Photovoltaic module and method for producing a photovoltaic module

Abstract

The application provides a photovoltaic module and a preparation method thereof, and relates to the technical field of photovoltaic technology.The photovoltaic module provided by the application comprises photovoltaic glass, adhesive film, cell pieces, flexible bus bars, heat dissipation plates and back plates which are sequentially stacked, the upper surface and the lower surface of the photovoltaic glass are both corrugated curved surface shapes, the adhesive film is glued between the lower surface of the photovoltaic glass and the cell pieces, the shape of the cell pieces matches the shape of the lower surface of the photovoltaic glass, the flexible bus bars are arranged on the cell pieces and match the shape of the cell pieces, the shape of the upper surface of the heat dissipation plates matches the shape of the flexible bus bars, the heat dissipation plates have heat dissipation channels, and the heat dissipation channels extend to the outside of the heat dissipation plates.The photovoltaic module and the preparation method thereof can stabilize the power generation of the photovoltaic module and improve the power generation efficiency of the photovoltaic module.

Description

Technical Field

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

[0002] Currently, most mainstream photovoltaic (PV) modules in the industry adopt a planar structure, consisting of laminated photovoltaic glass, solar cells, busbars, and backsheets. However, this type of PV module presents several problems during actual outdoor operation under complex conditions. First, existing solar cells have poor utilization of oblique and diffused light. In low-light environments, light is easily reflected and escapes, and the short optical path and low photon utilization rate affect power generation efficiency. Second, PV modules tend to accumulate heat and operate at higher temperatures outdoors. Under high-temperature conditions, the module's power generation efficiency will significantly decrease, and long-term operation can lead to permanent power degradation. Furthermore, the existing connection structure of solar cells and rigid busbars is subject to thermal expansion and contraction deformation under varying day-night temperatures, causing stress concentration at the solder joints. This can lead to failures such as desoldering and microcracks in the solar cells, resulting in a decrease in power generation efficiency and output. Summary of the Invention

[0003] This application provides a photovoltaic module and a method for manufacturing a photovoltaic module, which can stabilize the power generation of the photovoltaic module and improve the power generation efficiency of the photovoltaic module.

[0004] To achieve the above objectives, this application provides the following technical solution:

[0005] In a first aspect, this application provides a photovoltaic module, including photovoltaic glass, encapsulant film, solar cells, flexible busbar, heat sink, and backsheet stacked sequentially. The upper and lower surfaces of the photovoltaic glass are both corrugated curved surfaces. The encapsulant film is adhered between the lower surface of the photovoltaic glass and the solar cells. The shape of the solar cells matches the shape of the lower surface of the photovoltaic glass. The flexible busbar is disposed on the solar cells and matches the shape of the solar cells. The shape of the upper surface of the heat sink matches the shape of the flexible busbar. The heat sink has heat dissipation channels that extend to the outside of the heat sink.

[0006] As an optional implementation, it also includes a frame, in which the sides of the photovoltaic glass, the encapsulant film, the solar cells, the flexible busbar, the heat sink, and the backplate are all embedded, and the sides of the frame have vents that connect to the heat dissipation channel.

[0007] As an optional implementation, the photovoltaic glass is tempered glass with a thickness of 2.5mm-3.2mm and a spacing of 40mm-44mm between two adjacent peaks on the upper surface of the photovoltaic glass.

[0008] As an optional implementation, the thickness of the adhesive film is 0.3mm-0.5mm.

[0009] As an optional implementation, the film is doped with 0.4%-0.6% silicon dioxide by mass.

[0010] As an optional implementation, the thickness of the flexible busbar is 0.1mm-0.14mm.

[0011] As an alternative implementation, the lower surface of the heat sink has a corrugated curved shape, and the upper surface of the backplate matches the shape of the lower surface of the heat sink.

[0012] Secondly, this application provides a method for preparing a photovoltaic module, used to prepare the photovoltaic module of the first aspect, comprising the following steps:

[0013] The battery cells are pressed into a corrugated curved shape using a flexible pressing process.

[0014] The flexible busbar is bonded to the main busbar of the battery cell using ultrasonic welding technology.

[0015] The photovoltaic glass, encapsulant film, solar cells with welded flexible busbars, heat sink, and backsheet are stacked sequentially and laminated using a vacuum lamination process. The upper and lower surfaces of the photovoltaic glass are both corrugated curved surfaces. The shape of the solar cells matches the shape of the lower surface of the photovoltaic glass. The shape of the upper surface of the heat sink matches the shape of the flexible busbar. The heat sink has heat dissipation channels that extend to the outside of the heat sink.

[0016] As an optional implementation method, the solar cells are pressed into a corrugated arc-shaped structure using a flexible pressing process, specifically including:

[0017] The flexible pressing process is used to press the battery cells at a temperature of 120℃-130℃ and a pressure of 0.3MPa-0.35MPa for 10s-20s, thereby pressing them into a corrugated curved shape.

[0018] As an optional implementation method, a vacuum lamination process is used for lamination, specifically including: lamination at a temperature of 146℃-150℃ using a vacuum lamination process.

[0019] The photovoltaic module provided in this application uses photovoltaic glass with corrugated curved surfaces on both the upper and lower surfaces, and is equipped with solar cells whose shape perfectly matches the lower surface. The corrugated curved surface structure changes the angle of light incidence and extends the optical path of light within the module, significantly improving the solar cells' ability to absorb and capture outdoor low light, oblique light, and diffused light. This effectively reduces light reflection and escape, significantly improving photon utilization and solving the problems of poor low-light power generation performance and low power generation efficiency of traditional planar photovoltaic modules. A flexible busbar that matches the shape of the solar cells replaces the traditional rigid busbar. The flexible busbar's deformable nature effectively buffers and absorbs the thermal expansion and contraction stress generated by alternating day and night temperature differences outdoors, avoiding… Stress concentration at solderless joints prevents malfunctions such as desoldering and microcracks in cells during long-term operation, stabilizing the overall power generation and performance of photovoltaic modules. A heat dissipation plate with an upper surface shape matching the flexible busbar and featuring extended heat dissipation channels ensures efficient heat transfer through a well-fitting structure between the heat dissipation plate, the flexible busbar, and the cells. The heat dissipation channels extending to the outside of the heat dissipation plate quickly diffuse the accumulated heat generated during module operation, effectively reducing the overall operating temperature of the photovoltaic module. This addresses the issue of a sharp drop in module power generation efficiency under high-temperature conditions and suppresses permanent power degradation caused by long-term high-temperature operation, significantly improving the operational stability and lifespan of the photovoltaic modules. Attached Figure Description

[0020] To more clearly illustrate the technical solutions of the embodiments of this application, the drawings used in the description of the embodiments will be briefly introduced below. Obviously, the drawings described below are some embodiments of this application. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.

[0021] Figure 1 A schematic diagram of a photovoltaic module provided in an embodiment of this application;

[0022] Figure 2 This is a schematic flowchart illustrating the method for preparing a photovoltaic module according to an embodiment of this application.

[0023] Explanation of reference numerals in the attached figures:

[0024] 100. Photovoltaic module; 110. Photovoltaic glass; 120. Encapsulating film; 130. Solar cell; 140. Flexible busbar; 150. Heat sink; 151. Heat dissipation channel; 160. Back panel; 170. Frame; 171. Ventilation opening. Detailed Implementation

[0025] The technical solutions of the embodiments of this application will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of this application, and not all embodiments. Based on the embodiments of this application, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of this application.

[0026] In this application, the terms “upper,” “lower,” “left,” “right,” “front,” “back,” “top,” “bottom,” “inner,” “outer,” “vertical,” “horizontal,” “lateral,” and “longitudinal” indicate orientations or positional relationships based on the orientations or positional relationships shown in the accompanying drawings. These terms are primarily for the purpose of better describing this application and its embodiments, and are not intended to limit the indicated devices, elements, or components to having a specific orientation, or to be constructed and operated in a specific orientation.

[0027] Furthermore, in addition to indicating location or positional relationship, some of the aforementioned terms may also have other meanings. For example, the term "above" may also be used in some cases to indicate a certain dependency or connection relationship. Those skilled in the art can understand the specific meaning of these terms in this application based on the specific circumstances.

[0028] Furthermore, the terms "installation," "setup," "equipped with," "connection," and "linked" should be interpreted broadly. For example, they can refer to a fixed connection, a detachable connection, or an integral structure; they can refer to a mechanical connection or an electrical connection; they can refer to a direct connection or an indirect connection through an intermediate medium, or an internal connection between two devices, components, or parts. Those skilled in the art can understand the specific meaning of these terms in this application based on the specific circumstances.

[0029] Furthermore, the terms "first," "second," etc., are primarily used to distinguish different devices, elements, or components (which may be the same or different in specific type and construction), and are not intended to indicate or imply the relative importance or quantity of the indicated devices, elements, or components. Unless otherwise stated, "a plurality of" means two or more.

[0030] Most mainstream photovoltaic (PV) modules in the industry adopt a planar structure, consisting of laminated photovoltaic glass, solar cells, busbars, and backsheets. However, this type of PV module presents several problems during actual outdoor operation under complex conditions. First, existing solar cells have poor utilization of oblique and diffused light. In low-light environments, light is easily reflected and escapes, and the short optical path and low photon utilization rate affect power generation efficiency. Second, PV modules tend to accumulate heat and operate at higher temperatures outdoors. Under high-temperature conditions, the module's power generation efficiency will significantly decrease, and long-term operation can lead to permanent power degradation. In addition, the existing connection structure of solar cells and rigid busbars is subject to thermal expansion and contraction deformation under varying day and night temperatures outdoors. This causes stress concentration at the solder joints, making them prone to desoldering, microcracks in the solar cells, and other faults, resulting in a decrease in power generation efficiency and output.

[0031] In view of this, this application provides a photovoltaic module that uses photovoltaic glass with a corrugated curved surface structure on both the upper and lower surfaces, and is equipped with a solar cell whose shape is perfectly matched to its lower surface. By changing the incident angle of light and extending the optical path of light within the module through the corrugated curved surface structure, the solar cell's ability to absorb and capture outdoor weak light, oblique light, and diffuse light is greatly improved, effectively reducing light reflection and escape phenomena, and significantly improving photon utilization. This solves the problems of poor power generation performance and low power generation efficiency of traditional planar photovoltaic modules in weak light. A flexible busbar that matches the shape of the solar cell is used instead of the traditional rigid busbar. Through the deformable characteristics of the flexible busbar itself, thermal expansion and contraction deformation caused by alternating day and night temperature differences outdoors is effectively buffered and absorbed. Stress is minimized to prevent stress concentration at solder joints, thus eliminating faults such as desoldering and microcracks in cells during long-term operation and stabilizing the overall power generation and performance of the photovoltaic modules. A heat dissipation plate with an upper surface shape matching the flexible busbar and featuring extended heat dissipation channels ensures efficient heat conduction through a well-fitting structure between the heat dissipation plate, the flexible busbar, and the cells. The heat dissipation channels extending to the outside of the heat dissipation plate quickly diffuse the accumulated heat generated during module operation, effectively reducing the overall operating temperature of the photovoltaic modules. This addresses the issue of a sharp drop in module power generation efficiency under high-temperature conditions and suppresses permanent power degradation caused by long-term high-temperature operation, significantly improving the operational stability and lifespan of the photovoltaic modules.

[0032] Figure 1 A schematic diagram of a photovoltaic module provided in an embodiment of this application; Figure 2 This is a schematic flowchart illustrating the method for manufacturing a photovoltaic module according to an embodiment of this application. (See also...) Figure 1 and Figure 2This application provides a photovoltaic module 100, including a photovoltaic glass 110, an encapsulating film 120, a solar cell 130, a flexible busbar 140, a heat sink 150, and a backsheet 160 stacked sequentially. The upper and lower surfaces of the photovoltaic glass 110 are both corrugated curved surfaces. The encapsulating film 120 is adhered between the lower surface of the photovoltaic glass 110 and the solar cell 130. The shape of the solar cell 130 matches the shape of the lower surface of the photovoltaic glass 110. The flexible busbar 140 is disposed on the solar cell 130 and matches the shape of the solar cell 130. The shape of the upper surface of the heat sink 150 matches the shape of the flexible busbar 140. The heat sink 150 has a heat dissipation channel 151 that extends to the outside of the heat sink 150.

[0033] The photovoltaic module 100 provided in this application uses photovoltaic glass 110 with corrugated curved surfaces on both the upper and lower surfaces, and is matched with a solar cell 130 whose shape is perfectly matched to its lower surface. The corrugated curved surface structure changes the angle of light incidence and extends the optical path of light within the module, significantly improving the absorption and capture capability of the solar cell 130 for outdoor weak light, oblique light, and diffused light. This effectively reduces light reflection and escape, significantly improving photon utilization and solving the problems of poor low-light power generation performance and low power generation efficiency of traditional planar photovoltaic modules 100. A flexible busbar 140, matching the shape of the solar cell 130, replaces the traditional rigid busbar. The flexible busbar 140's deformable nature effectively buffers and absorbs the thermal expansion and contraction stress generated under alternating day and night temperature conditions, preventing stress at the solder joints. To address stress concentration issues and prevent faults such as desoldering and microcracks in the solar cells 130 during long-term operation, the overall power generation and performance of the photovoltaic module 100 are stabilized. A heat dissipation plate 150, with an upper surface shape matching the flexible busbar 140 and featuring an extended heat dissipation channel 151, is added. The well-fitting structure of the heat dissipation plate 150, flexible busbar 140, and solar cells 130 ensures efficient heat conduction. Furthermore, the heat dissipation channel 151 extending to the outside of the heat dissipation plate 150 quickly diffuses the accumulated heat generated during module operation, effectively reducing the overall operating temperature of the photovoltaic module 100. This mitigates the problem of a sharp drop in module power generation efficiency under high-temperature conditions and suppresses permanent power degradation caused by long-term high-temperature operation, significantly improving the operational stability and lifespan of the photovoltaic module 100.

[0034] In the above embodiments, the frame 170 may also be included, and the side of the photovoltaic glass 110, the side of the encapsulant film 120, the side of the battery cell 130, the side of the flexible busbar 140, the side of the heat sink 150 and the side of the back plate 160 are all embedded in the frame 170. The side of the frame 170 has a vent 171 that connects to the heat dissipation channel 151. By uniformly embedding the sides of photovoltaic glass 110, encapsulant film 120, solar cell 130, flexible busbar 140, heat sink 150, and backsheet 160 inside the frame 170, the photovoltaic module 100's multilayer structure can be enclosed, fixed, and protected as a whole. This effectively limits the interlayer shift, warping, delamination, and misalignment of each functional layer under long-term outdoor vibration, wind pressure, and temperature change conditions. It significantly improves the overall integrity, sealing, and structural strength of the photovoltaic module 100, effectively preventing external rainwater, dust, moisture, and other impurities from entering the module's interior. This avoids corrosion and moisture failure of core components such as the solar cell 130 and flexible busbar 140, thus improving the overall protection performance and operational reliability of the module. Meanwhile, by opening a vent 171 on the side of the frame 170 that is connected to the heat dissipation channel 151, a continuous convection ventilation path is formed between the heat dissipation channel 151 inside the heat dissipation plate 150 and the external atmospheric environment. This breaks the disadvantage of limited heat dissipation inside the closed module and uses the principle of air convection to continuously remove the heat accumulated inside the module conducted by the heat dissipation plate 150, which greatly improves the efficiency of heat exchange and heat dissipation, further reduces the overall operating temperature of the cell 130 and the module, effectively alleviates the problem of power generation efficiency degradation of the photovoltaic module 100 under high temperature conditions, continuously suppresses the permanent power degradation phenomenon caused by long-term high temperature service of the module, and further improves the power generation stability and overall service life of the photovoltaic module 100 under complex outdoor conditions.

[0035] In the above embodiments, the photovoltaic glass 110 can be tempered glass, with a thickness of 2.5mm-3.2mm and a spacing of 40mm-44mm between two adjacent crests on the upper surface of the photovoltaic glass 110. It is understood that using tempered glass can significantly improve the mechanical strength, impact resistance, and weather resistance of the corrugated photovoltaic glass 110, effectively resisting damage from external forces such as outdoor wind and sand impacts, hail strikes, and wind pressure loads, preventing damage and cracking of the corrugated glass structure, and ensuring the overall structural integrity and operational safety of the module. If the glass thickness is greater than 3.2mm, it will reduce light transmittance, increase the overall weight of the module, and increase raw material costs and transportation and installation load. If the glass thickness is less than 2.5mm, the structural rigidity will be insufficient, the bending and impact resistance will decrease, the corrugated surface will be prone to deformation, and cracks will be more likely to occur under outdoor conditions. This thickness range balances light transmittance, structural strength, and manufacturing cost.

[0036] Setting the crest spacing to 40mm-44mm allows for optimal matching between the corrugated surface curvature and light refraction angle of the photovoltaic glass 110 and the light-receiving surface of the solar cell 130. If the crest spacing is too small, the corrugation curvature will be too large, which may cause excessive light convergence, resulting in local hot spots on the solar cell 130, exacerbating the temperature rise of the module, increasing the difficulty of glass processing and forming, and increasing production costs. If the crest spacing is too large, the corrugated surface will tend to be a planar structure, making it difficult to effectively extend the light propagation path, weakening the ability to capture oblique and diffuse light, and significantly reducing the optical gain effect. This parameter range can balance the optical gain effect, suppress the risk of local hot spots, and ensure the feasibility of industrial processing, maximizing the extension of the light propagation path and improving the capture and utilization rate of weak and diffuse light, further stabilizing and improving the power generation efficiency and long-term outdoor operation reliability of the photovoltaic module 100.

[0037] In the above embodiments, the thickness of the adhesive film 120 can be 0.3mm-0.5mm. It is understandable that the thickness of the film 120 within this thickness range can fully adapt to the bonding requirements of the upper and lower curved structures, ensuring complete bonding between the photovoltaic glass 110 and the cell 130, effectively filling the curved gaps, improving the interfacial bonding strength after lamination, reducing the loss of light reflection at the interface, blocking moisture and impurities from eroding the cell 130, buffering minor deformations between layers, and ensuring the optical performance, bonding sealing, and long-term operational stability of the photovoltaic module 100. If the thickness of the film 120 is greater than 0.5mm, it will increase light propagation loss, reduce light transmittance, increase the overall thickness and weight of the module, increase material consumption, increase production costs, and is also prone to problems such as adhesive overflow and difficulty in removing air bubbles during the lamination process. If the thickness of the film 120 is less than 0.3mm, the filling margin of the film 120 is insufficient, and it cannot fully adapt to the curved gap between the corrugated photovoltaic glass 110 and the cell 130. After lamination, local adhesive shortage and delamination defects are prone to occur, reducing the reliability of interfacial bonding, making it difficult to effectively buffer interfacial stress, and failing to block moisture intrusion.

[0038] In the above embodiments, the encapsulant film 120 may be doped with silicon dioxide at a mass ratio of 0.4%-0.6%. This doping ratio range can utilize the silicon dioxide particles to regulate the light path, enhance the refractive power of the encapsulant film 120 for diffused light, change the propagation path of diffused light, allow more light to enter the light-receiving area of ​​the solar cell 130, improve the light energy utilization rate in low-light environments, enhance the ultraviolet shielding capability of the encapsulant film 120, slow down the yellowing rate of the encapsulant film 120 under long-term light exposure, reduce the water vapor permeation rate, improve the weather resistance of the encapsulant film 120, improve the creep characteristics of the encapsulant film 120, alleviate the interlayer slippage problem under high-temperature conditions, maintain a stable bonding interface between the corrugated photovoltaic glass 110 and the solar cell 130, reduce interface optical losses, and ensure the long-term power generation performance of the photovoltaic module 100. If the silica doping mass ratio is higher than 0.6%, the particle concentration inside the film 120 will be too high, which will aggravate excessive light scattering and absorption loss, reduce the light transmittance of the film 120, weaken the light capture efficiency of the solar cell 130, and reduce the cross-linking degree and adhesion performance of the film 120, affecting the interlayer bonding effect. If the silica doping mass ratio is lower than 0.4%, the silica content is insufficient, making it difficult to fully exert the refraction regulation effect on diffused light. The effect of resisting ultraviolet aging and inhibiting yellowing of the film 120 is limited, and the hydrolysis resistance is insufficient, so it cannot effectively delay the long-term outdoor aging failure of the film 120.

[0039] In the above embodiments, the thickness of the flexible busbar 140 can be 0.1mm-0.14mm. This thickness range balances conductivity and flexibility, allowing it to fully fit the corrugated solar cell 130, effectively absorbing the deformation stress caused by the temperature difference between day and night outdoors. This prevents stress concentration at the solder joints from causing desoldering or microcracks in the solar cell 130, ensuring stable current transmission, controlling heat loss, stabilizing the power generation of the photovoltaic module 100, and improving the long-term reliability of the module. If the thickness of the flexible busbar 140 is greater than 0.14mm, the material rigidity increases significantly, the deformation adaptability decreases, making it difficult to achieve a tight fit with the curved surface of the solar cell 130. The effect of buffering thermal expansion and contraction is weakened, easily causing stress concentration at the solder joints. It also increases the amount of conductive material used, raising the module production cost and increasing the overall thickness of the stacked structure. If the thickness of the flexible busbar 140 is less than 0.1mm, the conductive cross-sectional area is insufficient, the current carrying capacity decreases, more Joule heat is generated during operation, exacerbating the temperature rise of the module, and the mechanical strength is low, making it prone to breakage under temperature difference cycling and external vibration conditions.

[0040] In the above embodiments, the lower surface of the heat sink 150 can be a corrugated curved surface, and the upper surface of the back plate 160 matches the shape of the lower surface of the heat sink 150. Through the curved surface adaptation and bonding structure of the heat sink 150 and the back plate 160, the contact area between the heat sink 150 and the back plate 160 can be greatly increased, eliminating interlayer bonding gaps, reducing interface thermal resistance, and achieving efficient and continuous all-round heat conduction from the solar cells 130 and the flexible busbar 140 to the heat sink 150 and the back plate 160. Combined with the heat dissipation channel 151 of the heat sink 150 and the convection heat dissipation structure of the vents 171 of the frame 170, the overall heat dissipation efficiency of the module is further enhanced, the working heat of the module is evenly distributed, local high-temperature hot spots are avoided, and the power generation efficiency degradation and permanent power degradation caused by high temperature are effectively suppressed. At the same time, the corrugated curved surface adaptation structure can improve the fit and structural integrity of the module's stacked assembly, enhance the limiting bonding effect of each layer, and improve the overall structural stability of the photovoltaic module 100 and its operational reliability under complex outdoor conditions.

[0041] Furthermore, this application provides a method for preparing a photovoltaic module 100, which includes the following steps:

[0042] S100: The battery cell 130 is pressed into a corrugated curved surface shape using a flexible pressing process.

[0043] S200: The flexible busbar 140 is bonded to the main bus line of the battery cell 130 using ultrasonic welding process.

[0044] S300, photovoltaic glass 110, encapsulant film 120, solar cell 130 with welded flexible busbar 140, heat sink 150 and backplate 160 are stacked in sequence and laminated using vacuum lamination process. The upper and lower surfaces of photovoltaic glass 110 are corrugated curved surfaces. The shape of solar cell 130 matches the shape of the lower surface of photovoltaic glass 110. The shape of the upper surface of heat sink 150 matches the shape of flexible busbar 140. Heat sink 150 has heat dissipation channel 151 that extends to the outside of heat sink 150.

[0045] By employing a flexible pressing process to press the solar cell 130 into a corrugated curved shape, the solar cell 130 can be precisely molded into a curved structure that matches the corrugated photovoltaic glass 110. Compared to traditional rigid molding processes, this avoids problems such as microcracks, edge chipping, and breakage during the molding process of the solar cell 130, ensuring the structural integrity and photoelectric performance of the solar cell 130. This lays a structural foundation for subsequent precise bonding and assembly, and improved light-capturing capabilities. The flexible busbar 140 is bonded to the main grid line of the solar cell 130 using an ultrasonic welding process. This process offers high welding precision and a small heat-affected zone, effectively preventing thermal damage, deformation, and performance degradation of the curved solar cell 130 caused by high-temperature welding. Simultaneously, it ensures a tight bond and fixation between the flexible busbar 140 and the main grid line of the solar cell 130, guaranteeing uniform and firm welding points, eliminating problems such as incomplete welding and detachment, and fully utilizing the flexible busbar 140. The deformation buffering performance effectively avoids stress concentration faults caused by temperature difference deformation, ensuring the stability of current transmission. By sequentially stacking photovoltaic glass 110, encapsulant film 120, welded flexible busbar 140, solar cell 130, heat sink 150, and backsheet 160, and completing the overall lamination process with vacuum lamination, the air between each layer can be completely removed using the vacuum environment, avoiding defects such as bubbles and voids inside the module. This ensures that each functional layer is tightly bonded together, fully adapting to the matching structure of corrugated photovoltaic glass 110, curved solar cell 130, flexible busbar 140, and corrugated lower surface heat sink 150. This significantly reduces interlayer contact thermal resistance and optical loss, ensuring the optical gain effect, heat dissipation performance, and overall structural sealing and integrity of the module. It effectively improves the power generation efficiency, heat dissipation capacity, structural stability, and service life of the photovoltaic module 100 during long-term outdoor operation.

[0046] In the above embodiments, the flexible pressing process is used to press the battery cell 130 into a corrugated arc structure, which may specifically include:

[0047] A flexible pressing process is employed to press the solar cell 130 at a temperature of 120℃-130℃ and a pressure of 0.3MPa-0.35MPa for 10-20 seconds, thereby shaping it into a corrugated curved surface. This process parameter range ensures that the solar cell 130 is uniformly softened and precisely shaped into a standard corrugated arc structure while maintaining the structural integrity and without damage. This results in high molding consistency and dimensional accuracy, effectively avoiding defects such as microcracks, deformation, and performance degradation during the molding process. It also ensures a perfect fit between the curved surface of the solar cell 130 and the lower surface of the photovoltaic glass 110, providing a reliable process foundation for subsequently improving the module's light-capturing ability, eliminating interlayer assembly gaps, and reducing interface optical loss and thermal resistance. Furthermore, the process parameters are mild and controllable, with high molding efficiency, making it suitable for large-scale mass production and effectively improving the overall molding quality and power generation stability of the photovoltaic module 100.

[0048] If the pressing temperature exceeds 130℃, the pressure exceeds 0.35MPa, or the pressing time exceeds 20s, the excessive temperature and pressure will cause overheating damage to the solar cell 130, destruction of the crystal structure, resulting in microcracks, performance degradation, and decreased photoelectric conversion efficiency. It will also easily lead to excessive deformation of the solar cell 130, resulting in excessive corrugation curvature and poor molding precision. If the pressing temperature is below 120℃, the pressure is less than 0.3MPa, or the pressing time is less than 10s, the insufficient temperature and pressure will result in insufficient softening of the solar cell 130 material and insufficient release of molding stress, leading to incomplete corrugated surface molding and poor surface flatness. This will prevent precise matching and bonding with the corrugated photovoltaic glass 110, easily causing assembly gaps and affecting subsequent optical gain and lamination bonding effects.

[0049] In the above embodiments, a vacuum lamination process is used for lamination, specifically including lamination at a temperature of 146℃-150℃. This temperature range can adapt to the lamination molding requirements of corrugated curved stacked structures, ensuring that the adhesive film 120 is uniformly and fully melted and flows, perfectly fitting the irregular mating surfaces of the photovoltaic glass 110, curved solar cells 130, flexible busbar 140, and heat sink 150. This completely removes interlayer air, eliminates process defects such as bubbles, delamination, and insufficient adhesive, and ensures that each functional layer is tightly bonded and integrally molded. While ensuring the module's excellent optical transmittance, efficient heat dissipation and thermal conductivity, and structural stability, it effectively avoids material aging and device damage caused by high-temperature processes, improving the yield and long-term service reliability of the photovoltaic module 100. If the lamination temperature is higher than 150℃, the excessively high temperature will exacerbate the high-temperature aging of the adhesive film 120 and accelerate its yellowing. At the same time, it is easy to cause thermal shock to the curved solar cell 130 and the flexible busbar 140, leading to the degradation of the photoelectric performance of the solar cell 130 and the deformation failure of the flexible busbar 140. It will also cause excessive flow of the adhesive film 120, resulting in lamination defects such as overflow and local missing adhesive. If the lamination temperature is lower than 146℃, the melting and wetting effect of the adhesive film 120 will be insufficient, and it will not be able to fully fill the tiny gaps between the layers of the corrugated structure. The interlayer bonding and fusion will be insufficient, which will easily produce problems such as bubbles, delamination, and weak bonding, significantly reducing the interlayer sealing performance and structural integrity of the module.

[0050] To facilitate understanding of the solution in this application, several specific implementation examples are listed below:

[0051] Example 1

[0052] First, the solar cell 130 is pressed into shape using a flexible pressing process. Pressing is performed continuously for 10 seconds at a pressing temperature of 120℃ and a pressing pressure of 0.3MPa, uniformly pressing the solar cell 130 into a corrugated curved surface structure. Then, a flexible busbar 140 with a thickness of 0.1mm is precisely bonded to the main grid line position of the formed solar cell 130 using an ultrasonic welding process. Next, tempered photovoltaic glass 110 with corrugated curved surfaces on both the upper and lower surfaces, a thickness of 2.5mm, and an adjacent peak spacing of 40mm is sequentially layered. A 0.3mm thick adhesive film doped with 0.4% silicon dioxide is then added, and the flexible busbar 140 is welded together. The photovoltaic module 100 is assembled by stacking a corrugated solar cell 130, a heat sink 150 whose upper surface matches the shape of the flexible busbar 140 and whose lower surface is a corrugated curved surface with an extended heat dissipation channel 151, and a backplate 160 whose upper surface matches the shape of the lower surface of the heat sink 150. After the stacked assembly is completed, the entire module is placed in a laminating equipment and vacuum laminated at a temperature of 146°C. After lamination, the photovoltaic glass 110, encapsulant film 120, solar cell 130, flexible busbar 140, heat sink 150 and backplate 160 are embedded in the frame 170 with side ventilation openings 171, thus completing the fabrication of the entire photovoltaic module 100.

[0053] Example 2

[0054] First, laser doping is used to prepare staggered N-type and P-type doped regions on the back side of the silicon substrate 110, achieving a high-precision doped patterned structure. Then, atomic layer deposition is used to deposit a 200 nm thick aluminum oxide film on the outer side of all doped regions 120, forming a first insulating layer 130 with strong interfacial adhesion and excellent passivation performance. Next, chemical vapor deposition is used to deposit a 1000 nm thick carbon-doped silicon oxide film on the outer side of the first insulating layer 130, constituting a second insulating layer 140 with excellent stress-buffering performance. Finally, laser interferometry is used to deposit a second insulating layer 140 on the surface of the second insulating layer 140. An array of raised stress-relieving structures is fabricated on the surface to effectively release process thermal and mechanical stresses and improve interlayer bonding strength. Then, a 75nm thick aluminum nitride film is deposited on the outside of the second insulating layer 140 using magnetron sputtering to form a third insulating layer 150 with balanced mechanical protection and insulation withstand voltage performance. This, together with the first two insulating films, forms a composite insulating system with complementary performance. Finally, a metal electrode 160 is fabricated on the back side of the silicon substrate 110, so that one end of the metal electrode 160 stably conducts to the doped region 120, and the other end extends to cover the outside of the third insulating layer 150, completing the fabrication of the back contact battery 100.

[0055] Example 3

[0056] First, the solar cell 130 is pressed into shape using a flexible pressing process. Pressing is performed continuously for 20 seconds at a pressing temperature of 130℃ and a pressing pressure of 0.35MPa, uniformly pressing the solar cell 130 into a corrugated curved surface structure. Then, a flexible busbar 140 with a thickness of 0.14mm is precisely bonded to the main grid line position of the formed solar cell 130 using an ultrasonic welding process. Next, tempered photovoltaic glass 110, with corrugated curved surfaces on both the upper and lower surfaces, a thickness of 3.2mm, and an adjacent peak spacing of 44mm, is layered and stacked, along with a 0.5mm thick adhesive film doped with 0.6% silicon dioxide. The flexible busbar is then welded together. The photovoltaic module 100 is assembled by stacking the corrugated solar cell 130, the heat sink 150 whose upper surface matches the shape of the flexible busbar 140 and whose lower surface is a corrugated curved surface with an extended heat dissipation channel 151, and the back plate 160 whose upper surface matches the shape of the lower surface of the heat sink 150. After the stacked assembly is completed, the entire module is placed in a laminating equipment and vacuum laminated at a temperature of 150°C. After lamination, the photovoltaic glass 110, the encapsulant film 120, the solar cell 130, the flexible busbar 140, the heat sink 150 and the back plate 160 are embedded in the frame 170 with side ventilation openings 171, thus completing the fabrication of the entire photovoltaic module 100.

[0057] Finally, it should be noted that the above embodiments are only used to illustrate the technical solutions of this application, and are not intended to limit them. Although this application has been described in detail with reference to the foregoing embodiments, those skilled in the art should understand that modifications can still be made to the technical solutions described in the foregoing embodiments, or equivalent substitutions can be made to some or all of the technical features therein. Such modifications or substitutions do not cause the essence of the corresponding technical solutions to deviate from the scope of the technical solutions of the embodiments of this application.

Claims

1. A photovoltaic module, characterized in that, The device comprises photovoltaic glass, an encapsulating film, solar cells, a flexible busbar, a heat sink, and a backplate, which are stacked sequentially. The upper and lower surfaces of the photovoltaic glass are both corrugated curved surfaces. The encapsulating film is bonded between the lower surface of the photovoltaic glass and the solar cells. The shape of the solar cells matches the shape of the lower surface of the photovoltaic glass. The flexible busbar is disposed on the solar cells and matches the shape of the solar cells. The shape of the upper surface of the heat sink matches the shape of the flexible busbar. The heat sink has heat dissipation channels that extend to the outside of the heat sink.

2. The photovoltaic module according to claim 1, characterized in that, It also includes a frame, in which the side of the photovoltaic glass, the side of the encapsulant film, the side of the battery cell, the side of the flexible busbar, the side of the heat sink, and the side of the back plate are all embedded. The side of the frame has a vent that connects to the heat dissipation channel.

3. The photovoltaic module according to claim 1, characterized in that, The photovoltaic glass is tempered glass, the thickness of the photovoltaic glass is 2.5mm-3.2mm, and the distance between two adjacent peaks on the upper surface of the photovoltaic glass is 40mm-44mm.

4. The photovoltaic module according to claim 1, characterized in that, The thickness of the adhesive film is 0.3mm-0.5mm.

5. The photovoltaic module according to claim 1, characterized in that, The adhesive film is doped with silicon dioxide at a mass ratio of 0.4%-0.6%.

6. The photovoltaic module according to claim 1, characterized in that, The thickness of the flexible busbar is 0.1mm-0.14mm.

7. The photovoltaic module according to claim 1, characterized in that, The lower surface of the heat sink has a corrugated curved shape, and the upper surface of the back plate matches the shape of the lower surface of the heat sink.

8. A method for preparing a photovoltaic module, characterized in that, The method for preparing the photovoltaic module according to any one of claims 1 to 7 includes the following steps: The battery cells are pressed into a corrugated curved shape using a flexible pressing process. The flexible busbar is bonded to the main grid line of the battery cell using ultrasonic welding. The photovoltaic glass, encapsulant film, welded flexible busbar, solar cell, heat sink, and backplate are stacked sequentially and laminated using a vacuum lamination process. The upper and lower surfaces of the photovoltaic glass are both corrugated curved surfaces. The shape of the solar cell matches the shape of the lower surface of the photovoltaic glass. The shape of the upper surface of the heat sink matches the shape of the flexible busbar. The heat sink has heat dissipation channels that extend to the outside of the heat sink.

9. The method for preparing a photovoltaic module according to claim 8, characterized in that, The process of pressing the battery cells into a corrugated arc-shaped structure using a flexible pressing process specifically includes: The flexible pressing process is used to press the battery cells at a temperature of 120℃-130℃ and a pressure of 0.3MPa-0.35MPa for 10s-20s, thereby pressing them into a corrugated curved shape.

10. The method for preparing a photovoltaic module according to claim 8, characterized in that, The lamination process using vacuum lamination technology specifically includes lamination at a temperature of 146℃-150℃.

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