Photovoltaic module and manufacturing method thereof
By arranging the cell strings in different planes in the photovoltaic module and separating them with packaging materials and isolation films, the problem of string spacing affecting module area utilization and short-circuit risks is solved, and insulation isolation and power improvement are achieved.
Patent Information
- Application Number
- CN202510819916.8
- Authority / Receiving Office
- CN · China
- Patent Type
- Applications(China)
- Current Assignee / Owner
- Filing Date
- 2025-06-18
- Publication Date
- 2025-09-12
AI Technical Summary
In existing photovoltaic modules, the string spacing design between battery strings results in insufficient utilization of the photovoltaic module area and poses a short-circuit risk. How to reduce the string spacing while ensuring insulation isolation has become an urgent problem that needs to be solved.
By arranging battery strings along a preset arrangement direction in the packaging material, placing adjacent battery strings on different planes, and separating them using the packaging material and isolation membrane, short circuits in the battery strings are avoided, thereby achieving effective insulation isolation of the battery strings.
It effectively reduces the string spacing between battery strings, while ensuring the insulation isolation of photovoltaic modules when they overlap with each other, improving the power and efficiency of photovoltaic modules and avoiding the risk of short circuit.
Smart Images
Figure CN120640786A_ABST
Abstract
Description
Technical Field
[0001] The present application relates to the field of photovoltaic technology, and in particular to photovoltaic modules and methods for manufacturing the same. Background Art
[0002] PV panels are typically constructed by connecting several cells in series to form strings. These strings are then arranged into a matrix according to a design and then connected in series or parallel. There is typically spacing between the cells. However, sufficient space is required between adjacent strings to provide electrical insulation. This is because shifting of the strings during lamination can cause a short circuit between adjacent strings. Typically, the spacing between strings is designed to be 1.5mm to 3mm.
[0003] However, the power of photovoltaic modules mainly depends on the power of the cells. Increasing the effective area of the cells in the photovoltaic modules can also achieve the goal of improving the power and efficiency of the photovoltaic modules.
[0004] The spacing between cells can be reduced by stacking them. Because the stacking method aligns with the polarity of the cells, overlapping cells within a string will not cause a short circuit. This can increase the effective cell area within a photovoltaic module, improving both its power and efficiency.
[0005] However, adjacent cells within a battery string do not form a direct current transmission path between strings, and overlapping cells can cause some cells to short-circuit. Therefore, while string spacing is necessary to ensure insulation between strings, it also leads to technical issues such as insufficient utilization of the photovoltaic module area.
[0006] How to reduce the string spacing between battery strings while ensuring that the battery strings of photovoltaic modules are effectively insulated and isolated when overlapping each other is a technical problem that technical personnel in this field urgently need to solve. Summary of the Invention
[0007] Based on this, it is necessary to provide a photovoltaic module and a manufacturing method thereof to address the above-mentioned technical problems.
[0008] The present application provides a photovoltaic assembly, comprising:
[0009] a plurality of battery strings, wherein the plurality of battery strings are electrically connected to each other;
[0010] An encapsulating material is encapsulated outside the plurality of battery strings; the plurality of battery strings are arranged in the encapsulating material along a preset arrangement direction, and two adjacent battery strings along the preset arrangement direction are respectively located in different planes in the encapsulating material, thereby separating the two adjacent battery strings from each other in the encapsulating material.
[0011] In one embodiment, along the preset arrangement direction, the other two battery strings adjacent to any one battery string on the left and right are located in the same plane in the packaging material; and / or,
[0012] Each of the battery strings includes a plurality of connected battery cells, and the battery cells of two adjacent battery strings are separated from each other in the packaging material.
[0013] In one embodiment, a portion of the battery strings are located in a first plane in the packaging material, and another portion of the battery strings are located in a second plane in the packaging material.
[0014] The first plane and the second plane are configured as two different planes parallel to each other in the packaging material, and the two adjacent battery strings along the preset arrangement direction are respectively located in the first plane and the second plane in the packaging material.
[0015] In one embodiment, any one of the battery strings is selected as a selected battery string;
[0016] Along the preset arrangement direction, the other two battery strings adjacent to any one of the selected battery strings on the left and right are located on the same side of the selected battery string.
[0017] In one embodiment, the packaging material includes at least one isolation film and two packaging films, the isolation film is located between the two packaging films, and the two adjacent battery strings along the preset arrangement direction are respectively located on both sides of the isolation film.
[0018] In one embodiment, the photovoltaic module has a light-receiving side and a light-receiving side, and in a direction perpendicular to the plurality of cells, a light-shielding area exists between at least a portion of the cells in adjacent cell strings.
[0019] In one embodiment, the width of the light-blocking area along the preset arrangement direction is configured to be greater than or equal to 0 mm and less than or equal to 5 mm.
[0020] In one embodiment, the first plane is closer to the light-receiving side than the second plane, the cell string on the first plane is set as the front-side cell string, and the cell string on the second plane is set as the back-side cell string;
[0021] The surface area of the plurality of battery cells in the positive-side battery string is a first surface area, and the surface area of the plurality of battery cells in the back-side battery string is a second surface area, wherein the first surface area is smaller than the second surface area.
[0022] In one embodiment, the light-receiving area of the cell of the positive side cell string is the area where the cell of the positive side cell string can directly receive light, and the light-receiving area of the cell of the back side cell string is the area where the cell of the back side cell string can directly receive light, wherein the light-receiving area of the cell of the positive side cell string is equal to the light-receiving area of the cell of the back side cell string.
[0023] In one embodiment, the photovoltaic assembly comprises:
[0024] A welding ribbon is provided on the battery string, and the number of the welding ribbons is configured to be several. In the preset arrangement direction, a gap area exists between the welding ribbon closest to the edge of the battery string and the edge of the battery string, and in the preset arrangement direction, the width of the gap area is greater than the width of the light-blocked area.
[0025] In one embodiment, in the preset arrangement direction, the width of the gap area is configured to be greater than 0 mm and less than or equal to 30 mm.
[0026] In one embodiment, the number of the battery strings is configured as an even number, and every two battery strings in the battery strings are configured as a battery string group; the two battery strings in each battery string group are respectively located on different planes in the packaging material; the two battery strings in each battery string group are connected in parallel, and the battery string groups are connected in series; and / or,
[0027] The number of battery strings is configured to be six.
[0028] In one embodiment, in a direction perpendicular to the plurality of battery cells, the two battery strings in each battery string group are adjacent battery strings in the preset arrangement direction, and a light-shielded area exists between the two battery strings in each battery string group.
[0029] The present application provides a method for manufacturing a photovoltaic module, the method comprising:
[0030] Set up front glass;
[0031] Arranging a first layer of packaging film on the front glass;
[0032] Laying a first layer of multiple battery strings on the first layer of the packaging film along a preset arrangement direction, and setting a reserved gap between two adjacent battery strings along the preset arrangement direction;
[0033] Arranging a layer of isolation film on the plurality of battery strings of the first layer, and arranging a layer of release film on the isolation film;
[0034] Laminating the front glass, the first layer of the packaging film, the first layer of the plurality of battery strings, the isolation film and the release film;
[0035] After lamination is completed, the release film is removed, and a plurality of battery strings of the second layer are arranged on the isolation film, wherein the plurality of battery strings of the second layer are respectively opposite to the plurality of reserved gaps in a direction perpendicular to the battery strings;
[0036] Arranging a second layer of packaging film on the plurality of battery strings on the second layer;
[0037] Arranging a back glass on the second layer of the packaging film;
[0038] The front glass, the first layer of the packaging film, the first layer of the plurality of battery strings, the isolation film, the second layer of the plurality of battery strings, the second layer of the packaging film and the back glass are laminated so that two adjacent battery strings along the preset arrangement direction are respectively on different sides of the isolation film, thereby separating the two adjacent battery strings from each other.
[0039] In the above-mentioned photovoltaic module and its manufacturing method, if a number of battery strings are limited to be arranged along a preset arrangement direction in the packaging material, and at the same time, two adjacent battery strings along the preset arrangement direction are limited to be in different planes in the packaging material, then it can be ensured that the two adjacent battery strings are separated from each other in the packaging material, thereby making it impossible for any two battery strings in the packaging material to be connected, thereby avoiding the risk of contact short circuit between the battery strings.
[0040] At the same time, adjacent battery strings are separated by being in different planes and staggered. Therefore, when the string spacing between two adjacent battery strings is reduced in the direction of approaching each other in their respective planes, even if there is no string spacing between the two adjacent battery strings in the direction perpendicular to the battery strings (the string spacing is zero) or the string spacing is negative, the risk of short circuit caused by contact can be avoided by the two adjacent battery strings being in different planes.
[0041] It can be seen from this that the photovoltaic module of the present application limits the arrangement of several battery strings along a preset arrangement direction in the packaging material, and at the same time limits the two adjacent battery strings along the preset arrangement direction to be in different planes in the packaging material, thereby effectively reducing the string spacing between the battery strings and ensuring that the battery strings of the photovoltaic module are effectively insulated and isolated when they overlap with each other (the string spacing is a negative value). BRIEF DESCRIPTION OF THE DRAWINGS
[0042] Figure 1 Schematic diagram of the layer structure of a photovoltaic module in the prior art.
[0043] Figure 2A schematic diagram of the layer structure of a photovoltaic module provided in one embodiment of the present application.
[0044] Figure 3 A size comparison diagram of a photovoltaic module provided in one embodiment of the present application from a top view and a side view.
[0045] Figure 4 A schematic diagram of the connection structure of several battery strings of a photovoltaic module provided in one embodiment of the present application.
[0046] Figure 5 A schematic diagram of the layer structure of the first step of a photovoltaic module manufacturing method provided in one embodiment of the present application.
[0047] Figure 6 A schematic diagram of the layer structure of the second step of the photovoltaic module manufacturing method provided in one embodiment of the present application.
[0048] Figure Number:
[0049] 10. Preset arrangement direction;
[0050] 100, existing battery string; 200, front side film; 300, back side film; 400, front side glass; 500, back side glass; 600, cell spacing;
[0051] 1000, battery string; 2000, packaging material; 3000, solder ribbon; 4000, front glass; 5000, release film; 6000, back glass;
[0052] 1001. Light-blocked area;
[0053] 2100, isolation film; 2200, packaging film;
[0054] 2001, first plane; 2002, second plane. DETAILED DESCRIPTION
[0055] To make the above-mentioned objects, features, and advantages of the present application more clearly understood, the specific embodiments of the present application are described in detail below with reference to the accompanying drawings. The following description sets forth many specific details to facilitate a full understanding of the present application. However, the present application can be implemented in many other ways than those described herein, and those skilled in the art can make similar improvements without violating the scope of the present application. Therefore, the present application is not limited to the specific embodiments disclosed below.
[0056] In the description of this application, it should be understood that if the terms "center", "longitudinal", "lateral", "length", "width", "thickness", "up", "down", "front", "back", "left", "right", "vertical", "horizontal", "top", "bottom", "inside", "outside", "clockwise", "counterclockwise", "axial", "radial", "circumferential", etc. appear, the orientation or position relationship indicated by these terms is based on the orientation or position relationship shown in the accompanying drawings, which is only for the convenience of describing this application and simplifying the description, and does not indicate or imply that the device or element referred to must have a specific orientation, be constructed and operated in a specific orientation, and therefore cannot be understood as a limitation on this application.
[0057] In addition, if the terms "first" or "second" appear, these terms are used for descriptive purposes only and should not be understood to indicate or imply relative importance or implicitly specify the number of technical features indicated. Therefore, a feature specified as "first" or "second" may explicitly or implicitly include at least one of such features. In the description of this application, if the term "plurality" appears, "plurality" means at least two, for example, two, three, etc., unless otherwise specifically defined.
[0058] In this application, unless otherwise specified or limited, the terms "mounted," "connected," "connected," "fixed," etc., should be interpreted broadly. For example, these terms may refer to fixed connections, removable connections, or integration; mechanical connections or electrical connections; direct connections or indirect connections through an intermediary; and internal communication between two components or interaction between two components, unless otherwise specified. Those skilled in the art will understand the specific meanings of these terms in this application based on the specific circumstances.
[0059] In this application, unless otherwise expressly specified or limited, if a first feature is described as being "above" or "below" a second feature, or similar descriptions, this may mean that the first and second features are in direct contact, or that the first and second features are in indirect contact through an intermediate medium. Furthermore, when a first feature is described as being "above," "above," or "above" a second feature, it may mean that the first feature is directly above or diagonally above the second feature, or simply means that the first feature is at a higher level than the second feature. When a first feature is described as being "below," "below," or "below" a second feature, it may mean that the first feature is directly below or diagonally below the second feature, or simply means that the first feature is at a lower level than the second feature.
[0060] It should be noted that if an element is referred to as being "fixed to" or "disposed on" another element, it may be directly on the other element or there may be an intermediate element. If an element is considered to be "connected to" another element, it may be directly connected to the other element or there may be an intermediate element. If any, the terms "vertical", "horizontal", "upper", "lower", "left", "right" and similar expressions used in this application are for illustrative purposes only and do not represent the only embodiment.
[0061] See Figure 1 As shown, several existing cell strings 100 of an existing photovoltaic module are laminated on a front side film 200 and a back side film 300, and a front side glass 400 and a back side glass 500 are laminated on the outer layers of the front side film 200 and the back side film 300. Figure 1 In the orientation shown, conventional cell strings are arranged horizontally in a single layer (plane). Several strings are arranged in a matrix according to the design and then connected in series or parallel. Consequently, a typical intercell spacing of 600° exists between the cells in conventional strings. The spacing between strings is typically designed to be 1.5mm to 3mm. This reduces the effective cell area within a photovoltaic module, so reducing this spacing is key to improving the power and efficiency of photovoltaic modules.
[0062] See Figure 2 and Figure 3 As shown, the present application provides a photovoltaic module having a light-receiving side and a light-receiving side. The light-receiving side is the side of the photovoltaic module facing the sunlight, and the light-receiving side is the side of the photovoltaic module facing away from the sunlight. The photovoltaic module includes a plurality of cell strings 1000 and an encapsulating material 2000 for encapsulating the plurality of cell strings 1000. The encapsulating material 2000 is made of a transparent material. Therefore, the side of the cell strings 1000 in the photovoltaic module facing the sunlight is used to receive solar energy.
[0063] The photovoltaic module comprises a plurality of cell strings 1000 electrically connected to one another, each cell string 1000 comprising a plurality of connected cells. Typically, the cells in a cell string 1000 are sequentially connected along a straight line. Alternatively, those skilled in the art may sequentially connect the cells in a cell string 1000 along other linear paths, such as curved paths, broken-line paths, or other irregular paths, as needed, without limitation herein.
[0064] After the battery strings 1000 are arranged according to the preset arrangement direction 10, they can be encapsulated with a packaging material 2000 on the outside of the battery strings 1000, so that the battery strings 1000 can be arranged in the packaging material 2000 along the preset arrangement direction 10. Regarding the preset arrangement direction 10 mentioned above, those skilled in the art can define the direction of the preset arrangement direction 10 according to actual needs. In one embodiment of the present application, if the battery cells in the battery string 1000 are defined to be connected linearly in sequence along the length direction, the battery strings 1000 can generally be arranged along the width direction of the battery string 1000. In this case, arranging the battery strings 1000 along the width direction is equivalent to arranging along the preset arrangement direction 10 mentioned above.
[0065] In the aforementioned embodiment, the spacing between two adjacent cell strings 1000 along the predetermined arrangement direction 10 is referred to as the string spacing. The photovoltaic module provided herein primarily addresses how to reduce the string spacing between cell strings 1000 while ensuring effective insulation isolation between overlapping cell strings 1000. Therefore, the photovoltaic module of this application further stipulates that, along the aforementioned predetermined arrangement direction 10 (i.e., the width of the cell strings 1000), two adjacent cell strings 1000 are located on different planes within the encapsulation material 2000.
[0066] Because the packaging material 2000 is made of an insulating material, if the battery strings 1000 are not connected when encapsulated in the packaging material 2000 but are isolated by a portion of the packaging material 2000, there is no risk of short circuits between the battery strings 1000. Therefore, if the battery strings 1000 are arranged along a predetermined arrangement direction 10 in the packaging material 2000, and if two adjacent battery strings 1000 along the predetermined arrangement direction 10 are respectively located on different planes in the packaging material 2000, it is possible to ensure that the two adjacent battery strings 1000 are separated from each other in the packaging material 2000, thereby preventing any two battery strings 1000 in the packaging material 2000 from being connected, thereby avoiding the risk of contact short circuits between the battery strings 1000.
[0067] Because a battery string 1000 includes several connected battery cells, two adjacent battery strings 1000 are separated from each other in the encapsulation material 2000, which is equivalent to separating the battery cells of two adjacent battery strings 1000 from each other in the encapsulation material 2000. The short circuit risk between battery strings 1000 is actually the short circuit risk caused by contact between battery cells in different battery strings 1000.
[0068] At the same time, adjacent battery strings 1000 are separated by being displaced in different planes. Therefore, when the string spacing between two adjacent battery strings 1000 is reduced in the direction of approaching each other within their respective planes, even if there is no string spacing between the two adjacent battery strings 1000 in the direction perpendicular to the battery strings 1000 (the string spacing is zero) or the string spacing is negative, the risk of short circuit caused by contact can be avoided by the two adjacent battery strings 1000 being in different planes.
[0069] It can be seen from this that the photovoltaic module of the present application limits the arrangement of several battery strings 1000 along a preset arrangement direction 10 in the packaging material 2000, and at the same time limits the two adjacent battery strings 1000 along the preset arrangement direction 10 to be respectively located in different planes in the packaging material 2000. This can effectively reduce the string spacing between the battery strings 1000, and ensure that the battery strings 1000 of the photovoltaic module are effectively insulated and isolated when they overlap with each other (the string spacing is a negative value).
[0070] Continue reading Figure 2 As shown, regarding two adjacent battery strings 1000 being located in different planes in the packaging material 2000, the number of planes in the packaging material 2000 can be determined according to the number of battery strings 1000 in the packaging material 2000. For example, each battery string 1000 can be located individually in a plane in the packaging material 2000, or two or more battery strings 1000 can be located in the same plane in the packaging material 2000.
[0071] It should be noted that since the cell strings 1000 have a certain thickness, when the cell strings 1000 are located in different planes of the encapsulation material 2000 and form isolation between these planes, the greater the number of planes defined by the cell strings 1000 in the encapsulation material 2000 (i.e., the more layers), the thicker the photovoltaic module. Therefore, reducing the thickness of the photovoltaic module can be achieved by reducing the number of planes defined by the cell strings 1000 in the encapsulation material 2000. Those skilled in the art can configure the layout of the cell strings 1000 in the encapsulation material 2000 based on actual needs, as long as adjacent cell strings 1000 are located in different planes of the encapsulation material 2000. This is not a limitation here.
[0072] In one embodiment, any one of the plurality of cell strings 1000 can be selected, and the other two cell strings 1000 adjacent to the cell string 1000 along a predetermined arrangement direction 10 are limited to being located in the same plane within the encapsulant 2000. Furthermore, a portion of the cell strings 1000 can be limited to being located in a first plane 2001 within the encapsulant 2000, while another portion of the cell strings 1000 can be limited to being located in a second plane 2002 within the encapsulant 2000. The first plane 2001 and the second plane 2002 are configured as two parallel planes within the encapsulant 2000, and two adjacent cell strings 1000 along the predetermined arrangement direction 10 are respectively located in the first plane 2001 and the second plane 2002 within the encapsulant 2000. In this case, the plurality of cell strings 1000 can be arranged only within the first plane 2001 and the second plane 2002, thereby reducing the thickness of the photovoltaic module.
[0073] In the above arrangement, any one of the plurality of battery strings 1000 is selected as the selected battery string 1000 . Then, along the preset arrangement direction 10 , the other two battery strings 1000 adjacent to the selected battery string 1000 may be located on the same side of the selected battery string 1000 .
[0074] Continue reading Figure 2 As shown, in one embodiment, the encapsulating material 2000 may include at least one isolation film 2100 and two packaging films 2200. The isolation film 2100 is located between the two packaging films 2200, and two adjacent battery strings 1000 along the predetermined arrangement direction 10 are located on either side of the isolation film 2100. Therefore, with the plane of the isolation film 2100 as the boundary, a first plane 2001 and a second plane 2002 can be separated based on the plane of the isolation film 2100. This allows the battery strings 1000 located in the first plane 2001 and the second plane 2002 to not only be separated by the layer isolation in the encapsulating material 2000, but also to isolate adjacent battery strings 1000 through the isolation film 2100, further improving the insulation isolation capability between adjacent battery strings 1000.
[0075] It should be noted that the isolation film 2100 and the packaging film 2200 are both made of insulating materials, and the isolation film 2100 and the packaging film 2200 can be made of the same material or different materials. When the isolation film 2100 and the packaging film 2200 are made of the same material, after the isolation film 2100 and the packaging film 2200 encapsulate the multiple battery strings 1000, there will be no obvious boundary between the isolation film 2100 and the packaging film 2200. Therefore, the boundary between the isolation film 2100 and the packaging film 2200 can be reversely determined by the plane where the multiple battery strings 1000 are located. When the isolation film 2100 and the packaging film 2200 are made of different materials, it is also necessary to determine whether there is a clear boundary between the two based on the characteristics of the materials of the isolation film 2100 and the packaging film 2200. Those skilled in the art can select the materials of the isolation film 2100 and the packaging film 2200 according to actual needs, and no limitation is made here.
[0076] As can be seen from the above, there may be no string spacing between two adjacent battery strings 1000 in the direction perpendicular to the battery string 1000 (the string spacing is zero), or the string spacing may be a negative value. Figure 2 As shown, in one embodiment, a plurality of battery cells of a plurality of battery strings 1000 are parallel to each other, and when the string spacing between two adjacent battery strings 1000 in a direction perpendicular to the battery strings 1000 is a negative value, a light-blocking area 1001 may exist between the battery cells of the adjacent battery strings 1000 in a direction perpendicular to the plurality of battery cells. That is, in two adjacent battery strings 1000, the battery cells of the battery string 1000 close to the light-receiving side will, to a certain extent, block the battery cells of the battery string 1000 away from the light-receiving side, and the blocked area is the above-mentioned light-blocking area 1001.
[0077] In one embodiment, the width of the light-blocking area 1001 along the preset arrangement direction 10 is configured to be greater than or equal to 0 mm and less than or equal to 5 mm. For example, the width of the light-blocking area 1001 along the preset arrangement direction 10 can be set to 1 mm, 2 mm, 3 mm, 4 mm, or 5 mm, which is not limited here. It should be noted that, in extreme cases, if the battery cells of adjacent battery strings 1000 happen to be aligned with each other, the distance between the battery cells of adjacent battery strings 1000 can also be 0 mm, that is, the width of the light-blocking area 1001 along the preset arrangement direction 10 is configured to be 0 mm.
[0078] In one embodiment, the first plane 2001 is closer to the light-receiving side than the second plane 2002. Therefore, the cell string 1000 on the first plane 2001 can be designated as the front-side cell string 1000, and the cell string 1000 on the second plane 2002 can be designated as the back-side cell string 1000. The surface area of the cells in the front-side cell string 1000 is the first surface area, and the surface area of the cells in the back-side cell string 1000 is the second surface area. Because the cells in the front-side cell string 1000 block the cells in the adjacent back-side cell string 1000, the cells in the front-side cell string 1000 receive sunlight over their entire surface area. However, because the cells in the back-side cell string 1000 are blocked by the aforementioned light-blocking area 1001, the cells in the back-side cell string 1000 cannot receive sunlight over their entire surface area.
[0079] To ensure that the cells of the front-side cell string 1000 and the cells of the back-side cell string 1000 can both receive sunlight over the same surface area, the first surface area of the cells of the front-side cell string 1000 can be limited to be smaller than the second surface area of the cells of the back-side cell string 1000. Therefore, even if the cells of the front-side cell string 1000 block the cells of the adjacent back-side cell string 1000, so that the cells of the back-side cell string 1000 cannot receive sunlight over their entire surface area, the second surface area being larger than the first surface area can still offset the loss of area caused by the blocked light-receiving region 1001.
[0080] In this regard, if the light-receiving area of the cell of the front-side cell string 1000 is limited to the area where the cell of the front-side cell string 1000 can directly receive light, and the light-receiving area of the cell of the back-side cell string 1000 is limited to the area where the cell of the back-side cell string 1000 can directly receive light, wherein the second surface area is greater than the first surface area to offset the loss area of the blocked light-blocking region 1001, the light-receiving area of the cell of the front-side cell string 1000 can be made equal to the light-receiving area of the cell of the back-side cell string 1000.
[0081] In one embodiment, the light-receiving area of the cells of the front-side cell string 1000 is the first surface area. For any one of the plurality of back-side cell strings 1000, the sum of the light-blocking areas 1001 between the cells of any one back-side cell string 1000 and the cells of the other two left- and right-adjacent front-side cell strings 1000 is the total shielding area. Furthermore, the light-receiving area of the cells of the back-side cell string 1000 is the difference between the second surface area and the total shielding area.
[0082] For example, if a light-blocking region 1001 exists between the cells of the back cell string 1000 and the cells of one of the adjacent front cell strings 1000, the total blocked area is one light-blocking region 1001. If a light-blocking region 1001 exists between the cells of the back cell string 1000 and the cells of two adjacent front cell strings 1000, the total blocked area is the sum of the two light-blocking regions 1001. This makes the light-receiving area of the cells of the front cell string 1000 equal to the light-receiving area of the cells of the back cell string 1000.
[0083] See Figure 3 As shown, the photovoltaic module further includes a welding ribbon 3000, which is arranged on the cell string 1000. The number of welding ribbons 3000 is configured to be a plurality of. In the preset arrangement direction 10, a gap region exists between the welding ribbon 3000 closest to the edge of the cell string 1000 and the edge of the cell string 1000, and in the preset arrangement direction 10, the width of the gap region is greater than the width of the light-blocking region 1001. In one embodiment, in the preset arrangement direction 10, the width of the gap region is configured to be greater than 0 mm and less than or equal to 30 mm. For example, the width of the gap region can be set to 1 mm, 3 mm, 5 mm, 7 mm, 9 mm, 11 mm, 13 mm, 15 mm, 17 mm, 19 mm, 21 mm, 23 mm, 25 mm, 27 mm, 29 mm, or 30 mm, without limitation herein.
[0084] As Figure 3 In the illustrated embodiment, the width of the cell sheets of the battery strings 1000 in the first plane 2001 is set to W1. The spacing between the battery strings 1000 in the first plane 2001 is set to W3. The width of the cell sheets of the battery strings 1000 in the second plane 2002 is set to W2. W1 and W2 can be equal or different.
[0085] The cells of the backside cell string 1000 are blocked, resulting in the aforementioned light-blocked area 1001. The sizes of the two light-blocked areas 1001 where the cells of any backside cell string 1000 are blocked by the cells of two adjacent frontside cell strings 1000 are set to D1 and D2, respectively. D1 and D2 can be equal or different.
[0086] The size of the gap area is D3, so it is necessary to set D3>D1≥0mm, and D3>D2≥0mm. This design ensures that although there is a light-blocking area 1001 between the front-side cell string 1000 and the back-side cell string 1000, the light-blocking area 1001 does not cover or exceed the soldering ribbon 3000. Because if the light-blocking area 1001 covers or exceeds the soldering ribbon 3000, the thickness of the photovoltaic module will be superimposed with the thickness of the light-blocking area 1001 of the cell string 1000 and the thickness of the soldering ribbon 3000, resulting in an excessively large overall thickness of the photovoltaic module. The cells of the cell string 1000 will abut against the soldering ribbon, which can easily cause problems such as hidden cracks.
[0087] See Figure 4 As shown above, it can be seen that the cells of the back side cell string 1000 are blocked and have the light blocking area 1001 mentioned above. Therefore, the cells of the back side cell string 1000 cannot receive sunlight with their entire surface area. Therefore, the light receiving area of the cells of the back side cell string 1000 may be different from the light receiving area of the cells of the front side cell string 1000.
[0088] At the same time, the cells of the back-side cell string 1000 are farther from the light-receiving side of the photovoltaic module than the cells of the front-side cell string 1000. This results in a thicker encapsulant 2000 on the light-receiving side of the photovoltaic module. For example, the isolation film 2100 increases the thickness of the cells of the back-side cell string 1000 on the light-receiving side of the photovoltaic module. At this point, the light directed toward the cells of the back-side cell string 1000 is more absorbed by the encapsulant 2000.
[0089] If several battery strings 1000 are electrically connected by directly connecting the positive-side battery strings 1000 and the back-side battery strings 1000 in series, this will cause current mismatch in the overall circuit of the photovoltaic module, thereby reducing efficiency. Therefore, the number of cells in adjacent positive-side battery strings 1000 and back-side battery strings 1000 is set to be the same, and they are connected in parallel to form a parallel cell string. After the parallel cell strings are formed, each parallel cell string can be further connected in series or parallel with other parallel cell strings.
[0090] by Figure 4 The structure shown in is an embodiment, the number of battery strings 1000 can be configured as an even number, and every two battery strings 1000 in the battery strings 1000 are configured as a battery string group, the two battery strings 1000 in each battery string group are respectively located in different planes in the packaging material 2000, and the two battery strings 1000 in each battery string group are connected in parallel to each other, thereby forming the parallel unit string mentioned above, and the battery string groups are connected in series with each other.
[0091] The number of battery strings 1000 can be configured to be six, eight, ten, twelve, or any other number, and is not limited here. In one embodiment, in a direction perpendicular to the plurality of battery cells, the two battery strings 1000 in each battery string group are adjacent battery strings 1000 in a predetermined arrangement direction 10, and a light-shielded region 1001 exists between the two battery strings 1000 in each battery string group.
[0092] The present application provides a method for manufacturing a photovoltaic module. The method may include two steps. In the first step, referring to Figure 5 As shown, a front glass 4000 can be provided, a first packaging film 2200 can be provided on the front glass 4000, a first layer of multiple battery strings 1000 can be laid on the first packaging film 2200 along a predetermined arrangement direction 10, a reserved gap can be provided between two adjacent battery strings 1000 along the predetermined arrangement direction 10, an isolation film 2100 can be provided on the first layer of multiple battery strings 1000, and a release film 5000 can be provided on the isolation film 2100. The front glass 4000, the first packaging film 2200, the first layer of multiple battery strings 1000, the isolation film 2100, and the release film 5000 can be laminated.
[0093] After laminating the front glass 4000, the first layer of packaging film 2200, the first layer of several battery strings 1000, the isolation film 2100 and the release film 5000 in the first step, the surface of the photovoltaic module can be laminated to a relatively flat state. At the same time, the isolation film 2100 is cross-linked and fixed after lamination, and will not decompose or flow during the secondary lamination process in the subsequent second step, so that the isolation film 2100 can play a better isolation role.
[0094] In the second step, see Figure 6 As shown, after lamination is complete, the release film 5000 is removed, and a second layer of multiple battery strings 1000 is placed on the separator 2100. In a direction perpendicular to the battery strings 1000, the second layer of multiple battery strings 1000 are aligned with a number of reserved gaps. A second layer of packaging film 2200 is placed on the second layer of multiple battery strings 1000, and a back glass 6000 is placed on the second layer of packaging film 2200. The front glass 4000, the first layer of packaging film 2200, the first layer of multiple battery strings 1000, the separator 2100, the second layer of multiple battery strings 1000, the second layer of packaging film 2200, and the back glass 6000 are laminated so that two adjacent battery strings 1000 along a predetermined arrangement direction are located on different sides of the separator, i.e., on the first and second layers mentioned above, respectively. Thus, the two adjacent battery strings are separated from each other by the separator 2100.
[0095] The technical features of the above-mentioned embodiments can be combined arbitrarily. In order to make the description concise, not all possible combinations of the technical features in the above-mentioned embodiments are described. However, as long as there is no contradiction in the combination of these technical features, they should be considered to be within the scope of this specification.
[0096] The above-described embodiments merely represent several implementation methods of the present application. While the descriptions are relatively specific and detailed, they should not be construed as limiting the scope of the patent application. It should be noted that a person of ordinary skill in the art may make various modifications and improvements without departing from the spirit of the present application, and these modifications and improvements fall within the scope of protection of the present application. Therefore, the scope of protection of the present patent application shall be determined by the appended claims.
Claims
1. A photovoltaic module, characterized in that: The photovoltaic module comprises: a plurality of battery strings, wherein the plurality of battery strings are electrically connected to each other; An encapsulating material is encapsulated outside the plurality of battery strings; the plurality of battery strings are arranged in the encapsulating material along a preset arrangement direction, and two adjacent battery strings along the preset arrangement direction are respectively located in different planes in the encapsulating material, thereby separating the two adjacent battery strings from each other in the encapsulating material.
2. The photovoltaic module according to claim 1, characterized in that Along the preset arrangement direction, the other two battery strings adjacent to any one battery string on the left and right are located in the same plane in the packaging material; and / or, Each of the battery strings includes a plurality of connected battery cells, and the battery cells of two adjacent battery strings are separated from each other in the packaging material.
3. The photovoltaic module according to claim 2, characterized in that A portion of the battery strings among the plurality of battery strings are located on a first plane in the packaging material, and another portion of the battery strings among the plurality of battery strings are located on a second plane in the packaging material; The first plane and the second plane are configured as two different planes parallel to each other in the packaging material, and the two adjacent battery strings along the preset arrangement direction are respectively located in the first plane and the second plane in the packaging material.
4. The photovoltaic module according to claim 1, characterized in that Selecting any one of the plurality of battery strings as a selected battery string; Along the preset arrangement direction, the other two battery strings adjacent to any one of the selected battery strings on the left and right are located on the same side of the selected battery string.
5. The photovoltaic module according to claim 1, characterized in that The packaging material comprises at least one isolation film and two packaging films, the isolation film is located between the two packaging films, and the two adjacent battery strings along the preset arrangement direction are respectively located on both sides of the isolation film.
6. The photovoltaic module according to claim 3, characterized in that The photovoltaic module has a light-receiving side and a light-receiving side. In a direction perpendicular to the plurality of cells, a light-shielding area exists between at least a portion of the cells in adjacent cell strings.
7. The photovoltaic module according to claim 6, characterized in that: The width of the light-shielding area along the preset arrangement direction is configured to be greater than or equal to 0 mm and less than or equal to 5 mm.
8. The photovoltaic module according to claim 6, characterized in that: The first plane is closer to the light-receiving side than the second plane, the battery string on the first plane is set as the front-side battery string, and the battery string on the second plane is set as the back-side battery string; The surface area of the plurality of battery cells in the positive-side battery string is a first surface area, and the surface area of the plurality of battery cells in the back-side battery string is a second surface area, wherein the first surface area is smaller than the second surface area.
9. The photovoltaic module according to claim 8, characterized in that: The light-receiving area of the cell of the positive side cell string is the area where the cell of the positive side cell string can directly receive light, and the light-receiving area of the cell of the back side cell string is the area where the cell of the back side cell string can directly receive light, wherein the light-receiving area of the cell of the positive side cell string is equal to the light-receiving area of the cell of the back side cell string.
10. The photovoltaic module according to claim 6, characterized in that: The photovoltaic module comprises: A welding ribbon is provided on the battery string, and the number of the welding ribbons is configured to be several. In the preset arrangement direction, a gap area exists between the welding ribbon closest to the edge of the battery string and the edge of the battery string, and in the preset arrangement direction, the width of the gap area is greater than the width of the light-blocked area.
11. The photovoltaic module according to claim 10, characterized in that: In the preset arrangement direction, the width of the gap area is configured to be greater than 0 mm and less than or equal to 30 mm.
12. The photovoltaic module according to claim 6, characterized in that: The number of the battery strings is configured as an even number, and every two battery strings in the battery strings are configured as a battery string group; the two battery strings in each battery string group are respectively located on different planes in the packaging material; the two battery strings in each battery string group are connected in parallel, and the battery string groups are connected in series; and / or, The number of battery strings is configured to be six.
13. The photovoltaic module according to claim 12, characterized in that: In a direction perpendicular to the plurality of battery cells, the two battery strings in each battery string group are adjacent battery strings in the preset arrangement direction, and a light-shielded area exists between the two battery strings in each battery string group.
14. A method for manufacturing a photovoltaic module, characterized in that: The production method comprises: Set up front glass; Arranging a first layer of packaging film on the front glass; Laying a first layer of multiple battery strings on the first layer of the packaging film along a preset arrangement direction, and setting a reserved gap between two adjacent battery strings along the preset arrangement direction; Arranging a layer of isolation film on the plurality of battery strings of the first layer, and arranging a layer of release film on the isolation film; Laminating the front glass, the first layer of the packaging film, the first layer of the plurality of battery strings, the isolation film and the release film; After lamination is completed, the release film is removed, and a plurality of battery strings of the second layer are arranged on the isolation film, wherein the plurality of battery strings of the second layer are respectively opposite to the plurality of reserved gaps in a direction perpendicular to the battery strings; Arranging a second layer of packaging film on the plurality of battery strings on the second layer; Arranging a back glass on the second layer of the packaging film; The front glass, the first layer of the packaging film, the first layer of the plurality of battery strings, the isolation film, the second layer of the plurality of battery strings, the second layer of the packaging film and the back glass are laminated so that two adjacent battery strings along the preset arrangement direction are respectively on different sides of the isolation film, thereby separating the two adjacent battery strings from each other.