Photovoltaic module and manufacturing method thereof

Abstract

The invention relates to a photovoltaic module and a manufacturing method thereof, the photovoltaic module comprises a front plate, a first adhesive film layer, a battery piece layer, a second adhesive film layer and a back plate which are stacked in sequence, the battery piece layer comprises a plurality of battery strings which are arranged in parallel, and gaps exist between adjacent battery strings; a barrier piece is arranged between two adjacent groups of battery strings; the blocking piece comprises a blocking long strip, a plurality of blocking blocks are arranged on the blocking long strip at intervals in the length direction of the blocking long strip, one end of each blocking block is connected with the first face of the battery piece of one battery string, the other end of each blocking block is connected with the second face of the battery piece of the adjacent battery string, and the connecting modes of every two adjacent blocking blocks in every two adjacent battery strings are opposite. Therefore, the barrier blocks between two adjacent groups of battery strings form a cross interlocking structure. According to the invention, a cross interlocking structure is formed by arranging the barrier pieces, so that the string spacing is reduced, the stable control of the cell string spacing in the lamination stage can be ensured, and the packaging quality and the service cycle of the photovoltaic module can be improved.

Description

TECHNICAL FIELD

[0001] The application belongs to the technical field of photovoltaic power generation, and particularly relates to a photovoltaic module and a manufacturing method thereof. BACKGROUND

[0002] A photovoltaic module is a core component of a solar power generation system, which usually comprises a front plate, a back plate and a plurality of cell strings encapsulated between the front plate and the back plate. In a lamination process, the plurality of cell strings need to be arranged in parallel at a certain interval to prevent short circuit caused by contact between adjacent cell strings.

[0003] At present, the size of a cell sheet is small, resulting in a small power generation per unit area of the photovoltaic module, and further resulting in a low photoelectric conversion efficiency. The photoelectric conversion efficiency of the photovoltaic module can be improved by reducing the string interval (distance between two adjacent cell strings), and then the power generation per unit area of the photovoltaic module can be improved.

[0004] In the prior art, the string interval is usually controlled by dispensing or pasting adhesive tape on adjacent cell sheets. However, the form of the adhesive is difficult to accurately control during the coating process, and overflow of the adhesive is prone to occur, which affects the encapsulation quality. In addition, the adhesive has weak interfacial adhesion with the encapsulation adhesive film and the surface of the cell sheet, and the adhesive layer is prone to debonding in subsequent reliability tests, resulting in water vapor entering the interior of the photovoltaic module, thereby accelerating performance degradation and shortening the service life of the photovoltaic module. The traditional positioning adhesive tape is also prone to softening in a high-temperature environment, resulting in deviation of the string interval and other problems. SUMMARY

[0005] The application aims to provide a photovoltaic module and a manufacturing method thereof. By arranging a barrier piece to form a cross interlocking structure, the string interval can be reduced while the stability of the cell string interval during the lamination stage is ensured, and the service life and performance of the photovoltaic module are improved.

[0006] The application provides a photovoltaic module, which comprises a front plate, a first adhesive film layer, a cell sheet layer, a second adhesive film layer and a back plate which are stacked in sequence. The cell sheet layer comprises a plurality of cell strings arranged in parallel, and there is a gap between adjacent cell strings. A barrier piece is arranged between two adjacent cell strings along the width direction of the photovoltaic module. The barrier piece comprises a barrier strip, and a plurality of barrier blocks are arranged on the barrier strip at intervals along the length direction of the barrier strip. One end of the barrier block is connected to a first surface of a cell sheet of one cell string, and the other end of the barrier block is connected to a second surface of a cell sheet of an adjacent cell string. The connection modes of two adjacent barrier blocks in two adjacent cell strings are reversely arranged, so that the barrier blocks between two adjacent cell strings form a cross interlocking structure. The cell sheet has a first surface and a second surface which are oppositely arranged along the thickness direction.

[0007] In a further technical solution, two sides of each of the battery strings are respectively connected with the blocking long strips, the blocking long strips are connected with the first surfaces of all the battery pieces in the battery strings, a plurality of the blocking blocks are arranged on the same side of the blocking long strips, and the blocking blocks on the two sides of the battery strings are distributed in a staggered manner; the blocking blocks protrude from the edges of the battery pieces, and one end of the blocking block protruding from the edge of the battery piece is connected with the second surface of the battery piece in the adjacent battery string.

[0008] In a further technical solution, the blocking long strips are arranged between two adjacent battery strings, a plurality of the blocking blocks are arranged on the two sides of the blocking long strips, and the blocking blocks on the opposite sides are symmetrically arranged; the blocking block on one side of the blocking long strip is connected with the first surface of the battery piece in the battery string, and the blocking block on the opposite side of the blocking long strip is connected with the second surface of the battery piece in the adjacent battery string.

[0009] The application also provides a method for manufacturing the photovoltaic module, comprising the following steps: providing a front plate, a first adhesive film layer, a battery piece layer, a second adhesive film layer, and a back plate; stacking the front plate, the first adhesive film layer, the battery piece layer, the second adhesive film layer, and the back plate; laminating the front plate, the first adhesive film layer, the battery piece layer, the second adhesive film layer, and the back plate to form the photovoltaic module; The battery piece layer comprises a plurality of groups of battery strings, a blocking piece is arranged between two adjacent groups of battery strings, the blocking piece comprises a blocking long strip, a plurality of blocking blocks are arranged on the blocking long strip in a spaced manner along the length direction of the blocking long strip, one end of the blocking block is connected with the first surface of the battery piece of one battery string, the other end of the blocking block is connected with the second surface of the battery piece of the adjacent battery string, and the connection modes of two adjacent blocking blocks in two adjacent battery strings are reversely arranged, so that the blocking blocks between two adjacent groups of battery strings form a cross interlocking structure.

[0010] In a further technical solution, the battery piece layer is provided, comprising the following steps: S1, manufacturing a blocking long strip with a plurality of blocking blocks on one side; S2, fixing the blocking long strip on both sides of the first surface of the battery piece of each of the battery strings, and the blocking block on one side of the blocking long strip protrudes from the edge of the battery piece; S3, arranging two adjacent battery strings in a horizontal manner, and forming a cross interlocking structure with a plug-in fit by pressing the blocking block or turning over the battery string, so that the blocking block is attached to the second surface of the battery piece of the adjacent battery string.

[0011] In a further technical solution, the S3 comprises: In the horizontally arranged adjacent two battery strings, the blocking blocks protruding from the edges of the battery pieces in the previous battery string are pressed down to a predetermined angle by using a pneumatic device or a telescopic pressure rod device, and then the next battery string is moved obliquely downward and then horizontally, so that the blocking blocks on the next battery string can extend into and adhere to the second surface of the battery pieces in the previous battery string; the pneumatic device or the telescopic pressure rod device is released, and the pressed blocking blocks are elastically reset to adhere to the second surface of the battery pieces in the next battery string.

[0012] In further technical solutions, the pneumatic device includes an air pipe for connecting an air source device, a plurality of air holes are formed in the air pipe along the length direction of the air pipe, and the plurality of air holes correspond to the blocking blocks on the battery pieces in the battery string respectively, and the air holes are used to blow air to press down the blocking blocks; or the telescopic pressure rod device includes a top plate and a plurality of telescopic rods, the plurality of telescopic rods correspond to the blocking blocks on the battery pieces in the battery string respectively, the upper ends of the plurality of telescopic rods are connected to the top plate, and the lower ends of the telescopic rods are used to press down the blocking blocks.

[0013] In further technical solutions, the S3 includes: In the horizontally arranged adjacent two battery strings, the next battery string is flipped to a vertical state, and the flipped battery string is translated towards the previous battery string until the blocking blocks on the next battery string contact the side edges of the previous battery string; then the next battery string is flipped back to the horizontal state, and the blocking blocks on the next battery string adhere to the second surface of the battery pieces in the previous battery string, and the blocking blocks on the previous battery string adhere to the second surface of the battery pieces in the next battery string.

[0014] In further technical solutions, a battery piece layer is provided, including the following steps: S1, a blocking long strip with a plurality of blocking blocks on both sides and symmetrically arranged is made; S2, the blocking long strip is horizontally placed, and the blocking blocks on both sides of the blocking long strip are flipped to a predetermined angle; S3, two adjacent battery strings are horizontally placed, and the first surfaces of the battery pieces of the two battery strings are respectively positioned on the upper surfaces of the blocking blocks on both sides of the blocking long strip which are not flipped, and the edges between the two adjacent battery strings are closely adhered to the same blocking long strip, then the flipped blocking blocks are restored to the horizontal state and adhered to the second surfaces of the battery pieces of the battery strings, forming cross connection.

[0015] In a further technical solution, when the barrier long strip is made, the barrier long strip with multiple barrier blocks on one side or both sides can be formed by cutting, punching or laser cutting the barrier material.

[0016] Advantages The application provides a photovoltaic module and a manufacturing method thereof. In the width direction of the photovoltaic module, two adjacent groups of cell strings are connected in a cross manner by a barrier. Specifically, the barrier includes a barrier long strip and multiple barrier blocks arranged at intervals on the barrier long strip. One end of the barrier block is connected to a first surface of a cell piece of one cell string, the other end of the barrier block is connected to a second surface of a cell piece of an adjacent cell string, and the connection mode of two adjacent barrier blocks is reversely arranged, so that the barrier blocks between the two adjacent groups of cell strings form a cross interlocking structure. The cross interlocking structure introduced between the cell strings effectively limits the relative displacement between the cell strings, enhances the structural stability and mechanical load capacity of the photovoltaic module, and solves the problem of displacement between the cell strings caused by the softening of the traditional positioning adhesive tape in a high-temperature environment. At the same time, the delamination risk caused by the insufficient adhesion between the high-molecular adhesive, the adhesive film and the cell piece in the dispensing process is effectively avoided. Moreover, by constructing a stable cross interlocking structure in the gap between the cell strings, the distance between the cell strings can be accurately and stably kept in the range of 0.1-1 mm, which significantly improves the layout density and light-receiving area of the cell strings in the photovoltaic module, thereby effectively enhancing the photoelectric conversion efficiency and power generation capacity of the photovoltaic module. BRIEF DESCRIPTION OF DRAWINGS

[0017] Figure 1 A structural schematic diagram of a photovoltaic module in this embodiment 1 is shown; Figure 2 A schematic diagram of the barrier connected to both sides of the cell piece in this embodiment 1 is shown; Figure 3 A cutting schematic diagram of one side of the barrier in this embodiment 3 is shown; Figure 4 A schematic diagram of the barrier after cutting in this embodiment 3 is shown; Figure 5 A laser cutting schematic diagram of the middle of the barrier in this embodiment 3 is shown; Figure 6 A schematic diagram of the barrier after laser cutting in this embodiment 3 is shown; Figure 7 A schematic diagram of the barrier before the cross interlocking of the barrier blocks is achieved by pressing the barrier blocks in this embodiment 3 is shown; Figure 8 A schematic diagram of the barrier after the barrier blocks are pressed by the pneumatic device in this embodiment 3 is shown; Figure 9 A schematic diagram of the barrier after the cross interlocking of the barrier blocks is achieved by pressing the barrier blocks in this embodiment 3 is shown; Figure 10This diagram illustrates the use of a retractable pressure bar device to press down on the barrier block in Embodiment 3. Figure 11 This diagram illustrates the process before the interlocking of the barrier blocks is achieved by flipping the battery string in Embodiment 3. Figure 12 This diagram illustrates the cross-interlocking of the barrier blocks achieved by flipping the battery string in Embodiment 3. Figure 13 This shows a schematic diagram of the cutting of the barrier element in Embodiment 4; Figure 14 This shows a schematic diagram of the barrier element after it has been cut in Embodiment 4. Figure 15 This diagram illustrates the partial flipping of the barrier blocks in Embodiment 4. Figure 16 This diagram illustrates how, in Embodiment 4, a barrier strip is installed between two adjacent battery strings, and the barrier blocks achieve cross-interlocking.

[0018] Figure Labels 1. Front panel; 20. First adhesive film layer; 30. Battery string; 31. Battery cell; 40. Second adhesive film layer; 50. Back panel; 60. Barrier component; 61. Barrier strip; 611. Cutting block; 62. Barrier block; 70. Blocking component; 80. Pneumatic device; 81. Air pipe; 82. Air hole; 90. Telescopic pressure rod device; 91. Top plate; 92. Telescopic rod. Detailed Implementation

[0019] The technical solutions of this application are further illustrated below through specific embodiments. These specific embodiments do not represent a limitation on the scope of protection of this application. Any non-essential modifications and adjustments made by others based on the concept of this application still fall within the scope of protection of this application.

[0020] Example 1 Please refer to Figure 1 and Figure 2As shown, this embodiment provides a photovoltaic module, which, from top to bottom, includes a front panel 10, a first encapsulant layer 20, a cell layer, a second encapsulant layer 40, and a back panel 50. The cell layer includes multiple parallel cell strings 30, with a certain gap between adjacent sets of cell strings 30. Along the width direction X of the photovoltaic module, a barrier 60 is provided between the cells 31 of adjacent sets of cell strings 30. The barrier 60 includes a barrier strip 61, on which multiple barrier blocks 62 are spaced apart along its length. One end of the barrier block 62 is connected to the first surface of the cell 31 of one cell string 30, and the other end of the barrier block 62 is connected to the second surface of the cell 31 of the adjacent cell string 30. The connection methods of two adjacent barrier blocks 62 are opposite, thereby forming a cross-interlocking structure between the barrier blocks 62 of two adjacent sets of cell strings 30. The opposite connection methods of the two barrier blocks 62 can be understood as, for example, ... In two adjacent battery strings 30, the first surface of the battery cell 31 on the previous battery string 30 is connected to one end of the blocking block 62, and the other end of the blocking block 62 is connected to the second surface of the battery cell 31 on the next battery string 30. The first surface of the battery cell 31 on the next battery string 30 is connected to one end of another blocking block 62, and the other end of the blocking block 62 is connected to the second surface of the battery cell 31 on the previous battery string 30. Thus, a cross-interlocking structure with interlocking mating is formed between adjacent blocking blocks 62 in two adjacent battery strings 30. The battery cell 31 has a first surface and a second surface that are oppositely arranged along its thickness direction. It should be noted that the first surface of the battery cell 31 may be the front and the second surface the back, or vice versa; the specific arrangement is not limited in this embodiment.

[0021] In this embodiment, along the width direction X of the photovoltaic module, a barrier 60 is provided between two adjacent sets of battery strings 30. Specifically, the barrier 60 includes a barrier strip 61, on which multiple barrier blocks 62 are spaced apart along its length. One end of the barrier block 62 is connected to the first surface of the battery cell 31 of one battery string 30, and the other end of the barrier block 62 is connected to the second surface of the battery cell 31 of the adjacent battery string 30. The connection methods of adjacent two barrier blocks 62 in two adjacent battery strings 30 are opposite, thereby forming a cross-interlocking structure between the barrier blocks 62 of two adjacent sets of battery strings 30. The above-mentioned cross-interlocking structure effectively prevents the displacement of the battery strings 30 during lamination and operation, and can stably control the string spacing within the range of 0.1~1mm, for example, 0.1, 0.3mm, 0.4mm, 0.5mm, 0.6mm, 0.7mm, 0.8mm, 0.9mm, and 1mm. While keeping the width of the photovoltaic module constant, the arrangement density of the solar cells 31 can be increased, compensating for the reduced string spacing in the size of the solar cells 31. This increases the size of the solar cells 31 along the width of the photovoltaic module, improving the effective optical area and thus the photoelectric conversion efficiency of the photovoltaic module. Simultaneously, this method solves the problem of string spacing shift caused by the softening of traditional positioning tapes at high temperatures, and effectively avoids the risk of delamination due to insufficient adhesion between the polymer colloid and the adhesive film / solar cell during the dispensing process.

[0022] The above method reduces the string spacing and keeps it stable within the range of 0.1~1mm, which can improve the efficiency of photovoltaic modules and increase the power generation per unit area. Under the same installed capacity, high-density photovoltaic modules with a string spacing of 0.2mm can reduce the footprint by 23%. When the string spacing is ≤1mm, the incident light reflection loss is reduced to 0.8%. Moreover, reducing the string spacing can also reduce the use of silicon materials, reduce resource consumption, and conform to sustainable development.

[0023] Referring to Figure 2, in this embodiment, it should be noted that each battery string 30 has a barrier strip 61 connected to both sides. The barrier strip 61 extends along the length of the battery string 30 and is fixedly connected to the first edge of all battery cells 31 in the battery string 30. The barrier strip 61 can be connected to the first edge of the battery cells 31 through hot pressing or heating. By pre-connecting the barrier strip 61 to both sides of the battery string 30, it is convenient to stack the battery string 30 during the stacking stage, and the operation step of hot-melting and fixing the barrier strip 61 during the stacking stage is omitted. Multiple barrier blocks 62 are all disposed on the same side of the barrier strip 61, and each barrier block 62 corresponds to each battery cell 31. The barrier blocks 62 on both sides of the battery cell 31 are staggered to avoid overlapping positions. The barrier block 62 extends longitudinally along the length of the battery cell 31 beyond the edge of the battery cell 31. During the lamination stage, one end of the barrier block 62 extending beyond the edge of the battery cell 31 is used to adhere to the second surface of the battery cell 31 in the adjacent battery string 30, and is heat-fused and fixed during the lamination stage. It should be noted that the barrier strip 61 can be pre-fixed to the first surface of one end of the battery cell 31, or it can be pre-fixed to the second surface of one end of the battery cell 31.

[0024] Lamination is a process of bonding and fusing the various components of a photovoltaic module together under specific temperature, pressure, and vacuum conditions, thereby protecting the cell layers. The stacked photovoltaic modules are placed in a laminator, and air is extracted from the modules through vacuuming. Heating then melts and solidifies the first and second adhesive film layers 20 and 40, bonding multiple cell strings 30, the front panel 10, and the back panel 50 together. Finally, the photovoltaic modules are cooled and removed. During this process, the surface of the barrier blocks 62 is coated with a hot melt adhesive layer, which melts and adheres to and fixes the second side of the corresponding cell 31. This ensures that adjacent barrier blocks 62 cross-connect adjacent cell strings 30. Therefore, during the lamination stage, adjacent cell strings 30 are interlocked and locked together by these staggered and opposite barrier blocks 62, forming a robust mechanical interlocking structure that greatly enhances structural stability and ensures that the string spacing remains constant throughout the lamination process.

[0025] Furthermore, the material selected for the barrier component 60 should possess excellent high-temperature resistance to ensure that it does not easily soften at the lamination process temperature. The barrier component 60 is made of thermoplastic or thermosetting materials, and suitable materials include, but are not limited to: ethylene-vinyl acetate copolymer (EVA), polyolefin elastomer (POE), other polyolefin materials, polymethyl methacrylate (PMMA, acrylic), polyethylene terephthalate (PET), polyvinyl chloride (PVC), polycarbonate (PC), and other thermoplastic or appropriately modified thermosetting polymers. The material itself may be adhesive, or its surface may be treated (such as by coating with a hot melt adhesive layer) to facilitate adhesion to the battery cell 31.

[0026] In this embodiment, it should also be noted that, please refer to Figure 1 As shown, the photovoltaic module also includes a blocking member 70 disposed between the front panel 10 and the back panel 50. The blocking member 70 is disposed on the outer side of the cell strings 30 along both sides of the width direction of the photovoltaic module. The blocking member 70 extends along the length direction Y of the photovoltaic module, and the inner side of the blocking member 70 abuts against the outer side of the cell strings 30. The blocking member 70 is elongated and can be the same length as the cell strings 30. It should be noted that for the cell strings 30 along both sides of the width direction of the photovoltaic module, the blocking member 60 can be provided only on the inner side, while the use of the blocking member 70 on the outer side can suppress large deviations of the edge cell strings 30 during the lamination process.

[0027] Furthermore, the barrier 70 is made of a highly pre-crosslinked polymer material, with a crosslinking degree greater than 70%. Preferably, the crosslinking degree of the highly pre-crosslinked polymer material is 70%–80%, for example, 70%, 72%, 74%, 76%, 78%, 80%, etc. Preferably, the highly pre-crosslinked polymer material includes one or more of ethylene vinyl acetate copolymers and polyolefin thermoplastic elastomers. The highly pre-crosslinked material has low flowability during lamination, better maintains its shape, and thus provides an effective barrier function.

[0028] Example 2 The difference between Example 2 and Example 1 is that: A barrier strip 61 is provided between two adjacent battery strings 30, and the edges between the two adjacent battery strings 30 are tightly fitted with the barrier strip 61. Multiple barrier blocks 62 are respectively provided on both sides of the barrier strip 61, and the barrier blocks 62 on opposite sides are symmetrically arranged. One barrier block 62 on one side of the barrier strip 61 is connected to the first surface of the battery cell 31 in one battery string 30, and the barrier block 62 on the opposite side of the barrier strip 61 is connected to the second surface of the battery cell 31 in the adjacent battery string 30. Similarly, the barrier blocks 62 and the battery cell 31 are heat-fused and fixed during the lamination stage.

[0029] The above-mentioned barrier 60 is fixed in the following way: the barrier strip 61 does not need to be fixed to the surface of the battery cell 31 by hot bonding. It only needs to be placed in the gap between adjacent battery strings 30. This method effectively avoids the risk of thermal stress damage or microcracks in the battery cell 31 that may be caused by the hot bonding process, and improves the reliability of the process.

[0030] Example 3 This embodiment provides a method for manufacturing the photovoltaic module of Embodiment 1, the method including the following steps: Step 1: Provide a front panel 10, a first adhesive film layer 20, a battery cell layer, a second adhesive film layer 40, and a back panel 50; Step 2: Stack the front panel 10, the first adhesive film layer 20, the battery cell layer, the second adhesive film layer 40, and the back panel 50. Step 3: Laminate the front panel 10, the first encapsulant layer 20, the cell layer, the second encapsulant layer 40, and the back panel 50 to form a photovoltaic module; The battery cell layer includes multiple sets of battery strings 30. A barrier 60 is provided between two adjacent sets of battery strings 30. The barrier 60 includes a barrier strip 61. Multiple barrier blocks 62 are spaced apart along the length of the barrier strip 61. One end of the barrier block 62 is connected to the first surface of the battery cell 31 of one battery string 30, and the other end of the barrier block 62 is connected to the second surface of the battery cell 31 of the adjacent battery string 30. The connection methods of two adjacent barrier blocks 62 in two adjacent battery strings 30 are opposite 60, so that the barrier blocks 62 between two adjacent sets of battery strings 30 form a cross-interlocking structure.

[0031] In the fabrication of photovoltaic modules, the front panel 10, the first encapsulant layer 20, the cell layer, the second encapsulant layer 40, and the backsheet 50 are first stacked. There are two stacking sequences: the first is to place the front panel 10 on a platform, then sequentially place the first encapsulant layer 20, the cell layer, the second encapsulant layer 40, and the backsheet 50 to assemble the photovoltaic module; the second is to place the backsheet 50 on a platform, then sequentially place the second encapsulant layer 40, the cell layer, the first encapsulant layer 20, and the front panel 10. Then, the front panel 10, the first encapsulant layer 20, the cell layer, the second encapsulant layer 40, and the backsheet 50 are laminated to form the photovoltaic module.

[0032] In one specific embodiment, in step 1, providing the battery cell layer, the method includes the following steps: S1. Make a barrier strip 61 with multiple barrier blocks 62 on one side; In this embodiment, it should be noted that when making the barrier strip 61 with multiple barrier blocks 62 on one side, it can be formed by cutting, punching or laser cutting the barrier material.

[0033] For cutting and punching methods, please refer to... Figure 3 and Figure 4 As shown, it includes the following steps: (a) Pull out a section from the wound barrier material and cut it to obtain a barrier strip 61 with a length similar to that of the battery string 30; (b) Using a punching device, multiple cutting blocks 611 are punched away along a preset dotted line trajectory on the edge of the barrier strip 61, thereby forming a barrier strip 61 with a concave-convex shape (e.g., Figure 3 As shown), the corresponding protruding part is the barrier block 62 in this embodiment (as shown). Figure 4As shown in the figure, it should be noted that the cross-sectional shape of the barrier block 62 can be designed as a rectangle, circle, parallelogram or irregular shape according to the actual gap requirements of the battery string 30.

[0034] For information on laser cutting, please refer to [link / reference]. Figure 5 and Figure 6 As shown, it includes the following steps: like Figure 5 As shown, the barrier material, such as the barrier element 60, is precisely cut along a preset dotted line trajectory, separating it into two barrier strips 61 with complementary structures, each having concave and convex units (e.g., Figure 6 (As shown).

[0035] This method abandons the traditional punching method and avoids the waste generated by die punching, thus realizing the full utilization of materials. It not only reduces material loss, but also significantly improves production efficiency and economic benefits.

[0036] The laser cutting method described above forms two complementary barrier strips 61, which can be fixedly connected to the opposite sides of the battery string 30.

[0037] S2. On both sides of the first side of the battery cell 31 in each battery string 30, a blocking strip 61 is fixed, and a blocking block 62 on one side of the blocking strip 61 extends out of the edge of the battery cell 31. In this embodiment, it should be noted that, please refer to Figure 7 As shown, a barrier strip 61 is fixed on both sides of the first surface of the battery cell 31 in each battery string 30. The barrier strip 61 is fixed to the two sides of the first surface of all battery cells 31 in the battery string 30 by local heat treatment. The barrier block 62 on one side of the barrier strip 61 extends longitudinally along the length of the battery cell 31 to the edge of the battery cell 31. The barrier blocks 62 on both sides of the battery string 30 need to be staggered to avoid overlapping positions.

[0038] S3. Arrange two adjacent battery strings 30 horizontally, and make the blocking block 62 fit with the second side of the battery cell 31 of the adjacent battery string 30 by pressing down the blocking block 62 or flipping the battery string 30, forming a cross-interlocking structure with interlocking.

[0039] In this embodiment, it should be noted that for the method of pressing down the blocking block 62, please refer to... Figures 7-10 As shown, in two adjacent horizontally arranged battery strings 30, a pneumatic device 80 or a telescopic pressure rod device 90 is used to press down all the blocking blocks 62 protruding from the battery cells 31 in the previous battery string 30 to a predetermined angle (e.g., Figure 8(As shown), then move the next battery string 30 diagonally downwards and then horizontally, so that the blocking block 62 on the next battery string 30 extends into and adheres to the second surface of the battery cell 31 in the previous battery string 30; finally, release the pneumatic device 80 or the telescopic pressure rod device 90, so that the pressed blocking block 62 elastically returns to its original position and adheres to the second surface of the battery cell 31 in the next battery string 30 (as shown). Figure 9 (As shown).

[0040] Specifically, firstly, two adjacent battery strings 30 are arranged horizontally along the x-axis, with the blocking blocks 62 at the gap between the two battery strings 30 staggered in direction. For ease of explanation, one of the two adjacent battery strings 30 is defined as the previous battery string 30, and the other is defined as the next battery string 30. Then, the previous battery string 30 is positioned horizontally along the x-axis, and the protruding portion of the blocking block 62 is pressed downwards along the negative y-axis with the edge of the battery string 30 as the axis (e.g., ...). Figure 8 (As shown). Then, first move the next battery string 30 downwards along the negative y-axis by a distance slightly greater than the thickness of the battery cell 31, and then move it horizontally along the x-axis until the protruding part of the blocking block 62 is completely suspended on the second surface of the battery cell 31 of the previous battery string 30. At this time, remove the pressure of the pneumatic device 80. Because the blocking block 62 of the previous battery string 30 has a certain elasticity, it can return to the second surface of the battery cell 31 of the next battery string 30 by its own elasticity (as shown). Figure 9 As shown in the diagram, a stable cross-interlocking structure is formed at the gap between the two elements. Subsequent battery strings 30 can be operated repeatedly in this manner, and the entire system can be integrated into a conventional lamination machine. During the lamination process, the flow of the encapsulating film may cause micro-displacement of the battery strings 30, but the barrier 60 set at the gap can effectively suppress contact and parallel short circuits between battery strings. At the same time, combined with the physical limiting effect provided by the edge blocking element 70, the battery strings 30 are reliably constrained in the preset position, thereby ensuring high-precision control of the string spacing and the stability of photovoltaic module performance.

[0041] This section explains that, as Figure 7 As shown, the pneumatic device 80 includes an air pipe 81 for connecting to an external air source device. The air pipe 81 has multiple air holes 82 along its length, each corresponding to a blocking block 62 on each battery cell 31 in the battery string 30. The air holes 82 are used to blow air down and press down the blocking block 62. Thus, an external air source device provides airflow to the air pipe 81, and the airflow flows out from each corresponding air hole 82, thereby acting on the blocking block 62 and pressing it down to a predetermined angle.

[0042] Please refer to Figure 10As shown, in other embodiments, a telescopic pressure rod device 90 can be used to replace the traditional pneumatic device 80. This telescopic pressure rod device 90 applies precise and controllable pressure to the barrier blocks 62 of the battery string 30 through mechanical pressing, effectively overcoming the positioning deviation and insufficient pressure problems caused by airflow diffusion in the pneumatic device 80. The telescopic pressure rod device 90 not only avoids the risk of interfering with the position of the barrier blocks 62 due to excessive airflow range, but also ensures the sufficiency and reliability of the pressing action of the barrier blocks 62, thereby improving the accuracy of string spacing control and process stability.

[0043] In one specific implementation, such as Figure 10 As shown, the telescopic pressure rod device 90 includes a top plate 91 and telescopic rods 92. Multiple telescopic rods 92 are arranged at equal intervals along the length of the top plate 91. Each telescopic rod 92 corresponds to a blocking block 62 on each battery cell 31 in the battery string 30. The upper end of each telescopic rod 92 is vertically connected to the lower surface of the top plate 91, and the lower end of each telescopic rod 92 is used to press down on the blocking block 62. Thus, controllable pressure is applied to the blocking block 62 on the battery cell 31 by the telescopic rods 92, pressing the blocking block 62 down.

[0044] For the method of flipping the battery string 30, please refer to... Figure 11 and Figure 12 As shown, in two adjacent battery strings 30, the next battery string 30 is flipped to a vertical position, and the flipped battery string 30 is moved towards the previous battery string 30 until the blocking block 62 contacts the side of the previous battery string 30; then the flipped battery string 30 is flipped back to a horizontal position, and the blocking block 62 on the next battery string 30 is attached to the second side of the battery piece 31 in the previous battery string 30, and the blocking block 62 on the previous battery string 30 is attached to the second side of the battery piece 31 in the next battery string 30.

[0045] Specifically, firstly, two adjacent battery strings 30 are horizontally staggered vertically along the x-axis, with the blocking blocks 62 at the gap between the two battery strings 30 offset in direction. For ease of explanation, one of the two adjacent battery strings 30 is defined as the previous battery string 30, and the other is defined as the next battery string 30. Then, the next battery string 30 is rotated 90° counterclockwise with the edge of the battery piece 31 closest to the previous battery string 30 as the axis, so that it is in a vertical state, and the bottom of the next battery string 30 in the vertical state is higher than the plane of the previous battery string 30 (e.g., ...). Figure 11(As shown); After flipping, the next battery string 30 is moved horizontally towards the previous battery string 30 until the blocking block 62 of the next battery string 30 contacts the side of the previous battery string 30. Then, the next battery string 30 is rotated 90° clockwise along the edge of the same battery piece 31 to return it to a horizontal state. The blocking block 62 on the next battery string 30 is attached to the second surface of the battery piece 31 in the previous battery string 30, and the blocking block 62 on the previous battery string 30 is attached to the second surface of the battery piece 31 in the next battery string 30, achieving cross-interlocking (as shown). Figure 12 (As shown). The subsequent splicing process of battery strings 30 repeats the above flipping, translation and reset steps, and processes the remaining battery strings 30 in sequence, finally achieving cross-interlocking between the gaps of all battery strings 30.

[0046] Example 4 This embodiment provides a method for manufacturing the photovoltaic module of Embodiment 2. The steps are basically the same as those of Embodiment 3, except for the difference in step 1: In one specific embodiment, in step 1, providing the battery cell layer, the method includes the following steps: S1. Make a barrier strip 61 with multiple barrier blocks 62 on both sides and symmetrically arranged; In this embodiment, it should be noted that when making the barrier strip 61 with multiple barrier blocks 62 on both sides and symmetrically arranged, it can be formed by cutting, punching or laser cutting the barrier material.

[0047] For cutting and punching methods, the following steps are included: (a) Pull out a section from the wound barrier material and cut it to obtain a barrier strip 61 with a length similar to that of the battery string 30; (b) Using a punching device according to... Figure 13 The dashed lines indicate the locations where multiple cutting blocks 611 are symmetrically punched out along both sides of the barrier strip 61, thus forming a barrier strip 61 with a centrally symmetrical and concave-convex shape. The corresponding protruding parts are the barrier blocks 62 in this embodiment (e.g., Figure 14 As shown in the figure, for ease of understanding, this embodiment only uses the setting of eight blocking blocks 62 as an example, and they are respectively labeled as ①, ②, ③, ④, ⑤, ⑥, ⑦ and ⑧ in sequence.

[0048] S2. Place the blocking strip 61 horizontally and flip the blocking blocks 62 on both sides of the blocking strip 61 to a preset angle. In this embodiment, it should be noted that, please refer to Figure 15As shown, the cut barrier strip 61 is first placed horizontally. An adsorption device is used to grasp the protruding barrier blocks 62 on the barrier strip 61, and then the strip is vertically flipped at a certain angle (range from 90° to 180°) along the barrier strip 61. For example, the barrier blocks 62 marked ② and ⑥ are flipped 90° counterclockwise along the barrier strip 61, the barrier blocks 62 marked ③ and ⑦ are flipped 90° clockwise, while the barrier blocks 62 marked ①, ⑤, ④, and ⑧ remain in their original horizontal state. It should be noted that the adsorption device can be a vacuum suction cup, vacuum adsorption block, or other commonly used devices in this field, utilizing vacuum to adsorb the barrier blocks 62.

[0049] S3. Place two adjacent battery strings 30 horizontally, and position the first side of the battery cells 31 of the two battery strings 30 on the upper surface of the unfolded barrier block 62, with the edges between the two adjacent battery strings 30 tightly attached to the same barrier strip 61. Then restore the folded barrier blocks 62 to the horizontal state and attach them to the second side of the battery cells 31 of the battery strings 30 to form a cross connection.

[0050] In this embodiment, it should be noted that, please refer to Figure 15 and Figure 16 As shown, two adjacent battery strings 30 are placed horizontally along the x-axis and positioned on the upper surfaces of the unfolded barrier blocks 62 on both sides of the barrier strip 61 (this can be understood as the barrier blocks 62 being attached to the first surface of the battery cells 31 of the battery string 30), ensuring that the edges of the battery string 30 are tightly attached to the barrier strip 61. Finally, the previously folded barrier blocks 62 are restored to a horizontal state (the adsorption device breaks the vacuum to release the adsorption on the barrier blocks 62) and attached to the second surface of the battery cells 31 of the battery string 30. Thus, the two adjacent barrier blocks 62 form a cross connection, and all the barrier blocks 62 together constitute a mechanical interlocking structure, achieving a firm constraint on the gaps between adjacent battery strings 30 and precise control of the string spacing.

[0051] It is understood that this application has been described through some embodiments, and those skilled in the art will recognize that various changes or equivalent substitutions can be made to these features and embodiments without departing from the spirit and scope of this application. Furthermore, based on the teachings of this application, these features and embodiments can be modified to adapt to specific situations and materials without departing from the spirit and scope of this application. Therefore, this application is not limited to the specific embodiments disclosed herein, and all embodiments falling within the scope of the claims of this application are within the protection scope of this application.

Claims

1. A photovoltaic module, characterized in that, It includes a front panel (10), a first adhesive film layer (20), a battery cell layer, a second adhesive film layer (40), and a back panel (50) stacked in sequence. The battery cell layer includes a plurality of battery strings (30) arranged in parallel to each other, and there are gaps between adjacent battery strings (30). Along the width direction of the photovoltaic module, a barrier (60) is provided between two adjacent sets of battery strings (30). The barrier (60) includes a barrier strip (61), and multiple barrier blocks (62) are spaced apart along the length direction of the barrier strip (61). One end of the barrier block (62) is connected to the first surface of the battery cell (31) of one battery string (30), and the other end of the barrier block (62) is connected to the second surface of the battery cell (31) of the adjacent battery string (30). The connection methods of two adjacent barrier blocks (62) in two adjacent battery strings (30) are opposite (60), so that the barrier blocks (62) between two adjacent sets of battery strings (30) form a cross-interlocking structure. The battery cell (31) has a first surface and a second surface that are arranged opposite to each other along the thickness direction.

2. The photovoltaic module according to claim 1, characterized in that, Each of the battery strings (30) is connected to two sides of the barrier strip (61), the barrier strip (61) is connected to the first side of all the battery cells (31) in the battery string (30), and multiple barrier blocks (62) are disposed on the same side of the barrier strip (61), and the positions of the barrier blocks (62) on both sides of the battery string (30) are staggered. The barrier block (62) extends beyond the edge of the battery cell (31), and one end of the barrier block (62) extending beyond the edge of the battery cell (31) is connected to the second side of the battery cell (31) in the adjacent battery string (30).

3. The photovoltaic module according to claim 1, characterized in that, The barrier strip (61) is provided between two adjacent battery strings (30), and a plurality of barrier blocks (62) are respectively provided on both sides of the barrier strip (61), and the barrier blocks (62) on the opposite sides are symmetrically arranged; The blocking block (62) on one side of the blocking strip (61) is connected to the first side of the battery cell (31) in the battery string (30), and the blocking block (62) on the opposite side of the blocking strip (61) is connected to the second side of the battery cell (31) in the adjacent battery string (30).

4. A method for manufacturing a photovoltaic module as described in any one of claims 1-3, characterized in that, Includes the following steps: The system provides a front panel (10), a first adhesive film layer (20), a battery cell layer, a second adhesive film layer (40), and a back panel (50). The front panel (10), the first adhesive film layer (20), the battery cell layer, the second adhesive film layer (40), and the back panel (50) are stacked together; The front panel (10), the first adhesive film layer (20), the battery cell layer, the second adhesive film layer (40), and the back panel (50) are laminated to form the photovoltaic module; The battery cell layer includes multiple sets of battery strings (30), and a barrier (60) is provided between two adjacent sets of battery strings (30). The barrier (60) includes a barrier strip (61), and multiple barrier blocks (62) are spaced apart along its length on the barrier strip (61). One end of the barrier block (62) is connected to the first surface of the battery cell (31) of one of the battery strings (30), and the other end of the barrier block (62) is connected to the second surface of the battery cell (31) of the adjacent battery string (30). The connection methods of two adjacent barrier blocks (62) in two adjacent battery strings (30) are opposite (60), so that the barrier blocks (62) between two adjacent sets of battery strings (30) form a cross-interlocking structure.

5. The method according to claim 4, characterized in that, Providing a battery cell layer includes the following steps: S1. Make a barrier strip (61) with multiple barrier blocks (62) on one side; S2. The barrier strips (61) are fixed on both sides of the first side of the battery sheet (31) of each battery string (30), and the barrier block (62) on one side of the barrier strip (61) extends out of the edge of the battery sheet (31). S3. Arrange two adjacent battery strings (30) horizontally, and make the barrier block (62) fit with the second side of the battery cell (31) of the adjacent battery string (30) by pressing down the barrier block (62) or flipping the battery string (30), so that the barrier block (62) fits with the second side of the battery cell (31) of the adjacent battery string (30) to form a cross-interlocking structure with interlocking.

6. The method according to claim 5, characterized in that, The S3 includes: In two adjacent battery strings (30) arranged horizontally, a pneumatic device (80) or a telescopic pressure bar device (90) is used to press down all the blocking blocks (62) extending from the edge of the battery cell (31) in the previous battery string (30) to a predetermined angle. Then, the next battery string (30) is moved diagonally downward and then translated so that the blocking blocks (62) on the next battery string (30) can extend into and fit against the second surface of the battery cell (31) in the previous battery string (30). The pneumatic device (80) or the telescopic pressure bar device (90) is released so that the pressed blocking blocks (62) are elastically reset to fit against the second surface of the battery cell (31) in the next battery string (30).

7. The method according to claim 6, characterized in that, The pneumatic device (80) includes an air pipe (81) for connecting to an external air source device. The air pipe (81) has multiple air holes (82) along its length. The multiple air holes (82) correspond to the blocking blocks (62) on each battery cell (31) in the battery string (30). The air holes (82) are used to blow air down the blocking blocks (62). Alternatively, the retractable pressure rod device (90) includes a top plate (91) and a telescopic rod (92). Multiple telescopic rods (92) are provided, and each of the multiple telescopic rods (92) corresponds to a blocking block (62) on each battery cell (31) in the battery string (30). The upper ends of the multiple telescopic rods (92) are all connected to the top plate (91), and the lower ends of the telescopic rods (92) are used to press down on the blocking block (62).

8. The method according to claim 5, characterized in that, The S3 includes: In two adjacent battery strings (30) arranged horizontally, the next battery string (30) is flipped to a vertical position, and the flipped battery string (30) is moved towards the previous battery string (30) until the barrier block (62) on the next battery string (30) contacts the side of the previous battery string (30); then the next battery string (30) is flipped back to a horizontal position, and the barrier block (62) on the next battery string (30) is attached to the second side of the battery cell (31) in the previous battery string (30), and the barrier block (62) on the previous battery string (30) is attached to the second side of the battery cell (31) in the next battery string (30).

9. The method according to claim 4, characterized in that, Providing a battery cell layer includes the following steps: S1. Make a barrier strip (61) with multiple barrier blocks (62) on both sides and arranged symmetrically; S2. Place the barrier strip (61) horizontally and flip the barrier blocks (62) on both sides of the barrier strip (61) to a preset angle. S3. Place two adjacent battery strings (30) horizontally, and position the first surfaces of the battery pieces (31) of the two battery strings (30) on the upper surfaces of the unfolded barrier blocks (62) on both sides of the barrier strip (61), and ensure that the edges between the two adjacent battery strings (30) are tightly attached to the same barrier strip (61). Then restore the folded barrier blocks (62) to the horizontal state and attach them to the second surfaces of the battery pieces (31) of the battery strings (30) to form a cross connection.

10. The method according to claim 5 or 9, characterized in that, When making the barrier strip (61), the barrier strip (61) with multiple barrier blocks (62) on one or both sides can be formed by cutting, punching or laser cutting the barrier material.

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