A solar module and an assembling process thereof

Abstract

The application discloses a solar module and an assembling process thereof, and belongs to the technical field of solar photovoltaic. The solar module comprises a laminated piece, an insulating sealing edge tape attached to the edge of the laminated piece, and a metal frame installed around the laminated piece. The insulating sealing edge tape comprises an insulating base material layer and an adhesive layer, and a micropore penetrating through the insulating base material layer and the adhesive layer is arranged on the insulating sealing edge tape. In the laminating and vacuumizing stage, the micropore is used to discharge the air and volatile components inside the laminated piece, so that the generation of bubbles at the edge of the module is avoided. After the laminating, the micropore is completely closed by flexible local hot melting and pressurizing, so that the long-term moisture-proof sealing performance is ensured. In addition, the U-shaped attachment of the tape prolongs the electrical creep path of the cell group to the external metal frame, and the electrical safety under the high-voltage system is improved.

Description

Technical Field

[0001] This invention relates to the field of solar module technology, and more specifically to a solar module and its assembly process. Background Technology

[0002] In the manufacturing process of solar photovoltaic modules, edge sealing and insulation protection are key aspects that determine the long-term service life and electrical safety performance of the modules. During their outdoor service life of more than 25 years, photovoltaic modules are highly susceptible to exposure to harsh climatic conditions such as high temperature, high humidity, and strong ultraviolet radiation. Once external moisture or water vapor penetrates the module, it can easily lead to cell oxidation and corrosion, PID (potential-induced degradation) effect, and a sharp drop in system insulation impedance.

[0003] Currently, traditional solar module manufacturing processes typically use non-porous edge-sealing tape to seal the edges of the laminated components before sending them into lamination equipment for high-temperature vacuuming and lamination. However, this traditional design presents the following irreconcilable technical conflicts in actual production: During the vacuuming stage of lamination, the traditional edge-sealing tape forms a nearly sealed annular barrier, severely hindering the expulsion of residual air inside the laminated components and small-molecule volatile organic compounds (VOCs) generated by heating in the polymer encapsulation materials (such as EVA and POE). This easily leads to the formation of localized trapped air bubbles at the module edges. These edge bubbles not only reduce the yield of the modules but also become potential channels for moisture penetration and partial discharge during future outdoor use. If highly permeable fabrics or porous tapes are used for venting, although this facilitates venting during the vacuuming stage, the microchannels cannot be closed later, allowing moisture to easily seep back into the module along the tape's micropores during the service life, leading to complete seal failure.

[0004] Furthermore, with the increase in photovoltaic system voltage, the safety insulation resistance and creepage distance requirements between energized components (cells, busbars) and the external grounded aluminum frame increase exponentially under high-voltage operating conditions. In traditional module structures, the creepage path from the cell to the frame is mainly limited by the edge thickness of the first and second panel glass, making it highly susceptible to insulation breakdown or leakage when encountering high-voltage surges or humid environments.

[0005] During the transfer and positioning stage of the stacked components into the laminator, since the encapsulating film does not have the function of restricting slippage before melting, the first panel, the second panel and the middle battery cell group are prone to relative misalignment or uneven lamination during the high flow rate of the molten film, resulting in poor assembly alignment accuracy.

[0006] Therefore, developing a solar module structure and its assembly process that can ensure smooth venting during the lamination vacuuming stage, provide a long-term dense and waterproof seal after lamination, significantly improve the system's electrical creepage distance, and avoid lamination misalignment is a technically challenging problem of great industrial value that urgently needs to be solved in this field. Summary of the Invention

[0007] The purpose of this invention is to solve the problems in the prior art where lamination venting and long-term waterproof sealing are contradictory, electrical creepage distance is insufficient under high voltage operating conditions, and lamination components are prone to relative misalignment during the lamination process.

[0008] To achieve the above objectives, the present invention specifically adopts the following technical solution:

[0009] In a first aspect, the present invention provides a solar module, comprising: a laminate including a first panel, a second panel, and a cell assembly located between the first panel and the second panel; an encapsulating film between the cell assembly and the first panel, and between the cell assembly and the second panel; and an insulating sealing tape applied to the edge of the laminate; wherein the insulating sealing tape is configured such that: the insulating substrate layer has micropores penetrating its thickness direction for lamination venting and subsequent heat-sealing, and / or the adhesive layer has micropores penetrating its thickness direction for lamination venting and subsequent heat-sealing.

[0010] The micropores are configured to remain open during the lamination vacuuming stage of the laminate to expel air from inside the laminate, and to be heated and melted closed during the heating and pressurization stage after the lamination vacuuming stage to achieve sealing of the edge of the laminate. During the heating and pressurization stage, only the insulating sealing tape on the side is heated and pressurized, which is different from the heating and pressurization position of the laminate in the prior art.

[0011] In this invention, the heat-meltable micropore design on the insulating edge sealing tape enables the same edge sealing tape to possess diametrically opposed technical properties at different stages of lamination assembly: during the early vacuuming stage of lamination, the micropores remain geometrically open, providing outward-pointing microchannels for the gas inside the laminate and preventing edge bubbles from forming; while in the local heat-melting section after lamination, the tape undergoes micro-melting at a temperature higher than its melting point and under mild pressure, and the polymer chain recombination and flow cause the micropores to completely close and disappear, transforming into a seamless, water-impermeable, dense water-blocking shield.

[0012] Preferably, the diameter of the micropores is Preferred The diameter of the micropores has a decisive influence on venting and closure performance. If the pore diameter is smaller than... Due to the extremely low gas conductivity, the resistance to gas discharge during vacuuming increases dramatically, making it very easy for microbubbles to form locally; if the pore size is larger than... If the volume of the molten fluid required for hot-melt closure is too large, it cannot be completely sealed by its own capillary and flexible extrusion within the limited hot-pressing time, resulting in residual physical pathways.

[0013] Preferably, the distribution density of the micropores on the insulating sealing tape is: Preferred .

[0014] Preferably, the diameter of the micropores The thickness of the insulating sealing tape Satisfying the relation: Limiting the ratio of micropore diameter to tape thickness ensures the aspect ratio of the micropores along the tape thickness direction. If this ratio is less than... If the micropores are too deep and narrow, the gas flow resistance is too high, and the gas inside the pore wall is difficult to escape during heat melting; if the ratio is greater than If the micropores are too wide, the molten material cannot achieve sufficient cross-linking and sealing at the thickness level, and after hot melting, the micropores are prone to depression, thinning, or even thermal perforation.

[0015] Preferably, the sum of the cross-sectional areas of all micropores per meter along the length of the insulating sealing tape is... The width of the insulating sealing tape satisfy: (in The unit is , The unit is This area ratio reflects the effective gas flow characteristics of the tape. If the ratio is less than... If the exhaust rate is too slow, airflow will stagnate during the lamination vacuuming stage; if it is greater than... The excessively large total cross-sectional area of ​​the micropores leads to a significant decrease in the mechanical strength and electrical insulation tensile strength of the tape after heat fusion closure.

[0016] Preferably, the distribution density of the micropores With respect to the diameter of the micropore satisfy: This relationship further provides precise constraints on the size and spatial arrangement of the micropores.

[0017] Preferably, the micropores are tapered, with the opening diameter of the tape on the side facing the laminate being larger than the opening diameter on the side facing outwards. This tapered design provides a larger trapping cross-section on the inner side of the tape to facilitate airflow entry, while the smaller aperture on the outer side allows for faster melting and sealing of the outer surface under the pressure of the pressure head during hot melting.

[0018] Preferably, the adhesive layer has multiple air-guiding microchannels on its surface facing the laminate. These microchannels are connected to the micropores and extend to the edge of the insulating sealing tape. After the tape is applied, the microchannels act as lateral collectors, rapidly gathering residual gas at the interface between the laminate edge and the tape application point along the microgrooves on the tape surface to the nearest micropore and venting it out, thus solving the industry problem of localized air bubble trapping at the tape adhesion interface. During the subsequent heat-melting stage, the microchannels and micropores melt and disappear together.

[0019] Preferably, the insulating sealing tape has a thermosensitive color-changing indicator area on its outer surface surrounding the micropores. This area uses irreversible thermosensitive color-changing ink. When the local hot-melt pressure temperature reaches a specific energy threshold for complete melt closure of the micropores, a striking color change occurs in this area, which is highly beneficial for automatic quality judgment and quality traceability by the online AOI automatic optical inspection system on the production line.

[0020] Preferably, the insulating substrate layer is made of polyolefin (such as polyethylene, polypropylene or polybutene), polyester, polyimide, polyurethane or fluorinated polymer; the adhesive layer is made of high-strength polyacrylate, polyamide, epoxy resin or thermoplastic polyolefin elastomer with hot melt flowability.

[0021] The insulating substrate layer has a first softening temperature. The adhesive layer has a second softening temperature. And the first softening temperature With the second softening temperature satisfy: By limiting the softening temperature difference between the insulating substrate layer and the adhesive layer, it is ensured that both can soften synchronously and enter the rheological state during the hot-pressurized pore-closing process. This avoids defects such as excessive melting and dilution of the adhesive due to excessive temperature difference in softening points, or delamination and cracking or incomplete closure of the micropores due to insufficient softening of the substrate layer. This significantly improves the degree of intermolecular entanglement and homogeneous bonding after the micropores are closed by hot-melt.

[0022] Preferably, the thickness of the insulating sealing tape is [missing information]. Preferred .

[0023] To ensure that the present invention is applicable not only to conventional voltages, but especially to… even and Even under ultra-high voltage systems, it maintains excellent electrical safety. The initial thickness design of the tape in this invention is highly targeted: preferably, the thickness of the insulating sealing tape is... With the operating voltage of the solar module satisfy: .

[0024] Furthermore, the initial thickness of the insulating sealing tape The specific correspondence between the component's operating voltage and the voltage is as follows: When hour, ;when hour, ;when hour, Because the tape undergoes shear stress flow during the high-temperature, high-pressure heat fusion closure of micropores, the thickness around the micropores and the tape itself inevitably experiences a certain degree of localized stretching and thinning. This invention limits the thickness retention rate and residual insulation thickness after closure. ,Require and This allowance was intentionally added in the initial tape design to ensure that the insulation thickness at weak points after melting and deformation remains above the safe threshold for electrical breakdown, guaranteeing the entire component's resistance to DC current. No breakdown was detected in the HIPOT test.

[0025] Preferably, the insulating sealing tape has a U-shaped cross-section after application, and the two sides of the U-shape are respectively bonded to the outer surfaces of the first panel and the second panel, with a bonding width of [missing information]. At this point, the insulating sealing tape reconfigures the electrical creepage path from the battery pack to the external metal frame. Without the tape, the creepage path primarily involves the battery cell edges directly passing through the air / film interface at the edges of the first and second panel glass to reach the metal frame; this distance is extremely short, approximately equal to the glass thickness and the edge retraction distance. After applying the U-shaped insulating tape of this invention, the electrical creepage path changes to extend from the edge of the battery pack to the outer surface of the first / second panel, then further creeps along the outer surface of the insulating sealing tape to the end edge of the tape, finally reaching the metal frame. The creepage distance formula is as follows: By adjusting the bonding width It can easily extend the electric creepage distance. The above completely blocks the high-voltage discharge and leakage current path.

[0026] Preferably, the insulating sealing tape is, but is not limited to, a transparent white type, wherein the white insulating sealing tape contains titanium dioxide, with a mass fraction of [missing information]. It can reflect the light that would otherwise be lost at the edge of the module back into the first panel glass to form total internal reflection, increasing the secondary absorption of the cells and improving the photoelectric conversion efficiency of the module. At the same time, titanium dioxide gives the tape excellent resistance to ultraviolet aging.

[0027] Preferably, the insulating sealing tape includes, along its width, a central area, a first edge area, and a second edge area. The central area corresponds to the circumferential end face of the laminate, and the first and second edge areas correspond to the outer surfaces of the first and second panels, respectively. The thickness of both the first and second edge areas is less than the thickness of the central area. This design ensures both the physical impact strength and high-voltage insulation safety of the main side surface, while also reducing the edge protrusion height when the tape adheres to the first and second panels, facilitating component arrangement and subsequent aluminum frame assembly, and resulting in a more seamless fit of the tape edges.

[0028] Preferably, the adhesive layer is only provided in the first and second edge areas of the insulating sealing tape, and no adhesive layer is provided in the middle area. The middle side of the laminate is mostly molten adhesive film overflowing. The absence of an adhesive layer in this area can completely prevent excessive overflow of tape adhesive and adhesion to the heating head during lateral hot-melt pressure.

[0029] Preferably, the insulating sealing tape further includes a waterproof barrier layer, the waterproof barrier layer having a thickness of [missing information]. It consists of at least one of a thin metal film (such as aluminum or titanium), an inorganic metal oxide (such as aluminum oxide), or silicon oxide, disposed on the surface of an insulating substrate layer, thereby providing an extremely high waterproof barrier with almost zero water vapor permeability.

[0030] Preferably, the melting point temperature of the insulating sealing tape is... The actual temperature during the vacuuming stage of the lamination process satisfy: In the material system of this invention, the insulating substrate layer material does not need to be a high-melting-point heat-resistant material; it only needs to ensure that its melting temperature is slightly higher than the upper limit equilibrium temperature of the vacuuming stage (e.g., higher than...). This ensures the geometric integrity of the pore skeleton during the extraction stage. Relaxing the blending and compounding boundaries of industrial film particle resins facilitates control of tape extrusion yield and can significantly reduce the extreme heating temperature and thermodynamic load required for the later localized heat-pressurized pore-closing stage.

[0031] Secondly, the present invention provides an assembly process for the solar module, comprising the following steps:

[0032] S1. Stacking: The first panel, the first encapsulating film, the battery cell group, the second encapsulating film and the second panel are stacked in sequence to form the part to be laminated;

[0033] S2, edge sealing application: Apply insulating edge sealing tape to the four edges of the part to be laminated, and make it wrap around in a U-shape. The two sides of the U-shape of the insulating edge sealing tape are respectively bonded to the outer surfaces of the first panel and the second panel to fix the first panel and the second panel and prevent misalignment.

[0034] S3, Lamination Vacuuming: The part to be laminated with the insulating sealing tape is fed into the lamination equipment for lamination, and during the vacuuming stage of lamination, the air and volatiles inside the part to be laminated are discharged through the micropores penetrating the insulating sealing tape.

[0035] S4. Micropore Closure: The insulating sealing tape is subjected to heat-melting and pressurizing treatment, so that the insulating sealing tape at the micropores is heated and slightly melted and closed under pressure to seal the edge of the laminate.

[0036] Preferably, in step S4, the heating temperature of the hot melt pressurization process is: Preferred The heating temperature, melting time, and pressure must be closely matched: if the temperature is too low, the tape substrate and adhesive layer will not reach a fully melted and viscous flow state, making complete fusion and cell closure impossible; if the temperature is too high (e.g., exceeding...),... The tape material is prone to thermal degradation and aging, and its low molten viscosity easily leads to localized material being pushed apart under pressure, forming holes. In the process design of this invention, the heating temperature... Melting point temperature of insulating edge sealing tape satisfy: This temperature margin provides an optimal balance between surface melting activity and bulk strength.

[0037] Preferably, in step S4, the hot-melt pressurization process employs a flexible contact method, with pressure applied through a flexible tooling (such as elastic high-tear silicone or an inflatable flexible airbag), and the pressure range being [insert range here]. Preferred The component edges include brittle glass panels (first / second panels) and thin, fragile solar cells near the edges. Any rigid thermoforming contacts will cause catastrophic localized stress concentrations in the face of glass imperfect flatness, leading to crushing or microcracks. The flexible contact surfaces of the flexible tooling... Under its action, it can conform extremely gently, smoothly, and evenly to the arcs and corners of the U-shaped tape, providing isotropic closing pressure. The Shore hardness of the elastomer on the contact surface of the flexible tooling... With applied local pressure satisfy: This constraint ensures that the flexible tooling has appropriate micro-deformation compliance, preventing it from being too stiff and causing local pressure peaks that could damage the glass, or from being too soft and causing excessive swaying under pressure, thus failing to compact the micropores.

[0038] Preferably, in step S4, the heating time for the hot melt pressurization process is... And heating time With the thickness of insulating edge sealing tape satisfy: This ensures that heat has sufficient time to conduct symmetrically and evenly across the thickness of the tape, guaranteeing that the micropores are completely melted throughout the penetration direction without leaving any dead zones.

[0039] Preferably, in step S3, the vacuuming stage of the lamination includes a first stage and a second stage; the vacuuming rate of the first stage is... The vacuuming rate in the second stage is The rapid initial and slow subsequent air extraction control allows a large volume of free air to be rapidly extracted in a very short time. The subsequent slowing of the flow rate enables the polymer encapsulation film (EVA / POE, etc.) in a molten shear state at the edge of the laminate to slowly, uniformly, and precisely creep and fill the edge gap without violent shearing splashing or vacuum peeling.

[0040] Preferably, in step S3, when the distribution density of the micropores... The duration of the vacuuming phase of the lamination process. With the distribution density satisfy: This mathematical relationship characterizes the coupling law between gas transport efficiency and the number of micropore openings. When the micropores are densely packed, the auxiliary vacuum exhaust time can be shortened accordingly, achieving an extremely fast-paced production line for components.

[0041] Preferably, in step S2, after the insulating sealing tape is applied and wrapped, a roller or pressure strip structure is used to apply pressure to the insulating sealing tape. The pre-pressure and holding time are A room temperature settling process is set between step S2 and step S3. Pre-compression and sufficient room temperature wetting time allow the pressure-sensitive adhesive layer to fully flow and wet the pits and depressions on the surfaces of the first and second panel glass at the microscopic level, achieving an initial peel strength of [value missing]. The above ensures that the front and back panels are fully constrained during the initial conveying and heating phases of the laminator, thus minimizing alignment errors. .

[0042] Compared with the prior art, the beneficial effects of the present invention are as follows:

[0043] 1. The micropores of the insulating sealing tape used in this invention can be heat-melted and closed. During the lamination vacuum stage, the micropores remain open, allowing air and volatile gases inside the laminate to be smoothly discharged, preventing air bubbles from forming at the edges of the component. After the air is discharged, localized heat melting and pressurization cause the tape substrate to micro-melt at a specific temperature and close the micropores, thereby achieving a completely dense and water-impermeable seal, significantly improving the moisture resistance of the component, and significantly reducing its water vapor permeability.

[0044] 2. The insulating tape of this invention possesses excellent electrical insulation properties. By applying a U-shaped structure, the insulating tape covers the edges of the laminate. Compared to a structure without tape, this assembly redirects electrical creepage paths from the edges of the battery cells. The edges of the front / second panel are significantly extended to match the edges of the battery cells. Front / Second Panel Edge Extending along the surface of the insulating tape to its edge, it effectively blocks the discharge path between the battery cell assembly and the external aluminum frame, significantly improving the safety and high-voltage resistance of the module.

[0045] 3. In this invention, the first and second panels are applied and fixed before being fed into the laminator by means of insulating sealing tape. In the high temperature and high pressure flow channel of lamination, the relative misalignment of the second panel can be effectively prevented, thereby improving the alignment accuracy and yield of the lamination process. Attached Figure Description

[0046] Figure 1 This is a cross-sectional schematic diagram of the structure of the present invention.

[0047] Figure reference numerals: 10, laminate; 11, first panel; 12, second panel; 13, cell assembly; 14, encapsulating film; 20, insulating edge sealing tape; 21, micropore; 30, frame silicone; 40, metal frame; L2, conventional electrical creepage distance of the module without tape ( Figure 1 The path shown by the yellow line); L1, after applying the tape, the newly added electrical creepage path along the surface of the tape at the edge of the battery cell ( Figure 1 (Path shown by the red line). Detailed Implementation

[0048] The technical solutions of the present invention will be clearly and completely described below with reference to the embodiments of the present invention. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those of ordinary skill in the art without creative effort are within the scope of protection of the present invention.

[0049] Please see Figure 1 A solar module and its assembly process are described below, with specific embodiments and comparative examples:

[0050] I. Manufacturing and Preparation Instructions for Insulating Edge Sealing Tape 20 and Microchannel Universal Application

[0051] The manufacturing process of the insulating sealing tape 20 involved in this invention is as follows:

[0052] 1. Select insulating polymer base material particles with a specified ratio, such as polypropylene, polyester, polyimide, etc. If white insulating edge sealing tape 20 is to be prepared, the above resin particles and titanium dioxide particles are mixed evenly and then fed into a twin-screw extruder for extrusion casting; if transparent insulating edge sealing tape 20 is to be prepared, the above high-purity resin particles are directly fed into a twin-screw extruder for extrusion casting, thereby obtaining a specific thickness ( It also possesses a certain elongation at break and relative temperature index (RQ). A transparent or white insulating substrate layer.

[0053] In this general preparation, the insulating substrate layer has a specific first softening temperature. The adhesive layer has a specific second softening temperature. And satisfy: When testing the softening temperature, the Vicat softening temperature of the insulating substrate layer is tested according to GB / T1633 standard, and the softening temperature of the adhesive layer is tested according to GB / T12007.6 ring and ball method standard.

[0054] 2. If a waterproof barrier layer is required, a roll-to-roll vacuum magnetron sputtering system is used to sputter and deposit a dense inorganic water-blocking barrier, such as a metallic aluminum film, silicon dioxide, or aluminum oxide, onto the upper surface of the insulating substrate layer. The sputtering thickness is controlled within [specific parameters]. This is to prevent water vapor molecules from penetrating along the gaps between the polymer chains of the substrate while maintaining the flexibility of the insulating sealing tape 20.

[0055] 3. Apply an adhesive layer of a predetermined thickness, using a pressure-sensitive or heat-sensitive elastic adhesive, to the other surface of the substrate layer. After coating, use a precision embossing roller with specific embossed micro-stripes to roll out multiple parallel and staggered air-guiding microchannels on the adhesive surface of the adhesive layer facing the component. The depth of the air-guiding microchannels is... The channel spacing is .

[0056] 4. After coating and grooving are completed, the insulating sealing tape 20 is fed to a CNC high-speed pulsed laser drilling machine or an ultra-fine die-cutting needle-punching shaft for micro-hole 21 processing. By adjusting the laser pulse energy and focal spot diameter, conical micro-holes 21 are processed that penetrate the substrate layer and adhesive layer, with a larger diameter facing the glass side and a smaller diameter facing the outside. The laser thermodynamic effect is used to create a rounded or chamfered structure at the edge of the hole, with a chamfer radius / rounded corner radius of [value missing]. This is to prevent the micropores 21 from collapsing prematurely before exhaust due to uneven stress at the sharp corners of the edges during lamination.

[0057] 5. Using a micro-dot inkjet coating system, a ring of indicator ink containing microencapsulated thermochromic pigment is precisely printed on the outer surface of the insulating edge sealing tape 20 and around the circumference of each microhole 21, thereby producing an edge sealing insulating edge sealing tape 20 with thermosensitive melt monitoring characteristics.

[0058] II. Detailed Manufacturing Process and Parameters of Specific Embodiments

[0059] Example 1, applicable to System. This embodiment provides a system suitable for operating voltage. Specifications of double-glass tempered photovoltaic modules and their manufacturing process, with a cross-sectional view as follows. Figure 1 As shown, the specific process steps and material parameters are as follows:

[0060] S1. Stacking Steps: Thickness... The first panel 11 of the ultra-white patterned tempered glass is made of highly cross-linked POE resin with a thickness of [missing information]. The first encapsulating film 14, made of 182 size and Thick N-type monocrystalline bifacial TOPCon solar cells are connected in series via multiple main grid ribbons to form a solar cell assembly 13, made of a high water-resistant EPE composite film with a thickness of [missing information]. The second encapsulating film 14, and its thickness The tempered float glass backing glass second panel 12 is stacked sequentially from bottom to top and aligned to form the laminate 10.

[0061] The external dimensions of the first panel 11 and the second panel 12 are both The encapsulating film 14 has a circumferentially inward-sloping shape, and the distance between its edge and the outer edge of the first panel 11 and the second panel 12 remains constant. This creates stepped groove spaces around the perimeter.

[0062] S2. Edge Sealing and Applying Steps: After the laminated parts 10 are completed, they are fed into the online automatic edge sealing and film applying machine via a conveyor line. The process is carried out at an ambient temperature of [temperature missing]. The relative humidity of the environment is Insulating edge sealing tape 20 is applied under a stable production environment.

[0063] Insulating edge sealing tape 20 structure and material selection: The initial total thickness of the insulating edge sealing tape 20 used is... The thickness of the white polypropylene (PP) insulating substrate layer is [missing information]. Its relative temperature index The breakdown voltage is Tracking index The adhesive layer uses hot-melt modified acrylic pressure-sensitive adhesive, with a thickness of [missing information]. The PP insulating substrate is uniformly blended with a mass fraction of Rutile titanium dioxide ( ), reflectivity .

[0064] Material physical properties: In this embodiment, the melting point temperature of the white polypropylene (PP) insulating substrate is... Its first softening temperature is The adhesive layer, an acrylic pressure-sensitive adhesive, has a second softening temperature. The difference in softening temperatures between the two satisfies } The range.

[0065] Geometric parameters of micro-aperture 21: Micro-aperture 21 is formed by drilling with a numerically controlled pulsed carbon dioxide laser. Micro-aperture 21 has a circular conical hole structure and a diameter of... Micropore 21 depth-to-diameter ratio The micropores 21 are arranged in a single row with equal spacing along the length of the insulating sealing tape 20, with a distribution density of... .

[0066] Parameter calculation matching: product of density and diameter squared The sum of the cross-sectional areas of all micropores 21 per meter along the length of the insulating sealing tape 20. Insulating edge sealing tape, 20mm width area ratio .

[0067] Gradient Distribution and Microchannels: After application, the micropores 21 are located in the middle bend of the U-shaped insulating sealing tape 20, corresponding to the side wall end face of the laminate 10. The thickness of this middle zone is... The thickness gradient of the first and second edge regions, which are attached to the glass surface on both sides, is reduced to [a certain value]. Apply adhesive. The adhesive surface has a depth of [missing information]. The channel spacing is It is also connected to the longitudinal parallel air guiding microchannel of micropore 21.

[0068] A thermosensitive color-changing ring is provided around the outer surface of the micropore 21.

[0069] Application process control: Before applying the insulating edge sealing tape 20, the infrared heating plate on the automatic edge sealing machine preheats the insulating edge sealing tape 20 with infrared radiation online, raising the temperature of the insulating edge sealing tape 20 to [temperature value missing]. The preheating time is Subsequently, insulating sealing tape 20 is tightly wrapped in a U-shape around the four edges of the stacked components. After application, the film-applying roller immediately applies pressure to both sides of the insulating sealing tape 20. The clamping pressure, and maintaining pressure on each bonding surface. Ensure the insulating sealing tape 20 is completely wetted and adhered to the glass surface. After sealing, place the assembly on a resting rack and allow it to rest at room temperature. At room temperature, insulating edge sealing tape 20 and glass panel Peel strength measurement value The dynamic shear strength measurement value is .

[0070] S3. Lamination Vacuuming Step: After settling, the components are fed into a double-layer automatic laminator. The heating temperature of the laminator's base plate is set and maintained. When the upper rubber chamber is raised, the assembly enters the lower chamber and closes, and the two-stage rotary vane vacuum pump is immediately started to perform multi-stage vacuuming.

[0071] First stage of vacuuming: In the initial stage With a relatively fast pumping speed Pump the air pressure to This quickly extracts a large amount of free air from the edges of the cavity and components.

[0072] Second stage of vacuuming: The vacuuming rate is then automatically reduced. Slowly and steadily pump to the ultimate vacuum level. Total duration of the vacuuming phase During vacuuming, the melting point temperature of the 20PP substrate of the insulating edge sealing tape is... The actual equilibrium temperature at the edge of the component during the vacuuming phase. Temperature difference This ensures that the micropore 21 framework will not prematurely melt and close under strong airflow and temperature. The residual trace air inside the module and the organic volatile components generated by the heating of the adhesive film are smoothly collected into the conical micropore 21 through the gas guiding microchannel and discharged outward, with no gas obstruction at the edge of the entire module.

[0073] S4, Micropore 21 Closure Step: After vacuuming, the laminator airbag inflates and presses down, with a lamination pressure of [value missing]. The temperature is maintained at ,Keep The encapsulating film undergoes high-temperature cross-linking and curing. After the lamination and curing process is completed, the component is transferred by a robotic arm to the edge localized hot melt station.

[0074] The edge hot pressing equipment uses four sets of pneumatically-driven hot pressing steel bars arranged around the perimeter of the component. A high-strength, high-temperature-resistant fluorosilicone rubber flexible cushioning pad is firmly wrapped around the pressing contact surface of the hot pressing steel bars. (Shore hardness...) Temperature. Control the heating temperature of the local hot press head. The hot press head applies pressure locally to the micropores 21 area of ​​the insulating sealing tape 20. The uniform pressure, at which point the ratio of the Shore hardness of the flexible contact elastomer to the local compressive strength is determined. The duration of localized hot-melt pressurization is set to... Under these temperature and pressure conditions, the softening temperature difference between the substrate layer and the adhesive layer is only... The softening thermal flow states of the two materials are highly synergistic, and the molecules of the two layers undergo eutectic melting under thermal pressure. The interface molecules within the micropores 21 undergo mutual creep, entanglement, and fusion upon heating, while the microchannels simultaneously collapse, achieving complete melt sealing of the micropores 21 with a closure rate of [percentage missing]. .

[0075] As the heat is fully melted, the irreversible thermosensitive color-changing ring around the microhole 21 undergoes a phase change reaction, changing from the initial white to bright blue. The color difference sensor of the AOI industrial camera mounted on the edge of the component captures the color change signal, determining that the microhole 21 is closed successfully.

[0076] After the heat fusion is completed, the minimum residual thickness of the insulating sealing tape 20 at the closed position of the micropore 21 is measured. Thickness retention rate .

[0077] S5. Framing Step: The laminate 10, with edge sealing and fusion pores completed, is conveyed to the gluing and framing machine. Two-component polyurethane frame silicone 30 is evenly applied to the outer surface of the U-shaped insulating edge sealing tape 20 around the laminate 10, with a gluing width of [missing information]. Then, the anodized aluminum metal frame 40 with mounting grooves is pressed onto the laminate 10 to cover it.

[0078] The U-shaped insulating sealing tape 20 has a single-sided bonding width of 20mm on the first and second panel surfaces. It is wider than the 30mm width of the border silicone. The end edge of the insulating sealing tape 20 extends beyond the edge of the frame silicone 30. The insulating edge sealing tape 20 reconfigures the creepage distance from the cell assembly to the external metal frame. Without the insulating edge sealing tape 20, the creepage distance is... Only .

[0079] After applying the insulating edge sealing tape 20, the creepage path changes to extend outward from the edge of the battery cell assembly 13 to the end edge of the first / second panel, then around the outer surface of the U-shaped insulating edge sealing tape 20, and finally through the aluminum frame at its end edge. Creepage distance measurement value. This design achieves a significant improvement in electrical safety compared to traditional structures. The finished product is obtained after the components are cured.

[0080] Example 2, applicable to The system. The assembly process and structure of this embodiment are basically the same as those of Embodiment 1, with the main process and structural parameters adjusted as follows:

[0081] 1. The edge of the encapsulating film 14 is recessed from the edge of the first panel 11 and the second panel 12. .

[0082] 2. The initial total thickness of the insulating edge sealing tape 20 is The insulating substrate layer is made of transparent polyester PET and does not contain titanium dioxide. The substrate thickness is [missing information]. Its relative temperature index The breakdown voltage is Tracking index The adhesive layer uses reactive hot-melt polyurethane (PUR) adhesive, with a thickness of [missing information]. .

[0083] Waterproof partitioning and barrier: The insulating edge sealing tape 20 also has a silica water-blocking layer prepared by vacuum magnetron sputtering, which is placed between the substrate layer and the adhesive layer. The thickness of the sputtering layer is [missing information]. The insulating sealing tape 20 is divided into a middle area and an edge area along its width, with the thickness of the first edge area and the second edge area decreasing gradually. .

[0084] Micro-hole 21 and channel geometry parameters: Micro-hole 21 is formed by high-precision ultraviolet laser drilling, and the aperture... Micropore 21 depth-to-diameter ratio The micropores 21 are arranged in multiple staggered rows in the middle area of ​​the bending of the insulating sealing tape 20, with a distribution density of... .

[0085] Parameter calculation matching: Calculate The sum of the cross-sectional areas of the micropores per meter along the length direction. Insulating edge sealing tape, 20mm total width. Effective breathable area ratio The adhesive layer surface is rolled with a depth of [depth missing]. Spacing is It also connects to the gas-guiding microchannel of micropore 21. The outer side of micropore 21 is provided with a strain color critical temperature of... Thermosensitive irreversible color-changing indicator ring.

[0086] 3. During application, the insulating sealing tape 20 is bent in a U-shape, and its bonding width on the outer surface of the glass and the second panel 12 is [missing information]. .

[0087] 4. At room temperature, the insulating edge sealing tape 20 adheres to the glass and the second panel 12. Peel strength reached The dynamic shear strength is .

[0088] 5. In step S3, the melting point temperature of the transparent polyester PET insulating substrate is... The actual equilibrium temperature at the edge of the component during the vacuuming phase. Temperature difference During vacuuming, the micro-channels 21 remain unobstructed. Excess gas and volatile components within the laminate 10 are completely discharged through the micro-channels and tapered pores.

[0089] 6. In step S4, the heating temperature is controlled to be... Applying pressure to the edges of the components through inflatable air bladders inside the laminator The pressure causes the micropores 21 to close. Its Shore hardness is... Spend, The polyester (PET) insulating substrate layer has a first softening temperature. The active hot-melt polyurethane (PUR) adhesive layer has a second softening temperature. The softening temperature difference is .

[0090] The material at the 20 micropores and 21 of the insulating sealing tape is slightly melted by heat and completely melts and closes under flexible isotropic pressure, achieving a closure rate of 100%. The color-changing ring irreversibly changes from white to blue, facilitating online CCD optical judgment. After heat fusion closure, the thinnest residual thickness of the insulating sealing tape 20 at the closed position of the micropore 21 was measured. Thickness retention rate greater than Minimum design insulation thickness required by the system .

[0091] Example 3, applicable to The system. The assembly process and structure of this embodiment are basically the same as those of Embodiment 1, with the main process and structural parameters adjusted as follows:

[0092] 1. The edge of the encapsulating film 14 is recessed from the edge of the first panel 11 and the second panel 12. .

[0093] 2. The initial total thickness of the insulating edge sealing tape 20 is The white polyimide (PI) insulating substrate layer is selected, and its relative temperature index is [not specified]. The breakdown voltage is Tracking index Thickness is The adhesive layer uses modified epoxy thermoplastic resin adhesive, with a thickness of [missing information]. The PI insulating substrate layer contains an additive with a mass fraction of [missing information]. Titanium dioxide.

[0094] Waterproof partitions and barriers: Insulating edge sealing tape 20 also has a layer of thickness of Furthermore, the aluminum oxide waterproof layer, obtained by vacuum evaporation, is applied to the side of the substrate layer facing the adhesive layer. The insulating sealing tape 20 is divided into a middle area and an edge area along its width, with the thickness of the first edge area and the second edge area gradually reduced to [a certain value]. .

[0095] Micro-hole 21 and channel geometry parameters: Micro-hole 21 is drilled using a CNC precision high-speed femtosecond laser drilling system. Micro-hole 21 is an irregular polygonal conical hole with a diameter of... Micropore 21 depth-to-diameter ratio Micropores 21 are randomly distributed in the central region, with a distribution density of... .

[0096] Parameter calculation matching: Calculate The sum of the cross-sectional areas of all micropores per meter along the length direction. Insulating edge sealing tape, 20mm total width. effective area ratio The adhesive surface has a depth of The channel spacing is The longitudinal air-guiding microchannels. A thermosensitive, irreversible color-changing ring is provided around the outer surface of the micropores 21, with a color-changing response temperature of [temperature value missing]. .

[0097] 3. During application, the insulating sealing tape 20 is bent in a U-shape, and its bonding width on the outer surface of the glass and the second panel 12 is [missing information]. .

[0098] 4. At room temperature, the insulating edge sealing tape 20 adheres to the glass and the second panel 12. Peel strength reached The dynamic shear strength is .

[0099] 5. In step S3, the melting point temperature of the white polyimide (PI) insulating substrate is... The actual equilibrium temperature at the edge of the module during the vacuuming phase. Temperature difference During vacuuming and exhausting, the micropore 21 channels remained unobstructed. Residual gases and volatiles from the pyrolysis of the adhesive film inside the component were completely expelled.

[0100] 6. In step S4, the temperature of the heating block is controlled. The hot-melt mechanism applies heat to the localized area 21 of the 20 micropores of the insulating sealing tape. The pressure. Its Shore hardness at the contact point. Spend, The heating and pressurization period is [duration missing]. The polyimide (PI) substrate layer has a first softening temperature. The adhesive layer modified epoxy thermoplastic resin has a second softening temperature. The difference in softening temperature between the two is: .

[0101] Under heating and elastic isotropic pressure, the micropores 21 of the insulating sealing tape 20 undergo micro-melting and flow, eventually fusing and sealing completely. The color ring changes from white to bright blue, and the industrial camera colorimeter mounted on the component edge determines that the sealing is qualified. After the heat melting is completed, the minimum residual insulation thickness of the insulating sealing tape 20 at the closed micropore 21 is measured. Thickness retention rate ,satisfy Minimum design safety insulation thickness required by the system .

[0102] Example 4, Low-parameter boundary control group. This example uses the lower limit parameters of the design range for solar module assembly:

[0103] S1. Stacking Steps: In a cleanroom typesetting workshop, the thickness... The first panel of tempered glass 11 has a thickness of The first encapsulation film 14 (POE film), the battery cell assembly 13, and the thickness are The second encapsulating film 14 (POE film), and its thickness The second panel 12 of the tempered back glass is stacked sequentially. The encapsulating film 14 is recessed inward around its perimeter, and the distance between its edge and the outer edge of the first and second panels is [missing information]. .

[0104] S2. Edge sealing application steps: When the ambient temperature is... Relative humidity is The edge sealing is carried out in the film application room. Insulating edge sealing tape 20 structure and material selection: The initial total thickness of the insulating edge sealing tape 20 used is... The substrate layer is made of polyester PET, with a thickness of [missing information]. ,That The breakdown voltage is , The adhesive layer uses hot melt adhesive and has a thickness of [missing information]. The PET insulating substrate contains an additive with a mass fraction of [missing information]. Titanium dioxide.

[0105] Geometric parameters of micro-hole 21: Micro-hole 21 is formed by needle punching on insulating sealing tape 20 using a CNC precision needle punching roller. The diameter of micro-hole 21 is... Micropore 21 depth-to-diameter ratio Micropores 21 are distributed in a single row, with a distribution density of... .

[0106] Parameter calculation matching: Calculate The sum of the cross-sectional areas of the 21 micropores per meter Insulating edge sealing tape, 20mm total width. Effective breathable area ratio The adhesive layer surface is rolled with a depth of [depth missing]. Spacing is It is also connected to the longitudinal parallel air guiding channel of micropore 21.

[0107] Application process control: Before application, the insulating edge sealing tape 20 is preheated online with infrared technology until... The preheating time is Subsequently, insulating edge-sealing tape is folded in a U-shape and wrapped around the edge of laminate 10. The single-sided bonding width on the outer surface of the first and second panel glass is [missing information]. After application, the laminating machine's pressure claws apply pressure to the bonding areas on both sides. Slight pressure, holding pressure .

[0108] After bonding, let the components stand still. At room temperature, the peel strength of insulating edge sealing tape 20 is The dynamic shear strength is .

[0109] S3. Lamination Vacuuming Step: The components are fed into the laminator, and the temperature of the laminator is controlled at... Initiate vacuuming; the first stage is... Inner low pumping speed The second phase was slower. Pumping speed, pumping to ultimate vacuum Total duration of the vacuuming phase Because of the density of micropores 21 No trigger A long-cycle vacuum process was employed to compensate for the insufficient exhaust conductivity caused by the small pore size and low density of micropore 21. During the vacuum process, the melting point of the insulating sealing tape 20 substrate was [missing information]. The vacuum equilibrium temperature is... The temperature difference is The micropores 21 channels remain unobstructed, allowing air to escape from the laminate 10.

[0110] S4, Micropore 21 Closure Step: After lamination, the product is sent to the local hot-melt pore-closing station. The coating thickness on the contact surface is [thickness value missing]. The temperature-resistant fluororubber gasket has a Shore hardness of Temperature. Control the heating temperature to [temperature value]. The PET insulating substrate layer has a first softening temperature. The adhesive layer has a second softening temperature. Its softening temperature difference is only .

[0111] Under pressure, due to the small softening temperature difference and extremely small pore size, the micropores 21 completely melt-close at a relatively low temperature and pressure, resulting in a high closure rate. After heat melting, the minimum residual thickness at the closed position of micropore 21 was measured to be... Thickness retention rate .

[0112] S5. Framing steps: Apply 30g of silicone sealant to the frame and press in 40g of aluminum frame. Apply 20g of insulating edge sealing tape to one side of the width. The creepage distance is extended to Once cured, the finished product is obtained.

[0113] Example 5: High-parameter boundary control group. This example uses the upper limit parameters of the design range for solar module assembly:

[0114] S1. Stacking Steps: Thickness... The first panel of the fully tempered glass has a thickness of 11. The first encapsulation film 14 (POE film), the battery cell assembly 13, and the thickness are The second encapsulating film 14 (POE film), and its thickness The second panel 12 of the fully tempered back glass is stacked sequentially. The encapsulating film 14 is circumferentially recessed, and its edge is kept at a distance from the outer edges of the first panel 11 and the second panel 12. .

[0115] S2. Edge sealing application steps: When the ambient temperature is... Relative humidity is The sealing process is carried out in a high-humidity film-applying room. The structure and material selection of the insulating sealing tape 20: The initial total thickness of the insulating sealing tape 20 used is... The white modified polyurethane composite insulation substrate layer is selected, and its relative temperature index is [not specified]. The breakdown voltage is , Thickness is The adhesive layer uses polyolefin thermoplastic elastomer adhesive with a thickness of [thickness value missing]. The insulating substrate contains a mass fraction of Titanium dioxide.

[0116] Geometric parameters of micro-aperture 21: Micro-aperture 21 is created by multiple parallel drilling points using a high-energy pulsed laser system. Micro-aperture 21 is polygonal in shape, with a diameter of... Micropore 21 depth-to-diameter ratio Micropore 21 distribution density .

[0117] Parameter calculation matching: Calculate The sum of the cross-sectional areas of all micropores per meter along the length direction. Insulating edge sealing tape, 20mm total width. effective area ratio The adhesive layer surface is rolled with a depth of [depth missing]. The channel spacing is It is also connected to the parallel air-guiding microchannel of micropore 21.

[0118] Application process control: Before application, preheat online with infrared technology to... The preheating time is Subsequently, insulating edge-sealing tape in a 20U-shape is folded and applied to the edge of the component to be laminated 10. The bonding width on one side of the outer surface of the first and second panel glass is [missing information]. After application, the edge-sealing machine's clamping plate applies pressure to both sides. Pressure and pressure holding After application, allow the component to stand at room temperature. At room temperature, the peel strength of the insulating sealing tape reaches 20. The dynamic shear strength is .

[0119] S3. Lamination Vacuuming Step: The components are fed into the laminator, and the equilibrium temperature of the laminator is controlled at... The first stage of vacuuming is... The pumping speed quickly pumps the lower chamber to The second phase was slower. The pumping speed evacuates the lamination chamber to its ultimate vacuum. Total duration of the vacuuming phase During vacuuming, the melting point of the insulating sealing tape 20 substrate is... The actual equilibrium temperature of the module during the vacuuming stage is... The temperature difference is With the micropores 21 open, the gas inside the laminate 10 can be discharged.

[0120] S4, Micropore 21 Closure Step: After lamination, the laminated part 10 is sent to the local hot-melt sealing station by an automated flipping line. The coating thickness of the elastic contact surface of the local hot-pressing device is... High-temperature resistant, high-hardness silicone, its Shore hardness Temperature. Control the temperature of the hot press head. The modified polyurethane composite insulating substrate has a first softening temperature. The polyolefin thermoplastic elastomer adhesive layer has a second softening temperature. The absolute value of the difference in softening temperature between the two reaches .

[0121] Under pressure and high temperature, the micropore 21 is difficult to close due to its large pore size. However, under high pressure and high temperature, the micropore 21 still completely melts and closes, achieving a closure rate of [missing information]. After heat melting, the thinnest residual thickness at the closed position of micropore 21 was measured to be... Thickness retention rate .

[0122] S5. Framing steps: Apply 30g of silicone to the frame and install 40g of aluminum frame, fitting the width on one side. The creepage distance is Once cured, the finished product is obtained.

[0123] III. Detailed Explanation of Comparison Scale

[0124] To clarify and highlight the decisive technical contribution of the defined parameters and process control in this invention to the physical performance and electrical characteristics of solar modules, the following comparative control groups were designed and prepared in parallel. The basic structure of the modules and the selection of main materials in Comparative Examples 1 to 9 (except for the comparison-defined changes) are completely consistent with those in Example 1.

[0125] Comparative Example 1 uses a non-porous conventional insulating edge-sealing tape 20 as a control group. This comparative example aims to verify the impact of the non-porous design 21 on lamination venting efficiency.

[0126] The only difference between this comparative example and Example 1 is that the insulating sealing tape 20 used is a solid polyolefin insulating sealing tape 20 of the same material that is completely free of micropores 21 when applied, with an initial total thickness of substrate thickness Pressure-sensitive adhesive layer .

[0127] Assembly process: The edge sealing, multi-stage vacuuming, lamination, and framing process parameters are completely consistent with those in Example 1. Because the insulating edge sealing tape 20 is completely airtight and the U-shaped application was completed before the vacuuming process in the laminator, the edges of the laminate 10 are completely sealed.

[0128] Physical consequences: During the vacuuming and curing stages of lamination, trace amounts of small-molecule volatile organic compounds generated by the thermal degradation of air and polymer materials inside the module cannot escape through the edges. Ultimately, after the encapsulating film crosslinks and cures, a large number of visible and EL-coated bubbles remain at the module edges, with a tested bubble rate reaching [percentage missing]. This seriously affects the appearance quality and packaging stability.

[0129] Comparative Example 2: Control group where micropores 21 were not closed by heat fusion after lamination. This comparative example aims to verify the importance of the heat fusion pore-closure step for long-term reliability of moisture protection and electrical insulation.

[0130] Variation characteristics: The only difference between this comparative example and Example 1 is that after the lamination, vacuuming and curing are completed in step S3, the local hot-melt pressure closure process of the micropores 21 in step S4 is not performed.

[0131] Assembly Process: After lamination and cross-linking curing of the component 10 to be laminated with microporous insulating edge-sealing tape 20, the component 10 directly enters the framing station for silicone application and metal frame pressing. In the finished product state, the micropores 21 on the insulating edge-sealing tape 20 maintain an open, through-hole geometry, with a closure rate... .

[0132] Physical consequences: Despite good performance in lamination degassing, the micron-sized pores remain unsealed by melting due to the lack of melt sealing, resulting in problems in humid and hot environments. relative humidity It acts as a capillary channel, facilitating long-distance penetration of water vapor and corrosive water molecules into the component's interior. (This is followed by a description of humid heat aging.) After hours of testing, the water penetration depth exceeded This leads to electrochemical corrosion and delamination of the electrodes, resulting in power attenuation. Furthermore, due to the accumulation of moisture inside, the insulation breakdown occurred directly during the withstand voltage test.

[0133] Comparative Example 3: A control group using a rigid mold made of hard steel during hot-melt closure. This comparative example aims to verify the crucial role of flexible contact heating in protecting brittle panels and battery cells from stress fracture.

[0134] Variation characteristics: The only difference between this comparative example and Example 1 is that when the insulating sealing tape 20 is partially heat-melted and closed in step S4, no flexible padding such as fluorosilicone rubber or silicone is attached to the contact surface of the hot pressing block. Instead, a finely ground, high-gloss, flat, hard steel heating head is used to press the bending corner micro-hole 21 area of ​​the insulating sealing tape 20 directly.

[0135] Assembly process: The pressure head is set to a specific temperature. The local hot-pressing pressure is The remaining parameters are completely consistent with those in Example 1.

[0136] Physical consequences: Due to microscopic flatness deviations in the first panel glass, the second panel back glass, and the edges of the module, as well as the bending and microscopic unevenness of the glass manufacturing, the rigid indenter makes rigid-on-rigid contact with the hard glass, resulting in severe transient tensile and shear stress concentrations at the four corners and edges of the module. The pressure caused a large number of semi-tempered / tempered glass pieces to chip or crack at the edges, resulting in a glass / battery breakage rate of up to [percentage missing]. .

[0137] Comparative Example 4: Control group where the diameter of micropore 21 is too large relative to the thickness of insulating sealing tape 20. This comparative example aims to verify the negative impact of exceeding the depth-to-diameter ratio (D / T) of micropore 21 on the closure tightness of micropore 21.

[0138] The only difference between this comparative example and Example 1 is the thickness of the insulating sealing tape 20. The diameter of the microhole 21 produced by laser drilling is... .

[0139] Parameter matching calculation: its aperture to thickness ratio Far exceeding the limits of this invention The preferred range.

[0140] Assembly process: remaining stacking, application, vacuuming, and in Lower Local Flexible Thermal Fusion Closure pressure The process is the same as in Example 1.

[0141] Physical consequences: Because the cross-sectional area of ​​the micropore 21 is too large relative to the thickness of the insulating sealing tape 20 itself, during local heat melting, the volume of the molten substrate and adhesive material around the pore is insufficient to fill the central cavity of such a large diameter pore.

[0142] After the hot press head retracts, the complete closure rate of micropore 21 is only And the thinnest residual thickness at the closed position becomes thinner to Thickness retention rate is only Not satisfied And lower than Minimum insulation thickness required by the system ,exist After hours of humid and hot aging, moisture seeps in. Power attenuation reached .

[0143] Comparative Example 5: Control group where the local hot-melt temperature and melting point temperature difference do not meet the requirements. This comparative example aims to verify the effect of the closed temperature difference margin on polymer interface reconstruction and bonding force.

[0144] The difference between this comparative example and Example 1 lies only in that, during the partial heat-melting and closure of the insulating sealing tape 20 in step S4, the heating control temperature of the heating head is set to [temperature value missing]. .

[0145] Parameter matching calculation: Since the melting point temperature of the 20PP substrate layer of this insulating edge sealing tape is... The temperature difference between the heating control temperature and the substrate melting temperature Below the minimum limit defined by the process of this invention Melt contact temperature difference limit .

[0146] Assembly process: other structural parameters, hot pressing flexible pressure Holding time All are completely consistent with Example 1.

[0147] Physical consequences: Due to the extremely low temperature, the local polymer substrate did not enter the molten viscous flow state at all, and the polymer chain segments remained in the frozen crystalline phase.

[0148] After the hot press head retracts, the micropore 21 fully springs back and opens, with a complete closure rate of only [percentage missing]. It leaked water rapidly during the damp heat test, with water vapor penetrating to a depth of [insert depth here]. The power attenuation due to damp heat reaches .

[0149] Comparative Example 6 shows that the product of the area and distribution density of micropore 21 is insufficient compared to the control group. This comparative example aims to verify the limitation of exhaust rate caused by the excessive exhaust resistance of micropore 21.

[0150] The only difference between this comparative example and Example 1 is that the distribution density of the micropores 21 on the insulating sealing tape 20 is reduced. Furthermore, the diameter of the micropore 21 is designed to be extremely small. ( ).

[0151] Parameter matching calculation: Calculation It is far below the limits defined in this invention. The minimum technical specifications.

[0152] Assembly process: The structure of the remaining insulating sealing tape 20, the lamination vacuum rate, the local heat melting and assembly process are the same as in Example 1.

[0153] Physical consequences: Due to the extremely small pore size and sparse density of the micropores 21, the gas flow conductivity of each micropore 21 decreases exponentially. During the vacuuming phase of lamination, although vacuuming is maintained... However, the gas at the edge of the component cannot be completely discharged through the micropores 21 in time, resulting in a high bubble rate at the edge of the component after cross-linking and curing. .

[0154] Comparative Example 7: Control group with an imbalanced ratio of microporous area 21 to insulating sealing tape 20 width. This comparative example aims to verify the effect of mismatch between the air permeability area ratio and the lateral transmission distance.

[0155] The only difference between this comparative example and Example 1 is that the width of the insulating sealing tape 20 is increased. The density of its micropores 21 is , diameter is .

[0156] Parameter matching calculation: Calculate the sum of the cross-sectional areas of all micropores within a single meter length. .ratio Far below the limits defined in this invention The minimum air permeability ratio.

[0157] Assembly process: The remaining lamination vacuuming, hot melting and framing parameters are the same as in Example 1.

[0158] Physical consequences: The diffusion path from the end face of the adhesive film to the micropore 21 is affected by the width Increase and grow, while the effective proportion of exhaust channels The pressure was significantly too low, resulting in high vacuuming and exhaust resistance. Residual volatiles could not be expelled during the vacuuming stage, and the measured bubble rate at the component edge after curing reached [a certain percentage]. The power attenuation due to damp heat reaches .

[0159] Comparative Example 8: Thickness-free control group under high-voltage operating specifications. This comparative example aims to verify the technical limitations of initial thickness not matching the high-voltage breakdown safety thickness deformation loss.

[0160] The only difference between this comparative example and Example 1 is that the assembly is... High-voltage components, but the initial thickness of the selected insulating sealing tape is 20. .

[0161] Parameter matching calculation: Although the initial thickness satisfies the proportional formula The requirements are broad, but because the amount of thickness heat loss and deformation during the local hot-melt closure process was not considered and sufficient, the final residual insulation thickness at the micro-hole 21 after hot-pressing complete closure is... Thinning to .

[0162] Assembly process: stacking, application, and bonding The hot-melt and framing processes are exactly the same as in Example 1. After hot-melt, the closure rate of micropore 21 reaches [percentage missing]. However, the actual residual insulation thickness of the insulating sealing tape 20 at the closed micropore 21 becomes thinner. Thickness retention rate Because it is lower than The minimum design insulation thickness safety limit required by the system .

[0163] Physical consequences: In the HIPOT insulation withstand voltage test conducted under wet conditions, when the voltage is boosted to DC... At that time, a micro-dielectric discharge occurred at the micro-orifice 21, causing a transient breakdown of the air and the thinned insulating sealing tape 20, resulting in a severe high-voltage breakdown fault. This demonstrates that under ultra-high voltage specifications, the insulating sealing tape 20 not only needs to meet the initial design ratio but also must have sufficient shear flow redundancy thickness to ensure that the actual thickness after closure is greater than that corresponding to the high-voltage specification. Only in this way can the effective isolation of charges under ultra-high voltage be achieved.

[0164] Comparative Example 9: Control group with excessively large difference in softening temperatures between the substrate and adhesive layer. This comparative example aims to verify the effect of an excessively large difference in softening temperatures between the substrate and adhesive layer on the thermal melt flow density.

[0165] The only difference between this comparative example and Example 1 is the selection of a first softening temperature. The insulating substrate layer, and the second softening temperature The adhesive layer. The absolute value of the softening temperature difference between the two is Much greater than the limits defined in this invention. Scope of restrictions.

[0166] Assembly process: The remaining structure and lamination, hot melting and framing processes are completely consistent with those in Example 1.

[0167] Physical consequences: In During the localized heat-melting stage, the softening temperature of the adhesive layer is too low (only... Under the combined effects of high temperature and pressure, this layer undergoes severe melting and dilution, overflowing and flowing outwards to an extreme degree. Meanwhile, the substrate layer, due to its relatively high softening point, fails to simultaneously generate sufficient molten viscous flow deformation during hot pressing. This results in the failure of dense eutectic bonding within the micropores 21, extremely poor interfacial bonding of macromolecules within the pores, and even microscopic air cavities and localized interlayer delamination remaining within the closed channels due to binder loss, with a complete closure rate of only [percentage missing]. .exist After the damp heat aging test, moisture penetrated deeply along these microscopic layers and residual cavities, with water vapor penetrating to a depth of [insert depth here]. The power attenuation due to damp heat increased significantly to The leakage current surged during the leakage test, seriously threatening the safety of high-voltage electrical equipment.

[0168] IV. Component Performance Testing Methods and Result Analysis

[0169] The components prepared in Examples 1 to 5 and Comparative Examples 1 to 9 were tested using industry standards or the methods described in this invention:

[0170] Complete closure rate test: A high-resolution infrared non-destructive thermal wave sensor was used to perform a circumferential scan of the heat-melted insulating sealing tape 20, or a local section was cut and observed under a scanning electron microscope (SEM) to examine the internal interface of the micropores 21. If the original channel boundaries within the pores completely disappeared and the macromolecules were completely blended and fused, it was determined to be complete closure rate. Fuse closed pores and count the percentage of completely closed pores.

[0171] Residual thickness test: A high-precision contact thickness gauge was used to continuously measure the thickness of the insulating sealing tape 20 at the closed position of the microhole 21 after hot melting, and the thickness value of the thinnest position was recorded and the ratio of the thickness to the initial thickness before application was calculated.

[0172] Bubbles and Appearance: Utilizing visual inspection A magnifying glass was used, and the edges were analyzed using an EL (electroluminescence) detector.

[0173] High Voltage Insulation Test (HIPOT): The module's positive and negative terminals are short-circuited and connected to the high-voltage positive terminal of a withstand voltage tester, while the externally grounded aluminum frame is connected to the negative terminal. The module is then subjected to a test while wet. Apply DC boost speed Voltage, and maintain Read the limit leakage current value and detect the discharge or breakdown point.

[0174] Damp heat aging (DH1000): According to the standard relative humidity Aging in an environmental chamber The power difference before and after testing was measured, and the penetration depth was used to measure the penetration of dyeing water.

[0175] All test data are listed in Table 1 of the specification. Based on the data in Table 1 and the comparative analysis above, this invention achieves a systematic integrated breakthrough in venting, sealing, and ultra-high voltage insulation by limiting the ratio of the micropore diameter 21 to the thickness of the insulating sealing tape 20, the product of the micropore distribution density and pore diameter, the ratio of the total area of ​​the micropores 21 per unit length to the width of the insulating sealing tape 20, the correspondence between the thickness of the insulating sealing tape 20 and the working voltage, and the thickness retention rate and minimum thickness requirement of the micropore 21 position after closure.

[0176] The test results in Table 1 also perfectly demonstrate the excellent performance of the white and transparent insulating sealing tape 20 in actual tests.

[0177] Table 1: Comparison of Performance Test Results between Examples and Comparative Examples

[0178] Analysis of the physical control mechanism of the softening temperature difference in Comparative Example 9:

[0179] The test data in Table 1 clearly demonstrates the control mechanism of the softening point matching between the two material layers on the complete thermal fusion of micropore 21: In Comparative Example 9, the softening point of the insulating substrate layer is... The softening point of the adhesive layer is only The softening temperature difference between the two reached beyond the barrier limit. .

[0180] exist During the hot-pressing pore-closure process, uneven heating and flow occurred between the two components: the adhesive with the second softening temperature being too low transformed into an extremely thin liquid first and flowed out significantly to both sides of the micropores 21, while the substrate layer with the first softening temperature being too high had not yet formed sufficient rheological self-filling deformation. As a result, the micropores 21 failed to fully fuse after hot melting, leaving microscopic air cavities and localized delamination defects at the interface within the pores. The complete closure rate of the micropores 21 was only [percentage missing]. During long-term humid heat aging tests on the DH1000, micropaths were formed where moisture slowly permeated along the channels, with a water vapor penetration depth reaching [insert depth here]. The damp heat decay increased to Its DC leakage current also increased to This directly weakens the moisture-proof and insulation resistance levels of the ultra-high voltage system.

[0181] In contrast, in Examples 1 to 3, the softening temperature difference between the substrate layer and the adhesive layer was used... Strictly controlled at Within this range, due to the highly synergistic rheological states of the two components, synchronous interfacial creep rheology occurs under flexible local pressure. This allows the polymer chains to achieve tight, homogeneous interfacial interpenetration, completely melting the original microporous 21 physical interface into a homogeneous bulk, thus realizing… The ultimate closed-pore state means that after aging, the depth of water vapor penetration is below the minimum limit. The system power attenuation is controlled within The leakage current is extremely small and there is no high-voltage insulation breakdown, demonstrating outstanding electrical insulation safety and long-term water-blocking reliability.

[0182] The above description is merely a preferred embodiment of the present invention and is not intended to limit the invention. Various modifications and variations can be made to the present invention by those skilled in the art. Any modifications, equivalent substitutions, improvements, etc., made within the spirit and principles of the present invention should be included within the scope of protection of the present invention.

Claims

1. A solar energy module, characterized in that, include: A laminate, the laminate comprising a first panel, a second panel, and a battery cell assembly located between the first panel and the second panel; An encapsulating film located between the battery cell assembly and the first panel, and between the battery cell assembly and the second panel; Insulating edge sealing tape is applied to the edge of the laminate; The insulating sealing tape includes an insulating substrate layer and an adhesive layer. The insulating sealing tape is configured such that: the insulating substrate layer has micropores penetrating the insulating substrate layer, and / or the adhesive layer has micropores penetrating the insulating substrate layer. The micropores are configured to remain open during the lamination vacuuming stage of the laminate to expel air from inside the laminate, and to be heated and melted closed during the heating and pressurization process after the lamination vacuuming stage to achieve sealing of the edges of the laminate.

2. The solar module according to claim 1, characterized in that, The diameter of the micropore The thickness of the insulating sealing tape satisfy: .

3. The solar module according to claim 1, characterized in that, The sum of the cross-sectional areas of all micropores per meter along the length of the insulating sealing tape. The width of the insulating sealing tape satisfy: ,in The unit is , The unit is .

4. The solar module according to claim 1, characterized in that, The distribution density of the micropores With respect to the diameter of the micropore satisfy: ,in The unit is units / m. The unit is .

5. The solar module according to claim 1, characterized in that, The micropores are circular, elliptical, polygonal, or irregular in shape, and are arranged in a single row, multiple rows, or randomly distributed on the insulating sealing tape.

6. The solar module according to claim 1, characterized in that, The micropores are tapered holes, and the opening diameter of the tapered hole on the side of the insulating sealing tape facing the laminate is larger than the opening diameter on the side facing outward.

7. The solar module according to claim 1, characterized in that, The melting point temperature of the insulating sealing tape The temperature is higher than that of the laminated part during the vacuuming stage of the lamination process. ,and .

8. The solar module according to claim 1, characterized in that, The thickness of the insulating sealing tape With the operating voltage of the solar module satisfy: ,in The unit is , The unit is .

9. The solar module according to claim 1, characterized in that, The insulating sealing tape includes, in sequence along its width, a middle area, a first edge area, and a second edge area; the middle area corresponds to the circumferential end face of the laminate, and the first edge area and the second edge area correspond to the outer surfaces of the first panel and the second panel, respectively; wherein the thickness of the first edge area and the second edge area is less than the thickness of the middle area.

10. The solar module according to claim 1, characterized in that, The adhesive layer has multiple air-guiding microchannels on the side surface facing the laminate. The air-guiding microchannels are connected to the micropores and extend to the edge of the insulating sealing tape. During the lamination vacuuming stage, the air at the edge of the laminate gathers along the air-guiding microchannels and is discharged through the micropores. During the hot melt pressurization process, the air-guiding microchannels are heated, melted, and close and disappear.

11. The solar module according to claim 1, characterized in that, The insulating sealing tape has a thermosensitive color-changing indicator area on its outer surface and around the micropores. The thermosensitive color-changing indicator area is configured to undergo an irreversible color change after the micropores reach the set heat-melting closure temperature and pressure and are completely melted and closed.

12. The solar module according to claim 1, characterized in that, The insulating substrate layer has a first softening temperature. The adhesive layer has a second softening temperature. And the first softening temperature With the second softening temperature satisfy: .

13. An assembly process for a solar module as described in claim 1, characterized in that, Includes the following steps: S1. Stacking: The first panel, the first encapsulating film, the battery cell group, the second encapsulating film and the second panel are stacked in sequence to form the part to be laminated; S2, edge sealing application: Apply insulating edge sealing tape to the four edges of the part to be laminated, and make it wrap around in a U-shape. The two sides of the U-shape of the insulating edge sealing tape are respectively bonded to the outer surfaces of the first panel and the second panel to fix the first panel and the second panel and prevent misalignment. S3, Lamination Vacuuming: The part to be laminated with the insulating sealing tape is fed into the lamination equipment for lamination, and during the vacuuming stage of lamination, the air and volatiles inside the part to be laminated are discharged through the micropores penetrating the insulating sealing tape. S4. Micropore Closure: The insulating sealing tape is subjected to heat-melting and pressurizing treatment, so that the insulating sealing tape at the micropores is heated and slightly melted and closed under pressure to seal the edge of the laminate.

14. The assembly process according to claim 13, characterized in that, In step S4, the heating temperature of the hot melt pressurization process is: The heating temperature of the hot melt pressurization process The melting point temperature of the insulating sealing tape satisfy: ,and .

15. The assembly process according to claim 13, characterized in that, In step S4, the hot melt pressurization process applies local pressure using a flexible tooling, with a pressure range of [insert pressure range here]. The contact surface of the flexible tooling is made of silicone or an inflatable air bladder, and the Shore hardness of the elastomeric material of the contact surface of the flexible tooling is [not specified]. With applied local pressure satisfy: ,in The unit is degrees (Shore A). The unit is .

16. The assembly process according to claim 13, characterized in that, In step S4, the heating time for the hot melt pressurization process is... The heating time of the hot melt pressurization process The thickness of the insulating sealing tape satisfy: ,in The unit is seconds. The unit is .

17. The assembly process according to claim 13, characterized in that, In step S4, the hot-melt pressurization process is completed inside the laminating equipment, and the local heating temperature during the hot-melt pressurization stage is at least higher than the equilibrium temperature during the lamination vacuuming stage in step S3. .

18. The assembly process according to claim 13, characterized in that, In step S4, after the hot melt pressurization treatment, the minimum residual thickness of the insulating sealing tape at the micropore closure position. The initial thickness of the insulating sealing tape satisfy: ,and ,in This refers to the minimum insulation thickness required based on the operating voltage of the solar module.

19. The assembly process according to claim 13, characterized in that, When the distribution density of the micropores The duration of the vacuuming phase of the lamination process. With the distribution density satisfy: ,in The unit is minutes. The unit is .

20. The assembly process according to claim 13, characterized in that, In step S2, before applying the insulating edge sealing tape, the insulating edge sealing tape undergoes online infrared preheating treatment at a preheating temperature of [temperature value missing]. The preheating time is .

21. The assembly process according to claim 13, characterized in that, In step S2, after the insulating sealing tape is applied and wrapped, a roller or pressure strip structure is used to apply pressure to the insulating sealing tape. The pre-pressure and holding time are .

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