Photovoltaic module

Abstract

The invention provides a photovoltaic module. The photovoltaic module comprises a front packaging structure, a battery unit, a middle bus bar, a bypass module, an end bus bar, a jumper wire, a penetrating bus bar and a back packaging structure, the middle bus bar is located between the first battery subunit and the second battery subunit which are arranged in the first direction and connected in parallel, the middle bus bar extends in the second direction, and the middle bus bar comprises a first middle bus bar part, a second middle bus bar part and a third middle bus bar part which are electrically isolated from one another; the end bus bar extends along a second direction and comprises a first end bus sub-part, a second end bus sub-part, a third end bus sub-part and a fourth end bus sub-part; one end of the jumper wire is connected with the first end confluence sub-part, and the other end of the jumper wire is connected with the third end confluence sub-part; one end of the penetrating confluence belt is connected with the second end confluence sub-part, the other end is connected with the fourth end confluence sub-part, and the middle is connected with the second middle confluence sub-part; the sectional area of the middle bus bar is larger than that of the jumper wire.

Description

Technical Field

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

[0002] With the development and widespread application of solar cell technology, photovoltaic power generation has become one of the most competitive energy forms in the future. Current efforts focus on increasing the power output of photovoltaic modules, exploring ways to both improve module power and reduce costs. Related technologies typically use whole cells or cells laser-cut in half. However, as cell size increases, internal current loss within the module becomes increasingly higher, affecting module performance. Furthermore, current technologies have failed to consider differentiating the configuration of different circuits within the module, resulting in both high cost and low efficiency. Summary of the Invention

[0003] In view of this, in order to at least partially solve the aforementioned technical problems, this application provides a photovoltaic module.

[0004] According to one embodiment of this application, a photovoltaic module is provided, comprising: a front-side encapsulation structure, a battery cell, a central busbar, a bypass module, end busbars, a jumper, a through busbar, and a rear-side encapsulation structure; the battery cell includes a first battery sub-cell and a second battery sub-cell arranged in parallel along a first direction; the central busbar is located between the first battery sub-cell and the second battery sub-cell, and is connected to the first battery sub-cell and the second battery sub-cell, extending along a second direction intersecting the first direction, and includes a first central busbar portion, a second central busbar portion, and a third central busbar portion electrically isolated from each other. The end busbar extends along the second direction and includes a first end busbar portion, a second end busbar portion, a third end busbar portion, and a fourth end busbar portion; one end of the jumper is connected to the first end busbar portion, and the other end of the jumper is connected to the third end busbar portion. One end of the through-busbar connects to the second end busbar sub-section, and the other end connects to the fourth end busbar sub-section. The middle of the through-busbar connects to the second intermediate busbar sub-section. The cross-sectional area of ​​the intermediate busbar is larger than that of the jumper.

[0005] According to the photovoltaic modules provided in the above embodiments of this application, by differentiating the cross-sectional areas of the intermediate busbar and the jumpers, the intermediate busbar, as the main current channel, has a larger cross-sectional area, which increases the current carrying capacity, reduces heat generation, and decreases power loss, thus helping to improve efficiency and extend module life. The jumpers, on the other hand, do not carry current during normal operation of the battery pack, and their smaller cross-sectional area helps to save costs. This differentiated design can adapt to the current design and power requirements of the module, improving the long-term stability and reliability of the module. Attached Figure Description

[0006] The above and other objects, features and advantages of this application will become clearer from the following description of embodiments with reference to the accompanying drawings, in which:

[0007] Figure 1 A circuit diagram of a photovoltaic module according to an embodiment of this application is shown;

[0008] Figure 2 A current flow diagram of a photovoltaic module according to an embodiment of this application is shown;

[0009] Figure 3 This diagram illustrates the arrangement of the busbars and jumpers in a photovoltaic module according to an embodiment of this application.

[0010] Figure 4 A schematic diagram of the bend in the jumper and busbar according to an embodiment of this application is shown;

[0011] Figure 5 A schematic diagram showing the arrangement of jumpers and electrical connection wires near the first lead-out hole of a photovoltaic module according to an embodiment of this application is shown;

[0012] Figure 6 A partial top view showing the positional relationship between the first intermediate busbar and the second intermediate busbar of the first lead-out hole of a photovoltaic module according to an embodiment of this application;

[0013] Figure 7 This illustration shows a schematic diagram of the electrical connection wire arrangement at the second lead-out hole position of a photovoltaic module according to an embodiment of this application.

[0014] The meanings of the reference numerals in the above figures are as follows:

[0015] 1-Battery cell;

[0016] 11-First battery pack;

[0017] 12 - Second battery pack;

[0018] 13 - Third battery pack;

[0019] 14 - Fourth battery pack;

[0020] 15 - Fifth battery pack;

[0021] 16 - Sixth battery pack;

[0022] 17 - First battery sub-unit;

[0023] 18 - Second battery sub-cell;

[0024] 2-Intermediate busbar;

[0025] 21-First intermediate busbar sub-section;

[0026] 211 - The bend in the first intermediate busbar;

[0027] 22-Second intermediate busbar sub-section;

[0028] 221 - The bend in the second intermediate busbar;

[0029] 23-Third intermediate busbar sub-section;

[0030] 3-Bypass module;

[0031] 31-First bypass module;

[0032] 32 - Second bypass module;

[0033] 33 - Third bypass module;

[0034] 4-Jumper wire;

[0035] 41 - The bend in the jumper wire;

[0036] 5-First lead-out hole;

[0037] 6-Second lead-out hole;

[0038] 7-End busbar;

[0039] 71-First end busbar;

[0040] 72 - Second end busbar;

[0041] 73-Third terminal busbar;

[0042] 74 - Fourth terminal busbar;

[0043] 8- Penetrates the busbar;

[0044] 9-Electrical connection wire;

[0045] 91-First electrical connection line;

[0046] 92-Second electrical connection wire;

[0047] B1 - First gap;

[0048] B2 - Second gap;

[0049] A - Width of the jumper along the second direction;

[0050] M1 - The major axis dimension of the first lead-out hole;

[0051] M2 - The short axis dimension of the first lead-out hole;

[0052] N - Diameter of the second lead-out hole;

[0053] P - The distance between the end of the first intermediate busbar and the end of the second intermediate busbar inside the first outlet hole. Detailed Implementation

[0054] The embodiments of this application will now be described with reference to the accompanying drawings. However, it should be understood that these descriptions are exemplary only and are not intended to limit the scope of this application. In the following detailed description, numerous specific details are set forth to provide a thorough understanding of the embodiments of this application for ease of explanation. However, it will be apparent that one or more embodiments may be implemented without these specific details. Furthermore, descriptions of well-known structures and technologies are omitted in the following description to avoid unnecessarily obscuring the concepts of this application.

[0055] The terminology used herein is for the purpose of describing particular embodiments only and is not intended to limit the scope of this application. The term "comprising" as used herein indicates the presence of features, steps, or operations, but does not exclude the presence or addition of one or more other features.

[0056] When using expressions such as "at least one of A, B or C", they should generally be interpreted in accordance with the meaning that is commonly understood by those skilled in the art (e.g., "a system having at least one of A, B or C" should include, but is not limited to, a system having A alone, a system having B alone, a system having C alone, a system having A and B, a system having A and C, a system having B and C, and / or a system having A, B, and C, etc.).

[0057] As photovoltaic (PV) module technology matures, improving its efficiency becomes increasingly difficult. Related technologies typically increase module power by increasing silicon wafer size, but this places new demands on the performance of components such as the junction box rated current and bypass diodes, leading to increased costs.

[0058] Therefore, how to optimize component performance, reduce costs, and improve the stability and reliability of component operation has become an urgent problem to be solved.

[0059] The photovoltaic module provided in this application includes cells, which can be bifacial cells, such as HJT cells (heterojunction cells) or TOPCon cells (tunneling oxide passivation contact cells), or back-contact cells. Furthermore, the back-contact cell can be a conventional IBC cell, TBC cell, HBC cell, or other hybrid cell.

[0060] The aforementioned battery includes a battery body, which includes at least a substrate and a doped layer on the substrate. The substrate is a rectangular or square structure and may have multiple corners, such as four corners. The corners may include chamfers or not. If the corners include chamfers, the substrate may be a rectangular or square with chamfers.

[0061] The aforementioned HJT battery body has a first surface and a second surface arranged opposite to each other. The first surface can be a backlight surface, and the second surface can be a light-receiving surface. The doped layer includes n-doped regions and p-doped regions. The n-doped regions are located on the first surface, and the p-doped regions are located on the second surface. The two can also be interchanged as needed, without particular limitation.

[0062] The aforementioned TOPCon battery body has a first surface and a second surface arranged opposite to each other. The first surface can be a backlight surface, and the second surface can be a light-receiving surface. The doped layer includes n-doped regions and p-doped regions. The n-doped regions are located on the first surface, and the p-doped regions are located within the second surface. The two can also be interchanged as needed, without particular limitation here.

[0063] The aforementioned IBC battery body has a first surface and a second surface disposed opposite to each other. The first surface can be a backlight surface, and the second surface can be a light-receiving surface. The doped layer includes doped regions disposed alternately on the first surface of the substrate.

[0064] The aforementioned TBC cell body includes a tunneling oxide layer on a substrate and a doped layer formed by doping polycrystalline silicon. The TOPCon structure formed by the stacked tunneling oxide layer and the doped polycrystalline silicon layer provides higher carrier lifetime and lower surface recombination compared to IBC photovoltaic modules, thus improving the photoelectric conversion efficiency of TBC photovoltaic modules.

[0065] The aforementioned HBC cell comprises alternating doped layers of different polarities stacked on a substrate to form a heterojunction structure. HBC photovoltaic modules help improve carrier lifetime and reduce surface recombination. Furthermore, a transparent conductive oxide layer (TCO) can be disposed between the surface of the doped layer and the electrode, which is beneficial for collecting carriers in the doped layer and also provides some anti-reflection effect.

[0066] The battery body of the other hybrid batteries mentioned above can adopt a layer structure similar to that of IBC batteries or TBC batteries, and on this basis, a corresponding passivation layer structure can be configured, such as a combination of at least two of polycrystalline silicon passivation, amorphous silicon passivation and microcrystalline silicon passivation.

[0067] Photovoltaic modules based on any of the above-mentioned types of batteries, Figure 1 A circuit diagram of a photovoltaic module according to an embodiment of this application is shown; Figure 2 A current flow diagram of a photovoltaic module according to an embodiment of this application is shown.

[0068] like Figures 1-2 As shown, the photovoltaic module includes a front encapsulation structure (not shown in the figure), a cell 1, a middle busbar 2 and a bypass module 3, an end busbar 7, a jumper 4, a through busbar 8 and a back encapsulation structure (not shown in the figure).

[0069] Battery cell 1 includes a first battery sub-cell 17 and a second battery sub-cell 18 arranged in parallel along a first direction.

[0070] The intermediate busbar 2 is located between the first battery sub-unit 17 and the second battery sub-unit 18, and is electrically connected to the first battery sub-unit 17 and the second battery sub-unit 18. The intermediate busbar 2 extends along a second direction, which intersects with the first direction, and includes a first intermediate busbar sub-section 21, a second intermediate busbar sub-section 22, and a third intermediate busbar sub-section 23 that are electrically isolated from each other.

[0071] The front encapsulation structure may include, for example, an encapsulating film and a glass panel. The glass panel is located on the front of the battery cell 1, which serves as a protective element and has high light transmittance, reducing the adverse effects on light collection efficiency. The encapsulating film is suitable for attaching the glass panel to the battery cell 1, serving as an adhesive and fixing element, and must be made of transparent material.

[0072] Similarly, the back-side encapsulation structure also serves to protect battery cell 1. It should be noted that the encapsulating film in the back-side encapsulation structure can be made of different materials depending on the type of battery string. For example, in a module composed of bifacial cells, the back-side encapsulating film can be made of a transparent material to increase the light incidence efficiency at the back. In a module composed of back-contact cells, either transparent or non-transparent materials can be used, without particular limitation.

[0073] Bypass module 3 can be understood as providing a safe current bypass path in the event that the battery pack fails due to obstruction, or the battery pack is open-circuited or damaged, to prevent hot spot effects and maintain the normal and stable operation of the components.

[0074] A reliable bypass path is provided by jumper 4 and bypass module 3. When a battery pack fails severely, such as when it is shaded or open-circuited, or when the entire battery cell 1 is reverse biased, bypass module 3 will turn on to provide a path for the current to bypass the failed battery pack or failed battery cell, ensuring the normal operation of the entire photovoltaic module.

[0075] The end busbar 7 extends along a second direction, and the photovoltaic module has module edges at both ends along a first direction. The end busbar 7 is located between the cell pack closest to the module edge and the module edge. The end busbar 7 includes a first end busbar 71, a second end busbar 72, a third end busbar 73, and a fourth end busbar 74.

[0076] One end of jumper 4 is connected to the first end bus section 71, and the other end of jumper 4 is connected to the third end bus section 73.

[0077] The through-bus 8 extends along the first direction, and the middle part of the through-bus 8 is electrically connected to the second intermediate bus sub-section 22. One end of the through-bus 8 is connected to the second end bus sub-section 72, and the other end of the through-bus 8 is connected to the fourth end bus sub-section 74.

[0078] Furthermore, in order to solve the problem of balancing cost and heat dissipation performance.

[0079] In some implementations, the cross-sectional area of ​​the intermediate busbar 2 is greater than that of the jumper 4. By differentiating the cross-sectional areas of the intermediate busbar 2 and the jumper 4, the intermediate busbar 2, as the main current channel, has a relatively larger cross-sectional area, which not only improves the current carrying capacity but also reduces resistance, thereby reducing power loss during normal operation and bypass conduction, reducing heat generation, and contributing to improved efficiency and extended component lifespan. The jumper 4, on the other hand, only carries bypass current when the bypass module 3 is operating; its smaller cross-sectional area avoids material waste and saves costs. This differentiated configuration can adapt to the current design and power requirements of the component, thereby improving the stability and reliability of the component.

[0080] The following is based on Figures 1-2 Taking this as an example, the circuit connection of this application will be explained in detail.

[0081] Understandable, such as Figure 1 As shown in the embodiments of this application, the photovoltaic module is schematically presented with the left side as the negative electrode and the right side as the positive electrode; of course, the photovoltaic module can also be presented with the right side as the negative electrode and the left side as the positive electrode, and this application does not make any special limitation on this.

[0082] The first battery subunit 17 can be as follows: Figure 1 The diagram shows multiple battery packs connected in series, and the second electronic unit 18 can be as follows: Figure 1 The area shown includes multiple battery packs connected in series.

[0083] Furthermore, the multiple battery packs connected in series in the first battery sub-unit 17 may specifically include a first battery pack 11, a third battery pack 13, and a fifth battery pack 15. The multiple battery packs connected in series in the second electronic unit 18 may specifically include a second battery pack 12, a fourth battery pack 14, and a sixth battery pack 16 connected in series.

[0084] It can be understood that the first intermediate bus sub-section 21, the second intermediate bus sub-section 22, and the third intermediate bus sub-section 23 are all different regions on the intermediate bus strip 2, and the three intermediate bus sub-sections 21, 22, and 23 are physically separated and electrically isolated from each other.

[0085] The first battery pack 11 and the second battery pack 12 are arranged opposite each other along the first direction and are electrically connected to the first intermediate busbar 21. The third battery pack 13 and the fourth battery pack 14 are arranged opposite each other along the first direction and are electrically connected to the second intermediate busbar 22. The fifth battery pack 15 and the sixth battery pack 16 are arranged opposite each other along the first direction and are electrically connected to the third intermediate busbar 23.

[0086] It is understandable that the battery packs located on the upper and lower sides of the intermediate busbar 2 are arranged opposite each other on both sides of the intermediate busbar 2 along the first direction.

[0087] In this embodiment, the bypass module 3 may include a first bypass module 31, a second bypass module 32, and a third bypass module 33. The first battery pack 11 and the second battery pack 12 are connected in parallel to the first bypass module 31 via jumper 4. The third battery pack 13 and the fourth battery pack 14 are connected in parallel to the second bypass module 32 via jumper 4. The fifth battery pack 15 and the sixth battery pack 16 are connected in parallel to the third bypass module 33 via a through-busbar 8.

[0088] The first end busbar 71 is connected in series with the first battery pack 11 and the third battery pack 13. The second end busbar 72 is connected to one end of the busbar 8 and the fifth battery pack 15. The first end busbar 71 and the second end busbar 72 are spaced apart along the second direction and are electrically isolated.

[0089] The third end busbar 73 is connected in series with the second battery pack 12 and the fourth battery pack 14. The fourth end busbar 74 is connected in series with the other end of the busbar 8 and the sixth battery pack 16. The third end busbar 73 and the fourth end busbar 74 are spaced apart along the second direction and are electrically isolated.

[0090] according to Figure 2 The current flow direction in the battery pack is such that the current flowing out of the third battery pack 13 passes through the second intermediate busbar 22, the through busbar 8, the second end busbar 72, and the fifth battery pack 15 in sequence, thus forming a series connection.

[0091] In some implementations, the cross-sectional area of ​​the busbar 8 is greater than that of the jumper 4. When the circuit is on, current flows through the busbar 8, while when the battery pack is shaded, current flows through the jumper 4. This differentiated configuration accommodates the current design at different locations, meeting the power requirements of the modules and improving the reliability of the photovoltaic modules while saving costs.

[0092] In some implementations, the cross-sectional area of ​​the end bus 7 is greater than that of the jumper 4. Similarly, since current flows through the end bus 7 when the circuit is on, the larger cross-sectional area reduces heat generation, while the smaller cross-sectional area of ​​the jumper 4 can accommodate different current requirements, saving costs and further improving the reliability of the components.

[0093] In some implementations, the ratio of the cross-sectional area of ​​the intermediate busbar 2 to the cross-sectional area of ​​the jumper 4 is greater than 1 and less than or equal to 3. This setting ensures that the cross-sectional area of ​​the intermediate busbar 2 is larger than that of the jumper, thus preventing the intermediate busbar 2 from becoming a current bottleneck as a main line and reducing the risk of overheating. The ratio of less than or equal to 3 ensures that the cross-sectional area of ​​the jumper 4 is not too small, guaranteeing that the jumper 4 can also carry the required bypass current and preventing it from overheating or melting due to excessive current density when carrying current. This setting helps optimize current carrying capacity and thermal management, improves the overall thermal stability and lifespan of the components, and further reduces costs.

[0094] Optionally, the ratio of the cross-sectional area of ​​the intermediate busbar 2 to the cross-sectional area of ​​the jumper 4 can be, for example, 1.5, 2, 2.5 or 3, or a range consisting of any two of the above values.

[0095] In some implementations, the ratio of the cross-sectional area of ​​the end busbar 7 to the cross-sectional area of ​​the jumper 4 is greater than 1 and less than or equal to 3. Similarly, as described above, the end busbar 7, as a current flow path, will not become a current bottleneck, reducing the risk of overheating. The cross-sectional area of ​​the jumper 4 is set in the same manner as described above and will not be repeated here. This configuration helps optimize current carrying capacity and thermal management, improves thermal stability and lifespan, and reasonably reduces costs.

[0096] Optionally, the ratio of the cross-sectional area of ​​the end busbar 7 to the cross-sectional area of ​​the jumper 4 can be, for example, 1.5, 2, 2.5 or 3, or a range consisting of any two of the above values.

[0097] In some implementations, the ratio of the cross-sectional area of ​​the busbar 8 to the cross-sectional area of ​​the jumper 4 is greater than or equal to 1 and less than or equal to 3. Similarly, the busbar 8, as a current flow path, does not become a current bottleneck, reducing the risk of overheating. The cross-sectional area of ​​the jumper 4 is set in the same manner as described above and will not be repeated here. This configuration helps optimize current carrying capacity and thermal management, improves thermal stability and lifespan, and reasonably reduces costs.

[0098] Optionally, the ratio of the cross-sectional area of ​​the busbar 8 to the cross-sectional area of ​​the jumper 4 can be, for example, 1.5, 2, 2.5 or 3, or a range consisting of any two of the above values.

[0099] In some embodiments, the ratio of the cross-sectional area of ​​the intermediate busbar 2 to the cross-sectional area of ​​the end busbar 7 is 1.5 to 2.5. The intermediate busbar 2, located in the middle of the battery cell 1 along the first direction, needs to collect the total current of multiple rows of parallel-connected batteries, while the end busbar 7 needs to transmit the current on only one side of the intermediate busbar 2, resulting in a relatively smaller current load. This difference in configuration, matching different current densities with different cross-sectional areas, helps ensure that the intermediate busbar 2 has lower resistance, reduces heat loss during total current collection, thereby meeting current carrying capacity design requirements and improving component reliability.

[0100] Optionally, the ratio of the cross-sectional area of ​​the intermediate busbar 2 to the cross-sectional area of ​​the end busbar 7 can be, for example, 1.5, 2, or 2.5, or a range consisting of any two of the above values.

[0101] In some implementations, the ratio of the cross-sectional area of ​​the intermediate busbar 2 to the cross-sectional area of ​​the through busbar 8 is 1.5 to 2.5. Similar to the aforementioned, the intermediate busbar 2 needs to collect the total current of multiple rows of parallel battery packs, while the current load of the through busbar 8 is smaller. This configuration satisfies the current carrying capacity design and improves the reliability of the component.

[0102] Optionally, the ratio of the cross-sectional area of ​​the intermediate busbar 2 to the cross-sectional area of ​​the through busbar 8 can be, for example, 1.5, 2 or 2.5, or a range consisting of any two of the above values.

[0103] In some implementations, the ratio of the cross-sectional area of ​​the through busbar 8 to the cross-sectional area of ​​the end busbar 7 is 1:1. It is understood that both the through busbar 8 and the end busbar 7 collect current from one side of the intermediate busbar 2; therefore, having the same cross-sectional area allows for better adaptation to the corresponding current carrying capacity, improving the reliability of the component.

[0104] Optionally, the cross-sectional area of ​​the intermediate busbar 2 is ≥2mm². 2 For example, it could be 2mm 2 3mm 2 4mm 2 5mm 2 6mm 2 or 7mm 2 etc., or a range consisting of any two of the above values.

[0105] Optionally, the cross-sectional area of ​​the end busbar 7 is ≥1 mm². 2 For example, it could be 1mm 22mm 2 3mm 2 or 4mm 2 etc., or a range consisting of any two of the above values.

[0106] The cross-sectional area of ​​the busbar 8 is ≥1mm². 2 For example, it could be 1mm 2 2mm 2 3mm 2 or 4mm 2 etc., or a range consisting of any two of the above values.

[0107] In this application, the cross-sectional area mainly refers to the core layer cross-sectional area of ​​structures such as busbars (which may include intermediate busbars 2, end busbars 7, and through busbars 8) and jumpers 4. In some cases, the thickness design of the external auxiliary welding layers is basically uniform, and the cross-sectional area including the auxiliary welding layers also conforms to the above-mentioned size relationship of cross-sectional areas.

[0108] Figure 3 This illustration shows a schematic diagram of the arrangement between the busbars and jumpers of a photovoltaic module according to an embodiment of this application, to illustrate the schematic arrangement. Figures 1-3 For example, the overall circuit is described with the photovoltaic module as negative on the left and positive on the right.

[0109] according to Figure 2 The direction of current flow in the battery sub-unit 17 is as follows: the current flowing out from the negative electrode passes through the first battery pack 11, the first end busbar 71, the third battery pack 13, the second intermediate busbar 22, the through busbar 8, the second end busbar 72, and the fifth battery pack 15 in sequence to form the current loop of the first battery sub-unit 17.

[0110] Similarly, the current flowing out from the negative electrode passes sequentially through the second battery pack 12, the third end busbar 73, the fourth battery pack 14, the second intermediate busbar 22, the through busbar 8, the fourth end busbar 74, and the sixth battery pack 16 to form the current loop of the second battery sub-unit 18.

[0111] In some embodiments, the back-side encapsulation structure includes an encapsulation backplate and an encapsulation film. The encapsulation backplate can be made of any material, such as a glass backplate, one or more polymer sheets. The glass backplate can be tempered glass, semi-tempered glass, plexiglass, etc., and further, tempered glass includes physically tempered glass or chemically tempered glass. It serves to protect the back of the battery cell 1. The encapsulation backplate has a first lead-out hole 5 and a second lead-out hole 6. Jumper wire 4, the first intermediate busbar 21, and the second intermediate busbar 22 are led out through the first lead-out hole 5 and connected to the bypass module 3 (first bypass module 31 and second bypass module 32). The first bypass module 31 and the second bypass module 32 can be located in the same junction box, thus eliminating the need for a separate junction box. Since the junction box can obstruct the battery pack during photovoltaic power generation, affecting the reliability of the blocked hot spots, eliminating the junction box improves the reliability of the photovoltaic module and increases the module power.

[0112] It should be noted that the first bypass module 31 and the second bypass module 32 can be independent components or they can be packaged together as a module.

[0113] Similarly, the second intermediate busbar 22 and the third intermediate busbar 23 are led out through the second lead-out hole 6 and then connected to the third bypass module 33 to form bypass protection.

[0114] The first lead-out hole 5 and the second lead-out hole 6 have different shapes, and the size of the first lead-out hole 5 in the second direction is larger than the size of the second lead-out hole 6 in the second direction.

[0115] According to an embodiment of this application, the first lead-out hole 5 needs to pass through three conductors. The larger number of conductors requires more space and sufficient insulation spacing. The second lead-out hole 6, on the other hand, only needs to pass through two conductors, requiring relatively less space. This difference in size precisely matches the number and volume of conductors that each lead-out hole needs to pass through. This avoids the situation where, if both were the same size, the first lead-out hole 5 would be overcrowded, making it difficult for conductors to pass through or affecting the insulation layer on the conductor surface. Simultaneously, it avoids the situation where, if both were the same size, the second lead-out hole 6 would be too large, requiring a larger area to be cut from the packaging backplane or packaging material, thus weakening the sealing, mechanical strength, and moisture and dust resistance of that area.

[0116] It is understandable that the difference between the first lead-out hole 5 and the second lead-out hole 6 in the second direction helps to ensure the necessary electrical safety distance, avoid leakage between different lines, reduce the risk of insufficient safety distance due to conductor displacement, vibration or shrinkage and deformation of encapsulation materials, and improve the long-term reliability of photovoltaic modules.

[0117] In some implementations, the bypass module 3 can be understood as a bypass diode or a bypass MOS circuit, and this application does not make any special limitation thereto.

[0118] It is understood that the first bypass module 31 is used to control the first battery pack 11 and the second battery pack 12, and activates the bypass module for component protection when at least one of the battery packs fails. The second bypass module 32 is used to control the third battery pack 13 and the fourth battery pack 14, and activates the bypass module for component protection when at least one of the battery packs fails. The third bypass module 33 is used to control the fifth battery pack 15 and the sixth battery pack 16, and activates the bypass module for component protection when at least one of the battery packs fails.

[0119] In some embodiments, the intermediate busbar 2, jumper 4, end busbar 7, and through busbar 8 can be made of materials such as copper, silver, silver-clad copper, or copper-aluminum alloy as the core (which can be understood as the material of the core layer). From a cost perspective, copper or copper-aluminum alloy is preferred. Furthermore, an auxiliary welding layer is coated on the surface of the core. This auxiliary welding layer can be, for example, a solder layer. To achieve a strong weld, the thickness of the solder layer on the welding surface can be, for example, 0.02~0.03mm, and the thickness of the solder layer on the non-welding surface can be, for example, ≤0.01mm. It should be noted that during the welding process, the solder layer will experience localized flow after reaching its melting temperature, causing a reduction in the thickness of the solder layer on some non-welding surfaces.

[0120] The materials for the solder layer may include tin-lead, tin-lead-bismuth, etc., and can be selected according to the actual soldering requirements.

[0121] In some embodiments, the intermediate busbar 2, jumper 4, end busbar 7, and through busbar 8 can be metal strips with various cross-sectional shapes, such as circular, triangular, rectangular, flat, elliptical, or chamfered rectangles, etc., which are not particularly limited in this application.

[0122] In some embodiments, the first battery pack 11, the second battery pack 12, the third battery pack 13, the fourth battery pack 14, the fifth battery pack 15, and the sixth battery pack 16 each include a plurality of parallel battery strings, and each battery string includes a plurality of battery cells connected in series.

[0123] Solar cells can include uncut solar cells or cut solar cells.

[0124] Among them, non-cut solar cells refer to solar cells where silicon wafers are cut to the required size before solar cell manufacturing.

[0125] Cutting a solar cell refers to the process of dividing a single solar cell into M individual cells (or M segments), where 2 ≤ M ≤ 8. This application involves cutting a large silicon solar cell wafer (e.g., (120mm~300mm) × (156mm~300mm), where the entire cell can be square or rectangular) into 2~8 individual cells.

[0126] Optionally, M can be, for example, 2, 3, 4, 5, 6, 7 or 8, and this application does not impose any particular limitation on it.

[0127] In some embodiments, the length of the battery cell along the second direction is 156-220 mm, and the width along the first direction is 30-60 mm.

[0128] Optionally, the length of the solar cell along the second direction may be, for example, 156mm, 180mm, 182mm, 183mm, 185mm, 190mm, 205mm, 210mm, 215mm or 220mm, or a range consisting of any two of the above values.

[0129] Optionally, the width of the solar cell along the first direction may be, for example, 30mm, 31mm, 32mm, 33mm, 34mm, 35mm, 36mm, 37mm, 38mm, 39mm, 40mm, 41mm, 42mm, 43mm, 44mm, 45mm, 46mm, 47mm, 48mm, 49mm, 50mm, 51mm, 52mm, 53mm, 54mm, 55mm, 56mm, 57mm, 58mm, 59mm, or 60mm, or a range consisting of any two of the above values.

[0130] Preferably, for example, when M=4, the length of the solar cell along the second direction is 180~220mm, and the width along the first direction is 45~55mm. This setting of length and width achieves a balance between module power, output current, and output efficiency, resulting in better overall performance.

[0131] Preferably, the length of the solar cell along the second direction is 182~184mm or 190~230mm, which can make reasonable use of the silicon wafer, reduce raw material waste, be compatible with existing production lines, and avoid large-scale equipment modification. More preferably, it is 191~215mm.

[0132] In some embodiments, the first lead-out hole 5 is elliptical, with its major axis along the second direction. This configuration allows for better space utilization and optimized conductor layout based on the shape of the first lead-out hole 5. The first intermediate bus 21 and the second intermediate bus 22 can be led out from both ends along the major axis of the ellipse, and the jumper 4 can be led out from the middle along the major axis of the ellipse. This ensures sufficient spacing between the three conductors within the hole, helping to maintain a safe distance even if there is slight displacement due to conductor installation or thermal expansion and contraction. This effectively prevents short circuits or leakage between conductors with different potentials, especially between the first intermediate bus 21 and the second intermediate bus 22. The second lead-out hole 6 is circular. Similarly, the circular second lead-out hole 6 ensures sufficient spacing between the second intermediate bus 22 and the third intermediate bus 23, preventing short circuits or leakage between them. Furthermore, the smooth edges of the ellipse and the circle reduce the risk of partial discharge and improve electrical reliability.

[0133] It should be noted that the shapes of the first outlet hole 5 and the second outlet hole 6 can more easily form a better sealing effect during subsequent sealing, and the manufacturing process is easier to control, which is conducive to the standardization and consistency of large-scale production.

[0134] In some embodiments, to facilitate circuit connection, the first intermediate bus 21 has a bent portion 211 extending from a direction perpendicular to the component surface in the opposite direction to where the first intermediate bus 21 is located. One end of the second intermediate bus 22 has a bent portion 221 extending from a direction perpendicular to the component surface in the opposite direction to where the second intermediate bus 22 is located. The jumper 4 has a bent portion 41 extending from a direction perpendicular to the component surface in the opposite direction to where the jumper 4 is located. Figure 4 A schematic diagram of the bend in the jumper and busbar according to an embodiment of this application is shown. Figure 4 As shown, this configuration further avoids electrical interference between the three components, maintains a stable electrical insulation distance, and improves the stability and long-term service life of the components.

[0135] It is understood that the other end of the second intermediate busbar 22 and the third intermediate busbar 23 may also have bends, similar to the bends 211 of the first intermediate busbar, extending in opposite directions from a direction perpendicular to the component surface, to further avoid electrical interference between the two and improve component stability.

[0136] In some implementations... Figure 5 This diagram illustrates the arrangement of jumpers and electrical connections near the first lead-out hole of a photovoltaic module according to an embodiment of this application. Figure 5As shown, the first lead-out hole 5 has mutually perpendicular major and minor axes. The minor axis is parallel to the width direction of the intermediate busbar 2. The major axis dimension M1 of the first lead-out hole 5 is 19.5~25mm, and the minor axis dimension M2 is 11~13mm. Setting the major and minor axis dimensions within the above ranges can avoid adverse effects on airtightness and mechanical strength caused by excessively large openings, while ensuring sufficient electrical safety distance and reliability between the three conductors. If the major and minor axis dimensions are too small, the three conductors will be relatively crowded, making it difficult to provide the necessary electrical safety distance. If the major and minor axis dimensions are too large, the sealing performance will be affected, which may allow moisture and dust to enter the component. In addition, the corresponding mechanical stress will be large, which may cause the conductors to break or wear due to stress concentration at the edge of the hole.

[0137] Optionally, the major axis dimension M1 of the first lead-out hole 5 (e.g., Figure 5 (As shown) For example, it can be 19.5mm, 20mm, 20.5mm, 21mm, 21.5mm, 22mm, 23mm, 24mm or 25mm, or a range consisting of any two of the above values.

[0138] Optionally, the minor axis dimension M2 of the first lead-out hole 5 (e.g., Figure 5 (As shown) For example, it can be 11mm, 11.5mm, 12mm, 12.5mm or 13mm, or a range consisting of any two of the above values.

[0139] In some embodiments, the diameter N of the second outlet 6 is 11-13 mm. This configuration, similar to the first outlet 6, provides sufficient electrical safety distance and reliability. Setting the diameter too large, similar to the aforementioned, further affects sealing and mechanical strength. Setting the diameter too small makes it difficult to provide sufficient electrical safety distance, potentially leading to short circuits or leakage.

[0140] Optionally, the diameter N of the second lead-out hole 6 can be, for example, 11 mm, 11.5 mm, 12 mm, 12.5 mm or 13 mm, or a range consisting of any two of the above values.

[0141] It is understood that the diameter N of the second lead-out hole 6 may be the same as or different from the minor axis dimension of the first lead-out hole 5. For the sake of process convenience and component reliability, it is preferable that the diameter N of the second lead-out hole 6 is the same as the minor axis dimension of the first lead-out hole 5.

[0142] In some implementations, such as Figure 3As shown, the through busbar 8 does not pass through the second lead-out hole 6, meaning that in the second direction, the through busbar 8 and the second lead-out hole 6 are offset. Along the second direction, the second lead-out hole 6 is closer to the third battery pack 13 and the fourth battery pack 14, and further away from the fifth battery pack 15 and the sixth battery pack 16. This arrangement avoids electrical interference between the bypasses led out from the through busbar 8 and the second lead-out hole 6, thereby preventing adverse effects on component reliability.

[0143] In some embodiments, the thicknesses of the end busbar 7, the intermediate busbar 2, the through busbar 8, and the jumper 4 are all ≤0.4mm. Considering material savings and process requirements, setting the thickness within this range helps save material costs and reduce weight. It also helps alleviate stress caused by the difference in thermal expansion coefficients between the end busbar 7, the intermediate busbar 2, the through busbar 8, and the jumper 4 and the silicon substrate of the solar cell, reducing the risk of microcracks in the solar cell.

[0144] It is understood that the thicknesses of the end busbar 7, the middle busbar 2, the through busbar 8, and the jumper wire 4 can be the same or different. For ease of manufacturing and to avoid the risk of microcracks in the solar cells, it is preferable that the thicknesses of the end busbar 7, the middle busbar 2, the through busbar 8, and the jumper wire 4 are the same.

[0145] Optionally, the thickness of the end busbar 7, the intermediate busbar 2, the through busbar 8 and the jumper 4 can be independently selected from 0.1mm~0.2mm, 0.2mm~0.3mm or 0.3mm~0.4mm, etc.

[0146] It should be noted that, unless otherwise specified, "thickness" generally refers to the dimension along the direction perpendicular to the surface of the battery cell. In this application, the aforementioned thickness mainly refers to the overall thickness of structures such as busbars (end busbar 7, intermediate busbar 2, through busbar 8), jumper wires 4, etc., that is, the sum of the core layer thickness and the thickness of the external auxiliary welding layer.

[0147] In some implementations, the spacing between adjacent solar cells is -2 to 0 mm along the first direction and / or along the second direction. This arrangement helps to increase the effective light-receiving area of ​​the module and improve the module's output power.

[0148] For example, the spacing between adjacent solar cells along the first and / or second directions can be, for example, -2 mm, -1.5 mm, -1 mm, -0.5 mm, or 0 mm, or a range consisting of any two of the above values. Preferably, it is -1 to 0 mm.

[0149] In some implementations... Figure 5 This diagram illustrates the arrangement of jumpers and electrical connections near the first lead-out hole of a photovoltaic module according to an embodiment of this application. Figure 5As shown, the width A of jumper 4 along the second direction is ≤25mm. In some cases, jumper 4 is installed in the same layer as the solar cell and spaced apart, in which case the width A1 of the jumper is between 3-7mm. In other cases, jumper 4 is stacked with the solar cell, in which case the width of jumper 4 needs to be increased and the thickness reduced to reduce the stress with the solar cell; specifically, the width A2 is between 5-25mm.

[0150] Optionally, the width A of the jumper 4 along the second direction can be, for example, 3mm, 4mm, 5mm, 6mm, 7mm, 8mm, 9mm, 10mm, 12mm, 14mm, 16mm, 18mm, 20mm, 22mm, 24mm or 25mm, or a range consisting of any two of the above values.

[0151] In some implementations, the intermediate busbar 2, the end busbar 7, the through busbar 8, and the jumper wire 4 can be stacked with the battery cell 1. This arrangement helps to improve module efficiency, thereby increasing power generation.

[0152] In one embodiment, the intermediate busbar 2 is stacked with adjacent solar cells, and the intermediate busbar 2 and the stacked solar cells are isolated from each other by an insulating portion (not shown in the figure). The insulating portion can be an insulating coating adhesive (such as UV-curable adhesive or thermosetting adhesive), insulating tape, or strip-shaped insulating film, etc., and the insulating portion has good insulation and a certain adhesive effect, which can effectively fix the intermediate busbar 2. For the insulating coating adhesive, the insulating material can be applied to the corresponding position as needed, and then cured by light curing or heat curing. Preferably, the UV-curable adhesive or thermosetting adhesive can be transparent to reduce shading of the solar cells.

[0153] It is understandable that, in the case of the intermediate busbar 2 being stacked with adjacent battery cells, the first lead-out hole 5 and the second lead-out hole 6 can be positioned in the same way as described above (e.g., Figure 3 As shown in the figure, the positions of the first lead-out hole 5 and the second lead-out hole 6 can also be adjusted according to the stacking arrangement, and this application does not make any special limitation in this regard.

[0154] In another embodiment, the end busbar 7 is stacked with adjacent solar cells, and the end busbar 7 is isolated from the stacked solar cells by an insulating portion (not shown in the figure). The material and manufacturing process of the insulating portion are similar to those described above, and will not be repeated here. The insulating portion can effectively fix the end busbar 7.

[0155] It is understood that when the end busbar 7 is stacked with adjacent battery cells, the first lead-out hole 5 and the second lead-out hole 6 can be located in the same positions as described above (e.g., Figure 3As shown in the figure, the positions of the first lead-out hole 5 and the second lead-out hole 6 can also be adjusted according to the stacked arrangement, and this application does not particularly limit this. In another embodiment, the through busbar 8 is stacked with the adjacent battery cells, and the through busbar 8 and the stacked battery cells are isolated by an insulating part (not shown in the figure). The material and preparation process of the insulating part are similar to those described above, and will not be repeated here. The insulating part can better fix the through busbar 8.

[0156] It is understandable that, in the case of the busbar 8 and the adjacent battery cell stack arrangement, the first lead-out hole 5 and the second lead-out hole 6 can be in the same position as described above (e.g., Figure 3 As shown in the figure, the positions of the first lead-out hole 5 and the second lead-out hole 6 can also be adjusted according to the stacking arrangement, and this application does not make any special limitation in this regard.

[0157] In another embodiment, the jumper wire 4 is stacked with adjacent solar cells, and the jumper wire 4 is isolated from the stacked solar cells by an insulating portion (not shown in the figure). The material and preparation process of the insulating portion are similar to those described above, and will not be repeated here. The insulating portion can effectively fix the jumper wire 4.

[0158] It is understandable that, when jumper 4 is stacked with adjacent battery cells, the first lead-out hole 5 and the second lead-out hole 6 can be in the same positions as described above (e.g., Figure 3 As shown in the figure, the positions of the first lead-out hole 5 and the second lead-out hole 6 can also be adjusted according to the stacking arrangement, and this application does not make any special limitation in this regard.

[0159] Similarly, the width of the through-busbar 8 along the second direction is ≤25mm. In some cases, the through-busbar 8 is arranged in the same layer as the battery cell and spaced apart, in which case the width of the through-busbar 8 is between 3 and 7mm. In other cases, the through-busbar 8 is stacked with the battery cell, in which case the width of the through-busbar 8 needs to be increased and the thickness reduced to reduce the stress with the battery cell. Specifically, in this case, the width of the through-busbar 8 is between 5 and 25mm.

[0160] Optionally, the width of the busbar 8 along the second direction can be, for example, 3mm, 4mm, 5mm, 6mm, 7mm, 8mm, 9mm, 10mm, 12mm, 14mm, 16mm, 18mm, 20mm, 22mm, 24mm or 25mm, or a range consisting of any two of the above values.

[0161] In some embodiments, the photovoltaic module also includes multiple electrical connection lines 9 (also referred to as solder strips). The first battery sub-unit 17 and the second battery sub-unit 18 each include multiple battery packs connected in series. The connection relationship of the battery packs is as described above and will not be repeated here.

[0162] The battery pack consists of multiple parallel battery strings, and each battery string consists of multiple battery cells connected in series. Continuing... Figure 5 As shown, the electrical connection line 9 extends along the first direction to connect the battery cells in a string.

[0163] In some embodiments, the through busbar 8 is arranged between two adjacent electrical connection lines 9 along the second direction, and an insulating portion is provided between the through busbar 8 and the solar cell. This arrangement can optimize the spatial layout and improve the reliability of the module.

[0164] In some implementations, the thickness of the busbar 8 is less than or equal to the thickness of the electrical connection wire 9. This design avoids the busbar 8 being significantly thicker than the electrical connection wire 9, which would reduce the internal flatness of the module and increase the difficulty of the lamination process; it also reduces the risk of microcracks in the solar cells.

[0165] In some embodiments, the jumper 4 is arranged between two adjacent electrical connection lines 9 along the second direction, and an insulating portion is provided between the jumper 4 and the solar cell. This arrangement can optimize the spatial layout and improve the reliability of the component.

[0166] In some implementations, the thickness of jumper wire 4 is less than or equal to the thickness of electrical connection wire 9. This design avoids the jumper wire 4 being significantly thicker than the electrical connection wire 9, which would reduce the internal flatness of the module and increase the difficulty of the lamination process; it also reduces the risk of microcracks in the solar cells.

[0167] In some embodiments, the electrical connection line 9 includes a first electrical connection line 91 and a second electrical connection line 92 adjacent to each other along a second direction. The first electrical connection line 91 is located at the edge of the solar cell, and the second electrical connection line is located on the side of the first electrical connection line 91 away from the edge of the solar cell. In the solar cell near the first lead-out hole 5, the first electrical connection line 91 is not connected to the intermediate busbar 2, while the second electrical connection line 92 is connected to the intermediate busbar 2. This arrangement allows the first electrical connection line 91 to be positioned at the edge of the solar cell, effectively collecting the edge current of the solar cell, and preventing the first electrical connection line 91 from being led out, thereby avoiding interference with the bending lead-out of the intermediate busbar 2, and avoiding welding failure due to proximity to the bend lead-out location, thus ensuring the yield and reliability of the module.

[0168] In some embodiments, the solar cells in the photovoltaic module can be grid-less cells. In other embodiments, the solar cells in the photovoltaic module can be grid-connected cells, with electrical connection lines 9 connected to the grid. The electrical connection lines 9 are used to electrically connect the solar cells and can be considered as an interconnection structure between multiple solar cells.

[0169] Optionally, the electrical connector 9 can use copper, silver, silver-clad copper, copper-aluminum alloy, or other metals as its core. From a cost perspective, copper or copper-aluminum alloy is preferred. Similarly, an auxiliary soldering layer is coated on the surface of the core of the electrical connector 9. The auxiliary soldering layer can be, for example, a solder layer. The material and thickness of the solder layer are roughly the same as those of the jumper 4 mentioned above, and will not be described again here.

[0170] The electrical connection wire 9 can be made of metal strips with various cross-sectional shapes, such as circular, triangular, rectangular, flat, elliptical or chamfered rectangles, etc., and this application does not make any particular limitation in this regard.

[0171] The following will use the first battery pack 11 and the third battery pack 13 as examples to explain the positional relationship of the first electrical connection line 91 and the second electrical connection line 92 adjacent to the first lead hole 5.

[0172] like Figure 5 As shown, along the second direction, a first gap B1 may exist between the first battery pack 11 and the third battery pack 13. Closest to the first gap B1, a first electrical connection line 91 is respectively located on the surface of the first battery pack 11 and the third battery pack 13, closest to the edge of the battery cell. A second electrical connection line 92 is respectively located on the side of the first electrical connection line 91 away from the edge of the battery cell. The first electrical connection line 91 is not connected to the intermediate busbar 2, and its extension direction points towards the first lead-out hole 5. This arrangement allows the first electrical connection line 91 to be positioned at the edge of the battery cell, effectively collecting the edge current of the battery cell, avoiding interference with the bending lead-out of the intermediate busbar 2, and preventing welding failure due to proximity to the bend. The second electrical connection line 92 is electrically connected to the intermediate busbar 2. This arrangement optimizes space utilization and the compactness of the electrical connection line 92 layout, thereby improving power generation.

[0173] It is understood that the above positions are also applicable to the second battery pack 12 and the fourth battery pack 14, and this application will not elaborate further on this.

[0174] In some embodiments, the distance between the extending direction of the first electrical connection wire 91 and the end of the long axis closest to the first lead-out hole 5 of the first electrical connection wire 91 is 0.5 to 4 mm, for example, it can be 0.5 mm, 1 mm, 1.5 mm, 2 mm, 2.5 mm, 3 mm, 3.5 mm, or 4 mm, or a range consisting of any two of the above values. This arrangement ensures sufficient electrical insulation and avoids the risk of short circuits.

[0175] It should be noted that, in some cases, to avoid the electrical connection lines 9 overlapping and affecting the reliability of the components, the battery packs located on both sides of the intermediate busbar 2 along the first direction are staggered in the second direction. Specifically, the first battery sub-unit 17 can be offset to the left and the second battery sub-unit 18 can be offset to the right; or vice versa.

[0176] Furthermore, the distance between the extension direction of the first electrical connection line 91 on the first battery pack 11 and the end of the long axis of the first lead hole 5 closest to the first electrical connection line 91 can be the same as or different from the distance between the extension direction of the first electrical connection line 91 on the second battery pack 12 and the end of the long axis of the first lead hole 5 closest to the first electrical connection line 91.

[0177] For example, the distance between the extending direction of the first electrical connection line 91 on the first battery pack 11 and the end of the first lead-out hole 5 closest to the first electrical connection line 91 can be 0.97~2.97mm. The distance between the extending direction of the first electrical connection line 91 on the second battery pack 12 and the end of the first lead-out hole 5 closest to the first electrical connection line 91 can be 1.97~3.97mm. Of course, the aforementioned spacing can be interchanged, and this application does not impose any particular limitation on it.

[0178] In some embodiments, the second electrical connection line 92, located in the first battery pack 11 and the second battery pack 12 and adjacent to the first lead-out hole 5, is electrically connected to the first intermediate busbar 21. This arrangement allows for sufficient current collection without interfering with the bypass module 3.

[0179] In some embodiments, in the third battery pack 13 and the fourth battery pack 14, the second electrical connection line 92 of the battery cell adjacent to the first lead-out hole 5 is electrically connected to the second intermediate busbar 22. Similarly, this allows for sufficient current collection while avoiding mutual interference, thereby increasing the power of the assembly.

[0180] Figure 6 A partial top view shows the positional relationship between the first intermediate busbar and the second intermediate busbar of a photovoltaic module according to an embodiment of this application. (See attached image.) Figure 6 As shown, the distance P between the end of the first intermediate busbar 21 and the end of the second intermediate busbar 22 inside the first outlet hole 5 is 15~17mm.

[0181] Furthermore, the major axis dimension M1 of the first lead-out hole is greater than the distance P between the end of the first intermediate busbar 21 and the end of the second intermediate busbar 22 within the first lead-out hole 5. This arrangement provides sufficient distance between the three lead-out conductors while ensuring electrical insulation between them, thus improving the stability and reliability of the component.

[0182] Optionally, the distance P between the end of the first intermediate busbar 21 and the end of the second intermediate busbar 22 inside the first outlet hole 5 can be, for example, 15mm, 15.5mm, 16mm, 16.5mm or 17mm, or a range consisting of any two of the above values.

[0183] In some embodiments, in the fifth battery pack 15 and the sixth battery pack 16, the first electrical connection line 91 of the battery cell near the second lead-out hole 6 is not connected to the third intermediate busbar 23, and the second electrical connection line 92 is electrically connected to the third intermediate busbar; in the third battery pack 13 and the fourth battery pack 14, the first electrical connection line 91 of the battery cell near the second lead-out hole 6 is electrically connected to the second intermediate busbar 22, while the second electrical connection line 92 is not connected to the second intermediate busbar 22. This configuration allows the first electrical connection line 91 to be positioned at the edge of the battery cell, effectively collecting edge current and preventing interference from the bending and exiting of the intermediate busbar 2 (fifth battery pack 15 and sixth battery pack 16), thus ensuring module yield and reliability. Simultaneously, since the positions of the second lead-out hole 6 in the third battery pack 13 and fourth battery pack 14 do not conflict, the first electrical connection line 91 is electrically connected to the second intermediate busbar 22, enabling the effective collection of edge current while simultaneously channeling it into the intermediate busbar 2, thereby improving the module's current collection efficiency.

[0184] The following will use the third battery pack 13 and the fifth battery pack 15 as examples to explain the positional relationship between the first electrical connection line 91 and the second electrical connection line 92 near the second lead hole 6.

[0185] Figure 7 This diagram illustrates the arrangement of electrical connection wires at the second lead-out port of a photovoltaic module according to an embodiment of this application. Figure 7 As shown, along the second direction, a second gap B2 can be formed between the third battery pack 13 and the fifth battery pack 15. Closest to the second gap B2, a first electrical connection line 91 is located on the surface of both the third battery pack 13 and the fifth battery pack 15, closest to the edge of the battery cell. A second electrical connection line 92 is located on the side of the first electrical connection line 91 away from the edge of the battery cell. The first electrical connection line 91 on the fifth battery pack 15 is not connected to the third intermediate busbar 23, and its extension direction points towards the second lead-out hole 6. This arrangement, similar to the aforementioned arrangement, allows the first electrical connection line 91 to be positioned at the edge of the battery cell, effectively collecting the edge current of the battery cell and avoiding interference with the bending lead-out of the intermediate busbar 2, as well as avoiding welding failure due to proximity to the bend. The second electrical connection line 92 is electrically connected to the intermediate busbar 2. This arrangement optimizes space utilization and the compactness of the electrical connection line 9 layout, improving power generation.

[0186] In some embodiments, the first electrical connection line 91 located on the third battery pack 13, closest to the edge of the battery cell, is directly electrically connected to the second intermediate busbar 22 since it does not involve interference with the second lead-out hole 6. This arrangement further optimizes space utilization and the compactness of the electrical connection line 9 layout, thereby increasing power generation.

[0187] It is understood that the above positions are also applicable to the fourth battery pack 14 and the sixth battery pack 16, and this application will not elaborate further on this.

[0188] In some implementations, continue as Figure 7 As shown, the second outlet hole 6 and the second gap B2 are offset from each other in the second direction. This arrangement causes the ends of the bent portion 221 of the second intermediate busbar and the bent portion (not shown in the figure) of the third intermediate busbar to be offset from the second gap B2.

[0189] In some embodiments, the distance between the bent end of the second intermediate busbar in the second lead-out hole 6 and the bent end of the third intermediate busbar 23 is 5-7 mm. This arrangement provides sufficient physical spacing between the two lead-out conductors while ensuring electrical insulation between them, thus improving the stability and reliability of the component.

[0190] Optionally, the distance between the bent end of the second intermediate busbar in the second outlet hole 6 and the bent end of the third intermediate busbar 23 can be, for example, 5mm, 5.5mm, 6mm, 6.5mm or 7mm, or a range consisting of any two of the above values.

[0191] In some embodiments, along a first direction, the first battery cell 17 and the second battery cell 18 are arranged opposite each other with the intermediate busbar 2 as the axis of symmetry. The electrical connection lines 9 of the first battery cell 17 and the second battery cell 18, located on the intermediate busbar 2, are staggered. This arrangement helps optimize the current design and power requirements of the module, thereby improving the stability and reliability of the module.

[0192] It should be noted that the spacing between the jumper 4 and the first battery pack 11 or the third battery pack 13 along the second direction may be the same as or different from the spacing between the jumper 4 and the second battery pack 12 or the fourth battery pack 14 along the second direction. This application does not impose any special limitations on this.

[0193] Optionally, the distance between the jumper 4 and the first battery pack 11 or the third battery pack 13 along the second direction is 1 to 3 mm, for example, it can be 1 mm, 2 mm or 3 mm, or a range consisting of any two of the above values.

[0194] Optionally, the distance between the jumper 4 and the second battery pack 12 or the fourth battery pack 14 along the second direction is 2 to 4 mm, for example, it can be 2 mm, 3 mm or 4 mm, or a range consisting of any two of the above values.

[0195] In some embodiments, battery cells are connected in series to form a battery string, then connected in parallel to form a battery pack, and multiple battery packs are connected in series to form a battery cell, with an encapsulation structure surrounding the outer periphery of the battery cell. It is understood that the encapsulation structure includes the aforementioned front encapsulation structure and back encapsulation structure, which will not be elaborated upon further in this application.

[0196] The specific embodiments described above further illustrate the purpose, technical solution, and beneficial effects of this application. It should be understood that the above descriptions are merely specific embodiments of this application and are not intended to limit this application. Any modifications, equivalent substitutions, improvements, etc., made within the spirit and principles of this application should be included within the protection scope of this application.

Claims

1. A photovoltaic module, comprising: Front packaging structure, battery cell, middle busbar, bypass module, end busbar, jumper wire, through busbar and rear packaging structure; The battery unit includes a first battery sub-unit and a second battery sub-unit arranged in parallel along a first direction; The intermediate busbar is located between the first battery sub-unit and the second battery sub-unit, and is electrically connected to the first battery sub-unit and the second battery sub-unit. The intermediate busbar extends along a second direction, which intersects with the first direction. The intermediate busbar includes a first intermediate bus sub-section, a second intermediate bus sub-section, and a third intermediate bus sub-section that are electrically isolated from each other. The end busbar extends along a second direction, and the end busbar includes a first end busbar sub-section, a second end busbar sub-section, a third end busbar sub-section, and a fourth end busbar sub-section; One end of the jumper is connected to the first end bus sub-section, and the other end is connected to the third end bus sub-section. One end of the through-busbar is connected to the second end busbar sub-section, and the other end is connected to the fourth end busbar sub-section. The middle part of the through-busbar is connected to the second intermediate busbar sub-section. The cross-sectional area of ​​the intermediate busbar is larger than that of the jumper.

2. The photovoltaic module according to claim 1, wherein, The cross-sectional area of ​​the through busbar and the end busbar is greater than the cross-sectional area of ​​the jumper.

3. The photovoltaic module according to claim 1, wherein, The ratio of the cross-sectional area of ​​the intermediate busbar to the cross-sectional area of ​​the jumper is greater than 1 and less than or equal to 3; and / or, The ratio of the cross-sectional area of ​​the end busbar to the cross-sectional area of ​​the jumper is greater than 1 and less than or equal to 3; and / or, The ratio of the cross-sectional area of ​​the through-bus strip to the cross-sectional area of ​​the jumper is greater than 1 and less than or equal to 3.

4. The photovoltaic module according to claim 1, wherein, The ratio of the cross-sectional area of ​​the intermediate busbar to the cross-sectional area of ​​the end busbar is 1.5 to 2.5; and / or, The ratio of the cross-sectional area of ​​the intermediate busbar to the cross-sectional area of ​​the through busbar is 1.5 to 2.5; and / or, The ratio of the cross-sectional area of ​​the through-bus strip to the cross-sectional area of ​​the end bus strip is 1:1; and / or, The cross-sectional area of ​​the intermediate busbar is ≥2mm². 2 The cross-sectional area of ​​the end busbar is ≥1mm². 2 The cross-sectional area of ​​the through-bus strip is ≥1mm². 2 .

5. The photovoltaic module according to any one of claims 1 to 4, wherein, The back-side encapsulation structure includes an encapsulation backplate, which has a first lead-out hole and a second lead-out hole. The jumper, the first intermediate bus, and the second intermediate bus are led out through the first lead-out hole; the second intermediate bus and the third intermediate bus are led out through the second lead-out hole. The first lead-out hole and the second lead-out hole have different shapes, and the size of the first lead-out hole in the second direction is larger than the size of the second lead-out hole in the second direction.

6. The photovoltaic module according to claim 5, wherein, The first lead-out hole has a major axis and a minor axis that are perpendicular to each other. The major axis of the first lead-out hole has a size of 19.5~22mm, and the minor axis of the first lead-out hole has a size of 11~13mm. The diameter of the second lead-out hole is 11~13mm.

7. The photovoltaic module according to any one of claims 1 to 4, wherein, The thickness of the end busbar, the intermediate busbar, the through busbar, and the jumper wire is all ≤0.4mm; and / or, The width of the jumper wire along the second direction is ≤25mm.

8. The photovoltaic module according to any one of claims 5, wherein, The photovoltaic module also includes multiple electrical connection lines. The first battery sub-unit and the second battery sub-unit each include multiple battery packs connected in series. The battery packs include multiple battery strings connected in parallel. The battery strings include multiple battery cells connected in series. The electrical connection lines extend along a first direction to connect the battery cells into a string. The electrical connection line includes a first electrical connection line and a second electrical connection line that are adjacent to each other along the second direction. The first electrical connection line is located at the edge of the battery cell, and the second electrical connection line is located on the side of the first electrical connection line away from the edge of the battery cell. In the battery cell near the first lead-out hole, the first electrical connection line is not connected to the intermediate busbar, while the second electrical connection line is connected to the intermediate busbar.

9. The photovoltaic module according to claim 8, wherein, The first battery subunit includes a series of battery packs comprising: a first battery pack, a third battery pack, and a fifth battery pack; the second battery subunit includes a series of battery packs comprising: a second battery pack, a fourth battery pack, and a sixth battery pack; the first battery pack and the second battery pack are arranged opposite each other along a first direction, the third battery pack and the fourth battery pack are arranged opposite each other along a first direction, and the fifth battery pack and the sixth battery pack are arranged opposite each other along a first direction. In the first battery pack and the second battery pack, the second electrical connection line of the battery cell adjacent to the first lead-out hole is electrically connected to the first intermediate busbar; and / or, In the third and fourth battery packs, the second electrical connection line of the battery cell adjacent to the first lead hole is electrically connected to the second intermediate busbar.

10. The photovoltaic module according to claim 9, wherein, In the fifth battery pack and the sixth battery pack, the first electrical connection line of the battery cell adjacent to the second lead hole is not connected to the third intermediate busbar, while the second electrical connection line is electrically connected to the third intermediate busbar. In the third and fourth battery packs, the first electrical connection line of the battery cell near the second lead hole is electrically connected to the second intermediate busbar, while the second electrical connection line is not connected to the second intermediate busbar.

11. The photovoltaic module according to claim 10, wherein, The through-bus strip does not pass through the second outlet hole; In the second direction, the second outlet is closer to the third and fourth battery packs and further away from the fifth and sixth battery packs.

12. The photovoltaic module according to any one of claims 1 to 4, wherein, The intermediate busbar, the end busbar, the through busbar, and the jumper wire are respectively stacked with the battery cell.

13. The photovoltaic module according to claim 12, wherein, The photovoltaic module also includes multiple electrical connection lines. The first battery sub-unit and the second battery sub-unit each include multiple battery packs connected in series. Each battery pack includes multiple battery strings connected in parallel. Each battery string includes multiple battery cells connected in series. The multiple electrical connection lines extend along a first direction to connect the battery cells into a string. Wherein, the through-busbar is arranged between two adjacent electrical connection lines along the second direction, and an insulating portion is provided between the through-busbar and the battery cell; and / or, The jumper wire is arranged between two adjacent electrical connection wires along the second direction, and an insulating portion is provided between the jumper wire and the battery cell.

14. The photovoltaic module according to any one of claims 13, wherein, in, The thickness of the through-bus strip is less than or equal to the thickness of the electrical connection wire; and / or, the thickness of the jumper wire is less than or equal to the thickness of the electrical connection wire.

15. The photovoltaic module according to any one of claims 1 to 14, wherein, Along the first direction and / or the second direction, the spacing between adjacent solar cells is -2 to 0 mm; and / or, The solar cell is divided into M segments, where 2 ≤ M ≤ 8; and / or, The length of the battery cell along the second direction is 180~220mm, preferably 182~183mm or 210~220mm; the width along the first direction is 45~55mm.

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