Photovoltaic module and method of manufacturing the same

Abstract

The application relates to a photovoltaic module and a preparation method thereof. The photovoltaic module comprises a packaging panel, a first packaging adhesive film, a cell piece, a second packaging adhesive film and a packaging back plate which are arranged in a stack; the photovoltaic module further comprises a first barrier layer and / or a second barrier layer; the first barrier layer is arranged between the packaging panel and the first packaging adhesive film; and the second barrier layer is arranged between the second packaging adhesive film and the packaging back plate. The barrier layer comprises a polymer matrix and barrier-enhancing particles; the polymer matrix is selected from at least one of polyvinylidene fluoride, polytetrafluoroethylene and polyvinylidene chloride; and the barrier-enhancing particles are selected from at least one of nano-aluminum oxide, nano-titanium dioxide and nano-silicon dioxide. By arranging the barrier layer, the photovoltaic module has good salt mist corrosion resistance.

Description

TECHNICAL FIELD

[0001] The present application relates to the field of photovoltaic technology, in particular to a photovoltaic module and a preparation method thereof. BACKGROUND

[0002] With the continuous growth of renewable energy demand, offshore photovoltaic power generation has attracted widespread attention due to its advantages of not occupying land resources, sufficient sunlight, good cooling effect, etc. However, the marine environment has characteristics such as high salt fog, high humidity, strong ultraviolet radiation, and frequent temperature and humidity cycles, which pose a severe challenge to the reliability and service life of photovoltaic modules.

[0003] One of the core problems that traditional photovoltaic modules face in the marine environment is salt fog corrosion. Chloride ions in the marine environment can penetrate the packaging material and penetrate into the cell and metal electrode, causing electrochemical corrosion, and ultimately leading to power attenuation or even failure of the module. SUMMARY

[0004] Therefore, it is necessary to provide a photovoltaic module and a preparation method thereof to improve the salt fog corrosion resistance.

[0005] A first aspect of the present application provides a photovoltaic module, and the scheme is as follows:

[0006] A photovoltaic module, comprising a packaging panel, a first packaging adhesive film, a cell, a second packaging adhesive film, and a packaging backboard which are stacked.

[0007] The photovoltaic module further comprises a first barrier layer and / or a second barrier layer, the first barrier layer is arranged between the packaging panel and the first packaging adhesive film, and the second barrier layer is arranged between the second packaging adhesive film and the packaging backboard; the first barrier layer comprises a first polymer matrix and first barrier enhancement particles dispersed in the first polymer matrix, the first polymer matrix is selected from at least one of polyvinylidene fluoride, polytetrafluoroethylene, and polyvinylidene chloride, and the first barrier enhancement particles are selected from at least one of nano-aluminum oxide, nano-titanium dioxide, and nano-silicon dioxide; the second barrier layer comprises a second polymer matrix and second barrier enhancement particles dispersed in the second polymer matrix, the second polymer matrix is selected from at least one of polyvinylidene fluoride, polytetrafluoroethylene, and polyvinylidene chloride, and the second barrier enhancement particles are selected from at least one of nano-aluminum oxide, nano-titanium dioxide, and nano-silicon dioxide.

[0008] In some embodiments, in the first barrier layer, the mass ratio of the first polymer matrix and the first barrier enhancement particles is (1.5-20):1.

[0009] In some embodiments, the mass ratio of the second polymer matrix to the second barrier reinforcing particles in the second barrier layer is (1.5~20):1.

[0010] In some embodiments, the first encapsulating film includes a first film substrate and a first filler dispersed in the first film substrate, wherein the first film substrate is selected from at least one of POE, EPE and EVA, and the first filler is selected from at least one of nano zinc oxide, nano titanium dioxide and graphene.

[0011] In some embodiments, the second encapsulating film includes a second film substrate and a second filler dispersed in the second film substrate, wherein the second film substrate is selected from at least one of POE, EPE and EVA, and the second filler is selected from at least one of nano zinc oxide, nano titanium dioxide and graphene.

[0012] In some embodiments, the photovoltaic module further includes a hydrophobic self-cleaning coating disposed on the side of the encapsulation panel opposite to the first encapsulation film.

[0013] In some embodiments, the hydrophobic self-cleaning coating comprises nano-silica particles with a surface modified with fluorinated silanes.

[0014] In some embodiments, the photovoltaic module further includes a nano-silica porous film layer disposed between the hydrophobic self-cleaning coating and the encapsulation panel.

[0015] In some embodiments, the photovoltaic module further includes an edge sealing structure comprising a sealant and a frame that wraps around the edges of the encapsulation panel and the encapsulation backplate and the layers between them, with the sealant filling the inside of the frame.

[0016] In some embodiments, the sealant comprises butyl rubber and an organosilicon silicone located between the butyl rubber and the frame, wherein nano-silica is dispersed in the organosilicon silicone.

[0017] In some embodiments, the surface of the frame is provided with a fluorocarbon paint layer.

[0018] The second aspect of this application is to provide a method for preparing a photovoltaic module, the scheme of which is as follows:

[0019] A method for manufacturing a photovoltaic module includes the following steps:

[0020] The package comprises a stacked encapsulation panel, a first encapsulation film, a battery cell, a second encapsulation film, and an encapsulation backplane. A first barrier layer is further disposed between the encapsulation panel and the first encapsulation film, and / or a second barrier layer is further disposed between the second encapsulation film and the encapsulation backplane. The first barrier layer comprises a first polymer matrix and first barrier reinforcing particles dispersed in the first polymer matrix. The first polymer matrix is ​​selected from at least one of polyvinylidene fluoride, polytetrafluoroethylene, and polyvinylidene chloride. The first barrier reinforcing particles are selected from at least one of nano-alumina, nano-titanium dioxide, and nano-silica. The second barrier layer comprises a second polymer matrix and second barrier reinforcing particles dispersed in the second polymer matrix. The second polymer matrix is ​​selected from at least one of polyvinylidene fluoride, polytetrafluoroethylene, and polyvinylidene chloride. The second barrier reinforcing particles are selected from at least one of nano-alumina, nano-titanium dioxide, and nano-silica.

[0021] Lamination process.

[0022] Compared with traditional methods, the above-mentioned photovoltaic modules and their manufacturing methods have the following advantages:

[0023] The aforementioned photovoltaic module and its preparation method include a first barrier layer between the encapsulation panel and the first encapsulation film, and / or a second barrier layer between the second encapsulation film and the encapsulation backsheet. In these barrier layers, the polymer matrix is ​​selected from at least one of polyvinylidene fluoride, polytetrafluoroethylene, and polyvinylidene chloride, possessing excellent chemical stability and strong hydrophobicity. The strong electronegativity of its fluorine or chlorine atoms creates a shielding effect, inhibiting the penetration of salt ion corrosive media. By adding at least one of nano-alumina, nano-titanium dioxide, and nano-silica, a physical barrier can be formed, extending the penetration path of corrosive media and reducing the porosity of the film layer, improving structural density, and reducing the penetration rate of salt ion corrosive media. Therefore, the salt spray corrosion resistance of the photovoltaic module can be improved. Attached Figure Description

[0024] Figure 1 This is a schematic diagram of the structure of a photovoltaic module according to one embodiment.

[0025] Explanation of reference numerals in the attached figures:

[0026] 10. Photovoltaic module; 110. Encapsulation panel; 120. First encapsulation film; 130. Solar cell; 140. Second encapsulation film; 150. Encapsulation backsheet; 160. First barrier layer; 170. Second barrier layer; 180. Hydrophobic self-cleaning coating; 190. Nano-silica porous membrane layer; 200. Edge sealing structure; 210. Sealant; 211. Butyl rubber; 212. Silicone gel; 220. Frame. Detailed Implementation

[0027] To make the above-mentioned objectives, features, and advantages of this application more apparent and understandable, the specific embodiments of this application are described in detail below with reference to the accompanying drawings. Many specific details are set forth in the following description to provide a thorough understanding of this application. However, this application can be implemented in many other ways different from those described herein, and those skilled in the art can make similar modifications without departing from the spirit of this application. Therefore, this application is not limited to the specific embodiments disclosed below.

[0028] In the description of this application, it should be understood that the terms "center", "longitudinal", "lateral", "length", "width", "thickness", "upper", "lower", "front", "rear", "left", "right", "vertical", "horizontal", "top", "bottom", "inner", "outer", "clockwise", "counterclockwise", "axial", "radial", "circumferential", etc., indicating the orientation or positional relationship based on the orientation or positional relationship shown in the accompanying drawings, are only for the convenience of describing this application and simplifying the description, and do not indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation, and therefore should not be construed as a limitation of this application.

[0029] Furthermore, the terms "first" and "second" are used for descriptive purposes only and should not be construed as indicating or implying relative importance or implicitly specifying the number of technical features indicated. Thus, a feature defined as "first" or "second" may explicitly or implicitly include at least one of that feature. In the description of this application, "multiple" means at least two, such as two, three, etc., unless otherwise explicitly specified.

[0030] In this application, unless otherwise expressly specified and limited, the terms "installation," "connection," "joining," and "fixing," etc., should be interpreted broadly. For example, they can refer to a fixed connection, a detachable connection, or an integral part; they can refer to a mechanical connection or an electrical connection; they can refer to a direct connection or an indirect connection through an intermediate medium; they can refer to the internal communication of two components or the interaction between two components, unless otherwise expressly limited. Those skilled in the art can understand the specific meaning of the above terms in this application according to the specific circumstances.

[0031] Unless otherwise defined, all technical and scientific terms used herein have the same meaning as commonly understood by one of ordinary skill in the art to which this application belongs. The terminology used herein is for the purpose of describing particular embodiments only and is not intended to be limiting of the application. The term "and / or" as used herein includes any and all combinations of one or more of the associated listed items.

[0032] like Figure 1As shown, a photovoltaic module 10 in one embodiment includes a stacked encapsulation panel 110, a first encapsulation film 120, a solar cell 130, a second encapsulation film 140, and an encapsulation backplate 150.

[0033] Specifically, the photovoltaic module 10 further includes a first barrier layer 160 and / or a second barrier layer 170. The first barrier layer 160 is disposed between the encapsulation panel 110 and the first encapsulation film 120. The first barrier layer 160 includes a first polymer matrix and first barrier reinforcing particles dispersed in the first polymer matrix. The first polymer matrix is ​​selected from at least one of polyvinylidene fluoride, polytetrafluoroethylene, and polyvinylidene chloride. The first barrier reinforcing particles are selected from at least one of nano-alumina, nano-titanium dioxide, and nano-silica. The second barrier layer 170 is disposed between the second encapsulation film 140 and the encapsulation backsheet 150. The second barrier layer 170 includes a second polymer matrix and second barrier reinforcing particles dispersed in the second polymer matrix. The second polymer matrix is ​​selected from at least one of polyvinylidene fluoride, polytetrafluoroethylene, and polyvinylidene chloride. The second barrier reinforcing particles are selected from at least one of nano-alumina, nano-titanium dioxide, and nano-silica.

[0034] In the aforementioned barrier layer, the polymer matrix is ​​selected from at least one of polyvinylidene fluoride, polytetrafluoroethylene, and polyvinylidene chloride, possessing excellent chemical stability and strong hydrophobicity. The strong electronegativity of its fluorine or chlorine atoms creates a shielding effect, inhibiting the penetration of corrosive media such as chloride ions. By adding at least one of nano-alumina, nano-titanium dioxide, and nano-silica, a physical barrier can be formed, extending the penetration path of the corrosive medium, reducing the porosity of the film, improving structural density, and decreasing the penetration rate of corrosive media caused by salt ions.

[0035] The aforementioned barrier layer achieves a chloride ion blocking efficiency of over 99%. The aforementioned photovoltaic module 10 showed no significant corrosion after more than 1000 hours of salt spray testing.

[0036] In some examples, the mass ratio of the first polymer matrix to the first barrier reinforcing particles in the first barrier layer 160 is (1.5~20):1, specifically, for example, 2:1, 5:1, 10:1, 12:1, 15:1, 19:1, etc. Within the above ratio range, the first barrier layer 160 can effectively block salt ions and moisture, and has high light transmittance, without affecting the light absorption of the solar cell 130.

[0037] In some examples, the thickness of the first barrier layer 160 is 50μm to 100μm, specifically, for example, 50μm, 55μm, 60μm, 65μm, 70μm, 75μm, 80μm, 85μm, 90μm, 95μm, 100μm, etc.

[0038] In some examples, the mass ratio of the second polymer matrix to the second barrier reinforcing particles in the second barrier layer 170 is (1.5~20):1, specifically, for example, 2:1, 5:1, 10:1, 12:1, 15:1, 19:1, etc. Within the above ratio range, the second barrier layer 170 can effectively block salt ions and moisture, and has high light transmittance, without affecting the light absorption of the solar cell 130.

[0039] In some examples, the thickness of the second barrier layer 170 is 50μm to 100μm, specifically, for example, 50μm, 55μm, 60μm, 65μm, 70μm, 75μm, 80μm, 85μm, 90μm, 95μm, 100μm, etc.

[0040] In some of these examples, the encapsulation panel 110 is made of glass. In some of these examples, the encapsulation panel 110 is made of ultra-clear tempered glass. The iron content of the encapsulation panel 110 is less than 110 ppm. The light transmittance of the encapsulation panel 110 is above 92%, for example, 92% to 99%.

[0041] In some of these examples, the thickness of the encapsulation panel 110 is 2mm to 10mm, specifically 2μm, 4μm, 6μm, 8μm, 10mm, etc.

[0042] In some examples, the first encapsulating film 120 includes a first film substrate and a first filler dispersed in the first film substrate. The first film substrate is selected from at least one of POE, EPE, and EVA. The first filler is selected from at least one of nano-zinc oxide, nano-titanium dioxide, and graphene. In some examples, the first film substrate is selected as POE. POE has high resistance to PID (potential-induced degradation) and good hydrolysis resistance, as well as excellent ultraviolet (UV) resistance and anti-yellowing ability. Filling with at least one of nano-zinc oxide, nano-titanium dioxide, and graphene can form a synergistic weather-resistant system with POE, improving the UV shielding performance and aging resistance of the first encapsulating film 120.

[0043] In some of these examples, the mass ratio of the first film matrix to the first filler is (1.5~20):1, specifically, for example, 2:1, 5:1, 10:1, 12:1, 15:1, 19:1, etc.

[0044] In some of these examples, the volume resistivity of the first encapsulating film 120 is 1 × 10⁻⁶. 16 Ω·cm and above, such as 1×10 16 Ω·cm ~9×10 16 Ω·cm.

[0045] In some examples, the thickness of the first encapsulating film 120 is 400μm to 600μm, specifically 400μm, 450μm, 500μm, 550μm, 600μm, etc.

[0046] In some examples, the second encapsulating film 140 includes a second film substrate and a second filler dispersed in the second film substrate. The second film substrate is selected from at least one of POE, EPE, and EVA. The second filler is selected from at least one of nano-zinc oxide, nano-titanium dioxide, and graphene. In some examples, the second film substrate is selected from POE.

[0047] In some examples, the mass ratio of the second film matrix to the second filler is (1.5~20):1, specifically, for example, 2:1, 5:1, 10:1, 12:1, 15:1, 19:1, etc.

[0048] In some of these examples, the volume resistivity of the second encapsulating film 140 is 1 × 10⁻⁶. 16 Ω·cm and above, such as 1×10 16 Ω·cm ~9×10 16 Ω·cm.

[0049] In some examples, the thickness of the second encapsulating film 140 is 400μm to 600μm, specifically 400μm, 450μm, 500μm, 550μm, 600μm, etc.

[0050] In some of these examples, the photovoltaic module 10 also includes a hydrophobic self-cleaning coating 180. The hydrophobic self-cleaning coating 180 is disposed on the side of the encapsulation panel 110 facing away from the first encapsulation film 120.

[0051] In some examples, the hydrophobic self-cleaning coating 180 includes nano-silica particles with a surface modified with a fluorinated silane. The aforementioned hydrophobic self-cleaning coating 180 possesses superhydrophobicity and self-cleaning properties, reducing salt deposition on the component surface. The component surface can be automatically cleaned by rainwater, improving resistance to salt spray corrosion. The fluorinated silane is, for example, but not limited to, perfluorooctyltriethoxysilane. Perfluorooctyltriethoxysilane has a large number of fluorine atoms and long-chain alkyl groups, exhibiting low surface energy, which can significantly improve the hydrophobicity of the encapsulation panel 110 surface.

[0052] In some of these examples, the mass ratio of nano-silica particles to fluorinated silane is (2.5~100):1, specifically, for example, 5:1, 10:1, 20:1, 40:1, 60:1, 80:1, 100:1, etc.

[0053] In some of these examples, the water contact angle of the hydrophobic self-cleaning coating 180 is above 150°, such as 150°~175°.

[0054] In some of these examples, the thickness of the hydrophobic self-cleaning coating 180 is 0.5 μm to 2 μm, specifically for example, 0.5 μm, 0.7 μm, 0.9 μm, 1.1 μm, 1.3 μm, 1.5 μm, 1.7 μm, 1.9 μm, 2 μm, etc.

[0055] In some of these examples, the photovoltaic module 10 also includes a nano-silica porous film layer 190. The nano-silica porous film layer 190 is disposed between the hydrophobic self-cleaning coating 180 and the encapsulation panel 110.

[0056] The nano-silica porous film 190 is prepared, for example, by sol-gel method or magnetron sputtering, forming a porous or cavity structure and reducing the refractive index of the film. The refractive index of the nano-silica porous film 190 is about 1.32, forming a transition between air (refractive index 1) and glass (refractive index 1.52), reducing interface reflection loss and effectively reducing reflectivity.

[0057] In some examples, the thickness of the nano-silica porous film 190 is 100nm~275nm, specifically 100nm, 130nm, 160nm, 190nm, 220nm, 250nm, 275nm, etc. This film thickness is 1 / 4 of the main wavelength band of sunlight (400nm~1100nm), resulting in a 180° phase difference between the reflected light from the upper and lower interfaces. These phase differences cancel each other out, significantly reducing the intensity of the reflected light.

[0058] In some of these examples, the encapsulation backplane 150 is made of glass. In some of these examples, the encapsulation backplane 150 is made of ultra-clear tempered glass. The iron content of the encapsulation backplane 150 is less than 110 ppm. The light transmittance of the encapsulation backplane 150 is above 92%, for example, 92% to 99%.

[0059] In some of these examples, the thickness of the package backplane 150 is 2μm to 10mm, specifically 2μm, 4μm, 6μm, 8μm, 10mm, etc.

[0060] In some examples, the photovoltaic module 10 also includes an edge sealing structure 200. The edge sealing structure 200 includes sealant 210 and a frame 220. The frame 220 encapsulates the edges of the encapsulation panel 110 and the encapsulation backplate 150, as well as the layers between them. The sealant 210 fills the inside of the frame 220.

[0061] In some of these examples, sealant 210 includes butyl rubber 211 and silicone 212 located between butyl rubber 211 and frame 220.

[0062] The edges of photovoltaic modules are the main channels for moisture and salt spray intrusion. In the example above, the complementary material properties of butyl rubber 211 and silicone rubber 212 optimize sealing reliability. The excellent initial sealing performance and moisture barrier ability of butyl rubber 211 combined with the high and low temperature resistance and UV aging resistance of silicone rubber 212 improve the module's adaptability to harsh conditions such as drastic temperature and humidity fluctuations and strong ultraviolet radiation in the marine environment.

[0063] In some examples, nano-silica is dispersed in silicone 212. Filling with nano-silica improves the moisture barrier properties and mechanical strength of silicone 212. The mass fraction of nano-silica in silicone 212 is, for example, 5% to 10%, specifically, 5%, 6%, 7%, 8%, 9%, 10%, etc.

[0064] In some of these examples, the frame 220 is made of anodized aluminum alloy.

[0065] Traditional aluminum alloy frames 220 are prone to pitting corrosion and stress corrosion cracking in salt spray environments. In the examples above, forming an anodic oxide layer on the aluminum alloy effectively improves its corrosion resistance. In some examples, the thickness of the anodic oxide layer is greater than 20 μm, for example, 20 μm to 50 μm, specifically 20 μm, 30 μm, 40 μm, 50 μm, etc.

[0066] In some examples, the surface of the frame 220 is coated with a fluorocarbon paint layer. The fluorocarbon paint layer effectively improves the corrosion resistance of the frame 220. In some examples, the thickness of the fluorocarbon paint layer is 10μm to 50μm, specifically, for example, 10μm, 20μm, 30μm, 40μm, 50μm, etc.

[0067] Furthermore, this application also provides a method for preparing a photovoltaic module 10 according to any of the above examples.

[0068] A method for manufacturing a photovoltaic module 10 according to one embodiment includes the following steps:

[0069] Step S1: A stacked encapsulation panel 110, a first encapsulation film 120, a battery cell 130, a second encapsulation film 140, and an encapsulation backplate 150 are configured. A first barrier layer 160 is further provided between the encapsulation panel 110 and the first encapsulation film 120, and / or a second barrier layer 170 is further provided between the second encapsulation film 140 and the encapsulation backplate 150.

[0070] Step S2, lamination process.

[0071] In some of these examples, the method for manufacturing the photovoltaic module 10 further includes the following steps:

[0072] A hydrophobic self-cleaning coating 180 is prepared on the side of the encapsulation panel 110 opposite to the first encapsulation film 120.

[0073] In some of these examples, the hydrophobic self-cleaning coating 180 comprises nano-silica particles with a surface modified with fluorinated silanes.

[0074] In some of these examples, the method for preparing the hydrophobic self-cleaning coating 180 includes the following steps:

[0075] Nano-silica is dispersed in a dispersion solvent, fluorinated silane is added, and the mixture is stirred to react, thus obtaining a coating.

[0076] The coating is applied to the encapsulation panel 110 and dried to form a hydrophobic self-cleaning coating 180.

[0077] In some of these examples, the method for preparing the photovoltaic module 10 prior to preparing the hydrophobic self-cleaning coating 180 further includes the following steps:

[0078] A nano-silica porous film layer 190 is prepared on the side of the encapsulation panel 110 opposite to the first encapsulation film 120.

[0079] In the above example, the nano-silica porous film layer 190 is disposed between the hydrophobic self-cleaning coating 180 and the encapsulation panel 110.

[0080] In some of these examples, the method for manufacturing the photovoltaic module 10 further includes the following steps:

[0081] Mounting frame 220, which wraps around the package panel 110 and the package backplate 150 as well as the edges of each layer between them;

[0082] Inject sealant 210 into the inside of the frame 220.

[0083] The following specific embodiments further illustrate this application. These specific embodiments are provided to better understand this application, but are not limited to them and do not constitute a limitation on the content or scope of protection of this application.

[0084] Example 1

[0085] The photovoltaic module provided in this embodiment includes a laminated structure and an edge-sealing structure. The laminated structure includes a stacked encapsulation panel, a first barrier layer, a first encapsulation film, solar cells, a second encapsulation film, a second barrier layer, and an encapsulation backplate.

[0086] The encapsulation panel is made of ultra-clear tempered glass. The iron content of the encapsulation panel is less than 110 ppm. The light transmittance of the encapsulation panel is 92%. The thickness of the encapsulation panel is 2 μm.

[0087] A porous nano-silica film and a hydrophobic self-cleaning coating are disposed on the side of the encapsulation panel opposite to the first encapsulating film. The porous nano-silica film is disposed between the hydrophobic self-cleaning coating and the encapsulation panel. The hydrophobic self-cleaning coating comprises nano-silica particles with a surface modified with perfluorooctyltriethoxysilane. The thickness of the hydrophobic self-cleaning coating is 1 μm. The thickness of the porous nano-silica film is 200 nm.

[0088] The first barrier layer comprises polyvinylidene fluoride (PVDF) and nano-alumina dispersed within the PVDF. The mass ratio of PVDF to nano-alumina is 9:1. The thickness of the first barrier layer is 80 μm.

[0089] The first encapsulating film comprises a POE film matrix and nano-zinc oxide dispersed within the POE film matrix. The mass ratio of the POE film matrix to the nano-zinc oxide is 19:1. The thickness of the first encapsulating film is 500 μm.

[0090] The second encapsulating film comprises a POE film matrix and nano-zinc oxide dispersed within the POE film matrix. The mass ratio of the POE film matrix to the nano-zinc oxide is 47:3. The thickness of the second encapsulating film is 500 μm.

[0091] The second barrier layer comprises polyvinylidene fluoride (PVDF) and nano-alumina dispersed within the PVDF. The mass ratio of PVDF to nano-alumina is 4:1. The thickness of the second barrier layer is 80 μm.

[0092] The backplane is made of ultra-clear tempered glass. The iron content of the backplane is less than 110 ppm. The light transmittance of the backplane is 92%. The thickness of the backplane is 2 μm.

[0093] The edge sealing structure includes a sealant and a frame. The frame wraps around the edges of the package faceplate and the package backplate, as well as the layers between them. The sealant fills the inside of the frame. The frame is made of anodized aluminum alloy. The thickness of the anodized layer is 20 μm. A fluorocarbon varnish layer is applied to the surface of the frame. The thickness of the fluorocarbon varnish layer is 10 μm. The sealant includes a butyl rubber sealing strip and an silicone sealant located between the butyl rubber sealing strip and the frame. Nano-silica is dispersed in the silicone sealant. The mass fraction of nano-silica in the silicone sealant is 8%.

[0094] Example 2

[0095] The only difference between the photovoltaic module provided in this embodiment and that in Embodiment 1 is that the encapsulation panel does not have a hydrophobic self-cleaning coating.

[0096] Example 3

[0097] The only difference between the photovoltaic module provided in this embodiment and that in Embodiment 1 is that the nano-silica porous film layer is not provided on the encapsulation panel.

[0098] Example 4

[0099] The only difference between the photovoltaic module provided in this embodiment and that in Embodiment 1 is that both the first encapsulating film and the second encapsulating film are POE films without nano zinc oxide filling.

[0100] Example 5

[0101] The only difference between the photovoltaic module provided in this embodiment and that in Embodiment 1 is that the sealant in the edge sealing structure is butyl rubber, and no silicone is used.

[0102] Example 6

[0103] The photovoltaic module provided in this embodiment differs from that in Embodiment 1 only in that the polymer in the first barrier layer and the second barrier layer is polyvinylidene chloride matrix, and the barrier reinforcement particles are nano-titanium oxide.

[0104] Comparative Example 1

[0105] The photovoltaic module in this comparative example includes a laminated structure and an edge-sealed structure. The laminated structure includes a stacked encapsulation panel, a first encapsulation film, solar cells, a second encapsulation film, and an encapsulation backsheet.

[0106] The encapsulation panel is made of ultra-clear tempered glass. The iron content of the encapsulation panel is less than 150 ppm. The light transmittance of the encapsulation panel is 92%. The thickness of the encapsulation panel is 2 mm.

[0107] A porous nano-silica film layer is disposed on the side of the encapsulation panel opposite to the first encapsulation film. The thickness of the porous nano-silica film layer is 2μm.

[0108] The first encapsulating film comprises a POE film matrix and nano-zinc oxide dispersed within the POE film matrix. The mass ratio of the POE film matrix to the nano-zinc oxide is 19:1. The thickness of the first encapsulating film is 500 μm.

[0109] The second encapsulating film comprises a POE film matrix and nano-zinc oxide dispersed within the POE film matrix. The mass ratio of the POE film matrix to the nano-zinc oxide is 47:3. The thickness of the second encapsulating film is 500 μm.

[0110] The backplane material is ultra-clear tempered glass. The iron content of the backplane is less than 150 ppm. The light transmittance of the backplane is 92%. The thickness of the backplane is 200 nm.

[0111] The edge sealing structure includes a sealant and a frame. The frame wraps around the edges of the package faceplate and the package backplate, as well as the layers between them. The sealant fills the inside of the frame. The frame is made of anodized aluminum alloy. The thickness of the anodized layer is 20 μm. A fluorocarbon varnish layer is applied to the surface of the frame. The thickness of the fluorocarbon varnish layer is 10 μm. The sealant includes a butyl rubber sealing strip and an silicone sealant located between the butyl rubber sealing strip and the frame. Nano-silica is dispersed in the silicone sealant. The mass fraction of nano-silica in the silicone sealant is 8%.

[0112] Comparative Example 2

[0113] The photovoltaic module in this comparative example includes a laminated structure and an edge-sealed structure. The laminated structure includes a stacked encapsulation panel, a first encapsulation film, solar cells, a second encapsulation film, and an encapsulation backsheet.

[0114] The encapsulation panel is made of ultra-clear tempered glass. The iron content of the encapsulation panel is less than 150 ppm. The light transmittance of the encapsulation panel is [value missing]. The thickness of the encapsulation panel is 2 mm.

[0115] A porous nano-silica film is disposed on the side of the encapsulation panel opposite to the first encapsulating film. The thickness of the porous nano-silica film is 200 nm.

[0116] The first encapsulating film comprises a POE film matrix and nano-zinc oxide dispersed within the POE film matrix. The mass ratio of the POE film matrix to the nano-zinc oxide is 19:1. The thickness of the first encapsulating film is 500 μm.

[0117] The second encapsulating film comprises a POE film matrix and nano-zinc oxide dispersed within the POE film matrix. The mass ratio of the POE film matrix to the nano-zinc oxide is 47:3. The thickness of the second encapsulating film is 500 μm.

[0118] The backplate is made of ultra-clear tempered glass. The iron content of the backplate is less than 150 ppm. The light transmittance of the backplate is 92%. The thickness of the backplate is 2 mm.

[0119] The edge sealing structure includes sealant and a frame. The frame wraps around the edges of the package faceplate and package backplate, as well as the layers between them. Sealant fills the inside of the frame. The frame is made of anodized aluminum alloy. The thickness of the anodized layer is 10 μm. The sealant is a butyl rubber sealing strip.

[0120] Performance tests were conducted on the photovoltaic modules of Examples 1-6 and Comparative Examples 1-2, including salt spray 8 test, DH3000 aging test, and UV60 aging test. The duration of no visible corrosion during the salt spray 8 test, the power degradation rate of the modules after DH3000 aging, and the power degradation rate of the modules after UV60 aging were recorded. In addition, the power generation of the photovoltaic modules, i.e., the total amount of solar energy converted into electrical energy within a certain period of time, was tested, normalized to the power generation of Comparative Example 1 as 1. The test results are shown in Table 1.

[0121] Table 1 Performance test results of photovoltaic modules in Examples 1-6 and Comparative Examples 1-2

[0122]

[0123] As shown in Table 1, compared to Comparative Examples 1-2, the photovoltaic modules of Examples 1-6 exhibited significantly increased corrosion-free duration during the salt spray 8-hour test, indicating a significant improvement in salt spray corrosion resistance. This is mainly attributed to the efficient barrier properties of the first and second barrier layers against salt ions and water vapor, as well as the hydrophobic self-cleaning coating reducing salt deposition on the module surface. Compared to Examples 1 and 2, Example 1 showed an increase in power generation, thanks to the self-cleaning function of the hydrophobic self-cleaning coating, which reduced light shading by contaminants on the module surface and improved light energy utilization. Compared to Example 3, Example 1, by incorporating a porous nano-silica film, effectively reduced reflection, improved light energy utilization, and thus increased power generation. Comparing Examples 1 and 4, it is evident that filling the encapsulation film with nano-zinc oxide enhances the module's weather resistance. Compared to Example 5, Example 1 used a combination of butyl rubber and silicone sealant, whose complementary material properties optimized sealing reliability and improved the module's resistance to salt spray corrosion and damp heat.

[0124] The technical features of the above embodiments can be combined in any way. For the sake of brevity, not all possible combinations of the technical features in the above embodiments are described. However, as long as there is no contradiction in the combination of these technical features, they should be considered to be within the scope of this specification.

[0125] The embodiments described above are merely illustrative of several implementation methods of this application, and while the descriptions are specific and detailed, they should not be construed as limiting the scope of this patent application. It should be noted that those skilled in the art can make various modifications and improvements without departing from the concept of this application, and these all fall within the protection scope of this application. Therefore, the protection scope of this patent application should be determined by the appended claims.

Claims

1. A photovoltaic module, characterized by, The encapsulation panel, the first encapsulation adhesive film, the solar cell, the second encapsulation adhesive film, the encapsulation backboard, the nano-silicon dioxide porous film layer and the hydrophobic self-cleaning coating are stacked. The photovoltaic module further comprises a first barrier layer and a second barrier layer, the first barrier layer is arranged between the encapsulation panel and the first encapsulation adhesive film, and the second barrier layer is arranged between the second encapsulation adhesive film and the encapsulation backboard; the first barrier layer comprises a first polymer matrix and first barrier enhancement particles dispersed in the first polymer matrix, the first polymer matrix is selected from at least one of polyvinylidene fluoride and polytetrafluoroethylene, and the first barrier enhancement particles are selected from at least one of nano-aluminum oxide, nano-titanium dioxide and nano-silicon dioxide; the second barrier layer comprises a second polymer matrix and second barrier enhancement particles dispersed in the second polymer matrix, the second polymer matrix is selected from at least one of polyvinylidene fluoride and polytetrafluoroethylene, and the second barrier enhancement particles are selected from at least one of nano-aluminum oxide, nano-titanium dioxide and nano-silicon dioxide; the hydrophobic self-cleaning coating is arranged on a side of the encapsulation panel away from the first encapsulation adhesive film, and the nano-silicon dioxide porous film layer is arranged between the hydrophobic self-cleaning coating and the encapsulation panel.

2. The photovoltaic module of claim 1, wherein, In the first barrier layer, the mass ratio of the first polymer matrix to the first barrier enhancement particles is (1.5-20):

1. And / or, in the second barrier layer, the mass ratio of the second polymer matrix to the second barrier enhancement particles is (1.5-20):

1.

3. The photovoltaic module of claim 1, wherein, The first encapsulation adhesive film comprises a first adhesive film matrix and first fillers dispersed in the first adhesive film matrix, the first adhesive film matrix is selected from at least one of POE, EPE and EVA, and the first fillers are selected from at least one of nano-zinc oxide, nano-titanium dioxide and graphene; And / or, the second encapsulation adhesive film comprises a second adhesive film matrix and second fillers dispersed in the second adhesive film matrix, the second adhesive film matrix is selected from at least one of POE, EPE and EVA, and the second fillers are selected from at least one of nano-zinc oxide, nano-titanium dioxide and graphene.

4. The photovoltaic module of any of claims 1-3, wherein, The thickness of the hydrophobic self-cleaning coating is 0.5-2 μm.

5. The photovoltaic module of claim 1, wherein, The hydrophobic self-cleaning coating comprises nano-silicon dioxide particles modified with fluorine-containing silane on the surface.

6. The photovoltaic module of claim 1, wherein, The thickness of the nano-silicon dioxide porous film layer is 100-275 nm.

7. The photovoltaic module of any of claims 1-3, 5, 6, wherein, The photovoltaic module further comprises an edge sealing structure, the edge sealing structure comprises sealing adhesive and a frame, the frame wraps the edges of the encapsulation panel and the encapsulation backboard and each layer therebetween, and the sealing adhesive is filled in the inner side of the frame.

8. The photovoltaic module of claim 7, wherein, The sealing adhesive comprises butyl rubber and silicone adhesive between the butyl rubber and the frame, and nano-silicon dioxide is dispersed in the silicone adhesive.

9. The photovoltaic module of claim 7, wherein, The surface of the frame is provided with a fluorocarbon paint layer.

10. A method of making a photovoltaic module, characterized by, The method comprises the following steps: A laminated packaging panel, a first packaging adhesive film, a battery piece, a second packaging adhesive film and a packaging back plate are arranged; wherein a first barrier layer is further arranged between the packaging panel and the first packaging adhesive film, and a second barrier layer is further arranged between the second packaging adhesive film and the packaging back plate; the first barrier layer comprises a first polymer matrix and first barrier enhancement particles dispersed in the first polymer matrix, the first polymer matrix is selected from at least one of polyvinylidene fluoride and polytetrafluoroethylene, and the first barrier enhancement particles are selected from at least one of nano-alumina, nano-titanium dioxide and nano-silicon dioxide; the second barrier layer comprises a second polymer matrix and second barrier enhancement particles dispersed in the second polymer matrix, the second polymer matrix is selected from at least one of polyvinylidene fluoride and polytetrafluoroethylene, and the second barrier enhancement particles are selected from at least one of nano-alumina, nano-titanium dioxide and nano-silicon dioxide; Laminating treatment; A nano-silicon dioxide porous film layer is prepared on the side of the packaging panel away from the first packaging adhesive film; A hydrophobic self-cleaning coating layer is prepared on the nano-silicon dioxide porous film layer.

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