Photovoltaic module and manufacturing method thereof

Abstract

The invention belongs to the field of photovoltaic technology, and discloses a photovoltaic module and a manufacturing method of the photovoltaic module, the photovoltaic module comprises at least a plurality of battery pieces, interconnection wires and an isolation layer, and the adjacent battery pieces are connected through the interconnection wires to form a battery string; the edges of the ends, close to each other, of every two adjacent battery pieces are each covered with an isolation layer, the isolation layers separate the interconnection wires from the edges of the battery pieces, and when temperature changes occur in the bending forming process of the battery pieces and the using process of the photovoltaic module, the isolation layers directly bear pressure applied by the interconnection wires and disperse the pressure to the edges of the battery pieces, so that the photovoltaic module is prevented from being damaged. The isolation layer is arranged on the photovoltaic module, so that the effects of buffering and dispersing the pressure are achieved, subfissure and breakage of the edges of the battery pieces caused by direct pressure application of the interconnection wires on the edges of the battery pieces are avoided, the battery pieces are prevented from being damaged in the bending forming process, the yield is improved, and the service life of the photovoltaic module is prolonged due to the buffering and dispersing effects of the isolation layer in the using process.

Description

Technical Field

[0001] The present invention relates to the technical field of photovoltaics, and particularly to a photovoltaic module and a method for manufacturing the same. Background Art

[0002] To adapt to a curved installation surface and improve the integration of the photovoltaic module with the scene, the photovoltaic module can be made into a curved shape that fits the shape of the installation surface, such as photovoltaic tiles laid on the roof of a building, photovoltaic panels covered on the roof of a vehicle, etc. For an arc-shaped photovoltaic module, amorphous silicon solar cells (such as thin-film solar cells) can be used due to their advantages of being bendable and non-fragmentable, but their photoelectric conversion efficiency is too low and the power generation is small. However, using crystalline silicon solar cells with high photoelectric conversion efficiency and high power generation to prepare arc-shaped photovoltaic modules has the following defects.

[0003] Crystalline silicon itself has the characteristic of being easily broken. Multiple crystalline silicon cells need to be welded by interconnecting wires to form a series and parallel structure. When this structure is encapsulated on a curved surface, the bent interconnecting wires are at the edge position of the crystalline silicon cell, which will bring additional stress damage to the crystalline silicon cell, resulting in the appearance of hidden cracks or even fragmentation at the edge position of the cell. Moreover, the interconnecting wires usually have a structure with a copper substrate and a tin coating on the surface, and their thermal expansion coefficients are inconsistent with those of the crystalline silicon cell. During the use of the cell, temperature rise and fall will bring additional stress damage, especially to the edge position of the cell, where the degree of damage is higher. In addition, the series and parallel cell structure formed by welding multiple crystalline silicon cells with interconnecting wires needs to be laminated by stacking a front plate and a back plate on the front and back sides respectively. At least one of the front plate and the back plate needs to be a rigid arc-shaped plate that is consistent with the designed shape. The cell structure is placed on the arc-shaped plate, and lamination is completed after vacuum pumping. When the vacuum is pumped in the lamination chamber at a relatively fast speed, the cell structure with a certain flexibility will instantaneously adhere to the arc-shaped plate, resulting in fragmentation during the encapsulation of the crystalline silicon cell.

[0004] Therefore, there is an urgent need for a photovoltaic module and a method for manufacturing the same to solve the above problems. Summary of the Invention

[0005] The purpose of the present invention is to provide a photovoltaic module and a method for manufacturing the same, which can avoid the occurrence of hidden cracks or even fragmentation at the edge of the cell due to the concentrated stress given by the interconnecting wires, improve the yield rate during the production process of the photovoltaic module, and extend the service life of the photovoltaic module.

[0006] To achieve this purpose, the present invention adopts the following technical solutions:

[0007] In a first aspect, a photovoltaic module is provided, including:

[0008] At least two cell wafers;

[0009] Interconnecting wires, adjacent ones of the cell wafers are connected by the interconnecting wires to form a cell string;

[0010] Isolation layers, the isolation layers are provided on the end edges of adjacent ones of the cell wafers close to each other, and the isolation layers separate the end edges from the interconnecting wires.

[0011] As a preferred solution of the photovoltaic module provided by the present invention, the positive and negative electrodes of the cell wafer are located on the same side of the cell wafer, the interconnecting wires are located on the same side of adjacent ones of the cell wafers, and one isolation layer is separately provided on each of the ends of adjacent ones of the cell wafers close to each other or the same isolation layer is shared.

[0012] As a preferred solution of the photovoltaic module provided by the present invention, the positive and negative electrodes of the cell wafer are located on different sides of the cell wafer, the interconnecting wires are connected to different sides of adjacent ones of the cell wafers, and one isolation layer is separately provided on each of the ends of adjacent ones of the cell wafers close to each other.

[0013] As a preferred solution of the photovoltaic module provided by the present invention, the cell string is coated with a packaging layer.

[0014] As a preferred solution of the photovoltaic module provided by the present invention, one packaging layer is laid and fixed on each of the opposite sides of the cell string, and each packaging layer covers the same side of all the cell wafers.

[0015] As a preferred solution of the photovoltaic module provided by the present invention, the positive and negative electrodes of the cell wafer are located on different sides of the cell wafer, one packaging layer is laid on each of the two sides of each cell wafer, and one end of the packaging layer laid on one side of the cell wafer covers the end edge on the other side of the adjacent cell wafer as the isolation layer.

[0016] As a preferred solution of the photovoltaic module provided by the present invention, the cell wafers are arranged in a first direction, the isolation layer extends from one end of the cell wafer to the other end in a second direction, and the second direction is perpendicular to the first direction.

[0017] As a preferred solution of the photovoltaic module provided by the present invention, the material of the isolation layer is PET, PE, PC or PU.

[0018] As a preferred solution of the photovoltaic module provided by the present invention, an adhesive layer is provided on the isolation layer, and the adhesive layer adheres to the cell wafer.

[0019] As a preferred solution of the photovoltaic module provided by the present invention, the photovoltaic module further includes a curved surface support structure, and the cell string is encapsulated in the curved surface support structure.

[0020] Second aspect, a method for manufacturing a photovoltaic module is provided, including the following steps:

[0021] Lay an isolation layer on the edge of the cell;

[0022] Connect adjacent two cells through an interconnection wire to form a cell string, and the isolation layer separates the interconnection wire from the edge of the cell;

[0023] Package the cell string into a curved support structure.

[0024] As a preferred solution of the method for manufacturing a photovoltaic module provided by the present invention, the step of packaging the cell string into a curved support structure includes:

[0025] Package the cell string to form a cell string assembly;

[0026] Plasticize the cell string assembly into a curved shape;

[0027] Laminating the curved support structure on both sides of the cell string assembly.

[0028] As a preferred solution of the method for manufacturing a photovoltaic module provided by the present invention, when packaging the cell string, after wrapping a packaging layer around the cell string, heat and laminate it to achieve adhesive packaging of the packaging layer and the cell string;

[0029] Plasticize the cell string assembly into a curved shape before the temperature of the packaging layer drops to the softening point.

[0030] Advantages of the present invention:

[0031] For the photovoltaic module and the method for manufacturing a photovoltaic module provided by the present invention, by setting an isolation layer on the edge of the cell, the interconnection wire can be separated from the edge of the cell. During the bending process of the cell and when the temperature changes during the use of the photovoltaic module, the isolation layer is used to directly bear the pressure exerted by the interconnection wire and disperse the pressure to the edge of the cell, playing a role in buffering and dispersing the pressure. There is no concentrated stress point at the edge of the cell, so the cell can be protected from hidden cracks and breakages. That is, the setting of the isolation layer can prevent the pressure of the interconnection wire from being directly applied to the edge of the cell, prevent the cell from being damaged during the bending process, improve the yield rate during the production process of the photovoltaic module, and moreover, during use, due to the buffering and dispersing effect of the isolation layer, the service life of the photovoltaic module can be extended. Description of the Drawings

[0032] Figure 1 is a schematic structural diagram of the first cell string provided by the specific embodiment of the present invention;

[0033] Figure 2 is a schematic structural diagram of the second cell string provided by the specific embodiment of the present invention;

[0034] Figure 3 It is a schematic diagram of encapsulating the first type of battery string using the first type of encapsulation layer provided by the present invention;

[0035] Figure 4 It is a schematic diagram of encapsulating the second type of battery string using the first type of encapsulation layer provided by the present invention;

[0036] Figure 5 It is a schematic structural diagram of encapsulating the first type of battery string using the second type of encapsulation layer (one end of which serves as an isolation layer) provided by the present invention;

[0037] Figure 6 It is a schematic diagram of the arrangement of the second type of encapsulation layer between two adjacent battery cells provided by the present invention;

[0038] Figure 7 It is a flowchart of the manufacturing method of the photovoltaic module provided by the specific embodiment of the present invention;

[0039] Figure 8 It is a schematic diagram of the lamination of the photovoltaic module provided by the present invention before final lamination.

[0040] In the figure:

[0041] 10. Battery string assembly;

[0042] 1. Battery cell; 2. Interconnection wire; 3. Isolation layer; 4. Encapsulation layer;

[0043] 11. First battery cell; 12. Second battery cell;

[0044] 20. Front plate;

[0045] 30. Front adhesive film;

[0046] 40. Rear adhesive film;

[0047] 50. Backsheet. Specific embodiment

[0048] The present invention will be further described in detail below with reference to the accompanying drawings and embodiments. It can be understood that the specific embodiments described herein are only for explaining the present invention, rather than limiting the present invention. Additionally, it should be noted that for the sake of description, only parts related to the present invention are shown in the drawings, rather than all the structures.

[0049] In the description of the present invention, unless otherwise clearly defined and limited, the terms "connected", "connected to", and "fixed" shall be understood in a broad sense. For example, it may be a fixed connection, a detachable connection, or an integral body; it may be a mechanical connection or an electrical connection; it may be directly connected or indirectly connected through an intermediate medium, and it may be the communication inside two elements or the interaction relationship between two elements. For those of ordinary skill in the art, the specific meanings of the above terms in the present invention can be understood according to specific situations.

[0050] In the present invention, unless otherwise clearly defined and limited, the first feature being "above" or "below" the second feature may include the direct contact between the first and second features, or may include the situation where the first and second features are not in direct contact but in contact through other features therebetween. Moreover, the first feature being "above", "over", and "on top of" the second feature includes that the first feature is directly above and obliquely above the second feature, or merely indicates that the horizontal height of the first feature is higher than that of the second feature. The first feature being "below", "beneath", and "underneath" the second feature includes that the first feature is directly below and obliquely below the second feature, or merely indicates that the horizontal height of the first feature is lower than that of the second feature.

[0051] In the description of this embodiment, the orientation or positional relationships such as "above", "below", "left", and "right" are based on the orientation or positional relationship shown in the drawings, and are only for the convenience of description and simplifying the operation, rather than indicating or implying that the device or element referred to must have a specific orientation, be constructed and operated in a specific orientation, so it cannot be understood as a limitation to the present invention. In addition, the terms "first" and "second" are only used for distinction in description and have no special meaning.

[0052] This embodiment provides a photovoltaic module, especially a curved photovoltaic module, which can solve the problems of edge cracking and fragmentation of the battery, as well as the problem of fragmentation of the battery chip 1 caused by impact force during the vacuum lamination encapsulation process.

[0053] See Figure 1 , the photovoltaic module includes a battery chip 1 and an interconnection wire 2. The battery chip 1 in this embodiment is a crystalline silicon battery chip, and there are multiple battery chips 1 arranged in sequence along a first direction. Referring to the orientation in Figure 1 , the direction from left to right is the first direction. Conductive connection is achieved between adjacent two battery chips 1 through the interconnection wire 2. After all the battery chips 1 arranged along the first direction are connected by the interconnection wire 2, a battery string is formed to realize the convergence of current and voltage in all the battery chips 1. Isolation layers 3 are covered at the end edges of adjacent two battery chips 1 close to each other, and the isolation layers 3 separate the end edges of the battery chips 1 from the interconnection wire 2.

[0054] By providing an isolation layer 3 at the edge of the cell 1, the interconnection wire 2 can be separated from the edge of the cell 1. During the bending process of the cell 1 and when temperature changes occur during the use of the photovoltaic module, the isolation layer 3 is used to directly bear the pressure exerted by the interconnection wire 2 and disperse the pressure to the edge of the cell 1, playing a role in buffering and dispersing the pressure. There is no concentrated stress point at the edge of the cell 1, so the cell 1 can be protected from hidden cracks and breakage. That is, the provision of the isolation layer 3 can prevent the pressure of the interconnection wire 2 from being directly applied to the edge of the cell 1, prevent the cell 1 from being damaged during the bending process, improve the yield rate during the production process of the photovoltaic module, and moreover, during use, due to the buffering and dispersing effect of the isolation layer 3, the service life of the photovoltaic module can be extended.

[0055] The surface of the cell 1 includes an edge region and a non-edge region. The edge region is the region where the cell 1 extends inward from the outermost edge by a preset dimension, and the edge region surrounds the non-edge region. Taking the cell 1 as a rectangle as an example, the edge region is a rectangular ring, and the non-edge region is the region inside the rectangular ring. The interconnection wire 2 is connected to the non-edge region of the cell 1 and is specifically welded to the electrode grid line in the non-edge region to achieve the convergence of current. The interconnection wire 2 is a wire with a copper substrate and a tin plating on the surface. During welding, heating and a certain force need to be applied to complete the welding with the electrode grid line. Welding the interconnection wire 2 in the non-edge region can reduce the stress on the relatively fragile edge region and prevent the edge of the cell 1 from cracking during welding.

[0056] The above-mentioned preset dimension is the width of the edge region. The isolation layer 3 can be entirely covered within the width range of the edge region. Exemplarily, the width of the edge region is 2 mm to 5 mm, and in this embodiment, it is selected as 3 mm, and the width of the isolation layer 3 is also 3 mm. While ensuring that the edge region of the cell 1 is not damaged by concentrated stress, it will not interfere with the extraction of current through the interconnection wire 2 (if the width of the edge region is too wide, it may lead to a too short welding length between the interconnection wire 2 and the electrode grid line, and the converged current amount is relatively low).

[0057] Optionally, the isolation layer 3 extends from one end of the cell 1 to the other end along the second direction, and the second direction is perpendicular to the first direction. That is, the isolation area covers the entire length range of the edge region of the cell 1, dispersing the pressure exerted by the interconnection wire 2 to a larger area, further reducing the phenomenon of concentrated stress in the edge region. In other embodiments, on the premise of ensuring that the edge region is not damaged by concentrated stress, the length dimension of the isolation layer 3 can be adaptively shortened.

[0058] Optionally, the material of the isolation layer 3 is a polymer material that does not flow or decompose during the manufacturing process, such as PET (polyethylene terephthalate plastic), PE (polyethylene plastic), PC (polycarbonate plastic), PU (polyurethane plastic), etc. It has strong stability, excellent insulation effect, will not melt in a high-temperature welding environment, and can play a good buffering role, reducing the stress on the edge of the battery cell 1.

[0059] In order to achieve fixation between the isolation layer 3 and the battery cell 1 and prevent the isolation layer 3 from moving relative to the battery cell 1 during subsequent welding of the interconnection wires 2 and other processes, in this embodiment, an adhesive layer is provided on the isolation layer 3, and the isolation layer 3 is bonded to the battery cell 1 through the adhesive layer to ensure stability after covering.

[0060] In some embodiments, the adhesive layer may be an adhesive film compounded on the isolation layer 3, such as EVA (ethylene-vinyl acetate copolymer) film, POE (polyolefin elastomer) film, PVB (polyvinyl butyral) film and other thermosetting or thermoplastic films, which are heated and adhered to the battery cell 1 in a high-temperature welding environment and will not fall off due to the high temperature.

[0061] In some other embodiments, a high temperature resistant tape may also be used to assist in bonding the isolation layer 3 to the battery cell 1 .

[0062] To achieve current convergence, the interconnection wire 2 connects the positive electrode of one of two adjacent battery cells 1 and the negative electrode of the other. Figure 1 The positive electrode and the negative electrode of the battery cell 1 shown in FIG. 1 are located on different sides of the battery cell 1, and the orientation of the battery is the same. Figure 1 In the orientation, the positive electrode faces upward and the negative electrode faces downward, or the positive electrode faces downward and the negative electrode faces upward. At this time, the interconnection wire 2 is connected to different sides of two adjacent battery cells 1, and the interconnection wire 2 passes between the two adjacent battery cells 1 to achieve the convergence of the battery string. In the battery string, the edges of one end of two adjacent battery cells 1 close to each other are individually covered with a layer of isolation layer 3, and the isolation layer 3 is arranged on different sides of the battery cell 1 to separate the interconnection wire 2 and the edge of the battery cell 1.

[0063] Figure 2 The positive and negative electrodes of the battery cell 1 shown in FIG. 1 are located on the same side of the battery cell 1 , and the orientation of the batteries is the same. Figure 2 In this case, the interconnecting wires 2 are welded to the same side of all the battery cells 1 to realize the current converging of the battery string. In this battery string, the ends of two adjacent battery cells 1 close to each other can share the same isolation layer 3, such as Figure 2In this case, both ends of the isolation layer 3 are adhesively bonded to the edge regions on the same side of two adjacent solar cells 1 respectively. The isolation layer 3 has better mechanical properties, can achieve a better buffering effect, and at the same time can speed up the process of laying the isolation layer 3. Of course, in other embodiments, an isolation layer 3 can also be separately laid at one end of each of two adjacent solar cells 1 close to each other.

[0064] In this embodiment, referring to Figures 3 to 5 , after the series connection of the solar cells is completed, a packaging layer 4 is wrapped around the series-connected solar cells. On the one hand, the setting of the packaging layer 4 can protect the welding parts of the interconnection wires 2 from being damaged, making the subsequent processes proceed more smoothly. On the other hand, after the series connection of the solar cells is completed, the solar cells 1 can still move relative to each other and cannot form an integral body convenient for transportation. After wrapping the packaging layer 4, the positions of multiple solar cells 1 can be fixed, and the strength and hardness of the series-connected solar cells can be increased, which is convenient for transportation and not easily damaged.

[0065] In some embodiments, for Figure 1 and Figure 2 the series-connected solar cells shown, one packaging layer 4 is laid flat and fixed on each of the opposite sides of the series-connected solar cells, as shown in Figure 3 and Figure 4 . That is, the packaging layer 4 is of an integral structure. One packaging layer 4 is stacked and fixed on each side of the series-connected solar cells to complete the packaging.

[0066] In the above solution, the packaging layer 4 can be a thermosetting or thermoplastic film such as EVA, POE, PVB, etc. After heating, it can be adhesively fixed on both sides of the series-connected solar cells. Further, the packaging layer 4 can be laminated with a PET substrate material or laminated with a PE, PU, or PC substrate material to increase strength, thereby improving the strength and hardness of the packaged series-connected solar cells.

[0067] In some other embodiments, for Figure 1 the series-connected solar cell structure shown, if the materials selected for the isolation layer 3 and the packaging layer 4 are the same, the packaging layer 4 and the isolation layer 3 can be integrated. Specifically, referring to Figure 5 , one packaging layer 4 is laid on each side of each solar cell 1, and one end of the packaging layer 4 laid on one side of the solar cell 1 covers the end edge on the other side of the adjacent solar cell 1 as the isolation layer of this solar cell 1. At this time, the series-connected solar cells adopt a segmented packaging structure. Part of the packaging layer 4 is used for outer packaging, and part extends to the inside to isolate the interconnection wires 2 and the series-connected solar cells. When laying the isolation layer 3, the layout of the packaging layer 4 is also completed, saving processes and the number of components.

[0068] Such as Figure 6As shown in the figure, two adjacent solar cells 1 are defined as the first solar cell 11 and the second solar cell 12 respectively. The interconnection wire 2 is connected to different sides of the first solar cell 11 and the second solar cell 12. Defining the upward direction as the front and the downward direction as the back, one end of the encapsulation layer 4 on the front of the first solar cell 11 passes through the gap between the second solar cell 12 and the interconnection wire 2 and covers the back edge area of the second solar cell 12, serving as the isolation layer 3 on the edge area of the second solar cell 12; one end of the encapsulation layer 4 on the back of the second solar cell 12 passes through the gap between the first solar cell 11 and the interconnection wire 2 and covers the front edge area of the first solar cell 11, serving as the isolation layer 3 on the edge area of the first solar cell 11. With this setting, the layout of the encapsulation layer 4 can be completed between every two adjacent solar cells 1.

[0069] In the above solution, the encapsulation layer 4 can be a structure of a composite film on a PET base material, or a structure of a composite film on PE, PU, PC, etc. For example, a thermosetting or thermoplastic film such as EVA, POE, or PVB is laminated on a PET base material, and after heating, it can be adhesively fixed to both sides of the battery string and to the edge area of the solar cell 1.

[0070] Furthermore, referring to Figure 5 , for the two solar cells 1 located at both ends of the battery string, an encapsulation layer 4 is also provided on the side where the isolation layer 3 is not provided to complete the encapsulation of the battery string. The encapsulation layer 4 at this position does not need to extend into the battery string as an isolation layer, and its material can be a film or a composite of a film and substrates such as PET, PE, PU, PC, etc. Of course, on the solar cells 1 at both ends, since the side where the interconnection wire 2 is provided has been fixedly covered by the encapsulation layer 4, the encapsulation layer 4 may not be provided on the side where the isolation layer 3 is not provided.

[0071] The encapsulated battery string is defined as the battery string assembly 10. The photovoltaic module further includes a curved surface support structure, which is encapsulated outside the battery string assembly 10 and plays a role in shaping, supporting, and protecting the battery string assembly 10.

[0072] As Figure 7 shown, this embodiment also provides a method for manufacturing a photovoltaic module, including the following steps:

[0073] S1. Lay the isolation layer 3 on the edge of the solar cell 1;

[0074] Specifically, in step S1, the material of the isolation layer 3 is as described above, and it is adhered to the solar cell 1 to prevent relative movement along the edge of the solar cell 1 in subsequent processes.

[0075] S2. Connect adjacent solar cells 1 through the interconnection wire 2 to form a battery string, and the isolation layer 3 separates the interconnection wire 2 and the edge of the solar cell 1;

[0076] The interconnection wires 2 are welded to the electrode grid lines in the non-edge area of the solar cell 1. After all the solar cells 1 are welded through the interconnection wires 2, a battery string is formed.

[0077] S3. Package the battery string into the curved support structure to form a curved photovoltaic module.

[0078] Further, in step S3: packaging the battery string into the curved support structure specifically includes:

[0079] S31. Package the battery string to form a battery string assembly 10;

[0080] Wrap the encapsulation layer 4 around the battery string to encapsulate the battery string. For the battery string structures shown in Figure 1 and Figure 2 the encapsulation layer 4 can be stacked on both sides to achieve encapsulation and fixation. For the battery string structure shown in Figure 1 if the material of the isolation layer 3 is the same as that of the encapsulation layer, the layout method of the encapsulation layer 4 in Figure 5 can be referred to for encapsulation and fixation, which will not be elaborated here. After the battery string is wrapped with the encapsulation layer 4, it is heated and laminated in a vacuum environment to realize the adhesive encapsulation between the encapsulation layer 4 and the battery string, forming the battery string assembly 10.

[0081] S32. Laminate the curved support structure on both sides of the battery string assembly 10 with high strength and hardness to form a curved photovoltaic module.

[0082] Refer to Figure 8 The curved support structure includes a front plate 20 and a back plate 50 separately arranged on both sides of the battery string assembly 10. A front adhesive film 30 is provided between the front plate 20 and the battery string assembly 10, and a back adhesive film 40 is provided between the battery string assembly 10 and the back plate 50, and the front plate 20 faces the light-receiving surface of the solar cell 1. Before lamination, at least one of the front plate 20 and the back plate 50 is a rigid curved plate, which can maintain a certain shape to support the entire photovoltaic module to reach the designed form. For example, the front plate 20 is a rigid curved plate, and the back plate 50 is a flexible plate. During the lamination process, the shape of the front plate 20 remains unchanged, and the back plate 50 deforms into a structure with the same shape as the front plate 20, and the overall formed final product is curved. During the encapsulation process of the battery string assembly 10, after the front plate 20, the front adhesive film 30, the battery string assembly 10, the back adhesive film 40, and the back plate 50 are stacked in sequence, they need to be heated and laminated in a vacuum environment. If the battery string is flat, during the vacuum pumping process, the battery string assembly 10 and other flexible components will instantly adhere to the rigid curved plate, causing the solar cell 1 to be damaged by the instantaneous impact force, and the lamination yield is low.

[0083] In this embodiment, between step S31 and step S32, it further includes:

[0084] S310. Shape the battery string assembly 10 into a curved surface form adapted to the curved plate.

[0085] As Figure 8 shown, if the photovoltaic module to be formed is arc-shaped, then before lamination and encapsulation, at least one of the front plate 20 and the back plate 50 selected is arc-shaped. In step S310, the battery string assembly 10 is pre-bent and shaped into an arc shape, and this arc shape is consistent with or similar to the curvature of the curved plate. Then in step S32, after laminating the battery string assembly 10, the front plate 20, and the back plate 50, the arc-shaped battery string assembly 10 fits exactly or approximately fits the curved plate. Thus, during the vacuum pumping process, the battery string assembly 10 will not undergo instantaneous bending deformation, and the impact force between it and the curved plate is small. While other flexible structures (the front adhesive film 30, the back adhesive film 40, and the flexible plate among the front plate 20 and the back plate 50) act on the battery string assembly 10 instantaneously, it will not generate a large impact force and will not cause the breaking of the battery cells 1.

[0086] Moreover, during the process of bending and shaping the battery string assembly and during the encapsulation and lamination process of step S32, due to the existence of the isolation layer 3 at the edges of the battery cells 1, there is no concentrated stress point, which can avoid the edge cracking and breakage of the battery cells 1 and improve the yield rate of the final lamination process.

[0087] Optionally, after step S31, step S310 is implemented before the temperature of the encapsulation layer 4 drops to the softening point, which can shorten the heating time of the battery string or even reach the better temperature for bending and shaping without heating again, reduce the energy consumption during the production process, and speed up the production rhythm.

[0088] Furthermore, after the battery string assembly 10 is cooled, the lamination process in step S32 is implemented.

[0089] Exemplarily, the front plate 20 can be glass, PET, or other polymer materials, or can also be a single structure or composite structure of film layers such as PVDF (polyvinylidene fluoride), ETFE (ethylene-tetrafluoroethylene copolymer), etc. For example, it can be a structure of a PVDF film layer composite with a PET substrate (that is, a layer of PVDF is provided on the PET). The back plate 50 can be glass, a composite back plate, a fiber back plate, etc.

[0090] In this embodiment, the front plate 20 and / or the back plate 50 is a heat-bent glass plate or a PET plastic plate. For example, the front plate 20 is a heat-bent glass plate, which is rigid and its shape remains unchanged before and after lamination. The back plate 50 is a flexible PVDF film layer, and during the vacuum pumping process in the lamination process, it closely adheres to the curved surface-shaped battery string assembly 10 and deforms into a curved shape.

[0091] Exemplarily, the front encapsulant film 30 and the rear encapsulant film 40 are thermoplastic or thermosetting encapsulant films such as EVA, POE, and PVB, and can bond the structures on both sides thereof after heating and applying lamination pressure to achieve lamination and fixation.

[0092] Certainly, in other embodiments, the encapsulated battery string may not be pre-bent and shaped, and directly undergoes final lamination encapsulation in a planar form. During the lamination process, the battery string assembly 10 deforms and fits with the curved front plate 20 or the back plate 50.

[0093] Obviously, the above-mentioned embodiments of the present invention are merely examples for clearly illustrating the present invention, rather than limiting the implementation manners of the present invention. For those of ordinary skill in the art, various obvious changes, re-adjustments, and substitutions can be made without departing from the protection scope of the present invention. It is not necessary and impossible to enumerate all the implementation manners here. Any modifications, equivalent substitutions, and improvements made within the spirit and principle of the present invention shall be included in the protection scope of the claims of the present invention.

Claims

1. A photovoltaic module, characterized in that, Comprising: At least two solar cells; Interconnection wires, with adjacent two of the solar cells connected by the interconnection wires to form a battery string; Isolation layers, with the isolation layers provided on the end edges of adjacent two of the solar cells close to each other, and the isolation layers separating the end edges from the interconnection wires.

2. The photovoltaic module according to claim 1, wherein, The positive and negative electrodes of the solar cell are on the same side of the solar cell, the interconnection wires are on the same side of adjacent two of the solar cells, and one isolation layer is separately provided on each of the ends of adjacent two of the solar cells close to each other or the same isolation layer is shared.

3. The photovoltaic module according to claim 1, wherein, The positive and negative electrodes of the solar cell are on different sides of the solar cell, the interconnection wires are connected to different sides of adjacent two of the solar cells, and one isolation layer is separately provided on each of the ends of adjacent two of the solar cells close to each other.

4. The photovoltaic module according to claim 1, characterized in that, The battery string is encapsulated with an encapsulation layer.

5. The photovoltaic module according to claim 4, wherein One encapsulation layer is laid and fixed flat on each of the opposite sides of the battery string, and each encapsulation layer covers the same side of all the solar cells.

6. The photovoltaic module according to claim 4, characterized in that, The positive and negative electrodes of the solar cell are on different sides of the solar cell, one encapsulation layer is laid on each of the two sides of each solar cell, and one end of the encapsulation layer laid on one side of the solar cell covers the end edge on the other side of the adjacent solar cell as the isolation layer.

7. The photovoltaic module according to claim 1, characterized in that, The solar cells are arranged in a first direction, and the isolation layer extends from one end of the solar cell to the other end in a second direction, and the second direction is perpendicular to the first direction.

8. The photovoltaic module according to claim 1, wherein, The material of the isolation layer is PET, PE, PC or PU.

9. The photovoltaic module according to claim 1, wherein, An adhesive layer is provided on the isolation layer, and the adhesive layer adheres to the solar cell.

10. The photovoltaic module according to any one of claims 1-9, characterized in that, The photovoltaic module further includes a curved surface support structure, and the battery string is encapsulated in the curved surface support structure.

11. A method for manufacturing a photovoltaic module, characterized in that, Including the following steps: Laying an isolation layer on the edge of the solar cell; Connecting adjacent two of the solar cells through interconnection wires to form a battery string, and the isolation layer separating the interconnection wires from the edge of the solar cell; Encapsulating the battery string into the curved surface support structure.

12. The manufacturing method of the photovoltaic module according to claim 11, wherein, The step of encapsulating the battery string into the curved surface support structure includes: Encapsulating the battery string to form a battery string assembly; Shaping the battery string assembly into a curved surface form; Laminating the curved surface support structure on both sides of the battery string assembly.

13. The manufacturing method of the photovoltaic module according to claim 12, characterized in that, When encapsulating the battery string, after wrapping the battery string with an encapsulation layer, heating and laminating are performed to realize the adhesive encapsulation of the encapsulation layer and the battery string; The battery string assembly is shaped into a curved surface form before the temperature of the encapsulation layer drops to the softening point.

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