Photovoltaic module and preparation method thereof

Abstract

The invention provides a photovoltaic module and a preparation method thereof, and relates to the technical field of back contact cells. The preparation method of the photovoltaic module comprises the following steps: forming a battery string by adopting first equipment; and arranging the plurality of battery strings to form a component array by adopting second equipment. The assembly array comprises a plurality of rows and a plurality of columns, each row comprises a plurality of battery strings arranged in the second direction, and each column comprises a plurality of battery strings arranged in the first direction. The first direction intersects with the second direction. A plurality of bus bars are arranged on the assembly array, the bus bars are electrically connected with the battery strings, the plurality of bus bars comprise middle bus bars, and the middle bus bars are located in the lamination areas of the two adjacent battery strings in the first direction. Wherein the first device and the second device are two different devices. According to the method, the preparation of the full-screen component can be realized based on the existing first equipment and second equipment, the existing first equipment does not need to be greatly modified, and the manufacturing cost is reduced while the power and efficiency of the component are improved.

Description

Technical Field

[0001] This application relates to the field of back contact battery technology, and in particular to a photovoltaic module and its preparation method. Background Technology

[0002] In the field of solar cells, full-screen modules, by hiding the busbars on the back of the cells, can accommodate more cells within a limited module area, thereby improving the module's power and efficiency. However, existing full-screen modules use a long string design in their fabrication process. Fabricating full-screen modules using long strings has poor compatibility with current equipment, requiring significant modifications to existing equipment or the replacement of existing equipment with new equipment, which increases manufacturing costs. Summary of the Invention

[0003] This application proposes a photovoltaic module and its preparation method, aiming to improve the preparation method of full-screen modules, realize the preparation of full-screen modules with minimal modification to current equipment, and reduce manufacturing costs.

[0004] In a first aspect, this application provides a method for preparing a photovoltaic module, comprising the following steps S1 to S3: Step S1: Using the first device, a battery string is formed. The battery string includes multiple battery cells arranged along a first direction, with adjacent battery cells electrically connected.

[0005] Step S2: Using a second device, arrange multiple battery strings to form a component array. The component array includes multiple rows and columns, each row including multiple battery strings arranged along a second direction, and each column including multiple battery strings arranged along a first direction. The first and second directions intersect.

[0006] Step S3: Set multiple busbars on the component array. The busbars are electrically connected to the battery strings. The multiple busbars include a middle busbar. Along the first direction, the middle busbar is located in the stacking area of ​​two adjacent battery strings.

[0007] The first device and the second device are two different devices.

[0008] In some embodiments, step S1 forming a battery string includes steps S111 to S112: Step S111: Arrange multiple battery cells along the first direction.

[0009] Step S112: Place the non-lead solder strip on two adjacent solar cells, and electrically connect the non-lead solder strip to the two adjacent solar cells.

[0010] Before setting multiple busbars on the component array, the fabrication method also includes connecting the busbars to multiple lead-out solder strips.

[0011] Multiple busbars are set on the module array, including: setting the busbars and multiple lead-out solder strips on the module array, and the busbars are electrically connected to the battery series through the multiple lead-out solder strips.

[0012] In some embodiments, the plurality of busbars may further include end busbars.

[0013] Connecting a busbar to multiple lead-out solder strips includes: connecting an end busbar to the end of a lead-out solder strip, connecting an intermediate busbar to the midpoint of a lead-out solder strip, or, each lead-out solder strip includes a first sub-solder strip and a second sub-solder strip, connecting the intermediate busbar to the end of the first sub-solder strip and the end of the second sub-solder strip, wherein the first sub-solder strip and the second sub-solder strip are disconnected on the surface of the intermediate busbar.

[0014] The method of setting busbars and multiple lead-out solder strips on a module array includes: setting end busbars and multiple lead-out solder strips at opposite ends of the module array along a first direction, and setting intermediate busbars and multiple lead-out solder strips in the stacking area of ​​two adjacent battery strings along the first direction.

[0015] In some embodiments, before setting multiple busbars on the module array, the fabrication method further includes: setting insulating strips, the insulating strips being set at opposite ends of the module array along a first direction and in the stacking area of ​​two adjacent battery strings along the first direction; the insulating strips covering portions of the non-lead solder strips.

[0016] After multiple busbars are set on the module array, with the insulating strips extending continuously along the second direction and covering multiple non-lead solder strips, the busbars and multiple lead solder strips are set on the side of the insulating strips away from the solar cells.

[0017] In some embodiments, step S1 forming a battery string includes steps S121 to S122: Step S121: Arrange multiple battery cells along the first direction to form a battery string.

[0018] Step S122: Place multiple lead-out solder strips and multiple non-lead-out solder strips on multiple solar cells. The non-lead-out solder strips are electrically connected to two adjacent solar cells, and the lead-out solder strips are electrically connected to the solar cells at both ends of the solar cell string.

[0019] After multiple busbars are set on the component array, the busbars are electrically connected to the battery string through multiple lead-out solder strips.

[0020] In some embodiments, before setting multiple busbars on the module array, the fabrication method further includes: setting insulating strips, the insulating strips being set at opposite ends of the module array along a first direction and at the stacking regions of two adjacent battery strings along the first direction, the insulating strips covering portions of the non-lead solder strips and exposing portions of the lead solder strips.

[0021] After multiple busbars are set on the component array, the busbars are connected to the lead-out solder strips.

[0022] In some embodiments, after multiple busbars are arranged on the component array, the ends of the lead-out solder strips extend beyond the ends of the non-lead-out solder strips along a first direction. The busbars are connected to the ends of the lead-out solder strips that extend beyond the non-lead-out solder strips.

[0023] In some embodiments, before setting multiple busbars on the component array, the fabrication method further includes: setting a flexible material layer, the flexible material layer being located in the stacked region of two adjacent battery strings along a first direction.

[0024] In some embodiments, multiple busbars are disposed on the component array, including the following steps S311 to S312: Step S312: Form multiple through holes on the busbar.

[0025] Step S312: A lead-out solder strip is folded out from a via and electrically connected to the busbar.

[0026] In some embodiments, the first device includes a string welding platform and the second device includes a stack welding platform.

[0027] Secondly, this application also provides a photovoltaic module, which is prepared by the preparation method in any of the embodiments of the first aspect above.

[0028] In some embodiments, a photovoltaic module includes a module array and a plurality of busbars.

[0029] The module array includes multiple rows and columns of battery strings, each battery string comprising multiple cells arranged along a first direction, with adjacent cells electrically connected. The busbar includes end busbars and intermediate busbars. The end busbars are located at opposite ends of the module array along the first direction. The intermediate busbars are located in the stacking area of ​​two adjacent battery strings along the first direction.

[0030] In some embodiments, two adjacent battery strings along a first direction, one battery string having a first lead-out solder strip at one end near the stacking region, and the other battery string having a second lead-out solder strip at one end near the stacking region. An intermediate busbar is connected to the ends of the first and second lead-out solder strips, which are disconnected on the surface of the intermediate busbar.

[0031] In some embodiments, the photovoltaic module further includes a flexible material layer located in the stacked region of two adjacent cell strings along a first direction.

[0032] In some embodiments, the battery string further includes lead-out solder strips, and the busbar includes vias, through which the lead-out solder strips are folded and electrically connected to the busbar.

[0033] In this application, an improved fabrication method is employed. First, a first device is used to form a battery string, comprising multiple battery cells arranged along a first direction, with adjacent battery cells electrically connected. Then, a second device is used to arrange the multiple battery strings into a module array, comprising multiple rows and columns. Each row includes multiple battery strings arranged along a second direction, and each column includes multiple battery strings arranged along the first direction. Finally, multiple busbars are placed on the module array, electrically connected to the battery strings. Thus, a full-screen module can be fabricated using existing first and second devices. This fabrication method eliminates the need to form a long battery string for a full-screen module; here, a long battery string corresponds to all the battery cells included in each column of battery strings in the module array. In other words, this fabrication method achieves full-screen module fabrication without replacing the first device or making significant modifications to the existing first device. This improves the module's power and efficiency while reducing manufacturing costs. Attached Figure Description

[0034] To more clearly illustrate the technical solutions in this application, the accompanying drawings used in some embodiments of this application will be briefly described below. Obviously, the drawings described below are only drawings of some embodiments of this application, and those skilled in the art can obtain other drawings based on these drawings. In addition, the drawings described below can be regarded as schematic diagrams and are not actual dimensions of the products or actual processes of the methods involved in the embodiments of this application.

[0035] Figure 1 A flowchart illustrating a photovoltaic module fabrication method provided in this application embodiment; Figures 2-13 for Figure 1 Schematic diagrams of each step in the preparation method; Figure 14 This is a schematic diagram of the structure of a photovoltaic module provided in an embodiment of this application. Detailed Implementation

[0036] The technical solutions in some embodiments of this application will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of this application, and not all embodiments. All other embodiments obtained by those skilled in the art based on the embodiments provided in this application are within the scope of protection of this application.

[0037] Unless the context otherwise requires, throughout the specification and claims, the term "comprising" is interpreted as open and encompassing, that is, "including, but not limited to".

[0038] Hereinafter, 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 indicated technical features. Therefore, a feature defined as "first" or "second" may explicitly or implicitly include one or more of that feature. In the description of embodiments of this application, unless otherwise stated, "a plurality of" means two or more.

[0039] In describing some embodiments, the term "connection" and its derivative expressions may be used. The term "connection" should be interpreted broadly; for example, "connection" can be a fixed connection, a detachable connection, or an integral part; it can be a direct connection or an indirect connection through an intermediate medium. For example, in describing some embodiments, the term "connection" may be used to indicate that two or more components have direct physical or electrical contact with each other.

[0040] In addition, the use of “based on” implies openness and inclusivity, because processes, steps, calculations or other actions “based on” one or more of the stated conditions or values ​​may in practice be based on additional conditions or values ​​beyond those stated.

[0041] This document describes exemplary embodiments with reference to cross-sectional views, which are intended as idealized exemplary drawings. In the drawings, the thickness of the layers and the area of ​​the regions are enlarged for clarity. Therefore, variations in shape relative to the drawings are contemplated due to, for example, manufacturing techniques and / or tolerances. Thus, exemplary embodiments should not be construed as limited to the shapes of the regions shown herein, but rather include shape deviations caused, for example, by manufacturing processes. For example, etched areas shown as rectangular would typically have curved features. Therefore, the regions shown in the drawings are schematic in nature, and their shapes are not intended to show the actual shapes of the areas of the device, nor are they intended to limit the scope of the exemplary embodiments.

[0042] In the field of solar cells, back-contact solar cells have no grid lines obstructing the front side, resulting in higher cell efficiency and a more aesthetically pleasing module appearance. They have played a crucial role in the development of photovoltaics in recent years. In conventional solar cell module designs, busbars are located in the middle and on both sides of the module to collect and transmit current. However, these busbars occupy a certain area within the module, and photovoltaic power generation cannot occur in these areas, thus hindering further improvements in module efficiency.

[0043] Full-screen modules, by hiding the busbars on the back of the cells, can accommodate more cells within a limited module area, thereby improving the module's power and efficiency. However, existing full-screen modules use a long-string design in their manufacturing process. That is, multiple cells in one column of the full-screen module are first welded together to form a long battery string, and then multiple long battery strings are arranged in a row and stacked and welded together to form a full-screen module.

[0044] This method of preparing full-screen components using long strings has poor compatibility with current devices, requiring extensive modifications to existing equipment or the replacement of existing equipment, which increases manufacturing costs.

[0045] Based on this, this application provides a method for manufacturing a photovoltaic module, such as... Figure 1 As shown, Figure 1 This is a flowchart illustrating a photovoltaic module fabrication method provided in an embodiment of this application. Figures 2-13 for Figure 1 The diagram shows the steps of the preparation method.

[0046] like Figure 1 As shown, the preparation method includes the following steps S1 to S3: Step S1: For example, as Figure 2 As shown, a battery string 10 is formed using a first device. The battery string 10 includes a plurality of battery cells 11 arranged along a first direction Y, with adjacent battery cells 11 electrically connected.

[0047] For example, the first device includes a string welding platform.

[0048] For example, on a stringing platform, multiple battery cells 11 are connected in series to form a battery string 10. Each battery string 10 includes two battery cells 11 located at both ends, one of which is used to lead out the positive terminal of the battery string 10 and the other is used to lead out the negative terminal of the battery string 10.

[0049] Step S2: For example, as Figure 3 As shown, a second device is used to arrange multiple battery strings 10 to form a component array. The component array includes multiple rows and multiple columns, each row including multiple battery strings 10 arranged along a second direction X, and each column including multiple battery strings 10 arranged along a first direction Y. The first direction Y intersects the second direction X.

[0050] The first device and the second device are two different devices.

[0051] For example, the second device includes a lap welding platform.

[0052] For example, the battery string 10 includes string A and string B, which have a certain degree of symmetry. For instance, the first end of string A is used to lead out the positive terminal of the battery string, and the second end is used to lead out the negative terminal of the battery string, while the first end of string B is used to lead out the negative terminal of the battery string, and the second end is used to lead out the positive terminal of the battery string.

[0053] During the process of arranging multiple battery strings 10 to form a module array on the shingled platform, each row is arranged with alternating strings A and B, and each column is arranged with alternating strings A and B. After the arrangement is completed, for the same column, the adjacent ends of two adjacent battery strings 10 are used to lead out the same polarity, that is, they are used to lead out the positive terminal or the negative terminal simultaneously. For the same row, the first ends of two adjacent battery strings 10 are used to lead out different polarities (similarly, the second ends of two adjacent battery strings 10 are also used to lead out different polarities), and the two are electrically connected through the busbar 20 to realize the series connection of the two adjacent battery strings 10.

[0054] like Figure 3 As shown, taking a component array consisting of two rows of battery strings 10 as an example, denoted as the first row L1 and the second row L2 respectively. In the first row L1, the odd-numbered battery string 10 is string A, and the even-numbered battery string 10 is string B. Then, in the second row L2, the odd-numbered battery string 10 is string B, and the even-numbered battery string 10 is string A.

[0055] To accommodate more solar cells within a limited module area, a stacking area is typically formed where two adjacent cell strings are close together. Figure 3 and Figure 6 As shown, Figure 6 This is a magnified view of the module array at point M. In the stacking area, two cells 11 are stacked along the edge regions of the cells 11 in a direction perpendicular to the surface of the cells 11.

[0056] Step S3: For example, such as Figures 4-5 As shown, multiple busbars 20 are arranged on the component array, and the busbars 20 are electrically connected to the battery string 10.

[0057] For example, in combination Figure 5 As shown, taking a row with 6 battery strings as an example, for the first row L1, the first end of the first column of battery strings 10 (string A) is electrically connected to the first end of the second column of battery strings 10 (string B) via busbar 20. The first end of the third column of battery strings 10 (string A) is electrically connected to the first end of the fourth column of battery strings 10 (string B) via busbar 20. The first end of the fifth column of battery strings 10 (string A) is electrically connected to the first end of the sixth column of battery strings 10 (string B) via busbar 20.

[0058] Similarly, for the second row L2, the second end of the first column of battery strings 10 (string B) is electrically connected to the second end of the second column of battery strings 10 (string A) via busbar 20. The second end of the third column of battery strings 10 (string B) is electrically connected to the first end of the fourth column of battery strings 10 (string A) via busbar 20. The second end of the fifth column of battery strings 10 (string B) is electrically connected to the second end of the sixth column of battery strings 10 (string A) via busbar 20.

[0059] In the stacked area of ​​the second row L2 and the first row L1, the second end of the first column of battery strings 10 (A strings) in the first row L1 is electrically connected to the first end of the first column of battery strings 10 (B strings) in the second row L2 via busbar 20. The second ends of the second column of battery strings 10 (B strings) and the second ends of the third column of battery strings 10 (A strings) in the first row L1 are electrically connected to the first ends of the second column of battery strings 10 (A strings) and the first ends of the third column of battery strings 10 (B strings) in the second row L2 via busbar 20. The second ends of the fourth column of battery strings 10 (B strings) and the second ends of the fifth column of battery strings 10 (A strings) in the first row L1 are electrically connected to the first ends of the fourth column of battery strings 10 (A strings) and the first ends of the fifth column of battery strings 10 (B strings) in the second row L2 via busbar 20. The second end of the battery string 10 (B string) in the sixth column of the first row L1 is electrically connected to the first end of the battery string 10 (A string) in the sixth column of the second row L2 via busbar 20.

[0060] The busbar 20, which connects the second end of the first column of battery strings 10 (A strings) in the first row L1 and the first end of the first column of battery strings 10 (B strings) in the second row L2, and the busbar 20, which connects the second end of the sixth column of battery strings 10 (B strings) in the first row L1 and the first end of the sixth column of battery strings 10 (A strings) in the second row L2, corresponds to the two electrodes of the photovoltaic module and is used to realize the electrical lead-out of the photovoltaic module.

[0061] Based on their relative positions on the component array, the multiple busbars 20 include end busbars 21 and intermediate busbars 22. Combined Figure 5 Along the first direction Y, the end busbar 21 is located at the outermost end of the outermost cell 11 of the photovoltaic module. Here, "outer side" or "outer end" refers to the part close to the edge of the photovoltaic module.

[0062] Along the first direction Y, the intermediate busbar 22 is located in the stacking area of ​​two adjacent cell strings 10. Based on the above, it can be understood that among the multiple intermediate busbars 22 arranged along the second direction X, the two outermost intermediate busbars 22 correspond to the two electrodes of the photovoltaic module, and are used to realize the electrical lead-out of the photovoltaic module.

[0063] In related technologies, to completely conceal the busbars on the back of photovoltaic modules, long strings of cells are typically fabricated first, and then multiple long strings of cells are electrically connected via busbars. Here, the long strings of cells correspond to all the solar cells 11 included in each column of the module array in this application. For example, if the module array of this application includes two rows of solar strings 10, and each solar string 10 includes 6 solar cells 11, then the long strings of cells in the related technologies would correspond to 12 solar cells 11.

[0064] In related technologies, on the one hand, long battery strings (e.g., corresponding to the 12 battery cells 11 in this application) are relatively long and place high demands on the first device. On the other hand, the electrical connections in the middle region (i.e., the region corresponding to the middle busbar 22 in this application) are more complex, for example, referring to... Figure 5 The middle area of ​​the first long string of batteries needs to achieve parallel connection of two adjacent battery cells, and the middle area of ​​the second and third long strings of batteries needs to achieve electrical connection of four corresponding battery cells. The process is complex and requires the use of specialized equipment for preparation.

[0065] In other words, the manufacturing process for long battery strings is not well compatible with current equipment. To realize this process, a lot of modifications need to be made to the existing equipment or new equipment needs to be replaced, which will increase manufacturing costs.

[0066] In this application, a first device is used to form a battery string 10, followed by a second device to arrange multiple battery strings 10 into a module array. Finally, multiple busbars 20 are set on the module array to ultimately form a full-screen photovoltaic module. In the above embodiments of this application, the length of the battery string 10 and the related manufacturing process are not significantly different from conventional processes. Based on this, by optimizing the manufacturing method and using a short string splicing approach, full-screen module manufacturing can be achieved without making significant modifications to the existing first device. This improves the power and efficiency of the module while reducing manufacturing costs.

[0067] Furthermore, along the first direction Y, the intermediate busbar 22 is used to collect the current from the two battery strings 10 that are electrically connected to it. The intermediate busbar 22 is located in the stacked area of ​​the two adjacent battery strings 10, that is, the intermediate busbar 22 is located in the center of the two battery strings 10. With the intermediate busbar 22 as the axis, the two battery strings 10 are symmetrically arranged. This makes the current generated by the symmetrical positions of the two battery strings 10 reach the intermediate busbar 22 at the same distance. Along the first direction Y, the intermediate busbar 22 has a certain symmetry when collecting the current from the battery strings 10 on both sides, which helps to reduce the risk of current mismatch.

[0068] For example, such as Figure 2 As shown, the method for forming the battery string 10 in step S1 includes the following steps S111 to S112: Step S111: As Figure 2 As shown, multiple battery cells 11 are arranged along the first direction Y.

[0069] Step S112: As Figure 2 As shown, non-lead solder strips 31 are disposed on two adjacent battery cells 11, and the non-lead solder strips 31 are electrically connected to the two adjacent battery cells 11.

[0070] Before setting multiple busbars 20 on the component array, such as Figures 7A-7C As shown, the preparation method also includes connecting the busbar 20 to multiple lead-out solder strips 32.

[0071] Multiple busbars 20 are arranged on the module array, including: the busbars 20 and multiple lead-out solder strips 32 are arranged on the module array, and the busbars 20 are electrically connected to the battery string 10 through the multiple lead-out solder strips 32.

[0072] Understandably, the solar cell 11 is used to receive light energy and generate current. The non-lead solder ribbon 31 is used to collect and transmit the current generated on the solar cell 11 and connect adjacent solar cells 11 in series within a solar cell string 10. The lead solder ribbon 32 is used to collect and transmit the current in the solar cell string 10 and is electrically connected to the busbar 20. The busbar 20 collects and transmits the current on the module array.

[0073] In the above embodiments of this application, the non-lead solder strip 31 and the battery cell 11 are initially fixed on the stringing platform to form a battery string 10. The string length of the battery string 10 and the cutting length of the solder strip are similar to those of a conventional battery string. The conventional stringing machine can be modified to prepare the battery string 10.

[0074] Furthermore, in the above embodiments of this application, the busbar 20 and the lead-out solder strip 32 can be electrically connected at a location other than the battery string 10, and then the busbar 20 and the lead-out solder strip 32 are placed together on the module array to achieve the corresponding electrical connection between the battery strings 10. Based on this, it is beneficial to avoid cell breakage caused by the welding process of the busbar 20 and the lead-out solder strip 32, and to improve product reliability and yield.

[0075] In the above embodiments of this application, by first preparing the battery string 10 and then splicing it into a component array, there is no need to prepare AB strings and mirror solder ribbons as in related technologies, making the production process simpler.

[0076] In some embodiments, such as Figure 5 As shown, the multiple busbars 20 include end busbars 21 and intermediate busbars 22.

[0077] The method of setting the busbar 20 and multiple lead-out solder strips 32 on the module array includes: setting the end busbar 21 and multiple lead-out solder strips 32 at opposite ends of the module array along the first direction Y, and setting the middle busbar 22 and multiple lead-out solder strips 32 in the stacking area of ​​two adjacent battery strings 10 along the first direction Y.

[0078] That is, in a row of cell strings 10 of a photovoltaic module, the end busbar 21 is located at the end of the row and is electrically connected to one cell string, and the middle busbar 22 is located in the stacking area of ​​two adjacent cell strings 10 in the row and is electrically connected to both adjacent cell strings 10.

[0079] The connection between the busbar 20 and the lead-out solder strip 32 can be distinguished according to the type of busbar 20.

[0080] For example, for end busbar 21, such as Figure 7A As shown, the end busbar 21 is connected to the end of the lead-out solder strip 32. (Combined) Figure 5 It is understandable that the lead-out solder strip 32 here corresponds to the length of a single solar cell 11. That is, the length of the lead-out solder strip 32 must not exceed the length of a single solar cell 11 along the first direction Y, to avoid extending to adjacent solar cells 11 and causing a short circuit. For the battery string 10, the lead-out solder strip 32 is used to collect and transmit current at the end where the solar cell 11 is located. For intermediate busbar 22, such as Figure 7B As shown, the intermediate busbar 22 is connected to the midpoint of the lead-out solder strip 32, and then... Figure 5 It is understandable that the lead-out solder strip 32 here corresponds to the length of the two solar cells 11. That is, the lead-out solder strip 32 here needs to collect and transmit the current of the two adjacent cell strings 10 in each column of the module array.

[0081] Or, such as Figure 7C As shown, each lead-out solder strip 32 includes a first sub-solder strip 321 and a second sub-solder strip 322. The intermediate busbar 22 is connected to the ends of the first sub-solder strip 321 and the second sub-solder strip 322. The first sub-solder strip 321 and the second sub-solder strip 322 are disconnected on the surface of the intermediate busbar 22. Figure 5 and Figure 7C Understandably, the first sub-strip 321 is used to collect and transmit current at the second end of a battery string 10, and the second sub-strip 322 is used to collect and transmit current at the first end of another battery string 10 adjacent to it in a row.

[0082] like Figure 7C As shown, the first sub-strip 321 and the second sub-strip 322 are disconnected on the surface of the intermediate busbar 22. Therefore, in the extending direction of the lead-out strip 32, the area below the middle region of the busbar 20 is hollowed out. Combined with... Figure 6After the busbar 20 and the lead-out solder strip 32 are placed together on the module array, the hollow state below the middle area of ​​the busbar 20 provides space for the stacking process in the stacking area. There is no solder strip between the middle area of ​​the busbar 20 and the module array, which helps to reduce the film layer structure between the busbar 20 and the lower battery cell 11 and helps to improve the situation of lamination breakage.

[0083] In some embodiments, such as Figure 4 As shown, before setting multiple busbars 20 on the module array, the fabrication method further includes setting insulating strips 40. The insulating strips 40 are set at opposite ends of the module array along the first direction Y, and are also set in the stacking area of ​​two adjacent cell strings 10 along the first direction Y. The insulating strips 40 cover the portion of the non-lead solder strips 31.

[0084] For example, the insulating strip 40 can be Figure 4 The insulating strip 40, as shown, extends continuously along the second direction X and covers multiple non-lead solder strips 31. The insulating strip 40 includes a main body 41 and a connecting portion 42. The main body 41 covers the portion of the non-lead solder strips 31, and the connecting portion 42 connects two adjacent main body parts 41. Along the first direction Y, the width of the connecting portion 42 is less than the width of the main body 41; along the second direction X, the width of the connecting portion 42 is greater than or equal to the width of the lead solder strips. Based on this, the insulating strip 40 can both cover the non-lead solder strips 31 and provide space for the lead solder strips 32. Furthermore, since the insulating strip 40 is a continuous piece, the process of setting up the insulating strip 40 is simpler.

[0085] Alternatively, the insulating strip 10 may include multiple discretely arranged insulating blocks, wherein the insulating blocks cover the portion of the non-lead solder strip 31, and space is reserved between two adjacent insulating blocks for placing the lead solder strip 32.

[0086] After multiple busbars 20 are arranged on the module array, and the insulating strip 40 extends continuously along the second direction X and covers multiple non-lead solder strips 31, the busbars 20 and multiple lead solder strips 32 are arranged on the side of the insulating strip 40 away from the cell 11.

[0087] For example, along the first direction Y, the width of the busbar 20 is Y1, the width of the main body 41 is Y2, and the width of the connecting part 42 is Y3, wherein... This ensures the insulation effect between the insulating strip 40 and the busbar 20 and the non-lead solder strip 31, preventing short circuits caused by electrical connection between the busbar and the non-lead solder strip 31. Furthermore, This design not only allows for the placement of the lead-out solder strip 32 and ensures that the lead-out solder strip 32 is electrically connected to the battery string 11 to achieve current collection and transmission, but also ensures the connection effect of the connection part 42 and prevents the insulating strip 40 from breaking during the picking and placing process. As a result, the insulating strip 40 can be set as a whole instead of setting discrete insulating blocks in multiple steps, making the process simpler.

[0088] Along the second direction X, the width of the solder strip 32 is X1, and the width of the connecting part 42 is X2, wherein... This helps ensure that the lead-out solder strip 32 falls into the reserved space and that the lead-out solder strip 32 is electrically connected to the battery string 11 to achieve current collection and transmission.

[0089] In some embodiments, such as Figure 8 As shown, the method for forming the battery string 10 in step S1 may further include the following steps S121 to S122: Step S121: As Figure 8 As shown, multiple battery cells 11 are arranged along the first direction Y to form a battery string 10.

[0090] Step S122: As Figure 8 As shown, multiple lead-out solder strips 32 and multiple non-lead-out solder strips 31 are disposed on multiple battery cells 11. The non-lead-out solder strips 31 are electrically connected to two adjacent battery cells 11, and the lead-out solder strips 32 are electrically connected to the battery cells 11 at both ends of the battery string 10.

[0091] and Figure 2 Compared with the embodiments shown, in the above embodiments of this application, the placement of the battery cells 11, the length of the battery string 10, and the cutting and transfer of the welding strip in this step are not significantly different from the conventional manufacturing process. Existing equipment can be put into use without much modification, which is conducive to reducing production costs.

[0092] Based on this, such as Figure 9 As shown, a second device is used to arrange multiple battery strings 10 to form a component array.

[0093] After that, as Figure 10 As shown, in some embodiments, before setting multiple busbars 20 on the module array, the preparation method further includes setting insulating strips 40. The insulating strips 40 are set at opposite ends of the module array along the first direction Y and in the stacking area of ​​two adjacent battery strings 10 along the first direction Y. The insulating strips 40 cover the portion of the non-lead solder strips 31 and expose the portion of the lead solder strips 32.

[0094] Finally, as Figure 11As shown, multiple busbars 20 are set on the insulating strip 40. The busbars 20 are welded to the lead-out solder strips 32. After completing the relevant lamination process, the busbars 20 are finally electrically connected to the battery string 10 through multiple lead-out solder strips 32, thus completing the fabrication of the photovoltaic module.

[0095] The insulating strip 40 may include multiple discrete insulating blocks or a single insulating strip, used to block any electrical connection that may exist between the non-lead solder strip 31 and the busbar 20. Furthermore, the insulating strip 40 exposes a portion of the lead solder strip 32 so that after the busbar 20 is subsequently formed on the insulating strip 40, an electrical connection can be established between the busbar 20 and the lead solder strip 32.

[0096] When the insulating strip 40 extends continuously along the second direction X and covers multiple non-lead solder strips 31, the non-lead solder strips 31 and lead solder strips 32 are arranged on the side of the insulating strip 40 closer to the battery cell 11, and the busbar 20 is arranged on the side of the insulating strip 40 away from the battery cell 11. The size design of the insulating strip 40 is as mentioned above and will not be repeated here.

[0097] In some embodiments, the insulating strip 40 can be eliminated by staggering the non-lead solder strip 31 and the lead solder strip 32.

[0098] For example, such as Figure 12 As shown, Figure 12 A magnified view of a battery string 10 is shown. After multiple busbars 20 are arranged on the component array, along the first direction Y, the end of the lead-out solder strip 32 extends beyond the end of the non-lead-out solder strip 31. The busbar 20 is connected to the end of the lead-out solder strip 32 that extends beyond the non-lead-out solder strip 31.

[0099] like Figure 12 As shown, along the first direction Y, the distance between the end of the non-lead solder strip 31 and the end of the lead solder strip 32 is D1, and the distance between the end of the non-lead solder strip 31 and the edge of the busbar 20 is D2. There is no risk of short circuit between the busbar 20 and the non-lead solder strip 31. Based on this, the insulating strip 40 can be completely removed, which not only reduces material costs but also reduces the risk of laminate breakage.

[0100] In some embodiments, such as Figure 6 As shown, before setting multiple busbars 20 on the component array, the preparation method further includes: setting a flexible material layer 50, the flexible material layer 50 being located in the stacked area of ​​two adjacent battery strings 10 along the first direction Y.

[0101] For example, the flexible material layer 50 is made of ethylene-vinyl acetate copolymer, which has good flexibility, impact resistance, and stress cracking resistance, and can protect the battery cell 11 from mechanical impact and environmental impact, reducing the risk of microcracks and fragmentation.

[0102] In some embodiments, such as Figure 13 As shown, multiple busbars 20 are set on the component array, including the following steps S311 to S312: Step S312: As Figure 13 As shown, multiple through holes are formed on the busbar 20.

[0103] Step S312: As Figure 13 As shown, a lead-out solder strip 32 is folded out from a through hole and electrically connected to the busbar 20.

[0104] This method achieves electrical connection between the lead-out solder strip 32 and the busbar 20 by drilling holes in the busbar 20 and folding the solder strip. It has high process compatibility and is conducive to achieving a reliable connection between the lead-out solder strip 32 and the busbar 20.

[0105] Secondly, this application also provides a photovoltaic module, such as... Figure 14 As shown, Figure 14 This is a schematic diagram of the structure of a photovoltaic module provided in an embodiment of this application. The photovoltaic module 100 is prepared by the preparation method in any of the above embodiments.

[0106] like Figure 14 As shown, in some embodiments, the photovoltaic module 100 includes a module array and a plurality of busbars 20.

[0107] The module array includes multiple rows and columns of battery strings 10, each battery string 10 comprising a plurality of battery cells 11 arranged along a first direction Y, with adjacent battery cells 11 electrically connected. The busbar 20 includes end busbars 21 and intermediate busbars 22. The end busbars 21 are located at opposite ends of the module array along the first direction Y. The intermediate busbars 22 are located in the stacking area of ​​two adjacent battery strings 10 along the first direction Y.

[0108] like Figure 14 As shown, taking a component array comprising two rows of battery strings 10 as an example, the end busbar 21 is used to connect two adjacent battery strings in the same row in series and transmit current. The middle busbar 22 is used to collect the current from the first row L1 and the second row L2 of battery strings.

[0109] In this photovoltaic module 100, the end busbars 21 are located at both ends of the module array along the first direction Y, and the middle busbars 22 are located in the stacking area of ​​two adjacent rows of cell strings 10, with the middle busbars 22 centrally located. In a column of the module array, the busbars 20 are more evenly distributed. Along the first direction Y, the middle busbars 22 exhibit a certain degree of symmetry in collecting current from the cell strings 10 on both sides, which helps reduce the risk of current mismatch.

[0110] In some embodiments, such as Figure 14 As shown, two adjacent battery strings 10 along the first direction Y, one battery string 10 includes a first lead-out solder strip 321 at one end near the stacking area, and the other battery string 10 includes a second lead-out solder strip 322 at one end near the stacking area. An intermediate busbar 22 is connected to the ends of the first lead-out solder strip 321 and the second lead-out solder strip 322, and the first lead-out solder strip 321 and the second lead-out solder strip 322 are disconnected on the surface of the intermediate busbar 22.

[0111] Based on this, the area below the middle region of the busbar 20 is hollowed out in the extension direction of the lead-out solder strip 32. Combined with... Figure 6 The hollowed-out state below the middle area of ​​the busbar 20 provides space for the stacking process in the stacking area. There are no solder strips between the middle area of ​​the busbar 20 and the module array, which helps to reduce the film layer structure between the busbar 20 and the lower battery cell 11 and helps to improve the lamination breakage problem.

[0112] In some embodiments, combined with Figure 6 The photovoltaic module 100 also includes a flexible material layer 50, which is located in the stacking region of two adjacent cell strings 10 along the first direction Y. For example, the material of the flexible material layer 50 includes ethylene-vinyl acetate copolymer, which has good flexibility, impact resistance, and stress cracking resistance, and can protect the cell 11 from mechanical impact and environmental impact, reducing the risk of microcracks and fragmentation.

[0113] In some embodiments, combined with Figure 13 The battery string 10 also includes lead-out solder strips 32, and the busbar 20 includes vias. The lead-out solder strips 32 are folded through the vias and electrically connected to the busbar 20, which helps to improve the connection reliability of the lead-out solder strips 32 and the busbar 20, and helps to improve process compatibility.

[0114] The above description is merely a specific embodiment of this application, but the scope of protection of this application is not limited thereto. Any variations or substitutions conceived by those skilled in the art within the scope of the technology disclosed in this application should be included within the scope of protection of this application. Therefore, the scope of protection of this application should be determined by the scope of the claims.

Claims

1. A method for preparing a photovoltaic module, characterized in that, include: A first device is used to form a battery string; the battery string includes a plurality of battery cells arranged along a first direction, and adjacent battery cells are electrically connected. A second device is used to arrange multiple battery strings to form a component array; the component array includes multiple rows and multiple columns, each row includes multiple battery strings arranged along a second direction, and each column includes multiple battery strings arranged along a first direction; the first direction intersects the second direction; Multiple busbars are disposed on the component array, and the busbars are electrically connected to the battery strings; the multiple busbars include an intermediate busbar, which is located in the stacking area of ​​two adjacent battery strings along the first direction; The first device and the second device are two different devices.

2. The preparation method according to claim 1, characterized in that, The formation of the battery string includes: The plurality of battery cells are arranged along the first direction; Non-lead solder strips are placed on two adjacent solar cells, and the non-lead solder strips are electrically connected to the two adjacent solar cells; Before setting multiple busbars on the component array, the fabrication method further includes: connecting the busbars to multiple lead-out solder strips; The provision of multiple busbars on the component array includes: setting the busbars and the multiple lead-out solder strips on the component array, wherein the busbars are electrically connected to the battery string through the multiple lead-out solder strips.

3. The preparation method according to claim 2, characterized in that, The plurality of busbars also includes end busbars; The step of connecting the busbar to multiple lead-out solder strips includes: Connect the end busbar to the end of the lead-out solder strip; connect the intermediate busbar to the midpoint of the lead-out solder strip, or, each lead-out solder strip includes a first sub-solder strip and a second sub-solder strip, connect the intermediate busbar to the end of the first sub-solder strip and the end of the second sub-solder strip, and disconnect the first sub-solder strip and the second sub-solder strip on the surface of the intermediate busbar; The step of setting the busbar and the plurality of lead-out solder strips on the component array includes: The end busbar and the plurality of lead-out solder strips are disposed at opposite ends of the component array along the first direction; the middle busbar and the plurality of lead-out solder strips are disposed in the stacking area of ​​two adjacent battery strings along the first direction.

4. The preparation method according to claim 2, characterized in that, Before setting multiple busbars on the component array, the preparation method further includes: An insulating strip is provided at both ends of the component array opposite each other along the first direction, and in the stacking area of ​​two adjacent battery strings along the first direction; the insulating strip covers the portion of the non-lead solder strip. After multiple busbars are arranged on the component array, and the insulating strip extends continuously along the second direction and covers multiple non-lead solder strips, the busbars and the multiple lead solder strips are arranged on the side of the insulating strip away from the battery cell.

5. The preparation method according to claim 1, characterized in that, The formation of the battery string includes: The plurality of battery cells are arranged along the first direction to form the battery string; Multiple lead-out solder strips and multiple non-lead-out solder strips are disposed on the multiple battery cells. The non-lead-out solder strips are electrically connected to two adjacent battery cells, and the lead-out solder strips are electrically connected to the battery cells at both ends of the battery string. After multiple busbars are set on the component array, the busbars are electrically connected to the battery string through the multiple lead-out solder strips.

6. The preparation method according to claim 5, characterized in that, Before setting multiple busbars on the component array, the preparation method further includes: An insulating strip is provided at both ends of the component array opposite each other along the first direction, and in the stacking area of ​​two adjacent battery strings along the first direction; the insulating strip covers the portion of the non-lead solder strip and exposes the portion of the lead solder strip. After multiple busbars are set on the component array, the busbars are connected to the lead-out solder strips.

7. The preparation method according to claim 2 or 5, characterized in that, After multiple busbars are arranged on the component array, along the first direction, the end of the lead-out solder strip extends beyond the end of the non-lead-out solder strip; The busbar is connected to the end of the lead-out solder strip that extends beyond the non-lead-out solder strip.

8. The preparation method according to claim 2 or 5, characterized in that, Before setting multiple busbars on the component array, the preparation method further includes: A flexible material layer is provided, which is located in the stacked area of ​​two adjacent battery strings along the first direction.

9. The preparation method according to claim 2 or 5, characterized in that, The provision of multiple busbars on the component array includes: Multiple through holes are formed on the busbar; A lead-out solder strip is folded out from a through-hole and electrically connected to the busbar.

10. The preparation method according to claim 1, characterized in that, The first device includes a string welding platform, and the second device includes a stack welding platform.

11. A photovoltaic module, characterized in that, It is prepared by the preparation method according to any one of claims 1 to 10.

12. The photovoltaic module according to claim 11, characterized in that, The photovoltaic module includes a module array and multiple busbars. The module array includes multiple rows and columns of cell strings. Each cell string includes multiple cells arranged along a first direction, and adjacent cells are electrically connected. The busbar includes an end busbar and an intermediate busbar, wherein the end busbar is disposed at opposite ends of the component array along the first direction; The intermediate busbar is disposed in the stacked area of ​​two adjacent battery strings along the first direction.

13. The photovoltaic module according to claim 12, characterized in that, Two adjacent battery strings along the first direction, one of which has a first lead-out solder strip at one end near the stacked area, and the other of which has a second lead-out solder strip at one end near the stacked area; The intermediate busbar is connected to the end of the first lead-out solder strip and the end of the second lead-out solder strip, and the first lead-out solder strip and the second lead-out solder strip are disconnected on the surface of the intermediate busbar.

14. The photovoltaic module according to claim 13, characterized in that, The photovoltaic module further includes a flexible material layer located in the stacking area of ​​two adjacent cell strings along the first direction.

15. The photovoltaic module according to claim 12, characterized in that, The battery string also includes lead-out solder strips, and the busbar includes vias. The lead-out solder strips are folded through the vias and electrically connected to the busbar.

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