Lightweight assembly with synchronously packaged frames and preparation method thereof

Abstract

The invention relates to the technical field of photovoltaic modules, in particular to a light module with synchronously packaged frames and a preparation method of the light module. The light assembly with the frames synchronously packaged comprises a battery assembly and two side frames located on the periphery of the battery assembly, each side frame is of a left-opened E-shaped structure and comprises an upper groove, a middle protruding part and a lower groove, and the battery assembly comprises a front cover plate, an upper packaging adhesive film, a battery piece, a lower packaging adhesive film and a back plate which are sequentially stacked. The two ends of the front cover plate and the two ends of the upper packaging adhesive film are embedded into the upper grooves, the two ends of the lower packaging adhesive film and the two ends of the back plate are embedded into the lower grooves, lamination auxiliary tools are arranged above the front cover plate and below the back plate, and the outer surfaces of the two lamination auxiliary tools are flush with the upper top faces and the lower bottom faces of the side frames respectively. The two ends of the upper packaging adhesive film and the two ends of the lower packaging adhesive film are fused and overflow through vacuum lamination to fill lamination gaps formed between the battery assembly and the upper groove and between the battery assembly and the lower groove, the technological process is reduced, integration of the battery assembly and the side frame packaging structure is achieved, and the yield of light assemblies is increased.

Description

Technical Field

[0001] The present invention relates to the technical field of photovoltaic modules, and in particular to a lightweight photovoltaic module, in particular to a lightweight module with synchronous frame packaging and a preparation method thereof. Background Art

[0002] Lightweight photovoltaic modules refer to solar cell modules that significantly reduce the weight of traditional photovoltaic modules through material optimization and structural design weight reduction, while maintaining good power generation performance, mechanical strength and reliability. However, the existing "lamination before framing" process of lightweight photovoltaic modules faces three constraints: a. Structural damage: Lightweight substrates (polyolefin / composite boards) have weak mechanical strength, and the metal frame crimping process results in a component edge breakage rate as high as 5% to 6%; b. Process redundancy: After lamination, the glue-coated packaging frame needs to be heated again, which increases energy consumption by 18%. The temperature gradient also causes the risk of delamination (interface failure probability >3%). c. Yield loss: The connection between multiple processes causes problems such as component scratches and positioning deviations, resulting in an edge packaging defect rate exceeding 3.5%. Summary of the Invention

[0003] The technical problem to be solved by the present invention is: in order to solve the problems of structural damage, process redundancy and yield loss in the prior art in the above-mentioned background technology, a lightweight component with synchronous frame packaging is provided, and the glue overflowed from the film can be used for the packaging between the frame and the battery component, reducing the process steps, improving the yield of the lightweight component, and solving the problem of thinning of the edge lamination thickness.

[0004] The technical solution adopted by the present invention to solve its technical problems is: a lightweight component with synchronous frame packaging, comprising a battery component and two side frames located around the battery component, the side frames are a U-shaped structure, which includes an upper groove, a middle convex portion and a lower groove, the battery component includes a front cover, an upper packaging film, a battery cell, a lower packaging film and a back plate stacked in sequence, the two ends of the front cover and the upper packaging film are embedded in the upper groove, the two ends of the lower packaging film and the back plate are embedded in the lower groove, and lamination auxiliary tooling is provided above the front cover and below the back plate, the outer surfaces of the two lamination auxiliary toolings are flush with the upper top surface and the lower bottom surface of the side frames respectively, and the two ends of the upper packaging film and the lower packaging film are melted and overflowed through vacuum lamination to fill the lamination gap formed by the battery component and the upper groove and the lower groove, and the filling volume satisfies: the volume V1 of the lamination gap and the film overflow volume V2 satisfy: 0.85≤V1 / V2≤1.1.

[0005] Through the upper and lower groove design of the U-shaped side frame, the film melts and overflows during lamination to fill the gap, realizing the simultaneous packaging of the side frame and battery assembly, eliminating the mechanical fixing step of the traditional frame; the central convex part supports the battery cell, and the upper and lower grooves accommodate the packaging material, reducing redundant frame materials and the overall weight of the assembly; the film filling ratio is precisely controlled to avoid insufficient filling, air gaps leading to delamination, or excessive overflow leading to contamination of the side frame surface.

[0006] According to one embodiment of the present invention, the film overflow volume V2 is the total packaging film V 总 5% to 15% of the total packaging film V 总 = Volume of upper encapsulation film + volume of lower encapsulation film. Limiting the amount of film overflow ensures that the film fully fills the gaps during lamination without excessive leakage that could cause adhesive shortages in the battery area, thus avoiding film waste and reducing material costs.

[0007] According to one embodiment of the present invention, the inner walls of the upper and lower grooves are provided with a serration structure, with a serration height of 0.05 to 0.25 mm and a serration spacing of 0.2 to 1.5 mm. The serration structure increases the contact area between the adhesive film and the side frame, enhancing the adhesive film's interfacial anchoring strength and preventing post-lamination delamination. The serration distribution optimizes the filling path of the molten adhesive film and avoids local air gaps.

[0008] According to one embodiment of the present invention, the thickness of the central convex portion is 1.05 to 1.2 times the thickness of the battery cell, and the gap between the central convex portion and the battery cell is 10 to 60 mm. The central convex portion is slightly thicker than the battery cell to provide pressure resistance; the reserved gap prevents the battery cell from directly contacting the side frame when it expands due to heat, causing cracks.

[0009] According to one embodiment of the present invention, the front cover is made of ultra-thin tempered glass with a thickness of 0.2 to 1.6 mm. Ultra-thin glass reduces weight by more than 50% while maintaining high light transmittance, and the tempering process ensures wind pressure and impact resistance.

[0010] According to one embodiment of the present invention, the back panel is made of ultra-thin tempered glass, thermoplastic elastomer, or polyester thermoplastic elastomer, with a thickness between 0.2 and 1.6 mm. Ultra-thin tempered glass offers high rigidity and is suitable for high-reliability scenarios. Thermoplastic elastomer or polyester thermoplastic elastomer offers flexibility and weight reduction, making it suitable for curved surfaces or mobile devices. Polyester thermoplastic elastomer is particularly well-suited for high-temperature and high-humidity environments.

[0011] According to one embodiment of the present invention, the side frames are made of at least one of magnesium-aluminum alloy, carbon fiber-reinforced composite material, or injection-molded engineering plastic, with a wall thickness of 0.5 to 1.5 mm. Magnesium-aluminum alloy has a density only two-thirds that of aluminum and is corrosion-resistant; carbon fiber is extremely lightweight and has strength comparable to steel; and the side frames are injection-molded engineering plastic, which is low-cost and suitable for mass production.

[0012] According to one embodiment of the present invention, the upper and lower encapsulation films are made of one of ethylene-vinyl acetate copolymer, expanded polyethylene, and polyolefin elastomer. Ethylene-vinyl acetate copolymer is low-cost, has a mature process, and is suitable for conventional environments; expanded polyethylene provides shock absorption and weight reduction, making it suitable for fragile solar cells; and polyolefin elastomer offers high weather resistance and resistance to potential-induced degradation, making it suitable for bifacial modules.

[0013] According to one embodiment of the present invention, the melt viscosity of the upper and lower encapsulation films is 500-800 Pa·s. If the viscosity is less than 500 Pa·s, the film will flow excessively, easily overflowing and causing contamination; if the viscosity is greater than 800 Pa·s, insufficient filling will occur, resulting in air gaps.

[0014] A method for preparing the lightweight component with synchronous frame packaging described in the above solution is also provided, comprising the following process steps: S1. Assembly: stack the front cover, upper encapsulation film, battery cells, lower encapsulation film and backplane in sequence, and insert the two ends into the upper and lower grooves of the side frame respectively; S2. Vacuum lamination: The first stage: vacuum degree ≥ -90kPa, temperature rise to 80-100℃, lasting 5-10min; The second stage: the pressure is adjusted from -50kPa to normal pressure, and the temperature is raised to 120-160℃ to melt the film and overflow to fill the lamination gap; The third stage: cooling under pressure to below 70℃, curing time ≤15min; S3. Remove the lamination auxiliary tooling.

[0015] In the first stage, the film softens and pre-flows to avoid deformation caused by sudden temperature rise; in the second stage, the pressure is precisely controlled, and the film overflows to fill the laminate gaps; in the third stage, rapid curing is achieved to shorten the production cycle.

[0016] Beneficial effects of the present invention: (1) Through the upper and lower groove design of the U-shaped side frame, the film melts and overflows during lamination to fill the gap, realizing the synchronous packaging of the side frame and the battery assembly, eliminating the mechanical fixing step of the traditional frame; (2) The weight of the module is further reduced by using ultra-thin glass for the front cover and back panel, and a U-shaped side frame made of lightweight material; (3) By setting the inner walls of the upper and lower grooves to a serrated structure, the anchoring strength of the film interface is improved, and the support of the middle convex part ensures mechanical strength and long-term weather resistance; (4) Adaptable to various films such as ethylene-vinyl acetate copolymer, foamed polyethylene, polyolefin elastomer, etc. to meet the needs of different application scenarios; (5) Through the directional control of vacuum lamination parameters, the overflow glue is driven to form a continuous sealing interface along the groove, realizing the integration of the packaging structure. BRIEF DESCRIPTION OF THE DRAWINGS

[0017] The present invention will be further described below with reference to the accompanying drawings and examples.

[0018] Figure 1 It is a structural schematic diagram of the lightweight component with synchronous packaging of the frame of the present invention.

[0019] Figure 2 It is a structural schematic diagram of the side frame of the lightweight component with synchronous frame packaging of the present invention.

[0020] Figure 3 It is a flow chart of the method for preparing a lightweight component with synchronous frame packaging of the present invention.

[0021] Figure 4 It is a structural schematic diagram of the overflowing adhesive film after vacuum lamination in the method for preparing a lightweight component with synchronous frame packaging of the present invention.

[0022] In the figure: 1. Side frame; 10. Sawtooth structure; 11. Upper groove; 12. Middle convex part; 13. Lower groove; 2. Front cover; 3. Upper packaging film; 4. Battery cell; 5. Lower packaging film; 6. Back plate; 7. Lamination auxiliary tooling. DETAILED DESCRIPTION

[0023] The present invention will now be described in further detail with reference to the accompanying drawings, which are simplified schematic diagrams that illustrate the basic structure of the present invention in a schematic manner.

[0024] like Figure 1 As shown, a lightweight component with synchronous frame packaging includes a battery component and two side frames 1 located around the battery component, as shown in FIG. Figure 2 As shown, the side frame 1 is a U-shaped structure, which includes an upper groove 11, a middle convex portion 12 and a lower groove 13. The battery assembly includes a front cover plate 2, an upper packaging film 3, a battery cell 4, a lower packaging film 5 and a back plate 6 stacked in sequence. The two ends of the front cover plate 2 and the upper packaging film 3 are embedded in the upper groove 11, and the two ends of the lower packaging film 5 and the back plate 6 are embedded in the lower groove 13. Lamination auxiliary tooling 7 is provided above the front cover plate 2 and below the back plate 6. The outer surfaces of the two lamination auxiliary toolings 7 are flush with the upper top surface and the lower bottom surface of the side frame 1 respectively. Through vacuum lamination, the two ends of the upper packaging film 3 and the lower packaging film 5 are melted and overflowed to fill the lamination gap formed by the battery assembly and the upper groove 11 and the lower groove 13, and the filling volume satisfies: the volume V1 of the lamination gap and the film overflow volume V2 satisfy: 0.85≤V1 / V2≤1.1.

[0025] The front cover 2 is preferably made of ultra-thin tempered glass with a thickness of 0.2-1.6mm. Ultra-thin glass reduces weight by over 50% while maintaining high light transmittance, and the tempering process ensures wind and impact resistance. The back panel 6 can be made of ultra-thin tempered glass, thermoplastic elastomer (TPT), or polyester thermoplastic elastomer (TPE), with a thickness of 0.2-1.6mm. Ultra-thin tempered glass offers high rigidity and is suitable for high-reliability scenarios. TPE or polyester thermoplastic elastomer offers flexibility and weight reduction, making it suitable for curved surfaces or mobile devices. Polyester thermoplastic elastomer is particularly well-suited for high-temperature and high-humidity environments. The side frame 1 can be made of at least one of magnesium-aluminum alloy, carbon fiber-reinforced composite material, or engineering plastic injection molding, with a wall thickness of 0.5-1.5mm. Magnesium-aluminum alloy has a density of only two-thirds that of aluminum and is corrosion-resistant. Carbon fiber is extremely lightweight with strength comparable to steel. The side frame 1 is injection-molded from engineering plastic, which is low-cost and suitable for mass production. The upper and lower encapsulation films 3 and 5 can be made of ethylene-vinyl acetate copolymer (EVA), expanded polyethylene (EPE), or polyolefin elastomer (POE). EVA is low-cost, has a mature process, and is suitable for conventional environments; EPE provides shock absorption and weight reduction, making it suitable for fragile solar cells; and POE offers high weather resistance and resistance to potential-induced degradation, making it suitable for bifacial modules. The melt viscosity of the upper and lower encapsulation films 3 and 5 should be between 500 and 800 Pa·s. A viscosity below 500 Pa·s will result in excessive film flow and contamination; a viscosity above 800 Pa·s will result in insufficient filling, resulting in air gaps.

[0026] The lamination gap volume V1 precisely matches the film overflow volume V2, while the recess size is determined by the lightweight design of the side frame 1. For example, if the recess is too shallow, excess film overflow may occur even if V2 = 5%. If the recess is too deep, the film overflow volume V2 must be increased to 15% to fill it completely. In existing technology, the goal is to minimize film overflow (to avoid contamination). However, this embodiment actively utilizes overflow film to fill the gap, breaking with conventional thinking. This conflict between film filling and sealing reliability in lightweight components makes conventional processes inappropriate. The U-shaped side frame 1 design transforms film overflow from a process defect to a key packaging feature. Combining film properties (such as viscosity) with structural parameters (the lamination gap volume V1), extensive experiments have verified that 0.85 ≤ V1 / V2 ≤ 1.1 is the optimal solution.

[0027] like Figure 2 As shown, the thickness of the upper groove 11 is H1, the thickness of the middle convex portion 12 is H2, and the thickness of the lower groove 13 is H3. H1+H2+H3=the thickness of the front cover 2+the thickness of the upper packaging film 3+the thickness of the battery cell 4+the thickness of the lower packaging film 5+the thickness of the back plate 6.

[0028] As a preferred embodiment, the film overflow volume V2 is the total packaging film V 总5% to 15% of the total encapsulation film V 总 = volume of the upper encapsulation film 3 + volume of the lower encapsulation film 5. Limiting the overflow film ratio ensures that the film can fully fill the gap during lamination without excessive loss, preventing lack of film in the battery area, avoiding film waste, and reducing material costs.

[0029] Preferably, the inner walls of the upper groove 11 and the lower groove 13 are provided with a serrated structure 10, the height of the serrations is 0.05 - 0.25 mm, and the serration pitch is 0.2 - 1.5 mm. The serrated structure 10 increases the contact area between the film and the side frame 1, enhances the film interface anchoring strength, and prevents delamination at the interface after lamination; the serration distribution optimizes the filling path of the molten film, avoiding local air gaps.

[0030] Preferably, the thickness of the middle convex part 12 is 1.05 - 1.2 times the thickness of the battery cell 4, and the gap between the middle convex part 12 and the battery cell 4 is 10 - 60 mm. The middle convex part 12 is slightly thicker than the battery cell 4 to provide compressive protection; the reserved gap prevents the battery cell 4 from directly contacting the side frame 1 and cracking when heated and expanded.

[0031] As Figure 3 shown, the preparation method of the lightweight component with synchronous encapsulation of the frame includes the following process steps: S1. Assembly: Stack the front cover plate 2, upper encapsulation film 3, battery cell 4, lower encapsulation film 5, and back plate 6 in sequence, and embed the two ends into the upper groove 11 and the lower groove 13 of the side frame 1 respectively; S2. Vacuum lamination: First stage: The vacuum degree ≥ -90 kPa, heat up to 80 - 100 °C, and keep for 5 - 10 min; Second stage: Adjust the pressure to -50 kPa to atmospheric pressure, heat up to 120 - 160 °C, and make the film melt and overflow to fill the lamination gap; Third stage: Keep the pressure and cool down to below 70 °C, and the curing time ≤ 15 min; S3. Remove the lamination auxiliary tooling 7.

[0032] Example 1 Select a magnesium - aluminum alloy with a wall thickness of 1.2 mm, and process it into a "彐" shape by extrusion molding, and perform anodic oxidation treatment on the surface to form the side frame 1; lay a 0.6 mm ultra - white embossed glass (front cover plate 2), polyolefin elastomer film (POE film), battery cell 4, polyolefin elastomer film (POE film), and 1.0 mm tempered glass (back plate 6) in sequence to form a battery module; leave a 10 mm lamination margin on all four sides and embed it into the grooves (upper groove 11 and lower groove 13) of the 彐 - shaped side frame 1. Then, lamination auxiliary tooling 7 is respectively set on the top of the front cover plate 2 and the bottom of the back plate 6.

[0033] Vacuum lamination: Stage 1: vacuum degree -95kPa, heating to 90℃ (rate 3℃ / min), pre-pressing for 5min; The second stage: release the vacuum to -50kPa and heat to 150℃ (maintain pressure for 10 minutes); The third stage: Naturally cool to 70°C, open the mold and remove the battery components.

[0034] During the lamination process, the POE film overflows into the upper groove 11 and the lower groove 13 of the side frame 1 to form a continuous sealing surface without the need for secondary gluing. Figure 4 shown.

[0035] Example 2 The difference from the first embodiment is that the side frame 1 is made of glass fiber.

[0036] Example 3 The difference from the first embodiment is that the battery assembly is single-glass, has no front cover 2, and only uses the back plate 6.

[0037] Comparative Example 1 The preparation process of existing conventional lightweight components is as follows: Step 1: Material stacking Lay in the following order: 0.6mm ultra-clear patterned glass (front cover 2) → POE film → battery cell 4 → POE film → 1.0mm tempered back panel 6; Step 2: Lamination packaging Temperature 120 ~ 150 ℃, vacuum degree -90kPa to -50kPa, time 15 ~ 25 minutes, make the film melt and bond; Step 3: Trimming Mechanically cut the edges of the film that overflows after lamination to ensure component dimensional accuracy (tolerance ±1.5mm); Step 4: Glue Apply structural adhesive (such as silicone adhesive / epoxy resin) to the four sides of the component manually or by a robotic arm. The adhesive layer should be 0.3-0.8mm thick and then cured at room temperature or 80-100°C (taking 1-2 hours). Step 5: Frame Attach the aluminum alloy frame, apply pressure to fix it (5-10kPa), and let it stand until the adhesive is completely cured (usually ≥4 hours).

[0038] The performance comparison of Examples 1 to 3 and Comparative Example 1 is shown in Table 1.

[0039] Table 1 Technical Dimension Example 1 to Example 3 Comparative Example 1 Improved results Process steps One-step simultaneous lamination and encapsulation Lamination → Trimming → Gluing → Framing (Secondary Processing in Steps) The number of steps is reduced by 60%, and labor costs are reduced by 8%. Frame structure design Elbow frame (integrated upper and lower grooves and central convex part) Straight / simple bend frame Synchronous lamination possible Overflow packaging method The film melts and overflows to fill the groove (self-sealing) Artificial glue application (post-curing bonding) The interface bubble rate was reduced from >15% to <0.5% Material utilization The film overflow volume accounts for 5%-15% (precisely matching the groove) Cutting after lamination results in 10%-20% film loss 40% reduction in material waste Production cycle ≤45 minutes (including simultaneous lamination and packaging) ≥180 minutes (including glue curing and secondary frame assembly) Efficiency increased by 300% Quality test results EL crack rate is 0.15%, and transportation damage rate is less than 0.3% EL crack rate is 3.7%, breakage rate is 3.9% Component yield increased from 91.5% to 99.1% As shown in Table 1, compared to conventional lightweight modules (Comparative Example 1), Examples 1-3 achieve simultaneous lamination and packaging through the use of a curved side frame 1, eliminating the trimming, gluing, and framing processes and increasing efficiency by 300%. During the lamination phase, overflow glue is utilized to create an integrated packaging interface, eliminating the contradiction between redundant packaging processes and structural fragility in lightweight modules, and increasing the yield rate from 91.5% to 99.1%.

[0040] With the above-described preferred embodiments of the present invention as a guide, and with reference to the above description, relevant personnel are fully capable of making various changes and modifications without departing from the technical scope of this invention. The technical scope of this invention is not limited to the contents of the specification and must be determined according to the scope of the claims.

Claims

1. A lightweight component with synchronous frame packaging, comprising a battery component and two side frames (1) located around the battery component, characterized in that: The side frame (1) has a E-shaped structure, which includes an upper groove (11), a middle convex part (12) and a lower groove (13). The battery assembly includes a front cover plate (2), an upper encapsulation film (3), a battery cell (4), a lower encapsulation film (5) and a back plate (6) stacked in sequence. Both ends of the front cover plate (1) and the upper encapsulation film (3) are embedded in the upper groove (11), and both ends of the lower encapsulation film (5) and the back plate (6) are embedded in the lower groove (13). Laminating auxiliary tools (7) are arranged above the front cover plate (1) and below the back plate (6). The outer surfaces of the two laminating auxiliary tools (7) are flush with the upper top surface and the lower bottom surface of the side frame (1) respectively. Through vacuum lamination, both ends of the upper encapsulation film (3) and the lower encapsulation film (6) melt and overflow to fill the lamination gap formed by the battery assembly and the upper groove (11) and the lower groove (13), and the filling volume satisfies that the volume V1 of the lamination gap and the volume V2 of the film overflow satisfy: 0.85 ≤ V1 / V2 ≤ 1.

1.

2. The lightweight component with synchronous frame packaging according to claim 1, characterized in that: The film overflow volume V2 is the total packaging film V 总 5% to 15% of the total packaging film V 总 = the volume of the upper packaging film (3) + the volume of the lower packaging film (5).

3. The lightweight component with synchronous frame packaging according to claim 1, characterized in that: The inner walls of the upper groove (11) and the lower groove (13) are provided with a serrated structure (10). The height of the serrations is 0.05 - 0.25 mm, and the serration pitch is 0.2 - 1.5 mm.

4. The lightweight component with synchronous frame packaging according to claim 1, characterized in that: The thickness of the middle convex part (12) is 1.05 - 1.2 times the thickness of the battery cell (4), and the gap between the middle convex part (12) and the battery cell (4) is 10 - 60 mm.

5. The lightweight component with synchronous frame packaging according to claim 1, characterized in that: The front cover plate (2) is an ultra-thin tempered glass, and its thickness is between 0.2 - 1.6 mm.

6. The lightweight component with synchronous frame packaging according to claim 1, characterized in that: The back plate (6) is an ultra-thin tempered glass, a thermoplastic elastomer or a polyester thermoplastic elastomer, and its thickness is between 0.2 - 1.6 mm.

7. The lightweight component with synchronous frame packaging according to claim 1, characterized in that: The side frame (1) is at least one of a magnesium-aluminum alloy, a carbon fiber reinforced composite material or an engineering plastic injection molding, and its wall thickness is 0.5 - 1.5 mm.

8. The lightweight component with synchronous frame packaging according to claim 1, characterized in that: The upper encapsulation film (3) and the lower encapsulation film (5) are one of ethylene-vinyl acetate copolymer, foamed polyethylene, and polyolefin elastomer.

9. The lightweight component with synchronous frame packaging according to claim 1, characterized in that: The melt viscosity of the upper encapsulation film (3) and the lower encapsulation film (5) is 500 - 800 Pa·s.

10. A method for preparing a lightweight component with synchronous packaging of a frame according to any one of claims 1 to 9, characterized in that: It includes the following process steps: S1. Assembly: Stack the front cover plate (2), the upper encapsulation film (3), the battery cell ( ​ ​ ​ ​ ​

Images