Photovoltaic module and method of manufacturing the same

Abstract

Embodiments of the present application provide a photovoltaic module and a preparation method thereof, and relate to the technical field of photovoltaic. The photovoltaic module can be used to convert light energy into electrical energy. The photovoltaic module comprises a solar cell, a plurality of lead-out ribbons, a plurality of non-lead-out ribbons, a plurality of pairs of support components and a bus bar. The plurality of lead-out ribbons and the plurality of non-lead-out ribbons are arranged on the back of the solar cell. The lead-out ribbons and the non-lead-out ribbons are arranged along a first direction and extend along a second direction. The plurality of pairs of support components are arranged on the back of the solar cell. One non-lead-out ribbon corresponds to at least one pair of support components. The top surface height of the support component is greater than the upper surface height of the non-lead-out ribbon. The bus bar extends along the first direction. The bus bar is in electrical contact with the surface of the plurality of lead-out ribbons away from the solar cell. In addition, the bus bar is also in contact with the third surface of at least one pair of support components. The support component is used to support the bus bar across the non-lead-out ribbon, so as to realize the insulation between the bus bar and the non-lead-out ribbon.

Description

Technical Field

[0001] This application relates to the field of photovoltaic technology, and in particular to a photovoltaic module and its preparation method. Background Technology

[0002] Back-contact solar cells (BC cells) have no grid lines obstructing the front side, resulting in higher cell efficiency and a more aesthetically pleasing module appearance, playing a crucial role in the development of photovoltaics in recent years. With the continuous advancement of BC cell and module technology, many new connection methods and designs have emerged to improve module efficiency. Among these, the use of shingling technology and hidden busbars allows for the inclusion of more photovoltaic cells within a limited module area.

[0003] The concealed busbar design places the busbar on top of the solder strip on the back of the battery. The busbar makes point contact with the lead solder strip and is insulated from the non-lead solder strip. Currently, how to achieve insulation between the busbar and the non-lead solder strip has become an urgent problem to be solved in the field. Summary of the Invention

[0004] This application proposes a photovoltaic module and its manufacturing method, aiming to achieve insulation between the busbar and the non-lead solder strip.

[0005] In a first aspect, embodiments of this application provide a photovoltaic module, which includes a solar cell, multiple lead-out solder strips, multiple non-lead-out solder strips, multiple pairs of support components, and busbars. The solar cell includes a first surface and a second surface opposite to each other. The multiple lead-out solder strips and the multiple non-lead-out solder strips are disposed on the first surface, arranged along a first direction, and both the lead-out solder strips and the non-lead-out solder strips extend along a second direction. Both the first direction and the second direction are parallel to the first surface and intersect each other.

[0006] Multiple pairs of support members are disposed on the side of the first surface away from the second surface. One non-lead solder strip corresponds to at least one pair of support members. The support members include a third surface away from the solar cell. The non-lead solder strip includes a fourth surface away from the solar cell. The height of the third surface is greater than the height of the fourth surface compared to the first surface.

[0007] The busbar extends along a first direction and makes electrical contact with the surfaces of multiple lead-out solder strips on the side away from the solar cell. Furthermore, the busbar also contacts a third surface of at least one pair of support members used to support the busbar across the non-lead-out solder strips.

[0008] In some embodiments, the material of the support component includes at least one of thermosetting adhesive, light-curing adhesive, or silicone. Alternatively, the support component may include adhesive tape.

[0009] In some embodiments, the support component is disposed between the solar cell and the bus bar, and the surface of the support component close to the solar cell is in contact with the first surface. Along the first direction, at least one pair of support components is disposed on opposite sides of one non-lead-off tab.

[0010] In some embodiments, along the first direction, the minimum distance between the support component and the non-lead-off tab is D1. Along the first direction, the lead-off tabs and the non-lead-off tabs are arranged alternately, and the minimum distance between adjacent lead-off tabs and non-lead-off tabs is D2; wherein 0≤D1≤0.5D2.

[0011] In some embodiments, the ratio of the width of the support component along the first direction to the width of the non-lead-off tab along the first direction is in the range of 0.33-17.5; and the ratio of D1 to the width of the non-lead-off tab along the first direction is less than or equal to 2.5.

[0012] In some embodiments, the orthographic projection of the support component on the first surface is point-shaped; one non-lead-off tab corresponds to multiple pairs of support components, and along the second direction, the multiple pairs of support components corresponding to the same non-lead-off tab are arranged in sequence. Or the orthographic projection of the support component on the first surface is strip-shaped, the support component extends along the second direction, and one non-lead-off tab corresponds to one pair of support components.

[0013] In some embodiments, at least part of the support component is disposed between the non-lead-off tab and the bus bar, and is in contact with the fourth surface. Along the first direction, at least one pair of support components is disposed on opposite edges of the fourth surface.

[0014] In some embodiments, along the first direction, the distance between the inner sides of a pair of support components is D3, the distance between the outer sides of a pair of support components is D4, and the width of the non-lead-off tab is D5, wherein 0≤D3<D5, 0.5D5≤D4≤10D5.

[0015] In some embodiments, in the case of D4>D5, along the first direction, the outer boundary of the support component exceeds the edge of the non-lead-off tab. The part of the support component that exceeds the edge of the non-lead-off tab is connected to the first surface.

[0016] In some embodiments, the orthographic projection of the support component on the first surface is point-shaped, one non-lead-off tab corresponds to multiple pairs of support components, and along the second direction, the multiple pairs of support components corresponding to the same non-lead-off tab are arranged in sequence. Or the orthographic projection of the support component on the first surface is strip-shaped, the support component extends along the second direction, and one non-lead-off tab corresponds to at least one pair of support components. Or in each pair of support components, the two support components are integrally formed into one support strip, and the support strip extends along the first direction. One non-lead-off tab corresponds to multiple support strips, and the multiple support strips are arranged in sequence along the second direction.

[0017] In some embodiments, the photovoltaic module further comprises a plurality of intermediate support components disposed between the solar cells and the bus bars, the intermediate support components comprise a fifth surface distal to the solar cells, and the height of the fifth surface is greater than the height of the fourth surface compared to the first surface. In the first direction, the lead-out ribbons and the non-lead-out ribbons are arranged alternately, and the intermediate support components are disposed between adjacent lead-out ribbons and non-lead-out ribbons.

[0018] In some embodiments, the intermediate support components have a shape of a point in the orthographic projection on the first surface. The plurality of intermediate support components comprise a plurality of columns, and the plurality of intermediate support components in each column are arranged in sequence in the second direction. At least one column of intermediate support components is disposed between adjacent lead-out ribbons and non-lead-out ribbons.

[0019] In some embodiments, in the second direction, the distance between the outer boundaries of the two outermost intermediate support components in each column of intermediate support components is D6, and the width of the bus bar is D7, wherein 0.5D7≤D6≤2D7.

[0020] In some embodiments, the intermediate support components have a shape of a strip in the orthographic projection on the first surface, and the intermediate support components extend in the second direction. At least one intermediate support component is disposed between adjacent lead-out ribbons and non-lead-out ribbons.

[0021] In some embodiments, in the second direction, the length of each intermediate support component is D8, and the width of the bus bar is D7, wherein 0.5D7≤D8≤2D7.

[0022] In some embodiments, the photovoltaic module further comprises an insulating adhesive layer disposed between the solar cells and the lead-out ribbons, and between the solar cells and the non-lead-out ribbons. The insulating adhesive layer is discontinuously disposed in the interval region between adjacent lead-out ribbons and non-lead-out ribbons.

[0023] Embodiments of the present application provide a photovoltaic module, which comprises a solar cell, the solar cell comprising opposite first and second surfaces. The photovoltaic module further comprises a plurality of lead-out ribbons and a plurality of non-lead-out ribbons disposed on the first surface, the plurality of lead-out ribbons and the plurality of non-lead-out ribbons being arranged in a first direction and extending in a second direction, wherein the first and second directions are both parallel to the first surface, and the first and second directions intersect.

[0024] The photovoltaic module further comprises a plurality of pairs of support components disposed on a side of the first surface distal to the second surface, and at least one pair of support components corresponds to one non-lead-out ribbon. The support components comprise a third surface distal to the solar cell, and the non-lead-out ribbons comprise a fourth surface distal to the solar cell, and the height of the third surface is greater than the height of the fourth surface compared to the first surface.

[0025] The photovoltaic module further comprises a busbar extending along the first direction, the busbar being in electrical contact with the surface of the side of the plurality of lead-out ribbons away from the solar cell, and the busbar being in contact with the third surface of at least one pair of support components, the support components being configured to support the busbar to cross the non-lead-out ribbons and to keep the busbar above the non-lead-out ribbons, thereby achieving insulation between the busbar and the non-lead-out ribbons.

[0026] According to the above embodiments of the present application, the busbar can be kept above the non-lead-out ribbons by the pairs of support components, and the area where the busbar overlaps the non-lead-out ribbons does not need to be covered with the support components, and the width of the support components does not need to be greater than the width of the busbar, which is conducive to reducing the manufacturing cost of the photovoltaic module. Moreover, the support components only need to keep the busbar above the non-lead-out ribbons, and the placement precision of the support components is not high, and the process difficulty is low.

[0027] Compared with the small insulating strips, the support components have a smaller setting area and a smaller volume, and the support components will not produce a large deformation due to thermal expansion and cooling shrinkage, and the support components are not prone to delamination in long-term reliability tests. Moreover, during the welding process of the busbar and the lead-out ribbons, the deformation of the support components due to thermal expansion and cooling shrinkage is small, and the support components will not affect the non-lead-out ribbons, which is conducive to improving the welding performance between the non-lead-out ribbons and the solar cell.

[0028] In a second aspect, the present application further provides a method for manufacturing a photovoltaic module, the method comprising providing a solar cell, the solar cell comprising a first surface and a second surface opposite to each other. A plurality of lead-out ribbons and a plurality of non-lead-out ribbons are arranged on the first surface, the plurality of lead-out ribbons and the plurality of non-lead-out ribbons being arranged along a first direction, and the lead-out ribbons and the non-lead-out ribbons extending along a second direction, the first direction and the second direction being parallel to the first surface, and the first direction and the second direction intersecting each other.

[0029] A plurality of pairs of support components are formed on the side of the first surface away from the second surface, and one non-lead-out ribbon corresponds to at least one pair of support components. The support components comprise a third surface away from the solar cell, and the non-lead-out ribbons comprise a fourth surface away from the solar cell, and the height of the third surface is greater than the height of the fourth surface compared with the first surface.

[0030] The bus bar is arranged to extend along the first direction and is in contact with the third surface of the at least one pair of support members for supporting the bus bar across the non-tabbing ribbons. The bus bar is also in electrical contact with the surface of the plurality of tabbing ribbons away from the solar cells. The support members on both sides of the non-tabbing ribbons will make the bus bar suspended above the non-tabbing ribbons, thus insulating the two, further improving the insulation performance. The non-tabbing ribbons have a height difference compared to the first surface with the bus bar, so as to avoid short circuit caused by the contact between the two, thus eliminating the need to place an insulation strip during the assembly manufacturing process, reducing the cost of the assembly.

[0031] In some embodiments, the plurality of pairs of support members are formed by one of printing, dispensing, or inkjet.

[0032] In some embodiments, before the bus bar is formed, the method further comprises: forming a plurality of intermediate support members on the side of the first surface away from the second surface by one of printing, dispensing, or inkjet, the intermediate support members comprising a fifth surface away from the solar cells, the height of the fifth surface being greater than the height of the fourth surface compared to the first surface. In the first direction, the tabbing ribbons and the non-tabbing ribbons are arranged alternately, and the intermediate support members are arranged between adjacent tabbing ribbons and non-tabbing ribbons. BRIEF DESCRIPTION OF DRAWINGS

[0033] In order to more clearly illustrate the technical solutions in the present application, the following will briefly introduce the drawings needed to be used in some embodiments of the present application. Obviously, the drawings described in the following description are only the drawings of some embodiments of the present application, and other drawings can also be obtained by those skilled in the art according to these drawings. In addition, the drawings described in the following description can be regarded as schematic diagrams, and are not the actual size of the product involved in the embodiments of the present application or the actual flow of the method.

[0034] Figure 1 A structural schematic diagram of a photovoltaic module provided by an embodiment of the present application;

[0035] Figure 2 Another structural schematic diagram of a photovoltaic module provided by an embodiment of the present application;

[0036] Figure 3 A point-like structural schematic diagram of a support member of a photovoltaic module provided by an embodiment of the present application;

[0037] Figure 4 A strip-like structural schematic diagram of a support member of a photovoltaic module provided by an embodiment of the present application;

[0038] Figure 5 Another structural schematic diagram of a photovoltaic module provided by an embodiment of the present application;

[0039] Figure 6 A structure diagram of another photovoltaic module provided by an embodiment of the present application;

[0040] Figure 7 A support component of another photovoltaic module provided by an embodiment of the present application is a point structure diagram;

[0041] Figure 8 A support component of another photovoltaic module provided by an embodiment of the present application is a strip structure diagram;

[0042] Figure 9 A support component of another photovoltaic module provided by an embodiment of the present application is a strip structure diagram;

[0043] Figure 10 A structure diagram of another photovoltaic module provided by an embodiment of the present application;

[0044] Figure 11 A middle support component of a photovoltaic module provided by an embodiment of the present application is a point structure diagram;

[0045] Figure 12 A middle support component of a photovoltaic module provided by an embodiment of the present application is a strip structure diagram.

[0046] Reference signs:

[0047] Photovoltaic module 10; solar cell 101; insulating glue 102; non-extraction solder strip 103; extraction solder strip 104; bus bar 105; support component 106; support strip 107; middle support component 108; insulating small strip 109. DETAILED DESCRIPTION

[0048] The technical solutions in the embodiments of the present application will be clearly and completely described below with reference to the drawings. Obviously, the described embodiments are only some of the embodiments of the present application, but not all of the embodiments of the present application. Based on the embodiments provided by the present application, all other embodiments obtained by those of ordinary skill in the art belong to the scope of protection of the present application.

[0049] Unless otherwise required by the context, throughout the specification and claims, the term "comprising" is to be interpreted as open, inclusive meaning, i.e. "including, but not limited to".

[0050] Hereinafter, the terms "first" and "second" are only used for descriptive purposes, and cannot be understood as indicating or implying relative importance or implicitly indicating the number of the indicated technical features. Therefore, the features defined with "first" and "second" can explicitly or implicitly include one or more features. In the description of the embodiments of the present application, unless otherwise stated, the meaning of "multiple" is two or more.

[0051] In describing some embodiments, use is made of the term "connected" and its derivatives. The term "connected" is used broadly and essentially means connected directly or indirectly. For example, some embodiments are described as being "connected" to each other or to other components when they are in direct physical or electrical contact with each other or with the other components. Some embodiments are described as being "connected" to each other or to other components when they are in direct physical or electrical contact with each other or with the other components.

[0052] Additionally, use of "based on" means open and inclusive, as "based on" one or more stated conditions or values can in practice be based on additional conditions or values beyond those stated.

[0053] Exemplary embodiments are described herein with reference to cross-sectional illustrations that are idealized examples. In the drawings, the thickness of layers and regions are exaggerated for illustration. Accordingly, variations from the shapes of the illustrations as a result, for example, of manufacturing techniques and / or tolerances, are to be expected. Thus, the exemplary embodiments should not be construed as limited to the particular shapes of regions as illustrated herein but are to include deviations in shapes that result, for example, from manufacturing. For example, an etched region illustrated as a rectangle will typically have rounded or curved features. Thus, the regions illustrated in the figures are schematic in nature and their shapes are not intended to illustrate the precise shape of a region of a device and are not intended to limit the scope of the exemplary embodiments.

[0054] Figure 1 The structure diagram of hiding the BC battery assembly busbar at the back of the solar cell 101, where the insulating glue 102 is set on the solar cell 101, and the insulation between the lead-out ribbon 104 and the grid line with opposite polarity and the non-lead-out ribbon 103 is carried out respectively. The busbar 105 is set on the side of the lead-out ribbon 104 away from the surface of the solar cell 101, and the busbar 105 is welded with the lead-out ribbon 104 and insulated with the non-lead-out ribbon 103. Since the lead-out ribbon 104 and the non-lead-out ribbon 103 are distributed at intervals on the surface of the solar cell 101, an insulating strip 109 is needed to be set between the busbar 105 and the non-lead-out ribbon 103 to block the electrical connection between the busbar 105 and the non-lead-out ribbon 103. However, the use of the insulating strip 109 has the following problems: (1) In order to ensure the insulation effect, the width of the insulating strip 109 is often greater than the width of the busbar 105, thereby increasing the manufacturing cost of the assembly; (2) The equipment placement precision is high, and when the placement deviation is large, short circuit is easy to occur; (3) In the long-term reliability test, the insulating strip 109 has the risk of delamination; (4) During the welding of the busbar 105 and the lead-out ribbon 104, the insulating strip 109 has the process of thermal expansion and cooling shrinkage, which will cause the relative movement of the non-lead-out ribbon 103, and further affect the welding performance between the non-lead-out ribbon 103 and the solar cell 101.

[0055] To improve the process problem caused by the insulation small strip 109, the embodiment of the present application provides a photovoltaic module, Figure 2 A structural schematic diagram of a photovoltaic module 10 is provided for the embodiment of the present application.

[0056] As Figure 2 shown, the photovoltaic module 10 includes a solar cell 101, the solar cell 101 includes opposite first and second surfaces P1 and P2, a plurality of lead-out ribbons 104 and a plurality of non-lead-out ribbons 103 disposed on the first surface P1, wherein the plurality of lead-out ribbons 104 and the plurality of non-lead-out ribbons 103 are arranged along a first direction X direction and extend along a second direction Y direction, the first direction X direction and the second direction Y direction are both parallel to the first surface P1, and the first direction and the second direction intersect. This arrangement ensures that the ribbons can cover most of the area of the surface of the solar cell 101, thereby effectively collecting and transmitting current.

[0057] The photovoltaic module 10 also includes a plurality of pairs of support components 106 disposed on the side of the first surface P1 away from the second surface P2, and one non-lead-out ribbon 103 corresponds to at least one pair of support components 106. Among them, the support component 106 includes a third surface P3 away from the side of the solar cell 101. The non-lead-out ribbon 103 includes a fourth surface P4 away from the side of the solar cell 101. Compared with the first surface P1, the height H1 of the third surface P3 is greater than the height H2 of the fourth surface P4.

[0058] The photovoltaic module also includes a bus bar 105 extending along the first direction X direction, the bus bar 105 is in contact with the third surface P3 of at least one pair of support components 106, and at least one pair of support components 106 is used to support the bus bar 105 to cross the non-lead-out ribbon 103, so that the bus bar 105 is suspended above the non-lead-out ribbon 103, thereby insulating the two, and in the subsequent lamination process, the hollow area is filled with insulation film, further improving the insulation performance.

[0059] And the bus bar 105 is also in electrical contact with the surface of the plurality of lead-out ribbons 104 away from the side of the solar cell 101, wherein the bus bar 105 is used to collect current from a plurality of solar cells 101 or ribbons, and then transmitted to an external circuit or device.

[0060] The above embodiments of the present application use pairs of support components 106 to suspend the busbars 105, and the areas where the busbars 105 overlap the non-extraction solder strips 103 do not need to be covered with support components 106. The width of the support components 106 in the second direction Y is greater than the width of the busbars 105, which helps to reduce the manufacturing cost of the photovoltaic module. Moreover, the support components 106 only need to suspend the busbars 105, and the placement accuracy of the support components 106 is not high, which reduces the process difficulty.

[0061] Compared with the insulation strips 109, the support components 106 have a smaller setting area and a smaller volume, and the support components 106 do not produce large deformation due to thermal expansion and cooling shrinkage. In long-term reliability tests, the support components 106 are not prone to delamination. Moreover, during the welding of the busbars 105 and the extraction solder strips 104, the support components 106 produce small deformation due to thermal expansion and cooling shrinkage, which does not affect the non-extraction solder strips 103. This helps to improve the welding performance between the non-extraction solder strips 103 and the solar cells 101.

[0062] In some embodiments, the material of the support components 106 can be at least one of thermosetting glue, light-curing glue, or silicone glue. The thermosetting glue is an adhesive that solidifies and forms a stable structure after heating. It has good adhesion, high temperature resistance, and chemical corrosion resistance. The thermosetting glue used to make the support components 106 can provide stable physical support and prevent direct contact between the busbars 105 and the non-extraction solder strips 103, thereby avoiding the risk of short circuit.

[0063] The light-curing glue is an adhesive that rapidly solidifies after being irradiated by ultraviolet light or visible light. It has fast solidification speed, high strength, and transparency after solidification. The transparency helps to monitor the contact state between the busbars 105 and the non-extraction solder strips 103.

[0064] The silicone glue used as the material of the support components 106 can provide good cushioning and sealing effects, protecting the busbars 105 from mechanical damage and environmental erosion. The support components 106 also include adhesive tape, which is usually used to enhance the adhesion of the adhesive, provide additional physical support, and ensure stable contact between the busbars 105 and the non-extraction solder strips 103.

[0065] In some embodiments, as shown in FIG. 6, the support components 106 can be arranged in a staggered manner along the first direction X. The staggered arrangement of the support components 106 can help to further improve the stability of the busbars 105 and the non-extraction solder strips 103. Figure 2As shown, the support member 106 is arranged between the solar cell 101 and the busbar 105, and the surface of the support member 106 close to the solar cell 101 is in contact with the first surface P1. Along the first direction X, at least one pair of support members 106 is arranged on opposite sides of one non-lead tab 103. That is, the support member 106 is arranged between the solar cell 101 and the busbar 105, and the support member 106 is arranged on both sides of the non-lead tab 103, so that the busbar 105 is suspended above the non-lead tab 103.

[0066] In some embodiments, as shown in Figure 2 As shown, the minimum distance between the support member 106 and the non-lead tab 103 along the first direction X is D1, and the minimum distance between the lead tab 104 and the non-lead tab 103 along the first direction X is D2. Wherein, 0≤D1≤0.5D2, so as to ensure that the support member 106 provides effective support for the busbar 105 above the non-lead tab 103 without affecting the electrical contact between the busbar 105 and the lead tab 104, and ensuring the current transmission between the busbar 105 and the lead tab 104.

[0067] In some embodiments, as shown in Figure 2 As shown, the ratio of the width of the support member 106 along the first direction X to the width of the non-lead tab 103 along the first direction X is in the range of 0.33-17.5. Exemplarily, the ratio of the width of the support member 106 to the width of the non-lead tab 103 is 0.33, 3, 5.5, 6, 8.915, 12, 15 or 17.5. It can be understood that according to the width of the non-lead tab 103, the width of the support member 106 is selected to ensure that the support member 106 provides effective support for the busbar 105 above the non-lead tab 103.

[0068] For example, the width of the support member 106 along the first direction X is in the range of 0.5mm-7mm, and the width of the support member 106 can be 0.5mm, 2.5mm, 3.75mm, 5.5mm or 7mm. The width of the non-lead tab 103 along the first direction X is in the range of 0.4mm-1.5mm, and the width of the non-lead tab 103 can be 0.4mm, 0.5mm, 0.95mm, 1.2mm or 1.5mm.

[0069] Continuing to refer to Figure 2The ratio of the minimum distance D1 between the support component 106 and the non-extraction solder strip 103 to the width of the non-extraction solder strip 103 along the first direction X is less than or equal to 2.5, for example, the ratio of the minimum distance D1 to the width of the non-extraction solder strip 103 is 0.5, 1, 1.1, 1.25, 2.0 or 2.5. It can be understood that, according to the width of the non-extraction solder strip 103, the appropriate distance between the support component 106 and the non-extraction solder strip 103 can ensure that the support component 106 provides effective support for the bus bar 105 above the non-extraction solder strip 103.

[0070] For example, the minimum distance D1 between the support component 106 and the non-extraction solder strip 103 is less than or equal to 1 mm, and the minimum distance D1 can be 0, 0.1 mm, 0.4 mm, 0.55 mm, 0.8 mm or 1 mm. The width of the non-extraction solder strip 103 along the first direction X is in the range of 0.4 mm to 1.5 mm, and the width of the non-extraction solder strip 103 can be 0.4 mm, 0.5 mm, 0.95 mm, 1.2 mm or 1.5 mm.

[0071] In some embodiments, as shown in Figure 3 The shape of the orthographic projection of the support component 106 on the first surface P1 is a point; one non-extraction solder strip 103 corresponds to multiple pairs of support components 106, and the multiple pairs of support components 106 corresponding to the same non-extraction solder strip 103 are arranged in sequence along the second direction Y. This arrangement ensures that the support components 106 can be evenly distributed near the non-extraction solder strip 103, thereby providing stable support.

[0072] In some embodiments, as shown in Figure 4 The shape of the orthographic projection of the support component 106 on the first surface P1 is a strip, and the support component 106 extends along the second direction Y. One non-extraction solder strip 103 corresponds to one pair of support components 106, and the design of one non-extraction solder strip 103 corresponding to one pair of support components 106 simplifies the layout process of the support component 106.

[0073] In some embodiments, as shown in Figure 5 At least part of the support component 106 is arranged between the non-extraction solder strip 103 and the bus bar 105 and in contact with the fourth surface P4. Along the first direction X, at least one pair of support components 106 is arranged on the opposite edges of the fourth surface P4. That is, the support component 106 is supported between the non-extraction solder strip 103 and the bus bar 105, and the support component 106 is arranged on the two side edges of the surface of the non-extraction solder strip 103, so that the bus bar 105 is suspended above the non-extraction solder strip 103.

[0074] In some embodiments, as shown in Figure 5As shown, along the first direction X direction, the distance between the inner sides of the pair of support components 106 is D3, the distance between the outer sides of the pair of support components 106 is D4, and the width of the non-extraction solder strip 103 is D5; wherein 0≤D3D5, which ensures that at least part of the support component 106 is located above the non-extraction solder strip 103, and the support component 106 can keep the busbar 105 above the non-extraction solder strip 103 without losing stability due to the excessively large distance between the inner sides of the support component 106. Moreover, 0.5D5≤D4≤10D5, and by setting the distance between the outer sides of the support component 106 to be large enough, stable support can be provided for the busbar 105, so that the support component 106 can keep the busbar 105 above the non-extraction solder strip 103.

[0075] In some embodiments, as shown in FIG. 1, the support component 106 is arranged on the first surface P1 of the solar cell 101, and the support component 106 is arranged on the non-extraction solder strip 103. Figure 6 As shown in FIG. 1, in the case of D4>D5, along the first direction X direction, the outer side boundary of the support component 106 exceeds the edge of the non-extraction solder strip 103; the part of the support component 106 that exceeds the edge of the non-extraction solder strip 103 is connected to the first surface P1. The support component 106 exceeds the edge of the non-extraction solder strip 103 and overlaps with the solar cell 101, and due to the certain adhesive force between the support component 106 and the solar cell 101, not only can the support component 106 play an insulating role between the non-extraction solder strip 103 and the busbar 105 in the subsequent lamination process, but also can fix the non-extraction solder strip 103 to avoid the offset of the non-extraction solder strip 103 caused by the flow of the adhesive film during lamination.

[0076] In some embodiments, as shown in FIG. 1, the support component 106 is arranged on the first surface P1 of the solar cell 101, and the support component 106 is arranged on the non-extraction solder strip 103. Figure 7 As shown in FIG. 1, the orthographic projection of the support component 106 on the first surface P1 is a point. One non-extraction solder strip 103 corresponds to multiple pairs of support components 106, and along the second direction Y direction, the multiple pairs of support components 106 corresponding to the same non-extraction solder strip 103 are arranged in sequence. This design ensures that the non-extraction solder strip 103 and the surrounding area thereof are fully supported, which helps to improve the structural stability and durability of the solar cell module.

[0077] In some embodiments, as shown in FIG. 1, the support component 106 is arranged on the first surface P1 of the solar cell 101, and the support component 106 is arranged on the non-extraction solder strip 103. Figure 8 As shown in FIG. 1, the orthographic projection of the support component 106 on the first surface P1 is a strip, and the support component 106 extends along the second direction Y direction. One non-extraction solder strip 103 corresponds to at least one pair of support components 106. The strip-shaped support component 106 provides more stable and uniform support effect.

[0078] In some embodiments, as shown in FIG. 1, the support component 106 is arranged on the first surface P1 of the solar cell 101, and the support component 106 is arranged on the non-extraction solder strip 103. Figure 9As shown, in each pair of support components 106, two support components 106 are integrally formed into a support strip 107. The support strip 107 extends along the first direction X. One non-lead-out solder strip 103 corresponds to multiple support strips 107. The multiple support strips 107 are arranged sequentially along the second direction Y. The integrally formed support strip 107 provides stronger structural support.

[0079] In some embodiments, such as Figure 10 As shown, the photovoltaic module also includes multiple intermediate support components 108, which are disposed between the solar cell 101 and the busbar 105. Each intermediate support component 108 includes a fifth surface P5 on the side away from the solar cell 101. The height of the fifth surface P5 is greater than the height of the fourth surface P4 compared to the first surface P1, thus suspending the busbar 105 above the solar cell 101 and preventing electrical contact between the busbar 105 and the solar cell 101. Along the first direction X, lead-out solder strips 104 and non-lead-out solder strips 103 are arranged alternately, and the intermediate support components 108 are disposed between adjacent lead-out solder strips 104 and non-lead-out solder strips 103. In conventional solutions, such as... Figure 1 As shown, to avoid short circuits caused by direct contact between the busbar 105 and the non-lead solder strips 103, insulating adhesive 202 is applied to the area between two adjacent solder strips below the busbar 105 to prevent short circuits. This not only increases the component cost, but also increases battery warping after the insulating adhesive 202 cures. In this embodiment, because the area of ​​the intermediate support member 108 is smaller than... Figure 1 In this case, the area covered by insulating adhesive 202 can be reduced, thus reducing both cost and battery warping caused by the curing of insulating adhesive 202.

[0080] In some embodiments, such as Figure 11 As shown, the intermediate support member 108 has a dotted shape as the orthographic projection of P1 on the first surface; the multiple intermediate support members 108 include multiple columns, and the multiple intermediate support members 108 in each column are arranged sequentially along the second direction. At least one column of intermediate support members 108 is provided between adjacent lead-out solder strips 104 and non-lead-out solder strips 103. By providing at least one column of dotted intermediate support members 108, the portion of the busbar 105 located between the lead-out solder strips 104 and non-lead-out solder strips 103 is suspended to avoid direct contact between the busbar 105 and the solar cell 101.

[0081] In some embodiments, such as Figure 11As shown, the distance between the outer boundaries of the two outermost intermediate support components 108 in each column is D6, and the width of the busbar 105 is D7, where 0.5D7≤D6≤2D7. In the case of the minimum distance D6, the layout of the intermediate support components 108 can still maintain a certain stability and support force, while not occupying too much space inside the assembly. In the case of the maximum distance D6, the layout of the intermediate support components 108 can still effectively disperse and withstand the stress and deformation of the assembly during operation.

[0082] In some embodiments, as shown in FIG. 1, the intermediate support components 108 are arranged in a grid pattern, and the intermediate support components 108 are arranged in a staggered manner along the first direction X direction and the second direction Y direction. Figure 12 As shown, the intermediate support components 108 are arranged in a strip shape on the first surface P1, and the intermediate support components 108 extend along the second direction Y direction. At least one intermediate support component 108 is arranged between adjacent lead-out ribbons 104 and non-lead-out ribbons 103. By arranging at least one strip-shaped intermediate support component 108, the part of the busbar 105 between the lead-out ribbons 104 and the non-lead-out ribbons 103 is elevated to avoid direct contact between the busbar 105 and the solar cells 101.

[0083] In some embodiments, as shown in FIG. 1, the intermediate support components 108 are arranged in a grid pattern, and the intermediate support components 108 are arranged in a staggered manner along the first direction X direction and the second direction Y direction. Figure 12 As shown, the length of each intermediate support component 108 is D8, and the width of the busbar 105 is D7, where 0.5D7≤D8≤2D7. When D8 is equal to or greater than 0.5D7, it means that the length of the support component 108 is at least half the width of the busbar 105. Such a design can ensure that the intermediate support component 108 provides sufficient support area to prevent the busbar 105 from deforming or being damaged due to excessive stress. At the same time, such a lower limit setting is also helpful to maintain the overall structural stability and reliability of the photovoltaic assembly. When D8 is equal to or less than 2D7, it means that the length of the intermediate support component 108 will not exceed twice the width of the busbar 105. Such a design can limit the size and weight of the intermediate support component 108, making the photovoltaic assembly more lightweight and efficient. In addition, the upper limit setting is also helpful to avoid material waste and cost increase caused by the excessive length of the intermediate support component 108.

[0084] In some embodiments, as shown in FIG. 1, the intermediate support components 108 are arranged in a grid pattern, and the intermediate support components 108 are arranged in a staggered manner along the first direction X direction and the second direction Y direction. Figure 10 As shown, the photovoltaic assembly further comprises an insulating adhesive layer 102, which is arranged between the solar cells 101 and the lead-out ribbons 104, mainly to provide electrical insulation and prevent current from passing through unintended paths, thereby ensuring that the current can pass through the lead-out ribbons 104 according to the designed path. The insulating adhesive layer 102 is also arranged between the solar cells 101 and the non-lead-out ribbons 103. The non-lead-out ribbons 103 usually do not directly participate in the output of current, so it is necessary to arrange an insulating adhesive layer 102 between them and the solar cells 101 to avoid the risk of potential short circuit.

[0085] It can be understood that, by arranging the intermediate support component 108, the part of the bus bar 105 between the lead-out ribbons 104 and the non-lead-out ribbons 103 is suspended, the bus bar 105 is prevented from directly contacting the solar cell 101, and the insulating adhesive layer 102 is discontinuously arranged in the interval between the adjacent lead-out ribbons 104 and the non-lead-out ribbons 103, that is, a continuous insulating adhesive layer 102 is not required, and the bus bar 105 and the solar cell 101 are not required to be isolated by the insulating adhesive layer 102, so that the use amount of the material can be reduced while the performance is ensured, thereby reducing the production cost.

[0086] The embodiment of the present application provides a photovoltaic module 10, which comprises a solar cell 101, and the solar cell 101 comprises opposite first and second surfaces P1 and P2. A plurality of lead-out ribbons 104 and a plurality of non-lead-out ribbons 103 arranged on the first surface P1 are arranged along a first direction and extend along a second direction, wherein the first direction and the second direction are both parallel to the first surface P1, and the first direction and the second direction intersect.

[0087] The photovoltaic module 10 further comprises a plurality of pairs of support components 106 arranged on the side of the first surface P1 away from the second surface P2, and one non-lead-out ribbon 103 corresponds to at least one pair of support components 106. The support component 106 comprises a third surface P3 away from the solar cell, the non-lead-out ribbon 103 comprises a fourth surface P4 away from the solar cell, and the height H1 of the third surface P3 is greater than the height H2 of the fourth surface P4 compared with the first surface P1.

[0088] The photovoltaic module 10 further comprises a bus bar 105 extending along the first direction, the bus bar 105 is in contact with the third surface P3 of the at least one pair of support components 106, and the at least one pair of support components 106 is used for supporting the bus bar 105 to cross the non-lead-out ribbon 103. The bus bar 105 is also in electrical contact with the surface of the plurality of lead-out ribbons 104 away from the solar cell. The support components 106 on both sides of the non-lead-out ribbon 103 will make the bus bar 105 suspended above the non-lead-out ribbon 103, thereby insulating the two, and further improving the insulation performance. The non-lead-out ribbon 103 and the bus bar 105 have a height difference compared with the first surface P1, so that the two are prevented from contacting and causing short circuit, and therefore the insulating strip 109 does not need to be placed during the assembly manufacturing process, thereby reducing the cost of the assembly.

[0089] In a second aspect, the present application further provides a preparation method of a photovoltaic module, which comprises the following steps S1-S4:

[0090] Step S1: providing a solar cell 101, and the solar cell 101 comprises opposite first and second surfaces P1 and P2.

[0091] Step S2: The lead-out ribbons 104 and the non-lead-out ribbons 103 are firmly fixed on the first surface P1 of the solar cell 101 by welding, sticking or mechanical fixing, etc. Good contact between the ribbons and the surface of the solar cell 101 is ensured to reduce the contact resistance and improve the conduction efficiency. The ribbons are usually made of metal materials with high conductivity to ensure good current transmission. The lead-out ribbons 104 and the non-lead-out ribbons 103 are arranged along the first direction X direction, and the lead-out ribbons 104 and the non-lead-out ribbons 103 extend along the second direction Y direction. The first direction X direction and the second direction Y direction are parallel to the first surface P1, and the first direction and the second direction intersect.

[0092] Step S3: A plurality of pairs of support components 106 are formed on the side of the first surface P1 away from the second surface P2. At least one pair of support components 106 corresponds to one non-lead-out ribbon 103. The support component 106 includes a third surface P3 away from the solar cell 101, and the non-lead-out ribbon 103 includes a fourth surface P4 away from the solar cell 101. Compared with the first surface P1, the height H1 of the third surface P3 is greater than the height H2 of the fourth surface P4.

[0093] Step S4: A bus bar 105 extending along the first direction X direction is arranged. The bus bar 105 is in contact with the third surface P3 of at least one pair of support components 106. The at least one pair of support components 106 is used to support the bus bar 105 to cross the non-lead-out ribbon 103. The bus bar 105 is also in electrical contact with the surface of the lead-out ribbons 104 away from the solar cell 101. The support components 106 on both sides of the non-lead-out ribbon 103 will make the bus bar 105 over the non-lead-out ribbon 103, thereby insulating the two, further improving the insulation performance. The non-lead-out ribbon 103 and the bus bar 105 have a height difference compared with the first surface P1, so as to avoid contact and short circuit. Therefore, it is not necessary to place the insulation strip 109 during the assembly process, thereby reducing the cost of the assembly.

[0094] In some embodiments, a plurality of pairs of support components 106 can be formed by printing, dispensing or inkjet process. The insulation strip 109 is prevented from being heated and expanded, and the non-lead-out ribbon 103 is prevented from moving relatively due to the cooling and shrinking when the bus bar 105 is welded with the lead-out ribbons 104, thereby affecting the welding performance between the non-lead-out ribbon 103 and the solar cell 101.

[0095] In some embodiments, before forming the bus bar 105, the preparation method further comprises forming a plurality of intermediate support components 108 on the side of the first surface P1 away from the second surface P2 by printing, dispensing or inkjet process, the intermediate support component 108 comprises a fifth surface P5 away from the side of the solar cell 101, and the height of the fifth surface P5 is greater than the height of the fourth surface P4 compared to the first surface P1. In the first direction X, the lead-out solder strip 104 and the non-lead-out solder strip 103 are arranged alternately, and the intermediate support component 108 is arranged between adjacent lead-out solder strips 104 and non-lead-out solder strips 103.

[0096] The above merely provides a specific implementation of the present application, but the protection scope of the present application is not limited thereto, any person skilled in the art can think of changes or replacements within the technical range disclosed by the present application, which should be covered in the protection scope of the present application. Therefore, the protection scope of the present application should be subject to the protection scope of the claims.

Claims

1. A photovoltaic module, characterized by, The solar cell comprises: a solar cell comprising a first surface and a second surface opposite to the first surface; a plurality of lead-out ribbons and a plurality of non-lead-out ribbons disposed on the first surface; the plurality of lead-out ribbons and the plurality of non-lead-out ribbons are arranged along a first direction, and the lead-out ribbons and the non-lead-out ribbons extend along a second direction; the first direction and the second direction are both parallel to the first surface, and the first direction and the second direction intersect each other; a plurality of pairs of support components disposed on a side of the first surface away from the second surface, and at least one pair of support components corresponding to one non-lead-out ribbon; the support components comprise a third surface away from the solar cell, and the non-lead-out ribbons comprise a fourth surface away from the solar cell; compared with the first surface, the height of the third surface is greater than the height of the fourth surface; a bus bar extending along the first direction; the bus bar is in contact with the third surface of the at least one pair of support components, and the at least one pair of support components is used for supporting the bus bar to cross the non-lead-out ribbon; the bus bar is also in electrical contact with the surface of the plurality of lead-out ribbons away from the solar cell.

2. The photovoltaic module of claim 1, wherein, The material of the support components comprises at least one of a thermosetting adhesive, a light-curing adhesive or a silicone adhesive; or The support components comprise an adhesive tape.

3. The photovoltaic module of claim 1, wherein, The support components are disposed between the solar cell and the bus bar, and the surface of the support components close to the solar cell is in contact with the first surface; Along the first direction, at least one pair of support components is disposed on opposite sides of one non-lead-out ribbon.

4. The photovoltaic module of claim 3, wherein, Along the first direction, the minimum distance between the support components and the non-lead-out ribbons is D1; Along the first direction, the lead-out ribbons and the non-lead-out ribbons are arranged alternately, and the minimum distance between adjacent lead-out ribbons and non-lead-out ribbons is D2; Wherein, 0≤D1≤0.5D2.

5. The photovoltaic module of claim 4, wherein, The ratio of the width of the support components along the first direction to the width of the non-lead-out ribbons along the first direction ranges from 0.33 to 17.5; The ratio of D1 to the width of the non-lead-out ribbons along the first direction is less than or equal to 2.

5.

6. The photovoltaic module according to any of claims 3 to 5, characterized in that The shape of the orthographic projection of the support components on the first surface is point-like; one non-lead-out ribbon corresponds to a plurality of pairs of support components, and the plurality of pairs of support components corresponding to the same non-lead-out ribbon are arranged in sequence along the second direction; or The shape of the orthographic projection of the support components on the first surface is strip-like, the support components extend along the second direction, and one non-lead-out ribbon corresponds to one pair of support components.

7. The photovoltaic module of claim 1, wherein, At least part of the support components is disposed between the non-lead-out ribbons and the bus bar and in contact with the fourth surface; Along the first direction, at least one pair of support components is disposed on opposite side edges of the fourth surface.

8. The photovoltaic module of claim 7, wherein, Along the first direction, the distance between the inner sides of one pair of support components is D3, the distance between the outer sides of one pair of support components is D4, and the width of the non-lead-out ribbon is D5; Wherein, 0≤D3<D5, 0.5D5≤D4≤10D5.

9. The photovoltaic module of claim 8, wherein, In the case of D4>D5, the outer boundary of the support component exceeds the edge of the non-leading tab in the first direction; The part of the support component exceeding the edge of the non-leading tab is connected with the first surface.

10. The photovoltaic module according to any of claims 7 to 9, characterized in that, The shape of the orthographic projection of the support component on the first surface is a point; one non-leading tab corresponds to multiple pairs of support components, and the multiple pairs of support components corresponding to one non-leading tab are arranged in sequence along the second direction; or, The shape of the orthographic projection of the support component on the first surface is a strip, the support component extends along the second direction, and one non-leading tab corresponds to at least one pair of support components; or, In each pair of support components, the two support components are integrally formed into one support strip, and the support strip extends along the first direction; one non-leading tab corresponds to multiple support strips, and the multiple support strips are arranged in sequence along the second direction.

11. The photovoltaic module of claim 1, wherein, The photovoltaic module further comprises multiple intermediate support components, and the multiple intermediate support components are arranged between the solar cells and the bus bar; The intermediate support component comprises a fifth surface away from the solar cell, and the height of the fifth surface is greater than the height of the fourth surface compared with the first surface; In the first direction, the leading tab and the non-leading tab are arranged alternately, and the intermediate support component is arranged between adjacent leading tab and non-leading tab.

12. The photovoltaic module of claim 11, wherein, The shape of the orthographic projection of the intermediate support component on the first surface is a point; The multiple intermediate support components comprise multiple columns, and the multiple intermediate support components in each column are arranged in sequence along the second direction, and at least one column of intermediate support components is arranged between adjacent leading tab and non-leading tab.

13. The photovoltaic module of claim 12, wherein, In the second direction, the distance between the outer boundaries of the two outermost intermediate support components in each column of intermediate support components is D6, and the width of the bus bar is D7; 0.5D7≤D6≤2D7.

14. The photovoltaic module of claim 11, wherein, The shape of the orthographic projection of the intermediate support component on the first surface is a strip, and the intermediate support component extends along the second direction; At least one intermediate support component is arranged between adjacent leading tab and non-leading tab.

15. The photovoltaic module of claim 14, wherein, In the second direction, the length of each intermediate support component is D8, and the width of the bus bar is D7; 0.5D7≤D8≤2D7.

16. The photovoltaic module of any of claims 11-15, wherein, The photovoltaic module further comprises an insulating adhesive layer, and the insulating adhesive layer is arranged between the solar cell and the leading tab and between the solar cell and the non-leading tab; The insulating adhesive layer is discontinuously arranged in the interval region between adjacent leading tab and non-leading tab.

17. A method for preparing a photovoltaic module, characterized in that, Providing a solar cell, the solar cell comprising opposite first and second surfaces; A plurality of leading tabs and a plurality of non-leading tabs are arranged on the first surface, the plurality of leading tabs and the plurality of non-leading tabs are arranged along a first direction, and the leading tabs and the non-leading tabs both extend along a second direction, the first direction and the second direction are both parallel to the first surface, and the first direction and the second direction intersect; ​ a plurality of pairs of support components are formed on a side of the first surface away from the second surface, one non-extraction tab corresponds to at least one pair of support components; the support component comprises a third surface away from the solar cell, the non-extraction tab comprises a fourth surface away from the solar cell, the height of the third surface is greater than the height of the fourth surface compared with the first surface; a bus bar extending along the first direction is arranged, the bus bar is in contact with the third surface of the at least one pair of support components, the at least one pair of support components is used for supporting the bus bar across the non-extraction tab; the bus bar is also in electrical contact with the surface of the plurality of extraction tabs away from the solar cell.

18. The method of claim 17, wherein, The plurality of pairs of support components are formed by one of printing, dispensing or inkjet.

19. The method of manufacturing according to claim 17 or 18, wherein, Before forming the bus bar, the preparation method further comprises: a plurality of intermediate support components are formed on a side of the first surface away from the second surface by one of printing, dispensing or inkjet, the intermediate support component comprises a fifth surface away from the solar cell, the height of the fifth surface is greater than the height of the fourth surface compared with the first surface; along the first direction, the extraction tabs and the non-extraction tabs are arranged alternately, and the intermediate support component is arranged between adjacent extraction tabs and non-extraction tabs.

Images