Lightweight photovoltaic module and manufacturing method thereof

Abstract

The invention provides a light photovoltaic module and a manufacturing method, and relates to the technical field of photovoltaic modules, and the light photovoltaic module comprises a battery piece, an adhesive film piece, a packaging piece and a frame assembly. The first adhesive film layer is arranged on one side of the battery piece, the second adhesive film layer is arranged on one side of the battery piece, the first packaging layer is arranged on one side, deviating from the battery piece, of the first adhesive film layer, and the second packaging layer is arranged on one side, deviating from the battery piece, of the second adhesive film layer, so that the battery piece, the adhesive film pieces and the packaging piece are laminated to form a photovoltaic piece; the frame assembly surrounds the periphery of the photovoltaic piece. According to the manufacturing method, the battery piece is packaged and protected, the mechanical strength of the light photovoltaic module is enhanced, the impact resistance of the light photovoltaic module is improved, the good protection performance is achieved, the manufacturing method can be used for mass production of the light photovoltaic module, and the manufacturing cost is reduced. Damage or breakage of related parts in the light photovoltaic module in the manufacturing process can be reduced, and the product yield is improved.

Description

Technical Field

[0001] This invention relates to the field of photovoltaic module technology, and more specifically, to a lightweight photovoltaic module and its manufacturing method. Background Technology

[0002] Photovoltaic modules are the core component of a solar photovoltaic power generation system, their function being to directly convert sunlight into electrical energy. The cells within photovoltaic modules are prone to damage or breakage, have poor structural protection, and are often manufactured manually, resulting in a high product defect rate. Summary of the Invention

[0003] The purpose of this invention is to provide a lightweight photovoltaic module and its manufacturing method. The lightweight photovoltaic module encapsulates and protects the battery components, enhances the mechanical strength of the lightweight photovoltaic module, improves its impact resistance, and has better protective performance. The manufacturing method can be used for mass production of lightweight photovoltaic modules, which can reduce the occurrence of damage or breakage of related components in the lightweight photovoltaic module during the manufacturing process and improve product yield.

[0004] A first aspect of the present invention provides a lightweight photovoltaic module, the lightweight photovoltaic module comprising a battery component, a film component, an encapsulation component, and a frame component.

[0005] Battery components;

[0006] An adhesive film component, the adhesive film component including a first adhesive film layer and a second adhesive film layer, the first adhesive film layer being disposed on one side of the battery component, and the second adhesive film layer being disposed on the side of the battery component opposite to the first adhesive film layer;

[0007] An encapsulation component, comprising a first encapsulation layer and a second encapsulation layer, wherein the first encapsulation layer is disposed on the side of the first adhesive film layer opposite to the battery component, and the second encapsulation layer is disposed on the side of the second adhesive film layer opposite to the battery component, so that the battery component, the adhesive film component, and the encapsulation component are laminated to form a photovoltaic component;

[0008] A frame assembly that surrounds the photovoltaic element.

[0009] In one possible embodiment of the present invention, the frame assembly includes a connector, a first frame member, and a second frame member, wherein the first frame member is connected to the second frame member through the connector, and the first frame member and the second frame member are set at an angle.

[0010] In one possible embodiment of the present invention, both the first frame member and the second frame member are provided with mounting grooves, and the photovoltaic element can be snapped into the mounting grooves.

[0011] In one possible embodiment of the present invention, the lightweight photovoltaic module further includes a wiring component disposed on the side of the second encapsulation layer opposite to the second encapsulation film layer, and the wiring component is connected to the battery cell.

[0012] In one possible embodiment of the present invention, the warpage of both the first encapsulation layer and the second encapsulation layer after lamination is 'a', which satisfies: a≤5mm.

[0013] A second aspect of the present invention provides a method for manufacturing a lightweight photovoltaic module, comprising:

[0014] One-step laying: Pre-treat the first encapsulation layer and stack the first encapsulation layer with the first adhesive film layer;

[0015] String welding: The solar cells are laser-cut and then welded to the welding strips;

[0016] Lamination: The battery cells are laid on the first adhesive film layer and the busbar connection is completed to form a battery device;

[0017] Two-layer laying: The second encapsulation layer, the second adhesive film layer and the battery component are stacked, and an insulation component is covered on the second encapsulation layer;

[0018] Lamination and edge trimming: After lamination to form a photovoltaic component, the insulation component is removed, and the photovoltaic component is trimmed.

[0019] Install frame components: Install frame components around the photovoltaic element to form a lightweight photovoltaic module;

[0020] Testing: The lightweight photovoltaic module was tested.

[0021] In one possible embodiment of the present invention, the step of preprocessing the first encapsulation layer includes:

[0022] The first encapsulation layer is subjected to stress relief, and the processing time t1 is 10s to 40s. When the first encapsulation layer is processed by the first cavity, the first temperature T1 satisfies: 103℃≤T1≤107℃. When the first encapsulation layer is processed by the second cavity, the second temperature T2 satisfies: 145℃≤T2≤149℃.

[0023] In one possible embodiment of the present invention, the step of laminating to form a photovoltaic device includes:

[0024] Positioning and fixing: The encapsulation component, film component and battery component are stacked and positioned and fixed to obtain the part to be processed;

[0025] A vacuuming operation is performed to place the workpiece into the processing chamber and expel all air from the chamber.

[0026] Lamination: The workpiece is heated and pressurized, then cured and cooled.

[0027] In one possible embodiment of the present invention, the vacuuming time t2 is 600s, the lamination temperature T3 satisfies: 95℃≤T3≤150℃, the lamination time t3 is 600s, and the pressure P during curing satisfies: -70KPa≤P≤-25KPa.

[0028] In one possible embodiment of the present invention, the step of installing the border component includes:

[0029] Obtain the real-time location of the photovoltaic components;

[0030] The real-time position of the photovoltaic device is compared with the preset position;

[0031] Determine whether the real-time location conforms to the preset location standard;

[0032] If so, the photovoltaic components are adsorbed and fixed.

[0033] The four sides of the photovoltaic element are flattened, and the photovoltaic element is inserted into the mounting slots of the frame assembly around its perimeter, so that the frame assembly surrounds the photovoltaic element.

[0034] Compared with the prior art, the beneficial effects of the present invention are as follows: The present invention provides a lightweight photovoltaic module and a manufacturing method thereof. The lightweight photovoltaic module is provided with a first encapsulating layer and a second encapsulating layer. The first encapsulating layer and the second encapsulating layer are used to encapsulate and protect the battery components, enhance the mechanical strength of the lightweight photovoltaic module, reduce the occurrence of damage or breakage of the battery components, and extend the service life of the battery components. The first encapsulation layer and the second encapsulation layer are installed on the outside of the encapsulating layer to wrap the encapsulating layer and improve the impact resistance of the lightweight photovoltaic module. The frame component surrounds the photovoltaic component. The encapsulation component and the frame component cooperate to fix and support it, which has better protective performance, high structural stability, and is suitable for mass production. This manufacturing method can be used for mass production of lightweight photovoltaic modules. The use of one-layer and two-layer laying can reduce the occurrence of damage or breakage of related components in the lightweight photovoltaic module during the manufacturing process, improve the product yield, and cover the second encapsulation layer with a heat insulation component to keep the product warm during the lamination process, reduce the product's temperature loss, and prevent the lamination equipment from causing dirt to the second encapsulation layer, thus maintaining the cleanliness of the lightweight photovoltaic module. Attached Figure Description

[0035] To more clearly illustrate the technical solutions of the embodiments of the present invention, the accompanying drawings used in the embodiments will be briefly introduced below. It should be understood that the following drawings only show some embodiments of the present invention and should not be regarded as a limitation on the scope. For those skilled in the art, other related drawings can be obtained based on these drawings without creative effort.

[0036] Figure 1 This is a side view of a lightweight photovoltaic module provided in some embodiments of the present invention;

[0037] Figure 2 This is an exploded perspective view of a lightweight photovoltaic module provided in some embodiments of the present invention;

[0038] Figure 3 This is a schematic diagram of the structure of the bearing tooling provided in some embodiments of the present invention;

[0039] Figure 4 This is a side view of the insulation component of a lightweight photovoltaic module provided in some embodiments of the present invention;

[0040] Figure 5 This is a schematic diagram of the frame assembly of a lightweight photovoltaic module provided in some embodiments of the present invention;

[0041] Figure 6 This is a schematic diagram of the mounting groove for a lightweight photovoltaic module provided in some embodiments of the present invention;

[0042] Figure 7 This is a schematic flowchart illustrating a method for manufacturing lightweight photovoltaic modules according to some embodiments of the present invention.

[0043] Explanation of key component symbols;

[0044] 100-Lightweight photovoltaic module; 110-Battery component; 120-Encapsulating film component; 121-First encapsulating film layer; 122-Second encapsulating film layer; 130-Encapsulation component; 131-First encapsulation layer; 132-Second encapsulation layer; 140-Frame component; 141-First frame component; 142-Second frame component; 143-Connector; 144-Mounting groove; 1441-Anti-slip part; 1442-Card slot; 150-Wiring component; 160-Bearing fixture; 170-Insulation component. Detailed Implementation

[0045] To make the objectives, technical solutions, and advantages of the embodiments of the present invention clearer, the technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. The components of the embodiments of the present invention described and shown in the accompanying drawings can generally be arranged and designed in various different configurations.

[0046] Therefore, the following detailed description of the embodiments of the invention provided in the accompanying drawings is not intended to limit the scope of the claimed invention, but merely to illustrate selected embodiments of the invention. All other embodiments obtained by those skilled in the art based on the embodiments of the invention without inventive effort are within the scope of protection of the invention.

[0047] It should be noted that similar labels and letters in the following figures indicate similar items. Therefore, once an item is defined in one figure, it does not need to be further defined and explained in subsequent figures.

[0048] In the description of this invention, it should be noted that the terms "center," "upper," "lower," "left," "right," "vertical," "horizontal," "inner," and "outer," etc., indicate the orientation or positional relationship based on the orientation or positional relationship shown in the accompanying drawings, or the orientation or positional relationship commonly used when the product of this invention is in use. They are only for the convenience of describing this invention and simplifying the description, and do not indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation, and therefore should not be construed as a limitation of this invention. In addition, the terms "first," "second," "third," etc., are only used to distinguish descriptions and should not be construed as indicating or implying relative importance.

[0049] Furthermore, terms such as "horizontal," "vertical," and "sag" do not imply that components must be absolutely horizontal or suspended, but rather that they can be slightly tilted. For example, "horizontal" simply means that its direction is more horizontal relative to "vertical," and does not mean that the structure must be completely horizontal, but can be slightly tilted.

[0050] In the description of this invention, it should also be noted that, unless otherwise explicitly specified and limited, the terms "set," "install," "connect," and "link" should be interpreted broadly. For example, they can refer to a fixed connection, a detachable connection, or an integral connection; 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; and they can refer to the internal connection of two components. Those skilled in the art can understand the specific meaning of the above terms in this invention based on the specific circumstances.

[0051] The following detailed description of some embodiments of the present invention is provided in conjunction with the accompanying drawings. Unless otherwise specified, the following embodiments and features can be combined with each other.

[0052] Example 1

[0053] refer to Figure 1 As shown, an embodiment of this application provides a lightweight photovoltaic module 100, which includes a battery component 110, an encapsulant component 120, an encapsulation component 130, and a frame component 140.

[0054] Specifically, in combination Figure 1 and Figure 2 As shown, the adhesive film 120 includes a first adhesive film layer 121 and a second adhesive film layer 122. The first adhesive film layer 121 is disposed on one side of the battery component 110, and the second adhesive film layer 122 is disposed on the side of the battery component 110 opposite to the first adhesive film layer 121. The encapsulation component 130 includes a first encapsulation layer 131 and a second encapsulation layer 132. The first encapsulation layer 131 is disposed on the side of the first adhesive film layer 121 opposite to the battery component 110, and the second encapsulation layer 132 is disposed on the side of the second adhesive film layer 122 opposite to the battery component 110, so that the battery component 110, the adhesive film 120, and the encapsulation component 130 are laminated. The photovoltaic module is then formed. The frame assembly 140 surrounds the photovoltaic module. The first encapsulation layer 121 and the second encapsulation layer 122 are used to encapsulate and protect the battery component 110, enhance the mechanical strength of the lightweight photovoltaic module 100, reduce the occurrence of damage or breakage of the battery component 110, and extend the service life of the battery component 110. The first encapsulation layer 131 and the second encapsulation layer 132 are installed on the outside of the encapsulation layer 120 to wrap the encapsulation layer 120 and improve the impact resistance of the lightweight photovoltaic module 100. The frame assembly 140 surrounds the photovoltaic module. The encapsulation layer 130 and the frame assembly 140 cooperate to fix and support it, and have better protective performance.

[0055] It is understandable that the battery component 110 is a battery cell, and the first adhesive layer 121 and the second adhesive layer 122 serve to protect the battery cell. The first adhesive layer 121 and the second adhesive layer 122 enhance the sealing and weather resistance of the battery cell location. The performance of the first adhesive layer 121 and the second adhesive layer 122 is selected to block ultraviolet light penetration, protect the internal structure or materials from damage by ultraviolet radiation, and delay the aging process. The barrier effect is ≥99%, and it prevents external moisture from penetrating into the encapsulation, with a water permeability ≤1.5g / m³. 2 / day, to avoid corrosion and deterioration caused by moisture.

[0056] refer to Figure 2 and Figure 4As shown, the lightweight photovoltaic module 100 has a first orientation. Exemplarily, the first orientation is exemplified by the thickness direction of the lightweight photovoltaic module 100. It is understood that the above definitions are merely for ease of understanding the relative positional relationships of the various parts in the lightweight photovoltaic module 100 and should not be construed as limitations on this application.

[0057] In one embodiment, alternatively, referencing Figure 1 and Figure 5 As shown, the frame assembly 140 includes a connector 143, a first frame member 141, and a second frame member 142. The first frame member 141 is connected to the second frame member 142 via the connector 143, and the first frame member 141 and the second frame member 142 are arranged at an angle, so that the first frame member 141 and the second frame member 142 can form a frame structure. The first frame member 141 and the second frame member 142 are used to enclose the photovoltaic element, thereby protecting the photovoltaic element, reducing damage to the battery component 110, improving the stability of the lightweight photovoltaic module 100, and extending the service life of the battery component 110. Exemplarily, the first frame member 141 and the second frame member 142 are arranged perpendicularly.

[0058] Optionally, such as Figure 5 As shown, both the first frame member 141 and the second frame member 142 are provided with mounting grooves 144. The photovoltaic component can be snapped into the mounting groove 144. The photovoltaic component can be fixed and limited by the mounting groove 144, so that the photovoltaic component can be connected to the first frame member 141 and the second frame member 142 respectively, and the first frame member 141 and the second frame member 142 can protect the photovoltaic component.

[0059] Further, refer to Figure 6 As shown, the mounting groove 144 is also provided with a slot 1442 and an anti-slip part 1441. The anti-slip part 1441 and the slot 1442 are arranged opposite to each other, so that the groove wall of the slot 1442 can engage with the photovoltaic component. The anti-slip part 1441 can increase the friction at the connection position between the photovoltaic component and the frame assembly 140. Under the combined action of the anti-slip part 1441 and the slot 1442, the photovoltaic component will not move relative to the mounting groove 144, preventing the photovoltaic component from being misaligned or offset.

[0060] In one embodiment, optionally, the lightweight photovoltaic module 100 further includes a connector 150, which is disposed on the side of the second encapsulation layer 132 opposite to the second encapsulating film layer 122, and is connected to the battery module 110. The connector 150 is mounted on the second encapsulation layer 132 and is used for collecting and transmitting the current generated by the battery module 110, enabling the battery module 110 to connect to an external circuit through the connector 150 to transmit electrical energy. Exemplarily, the connector 150 is a junction box, which can connect the positive and negative wires of the battery module 110.

[0061] In one embodiment, optionally, the warpage of the first encapsulation layer 131 and the second encapsulation layer 132 after lamination is both 'a', satisfying: a≤5mm. The first encapsulation layer 131 and the second encapsulation layer 132 are used to encapsulate the battery component 110 and the encapsulation film component 120. The warpage of the first encapsulation layer 131 and the second encapsulation layer 132 can ensure the encapsulation quality of the lightweight photovoltaic module 100, making the warpage 'a' of the first encapsulation layer 131 less than or equal to 5mm and the warpage 'a' of the second encapsulation layer 132 less than or equal to 5mm, which facilitates quick and convenient installation through the first encapsulation layer 131 and the second encapsulation layer 132, and ensures the mechanical strength and power generation efficiency of the lightweight photovoltaic module 100.

[0062] In summary, the lightweight photovoltaic module 100 is provided with a first encapsulating film layer 121 and a second encapsulating film layer 122. The first encapsulating film layer 121 and the second encapsulating film layer 122 are used to encapsulate and protect the battery component 110, enhance the mechanical strength of the lightweight photovoltaic module 100, reduce the occurrence of damage or breakage of the battery component 110, and extend the service life of the battery component 110. The first encapsulation layer 131 and the second encapsulation layer 132 are installed on the outside of the encapsulating film component 120 to wrap the encapsulating film component 120 and improve the impact resistance of the lightweight photovoltaic module 100. The frame component 140 surrounds the photovoltaic component. The encapsulating component 130 and the frame component 140 cooperate to fix and support it, which has good protective performance, high structural stability, and is suitable for mass production.

[0063] Example 2

[0064] refer to Figure 7 As shown, embodiments of this application also provide a method for manufacturing a lightweight photovoltaic module 100, comprising:

[0065] S100: One-step laying: Pre-treat the first encapsulation layer 131 and stack the first encapsulation layer 131 with the first adhesive film layer 121; pre-treat the first encapsulation layer 131 before stacking and laying in order to release the stress of the first encapsulation layer 131 and ensure that the warpage of the first encapsulation layer 131 during installation lamination meets the manufacturing requirements.

[0066] S200: String welding: The solar cells are laser-cut and then welded to the welding strips;

[0067] S300: Lamination: The battery cells are laid on the first adhesive film layer 121 and the busbar connection is completed to form the battery component 110;

[0068] S400: Two-layer laying: The second encapsulation layer 132, the second adhesive film layer 122 and the battery component 110 are stacked, and the heat insulation component 170 is covered on the second encapsulation layer 132.

[0069] S500: Lamination edge trimming: The photovoltaic element is formed by lamination, the insulation part 170 is removed, and the photovoltaic element is trimmed.

[0070] S600: Install frame assembly 140: Install frame assembly 140 around the photovoltaic element to form a lightweight photovoltaic module 100;

[0071] S700: Test: Test the lightweight photovoltaic module 100.

[0072] In this application, such as Figure 7 As shown, the manufacturing method through steps S100 to S700 can be used for mass production of lightweight photovoltaic modules 100. The use of one-layer and two-layer lamination can reduce the occurrence of damage or breakage of related components in the lightweight photovoltaic modules 100 during the manufacturing process, improve product yield, and cover the second encapsulation layer 132 with an insulation component 170 to keep the product warm during the lamination process, reduce the product's temperature loss, and prevent the lamination equipment from causing dirt to the second encapsulation layer 132, thus maintaining the cleanliness of the lightweight photovoltaic modules 100.

[0073] In this application, the inventors discovered during their research that, due to the technical problem of poor structural performance of related components in the manufacturing process of lightweight components, referenced... Figure 3 As shown, during the production flow of the assembly line, the supporting fixture 160 can be used to provide good support for the relevant parts of the lightweight components. The first encapsulation layer 131 and the first adhesive film layer 121 are placed on the supporting fixture 160 and stacked. The properties of the first encapsulation layer 131 are selected to be exemplary. The material of the supporting fixture 160 can be tempered glass or aluminum plate.

[0074] String welding: The battery cells are laser-cut, and then the cut battery cells are welded to the welding strip; the battery cells can be laser-cut into half cells, and the welding strip and the cut battery cells can be welded together by a dicing and welding machine to form a battery string.

[0075] Stacking: The battery cells are laid on the first adhesive film layer 121 and connected to form the battery assembly 110. After string welding, the battery cells are laid on the first adhesive film layer 121 using a stacking machine, and the middle busbar and the two end busbars are welded. For example, the middle busbar divides the battery assembly 110 into two parts: one part consists of six battery strings connected in series, and the other part consists of six battery strings also connected in series. The battery strings in the two parts are then connected in parallel, thereby enabling the connection of multiple battery cells.

[0076] Second layer installation: The second encapsulation layer 132, the second adhesive film layer 122, and the battery component 110 are stacked, and an insulation component 170 is placed on the second encapsulation layer 132; the second adhesive film layer 122 is located between the battery component 110 and the second encapsulation layer 132, and the second adhesive film layer 122 is used to connect the battery component 110 and the second encapsulation layer 132, such as... Figure 4 As shown, a thermal insulation component 170 is laid on the side of the second encapsulation layer 132 away from the second adhesive film layer 122. The thermal insulation component 170 can provide thermal insulation for the lightweight photovoltaic module 100 and prevent the lightweight photovoltaic module 100 from getting dirty during the lamination process. The thermal insulation component 170 can be thermal insulation cloth or thermal insulation board.

[0077] Lamination and Edge Trimming: The first encapsulation layer 131, the first encapsulation film layer 121, the second encapsulation layer 132, the second encapsulation film layer 122, and the battery component 110 are sequentially stacked and laminated to form a photovoltaic component. The insulation component 170 is removed, and the photovoltaic component is trimmed. Frame components 140 are installed around the photovoltaic component to form a lightweight photovoltaic module 100. Lamination is performed using a laminator. After lamination, the insulation component 170 is separated. During the capture and positioning of the second encapsulation layer 132 and the edge trimming and cutting of the module, a vision robot ensures cutting accuracy through precise image recognition technology. Setting a cutting deviation value is a strategy used to fine-tune the cutting path, ensuring that even with slight deviations, the cutting results remain within a high precision range, i.e., the dimensions of the module after cutting meet the tolerance requirement of ±1mm. Alternatively, the cutting method can be one of wheel cutting, vibratory knife cutting, or laser cutting.

[0078] Install connector 150, apply adhesive to the bottom of connector 150 to provide waterproofing and fixation for subsequent assembly, reliably solder the wires of the component to the wires inside connector 150 to ensure stable current conduction, inject sealant into connector 150 after soldering to further enhance its waterproof and dustproof performance, move it to a curing chamber in a specific environment to allow the sealant to harden within a certain period of time to ensure its physical and chemical stability.

[0079] Install frame assembly 140: Install frame assembly 140 around the photovoltaic component to form a lightweight photovoltaic component 100. Flatten the four corners of the photovoltaic component. Use a robotic arm to surround and install the first frame component 141 and the second frame component 142 onto the photovoltaic component. The photovoltaic component can be snapped into the mounting groove 144 of the first frame component 141 and the second frame component 142. The first frame component 141 is connected to the second frame component 142 through connector 143.

[0080] Testing: The lightweight photovoltaic module 100 was tested. After the reinforced frame was installed, an IV test was performed using a top-lit method. The IV test measures its conversion efficiency and performance stability. In addition to the IV test, EL (Electroluminescence) testing is also a crucial quality control step for photovoltaic modules. EL testing is mainly used to detect microscopic defects inside the photovoltaic module, such as cracks, broken cells, and poor solder joints. These defects may not be easily detected during visual inspection but directly affect the module's power generation efficiency and lifespan. The EL test uses a single-camera top-mounted imaging method.

[0081] In one embodiment, the step of preprocessing the first encapsulation layer 131 may optionally include:

[0082] Stress relief is performed on the first encapsulation layer 131 for a processing time t1 of 10 to 40 seconds. When the first cavity is used to process the first encapsulation layer 131, a first temperature T1 is achieved, satisfying 103℃ ≤ T1 ≤ 107℃. When the second cavity is used to process the first encapsulation layer 131, a second temperature T2 is achieved, satisfying 145℃ ≤ T2 ≤ 149℃. In other words, the stress relief process of the first encapsulation layer 131 can be performed using both the first and second cavities. The first and second cavities have different temperature control ranges: the temperature control range of the first cavity is 103℃ ≤ T1 ≤ 107℃, and the temperature control range of the second cavity is 145℃ ≤ T2 ≤ 149℃. By processing the first encapsulation layer 131 in both cavities, a gradual heating process is achieved, reducing internal stress and thus improving the reliability of the first encapsulation layer 131. Alternatively, the first encapsulation layer 131 can also be stress-relieved using this method.

[0083] In one embodiment, optionally, the step of laminating to form a photovoltaic element includes:

[0084] S510: Positioning and fixing: The encapsulation component 130, the adhesive film component 120 and the battery component 110 are stacked and positioned and fixed to obtain the part to be processed. This reduces the possibility of the encapsulation component 130, the adhesive film component 120 and the battery component 110 shifting or slipping before lamination, improves processing efficiency, and facilitates subsequent operations on the part to be processed.

[0085] S520: Vacuuming operation, placing the workpiece to be processed into the processing chamber and venting all the air from the chamber to ensure that the processing environment is free of oxygen or other impurities, reducing the occurrence of impurities and improving the lamination quality.

[0086] S530: Lamination: The workpiece to be processed is heated and pressurized, then cured and cooled; correspondingly, the workpiece is preheated and the temperature is gradually increased to avoid stress inside the workpiece until the workpiece reaches the ideal state. The workpiece is kept for a period of time to promote cross-linking or chemical reaction between molecules, and the temperature of the heating system is slowly reduced so that the workpiece is cooled under controlled conditions to complete the curing and cooling process and achieve curing and cooling.

[0087] In one embodiment, optionally, the vacuuming time t2 is 600s to achieve the required vacuum level, and a stabilization period is required to ensure that all residual gas is effectively extracted and to prevent leakage. The lamination temperature T3 of the workpiece satisfies: 95℃ ≤ T3 ≤ 150℃, and the lamination time t3 is 600s. The lamination time t3 ensures that the material is sufficiently softened or flows while preventing damage or deformation. The lamination temperature T3 is any value between 95℃ and 150℃, ensuring that the lamination time and temperature are within the specified range until the material is fully melted or the adhesive begins to cure. The pressure P during pressure curing satisfies: -70KPa ≤ P ≤ -25KPa. The pressure P during pressure curing can be -70KPa, -50KPa, or -25KPa.

[0088] In one embodiment, optionally, the step of installing the border component 140 includes:

[0089] S610: Obtain the real-time location of the photovoltaic components;

[0090] S620: Compare the real-time position of the photovoltaic device with the preset position;

[0091] S630: Determine whether the real-time position conforms to the preset position standard;

[0092] S640: If so, the photovoltaic components are adsorbed and fixed.

[0093] S650: Flatten the four sides of the photovoltaic element, and insert the photovoltaic element into the mounting slots 144 of the frame assembly 140 around the photovoltaic element so that the frame assembly 140 surrounds the photovoltaic element.

[0094] Specifically, the real-time position of the photovoltaic component is obtained and compared with a preset position. If the real-time position of the photovoltaic component meets the standard of the preset position, the position of the photovoltaic component is identified and located so that the photovoltaic component can be adsorbed and fixed by the robotic arm. The flattening mechanism flattens the four sides of the photovoltaic component, and the four sides of the photovoltaic component are inserted into the mounting groove 144 of the frame assembly 140 so that the frame assembly 140 surrounds the photovoltaic component, thus completing the installation of the frame assembly 140.

[0095] Optionally, during the manufacturing process of lightweight photovoltaic modules, a robotic arm, an installation mechanism, and a handling mechanism are used to install the frame assembly 140. The robotic arm has a suction cup structure with an adsorption force ranging from -30Kpa to -80Kpa, which facilitates the adsorption of photovoltaic components by the robotic arm and reduces the occurrence of cracks or microcracks in the photovoltaic components. The flattening mechanism is equipped with multiple suction cups, which can disperse the adsorption force on the photovoltaic components. The flattening mechanism keeps the edges of the photovoltaic components flat, making it easier to install the photovoltaic components into the mounting groove 144 of the frame assembly 140. The handling mechanism can lift and support the photovoltaic components to avoid scratches or microcracks in the lightweight photovoltaic modules caused by belt transportation. Silicone is added to the mounting groove 144 of the frame assembly 140 to facilitate bonding with the photovoltaic components.

[0096] In all examples shown and described herein, any specific values ​​should be interpreted as merely exemplary and not as limitations; therefore, other examples of exemplary embodiments may have different values.

[0097] The above-described embodiments are merely illustrative of several implementations of the present invention, and while the descriptions are specific and detailed, they should not be construed as limiting the scope of the invention. It should be noted that those skilled in the art can make various modifications and improvements without departing from the concept of the present invention, and these modifications and improvements all fall within the scope of protection of the present invention.

Claims

1. A lightweight photovoltaic module, characterized in that, include: Battery components; An adhesive film component, the adhesive film component including a first adhesive film layer and a second adhesive film layer, the first adhesive film layer being disposed on one side of the battery component, and the second adhesive film layer being disposed on the side of the battery component opposite to the first adhesive film layer; An encapsulation component, comprising a first encapsulation layer and a second encapsulation layer, wherein the first encapsulation layer is disposed on the side of the first adhesive film layer opposite to the battery component, and the second encapsulation layer is disposed on the side of the second adhesive film layer opposite to the battery component, so that the battery component, the adhesive film component, and the encapsulation component are laminated to form a photovoltaic component; A frame assembly that surrounds the photovoltaic element.

2. The lightweight photovoltaic module according to claim 1, characterized in that, The frame assembly includes a connector, a first frame component, and a second frame component. The first frame component is connected to the second frame component via the connector, and the first frame component and the second frame component are set at an angle.

3. The lightweight photovoltaic module according to claim 2, characterized in that, Both the first and second frame components have mounting slots, and the photovoltaic component can be snapped into the mounting slots.

4. The lightweight photovoltaic module according to claim 1, characterized in that, It also includes a connector, which is disposed on the side of the second encapsulation layer opposite to the second adhesive film layer, and the connector is connected to the battery.

5. The lightweight photovoltaic module according to claim 1, characterized in that, The warpage of both the first and second encapsulation layers after lamination is 'a', which satisfies the condition: a≤5mm.

6. A method for manufacturing a lightweight photovoltaic module, characterized in that, include: One-step laying: Pre-treat the first encapsulation layer and stack the first encapsulation layer with the first adhesive film layer; String welding: The solar cells are laser-cut, and then the cut solar cells are welded to the welding strips; Lamination: The battery cells are laid on the first adhesive film layer and the busbar connection is completed to form a battery device; Two-layer laying: The second encapsulation layer, the second adhesive film layer and the battery component are stacked, and an insulation component is covered on the second encapsulation layer; Lamination and edge trimming: After lamination to form a photovoltaic component, the insulation component is removed, and the photovoltaic component is trimmed. Install frame components: Install frame components around the photovoltaic element to form a lightweight photovoltaic module; Testing: The lightweight photovoltaic module was tested.

7. The manufacturing method according to claim 6, characterized in that, The preprocessing steps for the first encapsulation layer include: The first encapsulation layer is subjected to stress relief, and the processing time t1 is 10s to 40s. When the first encapsulation layer is processed by the first cavity, the first temperature T1 satisfies: 103℃≤T1≤107℃. When the first encapsulation layer is processed by the second cavity, the second temperature T2 satisfies: 145℃≤T2≤149℃.

8. The manufacturing method according to claim 6, characterized in that, The steps of laminating to form a photovoltaic device include: Positioning and fixing: The encapsulation component, film component and battery component are stacked and positioned and fixed to obtain the part to be processed; Vacuum treatment is performed, the workpiece to be processed is placed into the processing chamber and all air in the chamber is expelled; Lamination: The workpiece is heated and pressurized, then cured and cooled.

9. The manufacturing method according to claim 8, characterized in that, The vacuuming time t2 is 600s, the lamination temperature T3 satisfies: 95℃≤T3≤150℃, the lamination time t3 is 600s, and the pressure P during curing satisfies: -70KPa≤P≤-25KPa.

10. The manufacturing method according to claim 6, characterized in that, The steps for installing the border component include: Obtain the real-time location of the photovoltaic components; The real-time position of the photovoltaic device is compared with the preset position; Determine whether the real-time location conforms to the preset location standard; If so, the photovoltaic components are adsorbed and fixed. The four sides of the photovoltaic element are flattened, and the photovoltaic element is inserted into the mounting slots of the frame assembly around its perimeter, so that the frame assembly surrounds the photovoltaic element.

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