Photovoltaic module and manufacturing method thereof

Abstract

The invention relates to a photovoltaic module and a manufacturing method thereof. The manufacturing method of the photovoltaic module comprises the following steps: providing a laminated piece, a reflective film belt, an isolating strip and a jumper wire; the reflective film tape is attached to the isolating strip to form a first composite part; or, the reflective film belt is attached to the jumper wire to form a first composite part; when the first composite part comprises the reflective film belt and the isolating strip, the first composite part is attached to the jumper wire to form a second composite part; when the first composite part comprises the reflective film belt and the jumper wire, the first composite part is attached to the isolating strip to form a second composite part; and the second composite part is welded on the laminated part to form the photovoltaic module. According to the photovoltaic module manufacturing method provided by the invention, the isolating strip, reflective film tape and jumper wire laminating and pasting process is completed in the material preparation process, the jumper wire is prevented from being interfered and influenced by the laminating piece in the reflective film tape pasting process, the film pasting operation of pasting the reflective film tape on the surface of the jumper wire is simplified, and the reflective film tape is laminated between the isolating strip and the jumper wire, so that the production efficiency is improved. And the photoelectric conversion efficiency and the aesthetic property of the photovoltaic module can be improved.

Description

Technical Field

[0001] The present application relates to the field of photovoltaic technology, and in particular to a photovoltaic module and a method for manufacturing the same. Background Art

[0002] Photovoltaic power generation technology, as the mainstream technology for utilizing solar energy resources, is an important area for the development of green energy and has already moved towards marketization and commercialization. In photovoltaic modules, light energy is converted into electrical energy through the photovoltaic effect of the cells. Multiple cells are connected in series through busbars, so that the electricity generated by the cells is collected and discharged by the busbars, and two adjacent cell strings are electrically connected by jumpers. Because jumpers are usually conductors made of conductive materials, when they overlap with the cell array, the interconnecting strips used to achieve electrical connections between the cells are prone to overlap with the jumpers. If the two come into direct contact, a short circuit will occur, affecting the normal operation of the photovoltaic module. Therefore, insulating strips are provided on the jumpers to prevent the adverse effects of short circuits caused by contact between the jumpers and the cells.

[0003] To improve the photovoltaic conversion efficiency and aesthetics of photovoltaic modules, jumper cables are typically painted or coated. Currently, this process is limited by the interference of solar panels, making the coating process difficult and resulting in poor quality. Summary of the Invention

[0004] Based on this, it is necessary to provide a photovoltaic module and a manufacturing method thereof to address the problems that the existing jumper surface filming operation is too difficult and the filming quality is poor.

[0005] A method for manufacturing a photovoltaic module, comprising:

[0006] Step S110: providing a laminate, a reflective film tape, a spacer strip, and a jumper wire;

[0007] Step S120: the reflective film tape is applied to the isolation strip to form a first composite member; or the reflective film tape is applied to the jumper wire to form the first composite member;

[0008] Step S130: When the first composite member includes the reflective film and the isolation strip, the first composite member is attached to the jumper wire to form a second composite member; when the first composite member includes the reflective film and the jumper wire, the first composite member is attached to the isolation strip to form a second composite member; wherein the second composite member includes the isolation strip, the reflective film, and the jumper wire in a stacked arrangement;

[0009] Step S140: the second composite member is stacked and welded to the stacked member to form a photovoltaic module.

[0010] In one embodiment, step S120 specifically includes:

[0011] Step S121: at least partially melting the reflective film tape or at least partially melting the isolation strip to form a molten layer;

[0012] Step S122: solidifying the molten layer, and rolling the reflective film tape or the isolation strip during the solidification process, so that the reflective film tape is attached to the isolation strip to form the first composite member;

[0013] or;

[0014] Step S123: the reflective film tape is at least partially melted to form a melt layer;

[0015] Step S124: solidifying the molten layer, and rolling the reflective film tape or the jumper wire during the solidification process, so that the reflective film tape is attached to the jumper wire to form the first composite component.

[0016] In one embodiment, step S130 specifically includes:

[0017] Step S131: When the first composite member includes the reflective film tape and the isolation strip, a side of the first composite member facing away from the isolation strip is at least partially melted to form a melt layer;

[0018] Step S132: solidifying the molten layer, and rolling the first composite member or the jumper wire during the solidification process, so that the first composite member is attached to the jumper wire to form the second composite member;

[0019] or;

[0020] Step S133: When the first composite member includes the reflective film tape and the jumper wire, at least a portion of the first composite member on a side facing away from the jumper wire is melted to form a melt layer;

[0021] Step S134 : solidifying the molten layer, and rolling the first composite member or the isolation strip during the solidification process, so that the first composite member is attached to the isolation strip to form the second composite member.

[0022] In one embodiment, the molten layer is formed by hot air heating, and the molten layer is solidified by cold air solidification;

[0023] Among them, the melting temperature is 300℃~500℃, the melting wind pressure is 0.2MPa~0.5MPa, and the curing wind pressure is 0.1MPa~0.2MPa.

[0024] In one embodiment, the second composite member is formed by rolling by a rolling mechanism, wherein the rolling pressure is 0.1 MPa to 0.2 MPa.

[0025] In one embodiment, the step S120 further includes:

[0026] Step S125: Pulling the reflective film tape and the isolation strip to an overlapping state so that the reflective film tape is attached to the isolation strip to form the first composite component; or pulling the reflective film tape and the jumper wire to an overlapping state so that the reflective film tape is attached to the jumper wire to form the first composite component.

[0027] In one embodiment, the step S130 further includes:

[0028] Step S135: When the first composite component includes the reflective film tape and the isolation strip, the first composite component and the jumper are pulled to an overlapping state, so that the first composite component is attached to the jumper to form the second composite component; when the first composite component includes the reflective film tape and the jumper, the first composite component and the isolation strip are pulled to an overlapping state, so that the first composite component is attached to the isolation strip to form the second composite component.

[0029] In one embodiment, during the process of forming the first composite member and the second composite member, the reflective film strip, the isolation strip, and the jumper wire are aligned.

[0030] In one embodiment, step S110 specifically includes:

[0031] Step S111: cutting the reflective film tape, the isolation strip, and the jumper wire to a preset length.

[0032] In one embodiment, the width of the reflective film tape after cutting is W1, the width of the isolation strip after cutting is W2, and the width of the jumper wire after cutting is W3;

[0033] Among them, 4.5mm≤W1≤9mm, 10mm≤W2≤20mm, 4mm≤W3≤8mm, and 0.5mm≤W1-W3≤1mm.

[0034] A photovoltaic module is obtained by using the photovoltaic module manufacturing method described in any one of the above technical solutions.

[0035] The above-mentioned photovoltaic module and its manufacturing method firstly apply the reflective film tape to the isolation strip or jumper to form a first composite part, then apply the first composite part to the jumper or isolation strip to form a second composite part, and finally weld the second composite part to the laminated part to form the photovoltaic module. The photovoltaic module manufacturing method provided by the present application completes the isolation strip, reflective film tape, and jumper laminated lamination process during the material preparation process, thereby preventing the jumper from being affected by the interference of the laminated part during the process of laminating the reflective film tape, simplifying the film lamination operation of the jumper surface, and improving the film lamination quality of the jumper surface. Since the reflective film tape is laminated between the isolation strip and the jumper, the reflective film tape can be seen on both the front and back of the photovoltaic module, which can improve the photoelectric conversion efficiency and aesthetics of the photovoltaic module. BRIEF DESCRIPTION OF THE DRAWINGS

[0036] Figure 1 Schematic diagram of the process for manufacturing photovoltaic modules provided in some embodiments.

[0037] Figure 2 Schematic diagram of the structure of the second composite member provided in some embodiments.

[0038] Figure 3 Schematic diagram of the structure of the second composite member provided in some embodiments.

[0039] Figure 4 Schematic diagram of the structure of the photovoltaic module provided in some embodiments.

[0040] Figure 5 Schematic diagram of the structure of the module composed of reflective film tape, isolation strips and jumper wires provided in some embodiments.

[0041] Figure 6 Schematic diagram of the structure of the film-sticking device provided in some embodiments.

[0042] Figure 7 Schematic diagram of the first composite part lamination process provided in some embodiments.

[0043] Figure 8 Schematic diagram of the second composite part lamination process provided in some embodiments.

[0044] Figure 9 Schematic diagram of the first composite part lamination process provided in some embodiments.

[0045] Figure 10 Schematic diagram of the second composite part lamination process provided in some embodiments.

[0046] Reference numerals:

[0047] 100. Second composite part;

[0048] 110, reflective film tape; 120, spacer; 130, jumper; 140, first composite;

[0049] 200, film pasting device;

[0050] 210, machine base; 220, first guide wheel set; 230, second guide wheel set; 240, pasting platform; 250, melting mechanism; 260, rolling mechanism; 270, first sliding module; 280, second sliding module;

[0051] 300, photovoltaic module; 310, cell string; 320, edge busbar; 330, middle busbar; 340, solder strip; 350, split cell; 360, sub cell string set; 370, cell string set; 371, first cell string set; 372, second cell string set; 373, third cell string set. DETAILED DESCRIPTION

[0052] In order to make the above objectives, features and advantages of the present application more apparent, specific embodiments of the present application will be described in detail below with reference to the accompanying drawings. In the following description, numerous specific details are set forth in order to provide a thorough understanding of the present application. It will be apparent, however, to one skilled in the art that the present application can be practiced in a variety of ways beyond the specific embodiments described herein without departing from the spirit of the present application, and that the present application is not limited to the specific embodiments disclosed below.

[0053] In the description of the present application, it should be understood that, if there are terms such as "center", "longitudinal", "transverse", "length", "width", "thickness", "upper", "lower", "front", "rear", "left", "right", "vertical", "horizontal", "top", "bottom", "inner", "outer", "clockwise", "counterclockwise", "axial", "radial", "circumferential", etc. appear, these terms indicate the orientation or positional relationship based on the orientation or positional relationship shown in the drawings, and are only for the purpose of facilitating the description of the present application and simplifying the description, and therefore cannot be understood as indicating or implying that the device or element referred to must have a particular orientation, be constructed and operated in a particular orientation, and therefore cannot be understood as limiting the present application.

[0054] In addition, if the terms "first", "second" appear, these terms are only for the purpose of description, and cannot be understood as indicating or implying relative importance or implicitly indicating the number of the technical features referred to. Therefore, the features limited by "first", "second" can explicitly or implicitly include at least one of the features. In the description of the present application, if the term "multiple" appears, the meaning of "multiple" is at least two, for example, two, three, etc., unless otherwise specifically limited.

[0055] In this application, unless otherwise explicitly specified and limited, if there are terms "mount", "connect", "connect", "fix", etc. These terms should be understood in a broad sense. For example, it can be fixedly connected, or it can be detachably connected, or it can be integrated; it can be mechanically connected, or it can be electrically connected; it can be directly connected, or it can be indirectly connected through an intermediate medium; it can be the internal communication of two elements or the interaction relationship between two elements, unless otherwise explicitly limited. For those skilled in the art, the specific meaning of the above terms in this application can be understood according to the specific circumstances.

[0056] In this application, unless otherwise explicitly specified and limited, if there are terms "mount", "connect", "connect", "fix", etc. These terms should be understood in a broad sense. For example, it can be fixedly connected, or it can be detachably connected, or it can be integrated; it can be mechanically connected, or it can be electrically connected; it can be directly connected, or it can be indirectly connected through an intermediate medium; it can be the internal communication of two elements or the interaction relationship between two elements, unless otherwise explicitly limited. For those skilled in the art, the specific meaning of the above terms in this application can be understood according to the specific circumstances.

[0057] It should be noted that if an element is referred to as "fixed to" or "disposed on" another element, it can be directly on another element or there can be a middle element. If an element is considered to be "connected" to another element, it can be directly connected to another element or there can be a middle element. If present, the terms "vertical", "horizontal", "up", "down", "left", "right" and similar expressions used in this application are for illustrative purposes only and are not the only embodiment.

[0058] The technical solutions provided by the embodiments of the present application are described below with reference to the accompanying drawings.

[0059] Referring to Figures 1-4 As shown in the drawings, the present application provides a photovoltaic module manufacturing method, the photovoltaic module manufacturing method comprising the following steps.

[0060] Step S110: Providing a laminate, reflective film tape 110, spacer strips 120, and jumper wires 130. During the process of providing the laminate, reflective film tape 110, spacer strips 120, and jumper wires 130, the laminate, reflective film tape 110, spacer strips 120, and jumper wires 130 need to be surface treated to remove impurities such as dust and rust attached to the surfaces of the laminate, reflective film tape 110, spacer strips 120, and jumper wires 130, thereby ensuring the quality of the subsequent application of the reflective film tape 110 to the surface of the jumper wires 130. In this embodiment, the laminate includes a front cover plate, a front adhesive film, and a battery string layer. The reflective film strip 110 is based on PET (Polyethylene terephthalate) and has an EVA / EPE / PO structure. The isolation strip 120 is based on PET and has an EVA / EPE / PO structure. The jumper 130 is a conductive metal strip. For example, the jumper 130 is based on pure copper or a copper-aluminum composite metal, and the surface of the jumper 130 is coated with Sn60Pb40, Sn63Pb37, Sn43Pb43Bi14, or Sn32Pb42Bi26.

[0061] Step S120: The reflective film strip 110 is attached to the isolation strip 120 to form a first composite member 140. Figure 2 Or, the reflective film tape 110 is attached to the jumper 130 to form a first composite member 140, such as Figure 3 When the reflective film 110 is applied to the jumper 130, the applied cross-section of the reflective film 110 is greater than or equal to the applied cross-section of the jumper 130, so that the reflective film 110 can completely cover the jumper 130, thereby improving the film application quality between the reflective film 110 and the jumper 130 and ensuring the aesthetics of the photovoltaic module 300.

[0062] Step S130: When the first composite member 140 includes the reflective film 110 and the isolation strip 120, the first composite member 140 is attached to the jumper wire 130 to form the second composite member 100. Figure 2 When the first composite member 140 includes the reflective film tape 110 and the jumper wire 130, the first composite member 140 is attached to the isolation strip 120 to form the second composite member 100, as shown. Figure 3 The second composite member 100 includes a stacked isolation strip 120 , a reflective film strip 110 and a jumper wire 130 , that is, the reflective film strip 110 is located between the isolation strip 120 and the jumper wire 130 .

[0063] Step S140 : The second composite member 100 is overlap-welded to the laminated member to form the photovoltaic module 300 .

[0064] In the above-mentioned photovoltaic module manufacturing method, the reflective film tape 110 is first applied to the isolation strip 120 or the jumper 130 to form a first composite member 140, and then the first composite member 140 is applied to the jumper 130 or the isolation strip 120 to form a second composite member 100. Finally, the second composite member 100 is welded to the laminate to form the photovoltaic module 300. The photovoltaic module manufacturing method provided in the present application completes the lamination process of the isolation strip 120, the reflective film tape 110, and the jumper 130 during the material preparation process, thereby preventing the jumper 130 from being affected by the interference of the laminate during the lamination process of the reflective film tape 110, simplifying the film application operation of the reflective film tape 110 on the surface of the jumper 130, and improving the film application quality of the jumper 130. Since the reflective film tape 110 is laminated between the isolation strip 120 and the jumper 130, the reflective film tape 110 can be seen on both the front and back of the photovoltaic module 300, which can improve the photoelectric conversion efficiency and aesthetics of the photovoltaic module 300.

[0065] In one embodiment, see Figure 1-Figure 3 As shown, step S120 specifically includes:

[0066] Step S121: At least a portion of the reflective film 110 or the separator 120 is melted to form a molten layer. Since both the reflective film 110 and the separator 120 are based on PET and have a composite structure of EVA / EPE / PO, melting the reflective film 110 or the separator 120 can cause at least a portion of the reflective film 110 or the separator 120 to become molten, thereby forming a molten layer.

[0067] Step S122: Solidify the molten layer and, during the solidification process, roll the reflective film tape 110 or the isolation strip 120 so that the reflective film tape 110 adheres to the isolation strip 120 to form the first composite member 140. The molten layer is solidified in a cold air or natural environment, and during the solidification process, a rolling force is applied to the reflective film tape 110 or the isolation strip 120 so that the reflective film tape 110 adheres evenly to the isolation strip 120 to form the first composite member 140.

[0068] Alternatively, step S120 specifically includes:

[0069] Step S123: The reflective film tape 110 is at least partially melted to form a molten layer. Since the reflective film tape 110 is based on PET and has a composite structure of EVA / EPE / PO, the reflective film tape 110 can be melted to form a molten layer.

[0070] Step S124: Curing the molten layer and rolling the reflective film tape 110 or the jumper wire 130 during the curing process to ensure that the reflective film tape 110 adheres to the jumper wire 130 to form a first composite member 140. The molten layer is cured in a cold air or natural environment, and a rolling force is applied to the reflective film tape 110 or the jumper wire 130 during the curing process to ensure that the reflective film tape 110 adheres evenly to the jumper wire 130 to form the first composite member 140.

[0071] Further, see Figure 1-Figure 3 As shown, step S130 specifically includes:

[0072] Step S131: When the first composite member 140 includes the reflective film 110 and the spacer strip 120, the side of the first composite member 140 facing away from the spacer strip 120 is at least partially melted to form a molten layer. Since the second composite member 100 includes the stacked spacer strip 120, the reflective film 110, and the jumper wire 130, the formation of at least a partial molten layer on the side of the first composite member 140 facing away from the spacer strip 120 enables the subsequent lamination operation of the first composite member 140 and the jumper wire 130.

[0073] Step S132: Solidify the melted layer and, during the solidification process, roll the first composite member 140 or the jumper wire 130 so that the first composite member 140 adheres to the jumper wire 130 to form the second composite member 100. The melted layer is solidified in a cold air or natural environment, and during the solidification process, a rolling force is applied to the first composite member 140 or the jumper wire 130 so that the first composite member 140 adheres evenly to the jumper wire 130 to form the second composite member 100.

[0074] Alternatively, step S130 specifically includes:

[0075] Step S133: When the first composite member 140 includes the reflective film 110 and the jumper wire 130, the side of the first composite member 140 facing away from the jumper wire 130 is at least partially melted to form a molten layer. Since the second composite member 100 includes the stacked isolation strip 120, the reflective film 110, and the jumper wire 130, the formation of at least a partial molten layer on the side of the first composite member 140 facing away from the jumper wire 130 facilitates the subsequent lamination operation between the first composite member 140 and the isolation strip 120.

[0076] Step S134: Solidify the molten layer and, during the solidification process, roll the first composite member 140 or the separator 120 so that the first composite member 140 adheres to the separator 120 to form the second composite member 100. The molten layer is solidified in a cold air or natural environment, and during the solidification process, a rolling force is applied to the first composite member 140 or the separator 120 so that the first composite member 140 adheres evenly to the separator 120 to form the second composite member 100.

[0077] Further, see Figure 1-Figure 3 As shown, the molten layer is formed by hot air heating, and the molten layer is solidified by cold air solidification. The melting temperature is 300°C to 500°C. If the melting temperature is too high, the reflective film tape 110 or the isolation strip 120 may quickly become fluid during the melting process, making it difficult to control the shaping quality of the reflective film tape 110 or the isolation strip 120 during the lamination process. If the melting temperature is too low, the molten layer may not form easily during the melting process, making subsequent lamination operations impossible. Therefore, setting the melting temperature to 300°C to 500°C ensures smooth lamination between the isolation strip 120, the reflective film tape 110, and the jumper wire 130, and facilitates the shaping control of the reflective film tape 110 or the isolation strip 120 during the subsequent curing process. In specific settings, the melting temperature can be any one of 300°C, 320°C, 340°C, 360°C, 380°C, 400°C, 420°C, 440°C, 460°C, 480°C, and 500°C. This application does not limit the specific value of the melting temperature.

[0078] Furthermore, the melting pressure is set to 0.2 MPa to 0.5 MPa. If the melting pressure is too high, the reflective film 110 or the separator 120 will melt too quickly, making it difficult to control the molten layer. If the melting pressure is too low, the melt rate will be too slow, and the molten layer may solidify slightly during formation, affecting the subsequent application of the separator 120, the reflective film 110, and the jumper wire 130. Therefore, setting the melting pressure to 0.2 MPa to 0.5 MPa can control the rate of molten layer formation and improve the quality of subsequent application of the separator 120, the reflective film 110, and the jumper wire 130. In specific settings, the melting wind pressure can be any one of 0.2MPa, 0.25MPa, 0.3MPa, 0.35MPa, 0.4MPa, 0.45MPa, and 0.5MPa. This application does not limit the specific value of the melting wind pressure.

[0079] Next, the curing pressure is set to 0.1 MPa to 0.2 MPa. Since the spacer strips 120, reflective film strips 110, and jumper wires 130 require simultaneous roller-coating during the curing process, if the curing pressure is too high, the molten layer solidifies too quickly, making roller-coating difficult and affecting the coating quality of the spacer strips 120, reflective film strips 110, and jumper wires 130. If the curing pressure is too low, the molten layer solidifies too slowly, resulting in the molten layer not being fully formed after roller-coating, which can affect the coating quality of the spacer strips 120, reflective film strips 110, and jumper wires 130. Therefore, setting the curing pressure to 0.1 MPa to 0.2 MPa can control the solidification rate of the molten layer to match the roller-coating speed without affecting the coating quality of the spacer strips 120, reflective film strips 110, and jumper wires 130. In specific settings, the curing wind pressure can be any one of 0.1MPa, 0.12MPa, 0.14MPa, 0.16MPa, 0.18MPa, and 0.2MPa. This application does not limit the specific value of the curing wind pressure.

[0080] Further, see Figure 1-Figure 3 As shown, the second composite member 100 is formed by rolling by a rolling mechanism 260, wherein the rolling pressure is 0.1 MPa to 0.2 MPa. During the forming process of the first composite member 140 and the second composite member 100, a rolling force is applied to the surfaces of the spacer strip 120, the reflective film tape 110, or the jumper wire 130 to laminate the spacer strip 120, the reflective film tape 110, and the jumper wire 130 to form the first composite member 140 and the second composite member 100. If the rolling pressure is too high, the spacer strip 120, the reflective film tape 110, and the jumper wire 130 may be damaged during the rolling process, affecting the subsequent photovoltaic conversion efficiency and aesthetics of the photovoltaic module 300. If the rolling pressure is too low, the adhesion between the spacer strip 120, the reflective film tape 110, and the jumper wire 130 may be poor, and delamination may occur during long-term operation. Therefore, setting the rolling pressure to 0.1 MPa to 0.2 MPa can not only ensure that the isolation strip 120, the reflective film strip 110, and the jumper wire 130 are not damaged during the rolling process, but also help improve the adhesion between the isolation strip 120, the reflective film strip 110, and the jumper wire 130. In specific settings, the rolling pressure can be any one of 0.1 MPa, 0.12 MPa, 0.14 MPa, 0.16 MPa, 0.18 MPa, and 0.2 MPa. The specific value of the rolling pressure is not limited in this application.

[0081] In one embodiment, see Figure 1-Figure 3As shown, step S120 further includes step S125: pulling the reflective film tape 110 and the isolation strip 120 to an overlapping state, so that the reflective film tape 110 is attached to the isolation strip 120 to form a first composite member 140; or pulling the reflective film tape 110 and the jumper wire 130 to an overlapping state, so that the reflective film tape 110 is attached to the jumper wire 130 to form the first composite member 140. It should be noted that during the pulling process, the isolation strip 120, the reflective film tape 110, or the jumper wire 130 can be pulled at one end to make the heights of the two ends of the pulled object inconsistent, and the reflective film tape 110 and the isolation strip 120 or the jumper wire 130 can be overlapped by pressing, and during the pressing process, it is ensured that no bubbles are generated between the two attached objects, thereby improving the adhesion quality between the reflective film tape 110 and the isolation strip 120 or the jumper wire 130.

[0082] In one embodiment, see Figure 1-Figure 3 As shown, step S130 also includes step S135: when the first composite component 140 includes the reflective film tape 110 and the isolation strip 120, the first composite component 140 and the jumper 130 are pulled to an overlapping state, so that the first composite component 140 is attached to the jumper 130 to form the second composite component 100; when the first composite component 140 includes the reflective film tape 110 and the jumper 130, the first composite component 140 and the isolation strip 120 are pulled to an overlapping state, so that the first composite component 140 is attached to the isolation strip 120 to form the second composite component 100. It should be noted that during the traction process, the heights of the two ends of the pulled object can be made inconsistent by pulling one side of the end of the first composite component 140, the jumper 130 or the isolation strip 120, and the first composite component 140 and the jumper 130 or the isolation strip 120 can be overlapped by pressing, and during the pressing process, it is ensured that no bubbles are generated between the two objects being pressed, thereby improving the pressing quality between the first composite component 140 and the jumper 130 or the isolation strip 120.

[0083] Further, see Figure 1-Figure 3 As shown, during the process of forming the first composite part 140 and the second composite part 100, the reflective film strip 110, the spacer strip 120, and the jumper wire 130 are aligned. For example, during the lamination process of the reflective film strip 110, the spacer strip 120, and the jumper wire 130, a CCD camera is used to take photos of the objects to be lamination for alignment. This ensures the positional accuracy of the reflective film strip 110, the spacer strip 120, and the jumper wire 130 during the lamination process, ensuring that the reflective film strip 110 is lamination-coated at the predetermined position of the spacer strip 120 and the jumper wire 130, thereby improving the forming quality of the second composite part 100.

[0084] In one embodiment, see Figure 1-Figure 3As shown, step S110 specifically includes step S111: cutting the reflective film 110, the spacer strips 120, and the jumper wires 130 to predetermined lengths. Thus, by cutting the reflective film 110, the spacer strips 120, and the jumper wires 130 to predetermined lengths, the reflective film 110, the spacer strips 120, and the jumper wires 130 are adhered to the predetermined lengths, further improving the adhesion quality between the reflective film 110, the spacer strips 120, and the jumper wires 130.

[0085] Further, participation Figure 1-Figure 5 As shown, the width of the cut reflective film strip 110 is W1, the width of the cut isolation strip 120 is W2, and the width of the cut jumper wire 130 is W3. Here, 4.5mm≤W1≤9mm, 10mm≤W2≤20mm, 4mm≤W3≤8mm, and 0.5mm≤W1-W3≤1mm. If the width of the isolation strip 120 is less than 10mm, the possibility of the jumper wire 130 contacting the multi-slice solar cells and causing a short circuit increases. If the width of the isolation strip 120 is greater than 20mm, the area of ​​the overlap between the isolation strip 120 and the multi-slice solar cells also increases, resulting in an increased impact of the isolation strip 120 on the multi-slice solar cells during the lamination process. Therefore, the width of the isolation strip 120 can be any of 10mm, 12mm, 14mm, 16mm, 18mm, and 20mm. Furthermore, if the width of jumper 130 is less than 4 mm, the cross-sectional area of ​​jumper 130 is small, resulting in poor current carrying capacity of jumper 130 and its inability to carry the current in photovoltaic module 300. If the width of jumper 130 is greater than 8 mm, the size of the area where jumper 130 overlaps with the multi-slice solar cell increases, increasing the risk of hidden cracks in the multi-slice solar cell caused by jumper 130 during the lamination process. If photovoltaic module 300 is a double-glass module, both sides of the multi-slice solar cell are used to absorb sunlight. An excessively large width of jumper 130 will increase shading of the multi-slice solar cell, thereby affecting power generation efficiency. Therefore, the width of jumper 130 can be any of 4 mm, 5 mm, 6 mm, 7 mm, and 8 mm. Next, 0.5mm≤W1-W3≤1mm is set so that the width of the reflective film 110 after cutting is slightly larger than the width of the jumper 130. This can prevent the reflective film 110 from not covering the jumper 130 due to misalignment between the two parts. This improves the adhesion quality between the reflective film 110 and the jumper 130 and ensures the aesthetics of the photovoltaic module 300. The width of the reflective film 110 after cutting can be any of 4.5mm, 5mm, 6mm, 7mm, 8mm, or 9mm, and the value of W1-W3 can be any of 0.5mm, 0.6mm, 0.7mm, 0.8mm, 0.9mm, or 1mm.

[0086] Preferably, the thickness of the cut isolation strip 120 is 0.1 mm to 0.8 mm, the thickness of the cut reflective film tape 110 is 0.05 mm to 0.4 mm, and the thickness of the cut jumper wire 130 is 0.1 mm to 0.4 mm. If the thickness of the isolation strip 120 is greater than 0.8 mm, the thickness of the jumper 130 and the isolation strip 120 is too large. During the lamination process, the stress at the position of the jumper 130 is relatively large, which can easily lead to hidden cracks in the multi-slice battery cell. The isolation strip 120 plays an insulating role between the jumper 130 and the multi-slice battery cell. The insulating performance of the isolation strip 120 decreases as the thickness of the isolation strip 120 decreases. If the thickness of the isolation strip 120 is less than 0.1 mm, the insulating performance of the isolation strip 120 is poor, and the possibility of a short circuit between the jumper 130 and the multi-slice battery cell is relatively high. Therefore, the thickness of the isolation strip 120 can be 0.1 mm, 0.2 mm, 0.3 mm, 0.4 mm, 0.6 mm, 0.7 mm, 0.8 mm, etc. If the jumper wire 130 is thicker than 0.4 mm, the jumper wire 130 will protrude significantly beyond the multi-slice solar cell. During the lamination process, the jumper wire 130 may squeeze the multi-slice solar cell, causing hidden cracks in the multi-slice solar cell. It may also increase the risk of the jumper wire 130 deforming, causing contact between the jumper wire 130 and the multi-slice solar cell, resulting in a short circuit. Therefore, the jumper wire 130 may have a thickness of 0.1 mm, 0.2 mm, 0.3 mm, 0.4 mm, etc. Furthermore, the reflective film tape 110 may have a thickness of 0.05 mm, 0.1 mm, 0.2 mm, 0.3 mm, 0.4 mm, etc.

[0087] For the above photovoltaic module manufacturing method, refer to Figures 6-10 As shown, the present application provides a film laminating device 200, which includes a base 210, a first guide wheel assembly 220, a second guide wheel assembly 230, a laminating platform 240, a melting mechanism 250, and a rolling mechanism 260. The film laminating device 200 is used to laminate the reflective film tape 110 onto the surface of the jumper wire 130, thereby stacking the isolation strip 120, the reflective film tape 110, and the jumper wire 130 to form the second composite member 100. During the material preparation process, the isolation strip 120, the reflective film tape 110, and the jumper wire 130 are stacked and coated, thereby preventing the jumper wire 130 from being affected by the interference of the stacking components during the coating process of the reflective film tape 110, simplifying the film coating operation of the jumper wire 130 surface, and improving the film coating quality of the jumper wire 130 surface. Since the reflective film tape 110 is stacked between the isolation strip 120 and the jumper wire 130, the reflective film tape 110 can be seen on both the front and back of the photovoltaic module 300, which can improve the photoelectric conversion efficiency and aesthetics of the photovoltaic module 300.

[0088] The first guide wheel assembly 220 is mounted on the machine base 210 and includes a plurality of first guide wheels spaced apart. The first guide wheel assembly 220 is used for pulling and winding the reflective film tape 110 and the first composite component 140. The second guide wheel assembly 230 is mounted on the machine base 210 and includes a plurality of second guide wheels spaced apart. The second guide wheel assembly 230 is used for pulling and winding the separator strip 120 and the jumper wire 130. The laminating platform 240 is mounted on the machine base 210 and is used for laminating and forming the first composite component 140 and the second composite component 100. The melting mechanism 250 is mounted on the machine base 210 and blows hot air toward the laminating platform 240. The hot air blown by the melting mechanism 250 melts the reflective film tape 110, the separator strip 120, or the first composite component 140 to form a molten layer. The rolling mechanism 260 is disposed on the machine base 210 to perform a rolling laminating operation on the first composite member 140 or the second composite member 100 on the laminating platform 240 .

[0089] For example, as in one embodiment, see Figure 6-Figure 8As shown, first, the reflective film tape 110 is wound around the first guide wheel group 220, and the reflective film tape 110 is transported to the coating platform 240 by the first guide wheel group 220. The isolation strip 120 is wound around the second guide wheel group 230, and the isolation strip 120 is transported to the coating platform 240 by the second guide wheel group 230. Then, the melting mechanism 250 blows hot air toward the surface of the reflective film tape 110 or the isolation strip 120 to melt at least part of the reflective film tape 110 or the isolation strip 120 to form a hot air layer. A molten layer is formed, and the melting temperature is ensured to be 300° C. to 500° C. and the melting pressure is ensured to be 0.2 MPa to 0.5 MPa. Then, the molten layer is solidified, and during the solidification process, the reflective film tape 110 or the isolation strip 120 is rolled by a rolling mechanism 260. The rolling mechanism 260 applies a rolling pressure of 0.1 MPa to 0.2 MPa to the surface of the reflective film tape 110 or the isolation strip 120, so that the reflective film tape 110 is attached to the isolation strip 120 to form a first composite member 140. Continuing, the first composite part 140 is wound around the first guide wheel group 220, and the first composite part 140 is transported to the laminating platform 240 through the first guide wheel group 220. The jumper wire 130 is wound around the second guide wheel group 230, and the jumper wire 130 is transported to the laminating platform 240 through the second guide wheel group 230. In addition, the melting mechanism 250 blows hot air toward the side of the first composite part 140 away from the isolation strip 120, so as to at least partially melt the side of the first composite part 140 away from the isolation strip 120. A molten layer is formed, and the melting temperature is ensured to be 300°C~500°C, and the melting wind pressure is 0.2MPa~0.5MPa; then, the molten layer is solidified, and during the solidification process, the first composite part 140 or the jumper wire 130 is rolled by the rolling mechanism 260, and the rolling pressure applied by the rolling mechanism 260 to the surface of the first composite part 140 or the jumper wire 130 is 0.1MPa~0.2MPa, so that the first composite part 140 is attached to the jumper wire 130 to form the second composite part 100.

[0090] As in another embodiment, see Figure 6 、 Figure 9 and Figure 10As shown, first, the reflective film tape 110 is wound around the first guide wheel assembly 220, and the reflective film tape 110 is transported to the coating platform 240 through the first guide wheel assembly 220. The jumper wire 130 is wound around the second guide wheel assembly 230, and the jumper wire 130 is transported to the coating platform 240 through the second guide wheel assembly 230. Then, the melting mechanism 250 blows hot air toward the surface of the reflective film tape 110 to at least partially melt the reflective film tape 110 to form a molten layer, and the melting temperature is ensured to be 30 0℃~500℃, melting wind pressure is 0.2MPa~0.5MPa; then, solidify the molten layer, and during the solidification process, the reflective film tape 110 or the jumper wire 130 is rolled by the rolling mechanism 260, and the rolling pressure applied by the rolling mechanism 260 to the surface of the reflective film tape 110 or the jumper wire 130 is 0.1MPa~0.2MPa, so that the reflective film tape 110 is attached to the jumper wire 130 to form the first composite member 140; continue, the first composite member 140 is wound around The first guide wheel group 220 is used to transport the first composite member 140 to the laminating platform 240, and the isolation strip 120 is wound around the second guide wheel group 230. The isolation strip 120 is transported to the laminating platform 240 through the second guide wheel group 230; and the melting mechanism 250 blows hot air toward the side of the first composite member 140 away from the jumper 130, so as to at least partially melt the side of the first composite member 140 away from the jumper 130 to form a molten layer, and keep The melting temperature is 300°C~500°C and the melting wind pressure is 0.2MPa~0.5MPa; then, the molten layer is solidified, and during the solidification process, the first composite part 140 or the isolation strip 120 is rolled by the rolling mechanism 260. The rolling pressure applied by the rolling mechanism 260 to the surface of the first composite part 140 or the isolation strip 120 is 0.1MPa~0.2MPa, so that the first composite part 140 is attached to the isolation strip 120 to form the second composite part 100.

[0091] It should be noted that in this embodiment, the film laminating device 200 further includes a first sliding module 270 and a second sliding module 280. At least one first guide wheel in the first guide wheel assembly 220 is slidably mounted on the first sliding module 270. The first sliding module 270 is used to adjust the position of the first guide wheel to adjust the tension of the reflective film strip 110 or the first composite component 140 during transport. At least one second guide wheel in the second guide wheel assembly 230 is slidably mounted on the second sliding module 280. The second sliding module 280 is used to adjust the position of the second guide wheel to adjust the tension of the isolation strip 120 or the jumper wire 130 during transport.

[0092] Also, see Figure 2-Figure 4As shown, the present application also provides a photovoltaic module 300, which is obtained using the photovoltaic module manufacturing method of the above-mentioned technical solution. The photovoltaic module manufacturing method can be used to form a multi-slice photovoltaic module 300. For example, the photovoltaic module manufacturing method can form a photovoltaic module 300 with a three-slice, four-slice, five-slice, etc. structure. Specifically, after the isolation strips 120, the reflective film strips 110 and the jumper wires 130 are stacked to form the second composite member 100, the second composite member 100 is welded to the stacked member, and then the backing film and back sheet are placed. After lamination and framing, the photovoltaic module 300 is formed. The photovoltaic module 300 includes a plurality of cell strings 310, a plurality of edge bus bars 320, a plurality of middle bus bars 330 and a plurality of jumper wires 130. The cell string 310 includes a plurality of sliced ​​cells 350 connected in series by a welding ribbon 340. An isolation strip 120 is provided on the jumper 130 to prevent the jumper 130 from contacting the adjacent battery string 310 and causing adverse effects of a short circuit, and a reflective film strip 110 is applied between the jumper 130 and the isolation strip 120 to improve the photoelectric conversion efficiency and aesthetics of the photovoltaic module 300.

[0093] In this embodiment, taking a photovoltaic module 300 in a four-slice structure as an example, the width direction of the photovoltaic module 300 is defined as the first direction (ie Figure 4 The longitudinal direction of the photovoltaic module 300 is defined as the second direction (ie, the X direction). Figure 4 The first direction X and the second direction Y are perpendicular to each other. Two battery strings 310 are arranged at intervals along the second direction Y to form a sub-battery string group 360, and two groups of sub-battery string groups 360 are arranged at intervals along the first direction X to form a battery string group 370. The four battery strings 310 in each battery string group 370 can be connected in parallel. Each battery string 310 includes a plurality of slice batteries 350. All slice batteries 350 of the same battery string 310 are arranged along the second direction Y and can be connected in series. Each intermediate bus bar 330 is located between two battery strings 310 of the same group of sub-battery string groups 360 in the second direction Y, and each intermediate bus bar 330 extends along the first direction X. Edge bus bars 320 are provided at opposite ends of the battery string group 370 in the second direction Y. Each edge bus bar 320 extends along the first direction X, and the end of each battery string 310 away from the intermediate bus bar 330 is connected to the edge bus bar 320. A portion of the jumper 130 is connected to the edge bus bar 320, and another portion is connected to an external device through a junction box. In some embodiments, the edge bus bar 320, the middle bus bar 330, and the jumper 130 are all formed of conductive metal strips.

[0094] For example, see Figure 4 As shown, the photovoltaic assembly 300 includes three battery string groups 370 arranged at intervals along a first direction X. Figure 4From left to right, they are defined as a first cell string group 371, a second cell string group 372, and a third cell string group 373. Each cell string group 370 includes two sub-cell strings 360 spaced apart along a first direction X (i.e., the photovoltaic module 300 includes six sub-cell strings 360). Of course, in other feasible embodiments, the photovoltaic module 300 can also be formed into other types of modules using multiple sliced ​​cells 350. This application does not limit the specific layout of the photovoltaic module 300.

[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 method for manufacturing a photovoltaic module, characterized in that: The photovoltaic module manufacturing method comprises: Step S110: providing a laminate, a reflective film tape, a spacer strip, and a jumper wire; Step S120: the reflective film tape is applied to the isolation strip to form a first composite member; or the reflective film tape is applied to the jumper wire to form the first composite member; Step S130: When the first composite member includes the reflective film and the isolation strip, the first composite member is attached to the jumper wire to form a second composite member; when the first composite member includes the reflective film and the jumper wire, the first composite member is attached to the isolation strip to form a second composite member; wherein the second composite member includes the isolation strip, the reflective film, and the jumper wire in a stacked arrangement; Step S140: the second composite member is stacked and welded to the stacked member to form a photovoltaic module.

2. The method for manufacturing a photovoltaic module according to claim 1, wherein: The step S120 specifically includes: Step S121: at least partially melting the reflective film tape or at least partially melting the isolation strip to form a molten layer; Step S122: solidifying the molten layer, and rolling the reflective film tape or the isolation strip during the solidification process, so that the reflective film tape is attached to the isolation strip to form the first composite member; or; Step S123: the reflective film tape is at least partially melted to form a melt layer; Step S124: solidifying the molten layer, and rolling the reflective film tape or the jumper wire during the solidification process, so that the reflective film tape is attached to the jumper wire to form the first composite component.

3. The method for manufacturing a photovoltaic module according to claim 1, wherein: The step S130 specifically includes: Step S131: When the first composite member includes the reflective film tape and the isolation strip, a side of the first composite member facing away from the isolation strip is at least partially melted to form a melt layer; Step S132: solidifying the molten layer, and rolling the first composite member or the jumper wire during the solidification process, so that the first composite member is attached to the jumper wire to form the second composite member; or; Step S133: When the first composite member includes the reflective film tape and the jumper wire, at least a portion of the first composite member on a side facing away from the jumper wire is melted to form a melt layer; Step S134 : solidifying the molten layer, and rolling the first composite member or the isolation strip during the solidification process, so that the first composite member is attached to the isolation strip to form the second composite member.

4. The method for manufacturing a photovoltaic module according to any one of claims 2 or 3, characterized in that: The molten layer is formed by heating with hot air, and the solidification of the molten layer is completed by solidification with cold air; Among them, the melting temperature is 300℃~500℃, the melting wind pressure is 0.2MPa~0.5MPa, and the curing wind pressure is 0.1MPa~0.2MPa.

5. The method for manufacturing a photovoltaic module according to any one of claims 2 or 3, characterized in that: The second composite member is formed by rolling by a rolling mechanism, wherein the rolling pressure is 0.1 MPa to 0.2 MPa.

6. The method for manufacturing a photovoltaic module according to claim 1, wherein: The step S120 further includes: Step S125: Pulling the reflective film tape and the isolation strip to an overlapping state so that the reflective film tape is attached to the isolation strip to form the first composite component; or pulling the reflective film tape and the jumper wire to an overlapping state so that the reflective film tape is attached to the jumper wire to form the first composite component.

7. The method for manufacturing a photovoltaic module according to claim 1, wherein: The step S130 further includes: Step S135: When the first composite component includes the reflective film tape and the isolation strip, the first composite component and the jumper are pulled to an overlapping state, so that the first composite component is attached to the jumper to form the second composite component; when the first composite component includes the reflective film tape and the jumper, the first composite component and the isolation strip are pulled to an overlapping state, so that the first composite component is attached to the isolation strip to form the second composite component.

8. The method for manufacturing a photovoltaic module according to any one of claims 6 or 7, characterized in that: During the process of forming the first composite component and the second composite component, the reflective film strip, the isolation strip and the jumper are aligned.

9. The method for manufacturing a photovoltaic module according to claim 1, wherein: The step S110 specifically includes: Step S111: cutting the reflective film tape, the isolation strip, and the jumper wire to a preset length.

10. The method for manufacturing a photovoltaic module according to claim 9, characterized in that: The width of the reflective film tape after cutting is W1, the width of the isolation strip after cutting is W2, and the width of the jumper wire after cutting is W3; Among them, 4.5mm≤W1≤9mm, 10mm≤W2≤20mm, 4mm≤W3≤8mm, and 0.5mm≤W1-W3≤1mm.

11. A photovoltaic module, characterized in that: The photovoltaic module is obtained by using the photovoltaic module manufacturing method according to any one of claims 1 to 10.

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