Photovoltaic module and lamination method thereof

Abstract

The invention discloses a photovoltaic module and a lamination method thereof. The method comprises the following steps: S1, laminating to obtain a pavement piece; s2, performing low-temperature feeding in a first chamber; s3, the first chamber is vacuumized; s4, performing low-temperature discharging in the first cavity: after the vacuumizing treatment of the first cavity is finished, directly discharging without cooling; s4, after low-temperature vacuumizing treatment of the first cavity is finished, low-temperature discharging is directly conducted without cooling; s5, performing high-temperature feeding in a second chamber; s6, the second chamber is vacuumized for a short time; s7, performing high-temperature long-time lamination in the second chamber to crosslink the materials together; s8, performing high-temperature discharging in the second chamber; and S9, cooling and taking materials to obtain the photovoltaic module. According to the invention, the problems that the material is easily affected with damp or is accidentally affected with damp, and wrinkles, bubbles, delamination, lack of glue, too shallow film embossing, product deformation and the like are easily caused after lamination can be solved.

Description

A photovoltaic module and its lamination method Technical Field

[0001] This invention relates to the field of photovoltaics, and more particularly to a photovoltaic module and its lamination method. Background Technology

[0002] Photovoltaic module lamination is a key process in photovoltaic power generation systems. A laminator stacks solar cells, EVA film, and other materials together to form a module with a certain degree of rigidity and stability. Traditional lamination methods use a high-temperature-in-high-temperature-out-of-laminator process, making the materials and components susceptible to moisture. This can lead to defects such as wrinkles, bubbles, delamination, insufficient adhesive, and shallow film embossing after lamination. Summary of the Invention

[0003] To address the problems existing in the prior art, this invention provides a photovoltaic module and its lamination method, which can solve the problems that materials and mounting components are susceptible to moisture, and that wrinkles, bubbles, delamination, insufficient adhesive, shallow film embossing, and product deformation are likely to occur after lamination.

[0004] Specifically, a photovoltaic module lamination method includes the following steps: S1, stacking a transparent encapsulation pre-film, a first encapsulating film, a solar cell layer, a second encapsulating film, a support layer, a third encapsulating film, and a photovoltaic backsheet from top to bottom to obtain a layup; a laminator is pre-set, the laminator including a first chamber and a second chamber; S2, low-temperature feeding into the first chamber: setting the temperature of the first chamber of the laminator below the melting temperature T1 of the first, second, and third encapsulating films, and placing the layup into the first chamber; S3, vacuuming the first chamber: the vacuuming time of the first chamber is within a long time range t1; S4, low-temperature discharging from the first chamber: after the vacuuming of the first chamber, discharging directly at low temperature without cooling; S5, high-temperature feeding into the second chamber: after the low-temperature discharging of the first chamber, the material enters the second chamber, and the temperature of the second chamber is set within a high temperature range T2; S6, short-time vacuuming of the second chamber: the vacuuming time of the second chamber is within a short time range t2; S7, ... Second chamber high-temperature long-term lamination: Lamination and cross-linking are carried out within the high temperature range T2 to form laminated parts, and the lamination time is within the long time range t1; S8, high-temperature discharge from the second chamber: After S7, without changing the temperature, the cover of the second chamber is opened directly to remove the laminated parts and place them on the discharge platform for cooling; S9, cooling and unloading: The laminated parts on the discharge platform are covered with high-temperature cloth and cooled with cooling equipment for t3 to obtain photovoltaic modules.

[0005] Furthermore, the T2 range is 135℃~155℃.

[0006] Furthermore, the t2 range is 3 to 6 minutes.

[0007] Furthermore, the range of t1 is 30 to 60 minutes.

[0008] Furthermore, the t3 range is 20 to 30 minutes.

[0009] Furthermore, the S2 low-temperature feeding also includes: using high-temperature tape to fix the edge of the paving component.

[0010] Furthermore, the first encapsulating film, the second encapsulating film, and the third encapsulating film are any one of the following materials: EVA, POE, and EPE.

[0011] The EPE has a three-layer structure of EVA / PET / EVA.

[0012] Furthermore, the material of the transparent encapsulation front film includes: ETFE film, PVDF film, transparent CPC front plate, and FFC front plate, and the light transmittance of the transparent encapsulation front layer is ≥90%.

[0013] Furthermore, T1 ranges from 30℃ to 70℃.

[0014] On the other hand, the present invention also provides a photovoltaic module, which is obtained by laminating using the above-described photovoltaic module lamination method.

[0015] Compared with the prior art, the present invention has the following advantages: The present invention can solve the problems that the material is easily affected by moisture or has been accidentally affected by moisture, and that wrinkles, bubbles, delamination, lack of glue, shallow film embossing and product deformation are likely to occur after lamination. Attached Figure Description

[0016] Figure 1 is a schematic diagram of a photovoltaic module lamination method in one embodiment of the present invention. Detailed Implementation

[0017] To make the objectives, technical solutions, and advantages of this invention clearer, the invention will be further described in detail below with reference to the accompanying drawings and embodiments. It should be understood that the specific embodiments described herein are merely illustrative and not intended to limit the invention.

[0018] As shown in Figure 1, this embodiment provides a photovoltaic module lamination method, including the following steps: S1, stacking a transparent encapsulation front film, a first encapsulation film, a solar cell layer, a second encapsulation film, a support layer, a third encapsulation film, and a photovoltaic backsheet from top to bottom to obtain a layup; pre-setting one dual-cavity laminator or two single-cavity laminators, wherein the laminator includes a first chamber and a second chamber; the chambers of the two single-cavity laminators correspond to the first chamber and the second chamber, respectively.

[0019] S2, Low-temperature feeding in the first chamber: The temperature of the first chamber of the laminator is reduced to below the melting temperature T1 of the first, second, and third encapsulating films, and the packaged parts are placed into the first chamber. It should be noted that the temperature of the first chamber of the laminator is set to be below the melting temperature of the encapsulating film (e.g., EVA). At this temperature, the encapsulating film will not melt after the product enters the first chamber of the laminator.

[0020] S3. Vacuum treatment of the first chamber: The vacuum treatment of the first chamber is carried out for a long time within the range of t1; further, the range of t1 is 30 to 60 minutes.

[0021] In this embodiment, ~ represents [ ].

[0022] Preferably, t1 can be selected as 30 minutes, 31 minutes, 32 minutes, 33 minutes, 34 minutes, 35 minutes, 36 minutes, 37 minutes, 38 minutes, 39 minutes, 40 minutes, 41 minutes, 42 minutes, 43 minutes, 44 minutes, 45 minutes, 46 minutes, 47 minutes, 48 ​​minutes, 49 minutes, 50 minutes, 51 minutes, 52 minutes, 53 minutes, 54 minutes, 55 minutes, 56 minutes, 57 minutes, 58 minutes, 59 minutes, or 60 minutes.

[0023] It should be noted that prolonged low-temperature vacuuming can remove moisture from the product, including the carrier plate and other materials, thus solving the problem of poor bubble formation after two-cavity lamination, which is caused by the evaporation of moisture and other materials. S4, Low-temperature discharge from the first chamber: After the vacuuming process in the first chamber is completed, the material is discharged directly without cooling. S5, High-temperature feeding from the second chamber: After the low-temperature discharge from the first chamber is completed, the material enters the second chamber, and the temperature of the second chamber is set within the high-temperature range T2. S6, Short-time vacuuming in the second chamber: The vacuuming time in the second chamber is within the short time range t2. Further, the range of t2 is 3 to 6 minutes.

[0024] The advantage of short-term vacuuming of the second chamber is that this short-term vacuuming can completely remove the air inside the product and prevent the encapsulation film (such as EVA) from flowing and causing wrinkles or defects during the vacuuming process.

[0025] Preferably, t2 can be set to 3 minutes, 3 minutes 20 seconds, 3 minutes 40 seconds, 4 minutes, 4 minutes 20 seconds, 4 minutes 40 seconds, 5 minutes, 5 minutes 20 seconds, 5 minutes 40 seconds, or 6 minutes.

[0026] S7. High-temperature long-term lamination in the second chamber: Lamination and cross-linking are carried out in the high temperature range T2 to form a laminated part, and the lamination time is within the long time range t1. The advantage of high-temperature long-term lamination in the second chamber is that it ensures that the cross-linking degree of the encapsulating film (e.g., EVA) of this complex structure thin-film photovoltaic module is qualified during the lamination process, and ensures that the thin film layer and the encapsulating film (e.g., EVA) will not delaminate, thus affecting the reliability of the product.

[0027] S8. High-temperature discharge from the second chamber: After S7, without changing the temperature, directly open the cover of the second chamber to remove the laminate and place it on the discharge platform to cool; S9. Cooling and unloading: Cover the laminate on the discharge platform with a high-temperature cloth and use a cooling device to cool the laminate for a cooling time of t3 to obtain the photovoltaic module.

[0028] It should be noted that the high-temperature cloth needs to be opened when taking out the product.

[0029] Furthermore, the T2 range is 135℃~155℃.

[0030] Preferably, T2 can be selected from 135℃, 137℃, 139℃, 140℃, 142℃, 144℃, 146℃, 148℃, 150℃, 152℃, 154℃, and 155℃.

[0031] Furthermore, the t3 range is 20 to 30 minutes.

[0032] Preferably, t3 can be set to 20 minutes, 21 minutes, 22 minutes, 23 minutes, 24 minutes, 25 minutes, 26 minutes, 27 minutes, 28 minutes, 29 minutes, or 30 minutes.

[0033] Cooling the material before removing it from the oven can prevent the product from deforming, lacking glue, or having shallow embossing due to excessive temperature difference between the material and the temperature when it is removed from the oven at high temperature.

[0034] Furthermore, the S2 low-temperature feeding also includes: using high-temperature tape to fix the edge of the paving component.

[0035] Furthermore, the first encapsulating film, the second encapsulating film, and the third encapsulating film are any one of the following materials: EVA, POE, and EPE.

[0036] Preferably, the first encapsulating film, the second encapsulating film, and the third encapsulating film are EVA.

[0037] The EPE has a three-layer structure of EVA / PET / EVA.

[0038] Furthermore, the material of the transparent encapsulation front film includes: ETFE film, PVDF film, transparent CPC front plate, and FFC front plate, and the light transmittance of the transparent encapsulation front layer is ≥90%.

[0039] Furthermore, T1 ranges from 30℃ to 70℃.

[0040] Preferably, T1 can be selected from 30℃, 35℃, 40℃, 45℃, 50℃, 55℃, 60℃, 65℃, and 70℃.

[0041] On the other hand, the present invention also provides a photovoltaic module, which is obtained by laminating using the above-described photovoltaic module lamination method.

[0042] Compared with the prior art, the present invention has the following advantages: The present invention can solve the problems that the material is easily affected by moisture, or has been accidentally affected by moisture, and is prone to wrinkles, bubbles, delamination, lack of glue, shallow film embossing and product deformation after lamination.

[0043] Finally, it should be noted that the above descriptions are merely preferred embodiments of the present invention and are not intended to limit the present invention. Although the present invention has been described in detail with reference to the foregoing embodiments, those skilled in the art can still modify the technical solutions described in the foregoing embodiments or make equivalent substitutions for some of the technical features. Any modifications, equivalent substitutions, improvements, etc., made within the spirit and principles of the present invention should be included within the protection scope of the present invention.

Claims

1. A photovoltaic module lamination method, characterized in that, The process includes the following steps: S1, Lamination: The transparent encapsulation front film, the first encapsulation film, the solar cell layer, the second encapsulation film, the support layer, the third encapsulation film, and the photovoltaic backsheet are laminated from top to bottom to obtain the layup. A laminator is pre-installed, comprising a first chamber and a second chamber; S2, Low-temperature feeding to the first chamber: The temperature of the first chamber of the laminator is set below the melting temperature T1 of the first, second, and third encapsulating films, and the packaged parts are placed into the first chamber; S3, Vacuuming of the first chamber: The vacuuming time of the first chamber is within a long time range t1; S4, Low-temperature discharge from the first chamber: After the vacuuming of the first chamber is completed, the parts are discharged directly at low temperature without cooling; S5, High-temperature feeding to the second chamber: After the low-temperature discharge from the first chamber is completed, the parts enter the second chamber, and the temperature of the second chamber is set within a high-temperature range T2; S6, Short-time vacuuming of the second chamber: The vacuuming time of the second chamber is within a short time range t2; S7, Second chamber high-temperature long-term lamination: Lamination and cross-linking are carried out within the high temperature range T2 to form a laminate, and the lamination time is within the long time range t1; S8, Second chamber high-temperature discharge: After S7, without changing the temperature, the cover of the second chamber is opened directly to take out the laminate and place it on the discharge platform for cooling; S9, Cooling and material removal: The laminate on the discharge platform is covered with a high-temperature cloth and the laminate is cooled using a cooling device for a cooling time of t3 to obtain the photovoltaic module.

2. The photovoltaic module lamination method according to claim 1, characterized in that, The T2 range is 135℃~155℃.

3. The photovoltaic module lamination method according to claim 1, characterized in that, The t1 range is 30 to 60 minutes.

4. The photovoltaic module lamination method according to claim 1, characterized in that, The t2 range is 3 to 6 minutes.

5. The photovoltaic module lamination method according to claim 1, characterized in that, The t3 range is 20 to 30 minutes.

6. The photovoltaic module lamination method according to claim 1, characterized in that, The S2 low-temperature feeding also includes: using high-temperature tape to fix the edge of the paving component.

7. The photovoltaic module lamination method according to claim 1, characterized in that, The first encapsulating film, the second encapsulating film, and the third encapsulating film are any one of the following materials: EVA, POE, and EPE.

8. The photovoltaic module lamination method according to claim 1, characterized in that, The materials of the transparent encapsulation front film include: ETFE film, PVDF film, transparent CPC front plate, and FFC front plate, and the light transmittance of the transparent encapsulation front layer is ≥90%.

9. The photovoltaic module lamination method according to claim 1, characterized in that, The temperature range of T1 is 30℃~70℃.

10. A photovoltaic module, characterized in that, The photovoltaic module is obtained by laminating using the photovoltaic module lamination method described in any one of claims 1 to 9.

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