Photovoltaic module
By employing a double-layer serrated butyl rubber sealing structure in photovoltaic modules, the problems of air bubbles and glue overflow during the lamination process are solved, achieving high reliability and long-term stability in photovoltaic module sealing, which is suitable for various encapsulation systems and module structures.
Patent Information
- Authority / Receiving Office
- CN · China
- Patent Type
- Applications(China)
- Current Assignee / Owner
- JINKO SOLAR CO LTD
- Filing Date
- 2026-03-24
- Publication Date
- 2026-06-23
Smart Images
Figure CN122269813A_ABST
Abstract
Description
Technical Field
[0001] This application relates to the field of photovoltaics, and in particular to a photovoltaic module. Background Technology
[0002] Butyl rubber, as a key sealing material for photovoltaic modules, can form an effective seal at the module edges, preventing moisture intrusion, delaying module aging, and reducing power degradation. It plays a crucial role in ensuring the reliability and safety of the module during its 25-year lifespan. However, in existing technologies, the following problems frequently occur during the lamination process of photovoltaic modules: Lamination bubble problem: During high-temperature and high-pressure lamination, poor venting can easily lead to the formation of bubbles inside the rubber layer or between the rubber layer and the module material interface. These bubbles can cause local seal failure, becoming channels for moisture intrusion; Lamination film overflow problem: During lamination, butyl rubber softens and flows when heated. If the amount of rubber is excessive or the pressure distribution is uneven, the film can overflow, causing material waste and potentially affecting the module's appearance and subsequent installation; Decreased sealing performance: Lamination bubbles and film overflow directly lead to the failure of the module's water-blocking performance, accelerating module performance degradation and seriously affecting the long-term stable operation of the module.
[0003] Existing solutions mainly involve optimizing lamination process parameters and adjusting butyl rubber formulations, but these methods have limited effectiveness and fail to fundamentally solve the structural problems of air bubbles and adhesive overflow. Therefore, there is an urgent need to develop a novel butyl rubber sealing structure that can effectively solve the problems of air bubbles and adhesive overflow during lamination while ensuring sealing performance after lamination. Summary of the Invention
[0004] This application provides a photovoltaic module, the main purpose of which is to solve the problem that butyl rubber sealing structures in the prior art are prone to air bubbles and glue overflow during the lamination process, which leads to a decrease in the sealing performance of the module.
[0005] According to some embodiments of this application, one aspect of this application provides a photovoltaic module, including:
[0006] positive plate;
[0007] Back panel, the back panel and the front panel are positioned opposite each other;
[0008] A sealing assembly is located between the front and back panels and at the edge.
[0009] The sealing assembly includes a first seal and a second seal, which are disposed opposite to each other.
[0010] The first seal has a first flat surface and a first concave-convex surface; the first flat surface is in contact with the inner surface of the plate; the first concave-convex surface has a first groove and a first tooth;
[0011] The second seal has a second plane and a second concave-convex surface, the second plane and the inner surface of the back plate are in contact; the second concave-convex surface has a second groove and a second tooth;
[0012] The first and second concave-convex surfaces are arranged opposite to each other with a gap between them for fluid to pass through; wherein, the first protruding tooth is arranged opposite to the second groove, and the second protruding tooth is arranged opposite to the first groove.
[0013] Adhesive film is placed between the front panel and the back panel.
[0014] Furthermore, the gap width is 1~2mm.
[0015] Furthermore, the gap connects the membrane to the outside world.
[0016] Furthermore, the first groove and the first protrusion are alternately arranged on the first concave and convex surfaces.
[0017] Furthermore, the second groove and the second convex tooth are alternately arranged on the second concave and convex surfaces.
[0018] Furthermore, the density of the first groove on the first uneven surface is 5~10 grooves / cm. 2 .
[0019] Furthermore, the density of the first convex teeth on the first concave and convex surfaces is 5~10 per cm. 2 .
[0020] Furthermore, the density of the second groove on the second uneven surface is 5~10 grooves / cm. 2 .
[0021] Furthermore, the density of the second convex teeth on the second concave and convex surfaces is 5~10 per cm. 2 .
[0022] Furthermore, the depth of the first groove is 1~2mm.
[0023] Furthermore, the width of the groove in the first groove is 1~2mm.
[0024] Furthermore, the width of the root of the first tooth is 1~2mm.
[0025] Furthermore, the height of the first convex tooth is 1~2mm.
[0026] Furthermore, the depth of the second groove is 1~2mm.
[0027] Furthermore, the width of the groove in the second groove is 1~2mm.
[0028] Furthermore, the width of the root of the second tooth is 1~2mm.
[0029] Furthermore, the height of the second convex tooth is 1~2mm.
[0030] Furthermore, both the first and second seals are made of polyethylene terephthalate and / or butyl rubber.
[0031] Furthermore, the first sealing element includes a first butyl adhesive layer, a first substrate, and a first uneven layer stacked sequentially; the first butyl adhesive layer has a first flat surface, the first butyl adhesive layer is bonded to the inner surface of the positive plate, and the first uneven layer has a first uneven surface.
[0032] Furthermore, the second sealing element includes a second butyl rubber layer, a second substrate, and a second uneven layer stacked sequentially; the second butyl rubber layer has a second plane, the second butyl rubber layer is bonded to the inner surface of the back plate, and the second uneven layer has a second uneven surface.
[0033] Furthermore, the materials of the first substrate, the second substrate, the first uneven layer, and the second uneven layer are all polyethylene terephthalate.
[0034] The technical solution provided in this application has at least the following advantages:
[0035] This application addresses the problems of bubbles, glue overflow, and seal failure that easily occur with existing butyl rubber during photovoltaic module lamination. It provides a double-layer serrated butyl rubber sealing structure. By setting interlocking serrated protrusions and grooves on the inner side of the upper and lower rubber strips, air venting and glue overflow channels are formed before lamination, effectively releasing gas and accommodating excess glue. After lamination, the interlocking teeth form a continuous and dense sealing interface. This structure significantly reduces bubbles and glue overflow defects, improves edge sealing reliability, and meets the stringent aging test requirements such as DH1000. Attached Figure Description
[0036] One or more embodiments are illustrated by way of example with reference to the accompanying drawings. These illustrations do not constitute a limitation on the embodiments. Unless otherwise stated, the drawings 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 art, 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.
[0037] Figure 1 This is a schematic diagram of the structure of a photovoltaic module provided in Embodiment 1 of this application;
[0038] Figure 2 This is a schematic diagram of another photovoltaic module provided in Embodiment 2 of this application;
[0039] Figure 3 This is a schematic diagram of the sealing assembly provided in Embodiments 1-2 of this application, where the groove and protrusion are triangular in shape.
[0040] Figure 4 This is a schematic diagram of the sealing assembly provided in Embodiment 4 of this application, where the groove and protrusion are arc-shaped.
[0041] Figure 5 This is a schematic diagram of the sealing assembly provided in Embodiment 5 of this application, where the groove and protrusion of the sealing assembly are trapezoidal in shape.
[0042] Figure 6 A schematic diagram of the sealing structure of a conventional photovoltaic module is provided as a comparative example in this application.
[0043] Figure label:
[0044] 1. Positive plate;
[0045] 2. Back panel;
[0046] 3. Sealing components;
[0047] 31. First seal; 311. First groove; 312. First tooth; 313. First butyl rubber layer; 314. First substrate; 315. First uneven layer;
[0048] 32. Second seal; 321. Second groove; 322. Second protrusion; 323. Second butyl rubber layer; 324. Second substrate; 325. Second uneven layer;
[0049] 33. Gap; W, Gap width;
[0050] 4. Adhesive film; 41. Battery cell;
[0051] 5. Photovoltaic modules;
[0052] 6. Butyl rubber strips; 61. Excess adhesive and air bubbles. Detailed Implementation
[0053] like Figure 6 It is known that existing butyl rubber sealing structures for photovoltaic modules are prone to air bubble formation during high-temperature and high-pressure lamination due to poor venting. This air bubble formation can cause localized sealing failure, becoming a channel for moisture intrusion. During lamination, the butyl rubber softens and flows when heated. If the amount of rubber is excessive or the pressure distribution is uneven, the adhesive film can overflow, resulting in material waste and potentially affecting the module's appearance and subsequent installation. Lamination air bubbles and adhesive film overflow directly lead to the failure of the module's water-blocking performance, accelerating performance degradation and severely impacting the module's long-term stable operation. To address this problem, this application designs a special photovoltaic module sealing structure.
[0054] According to the first aspect of this application, Figure 1 , Figure 2 , Figure 3 , Figure 4 and Figure 5 As shown, a photovoltaic module 5 is provided, which includes:
[0055] Positive board 1;
[0056] Back panel 2, which is positioned opposite to front panel 1;
[0057] The sealing component 3 is disposed between the front panel 1 and the back panel 2 and located at the edge; the sealing component 3 is used to seal the edge of the photovoltaic module;
[0058] The sealing assembly 3 includes a first sealing element 31 and a second sealing element 32, which are disposed opposite to each other.
[0059] The first sealing element 31 has a first flat surface and a first concave-convex surface; the first flat surface is in contact with the inner surface of the plate; the first concave-convex surface has a first groove 311 and a first protrusion 312;
[0060] The second seal 32 has a second plane and a second concave-convex surface; the second plane fits against the inner surface of the back plate; the second concave-convex surface has a second groove 321 and a second protrusion 322.
[0061] The first and second concave-convex surfaces are arranged opposite to each other with a gap 33 between them, which is used for fluid passage; wherein, the first protruding tooth 312 is arranged opposite to the second groove 321, and the second protruding tooth 322 is arranged opposite to the first groove 311; the first sealing member 31 and the second sealing member 32 are used to discharge excess fluid (such as colloid and gas) inside the photovoltaic module to the outside through the gap 33 when subjected to extrusion pressure (high temperature lamination) in opposite directions, and to perform edge sealing of the photovoltaic module by means of the meshing structure formed by the first protruding tooth 312 and the second groove 321 and the meshing structure formed by the second protruding tooth 322 and the first groove 311;
[0062] Adhesive film 4 is disposed between the front plate 1 and the back plate 2; specifically, adhesive film 4 is disposed in the cavity enclosed by the front plate 1, the back plate 2 and the sealing component 3, and the adhesive film is used to bond the front plate and the back plate together; the adhesive film material is ethylene-vinyl acetate copolymer (EVA), ethylene-octene copolymer elastomer (POE) or a three-layer composite adhesive film of EVA and POE (EPE).
[0063] The photovoltaic module sealing structure provided in this application is used to seal the solar cell 41. The photovoltaic module effectively guides the gas to be discharged in a directional manner during the lamination heating stage through the pre-set micro-gap channel between the upper and lower adhesive strips, avoiding the formation of closed cavities. The measured bubble occurrence rate is reduced from 12~18% in the traditional solution to 0%, which greatly improves the appearance yield and production efficiency of the module. The serrated groove can accommodate the flow of excess adhesive during the lamination process. Even if the amount of adhesive fluctuates by ±0.5g / m, there is no overflow. This solves the problems of frame assembly difficulties, junction box interference and appearance defects caused by adhesive overflow, and improves the process tolerance. After lamination, the upper and lower serrations are completely interlocked to form a continuous, interface gap-free mechanical interlocking sealing structure, which enhances the reliability of edge sealing. The water vapor transmission rate (WVTR) is significantly reduced. In the DH1000 damp heat aging test, the average power decay of the module is only 0.8~1.0%, which is far better than the industry average (2.5~3.0%). The adhesive strip can be prepared using a standard extrusion process. Mounting requires only a simple alignment fixture, and lamination parameters do not need adjustment. It can be directly implemented in existing photovoltaic module production lines, achieving both high reliability and high yield. This sealing structure is suitable for various encapsulation systems such as EVA, POE, and co-extruded films, as well as various module structures including single-glass, double-glass, and frameless modules. It performs particularly well in highly sensitive processes such as 210mm large silicon wafers and thin-film (≤130μm) applications. In summary, this application not only fundamentally solves the three major problems of bubbles, adhesive overflow, and sealing failure in the lamination process of traditional butyl adhesive, but also simultaneously improves the long-term reliability, electrical safety, and production economy of the modules.
[0064] In some specific embodiments, the gap width W is 1~2mm; the gap 33 connects the adhesive film and the outside. Setting the gap width between the two opposing serrated sealing structures within the above range ensures that excess adhesive or gas in the cavity can be fully discharged to the outside through the microchannel formed by the gap during the high-temperature lamination process of the photovoltaic module; at the same time, after the photovoltaic module is laminated, the upper and lower serrations are completely interlocked, forming a continuous, gapless mechanical interlocking sealing structure, thereby enhancing the reliability of the edge seal.
[0065] In some specific embodiments, the first groove 311 and the first protrusion 312 are alternately arranged on the first concave-convex surface; correspondingly, the second groove 321 and the second protrusion 322 are alternately arranged on the second concave-convex surface. This arrangement allows the first and second concave-convex surfaces to form a bidirectional interlocking structure under lamination, wherein the first protrusion is embedded in the second groove, and the second protrusion is embedded in the first groove, creating a continuous, uninterrupted three-dimensional mechanically interlocked sealing interface between the upper and lower adhesive layers. This alternating concave-convex structure requires water vapor molecules to pass through the adhesive layer along an S-shaped tortuous path, rather than through a straight line, thus extending the water vapor penetration path, reducing water vapor permeability, and improving resistance to damp heat aging. Furthermore, the symmetrical arrangement of alternating concave-convex surfaces ensures that thermal expansion and contraction stresses are evenly distributed during lamination, preventing localized stress concentrations that could lead to adhesive layer cracking. This structure, through its periodic alternating design, facilitates the synergistic optimization of multiple physical properties, including material flow, gas diffusion, electric field distribution, and mechanical strength.
[0066] In some specific embodiments, the density of the first grooves 311 on the first uneven surface is 5 to 10 per cm. 2 The density of the first protruding tooth 312 on the first concave and convex surface is 5~10 per cm. 2 Correspondingly, the density of the second groove 321 on the second uneven surface is 5~10 per cm. 2 The density of the second convex tooth 322 on the second concave and convex surfaces is 5~10 per cm. 2 Controlling the number or density of grooves and protrusions on the upper and lower adhesive strips within the above-mentioned range facilitates gas discharge and provides good sealing performance. This reduces the bubble defect rate to zero, lowers water vapor permeability, and improves peel resistance and lamination yield. The number of grooves and protrusions can be set according to the area of the adhesive strip, as long as it can achieve adhesive discharge and interlocking sealing structure.
[0067] In some specific embodiments, the depth of the first groove 311 is 1~2mm, the groove width of the first groove 311 is 1~2mm; the root width of the first tooth 312 is 1~2mm; the height of the first tooth 312 is 1~2mm; correspondingly, the depth of the second groove 321 is 1~2mm, the groove width of the second groove 321 is 1~2mm; the root width of the second tooth 322 is 1~2mm, and the height of the second tooth 322 is 1~2mm. The aforementioned groove width refers to the width of the opening at the top of the groove, and the width of the root of the protrusion tooth refers to the widest part of the connection with the adhesive strip body. Within the aforementioned selectable range, the groove width of the upper adhesive strip groove and the root width of the protrusion tooth of the lower adhesive strip should match each other. When the two are equal or approximately equal, or the width of the protrusion tooth is slightly smaller than the groove width, the protrusion tooth of the lower adhesive strip can be embedded and fill the groove of the upper adhesive strip, and the protrusion tooth of the upper adhesive strip can be embedded and fill the groove of the lower adhesive strip. After lamination, there are no macroscopic gaps, which can achieve a fully fitted, gapless, and extrusion-free interlocking sealing interface. At the same time, the groove width and depth of the upper or lower adhesive strip, or the width or height of the protrusion tooth, can be designed according to the size of the adhesive strip area, as long as the interlocking structure of the upper and lower adhesive strips can be fully fitted, thereby achieving the sealing effect of the photovoltaic module.
[0068] In some specific embodiments, the outer contours of the first groove 311, the second groove 321, the first protrusion 312, and the second protrusion 322 are each independently triangular. Figure 3 ),arc( Figure 4 ), semi-circle, trapezoid ( Figure 5 Furthermore, the upper and lower layers of oppositely arranged grooves and protruding teeth are matched to each other to form a complementary interlocking structure; the above triangles can be straight sides, pointed apex, acute angles, etc., such as isosceles triangles; trapezoids have an upper base smaller than the lower base and a transitional hypotenuse; arcs / semicircles are smooth curves without sharp corners; the shapes of the protruding teeth or grooves can be designed in the above shapes to achieve complementary interlocking, and the protruding teeth and grooves are mirror-matched; at the same time, the shapes of the grooves or protruding teeth can also be designed in other shapes, as long as the upper and lower grooves and protruding teeth can interlock and seal.
[0069] In some specific embodiments, the first seal 31 and the second seal 32 are both made of polyethylene terephthalate and / or butyl rubber; the thickness of the first seal 31 or the second seal 32 (the distance from the plane to the root of the protrusion of the concave and convex surfaces or the bottom of the groove, excluding the height of the protrusion) is 2~5mm; this thickness can be adjusted according to the actual application.
[0070] When the sealing material is butyl rubber, in addition to the sealing effect mentioned above, the serrated interlocking structure significantly extends the surface creepage path, with a measured creepage distance of 4.6~4.9mm, which meets the safety requirements of IEC61730 for 1500V system components (≥4.0 mm), and is suitable for large-size, high-power double-glass modules.
[0071] In some specific embodiments, the first sealing member 31 includes a first butyl rubber layer 313, a first substrate 314, and a first uneven layer 315 stacked sequentially; the first butyl rubber layer 313 has a first flat surface and is attached to the inner surface of the front plate 1, and the first uneven layer 315 has a first uneven surface; correspondingly, the second sealing member 32 includes a second butyl rubber layer 323, a second substrate 324, and a second uneven layer 325 stacked sequentially; the second butyl rubber layer 323 has a second flat surface and is attached to the inner surface of the back plate 2, and the second uneven layer 325 has a second uneven surface; wherein, the materials of the first substrate 314, the second substrate 324, the first uneven layer 315, and the second uneven layer 325 are all polyethylene terephthalate (PET), and the PET material has sealing and insulating functions.
[0072] In some specific embodiments, the front panel is a front glass panel with a thickness of 2.0~2.5mm; the back panel is a back glass panel with a thickness of 1.1~2.0mm; the thickness and size of the front and back glass panels can be selected from existing technologies according to the actual application.
[0073] In some specific embodiments, the thickness of the first butyl adhesive layer 313 is 1~2mm; the thickness of the second butyl adhesive layer 323 is 1~2mm; the thickness of the first substrate 314 is 1~2mm; the thickness of the second substrate 324 is 1~2mm; at the same time, the individual thickness of the three layers or the total thickness can be designed according to the actual situation.
[0074] The method for preparing the photovoltaic module described in this application can be operated according to actual conditions and is not limited, as long as the structure can be achieved. As an example, a method for preparing a photovoltaic module includes the following steps:
[0075] Step S1: Using a mold, the first material is formed into a first sealing member 31 having a first flat surface and a first concave-convex surface; the first concave-convex surface has a first groove 311 and a first tooth 312;
[0076] Step S2: Using a mold, the second material is used to form a second sealing member 32 having opposing second planes and second concave and convex surfaces; the second concave and convex surfaces have a second groove 321 and a second protrusion 322;
[0077] Step S3: Attach the first plane to the inner surface of the edge of the front plate 1; attach the second plane to the inner surface of the edge of the back plate 2, so that the first and second concave-convex surfaces are arranged opposite each other and a gap 33 is left between them.
[0078] Step S4: Apply adhesive to the cavity formed by the front plate 1, back plate 2, first seal 31 and second seal 32. After the adhesive cures, it forms a film 4. The first seal 31 and the second seal 32 are combined to form a sealing assembly 3 to seal the edge of the photovoltaic module.
[0079] Specifically, a first substrate 314 and a first uneven layer 315 with an integral structure are first prepared using a mold. Both are made of PET. Then, butyl adhesive is applied to the surface of the first substrate to form a first butyl adhesive layer 313. The first plane of the first butyl adhesive layer 313 is attached to the inner surface of the front plate 1. The first uneven layer 315 has a first uneven surface. This integral structure serves as the first sealing element 31. The second sealing element 32 is prepared using the same method, including a second butyl adhesive layer 323, a second substrate 324 (PET), and a second uneven layer 325 (PET) stacked in sequence. The second butyl adhesive layer 323 has a second plane and is attached to the inner surface of the back plate 2. The second uneven layer 325 has a second uneven surface.
[0080] 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.
[0081] 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.
[0082] 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.
[0083] Example 1
[0084] like Figure 1 As shown, a photovoltaic module 5 includes:
[0085] Front panel 1 (front glass), thickness is 2.0mm;
[0086] Back panel 2 (back glass), 2.0mm thick; the back panel and the front panel are positioned opposite each other;
[0087] The sealing assembly 3 is located between the front panel 1 and the back panel 2 and at the edge; the sealing assembly is used to seal the edge of the photovoltaic module.
[0088] like Figure 3 As shown, the sealing assembly 3 includes a first sealing element 31 (made of butyl rubber) and a second sealing element 32 (made of butyl rubber) disposed opposite to each other; wherein, the first sealing element 31 has a first flat surface and a first concave-convex surface; the first concave-convex surface has alternating first grooves 311 and first protrusions 312, both of which are triangular in shape; the first flat surface is in contact with the inner surface of the plate; the density of the first grooves on the first concave-convex surface is 5 per cm. 2 The density of the first convex tooth on the first concave and convex surface is 5 per cm. 2 The depth of the first groove is 1.5mm, the width of the groove opening is 1.5mm, the width of the root of the first tooth is 1mm, the height of the first tooth is 1.5mm, and the thickness of the first seal from the first plane to the bottom of the groove or the root of the tooth on the first concave-convex surface is 5mm.
[0089] The second seal 32 has a second flat surface and a second concave-convex surface, the second concave-convex surface having alternately arranged second grooves 321 and second protrusions 322, both the grooves and protrusions being triangular in shape; the second flat surface and the inner surface of the back plate are in contact; the arrangement density of the second grooves on the second concave-convex surface is 5 / cm². 2 The density of the second convex tooth on the second concave and convex surface is 5 per cm. 2 The depth of the second groove is 1.5mm, and the width of the groove opening is 1.5mm; the width of the root of the second protrusion is 1mm, and the height of the second protrusion is 1.5mm; the thickness of the second seal from the second plane to the bottom of the groove or the root of the protrusion on the second concave-convex surface is 5mm.
[0090] The first and second concave-convex surfaces are arranged opposite to each other with a gap 33 between them. The gap width W is 1.5 mm. The gap is used for fluid passage. The first protruding tooth 312 is arranged opposite to the second groove 321, and the second protruding tooth 322 is arranged opposite to the first groove 311. The first and second sealing elements are used to discharge excess fluid (such as colloid and gas) in the photovoltaic module to the outside through the gap 33 when subjected to extrusion pressure (high temperature lamination) in opposite directions. The first sealing element and the second sealing element are used to perform edge sealing by the meshing structure formed by the first protruding tooth 312 and the second groove 321, and the meshing structure formed by the second protruding tooth 322 and the first groove 311.
[0091] The adhesive film 4 is disposed in the cavity enclosed by the front plate, the back plate and the sealing assembly. The adhesive film is used to bond the front plate and the back plate together. The adhesive film material is ethylene-vinyl acetate copolymer (EVA). The gap 33 connects the adhesive film and the outside world to facilitate the discharge of air bubbles and excess adhesive generated by the adhesive film during high-temperature lamination to the outside world. The battery cell 41 is disposed in the adhesive film and is sealed by the adhesive film and the sealing assembly.
[0092] The photovoltaic module is placed in a laminator and subjected to high-temperature lamination at a temperature of 125°C and a pressure of 70MPa. The first tooth 312 of the first seal 31 of the photovoltaic module is embedded in the second groove 321 of the second seal 32, and the second tooth 322 of the second seal 32 is embedded in the first groove 311 of the first seal 31. During the lamination heating process, the pre-set micro-gap channel between the upper and lower saw teeth guides the gas to be discharged in a directional manner. The saw tooth groove accommodates the flow of excess colloid during the lamination process, and there is no overflow. After lamination, the upper and lower saw teeth are completely interlocked to form a continuous, gapless mechanical interlocking sealing structure, and the photovoltaic module has a good appearance.
[0093] Example 2
[0094] like Figure 2 As shown, a photovoltaic module 5 includes:
[0095] Front panel 1 (front glass), 2mm thick;
[0096] Back panel 2 (back glass), 2mm thick; the back panel and the front panel are positioned opposite each other;
[0097] The sealing assembly 3 is located between the front panel 1 and the back panel 2 and at the edge; the sealing assembly is used to seal the edge of the photovoltaic module.
[0098] like Figure 3 As shown, the sealing assembly 3 includes a first seal 31 and a second seal 32, which are disposed opposite to each other.
[0099] The first sealing element 31 comprises a first butyl rubber layer 313 (1 mm thick), a first substrate 314 (PET material, 2 mm thick), and a first uneven layer 315 (PET material, 2 mm thick, excluding grooves or protrusions) stacked sequentially. The first butyl rubber layer has a first flat surface and is bonded to the inner surface of the positive plate. The first uneven layer has a first uneven surface. The first uneven surface has alternating first grooves 311 and first protrusions 312, both of which are triangular in shape. The density of the first grooves on the first uneven surface is 5 per cm. 2 The density of the first convex tooth on the first concave and convex surface is 5 per cm. 2The depth of the first groove is 1.5mm, the width of the groove opening is 1.5mm, the width of the root of the first protrusion is 1mm, and the height of the first protrusion is 1.5mm.
[0100] The second sealing element 32 includes a second butyl rubber layer 323 (1 mm thick), a second substrate 324 (PET material, 2 mm thick), and a second uneven layer 325 (PET material, 2 mm thick, excluding groove or tooth height) stacked sequentially. The second butyl rubber layer has a second flat surface and is bonded to the inner surface of the back plate. The second uneven layer has a second uneven surface. The second uneven surface has alternating second grooves 321 and second teeth 322, both of which are triangular in shape. The second flat surface is bonded to the inner surface of the back plate. The arrangement density of the second grooves on the second uneven surface is 5 / cm². 2 The density of the second convex tooth on the second concave and convex surface is 5 per cm. 2 The depth of the second groove is 1.5mm, and the width of the groove opening is 1.5mm; the width of the root of the second protrusion is 1mm, and the height of the second protrusion is 1.5mm.
[0101] The first and second concave-convex surfaces are arranged opposite to each other with a gap 33 between them. The gap width W is 1 mm. The gap is used for fluid passage. The first protruding tooth 312 is arranged opposite to the second groove 321, and the second protruding tooth 322 is arranged opposite to the first groove 311. The first and second sealing elements are used to discharge excess fluid (such as colloid and gas) in the photovoltaic module to the outside when subjected to extrusion pressure (high temperature lamination) in opposite directions. The first sealing element and the second sealing element are used to perform edge sealing by using the gap.
[0102] The adhesive film 4 is disposed in the cavity enclosed by the front plate, the back plate and the sealing assembly. The adhesive film is used to bond the front plate and the back plate together. The adhesive film material is ethylene-vinyl acetate copolymer (EVA). The gap 33 connects the adhesive film and the outside world to facilitate the discharge of air bubbles and excess adhesive generated by the adhesive film during high-temperature lamination to the outside world. The battery cell 41 is disposed in the adhesive film and is sealed by the adhesive film and the sealing assembly.
[0103] High-temperature lamination: The photovoltaic module is placed in a laminator and laminated at a temperature of 125℃ and a pressure of 70MPa. The first tooth 312 of the first seal 31 of the photovoltaic module is embedded in the second groove 321 of the second seal 32, and the second tooth 322 of the second seal 32 is embedded in the first groove 311 of the first seal 31. During the lamination heating process, the pre-set micro-gap channel between the upper and lower saw teeth guides the gas to be discharged in a directional manner. The saw tooth groove accommodates the flow of excess colloid during the lamination process, and there is no overflow. After lamination, the upper and lower saw teeth are completely interlocked to form a continuous, gapless mechanical interlocking sealing structure, and the photovoltaic module has a good appearance.
[0104] Example 3
[0105] The difference between Example 3 and Example 1 is that the density of the first groove on the first uneven surface is replaced with 10 grooves / cm. 2 The density of the first convex tooth on the first concave-convex surface is 10 teeth / cm². 2 The density of the second groove on the second uneven surface is 10 grooves / cm². 2 The density of the second convex tooth on the second concave and convex surface is 10 teeth / cm². 2 .
[0106] Example 4
[0107] The difference between Example 4 and Example 1 is that the shapes of the first groove and the first protrusion, and the shapes of the second groove and the second protrusion, are all replaced with arc shapes; for example... Figure 1 and Figure 4 As shown.
[0108] Example 5
[0109] The difference between Example 5 and Example 1 is that the shapes of the first groove and the first protrusion, and the shapes of the second groove and the second protrusion, are all replaced with trapezoids; for example... Figure 1 and Figure 5 As shown.
[0110] Example 6
[0111] The difference between Example 6 and Example 1 is that the materials of both the first and second seals are replaced with PET material.
[0112] Comparative Example 1
[0113] like Figure 6 As shown, a photovoltaic module includes:
[0114] Front panel 1 (front glass), 2mm thick;
[0115] Back panel 2 (back glass), 2mm thick; back panel 2 and front panel 1 are positioned opposite each other;
[0116] Butyl rubber strip 6, located between the front plate 1 and the back plate 2 at the edge, has a thickness of 10mm; this strip is used to seal the edge of the photovoltaic module.
[0117] The adhesive film 4 is disposed in the cavity formed by the front plate 1, the back plate 2 and the butyl rubber strip 6. The adhesive film 4 is used to bond the front plate 1 and the back plate 2 together. The adhesive film material is ethylene-vinyl acetate copolymer (EVA). The battery cell 41 is disposed in the adhesive film 4, and the battery cell is sealed by the adhesive film 4 and the butyl rubber strip 6.
[0118] High-temperature lamination: The photovoltaic modules are placed in a laminator and laminated at a temperature of 125°C and a pressure of 70MPa. This results in excess adhesive and air bubbles 61 between the front panel 1 and the back panel 2. The adhesive overflows from the frame of the photovoltaic modules, making the photovoltaic modules look unattractive and reducing their sealing performance.
[0119] Performance testing
[0120] The sealing performance and resistance to damp heat aging of the photovoltaic modules in each embodiment and comparative example were tested, and the test results are shown in Table 1.
[0121] (1) Water vapor transmission rate: The water vapor transmission rate was tested using a water vapor transmission meter in accordance with the IEC61730 national standard.
[0122] (2) Resistance to damp heat aging: The resistance to damp heat aging was tested using a high and low temperature damp heat aging chamber in accordance with IEC61215-2:2016.
[0123] Table 1
[0124]
[0125] By applying the photovoltaic module sealing structure provided in this application, the pre-set micro-gap channels between the upper and lower adhesive strips effectively guide the gas outward during the lamination heating stage, avoiding the formation of closed cavities. The measured bubble occurrence rate is reduced from 12-18% in traditional solutions to 0%, significantly improving the module appearance yield and production efficiency. The serrated grooves can accommodate excess adhesive flow during lamination, and even with adhesive fluctuations of ±0.5g / m, there is no overflow, solving the problems of frame assembly difficulties, junction box interference, and poor appearance caused by adhesive overflow, and improving process tolerance. After lamination, the upper and lower serrations are completely interlocked, forming a continuous, gapless mechanical interlocking sealing structure, enhancing the reliability of edge sealing. The water vapor transmission rate (WVTR) is reduced to 0.25g / m. 2• After PCT96, the average power degradation of the module in the DH1000 damp heat aging test is only 0.8~1.0%, far better than the industry average (2.5~3.0%), thus delaying power degradation. The adhesive strip can be prepared by standard extrusion process, and only a simple alignment fixture needs to be added for mounting. The lamination parameters do not need to be adjusted, and it can be directly introduced into the existing photovoltaic module production line to achieve high reliability and high yield at the same time (first-pass yield increased to 99.3%). This sealing structure is suitable for various encapsulation systems such as EVA, POE, and co-extruded film, as well as various module structures such as single glass, double glass, and frameless, especially in highly sensitive processes such as 210mm large silicon wafers and thin wafers (≤130μm). In summary, this application not only fundamentally solves the three major problems of bubbles, glue overflow and sealing failure in the lamination process of traditional butyl sealant, but also simultaneously improves the long-term reliability, electrical safety and production economy of the module.
[0126] 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 photovoltaic module, characterized in that, include: positive plate(1); A back plate (2) is provided opposite to the front plate (1); A sealing assembly (3) is disposed between the front plate (1) and the back plate (2) and located at the edge. The sealing assembly (3) includes a first sealing element (31) and a second sealing element (32) and the two are arranged opposite to each other. The first sealing element (31) has a first flat surface and a first concave-convex surface; the first flat surface is in contact with the inner surface of the positive plate (1); the first concave-convex surface has a first groove (311) and a first tooth (312). The second seal (32) has opposing second planes and second concave and convex surfaces; the second plane is in contact with the inner surface of the back plate (2); the second concave and convex surfaces have a second groove (321) and a second tooth (322); The first and second concave-convex surfaces are arranged opposite to each other and a gap (33) is provided between them, the gap (33) is used for fluid to pass through; wherein, the first protruding tooth (312) is arranged opposite to the second groove (321), and the second protruding tooth (322) is arranged opposite to the first groove (311); Adhesive film (4) is disposed between the front plate (1) and the back plate (2).
2. The photovoltaic module according to claim 1, characterized in that, The gap width of the gap (33) is 1~2mm; And / or, the gap (33) connects the film to the outside.
3. The photovoltaic module according to claim 1, characterized in that, The first groove (311) and the first protrusion (312) are alternately arranged on the first concave and convex surface; And / or, the second groove (321) and the second protrusion (322) are alternately arranged on the second concave-convex surface.
4. The photovoltaic module according to any one of claims 1 to 3, characterized in that, The density of the first groove (311) on the first uneven surface is 5~10 per cm. 2 ; And / or, the density of the first protruding teeth (312) on the first concave-convex surface is 5~10 per cm. 2 .
5. The photovoltaic module according to any one of claims 1 to 3, characterized in that, The density of the second groove (321) on the second uneven surface is 5~10 per cm. 2 ; And / or, the density of the second convex tooth (322) on the second concave-convex surface is 5~10 per cm. 2 .
6. The photovoltaic module according to any one of claims 1 to 3, characterized in that, The depth of the first groove (311) is 1~2mm; And / or, the groove width of the first groove (311) is 1~2mm; And / or, the width of the root of the first protruding tooth (312) is 1~2mm; And / or, the height of the first protrusion (312) is 1~2mm.
7. The photovoltaic module according to any one of claims 1 to 3, characterized in that, The depth of the second groove (321) is 1~2mm; And / or, the groove width of the second groove (321) is 1~2mm; And / or, the root width of the second protruding tooth (322) is 1~2mm; And / or, the height of the second protrusion (322) is 1~2mm.
8. The photovoltaic module according to any one of claims 1 to 3, characterized in that, The materials of the first seal (31) and the second seal (32) are both polyethylene terephthalate and / or butyl rubber.
9. The photovoltaic module according to any one of claims 1 to 3, characterized in that, The first sealing element (31) includes a first butyl rubber layer (313), a first substrate (314) and a first uneven layer (315) stacked in sequence; the first butyl rubber layer (313) has the first plane, the first butyl rubber layer (313) is attached to the inner surface of the positive plate (1), and the first uneven layer (315) has the first uneven surface; And / or, the second seal (32) includes a second butyl rubber layer (323), a second substrate (324) and a second uneven layer (325) stacked in sequence; the second butyl rubber layer (323) has the second plane, the second butyl rubber layer (323) is attached to the inner surface of the back plate (2), and the second uneven layer (325) has the second uneven surface.
10. The photovoltaic module according to claim 9, characterized in that, The first substrate (314), the second substrate (324), the first uneven layer (315) and the second uneven layer (325) are all made of polyethylene terephthalate.