Photovoltaic module and photovoltaic system

Abstract

The utility model is applicable to the technical field of photovoltaic modules, and provides a photovoltaic module and a photovoltaic system, the photovoltaic module comprises a frame and a laminated member fixed in the frame, and the laminated member comprises a back cover plate, a rear packaging layer, a cell layer, a front packaging layer and a front cover plate which are stacked in sequence; the battery piece layer comprises a plurality of battery pieces, a first gap is formed between every two adjacent battery pieces, and a second gap is formed between the battery piece at the edge position of the battery piece layer and the frame; the part, corresponding to the first gap, of the front packaging layer has a first thickness, the part, corresponding to the second gap, of the front packaging layer has a second thickness, the part, corresponding to the battery piece, of the front packaging layer has a third thickness, and the part, corresponding to the battery piece, of the rear packaging layer has a fourth thickness; the first thickness and the second thickness are larger than the third thickness, and the third thickness is smaller than the fourth thickness. According to the photovoltaic assembly, the material consumption of the front packaging layer can be reduced, the cost of the photovoltaic assembly is reduced, and the influence of the front packaging layer on the sunlight transmittance can be reduced.

Description

Technical Field

[0001] This utility model relates to the field of photovoltaic module technology, specifically to a photovoltaic module and a photovoltaic system. Background Technology

[0002] Photovoltaic power generation utilizes solar-grade semiconductor electronic devices to effectively absorb solar radiation energy and convert it into electrical energy. A photovoltaic module mainly consists of a frame and laminated components fixed within the frame. The laminated components include a front panel, a front encapsulation layer, a cell layer, a rear encapsulation layer, and a backsheet. The laminated components are formed through vacuum thermal lamination and then encapsulated using the frame. Multiple cell strings are connected in series, parallel, or series-parallel to form a cell layer. During the lamination process, air trapped between the layers of the photovoltaic module is extracted through vacuum evacuation, and then the encapsulation layer is melted by heating, bonding the front panel, front encapsulation layer, cell layer, rear encapsulation layer, and backsheet together.

[0003] In related technologies, during the lamination process of photovoltaic modules, gaps exist between adjacent cells and between edge cells and the frame. During lamination, as the encapsulation layer melts, some encapsulation material enters these gaps, causing thinning of the encapsulation layer in these areas. This affects the encapsulation performance. To improve encapsulation performance, a thicker encapsulation layer is required. However, this increased thickness significantly increases the cost of the encapsulation layer, leading to higher production costs for photovoltaic modules. Utility Model Content

[0004] This invention provides a photovoltaic module that aims to solve the problem of high production costs of photovoltaic modules due to the high cost of the encapsulation layer.

[0005] This utility model provides a photovoltaic module, including a frame and a laminate fixed within the frame. The laminate includes a back cover, a rear encapsulation layer, a cell layer, a front encapsulation layer, and a front cover, which are stacked in sequence. The cell layer includes a plurality of cells, with a first gap between adjacent cells and a second gap between the cells at the edge of the cell layer and the frame.

[0006] The front encapsulation layer has a first thickness corresponding to the first gap, the front encapsulation layer has a second thickness corresponding to the second gap, the front encapsulation layer has a third thickness corresponding to the battery cell, and the rear encapsulation layer has a fourth thickness corresponding to the battery cell; the first thickness and the second thickness are greater than the third thickness, and the third thickness is less than the fourth thickness.

[0007] Preferably, the third thickness is 180~380 micrometers.

[0008] Preferably, the third thickness is 200-250 micrometers.

[0009] Preferably, the fourth thickness is 300-480 micrometers.

[0010] Preferably, the ratio of the first thickness and the second thickness to the third thickness is 1.2 to 3.

[0011] Preferably, the ratio of the third thickness to the fourth thickness is 0.3 to 0.8.

[0012] Preferably, the area of ​​the front encapsulation layer near the front cover plate corresponding to the first gap is planar; or, the area of ​​the front encapsulation layer near the front cover plate corresponding to the first gap protrudes towards the front cover plate to form a first protrusion.

[0013] Preferably, the area of ​​the front encapsulation layer near the front cover plate corresponding to the second gap is planar; or, the area of ​​the front encapsulation layer near the front cover plate corresponding to the second gap protrudes towards the front cover plate to form a second protrusion.

[0014] Preferably, the front encapsulation layer includes an adhesive film and a filler film, with the filler film disposed between the front cover plate and the adhesive film; or, the filler film is disposed between the adhesive film and the battery cell layer; the filler film includes a first filling portion corresponding to the first gap position and a second filling portion corresponding to the second gap.

[0015] Preferably, the filler film and the adhesive film are an integral structure.

[0016] Preferably, the filler film and the adhesive film are separate structures.

[0017] Preferably, the filler film is bonded between the front cover plate and the adhesive film, or the filler film is bonded between the adhesive film and the battery cell layer.

[0018] Preferably, the width of the first filling portion is greater than the width of the first gap.

[0019] Preferably, the width of the second filling portion is greater than the width of the second gap.

[0020] Preferably, the thickness of the first filling portion and the second filling portion is 80~400 micrometers.

[0021] Preferably, the thickness of the first filling portion and the second filling portion is 200~250 micrometers.

[0022] Preferably, the filler film is made of the same material as the adhesive film, and the pre-crosslinking degree of the filler film is greater than that of the adhesive film.

[0023] Preferably, the ratio of the pre-crosslinking degree of the filler film to the pre-crosslinking degree of the adhesive film is 5 to 30.

[0024] Preferably, the pre-crosslinking degree of the filler film and the adhesive film is 0~60%.

[0025] Preferably, the filler film is made of a different material than the adhesive film.

[0026] This utility model also provides a photovoltaic system, including the photovoltaic module described above.

[0027] This utility model provides a photovoltaic module with a front encapsulation layer having a first thickness corresponding to the gap between adjacent cells, a second thickness corresponding to the gap between the cells and the frame, and a third thickness corresponding to the cells. By setting the first and second thicknesses to be greater than the third thickness, only the portions of the front encapsulation layer corresponding to the first and second gaps are thickened. This allows the material of the thickened portion of the front encapsulation layer corresponding to the first gap to fill the first gap during lamination, and the material of the thickened portion of the front encapsulation layer corresponding to the second gap to fill the second gap during lamination. This reduces the thickness design of the portions of the front encapsulation layer not corresponding to the first and second gaps, eliminating the need for overall thickening of the front encapsulation layer. The thickness of the portion of the front encapsulation layer corresponding to the cells is smaller than that of the portion of the rear encapsulation layer corresponding to the cells, thus reducing the thickness design of the portion of the front encapsulation layer corresponding to the cells. Consequently, the impact of the front encapsulation layer on solar transmittance is reduced, improving the solar utilization rate of the cells and thereby increasing the power of the photovoltaic module. Furthermore, by reducing the amount of material used in the front encapsulation layer, the production cost of the photovoltaic module is significantly reduced, while maintaining good encapsulation performance of the front encapsulation layer. Attached Figure Description

[0028] Figure 1 A cross-sectional schematic diagram of a photovoltaic module provided for an embodiment of this utility model;

[0029] Figure 2 A cross-sectional schematic diagram of another photovoltaic module provided for an embodiment of this utility model;

[0030] Figure 3 A schematic diagram of a photovoltaic module before lamination is provided in an embodiment of this utility model;

[0031] Figure 4 This is a schematic diagram of another photovoltaic module before lamination, provided as an embodiment of the present invention.

[0032] Figure 5 A schematic diagram of a filling film for a photovoltaic module provided in an embodiment of this utility model;

[0033] Figure 6 For along Figure 5 A cross-sectional view along the AA direction. Detailed Implementation

[0034] To make the objectives, technical solutions, and advantages of this utility model clearer, the present utility model will be further described in detail below with reference to the accompanying drawings and embodiments. It should be understood that the specific embodiments described herein are merely illustrative of the present utility model and are not intended to limit the present utility model.

[0035] This embodiment of the invention provides a photovoltaic module with a front encapsulation layer having a first thickness corresponding to the gap between adjacent cells, a second thickness corresponding to the gap between the cells and the frame, and a third thickness corresponding to the cells. By setting the first and second thicknesses to be greater than the third thickness, only the portions of the front encapsulation layer corresponding to the first and second gaps are thickened. This allows the material of the thickened portion corresponding to the first gap to fill the first gap during lamination, and the material of the thickened portion corresponding to the second gap to fill the second gap during lamination. The front encapsulation layer does not need to be thickened overall. Compared to the rear encapsulation layer, the reduced thickness of the portion corresponding to the cells reduces the impact of the front encapsulation layer on solar transmittance, improves the solar utilization rate of the cells, and thus increases the power of the photovoltaic module. Furthermore, by reducing the amount of material used in the front encapsulation layer, the production cost of the photovoltaic module is significantly reduced, while maintaining good encapsulation performance.

[0036] Please refer to Figures 1-2 This utility model provides a photovoltaic module, including a frame 1 and a laminate 2 fixed in the frame 1. The laminate 2 includes a back cover plate 3, a rear encapsulation layer 4, a cell layer 5, a front encapsulation layer 6 and a front cover plate 7 stacked in sequence. The cell layer 5 includes a plurality of cells 51, with a first gap 52 between adjacent cells 51 and a second gap 53 between the cells 51 at the edge of the cell layer 5 and the frame 1.

[0037] The portion of the front encapsulation layer 6 corresponding to the first gap 52 has a first thickness D1, the portion of the front encapsulation layer 6 corresponding to the second gap 53 has a second thickness D2, the portion of the front encapsulation layer 6 corresponding to the battery cell 51 has a third thickness D3, and the portion of the rear encapsulation layer 4 corresponding to the battery cell 51 has a fourth thickness D4. The first thickness D1 and the second thickness D2 are greater than the third thickness D3, and the third thickness D3 is less than the fourth thickness D4.

[0038] In this embodiment of the present invention, the front cover plate 7 is located on the sunlit surface of the photovoltaic module, the back cover plate 3 is located on the sunlit back surface of the photovoltaic module, the rear encapsulation layer 4 is disposed near the back of the solar cell, and the front encapsulation layer 6 is disposed near the front of the solar cell.

[0039] The photovoltaic module can be a double-glass module or a single-glass module. When the photovoltaic module is a double-glass module, both the back cover plate 3 and the front cover plate 7 are transparent glass. When the photovoltaic module is a single-glass module, one of the back cover plate 3 and the front cover plate 7 is transparent glass, and the other is a back sheet. For example, the back cover plate 3 is transparent glass, and the front cover plate 7 is a back sheet.

[0040] In this embodiment of the present invention, the rear encapsulation layer 4 and the front encapsulation layer 6 are respectively located on the back and front of the cell layer 5. The rear encapsulation layer 4 and the front encapsulation layer 6 are used to encapsulate the cell layer 5. Their main function is to protect the cell layer 5, prevent water and oxygen from entering and causing the cell 51 in the cell layer 5 to fail, and encapsulate it into a photovoltaic module that can output DC power.

[0041] In this embodiment of the present invention, the front encapsulation layer 6 of a photovoltaic module has a first thickness D1 corresponding to the first gap 52, a second thickness D2 corresponding to the second gap 53, and a third thickness D3 corresponding to the solar cell 51. The first thickness D1 and the second thickness D2 are set to be greater than the third thickness D3. Only the portions of the front encapsulation layer 6 corresponding to the first gap 52 and the second gap 53 are thickened, allowing the material of the thickened portion of the front encapsulation layer 6 corresponding to the first gap 52 to fill the first gap 52 during lamination. The thickened portion of the front encapsulation layer 6 corresponding to the second gap 53... The material used in the lamination process can fill the second gap 53, eliminating the need for overall thickening of the front encapsulation layer 6. This allows for a reduction in the thickness of the front encapsulation layer 6 outside of the first and second gaps 52 and 53. The third thickness D3 of the front encapsulation layer 6 corresponding to the cell 51 is smaller than the fourth thickness D4 of the rear encapsulation layer 4 corresponding to the cell 51, reducing the impact of the front encapsulation layer 6 on solar transmittance and improving the solar utilization rate of the cell 51, thereby increasing the power of the photovoltaic module. Furthermore, it reduces the amount of material used in the front encapsulation layer 6, thus lowering the production cost of the photovoltaic module while maintaining its good encapsulation performance. The rear encapsulation layer 4 can use a film of conventional thickness; only the portions of the front encapsulation layer 6 corresponding to the first and second gaps 53 need to be thickened, facilitating processing.

[0042] The thickening of the portion of the front encapsulation layer 6 corresponding to the first gap 52 and the portion corresponding to the second gap 53 can be achieved by using an additional filling film for thickening, or by directly designing the portion of the front encapsulation layer 6 corresponding to the first gap 52 and the portion corresponding to the second gap 53 to be thicker.

[0043] As one embodiment of this utility model, the third thickness D3 is 180~380 micrometers.

[0044] In this embodiment, the third thickness D3 of the front encapsulation layer 6 can be set to any value between 180 and 380 micrometers. For example, the third thickness D3 can be any value among 180 micrometers, 200 micrometers, 220 micrometers, 240 micrometers, 250 micrometers, 280 micrometers, 320 micrometers, 350 micrometers, 370 micrometers, 375 micrometers, and 380 micrometers.

[0045] In a preferred embodiment of this utility model, the third thickness D3 is 200~250 micrometers.

[0046] In this embodiment, the third thickness D3 of the front encapsulation layer 6 is set to 200~250 micrometers, which can not only achieve good encapsulation of the battery cell area by the front encapsulation layer 6, but also further reduce the amount of material used in the front encapsulation layer 6, thereby greatly reducing the cost.

[0047] As one embodiment of this utility model, the fourth thickness D4 is 300~480 micrometers.

[0048] The fourth thickness D4 can be any value between 300 and 480 micrometers. For example, the fourth thickness D4 can be any value among 300 micrometers, 320 micrometers, 350 micrometers, 380 micrometers, 400 micrometers, 420 micrometers, 450 micrometers, and 480 micrometers.

[0049] In this embodiment, the thickness of the rear encapsulation layer 4 can be uniformly set, that is, the thickness of the rear encapsulation layer 4 corresponding to the first gap 52 portion, the thickness corresponding to the second gap 53 portion, and the thickness of other areas of the rear encapsulation layer 4 are equal, and all are the fourth thickness D4. For example, the rear encapsulation layer 4 can be an adhesive film with uniform thickness and the fourth thickness D4. Of course, in some other embodiments, the thickness of the rear encapsulation layer 4 can be non-uniformly set, that is, the thickness of the rear encapsulation layer 4 corresponding to the first gap 52 portion, the thickness corresponding to the second gap 53 portion, and the thickness of other areas of the rear encapsulation layer 4 can be unequal.

[0050] In one embodiment of this utility model, the ratio of the third thickness D3 to the fourth thickness D4 is 0.3 to 0.8.

[0051] In this embodiment, the ratio of the third thickness D3 to the fourth thickness D4 is 0.3 to 0.8. By reasonably setting the range of the ratio of the third thickness D3 to the fourth thickness D4, the thickness difference between the front encapsulation layer 4 and the rear encapsulation layer 6 is designed to be within a suitable range. This can achieve a good encapsulation effect between the front encapsulation layer 4 and the rear encapsulation layer 6, and also make the material usage of the front encapsulation layer 4 and the rear encapsulation layer 6 more appropriate, thereby reducing costs.

[0052] In this embodiment of the invention, the specific thicknesses of the first thickness D1 and the second thickness D2 are not limited, and the difference between the first thickness D1, the second thickness D2 and the third thickness D3 is not specifically limited. The thicknesses of the first thickness D1 and the second thickness D2 may be equal or unequal.

[0053] In a preferred embodiment of the present invention, the ratio of the thickness of the first thickness D1 and the second thickness D2 to the third thickness D3 is 1.2 to 3.

[0054] In this embodiment, the ratio of the first thickness D1 to the third thickness D3 and the ratio of the second thickness D2 to the third thickness D3 are both 1.2 to 3. By reasonably setting the difference between the thickness of the first thickness D1 and the second thickness D2 and the third thickness D3, a good encapsulation effect can be achieved in each region of the front encapsulation layer 4, and the amount of material used in the front encapsulation layer 6 can be greatly reduced, thereby significantly reducing costs. More preferably, the ratio of the thickness of the first thickness D1 and the second thickness D2 to the third thickness D3 is 1.2 to 2.

[0055] In a preferred embodiment of this utility model, the first thickness D1 and the second thickness D2 are greater than 300 micrometers.

[0056] In this embodiment, the first thickness D1 and the second thickness D2 are greater than 300 micrometers, which can better achieve the encapsulation of the first gap 52 region and the second gap 53 region.

[0057] In this embodiment of the utility model, the number of battery cells 51 included in the battery cell layer 5 is not limited. Multiple battery cells 51 of the battery cell layer 5 are laid flat between the rear encapsulation layer 4 and the front encapsulation layer 6. Multiple batteries in the battery cell layer 5 can be connected in series, in parallel, or in a combination of series and parallel.

[0058] In this embodiment of the invention, the first gap 52 can be the gap between adjacent battery cells 51 between battery strings, or the gap between adjacent battery cells 51 within the same battery string. The gap between adjacent battery cells 51 between battery strings and the gap between adjacent battery cells 51 within the same battery string can be equal or unequal. For example, the gap between adjacent battery cells 51 between battery strings is 0.5~2.5 mm, and the gap between adjacent battery cells 51 within the same battery string is 0.5~1.5 mm; that is, the width of the first gap 52 is 0.5~2.5 mm. A second gap 53 exists between the battery cells 51 at the edge of the battery cell layer 5 and the frame 1, and the width of the second gap 53 is 7~20 mm.

[0059] As an embodiment of the present invention, the battery cell layer 5 includes at least one battery string, and the battery cells 51 in each battery string are connected by solder strips (not shown).

[0060] The number of battery strings in the cell layer 5 is unlimited. These battery strings can be connected in series or parallel via busbars. The specific number of battery cells 51 within each battery string is also unlimited. The battery strings are arranged sequentially along a first direction, and the battery cells 51 within each battery string are arranged sequentially along a second direction, with the first and second directions perpendicular. For example, the cell layer 5 may include six battery strings, and each battery string contains nine battery cells 51.

[0061] In a preferred embodiment of this utility model, the welding strip is specifically a flat welding strip. The flat welding strip has a square cross-section, and there is planar contact between the flat welding strip and the battery cell 51, resulting in almost no gap between the flat welding strip and the surface of the battery cell 51.

[0062] In related technologies, since the solar cells 51 are connected by circular solder ribbons, there will be gaps between the circular solder ribbons and the solar cells 51. This will cause the encapsulation layer to thin after lamination in the solder ribbon area, affecting the encapsulation performance of the encapsulation layer. Moreover, the thickness of the encapsulation layer is uneven around the solder ribbon after lamination, which easily generates bubbles, resulting in low production yield. In this embodiment, since the solar cells 51 are connected by flat solder ribbons, there are no gaps between the flat solder ribbons and the surface of the solar cells 51. The area corresponding to the flat solder ribbon will not be thinned after lamination of the rear encapsulation layer 4 or the front encapsulation layer 6. Therefore, the rear encapsulation layer 4 or the front encapsulation layer 6 in the area corresponding to the flat solder ribbon does not need to be thickened or filled with adhesive strips. This can reduce the material usage of the encapsulation layer, reduce costs, and simplify the process. At the same time, it can make the thickness of the rear encapsulation layer 4 or the front encapsulation layer 6 more uniform around the solder ribbon, making it less prone to bubbles, thereby improving the production yield of photovoltaic modules.

[0063] As one embodiment of this utility model, the thickness of the solder strip is 0.07~0.3 mm and the width is 0.5~3 mm.

[0064] For example, the solder strip is a flat solder strip, and the thickness of the solder strip can be any value among 0.07 mm, 0.08 mm, 0.1 mm, 0.12 mm, 0.15 mm, 0.17 mm, 0.18 mm, 0.2 mm, 0.4 mm, 0.6 mm, 0.25 mm, 0.27 mm, 0.29 mm, and 0.3 mm; for example, the width of the solder strip can be any value among 0.5 mm, 0.6 mm, 0.65 mm, 0.8 mm, 0.9 mm, 1.1 mm, 1.5 mm, 1.6 mm, 1.8 mm, 2.0 mm, 2.2 mm, 2.5 mm, 2.7 mm, 2.8 mm, and 3.0 mm.

[0065] In this embodiment, the thickness of the solder ribbon on the battery cell layer 5 is controlled to be 0.07~0.3 mm and the width is 0.5~3 mm. This not only achieves good conductivity of the solder ribbon, but also reduces the material usage of the rear encapsulation layer 4 and the front encapsulation layer 6, thus reducing costs. Furthermore, the thickness of the rear encapsulation layer 4 and the front encapsulation layer 6 is more uniform around the solder ribbon after lamination, making it less prone to air bubbles.

[0066] As an embodiment of the present invention, the area of ​​the front encapsulation layer 6 near the front cover plate 7 corresponding to the solder strip is planar, or the area of ​​the front encapsulation layer 6 near the front cover plate 7 corresponding to the solder strip protrudes toward the front cover plate 7.

[0067] In this embodiment, the area of ​​the front encapsulation layer 6 near the front cover plate 7 corresponding to the first gap 52 can be planar or protrude towards the front cover plate 7 to form a protrusion.

[0068] In related technologies, during the lamination process of photovoltaic modules, some of the encapsulation layer material enters the gap between the solder ribbon and the cell 51 after the encapsulation layer melts, causing the encapsulation layer to thin at the corresponding solder ribbon position and resulting in local depression, which affects the encapsulation performance of the encapsulation layer. In this utility model, since flat solder ribbons are used instead of circular solder ribbons, the encapsulation layer at the corresponding solder ribbon position will not thin during the lamination process of the photovoltaic module, and therefore will not affect the encapsulation performance of the cell 51. The surface of the front encapsulation layer 6 near the front cover plate 7 will remain flat or bulge towards the front cover plate 7 to form a protrusion, maintaining the good encapsulation performance of the front encapsulation layer 6. Moreover, there is no need to pre-thicken the thickness of the front encapsulation layer 6 at the corresponding flat solder ribbon position, which can reduce production costs and simplify the production process.

[0069] Please refer to Figure 1 As an embodiment of the present invention, the surface of the front encapsulation layer 6 near the front cover plate 7 is planar in the area corresponding to the first gap 52.

[0070] In this embodiment, when the volume of the material thickened in the first gap 52 corresponding to the current encapsulation layer 6 is equal to the volume of the first gap 52, the area of ​​the front encapsulation layer 6 near the front cover plate 7 corresponding to the first gap 52 is planar, which can satisfy that the first thickness D1 is greater than the third thickness D3, thus achieving good encapsulation performance. Furthermore, since the area of ​​the front encapsulation layer 6 corresponding to the first gap 52 is in planar contact with the front cover plate 7, the front encapsulation layer 6 and the front cover plate 7 are subjected to more uniform force, which is beneficial to improving the overall structural stability of the photovoltaic module.

[0071] Please refer to Figure 2 In another embodiment of the present invention, the surface of the front encapsulation layer 6 near the front cover plate 7 protrudes in the direction of the front cover plate 7 to form a first protrusion 61 corresponding to the area of ​​the first gap 52.

[0072] In this embodiment, when the volume of the thickened material corresponding to the first gap 52 in the current encapsulation layer 6 is greater than the volume of the first gap 52, the area of ​​the front encapsulation layer 6 near the front cover plate 7 corresponding to the first gap 52 protrudes towards the second plate to form a first protrusion 61. This satisfies the requirement that the first thickness D1 is greater than the third thickness D3, and further increases the thickness of the portion of the front encapsulation layer 6 corresponding to the first gap 52, thereby further improving the encapsulation performance of the front encapsulation layer 6. Moreover, the presence of the first protrusion 61 increases the bonding force between the front encapsulation layer 6 and the front cover plate 7 after lamination, thereby improving the structural strength of the photovoltaic module and extending its service life. The first protrusion 61 can be an arc-shaped protrusion or a square protrusion. Preferably, the first protrusion 61 is an arc-shaped protrusion to reduce the concentrated stress on the first protrusion 61.

[0073] The height of the first protrusion 61 is not specifically limited and can be determined by the volume of the thickened material of the front encapsulation layer 6 corresponding to the first gap 52.

[0074] Please refer to Figure 1 As an embodiment of the present invention, the surface of the front encapsulation layer 6 near the front cover plate 7 is planar in the area corresponding to the second gap 53.

[0075] In this embodiment, when the volume of the material thickened in the second gap 53 corresponding to the current encapsulation layer 6 is equal to the volume of the second gap 53, the area of ​​the front encapsulation layer 6 near the front cover plate 7 corresponding to the second gap 53 is planar, which can satisfy that the second thickness D2 is greater than the third thickness D3, thus achieving good encapsulation performance. Furthermore, since the area of ​​the front encapsulation layer 6 corresponding to the second gap 53 is in planar contact with the front cover plate 7, the front encapsulation layer 6 and the front cover plate 7 are subjected to more uniform force, which is beneficial to improving the overall structural stability of the photovoltaic module.

[0076] Please refer to Figure 2 As an embodiment of the present invention, the surface of the front encapsulation layer 6 near the front cover plate 7, corresponding to the area of ​​the second gap 53, protrudes towards the front cover plate 7 to form a second protrusion 62.

[0077] In this embodiment, when the volume of the thickened material corresponding to the second gap 53 in the current encapsulation layer 6 is greater than the volume of the second gap 53, the area of ​​the front encapsulation layer 6 near the front cover plate 7 corresponding to the second gap 53 protrudes in the direction of the second plate to form a second protrusion 62. This satisfies the requirement that the second thickness D2 is greater than the third thickness D3, and further increases the thickness of the portion of the front encapsulation layer 6 corresponding to the second gap 53, thereby further improving the encapsulation performance of the front encapsulation layer 6. Moreover, the presence of the second protrusion 62 also increases the bonding force between the front encapsulation layer 6 and the front cover plate 7 after lamination, thereby improving the structural strength of the photovoltaic module and extending its service life. The second protrusion 62 can be an arc-shaped protrusion or a square protrusion. Preferably, the second protrusion 62 is also an arc-shaped protrusion.

[0078] The height of the second protrusion 62 is not specifically limited and can be determined by the volume of the thickened material of the front encapsulation layer 6 corresponding to the second gap 53.

[0079] Please refer to Figures 3-6 As an embodiment of the present invention, the front encapsulation layer 6 includes an adhesive film 62 and a filling film 63. The filling film 63 is disposed between the front cover plate 7 and the adhesive film 62, or the filling film 63 is disposed between the adhesive film 62 and the battery cell layer 5. The filling film 63 includes a first filling portion 631 corresponding to the position of the first gap 52 and a second filling portion 632 corresponding to the second gap 53.

[0080] In this embodiment, the front encapsulation layer 6 is composed of an adhesive film 62 and a filler film 63. The number and position of the first filler portions 631 correspond to the number and position of the first gaps 52, and the number and position of the second filler portions 632 correspond to the number and position of the second gaps 53. Preferably, the first filler portions 631 and the second filler portions 632 are specifically elongated strips, and the filler film 63 is generally a mesh film.

[0081] Before laminating the photovoltaic module, the filler film 63 can be placed between the front cover plate 7 and the encapsulant film 62, or the filler film 63 can be placed between the encapsulant film 62 and the cell layer 5; the filler film 63 can also be placed between the front cover plate 7 and the encapsulant film 62, or the filler film 63 can be placed between the front cover plate 7 and the encapsulant film 62 at the same time. After the filler film 63 is placed, the first filling part 631 of the filler film 63 corresponds to the position of the first gap 52, and the second filling part 632 of the filler film 63 corresponds to the position of the second gap 53.

[0082] like Figure 3 As shown, when the filler film 63 is placed between the encapsulant film 62 and the cell layer 5, during the lamination process of the photovoltaic module, after the material of the first filler portion 631 melts, part or all of the material of the first filler portion 631 fills into the first gap 52. After the material of the second filler portion 632 melts, part or all of the material of the second filler portion 632 fills into the second gap 53. Since the first filler portion 631 can fill the first gap 52 and the second filler portion 632 can fill the second gap 53, the material melted by the encapsulant film 62 will not fill into the first gap 52 and the second gap 53. Therefore, the front encapsulation layer 6 will not be thinned in the first gap 52 and the second gap 53, thus achieving good cell encapsulation performance of the encapsulant film 6.

[0083] like Figure 4 As shown, when the filler film 63 is placed between the front cover plate 7 and the encapsulant film 62, during the lamination process of the photovoltaic module, after the encapsulant film 62 melts, some of the encapsulant film 62 will fill into the first gap 52. The melting of the first filler portion 631 can compensate for the encapsulant film 62 material entering the first gap 52, thus preventing the area of ​​the front encapsulation layer 6 corresponding to the first gap 52 from sinking, and allowing the area of ​​the front encapsulation layer 6 corresponding to the first gap 52 to still maintain good encapsulation performance. Similarly, during the lamination process of the photovoltaic module, after the encapsulant film 62 melts, some of the encapsulant film 62 will fill into the second gap 53. The melting of the second filler portion 632 can compensate for the encapsulant film 62 material entering the second gap 53, thus preventing the area of ​​the front encapsulation layer 6 corresponding to the second gap 53 from sinking, and allowing the area of ​​the front encapsulation layer 6 corresponding to the second gap 53 to also maintain good encapsulation performance.

[0084] Therefore, since the filler film 63 is used to fill the first gap 52 and the second gap 53, a thinner adhesive film 62 can be selected to encapsulate the battery cell layer 5. The required thickness of the adhesive film 62 is the third thickness D3. The adhesive film 62 can be set to 180~380 micrometers, while the conventional adhesive film 62 needs to be at least 380 micrometers. Therefore, the thickness design of the adhesive film 62 can be reduced, the amount of material used can be reduced, thereby reducing the cost, while maintaining the good encapsulation performance of the adhesive film 62. Moreover, it is only necessary to place the corresponding filler film 63 before lamination, making the process very simple and the cost low.

[0085] As one embodiment of this utility model, the filler film 63 and the adhesive film 62 are an integral structure.

[0086] In this embodiment, the filler film 63 and the adhesive film 62 can be integrally formed to form the encapsulation layer 4. Before lamination, the front encapsulation layer 6 can be placed between the front cover plate 7 and the battery cell layer 5 at one time, which can improve production efficiency.

[0087] In another embodiment of this utility model, the filling film 63 and the adhesive film 62 are separate structures.

[0088] In this embodiment, the filler film 63 and the adhesive film 62 can be separate structures. Before lamination, the filler film 63 can be placed separately between the front cover plate 7 and the adhesive film 62 or between the adhesive film 62 and the battery cell layer 5. This facilitates the separate preparation of the filler film 63 and the adhesive film 62, reduces production costs, and lowers the difficulty of the production process of the filler film 63 and the adhesive film 62. Moreover, it also makes it easy to flexibly change the placement position of the filler film 63 according to actual needs.

[0089] As one embodiment of this utility model, the filler film 63 is bonded between the front cover plate 7 and the adhesive film 62, or the filler film 63 is bonded between the adhesive film 62 and the battery cell layer 5.

[0090] In this embodiment, the filler film 63 is bonded between the front cover plate 7 and the adhesive film 62, or between the adhesive film 62 and the battery cell layer 5. This prevents the filler film 63 from shifting during lamination and improves the reliability of filling the first gap 52 and the second gap 53. When the filler film 63 is disposed between the front cover plate 7 and the adhesive film 62, the filler film 63 is fixed to the side of the front cover plate 7 near the adhesive film 62 by thermal bonding, or it can be thermally bonded to the side of the adhesive film 62 near the front cover plate 7. When the filler film 63 is disposed between the adhesive film 62 and the battery cell layer 5, the filler film 63 can be thermally bonded to the side of the adhesive film 62 near the battery cell layer 5, or it can be thermally bonded to the side of the battery cell layer 5 near the adhesive film 62. Of course, the filler film 63 can also be placed directly between the front cover plate 7 and the adhesive film 62, or the filler film 63 can be placed between the adhesive film 62 and the battery cell layer 5.

[0091] In one embodiment of this utility model, the width of the first filling part 631 is greater than the width of the first gap 52.

[0092] In this embodiment, the width of the first filling portion 631 is greater than the width of the first gap 52, which allows the first filling portion 631 to fill the first gap 52 as much as possible, improving the filling effect of the first filling portion 631, and also making it easier for the first filling portion 631 to overlap and be placed on top of the battery cell 51. The specific difference between the width of the first filling portion 631 and the width of the first gap 52 can be determined according to the actual design and is not limited here.

[0093] In one embodiment of this utility model, the width of the second filling portion 632 is greater than the width of the second gap 53.

[0094] In this embodiment, the width of the second filling portion 632 is greater than the width of the second gap 53, which allows the second filling portion 632 to fill the second gap 53 as much as possible, thereby improving the filling effect of the first filling film 63. The specific difference between the width of the second filling portion 632 and the width of the second gap 53 can be determined according to actual design and is not limited here.

[0095] As an embodiment of the present invention, the thickness of the first filling part 631 and the second filling part 632 is 80~400 micrometers.

[0096] In this embodiment, the thickness of the first filling part 631 and the second filling part 632 is set to 80~400 micrometers, which can make the first filling part 631 fill the first gap 52 as much as possible, and the first filling part 631 fill the second gap 53 as much as possible, thereby improving the filling effect of the first filling part 631 and the second filling part 632.

[0097] Further preferably, the thickness of the first filling portion 631 and the second filling portion 632 is 200-250 micrometers, which can improve the filling effect of the first filling portion 631 and the second filling portion 632 and achieve lower production costs. Preferably, the thickness of the first filling portion 631 and the second filling portion 632 is the same, which facilitates the one-time processing and forming of the filling film 63.

[0098] In this embodiment of the invention, the materials of the filler film 63 and the adhesive film 62 can be the same or different.

[0099] As an embodiment of this utility model, the filler film 63 and the adhesive film 62 are made of the same material, and the pre-crosslinking degree of the filler film 63 is greater than that of the adhesive film 62.

[0100] In this embodiment, the pre-crosslinking degree of the filler film 63 is set to be greater than that of the adhesive film 62, which can reduce the flowability of the filler film 63. During the lamination process, the first filling part 631 of the filler film 63 can fill the first gap 52 well, and the second filling part 632 of the filler film 63 can fill the second gap 53 well. This can prevent the first filling part 631 and the second filling part 632 from flowing to other areas as much as possible, thereby better achieving the pre-filling effect of the filler film 63.

[0101] Among them, the filler film 63 and the adhesive film 62 can be EVA (ethylene oxide). Vinyl acetate copolymer, ethylene vinylacetate copolymer), POE (polymer of ethylene and butene), EPE (EVA) POE EVA three-layer co-extruded film), EE (EVA) EVA double-layer co-extruded film), PE (PET) One or a combination of EVA double-layer backsheet membranes.

[0102] As one embodiment of the present invention, the pre-crosslinking degree of the filler film 63 and the adhesive film 62 is 0~60%.

[0103] In this embodiment, the pre-crosslinking degree of the filler film 63 and the adhesive film 62 is 0-60%, which can better control the flow properties of the filler film 63 and the adhesive film 62 during the lamination process, achieve a good encapsulation effect of the filler film 63 and the adhesive film 62, and prevent the battery cell 51 from shifting during the lamination process. The pre-crosslinking degree of the filler film 63 and the adhesive film 62 can be the same or different. For example, the pre-crosslinking degree of the filler film 63 and the adhesive film 62 can be any value from 1%, 2%, 5%, 10%, 12%, 20%, 26%, 28%, 30%, 36%, 39%, 40%, 46%, 50%, 55%, and 60%. More preferably, the pre-crosslinking degree of the filler film 63 and the adhesive film 62 is 5%-60%.

[0104] The pre-crosslinking degree of the filler film 63 is greater than that of the adhesive film 62. The pre-crosslinking degree of both the filler film 63 and the adhesive film 62 is 0-60%, and it is sufficient that the pre-crosslinking degree of the filler film 63 is greater than that of the adhesive film 62. For example, the pre-crosslinking degree of the filler film 63 is 30%, and the pre-crosslinking degree of the adhesive film 62 is 2%; or, for another example, the pre-crosslinking degree of the filler film 63 is 50%, and the pre-crosslinking degree of the adhesive film 62 is 10%.

[0105] As an embodiment of this utility model, the ratio of the pre-crosslinking degree of the filler film 63 to the pre-crosslinking degree of the adhesive film 62 is 5~30.

[0106] In this embodiment, the ratio of the pre-crosslinking degree of the filler film 63 to the pre-crosslinking degree of the adhesive film 62 is controlled at 5 to 10, so that the pre-crosslinking degree of the filler film 63 and the pre-crosslinking degree of the adhesive film 62 maintain a suitable difference. This can prevent the first filler portion 631 and the second filler portion 632 from flowing to other areas, better achieve the pre-filling effect of the filler film 63, and facilitate the processing and production of the filler film 63 and the adhesive film 62.

[0107] In another embodiment of this utility model, the filler film 63 and the adhesive film 62 are made of different materials, which makes it easier to select different materials according to the difference in flowability between the filler film 63 and the adhesive film 62, thereby reducing the implementation cost.

[0108] For example, the filler film 63 is made of EVA and the adhesive film 62 is made of EPE. By using this material combination, the pre-crosslinking degree of the filler film 63 and the pre-crosslinking degree of the adhesive film 62 can maintain a suitable difference. This can reduce the flow performance of the first filler portion 631 and the second filler portion 632 to other areas, better achieve the pre-filling effect of the filler film 63, and facilitate the processing and production of the filler film 63 and the adhesive film 62.

[0109] For example, the filler film 63 is made of POE and the adhesive film 62 is made of EE. By using this material combination, the pre-crosslinking degree of the filler film 63 and the pre-crosslinking degree of the adhesive film 62 are kept at a suitable difference, which can reduce the flow performance of the first filler portion 631 and the second filler portion 632 to other areas, and facilitate the processing and production of the filler film 63 and the adhesive film 62.

[0110] This utility model embodiment also provides a photovoltaic system, which includes the photovoltaic module described in the above embodiment. It should be noted that this photovoltaic system has the same or similar beneficial effects as the photovoltaic module described above, and the related aspects between the two can be referred to each other; to avoid repetition, they will not be repeated here.

[0111] In this embodiment, the photovoltaic system can be applied in photovoltaic power plants, such as ground-mounted power plants, rooftop power plants, and floating power plants. It can also be applied to equipment or devices that utilize solar energy to generate electricity, such as user solar power supplies, solar streetlights, solar cars, and solar buildings. Of course, it is understood that the application scenarios of the photovoltaic system are not limited to these; that is, the photovoltaic system can be applied in all fields that require solar energy to generate electricity. Taking a photovoltaic system network as an example, the photovoltaic system may include a photovoltaic array, a combiner box, and an inverter. The photovoltaic array may be an array combination of multiple photovoltaic modules; for example, multiple photovoltaic modules can form multiple photovoltaic arrays. The photovoltaic array is connected to the combiner box, which can collect the current generated by the photovoltaic array. The collected current flows through the inverter and is converted into AC power required by the mains power grid before being connected to the mains power grid to achieve solar power supply.

[0112] The above are merely preferred embodiments of the present utility model and are not intended to limit the present utility model. Any modifications, equivalent substitutions, and improvements made within the spirit and principles of the present utility model should be included within the protection scope of the present utility model.

Claims

1. A photovoltaic module, characterized in that, The device includes a frame and a laminated component fixed within the frame. The laminated component includes a back cover, a rear encapsulation layer, a battery cell layer, a front encapsulation layer, and a front cover, which are stacked sequentially. The battery cell layer includes a plurality of battery cells, with a first gap between adjacent battery cells and a second gap between the battery cells at the edge of the battery cell layer and the frame. The front encapsulation layer has a first thickness corresponding to the first gap, the front encapsulation layer has a second thickness corresponding to the second gap, the front encapsulation layer has a third thickness corresponding to the battery cell, and the rear encapsulation layer has a fourth thickness corresponding to the battery cell; the first thickness and the second thickness are greater than the third thickness, and the third thickness is less than the fourth thickness.

2. The photovoltaic module according to claim 1, characterized in that, The third thickness is 180~380 micrometers.

3. The photovoltaic module according to claim 2, characterized in that, The third thickness is 200-250 micrometers.

4. The photovoltaic module according to claim 1, characterized in that, The fourth thickness is 300~480 micrometers.

5. The photovoltaic module according to claim 1, characterized in that, The ratio of the first thickness and the second thickness to the third thickness is 1.2 to 3.

6. The photovoltaic module according to claim 1, characterized in that, The ratio of the third thickness to the fourth thickness is 0.3 to 0.

8.

7. The photovoltaic module according to claim 1, characterized in that, The area of ​​the front encapsulation layer near the front cover plate corresponding to the first gap is planar; or, the area of ​​the front encapsulation layer near the front cover plate corresponding to the first gap protrudes towards the front cover plate to form a first protrusion.

8. The photovoltaic module according to claim 1, characterized in that, The area of ​​the front encapsulation layer near the front cover plate corresponding to the second gap is planar; or, the area of ​​the front encapsulation layer near the front cover plate corresponding to the second gap protrudes towards the front cover plate to form a second protrusion.

9. The photovoltaic module according to claim 1, characterized in that, The front encapsulation layer includes an adhesive film and a filler film. The filler film is disposed between the front cover plate and the adhesive film; or, the filler film is disposed between the adhesive film and the battery cell layer. The filler film includes a first filling portion corresponding to the first gap position and a second filling portion corresponding to the second gap position.

10. The photovoltaic module according to claim 9, characterized in that, The filler film and the adhesive film are an integral structure.

11. The photovoltaic module according to claim 9, characterized in that, The filler film and the adhesive film are separate structures.

12. The photovoltaic module according to claim 9, characterized in that, The filler film is bonded between the front cover plate and the adhesive film, or the filler film is bonded between the adhesive film and the battery cell layer.

13. The photovoltaic module according to claim 9, characterized in that, The width of the first filling portion is greater than the width of the first gap.

14. The photovoltaic module according to claim 9, characterized in that, The width of the second filling portion is greater than the width of the second gap.

15. The photovoltaic module according to claim 9, characterized in that, The thickness of the first filling portion and the second filling portion is 80~400 micrometers.

16. The photovoltaic module according to claim 9, characterized in that, The thickness of the first filling portion and the second filling portion is 200~250 micrometers.

17. The photovoltaic module according to claim 9, characterized in that, The filler film is made of the same material as the adhesive film, and the pre-crosslinking degree of the filler film is greater than that of the adhesive film.

18. The photovoltaic module according to claim 17, characterized in that, The ratio of the pre-crosslinking degree of the filler film to the pre-crosslinking degree of the adhesive film is 5 to 30.

19. The photovoltaic module according to claim 17, characterized in that, The pre-crosslinking degree of the filler film and the adhesive film is 0~60%.

20. The photovoltaic module according to claim 9, characterized in that, The filler film is made of a different material than the adhesive film.

21. A photovoltaic system, characterized in that, Including the photovoltaic module as described in any one of claims 1 to 20.

Images