Photovoltaic module, manufacturing process and manufacturing equipment

Abstract

The invention relates to a photovoltaic module, a manufacturing process and manufacturing equipment. The hidden crack risk of the photovoltaic module battery piece is low, the product quality is good, the technological process is simplified, and the manufacturing cost is low. The photovoltaic module comprises a battery piece and a bus bar, and an electrode of the battery piece is arranged on the back surface of the battery piece; the bus bar is located on the back face of the battery piece and comprises a conductive side and an insulation side in the thickness direction of the photovoltaic module, the conductive side is electrically connected with the battery piece, the insulation side faces the back face of the battery piece, the insulation side is provided with a buffer structure, the buffer structure protrudes out of the insulation side, and the insulation side makes contact with the back face of the battery piece through the buffer structure.

Description

Technical Field

[0001] This application relates to the field of solar cell technology, and in particular to a photovoltaic module, manufacturing process and manufacturing equipment. Background Technology

[0002] Photovoltaic modules are core devices that convert solar energy into electrical energy and are a key component of photovoltaic power generation systems. Photovoltaic modules can directly convert solar energy into direct current (DC) electricity and are widely used in distributed rooftop power stations, large-scale ground-mounted photovoltaic power stations, off-grid systems, and various photovoltaic products.

[0003] Typically, photovoltaic (PV) modules consist of solar cells and busbars. After the cells and busbars are connected by solder strips, the busbars are bent to the back of the cells to conceal them and increase the photoelectric conversion area of ​​the cells. In related technologies, to prevent short circuits, an insulating material is required between the back of the cell and the busbar. However, due to the relatively high thickness of the insulating material, the cells are susceptible to microcracks caused by external forces during subsequent processes, affecting the product quality of the PV module. Furthermore, the manufacturing process for such PV modules is relatively complex and costly. Summary of the Invention

[0004] Therefore, it is necessary to provide a photovoltaic module, manufacturing process, and manufacturing equipment to address the issues of hidden crack risk, impact on product quality, complex processes, and high manufacturing costs associated with photovoltaic modules.

[0005] A photovoltaic module, comprising:

[0006] A solar cell, wherein the electrodes are disposed on the back side of the solar cell;

[0007] A busbar is located on the back of the solar cell. In the thickness direction of the photovoltaic module, the busbar includes a conductive side and an insulating side. The conductive side is electrically connected to the solar cell, and the insulating side faces the back of the solar cell. The insulating side is provided with a buffer structure, which protrudes from the insulating side and contacts the back of the solar cell through the buffer structure.

[0008] In one embodiment of this application, the buffer structure includes a plurality of protrusions, with adjacent protrusions spaced apart.

[0009] In one embodiment of this application, at least two of the protrusions are grouped together in the width direction of the busbar, and adjacent groups of protrusions are staggered or aligned in the length direction of the busbar.

[0010] In one embodiment of this application, the cross-sectional shape of the protrusion perpendicular to its extension direction is circular, and the maximum diameter of the protrusion is 1mm-1.5mm.

[0011] In one embodiment of this application, a first connecting strip is further included. The first connecting strip includes a connecting portion and a bent portion connected together. The connecting portion is electrically connected to the battery cell, and the bent portion is bent toward the back of the battery cell and electrically connected to the conductive side.

[0012] In one embodiment of this application, the extending direction of the connecting portion is set at an angle to the extending direction of the bending portion.

[0013] In one embodiment of this application, a plurality of battery cells are provided, and the plurality of battery cells are electrically connected to form a battery string. The busbar is located on the back side of one of the battery cells, and other battery cells adjacent to the battery cell are electrically connected to the conductive side through other first connecting strips.

[0014] A manufacturing process for a photovoltaic module, the manufacturing process comprising:

[0015] Electrically connect the conductive side of the busbar to the battery cell;

[0016] The busbar is placed on the back of the battery cell, with the insulating side of the busbar facing the back of the battery cell.

[0017] In one embodiment of this application, the method further includes electrically connecting adjacent battery cells to the conductive side.

[0018] A photovoltaic module manufacturing apparatus, the manufacturing apparatus comprising:

[0019] Welding equipment is used to electrically connect the conductive side of the busbar to the battery cell;

[0020] A clamping device for clamping the busbar and placing the busbar on the back of the battery cell, such that the insulating side of the busbar faces the back of the battery cell.

[0021] The aforementioned photovoltaic module includes solar cells and busbars. The busbars have a conductive side and an insulating side. The conductive side is electrically connected to the solar cells, while the insulating side faces the back of the solar cells. This eliminates the need for additional insulating materials between the back of the solar cells and the busbars, reducing the height difference between them and thus lowering the risk of microcracks in the solar cells during subsequent processing. This improves the quality of the photovoltaic module, simplifies the manufacturing process, increases production efficiency, and reduces costs. Furthermore, the insulating side of the busbar contacts the back of the solar cells through a buffer structure. This buffer structure isolates the insulating side from the back of the solar cells, creating a clearance and preventing direct contact, further enhancing the insulation between the back of the solar cells and the busbars. The buffer structure is made of a flexible material, reducing the possibility of relative sliding between the busbars and the back of the solar cells during subsequent processing. This reduces scratches on the solar cells caused by sliding, effectively protecting them and improving the quality and yield of the photovoltaic module.

[0022] The aforementioned photovoltaic module manufacturing process, used to manufacture the aforementioned photovoltaic module, has the same beneficial effects as the photovoltaic module itself, and will not be elaborated further.

[0023] The aforementioned photovoltaic module manufacturing equipment is used to manufacture the aforementioned photovoltaic module and has the same beneficial effects as the photovoltaic module, which will not be elaborated here. Attached Figure Description

[0024] Figure 1 This is a schematic diagram of the photovoltaic module of this application.

[0025] Figure 2 This is a three-dimensional schematic diagram of the photovoltaic module of this application.

[0026] Figure 3 This is a schematic diagram of another embodiment of the photovoltaic module of this application.

[0027] Figure 4 This is a schematic diagram of the busbar in the photovoltaic module of this application.

[0028] Explanation of reference numerals in the attached drawings: 1. Battery cell; 101. First battery cell; 102. Second battery cell; 2. Busbar; 201. Conductive side; 202. Insulating side; 203. Protrusion; 3. First connecting strip; 301. Connecting part; 302. Bending part; 31. First welding strip; 32. Second welding strip; 4. Second connecting strip. Detailed Implementation

[0029] To make the above-mentioned objectives, features, and advantages of this application more apparent and understandable, the specific embodiments of this application are described in detail below with reference to the accompanying drawings. Many specific details are set forth in the following description to provide a thorough understanding of this application. However, this application can be implemented in many other ways different from those described herein, and those skilled in the art can make similar modifications without departing from the spirit of this application. Therefore, this application is not limited to the specific embodiments disclosed below.

[0030] In the description of this application, it should be understood that if terms such as "center", "longitudinal", "lateral", "length", "width", "thickness", "upper", "lower", "front", "rear", "left", "right", "vertical", "horizontal", "top", "bottom", "inner", "outer", "clockwise", "counterclockwise", "axial", "radial", "circumferential" appear, these terms indicate the orientation or positional relationship based on the orientation or positional relationship shown in the accompanying drawings, and are only for the convenience of describing this application 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 application.

[0031] Furthermore, where the terms "first" and "second" appear, these terms are for descriptive purposes only and should not be construed as indicating or implying relative importance or implicitly specifying the number of technical features indicated. Thus, a feature defined with "first" or "second" may explicitly or implicitly include at least one of that feature. In the description of this application, where the term "multiple" appears, "multiple" means at least two, such as two, three, etc., unless otherwise explicitly specified.

[0032] In this application, unless otherwise expressly specified and limited, the terms "installation," "connection," "joining," and "fixing," etc., should be interpreted broadly. For example, they can refer to a fixed connection, a detachable connection, or an integral part; they can refer to a mechanical connection or an electrical connection; they can refer to a direct connection or an indirect connection through an intermediate medium; they can refer to the internal communication of two components or the interaction between two components, unless otherwise expressly limited. Those skilled in the art can understand the specific meaning of the above terms in this application based on the specific circumstances.

[0033] In this application, unless otherwise expressly specified and limited, the use of descriptions such as "above" or "below" the second feature indicates that the first and second features are in direct contact or indirect contact via an intermediate medium. Furthermore, "above," "on top of," and "over" the second feature can mean that the first feature is directly above or diagonally above the second feature, or simply that the first feature is at a higher horizontal level than the second feature. Similarly, "below," "below," and "under" the second feature can mean that the first feature is directly below or diagonally below the second feature, or simply that the first feature is at a lower horizontal level than the second feature.

[0034] It should be noted that if an element is referred to as being "fixed to" or "set on" another element, it can be directly on the other element or there may be an intervening element. If an element is considered to be "connected to" another element, it can be directly connected to the other element or there may be an intervening element. If so, the terms "vertical," "horizontal," "upper," "lower," "left," "right," and similar expressions used in this application are for illustrative purposes only and do not represent the only possible implementation.

[0035] See Figures 1-4 As shown, a photovoltaic module provided in one embodiment of this application includes: a solar cell 1 and a busbar 2. The electrodes of the solar cell 1 are disposed on the back side of the solar cell 1. The busbar 2 is located on the back side of the solar cell 1. In the thickness direction of the photovoltaic module, the busbar 2 includes a conductive side 201 and an insulating side 202. The conductive side 201 is electrically connected to the solar cell 1. The insulating side 202 faces the back side of the solar cell 1. The insulating side 202 is provided with a buffer structure. The buffer structure protrudes from the insulating side 202 and contacts the back side of the solar cell 1 through the buffer structure.

[0036] In this type of photovoltaic module, the conductive side 201 of the busbar 2 is electrically connected to the solar cell 1, while the insulating side 202 faces the back of the solar cell 1. This eliminates the need for additional insulating materials between the back of the solar cell 1 and the busbar 2, reducing the height difference between them. This lowers the risk of microcracks in the solar cell 1 caused by external forces during subsequent processes, improving the quality of the photovoltaic module and simplifying the manufacturing process, thus increasing production efficiency. Furthermore, the insulating side 202 of the busbar 2 contacts the back of the solar cell 1 through a buffer structure. This buffer structure isolates the insulating side 202 from the back of the solar cell 1, creating a clearance between them and preventing direct contact, further enhancing the insulation between the back of the solar cell 1 and the busbar 2. Furthermore, the buffer structure is made of flexible buffer material, which can reduce the relative sliding between the busbar 2 and the back of the cell 1 in subsequent processes. This reduces the potential scratches on the cell 1 caused by the sliding of the busbar 2 relative to the back of the cell 1, effectively protecting the cell 1 and improving the product quality and yield of the photovoltaic module.

[0037] The photovoltaic module involved in this application is the core power generation unit of a photovoltaic power generation system, which can directly convert solar energy into direct current energy through the photovoltaic effect of semiconductor materials. The photovoltaic module of this application is a back contact photovoltaic module (BC module, also known as a full-screen module), in which the positive and negative electrodes are all integrated on the back of the cell, and there is no grid line obstruction on the front of the cell, which can eliminate the light loss from the front shading, optimize current collection, and achieve higher photoelectric conversion efficiency.

[0038] A photovoltaic module includes a solar cell 1, which is the basic unit of the photovoltaic module. The front side of the solar cell 1 is the light-receiving surface, and the electrodes of the solar cell 1 are located on the back side of the solar cell 1. That is, both the positive and negative electrodes of the solar cell 1 are located on the back side of the solar cell 1, so as to maximize the photoelectric conversion area of ​​the solar cell 1 and improve the photoelectric conversion efficiency.

[0039] The photovoltaic module also includes a busbar 2, which is electrically connected to the solar cells 1. The busbar 2 is used to collect the current generated by each solar cell 1 to achieve a stable current output. After the busbar 2 is electrically connected to the solar cell 1, the busbar 2 is located on the back of the solar cell 1 to avoid the busbar 2 blocking the light-receiving area on the front of the solar cell 1, thereby improving the photoelectric conversion efficiency of the solar module.

[0040] See Figures 1-2 As shown, in the thickness direction of the photovoltaic module, the busbar 2 includes a conductive side 201 and an insulating side 202, meaning that the busbar 2 is a single-sided insulated busbar. The thickness direction of the photovoltaic module is as follows... Figure 2As indicated by the middle arrow a-a', the busbar 2 is a thin sheet structure with a certain width. In the thickness direction of the photovoltaic module, the busbar 2 includes a conductive side 201 and an insulating side 202, which are arranged opposite to each other.

[0041] In one embodiment, the conductive side 201 is the front side of the busbar 2, and is a tin layer. The tin layer can be made of a tin-lead alloy (high temperature) or a tin-lead alloy with bismuth (low temperature). The conductive side 201 is used for electrical connection with the battery cell 1. The insulating side 202 is the back side of the busbar 2, and is an insulating layer. The insulating layer can be made of materials such as acrylic resin, silicone rubber, polyvinyl chloride, or polyimide. When the busbar 2 is placed on the back side of the battery cell 1, the insulating side 202 faces the back side of the battery cell 1, and the insulating side 202 is used to achieve insulation between the busbar 2 and the back side of the battery cell 1.

[0042] See Figures 1-3 As shown, specifically, the back of the battery cell 1 is provided with positive grid lines and negative grid lines. For example, the conductive side 201 of a certain busbar 2 is electrically connected to the positive grid line, and the insulating side 202 of the busbar 2 faces the back of the battery cell 1. The insulating side 202 achieves insulation between the conductive side 201 and the negative grid line, thereby reducing the short circuit risk between the busbar 2 and the negative grid line.

[0043] When manufacturing busbar 2, a tin layer material is applied to one side of the copper strip, and an insulating layer material is applied to the other side, forming a busbar 2 structure with one side being a conductive side 201 and the other side being an insulating side 202. Alternatively, a tin layer material is applied to both sides of the copper strip, and then an insulating layer material is applied to the tin layer material on one side, thereby forming a busbar 2 structure with one side being a conductive side 201 and the other side being an insulating side 202.

[0044] In one embodiment, the method for setting the insulating layer on the busbar 2 includes: 1. Oxidation method, which accelerates the oxidation reaction on the metal surface through heating, electrolysis, chemical treatment, etc., to form a thicker, more uniform, and denser oxide film, such as tin monoxide. 2. Applying insulating adhesive or insulating tape to the surface, wherein the insulating adhesive or insulating tape can be made of acrylic resin, silicone rubber, polyvinyl chloride, polyimide, etc. 3. Spraying method, which uses high temperature or high pressure to spray insulating material onto the metal surface to form an insulating coating layer, wherein the insulating material can be made of acrylic insulating varnish, epoxy coating, silicone resin coating, etc.

[0045] In addition, the insulating side 202 is provided with a buffer structure, which is made of a flexible buffer material and has a certain degree of elasticity. Furthermore, the buffer structure protrudes from the insulating side 202, that is, the buffer structure protrudes outward relative to the surface of the insulating side 202.

[0046] When the busbar 2 is placed on the back of the solar cell 1, the insulating side 202 faces the back of the solar cell 1, but the insulating side 202 does not directly contact the back of the solar cell 1. The insulating side 202 contacts the back of the solar cell 1 through a buffer structure to improve the insulation between the back of the solar cell 1 and the busbar 2, ensuring the safety performance of the photovoltaic module. Moreover, since the buffer structure is made of a flexible buffer material, such as silicone, after the insulating side 202 contacts the back of the solar cell 1 through the buffer structure, there is a certain friction between the busbar 2 and the solar cell 1. This can reduce the relative sliding between the busbar 2 and the back of the solar cell 1 in subsequent processes, thereby reducing the scratches on the solar cell 1 that may be caused by the busbar 2 sliding relative to the back of the solar cell 1, effectively protecting the solar cell 1, and improving the product quality and yield of the photovoltaic module.

[0047] In one embodiment of this application, the buffer structure includes a plurality of protrusions 203, with adjacent protrusions 203 spaced apart.

[0048] The buffer structure includes several protrusions 203, which protrude outward relative to the surface of the insulating side 202, thereby creating an uneven surface structure on the insulating side 202. Multiple protrusions 203 can be provided, and the number of protrusions 203 can be determined according to the area of ​​the insulating side 202. For example, 50, 95, 120, or 200 protrusions 203 can be provided.

[0049] In one embodiment, in the width direction of the busbar 2 (e.g.) Figure 4 (As indicated by the middle arrow b-b') The number of protrusions 203 can be determined according to the width of the busbar 2. For example, one, three, four, or seven protrusions 203 can be provided. The width of the busbar 2 ranges from 4mm to 12mm. For example, when the width of the busbar 2 is 4mm, two protrusions 203 can be provided in the horizontal direction of the busbar 2.

[0050] In one embodiment, adjacent protrusions 203 are spaced apart, that is, adjacent protrusions 203 are spaced a certain distance apart, so that the protrusions 203 are distributed on the insulating side 202, so that the protrusions 203 can reliably separate the insulating side 202 from the back of the cell 1, ensuring the insulation between the busbar 2 and the back of the cell 1, and improving the safety performance of the photovoltaic module.

[0051] In one embodiment, the protrusion 203 protrudes outward relative to the surface of the insulating side 202. The protrusion direction of the protrusion 203 is its extension direction. In its extension direction, one end of the protrusion 203 is connected to the insulating side 202, and the other end contacts the back of the battery cell 1. To avoid scratching the back of the battery cell 1 and to provide reliable protection for the battery cell 1, the end of the protrusion 203 that contacts the back of the battery cell 1 is an arc-shaped end, reducing the risk of damage to the battery cell 1.

[0052] In one embodiment, the protrusion 203 is a raised structure. The arrangement of the raised structure on the insulating side 202 is not limited, as long as it can isolate the insulating side 202 from the back of the battery cell 1.

[0053] In one embodiment, adjacent protrusions 203 are evenly spaced to further optimize the interaction force between the protrusions 203 and the back of the battery cell 1, thereby reducing stress concentration problems.

[0054] In one embodiment of this application, at least two protrusions 203 are grouped together in the width direction of the busbar 2, and adjacent groups of protrusions 203 are staggered or aligned in the length direction of the busbar 2.

[0055] On the insulating side 202 of the busbar 2, the arrangement of several protrusions 203 can be selected according to the width and length of the busbar 2. In one embodiment, at least two protrusions 203 are provided in the width direction of the busbar 2, for example, two, three, four, five, or other numbers of protrusions 203 are provided. At least two protrusions 203 form a group, forming a protrusion group, and the protrusions 203 within the same protrusion group are spaced apart.

[0056] At the same time, in the length direction of busbar 2 (e.g. Figure 4 In the direction indicated by the middle arrow c-c', the protrusions 203 of adjacent groups are either staggered or aligned. When the protrusions 203 of adjacent groups are staggered, the protrusions 203 on the insulating side 202 form an interlaced layout, making the distribution of the protrusions 203 more uniform, dispersing the contact force, reducing stress concentration between the protrusions 203 and the battery cell 1, and improving the stability of the contact between the busbar 2 and the back of the battery cell 1. When the protrusions 203 of adjacent groups are aligned, the protrusions 203 on the insulating side 202 form an arranged layout, which simplifies the setting of the protrusions 203, facilitates processing, and improves process consistency, while also improving the reliability of the contact between the busbar 2 and the back of the battery cell 1.

[0057] In one embodiment of this application, the cross-sectional shape of the protrusion 203 perpendicular to its extension direction is circular, and the maximum diameter of the protrusion 203 is 1mm-1.5mm.

[0058] The protrusion direction of the protrusion 203 is its extension direction; specifically, the extension direction of the protrusion 203 is consistent with the thickness direction of the photovoltaic module. The extension direction of the protrusion 203 is perpendicular to the plane where the busbar 2 is located, and the size of the protrusion 203 can be set according to the area of ​​the insulating side 202.

[0059] In one embodiment, the protrusion 203 has a circular cross-sectional shape perpendicular to its extension direction. This type of protrusion 203 has a regular structure, is easy to set, simplifies the manufacturing process, and makes it easier to control the size and consistency of the protrusion 203, thus reducing manufacturing difficulty. Furthermore, when this protrusion 203 contacts the back of the battery cell 1, the contact force between the protrusion 203 and the back of the battery cell 1 is more balanced, reducing stress concentration and improving structural reliability.

[0060] In one embodiment, the protrusion 203 has a circular cross-sectional shape perpendicular to its extending direction, and the projection of the protrusion 203 onto the surface of the insulating side 202 is its outer circular outline. The diameter of this outer circular outline is defined as the maximum diameter of the protrusion 203. The maximum diameter of the protrusion 203 ranges from 1 mm to 1.5 mm; for example, the maximum diameter of the protrusion 203 can be 1 mm, 1.1 mm, 1.2 mm, 1.3 mm, 1.4 mm, 1.5 mm, etc. The protrusion 203 within the above-mentioned maximum diameter range can reliably separate the back side of the battery cell 1 and the conductive side 201 of the busbar 2, while also facilitating the installation of the protrusion 203.

[0061] In one embodiment of this application, the photovoltaic module further includes a first connecting strip 3, which includes a connecting portion 301 and a bending portion 302 connected to each other. The connecting portion 301 is electrically connected to the solar cell 1, and the bending portion 302 is bent toward the back of the solar cell 1 and electrically connected to the conductive side 201.

[0062] The photovoltaic module also includes a first connecting strip 3, which is used to achieve electrical connection between the conductive side 201 of the busbar 2 and the back electrode of the cell 1. In one embodiment, the first connecting strip 3 is specifically a solder strip, which can be soldered to the positive or negative electrode on the back of the cell 1.

[0063] In one embodiment, the busbar 2 can be bent to the back of the battery cell 1 after being welded to the first connecting strip 3, or the busbar 2 can be placed on the back of the battery cell 1 first and then welded to the first connecting strip 3. That is, the busbar 2 and the first connecting strip 3 can be welded first and then bent, or the position of the busbar 2 can be set first and then welded to the first connecting strip 3. The specific processing steps can be selected according to the actual situation.

[0064] See Figures 1-2As shown, the first connecting strip 3 includes a connecting portion 301 and a bending portion 302, which are connected together. Specifically, the connecting portion 301 and the bending portion 302 are two parts of a single integral welded strip. The connecting portion 301 is electrically connected to the battery cell 1, that is, the connecting portion 301 is electrically connected to the electrode of the battery cell 1. The bending portion 302 bends towards the back of the battery cell 1 and is electrically connected to the conductive side 201 of the busbar 2.

[0065] See Figures 1-3 As shown, specifically, the back of the battery cell 1 is provided with positive and negative grid lines. For example, the first connecting strip 3 electrically connects the conductive side 201 of a busbar 2 to the positive grid line, and the negative grid line on the back of the battery cell 1 is electrically connected to the second connecting strip 4. The insulating side 202 of the busbar 2 faces the back of the battery cell 1, and the insulating side 202 achieves insulation between the conductive side 201 and the second connecting strip 4, thereby reducing the short-circuit risk between the busbar 2 and the negative grid line. In other embodiments, the second connecting strip 4 is a solder strip, which can be soldered to either the positive or negative electrode on the back of the battery cell 1. That is, on the back of the battery cell 1, one of the positive and negative electrodes is soldered to the first connecting strip 3, and the other is soldered to the second connecting strip 4.

[0066] It should be noted that at the battery cell 1 where the busbar 2 is provided on the back, the first connecting strip 3 has a connecting portion 301 and a bending portion 302 to achieve electrical connection between the battery cell 1 and the busbar 2, while placing the busbar 2 on the back of the battery cell 1. However, at the battery cell 1 where the busbar 2 is not required on the back, the first connecting strip 3 is only used to achieve electrical connection between the battery cell 1 and the busbar 2, and in this case, the first connecting strip 3 does not have a bending portion 302.

[0067] In one embodiment of this application, the extending direction of the connecting portion 301 is set at an angle to the extending direction of the bending portion 302.

[0068] The extension direction of the connecting part 301 is set at an angle to the extension direction of the bending part 302, that is, the extension direction of the connecting part 301 is not parallel to the extension direction of the bending part 302. This allows the bending part 302 to be misaligned with the connecting part 301 after bending, reducing the possibility of the bending part 302 and the connecting part 301 overlapping in the thickness direction of the photovoltaic module. This arrangement can reduce the thickness of the photovoltaic module at this position, reduce the stress on the photovoltaic module in the subsequent lamination process, reduce the risk of microcracks in the cell 1, reduce the possibility of damage to the photovoltaic module, and thus improve the product quality of the photovoltaic module.

[0069] In one embodiment of this application, multiple battery cells 1 are provided, and the multiple battery cells 1 are electrically connected to form a battery string. A busbar 2 is located on the back of one of the battery cells 1, and other battery cells 1 adjacent to the battery cell 1 are electrically connected to the conductive side 201 through other first connecting strips 3.

[0070] One or more solar cells 1 can be installed (e.g., two, five, eight, etc.). When multiple solar cells 1 are installed, they are electrically connected to form a solar cell string. The number of solar cells 1 in the solar cell string can be selected according to the design requirements and dimensions of the photovoltaic module. The length direction of the solar cell string is as follows: Figure 1 and Figure 3 As shown by the middle arrow x-x', the width direction of the battery string is as follows. Figure 1 and Figure 3 As shown by the middle arrow y-y', each battery cell 1 in the same battery string is arranged along the length direction x-x' of the battery string.

[0071] See Figure 1 As shown, at the end of the battery string, the busbar 2 is located on the back side of the end battery cell 1, and at this time, the busbar 2 is the end busbar. The electrode on the back side of the battery cell 1 is electrically connected to the conductive side 201 of the busbar 2 through the first connecting strip 3. For example, the positive grid line on the back side of the end battery cell 1 is welded to the conductive side 201 of the busbar 2 through the first connecting strip 3, and the negative grid line on the back side of the battery cell 1 is welded with the second connecting strip 4. The insulating side 202 insulates the conductive side 201 from the second connecting strip 4.

[0072] See Figure 3 As shown, in the middle (not at the end) of the battery string, the busbar 2 is located on the back of one of the battery cells 1, making it a middle busbar. The electrode on the back of the battery cell 1 is electrically connected to the conductive side 201 of the busbar 2 via a first connecting strip 3 (referred to as the first solder strip 31 for convenience). Other battery cells 1 adjacent to this battery cell 1 are electrically connected to the conductive side 201 of the busbar 2 via other first connecting strips 3 (referred to as second solder strips 32 for convenience). For example, if the first battery cell 101 and the second battery cell 102 are arranged adjacent to each other, the electrode on the back of the first battery cell 101 is electrically connected to the conductive side 201 of the busbar 2 via the first solder strip 31, and the electrode on the back of the second battery cell 102 is electrically connected to the conductive side 201 of the busbar 2 via the second solder strip 32.

[0073] In one embodiment, the second solder ribbon 32 can be soldered to any position on the conductive side 201 to achieve electrical connection between adjacent solar cells 1. Alternatively, the second solder ribbon 32 can be soldered (or overlapped) to the first solder ribbon 31 on the conductive side 201 to achieve electrical connection between adjacent solar cells 1. In this case, the first solder ribbon 31 and the second solder ribbon 32 should be staggered on the conductive side 201, that is, the first solder ribbon 31 and the second solder ribbon 32 do not overlap in the thickness direction of the photovoltaic module to reduce the thickness of the photovoltaic module.

[0074] This application also provides a manufacturing process for a photovoltaic module, which is used to manufacture the aforementioned photovoltaic module. The manufacturing process includes: electrically connecting the conductive side 201 of the busbar 2 to the solar cell 1; placing the busbar 2 on the back side of the solar cell 1, with the insulating side 202 of the busbar 2 facing the back side of the solar cell 1.

[0075] The photovoltaic module manufactured using the above process does not require additional insulating materials between the back side of the cell 1 and the busbar 2, reducing the height difference between the busbar 2 and the cell 1. This lowers the risk of microcracks in the cell 1 caused by external forces during subsequent processes, improving the product quality of the photovoltaic module. It also simplifies the manufacturing process and increases production efficiency. Furthermore, the insulating side 202 of the busbar 2 contacts the back side of the cell 1 through a buffer structure. This buffer structure isolates the insulating side 202 from the back side of the cell 1, creating a clearance between them and preventing direct contact, further enhancing the insulation between the back side of the cell 1 and the busbar 2. Moreover, the buffer structure is made of a flexible buffer material, reducing the possibility of relative sliding between the busbar 2 and the back side of the cell 1 during subsequent processes. This reduces scratches on the cell 1 caused by the busbar 2 sliding relative to the back side of the cell 1, effectively protecting the cell 1 and improving the product quality and yield of the photovoltaic module.

[0076] The manufacturing process of photovoltaic modules is described below.

[0077] Step S01: Electrically connect the conductive side 201 of the busbar 2 to the battery cell 1.

[0078] The conductive side 201 of the busbar 2 is electrically connected to the battery cell 1 via the first connecting strip 3. Specifically, the connecting part 301 of the first connecting strip 3 is first welded to the electrode of the battery cell 1, and then the bent part 302 is welded to the conductive side 201 of the busbar 2, thereby achieving an electrical connection between the conductive side 201 of the busbar 2 and the battery cell 1.

[0079] Step S02: Place the busbar 2 on the back of the battery cell 1, and make the insulating side 202 of the busbar 2 face the back of the battery cell 1.

[0080] Then, the bending portion 302 is bent toward the back of the battery cell 1, so that the busbar 2 is placed on the back of the battery cell 1, and the insulating side 202 of the busbar 2 faces the back of the battery cell 1. At this time, the protrusion 203 contacts the back of the battery cell 1, realizing insulation between the back of the battery cell 1 and the busbar 2, reducing the risk of short circuit.

[0081] After completing steps S01 and S02, the end busbar installation is completed, or a portion of the middle busbar installation is completed.

[0082] In one embodiment of this application, the fabrication process further includes: electrically connecting adjacent battery cells 1 to the conductive side 201.

[0083] When the busbar 2 is located in the middle of the battery string, the manufacturing process further includes: electrically connecting adjacent battery cells 1 to the conductive side 201. Specifically, after steps S01 and S02, the busbar 2 located in the middle of the battery string is placed on the back of one of the battery cells 1 and electrically connected to that battery cell 1. The other battery cells 1 adjacent to that battery cell 1 are electrically connected to the conductive side 201 of the busbar 2 through other first connecting strips 3, thereby completing the setting of the middle busbar.

[0084] Of course, the manufacturing process of this application also includes other existing process steps necessary for the preparation of photovoltaic modules, such as stacking and lamination, which will not be elaborated here.

[0085] This application also provides a photovoltaic module manufacturing apparatus for preparing the aforementioned photovoltaic module. The manufacturing apparatus includes: a welding device for electrically connecting the conductive side 201 of the busbar 2 to the solar cell 1; and a clamping device for clamping the busbar 2 and placing the busbar 2 on the back side of the solar cell 1, such that the insulating side 202 of the busbar 2 faces the back side of the solar cell 1.

[0086] The welding equipment is used to electrically connect the conductive side 201 of the busbar 2 to the solar cell 1. In one embodiment, the conductive side 201 of the busbar 2 is electrically connected to the electrode of the solar cell 1 via a first connecting strip 3. Specifically, the connecting portion 301 of the first connecting strip 3 is welded to the electrode of the solar cell 1, and the bent portion 302 is welded to the conductive side 201 of the busbar 2. All of the above welding processes are completed by the welding equipment to improve welding efficiency and accuracy, which helps ensure the product quality of the photovoltaic module.

[0087] The clamping device is used to clamp the busbar 2 and place it on the back of the solar cell 1, with the insulating side 202 of the busbar 2 facing the back of the solar cell 1. After the conductive side 201 of the busbar 2 is electrically connected to the electrode of the solar cell 1 via the first connecting strip 3, the clamping device clamps the busbar 2, bending the bent portion 302 towards the back of the solar cell 1, placing the busbar 2 on the back of the solar cell 1, with the insulating side 202 of the busbar 2 facing the back of the solar cell 1. The clamping device can securely clamp the busbar 2 and avoid damage to it, allowing the busbar 2 to be placed in a designated position, achieving precise setting of the busbar 2, improving process consistency, automating the manufacturing process, reducing labor costs, and improving the quality of photovoltaic modules.

[0088] The technical features of the above embodiments can be combined in any way. For the sake of brevity, not all possible combinations of the technical features in the above embodiments are described. However, as long as there is no contradiction in the combination of these technical features, they should be considered to be within the scope of this specification.

[0089] The above embodiments merely illustrate several implementation methods of this application, and while the descriptions are relatively specific and detailed, they should not be construed as limiting the scope of the patent application. It should be noted that those skilled in the art can make various modifications and improvements without departing from the concept of this application, and these all fall within the protection scope of this application. Therefore, the protection scope of this patent application should be determined by the appended claims.

Claims

1. A photovoltaic module, characterized in that, include: A battery cell (1), whose electrodes are disposed on the back side of the battery cell (1); Busbar (2), located on the back of the solar cell (1), in the thickness direction of the photovoltaic module, the busbar (2) includes a conductive side (201) and an insulating side (202). The conductive side (201) is electrically connected to the solar cell (1). The insulating side (202) faces the back of the solar cell (1). The insulating side (202) is provided with a buffer structure. The buffer structure protrudes from the insulating side (202). The insulating side (202) contacts the back of the solar cell (1) through the buffer structure.

2. The photovoltaic module according to claim 1, characterized in that, The buffer structure includes a plurality of protrusions (203), which are spaced apart from each other.

3. The photovoltaic module according to claim 2, characterized in that, In the width direction of the busbar (2), at least two of the protrusions (203) are grouped together, and in the length direction of the busbar (2), the protrusions (203) of adjacent groups are staggered or aligned.

4. The photovoltaic module according to claim 2, characterized in that, The cross-sectional shape of the protrusion (203) perpendicular to its extension direction is circular, and the maximum diameter of the protrusion (203) is 1mm-1.5mm.

5. The photovoltaic module according to any one of claims 1-4, characterized in that, It also includes a first connecting strip (3), which includes a connecting part (301) and a bending part (302) connected to each other. The connecting part (301) is electrically connected to the battery cell (1), and the bending part (302) is bent toward the back of the battery cell (1) and electrically connected to the conductive side (201).

6. The photovoltaic module according to claim 5, characterized in that, The extending direction of the connecting part (301) is set at an angle to the extending direction of the bending part (302).

7. The photovoltaic module according to claim 5, characterized in that, The battery cells (1) are provided in multiple ways, and the multiple battery cells (1) are electrically connected to form a battery string. The bus bar (2) is located on the back of one of the battery cells (1). The other battery cells (1) adjacent to the battery cell (1) are electrically connected to the conductive side (201) through other first connecting strips (3).

8. A manufacturing process for a photovoltaic module, characterized in that, The preparation process includes: Electrically connect the conductive side (201) of the busbar (2) to the battery cell (1); The busbar (2) is placed on the back of the battery cell (1), with the insulating side (202) of the busbar (2) facing the back of the battery cell (1).

9. The preparation process according to claim 8, characterized in that, Also includes: The adjacent battery cell (1) is electrically connected to the conductive side (201).

10. A photovoltaic module manufacturing equipment, characterized in that, The manufacturing equipment includes: A welding device for electrically connecting the conductive side (201) of the busbar (2) to the battery cell (1); A clamping device is used to clamp the busbar (2) and place the busbar (2) on the back of the battery cell (1) such that the insulating side (202) of the busbar (2) faces the back of the battery cell (1).

Images