Solar module and preparation method thereof

Abstract

The invention discloses a solar module and a preparation method thereof, and the method comprises the steps: S1, laminating materials for preparing the solar module according to a preset sequence, and obtaining a to-be-laminated module; s2, presetting a solar turnover table; s3, the product clamp is opened, the to-be-laminated assembly is put into the feeding table, the discharging table is turned over to cover the feeding table, and the adjustable lock catch is locked; s4, the product clamp is overturned by 180 degrees around the bearing; and S5, opening the product clamp, taking out the overturned to-be-laminated assembly, and laminating the overturned to-be-laminated assembly through a laminating machine to integrally form the solar assembly. According to the scheme, the manufacturing cost is low, operation is easy, reliability is high, the surface crosslinking degree can be improved, and the production time is shortened; and the bad problems of cavities, glue shortage and the like are solved.

Description

Technical Field

[0001] The present invention relates to the field of solar photovoltaic technology, in particular to a solar module and a preparation method thereof. Background Art

[0002] With the growing global demand for sustainable energy, solar energy, a clean, renewable energy source, is experiencing continuous innovation in its conversion technology. Among the numerous solar energy conversion technologies, flexible photovoltaic modules, with their unique technical characteristics and broad application prospects, are gradually changing our understanding of traditional photovoltaic technology and heralding a new technological revolution in the solar industry.

[0003] The demand for large photovoltaic modules is gradually increasing due to their high power output characteristics. Large photovoltaic modules have the following problems:

[0004] The high cost of lamination, which heats from the bottom up, also leads to long lamination times, low surface crosslinking, short product lifespan, front-side adhesive defects, and cavities. Reverse lamination, however, prevents front-side inspection and is more likely to cause surface defects, resulting in low yields, high costs, and waste. Conventional flipping methods make it difficult to re-flip materials and can easily cause internal material shifting, leading to product failure.

[0005] How to solve the above problems is the industry’s top priority. Summary of the Invention

[0006] Purpose of the Invention: To address the problems and shortcomings of existing technical solutions, the present invention provides a solar module and a method for manufacturing the same. The solution provided by this application is low-cost, easy to operate, highly reliable, can improve surface cross-linking, reduce production time, and address issues such as cavities and glue shortages.

[0007] The specific technical solutions are as follows:

[0008] A method for preparing a solar module, comprising:

[0009] S1. Laminating materials for preparing solar modules in a predetermined order to obtain modules to be laminated;

[0010] S2. A solar flip table is provided. The solar flip table comprises: table legs, a table frame, an adjustable lock, a bearing, and a product fixture. The product fixture is located inside the table frame and includes: an infeed table and an outfeed table. The bearing is located in the middle of the table frame, and the product fixture can flip around the bearing inside the table frame. The adjustable lock is located on the table frame.

[0011] S3. Open the product fixture, place the component to be laminated on the feed table, flip the discharge table over to cover the feed table, and lock the adjustable lock;

[0012] S4: Turn the product fixture 180° around the bearing;

[0013] S5: Open the product fixture, take out the flipped components to be laminated, and laminate the flipped components to be laminated into one piece by a laminator to form a solar panel.

[0014] Furthermore, after S1, the following step is also included: inspecting the surface of the component to be laminated. If the surface is intact, S2 is executed; if there are damages, cracks, hot spots, or foreign objects blocking the surface, new materials for preparing the solar component need to be replaced for re-lamination.

[0015] Furthermore, S1, stacking materials for preparing solar modules in a predetermined order, including:

[0016] The front film, the first packaging film, the solar cell layer, the second packaging film, the support layer, the third packaging film and the back plate are stacked from top to bottom.

[0017] Furthermore, S1, stacking materials for preparing solar modules in a predetermined order, including:

[0018] The back sheet, the third packaging film, the support layer, the second packaging film, the solar cell layer, the first packaging film and the front film are stacked from top to bottom.

[0019] Furthermore, the first packaging film, the second packaging film, and the third packaging film are made of any one of the following materials: EVA, POE, and EPE.

[0020] Furthermore, the materials of the support layer and the back plate include any one of the following: PCB, CPC, KPF, polyolefin, glass fiber reinforced polypropylene

[0021] On the other hand, the present application also provides a solar module, which is prepared by the above-mentioned method for preparing a solar module.

[0022] Beneficial effects:

[0023] This application uses a flip table to flip the inspected laminated parts, solving the problem of the product surface being unable to be inspected, reducing the product surface defect rate; and improving the surface cross-linking degree, reducing production time; and solving defects such as cavities and glue shortages;

[0024] On the one hand, by using this structure to flip the product, the surface of the product can be checked first, thus reducing the defective rate of the surface;

[0025] On the other hand, using the flip table with this structure to flip the product surface downward for lamination can allow the product surface to be heated first, increase the cross-linking degree of the product surface, and reduce the lamination time.

[0026] In addition, the flip table is inexpensive and uses a central bearing for flipping, making it easy to operate and even easy to flip heavy, large products. It is highly practical and simple to manufacture. Its structure uses a central bearing for flipping, allowing it to rotate to any angle, unlike a book flip, which can only flip on one side.

[0027] In summary, the solution proposed in this application is low-cost, easy to operate, can improve surface crosslinking, reduce production time, and solve problems such as cavities and adhesive deficiencies. During lamination, if this solution is not used and direct forward lamination is performed, it may cause cell breakage, affecting product function and lifespan. This solution can overcome this problem. BRIEF DESCRIPTION OF THE DRAWINGS

[0028] Figure 1 A flow chart of a method for preparing a solar module according to an embodiment of the present invention;

[0029] Figure 2 This is a schematic diagram of a solar flip table in one embodiment of the present invention.

[0030] Figure 3 A schematic diagram of a solar flip table after placing components to be laminated in one embodiment of the present invention.

[0031] Figure 4 This is a schematic diagram of a solar flip table with a rotating product fixture in one embodiment of the present invention.

[0032] Figure 5 This is a schematic diagram of a solar flip table after the product fixture is rotated 180 degrees in one embodiment of the present invention.

[0033] Figure 6 A schematic diagram of a solar flip table after removing components to be laminated in one embodiment of the present invention. DETAILED DESCRIPTION

[0034] The present invention will be further described below in conjunction with the embodiments, but this does not constitute any limitation to the present invention. Any limited number of modifications made by anyone within the scope of the claims of the present invention are still within the scope of the claims of the present invention.

[0035] Example 1

[0036] like Figure 1 As shown, this example provides a method for preparing a solar module, comprising:

[0037] S1. Laminating materials for preparing solar modules in a predetermined order to obtain modules to be laminated;

[0038] S2. A solar flip table is provided. The solar flip table comprises: table legs, a table frame, an adjustable lock, a bearing, and a product fixture. The product fixture is located inside the table frame and includes: an infeed table and an outfeed table. The bearing is located in the middle of the table frame, and the product fixture can flip around the bearing inside the table frame. The adjustable lock is located on the table frame.

[0039] S3. Open the product fixture, place the component to be laminated on the feed table, flip the discharge table over to cover the feed table, and lock the adjustable lock;

[0040] S4: Turn the product fixture 180° around the bearing;

[0041] S5: Open the product fixture, take out the flipped components to be laminated, and laminate the flipped components to be laminated into one piece by a laminator to form a solar panel.

[0042] Furthermore, after S1, the following step is also included: inspecting the surface of the component to be laminated. If the surface is intact, S2 is executed; if there are damages, cracks, hot spots, or foreign objects blocking the surface, new materials for preparing the solar component need to be replaced for re-lamination.

[0043] Furthermore, S1, stacking materials for preparing solar modules in a predetermined order, including:

[0044] The front film, the first packaging film, the solar cell layer, the second packaging film, the support layer, the third packaging film and the back plate are stacked from top to bottom.

[0045] Furthermore, S1, stacking materials for preparing solar modules in a predetermined order, including:

[0046] The back sheet, the third packaging film, the support layer, the second packaging film, the solar cell layer, the first packaging film and the front film are stacked from top to bottom.

[0047] Furthermore, the first packaging film, the second packaging film, and the third packaging film are made of any one of the following materials: EVA, POE, and EPE.

[0048] Furthermore, the materials of the support layer and the back plate include any one of the following: PCB, CPC, KPF, polyolefin, and glass fiber reinforced polypropylene.

[0049] On the other hand, the present application also provides a solar module, which is prepared by the above-mentioned method for preparing a solar module.

[0050] Beneficial effects:

[0051] This application uses a flip table to flip the inspected laminated parts, solving the problem of the product surface being unable to be inspected, reducing the product surface defect rate; and improving the surface cross-linking degree, reducing production time; and solving defects such as cavities and glue shortages;

[0052] On the one hand, by using this structure to flip the product, the surface of the product can be checked first, thus reducing the defective rate of the surface;

[0053] On the other hand, using the flip table with this structure to flip the product surface downward for lamination can allow the product surface to be heated first, increase the cross-linking degree of the product surface, and reduce the lamination time.

[0054] In addition, the flip table is inexpensive to manufacture and uses an intermediate bearing for flipping, making operation easy and convenient.

[0055] In summary, the solution of the present application is low in cost, easy to operate, can improve the surface cross-linking degree, reduce production time; and solve problems such as cavities and glue shortages.

[0056] Example 2

[0057] like Figure 2 As shown, this example provides a solar flip table: including: table legs 1, table frame 10 and product fixtures; the product fixture includes a feeding table 4 and a discharging table 5; a first rotating shaft 3 is provided in the middle position of the feeding table 4, and a first bearing 8 is provided at the connection between the first rotating shaft 3 and the table frame 10; the feeding table 4 and the discharging table 5 are connected by a second rotating shaft 9; second bearings 6 are provided at both ends of the second rotating shaft 9.

[0058] Furthermore, support rods 7 are provided between adjacent table legs 1 .

[0059] Furthermore, the product fixture is used to fix photovoltaic products.

[0060] Furthermore, the table frame 10 is provided with an adjustable lock 2 for fixing the discharge platform 5 and the feed platform 4 .

[0061] The operation process is as follows:

[0062] Open the product clamp, place the component to be laminated on the feed table, flip the outfeed table over to cover the feed table, and lock the adjustable lock; Figure 3 shown.

[0063] Turn the product fixture 180° around the bearing; Figure 4-5 shown.

[0064] Open the product fixture, take out the flipped components to be laminated, and laminate the flipped components to be laminated into a whole to form a solar panel through a laminator. Figure 6 shown.

[0065] The beneficial effects are as follows:

[0066] The product provided by the present application is inexpensive, uses an intermediate bearing for flipping, has high safety, is easy and convenient to operate, and can improve process efficiency.

[0067] Finally, it should be noted that the above descriptions are merely preferred embodiments of the present invention and are not intended to limit the present invention. Although the present invention has been described in detail with reference to the aforementioned embodiments, those skilled in the art will be able to modify the technical solutions described in the aforementioned embodiments or substitute equivalents for some of the technical features. Any modifications, equivalent substitutions, and improvements made within the spirit and principles of the present invention shall be included within the scope of protection of the present invention.

Claims

1. A method for preparing a solar module, characterized in that: include: S1. Laminating materials for preparing solar modules in a predetermined order to obtain modules to be laminated; S2. A solar flip table is provided. The solar flip table includes: table legs, a table frame, adjustable locks, bearings, and a product fixture. The product fixture is located inside the table frame and includes: a feed table and a discharge table. The bearing is located in the middle of the table frame, and the product fixture can flip around the bearing inside the table frame. The adjustable latch is located on the table frame; S3. Open the product fixture, place the component to be laminated on the feed table, flip the discharge table over to cover the feed table, and lock the adjustable lock; S4: Turn the product fixture 180° around the bearing; S5: Open the product fixture, take out the flipped components to be laminated, and laminate the flipped components to be laminated into one piece by a laminator to form a solar panel.

2. The method for preparing a solar module according to claim 1, wherein: After S1, the process also includes: inspecting the surface of the component to be laminated. If the surface is intact, S2 is executed; if the surface is damaged, cracked, has a hot spot, or is blocked by foreign matter, new materials for preparing the solar component need to be replaced for re-lamination.

3. The method for preparing a solar module according to claim 1, wherein: S1. Laminating materials for preparing solar panels in a predetermined order, including: The front film, the first packaging film, the solar cell layer, the second packaging film, the support layer, the third packaging film and the back plate are stacked from top to bottom.

4. The method for preparing a solar module according to claim 1, wherein: S1. Laminating materials for preparing solar panels in a predetermined order, including: The back sheet, the third packaging film, the support layer, the second packaging film, the solar cell layer, the first packaging film and the front film are stacked from top to bottom.

5. The method for preparing a solar module according to claim 3 or 4, characterized in that: The first packaging film, the second packaging film, and the third packaging film are made of any one of the following materials: EVA, POE, and EPE.

6. The method for preparing a solar module according to claim 3 or 4, characterized in that: The materials of the support layer and the back plate include any one of the following: PCB, CPC, KPF, polyolefin, and glass fiber reinforced polypropylene.

7. A solar module, characterized in that: The solar cell module is prepared by the preparation method of any one of claims 1 to 6.

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