Solar cell packaging method
By leaving a gap between the substrate glass and the laminated glass and filling it with glass wires or glass strips, combined with vacuum treatment and laser heating, the problem of poor sealing effect of double-layer glass is solved, achieving efficient water and oxygen isolation and improving the quality and lifespan of solar cells.
Patent Information
- Authority / Receiving Office
- CN · China
- Patent Type
- Applications(China)
- Current Assignee / Owner
- HUANENG CLEAN ENERGY RES INST
- Filing Date
- 2026-01-22
- Publication Date
- 2026-04-21
AI Technical Summary
In existing technologies, double-glass solar cell modules have poor sealing performance, leading to water and oxygen penetration and affecting the lifespan of the cells.
A gap is reserved between the substrate glass and the laminated glass, glass wires or glass strips are set as fillers, and the glass structure is placed in a vacuum container for vacuum treatment. The fillers are then heated to melt by a laser to achieve circumferential sealing.
It effectively prevents water and oxygen from penetrating, improving the sealing performance and lifespan of solar cells.
Smart Images
Figure CN121908684A_ABST
Abstract
Description
Technical Field
[0001] This invention relates to the technical field of solar cell manufacturing processes, and in particular to a solar cell encapsulation method. Background Technology
[0002] Solar cell encapsulation methods typically involve combining two glass panes with a solar cell. Compared to ordinary solar modules, photovoltaic modules assembled in this way offer advantages such as longer lifespan, higher power generation, lower degradation, better barrier properties, aesthetic appeal allowing for seamless integration with buildings, easier recycling, less susceptibility to snow and dust accumulation, and reduced likelihood of microcracks.
[0003] However, in existing technologies, encapsulation methods often employ lamination combined with adhesive film materials (such as EVA and POE) for sealing. This encapsulation method has the following drawbacks: First, the encapsulation edges are prone to micro-gaps due to material shrinkage or environmental stress, leading to water and oxygen penetration and accelerating battery module aging. Second, traditional hot-pressing processes struggle to achieve uniform sealing at the edges, especially for complex-shaped battery modules. In summary, if effective sealing to prevent water and oxygen penetration cannot be achieved, the lifespan of the solar cell will be affected. Summary of the Invention
[0004] The purpose of this invention is to provide a solar cell encapsulation method to alleviate the technical problem in the prior art where poor sealing between double-layer glass leads to the inability to prevent water and oxygen penetration, which in turn affects the lifespan of the solar cell.
[0005] To achieve the above objectives, the present invention adopts the following technical solution: In a first aspect, the present invention provides a solar cell encapsulation method, comprising: The substrate glass and laminated glass are initially encapsulated, with gaps left at the edges; A filler is provided in the gap between the substrate glass and the laminated glass to form a glass structure; The glass structure is placed in a vacuum container, and the vacuum container is evacuated. The filler is heated to melt using a laser and then used to fill the gaps.
[0006] Further, the substrate glass and laminated glass are initially encapsulated, with gaps left at the edges, including: After laying POE film and butyl adhesive between the substrate glass and the laminated glass, preliminary lamination and encapsulation are performed.
[0007] Further, the substrate glass and laminated glass are initially encapsulated, with gaps left at the edges, including: After the initial lamination and encapsulation, a gap of 5-8 mm is reserved around the edges of the substrate glass and the laminated glass.
[0008] Furthermore, a filler is provided in the gap between the substrate glass and the laminated glass to form a glass structure, including: Glass filaments or glass strips are used as fillers to fill the gaps.
[0009] Furthermore, a filler is provided in the gap between the substrate glass and the laminated glass to form a glass structure, including filling with glass filaments or glass strips with a melting point range of 600-800°C.
[0010] Further, the glass structure is placed in a vacuum container, and the vacuum container is evacuated, including: Connect the connection port of the vacuum container to an external vacuum pump, and perform vacuum dehumidification treatment on the vacuum container.
[0011] Further, the glass structure is placed in a vacuum container, and the vacuum container is evacuated, including: The vacuum container is evacuated to a pressure not exceeding 10. - Apply pressure at 2 Pa for 5-10 minutes.
[0012] Further, the glass structure is placed in a vacuum container, and the vacuum container is evacuated, including: The upper surface of the vacuum container is made of a transparent material with a light transmittance of ≥90%.
[0013] Further, the filler is heated to a melt state using a laser and then used to fill the gaps, including: The laser with a power of 200W-500W and a wavelength range of 1064nm-1080nm is used, and the laser is scanned along the gap and repeated multiple times.
[0014] Further, the filler is heated to a melt state using a laser and then used to fill the gaps, including: A temperature sensor is installed inside the vacuum container, and during the melting process of the filling material, the temperature change inside the vacuum container is monitored in real time by the temperature sensor.
[0015] The present invention can achieve the following beneficial effects: In a first aspect, the present invention provides a solar cell encapsulation method, comprising: initially encapsulating a substrate glass and a laminated glass, and leaving a gap at the edge; placing a filler in the gap between the substrate glass and the laminated glass to form a glass structure; placing the glass structure in a vacuum container and evacuating the vacuum container; and filling the gap by heating the filler to melt using a laser.
[0016] In this invention, the substrate glass and the laminated glass are first stacked, and a gap of a certain width is formed at their edges. Then, a filler is placed in this gap, and it should be noted that the filler should not exceed the width of the gap. The stacked glass structure is then placed in a vacuum container, and the vacuum container is evacuated until the pressure inside the vacuum container reaches a specified pressure value. Finally, the filler in the gap is heated to melt using a laser to achieve circumferential connection between the substrate glass and the laminated glass.
[0017] Compared with the prior art, the solar cell encapsulation method provided by the present invention fills the gap between the substrate glass and the laminated glass with a filler; after placing the glass structure in a vacuum container, the filler is heated and melted by a laser to achieve circumferential sealing of the substrate glass and the laminated glass, thereby sealing the double-layer glass to prevent water and oxygen penetration and thus ensuring the quality of the solar cell.
[0018] In summary, this invention at least alleviates the technical problem in the prior art where poor sealing between the double-layered glass layers leads to the inability to prevent water and oxygen penetration, which in turn affects the quality of solar cells. Attached Figure Description
[0019] To more clearly illustrate the specific embodiments of the present invention or the technical solutions in the prior art, the drawings used in the description of the specific embodiments or the prior art will be briefly introduced below. Obviously, the drawings described below are some embodiments of the present invention. For those skilled in the art, other drawings can be obtained from these drawings without creative effort.
[0020] Figure 1 This is a schematic diagram of the glass structure of the solar cell encapsulation method provided in an embodiment of the present invention; Figure 2 This is a schematic diagram of the processing structure of the solar cell encapsulation method provided in an embodiment of the present invention.
[0021] Icons: 1-Glass structure; 11-Substrate glass; 12-Laminated glass; 13-Filling material; 2-Vacuum container; 21-Connecting hole; 3-Laser. Detailed Implementation
[0022] 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.
[0023] 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.
[0024] 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.
[0025] In the description of this invention, it should be noted that the terms "upper," "lower," "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," and "third," etc., are only used to distinguish descriptions and should not be construed as indicating or implying relative importance.
[0026] Furthermore, terms such as "horizontal" and "vertical" 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 than "vertical," and does not mean that the structure must be completely horizontal, but can be slightly tilted.
[0027] In the description of this invention, it should also be noted that, unless otherwise explicitly specified and limited, the terms "set," "install," and "connect" 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.
[0028] 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.
[0029] Example 1 This embodiment provides a solar cell encapsulation method, referring to... Figure 1 and Figure 2 The solar cell encapsulation method includes: The substrate glass 11 and the laminated glass 12 are initially encapsulated, with gaps left at the edges; A filler 13 is provided in the gap between the substrate glass 11 and the laminated glass 12 to form a glass structure 1; The glass structure 1 is placed in the vacuum container 2, and the vacuum container 2 is evacuated. The filler 13 is heated to melt by laser 3 and then filled into the gap.
[0030] The embodiments of the present invention at least alleviate the technical problem in the prior art that the poor sealing effect between the double-layer glass layers can not prevent water and oxygen penetration, which in turn affects the quality of solar cells.
[0031] In this embodiment of the invention, the substrate glass 11 and the laminated glass 12 are first stacked, and a gap of a certain width is formed at their edges. Then, a filler 13 is placed in this gap, and it should be noted that the filler 13 should not exceed the width of the gap. Then, the stacked glass structure 1 is placed in a vacuum container 2, and the vacuum container 2 is then evacuated until the air pressure inside the vacuum container reaches a specified air pressure value. Finally, the filler 13 in the gap is heated to melt by a laser 3, so as to connect the substrate glass 11 and the laminated glass 12 in the circumferential direction.
[0032] Compared with the prior art, the solar cell encapsulation method provided in this embodiment of the invention provides a filler 13 in the gap between the substrate glass 11 and the laminated glass 12; after placing the glass structure 1 in the vacuum container 2, the filler 13 is heated and melted by a laser 3 to achieve circumferential sealing between the substrate glass 11 and the laminated glass 12, thereby sealing the double-layer glass to prevent water and oxygen penetration and thus ensuring the quality of the solar cell.
[0033] In an optional implementation of this embodiment, refer to Figure 1 and Figure 2 The substrate glass 11 and the laminated glass 12 are initially encapsulated, with gaps left at the edges. This includes laying POE film and butyl adhesive between the substrate glass 11 and the laminated glass 12, followed by initial lamination encapsulation.
[0034] Specifically: A POE film and butyl adhesive are provided between a rectangular substrate glass 11 and a rectangular laminated glass 12. The coated POE film and butyl adhesive have a rectangular film structure, and there is a gap between the edge of the film and the edge of the glass. This gap is used to set the filler 13, thereby achieving preliminary encapsulation.
[0035] Furthermore, referring to Figure 1 and Figure 2The substrate glass 11 and the laminated glass 12 are initially encapsulated, and a gap is reserved at the edge, including: after the initial lamination encapsulation, a gap of 5-8 mm is reserved at the four edges of the substrate glass 11 and the laminated glass 12.
[0036] Specifically, the width of the gap between the adhesive film and the glass can be 5-8mm, so that the filler 13 can have the same width as the gap. Therefore, after the filler 13 is melted, it can effectively connect the substrate glass 11 and the laminated glass 12, so as to avoid the situation that the connection is not firm and gaps appear due to insufficient amount of filler 13, which would cause technical problems such as easy water and oxygen penetration.
[0037] In an optional implementation of this embodiment, refer to Figure 1 and Figure 2 A filler 13 is provided in the gap between the substrate glass 11 and the laminated glass 12 to form a glass structure 1, including filling the gap with glass filaments or glass strips as filler 13.
[0038] Specifically, the filler 13 can be glass wire or glass strip, and the size of the glass wire or glass strip matches the size of the gap so that the glass wire or glass strip can completely fill the gap after melting, forming a seamless sealing structure; thereby completely preventing water and oxygen penetration and effectively improving the service life of solar cells.
[0039] Furthermore, referring to Figure 1 and Figure 2 A filler 13 is provided in the gap between the substrate glass 11 and the laminated glass 12 to form a glass structure 1, including filling with glass wire or glass strip with a melting point range of 600-800℃.
[0040] Specifically: the melting point of the glass filaments or glass strips is in the range of 600-800℃, and the melting point of the glass filaments or glass strips must be lower than that of the substrate glass 11. Furthermore, the glass filaments or glass strips must form a chemical bond with the substrate glass 11 after melting. This is to avoid damage to the substrate glass 11 when the glass filaments or glass strips are melted.
[0041] In an optional implementation of this embodiment, refer to Figure 1 and Figure 2 The glass structure 1 is placed in the vacuum container 2, and the vacuum container 2 is evacuated, including connecting the connection hole 21 of the vacuum container 2 to an external vacuum pump and evacuating the vacuum container 2 for dehumidification.
[0042] Specifically, a connection hole 21 is provided on one side wall of the vacuum container 2. By connecting the connection hole 21 to an external vacuum pump, vacuum dehumidification treatment can be achieved inside the vacuum container. The vacuum container 2 can be a flat rectangular container for precise heating by combining a vacuum environment with laser technology. That is, through a controllable process, thermal stress damage during the packaging process can be avoided.
[0043] Furthermore, referring to Figure 1 and Figure 2 The glass structure 1 is placed in the vacuum container 2, and the vacuum container 2 is evacuated, including: evacuating the vacuum container 2 to a pressure value not exceeding 10. - Apply pressure at 2 Pa for 5-10 minutes.
[0044] Specifically: When using it, vacuum container 2 needs to be evacuated until the pressure value does not exceed 10. - 2 Pa, and maintain for 5-10 minutes to achieve thorough dehumidification; and taking a rigid monocrystalline silicon cell with dimensions of 156mm×156mm as an example, it is necessary to evacuate the vacuum container 2 to 5×10 Pa. - Set the air pressure to 3 Pa and maintain it for 8 minutes.
[0045] In an optional implementation of this embodiment, refer to Figure 1 and Figure 2 The glass structure 1 is placed in the vacuum container 2, and the vacuum container 2 is evacuated, including: the upper surface of the vacuum container 2 is made of a transparent material with a light transmittance of ≥90%.
[0046] Specifically: the upper surface of the vacuum container 2 is made of a transparent material with a light transmittance of ≥90%, and the material of the upper surface of the vacuum container 2 can be tempered glass or polycarbonate, etc.; so that the laser 3 can pass smoothly through the upper surface of the vacuum container 2 and irradiate the glass structure 1.
[0047] In an optional implementation of this embodiment, refer to Figure 1 and Figure 2 The gap is filled by heating the filler 13 to melt using a laser 3, including using a laser 3 with a power of 200W-500W and a wavelength range of 1064nm-1080nm, and scanning the laser 3 along the gap and repeating the process multiple times.
[0048] Specifically, laser 3 needs to scan along the gap and repeat multiple times to ensure that the filler 13 is fully melted to effectively seal the gap. Taking a rigid monocrystalline silicon cell with dimensions of 156mm × 156mm as an example, laser 3 can be a 300W fiber laser, which melts glass filaments or glass strips along the gap at a scanning speed of 0.5m / s and repeats the scan three times.
[0049] Furthermore, referring to Figure 1 and Figure 2 The gap is filled by heating the filler 13 to melt using a laser 3, including: setting a temperature sensor inside the vacuum container 2, and monitoring the temperature change inside the vacuum container 2 in real time during the melting process of the filler 13.
[0050] Specifically, during use, the focal point is precisely controlled via an optical system, and then a high-power laser 3 heats and melts the filler 13. A temperature sensor located inside the vacuum container 2 monitors temperature changes during the melting process in real time, effectively preventing localized overheating and ensuring uniform melting. This achieves seamless sealing by melting glass material with laser, completely preventing water and oxygen penetration through a highly airtight seal. This method improves the sealing and weather resistance of the battery module, making it suitable for large-scale production of various rigid solar cells.
[0051] Finally, it should be noted that the various embodiments in this specification are described in a progressive manner, with each embodiment focusing on the differences from other embodiments. Similar or identical parts between embodiments can be referred to interchangeably. The above embodiments in this specification are only used to illustrate the technical solutions of the present invention and are not intended to limit it. Although the present invention has been described in detail with reference to the foregoing embodiments, those skilled in the art should understand that modifications can still be made to the technical solutions described in the foregoing embodiments, or equivalent substitutions can be made to some or all of the technical features. These modifications or substitutions do not cause the essence of the corresponding technical solutions to deviate from the scope of the technical solutions of the embodiments of the present invention.
Claims
1. A method for encapsulating a solar cell, characterized in that, include: The substrate glass (11) and laminated glass (12) are initially encapsulated, and gaps are reserved at the edges; A filler (13) is provided in the gap between the substrate glass (11) and the laminated glass (12) to form a glass structure (1). The glass structure (1) is placed in a vacuum container (2), and the vacuum container (2) is evacuated. The filler (13) is heated to melt by a laser (3) and then used to fill the gap.
2. The solar cell encapsulation method according to claim 1, characterized in that, The substrate glass (11) and laminated glass (12) are initially encapsulated, with gaps left at the edges, including: After laying POE film and butyl glue between the substrate glass (11) and the laminated glass (12), preliminary lamination and encapsulation are performed.
3. The solar cell encapsulation method according to claim 2, characterized in that, The substrate glass (11) and laminated glass (12) are initially encapsulated, with gaps left at the edges, including: After the initial lamination and encapsulation, a gap of 5-8 mm is reserved around the edges of the substrate glass (11) and the laminated glass (12).
4. The solar cell encapsulation method according to claim 1, characterized in that, A filler (13) is disposed in the gap between the substrate glass (11) and the laminated glass (12) to form a glass structure (1), comprising: Glass filaments or glass strips are used as filler (13) to fill the gap.
5. The solar cell encapsulation method according to claim 4, characterized in that, A filler (13) is disposed in the gap between the substrate glass (11) and the laminated glass (12) to form a glass structure (1), comprising: The glass wire or glass strip with a melting point range of 600-800℃ is selected for filling.
6. The solar cell encapsulation method according to claim 1, characterized in that, The glass structure (1) is placed in a vacuum container (2), and the vacuum container (2) is evacuated, including: Connect the connection hole (21) of the vacuum container (2) to an external vacuum pump, and perform vacuum dehumidification treatment on the vacuum container (2).
7. The solar cell encapsulation method according to claim 6, characterized in that, The glass structure (1) is placed in a vacuum container (2), and the vacuum container (2) is evacuated, including: The vacuum container (2) is evacuated to a pressure value not exceeding 10. - Apply pressure at 2 Pa for 5-10 minutes.
8. The solar cell encapsulation method according to claim 6, characterized in that, The glass structure (1) is placed in a vacuum container (2), and the vacuum container (2) is evacuated, including: The upper surface of the vacuum container (2) is made of a transparent material with a light transmittance of ≥90%.
9. The solar cell encapsulation method according to claim 1, characterized in that, The gap is filled by heating the filler (13) to a molten state using a laser (3), including: The laser (3) with a power of 200W-500W and a wavelength range of 1064nm-1080nm is used, and the laser (3) is scanned along the gap and repeated multiple times.
10. The solar cell encapsulation method according to claim 9, characterized in that, The gap is filled by heating the filler (13) to a molten state using a laser (3), including: A temperature sensor is installed inside the vacuum container (2), and during the melting process of the filler (13), the temperature change inside the vacuum container (2) is monitored in real time by the temperature sensor.