Photovoltaic module
By using granular water-blocking materials and isolation structures in photovoltaic modules, the contradiction between water blocking and improving production line efficiency of photovoltaic modules is resolved, achieving efficient sealing and long-term reliability.
Patent Information
- Application Number
- CN202422819534.9
- Authority / Receiving Office
- CN · China
- Patent Type
- Utility models(China)
- Current Assignee / Owner
- Filing Date
- 2024-11-19
- Publication Date
- 2025-09-26
- Estimated Expiration
- 2034-11-19
AI Technical Summary
Existing photovoltaic modules cannot improve production line efficiency while forming an effective water barrier, and there is a problem of insufficient sealing at the lead-out wires.
Granular water-blocking material is used to fill the lead holes, combined with an isolation structure and high-temperature cloth, and heated and pressed by a laminator to form a sealed structure that tightly wraps the lead wires, simplifying the operation steps and improving the degree of automation.
It achieves effective water-blocking performance, reduces the risk of breakage at the lead-out wires, and improves the long-term reliability of the components and production line efficiency.
Smart Images
Figure CN223391624U_ABST
Abstract
Description
Technical Field
[0001] The present application relates to the field of photovoltaic modules, and specifically provides a photovoltaic module. Background Art
[0002] In photovoltaic modules, holes must be created in the module cover to route the lead wires from the cell. To prevent moisture from entering the module through these holes, the current mainstream practice is to seal the holes with butyl adhesive. For example, some companies apply a ring of butyl adhesive around the holes and then laminarize the holes, allowing the adhesive to flow and fill the holes. However, due to the material of the encapsulation layer used to encapsulate the cell, the encapsulation layer may have greater fluidity than the butyl adhesive during the initial lamination phase. Before the butyl adhesive seals the holes, some of the encapsulation material can squeeze out of the butyl adhesive, creating a permeable channel and causing water barrier failure. Alternatively, some manufacturers use butyl adhesive gaskets placed over the holes. To improve the efficiency and quality of lead wire routing on the production line, some of the butyl adhesive is stamped out of the holes, resulting in poor butyl adhesive coverage of the lead wires. This leads to a lack of butyl adhesive in the holes, and during lamination, due to the poor fluidity of the butyl adhesive, it cannot fill the missing area in time. As a result, some of the encapsulation material can bleed through the base of the lead wires, causing water barrier failure in that area. Utility Model Content
[0003] The present application aims to solve the above-mentioned technical problem, namely, to solve the problem that existing photovoltaic modules cannot form an effective water barrier while also improving production line efficiency.
[0004] The present application provides a photovoltaic module, characterized in that it includes: a first cover plate, a battery encapsulation layer and a second cover plate stacked in sequence, the first cover plate is provided with a lead hole, the battery encapsulation layer has battery cells, the lead wires on the battery cells are passed through the lead hole, the lead hole is filled with granular water-blocking material, and the water-blocking material covers the lead wires.
[0005] In an optional technical solution of the above photovoltaic module, the maximum melt viscosity of the water-blocking material is greater than the maximum melt viscosity of the battery encapsulation layer.
[0006] In an optional technical solution of the above photovoltaic assembly, an isolation structure is provided on a side of the first cover plate facing away from the battery encapsulation layer. The isolation structure covers the lead hole, and the lead wire passes through the isolation structure.
[0007] In an optional technical solution of the above photovoltaic assembly, the isolation structure is made of fabric; and / or the isolation structure is made of waterproof material.
[0008] In the optional technical solution of the above photovoltaic module, the water-blocking material is any one of glass powder, butyl rubber, polyvinyl butyral, polyolefin elastomer, and epoxy resin.
[0009] In an optional technical solution of the above photovoltaic module, the material of the battery encapsulation layer is ethylene-vinyl acetate copolymer or polyolefin elastomer.
[0010] In an optional technical solution of the above photovoltaic module, the particle size of the water-blocking material is less than 1 mm; and / or the distance between the lead wire and the lead hole is in the range of 1 mm to 4 mm.
[0011] In the optional technical solution of the above photovoltaic module, the melting temperature of the water-blocking material ranges from 50°C to 250°C.
[0012] In an optional technical solution of the above photovoltaic module, the first cover plate is configured as back glass, and the second cover plate is configured as front glass.
[0013] In an optional technical solution of the above photovoltaic module, the battery encapsulation layer includes a first adhesive film and a second adhesive film, and the battery cell is arranged between the first adhesive film and the second adhesive film.
[0014] Those skilled in the art can understand that the photovoltaic module of the present application includes a first cover plate, a battery packaging layer and a second cover plate stacked in sequence, the first cover plate is provided with a lead hole, the battery packaging layer contains battery cells, the lead wires on the battery cells are passed through the lead hole, the lead hole is filled with granular water-blocking material, and the water-blocking material covers the lead wires.
[0015] The present invention uses granular water-blocking material to fill the lead holes, rather than using perforated rubber blocks. This allows the water-blocking material to fully wrap the lead wires. When the photovoltaic module is laminated through equipment such as a laminator, the water-blocking material is fully pressed and tightly wrapped around the lead wires under heating, improving the sealing and reducing the presence of gaps in the lead holes. Furthermore, because the water-blocking material fully wraps the lead wires, even if the fluidity of the battery encapsulation layer is better than that of the water-blocking material, it is not easy to penetrate along the lead wires, thereby forming an effective water barrier. Compared with the traditional method of using perforated rubber blocks, the application of granular water-blocking material does not require pre-drilling holes for the lead wires, simplifying the lead wire perforation process. In addition, the granular material can be directly quantitatively filled into the lead holes, making it easier to achieve automation and improve production line efficiency. Furthermore, the granular water-blocking material can be evenly distributed during the lamination process and becomes flexible when heated, which can effectively reduce stress concentration that may occur during the lamination process, reduce the risk of breakage at the lead wires, and improve the long-term reliability of the module. BRIEF DESCRIPTION OF THE DRAWINGS
[0016] Possible implementations of the present application are described below with reference to the accompanying drawings, in which:
[0017] Figure 1It is a schematic structural diagram of the photovoltaic module of this application.
[0018] Description of reference numerals:
[0019] 1-first cover plate; 11-lead hole; 2-battery packaging layer; 21-first adhesive film; 22-second adhesive film; 3-second cover plate; 4-battery cell; 41-lead wire; 5-water-blocking material; 6-isolation structure. DETAILED DESCRIPTION
[0020] The preferred embodiments of the present application are described below with reference to the accompanying drawings. Those skilled in the art should understand that these embodiments are merely intended to illustrate the technical principles of the present application and are not intended to limit the scope of protection of the present application. Those skilled in the art may adjust these embodiments as needed to suit specific applications.
[0021] It should be noted that, in the description of this application, unless otherwise expressly specified or limited, the terms "connected" and "connected" should be understood in a broad sense, and may refer to direct connection, connection through an intermediate medium, etc. For those skilled in the art, the specific meanings of the above terms in this application can be understood based on the specific circumstances. In addition, it should be noted that, in the description of this application, ordinal numbers such as "first" and "second" are used only for descriptive purposes and should not be understood as indicating or implying relative importance or implicitly indicating the number of technical features indicated.
[0022] This application provides a photovoltaic module, such as Figure 1 As shown, it includes a first cover plate 1, a battery encapsulation layer 2, and a second cover plate 3 stacked in sequence. The first cover plate 1 is provided with a lead hole 11. The battery encapsulation layer 2 has a battery cell 4. The lead wire 41 on the battery cell 4 is passed through the lead hole 11. The lead hole 11 is filled with a granular water-blocking material 5, and the water-blocking material 5 covers the lead wire 41. It can be understood that the lead wire 41 on the battery cell 4 can also be called a bus bar, which is electrically connected to the battery cell 4. The number of battery cells 4 can be multiple, and each battery cell 4 can be electrically connected to form a battery string through an interconnection bar, so that the lead wire 41 is electrically connected to the battery string to output the electrical energy generated by the battery string. Among them, the photovoltaic module can be a heterojunction module or a perovskite module, etc., and this application does not impose specific restrictions on it.
[0023] Since the present application uses granular water-blocking material 5 to fill the lead holes 11, rather than using perforated rubber blocks to fill the lead holes 11, the water-blocking material 5 can fully wrap the lead wires 41. Then, when the photovoltaic modules are laminated through equipment such as a laminator, the water-blocking material 5 is fully pressed and tightly wrapped around the lead wires 41 in a heated state, thereby improving the sealing and reducing the presence of gaps in the lead holes 11. Among them, since the water-blocking material 5 fully wraps the lead wires 41, even if the fluidity of the battery encapsulation layer 2 is better than that of the water-blocking material 5 during lamination, it is not easy to pass through along the lead wires 41, thereby forming an effective water barrier. Compared with the traditional method of using perforated rubber blocks, the application of granular water-blocking material 5 does not require pre-drilling for the lead wires 41, which simplifies the operational steps of perforating the lead wires 41. In addition, the granular material can be directly and quantitatively filled into the lead holes 11, making it easier to achieve automation and improve production line efficiency. Furthermore, the granular water-blocking material 5 can be evenly distributed during the lamination process and can effectively reduce stress concentration that may occur during the lamination process when heated, thereby reducing the risk of breakage at the lead wires 41 and improving the long-term reliability of the component.
[0024] As a possible embodiment, the maximum melt viscosity of the water-blocking material 5 is greater than the maximum melt viscosity of the battery encapsulation layer 2. That is, the MH value of the water-blocking material 5 is greater than the MH value of the battery encapsulation layer 2. Because the water-blocking material 5 has a higher melt viscosity and relatively lower fluidity, it can more stably remain around the lead holes 11 during the lamination process, forming an effective water barrier. This prevents the battery encapsulation layer 2, which has lower fluidity, from easily penetrating the water-blocking material 5, thus preventing glue cross-contamination during the lamination process. Specifically, the encapsulation layer material is less likely to flow into the lead holes 11 or the water-blocking material 5 area, ensuring that the lead wires 41 remain well sealed, thereby improving the overall water-blocking performance of the photovoltaic module and preventing performance degradation or damage to the cell 4 due to glue cross-contamination.
[0025] As a possible embodiment, the granular water-blocking material 5 of the present application is a thermoplastic or thermosetting material. It can be granular or powdered, which can be referred to as granular, and this application does not impose specific restrictions on it. The water-blocking material 5 can be any one of glass powder, granular butyl rubber, granular polyvinyl butyral (PVB), granular polyolefin elastomer (POE), and granular epoxy resin. The material of the battery encapsulation layer 2 can be ethylene-vinyl acetate copolymer (EVA) or polyolefin elastomer, etc.
[0026] As a possible embodiment, the particle size of the water-blocking material 5 is less than 1 mm. Since the lead-out hole has a diameter of approximately 12 mm, the distance between the lead-out wire 41 and the wall of the lead-out hole 11 is typically between 1 mm and 4 mm, for example, 3 mm. Having a particle size of less than 1 mm helps ensure that the granular water-blocking material 5 can be smoothly filled into all areas of the lead-out hole 11 during the filling process, forming a tightly enclosed seal and avoiding potential water leakage caused by incomplete filling. Furthermore, because the smaller particle size of the water-blocking material 5 can more effectively fill the space, it reduces voids during the filling process, preventing these voids from affecting the water-blocking effect or sealing performance during the lamination process.
[0027] It should be noted that while the particle size of the water-blocking material 5 described in this application is less than 1 mm, this is not the only applicable particle size range. In actual applications, the particle size of the water-blocking material 5 can be adjusted based on the specific size and design requirements of the lead hole 11. For example, if the lead hole 11 has a large diameter, a water-blocking material 5 with a slightly larger particle size can be selected to better match the hole size and improve filling efficiency. Correspondingly, if the lead hole 11 is small, a finer particle size of water-blocking material 5 is required to ensure complete filling.
[0028] As a possible embodiment, the melting temperature of the water-blocking material 5 ranges from 50°C to 250°C. The melting temperature range of the water-blocking material 5 covers two key temperature sections in the production of photovoltaic modules, namely the lamination stage and the junction box welding stage. Normally, the temperature of the laminator for laminating photovoltaic modules is usually between 140°C and 170°C, and the temperature for junction box welding is usually set at 200°C to 300°C. For example, for water-blocking materials 5 with a melting temperature below 140°C, they can be melted during lamination to be fully pressed, thereby forming a good water-blocking structure. For water-blocking materials 5 with a melting temperature greater than 170°C, they can play a pre-fixing role in the lamination stage and can be melted during the junction box welding stage to fully wrap the lead wires 41. In addition, after the low-melting-point material (such as 50°C) is completely melted during the lamination stage, it can fill the tiny gaps in the module, forming a strong water-blocking structure to prevent the penetration of environmental factors such as moisture and rainwater, thereby extending the service life of the photovoltaic module. After the high melting point material (such as 250°C) melts during the welding stage, it can wrap the lead wire 41 of the junction box and complete the sealing at this time. After solidification, it forms a strong and stable sealing layer to resist the erosion of the external environment, thereby extending the service life of the component.
[0029] As a possible embodiment, an isolation structure 6 is provided on the side of the first cover plate 1 facing away from the battery packaging layer 2. The isolation structure 6 covers the lead hole 11, and the lead wire 41 passes through the isolation structure 6 so that the lead wire 41 can be connected to the junction box, etc. Perforations can be provided on the isolation structure 6, for example, two parallel strip holes are provided, so that multiple lead wires 41 can pass through the strip holes. Among them, the isolation structure 6 can be composed of fabric, specifically high-temperature cloth such as glass fiber cloth, silicone-coated glass fiber cloth, ceramic fiber cloth, graphite cloth, etc. Before high-temperature lamination, the lead wire 41 can be bent and flattened, so that the high-temperature cloth is pre-fixed by the lead wire 41, and then high-temperature lamination is performed so that the water-blocking material 5 becomes compact and in close contact with the lead wire 41. Since the high temperature is arranged on the side of the first cover plate 1 away from the battery packaging layer 2 and covers the lead hole 11, the water-blocking material 5 can be kept in the lead hole 11, avoiding overflow of the water-blocking material 5 during the lamination process, thereby ensuring the cleanliness of the hole.
[0030] As a possible embodiment, the isolation structure 6 is made of a waterproof material. For example, the isolation structure 6 can be a rubber sheet, a silicone sheet, or a ceramic fiber board. It can be placed outside the lead hole 11 or on the side of the lead hole 11 facing away from the battery packaging layer 2. Thus, the isolation structure 6 not only provides isolation to ensure hole cleanliness but also further prevents glue penetration. Furthermore, on top of the initial water barrier formed by the waterproof material, the isolation structure 6 can also provide an additional water barrier, significantly improving the sealing performance of the lead hole 11 and further enhancing the water-blocking effect.
[0031] As a possible embodiment, the first cover plate 1 is configured as back glass, and the second cover plate 3 is configured as front glass. The thickness of the front and back glass can be 1.5 mm to 3 mm, for example, 2 mm. Since the lead hole 11 is provided on the back glass, it is convenient to place components such as the junction box connected to the lead wire 41 on the back glass, thereby avoiding light obstruction and reduced power generation efficiency caused by the junction box and other components being placed on the front glass. In addition, since the cover plate is made of glass, it can also provide a good water-blocking effect.
[0032] It should be noted that although this application describes an example in which the first cover plate 1 is the back glass and the second cover plate 3 is the front glass, this is not intended to limit the scope of protection of this application. For example, the first cover plate 1 and the second cover plate 3 can be replaced with a metal composite plate, a composite polymer plate containing a metal film layer, a composite polymer plate containing an inorganic non-metallic film layer, or a polymer plate. These specific adjustments do not deviate from the principles of this application and are within the scope of protection of this application.
[0033] As a possible embodiment, the battery encapsulation layer 2 includes a first adhesive film 21 and a second adhesive film 22, with the battery cell 4 disposed between the first and second adhesive films 21, 22. Because the first and second adhesive films 21, 22 tightly encapsulate the battery cell 4, they effectively prevent moisture, oxygen, dust, and other substances from the external environment from entering the module, protecting the battery cell 4 from corrosion and oxidation, thereby extending the service life of the photovoltaic module. This also enhances the mechanical strength of the photovoltaic module. Because the adhesive film has good flexibility, it can provide a buffer against external forces, reducing physical damage to the battery cell 4 caused by vibration, impact, or bending.
[0034] The first adhesive film 21 and the second adhesive film 22 can both be made of EVA (ethylene vinyl acetate) or POE (polyolefin elastomer) with good light transmittance, to ensure that sunlight can pass through the adhesive film smoothly and reach the surface of the solar cell 4 to the greatest extent possible.
[0035] For ease of understanding, a possible specific embodiment of the present application is introduced below.
[0036] The lead holes 11 on the back glass of the photovoltaic module are filled with 0.5mm-diameter butyl rubber particles, with 0.38g of butyl rubber particles filling each position of the lead holes 11. A high-temperature cloth with holes is then placed over the lead holes 11, pressing the butyl rubber particles against the cloth. The lead wires 41 are then bent so that they contact the cloth and the glass, pre-fixing the cloth. High-temperature lamination is then performed to melt and compact the butyl rubber, creating a close contact with the inner wall of the lead holes 11 and the lead wires 41, ensuring effective water blocking and maintaining the cleanliness of the glass surface.
[0037] It should be noted that the above embodiments are only used to explain the technical principles of the present application and are not intended to limit the scope of protection of the present application. In order to better illustrate the present application, numerous specific details are provided in the above specific embodiments. It should be understood by those skilled in the art that the present application can also be implemented without certain specific details.
Claims
1. A photovoltaic module, characterized in that: include: A first cover plate, a battery packaging layer, and a second cover plate are stacked in sequence. The first cover plate is provided with a lead hole. The battery packaging layer has battery cells. The lead wires on the battery cells are passed through the lead hole. The lead hole is filled with granular water-blocking material, and the water-blocking material covers the lead wires.
2. The photovoltaic module according to claim 1, characterized in that The maximum melt viscosity of the water-blocking material is greater than the maximum melt viscosity of the battery encapsulation layer.
3. The photovoltaic module according to claim 1 or 2, characterized in that: An isolation structure is provided on a side of the first cover plate facing away from the battery packaging layer. The isolation structure covers the lead hole, and the lead wire passes through the isolation structure.
4. The photovoltaic module according to claim 3, characterized in that The insulating structure is composed of fabric; and / or The isolation structure is made of waterproof material.
5. The photovoltaic module according to claim 1, characterized in that The water-blocking material is any one of glass powder, butyl rubber, polyvinyl butyral, polyolefin elastomer, and epoxy resin.
6. The photovoltaic module according to claim 1, characterized in that The material of the battery packaging layer is ethylene-vinyl acetate copolymer or polyolefin elastomer.
7. The photovoltaic module according to claim 1, characterized in that The particle size of the water-blocking material is less than 1 mm; and / or The distance between the lead wire and the lead wire hole ranges from 1 mm to 4 mm.
8. The photovoltaic module according to claim 1, characterized in that The melting temperature of the water-blocking material is in the range of 50°C to 250°C.
9. The photovoltaic module according to claim 1, characterized in that: The first cover plate is configured as a rear glass, and the second cover plate is configured as a front glass.
10. The photovoltaic module according to claim 1, characterized in that: The battery encapsulation layer includes a first adhesive film and a second adhesive film, and the battery cell is arranged between the first adhesive film and the second adhesive film.