Photovoltaic module and method of manufacturing the same

Abstract

The application relates to the photovoltaic field, and provides a photovoltaic module and a preparation method thereof, and the application can at least improve the performance of the photovoltaic module. The preparation method of the photovoltaic module comprises the following steps: providing an initial laminated piece, the initial laminated piece comprising a cell string, a first cover plate, a second cover plate and a film layer, the first cover plate and the second cover plate being respectively located at two sides of the cell string, the first cover plate having a first surface, and the second cover plate having a second surface; the film layer being located at the two sides of the cell string; providing a tool, the tool being arranged around the initial laminated piece, the tool and the first surface, the second surface and the side wall of the initial laminated piece forming a containing cavity; performing a laminating treatment, so that the initial laminated piece is changed into a laminated piece, and the film layer is changed into an encapsulating part and a functional part; the encapsulating part is located between the first cover plate and the second cover plate, and covers the cell string; in the laminating treatment, part of the film layer is cast to the containing cavity, so as to form the functional part; the functional part is located at the first surface, the second surface and the side wall of the laminated piece; and the tool is removed.

Description

Technical Field

[0001] This application relates to the field of photovoltaics, and in particular to a photovoltaic module and its preparation method. Background Technology

[0002] As fossil fuels are gradually depleted, solar energy is becoming increasingly widely used as a new energy alternative. A solar cell is a device that converts sunlight into electrical energy. Solar cells utilize the photovoltaic principle to generate charge carriers, which are then extracted using electrodes, thus facilitating the efficient use of electrical energy.

[0003] Photovoltaic modules are crucial devices for converting solar energy into electrical energy. Improving the performance of photovoltaic modules is a pressing issue that needs to be addressed. Summary of the Invention

[0004] This application provides a photovoltaic module and a method for its preparation, which can at least improve the performance of the photovoltaic module.

[0005] This application provides a method for manufacturing a photovoltaic module. The method includes: providing an initial laminate comprising: a battery string including multiple battery cells; a first cover plate and a second cover plate, the first cover plate and the second cover plate being located on opposite sides of the battery string, the first cover plate having a first surface and the second cover plate having a second surface; a film layer located between the first cover plate and the second cover plate, and on opposite sides of the battery string; providing a tooling fixture surrounding the initial laminate, the tooling fixture abutting against the first cover plate and the second cover plate respectively, and forming a receiving cavity with the first surface, the second surface, and the sidewall of the initial laminate; performing a lamination process to transform the initial laminate into a laminate, transforming the film layer into an encapsulation portion and a functional portion, the encapsulation portion being located between the first cover plate and the second cover plate and covering the battery string, wherein during the lamination process, a portion of the film layer is cast into the receiving cavity to form the functional portion, the functional portion being located on the first surface, the second surface, and the sidewall of the laminate; and removing the tooling fixture.

[0006] Optionally, the film layer includes an initial encapsulation portion and an initial functional portion disposed around the initial encapsulation portion; wherein the lamination process transforms the initial encapsulation portion into an encapsulation portion and transforms the initial functional portion into a functional portion.

[0007] Optionally, the thickness of the initial functional part is greater than or equal to the thickness of the initial encapsulation part.

[0008] Optionally, the battery cell is located on the initial packaging portion, and the initial functional portion is spaced apart from the battery cell.

[0009] Optionally, the tooling includes: a first part, located on the side of the first cover plate opposite to the second cover plate and abutting against the first cover plate; a second part, located on the side of the second cover plate opposite to the first cover plate and abutting against the second cover plate; and a third part, connecting the first part and the second part; wherein the first part is an elastic part and can apply a force to the first cover plate, and / or the second part is an elastic part and can apply a force to the second cover plate.

[0010] Optionally, the first part, the second part, and the third part are an integral elastic structure.

[0011] Optionally, the tooling includes: a first portion that abuts against the first cover plate; a second portion that abuts against the second cover plate; and an elastic element that connects the first portion and the second portion. During the lamination process, under the action of the elastic element, the first portion abuts against the first cover plate, and the second portion abuts against the second cover plate.

[0012] Optionally, the second portion has a mounting groove, and the elastic element is located within the mounting groove, wherein the first portion extends into the mounting groove and abuts against the elastic element.

[0013] Optionally, the tooling includes: a main body portion, which together with the initial laminate forms the receiving cavity; and a protective layer, which is located at least on the surface of the main body portion facing the initial laminate.

[0014] This application also provides a photovoltaic module. The photovoltaic module includes: a laminate, the laminate including: a battery string including a plurality of battery cells; a first cover plate and a second cover plate, the first cover plate and the second cover plate being respectively located on both sides of the battery string, the first cover plate having a first surface and the second cover plate having a second surface; an encapsulation portion located between the first cover plate and the second cover plate; and a functional portion located on the first surface, the second surface, and the sidewall of the laminate.

[0015] The technical solution provided in this application has at least the following advantages: In the photovoltaic module manufacturing method provided in this application, after providing the initial laminate, a tooling is also provided that abuts against the first cover plate and the second cover plate respectively. The tooling, the first surface, the second surface, and the sidewall of the initial laminate form a receiving cavity. During the lamination process, the film layer located between the first cover plate and the second cover plate can be cast into the receiving cavity to form functional parts. The functional parts are located on the first surface, the second surface, and the sidewall of the laminate, which can improve the creepage distance of the photovoltaic module, thereby improving the safety performance of the photovoltaic module. By using the lamination process to cast the film layer onto the sidewall of the initial laminate, the first surface of the first cover plate, and the second surface of the second cover plate to form functional parts, the functional parts can be tightly fitted to the sidewall of the laminate, which helps to reduce the number of pores between the sidewall of the laminate and the functional parts, thereby improving the performance of the photovoltaic module. In addition, some of the film layers after lamination will be transformed into an encapsulation part. The encapsulation part is located between the first cover plate and the second cover plate and covers the battery string. It can bond the battery string to the first cover plate and the second cover plate, improve the structural stability of the laminate, thereby improving the performance of the photovoltaic module. It can also protect the battery string from external environmental corrosion, which is also conducive to improving the performance of the photovoltaic module. Attached Figure Description

[0016] One or more embodiments are illustrated by way of example with corresponding pictures in the accompanying drawings. These illustrations do not constitute a limitation on the embodiments. Unless otherwise stated, the pictures in the accompanying drawings do not constitute a limitation on scale. In order to more clearly illustrate the technical solutions in the embodiments of this application or in the conventional technology, the drawings used in the embodiments will be briefly introduced below. Obviously, the drawings described below are only some embodiments of this application. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.

[0017] Figure 1 This is a schematic diagram of a structure of a laminated component; Figure 2 A schematic diagram of a structure of a laminated component and an insulating film; Figure 3 A schematic flowchart illustrating a method for manufacturing a photovoltaic module according to an embodiment of this application; Figure 4 A schematic diagram of the structure of the initial laminate provided in the method for manufacturing a photovoltaic module according to an embodiment of this application; Figure 5 This is a schematic diagram of the initial laminate and tooling in the photovoltaic module fabrication method provided in the embodiments of this application; Figure 6 A schematic diagram of a laminate and tooling in the photovoltaic module manufacturing method provided in this application embodiment; Figure 7A schematic diagram of a laminate obtained in the manufacturing method of the photovoltaic module provided in this application embodiment; Figure 8 Another schematic diagram of the initial laminate provided in the method for manufacturing photovoltaic modules according to the embodiments of this application; Figure 9 A top view schematic diagram of the film layer provided in the method for preparing a photovoltaic module according to an embodiment of this application; Figure 10 This is another schematic diagram of the initial laminate provided in the method for manufacturing photovoltaic modules according to the embodiments of this application; Figure 11 This is another schematic diagram of the tooling and initial laminate in the photovoltaic module manufacturing method provided in the embodiments of this application; Figure 12 This is a schematic diagram of another structure of the laminate and tooling in the photovoltaic module manufacturing method provided in the embodiments of this application; Figure 13 A schematic diagram of a tooling provided in the method for manufacturing a photovoltaic module according to an embodiment of this application; Figure 14 A top view of the tooling provided in the method for manufacturing photovoltaic modules according to the embodiments of this application; Figure 15 This is a top view schematic diagram of another tooling structure provided in the method for manufacturing photovoltaic modules according to the embodiments of this application; Figure 16 This is another schematic diagram of the laminate obtained in the photovoltaic module manufacturing method provided in the embodiments of this application.

[0018] Explanation of reference numerals in the attached figures: 10. Laminated component; 101. Sidewall; 11. Top cover plate; 12. Bottom cover plate; 13. Adhesive film; 14. Battery substrate; 15. Solder ribbon; 16. Insulating film; 20. Initial laminate; 21. First cover plate; 211. First surface; 22. Second cover plate; 221. Second surface; 23. Film layer; 231. First sub-film; 232. Second sub-film; 233. Initial encapsulation part; 234. Initial functional part; 24. Battery cell; 25. Encapsulation part; 26. Functional part; 27. Third surface; 30. Tooling; 31. First part; 32. Second part; 33. Third part; 34. First section; 341. First protrusion; 35. Second section; 351. Second protrusion; 36. Elastic element; 37. First part; 38. Second part. Detailed Implementation

[0019] Figure 1 This is a schematic diagram of a stacked component.

[0020] refer to Figure 1 The photovoltaic module includes a laminate 10 (also known as a stacked assembly). The laminate 10 includes a cell string, an upper cover plate 11, a lower cover plate 12, and an encapsulant film 13. The cell string includes multiple cell substrates 14 and solder strips 15 electrically connecting adjacent cell substrates 14; the upper cover plate 11 and the lower cover plate 12 are located on opposite sides of the cell string, and the encapsulant film 13 is located between the upper cover plate 11 and the lower cover plate 12, covering the cell string.

[0021] Figure 2 This is a schematic diagram of a structure of a laminated component and an insulating film.

[0022] refer to Figure 1 and Figure 2 In related technologies, to improve the creepage distance of photovoltaic modules, an insulating film 16 is applied to the edge of the laminate 10. However, due to the unevenness of the sidewall 101 of the laminate 10 (this may be due to incomplete alignment between the upper cover plate 11 and the lower cover plate 12, or manufacturing errors during the edge trimming process of the laminate 10), applying the insulating film 16 to the sidewall 101 of the laminate 10 results in gaps between the insulating film 16 and the sidewall 101 of the laminate 10, making it difficult for the insulating film 16 to effectively improve the safety performance of the photovoltaic module. It should be noted that because the size of the gaps between the insulating film 16 and the sidewall 101 of the laminate 10 is small, Figure 2 The pore is not shown in the diagram.

[0023] Therefore, the performance of photovoltaic modules in related technologies needs to be improved.

[0024] Therefore, this application provides a photovoltaic module and its manufacturing method. After lamination, the film layer transforms into functional parts and encapsulation parts. The functional parts are located on the first surface, the second surface, and the sidewalls of the laminate, which can increase the creepage distance of the photovoltaic module, thereby improving its safety performance. The encapsulation parts are located between the first cover plate and the second cover plate, covering the battery string. This can bond the battery string to the first and second cover plates, improving the structural stability of the laminate and thus enhancing the performance of the photovoltaic module. It also protects the battery string from external environmental corrosion, further contributing to improved photovoltaic module performance. Furthermore, by using lamination to cast the film layer onto the sidewalls of the initial laminate, the first surface of the first cover plate, and the second surface of the second cover plate to form functional parts, the functional parts can be tightly fitted to the sidewalls of the laminate, reducing the number of pores between the sidewalls of the laminate and the functional parts, thereby improving the performance of the photovoltaic module.

[0025] In the description of the embodiments of this application, technical terms such as "first" and "second" are used only to distinguish different objects and should not be construed as indicating or implying relative importance or implicitly specifying the number, specific order, or primary and secondary relationship of the indicated technical features. In the description of the embodiments of this application, "multiple" means two or more, unless otherwise explicitly defined.

[0026] In this document, the term "embodiment" means that a particular feature, structure, or characteristic described in connection with an embodiment may be included in at least one embodiment of this application. The appearance of this phrase in various places throughout the specification does not necessarily refer to the same embodiment, nor is it a separate or alternative embodiment mutually exclusive with other embodiments. It will be explicitly and implicitly understood by those skilled in the art that the embodiments described herein can be combined with other embodiments.

[0027] In the description of the embodiments in this application, the term "and / or" is merely a description of the relationship between related objects, indicating that three relationships can exist. For example, A and / or B can represent three cases: A exists, A and B exist simultaneously, and B exists. In addition, the character " / " in this document generally indicates that the related objects before and after it have an "or" relationship.

[0028] In the description of the embodiments of this application, the term "multiple" refers to two or more (including two), similarly, "multiple sets" refers to two or more (including two sets), and "multiple pieces" refers to two or more (including two pieces).

[0029] In the description of the embodiments of this application, the technical terms "center," "longitudinal," "lateral," "length," "width," "thickness," "upper," "lower," "front," "rear," "left," "right," "vertical," "horizontal," "top," "bottom," "inner," "outer," "clockwise," "counterclockwise," "axial," "radial," and "circumferential" indicate the orientation or positional relationship based on the orientation or positional relationship shown in the accompanying drawings. They are only for the convenience of describing the embodiments of this application and simplifying the description, and are not intended to indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation. Therefore, they should not be construed as limitations on the embodiments of this application.

[0030] In the description of the embodiments of this application, unless otherwise expressly specified and limited, the technical terms such as "installation," "connection," "joining," and "fixing" 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. For those skilled in the art, the specific meaning of the above terms in the embodiments of this application can be understood according to the specific circumstances.

[0031] In the description of the embodiments of this application, electrical connection between one component and another means that both components are made of conductive materials, and the two components are in direct contact and connected or connected via other conductive materials. Therefore, when the photovoltaic module is generating electricity, current is transferred between the two components. Electrical contact between one component and another means that the two components not only come into contact with each other, but also, because both components are made of conductive materials, current is transferred between the two components when the photovoltaic module is generating electricity.

[0032] In the accompanying drawings corresponding to the embodiments of this application, the thickness and / or area of ​​layers, films, panels, regions, etc., are enlarged for better understanding and ease of description. Throughout the specification, the same reference numerals denote the same elements. It should be understood that when describing a component (such as a layer, film, region, or substrate) on or on the surface of another component, the component may be "directly" located on the surface of the other component, or there may be an intermediate component between the two components. Conversely, when describing a component on the surface of another component, or a component "directly" on another component, or a component surface on which another component is formed or disposed, it indicates that there is no intermediate component between the two components. Furthermore, when describing a component as "generally" formed on another component, it means that the component is not formed on the entire surface (or front surface) of the other component, nor is it formed on a portion of the edge of the entire surface.

[0033] In the description of the embodiments of this application, when a component "includes" another component, other components are not excluded unless otherwise stated, and other components may be further included. Furthermore, when a component such as a layer, film, region, or plate is referred to as being "on / located" on another component, it can be "directly on" the other component (i.e., located on the surface of the other component with no other components between them), or another component may be present therein. Moreover, when a component such as a layer, film, region, or plate is "directly located" on another component, or when a component such as a layer, film, region, or plate is located on the surface of another component, it indicates that no other components are located therein.

[0034] The embodiments of this application will now be described in detail with reference to the accompanying drawings. However, those skilled in the art will understand that many technical details have been provided in the embodiments of this application to facilitate a better understanding of the application. However, the technical solutions claimed in this application can be implemented even without these technical details and various variations and modifications based on the following embodiments.

[0035] Figure 3 This is a schematic flowchart of a method for manufacturing a photovoltaic module provided in an embodiment of this application. Figure 4This is a schematic diagram of the structure of an initial laminate provided in the method for manufacturing a photovoltaic module according to an embodiment of this application. Figure 5 This is a schematic diagram of the initial laminate and tooling used in the photovoltaic module fabrication method provided in this application embodiment. Figure 6 This is a schematic diagram of a laminate and tooling used in the fabrication method of a photovoltaic module provided in this application. Figure 7 This is a schematic diagram of a laminate obtained in the method for preparing a photovoltaic module according to an embodiment of this application.

[0036] The photovoltaic module manufacturing method provided in this application includes steps S1 to S4, as detailed below: refer to Figure 3 and Figure 4 Step S1: Provide an initial laminate 20. The initial laminate 20 includes: a battery string, a first cover plate 21, a second cover plate 22, and a film layer 23. The battery string includes multiple battery cells 24, and the first cover plate 21 and the second cover plate 22 are located on both sides of the battery string. The first cover plate 21 has a first surface 211, and the second cover plate 22 has a second surface 221. The film layer 23 is located between the first cover plate 21 and the second cover plate 22, and on both sides of the battery string.

[0037] refer to Figure 3 and Figure 5 In step S2, a tooling 30 is provided. The tooling 30 is arranged around the initial laminate 20. The tooling 30 abuts against the first cover plate 21 and the second cover plate 22 respectively, and forms a receiving cavity with the first surface 211, the second surface 221 and the side wall of the initial laminate 20.

[0038] refer to Figure 3 , Figure 5 and Figure 6 In step S3, a lamination process is performed to transform the initial laminate 20 into a laminate, and to transform the film layer 23 into an encapsulation portion 25 and a functional portion 26. The encapsulation portion 25 is located between the first cover plate 21 and the second cover plate 22, and covers the battery string. During the lamination process, a portion of the film layer 23 is cast into the receiving cavity to form the functional portion 26, which is located on the first surface 211, the second surface 221, and the sidewalls of the laminate.

[0039] refer to Figure 3 , Figure 6 and Figure 7 Step S4: Remove tooling 30.

[0040] In step S1, the initial laminate 20 ( Figure 4 and Figure 5 (As shown) is used to form a laminate, which is used to convert solar energy into electrical energy.

[0041] The battery string includes multiple battery cells 24 and solder strips (not shown) that electrically connect adjacent battery cells 24.

[0042] The solar cell 24 can be one or any combination of BC (Back Contact) cells, TOPCON (Tunnel Oxide Passivated Contact) cells, HIT / HJT (Heterojunction Technology) cells, PERC (Passivated Emitter Rear Cell) cells, thin-film solar cells, and tandem solar cells. Thin-film solar cells include, but are not limited to, perovskite thin-film solar cells, copper indium selenide (CIGS) thin-film solar cells, gallium arsenide (GaAs) thin-film solar cells, and cadmium sulfide (CdS) thin-film solar cells. Tandem solar cells include, but are not limited to, perovskite cells stacked with crystalline silicon cells, perovskite cells stacked with perovskite cells, and perovskite cells stacked with thin-film cells.

[0043] In some embodiments, there is a gap between adjacent solar cells 24. In other embodiments, adjacent solar cells 24 may be stacked.

[0044] The first cover plate 21 and the second cover plate 22 are located on opposite sides of the battery string, respectively, and are used to protect the battery string.

[0045] The first cover plate 21 can be a glass cover plate, a plastic cover plate, or other cover plate with light-transmitting function. In some cases, the surface of the first cover plate 21 facing the battery cell 24 can be an uneven surface or a textured surface containing multiple raised structures, thereby increasing the utilization rate of incident light.

[0046] The second cover plate 22 can be a glass cover plate, a plastic cover plate, or other cover plate with light-transmitting function. The second cover plate 22 can also be a white cover plate. In some cases, the surface of the second cover plate 22 facing the battery cell 24 can be an uneven surface or a textured surface with multiple raised structures, thereby increasing the utilization rate of incident light.

[0047] The first cover plate 21 has a first surface 211, which is the surface of the first cover plate 21 facing away from the second cover plate 22. The second cover plate 22 has a second surface 221, which is the surface of the second cover plate 22 facing away from the first cover plate 21.

[0048] The film layer 23 is used to form the encapsulation part 25 and the functional part 26 after lamination.

[0049] Figure 8 This is another structural schematic diagram of the initial laminate 20 provided in the photovoltaic module manufacturing method provided in the embodiments of this application.

[0050] refer to Figure 8 In some embodiments, the membrane layer 23 includes a first sub-membrane 231 and a second sub-membrane 232. The first sub-membrane 231 is located between the battery string and the first cover plate 21, and the second sub-membrane 232 is located between the battery string and the second cover plate 22. That is, the first sub-membrane 231 and the second sub-membrane 232 are located on opposite sides of the battery string.

[0051] Figure 9 This is a top view schematic diagram of the film layer provided in the photovoltaic module fabrication method according to the embodiments of this application. Figure 10 This is another schematic diagram of the initial laminate provided in the method for preparing a photovoltaic module according to the embodiments of this application.

[0052] refer to Figure 7 Figure 9 and Figure 10 In some embodiments, the film layer 23 includes an initial encapsulation portion 233 and an initial functional portion 234 disposed around the initial encapsulation portion 233. The lamination process transforms the initial encapsulation portion 233 into an encapsulation portion 25 and the initial functional portion 234 into a functional portion 26. The initial functional portion 234 is disposed around the initial encapsulation portion 233, allowing it to flow outwards and into the receiving cavity during the lamination process, forming the functional portion 26.

[0053] After lamination, the initial encapsulation part 233 can form an encapsulation part 25 with good adhesion to bond the battery string, the first cover plate 21 and the second cover plate 22.

[0054] The material of the initial functional part 234 is an insulating material.

[0055] In some embodiments, the breakdown voltage of the initial functional part 234 is greater than or equal to 8KV; the CTI (Comparative Tracking Index) of the initial functional part 234 is greater than 175V; the RTI (Relative Thermal Index) of the initial functional part 234 is greater than 90°C; and the DTI (Relative Thermal Index for Tracking) of the initial functional part 234 is greater than 300μm. The initial functional part 234 satisfies the above conditions, giving it excellent insulation performance, which in turn allows the subsequently formed functional part 26 to improve the creepage distance of the photovoltaic module.

[0056] The light transmittance of the initial encapsulation portion 233 is greater than that of the initial functional portion 234, and the insulation performance of the initial functional portion 234 is better than that of the initial encapsulation portion 233.

[0057] The material of the initial encapsulation section 233 may include at least one of polyvinyl butyral, ethylene-vinyl acetate copolymer, polyvinyl octene elastomer, and polyethylene terephthalate.

[0058] The material of the initial functional part 234 may include polyolefin.

[0059] In some embodiments, the width of the initial functional part 234 in the first direction X is 6mm to 10mm, for example 6mm, 7mm, 8mm, 9mm or 10mm.

[0060] The first direction X is defined as the direction in which the initial functional unit 234 points to the initial packaging unit 233.

[0061] In some embodiments, the thickness of the initial functional portion 234 is greater than or equal to the thickness of the initial encapsulation portion 233. When the thickness of the initial functional portion 234 is greater than the thickness of the initial encapsulation portion 233, it is beneficial for the final encapsulation portion 25 to fill the receiving cavity.

[0062] It should be noted that there may be a difference between the thickness of the initial functional part 234 and the thickness of the initial packaging part 233. When the difference is within the measurement tolerance range or the manufacturing error range, they should be regarded as substantially equal.

[0063] In some embodiments, the thickness of the initial encapsulation portion 233 can be 0.3 mm to 1 mm. For example, the thickness of the initial encapsulation portion 233 can be 0.3 mm to 0.5 mm, 0.5 mm to 0.7 mm, or 0.7 mm to 1 mm. Optionally, the thickness of the initial encapsulation portion 233 can be 0.3 mm, 0.4 mm, 0.5 mm, 0.6 mm, 0.7 mm, 0.85 mm, or 1 mm.

[0064] In some embodiments, the thickness of the initial functional part 234 can be 0.3 mm to 1.1 mm. For example, the thickness of the initial functional part 234 can be 0.3 mm to 0.5 mm, 0.5 mm to 0.7 mm, or 0.7 mm to 1.1 mm. Optionally, the thickness of the initial functional part 234 can be 0.3 mm, 0.4 mm, 0.5 mm, 0.6 mm, 0.7 mm, 0.9 mm, or 1.1 mm.

[0065] In some embodiments, the solar cell 24 is located on the initial encapsulation portion 233, and the initial functional portion 234 is spaced apart from the solar cell 24. The solar cell 24 is located on the initial encapsulation portion 233 to facilitate the subsequent formation of the encapsulation portion 25 covering the solar cell 24. The initial functional portion 234 is spaced apart from the solar cell 24 to prevent the subsequently formed functional portion 26 from contacting the solar cell 24, which would result in the functional portion 26 having low light transmittance affecting the solar cell 24's reception of sunlight.

[0066] In some embodiments, in the first direction X, the distance between the initial functional unit 234 and the adjacent battery cell 24 is 3mm to 8mm, for example 3mm, 4mm, 5mm, 6mm, 7mm or 8mm.

[0067] In other embodiments, the material of the film layer 23 is the same everywhere, that is, the film layer 23 does not distinguish between the initial functional part 234 and the initial encapsulation part 233, and is directly made of a material with excellent insulation properties, good light transmittance properties, and good adhesion properties after lamination.

[0068] Continue to refer to Figure 5 and Figure 6 In step S2, the provided tooling 30 is used to form a receiving cavity with the initial laminate 20 to accommodate the subsequently formed functional part 26.

[0069] In some embodiments, the tooling 30 includes a first part 31, a second part 32 and a third part 33. The first part 31 is located on the side of the first cover plate 21 away from the second cover plate 22 and abuts against the first cover plate 21. The second part 32 is located on the side of the second cover plate 22 away from the first cover plate 21 and abuts against the second cover plate 22. The third part 33 connects the first part 31 and the second part 32.

[0070] In some embodiments, the first part 31 is an elastic part and can apply a force to the first cover plate 21. Thus, during the lamination process, the distance between the first cover plate 21 and the second cover plate 22 along the second direction Y gradually decreases. By setting the first part 31 as an elastic part, the first part 31 can undergo elastic deformation in the second direction Y when subjected to the force of the lamination equipment, apply a force to the first cover plate 21, and abut against the first cover plate 21, thereby reducing the risk of the final formed functional part 26 overflowing from between the first part 31 and the first cover plate 21.

[0071] The second direction Y is defined as the direction in which the second cover plate 22 points to the first cover plate 21.

[0072] In some embodiments, the second part 32 is an elastic part and can apply a force to the second cover plate 22. Thus, during the lamination process, the distance between the second cover plate 22 and the first cover plate 21 along the second direction Y gradually decreases. By making the second part 32 an elastic part, the second part 32 can undergo elastic deformation in the second direction Y when subjected to the force of the lamination equipment, apply a force to the second cover plate 22, and abut against the second cover plate 22, thereby reducing the risk of the finally formed functional part 26 overflowing from between the second part 32 and the second cover plate 22.

[0073] In some embodiments, the first part 31 is an elastic part that can apply force to the first cover plate 21, and the second part 32 is an elastic part that can apply force to the second cover plate 22. Thus, during the lamination process, the first part 31, as an elastic part, can undergo elastic deformation in the second direction Y when subjected to the force of the lamination equipment, applying force to the first cover plate 21 and abutting against it, thereby reducing the risk of the finally formed functional part 26 overflowing between the first part 31 and the first cover plate 21. Similarly, the second part 32, as an elastic part, can also undergo elastic deformation in the second direction Y when subjected to the force of the lamination equipment, applying force to the second cover plate 22 and abutting against it, thereby reducing the risk of the finally formed functional part 26 overflowing between the second part 32 and the second cover plate 22.

[0074] In some embodiments, the first part 31, the second part 32, and the third part 33 are an integral elastic structure. This integral elastic structure can be formed from a sheet of spring steel through a bending process; wherein, the sheet refers to a metal plate processed from a metal billet through processes such as forging, rolling, or casting, and the shape of the sheet is typically a flat cuboid. Compared to a scheme where the first part 31, the second part 32, and the third part 33 are formed separately and then welded together to form the tooling 30, using a sheet of spring steel through a bending process to form the tooling 30 facilitates the preparation of the tooling 30. Furthermore, spring steel is a material with high elastic limit and high yield strength, giving the first part 31, the second part 32, and the third part 33 elasticity.

[0075] Figure 11 This is a schematic diagram of another structure of the tooling and initial laminate in the photovoltaic module fabrication method provided in the embodiments of this application. Figure 12 This is another schematic diagram of the laminate and tooling in the photovoltaic module manufacturing method provided in the embodiments of this application.

[0076] refer to Figure 11 and Figure 12In some embodiments, the tooling 30 includes a first portion 34, a second portion 35, and an elastic member 36. The first portion 34 abuts against the first cover plate 21; the second portion 35 abuts against the second cover plate 22; and the elastic member 36 connects the first portion 34 and the second portion 35. During the lamination process, under the action of the elastic member 36 and the force provided by the lamination equipment, the first portion 34 abuts against the first cover plate 21, and the second portion 35 abuts against the second cover plate 22. During the lamination process, the distance between the first cover plate 21 and the second cover plate 22 along the second direction Y will decrease. An elastic element 36 is provided to connect the first portion 34 and the second portion 35, so that under the force provided by the laminating equipment, the first portion 34 can abut against the first cover plate 21 and the second portion 35 can abut against the second cover plate 22, thereby reducing the risk of the final functional part 26 overflowing from between the first portion 34 and the first cover plate 21, and reducing the risk of the functional part 26 overflowing from between the second portion 35 and the second cover plate 22.

[0077] During the lamination process, at least one of the first portion 34 and the second portion 35 will be subjected to the force applied by the laminating equipment, and the elastic element 36 will be compressed, so that the distance along the second direction Y between the portion of the first portion 34 in contact with the first cover plate 21 and the portion of the second portion 35 in contact with the second cover plate 22 can decrease synchronously with the distance along the second direction Y between the first cover plate 21 and the second cover plate 22. Thus, under the force provided by the laminating equipment, the first portion 34 can always abut against the first cover plate 21, and the second portion 35 can always abut against the second cover plate 22.

[0078] In some embodiments, the second portion 35 has a mounting groove, and the elastic member 36 is located within the mounting groove. The first portion 34 extends into the mounting groove and abuts against the elastic member 36. One end of the first portion 34 abuts against the first cover plate 21, and the other end of the first portion 34 extends into the mounting groove and abuts against the elastic member 36. One end of the elastic member 36 abuts against the first portion 34, and the other end abuts against the bottom of the mounting groove of the second portion 35. The elastic member 36 has elastic deformation capability in the second direction Y. When the distance between the first cover plate 21 and the second cover plate 22 decreases along the second direction Y, under the force provided by the laminating equipment, the first portion 34 can always abut against the first cover plate 21, and the second portion 35 can always abut against the second cover plate 22.

[0079] Figure 13 This is a schematic diagram of a tooling provided in the method for manufacturing photovoltaic modules according to an embodiment of this application.

[0080] refer to Figures 11 to 13In some embodiments, the first portion 34 has a first protrusion 341 near the end of the elastic member 36, and the second portion 35 has two opposing second protrusions 351, which are disposed in the opening of the mounting groove. In the first direction X, the distance between two adjacent second protrusions 351 is less than the maximum size of the first protrusion 341. Thus, the two adjacent second protrusions 351 can ensure that the first protrusion 341 is engaged in the mounting groove, preventing the first portion 34 from falling out of the mounting groove.

[0081] In some embodiments, the second protrusion 351 is elastic and can elastically deform in the first direction X. This configuration allows a force to be applied to one second protrusion 351 away from the other, increasing the distance between the two second protrusions 351 along the first direction X, so that the first protrusion 341 can extend into the mounting groove. Once the first protrusion 341 has extended into the mounting groove, the force is removed. At this point, the distance between two adjacent second protrusions 351 is less than the maximum size of the first protrusion 341, ensuring that the first protrusion 341 is engaged within the mounting groove.

[0082] In some embodiments, in the first direction X, the length of the bottom of the first protrusion 341 (i.e., the end near the elastic member 36) is less than the length of the top of the first protrusion 341 (i.e., the end away from the elastic member 36). In the first direction X, the distance between the bottoms (i.e., the ends near the elastic member 36) of two adjacent second protrusions 351 is less than the distance between the tops (i.e., the ends away from the elastic member 36) of two adjacent second protrusions 351. Thus, the length of the bottom of the first protrusion 341 is smaller, and the distance between the tops of two adjacent second protrusions 351 is larger, so that the first protrusion 341 extends into the mounting groove.

[0083] For example, the two surfaces of the first protrusion 341 along the first direction X are sloped surfaces, and the opposing surfaces of the two second protrusions 351 are also sloped surfaces.

[0084] In some embodiments, the tooling 30 includes a main body (not shown) and a protective layer (not shown), the main body and the initial laminate 20 forming a receiving cavity; the protective layer is located at least on the surface of the main body facing the initial laminate 20. The main body is the main structure of the tooling 30. The protective layer provided on the surface of the main body facing the initial laminate 20 can prevent the tooling 30 from adhering to the functional part 26, which facilitates the removal of the tooling 30 after the lamination process is completed.

[0085] In some embodiments, the protective layer may cover the main body. That is, the protective layer may be located on all the outer surfaces of the main body, so that the main body can withstand the high temperature environment during the lamination process, which is beneficial to improving the structural stability of the tooling 30.

[0086] The material for the protective layer can include Teflon.

[0087] Figure 14 This is a top view of a tooling provided in the method for manufacturing photovoltaic modules according to an embodiment of this application.

[0088] refer to Figure 14 The tooling 30 is set around the initial laminate 20.

[0089] In some embodiments, the tooling 30 may include four first portions 37, which are respectively disposed around the initial laminate 20, and adjacent first portions 37 may be connected by connectors (not shown).

[0090] For example, the connector has a slot and the first portion 37 has a protrusion (not shown), and the connection of adjacent first portions 37 is achieved by placing the protrusion in the slot.

[0091] Figure 15 This is a top view of another tooling structure provided in the method for manufacturing photovoltaic modules according to the embodiments of this application.

[0092] refer to Figure 15 In some embodiments, the tooling 30 may include two second portions 38, which are L-shaped. One second portion 38 is configured to correspond to one long side and one wide side of the initial laminate 20, and the other second portion 38 is configured to correspond to the other long side and the other wide side of the initial laminate 20, i.e., the two second portions 38 are arranged diagonally. Adjacent second portions 38 may be connected by connectors.

[0093] In some embodiments, all corners of the tooling 30 can be chamfered. This can reduce the safety of the corners of the tooling 30 and prevent sharp corners from causing injury to workers or other objects.

[0094] In some embodiments, the fixture 30 has multiple vent holes (not shown) that penetrate the fixture 30 and communicate with the receiving cavity, for discharging gas from the receiving cavity during the lamination process. The vent holes have a diameter less than 0.1 mm, for example, 0.01 mm, 0.02 mm, 0.03 mm, 0.04 mm, 0.05 mm, 0.06 mm, 0.07 mm, 0.08 mm, or 0.09 mm. The smaller vent hole diameter reduces the risk of gas overflow from the functional unit 26 while discharging gas.

[0095] Figure 16 This is another schematic diagram of the laminate obtained in the photovoltaic module manufacturing method provided in the embodiments of this application.

[0096] refer to Figure 5 , Figure 6 and Figure 16 In step S3, lamination transforms the initial laminate 20 into a laminate and converts the film layer 23 into an encapsulation portion 25 and a functional portion 26. The encapsulation portion 25 is located between the first cover plate 21 and the second cover plate 22, covering the battery string. The encapsulation portion 25 bonds the battery string to the first cover plate 21 and the second cover plate 22 and protects the battery string from external environmental corrosion. The functional portion 26 is located on the first surface 211, the second surface 221, and the sidewalls of the laminate, increasing the creepage distance of the laminate and improving the safety performance of the photovoltaic module. Using lamination to transform the film layer 23 into the encapsulation portion 25 and the functional portion 26 also facilitates a tight fit between the encapsulation portion 25 and the functional portion 26, reducing the porosity between them and improving the reliability of the photovoltaic module.

[0097] The sidewall of the laminate is the third surface 27 that connects the first surface 211 and the second surface 221 in the laminate.

[0098] In some embodiments, the average thickness of the functional portion 26 located on the first surface 211 can be 0.3 mm to 0.45 mm, for example 0.3 mm, 0.32 mm, 0.35 mm, 0.37 mm, 0.4 mm, 0.42 mm or 0.45 mm.

[0099] In some embodiments, the width of the functional portion 26 located on the first surface 211 in the first direction X is 3mm to 8mm, for example 3mm, 4mm, 5mm, 6mm, 7mm or 8mm.

[0100] In some embodiments, the average thickness of the functional portion 26 located on the third surface 27 can be 0.3 mm to 0.45 mm, for example 0.3 mm, 0.32 mm, 0.35 mm, 0.37 mm, 0.4 mm, 0.42 mm or 0.45 mm.

[0101] In some embodiments, the width of the functional portion 26 located on the third surface 27 in the first direction X is 3mm to 8mm, for example 3mm, 4mm, 5mm, 6mm, 7mm or 8mm.

[0102] refer to Figure 16 In some embodiments, the functional part 26 is located on the first surface 211, the second surface 221, and the third surface 27.

[0103] refer to Figure 7 In some embodiments, a portion of the functional part 26 is also located between the first cover plate 21 and the second cover plate 22. The functional part 26 located between the first cover plate 21 and the second cover plate 22 also helps to increase the creepage distance of the laminate, thereby improving the safety performance of the photovoltaic module.

[0104] In some embodiments, the width of the functional portion 26 located between the first cover plate 21 and the second cover plate 22 in the first direction X can be 2mm to 8mm. For example, the width of the functional portion 26 located between the first cover plate 21 and the second cover plate 22 can be 2mm to 4mm, 4mm to 6mm, or 6mm to 8mm. Optionally, the width of the functional portion 26 located between the first cover plate 21 and the second cover plate 22 can be 2mm, 3mm, 4mm, 5mm, 6mm, 7mm, or 8mm.

[0105] refer to Figure 5 and Figure 6 Before the initial laminate 20 undergoes lamination, the initial laminate 20 and tooling 30 are placed in the lamination equipment. The lamination equipment provides a high-temperature environment, causing the film layer 23 to transform into a fluid molten state. The fluid film layer 23 fills the gaps between adjacent battery strings and adjacent battery cells 24 to form an encapsulation portion 25 covering the battery strings. The fluid film layer 23 also flows into the receiving cavity, ultimately forming the functional portion 26. In addition, the laminating equipment applies a force to the portion of the first cover plate 21 and the tooling 30 located on the side of the first cover plate 21 away from the second cover plate 22, and / or applies a force to the portion of the second cover plate 22 and the tooling 30 located on the side of the second cover plate 22 away from the first cover plate 21, which also promotes the flow of the molten film layer 23 into the receiving cavity, and makes the distance between the first cover plate 21 and the second cover plate 22 along the second direction Y after lamination less than the distance between the first cover plate 21 and the second cover plate 22 along the second direction Y before lamination.

[0106] refer to Figure 5 , Figure 6 and Figure 10 It should be noted that during the lamination process, the initial functional part 234 has weaker fluidity than the initial encapsulation part 233. When the initial encapsulation part 233 with better fluidity flows outwards, it can push the initial encapsulation part 233 with weaker fluidity to move into the receiving cavity, and ultimately the functional part 26 located on the first surface 211, the second surface 221 and the third surface 27 can still be formed.

[0107] In some embodiments, the lamination apparatus includes a lamination chamber that provides space for laminating the initial laminate 20. The initial laminate 20 needs to be placed in the lamination chamber before lamination.

[0108] In some embodiments, the lamination apparatus includes a support platform and a pressure device located within a lamination chamber. An initial laminate 20 is placed on the support platform for lamination. The pressure device applies force (i.e., pressure) to the tooling and the initial laminate 20 to promote the flow of the film layer 23, expel air from the initial laminate 20, and reduce the distance between the first cover plate 21 and the second cover plate 22 along the second direction Y. Exemplarily, the support platform is in contact with the second cover plate 22, and the pressure device applies pressure to the portion of the tooling 30 facing away from the second cover plate 22 and the first cover plate 21.

[0109] In some embodiments, the area of ​​the support platform for supporting the initial laminate 20 is smaller than the area of ​​the second cover plate 22, so that the support platform can directly contact the second cover plate 22 without directly contacting the tooling 30.

[0110] In some embodiments, the pressure device directly applies pressure to the tooling 30, and indirectly applies pressure to the cover plate (at least one of the first cover plate 21 and the second cover plate 22) by applying force to the tooling 30.

[0111] In some embodiments, the pressure device applies pressure directly to both the tooling 30 and the cover plate (at least one of the first cover plate 21 and the second cover plate 22).

[0112] In some embodiments, the pressure device includes a hydraulic cylinder assembly, a servo electric actuator, a lead screw lifting mechanism, etc.

[0113] In some embodiments, before lamination, the distance between the first cover plate 21 and the second cover plate 22 along the second direction Y is 0.7mm to 2mm, for example 0.7mm, 0.9mm, 1.1mm, 1.3mm, 1.5mm, 1.7mm or 2mm.

[0114] In some embodiments, after lamination, the distance between the first cover plate 21 and the second cover plate 22 along the second direction Y is 0.6mm to 1.9mm, for example, 0.6mm, 0.7mm, 0.9mm, 1.1mm, 1.3mm, 1.5mm, 1.7mm or 1.9mm.

[0115] refer to Figure 6 and Figure 7 In step S4, tooling 30 is removed.

[0116] In some embodiments, after the lamination process is completed, the laminating equipment removes the force applied to the tooling 30. Figure 6 The tooling shown here will move away from the laminate by at least one of the first part 31 and the second part 32, which has elastic deformation capability, so that the tooling 30 can be separated from the laminate.

[0117] In some embodiments, after the lamination process is completed, the laminating equipment removes the force applied to the tooling 30. Figure 12 The tooling shown here, at this time, the elastic element 36 with elastic deformation capability will drive the first part 34 and the second part 35 to move away from the laminate, so that the tooling 30 can be separated from the laminate.

[0118] In other embodiments, the tooling 30 can be detached from the laminate by directly applying a force away from the laminate to the tooling 30.

[0119] refer to Figure 5 and Figure 6 In some embodiments, after removing the tooling 30, the functional part 26 can be ground flat to make its surface smoother. For example... Figure 12 In the process of removing tooling 30, the surface of the functional part 26 located on the side wall of the laminate is uneven. It can be ground flat to make the surface of the functional part 26 located on the side wall of the laminate more flat.

[0120] Continue to refer to Figure 5 and Figure 6 In the above-mentioned photovoltaic module manufacturing method, the film layer 23 is cast onto the sidewall, first surface 211 and second surface 221 of the initial laminate 20 by lamination to form the functional part 26. This allows the functional part 26 to be tightly attached to the sidewall of the laminate, which helps to reduce the number of pores between the sidewall of the laminate and the functional part 26, thereby improving the performance of the photovoltaic module.

[0121] Accordingly, another aspect of this application also provides a photovoltaic module. This photovoltaic module can be prepared by the photovoltaic module preparation method in any of the above embodiments. It should be noted that the parts that are the same as or corresponding to the foregoing embodiments can be referred to the corresponding descriptions in the foregoing embodiments, and will not be repeated below.

[0122] Continue to refer to Figure 7 and Figure 16 The photovoltaic module includes a laminate. The laminate includes a cell string, a first cover plate 21, a second cover plate 22, and an encapsulation part 25. The cell string includes multiple solar cells 24. The first cover plate 21 and the second cover plate 22 are located on opposite sides of the cell string. The first cover plate 21 has a first surface 211, and the second cover plate 22 has a second surface 221. The encapsulation part 25 is located between the first cover plate 21 and the second cover plate 22. The photovoltaic module also includes a functional part 26, which is located on the first surface 211, the second surface 221, and the sidewall of the laminate.

[0123] In the photovoltaic module provided in this application embodiment, the encapsulation part 25 is located between the first cover plate 21 and the second cover plate 22, and covers the battery string. It can bond the battery string to the first cover plate 21 and the second cover plate 22, improve the structural stability of the laminate, thereby improving the performance of the photovoltaic module. It can also protect the battery string from external environmental corrosion, which is also beneficial to improving the performance of the photovoltaic module. The functional part 26 is located on the first surface 211, the second surface 221 and the sidewall of the laminate, which can increase the creepage distance of the photovoltaic module, thereby improving the performance of the photovoltaic module.

[0124] Those skilled in the art will understand that the above embodiments are specific examples of implementing this application, and in practical applications, various changes in form and detail can be made without departing from the spirit and scope of this application. Any person skilled in the art can make various alterations and modifications without departing from the spirit and scope of this application; therefore, the scope of protection of this application should be determined by the scope defined in the claims.

Claims

1. A method for preparing a photovoltaic module, characterized in that, include: An initial laminate is provided, the initial laminate comprising: A battery string, wherein the battery string comprises multiple battery cells; A first cover plate and a second cover plate are respectively located on both sides of the battery string. The first cover plate has a first surface and the second cover plate has a second surface. A membrane layer is located between the first cover plate and the second cover plate, and on both sides of the battery string; A tooling is provided, the tooling being arranged around the initial laminate, the tooling abutting against the first cover plate and the second cover plate respectively, and forming a receiving cavity with the first surface, the second surface and the side wall of the initial laminate; A lamination process is performed to transform the initial laminate into a laminate, transforming the film layer into an encapsulation portion and a functional portion. The encapsulation portion is located between the first cover plate and the second cover plate and covers the battery string. During the lamination process, a portion of the film layer is cast into the receiving cavity to form the functional portion, which is located on the first surface, the second surface, and the sidewall of the laminate. The tooling includes: a first portion abutting against the first cover plate; a second portion abutting against the second cover plate; and an elastic member connecting the first portion and the second portion. During the lamination process, under the action of the elastic member, the first portion abuts against the first cover plate, and the second portion abuts against the second cover plate. The second portion has a mounting groove, and the elastic member is located within the mounting groove. The first portion extends into the mounting groove and abuts against the elastic member. Remove the tooling.

2. The method for preparing a photovoltaic module according to claim 1, characterized in that, The film layer includes an initial encapsulation portion and an initial functional portion disposed around the initial encapsulation portion; wherein the lamination process transforms the initial encapsulation portion into an encapsulation portion and transforms the initial functional portion into a functional portion.

3. The method for preparing a photovoltaic module according to claim 2, characterized in that, The thickness of the initial functional part is greater than or equal to the thickness of the initial encapsulation part.

4. The method for preparing a photovoltaic module according to claim 2, characterized in that, The battery cell is located on the initial packaging section, and the initial functional section is spaced apart from the battery cell.

5. The method for preparing a photovoltaic module according to claim 1, characterized in that, The tooling includes: The main body and the initial laminate form the receiving cavity; A protective layer, the protective layer being located at least on the surface of the main body facing the initial laminate.

6. A photovoltaic module, characterized in that, The photovoltaic module is prepared by the method for preparing a photovoltaic module according to any one of claims 1 to 5, and the photovoltaic module comprises: The laminate includes: A battery string, wherein the battery string comprises multiple battery cells; A first cover plate and a second cover plate are respectively located on both sides of the battery string. The first cover plate has a first surface and the second cover plate has a second surface. The encapsulation section is located between the first cover plate and the second cover plate; The functional part is located on the first surface, the second surface, and the sidewall of the laminate.

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