A method and apparatus for the production of photovoltaic modules

Abstract

This application discloses a method for manufacturing photovoltaic modules, relating to the field of photovoltaic modules. It includes inserting a support member into the back of at least one end of a cell string, laying an insulating strip and bending it in reverse, and pressing a first busbar having a voltage-sensitive adhesive layer and a double conductive layer onto the side of the bent portion facing away from the insulating strip. The voltage-sensitive adhesive layer faces the bent portion. This application also discloses a photovoltaic module manufacturing apparatus, including a conveying mechanism and a processing mechanism, wherein at least one processing mechanism is provided for processing the bent portion. By designing the first busbar as a composite structure of a voltage-sensitive adhesive layer and a double conductive layer, and by replacing the traditional high-temperature welding process with pressing, this application achieves bonding and electrical connection between the bent portion of the interconnecting strip and the double conductive layer, simplifying the photovoltaic module busbar process steps, reducing production energy consumption, and avoiding the use of flux, significantly improving the working environment of the photovoltaic module production busbar stage.

Description

Technical Field

[0001] This application relates to the field of photovoltaic module technology, and in particular to a method and equipment for manufacturing photovoltaic modules. Background Technology

[0002] A photovoltaic module consists of several cell strings with interconnecting strips welded onto them. Some of these interconnecting strips extend from the ends of the cell strings. To reduce the area occupied by the cell strings per unit area of ​​the photovoltaic module, as shown in CN120603364A, the extended interconnecting strips need to be bent and welded with busbars to achieve electrical connection. At the same time, the cell strings and interconnecting strips are isolated by insulating strips to prevent short circuits.

[0003] Traditional welding-type electrical connections require the use of flux, have a poor working environment, and involve direct welding operations on the surface of the solar cells, which can easily cause microcracks or cracks in the solar cells, reducing product yield. Summary of the Invention

[0004] To address the problems arising from traditional welded electrical connections, this application provides a method and apparatus for manufacturing photovoltaic modules.

[0005] Firstly, this application provides a method for manufacturing a photovoltaic module, comprising the following steps:

[0006] S1: Provide at least one battery string, wherein the length direction of the battery string is set as a first direction, the battery string is formed by welding and connecting several battery cells in series along the first direction via interconnecting strips, the battery string has two ends along the first direction, the interconnecting strips extend outward along at least one end and the extended portion is set as a bent portion, and in the initial state, the bent portion is in a posture perpendicular to the first direction.

[0007] S2: A support member extends into the back of at least one end, the support member forming an angle of 5°-15° with the first direction, and an insulating strip is attached to the support member;

[0008] S3: Bend the bent portion toward the back of the battery string and stack it on the insulating strip;

[0009] S4: A first busbar is arranged on the side of the bent portion away from the insulating strip. The first busbar has a voltage-sensitive adhesive layer and a double conductive layer. The voltage-sensitive adhesive layer faces the bent portion. Pressure is applied to the first busbar in a direction perpendicular to the support member so that the bent portion is pressed and fixed between the insulating strip and the first busbar. The bending portion and the double conductive layer are bonded, fixed and electrically connected through pressing.

[0010] S5: Remove the support.

[0011] By adopting the above technical solution, the first busbar with a conductive voltage-sensitive adhesive layer and a double conductive layer structure is press-fitted to the bending part to conduct electricity, replacing welding, simplifying the busbar steps, reducing energy consumption, and improving the working environment; the support component bears the pressing force, avoiding microcracks and cracks in the battery string, improving product yield, and the support component is at an angle of 5°-15° with the first direction, which is convenient for automated processing and adapts to the pace of mass production.

[0012] Optionally, the voltage-sensitive adhesive layer is a pressure-sensitive adhesive filled with conductive filler, and the thickness of the voltage-sensitive adhesive layer is 0.03mm-0.05mm.

[0013] By adopting the above technical solution, the conductive voltage-sensitive adhesive layer is made of pressure-sensitive adhesive filled with conductive filler and the thickness is controlled at 0.03mm-0.05mm. This ensures elastic deformation and tight adhesion under pressure, guarantees the bonding area and initial adhesion, and avoids local contact resistance increase and unreliable connection due to excessive thinness, or overall resistance increase and short circuit due to excessive thickness.

[0014] Optionally, the conductive filler is a metal filler or a non-metal filler, the filling ratio of the conductive filler is 10%-20%, and the pressure-sensitive adhesive is one of acrylic pressure-sensitive adhesive, polyurethane pressure-sensitive adhesive, polyvinyl chloride pressure-sensitive adhesive, polyethylene pressure-sensitive adhesive or silicone pressure-sensitive adhesive.

[0015] By adopting the above technical solution, the filling ratio of conductive filler can be controlled at 10%-20%, which can reduce the amount of conductive filler used and reduce material costs while avoiding adverse phenomena, provided that the current conductivity is met. Selecting a specific pressure-sensitive adhesive can ensure that elastic deformation occurs under pressure, close adhesion is achieved, and the initial adhesion is maintained.

[0016] Optionally, the double conductive layer is a metal foil or a carbon-based conductive film, and the thickness of the double conductive layer is 0.01mm-0.08mm.

[0017] By adopting the above technical solution, the double conductive layer is set as a metal foil or a carbon-based conductive film, and its thickness is controlled between 0.01mm and 0.08mm. This can meet the current conduction requirements while ensuring flexibility to fit tightly to the bending part, reducing stress concentration, improving long-term reliability, and avoiding increased material costs.

[0018] Optionally, in step S4, the first busbar is laid on the side of the bend away from the insulating strip using a rolling method, with a rolling pressure of 10N-20N.

[0019] By adopting the above technical solution, the first busbar can be laid out and crimped simultaneously using roll bonding, which can further simplify the busbar preparation process and improve the production speed; the pressure of 10N-20N can fully deform the conductive voltage-sensitive adhesive layer, fill the gap between the bending part and the double conductive layer, and realize the bonding and electrical connection between the two.

[0020] Optionally, step S6 is also included: applying a second pressure again in a direction perpendicular to the battery string to eliminate the angle between the insulating strip and the first direction.

[0021] By adopting the above technical solution, applying a second pressure can make the insulating strip adhere tightly to the back of the battery string, thereby improving the stability of the interlayer structure and enhancing the long-term reliability of the photovoltaic module.

[0022] Optionally, step S6 is also included: a second busbar is insulated and connected to the first busbar by crimping.

[0023] By adopting the above technical solution, a second busbar is added and connected to the first busbar by press-fitting, expanding the current collection path, meeting the current output requirements of multiple cells in photovoltaic modules, and adapting to the fabrication of photovoltaic modules with different circuit connection forms.

[0024] Secondly, this application also provides a photovoltaic module manufacturing apparatus, which applies a photovoltaic module manufacturing method provided in the first aspect, including:

[0025] A conveying mechanism for conveying the battery string;

[0026] A processing mechanism, at least one of which is provided, is used to process the bent portion;

[0027] The processing mechanism includes:

[0028] A support assembly for providing or removing support for the rear end of the battery string;

[0029] An attachment assembly for attaching the insulating strip to the support member;

[0030] A folding assembly, wherein the folding assembly is used to bend the bent portion and stack it on the insulating strip;

[0031] A laying assembly is used to lay the first busbar and to achieve bonding and conductive connection between the bent portion and the double conductive layer through pressing.

[0032] By adopting the above technical solution, the equipment can apply specific photovoltaic module manufacturing methods, automatically transport battery strings with the help of a conveying mechanism, and integrate multiple processes such as support, attachment, folding, and layout using a processing mechanism to realize automated processing of the photovoltaic module junction link, thereby improving production efficiency and processing accuracy.

[0033] Optionally, the support component includes:

[0034] Two upright panels are arranged symmetrically.

[0035] Two servo modules are respectively mounted on adjacent surfaces of the upright plate and inclinedly matched with the support member. The two ends of the support member are mounted on the movable ends of the two servo modules. The servo modules are used to drive the support member to extend into or retract from the rear end. The direction in which the servo modules drive the support member to extend into or retract is set as a second direction.

[0036] By adopting the above technical solution, and by using symmetrical uprights and servo modules, the insertion and withdrawal of the support components can be smoothly realized, ensuring the stability and positional accuracy of the support components.

[0037] Optionally, an installation plate that is inclined and matched with the support member is fixed on the upright plate, and a first guide member is fixed on the installation plate. The first guide member is slidably connected to a first guide rod, and the first guide rod is fixedly connected to the support member. The first guide rod is used to guide the support member to move in a second direction.

[0038] By adopting the above technical solution, the degrees of freedom of the support can be restricted, avoiding swaying and jamming during its movement, ensuring the positional and angular accuracy of the support, and improving the linearity of the support's movement.

[0039] Optionally, a locking cylinder is installed on the opposite surface of the two upright plates. The locking cylinder is used to press against both ends of the support member after the support member extends into the back of the end.

[0040] By adopting the above technical solution, the two ends of the support can be tightened and locked after the support is in place, which can counteract the lateral tilting moment of the support, achieve position locking, and improve the support stability of the support.

[0041] Optionally, the anti-folding assembly includes an anti-folding plate, a first cylinder, and a second cylinder;

[0042] The second cylinder is mounted on the movable end of the first cylinder, and the reverse-bending plate is mounted on the movable end of the second cylinder;

[0043] The first cylinder is used to drive the reverse plate to move in a direction perpendicular to the battery string, and the second cylinder is used to drive the reverse plate to move in a direction parallel to the battery string.

[0044] By adopting the above technical solution, the double-cylinder driven anti-folding plate achieves two-dimensional movement. The first cylinder drives the anti-folding plate to move perpendicular to the battery string, and the second cylinder drives the anti-folding plate to move parallel to the battery string, so that the bending part is accurately bent and stacked on the insulating strip.

[0045] Optionally, a connecting plate is installed on the movable end of the first cylinder, and a second guide is installed on the connecting plate. The second guide slides through a second guide rod, which is fixedly connected to the reverse folding plate. The second guide rod is used to guide the reverse folding plate to move in a direction parallel to the battery string.

[0046] By adopting the above technical solution, the movement direction of the folding plate is constrained, and the second guide rod can guide the folding plate to move in a direction parallel to the battery string, avoiding swaying during its movement and ensuring the accuracy of the folding position.

[0047] Optionally, a release film is affixed to the first busbar;

[0048] The laying assembly includes a feeding tray, a waste tray, a laying module, and guide rollers;

[0049] The feeding tray is used to feed the first manifold strip onto which the release film is applied;

[0050] The waste tray is used to rewind the separated release film;

[0051] The deployment module is used to apply pressure to roll the first busbar and cut it when it reaches a preset length, thus completing the deployment of the first busbar.

[0052] The guide roller is used to guide the release film to separate from the first busbar, and to guide the release film to be wound up and the first busbar to be conveyed to the deployment module.

[0053] By adopting the above technical solution, the deployment component integrates the functions of unwinding the first busbar, rewinding waste material, and rolling and cutting, and automatically completes the release film separation and deployment cutting of the first busbar, realizing the full automation of the busbar deployment process.

[0054] Optionally, a pressure-applying mechanism is also included, which is used to apply a second pressure of 10N-20N in a direction perpendicular to the battery string after the support assembly removes the support member.

[0055] By adopting the above technical solutions, the slight angle caused by the tilt of the support can be eliminated, the structural stability caused by the component lifting can be avoided, and the long-term reliability of the photovoltaic module can be improved.

[0056] In summary, this application includes at least one of the following beneficial technical effects:

[0057] By designing the first busbar as a composite structure of a voltage-sensitive adhesive layer and a double conductive layer, and replacing the traditional high-temperature welding process with press-fitting, the bonding and electrical connection between the bent part of the interconnecting strip and the double conductive layer are achieved. This simplifies the busbar process, reduces production energy consumption, and avoids the use of flux, significantly improving the working environment of the busbar production process in photovoltaic modules. By using a support to bear the press-fitting force, the microcracks and cracks of the cells caused by direct welding and press-fitting on the surface of the cell string can be avoided, improving product yield. Furthermore, the specific angle design facilitates automated processing and adapts to the pace of mass production. Attached Figure Description

[0058] To more clearly illustrate the technical solutions in the embodiments of this application, the accompanying drawings used in the description of the embodiments will be briefly introduced below. Obviously, the accompanying 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.

[0059] Figure 1 This is a schematic diagram of step S1 in the photovoltaic module manufacturing method of this application;

[0060] Figure 2 This is a schematic diagram of step S2 in the photovoltaic module manufacturing method of this application;

[0061] Figure 3 This is a schematic diagram of step S3 in the photovoltaic module manufacturing method of this application;

[0062] Figure 4 This is a schematic diagram of step S4 in the photovoltaic module manufacturing method of this application;

[0063] Figure 5 This is a schematic diagram of step S5 in the photovoltaic module manufacturing method of this application;

[0064] Figure 6 This is a schematic diagram of the first busbar structure in the photovoltaic module manufacturing method of this application;

[0065] Figure 7 This is an overall structural diagram of the photovoltaic module manufacturing equipment of this application;

[0066] Figure 8 This is a partial structural diagram of the photovoltaic module manufacturing equipment of this application;

[0067] Figure 9 This is a schematic diagram of the support component and inverted component structure of the photovoltaic module manufacturing equipment of this application;

[0068] Figure 10 This is a schematic diagram of the supporting component structure of the photovoltaic module manufacturing equipment of this application;

[0069] Figure 11 This is a schematic diagram of the inverted folding module structure of the photovoltaic module manufacturing equipment of this application;

[0070] Figure 12 This is a schematic diagram of the photovoltaic module manufacturing equipment layout in this application;

[0071] Figure 13 This is a schematic diagram of the first busbar structure of the release film in the photovoltaic module manufacturing equipment of this application.

[0072] Reference numerals: 1. Battery string; 11. End; 2. Interconnecting strip; 21. Bending part; 3. Support component; 4. Insulating strip; 5. First busbar; 51. Conductive voltage-sensitive adhesive layer; 52. Double conductive layer; 6. Conveying mechanism; 7. Processing mechanism; 71. Support assembly; 711. Vertical plate; 712. Servo module; 713. Mounting plate; 714. First guide component; 715. First guide rod; 716. Locking cylinder; 7 2. Applying assembly; 73. Reverse folding assembly; 731. Reverse folding plate; 732. First cylinder; 733. Second cylinder; 734. Connecting plate; 735. Second guide; 736. Second guide rod; 737. Base plate; 74. Laying assembly; 741. Feeding tray; 742. Waste tray; 743. Laying module; 744. Guide roller; 8. Release film; 91. Support; 92. Moving assembly; 93. Gantry. Detailed Implementation

[0073] The following is in conjunction with the appendix Figures 1-13 This application will be described in further detail.

[0074] In a first aspect, embodiments of this application disclose a method for manufacturing photovoltaic modules, comprising the following steps:

[0075] like Figure 1 As shown, in step S1, at least one battery string 1 is provided. The battery string 1 is formed by welding and connecting several battery cells in series along a first direction (the length direction of the battery string 1) by an interconnecting strip 2. The battery string 1 has two ends 11 formed at both ends along the first direction. The interconnecting strip 2 extends outward along at least one end 11 of the battery string 1, and the extended portion is set as a bent portion 21. In the initial state, the bent portion 21 is in a posture perpendicular to the first direction.

[0076] like Figure 2 As shown, in step S2, a support member 3 is inserted into the back of at least one end 11 of the battery string 1. The support member 3 forms an angle of 5°-15° with the first direction, and an insulating strip 4 is attached to the support member 3.

[0077] like Figure 3 As shown, in step S3, the bent part 21 is bent toward the back of the battery string 1 and stacked on the insulating strip 4;

[0078] like Figure 4 , Figure 6 As shown, in step S4, a first busbar 5 is arranged on the side of the bent portion 21 away from the insulating strip 4. The first busbar 5 has a voltage-sensitive adhesive layer 51 and a double conductive layer 52, with the voltage-sensitive adhesive layer 51 facing the bent portion 21. Pressure is applied to the first busbar 5 in a direction perpendicular to the support member 3, so that the bent portion 21 is pressed and fixed between the insulating strip 4 and the first busbar 5. The bending portion 21 and the double conductive layer 52 are bonded, fixed and electrically connected through pressing.

[0079] like Figure 5 As shown, after the first busbar 5 is laid out, the support member 3 is removed, forming a three-layer busbar structure consisting of the insulating strip 4, the bent portion 21, and the first busbar 5.

[0080] like Figure 6 As shown, this preparation method designs the first busbar 5 as a composite structure of a voltage-sensitive adhesive layer 51 and a double conductive layer 52. By replacing the traditional high-temperature welding process with press-fitting, the bending part 21 of the interconnecting strip 2 and the double conductive layer 52 are bonded, fixed and electrically connected. This simplifies the busbar process steps, reduces production energy consumption, avoids the use of flux, reduces high-temperature flux exhaust emissions, eliminates the operational safety risks of high-temperature welding, and significantly improves the working environment of the photovoltaic module busbar production process.

[0081] like Figure 4 As shown, because pressing requires applying a certain pressure, and the battery string 1 itself is fragile, if the first busbar 5, the bend 21 and the insulating strip 4 are directly pressed onto its surface, it is very easy to cause the battery string 1 to crack. Therefore, this preparation method sets up a support member 3 as an independent rigid bearing carrier for pressing the insulating strip 4, the interconnecting strip 2, the bend 21 and the first busbar 5, so that the pressing force is completely borne by the support member 3, completely eliminating the problem of hidden cracks and cracks in the battery cells caused by welding and pressing directly on the surface of the battery string 1, and greatly improving the product yield of photovoltaic modules.

[0082] like Figure 4 As shown, by setting the support member 3 at an angle of 5°-15° with the first direction, on the one hand, this angle facilitates the insertion and removal of the support member 3 in automated processing, avoiding bumps and scratches on the battery string 1, and adapting to the pace of mass production; on the other hand, the small angle design allows the first busbar 5, the bent part 21 and the insulating strip 4 to be close to the back of the battery string 1 after pressing. They can be naturally pressed together by the weight of the subsequent stacked materials, eliminating the angle without additional operation and simplifying the subsequent bonding steps. Alternatively, light pressure can be applied to make the three parts fall smoothly to the back of the battery string 1, avoiding damage to the battery string 1 caused by secondary pressing under high pressure.

[0083] like Figure 1As shown, the perpendicularity to the first direction referred to in step S1 includes both strictly perpendicular and approximately perpendicular cases, that is, the bent part 21 is in a vertical and upright state, rather than in a horizontally laid-out state parallel to the first direction; the bent part 21 in this vertical state is formed by the bending process of the pre-dedicated interconnecting strip 2.

[0084] like Figure 1 , Figure 4 As shown, the insulating strip 4 is used to achieve insulation between the bent part 21 and the battery string 1. The insulating strip 4 can prevent the bent part 21 from contacting the back of the battery string 1 and prevent the first busbar 5 from contacting the back of the battery string 1, thus preventing the bent part 21, the first busbar 5 and the back of the battery string 1 from colliding and short-circuiting.

[0085] like Figure 6 As shown, the first busbar 5 has a voltage-sensitive adhesive layer 51 and a double conductive layer 52. The voltage-sensitive adhesive layer 51 is a pressure-sensitive adhesive filled with conductive filler. The voltage-sensitive adhesive layer 51 can achieve bonding and fixation between the bending part 21 and the double conductive layer 52 through pressure sensitivity, and establish a conductive path through the conductive filler to achieve electrical connection between the bending part 21 and the double conductive layer 52. This changes the traditional welding electrical connection method because welding is not required, avoiding the use of flux that is harmful to human health, and can improve the working environment of the busbar link in photovoltaic module production.

[0086] Specifically, the conductive filler can be either metallic or non-metallic. Metallic fillers include silver powder, copper powder, nickel powder, as well as silver-plated copper powder and silver-coated copper powder; non-metallic fillers are mainly carbon-based materials, such as nano-graphite powder, nano-carbon black, and carbon nanotubes (CNTs). The conductive filler filling ratio of the voltage-sensitive adhesive layer 51 is 10% to 20%, relying on pressure to achieve direct physical contact and complete conductivity. This satisfies the conductivity required for current collection while reducing the amount of conductive filler used, thus lowering material costs. If the filling ratio is too low, it is difficult to form effective conductive contact points, leading to increased and unstable connection resistance; if the filling ratio is too high, it will increase material costs and impair the cohesion, flexibility, and processing performance of the adhesive layer.

[0087] Specifically, the pressure-sensitive adhesive can be selected from acrylic pressure-sensitive adhesive, polyurethane pressure-sensitive adhesive, polyvinyl chloride pressure-sensitive adhesive, polyethylene pressure-sensitive adhesive, or silicone pressure-sensitive adhesive, etc. Its thickness should be controlled between 0.03mm and 0.05mm to ensure that the conductive pressure-sensitive adhesive layer 51 can undergo elastic deformation under pressure, allowing the double conductive layer 52 to adhere tightly to the bent portion 21, ensuring the effective bonding area between the two and maintaining good initial adhesion. If the conductive pressure-sensitive adhesive layer 51 is too thin, it will not be able to effectively fill the gaps, leading to a sharp increase in local contact resistance and unreliable connection between the double conductive layer 52 and the bent portion 21. If the conductive pressure-sensitive adhesive layer 51 is too thick, it will easily increase the overall resistance, and excessive flow during lamination may cause adhesive overflow, which may contaminate the surface or cause a short circuit.

[0088] Specifically, the double conductive layer 52 can be a double-sided conductive metal foil or a carbon-based conductive film. The metal foil can be copper foil, aluminum foil, nickel foil, tin foil, silver foil, or their alloy foils, as well as composite metal foils such as copper-tin composite foil and aluminum-polymer composite film. The carbon-based conductive film can be graphene film, carbon nanotube film, conductive polymer film, etc. The thickness of the double conductive layer 52 should be controlled between 0.01 mm and 0.08 mm to meet the requirements of current conduction and long-term reliability, while ensuring good flexibility and tight adhesion to the surface to be connected. If the double conductive layer 52 is too thin, it cannot meet the requirements of current conduction, and the long-term reliability may decrease. If the double conductive layer 52 is too thick, the flexibility will decrease, making it difficult to fit tightly, which will increase the thickness and weight of the entire component and increase material costs.

[0089] like Figure 4 As shown, in step S4, the first busbar 5 can be laid on the side of the bent portion 21 away from the insulating strip 4 by rolling. Rolling can simultaneously realize the laying and pressing of the first busbar 5, which can further simplify the busbar preparation process and improve the production speed. The applied pressure is 10N-20N and the pressure is applied for 3-5 seconds, so that the conductive voltage-sensitive adhesive layer 51 can be fully deformed and fill the gap between the bent portion 21 and the double conductive layer 52, so as to realize the bonding and electrical connection between the bent portion 21 and the double conductive layer 52.

[0090] In a further embodiment, the photovoltaic module manufacturing method also includes applying a secondary light pressure in a direction perpendicular to the first direction after the support member 3 is removed in step S5, eliminating the slight angle caused by the tilt of the support member 3, so that the insulating strip 4 is tightly attached to the back of the battery string 1, improving the stability of the interlayer structure and enhancing the long-term reliability of the photovoltaic module.

[0091] In a further embodiment, the photovoltaic module manufacturing method also includes insulatingly installing a second busbar on the cell string 1. The structure and material of the second busbar are the same as those of the first busbar 5, and will not be described in detail here. By adding the second busbar, the current collection path is expanded to meet the current output requirements of multiple cell strings in the photovoltaic module. For example, the second busbar is crimped and interconnected with the first busbar 5, and the second busbar is also electrically connected to the junction box to transmit the current generated by the cell string 1 to the junction box.

[0092] Specifically, the voltage-sensitive adhesive layer 51 of the second busbar is electrically interconnected with the double conductive layer 52 of the first busbar 5, and the double conductive layer 52 of the second busbar is electrically connected to the junction box to transmit the current generated by the battery string 1 to the junction box.

[0093] The first busbar 5 can be electrically connected to the bend 21 of one battery string 1 or to the bend 21 of multiple battery strings 1, depending on the series and parallel connection type of the photovoltaic module circuit. For example, when all the battery strings 1 of the photovoltaic module are connected in parallel, the electrical polarity of the same end of any adjacent battery strings 1 is the same, that is, one end of all battery strings 1 is positive and the other end is negative. In this case, the first busbar 5 connects to the bend 21 of all battery strings 1 to achieve the parallel connection of all battery strings 1. When all the battery strings 1 of the photovoltaic module are connected in series, the electrical polarity of the same end of any adjacent battery strings 1 is opposite. The positive terminal of one string of any adjacent battery strings 1 is connected in series with the negative terminal of the other string. The photovoltaic module is provided with several first busbars 5, and each first busbar 5 connects to the bend 21 of the same end of adjacent battery strings 1 to achieve the series connection of all battery strings 1.

[0094] Secondly, this application discloses a photovoltaic module manufacturing equipment that applies the photovoltaic module manufacturing method of the first aspect to achieve automated processing of the photovoltaic module's current-carrying link, thereby improving production efficiency and processing accuracy.

[0095] like Figure 7 As shown, the photovoltaic module manufacturing equipment includes: a conveying mechanism 6 and a processing mechanism 7. The equipment in this application also includes... Figure 7 The base frame, not shown, serves as the foundation for mounting the conveyor mechanism 6 and the processing mechanism 7. The base frame is a conventional load-bearing frame.

[0096] The conveying mechanism 6 is used to convey the battery string 1 or battery string 1 group along a preset direction; the processing mechanism 7 is used to process the bent portion 21 of the battery string 1, and at least one processing mechanism 7 is provided. In a preferred embodiment, two processing mechanisms 7 are provided, and the two processing mechanisms 7 are symmetrically and alternately arranged on the side of the conveying mechanism 6 along a preset direction, so as to process the bent portion 21 of the two ends 11 of the battery string 1 respectively.

[0097] Specifically, such as Figure 7 , Figure 8 As shown, the conveying mechanism 6 is mounted on the base frame, which is a conventional technical means; there are two processing mechanisms 7, both mounted on the base frame. The two processing mechanisms 7 are staggered and distributed on both sides of the conveying mechanism 6. Each processing mechanism 7 includes: a support component 71, a folding component 73, a pasting component 72, and a laying component 74, which can process the bent portions 21 of the two ends 11 of the battery string 1 respectively.

[0098] The support assembly 71, the attaching assembly 72, the folding assembly 73, and the laying assembly 74 are all located on the same side of the conveying mechanism 6. The support assembly 71 is used to drive the support member 3 to extend into or out of the back of the end 11 of the battery string 1, providing or removing support for the back of the end 11 of the battery string 1. The folding assembly 73 is used to bend the bent portion 21 toward the back of the battery string 1 and stack it on the insulating strip 4. The attaching assembly 72 is mounted on the base frame and is used to attach the insulating strip 4 to the support member 3. The laying assembly 74 is used to lay the first busbar 5 on the side of the bent portion 21 away from the insulating strip 4, and to achieve the bonding and conductive connection between the bent portion 21 and the double conductive layer 52 by pressing.

[0099] Specifically, such as Figures 9-10 As shown, the support assembly 71 includes two opposing upright plates 711, which are fixedly mounted on the base frame; and two servo modules 712, which are respectively fixedly mounted on the adjacent surfaces of the two upright plates 711 and inclined to match the support member 3. The servo modules 712 can be replaced with other structures or devices with linear motion. The two ends of the support member 3 are fixedly mounted on the movable ends of the two servo modules 712 to ensure that the force on both ends of the support member 3 is uniform. The servo modules 712 drive the support member 3 to extend into or out of the back of the battery string 1 end 11. The direction in which the servo modules 712 drive the support member to extend into or out of the back is set to a second direction. By using symmetrical upright plates 711 and servo modules 712, the extension and retraction of the support member 3 can be smoothly realized, ensuring the stability and positional accuracy of the support member 3.

[0100] In a further embodiment, the support component 71 also includes a first guide structure, which is connected to the support member 3 and is used to guide the support member 3 to move linearly along a second direction; for example... Figure 10 As shown, the first guide structure includes a mounting plate 713, a first guide member 714, and a first guide rod 715. A mounting plate 713, which is inclined and matched to the support member 3, is fixed between two upright plates 711. Several first guide members 714 are fixedly installed on the mounting plate 713. A first guide rod 715 is slidably inserted inside each first guide member 714. Each first guide rod 715 is fixedly connected to the support member 3. The first guide rod 715 is used to guide the support member 3 to move linearly in the second direction, thereby improving the linearity of the movement of the support member 3, avoiding swaying or jamming during its movement, and ensuring the positional and angular accuracy of the support member.

[0101] In a further embodiment, the support component 71 also includes a locking structure, such as... Figure 10As shown, locking cylinders 716 are fixed on the opposite surfaces of the two upright plates 711. The movable end of the locking cylinder 716 passes through the upright plate 711 and is used to press against both ends of the support member 3 after the support member 3 extends into the back of the end 11. When the servo module 712 drives the support member 3 to perform translational movement, the movable end of the locking cylinder 716 retracts and does not interfere with the translational movement trajectory of the support member 3. When the support member 3 moves into the back of the end 11, the movable end of the locking cylinder 716 extends and outputs a pressing force perpendicular to the translational movement direction of the support member 3 to counteract the tilting moment of the support member 3, realize position locking, and improve the support stability of the support member 3.

[0102] Specifically, the anti-folding assembly 73 includes a driving structure and an anti-folding plate 731. The anti-folding plate 731 is inclined and matched with the support member 3 near the edge of the support member 3. The driving structure can drive the anti-folding plate 731 to move in a direction perpendicular to the battery string 1 and in a direction parallel to the battery string 1, so as to bend the bending part 21 and place it on the insulating strip 4 located on the support member 3.

[0103] Specifically, such as Figure 11 As shown, the driving structure of the anti-folding assembly 73 includes a first cylinder 732 and a second cylinder 733. The first cylinder 732 is mounted on the base frame via a base plate 737. The second cylinder 733 is fixedly mounted on the top of the movable end of the first cylinder 732. The anti-folding plate 731 is fixedly mounted on the movable end of the second cylinder 733. The first cylinder 732 is used to drive the second cylinder 733 and the anti-folding plate 731 to move in a direction perpendicular to the battery string 1. The second cylinder 733 is used to drive the anti-folding plate 731 to move in a direction parallel to the battery string 1.

[0104] In a further embodiment, the anti-folding assembly 73 also includes a second guide structure, which is connected to the anti-folding plate 731 and is used to guide the anti-folding plate 731 to move in a direction parallel to the battery string 1; such as Figure 11 As shown, the second guide structure includes a connecting plate 734, a second guide member 735, and a second guide rod 736. The connecting plate 734 is fixedly installed on the movable end of the first cylinder 732. The connecting plate 734 can be driven by the first cylinder 732 to move in a direction perpendicular to the battery string 1. Several second guide members 735 are symmetrically fixedly installed on the connecting plate 734. A second guide rod 736 is slidably inserted inside each second guide member 735. Each second guide rod 736 is fixedly connected to the anti-folding plate 731. The second guide rod 736 is used to guide the anti-folding plate 731 to move in a direction parallel to the battery string 1, thereby improving the linearity of the movement of the anti-folding plate 731.

[0105] Specifically, the application component 72 includes a feeding mechanism and a suction and release mechanism. The feeding mechanism is used to feed the sheet-like insulating strip 4, and the suction and release mechanism is used to pick up the insulating strip 4 and apply it to a designated position on the support member 3. The application component 72 is a conventional technical means, and will not be described in detail in this application.

[0106] like Figure 7 As shown, the placement component 74 is mounted on the moving component 92 via the bracket 91, and the placement component 74 is inclined to match the support member 3. The placement component 74 can be driven by the moving component 92 to place the first busbar 5 along the extension direction of the support member 3 and press and fix it in the direction perpendicular to the support member 3. The moving component 92 is mounted on the base frame via the gantry frame 93. The moving component 92 is a conventional technical means, which can be set as a linear drive such as a ball screw or linear motor to realize the composite movement of the placement component 74 along the extension direction of the support member 3 and in the direction perpendicular to the support member 3.

[0107] Specifically, such as Figure 12 As shown, the laying assembly 74 includes: a feeding tray 741, a waste tray 742, a laying module 743, and a guide roller 744. (As shown...) Figure 13 As shown, a release film 8 is attached to the side of the voltage-sensitive adhesive layer 51 of the first busbar 5 away from the double conductive layer 52. The release film 8 is used to protect the first busbar 5.

[0108] Furthermore, the feeding tray 741 is circular with an annular groove inside. The feeding tray 741 is rotatably connected to the bracket 91 and is used to clamp and feed the first busbar 5 on which the release film 8 is applied. The waste tray 742 is circular with an annular groove inside and is rotatably connected to the bracket 91. The waste tray 742 is used to wind up the release film 8 after the first busbar 5 has separated. The placement module 743 is mounted on the bracket 91 and is used to apply and cut the first busbar 5. Specifically, the placement module 743 includes a roller-type adhesive applicator and a cutting structure, which are arranged adjacent to each other along the placement direction of the first busbar 5. The roller-type adhesive applicator is located at the bottom and can apply 10N-20N of pressure to the first busbar 5 in a direction perpendicular to the support member 3 for rolling, so that the bent part 21 is pressed and fixed between the insulating strip 4 and the first busbar 5. The rolling achieves the bonding and electrical connection between the insulating strip 4 and the double conductive layer 52. The cutting structure is used to perform the cutting action when the first busbar 5 is rolled to a preset length, completing the placement of a single segment of the first busbar 5. At least three guide rollers 744 are provided, all rotatably connected to the bracket 91, and are used to guide the separation of the release film 8 and the first busbar 5, guide the release film 8 to the waste tray 742 for winding, and guide the first busbar 5 to the placement module 743 for application and cutting.

[0109] In a further embodiment, the photovoltaic module manufacturing equipment also includes a pressure application mechanism. This pressure application mechanism is used to apply a second pressure of 10N-20N in a direction perpendicular to the battery string 1 after the support component 71 removes the support member 3, so as to eliminate the included angle caused by the tilt of the support member 3, avoid the structural stability decrease caused by the component lifting, and improve the long-term reliability of the photovoltaic module.

[0110] The implementation principle of the photovoltaic module manufacturing equipment of this application is as follows: After the battery string 1 or battery string 1 group is conveyed to the processing station by the conveying mechanism 6 along a preset direction, the support component 71 drives the support member 3 to extend into the working position on the back of the end 11 of the battery string 1 through the servo module 712, forming a shape as shown in the figure. Figure 2 The support state is shown; then, the attaching component 72 attaches the insulating strip 4 at the preset position of the support member 3; then, the folding component 73 drives the folding plate 731 through the cooperation of the first cylinder 732 and the second cylinder 733, bending the bent part 21 towards the back of the battery string 1 and stacking it on the insulating strip 4, completing the process as shown. Figure 3 The reverse folding operation is shown; then, the moving component 92 drives the laying component 74 to the working position, and the first busbar 5 is laid on the side of the bend 21 away from the insulating strip 4, forming as shown. Figure 4 The assembly state is shown; finally, the support assembly 71 drives the support member 3 out of the working position, forming the assembly state shown. Figure 5 The shown assembly structure completes single-station assembly processing.

[0111] Unless otherwise defined, the terms or scientific terms used in this application shall have the ordinary meaning understood by one of ordinary skill in the art to which this application pertains. The terms "first," "second," "third," and similar words used in this application description do not indicate any order, quantity, or importance, but are merely used to distinguish different components. The terms "a" or "one," and similar words do not indicate a quantity limitation, but rather indicate the presence of at least one. The terms "comprising," "including," and similar words mean that the elements or objects preceding "comprising" or "including" encompass the elements or objects listed following "comprising" or "including" and their equivalents, and do not exclude other elements or objects. "Above," "below," "left," "right," etc., are used only to indicate relative positional relationships; when the absolute position of the described object changes, the relative positional relationship may also change accordingly.

[0112] The above are all preferred embodiments of this application, and are not intended to limit the scope of protection of this application. Therefore, all equivalent changes made in accordance with the structure, shape and principle of this application should be covered within the scope of protection of this application.

Claims

1. A method for manufacturing a photovoltaic module, characterized in that: Includes the following steps: S1: Provide at least one battery string (1), the length direction of the battery string (1) is set as a first direction, the battery string (1) is formed by welding and connecting several battery cells in series along the first direction through interconnecting strips (2), the battery string (1) has two ends (11) along the first direction, the interconnecting strips (2) extend outward along at least one end (11) and the extended part is set as a bent part (21), in the initial state, the bent part (21) is perpendicular to the first direction; S2: A support member (3) extends into the back of at least one end (11), the support member (3) forming an angle of 5°-15° with the first direction, and an insulating strip (4) is attached to the support member (3). S3: Bend the bent portion (21) toward the back of the battery string (1) and stack it on the insulating strip (4); S4: A first busbar (5) is arranged on the side of the bent portion (21) away from the insulating strip (4). The first busbar (5) has a voltage-sensitive adhesive layer (51) and a double conductive layer (52). The voltage-sensitive adhesive layer (51) faces the bent portion (21). Pressure is applied to the first busbar (5) in a direction perpendicular to the support member (3) so that the bent portion (21) is pressed and fixed between the insulating strip (4) and the first busbar (5). The bending portion (21) and the double conductive layer (52) are bonded, fixed and electrically connected through pressing. S5: Remove the support (3).

2. The photovoltaic module manufacturing method according to claim 1, characterized in that: The voltage-sensitive adhesive layer (51) is a pressure-sensitive adhesive filled with conductive filler, and the thickness of the voltage-sensitive adhesive layer (51) is 0.03mm-0.05mm.

3. The photovoltaic module manufacturing method according to claim 2, characterized in that: The conductive filler is a metal filler or a non-metal filler, and the filling ratio of the conductive filler is 10%-20%. The pressure-sensitive adhesive is one of acrylic pressure-sensitive adhesive, polyurethane pressure-sensitive adhesive, polyvinyl chloride pressure-sensitive adhesive, polyethylene pressure-sensitive adhesive or silicone pressure-sensitive adhesive.

4. The photovoltaic module manufacturing method according to claim 1, characterized in that: The double conductive layer (52) is a metal foil or a carbon-based conductive film, and the thickness of the double conductive layer (52) is 0.01mm-0.08mm.

5. The photovoltaic module manufacturing method according to claim 1, characterized in that: In step S4, the first busbar (5) is laid on the side of the bent portion (21) away from the insulating strip (4) by rolling, and the rolling pressure is 10N-20N.

6. The photovoltaic module manufacturing method according to claim 1, characterized in that: It also includes step S6: applying a second pressure again in a direction perpendicular to the battery string (1) to eliminate the angle between the insulating strip (4) and the first direction.

7. The photovoltaic module manufacturing method according to claim 1, characterized in that: It also includes step S6: a second busbar is provided on the battery string (1) with insulation, and the second busbar is crimped and interconnected with the first busbar (5).

8. A photovoltaic module manufacturing equipment, characterized in that: The photovoltaic module manufacturing method according to any one of claims 1-7 includes: Conveying mechanism (6), the conveying mechanism (6) is used to convey the battery string (1); At least one processing mechanism (7) is provided, and the processing mechanism (7) is used to process the bent part (21). The processing mechanism (7) includes: Support assembly (71) for providing or removing support for the back of the end (11) of the battery string (1); A bonding component (72) is used to bond the insulating strip (4) onto the support (3). A folding assembly (73) is used to bend the bent portion (21) and stack it on the insulating strip (4); The laying component (74) is used to lay the first busbar (5) and to achieve the bonding and conductive connection between the bent part (21) and the double conductive layer (52) by pressing.

9. The photovoltaic module manufacturing equipment according to claim 8, characterized in that: The support component (71) includes: Two upright plates (711) are arranged symmetrically. Two servo modules (712) are respectively mounted on adjacent surfaces of the upright plate (711) and are inclined to match the support member (3). The two ends of the support member (3) are mounted on the movable ends of the two servo modules (712). The servo modules (712) are used to drive the support member (3) to extend into or out of the back of the end (11). The direction in which the servo modules (712) drive the support member (3) to extend into or out is set to a second direction.

10. The photovoltaic module manufacturing equipment according to claim 9, characterized in that: An installation plate (713) is fixed on the upright plate (711) and is inclined to match the support member (3). A first guide member (714) is fixed on the installation plate (713). A first guide rod (715) is slidably passed through the first guide member (714). The first guide rod (715) is fixedly connected to the support member (3). The first guide rod (715) is used to guide the support member (3) to move in the second direction.

11. The photovoltaic module manufacturing equipment according to claim 9, characterized in that: Locking cylinders (716) are installed on the opposite surfaces of the two upright plates (711). The locking cylinders (716) are used to press against both ends of the support member (3) after the support member (3) extends into the back of the end (11).

12. The photovoltaic module manufacturing equipment according to claim 8, characterized in that: The reverse bending assembly (73) includes a reverse bending plate (731), a first cylinder (732), and a second cylinder (733); The second cylinder (733) is mounted on the movable end of the first cylinder (732), and the reverse folding plate (731) is mounted on the movable end of the second cylinder (733); The first cylinder (732) is used to drive the reverse plate (731) to move in a direction perpendicular to the battery string (1), and the second cylinder (733) is used to drive the reverse plate (731) to move in a direction parallel to the battery string (1).

13. The photovoltaic module manufacturing equipment according to claim 12, characterized in that: A connecting plate (734) is installed on the movable end of the first cylinder (732), and a second guide (735) is installed on the connecting plate (734). The second guide (735) is slidably connected to a second guide rod (736), which is fixedly connected to the reverse folding plate (731). The second guide rod (736) is used to guide the reverse folding plate (731) to move in a direction parallel to the battery string (1).

14. The photovoltaic module manufacturing equipment according to claim 8, characterized in that: The first busbar (5) is fitted with a release film (8); The laying assembly (74) includes a feeding tray (741), a waste tray (742), a laying module (743), and a guide roller (744). The feeding tray (741) is used to feed the first manifold (5) on which the release film (8) is attached; The waste tray (742) is used to rewind the separated release film (8); The laying module (743) is used to apply pressure to roll the first busbar (5) and cut it when it reaches a preset length, thus completing the laying of the first busbar (5); The guide roller (744) is used to guide the release film (8) to separate from the first busbar (5), and to guide the release film (8) to be wound up and the first busbar (5) to be conveyed to the laying module (743).

15. The photovoltaic module manufacturing equipment according to claim 8, characterized in that: It also includes a pressure-applying mechanism for applying a second pressure of 10N-20N in a direction perpendicular to the battery string (1) after the support assembly (71) removes the support member (3).

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