Photovoltaic module and manufacturing method thereof

Abstract

The invention discloses a photovoltaic module and a manufacturing method thereof, the photovoltaic module comprises a panel, a battery piece layer and a back plate, the battery piece layer is located between the panel and the back plate, packaging adhesive film layers are arranged between the battery piece layer and the back plate and between the battery piece layer and the panel, the area of the battery piece layer is smaller than the area of the panel and / or the area of the back plate, and the area of the battery piece layer is smaller than the area of the panel and / or the area of the back plate. The panel and / or the back plate are / is provided with a sealing edge extending out of the peripheral edge of the battery piece, and the inner surface of the sealing edge is provided with a plurality of protruding parts. The photovoltaic module further comprises a sealing rubber strip arranged on the periphery of the battery piece layer, the sealing rubber strip is laminated between the panel and the back plate, at least one of the upper surface and the lower surface of the sealing rubber strip is in contact fit with the protruding parts, and a part of the sealing rubber strip is squeezed into a to-be-filled area between the protruding parts. According to the photovoltaic module, the interface water blocking capability is improved, and the water vapor resistance of the photovoltaic module is improved.

Description

Photovoltaic module and manufacturing method thereof Technical Field

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

[0002] The National Energy Administration issued a notice regarding the preparation of the 14th Five-Year Plan for Renewable Energy: During the 14th Five-Year Plan period, renewable energy will become the primary source of incremental energy consumption, with the goal of achieving the strategic goal of non-fossil energy accounting for 20% of total energy consumption by 2030. Renewable energy sources such as solar photovoltaics will have broad development potential in the future. With the rapid expansion of N-type battery production and market launch, they are sensitive to moisture and acid. Photovoltaic cells are typically encapsulated in glass and backsheet materials, surrounded by a frame and sealant to prevent moisture from penetrating the cell interior. The sealant serves to bond the laminate and frame, prevent moisture from penetrating, and provides long-term resistance to UV aging and high temperatures.

[0003] Currently, single-component silicone sealants are commonly used around the perimeter of modules, with a service life of approximately 25 years. However, over time, moisture can penetrate the silicone and enter the module from the perimeter, causing degradation of the internal material and impacting the module's power generation and safety performance. Currently, in PV modules, sealing strips are often added directly to the interlayer around the panel, or to the frame notches and laminates. If the sealing strips around the cell layers do not adhere well to the panel, they can easily shift, affecting the cell strings and requiring repairs that impact production capacity. Furthermore, after years of outdoor high-temperature exposure, there is a risk of aging and delamination, resulting in poor moisture resistance for PV modules.

[0004] Summary of the Invention

[0005] The purpose of the present disclosure is to provide a photovoltaic module and a manufacturing method thereof, so as to improve the water resistance of the interface and increase the water vapor resistance of the photovoltaic module.

[0006] The present disclosure provides a photovoltaic module, comprising a panel, a cell layer, and a backplane, wherein the cell layer is located between the panel and the backplane, and an encapsulation film layer is provided between the cell layer and the backplane, and between the cell layer and the panel. The area of ​​the cell layer is smaller than that of the panel and / or the backplane, so that the panel and / or the backplane has a sealing edge extending beyond the four edges of the cell layer, and the inner surface of the sealing edge is provided with a plurality of protrusions; the photovoltaic module also includes a sealing strip arranged around the cell, the sealing strip is laminated between the panel and the backplane, and at least one of its upper and lower surfaces is in contact with the protrusions, and a portion of the sealing strip is squeezed into the area to be filled between the protrusions.

[0007] In some embodiments, the protrusion is a strip structure along the long side and / or short side of the panel.

[0008] In some embodiments, the protrusion is triangular prism-shaped. The structure of the protrusion increases the contact area with the sealing strip, improves adhesion and reduces delamination, increases the path for water vapor to enter the to-be-filled area inside the component along the interface, and improves the water resistance of the interface.

[0009] In some embodiments, the sealing strip includes a fluororesin layer and an adhesive layer, wherein the adhesive layer is bonded to the fluororesin layer. The fluororesin layer and the adhesive layer are disposed adjacent to each other. The adhesive layer is a butyl sealant layer, and the fluororesin layer enhances the UV resistance and adhesion of the butyl sealant, facilitating initial fixation.

[0010] In some embodiments, the adhesive layer is in the form of a solid adhesive strip or paste.

[0011] In some embodiments, the sealing strip has a single-layer or multi-layer structure.

[0012] In some embodiments, the adhesive layer is located between the two fluororesin layers or the adhesive layer is located on the inner side of the sealing edge, and the fluororesin layer is located on the outer side of the sealing edge.

[0013] In some embodiments, the width of the adhesive layer is greater than or equal to the width of the fluororesin layer.

[0014] In some embodiments, the thickness of the fluororesin layer is 0.1 to 0.5 mm, and the thickness of the adhesive layer is 0.5 to 1.5 mm.

[0015] In some embodiments, the width of the fluororesin layer is 0.1 to 1 mm, the width of the adhesive layer is 4.9 to 14 mm, or the widths of the fluororesin layer and the adhesive layer are 5 to 15 mm.

[0016] In some embodiments, the width of the protrusion is 5 to 15 mm, and the height of the protrusion is 10 to 20 μm.

[0017] In some embodiments, an outer edge of the packaging film layer and an inner edge of the sealing strip are connected.

[0018] In some embodiments, the panel is glass; and the packaging film layer is a POE or EPE film layer.

[0019] The present disclosure further provides a method for manufacturing a photovoltaic module, wherein the method for manufacturing the photovoltaic module adopts any of the photovoltaic modules described above, and the method for manufacturing the photovoltaic module comprises the following steps:

[0020] S1. Lay an encapsulation film layer between the battery cell layer and the panel and make a sealing strip on the sealing edge of the panel or lay the prepared sealing strip on the sealing edge of the panel, with the outer edge of the encapsulation film layer and the inner edge of the sealing strip in contact;

[0021] S2. Place the battery cell layer on the encapsulation film layer, apply the encapsulation film layer to the other side of the battery cell layer, and cover it with a backplane;

[0022] S3, applying pressure to the sealing edge of the panel using a load and maintaining it for a period of time;

[0023] S4. The photovoltaic module is laminated at high temperature, the sealing strip is melted by the heat, and a portion of the sealing strip is squeezed into the area to be filled between the protrusions.

[0024] In some embodiments, in step S3, the peel strength between the panel and / or the back panel and the sealing strip is 5.5N / 25MM.

[0025] In some embodiments, in step S1, when making the sealing strip, the fluororesin layer of the sealing strip is first brushed on the sealing edge of the panel, and then the adhesive layer of the sealing strip is bonded above or inside the fluororesin layer, or the adhesive layer is suspended in the air and the fluororesin layer is brushed on the upper and lower sides of the adhesive layer.

[0026] The present disclosure adopts the above solution, which has the following advantages over the prior art:

[0027] The photovoltaic module disclosed herein has an encapsulation film layer provided between the cell layer and the panel, and between the cell layer and the backplane. The protrusions on the panel are in contact with the sealing strips around the cell, and part of the sealing strips is squeezed into multiple areas to be filled, thereby increasing the contact area between the sealing strips and the panel, making the panel and the backplane more tightly combined, increasing adhesion and reducing delamination, improving the interface water resistance, and increasing the water vapor resistance of the photovoltaic module. BRIEF DESCRIPTION OF THE DRAWINGS

[0028] In order to more clearly illustrate the embodiments of the present disclosure or the technical solutions of the prior art, the following briefly introduces the drawings required for use in the embodiments or the description of the prior art. Obviously, the drawings described below are only some embodiments of the present disclosure. For ordinary technicians in this field, other drawings can be obtained based on these drawings without any creative work.

[0029] FIG1 is a schematic diagram of a photovoltaic assembly according to an embodiment of the present disclosure;

[0030] FIG2 is a top view of a photovoltaic assembly according to an embodiment of the present disclosure;

[0031] FIG3 is a cross-sectional view of a photovoltaic module according to an embodiment of the present disclosure;

[0032] FIG4a is a schematic structural diagram of a sealing strip;

[0033] FIG4 b is another schematic diagram of the structure of the sealing strip;

[0034] FIG4 c is another structural schematic diagram of the sealing strip.

[0035] in,

[0036] 1. Photovoltaic module; 11. Panel; 111. Protrusion; 12. Backsheet; 13. Cell layer; 14. Encapsulation film layer; 15. Sealing strip; 151. Fluororesin layer; 152. Adhesive layer;

[0037] 2. Area to be filled. DETAILED DESCRIPTION

[0038] In order to enable those skilled in the art to better understand the present disclosure, the present disclosure is further described in detail below in conjunction with the accompanying drawings and specific embodiments. Obviously, the embodiments described are only some of the embodiments of the present disclosure, and not all of them. Based on the embodiments of the present disclosure, all other embodiments obtained by those skilled in the art without creative work are within the scope of protection of the present disclosure.

[0039] In the following description, many specific details are set forth to facilitate a full understanding of the present invention. However, the present invention may also be implemented in other ways different from those described herein. Those skilled in the art may make similar generalizations without violating the connotation of the present invention. Therefore, the present invention is not limited to the specific embodiments disclosed below.

[0040] 1 to 3 , this embodiment provides a photovoltaic module 1 , including a panel 11 , a cell layer 13 , a back sheet 12 , and a frame (not shown in the figures).

[0041] Furthermore, the cell layer 13 is located between the panel 11 and the back panel 12. The front surfaces of the panel 11 and the cell layer 13 are bonded together, and the back surface of the back panel 12 and the cell layer 13 are bonded together. The area of ​​the cell layer 13 is smaller than the areas of the panel 11 and the back panel 12, so that the panel 11 and the back panel 12 have a sealing edge extending beyond the four edges of the cell layer 13. The frame connects the four edges of the panel 11 and the back panel 12. An encapsulation film layer 14 is provided between the cell layer 13 and the back panel 12, and between the cell layer 13 and the panel 11. Specifically, the encapsulation film layer 14 is a POE or EPE film layer. The cell layer 13 includes a plurality of conductively connected solar cells. The layout of each cell is not fixed and can be designed according to needs.

[0042] Furthermore, as shown in Figures 1 and 2 , the inner surface of the sealing edge is provided with a plurality of protrusions 111. These protrusions 111 are strip-shaped structures extending along the long and short sides of the panel 11 and are shaped like triangular prisms. Specifically, in this embodiment, the panel 11 is made of glass, and the inner surface of the sealing edge of the glass is provided with the plurality of protrusions 111. In other embodiments, the inner surface of the sealing edge of the back panel 12 may also be provided with the plurality of protrusions, or the inner surfaces of the sealing edges of both the panel 11 and the back panel 12 may also be provided with the plurality of protrusions.

[0043] Furthermore, the width of the protrusion 111 is 5 to 15 mm, and the height of the protrusion 111 is 10 to 20 μm. More specifically, the width of the protrusion is 8 mm, and the height of the protrusion 111 is 15 μm.

[0044] Sealing strips 15 are provided around the cell layer 13, and the outer edge of the encapsulation film layer 14 is connected to the inner edge of the sealing strips 15. The sealing strips 15 are laminated between the panel 11 and the back panel 12, and at least one of the upper surface and the lower surface thereof is in contact with the protrusion 111. Specifically, the upper surface of the sealing strips 15 is in contact with the protrusion 111. After the photovoltaic module 1 is laminated, a portion of the sealing strips 5 is squeezed into the area to be filled 2 between the protrusions 111, which increases the contact area between the sealing strips 15 and the panel 11, increases adhesion and reduces delamination, prolongs the path for water vapor to enter the interior of the module along the interface, and improves the water resistance of the interface.

[0045] Furthermore, the panel 11 and the back plate 12 in the photovoltaic module are vacuumed to discharge non-condensable gas and moisture between the panel 11 and the back plate 12, and the air pressure between the panel 11 and the back plate 12 is lower than the atmospheric pressure.

[0046] The edges of the front panel 11 and back panel 12 are inserted into the frame, thereby connecting them as a whole. Sealing strips 15 are provided around the perimeter of the cell layer 13 to prevent uneven sealing strips 15 or varying edge stresses from overflowing outside the frame during lamination, which could negatively impact the aesthetics. This means that the photovoltaic module 1 of this embodiment maintains good aesthetics even after lamination.

[0047] Sealing strip layer 15 comprises a fluororesin layer 151 and an adhesive layer 152. Adhesive layer 152 is bonded to fluororesin layer 151 and positioned adjacent to it. Before high-temperature lamination, the width of sealing strip 15 is 5 to 15 mm, and after lamination, it is 7 to 18 mm. Fluororesin layer 151 is a fluorine-containing adhesive layer, while adhesive layer 152 is a butyl sealant layer. The width of adhesive layer 152 is greater than or equal to that of fluororesin layer 151.

[0048] The sealing strip 15 can be constructed as a single layer or multiple layers. Referring to FIG4a , the sealing strip 15 of this embodiment is a three-layer co-extruded structure, with two fluororesin layers 151 and an adhesive layer 152 disposed between the fluororesin layers 151. The thickness of the fluororesin layer 151 is 0.1 to 0.5 mm, the thickness of the adhesive layer 152 is 0.5 to 1.5 mm, and the width of the fluororesin layer 151 and the adhesive layer 152 is 5 to 15 mm. Referring to FIG4b , the sealing strip 15 can also be constructed as follows: the middle layer is the adhesive layer 152, and the upper and lower layers bonded to the middle layer are both composed of the fluororesin layer 151 and the adhesive layer 152. In this case, the width of the fluororesin layer 151 is 0.1 to 1 mm, and the width of the adhesive layer 152 is 4.9 to 14 mm. As shown in Figure 4c, the sealing strip 15 has a single-layer structure. The adhesive layer 152 of the sealing strip 15 is located on the inner side of the sealing edge, and the fluororesin layer 151 is located on the outer side of the sealing edge. The width of the fluororesin layer 151 is 0.1 to 1 mm, the width of the adhesive layer 152 is 4.9 to 14 mm, and the thickness of the fluororesin layer 151 and the adhesive layer 152 is 0.5 to 1.5 mm. In the structure of the sealing strip 15 shown in Figures 4b and 4c, the area of ​​the adhesive layer 152 is larger than the area of ​​the fluororesin layer 151. While ensuring that the sealing strip 15 has UV resistance, it also has better water-blocking properties. It should be noted that the adhesive layer 152 and the fluororesin layer 151 of this embodiment can be designed as a one-layer, two-layer, three-layer, or multi-layer structure.

[0049] Since butyl sealant itself lacks excellent UV resistance, its UV resistance rapidly declines after 30 years of outdoor use. The combination of the butyl sealant layer and the fluororesin layer enhances the sealant's UV resistance and adhesion, facilitating initial fixation. Butyl sealant is a single-component sealant primarily made of an isobutylene polymer. Using a special process, butyl rubber is processed into an environmentally friendly, non-curing, self-adhesive sealant. Its key advantages include: single-component ease of use, excellent stability within a temperature range of -40°C to 120°C; non-curing, non-corrosive properties to metal, coated glass, concrete, marble, granite, and other materials, making it widely applicable; UV, ozone, water, and chemical resistance; and the absence of any solvents, making it safe and environmentally friendly. It boasts a service life exceeding 20 years, allowing for extended storage; and excellent aging, heat, acid, and alkali resistance, as well as excellent airtightness and electrical insulation properties.

[0050] The butyl rubber of this embodiment must contain modifying additives such as UV inhibitors and antioxidants to further enhance its UV and oxidation resistance. Available in solid strip or hot-melt paste form, the paste has a viscosity of 30-90 mm² / s at 20°C, a melt index (130°C, 10 kg) of 16-26 cm / 10 min, and a water vapor transmission rate of 0.01-0.03 g / m² / day. The paste-like butyl rubber is easier to squeeze into the area to be filled 2, providing a better water-blocking effect.

[0051] Applying hot-melt butyl adhesive to the frame notch and laminate is not as effective as applying it directly inside the laminate. It's also difficult and costly, and there's a risk of delamination for outdoor use. The laminate in this area primarily refers to the stacked panel 11, encapsulant film layer 14, cell layer 13, encapsulant film layer 14, and backsheet 12. The protrusion 111 is triangular prism-shaped, increasing the contact area with the sealing strip 15, improving adhesion and reducing delamination, enhancing the interfacial water resistance, and improving the aesthetics of the photovoltaic module after high-temperature vacuuming.

[0052] This embodiment also provides a method for manufacturing a photovoltaic module, which includes the following steps:

[0053] S1. Lay the encapsulating film layer 14 between the cell layer 13 and the panel 11 and make a sealing strip 15 on the sealing edge of the panel 11 on site or lay the made sealing strip 15 on the sealing edge of the panel 11, with the outer edge of the encapsulating film layer 14 and the inner edge of the sealing strip 15 in contact;

[0054] S2, placing the battery cell layer 13 on the packaging film layer 14, and applying the packaging film layer 14 to the other side of the battery cell layer 13, and covering it with the back plate 12;

[0055] S3, applying pressure to the sealing edge of the panel 11 using a load and maintaining it for a period of time;

[0056] S4 , performing high-temperature lamination on the photovoltaic module 1 , the sealing strip 15 is melted by the heat, and a portion of the sealing strip 15 is squeezed into the area to be filled 2 between the protrusions 111 .

[0057] In step S1, the sealing strip 15 can be made on-site or the finished sealing strip 15 can be applied to the sealing edge. When the sealing strip 15 is made on-site, a fluororesin layer 151 is first placed on the sealing edge of the panel 11, and then an adhesive layer 152 is placed above or inside the fluororesin layer 151, and the adhesive layer 152 and the fluororesin layer 151 are bonded together. If the sealing strip 15 is not made on-site on the sealing edge of the panel 11, the two ends of the adhesive layer 152 are manually pinched and the adhesive layer 152 is left suspended, and then the fluororesin layer 151 is brushed on the upper and lower layers of the adhesive layer 152, and finally the sealing strip is transferred to the sealing edge of the panel 11.

[0058] In step S3, the glass strength between panel 11 and sealing strip 15 is 5.5N / 25MM. Before lamination of photovoltaic module 1, a load is placed around panel 11, specifically at the sealing edge of panel 11, and held for 1 to 5 minutes. This pre-fixes sealing strip 15 and facilitates long-term outdoor use.

[0059] The photovoltaic module 1 of this embodiment has a simple structure and low cost, improves the module's water vapor resistance, and provides greater stability. The structural design of the sealing strip 15 provides excellent bonding and UV resistance. After lamination with a special glass structure, the sealing strip is neatly aligned within the module, achieving both performance and aesthetics.

[0060] Unless the context clearly indicates otherwise, the indefinite articles "a", "an" and "an" preceding an element or component herein are intended to indicate the quantity of the element or component without limitation. Therefore, "a", "an" and "an" should be understood to include one or at least one, and the singular form of the element or component also includes the plural form.

[0061] Throughout this specification, reference to terms such as "one embodiment," "some embodiments," "examples," "specific examples," or "some examples" means that a specific feature, structure, material, or characteristic described in conjunction with that embodiment or example is included in at least one embodiment or example of the present disclosure. In this specification, schematic representations of the above terms do not necessarily refer to the same embodiment or example. Furthermore, the specific features, structures, materials, or characteristics described may be combined in any suitable manner in any one or more embodiments or examples.

[0062] The various embodiments in this specification are described in a progressive manner, with each embodiment focusing on its differences from the other embodiments. Reference can be made to the descriptions of the identical or similar parts between the various embodiments. For the devices disclosed in the embodiments, since they correspond to the methods disclosed in the embodiments, the descriptions are relatively simple, and the relevant parts can be referred to the descriptions of the methods.

[0063] The photovoltaic module and its manufacturing method provided by the present disclosure are introduced in detail above. Specific examples are used herein to illustrate the principles and implementation methods of the present disclosure. The description of the above embodiments is only intended to help understand the method and core concept of the present disclosure. It should be noted that for ordinary technicians in this technical field, various improvements and modifications can be made to the present disclosure without departing from the principles of the present disclosure, and such improvements and modifications also fall within the scope of protection of the claims of the present disclosure.

Claims

1. A photovoltaic module, comprising a panel, a battery layer and a backplane, wherein the battery layer is located between the panel and the backplane, and an encapsulation film layer is provided between the battery layer and the backplane and between the battery layer and the panel, characterized in that: The area of ​​the cell layer is smaller than that of the panel and / or the back panel, so that the panel and / or the back panel has a sealing edge extending beyond the edges of the cell layer, and the inner surface of the sealing edge is provided with a plurality of protrusions; the photovoltaic module also includes a sealing strip arranged around the cell layer, the sealing strip is laminated between the panel and the back panel and at least one of its upper and lower surfaces is in contact with the protrusions, and a portion of the sealing strip is squeezed into the area to be filled between the protrusions.

2. The photovoltaic module according to claim 1, characterized in that: The protrusion is a strip structure along the long side and / or short side of the panel.

3. The photovoltaic module according to claim 2, characterized in that: The protrusion is in the shape of a triangular prism.

4. The photovoltaic module according to claim 1, characterized in that: The sealing strip comprises a fluororesin layer and an adhesive layer, and the adhesive layer is bonded to the fluororesin layer.

5. The photovoltaic module according to claim 4, characterized in that: The adhesive layer is in the form of a solid adhesive strip or paste.

6. The photovoltaic module according to claim 4, characterized in that: The structure of the sealing strip is single-layer or multi-layer.

7. The photovoltaic module according to claim 6, characterized in that: The adhesive layer is located between the two fluororesin layers or the adhesive layer is located on the inner side of the sealing edge, and the fluororesin layer is located on the outer side of the sealing edge.

8. The photovoltaic module according to claim 7, characterized in that: The width of the adhesive layer is greater than or equal to the width of the fluororesin layer.

9. The photovoltaic module according to claim 7, characterized in that: The thickness of the fluororesin layer is 0.1 to 0.5 mm, and the thickness of the adhesive layer is 0.5 to 1.5 mm.

10. The photovoltaic module according to claim 7, characterized in that: The width of the fluororesin layer is 0.1 to 1 mm, the width of the adhesive layer is 4.9 to 14 mm, or the widths of the fluororesin layer and the adhesive layer are 5 to 15 mm.

11. The photovoltaic module according to claim 1, characterized in that: The width of the protrusion is 5 to 15 mm, and the height of the protrusion is 10 to 20 μm.

12. The photovoltaic module according to claim 1, characterized in that: The outer edge of the packaging film layer is connected to the inner edge of the sealing strip.

13. The photovoltaic module according to claim 1, characterized in that: The panel is glass; the packaging film layer is a POE or EPE film layer.

14. A method for manufacturing a photovoltaic module, characterized in that: Using the photovoltaic module according to any one of claims 1 to 13, the manufacturing method of the photovoltaic module comprises the following steps: S1. Paste a packaging film layer between the battery cell layer and the panel and make a sealing strip on the sealing edge of the panel or paste the prepared sealing strip on the sealing edge of the panel, so that the outer edge of the packaging film layer and the inner edge of the sealing strip are connected; S2, placing a battery cell layer on the packaging film layer, and pasting the packaging film layer on the other side of the battery cell layer, and covering it with a back plate; S3, applying pressure to the sealing edge of the panel using a load and maintaining it for a period of time; S4. The photovoltaic module is laminated at high temperature, the sealing strip is melted by the heat, and a part of the sealing strip is squeezed into the area to be filled between the protrusions.

15. The manufacturing method according to claim 14, characterized in that: In step S3, the peeling strength between the panel and / or the back panel and the sealing strip is 5.5N / 25MM.

16. The method of claim 14, wherein: In step S1, when making the sealing strip, first brush the fluororesin layer of the sealing strip on the sealing edge of the panel, and then bond the adhesive layer of the sealing strip above or inside the fluororesin layer, or suspend the adhesive layer and brush the fluororesin layer on the upper and lower sides of the adhesive layer.

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