, 5 laminate, 6 conventional solar cell, 61 positive interconnection strip, 62 negative interconnection strip, 7 back-contact solar cell, 71 positive grid line, 72 negative grid line, 8 autoclave body, 9 diode string, 10 solar cell string, 11 guide rail, 12 conductive tape, 21 vacuum pump, 22 main pipeline, 23 first main pipeline, 24 first branch pipeline, 25 movable pipeline, 31 chassis, 32 upright frame, 33 through hole, 34 support rod, 35 second main pipeline, 36 second branch pipeline, 38 wheel, 41 air extraction valve, 221 main pipeline valve, 241 first branch pipeline valve, 361 second branch pipeline valve. Detailed implementation manners

[0032] The following makes a clear, complete and detailed description of the present invention with reference to the accompanying drawings. The described implementation manners and embodiments are only a part of the embodiments of the present invention, rather than all embodiments. Based on the given embodiments, all other embodiments obtained by those of ordinary skill in the art without creative efforts belong to the scope of the present invention. The technical solutions between various implementation manners and embodiments can be combined with each other without conflict. When the combination of technical solutions results in contradictions or cannot be implemented, it should be considered that such a combination of technical solutions does not exist and is not within the protection scope required by the present invention.

[0033] A manufacturing method of a curved glass photovoltaic module includes the following steps: First step, manufacturing a pre-pressed part: Horizontally place a support flat plate on a platform, lay a first release film on the support flat plate, lay a first interlayer film on the first release film, place a plurality of photovoltaic cell strings on the first interlayer film, each cell string includes a plurality of photovoltaic cells connected in series by soldering, and perform series or parallel soldering on the cell strings with solder strips according to the design scheme to make it have certain electrical properties such as voltage and current. Then cover the cells with a second interlayer film, lay a second release film on the second interlayer film, and then transfer the support flat plate and the objects carried thereon to a conventional flat laminator for pre-pressing and laminating, so that the first interlayer film and the second interlayer film are melted into an integrated adhesive film layer, and the adhesive film layer wraps the cells inside. After laminating, tear off the first release film and the second release film to obtain the pre-pressed part.

[0034] Among them, the supporting flat plate plays a role of temporarily supporting for convenient transfer, and flat glass can be selected as the supporting flat plate; the first interlayer and the second interlayer are made of the same material, and the material can be selected from EVA or PVB, and the thickness can be selected from different specifications such as 0.38 mm, 0.5 mm, 0.76 mm, etc.; when EVA is selected as the interlayer, the crosslinking degree of EVA in the pre-pressing member can be controlled to be less than or equal to 70%, preferably 50-60%, leaving a margin for subsequent crosslinking; the photovoltaic cell can be various types of cells, such as CIGS, cadmium telluride, perovskite, crystalline silicon, amorphous silicon, etc.; among them, the crystalline silicon cell can be a conventional cell, such as Figure 6 As shown, grid lines are arranged on both the front and back of the conventional cell 6 and respectively correspond to the positive and negative electrodes of the cell. The positive interconnection strip 61 and the negative interconnection strip 62 can be welded on the positive and negative grid lines to facilitate subsequent series connection; the crystalline silicon cell can also be a back contact cell, such as Figure 7 As shown, there are no grid lines on the front (light-receiving surface) of the back contact cell 7, and positive grid lines 71 and negative grid lines 72 are evenly spaced on its back. The solder strip interconnection strips are all welded on the grid lines on the back of the cell. The interconnection strip solder strip usually selects a tin-plated copper strip. Due to the different coefficients of thermal expansion between the solder strip and the cell, when the back contact cell is welded with the interconnection strip, the cell will bend naturally. The bending direction is convex on the front and concave on the back. The present invention arranges the natural bending direction of the back contact cell and the bending direction of the curved glass in the same direction, so that the stress of the cell itself can be reduced and the fragmentation rate can be reduced. The release film is a non-sticking film, also called non-sticking cloth. The melted interlayer does not adhere to it, which is convenient for tearing off the release film after lamination. For the pre-pressing member prepared in this step, after lamination, the first interlayer and the second interlayer are melted into one body, encapsulating and wrapping the cells and the cell string in the middle, fixing the distance between the cell strings, which will not change during the subsequent bending process. At the same time, the adhesive film layer has certain elasticity and flexibility, protecting the cells from being easily broken during the subsequent bending process.

[0035] In the process of manufacturing the pre-pressed component in the first step above, after the battery strings are connected in series or parallel, one or more diode strings can be connected in parallel on one side of the corresponding battery string. Each diode string includes a plurality of diodes connected in series. The diodes are surface-mounted diodes, such as Schottky butterfly diodes, with a thickness less than 0.3 mm, extremely thin and light, safe and reliable. Then, the second laminated layer is covered. In this way, the number of battery strings in the photovoltaic module is m, the number of diode strings is p, each battery string includes n series-connected solar cells, each diode string includes q series-connected diodes, the n solar cells are aligned in the same direction and arranged in a straight line, the q diodes are aligned in the same direction and arranged in a straight line, the diode string is reversely connected in parallel with the corresponding one or more battery strings, and the diode is reversely connected in parallel with the corresponding one or more solar cells, where m, n, p, and q are all positive integers, m≥1, n≥2, p≤m, and q≤n. In this way, the diode string is also pre-encapsulated in the glue film layer of the pre-pressed component. When any one or more solar cells in the photovoltaic module are shaded or damaged, there are corresponding bypass diodes for bypass protection, minimizing the impact on the power generation output of the photovoltaic module, improving the reliability of the photovoltaic module, and solving the problems of insufficient number of diodes in traditional photovoltaic modules and inability to integrate multiple diodes in the laminated layer of the photovoltaic module.

[0036] Second step, laminating: Place the front plate curved glass with its concave surface facing up, then place the pre-pressed component in S1 so that the light-receiving surface of the solar cells in the pre-pressed component faces the front plate glass. The pre-pressed component naturally bends under its own gravity to fit the shape of the front plate curved glass, and finally place the back plate to obtain a laminated component.

[0037] The back plate can also be curved glass, and the curvature direction and size of the back plate are the same as those of the front plate. For example, the front plate glass and the back plate glass are matching single-curved or compound-curved glass. When used as automotive glass, the radius of curvature is between 2000 - 10000 mm, the normal chord height is 3 - 50 mm, and the horizontal chord height is 50 - 185 mm. The component made in this way is a curved double-glass photovoltaic module. During the laminating process, the following steps can also be adopted: Place the front plate curved glass with its concave surface facing up, then place the third laminated layer, then place the pre-pressed component in the first step, then place the fourth laminated layer, and finally place the back plate glass to obtain a laminated component. The materials of the third laminated layer and the fourth laminated layer are the same as those of the first laminated layer and the second laminated layer, and the thickness can be reduced, which can improve the adhesion between the front plate glass, the pre-pressed component, and the back plate glass. For example, PVB material is used, the thickness of the first laminated layer and the second laminated layer is 0.5 mm, and the thickness of the third laminated layer and the fourth laminated layer is 0.38 mm.

[0038] Third step, transfer the laminated component in the second step into a vacuum bag, seal it, and pre-pump the vacuum. The vacuum bag has a certain flexibility and can be made of silica gel plates, including upper and lower sheets, such as Figure 4As shown, it can be opened to facilitate the loading of the laminate 5. Air guide nets can also be laid on the upper and lower surfaces of the laminate respectively to facilitate vacuum exhaust. After the upper and lower sheets are aligned, the edge parts around them can be nested and sealed with each other. An exhaust valve 41 and an air pipe are installed on the upper sheet. After it is externally connected to a pre-vacuum pump, pre-vacuum is carried out for a certain period of time so that the upper and lower sheets of the vacuum bag are tightly pressed against the front plate and the back plate of the laminate to prevent the components of the laminate from being misplaced during subsequent movement. Then the exhaust valve 41 is closed, and the connection between the air pipe and the pre-vacuum pump is disconnected to put the vacuum bag in an isolated vacuum state.

[0039] The fourth step is to transfer the vacuum bag that has been pre-vacuumed in the third step and place it flat in the laminated glass equipment. The laminated glass equipment can choose to use a normal pressure oven system or an autoclave system, both of which are equipped with a vacuum pump and a vacuuming system. The vacuum pump can evacuate each vacuum bag individually or simultaneously, continue to cold-evacuate the vacuum bag for a certain period of time, and then heat it while evacuating the vacuum bag to melt the film layer and the interlayer layer under the external air pressure to bond the front curved glass and the back plate into a whole. Finally, cool down, break the vacuum, take out the laminate from the vacuum bag, trim and install the junction box to obtain a finished curved glass photovoltaic module.

[0040] The autoclave system is Figure 8 As shown, it comprises a cylindrical kettle body 8, a heating system is arranged in the kettle body, and a track 11 is arranged at the lower part of the kettle body, and a plurality of glass frame vehicles 3 can be placed on the track 11. The glass frame vehicles 3 are as shown in FIG. Figures 2-3 As shown, the glass carriage 3 includes a bottom frame 31, and wheels 38 are provided below the bottom frame 31. The wheels 38 can roll along the track 11 to facilitate the glass carriage to enter and exit the autoclave. A vertical frame 32 is provided in the middle of the bottom frame 31, and multiple rows (layers) of transverse through holes 33 are provided on the vertical frame 32. Each through hole 33 allows a support rod 34 to be inserted. Multiple support rods can be passed through each row of transverse through holes as needed. The support rods 34 are symmetrically distributed about the vertical frame 32. The vacuum bag 4 containing the laminated parts can be suspended and supported by two support rods 34 at the same height and adjacent to each other. The spacing between the adjacent support rods can be adjusted according to the size of the glass. Figure 4 As shown; at the same time, the spacing between adjacent support rods in the vertical direction can also be adjusted to adapt to the arch height of the curved glass; Figures 2-3 The stand shown in the figure is provided with five layers of supporting rods, so that at least ten and at most dozens of vacuum bags can be placed on a glass frame cart. Assuming that each kettle can accommodate five glass frame carts, each kettle can accommodate dozens to hundreds of vacuum bags, and the production efficiency is high.

[0041] The autoclave system is also equipped with a vacuum system 2, such as Figure 1 , Figure 3 and Figure 5As shown in the figure, the vacuum pumping system 2 includes a vacuum pump 21, a main pipeline 22, and a first main pipeline 23. The vacuum pump 21 is located outside the kettle body 1, and the first main pipeline 23 is located inside the kettle body 1. The main pipeline 22 passes through the kettle wall and is respectively connected to the vacuum pump 21 and the first main pipeline 23. A main pipeline valve 221 is provided on the main pipeline 22. A plurality of first branch pipelines 24 are arranged in parallel on the first main pipeline 23. A first branch pipeline valve 241 is provided on each first branch pipeline 24. Each first branch pipeline 24 can be connected to a glass trolley through a movable pipeline 25 to evacuate all or part of the vacuum bags on the trolley. Specifically, a second main pipeline 35 is installed on the vertical frame 32 of the glass trolley. A plurality of second branch pipelines 36 are arranged in parallel on the second main pipeline 35. A second branch pipeline valve 361 is provided on each second branch pipeline 36. Each second branch pipeline 36 can be connected to a vacuum bag 4. The two ends of the movable pipeline 25 are respectively connected to the first branch pipeline 24 and the second main pipeline 35.

[0042] The working process is as follows: Place multiple vacuum bags wrapped with laminates and pre-evacuated on the support rods of the glass trolley, push the glass trolley into the autoclave, connect the air extraction pipes on each vacuum bag to a second branch pipe 36, connect the second main pipe 35 to the first branch pipe 24 with the movable pipe 25, then turn on the vacuum pump 21, and sequentially open the main pipe valve 221, the first branch pipe valve 241, the second branch pipe valve 361 and the air extraction valve 41 on the vacuum bag to perform secondary evacuation on the vacuum bag. The valves on the unused branch pipes are closed. Then push the second glass trolley into the autoclave, repeat the above similar pipe connection sequence and valve opening sequence, and then close the autoclave door to make the inside of the autoclave a sealed system; continue to perform cold evacuation for a certain period of time, and then turn on the heating device inside the autoclave to start heating while evacuating. As the temperature inside the autoclave rises, the pressure inside the autoclave will also gradually increase. The pressure on the vacuum bag will exceed one atmospheric pressure. The adhesive film of the laminate inside the vacuum bag will melt and release a small amount of gas after heating up. This part of the gas will be evacuated by the vacuum pump until the lamination is completed; optionally, when the temperature and pressure inside the autoclave reach a certain value, close the main pipe valve 221 to stop evacuation; optionally, while heating up or maintaining temperature and evacuating, compressed air can also be injected into the autoclave until the pressure inside the autoclave reaches 10 - 12 atmospheric pressures. After maintaining the temperature and pressure for a certain period of time, lower the temperature inside the autoclave to below 40 degrees, then release the high pressure inside the autoclave, open the autoclave cover, remove the evacuation connection pipeline, pull out the glass trolley, remove the vacuum bag, take out the laminated part after lamination, trim the edges, and install the junction box to obtain the finished curved glass photovoltaic module. This method can apply a pressure above one atmospheric pressure and even above ten atmospheric pressures between the front plate glass and the back plate glass. The adhesive film is preferably PVB, which has good adhesion to the glass, and at the same time has good evacuation and exhaust effects. There are fewer defects such as air bubbles in the photovoltaic module, and the production efficiency is relatively high; of course, the adhesive film can also be EVA; however, the autoclave system needs to withstand high pressure, belongs to special equipment, occupies a large area, and the equipment investment cost and maintenance cost are relatively high.

[0043] In order to reduce the equipment investment cost, the laminated glass equipment can also adopt an atmospheric-pressure oven system, as Figure 1As shown in the figure, it includes a cuboid box body 1 and a vacuum pumping system 2. A heating system and a track 11 are also provided inside the box body. A plurality of glass trolley racks 3 are arranged on the track 11. The structures and configurations of the vacuum pumping system 2 and the glass trolley racks 3 are basically the same as those of the autoclave system described above, and the two can be used interchangeably, so no further description will be given. The working process is briefly described as follows: Place a plurality of vacuum bags wrapped with laminated parts and pre-evacuated on the support rods of the glass trolley rack, push the glass trolley rack into the box body 8, connect the air extraction pipe on each vacuum bag to a second branch pipe 36, connect the second main pipe 35 to the first branch pipe 24 with a movable pipe 25, then turn on the vacuum pump 21, and sequentially open the main pipe valve 221, the first branch pipe valve 241, the second branch pipe valve 361 and the air extraction valve 41 on the vacuum bag to perform secondary evacuation on the vacuum bag. Then push the second glass trolley rack into the box body, repeat the above similar pipe connection sequence and valve opening sequence, and then close the oven door to make the inside of the box body an approximately sealed system; continue to perform cold evacuation for a certain period of time, and then turn on the heating device inside the box while evacuating to start heating up. The adhesive film of the laminated parts in the vacuum bag is heated up by heat conduction, melts and releases a small amount of gas after heating up, and this part of the gas will be pumped away by the vacuum pump. After heating up to a certain temperature, keep it warm for a certain period of time, then lower the temperature inside the box to below 40 degrees, stop evacuating, then open the box door, remove the evacuation connection pipeline, pull out the glass trolley rack, remove the vacuum bag, take out the laminated parts after lamination, trim the edges and install the junction box to obtain the finished curved glass photovoltaic module. The atmospheric pressure oven system mainly uses the atmospheric pressure generated by evacuation to bond the front plate and the back plate with an adhesive film, and the pressure that can be applied is less than or equal to 1 atmosphere. The adhesive film is preferably EVA; after lamination, the final crosslinking degree of the EVA in the third interlayer, the fourth interlayer and the pre-pressed parts reaches 85%-90%, so that all the EVA melts into a whole, without delamination, and the bonding and protection performance reaches the best. Of course, if compressed air is not injected into the autoclave system described above to form a positive pressure, its kettle body can also be used only as an oven. Therefore, although Figure 1 the box body shown in the figure is in a cuboid shape, it should be understood that the box body can also be of other shapes, and the present invention does not limit the shape of the oven box body.

[0044] The layout of the battery cells and diodes in the curved glass photovoltaic module will be described below through several embodiments.

[0045] Embodiment 1 As Figure 9 shown, in this example, there are two strings of battery strings connected in series in the curved glass photovoltaic module. Each string of battery strings is composed of 16 small battery cells connected in series. Each small battery cell is a quarter slice of a complete crystalline silicon battery cell, and the battery cells are conventional battery cells; there is no diode string configured in this example. In this example, m = 2, n = 16, p = q = 0.

[0046] Example 2 As Figure 10 shown, in this example, there are two strings of cell strings 10 connected in series in the curved glass photovoltaic module. Each string of cell strings 10 is composed of 4 crystalline silicon cells in full size connected in series, and the cells are conventional crystalline silicon cells 6; a diode string 9 is connected in anti-parallel on the outside of each string of cell strings. Each diode string 9 includes four diodes connected in series, and each diode is connected in anti-parallel with a cell. In this example, m = 2, n = 4, p = 2, q = 4. The corresponding circuit diagram is as Figure 11 . The structure of the diode string 9 is as Figure 12 shown, including a strip-shaped substrate 91, which mainly plays a supporting role to facilitate the production and transfer of the diode string. The material can be selected from PET, EPE, EVA, etc.; a plurality of diodes 92 are arranged at intervals on the substrate 91. The distance between the diodes is adjusted according to the distance between the cells. Adjacent diodes are connected in series through a conductive layer 93, and the positive or negative electrode of the diode at the end is also led out through the conductive layer 93. In this example, when making the pre-pressing piece, the steps are as follows: lay the first interlayer film, place two cell strings 10 on the first interlayer film with the back of the cells facing up, connect the cell strings in series and weld them according to the design scheme, lay the diode string 9 in parallel on the outside of each string of cell strings, then paste conductive tapes 12 in the middle of the back of each cell, and paste conductive tapes 12 on the interconnection bars at the ends of the cell strings, and use the conductive tapes 12 to conductively connect the interconnection bars on the back of the corresponding cells to the conductive layers at both ends of the corresponding diodes, so as to realize the anti-parallel connection of the diodes and the cells; then cover the second interlayer film and the second release film on the cells and the diode string, and finally laminate, so as to realize the synchronous lamination of the cell string and the diode string into the pre-pressing piece, and the two are perfectly combined together to achieve the effect of one diode bypass protecting one cell.

[0047] Example 3 As Figure 13 shown, the difference between this example and Example 2 is that in this example, m = 2, n = 4, p = 2, q = 2. The corresponding circuit diagram of the photovoltaic module in this example is as Figure 14 , and in this example, one diode bypass protects two cells.

[0048] Example 4 As Figure 15 shown, the difference between this example and Example 2 is that in this example, m = 2, n = 4, p = 1, q = 4. In this example, two strings of cell strings are connected in parallel, and a diode string is connected in anti-parallel between the two strings of cell strings. The corresponding circuit diagram of the photovoltaic module in this example is as Figure 16 , so that one diode can also bypass protect two cells.

[0049] Example 5 As Figures 17-18As shown, in this example, m = 2, n = 4, p = 2, q = 4; the difference between this example and Example 2 lies in the type of solar cell used. The crystalline silicon solar cell in this example is a full-size back-contact solar cell 7, and one end of the conductive tape is bonded to the interconnection strip between adjacent solar cells and the interconnection strip of the end solar cell, and the other end of the conductive tape is bonded to the conductive layer on the diode string, achieving the effect of one diode bypassing and protecting one solar cell. The circuit diagram of this example is also as Figure 11 shown. When the long strip substrate 91 is made of an opaque material, the bypass diode cannot be seen from the front of the photovoltaic module, and there is no grid line obstruction on the front of the back-contact solar cell, and the appearance is also more beautiful.

Claims

1. A manufacturing method of a curved glass photovoltaic module, characterized in that, The steps include: S1. Making a pre-pressed part: placing a support plate horizontally on a platform, laying a first release film on the support plate, laying a first interlayer on the first release film, placing a plurality of photovoltaic cell strings on the first interlayer, each cell string comprising a plurality of photovoltaic cells connected by series welding, and welding the cell strings in series or in parallel with welding strips according to the design scheme, then covering the cells with a second interlayer, laying a second release film on the second interlayer, and then transferring the support plate and the load thereon to a conventional flat-plate laminator for pre-pressing and laminating, so that the first interlayer and the second interlayer are melted into an integrated adhesive film layer, the adhesive film layer wraps the cells, and after lamination, tearing off the first release film and the second release film to obtain a pre-pressed part; S2, Lamination: Place the front curved glass with the concave surface facing up, then place the pre-pressed part in S1, with the light-receiving surface of the cell in the pre-pressed part facing down. The pre-pressed part will naturally bend under its own gravity to fit the shape of the front curved glass, and finally place the back plate to obtain a laminated part; S3, transferring the laminated parts in S2 into a vacuum bag, sealing it, and pre-evacuating it; S4, transfer the vacuum bag after pre-vacuuming in S3 to the laminated glass equipment, continue to evacuate and heat the vacuum bag, so that the integrated adhesive film layer of the pre-pressed part can bond the front curved glass and the back plate into a whole, finally cool down, break the vacuum, take out the laminate from the vacuum bag, trim and install the junction box to obtain the finished curved glass photovoltaic module.

2. The manufacturing method of a curved glass photovoltaic module according to claim 1, characterized in that, During the lamination process of S2, the following steps may also be adopted: placing the front curved glass with the concave surface facing upward, then placing the third interlayer, then placing the pre-pressed part in S1, then placing the fourth interlayer, and finally placing the back panel to obtain a laminated part.

3. The manufacturing method of a curved glass photovoltaic module according to claim 2, characterized in that, The first interlayer, the second interlayer, the third interlayer and the fourth interlayer are made of the same material.

4. The manufacturing method of a curved glass photovoltaic module according to claim 1, characterized in that In S3, air guide nets are laid on the upper and lower surfaces of the laminate in the vacuum bag, respectively.

5. The manufacturing method of a curved glass photovoltaic module according to claim 1, characterized in that, The back panel in the S2 is also a curved glass, and the curvature direction and size of the back panel are consistent with those of the front panel.

6. The manufacturing method of a curved glass photovoltaic module according to claim 1, characterized in that, The photovoltaic cell in S1 is a crystalline silicon cell.

7. The manufacturing method of a curved glass photovoltaic module according to claim 6, characterized in that, The crystalline silicon cell is a back-contact cell, and the light-receiving surface of the back-contact cell faces the front curved glass.

8. The manufacturing method of a curved glass photovoltaic module according to claim 1, characterized in that, The laminated glass equipment in S3 is an oven or an autoclave, and is equipped with a vacuum system. A track is provided in the oven or the autoclave, and multiple glass trolleys can be placed on the track. Multiple vacuum bags are placed flat on the glass trolleys. The vacuum system can vacuum each vacuum bag individually or vacuum multiple vacuum bags simultaneously.

9. The manufacturing method of a curved glass photovoltaic module according to claim 8, characterized in that, The glass frame vehicle comprises a base frame, wheels are arranged under the base frame, the wheels can roll along tracks, a vertical frame is arranged in the middle of the base frame, a plurality of rows of transverse through holes are arranged on the vertical frame, a support rod is allowed to be inserted into each through hole, a plurality of support rods are passed through each row of transverse through holes, the support rods are symmetrically distributed about the vertical frame, the vacuum bag is suspended and supported by two support rods at adjacent intervals at the same height, and the spacing between adjacent support rods can be adjusted according to the size of the glass.

10. The manufacturing method of a curved glass photovoltaic module according to claim 3, characterized in that, The material of the interlayer is EVA, the cross-linking degree of the EVA in the pre-pressed part is 50-60%, and the cross-linking degree of the EVA in the finished curved glass photovoltaic module is 85-90%.

Images