Photovoltaic module and preparation method thereof

Abstract

The invention relates to the field of photovoltaic technology, provides a photovoltaic module and a preparation method thereof, and at least can improve the reliability of the photovoltaic module. The preparation method of the photovoltaic module comprises the steps that a laminated piece is provided, the laminated piece comprises a main body area and an edge area connected with the main body area, and the edge area is provided with a first face and second faces which are connected with the two opposite ends of the first face respectively and directly face each other; an insulating film is provided and placed on the first face and the second face, the insulating film comprises an adhesive layer and an insulating base layer, and the adhesive layer is located between the insulating base layer and the laminated piece; an exhaust channel communicated with the outside is arranged in the adhesive layer on the second surface; and heating the insulating film to enable the adhesive layer to be adhered to the laminated piece and the insulating base layer.

Description

TECHNICAL FIELD

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

[0002] At present, the global energy consumption is rapidly increasing, and the traditional fossil energy is increasingly exhausted. Energy problems and environmental problems have gradually become two major global concerns. Under the pressure of environmental pollution and sustainable development, researchers have included the solar photovoltaic industry in the focus of renewable energy development and utilization.

[0003] The photovoltaic module includes a laminated part, and the laminated part is an important device for converting solar energy into electrical energy. In order to increase the creepage distance and ensure the safety and reliability of the laminated part during use, an insulating film is arranged at the edge of the laminated part. However, the current insulating film arrangement has certain problems, which will affect the reliability of the photovoltaic module. SUMMARY

[0004] The present application provides a photovoltaic module and a preparation method thereof, which can at least improve the reliability of the photovoltaic module.

[0005] In one aspect, the present application provides a preparation method of a photovoltaic module, which includes: providing a laminated part, the laminated part including a main body area and an edge area connected with the main body area, the edge area having a first surface and a second surface opposite to the first surface and connected with the first surface at two ends respectively; providing an insulating film and placing the insulating film on the first surface and the second surface, the insulating film including a glue layer and an insulating base layer, the glue layer being located between the insulating base layer and the laminated part; wherein the glue layer on the second surface has an exhaust passage in communication with the outside; heating the insulating film to make the glue layer bond the laminated part and the insulating base layer.

[0006] Optionally, a part of the insulating film on the second surface and having a distance greater than a first threshold value from the plane where the first surface is located is a first part, and the first part has the exhaust passage.

[0007] Optionally, the insulating film includes a plurality of exhaust passages, and the distance between adjacent exhaust passages is the same.

[0008] Optionally, a part of the insulating film on the second surface and having a distance greater than a first threshold value from the plane where the first surface is located is a first part, and the first part has a first hole penetrating through the insulating base layer.

[0009] Optionally, in the direction of the glue layer pointing to the insulating base layer, the size of the first hole gradually decreases.

[0010] Optionally, the first part has a second hole penetrating through at least part of the thickness of the adhesive layer, and the second hole is in communication with the first hole and / or the exhaust passage.

[0011] Optionally, the insulating film comprises: a first part located on the second surface and having a distance greater than a first threshold value from the plane where the first surface is located; and a second part located on the first surface and part of the second surface, the first part being adjacent to the second part, wherein the thickness of the adhesive layer of the first part is greater than the thickness of the adhesive layer of the second part.

[0012] Optionally, the thickness of the adhesive layer of the second part is 30 μm-110 μm, and the thickness of the adhesive layer of the first part is 40 μm-120 μm.

[0013] Optionally, the insulating film comprises: a first part located on the second surface and having a distance greater than a first threshold value from the plane where the first surface is located; and a second part located on the first surface and part of the second surface, the first part being adjacent to the second part, wherein the thickness of the adhesive layer of the first part is greater than the thickness of the adhesive layer of the second part.

[0014] Another aspect of the present application also provides a photovoltaic module, which is prepared by the preparation method of any one of the photovoltaic modules, and comprises: a laminate, the laminate comprising a main body area and an edge area connected to the main body area, the edge area having a first surface and a second surface opposite to the first surface and connected to the first surface at two opposite ends; and an insulating film, the insulating film being located on the first surface and the second surface, the insulating film comprising an adhesive layer and an insulating base layer, the adhesive layer being located between the insulating base layer and the laminate.

[0015] The technical scheme provided by the present application has at least the following advantages: In the provided insulating film, the adhesive layer has an exhaust passage in communication with the outside, when the insulating film is heated, the exhaust passage can provide an escape channel for the bubbles between the adhesive layer and the laminate and the bubbles in the adhesive layer, which is beneficial to reduce the number of bubbles in the photovoltaic module, thereby improving the reliability of the photovoltaic module. BRIEF DESCRIPTION OF DRAWINGS

[0016] One or more embodiments are illustrated by way of example with corresponding pictures in the accompanying drawings. These illustrations do not constitute a limitation on the embodiments. Unless otherwise stated, the pictures in the accompanying drawings do not constitute a limitation on scale. In order to more clearly illustrate the technical solutions in the embodiments of this application or in the conventional technology, the drawings used in the embodiments will be briefly introduced below. Obviously, the drawings described below are only some embodiments of this application. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.

[0017] Figure 1 This is a partial structural diagram of the laminate and insulating film in a photovoltaic module provided in an embodiment of this application; Figure 2 This is a top view of the laminate and insulating film in a photovoltaic module provided in an embodiment of this application; Figure 3 This is a partially enlarged structural diagram of the laminate and insulating film in a photovoltaic module provided in an embodiment of this application; Figure 4 This is a schematic diagram of a structure of a laminate in a photovoltaic module provided in an embodiment of this application; Figure 5 This is a partially enlarged structural diagram of the laminate and insulating film in a photovoltaic module provided in an embodiment of this application; Figure 6 This is a partially enlarged structural diagram of the laminate and insulating film in a photovoltaic module provided in the embodiments of this application; Figure 7 This is a schematic diagram of a structure of a photovoltaic module, including the laminate, insulating film, and frame, provided in an embodiment of this application.

[0018] Explanation of reference numerals in the attached figures: 1. Laminated component; 11. First side; 12. Second side; 13. Encapsulating film; 14. Cover plate; 15. Battery cell; 16. Solder ribbon; 2. Insulating film; 21. Adhesive layer; 211. Venting channel; 212. Second hole; 22. Insulating base layer; 221. First hole; 23. First part; 24. Second part; 241. First sub-part; 242. Second sub-part; 3. Frame; 31. Receiving groove. Detailed Implementation

[0019] A photovoltaic (PV) module comprises a laminate and an insulating film. The laminate includes a front and a back side disposed opposite each other, as well as a side connecting the front and back sides. The insulating film is disposed around the perimeter of the laminate and is located on the front, back, and side sides, wrapping around the laminate in a C-shape. The insulating film includes an adhesive layer and an insulating base layer, with the adhesive layer located between the insulating base layer and the laminate. When the insulating film is bonded to the laminate, a certain number of air bubbles may exist between the adhesive layer and the laminate, and air bubbles may also exist within the adhesive layer. The presence of air bubbles may prevent the insulating film from effectively improving the creepage distance of the PV module and affect the lifespan of the PV module, resulting in lower reliability.

[0020] Therefore, this application provides a photovoltaic module and its manufacturing method. In the provided insulating film, the adhesive layer has an exhaust channel that communicates with the outside. When the insulating film is heated, the exhaust channel can provide an escape channel for air bubbles between the adhesive layer and the laminate, as well as air bubbles within the adhesive layer, which helps to reduce the number of air bubbles in the photovoltaic module and thus improve the reliability of the photovoltaic module.

[0021] In the description of the embodiments of this application, technical terms such as "first" and "second" are used only to distinguish different objects and should not be construed as indicating or implying relative importance or implicitly specifying the number, specific order, or primary and secondary relationship of the indicated technical features. In the description of the embodiments of this application, "multiple" means two or more, unless otherwise explicitly defined.

[0022] In this document, the term "embodiment" means that a particular feature, structure, or characteristic described in connection with an embodiment may be included in at least one embodiment of this application. The appearance of this phrase in various places throughout the specification does not necessarily refer to the same embodiment, nor is it a separate or alternative embodiment mutually exclusive with other embodiments. It will be explicitly and implicitly understood by those skilled in the art that the embodiments described herein can be combined with other embodiments.

[0023] In the description of the embodiments in this application, the term "and / or" is merely a description of the relationship between related objects, indicating that three relationships can exist. For example, A and / or B can represent three cases: A exists, A and B exist simultaneously, and B exists. In addition, the character " / " in this document generally indicates that the related objects before and after it have an "or" relationship.

[0024] In the description of the embodiments of this application, the term "multiple" refers to two or more (including two), similarly, "multiple sets" refers to two or more (including two sets), and "multiple pieces" refers to two or more (including two pieces).

[0025] In the description of the embodiments of this application, the technical terms "center," "longitudinal," "lateral," "length," "width," "thickness," "upper," "lower," "front," "rear," "left," "right," "vertical," "horizontal," "top," "bottom," "inner," "outer," "clockwise," "counterclockwise," "axial," "radial," and "circumferential" indicate the orientation or positional relationship based on the orientation or positional relationship shown in the accompanying drawings. They are only for the convenience of describing the embodiments of this application and simplifying the description, and are not intended to indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation. Therefore, they should not be construed as limitations on the embodiments of this application.

[0026] In the description of the embodiments of this application, unless otherwise expressly specified and limited, technical terms such as "installation," "connection," "joining," and "fixing" 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. Those skilled in the art can understand the specific meaning of the above terms in the embodiments of this application according to the specific circumstances.

[0027] In the description of the embodiments of this application, "electrically connected to one component" means that both components are made of conductive materials and are directly connected or connected via other conductive materials. Therefore, when the photovoltaic module is generating electricity, current flows between the two components. "Electrically contacting one component to another" means that the two components are not only in contact, but also, because both components are made of conductive materials, current flows between them when the photovoltaic module is generating electricity.

[0028] In the accompanying drawings corresponding to the embodiments of this application, the thickness and area of ​​the layers are enlarged for better understanding and ease of description. When describing a component (such as a layer, film, region, or substrate) on or on the surface of another component, the component may be "directly" located on the surface of the other component, or there may be a third component between the two components. Conversely, when describing a component on the surface of another component, or when another component is formed or disposed on the surface of a component, it indicates that there is no third component between the two components. Furthermore, when describing a component as being "generally" formed on another component, it means that the component is not formed on the entire surface (or front surface) of the other component, nor is it formed on a portion of the edge of the entire surface.

[0029] In the description of the embodiments of this application, when a component "includes" another component, other components are not excluded unless otherwise stated, and other components may be further included. Furthermore, when a component such as a layer, film, region, or plate is referred to as being "on / located" on another component, it can be "directly on" the other component (i.e., located on the surface of the other component with no other components between them), or another component may be present therein. Moreover, when a component such as a layer, film, region, or plate is "directly located" on another component, or when a component such as a layer, film, region, or plate is located on the surface of another component, it indicates that no other components are located therein.

[0030] The embodiments of this application will now be described in detail with reference to the accompanying drawings. However, those skilled in the art will understand that many technical details have been provided in the embodiments of this application to facilitate a better understanding of the application. However, the technical solutions claimed in this application can be implemented even without these technical details and various variations and modifications based on the following embodiments.

[0031] Figure 1 This is a partial structural diagram of the laminate and insulating film in a photovoltaic module provided in an embodiment of this application. Figure 2 This is a top view schematic diagram of the laminate and insulating film in a photovoltaic module provided in an embodiment of this application. Figure 3 This is a partially enlarged structural diagram of the laminate and insulating film in a photovoltaic module provided in an embodiment of this application. The diagram is shown to facilitate observation of the exhaust channel. Figure 3 A partial magnified view of the insulating film located on the second surface is shown.

[0032] refer to Figures 1 to 3 The method for manufacturing a photovoltaic module includes: providing a laminate 1, the laminate 1 including a main body region and an edge region connected to the main body region, the edge region having a first surface 11 and a second surface 12 connected to and facing each other at opposite ends of the first surface 11; providing an insulating film 2 and placing the insulating film 2 on the first surface 11 and the second surface 12, the insulating film 2 including an adhesive layer 21 and an insulating base layer 22, the adhesive layer 21 being located between the insulating base layer 22 and the laminate 1; wherein the adhesive layer 21 located on the second surface 12 has an exhaust channel 211 communicating with the outside; heating the insulating film 2 to bond the adhesive layer 21 to the laminate 1 and the insulating base layer 22.

[0033] The laminate 1 includes a main body area and an edge area. The main body area is the primary region of the laminate 1 that converts solar energy into electrical energy, while the edge area is located around the main body area and surrounds it.

[0034] The laminate 1 has a front and a back side arranged opposite to each other, with two first surfaces 11 facing each other as the front and back sides of the edge area, respectively. The second surface 12 is a side surface connecting the front and the back sides.

[0035] Figure 4 This is a schematic diagram of a laminate in a photovoltaic module provided in an embodiment of this application.

[0036] refer to Figure 4 In some embodiments, the laminate 1 includes a battery string, an encapsulating film 13, and a cover plate 14, wherein the encapsulating film 13 covers the surface of the battery string, and the cover plate 14 covers the surface of the encapsulating film 13 opposite to the battery string.

[0037] The battery string includes multiple battery cells 15 and solder ribbons 16, which are used to electrically connect adjacent battery cells 15.

[0038] The solar cell 15 can be one or any combination of BC (Back Contact) cells, PERC (Passivated Emitter Rear Cell) cells, IBC (Interdigitated Back Contact) cells, TOPCON (Tunnel Oxide Passivated Contact) cells, heterojunction cells, thin-film solar cells, and tandem cells. Thin-film solar cells include, but are not limited to, perovskite thin-film solar cells, copper indium selenide (CIGS) thin-film solar cells, gallium arsenide (GaAs) thin-film solar cells, and cadmium sulfide (CdS) thin-film solar cells. Tandem cells include, but are not limited to, perovskite cells stacked with crystalline silicon cells, perovskite cells stacked with perovskite cells, and perovskite cells stacked with thin-film cells. Figure 4 Taking cell 15 as an example of a TOPCON battery.

[0039] The solar cell 15 can be a cell with a main grid, which can shorten the current conduction path and reduce internal losses, thereby increasing the power of the photovoltaic module. The solar cell 15 can also be a cell without a main grid, in which case the solder ribbon 16 is used to replace the original main grid and is directly connected to the fine grid, which can significantly reduce the consumption of silver paste, thereby reducing the cost of the photovoltaic module.

[0040] The battery cell 15 can be a whole cell or a sliced ​​cell. A sliced ​​cell refers to a cell formed by cutting a complete cell. Sliced ​​cells can be two-piece sliced ​​cells, three-piece sliced ​​cells, or four-piece sliced ​​cells, etc.

[0041] In some embodiments, the encapsulating film 13 includes a first encapsulating layer and a second encapsulating layer. The first encapsulating layer covers one of the front and back sides of the battery cell 15, and the second encapsulating layer covers the other of the front and back sides of the battery cell 15. Specifically, at least one of the first and second encapsulating layers can be an organic encapsulating film such as polyvinyl butyral (PVB) film, ethylene-vinyl acetate copolymer (EVA) film, polyvinyl octene elastomer (POE) film, or polyethylene terephthalate (PET) film. Alternatively, at least one of the first and second encapsulating layers can also be an EP film, an EPE film, or a PVP film. Here, EP film refers to a co-extruded film composed of stacked EVA and POE films; EPE film refers to a co-extruded film formed by sequentially stacking EVA, POE, and EVA films; and PVP film refers to a co-extruded film formed by stacking POE, EVA, and POE films. Co-extruded films can be prepared by sequentially extruding one or more raw materials onto another pre-made film during the film processing, or by bonding different types of pre-made films together.

[0042] In some cases, the first encapsulation layer and the second encapsulation layer still have a boundary line before lamination. After the photovoltaic module is formed by lamination, there is no longer a concept of the first encapsulation layer and the second encapsulation layer. That is, the first encapsulation layer and the second encapsulation layer have formed an integral encapsulation film 13.

[0043] In some embodiments, the cover plate 14 can be a glass cover plate, a plastic cover plate, or other cover plate with light-transmitting function. Specifically, the surface of the cover plate 14 facing the encapsulating film 13 can be an uneven surface or a textured surface containing multiple raised structures, thereby increasing the utilization rate of incident light. The cover plate 14 includes a first cover plate and a second cover plate, the first cover plate being opposite to the first encapsulation layer, and the second cover plate being opposite to the second encapsulation layer.

[0044] Continue to refer to Figure 1 and Figure 2 The insulating film 2 includes an adhesive layer 21 and an insulating base layer 22. The adhesive layer 21 is used to bond the insulating base layer 22 and the laminate 1. The insulating base layer 22 has insulating properties and is used to increase the creepage distance of the photovoltaic module to improve the safety of the photovoltaic module.

[0045] It should be noted that the adhesive layer 21 has venting channels 211 before heating. After heating, the adhesive layer 21 transforms into a molten state, wetting the surface of the laminate 1 and the surface of the insulating base layer 22. After cooling and solidification, the adhesive layer 21 forms a stable interfacial bond with the laminate 1 and the insulating base layer 22, thus allowing the adhesive layer 21 to bond the laminate 1 and the insulating base layer 22. During the heating process of the insulating film 2, the adhesive layer 21 gradually transforms into a flowing molten state, and the venting channels 211 are gradually sealed by the molten adhesive layer 21. Therefore, the adhesive layer 21 of the final photovoltaic module may not contain venting channels 211.

[0046] In some embodiments, the adhesive layer 21 may be made of polyolefin, epoxy resin, polyurethane or silicone polymer.

[0047] In some embodiments, the material of the insulating base layer 22 may be polyethylene terephthalate, polyolefin, polyethylene or polyimide, etc.

[0048] In some embodiments, the portion of the insulating film 2 located on the second surface 12 and at a distance greater than a first threshold L1 from the plane containing the first surface 11 is designated as a first portion 23, which has an exhaust channel 211. The first threshold L1 is also the length along the first direction X of the remaining portion of the insulating film 2 on the second surface 12 excluding the first portion 23. This configuration, where exhaust channels 211 are provided at both ends of the insulating film 2, facilitates communication between the exhaust channels 211 and the outside environment, and eliminates the need for exhaust channels 211 elsewhere on the insulating film 2, thus ensuring the adhesive performance of the adhesive layer 21.

[0049] In some embodiments, the insulating film 2 includes a plurality of venting channels 211, with adjacent venting channels 211 being equidistant from each other. That is, the venting channels 211 are evenly distributed on the adhesive layer 21, which is beneficial to improving the air bubble removal effect of the venting channels 211.

[0050] It is understandable that if there is a certain difference in the distance between adjacent exhaust channels 211, and this difference is within the measurement tolerance or manufacturing error range, they should be considered substantially the same. In other words, the same distance between adjacent exhaust channels 211 includes two cases: equal distance and nearly equal distance.

[0051] The width of the venting channel 211 is 0.01mm to 0.11mm, for example, 0.01mm, 0.03mm, 0.05mm, 0.08mm, 0.1mm, or 0.11mm. The width of the venting channel 211 is within this range. This avoids the venting channel 211 being too narrow, making it difficult to effectively provide an escape channel for air bubbles, and also avoids the venting channel 211 being too wide, causing it to occupy too large a proportion of the adhesive layer 21, making it difficult for the adhesive layer 21 to effectively bond the insulating base layer 22 and the laminate 1.

[0052] In some embodiments, the distance between adjacent exhaust channels 211 is 0.1mm to 2mm, for example, 0.1mm, 0.3mm, 0.5mm, 0.8mm, 1mm, 1.5mm, or 2mm. The distance between adjacent exhaust channels 211 is within the above range to ensure that the distance is not too large, which would result in a longer path for air bubbles to reach the exhaust channel 211 and make it difficult for them to escape effectively. It also avoids the spacing being too small, which would result in an excessive number of exhaust channels 211, making it difficult for the adhesive layer 21 to effectively bond to the insulating base layer 22 and the laminate 1.

[0053] The distance between adjacent exhaust channels 211 is the distance between the adjacent edges of two adjacent exhaust channels 211.

[0054] In some embodiments, the exhaust channel 211 extends along a first direction X. That is, the exhaust channel 211 is a straight channel, which facilitates the preparation of the exhaust channel 211 and facilitates the escape of bubbles from the exhaust channel 211. Herein, the first direction X is the direction from the first sub-part 241 to the first part 23.

[0055] In some embodiments, the length of the venting channel 211 along the first direction X is 0.1 mm to 2 mm, for example, 0.1 mm, 0.3 mm, 0.5 mm, 0.8 mm, 1 mm, 1.5 mm, or 2 mm. The length of the venting channel 211 within the above range avoids being too short, making it difficult to provide an escape channel for the adhesive layer 21 on the second surface 12, and also avoids being too long, which would make it difficult for the venting channel 211 to be completely filled after the adhesive layer 21 is heated, resulting in pores in the heated and cooled cured adhesive layer 21, affecting the adhesive performance of the adhesive layer 21.

[0056] Figure 5 This is a partially enlarged structural diagram of the laminate and insulating film in a photovoltaic module provided in an embodiment of this application.

[0057] refer to Figure 1 and Figure 5 In some embodiments, the portion of the insulating film 2 located on the second surface 12 and at a distance greater than a first threshold L1 from the plane containing the first surface 11 is designated as the first part 23. The first part 23 has a first hole 221 penetrating the insulating base layer 22. The first hole 221 can also provide an escape channel for air bubbles, which is beneficial for reducing the number of air bubbles and thus improving the reliability of the photovoltaic module. The presence of the first hole 221 will reduce the insulation performance of the insulating base layer 22 in the first part 23. By placing the first hole 221 within the first part 23, i.e., at both ends of the insulating film 2, the position of the first hole 221 between the two ends can be avoided, as this would affect the overall insulation performance of the insulating film 2 and prevent the insulating film 2 from being unable to effectively improve the creepage distance of the photovoltaic module.

[0058] In some embodiments, the size of the first hole 221 is 0.01mm to 1mm, for example, 0.01mm, 0.05mm, 0.1mm, 0.3mm, 0.5mm, 0.8mm, or 1mm. The size of the first hole 221 is within the above range. This avoids the first hole 221 being too small, making it difficult to effectively provide an escape channel for air bubbles, and also avoids the first hole 221 being too large, resulting in the first hole 221 occupying too large a proportion of the insulating substrate 22, making it difficult for the insulating substrate 22 to effectively increase the creepage distance of the photovoltaic module.

[0059] When the first hole 221 is circular, its size is the diameter of the circle; when the first hole 221 is elliptical, its size is the major or minor axis of the ellipse; and when the first hole 221 is polygonal, its size is the side length or diagonal length of the polygon.

[0060] In some embodiments, the distance between adjacent first holes 221 is 0.1mm to 3mm, for example, 0.1mm, 0.3mm, 0.5mm, 0.8mm, 1mm, 1.5mm, 2mm, 2.5mm, or 3mm. The distance between adjacent first holes 221 is the distance between the geometric centers of two adjacent first holes 221. Maintaining the distance between adjacent first holes 221 within this range ensures that the distance is not too large, resulting in a longer path for bubbles to reach the first hole 221 and hindering their effective escape; it also avoids the spacing being too small, leading to an excessive number of first holes 221, which would make it difficult for the insulating base layer 22 to effectively improve the creepage distance of the photovoltaic module.

[0061] Figure 6 This is a partially enlarged structural diagram of the laminate and insulating film in a photovoltaic module provided in the embodiments of this application.

[0062] refer to Figure 1 and Figure 6 In some embodiments, the size of the first hole 221 gradually decreases in the direction from the adhesive layer 21 to the insulating base layer 22. This results in a larger size for the portion of the first hole 221 closer to the adhesive layer 21 and a smaller size for the portion farther away from the adhesive layer 21. This provides an escape channel for air bubbles while preventing the molten adhesive layer 21 from overflowing, which is beneficial for improving the reliability of the photovoltaic module.

[0063] During the process of heating the insulating base layer 22 to bond the insulating base layer 22 to the laminate 1, the material of the insulating base layer 22 is relatively stable, so the photovoltaic module formed in the end still has a first hole 221.

[0064] refer to Figure 1 , Figure 4 and Figure 5In some embodiments, the first part 23 has a second hole 212 penetrating at least a portion of the thickness of the adhesive layer 21, and the second hole 212 communicates with the first hole 221 and / or the venting channel 211. The second hole 212 communicates with at least one of the first hole 221 and the venting channel 211, and the second hole 212 can also provide an escape channel for bubbles, which helps to reduce the number of bubbles in the photovoltaic module, thereby improving the reliability of the photovoltaic module.

[0065] It is understandable that the adhesive layer 21 has a second pore 212 before heating. During the heating process of the insulating film 2, the adhesive layer 21 transforms into a flowing molten state, and the second pore 212 will be gradually sealed by the molten adhesive layer 21, so that the adhesive layer 21 of the final photovoltaic module may not have the second pore 212.

[0066] In some embodiments, the size of the second hole 212 is 0.1 mm to 1 mm, for example, 0.1 mm, 0.3 mm, 0.5 mm, 0.8 mm, or 1 mm. The size of the second hole 212 is within the above range to avoid it being too small, making it difficult to effectively provide an escape channel for air bubbles, and also to avoid it being too large, causing the second hole 212 to occupy too large a proportion of the adhesive layer 21, making it difficult for the adhesive layer 21 to effectively bond the insulating base layer 22 and the laminate 1.

[0067] When the shape of the second hole 212 is circular, the size of the second hole 212 is the diameter of the circle; when the shape of the second hole 212 is elliptical, the size of the second hole 212 is the major axis or minor axis of the ellipse; when the shape of the second hole 212 is polygonal, the size of the second hole 212 is the side length or diagonal length of the polygon.

[0068] In some embodiments, the distance between adjacent second holes 212 is 0.05mm to 2mm, for example, 0.05mm, 0.1mm, 0.3mm, 0.5mm, 0.8mm, 1mm, 1.5mm, or 2mm. The distance between adjacent second holes 212 is the distance between the geometric centers of two adjacent second holes 212. Maintaining the distance between adjacent second holes 212 within the above range ensures that the distance is not too large, resulting in a longer path for air bubbles to reach the second holes 212 and hindering their effective escape; it also avoids the spacing being too small, leading to an excessive number of second holes 212, which would make it difficult for the adhesive layer 21 to effectively bond the insulating base layer 22 and the laminate 1.

[0069] In some embodiments, the insulating film 2 includes a first part 23 and a second part 24. The first part 23 is located on the second surface 12 and the distance between it and the plane containing the first surface 11 is greater than a first threshold L1. The second part 24 is located on the first surface 11 and a portion of the second surface 12. The first part 23 and the second part 24 are adjacent to each other. The thickness of the adhesive layer 21 in the first part 23 is greater than the thickness of the adhesive layer 21 in the second part 24. The first part 23 has an exhaust channel 211. When the adhesive layer 21 is heated and transforms into a molten state with a certain fluidity, the exhaust channel 211 is closed, thereby reducing the thickness of the molten adhesive layer 21 in the first part 23 after heating. Setting the thickness of the adhesive layer 21 in the first part 23 to be greater than the thickness of the adhesive layer 21 in the second part 24 helps to make the thickness of the adhesive layer 21 after heating more consistent in the first part 23 and the second part 24, thereby improving the bonding reliability of the adhesive layer 21.

[0070] In some embodiments, the thickness of the adhesive layer 21 of the first part 23 is 40 μm to 120 μm, for example, 40 μm, 50 μm, 70 μm, 90 μm, 100 μm, or 120 μm. The thickness of the adhesive layer 21 of the first part 23 within the above range allows the first part 23 to provide a sufficient number of venting channels 211 while ensuring the adhesive performance of the adhesive layer 21 of the first part 23. Here, the thickness of the adhesive layer 21 of the first part 23 refers to the thickness of the adhesive layer 21 of the first part 23 before heating.

[0071] The thickness of the adhesive layer 21 in the second part 24 is 30μm to 110μm, for example, 30μm, 50μm, 70μm, 90μm, 100μm, or 110μm. The thickness of the adhesive layer 21 in the second part 24 is within the above range, ensuring that the adhesive layer 21 provides sufficient adhesion between the adhesive layer 21 pressing member 1 and the insulating base layer 22. Here, the thickness of the adhesive layer 21 in the second part 24 refers to the thickness of the adhesive layer 21 in the second part 24 before heating.

[0072] In some embodiments, the insulating film 2 includes a first portion 23 and a second portion 24. The first portion 23 is located on the second surface 12 and is at a distance greater than a first threshold L1 from the plane containing the first surface 11. The second portion 24 is located on the first surface 11 and a portion of the second surface 12, with the first portion 23 adjacent to the second portion 24. The second portion 24 does not have any holes penetrating at least a portion of the thickness of the insulating base layer 22. This ensures the insulation performance of the insulating base layer 22 of the second portion 24, allowing the insulating film 2 to effectively increase the creepage distance of the photovoltaic module and improve the safety of the photovoltaic module.

[0073] In some embodiments, the second part 24 includes a first sub-part 241 and a second sub-part 242. The first sub-part 241 is located on the second surface 12 and adjacent to the first part 23, and the second sub-part 242 is located on the first surface 11 of the laminate 1 and adjacent to the first sub-part 241. The first threshold L1 is the length of the first sub-part 241 along the first direction X. No holes penetrating at least a portion of the thickness are provided in the insulating base layer 22 of the first sub-part 241, meaning the insulating base layer 22 of the first sub-part 241 has a high density, resulting in superior insulation performance and effectively increasing the creepage distance of the photovoltaic module.

[0074] In some embodiments, along the first direction X, the ratio of the first threshold L1 to the length L2 of the first portion 23 is 1.5 to 12. A ratio of the first threshold L1 to the length L2 of the first portion 23 within the above range results in a larger first threshold L1, meaning a larger length of the first sub-portion 241 with superior performance, thereby effectively increasing the creepage distance of the photovoltaic module.

[0075] In some embodiments, along the first direction X, the first threshold L1 is 3mm to 6mm, for example, 3mm, 3.5mm, 4mm, 4.5mm, 5mm, 5.5mm, or 6mm. The first threshold L1 is within the above range, that is, the length of the first sub-part 241 is within the above range. The larger length of the first sub-part 241 allows the insulating layer to effectively increase the creepage distance of the photovoltaic module.

[0076] Along the first direction X, the length L2 of the first part 23 is 0.5mm to 2mm, for example, 0.5mm, 0.8mm, 1mm, 1.5mm, or 2mm. A first hole 221 is provided in the insulating base layer 22 of the first part 23. The presence of the first hole 221 will result in poor insulation performance of the insulating base layer 22 of the first part 23. The length L2 of the first part 23 is within the above range. A smaller length L2 of the first part 23 avoids the insulating film 2 from being unable to effectively increase the creepage distance of the photovoltaic module and wasting material due to a larger length L2.

[0077] Figure 7 This is a schematic diagram of a structure of a photovoltaic module, including the laminate, insulating film, and frame, provided in an embodiment of this application.

[0078] refer to Figure 1 , Figure 4 and Figure 7 In some embodiments, the photovoltaic module also includes a frame 3, which is provided with a receiving groove 31, and the edge of the laminate 1 and the insulating film 2 are located in the receiving groove 31.

[0079] The frame 3 is located at the edge of the laminate 1. The frame 3 has a receiving groove 31 to accommodate the edge of the laminate 1, and can be bonded using sealant such as silicone (not shown), forming a stable connection between the laminate 1 and the frame 3. The photovoltaic module can be mounted on a bracket or other support using the frame 3. The frame 3 completely encapsulates the four edges of the laminate 1. The frame 3 can be made of aluminum alloy to achieve a lightweight photovoltaic module.

[0080] In some embodiments, the insulating film 2 does not extend beyond the receiving groove 31. That is, the edge of the insulating film 2 is covered by the frame 3. The frame 3 can completely accommodate the insulating film 2 within the receiving groove 31. By ensuring that the edge of the insulating film 2 does not protrude beyond the edge of the frame 3, the aesthetics of the photovoltaic module can be ensured, and the frame 3 can be used to encapsulate the insulating film 2 to form protection.

[0081] In some embodiments, the insulating film 2 is located on the edge area and can also be used to seal the gap between the laminate 1 and the frame 3 to prevent water vapor, dust and other pollutants from entering the interior of the photovoltaic module, thereby protecting the cell 15 and the internal circuit, and ensuring the long-term reliability and service life of the photovoltaic module.

[0082] Some embodiments of this application also provide a photovoltaic module, which is prepared by the preparation method of the photovoltaic module of any of the above embodiments. It should be noted that the parts that are the same as or corresponding to the above embodiments can be referred to the above embodiments, and will not be repeated below.

[0083] refer to Figure 1 and Figure 2 The photovoltaic module includes: a laminate 1 and an insulating film 2. The laminate 1 includes a main body area and an edge area connected to the main body area. The edge area has a first surface 11 and a second surface 12 that is connected to and faces the opposite ends of the first surface 11. The insulating film 2 is located on the first surface 11 and the second surface 12. The insulating film 2 includes an adhesive layer 21 and an insulating base layer 22. The adhesive layer 21 is located between the insulating base layer 22 and the laminate 1.

[0084] Those skilled in the art will understand that the above embodiments are specific examples of implementing this application, and in practical applications, various changes in form and detail can be made without departing from the spirit and scope of this application. Any person skilled in the art can make various alterations and modifications without departing from the spirit and scope of this application; therefore, the scope of protection of this application should be determined by the scope defined in the claims.

Claims

1. A method of making a photovoltaic module, characterized by, The application provides a photovoltaic module and a preparation method thereof. The application provides a photovoltaic module and a preparation method thereof. The application provides a photovoltaic module and a preparation method thereof. The application provides a photovoltaic module and a preparation method thereof.

2. The method of claim 1, wherein the method further comprises: The application provides a photovoltaic module and a preparation method thereof.

3. The method of claim 1, wherein the method further comprises: The application provides a photovoltaic module and a preparation method thereof.

4. The method of claim 1, wherein the method further comprises: The application provides a photovoltaic module and a preparation method thereof.

5. The method of claim 4, wherein the step of applying the encapsulant is performed after the step of applying the backsheet. The application provides a photovoltaic module and a preparation method thereof.

6. The method of claim 4, wherein the step of applying the encapsulant is performed by a method selected from the group consisting of: extrusion, injection molding, and transfer molding. The application provides a photovoltaic module and a preparation method thereof.

7. The method of producing a photovoltaic module according to any one of claims 1 to 6, characterized in that, The application provides a photovoltaic module and a preparation method thereof. The application provides a photovoltaic module and a preparation method thereof. The application provides a photovoltaic module and a preparation method thereof.

8. The method of claim 7, wherein the method further comprises, The application provides a photovoltaic module and a preparation method thereof.

9. The method of claim 1, wherein the method further comprises, The application provides a photovoltaic module and a preparation method thereof. The application provides a photovoltaic module and a preparation method thereof. The application provides a photovoltaic module and a preparation method thereof.

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