Insulating tin-plated copper strip prefabricated structure, preparation method thereof and photovoltaic module

Abstract

The invention provides an insulating tinned copper strip prefabricated structure, a preparation method thereof and a photovoltaic module, and particularly relates to the technical field of solar cell preparation. The insulating tin-plated copper strip prefabricated structure comprises a tin-plated copper strip body and an insulating layer arranged on at least one side surface of the tin-plated copper strip body, the insulating layer is formed on the tinned copper strip body in a bonding or spraying mode, and the insulating layer is used for making contact with the back face of a battery piece in the photovoltaic module assembling process to achieve electrical insulation. According to the insulating tin-plated copper strip prefabricated structure, the insulating layer and the tin-plated copper strip body are integrated through bonding or spraying, so that the process is simplified, and the cost is reduced; meanwhile, the integrated structure avoids relative displacement, does not need to widen an insulating layer, is controllable in thickness, reduces the increase of string spacing after lamination, and improves the appearance. The insulating layer is in direct contact with the battery piece, short circuit is prevented, the electrical safety and long-term stability of the assembly in a complex environment are improved, and the later assembly problem is also simplified.

Description

Technical Field

[0001] This invention relates to the field of solar cell fabrication technology, and in particular to an insulating tin-plated copper strip prefabricated structure, its fabrication method, and a photovoltaic module. Background Technology

[0002] Currently, the busbars of shingled solar modules are typically hidden on the back of the module, usually placed between the string spacing of the solar cells. Since the busbars use tin-plated copper strips (copper as the base material with a tin-plated surface), direct contact between them and the solar cells would cause a short circuit. Therefore, insulation between the busbars and the back of the solar cells is essential. In conventional processes, this insulation is achieved using a combination of PET insulating strips and EVA film: the PET insulating strips primarily provide insulation, while the EVA film acts as a buffer, preventing the PET insulating strips from directly contacting the solar cells and causing breakage or microcracks.

[0003] However, existing technologies have significant shortcomings: the combination of PET insulating strips and EVA film is not only complex in process but also increases product costs; the two can be used as a single unit or placed separately, but placing them separately requires two placement processes, further increasing the complexity of the process; since there may be relative displacement between the PET insulating strip, EVA film and busbar, the width of the former two must be greater than the width of the busbar; at the same time, the total thickness of the PET insulating strip and EVA film is usually between 0.2 and 0.6 mm, and placing them after the string spacing will increase the string spacing of the module after lamination by nearly 1 mm, which will have an adverse effect on the appearance of the module.

[0004] Therefore, the key technological direction that needs to be addressed is to effectively solve the insulation problem between the busbar and the solar cell, further reduce product costs, and improve the appearance of the laminated module.

[0005] In view of this, the present invention is hereby proposed. Summary of the Invention

[0006] The purpose of this invention is to provide an insulating tin-plated copper strip prefabricated structure, its preparation method, and a photovoltaic module, aiming to solve at least one of the above-mentioned technical problems in the prior art.

[0007] In order to achieve the above-mentioned objectives of the present invention, the following technical solution is adopted: A first aspect of the present invention provides an insulating tin-plated copper strip prefabricated structure, comprising: a tin-plated copper strip body and an insulating layer disposed on at least one surface of the tin-plated copper strip body; The insulating layer is formed on the tin-plated copper strip body by bonding or spraying. The insulating layer is used to contact the back of the solar cell during the assembly of the photovoltaic module to achieve electrical insulation.

[0008] In some embodiments of the present invention, the insulating layer is a transparent PET tape, which is composed of a PET insulating layer and an adhesive layer disposed on one side thereof, and the width of the transparent PET tape is 1-2 mm wider than the width of the tin-plated copper strip body.

[0009] In some embodiments of the present invention, the insulating layer is an insulating coating sprayed onto the surface of the tin-plated copper strip body.

[0010] Preferably, the material of the insulating coating is selected from at least one of polyethylene, polypropylene, epoxy resin and fluorocarbon paint.

[0011] Preferably, the insulating coating is transparent or metallic in color.

[0012] In some embodiments of the present invention, the insulating coating is sprayed on one side surface of the tin-plated copper strip body, or simultaneously sprayed on both sides of the tin-plated copper strip body.

[0013] In some embodiments of the present invention, the thickness of the insulating layer is 0.01~0.2 mm.

[0014] In some embodiments of the present invention, the tin-plated copper strip body and the insulating layer are combined to form a rollable strip structure and packaged in the form of a roll.

[0015] In some embodiments of the present invention, the roll form is adapted to thickness detection equipment and cutting equipment in the photovoltaic module manufacturing process.

[0016] A second aspect of the present invention provides a method for preparing the aforementioned insulating tin-plated copper strip prefabricated structure, comprising the following steps: Provide tin-plated copper strip body; An insulating layer is formed by bonding or spraying onto at least one surface of the tin-plated copper strip body; The tin-plated copper strip that has undergone insulation treatment is wound into a roll.

[0017] A third aspect of the present invention provides a photovoltaic module, comprising a plurality of cell strings and the insulating tin-plated copper strip prefabricated structure described in the first aspect.

[0018] The prefabricated structure of the insulating tin-plated copper strip is set in the gap between adjacent battery cell strings and contacts the back of the battery cell to achieve electrical insulation between the tin-plated copper strip body and the battery cell.

[0019] In some embodiments of the present invention, the photovoltaic module is a shingled structure module.

[0020] Compared with the prior art, the present invention has at least the following beneficial effects: The prefabricated structure of insulated tin-plated copper strip provided by this invention integrates the insulating layer and the tin-plated copper strip body into a single structure through bonding or spraying. This eliminates the separate placement process of PET insulating strip and EVA film in the original process, simplifying the manufacturing process, reducing the complexity caused by two placements, and thus lowering product costs. On the other hand, the integrated structure avoids relative displacement between the insulating layer and the tin-plated copper strip body, eliminating the need to design a wider insulating layer to accommodate displacement. At the same time, the insulation layer thickness can be precisely controlled, reducing the increase in module string spacing after lamination and improving the module appearance. Furthermore, the insulating layer directly contacts the back of the solar cell, fully utilizing its electrical insulation function to prevent short circuits and improving the electrical safety and long-term operational stability of photovoltaic modules in complex environments such as high humidity and high temperature. It also simplifies the module assembly process and reduces production costs.

[0021] The method for preparing the prefabricated structure of insulated tin-plated copper strip provided by this invention eliminates the need for complex multi-step operations, greatly simplifying the production process. It is easy to operate, and the bonding or spraying processes are readily automated, effectively improving production efficiency and reducing labor costs. The resulting insulating layer is tightly bonded to the tin-plated copper strip body, reducing the relative displacement between the insulating layer and the copper strip during subsequent assembly. Furthermore, the roll-up form facilitates storage, transportation, and continuous use in photovoltaic module assembly, further adapting to automated production lines and enhancing the overall continuity and stability of production.

[0022] The photovoltaic module provided by this invention, given the advantages of the aforementioned insulated tin-plated copper strip prefabricated structure, simplifies the photovoltaic module assembly process, adapts to automated production lines, improves assembly efficiency, and reduces labor costs; in terms of performance, it effectively avoids short-circuit risks; in terms of appearance and cost, it improves the consistency of module appearance, while the integrated structure reduces the overall product cost. Attached Figure Description

[0023] To more clearly illustrate the specific embodiments of the present invention or the technical solutions in the prior art, the drawings used in the description of the specific embodiments or the prior art will be briefly introduced below. Obviously, the drawings described below are some embodiments of the present invention. For those skilled in the art, other drawings can be obtained from these drawings without creative effort.

[0024] Figure 1 This is a schematic diagram of the structure of a shingled module in the prior art; Figure 2 This is a schematic diagram of an insulating tin-plated copper strip prefabricated structure provided in Example 1; Figure 3 This is a schematic diagram of another prefabricated structure for insulating tin-plated copper strip provided in Example 2; Figure 4This is a diagram of the packaging of a prefabricated structure of insulated tin-plated copper strip.

[0025] Explanation of key component symbols: 100-shingled module; 110-cell; 115-insulating tin-plated copper strip prefabricated structure; 120-tin-plated copper strip body; 130-insulating strip; 140-adhesive layer; 150-insulating layer; 200-reel core. Detailed Implementation

[0026] To make the objectives, technical solutions, and advantages of the present invention clearer, the technical solutions in the embodiments of the present invention will be clearly and completely described below in conjunction with the embodiments of the present invention. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments.

[0027] In the following, the terms “comprising,” “having,” and their cognates, which may be used in various embodiments of the invention, are intended only to indicate a particular feature, number, step, operation, element, component, or combination thereof, and should not be construed as excluding, firstly, the presence of one or more other features, numbers, steps, operations, elements, components, or combinations thereof, or adding the possibility of one or more features, numbers, steps, operations, elements, components, or combinations thereof.

[0028] Figure 1 The diagram shows a structural schematic of a shingled module 100 in the prior art. Several solar cells 110 are arranged in an array to form the main body of the shingled module 100. The string spacing space between adjacent solar cells 110 is used to arrange the tin-plated copper strip body 120. The insulating strip 130 is set between the tin-plated copper strip body 120 and the solar cells 110, covering the string spacing area to prevent short circuit between the tin-plated copper strip body 120 and the solar cells 110 due to contact, thus ensuring the power generation performance of the module.

[0029] According to a first aspect of the present invention, an insulating tin-plated copper strip prefabricated structure 115 includes: a tin-plated copper strip body 120 and an insulating layer 150 disposed on at least one side surface of the tin-plated copper strip body 120. The insulating layer 150 is formed on the tin-plated copper strip body 120 by bonding or spraying. The insulating layer 150 is used to contact the back of the solar cell 110 during the photovoltaic module assembly process to achieve electrical insulation.

[0030] The tin-plated copper strip prefabricated structure 115 provided by this invention integrates the insulating layer 150 and the tin-plated copper strip body 120 through bonding or spraying. This eliminates the separate placement process of the PET insulating strip 130 and EVA film in the original process, simplifying the manufacturing process, reducing the complexity caused by two placements, and thus reducing product costs. On the other hand, the integrated structure avoids relative displacement between the insulating layer 150 and the tin-plated copper strip body 120, eliminating the need to design a wider insulating layer 150 to accommodate displacement. At the same time, the thickness of the insulating layer 150 can be precisely controlled, reducing the increase in module string spacing after lamination and improving the module appearance. Furthermore, the insulating layer 150 directly contacts the back of the solar cell 110, which can fully exert its electrical insulation function, prevent short circuits, and improve the electrical safety and long-term operational stability of photovoltaic modules in complex environments such as high humidity and high temperature. It also simplifies the module assembly process and reduces production costs.

[0031] The insulated tin-plated copper strip prefabricated structure 115 is designed to meet the electrical connection and insulation requirements of the photovoltaic shingled module 100. It comprises two core components: a tin-plated copper strip body 120 and an insulating layer 150. The tin-plated copper strip body 120 serves as a conductive substrate, assuming the function of current collection in the photovoltaic module. The insulating layer 150 is applied to at least one side of the tin-plated copper strip body 120 through bonding or spraying processes, forming an integrated structure. In photovoltaic module assembly scenarios, the insulating layer 150 directly contacts the back of the solar cell 110. Utilizing its own insulating properties, it blocks the electrical conduction path between the tin-plated copper strip body 120 and the solar cell 110, avoiding short-circuit risks. Simultaneously, relying on the compatibility of bonding / spraying processes, it ensures the stability of the bond between the insulating layer 150 and the tin-plated copper strip body 120. This simplifies the assembly process for photovoltaic module insulation protection and, through integrated structural design, improves the electrical reliability of the product in complex environments, providing fundamental support for the efficient and stable operation of the shingled module 100.

[0032] In some embodiments of the present invention, the insulating layer 150 is a transparent PET tape, which is composed of a PET insulating layer 150 and an adhesive layer disposed on one side thereof, and the width of the transparent PET tape is 1-2 mm wider than the width of the tin-plated copper strip body 120.

[0033] In some embodiments of the present invention, the insulating layer 150 is made of transparent PET tape, and its structure is composed of a PET insulating layer 150 and a single-sided adhesive layer. The PET insulating layer 150, with its excellent electrical insulation properties, can effectively block the conductive path between the tin-plated copper strip body 120 and the back of the solar cell 110. The adhesive layer serves a dual function: on the one hand, through the bonding process, it achieves a stable bond between the transparent PET tape and the tin-plated copper strip body 120, constructing an integrated prefabricated structure and simplifying the insulation protection process during photovoltaic module assembly; on the other hand, in process steps such as module lamination, the buffering properties of the adhesive adapt to changes in thermal and mechanical stress between the solar cell 110 and the tin-plated copper strip, reducing the risk of microcracks and breakage of the solar cell 110.

[0034] Meanwhile, the width of the transparent PET tape is designed to be 1-2 mm wider than the tin-plated copper strip body 120. This dimensional difference accommodates the potential relative displacement between the tin-plated copper strip and the insulation layer 150 during photovoltaic module assembly, ensuring that even with displacement deviations, the insulation layer 150 can still completely cover the contact area between the tin-plated copper strip body 120 and the solar cell 110, preventing short circuits caused by insulation failure. This insulation layer 150 design, based on material properties, process adaptability, and operational redundancy, utilizes the insulation stability of PET material and improves the reliability and ease of assembly of the prefabricated structure throughout the entire lifecycle of the photovoltaic module through structural composite and dimensional optimization, providing a more practical technical path for the insulation protection of the shingled module 100.

[0035] In some embodiments of the present invention, the insulating layer 150 is an insulating coating sprayed onto the surface of the tin-plated copper strip body 120. The spraying process uniformly covers the copper strip surface with insulating material, forming an integrated insulating structure tightly bonded to the tin-plated copper strip body 120. This process eliminates the need for an additional adhesive layer, simplifying the prefabrication process, reducing material usage, further lowering costs, and preventing the insulating layer 150 from detaching due to adhesive aging, thus improving the long-term stability of the structure.

[0036] Preferably, the insulating coating material is selected from at least one of polyethylene, polypropylene, epoxy resin, and fluorocarbon varnish. These materials all possess excellent electrical insulation properties, effectively blocking current conduction between the tin-plated copper strip and the solar cell 110, and exhibit good weather resistance, high-temperature resistance, and chemical stability. They can adapt to the complex environments faced by photovoltaic modules during long-term outdoor use, such as high temperature, high humidity, and ultraviolet radiation, ensuring the durability of the insulation effect. Epoxy resin has strong adhesion and can form a firm bond with the surface of the tin-plated copper strip; fluorocarbon varnish has excellent corrosion resistance and aging resistance, further extending the service life of the insulating coating. The selection of different materials can be flexibly adapted according to the module's usage environment and performance requirements.

[0037] Preferably, the insulating coating is transparent or metallic. A transparent coating does not obscure the internal structure of the photovoltaic module, facilitating visual inspection during subsequent production processes and ensuring the consistency of the overall appearance of the module. A metallic coating, in addition to its insulating function, can also provide some light-shielding or decorative effects, adapting to the appearance requirements of different module designs. This flexibility in appearance design allows the prefabricated structure to better accommodate the production processes and appearance standards of various photovoltaic modules, thus expanding its applicability.

[0038] In some embodiments of the present invention, the insulating coating is sprayed onto one side surface of the tin-plated copper strip body 120, or simultaneously onto both sides of the tin-plated copper strip body 120. The spraying position of the insulating coating can be flexibly adjusted according to actual insulation requirements: it can be sprayed only onto one side surface of the tin-plated copper strip body 120, specifically covering the area in contact with the back of the solar cell 110, reducing material consumption while meeting basic insulation requirements; or it can be sprayed simultaneously onto both sides of the edge, forming a wrap-around protection for the copper strip edge, which is particularly suitable for scenarios where the copper strip edge may come into contact with the solar cell 110 or other conductive components, further improving insulation redundancy and avoiding the risk of local short circuits caused by assembly deviations. This differentiated spraying design can adapt to the structural layout of different photovoltaic modules.

[0039] In some embodiments of the present invention, the thickness of the insulating layer 150 is 0.01~0.2mm, which ensures that the insulating layer 150 has sufficient electrical insulation strength to effectively block current conduction, and also minimizes the impact on the string spacing of the photovoltaic module. Compared with the combined thickness of the traditional PET insulating strip 130 and EVA film, the thinner insulating layer 150 can significantly reduce the expansion of the string spacing after lamination, which helps to improve the flatness and consistency of the module appearance.

[0040] In some embodiments of the present invention, the tin-plated copper strip body 120 and the insulating layer 150 are combined to form a rollable strip structure, which is packaged in the form of a roll, meeting the flow requirements of automated production of photovoltaic modules: the roll packaging facilitates storage and transportation and can reduce structural damage during handling; at the same time, the strip structure can be directly adapted to the continuous feeding mechanism of the production line without additional cutting pretreatment, which greatly improves assembly efficiency.

[0041] In some embodiments of the present invention, the reel form is adapted to the thickness detection and cutting equipment in the photovoltaic module manufacturing process, and can complete the cutting according to specifications without additional adjustment of equipment parameters. This adaptability design allows the prefabricated structure 115 of the insulating tin-plated copper strip to be directly integrated into the existing photovoltaic module production line, without requiring enterprises to replace key equipment such as thickness detection and cutting equipment to introduce the new structure, nor requiring large-scale modification of the production line's process flow and equipment layout, thereby minimizing the enterprise's equipment investment costs and production line adjustment risks, and ensuring the continuity and stability of production.

[0042] A second aspect of the present invention provides a method for preparing the insulating tin-plated copper strip prefabricated structure 115, comprising the following steps: Provide 120 tin-plated copper strip body; An insulating layer 150 is formed by bonding or spraying onto at least one surface of the tin-plated copper strip body 120. The tin-plated copper strip that has undergone insulation treatment is wound into a roll.

[0043] The method for preparing the insulated tin-plated copper strip prefabricated structure 115 provided by this invention eliminates the need for complex multi-step operations, significantly simplifying the production process. It is convenient to operate, and the bonding or spraying processes are easily automated, effectively improving production efficiency and reducing labor costs. The formed insulating layer 150 is tightly bonded to the tin-plated copper strip body 120, reducing the relative displacement between the insulating layer 150 and the copper strip during subsequent assembly. Furthermore, the roll-up form facilitates storage, transportation, and continuous use in photovoltaic module assembly, further adapting to automated production lines and improving the overall continuity and stability of production. A third aspect of this invention provides a photovoltaic module comprising multiple strings of solar cells 110 and the insulated tin-plated copper strip prefabricated structure 115 described in the first aspect.

[0044] The prefabricated structure 115 of the insulating tin-plated copper strip is disposed in the gap between adjacent battery cells 110 strings and contacts the back of the battery cell 110 to achieve electrical insulation between the tin-plated copper strip body 120 and the battery cell 110.

[0045] The photovoltaic module provided by this invention, given the advantages of the aforementioned insulated tin-plated copper strip prefabricated structure 115, simplifies the photovoltaic module assembly process, adapts to automated production lines, improves assembly efficiency, and reduces labor costs; in terms of performance, it effectively avoids short-circuit risks; in terms of appearance and cost, it improves the consistency of module appearance, while the integrated structure reduces the overall product cost.

[0046] In some embodiments of the present invention, the photovoltaic module is a shingled structure module.

[0047] The present invention is further illustrated below with specific embodiments and comparative examples. However, it should be understood that these embodiments are merely for illustrative purposes and should not be construed as limiting the invention in any way. Unless otherwise specified, the raw materials used in the embodiments and comparative examples of the present invention were carried out under conventional conditions or conditions recommended by the manufacturer. Reagents or instruments used, unless otherwise specified, are all commercially available conventional products.

[0048] Example 1 This embodiment provides an insulating tin-plated copper strip prefabricated structure 115, such as Figure 2 As shown: the tin-plated copper strip body 120 is a conductive substrate that undertakes the current collection function of the photovoltaic module. Its surface is tin-plated, which has both conductivity and oxidation resistance. The adhesive layer 140 (or adhesive layer) is tightly attached to the surface of the tin-plated copper strip body 120, which plays a bonding and fixing role, so that the insulating layer 150 and the tin-plated copper strip body 120 form an integrated structure.

[0049] Example 2 This embodiment provides an insulating tin-plated copper strip prefabricated structure 115, such as Figure 3 As shown: The tin-plated copper strip body 120 is coated with an insulating coating through a spraying process. This insulating coating prevents electrical connection between the tin-plated copper strip body 120 and components such as the battery cell 110, thus avoiding the risk of short circuit.

[0050] The materials can be polyethylene, polypropylene, epoxy resin or fluorocarbon paint. These materials have electrical insulation properties, are suitable for outdoor use of photovoltaic modules, and provide electrical safety and stable operation when the prefabricated structure is applied to photovoltaic modules. They achieve integrated conductivity and insulation protection, simplify the photovoltaic module assembly process, and improve production efficiency and product reliability.

[0051] After the tin-plated copper strip prefabricated structures obtained in Examples 2 and 3 are produced, they can both be processed... Figure 4 The packaging is done in a reel format for easy storage, transportation, and subsequent use. The insulated tin-plated copper strip prefabricated structure 115 is wound around the reel core 200. The reel core 200 serves as a support core, supporting the strip material of the insulated tin-plated copper strip prefabricated structure 115. The reel core 200 is typically a cylindrical structure made of materials with sufficient strength and stability (such as plastic, metal, or composite materials) to ensure structural integrity during transportation and use.

[0052] Finally, it should be noted that the above-described embodiments are merely specific implementations of the present invention, used to illustrate the technical solutions of the present invention, and not to limit it. The scope of protection of the present invention is not limited thereto. Although the present invention has been described in detail with reference to the foregoing embodiments, those skilled in the art should understand that any person skilled in the art can still modify or easily conceive of changes to the technical solutions described in the foregoing embodiments within the technical scope disclosed in the present invention, or make equivalent substitutions for some of the technical features; and these modifications, changes, or substitutions do not cause the essence of the corresponding technical solutions to deviate from the spirit and scope of the technical solutions of the embodiments of the present invention, and should all be covered within the scope of protection of the present invention. Therefore, the scope of protection of the present invention should be determined by the scope of the claims.

Claims

1. A prefabricated structure for insulating tin-plated copper strip, characterized in that, include: A tin-plated copper strip body and an insulating layer disposed on at least one side surface of the tin-plated copper strip body; The insulating layer is formed on the tin-plated copper strip body by bonding or spraying. The insulating layer is used to contact the back of the solar cell during the assembly of the photovoltaic module to achieve electrical insulation.

2. The prefabricated structure of insulating tin-plated copper strip according to claim 1, characterized in that, The insulating layer is a transparent PET tape, which consists of a PET insulating layer and an adhesive layer disposed on one side thereof. The width of the transparent PET tape is 1-2 mm wider than the width of the tin-plated copper strip body.

3. The prefabricated structure of insulating tin-plated copper strip according to claim 1, characterized in that, The insulating layer is an insulating coating sprayed onto the surface of the tin-plated copper strip body; Preferably, the material of the insulating coating is selected from at least one of polyethylene, polypropylene, epoxy resin and fluorocarbon paint; Preferably, the insulating coating is transparent or metallic in color.

4. The prefabricated structure of insulating tin-plated copper strip according to claim 3, characterized in that, The insulating coating is sprayed onto one side of the tin-plated copper strip body, or simultaneously onto both sides of the tin-plated copper strip body.

5. The prefabricated structure of insulating tin-plated copper strip according to any one of claims 1 to 4, characterized in that, The thickness of the insulating layer is 0.01~0.2mm.

6. The prefabricated structure of insulating tin-plated copper strip according to any one of claims 1 to 4, characterized in that, The tin-plated copper strip body and the insulating layer are combined to form a rollable strip structure, which is then packaged in the form of a roll.

7. The prefabricated structure of insulating tin-plated copper strip according to claim 6, characterized in that, The reel design is compatible with thickness detection and cutting equipment used in the photovoltaic module manufacturing process.

8. A method for preparing an insulating tin-plated copper strip prefabricated structure as described in any one of claims 1 to 7, characterized in that, Includes the following steps: Provide tin-plated copper strip body; An insulating layer is formed by bonding or spraying onto at least one surface of the tin-plated copper strip body; The tin-plated copper strip that has undergone insulation treatment is wound into a roll.

9. A photovoltaic module, characterized in that, Includes multiple battery cell strings and the prefabricated structure of insulating tin-plated copper strip as described in any one of claims 1 to 7; The prefabricated structure of the insulating tin-plated copper strip is set in the gap between adjacent battery cell strings and contacts the back of the battery cell to achieve electrical insulation between the tin-plated copper strip body and the battery cell.

10. The photovoltaic module according to claim 9, characterized in that, The photovoltaic module is a shingled structure module.

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