Photovoltaic module and lamination method
By using EVA material pads in photovoltaic modules, adjusting the VA content to melt before the film, filling the gaps and increasing the thickness, the problem of edge bubbles during the lamination of photovoltaic modules is solved, and good sealing and electrical performance are improved.
Patent Information
- Application Number
- CN202510615230.7
- Authority / Receiving Office
- CN · China
- Patent Type
- Applications(China)
- Current Assignee / Owner
- Filing Date
- 2025-05-13
- Publication Date
- 2025-07-25
AI Technical Summary
Existing photovoltaic modules are prone to edge bubbles during lamination, which affects production yield and product quality.
The first pad and the second pad are made of EVA material are located on the light-receiving surface and the backlight surface of the cell layer respectively. By adjusting the VA content, the first pad is melted before the first film at high temperature, fill the gap between the film and the cell layer, and add thickness at the edge of the photovoltaic module and the bus bar to prevent puncture.
It effectively reduces the possibility of producing bubbles at the edge of photovoltaic modules, improves sealing performance and electrical performance, reduces film production costs, and enhances structural stability.
Smart Images
Figure CN120379355A_ABST
Abstract
Description
Technical Field
[0001] The present application relates to the technical field of photovoltaic technology, in particular to a photovoltaic module and a lamination method. Background Art
[0002] A photovoltaic module generally includes a cover plate, a glue film and a cell stack arranged in layers. The glue film is distributed on both sides of the cell stack along the thickness direction of the photovoltaic module, and the cover plate is distributed on the side of the glue film away from the cell stack along the thickness direction of the photovoltaic module. Currently, during the lamination process of the cover plate, the glue film and the cell stack, if the glue film is relatively thin, the phenomenon of lack of glue is likely to occur, resulting in the glue film being unable to cover the cell stack evenly and tightly, so that a large number of bubbles are generated at the edges of the laminated photovoltaic module, thereby affecting the production yield of the photovoltaic module. Summary of the Invention
[0003] In view of this, the present application provides a photovoltaic module and a lamination method to solve the technical problem that there are many bubbles at the edges of the laminated photovoltaic module in the prior art, which affects the product quality of the photovoltaic module.
[0004] The present application provides a photovoltaic module, which includes a first cover plate, a first glue film, a cell stack, a second glue film and a second cover plate arranged in layers in sequence along its thickness direction. The first cover plate and the first glue film are located on the light-receiving surface of the cell stack, and the second glue film and the second cover plate are located on the backlight surface of the cell stack.
[0005] The photovoltaic module further includes a first spacer bar and a second spacer bar. Along the thickness direction of the photovoltaic module, the first spacer bar is located on the light-receiving surface of the cell stack, and the projection of the first spacer bar covers the long-edge edge area and the short-edge edge area of the photovoltaic module. The second spacer bar is located on the backlight surface of the cell stack, and the projection of the second spacer bar covers the bus bar of the cell stack.
[0006] Wherein, the materials of the first glue film and the first spacer bar are both EVA. The VA content in the first glue film is Y1, and the VA content in the first spacer bar is Y2, and Y1 and Y2 satisfy Y1 < Y2.
[0007] In the embodiments of the present application, the first cushion strip and the second cushion strip can respectively increase the thickness of the light-receiving surface and the backlight surface of the cell layer, so that after reducing the grammage of the glue film, it can not only avoid the risk that the glue film cannot completely wrap the cell layer due to lack of glue in the edge area of the photovoltaic module, but also avoid the risk that the joint of the solder strip and the bus bar is easily punctured due to the too thin glue film thickness in the local area of the photovoltaic module. Therefore, by compensating the glue film with the cushion strip, it can not only reduce the production cost of the glue film, but also ensure that the photovoltaic module has good sealing performance and electrical performance. And the VA content of the first cushion strip is greater than the VA content of the first glue film, so that the first cushion strip has good elasticity and flexibility in a high-temperature environment, so as to melt prior to the first glue film during the lamination process, improve the bonding effect with the first glue film, and avoid the risk of bubbles caused by poor bonding. Therefore, by changing the VA content, the bonding effect between the first cushion strip and the first glue film can be improved, and further the structural stability of the photovoltaic module can be improved.
[0008] In a possible implementation manner, the first cushion strip includes a first long-side cushion strip and a first short-side cushion strip. Along the length direction and the width direction of the photovoltaic module, the first long-side cushion strip is flush with the outer edge of the long-side edge area and extends along the length direction of the photovoltaic module, and the first short-side cushion strip is flush with the outer edge of the short-side edge area and extends along the width direction of the photovoltaic module.
[0009] Wherein, the ends of the first long-side cushion strip and the ends of the first short-side cushion strip are stacked in the corner area of the photovoltaic module.
[0010] In a possible implementation manner, the second cushion strip includes a second short-side cushion strip and a middle cushion strip. Along the length direction and the width direction of the photovoltaic module, the second short-side cushion strip is flush with the outer edge of the short-side edge area and extends along the width direction of the photovoltaic module, and the middle cushion strip is located between the two second short-side cushion strips and extends along the width direction of the photovoltaic module.
[0011] Wherein, along the thickness direction of the photovoltaic module, the projections of the second short-side cushion strip and the middle cushion strip respectively overlap with the projection of the bus bar.
[0012] In a possible implementation manner, the second cushion strip includes a second long-side cushion strip, a second short-side cushion strip and a middle cushion strip. Along the length direction and the width direction of the photovoltaic module, the second long-side cushion strip is flush with the outer edge of the long-side edge area and extends along the length direction of the photovoltaic module, the second short-side cushion strip is flush with the outer edge of the short-side edge area and extends along the width direction of the photovoltaic module, and the middle cushion strip is located between the two second short-side cushion strips and is arranged parallel to the two second short-side cushion strips.
[0013] Among them, the end of the second long-side cushion strip and the end of the second short-side cushion strip are stacked in the corner area of the photovoltaic module, and the end of the middle cushion strip and the second long-side cushion strip are stacked in the long-edge edge area.
[0014] In a possible implementation, the width of the first cushion strip is L1, and L1 satisfies 30 mm ≤ L1 ≤ 50 mm; the width of the second cushion strip is L2, and L2 satisfies 20 mm ≤ L2 ≤ 40 mm.
[0015] In a possible implementation, the grammage of the first cushion strip is X1, and X1 satisfies 260 g / m 2 ≤ X1 ≤ 370 g / m 2 ; the grammage of the second cushion strip is X2, and X2 satisfies 160 g / m 2 ≤ X2 ≤ 270 g / m 2 .
[0016] In a possible implementation, the grammage of the first encapsulant film is X3, and X3 satisfies 280 g / m 2 < X3 < 300 g / m 2 ; the grammage of the second encapsulant film is X4, and X4 satisfies 280 g / m 2 < X4 < 300 g / m 2 .
[0017] In a possible implementation, the material of the second cushion strip is EPE, and the material of the second encapsulant film is EVA.
[0018] This application also provides a lamination method for a photovoltaic module for preparing the photovoltaic module according to any one of the above, and the preparation method includes: Stack the first cover plate, the first encapsulant film, the first cushion strip, the cell layer, the second cushion strip, the second encapsulant film and the second cover plate in sequence to form a stacked structure of the photovoltaic module.
[0019] Perform multiple lamination treatments on the stacked structure in a high-temperature environment, so that after the first encapsulant film and the first cushion strip are melted, they are closely attached to the light-receiving surface of the first cover plate and the cell layer respectively, and after the second cushion strip and the second encapsulant film are melted, they are closely attached to the backlight surface of the cell layer and the second cover plate respectively, to obtain a laminated structure of the photovoltaic module.
[0020] Among them, the materials of the first encapsulant film and the first cushion strip are both EVA, the VA content in the first encapsulant film is Y1, the VA content in the first cushion strip is Y2, and Y1 and Y2 satisfy Y1 < Y2.
[0021] In the embodiments of the present application, the first cushion strip in a molten state can fill the gap between the first adhesive film and the cell layer, and the second cushion strip in a molten state can fill the gap between the cell layer and the second adhesive film, so that the light-receiving surface and the backlight surface of the cell layer are completely wrapped, thereby effectively reducing the possibility of generating bubbles at the edge region and through holes (through holes for accommodating the lead-out wires of the bus bars) of the photovoltaic module during lamination. And when the overlapping portion of the solder tape and the bus bar is located on the backlight surface of the cell layer, the second cushion strip can also prevent the overlapping portion from piercing the second adhesive film, so as to ensure that the laminated photovoltaic module has good electrical performance.
[0022] In a possible implementation manner, when performing multiple lamination processes on the stacked structure to make the first adhesive film and the first cushion strip melt and then closely adhere to the first cover plate and the light-receiving surface of the cell layer respectively, and make the second cushion strip and the second adhesive film melt and then closely adhere to the backlight surface of the cell layer and the second cover plate respectively to obtain the laminated structure of the photovoltaic module, the preparation method further includes: Performing a first lamination process on the stacked structure to discharge the bubbles in the stacked structure.
[0023] Performing a second lamination process on the stacked structure to bond the layers in the stacked structure to each other.
[0024] Performing a third lamination process on the stacked structure to cure the stacked structure.
[0025] Wherein, the vacuum degree during the first lamination process on the stacked structure is p1, and p1 satisfies -65 kPa ≤ p1 ≤ -60 kPa; the vacuum degree during the second lamination process on the stacked structure is p2, and p2 satisfies -50 kPa ≤ p2 ≤ -40 kPa; the vacuum degree during the third lamination process on the stacked structure is p3, and p3 satisfies -25 kPa ≤ p3 ≤ -20 kPa.
[0026] It should be understood that the above general description and the following detailed description are only exemplary and do not limit the present application. BRIEF DESCRIPTION OF THE DRAWINGS
[0027] In order to more clearly illustrate the technical solutions of the embodiments of the present application, the drawings required to be used in the embodiments will be briefly introduced below. Obviously, the drawings in the following description are only some embodiments of the present application. For those of ordinary skill in the art, other drawings can be obtained based on these drawings without creative efforts.
[0028] Figure 1 is a schematic structural diagram of a photovoltaic module provided by the present application in one embodiment; Figure 2 is a schematic structural diagram of a solder tape and a bus bar provided by the present application; Figure 3 It is a schematic structural diagram of the long-edge edge area, short-edge edge area and corner area provided by this application; Figure 4 It is a schematic structural diagram of the first cushion strip in one embodiment provided by this application; Figure 5 It is a schematic structural diagram of the first cushion strip in another embodiment provided by this application; Figure 6 It is a schematic structural diagram of the second cushion strip in one embodiment provided by this application; Figure 7 It is a schematic structural diagram of the second cushion strip in another embodiment provided by this application.
[0029] Explanation of reference numerals: 1 - Photovoltaic module; 11 - First cover plate; 12 - First encapsulant film; 13 - First cushion strip; 131 - First long-edge cushion strip; 132 - First short-edge cushion strip; 14 - Cell layer; 141 - Welding ribbon; 142 - Bus bar; 15 - Second cushion strip; 151 - Second long-edge cushion strip; 152 - Second short-edge cushion strip; 153 - Intermediate cushion strip; 16 - Second encapsulant film; 17 - Second cover plate; 2 - Long-edge edge area; 3 - Short-edge edge area; 4 - Corner area.
[0030] The accompanying drawings here are incorporated into the specification and constitute a part of this specification, showing embodiments in line with this application, and are used together with the specification to explain the principles of this application. Detailed implementation manners
[0031] To better understand the technical solution of this application, the embodiments of this application will be described in detail below with reference to the accompanying drawings.
[0032] It should be clear that the described embodiments are only a part of the embodiments of this application, rather than all of the embodiments. All other embodiments obtained by those of ordinary skill in the art based on the embodiments in this application without creative efforts belong to the scope of protection of this application.
[0033] The terms used in the embodiments of the present application are for the purpose of describing specific embodiments only and are not intended to limit the present application. The singular forms "a", "the", and "said" used in the embodiments of the present application and the appended claims are also intended to include the plural forms unless the context clearly indicates otherwise.
[0034] It should be understood that the term "and / or" used herein is only a description of the association relationship of associated objects, indicating that there can be three relationships. For example, A and / or B can represent: A exists alone, A and B exist simultaneously, and B exists alone. In addition, the character " / " herein generally represents an "or" relationship between the associated objects before and after.
[0035] Embodiments of the present application provide a photovoltaic module, such as Figure 1 , Figure 2 and Figure 3 As shown, the photovoltaic module 1 includes a first cover plate 11, a first encapsulant film 12, a cell layer 14, a second encapsulant film 16, and a second cover plate 17 that are stacked in sequence along its thickness direction. The first cover plate 11 and the first encapsulant film 12 are located on the light-receiving surface of the cell layer 14, and the second encapsulant film 16 and the second cover plate 17 are located on the backlight surface of the cell layer 14.
[0036] The photovoltaic module 1 further includes a first spacer 13 and a second spacer 15. Along the thickness direction of the photovoltaic module 1, the first spacer 13 is located on the light-receiving surface of the cell layer 14, and the projection of the first spacer 13 covers the long-edge region 2 and the short-edge region 3 of the photovoltaic module 1. The second spacer 15 is located on the backlight surface of the cell layer 14, and the projection of the second spacer 15 covers the bus bar 142 of the cell layer 14.
[0037] Among them, the materials of the first encapsulant film 12 and the first spacer 13 are both ethylene-vinyl acetate copolymer (EVA). The vinyl acetate (VA) content in the first encapsulant film 12 is Y1, and the VA content in the first spacer 13 is Y2, and Y1 and Y2 satisfy Y1 < Y2.
[0038] In the embodiment of the present application, along the thickness direction of the photovoltaic module 1, the first cushion strip 13 is located on the light-receiving surface side of the cell layer 14, and the second cushion strip 15 is located on the light-shielding surface side of the cell layer 14, so that the first cushion strip 13 and the second cushion strip 15 can increase the thickness of the light-receiving surface side of the photovoltaic module 1 and the thickness of the light-shielding surface side of the photovoltaic module 1 respectively. During the lamination process of the photovoltaic module 1, the heat-melting property and fluidity of the first cushion strip 13 can be utilized to fill the gap between the first cover plate 11 and the first adhesive film 12, or fill the gap between the first adhesive film 12 and the cell layer 14. The heat-melting property and fluidity of the second cushion strip 15 can be utilized to fill the gap between the cell layer 14 and the second adhesive film 16, or the gap between the second adhesive film 16 and the second cover plate 17.
[0039] Through such a design method, the risk that the gas inside the photovoltaic module 1 is not easily discharged during the lamination process due to the uneven structural differences inside the photovoltaic module 1 can be avoided, which is beneficial to reducing the possibility of generating bubbles during the lamination process of the photovoltaic module 1, improving the tightness of the connection between layers, and further beneficial to improving the overall integrity and structural stability of the photovoltaic module 1.
[0040] Among them, along the thickness direction of the photovoltaic module 1, the projection of the first cushion strip 13 can cover the long-edge edge area 2 and the short-edge edge area 3 of the photovoltaic module 1, so that the first cushion strip 13 can increase the thickness of the edge area of the light-receiving surface of the photovoltaic module 1. Through such a design method, during the lamination process of the photovoltaic module 1, after the weight per unit area of the first adhesive film 12 is reduced, the risk that the edge area of the light-receiving surface of the photovoltaic module 1 lacks glue and cannot completely wrap the cell layer 14 due to its too thin thickness can be avoided, and the possibility of generating bubbles in the edge area of the light-receiving surface of the photovoltaic module 1 during the lamination process can be reduced. Therefore, it is beneficial to ensure the sealing and integrity of the light-receiving surface of the photovoltaic module 1 while reducing the production cost of the first adhesive film 12.
[0041] At the same time, along the thickness direction of the photovoltaic module 1, the projection of the second cushion strip 15 can cover the bus bar 142 of the cell layer 14, so that the second cushion strip 15 can increase the thickness of the local area of the light-shielding surface of the photovoltaic module 1. Through such a design method, during the lamination process of the photovoltaic module 1, after the weight per unit area of the second adhesive film 16 is reduced, the risk that the lap joint of the welding strip 141 and the bus bar 142 is punctured due to its too thin thickness can be avoided, which is beneficial to ensuring the sealing and integrity of the light-shielding surface of the photovoltaic module 1 while reducing the production cost of the second adhesive film 16.
[0042] In addition, along the length and width directions of the photovoltaic module 1, when the bus bar 142 is distributed in the edge area of the cell layer 14 (i.e., the long-side edge area 2 or the short-side edge area 3), along the thickness direction of the photovoltaic module 1, the second spacer 15 can not only increase the thickness of the backlight surface of the photovoltaic module 1 at the position corresponding to the bus bar 142, but also increase the thickness of at least part of the edge area of the backlight surface of the photovoltaic module 1, so that the second spacer 15 and the second adhesive film 16 can not only jointly prevent the lap joint of the welding tape 141 and the bus bar 142 from being punctured during lamination, but also reduce the possibility of generating bubbles in the edge area of the backlight surface of the photovoltaic module 1 during the lamination process.
[0043] In a possible implementation manner, along the thickness direction of the photovoltaic module 1, the first spacer 13 can be located between the first cover plate 11 and the first adhesive film 12, so that the stacking order of the light-receiving surface of the photovoltaic module 1 is the first cover plate 11, the first spacer 13, the first adhesive film 12, and the cell layer 14 in sequence. Alternatively, the first spacer 13 can be located between the first adhesive film 12 and the cell layer 14, so that the stacking order of the light-receiving surface of the photovoltaic module 1 is the first cover plate 11, the first adhesive film 12, the first spacer 13, and the cell layer 14 in sequence.
[0044] It should be noted that along the thickness direction of the photovoltaic module 1, regardless of whether the lap joint of the welding tape 141 and the bus bar 142 is located on the light-receiving surface or the backlight surface of the cell layer 14, the first spacer 13 can be located between the first cover plate 11 and the first adhesive film 12, or between the first adhesive film 12 and the cell layer 14, so that the first spacer 13 can increase the thickness of the long-side edge area 2 and the short-side edge area 3 of the light-receiving surface of the photovoltaic module 1.
[0045] In a possible implementation manner, when the lap joint of the welding tape 141 and the bus bar 142 is located on the light-receiving surface of the cell layer 14, and the bus bar 142 is distributed in the edge area of the cell layer 14 (i.e., the long-side edge area 2 or the short-side edge area 3), along the thickness direction of the photovoltaic module 1, the first spacer 13 can increase the thickness of the light-receiving surface of the photovoltaic module 1 at the position corresponding to the bus bar 142, so that the first spacer 13 and the first adhesive film 12 can not only jointly prevent the lap joint of the welding tape 141 and the bus bar 142 from being punctured during lamination, but also reduce the possibility of generating bubbles on the light-receiving surface of the photovoltaic module 1 during the lamination process.
[0046] In a possible implementation manner, along the thickness direction of the photovoltaic module 1, the second spacer 15 may be located between the cell layer 14 and the second encapsulant film 16, so that the lamination sequence of the backlight side of the photovoltaic module 1 is the cell layer 14, the second spacer 15, the second encapsulant film 16, and the second cover plate 17. Alternatively, the second spacer 15 may be located between the second encapsulant film 16 and the second cover plate 17, so that the lamination sequence of the backlight side of the photovoltaic module 1 is the cell layer 14, the second encapsulant film 16, the second spacer 15, and the second cover plate 17.
[0047] It should be noted that along the thickness direction of the photovoltaic module 1, when the overlapping portion of the welding tape 141 and the bus bar 142 is located on the backlight side of the cell layer 14 and the second spacer 15 and the second encapsulant film 16 are made of the same material, the second spacer 15 may be located between the cell layer 14 and the second encapsulant film 16, or may be located between the second encapsulant film 16 and the second cover plate 17, as long as the overlapping portion of the welding tape 141 and the bus bar 142 cannot pierce the second spacer 15 or the second encapsulant film 16 during lamination.
[0048] In the embodiments of the present application, the first encapsulant film 12 and the first spacer 13 are both made of EVA. The VA content in the first encapsulant film 12 is Y1, and the VA content in the first spacer 13 is Y2, and Y1 and Y2 satisfy Y1 < Y2.
[0049] Among them, the first encapsulant film 12 and the first spacer 13 being made of the same material is conducive to reducing the types of materials used in the production process, improving the uniformity of the materials, avoiding the risk of complicating the production process due to excessive types of materials, thereby being conducive to reducing the production cost of the photovoltaic module 1, and also being conducive to improving the compatibility between the first encapsulant film 12 and the first spacer 13, so that the two are more firmly bonded during lamination, thereby being conducive to reducing the possibility of delamination or bubbles during lamination.
[0050] At the same time, when the first encapsulant film 12 and the first spacer 13 have the same material, by setting the VA content in the first encapsulant film 12 to be less than the VA content in the first spacer 13, the melting point of the first encapsulant film 12 can be made higher than the melting point of the first spacer 13 (that is, the higher the VA content, the lower the melting point), so that the first spacer 13 can melt prior to the first encapsulant film 12 during the lamination of the photovoltaic module 1. And because the VA content in the first spacer 13 is relatively high, it can have good elasticity and flexibility. Therefore, the first spacer 13 that melts first is not only conducive to reducing the possibility of hidden cracks in the edge area of the photovoltaic module 1 during the lamination process, but also conducive to further improving the stability and reliability of the connection between the first encapsulant film 12 and the first spacer 13, thereby being able to further reduce the possibility of bubbles generated during the lamination process and improve the sealing performance of the photovoltaic module 1.
[0051] In one possible implementation, Y1 satisfies 18%≤Y1≤24%, and Y1 can be 18%, 18.2%, 18.4%, 18.6%, 18.8%, 19%, 19.2%, 19.4%, 19.6%, 19.8%, 20%, 20.2%, 20.4%, 20.6%, 20.8%, 21%, 21.2%, 21.4%, 21.6%, 21.8%, 22%, 22.2%, 22.4%, 22.6%, 22.8%, 23%, 23.2%, 23.4%, 23.6%, 23.8%, 24%, etc.
[0052] In one possible implementation, Y2 satisfies 25%≤Y2≤30%, and Y2 can be 25%, 25.2%, 25.4%, 25.6%, 25.8%, 26%, 26.2%, 26.4%, 26.6%, 26.8%, 27%, 27.2%, 27.4%, 27.6%, 27.8%, 28%, 28.2%, 28.4%, 28.6%, 28.8%, 29%, 29.2%, 29.4%, 29.6%, 29.8%, 30%, etc.
[0053] In summary, in this embodiment, the first gasket 13 and the second gasket 15 can increase the thickness of the light-receiving surface and the backlight surface of the cell layer 14 respectively, so that after reducing the weight of the adhesive film, it can avoid the risk that the edge area of the photovoltaic module 1 cannot completely wrap the cell layer 14 due to lack of adhesive, and can avoid the risk that the overlap of the welding strip 141 and the bus bar 142 in the local area of the photovoltaic module 1 is easily pierced due to the excessive thickness of the adhesive film, so that the gasket can compensate the adhesive film to achieve the reduction of the production cost of the adhesive film while ensuring that the photovoltaic module 1 has good sealing performance and electrical performance. In this embodiment, the VA content of the first gasket 13 is greater than the VA content of the first adhesive film 12, so that the first gasket 13 has good elasticity and flexibility in a high temperature environment, so that it melts before the first adhesive film 12 during the lamination process to improve the bonding effect between the two and avoid the risk of bubbles due to poor bonding, so that the bonding effect between the first gasket 13 and the first adhesive film 12 can be improved by changing the VA content, and then the structural stability of the photovoltaic module 1 can be improved.
[0054] In a specific embodiment, Figure 3 , Figure 4 and Figure 5As shown in the figure, the first cushion strip 13 includes a first long-edge cushion strip 131 and a first short-edge cushion strip 132. Along the length direction and width direction of the photovoltaic module 1, the first long-edge cushion strip 131 is flush with the outer edge of the long-edge edge area 2 and extends along the length direction of the photovoltaic module 1. The first short-edge cushion strip 132 is flush with the outer edge of the short-edge edge area 3 and extends along the width direction of the photovoltaic module 1. Among them, the ends of the first long-edge cushion strip 131 and the ends of the first short-edge cushion strip 132 are stacked in the corner area 4 of the photovoltaic module 1.
[0055] In the embodiment of the present application, along the thickness direction of the photovoltaic module 1, during the process of laying the first long-edge cushion strip 131 and the first short-edge cushion strip 132, the first long-edge cushion strip 131 can be laid first and then the first short-edge cushion strip 132 can be laid, so that the end of the first long-edge cushion strip 131 can cover the end of the first short-edge cushion strip 132, or the first short-edge cushion strip 132 can be laid first and then the first long-edge cushion strip 131 can be laid, so that the end of the first short-edge cushion strip 132 can cover the end of the first long-edge cushion strip 131, so that the two can be stacked in the corner area 4 of the photovoltaic module 1, so as to thicken the corner area 4 of the photovoltaic module 1 while thickening the edge area of the photovoltaic module 1 through the first cushion strip 13. Through such a design method, not only can the structural strength of the corner area 4 of the photovoltaic module 1 be improved, but also the uniformity of the force on the light-receiving surface of the photovoltaic module 1 can be improved by further dispersing the concentrated stress, so as to avoid the risk of the photovoltaic module 1 cracking due to excessive local stress.
[0056] At the same time, along the length direction and width direction of the photovoltaic module 1, the outer edges of the first long-edge cushion strip 131 and the first short-edge cushion strip 132 are both flush with the outer edge of the photovoltaic module 1. Through such a design method, a continuous sealing path can be formed by the first long-edge cushion strip 131 and the first short-edge cushion strip 132, so as to reduce the possibility of water vapor or dust penetrating into the interior of the photovoltaic module 1 through the edge gap.
[0057] In addition, by designing the first long-edge cushion strip 131 and the first short-edge cushion strip 132 as two independent components, not only can the installation difficulty of the first cushion strip 13 be reduced, so as to more easily realize the installation and positioning of the first long-edge cushion strip 131 and the first short-edge cushion strip 132 during the process of laying the first cushion strip 13, which is beneficial to improving the assembly efficiency of the photovoltaic module 1, but also the production cost of the first cushion strip 13 can be reduced, so as to be able to adjust the sizes of the first long-edge cushion strip 131 and the first short-edge cushion strip 132 at any time according to actual needs during the process of processing the first cushion strip 13, which is beneficial to reducing the production cost of the photovoltaic module 1.
[0058] In a possible implementation manner, the first long-side cushion strip 131 and the second short-side cushion strip 152 are of an integrally formed structure, which is beneficial to simplifying the production process of the first cushion strip 13 and reducing the assembly error between the first long-side cushion strip 131 and the second short-side cushion strip 152 during the lamination process.
[0059] In a possible implementation manner, the first cushion strip 13 in this embodiment includes two first long-side cushion strips 131 and two second short-side cushion strips 152. Along the length direction and the width direction of the photovoltaic module 1, the two first long-side cushion strips 131 are respectively flush with the outer edges of the two long-side edge regions 2 of the photovoltaic module 1 and both extend along the length direction of the photovoltaic module 1, and the two second short-side cushion strips 152 are respectively flush with the outer edges of the two short-side edge regions 3 and both extend along the width direction of the photovoltaic module 1. Moreover, during the process of laying the first long-side cushion strips 131 and the first short-side cushion strips 132, the two first long-side cushion strips 131 can be laid first and then the two first short-side cushion strips 132, so that the ends of the two first long-side cushion strips 131 can both cover the ends of the two first short-side cushion strips 132; alternatively, the two first short-side cushion strips 132 can be laid first and then the two first long-side cushion strips 131, so that the ends of the two first short-side cushion strips 132 can both cover the ends of the two first long-side cushion strips 131; alternatively, the two first long-side cushion strips 131 and the two first short-side cushion strips 132 can be laid in sequence in the clockwise or counterclockwise direction, so that one end of each of the two first long-side cushion strips 131 is located above the first short-side cushion strip 132 adjacent to this end, and the other end of each of the two first long-side cushion strips 131 is located below the first short-side cushion strip 132 adjacent to this end.
[0060] In a specific implementation manner, as Figure 3 and Figure 6 shown, the second cushion strip 15 includes a second short-side cushion strip 152 and an intermediate cushion strip 153. Along the length direction and the width direction of the photovoltaic module 1, the second short-side cushion strip 152 is flush with the outer edge of the short-side edge region 3 and extends along the width direction of the photovoltaic module 1, and the intermediate cushion strip 153 is located between the two second short-side cushion strips 152 and is arranged parallel to the two second short-side cushion strips 152. Among them, along the thickness direction of the photovoltaic module 1, the projections of the second short-side cushion strip 152 and the intermediate cushion strip 153 respectively overlap the projection of the bus bar 142.
[0061] In the embodiment of the present application, the cell layer 14 generally includes a plurality of solder tapes 141 and a plurality of bus bars 142. The plurality of solder tapes 141 all extend along the length direction of the photovoltaic module 1 and are spaced apart along the width direction of the photovoltaic module 1. The plurality of bus bars 142 all extend along the width direction of the photovoltaic module 1 and are spaced apart along the length direction of the photovoltaic module 1, so that the cell layer 14 has overlapping portions of the plurality of solder tapes 141 and bus bars 142. In this embodiment, by arranging the second short-side spacer 152 and the middle spacer 153 to extend along the width direction of the photovoltaic module 1 and be spaced apart along the length direction of the photovoltaic module 1, the projections of the second short-side spacer 152 and the middle spacer 153 along the thickness direction of the photovoltaic module 1 can completely cover all the bus bars 142 of the cell layer 14, so that the projection of the second spacer 15 along the thickness direction of the photovoltaic module 1 can completely cover all the overlapping portions of the cell layer 14. Through such a design method, the second short-side spacer 152 and the middle spacer 153 can jointly prevent the overlapping portions of the solder tapes 141 and the bus bars 142 from being punctured during lamination, thereby reducing the possibility of bubbles generated on the backlight surface of the photovoltaic module 1 during the lamination process.
[0062] Meanwhile, along the length direction and the width direction of the photovoltaic module 1, the outer edge of the second short-side spacer 152 is flush with the outer edge of the short-side edge area 3 of the photovoltaic module 1, and the ends of the second short-side spacer 152 and the middle spacer 153 are both flush with the outer edge of the long-side edge area 2 of the photovoltaic module 1. Through such a design method, while the projection of the second spacer 15 along the thickness direction of the photovoltaic module 1 can accurately cover the overlapping portions of the solder tapes 141 and the bus bars 142, it can also increase the thickness of some areas of the backlight surface of the photovoltaic module 1 to improve the sealing performance and integrity of the backlight surface of the photovoltaic module 1.
[0063] In addition, by designing the second short-side spacer 152 and the middle spacer 153 as two independent components, not only can the installation difficulty of the second spacer 15 be reduced, so as to more easily realize the installation and positioning of the second short-side spacer 152 and the middle spacer 153 during the laying process of the second spacer 15, which is beneficial to improving the assembly efficiency of the photovoltaic module 1, but also the production cost of the second spacer 15 can be reduced, so as to adjust the sizes of the second short-side spacer 152 and the middle spacer 153 at any time according to actual needs during the processing of the second spacer 15, which is beneficial to reducing the production cost of the photovoltaic module 1.
[0064] In a specific embodiment, such as Figure 3 and Figure 7As shown, the second cushion strip 15 includes a second long-side cushion strip 151, a second short-side cushion strip 152, and a middle cushion strip 153. Along the length direction and width direction of the photovoltaic module 1, the second long-side cushion strip 151 is flush with the outer edge of the long-side edge area 2 and extends along the length direction of the photovoltaic module 1. The second short-side cushion strip 152 is flush with the outer edge of the short-side edge area 3 and extends along the width direction of the photovoltaic module 1. The middle cushion strip 153 is located between the two second short-side cushion strips 152 and extends along the width direction of the photovoltaic module 1.
[0065] Among them, the ends of the second long-side cushion strip 151 and the ends of the second short-side cushion strip 152 are stacked in the corner area 4 of the photovoltaic module 1. The end of the middle cushion strip 153 is stacked with the second long-side cushion strip 151 in the long-side edge area 2.
[0066] In the embodiment of the present application, the second cushion strip 15 further includes a second long-side cushion strip 151, and the ends of the second long-side cushion strip 151 and the ends of the second short-side cushion strip 152 are stacked in the corner area 4 of the photovoltaic module 1. The end of the middle cushion strip 153 is stacked with the second long-side cushion strip 151 in the long-side edge area 2. Through such a design method, the projection of the second cushion strip 15 can not only completely cover the bus bar 142, but also cover the long-side edge area 2 and the short-side edge area 3 of the photovoltaic module 1, so that the second cushion strip 15 can also increase the thickness of the edge area of the backlight surface of the photovoltaic module 1, thereby avoiding the risk that the weight of the second cushion strip 15 decreases during the lamination process of the photovoltaic module 1, and the lack of glue in the edge area of the backlight surface of the photovoltaic module 1 cannot completely wrap the battery sheet layer 14 due to its too thin thickness. Furthermore, while ensuring the sealing and integrity of the backlight surface of the photovoltaic module 1, the possibility of the overlap of the welding strip 141 and the bus bar 142 being punctured during lamination can be reduced.
[0067] Among them, along the thickness direction of the photovoltaic module 1, during the process of laying the second long-side strip 151, the second short-side strip 152, and the middle strip 153, the second long-side strip 151 can be laid first, and then the second short-side strip 152 and the middle strip 153 can be laid, so that the second long-side strip 151 can cover the second short-side strip 152 and the middle strip 153; alternatively, the second short-side strip 152 and the middle strip 153 can be laid first, and then the second long-side strip 151 can be laid, so that the second short-side strip 152 and the middle strip 153 can cover the second long-side strip 151; alternatively, the second short-side strip 152 can be laid first, then the second long-side strip 151 can be laid, and then the middle strip 153 can be laid, or the middle strip 153 can be laid first, then the second long-side strip 151 can be laid, and then the second short-side strip 152 can be laid, so that the second long-side strip 151 is located between the second short-side strip 152 and the middle strip 153, so that the three can be stacked in the long-edge edge area 2 and the corner area 4 of the photovoltaic module 1, so as to thicken the corner area 4 of the photovoltaic module 1 while thickening the edge area of the photovoltaic module 1 by the second strip 15. Through such a design method, not only can the structural strength of the corner area 4 of the photovoltaic module 1 be improved, but also the uniformity of the force on the backlight surface of the photovoltaic module 1 can be improved by further dispersing the concentrated stress, so as to avoid the risk of the photovoltaic module 1 suffering from hidden cracks due to excessive local stress.
[0068] In a possible implementation manner, the second long-side strip 151, the second short-side strip 152, and the middle strip 153 are integrally formed structures, which is beneficial to simplifying the production process of the second strip 15 and reducing the assembly error of the second long-side strip 151, the second short-side strip 152, and the middle strip 153 during the stacking process.
[0069] In a specific implementation manner, as Figure 1 shown, the width of the first strip 13 is L1, and L1 satisfies 30 mm < L1 < 50 mm.
[0070] In the embodiment of the present application, the width of the first strip 13 can be other values within the range such as 31 mm, 32 mm, 33 mm, 34 mm, 35 mm, 36 mm, 37 mm, 38 mm, 39 mm, 40 mm, 41 mm, 42 mm, 43 mm, 44 mm, 45 mm, 46 mm, 47 mm, 48 mm, 49 mm, etc.
[0071] When the width of the first spacer 13 satisfies 30 mm < L1 < 50 mm, the width of the first spacer 13 is appropriate. During the lamination process of the photovoltaic module 1, its own heat meltability and fluidity can fill the gaps between the first cover plate 11 and the first adhesive film 12 or between the first adhesive film 12 and the cell layer 14, so as to avoid the risk that after the gram weight of the first adhesive film 12 decreases and due to its too thin thickness, the edge area of the light-receiving surface of the photovoltaic module 1 lacks glue and cannot completely wrap the cell layer 14. Thus, it is beneficial to ensure the sealing and integrity of the light-receiving surface of the photovoltaic module 1 while reducing the production cost of the first adhesive film 12.
[0072] In a specific embodiment, as Figure 1 shown, the width of the second spacer 15 is L2, and L2 satisfies 20 mm ≤ L2 ≤ 40 mm.
[0073] In the embodiment of the present application, the width of the second spacer 15 can be other values within the range such as 20 mm, 21 mm, 22 mm, 23 mm, 24 mm, 25 mm, 26 mm, 27 mm, 28 mm, 29 mm, 30 mm, 31 mm, 32 mm, 33 mm, 34 mm, 35 mm, 36 mm, 37 mm, 38 mm, 39 mm, 40 mm, etc.
[0074] When the width of the second spacer 15 satisfies 20 mm ≤ L2 ≤ 40 mm, the width of the second spacer 15 is appropriate. During the lamination process of the photovoltaic module 1, its own heat meltability and fluidity can fill the gaps between the cell layer 14 and the second adhesive film 16 or between the second adhesive film 16 and the second cover plate 17, so as to avoid the risk that after the gram weight of the second adhesive film 16 decreases and due to its too thin thickness, the lap joint of the welding strip 141 and the bus bar 142 is punctured. Thus, it is beneficial to ensure the sealing and integrity of the backlight surface of the photovoltaic module 1 while reducing the production cost of the second adhesive film 16.
[0075] In a specific embodiment, the gram weight of the first spacer 13 is X1, and X1 satisfies 260 g / m 2 ≤ X1 ≤ 370 g / m 2 .
[0076] In the embodiment of the present application, the gram weight of the first spacer 13 can be 260 g / m 2 , 265 g / m 2 , 270 g / m 2 , 275 g / m 2 , 280 g / m 2 , 285 g / m 2 , 290 g / m 2 , 295 g / m 2 , 300 g / m 2 , 305 g / m2 、 310 g / m 2 、 315 g / m 2 、 320 g / m 2 、 325 g / m 2 、 330 g / m 2 、 335 g / m 2 、 340 g / m 2 、 345 g / m 2 、 350 g / m 2 、 355 g / m 2 、 360 g / m 2 、 365 g / m 2 、 370 g / m 2 、 375 g / m 2 、 380 g / m 2 、 385 g / m 2 、 390 g / m 2 and other values within the above range.
[0077] When the grammage of the first spacer 13 satisfies 260 g / m 2 ≤ X1 ≤ 370 g / m 2 the grammage of the first spacer 13 is appropriate, enabling it to reduce the grammage of the first adhesive film 12 while ensuring the mechanical properties and sealing properties of the light-receiving surface of the photovoltaic module 1. Thus, the photovoltaic module 1 can be laminated with a first adhesive film 12 of lower grammage, which is beneficial to reducing the production cost of the photovoltaic module 1 while ensuring that the photovoltaic module 1 still has a high lamination yield.
[0078] In a specific embodiment, the grammage of the second spacer 15 is X2, and X2 satisfies 160 g / m 2 ≤ X2 ≤ 270 g / m 2 .
[0079] In the embodiments of the present application, the grammage of the second spacer 15 can be 160 g / m 2 、 165 g / m 2 、 170 g / m 2 、 175 g / m 2 、 180 g / m 2 、 185 g / m 2 、 190 g / m 2 、 195 g / m 2 、 200 g / m 2 、 205 g / m 2 、 210 g / m 2 、 215 g / m 2 、 220 g / m 2 、 225 g / m 2 、 230 g / m2 , 235 g / m 2 , 240 g / m 2 , 245 g / m 2 , 250 g / m 2 , 255 g / m 2 , 260 g / m 2 , 265 g / m 2 , 270 g / m 2 and other values within the range, etc.
[0080] When the gram weight of the second spacer 15 satisfies 160 g / m 2 ≤ X2 ≤ 270 g / m 2 , the gram weight of the second spacer 15 is appropriate, enabling it to reduce the gram weight of the second spacer 15 while ensuring that the overlapping part of the welding tape 141 and the bus bar 142 cannot pierce through the second spacer 15 and the second adhesive film 16 during lamination. Thus, the photovoltaic module 1 can be laminated using a second spacer 15 with a lower gram weight, which is conducive to reducing the production cost of the photovoltaic module 1 while ensuring the mechanical properties, sealing properties, and electrical properties of the backlight side of the photovoltaic module 1.
[0081] In a specific embodiment, the gram weight of the first adhesive film 12 is X3, and X3 satisfies 280 g / m 2 < X3 < 300 g / m 2 ; the gram weight of the second adhesive film 16 is X4, and X4 satisfies 280 g / m 2 < X4 < 300 g / m 2 .
[0082] In the embodiment of the present application, the gram weight of the first adhesive film 12 can be 282 g / m 2 , 284 g / m 2 , 286 g / m 2 , 288 g / m 2 , 290 g / m 2 , 292 g / m 2 , 294 g / m 2 , 296 g / m 2 , 298 g / m 2 and other values within the range, etc. The gram weight of the second adhesive film 16 can be 281 g / m 2 , 283 g / m 2 , 285 g / m 2 , 287 g / m 2 , 291 g / m 2 , 293 g / m 2 , 295 g / m 2 , 297 g / m 2 , 299 g / m 2Other values within the range, etc.
[0083] When the grammage of the first adhesive film 12 satisfies 280 g / m 2 <X3<300 g / m 2 and the grammage of the second adhesive film 16 satisfies 280 g / m 2 <X4<300 g / m 2 it is beneficial to reduce the input of production materials for the first adhesive film 12 and the second adhesive film 16, thereby reducing the production cost and overall weight of the photovoltaic module 1, and facilitating the installation and transportation of the photovoltaic module 1.
[0084] In a specific embodiment, the material of the second spacer 15 is an EVA-POE-EVA co-extruded adhesive film (EPE), and the material of the second adhesive film 16 is EVA.
[0085] In the embodiment of the present application, the EPE material is a three-layer structural adhesive film formed by co-extruding EVA and polyolefin elastomer (POE), combining the adhesiveness of EVA and the weather resistance of POE.
[0086] When the second spacer 15 uses the EPE material, it can have good adhesiveness and high barrier properties. During the lamination process of the photovoltaic module 1, the second spacer 15 in the molten state also has low fluidity (compared with the EVA material) to avoid the risk of the second spacer 15 shifting relative to the cell layer 14 and the second adhesive film 16 during lamination, thereby improving the bonding effect between the second spacer 15 and the cell layer 14 and the second adhesive film 16.
[0087] Among them, when the lead-out wires of the solder ribbons 141 and the busbars 142 are located on the backlight side of the cell layer 14, through holes corresponding to the lead-out wires are provided on the second spacer 15, the second adhesive film 16 and the second cover plate 17 along the thickness direction of the photovoltaic module 1, so that the lead-out wires can extend out of the photovoltaic module 1 through the through holes to be connected to the junction box. The second spacer 15 made of the EPE material can also avoid the risk of the root of the lead-out wire shifting and reduce the possibility of the lead-out wire being bent, thereby avoiding the possibility of the current transmission performance of the lead-out wire being reduced due to bending, and further ensuring the working performance of the photovoltaic module 1.
[0088] At the same time, the second spacer 15 made of the EPE material also has a low density, making its weight low, thereby further reducing the overall weight of the photovoltaic module 1, which is beneficial to achieving the purpose of lightweight design of the photovoltaic module 1 and is more convenient for the subsequent transportation and installation of the photovoltaic module 1.
[0089] In addition, since the interior of the EPE material has multiple independent air bubbles, when it is subjected to mechanical impact, the multiple independent air bubbles can absorb energy through compression and deformation to evenly disperse the stress throughout the material, thereby avoiding direct penetration by sharp parts. Furthermore, the second cushion strip 15 made of EPE material also has good puncture resistance, so as to reduce the possibility of puncture at the lap joint of the welding strip 141 and the bus bar 142 during the lamination process, and to ensure the electrical performance of the photovoltaic module 1.
[0090] When the second adhesive film 16 is made of EVA material, it can have good transparency and stable chemical properties. During the lamination process of the photovoltaic module 1, the second adhesive film 16 in the molten state also has good fluidity, can easily flow into the gap between the cell layer 14 and the second cushion strip 15, and bond and cure the two, or flow into the gap between the second cushion strip 15 and the second cover plate 17, and bond and cure the two, thereby improving the structural stability of the backlight surface of the photovoltaic module 1. And the cured second adhesive film 16 has good light transmittance, bonding strength, thermal stability, airtightness and aging resistance, thereby ensuring the working performance of the photovoltaic module 1.
[0091] The embodiment of the present application also provides a lamination method for a photovoltaic module, which is used to prepare the photovoltaic module 1 described in any one of the above, and the preparation method includes: Stack the first cover plate 11, the first adhesive film 12, the first cushion strip 13, the cell layer 14, the second cushion strip 15, the second adhesive film 16 and the second cover plate 17 in sequence to form a laminated structure of the photovoltaic module 1; perform multiple lamination treatments on the laminated structure in a high-temperature environment, so that the first adhesive film 12 and the first cushion strip 13 melt and are respectively closely attached to the light-receiving surface of the first cover plate 11 and the cell layer 14, and the second cushion strip 15 and the second adhesive film 16 melt and are respectively closely attached to the backlight surface of the cell layer 14 and the second cover plate 17, so as to obtain a laminated structure of the photovoltaic module 1.
[0092] Among them, the materials of the first adhesive film 12 and the first cushion strip 13 are both EVA, the VA content in the first adhesive film 12 is Y1, the VA content in the first cushion strip 13 is Y2, and Y1 and Y2 satisfy Y1 < Y2.
[0093] In the embodiment of the present application, first, the first cover plate 11, the first adhesive film 12, the first spacer 13, the cell layer 14, the second spacer 15, the second adhesive film 16, and the second cover plate 17 are stacked in sequence, and the projection of the first spacer 13 along the thickness direction of the photovoltaic module 1 covers the long-side edge region 2 and the short-side edge region 3 of the cell layer 14, and the projection of the second spacer 15 along the thickness direction of the photovoltaic module 1 covers the bus bar 142 of the cell layer 14; then, the air in the laminated structure is evacuated by a vacuum pumping method; then, the laminated structure is heated to make it in a high-temperature and high-pressure environment, so that the first adhesive film 12 and the first spacer 13 are melted to bond the first cover plate 11 and the cell layer 14 together, and the second spacer 15 and the second adhesive film 16 are melted to bond the cell layer 14 and the second cover plate 17 together, thereby obtaining the laminated structure of the photovoltaic module 1.
[0094] Among them, the first spacer 13 in the molten state can fill the gap between the first adhesive film 12 and the cell layer 14, and the second spacer 15 in the molten state can fill the gap between the cell layer 14 and the second adhesive film 16, so that both the light-receiving surface and the backlight surface of the cell layer 14 are completely wrapped, thereby effectively reducing the possibility of generating bubbles at the edge region and through holes (the through holes for accommodating the lead-out wires of the bus bar 142) of the photovoltaic module 1 during lamination. And when the overlapping portion of the solder strip 141 and the bus bar 142 is located on the backlight surface of the cell layer 14, the second spacer 15 can also prevent the overlapping portion from piercing the second adhesive film 16, so as to ensure that the laminated photovoltaic module 1 has good electrical performance.
[0095] At the same time, using the first adhesive film 12 and the first spacer 13 of the same material can reduce the types of materials used in the production process, improve the uniformity of the materials, so as to avoid the risk of complicating the production process due to too many types of materials, which is conducive to reducing the production cost of the photovoltaic module 1. And when the first adhesive film 12 and the first spacer 13 have the same material, by setting the VA content in the first adhesive film 12 to be less than the VA content in the first spacer 13, the melting point of the first adhesive film 12 can be made higher than the melting point of the first spacer 13 (that is, the higher the VA content, the lower the melting point), so that the first spacer 13 can melt prior to the first adhesive film 12 during the lamination of the photovoltaic module 1. And because the VA content in the first spacer 13 is relatively high, it can have good elasticity and flexibility. Therefore, the first spacer 13 that melts first is not only conducive to reducing the possibility of generating hidden cracks in the edge region of the photovoltaic module 1 during the lamination process, but also conducive to further improving the stability and reliability of the connection between the first adhesive film 12 and the first spacer 13, thereby further reducing the possibility of generating bubbles during the lamination process and improving the sealing performance of the photovoltaic module 1.
[0096] In addition, the second cushion strip 15 is made of EPE, and the second adhesive film 16 is made of EVA. Through such a design, the second cushion strip 15 in a molten state has lower fluidity than the second adhesive film 16, so as to avoid the risk of the second cushion strip 15 shifting relative to the cell layer 14 and the second adhesive film 16 during lamination, thereby improving the bonding effect between the second cushion strip 15 and the cell layer 14 and the second adhesive film 16.
[0097] In a possible implementation manner, the stacking order of the photovoltaic module 1 can also be to stack the first cover plate 11, the first cushion strip 13, the first adhesive film 12, the cell layer 14, the second adhesive film 16, the second cushion strip 15, and the second cover plate 17 in sequence; or it can also be to stack the first cover plate 11, the first cushion strip 13, the first adhesive film 12, the cell layer 14, the second cushion strip 15, the second adhesive film 16, and the second cover plate 17 in sequence; or it can also be to stack the first cover plate 11, the first adhesive film 12, the first cushion strip 13, the cell layer 14, the second adhesive film 16, the second cushion strip 15, and the second cover plate 17 in sequence.
[0098] In a possible implementation manner, the first cover plate 11 is located on one side of the light-receiving surface of the cell layer 14, and it can be ultra-white photovoltaic embossed glass or ultra-white processed float glass, etc., so as to have good light transmittance to ensure the photoelectric conversion efficiency of the photovoltaic module 1; the second cover plate 17 is located on one side of the backlight surface of the cell layer 14, and it can be rolled glass or ultra-white rolled glass, etc., so as to have good weather resistance to ensure the impact resistance of the photovoltaic module 1.
[0099] In a possible implementation manner, when the laminated structure is subjected to multiple lamination treatments so that the first adhesive film 12 and the first cushion strip 13 are melted and closely attached to the light-receiving surface of the first cover plate 11 and the cell layer 14 respectively, and the second cushion strip 15 and the second adhesive film 16 are melted and closely attached to the backlight surface of the cell layer 14 and the second cover plate 17 respectively to obtain the laminated structure of the photovoltaic module 1, the preparation method further includes: Performing a first lamination treatment on the laminated structure to discharge the bubbles in the laminated structure; performing a second lamination treatment on the laminated structure to bond the layers in the laminated structure to each other; performing a third lamination treatment on the laminated structure to cure the laminated structure.
[0100] Among them, the vacuum degree during the first lamination treatment of the laminated structure is p1, and p1 satisfies -65 kPa ≤ p1 ≤ -60 kPa; the vacuum degree during the second lamination treatment of the laminated structure is p2, and p2 satisfies -50 kPa ≤ p2 ≤ -40 kPa; the vacuum degree during the third lamination treatment of the laminated structure is p3, and p3 satisfies -25 kPa ≤ p3 ≤ -20 kPa.
[0101] In the embodiment of the present application, the first lamination process is mainly used to improve the efficiency of discharging bubbles and preliminarily locate the positions of various components, laying a foundation for subsequent lamination; the second lamination process is mainly used to achieve deep bonding between layers and continue to control the thermal stress of the overall laminated structure, optimizing the fluidity and lamination uniformity of the adhesive film and spacer bar; the third lamination process is mainly used to cure the structure and release residual stress to improve the finished product quality and reduce the defect rate.
[0102] Among them, a high vacuum degree is adopted during the first lamination process, which can effectively extrude the bubbles in the laminated structure, avoid more bubbles remaining in the edge area and through holes of the subsequent photovoltaic module 1, is beneficial to improving the bonding effect between layers, and improving the structural stability of the photovoltaic module 1. Moreover, the negative pressure applied by the high vacuum degree can preliminarily locate the laminated structure, reducing the possibility of relative displacement between layers during the subsequent lamination process.
[0103] At the same time, a medium vacuum degree is adopted during the second lamination process. By reducing the vacuum degree and the adhesive film and spacer bar in a molten state under a high-temperature environment, the adhesive film and spacer bar can further discharge the remaining bubbles in the laminated structure while filling the voids, making the connection between adjacent layers tighter and more reliable. Moreover, the medium vacuum degree combined with an appropriate temperature can balance the thermal expansion difference of the laminated structure during the lamination process, reducing the possibility of cracks generated after lamination, which is thus beneficial to improving the lamination yield of the photovoltaic module 1.
[0104] In addition, a low vacuum degree is adopted during the third lamination process, which can cure the laminated structure and release residual stress to form the lamination structure of the photovoltaic module 1, being beneficial to improving the mechanical strength and service life of the lamination structure.
[0105] In a possible implementation manner, the vacuum degree during the first lamination process of the laminated structure can be other values within the range of -65 kPa, -64.5 kPa, -64 kPa, -63.5 kPa, -63 kPa, -62.5 kPa, -62 kPa, -61.5 kPa, -61 kPa, -60.5 kPa, -60 kPa, etc.
[0106] In a possible implementation manner, the vacuum degree during the second lamination process of the laminated structure can be other values within the range of -50 kPa, -49 kPa, -48 kPa, -47 kPa, -46 kPa, -45 kPa, -44 kPa, -43 kPa, -42 kPa, -41 kPa, -40 kPa, etc.
[0107] In a possible implementation, the vacuum degree during the third lamination process of the laminate structure can be other values within the range of -25 kPa, -24.5 kPa, -24 kPa, -23.5 kPa, -23 kPa, -22.5 kPa, -22 kPa, -21.5 kPa, -21 kPa, -20.5 kPa, -20 kPa, etc.
[0108] In a possible implementation, the photovoltaic module 1 includes the above laminate structure and a frame. The laminate structure can be a first cover plate 11, a first encapsulant film 12, a first spacer 13, a cell layer 14, a second spacer 15, a second encapsulant film 16, and a second cover plate 17. The first cover plate 11 is disposed on the light-receiving surface of the photovoltaic module 1, and the second cover plate 17 is disposed on the backlight surface of the photovoltaic module 1. Among them, the cell layer 14 includes a plurality of cell strings connected in parallel by busbars 142. Each cell string includes a plurality of cells connected in series by welding tapes 141. Each cell can be a whole cell or a segmented cell that is one-Nth of a whole cell. The specific type of cell can be selected according to actual needs, and the present application does not limit this here.
[0109] In a possible implementation, the type of cell used in the present application is a Passivated Emitter Rear Cell (PERC). This cell uses a passivation film to passivate the back surface of the cell, replacing the full aluminum back field of the traditional cell, so as to enhance the internal back reflection of light in the silicon substrate, thereby reducing the recombination rate on the back surface of the cell and enabling it to have a high photoelectric conversion efficiency.
[0110] In a possible implementation, the type of cell used in the present application is a Tunnel Oxide Passivated Contact (TOPCon) cell. This cell mainly includes an N-type monocrystalline silicon substrate, a tunneling dielectric layer formed by depositing ultrathin silicon oxide (SiOx) or silicon nitride (SiNx) on the N-type monocrystalline silicon substrate, and a doped polysilicon layer covering the tunneling dielectric layer. Among them, the passivation effect of the tunneling dielectric layer enables electrons to reach the doped polysilicon layer or the N-type monocrystalline silicon substrate in contact with the tunneling dielectric layer through the tunneling effect, while blocking the passage of holes, reducing the recombination of electrons and holes at the interface, thereby forming a selective transport of carriers, making it have a high photoelectric conversion efficiency and stability, as well as a low attenuation rate.
[0111] In a possible implementation, the type of cell used in this application is an intrinsic thin-film heterojunction cell (Heterojunction with Intrinsic Thin-film, HJT, or Heterojunction with Intrinsic Thin-layer, HIT). This cell has a symmetric double-sided cell structure. In the middle is an N-type crystalline silicon. On the front side, an intrinsic amorphous silicon thin film and a P-type amorphous silicon thin film are sequentially deposited to form a P-N junction. On the back side, an intrinsic amorphous silicon thin film and an N-type amorphous silicon thin film are sequentially deposited to form a back surface field. Due to the dual passivation effect of the N-type silicon substrate and amorphous silicon on the substrate surface defects of this cell, it has a high photoelectric conversion efficiency.
[0112] In a possible implementation, the type of cell used in this application is a back contact cell (Back Contact, BC). The two-pole metal grid lines (including the two-pole main grid lines and the two-pole fine grid lines) and the P-N junction of this cell are all arranged on the back side of this cell, and the two-pole metal grid lines are alternately and spaced apart, so that there is no obstruction from structures such as the two-pole metal grid lines on the front side (light-receiving surface) of this cell. As a result, the front side of this cell can be completely exposed to sunlight to maximize the light absorption area, which is conducive to reducing optical losses and increasing the short-circuit current Jsc. At the same time, the back side of this cell can allow relatively wide two-pole metal grid lines to reduce the series resistance Rs of the cell and increase the fill factor FF. In addition, the front surface field and good passivation effect of this cell can increase the open-circuit voltage gain and the output power of this cell, making it have a high photoelectric conversion efficiency.
[0113] In a possible implementation, the type of cell used in this application is a perovskite solar cell (Perovskite Solar Cells, PSCs). This cell is a new photovoltaic technology based on perovskite-type organometallic halide semiconductors. It uses a semiconductor material with an ABX3 structure to capture sunlight and convert it into electrical energy, where A is a large-volume cation, B is a transition metal ion, and X is a halogen anion, making it have a low production cost.
[0114] In a possible implementation, the type of cell used in this application is a multi-busbar cell (Multi-Busbar, MBB). By increasing the number of main grid lines to shorten the current transmission path of the fine grid lines, this cell can reduce resistance losses and increase the fill factor FF and the photoelectric conversion efficiency.
[0115] In a possible implementation, the type of solar cell used in this application is a zero-busbar (0BB) solar cell. By completely removing the front main busbar, the front side of the solar cell can be fully exposed to sunlight, maximizing the light absorption area, thereby reducing optical losses and increasing the short-circuit current Jsc. At the same time, by retaining the fine grid and the back electrode, the solar cell has a high photoelectric conversion efficiency and a low production cost.
[0116] The structure, features, and effects of this application have been described in detail based on the embodiments shown in the drawings. The above are only the preferred embodiments of this application, but this application is not limited to the implementation scope shown in the drawings. Any changes made according to the concept of this application, or equivalent embodiments modified to equivalent changes, should still be within the protection scope of this application as long as they do not exceed the spirit covered by the description and the drawings.
Claims
1. A photovoltaic module, characterized in that, The photovoltaic module includes a first cover plate, a first encapsulant film, a cell layer, a second encapsulant film and a second cover plate which are sequentially stacked along the thickness direction thereof. The first cover plate and the first encapsulant film are located on the light-receiving surface of the cell layer, and the second encapsulant film and the second cover plate are located on the backlight surface of the cell layer; The photovoltaic module further includes a first spacer bar and a second spacer bar. Along the thickness direction of the photovoltaic module, the first spacer bar is located on the light-receiving surface of the cell layer, and the projection of the first spacer bar covers the long-side edge area and the short-side edge area of the photovoltaic module. The second spacer bar is located on the backlight surface of the cell layer, and the projection of the second spacer bar covers the bus bar of the cell layer; Wherein, the materials of the first encapsulant film and the first spacer bar are both EVA. The VA content in the first encapsulant film is Y1, the VA content in the first spacer bar is Y2, and Y1 and Y2 satisfy Y1 < Y2.
2. The photovoltaic module according to claim 1, wherein, The first spacer bar includes a first long-side spacer bar and a first short-side spacer bar. Along the length direction and the width direction of the photovoltaic module, the first long-side spacer bar is flush with the outer edge of the long-side edge area and extends along the length direction of the photovoltaic module. The first short-side spacer bar is flush with the outer edge of the short-side edge area and extends along the width direction of the photovoltaic module; Wherein, the ends of the first long-side spacer bar and the first short-side spacer bar are stacked in the corner area of the photovoltaic module.
3. The photovoltaic module according to claim 1, characterized in that, The second spacer bar includes a second short-side spacer bar and a middle spacer bar. Along the length direction and the width direction of the photovoltaic module, the second short-side spacer bar is flush with the outer edge of the short-side edge area and extends along the width direction of the photovoltaic module. The middle spacer bar is located between the two second short-side spacer bars and extends along the width direction of the photovoltaic module; Wherein, along the thickness direction of the photovoltaic module, the projections of the second short-side spacer bar and the middle spacer bar respectively overlap with the projection of the bus bar.
4. The photovoltaic module according to claim 1, characterized in that, The second spacer bar includes a second long-side spacer bar, a second short-side spacer bar and a middle spacer bar. Along the length direction and the width direction of the photovoltaic module, the second long-side spacer bar is flush with the outer edge of the long-side edge area and extends along the length direction of the photovoltaic module. The second short-side spacer bar is flush with the outer edge of the short-side edge area and extends along the width direction of the photovoltaic module. The middle spacer bar is located between the two second short-side spacer bars and is arranged in parallel with the two second short-side spacer bars; Wherein, the ends of the second long-side spacer bar and the second short-side spacer bar are stacked in the corner area of the photovoltaic module, and the end of the middle spacer bar is stacked with the second long-side spacer bar in the long-side edge area.
5. The photovoltaic module according to any one of claims 1-4, characterized in that, The width of the first spacer bar is L1, and L1 satisfies 30mm ≤ L1 ≤ 50mm; the width of the second spacer bar is L2, and L2 satisfies 20mm ≤ L2 ≤ 40mm.
6. The photovoltaic module according to any one of claims 1-4, characterized in that, The grammage of the first cushion strip is X1, and X1 satisfies 260 g / m 2 ≤ X1 ≤ 370 g / m 2 ; the grammage of the second cushion strip is X2, and X2 satisfies 160 g / m 2 ≤ X2 ≤ 270 g / m 2 .
7. The photovoltaic module according to any one of claims 1-4, characterized in that, The grammage of the first adhesive film is X3, and X3 satisfies 280 g / m 2 <X3<300 g / m 2 ; The grammage of the second adhesive film is X4, and X4 satisfies 280 g / m 2 <X4<300 g / m 2 .
8. The photovoltaic module according to any one of claims 1-4, characterized in that The material of the second spacer bar is EPE, and the material of the second encapsulant film is EVA.
9. A lamination method for a photovoltaic module, used for preparing the photovoltaic module according to any one of claims 1-8, characterized in that, The preparation method includes: Stack the first cover plate, the first adhesive film, the first spacer, the cell layer, the second spacer, the second adhesive film, and the second cover plate in sequence to form the laminated structure of the photovoltaic module; Perform multiple lamination treatments on the laminated structure in a high-temperature environment, so that after the first adhesive film and the first spacer melt, they are tightly attached to the light-receiving surface of the first cover plate and the cell layer respectively, and after the second spacer and the second adhesive film melt, they are tightly attached to the backlight surface of the cell layer and the second cover plate respectively, to obtain the laminated structure of the photovoltaic module; Wherein, the materials of the first adhesive film and the first spacer are both EVA, the VA content in the first adhesive film is Y1, the VA content in the first spacer is Y2, and Y1 and Y2 satisfy Y1 < Y2.
10. The lamination method according to claim 9, characterized in that, When performing multiple lamination treatments on the laminated structure, so that after the first adhesive film and the first spacer melt, they are tightly attached to the light-receiving surface of the first cover plate and the cell layer respectively, and after the second spacer and the second adhesive film melt, they are tightly attached to the backlight surface of the cell layer and the second cover plate respectively, to obtain the laminated structure of the photovoltaic module, the preparation method further includes: Perform the first lamination treatment on the laminated structure to discharge the bubbles in the laminated structure; Perform the second lamination treatment on the laminated structure to bond the layers in the laminated structure to each other; Perform the third lamination treatment on the laminated structure to cure the laminated structure; Wherein, the vacuum degree during the first lamination treatment on the laminated structure is p1, and p1 satisfies -65 kPa ≤ p1 ≤ -60 kPa; the vacuum degree during the second lamination treatment on the laminated structure is p2, and p2 satisfies -50 kPa ≤ p2 ≤ -40 kPa; the vacuum degree during the third lamination treatment on the laminated structure is p3, and p3 satisfies -25 kPa ≤ p3 ≤ -20 kPa.