A laminated assembly, a lamination tool and a laminate

Abstract

This invention discloses a laminating assembly, laminating tooling, and laminating component. The laminating assembly includes at least: a front panel glass, a front encapsulating film, a battery string layer, a back encapsulating film, and a back panel glass, stacked sequentially along the thickness direction. The front panel glass includes a main front panel region and an exposed area at least a portion of the edge of the main front panel region. The front encapsulating film, battery string layer, back encapsulating film, and back panel glass are disposed on the main front panel region of the front panel glass and do not cover the exposed area of ​​the front panel glass. Embodiments of this invention allow the corresponding area of ​​the laminating assembly to be exposed by the front panel glass after stacking. Combined with a laminating tooling having a pressing function, the pressing component of the tooling abuts against the exposed area of ​​the front panel glass, preventing the exposed area of ​​the front panel glass from warping due to heat, mitigating or avoiding edge-separated adhesive bubbles and insufficient laminating component thickness during the lamination process, thereby improving the process yield and long-term reliability of the laminating component.

Description

Technical Field

[0001] This invention relates to the field of photovoltaic technology, and specifically to a laminated module, lamination tooling, and lamination component. Background Technology

[0002] The laminated assembly comprises a front glass panel, a front encapsulating film, a battery string layer, a back encapsulating film, and a back glass panel, stacked sequentially along the thickness direction. The lamination process involves placing the laminated assembly in a laminator, removing the air from the assembly through vacuuming, and heating and laminating to melt the upper and lower encapsulating films, thus encapsulating the laminated assembly into a single unit under atmospheric pressure.

[0003] During the fabrication of laminated components, the front glass directly contacts the laminating substrate. Uneven heating of the front glass during the heating process can cause warping at the corners or in other areas. Furthermore, pressure is applied from the back glass to the laminated assembly during lamination. These combined effects result in edge defects, air bubbles, and insufficient laminate thickness. The former affects the yield rate of the laminated component, causing losses; the latter affects the long-term reliability of the laminated component, leading to eventual failure. Summary of the Invention

[0004] This invention provides a laminated assembly, a laminating fixture, and a laminated component. By ensuring that the front adhesive film, battery string layer, back adhesive film, and backsheet glass do not cover the exposed area of ​​the front sheet glass, the corresponding area of ​​the laminated assembly after stacking is exposed to the front sheet glass. When used with a laminating fixture that has a pressing function, the pressing component of the fixture abuts against the exposed area of ​​the front sheet glass, which can prevent the exposed area of ​​the front sheet glass from warping due to heat, reduce or avoid edge missing adhesive bubbles and insufficient thickness of the laminated component during the lamination process, and improve the process yield and long-term reliability of the laminated component.

[0005] According to a first aspect of the present invention, a laminated assembly is provided, comprising at least: a front glass panel, a front encapsulating film, a battery string layer, a back encapsulating film, and a back glass panel, sequentially stacked along the thickness direction; wherein, The front panel glass includes: a front panel body area and an exposed area located at least a portion of the edge of the front panel body area; the front encapsulant film, the battery string layer, the back encapsulant film and the back panel glass are disposed on the front panel body area of ​​the front panel glass and do not cover the exposed area of ​​the front panel glass.

[0006] Optionally, the back glass includes: a back main area and a through area located at least a portion of the edge of the back main area; the exposed area is the projection area of ​​the through area onto the front glass along the thickness direction.

[0007] Optionally, the through area is an open or closed groove located at the edge of the main body area on the back side.

[0008] Optionally, the processing depth of the through area is less than or equal to 10 mm, and the processing depth of the through area is the dimension of the through area along the long or short side of the back glass.

[0009] According to a second aspect of the present invention, a lamination fixture is provided, comprising: a fixture body and a pressing member; wherein, the fixture body includes a fixture frame, the pressing member is disposed on the inner side of the fixture frame, and the lower side of the pressing member is higher than the lower side of the fixture frame. During lamination, the tooling frame is fitted around the lamination assembly, and the lower side of the pressed part abuts against the exposed area of ​​the front glass panel in the lamination assembly.

[0010] Optionally, the lamination fixture also includes a buffer, which is disposed on the lower side of the pressing component; optionally, the height of the buffer is less than the thickness of the front glass; the height of the buffer is the distance between the lower side of the buffer and the lower side of the fixture frame.

[0011] Optionally, at least a portion of the pressed part is a magnet.

[0012] Optionally, the tooling frame is a rectangular frame; the tooling body also includes tooling fasteners disposed at the corners of the tooling frame.

[0013] Optionally, the height of the pressing component is less than the thickness of the front glass; the height of the pressing component is the distance between the lower side of the pressing component and the lower side of the tooling frame. And / or, the projected area of ​​the pressed component along its thickness direction on the front glass is smaller than the area of ​​the exposed area it contacts.

[0014] According to a third aspect of the present invention, a laminate is provided, which is obtained by laminating a laminate assembly provided in the first aspect of the present invention using a lamination tooling provided in the second aspect of the present invention.

[0015] The technical solution of the first aspect of the above invention has the following advantages or beneficial effects: by ensuring that the front adhesive film, battery string layer, back adhesive film and back glass do not cover the exposed area of ​​the front glass, the corresponding area of ​​the laminated component can be exposed by the front glass after lamination. With the lamination tooling having a pressing function, the pressing part of the tooling abuts against the exposed area of ​​the front glass, which can prevent the front glass in the exposed area from warping due to heat, reduce or avoid the generation of edge missing adhesive bubbles and low thickness of the laminated component during the lamination process, and improve the process yield and long-term reliability of the laminated component. Attached Figure Description

[0016] The accompanying drawings are provided to better understand the invention and are not intended to unduly limit the scope of the invention. Wherein: Figure 1 This is a schematic diagram of the lamination assembly in an optional embodiment of the present invention; Figure 2This is a schematic diagram of the back glass in some embodiments of the present invention; Figure 3 This is a schematic diagram of the processing of the through area in the back glass in some embodiments of the present invention; Figure 4 This is a schematic diagram of the back glass in some embodiments of the present invention; Figure 5 This is a schematic diagram of the back glass in some other embodiments of the present invention; Figure 6 yes Figure 5 Enlarged schematic diagram of region B in the middle; Figure 7 This is a partial schematic diagram of the lamination tooling in some optional embodiments of the present invention; Figure 8 This is a partial schematic diagram of the lamination tooling in some alternative embodiments of the present invention; Figure 9 This is a schematic diagram of the lamination effect of the lamination tooling and lamination assembly in an optional embodiment of the present invention; Figure 10 This is a schematic diagram of the lamination tooling in some optional embodiments of the present invention; Figure 11 This is a schematic diagram of the lamination tooling in some alternative embodiments of the present invention; Figure 12 yes Figure 11 Schematic diagram of the suppression area in region A; Figure 13 This is a schematic diagram of the lamination tooling in some alternative embodiments of the present invention; Figure 14 yes Figure 13 Schematic diagram of the suppression area in region C; Figure 15 This is a schematic diagram of the laminated component after being framed in an optional embodiment of the present invention.

[0017] The attached figures are labeled as follows: 100-Laminated module; 110-Front panel glass, 111-Front panel main area, 112-Exposed area, 120-Front side film, 130-Battery string layer, 140-Back side film, 150-Back panel glass, 151-Back side main area, 152-Through area; 200-Lamination fixture, 210-Main fixture, 211-Fitting fixture frame, 212-Fitting fixture fastener, 2121-First clamping part, 2122-Second clamping part, 213-Isolation liner, 220-Pressing part, 230-Buffering part; 300-Component border. Detailed Implementation

[0018] The exemplary embodiments of the present invention will be described below with reference to the accompanying drawings.

[0019] It should be noted that the terms "upper", "lower", "inner", "outer", "end", etc., indicate the orientation or positional relationship based on the orientation or positional relationship shown in the accompanying drawings. They are only for the convenience of describing the present invention and simplifying the description, and do not indicate or imply that the elements referred to must have a specific orientation or be constructed and operated in a specific orientation. Therefore, they should not be construed as limiting the present invention.

[0020] Unless otherwise explicitly specified and limited, the terms “assembly”, “connection”, etc., should be interpreted broadly. For example, they can refer to fixed connections, detachable connections, or integral connections; they can refer to direct connections or indirect connections through an intermediate medium; and they can refer to the internal connection between two components.

[0021] A laminated assembly comprises a front glass panel, a front encapsulating film, battery strings, a back encapsulating film, and a back glass panel, stacked sequentially along the thickness direction. The lamination process involves placing the laminated assembly in a laminator, evacuating the air from the assembly through a vacuum process, and then heating and laminating to melt the upper and lower encapsulating films. Under atmospheric pressure, the laminated assembly is then encapsulated into a single unit. During the fabrication of the laminated component, the front glass panel directly contacts the laminating substrate. Uneven heating of the front glass panel during the heating process can cause warping at the corners or in other areas. Furthermore, pressure is applied from the back glass panel to the laminated assembly during lamination. These combined effects result in edge defects, air bubbles, and insufficient thickness in the laminated component. The former affects the yield rate of the laminated component, causing losses; the latter affects the long-term reliability of the laminated component, leading to eventual failure.

[0022] To address the aforementioned issues, embodiments of the present invention improve the front and / or back glass of the laminated assembly by exposing a portion of the edge area of ​​the front glass. During lamination of the laminated assembly, the laminating fixture abuts against the exposed area of ​​the front glass. This abutment prevents heat-induced warping of the front glass edges, reduces or avoids edge defects, air bubbles, and insufficient laminate thickness during lamination, thereby improving the process yield and long-term reliability of the laminated components.

[0023] According to a first aspect of the present invention, a lamination assembly is provided. Figure 1 This is a schematic diagram of the lamination assembly in an optional embodiment of the present invention. Figure 1 In the optional embodiment shown, X represents the length direction of the laminate 100, Y represents the width direction of the laminate 100, and Z represents the thickness direction of the laminate 100. Figure 1 As shown, the laminated assembly 100 includes at least: a front panel glass 110, a front encapsulating film 120, a battery string layer 130, a back encapsulating film 140, and a back panel glass 150, sequentially stacked along the thickness direction Z. Figure 9As shown, the front panel glass 110 includes a front panel main body region 111 and an exposed region 112 located at least a portion of the edge of the front panel main body region 111. In this embodiment of the invention, the front adhesive film 120, the battery string layer 130, the back adhesive film 140, and the back panel glass 150 are disposed on the front panel main body region 111 of the front panel glass 110, and the front adhesive film 120, the battery string layer 130, the back adhesive film 140, and the back panel glass 150 do not cover the exposed region 112 of the front panel glass 110. Since the front adhesive film 120, battery string layer 130, back adhesive film 140 and back glass 150 do not cover the exposed area 112 of the front glass 110, when laminating the laminated assembly 100, the laminating fixture can be made to abut against the exposed area 112 in the front glass 110, thereby preventing the exposed area 112 in the front glass 110 from warping due to heat, slowing down or avoiding edge missing adhesive bubbles and low thickness of the laminated part during the lamination process, and improving the process yield and long-term reliability of the laminated part.

[0024] In this embodiment of the invention, the forming method of the exposed area 112 in the front glass 110 can be selectively configured. In some optional embodiments of the invention, part or all of the edge of the front glass 110 is extended outward, with the extended portion forming the exposed area 112, so that the edge of the front glass 110 will be exposed at the corresponding position during lamination. In this embodiment, the front glass 110 and the back glass 150 may have different lengths and / or widths. The length mentioned herein refers to the dimension along the length direction X, and the width mentioned herein refers to the dimension along the width direction Y. For example, if the exposed areas 112 of the front glass 110 are located at the four corners, then during the fabrication of the front glass 110, the four corners of the front glass 110 are extended outward along the length direction X and the width direction Y, respectively, to form four exposed areas 112. The length of the front glass 110 is greater than the length of the back glass 150, and the width of the front glass 110 is greater than the width of the back glass 150. If the exposed areas 112 of the front glass 110 are located on a pair of long sides of the front glass 110, then during the fabrication of the front glass 110, the pair of long sides of the front glass 110 are extended outward along the width direction Y, forming four exposed areas 112. The exposed areas 112 are located on the two long sides of the front glass 110. The length of the front glass 110 is equal to the length of the back glass 150, and the width of the front glass 110 is greater than the width of the back glass 150. If the exposed areas 112 of the front glass 110 are located on a pair of short sides of the front glass 110, then during the fabrication of the front glass 110, the pair of short sides of the front glass 110 are extended outward along the length direction X to form the exposed areas 112 located on the two short sides of the front glass 110. The length of the front glass 110 is greater than the length of the back glass 150, and the width of the front glass 110 is equal to the width of the back glass 150. By extending part or all of the edge of the front glass 110 outward to form the exposed areas 112, the forming method is flexible. The position, shape, and area of ​​the exposed areas 112 can be freely designed, and they can be extended outward in any area of ​​the front glass 110 as needed.

[0025] In some alternative embodiments of the invention, the exposed area 112 in the front glass 110 is formed by subtractive processing of the back glass 150. In this embodiment, the front glass 110 and the back glass 50 may have the same length and width. Figure 2-6As shown, the back glass 150 includes a back main area 151 and a through area 152 located at least part of the edge of the back main area 151. The exposed area 112 in the front glass 110 is the projection area of ​​the through area 152 along the thickness direction Z on the front glass 110. The through area 152 can be formed by grinding or drilling. For example, for the area in the front glass 110 that needs to be exposed, the material at the corresponding position in the back glass 150 is removed by grinding or drilling, reducing the coverage area of ​​the back glass 150, thereby exposing the corresponding area in the front glass 110 to form the exposed area 112. By forming the exposed area 112 in the front glass 110 by subtracting material from the back glass 150, it is not necessary to adjust the size of the front glass 150 or the component frame used for encapsulating the laminate. Furthermore, both the front glass 110 and the back glass 150 can be processed and manufactured by purchasing standardized glass templates, resulting in a high degree of standardization.

[0026] The number, specific location, outline shape, and size of the exposed areas 112 in the front glass 110 can all be designed and adjusted as needed. When the exposed areas 112 are formed by extending part or all of the edge of the front glass 110 outward, the exposed areas 112 can be freely set on the entire long side, the entire short side, a local point on the long side, or a local point on the short side of the front glass 110 according to actual usage requirements. The total number and arrangement of the exposed areas 112 can be adjusted according to actual needs. The outline shape of the exposed areas 112 can also be flexibly set as rectangle, circle, triangle, irregular outline, etc. At the same time, the size of the exposed areas 112 can be precisely changed by controlling the outward extension distance of the front glass 110. When the exposed area 112 in the front glass 110 is formed by subtracting material from the back glass 150, the number, position, outline shape, and area of ​​the exposed area 112 in the front glass 110 are adjusted accordingly by adjusting the number of grinding and / or opening points, the edge orientation, the outline style of the grinding and opening, and the processing range size of the back glass 150. Figure 1-3 In the optional embodiment shown, a triangular area is removed from each of the four corners of the back glass 150 by grinding. The removed triangular areas correspond to the through areas 152 of the back glass 150, thereby forming an exposed area 112 at each of the four corners of the front glass 110. The outline shape of each exposed area 112 is triangular. Figure 4In the optional embodiment shown, a fan-shaped through area 152 is provided at regular intervals along the long and short sides of the back panel glass 150, and a fan-shaped through area 152 is provided at each of the four corners of the back panel glass 150, thereby forming a plurality of exposed areas 112 in the front panel glass 110, each exposed area 112 having a fan-shaped outline. Figure 5-6 In the optional embodiment shown, a rectangular through-area 152 is provided at regular intervals along the long and short sides of the back panel glass 150, and a rectangular through-area 152 is provided at each of the four corners of the back panel glass 150, thereby forming a plurality of exposed areas 112 in the front panel glass 110, each exposed area 112 having a rectangular outline. Those skilled in the art should understand that... Figure 1-6 The outline shape of the exposed area 112 shown is only an example. Those skilled in the art can set the exposed area 112 to other outline shapes according to the actual situation, such as ellipse, star, L-shape, cross shape, etc. The embodiments of the present invention do not specifically limit the outline shape of the exposed area 112.

[0027] When the exposed area 112 in the front glass 110 is formed by subtracting material from the back glass 150, the through area 152 can be an open or closed groove located at the edge of the back main body area 151. An open groove refers to a groove whose cavity is connected to the edge of the back main body area 151 and whose opening faces outwards; a closed groove refers to a groove whose cavity is surrounded by the back main body area 151 and whose cavity is not connected to the edge of the back main body area 151 in any area. Figure 1-6 In the optional embodiment shown, the through region 152 is an open groove provided at the edge of the back main body region 151. Those skilled in the art can also set the through region 152 as a closed groove at the edge of the back main body region 151 (not shown in the figure) according to actual needs. The embodiments of the present invention do not specifically limit this.

[0028] exist Figure 3 In the illustrated alternative embodiment, material is removed from the four corners of the back panel glass 150 by grinding, thereby forming through regions 152 with triangular outlines at the four corners of the back panel glass 150. In the figure, W1 represents the dimension of the back panel main body region 151 along the short side (Y direction) of the back panel glass 150, W2 represents the dimension of the corner regions removed by grinding along the short side (Y direction) of the back panel glass 150 (i.e., the dimension of the through regions 152 along the Y direction), L1 represents the dimension of the back panel main body region 151 along the long side (X direction) of the back panel glass 150, and L2 represents the dimension of the corner regions removed by grinding along the long side (X direction) of the back panel glass 150 (i.e., the dimension of the through regions 152 along the X direction). Figure 6 and Figure 13In the optional embodiment shown, material is removed from the four corners of the back glass 150 by grinding, thereby forming through regions 152 with rectangular outlines at the four corners of the back glass 150. In the figure, W2 represents the dimension of the corner region removed by grinding along the short side (Y direction) of the back glass 150 (i.e., the dimension of the through region 152 along the Y direction), and L2 represents the dimension of the corner region removed by grinding along the long side (X direction) of the back glass 150 (i.e., the dimension of the through region 152 along the X direction).

[0029] In this embodiment of the invention, the dimension of the through region 152 along the long side (X direction) or short side (Y direction) of the back glass 150 is referred to as the processing depth of the through region 152. For example, the larger of the dimensions of the through region 152 along the long side (X direction) and short side (Y direction) of the back glass 150 is referred to as the processing depth of the through region 152. The processing depth of the through region 152 can be selectively set according to actual conditions. For example, the processing depth of the through region 152 is less than or equal to 10 mm, such as 10 mm, 8 mm, or 5 mm.

[0030] According to a second aspect of the present invention, a lamination tooling is provided. Figure 7 This is a schematic diagram of the lamination tooling in some optional embodiments of the present invention, such as... Figure 7 As shown, the lamination fixture 200 includes: a fixture body 210 and a pressing component 220; wherein, the fixture body 210 includes a fixture frame 211, the pressing component 220 is disposed on the inner side of the fixture frame 211, and the lower side of the pressing component 220 is higher than the lower side of the fixture frame 211; during lamination, the fixture frame 211 is fitted around the lamination assembly 100, and the lower side of the pressing component 220 abuts against the exposed area 112 of the front glass 110 in the lamination assembly 100. In this embodiment of the invention, the pressing component 220 of the laminating fixture 200 has a pressing function. The front adhesive film 120, the battery string layer 130, the back adhesive film 140, and the back glass 150 do not cover the exposed area 112 of the front glass 110. After the laminating assembly 100 is stacked, the exposed area 112 in the front glass 110 is exposed. With the laminating fixture 200 of this embodiment of the invention having a pressing function, the pressing component 220 abuts against the exposed area 112 of the front glass 110, which can prevent the front glass of the exposed area 112 from warping due to heat, reduce or avoid edge missing adhesive bubbles and low thickness of the laminate during the lamination process, and improve the process yield and long-term reliability of the laminate.

[0031] The pressing component 220 is disposed on the inner side of the tooling frame 211. Its overall structural parameters and manufacturing material can be selectively and flexibly set according to the overall specifications of the component, assembly clamping force requirements, assembly space, and production process conditions. This embodiment of the invention does not specifically limit the material of the pressing component 220, as long as it meets the basic requirements for structural support, pressure bearing, and mechanical strength. For example, the pressing component 220 can be made of metal, such as aluminum alloy, cold-rolled carbon steel, stainless steel, or other metal profiles. Alternatively, it can be made of non-metallic rigid materials such as high-strength rigid engineering plastics selected based on lightweight and corrosion-resistant assembly requirements. Furthermore, the gravity generated by the pressing component 220 itself can apply a pre-compression force to the front glass 110. During lamination, as the temperature rises, the thrust generated by the material expansion of the front glass 110 can offset the aforementioned pre-compression force, thereby reducing the internal stress of the front glass 110 at the high lamination temperature. This prevents the exposed area 112 in the front glass 110 from warping due to heat, while mitigating or avoiding the risk of the front glass 110 developing microcracks or breaking due to overpressure. In some optional embodiments of the present invention, at least a portion of the pressing member 220 is a magnet. For example, the pressing member 220 is made of a material with magnets, or the pressing member 220 includes components with magnets. The lamination equipment base plate is typically an iron plate. By making at least a portion of the pressing member 220 a magnet, a pre-compression force can be applied to the front glass 110 through the magnetic attraction between the pressing member 220 and the base plate. During the lamination process, when the temperature rises, the thrust generated by the material expansion of the front glass 110 can be offset by the pre-compression force generated by the magnetic attraction force, thereby further reducing the internal stress of the front glass 110 at the high temperature of lamination. While preventing the exposed area 112 in the front glass 110 from warping due to heat, it further mitigates or avoids the risk of the front glass 110 developing hidden cracks or breaking due to overpressure.

[0032] The pressing member 220 is disposed on the inner side of the tooling frame 211 and extends inward from the inner side of the tooling frame 211. The extending direction of the pressing member 220 can be parallel to the long side direction X or the short side direction Y of the laminating assembly 100, or it can be in other directions. The pressing member 220 extends inward from the inner side of the tooling frame 211 along its extending direction and contacts the back side of the front panel glass 110 during lamination. In this embodiment of the invention, the dimension of the contact area between the pressing member 220 and the front panel glass 110 along the extending direction of the pressing member 220 is called the intrusion assembly length of the pressing member 220, and the dimension of the contact area between the pressing member 220 and the front panel glass 110 in the direction perpendicular to the extending direction of the pressing member 220 is called the intrusion assembly width of the pressing member 220. Figure 11 This is a schematic diagram of the lamination tooling in some optional embodiments of the present invention. Figure 12 yes Figure 11 A schematic diagram of the suppression area in region A of the middle region. Figure 11 and Figure 12 In the optional embodiment shown, the direction in which the pressing member 220 extends inward is in the same plane as the long side direction X and the short side direction Y, and the angle between the pressing member 220 and the long side direction X and the short side direction Y is 45°. The length of the intrusion component of the pressing member 220 is L3 and the width of the intrusion component is W3. Figure 13 This is a schematic diagram of the lamination tooling in some optional embodiments of the present invention. Figure 14 yes Figure 13 A schematic diagram of the suppression area in region C of the middle region. Figure 13 and Figure 14 In the optional embodiment shown, the direction in which the pressing member 220 extends inward is in the same plane as the long side direction X and the short side direction Y, and is parallel to the short side direction Y. The length of the intrusion component of the pressing member 220 is L3 and the width of the intrusion component is W3.

[0033] The thickness of the pressing component 220 refers to its dimension along the thickness direction Z. The thickness of the pressing component 220 can be selectively set, for example, based on the required clamping load, assembly clearance, structural load-bearing requirements, and assembly space allowance. The outline shape of the pressing component 220 can also be selectively set. In practical applications, it can be flexibly selected based on the shape of the assembly area, the edge shape of the front glass 110, and the avoidance requirements of surrounding components. For example, the outline shape of the pressing component 220 can be rectangular, circular, arc-shaped, irregularly shaped, stepped, or any other outline shape that fits the assembly space and meets the avoidance assembly requirements.

[0034] The height of the pressed part 220 is the distance between the lower side of the pressed part 220 and the lower side of the tooling frame 211. Figure 7In the optional embodiments shown, H1 represents the height of the pressing member 220. The height of the pressing member 220 can be selectively set according to actual needs. Setting a higher height for the pressing member 220 can avoid excessive pressure on the front glass 110, reducing the risk of microcracks or breakage of the front glass 110 due to excessive pressure. Setting a lower height for the pressing member 220 can ensure effective contact between the pressing member 220 and the exposed area 112 of the front glass 110, preventing warping of the exposed area 112 of the front glass 110. In some optional embodiments of the present invention, the height of the pressing member 220 is less than or equal to the thickness of the front glass 110. Further, the height difference between the back surface of the front glass 110 and the lower side surface of the pressing member 220 is less than or equal to 0.5 mm, for example, the height difference between the back surface of the front glass 110 and the lower side surface of the pressing member 220 is 0.5 mm, or 0.4 mm, or 0.3 mm, or 0.2 mm, etc. In this embodiment of the invention, by making the height of the pressing member 220 less than or equal to the thickness of the front glass 110, the pressing member 220 deforms when its lower surface abuts against the back surface of the front glass 110. After deformation, the pressing member has a recovery tendency. Under this recovery tendency, the pressing member 220 is tightly pressed against the back surface of the front glass 110, which can ensure effective contact between the pressing member 220 and the exposed area 112 of the front glass 110, and prevent the exposed area 112 of the front glass 110 from warping. By setting the height difference between the back surface of the front glass 110 and the lower side surface of the pressing member 220 to be less than or equal to 0.5 mm, it can prevent the pressing member 220 from over-pressing the exposed area of ​​the front glass 110, and reduce the risk of the front glass 110 developing microcracks or breaking due to over-pressure.

[0035] The contact area between the pressing component 220 and the front glass 110 can be selectively set according to actual needs. Typically, the exposed area 112 of the front glass 110 is the area prone to warping. During lamination, the projected area of ​​the pressing component 220 along its thickness direction on the front glass 110 can be made smaller than the area of ​​the exposed area 112 it contacts. In other words, the contact area between the laminating component 220 and the front glass 110 is smaller than the area of ​​the corresponding exposed area 112 in the front glass 110. By making the contact area between the pressing component 220 and the front glass 110 smaller than the area of ​​the corresponding exposed area 112 in the front glass 110, the pressing component 220 can be prevented from obstructing the effective area of ​​the front glass 110, thereby improving the photoelectric conversion efficiency of the laminating component.

[0036] The size of the contact area between the pressing component 220 and the exposed area 112 of the front glass 110, as well as the arrangement of the contact area, can be selectively set. For example, it can be flexibly adjusted according to stress dispersion requirements, the range where warping is likely to occur, and the size of the exposed area in the front glass 110. For example, it can be set with small-area dot-like bonding, narrow strip linear bonding, large-area full-coverage bonding, or partial hollow bonding structure, etc. The embodiments of the present invention do not specifically limit this.

[0037] Figure 8 This is a schematic diagram of the lamination tooling in some optional embodiments of the present invention. Figure 8 In the optional embodiment shown, the laminating fixture 200 further includes a buffer 230; the pressing member 220 is disposed on the inner side of the fixture frame 211, and the buffer 230 is disposed on the lower side of the pressing member 220. Figure 9 This is a schematic diagram of the lamination effect of the lamination tooling and lamination assembly in an optional embodiment of the present invention, as shown below. Figure 9 As shown, during lamination, the pressing member 220 does not directly abut against the exposed area 112 of the front glass panel 110, but rather abuts against the exposed area 112 of the front glass panel 110 through the buffer member 230. The height of the buffer member 230 is the distance between the lower side of the buffer member 230 and the lower side of the tooling frame 211. Figure 8In the optional embodiments shown, H2 represents the height of the buffer 230. The thickness of the buffer 230 can be selectively set according to actual needs. Setting a thicker buffer 230 can improve the buffering effect between the pressing member 220 and the exposed area 112 of the front glass 110; setting a thinner buffer 230 can avoid the buffer 230 from over-pressing the front glass 110, reducing the risk of the front glass 110 developing microcracks or breaking due to over-pressing. In some optional embodiments of the present invention, the height of the buffer 230 is less than or equal to the thickness of the front glass 110. Further, the height difference between the back side of the front glass 110 and the lower side of the buffer 230 is less than or equal to 0.5 mm, for example, the height difference between the back side of the front glass 110 and the lower side of the buffer 230 is 0.5 mm, or 0.4 mm, or 0.3 mm, or 0.2 mm, etc. In this embodiment of the invention, by making the height of the buffer 230 less than or equal to the thickness of the front glass 110, the buffer 230 deforms when its lower surface abuts against the back of the front glass 110. After deformation, the buffer 230 has a recovery tendency. Under this recovery tendency, the buffer 230 is tightly pressed against the back of the front glass 110, which can ensure effective contact between the buffer 230 and the exposed area 112 of the front glass 110, and prevent the exposed area 112 of the front glass 110 from warping. By setting the height difference between the back of the front glass 110 and the lower side of the buffer 230 to less than or equal to 0.5 mm, it can prevent the buffer 230 from excessively pressing the exposed area 112 of the front glass 110, and reduce the risk of the front glass 110 developing microcracks or breaking due to overpressure.

[0038] The buffer component 230 is a non-mandatory, optional assembly accessory that can be omitted. Its selection can be flexibly adjusted based on parameters such as the component assembly process, lamination process parameters, contact area with the exposed area 112, and the thickness of the front glass 110. The core function of the buffer component 230 is to isolate the rigid contact between the pressing component 220 and the front glass 110, buffer instantaneous impact stress during the lamination process, evenly distribute localized concentrated loads, and eliminate defects such as microcracks, edge chipping, surface scratches, and residual stress in the front glass 110 caused by direct squeezing, bumping, and friction from the pressing component 220. Simultaneously, it can fill gaps between components, reducing frictional noises and structural fretting wear caused by temperature deformation, mechanical vibration, and wind pressure loads during long-term outdoor service. The material selection for the buffer component 230 can be selectively configured according to actual needs. Considering the high-temperature conditions of photovoltaic module lamination production, outdoor high and low temperature alternation, ultraviolet radiation, and moisture corrosion service environment, elastic materials with high temperature resistance, UV aging resistance, damp heat resistance, high resilience, low exudation, and low pollution characteristics can be selected. For example, the buffer 230 is made of high-temperature resistant elastic rubber, such as silicone rubber, EPDM rubber, fluororubber, and nitrile rubber. These materials exhibit excellent resilience, low compression set, and resistance to outdoor UV aging and damp heat corrosion. They are suitable for high-temperature lamination processes and are not prone to hardening, cracking, or powdering with long-term use. As another example, the buffer 230 is made of heat-resistant elastic plastic and foamed substrates, such as high-density polyurethane foam, cross-linked polyethylene closed-cell foam, modified polypropylene elastic engineering plastic, polyimide flexible plastic, and PET flexible cushioning plastic. These materials have a dense structure, strong dimensional stability, controllable compression rebound, and no adhesive exudates, preventing contamination of the glass surface and component encapsulation layer, thus meeting the requirements for lightweight and thin assembly.

[0039] In this embodiment of the invention, the tooling body 210 is used to fix the lamination assembly 100 during the lamination process. The structure of the tooling body 210 can be selectively configured. For example, the tooling body 210 can be several discrete structures; for instance, the tooling body 210 may include corner protection structures for fixing the exposed areas 112 in the front glass 110, or the tooling body 210 may include strip structures for fixing a pair of long sides or a pair of short sides of the lamination assembly 100. The tooling body 210 can also be a frame structure; for example, the tooling body 210 may include a tooling frame 211 for fixing the lamination assembly 100 (e.g., ...). Figure 7-14 (As shown). When the fixture body 210 is a frame structure, the outline shape of the fixture border 211 can be selectively set, such as a rectangle or other shapes.

[0040] In an optional embodiment of the present invention, the tooling body 210 has a rectangular frame, and the tooling body 210 further includes a tooling fastener 212 disposed at the corner of the tooling frame 211. Figure 7-14As shown, the tooling fastener 212 is disposed on the upper side of the tooling frame 211. Due to the deformation of the glass itself during lamination, such as warping at the three corners, and the melting of the adhesive film inside the laminating assembly 100 during lamination, which overflows to all four sides of the laminating assembly 100, the four corners of the laminating assembly 100 experience high pressure. Combined with the glass warping, the pressure on the tooling frame 211 is uneven, making the four corners of the tooling frame 211 prone to deformation and affecting its fixing stability. This embodiment of the invention increases the fixing stability of the four corners of the tooling frame 211 by placing tooling fasteners 212 at the corners of the tooling frame 211, making the thickness of the four corners of the tooling frame 211 greater than the thickness of the rest of the tooling frame 211. The outline shape and structure of the tooling fastener 212 can be selectively set according to actual conditions. Figure 10-14 In the optional embodiment shown, the tooling fastener 212 is L-shaped and includes a first clamping portion 2121 and a second clamping portion 2122 that are perpendicular to each other. The first clamping portion 2121 is disposed on the outer side of the short side of the laminate assembly 100, and the second clamping portion 2122 is disposed on the outer side of the long side of the laminate assembly 100. The first clamping portion 2121 and the second clamping portion 2122 can be integrally formed or connected together by welding or other methods.

[0041] In some optional embodiments of the present invention, such as Figure 10-14 As shown, the lamination fixture 200 may also include an isolation liner 213. In addition to including the fixture body 210 and... Figure 10 This is a schematic diagram of the lamination tooling in some optional embodiments of the present invention. Figure 10 In the alternative embodiment shown, the laminating fixture 200 includes not only the fixture frame 211 and the fixture fastener 212, but also the isolation liner 213.

[0042] During lamination, the glass itself is prone to deformation, such as warping at the corners. Furthermore, the melted adhesive film in the laminating assembly 100 easily overflows to all four sides, leading to uneven pressure distribution at different locations within the laminating assembly 100. Additionally, if the inner wall of the fixture body 210 is in contact with the edge of the front glass 110 in the laminating assembly 100 during lamination, the adhesive film is easily blocked from overflowing or pushed to the back of the laminating assembly 100 by the fixture body 210, resulting in poor bonding in certain areas of the laminating assembly 100. The lamination fixture 200 in this embodiment of the invention includes an isolation liner 213. The isolation liner 213 allows for a certain gap between the inner side of the fixture body 210 and the lamination assembly 100, preventing poor bonding in some areas of the lamination assembly 100 due to the adhesive film failing to overflow or being pushed onto the back of the lamination assembly 100 by the fixture body 210. Furthermore, it evenly distributes the lamination pressure to all locations within the lamination assembly 100, preventing uneven pressure in some areas. In addition, the isolation liner 213 also provides cushioning, low-friction anti-sticking, and heat insulation, protecting the appearance of the lamination assembly 100. The isolation liner 213 is an optional assembly structure, and different materials can be flexibly selected according to lamination temperature, lamination pressure, and production cost requirements. For example, the isolation liner 213 is polytetrafluoroethylene coated fiberglass cloth (PTFE cloth), or silicone rubber coated fiberglass cloth, or FEP (Fluorinated ethylene propylene) film, or PFA (Perfluoroalkoxy) film, or ETFE (Ethylene Tetra FluoroEthylene) fluoroplastic film, or high-temperature resistant PET (Polyethylene terephthalate) release film, or polyimide PI (Polyimide) film, or high-silica fiberglass cloth, or ceramic fiber cloth, etc.

[0043] The location of the isolation liner 213 can be selectively set according to actual conditions, such as setting it at one or more corners of the tooling body 210, or connecting the two long sides of the tooling body 210, or connecting the two short sides of the tooling body 210, etc. Figure 10 In the optional embodiment shown, the isolation liner 213 is disposed at the four corners of the tooling body 210 and between the two long sides of the tooling body 210; Figure 11 and Figure 13 In the optional embodiment shown, the isolation liner 213 is disposed between the two long sides of the tooling body 210. The embodiments of the present invention do not specifically limit the placement of the isolation liner 213.

[0044] According to a third aspect of the present invention, a laminate is provided, which is obtained by laminating a laminating assembly 100 provided in the first aspect of the present invention using a laminating fixture 200 provided in the second aspect of the present invention.

[0045] The method for preparing the laminated component according to embodiments of the present invention may include the following steps: S1. Lamination. A front adhesive film 120, a battery string layer 130, and a back adhesive film 140 are laid on the back of the front glass 110; the front adhesive film 120, the battery string layer 130, the back adhesive film 140, and the back glass 150 do not cover the exposed area 112 of the front glass 110; S2. Center the back glass 150 over the back adhesive film 140 to obtain the laminated assembly 100. S3. Use edge sealing tape to seal the edges of the laminated assembly 100; S4. Place a laminating fixture 200 above the back glass 150 of the edge-sealed laminated assembly 100, wherein the pressing part 220 of the laminating fixture 200 is positioned corresponding to the exposed area 112 of the edge of the front glass 110. S5. The above-mentioned laminating components are fed into a laminator for lamination to obtain the laminated component in the embodiment of the present invention.

[0046] In practical applications, after obtaining the laminate through step S5, operations such as edge trimming, framing, and junction box installation can be performed on the laminate to obtain the photovoltaic module. A schematic diagram of the exposed area 112 after framing is shown below. Figure 15 As shown in the figure, 300 represents the component border.

[0047] The following detailed description is provided in conjunction with specific embodiments.

[0048] Example 1: Select a front glass panel 110 with a thickness of 2.0mm, a length of 2272mm, and a width of 1128mm, and a back glass panel 150. Perform large chamfering and edge grinding on the four corners of the back glass panel 150. The chamfer dimensions L2 along the length direction X and W2 along the width direction Y are both 6mm. The structure is as follows: Figure 2 and Figure 3 As shown in the figure. Figure 2 The shadowed areas at the four corners correspond to the exposed areas 112 in the front glass panel 110.

[0049] The laminated module is stacked using conventional processes, consisting of a front glass 110, a front encapsulating film 120, a battery string layer 130, a back encapsulating film 140, and a back glass 150. The lengths (X) of the front and back encapsulating films 120 and 140 are less than or equal to the length (L1) of the back main body region 151 of the back glass 150 along the length direction, and the widths (Y) of the front and back encapsulating films 120 and 140 are less than or equal to the width (W1) of the back main body region 151 of the back glass 150 along the width direction. After the module is laminated, edge sealing tape is applied, avoiding the ground edge treatment area of ​​the back glass 150. Simultaneously, a laminating fixture 200 is placed on the back glass 150, with the pressing component 220 corresponding to the exposed area 112 in the front glass 110. A lamination diagram is shown below. Figure 9 As shown in the figure. In this embodiment, the four corner areas of the lamination fixture are equipped with pressing components 220 compared to conventional lamination fixtures. The pressing components 220 are made of 2mm thick steel and extend into the exposed area 112 of the front glass 110. The lower side of the extended part is provided with a 1mm thick high-temperature resistant rubber as a buffer 230. The specific structure is as follows. Figure 8 As shown. The height H1 of the pressing component 220 is less than or equal to the thickness of the front glass 110, and the intrusion width W3 of the pressing component 220 into the assembly is less than or equal to the chamfer width W2 in the back glass 150. See the enlarged view of the corner pressing area A of the laminated assembly 100. Figure 12 As shown. In this example, the height H1 of the pressed component 220 is 2mm, the width W3 of the intrusion component is 5mm, and the length L3 of the intrusion component is 4mm.

[0050] The laminate prepared using the method in this embodiment has a significantly improved edge thickness compared to conventional double-glass laminates, with an increase of 0.27-0.37 mm at the edges and a reduction in the thickness difference between the center and the four corners to 0.16 mm. Simultaneously, the internal encapsulant thickness reaches 1.06 mm, which can greatly improve module reliability and avoid problems such as delamination caused by glass springback after aging.

[0051] Example 2: In this embodiment, the dimensions of the front and back glass are the same as in Embodiment 1, using a front glass 110 with a thickness of 2.0 mm, a length of 2272 mm, and a width of 1128 mm, and a back glass 150. Unlike Embodiment 1, this embodiment features an edge-drilled design for the back glass 150, with five openings on the long side and two on the short side. The openings are rectangular. The width W2 of the openings on the long side is 5 mm and the length L2 is 10 mm, and the width W2 of the openings on the short side is 10 mm and the length L2 is 5 mm, respectively. Figure 4-6 As shown.

[0052] In this embodiment, the position of the pressing component 220 in the lamination fixture 200 corresponds to the position of the opening slot in the back glass 150, such as... Figure 13 and Figure 14 As shown. The pressing component 220 is made of 2mm thick aluminum, and the lower side of the inserted part is provided with 1mm thick high-temperature resistant rubber as a buffer component 230. In this example, the height H1 of the pressing component 220 is 2mm, the width W3 of the inserted component is 8mm, and the length L3 of the inserted component is 4mm.

[0053] The laminate prepared using the method in this embodiment has a significantly improved edge thickness compared to conventional double-glass laminates, with an increase of 0.28-0.40 mm at the edges and a reduction in the thickness difference between the center and the four corners to 0.16 mm. Simultaneously, the internal encapsulant thickness of 1.08 mm significantly improves module reliability and avoids delamination problems caused by glass springback after aging.

[0054] The laminating fixture 200 with pressing function in this embodiment of the invention is used to laminate the laminating assembly 100 provided in the first aspect of the invention. The pressing element 220 in the laminating fixture 200 abuts against the back edge of the exposed area 112 in the front glass 110, preventing warping of the exposed area 112 of the front glass 110 during the lamination process. The laminating fixture 200 in this embodiment of the invention has a significant improvement effect on the edge thickness of the laminating assembly 100, resulting in a laminating assembly with high edge thickness uniformity and a very small thickness difference between the middle area and the four corners. The thickness difference between the middle area and the four corners of a conventional laminating assembly is close to 0.5 mm, and the thinnest adhesive film at the four corners is only 0.4-0.5 mm, posing a serious reliability risk. The lamination fixture 200 in this embodiment of the invention is used to laminate the lamination assembly 100 provided in the first aspect of the invention. The thickness difference between the middle area and the four corners of the laminate is usually less than or equal to 0.2 mm, and the overall thickness of the adhesive film in the laminate is greater than or equal to 0.5 mm. This can solve the reliability problems caused by overpressure bubbles and glass warping after aging in conventional lamination assembly processes, and improve the long-term reliability of the laminate.

[0055] In this embodiment of the invention, by ensuring that the front adhesive film, battery string layer, back adhesive film, and backplate glass do not cover the exposed area of ​​the front glass, the corresponding area of ​​the laminated assembly can be exposed by the front glass after lamination. With the lamination tooling having a pressing function, the pressing component of the tooling abuts against the exposed area of ​​the front glass, which can prevent the exposed area of ​​the front glass from warping due to heat, reduce or avoid edge missing adhesive bubbles and low thickness of the laminated parts during the lamination process, and improve the process yield and long-term reliability of the laminated parts.

[0056] The above steps are provided only to help understand the method, structure, and core ideas of this invention. Those skilled in the art can make various improvements and modifications to this invention without departing from its principles, and these improvements and modifications also fall within the scope of protection of the claims.

Claims

1. A laminated assembly, characterized in that, At least including: The front panel glass (110), front adhesive film (120), battery string layer (130), back adhesive film (140), and back panel glass (150) are sequentially stacked along the thickness direction; among them, The front panel glass (110) includes: a front panel main body area (111) and an exposed area (112) located at least a portion of the edge of the front panel main body area (111); the front adhesive film (120), the battery string layer (130), the back adhesive film (140) and the back panel glass (150) are disposed on the front panel main body area (111) of the front panel glass (110) and do not cover the exposed area (112) of the front panel glass (110).

2. The laminated assembly according to claim 1, characterized in that, The back panel glass (150) includes: a back main body region (151) and a through region (152) located at least a portion of the edge of the back main body region (151); the exposed region (112) is the projection area of ​​the through region (152) onto the front panel glass (110) along the thickness direction.

3. The laminated assembly according to claim 2, characterized in that, The through area (152) is an open or closed groove located at the edge of the main body area (151) on the back side.

4. The laminated assembly according to claim 2, characterized in that, The processing depth of the through area (152) is less than or equal to 10 mm, and the processing depth of the through area (152) is the dimension of the through area (152) along the long or short side of the back glass (150).

5. A lamination tooling, characterized in that, include: The tooling body (210) and the pressing component (220) are provided; wherein the tooling body (210) includes a tooling frame (211), the pressing component (220) is disposed on the inner side of the tooling frame (211), and the lower side of the pressing component (220) is higher than the lower side of the tooling frame (211); During lamination, the tooling frame (211) is fitted around the lamination assembly (100), and the lower side of the pressing component (220) abuts against the exposed area (112) of the front glass (110) in the lamination assembly (100).

6. The lamination tooling according to claim 5, characterized in that, The lamination fixture also includes a buffer (230), which is disposed on the lower side of the pressing component (220); optionally, the height of the buffer (230) is less than the thickness of the front glass (110); the height of the buffer (230) is the distance between the lower side of the buffer (230) and the lower side of the fixture frame (211).

7. The lamination tooling according to claim 5 or 6, characterized in that, At least a portion of the pressing element (220) is a magnet.

8. The lamination tooling according to claim 5, characterized in that, The tooling frame (211) is a rectangular frame; the tooling body (210) also includes a tooling fastener (212) disposed at the corner of the tooling frame (211).

9. The lamination tooling according to claim 5, characterized in that, The height of the pressing member (220) is less than the thickness of the front glass (110); the height of the pressing member (220) is the distance between the lower side of the pressing member (220) and the lower side of the tooling frame (211); And / or, the projected area of ​​the pressing member (220) along the thickness direction on the front panel glass (110) is smaller than the area of ​​the exposed area (112) it abuts.

10. A laminate, characterized in that, The laminated assembly (100) according to any one of claims 1-4 is obtained by laminating the lamination assembly (100) according to any one of claims 5-9 using the lamination tooling (200) according to any one of claims 5-9.

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