Solar cell modules and their manufacturing methods, and electrical devices

Abstract

This application relates to the field of photovoltaic technology, and discloses a solar cell module, its preparation method, and an electrical device thereof. The solar cell module includes: a solar cell, the solar cell including positive and negative electrode wires; an encapsulation layer, the encapsulation layer wrapping the solar cell and having a wiring opening from which the positive and negative electrode wires extend; and a junction box, the junction box including a box body and a cover on top of the box body, the bottom of the box body being connected to the encapsulation layer, the junction box and the encapsulation layer jointly defining an encapsulation space, and the wiring opening being located within the encapsulation space, the positive and negative electrode wires extending through the box body to the outside of the junction box; wherein, the encapsulation space includes a first space and a second space, the wiring opening constituting the first space, and the portion outside the first space constituting the second space; at least one of the first space and the second space contains a molecular sieve. This solar cell module exhibits excellent water and oxygen barrier effects.

Description

Technical Field

[0001] This application relates to the field of photovoltaic technology, specifically to a solar cell module and its preparation method, as well as an electrical device thereof. Background Technology

[0002] Perovskite-structured photovoltaic materials represent a disruptive development direction for next-generation photovoltaic technology. Perovskite itself can be used to make photovoltaic modules (solar cells), or it can be combined with traditional crystalline silicon photovoltaic technology to make heterojunction photovoltaic modules, both of which have broad application prospects.

[0003] However, when photovoltaic (PV) modules are used in humid regions, such as tropical rainforests, on the sea surface, or lakes, the cell grid lines are prone to corrosion and oxidation, leading to a decrease in power output and consequently a shortened lifespan. Furthermore, the encapsulation requirements for perovskite PV modules are more stringent than those for traditional crystalline silicon PV modules, necessitating better solutions to water and oxygen barrier issues. Current junction box designs in PV modules cannot completely resolve these problems; therefore, improving water and oxygen barrier properties in solar cell modules remains a significant challenge.

[0004] Application content This application aims to at least partially solve one of the technical problems in the related art. Therefore, one objective of this application is to provide a solar cell module and its manufacturing method, as well as an electrical device thereof, wherein the solar cell module of this application has a long service life.

[0005] A first aspect of this application discloses a solar cell module, comprising: The battery cell includes positive and negative electrode wires; An encapsulation layer, which encapsulates the battery cell and has a wiring opening, through which the positive and negative wires are led out; A junction box includes a box body and a cover on top of the box body. The bottom of the box body is connected to the encapsulation layer. The junction box and the encapsulation layer together define an encapsulation space, and the wiring opening is located within the encapsulation space. The positive and negative wires extend through the box body to the outside of the junction box. The encapsulation space includes a first space and a second space. The wiring opening constitutes the first space, and the portion outside the first space constitutes the second space. A molecular sieve is disposed in at least one of the first space and the second space.

[0006] The solar cell module of this application improves the water-blocking performance by filling the first and second spaces with molecular sieves.

[0007] In addition, the solar cell module according to the above embodiments of this application may also have the following additional technical features: In some embodiments, at least one of the following conditions is met; The molecular sieve fills the first space; The potting compound fills the second space, and the molecular sieve is dispersed in the potting compound. This helps to improve the water-blocking performance of the solar cell module.

[0008] In some embodiments, at least one of the following conditions is met: The molecular sieve includes aluminosilicate molecular sieves; The potting compound includes at least one of epoxy potting compound and silicone potting compound. This helps to further improve the water and oxygen barrier properties of solar cell modules.

[0009] In some embodiments, the solar cell module further includes a water-blocking film that covers the wiring opening and attaches the positive and negative electrode wires to the surface of the encapsulation layer. This helps to further improve the water-blocking performance of the solar cell module.

[0010] In some embodiments, at least one of the following conditions is met: The water-blocking membrane includes at least one of a polyethylene terephthalate membrane coated with silicon dioxide and a polyethylene terephthalate membrane coated with aluminum oxide. The thickness of the water-blocking membrane is 50μm to 150μm.

[0011] In some embodiments, an adhesive layer is provided between the housing and the encapsulation layer, the adhesive layer comprising a butyl rubber layer and an adhesive layer, the butyl rubber layer being located inside the adhesive layer.

[0012] In some embodiments, at least one of the following conditions is met: The adhesive layer includes at least one of silicone adhesives, polyurethane adhesives, and epoxy adhesives; The butyl rubber layer includes at least one of single-component hot melt butyl rubber, isocyanate-based hot melt butyl rubber, and halogenated hot melt butyl rubber. The width ratio of the adhesive layer to the butyl rubber layer is (2~3):1; The thickness of the adhesive layer is 0.5mm to 2mm.

[0013] A second aspect of this application provides a method for preparing the aforementioned solar cell module, comprising: An encapsulation layer with wiring openings is formed on the surface of the solar cell; Connect the junction box body to the surface of the encapsulation layer; The molecular sieve is placed in the encapsulation space defined by the box and the encapsulation layer; The junction box cover is placed on top of the box body. Thus, the solar cell module of this application is prepared.

[0014] In some embodiments, disposing of the molecular sieve within the encapsulation space defined by the housing and the encapsulation layer includes at least one of the following: The molecular sieve is filled into the wiring opening; The mixture of the molecular sieve and potting compound is filled into the encapsulation space except for the wiring opening, and the potting compound is allowed to cure.

[0015] In some embodiments, the method further includes: covering the wiring opening with a water-blocking membrane and attaching the positive and negative wires to the surface of the encapsulation layer.

[0016] A third aspect of this application provides an electrical device including the aforementioned solar cell module. Therefore, the electrical device has a long service life. Attached Figure Description

[0017] Figure 1 This is a schematic diagram of the structure of a solar cell module according to an embodiment of this application.

[0018] Reference numerals: 1. Battery cell; 2. Encapsulation layer; 3. Junction box; 4. Positive and negative electrode wires; 5. Water-blocking film; 6. Adhesive layer; 21. Wiring opening; 31. Box body; 32. Box cover; 41. First space; 42. Second space 61. Butyl rubber layer; 62. Adhesive layer Detailed Implementation The embodiments of this application are described in detail below. The embodiments described below are exemplary and intended to explain this application, and should not be construed as limiting this application.

[0019] This application is based on the applicant's following findings and insights: In related technologies, the solar cells in solar modules are encapsulated by encapsulation materials and junction boxes, and the electricity generated by the cells is led out from the junction box through wires and connected to the external circuit. Therefore, the connection area between the junction box and the encapsulation material, as well as the area where the wires are led out, become the main channels for water and oxygen intrusion. This intrusion causes rapid performance degradation and aging of solar modules and related technologies, thus affecting the lifespan of the solar modules.

[0020] To address these issues, potting compound can be filled into the junction box, and adhesive can be used to firmly bond the encapsulation material to the junction box. However, both adhesives and potting compounds have a certain water vapor permeability (generally ranging from several grams to tens of grams under standard testing conditions), and gaps exist between the junction box body and cover, allowing water vapor to penetrate. For conventional crystalline silicon photovoltaic modules, this setup generally meets waterproofing requirements and does not affect their long-term use. However, it fails to meet the long-term use requirements for perovskite and other highly water vapor-sensitive solar cell modules.

[0021] Therefore, in the first aspect of this application, a solar cell module is proposed, referring to... Figure 1 The system includes a battery cell 1, an encapsulation layer 2, and a junction box 3. The battery cell 1 includes positive and negative conductors 4. The encapsulation layer 2 encloses the battery cell 1 and has a wiring opening 21 through which the positive and negative conductors 4 extend. The junction box 3 includes a box body 31 and a cover 32 on top of the box body. The bottom of the box body 31 is connected to the encapsulation layer 2. The junction box 3 and the encapsulation layer 2 together define an encapsulation space, and the wiring opening 21 is located within the encapsulation space. The positive and negative conductors 4 extend through the box body 31 to the outside of the junction box 3.

[0022] Furthermore, the encapsulation space includes a first space 41 and a second space 42, the wiring opening 21 constitutes the first space 41, the portion outside the first space 41 constitutes the second space 42, and a molecular sieve is disposed in at least one of the first space 41 and the second space 42.

[0023] The solar cell module of this application improves its water and oxygen barrier properties by filling the first and second spaces with molecular sieves. Specifically, molecular sieves, as an adsorbent material with a microporous structure, can precisely adsorb water molecules and oxygen. When placed in the first and second spaces, even if trace amounts of water vapor enter the solar cell module, the molecular sieves can capture these trace amounts of water vapor and oxygen, thereby controlling the humidity and oxygen content in the solar cell module at extremely low levels. This ultimately reduces the corrosion of the solar cells by water vapor and further improves the lifespan of the solar cell module.

[0024] In some embodiments, refer to Figure 1 The solar cell module also includes a water-blocking film 5, which covers the wiring opening 21 and attaches the positive and negative electrode wires 4 to the surface of the encapsulation layer 2. Specifically, the water-blocking film attaches the positive and negative electrode wires to the surface of the encapsulation layer, minimizing gaps. The water-blocking film helps to isolate moisture in the second space, preventing moisture from entering the second space or even the solar cells. This further improves the performance of the solar cell module and extends its lifespan.

[0025] In some embodiments, refer to Figure 1 An adhesive layer 6 is provided between the box body 31 and the encapsulation layer 2. The adhesive layer includes a butyl rubber layer 61 and an adhesive layer 62, with the butyl rubber layer 61 located on the inner side of the adhesive layer (the side closer to the second space). The adhesive layer 62 effectively ensures a firm bond between the box body 31 and the encapsulation layer 2. The butyl rubber layer 61 has extremely low permeability to gas and moisture; its placement on the inner side of the adhesive layer further enhances its water and oxygen barrier properties, further achieving a sealed and waterproof effect between the box body 31 and the encapsulation layer 2.

[0026] In some embodiments, refer to Figure 1 Molecular sieves are filled into the first space 41. This captures moisture entering the first space, reducing the probability of moisture further entering the solar cell. This helps improve the performance and lifespan of the solar cell module.

[0027] In some embodiments, refer to Figure 1 The second space 42 is filled with potting compound, and molecular sieves are dispersed within the potting compound. That is, the second space 42 is filled with a mixture of potting compound and molecular sieves. Although the potting compound has certain water and oxygen barrier properties, it also has a certain water vapor permeability, allowing trace amounts of water vapor to pass through and enter the second space. Dispersing the molecular sieves within the potting compound adsorbs these trace amounts of water vapor, thus effectively preventing further entry of water vapor into the second space or even the solar cell. This further enhances its water-blocking effect.

[0028] In some embodiments, the adhesive layer includes silicone-based adhesives, polyurethane-based adhesives, epoxy-based adhesives, etc. These adhesives can form a continuous adhesive interface between the housing and the encapsulation layer, firmly bonding the housing and encapsulation layer into a single unit, ensuring the structural stability of the solar cell module.

[0029] In some embodiments, the butyl rubber layer includes single-component hot-melt butyl rubber, isocyanate-based hot-melt butyl rubber, halogenated hot-melt butyl rubber, etc. The high molecular chain regularity and low branching of these butyl rubbers result in a very dense internal structure, making it difficult for moisture to penetrate through the pores between molecules, thus forming a physical waterproof layer. This helps improve the performance of solar cell modules.

[0030] In some embodiments, the width ratio of the adhesive layer to the butyl rubber layer in the adhesive layer is (2~3):1. For example, the width ratio of the adhesive layer to the butyl rubber layer can be 2:1, 2.2:1, 2.4:1, 2.6:1, 2.8:1, 3:1, etc. This ensures the structural stability of the component while also improving its water and oxygen barrier properties to a certain extent.

[0031] In some embodiments, the thickness of the adhesive layer is 0.5 mm to 2 mm. For example, the thickness of the adhesive layer can be 0.5 mm, 0.7 mm, 0.9 mm, 1.0 mm, 1.2 mm, 1.4 mm, 1.6 mm, 1.8 mm, 2 mm, etc. This helps to further ensure the structural stability of the component and maximizes the waterproof sealing effect of the component.

[0032] In some embodiments, the molecular sieve comprises an aluminosilicate molecular sieve. This molecular sieve can effectively adsorb trace amounts of water vapor. This helps control humidity within the solar cell module, thereby contributing to improved module performance.

[0033] In some embodiments, the potting compound includes epoxy potting compound, silicone potting compound, etc. The above-mentioned potting compounds have good flexibility and impact resistance, fast curing speed, and can be rapidly molded at room temperature. At the same time, they have low water vapor permeability, providing excellent moisture barrier properties.

[0034] In some embodiments, the mass ratio of molecular sieve to potting compound in the second space is (5~30):(70~95). For example, the mass ratio of molecular sieve to potting compound in the second space can be 5:95, 30:70, 20:80, 10:90, etc. This helps to achieve the dual effect of external water resistance and internal dryness.

[0035] In some embodiments, the water-blocking membrane can be a polyethylene terephthalate membrane coated with silicon dioxide, a polyethylene terephthalate membrane coated with aluminum oxide, etc. The above-mentioned water-blocking membranes have extremely low water vapor permeability and can maintain their barrier properties for a long time in high-temperature and high-humidity environments.

[0036] In some embodiments, the thickness of the water-blocking film is 50 μm to 150 μm. Specifically, the thickness of the water-blocking film can be 50 μm, 70 μm, 90 μm, 100 μm, 120 μm, 140 μm, 150 μm, etc. A water-blocking film with a thickness within the above range ensures excellent water-blocking performance, while also helping to minimize the gap between the water-blocking film and the encapsulation layer.

[0037] In some embodiments, the width by which the edge of the water-blocking membrane extends beyond the wiring opening is not limited. It can be adjusted according to process requirements. The goal is to ensure the water-blocking effect of the water-blocking membrane, making it difficult for moisture to enter the first space from the wiring opening.

[0038] The solar cell of this application has the following beneficial effects: The butyl rubber layer acts as the first line of defense against water and oxygen, effectively preventing moisture and oxygen from entering the junction box. The mixture of potting compound and molecular sieve absorbs moisture intruding into the box (second space), further slowing its penetration into the second space and even the solar cells. The water-blocking film has excellent water-blocking properties, further preventing moisture from entering the second space. The molecular sieve filling the second space is the final line of defense against water intrusion, effectively absorbing any intruding moisture. With this quadruple waterproofing, the solar cell module of this application effectively prevents moisture intrusion.

[0039] In a second aspect of this application, a method for preparing the aforementioned solar cell module is provided, comprising: S10: An encapsulation layer with wiring openings is formed on the surface of the solar cell.

[0040] In this step, for example, the battery cell is placed on the surface of the encapsulation substrate. According to the actual installation position of the junction box, the position and size of the wiring opening are marked on the encapsulation film. A special mold is used to pre-drill holes in the encapsulation film. Finally, the encapsulation film with holes is covered on the surface of the battery and cured and bonded.

[0041] S20: Connect the junction box body to the surface of the encapsulation layer.

[0042] In this step, first determine the location of the junction box. For example, mark the target position where the box body and the encapsulation material will contact each other, and apply adhesive and butyl glue to the corresponding positions (butyl glue applied to the inside). Simultaneously, attach the positive and negative electrode wires of the battery cell to the surface of the encapsulation layer (the length of the wires attached to the surface of the encapsulation layer can be changed according to the actual situation), ultimately leading the wires out from the wiring holes on the side wall of the junction box. Then place the box body on the adhesive layer according to the target position and allow it to cure naturally.

[0043] Furthermore, after the adhesive layer mentioned above has cured naturally, an appropriate amount of adhesive can be applied to the outside of the junction box. This further improves the seal between the junction box and the encapsulation layer.

[0044] S30: The molecular sieve is placed in the encapsulation space defined by the box and the encapsulation layer.

[0045] In this step, the molecular sieve is first filled into the wiring opening (i.e., the first space), and then the mixture of the molecular sieve and potting compound is filled into the encapsulation space (i.e., the second space) excluding the wiring opening, and the potting compound is cured.

[0046] In some embodiments, before filling the encapsulation space (excluding the wiring opening) with the mixture of molecular sieve and potting compound, the method further includes: covering the wiring opening with a water-blocking film and attaching the positive and negative electrode wires to the surface of the encapsulation layer. That is, the positive and negative electrode wires are sandwiched between the water-blocking film and the encapsulation material.

[0047] S40: Place the cover of the junction box on the top of the box body.

[0048] The specific steps for this process are not limited. Simply place the lid on top of the box and glue it in place, following standard procedures.

[0049] In a third aspect of this application, an electrical device is provided, including the aforementioned solar cell module. Therefore, the electrical device has a long service life.

[0050] In some embodiments, the solar cell module can be used as a power source for the electrical device or as an energy storage unit for the electrical device. The electrical device may include, but is not limited to, lighting fixtures, electric bicycles, electric vehicles, etc.

[0051] In the description of this application, it should be understood that the terms "first" and "second" are used for descriptive purposes only and should not be construed as indicating or implying relative importance or implicitly specifying the number of technical features indicated. Therefore, a feature defined as "first" or "second" may explicitly or implicitly include at least one of that feature. In the description of this application, "multiple" means at least two, such as two, three, etc., unless otherwise explicitly specified.

[0052] In the description of this specification, the references to terms such as "one embodiment," "some embodiments," "example," "specific example," or "some examples," etc., indicate that a specific feature, structure, material, or characteristic described in connection with that embodiment or example is included in at least one embodiment or example of this application. In this specification, the illustrative expressions of the above terms do not necessarily refer to the same embodiment or example. Furthermore, the specific features, structures, materials, or characteristics described may be combined in any suitable manner in one or more embodiments or examples. Moreover, without contradiction, those skilled in the art can combine and integrate the different embodiments or examples described in this specification, as well as the features of different embodiments or examples.

[0053] Although embodiments of this application have been shown and described above, it is understood that the above embodiments are exemplary and should not be construed as limiting this application. Those skilled in the art can make changes, modifications, substitutions and variations to the above embodiments within the scope of this application.

Claims

1. A solar cell module, characterized in that, include: The battery cell includes positive and negative electrode wires; An encapsulation layer, which encapsulates the battery cell and has a wiring opening, through which the positive and negative wires are led out; A junction box, comprising a box body and a cover disposed on the top of the box body, the bottom of the box body being connected to the encapsulation layer, the junction box and the encapsulation layer together defining an encapsulation space, and the wiring opening being located within the encapsulation space, the positive and negative wires extending through the box body to the outside of the junction box; The encapsulation space includes a first space and a second space, the wiring opening constitutes the first space, and the portion outside the first space constitutes the second space; a molecular sieve is disposed in at least one of the first space and the second space.

2. The solar cell module according to claim 1, characterized in that, At least one of the following conditions must be met; The molecular sieve fills the first space; The potting compound fills the second space, and the molecular sieve is dispersed in the potting compound.

3. The solar cell module according to claim 1, characterized in that, At least one of the following conditions must be met: The molecular sieve includes aluminosilicate molecular sieves; The potting compound includes at least one of epoxy potting compound and silicone potting compound.

4. The solar cell module according to claim 1, characterized in that, It also includes a water-blocking membrane, which covers the wiring opening and attaches the positive and negative wires to the surface of the encapsulation layer.

5. The solar cell module according to claim 4, characterized in that, At least one of the following conditions must be met: The water-blocking membrane includes at least one of a polyethylene terephthalate membrane coated with silicon dioxide and a polyethylene terephthalate membrane coated with aluminum oxide. The thickness of the water-blocking membrane is 50μm to 150μm.

6. The solar cell module according to claim 1, characterized in that, An adhesive layer is provided between the box body and the encapsulation layer. The adhesive layer includes a butyl rubber layer and an adhesive layer, with the butyl rubber layer located inside the adhesive layer.

7. The solar cell module according to claim 1, characterized in that, At least one of the following conditions must be met: The adhesive layer includes at least one of silicone adhesives, polyurethane adhesives, and epoxy adhesives; The butyl rubber layer includes at least one of single-component hot melt butyl rubber, isocyanate-based hot melt butyl rubber, and halogenated hot melt butyl rubber. The width ratio of the adhesive layer to the butyl rubber layer is (2~3):1; The thickness of the adhesive layer is 0.5mm to 2mm.

8. A method for preparing a solar cell module according to any one of claims 1 to 7, characterized in that, include: An encapsulation layer with wiring openings is formed on the surface of the solar cell; Connect the junction box body to the surface of the encapsulation layer; The molecular sieve is placed in the encapsulation space defined by the box and the encapsulation layer; The junction box cover is placed on top of the box body.

9. The method according to claim 8, characterized in that, The molecular sieve is disposed in the encapsulation space defined by the housing and the encapsulation layer, including at least one of the following: The molecular sieve is filled into the wiring opening; The mixture of the molecular sieve and potting compound is filled into the encapsulation space except for the wiring opening, and the potting compound is allowed to cure.

10. The method according to claim 8, characterized in that, Also includes: A water-blocking membrane is placed over the wiring opening, and the positive and negative wires are attached to the surface of the encapsulation layer.

11. An electrical appliance, characterized in that, The solar cell module includes any one of claims 1 to 7.

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