Efficient Top-con light component

Abstract

The utility model discloses a high-efficiency Top-con (Top-con) light component. The top surface of the Top-con battery layer is bonded with a CPC material barrier front plate layer through a second adhesive film layer, the top surface of the CPC material barrier front plate layer is bonded with the composite front plate layer through a first adhesive film layer, and the top surface of the top surface of the Top-con battery layer is bonded with the aluminum-containing metal back plate through a second adhesive film layer. The bottom surface of the Top-con battery layer is bonded with the top surface of the glass fiber reinforced layer through a third adhesive film layer, and the bottom surface of the glass fiber reinforced layer is bonded with the aluminum-containing metal backboard through a fourth adhesive film layer. The advantages are that the multi-layer structure design obviously improves the flexibility and impact resistance of the assembly, and the assembly can adapt to complex curved surfaces and special installation environments; through scientific matching of multiple layers of materials, the problems that a traditional packaging material is prone to water vapor permeation, adhesive film degradation, grid line corrosion and the like are solved, the packaging reliability of the Top-con light assembly is comprehensively improved, and it is ensured that the assembly has excellent electrical property stability and use safety in long-term operation.

Description

Technical Field

[0001] This utility model relates to the field of photovoltaic module technology, and in particular to a high-efficiency Top-con lightweight module. Background Technology

[0002] The photovoltaic industry is currently facing technical challenges in improving photovoltaic cell conversion efficiency, reducing production costs, and achieving lightweight modules. Traditional lightweight modules typically use tempered glass or transparent backsheets as encapsulation materials. While these reduce weight to some extent, they still suffer from insufficient flexibility, poor hail impact resistance, and low weather resistance, making them unsuitable for complex applications such as corrugated steel roofs, RV roofs, and curved surfaces. Meanwhile, as the advantages of PERC cell technology gradually diminish, photovoltaic cells are upgrading from P-type to N-type technology, with Top-con cells becoming the mainstream solution due to their contact passivation system and lower mass production costs. However, Top-con cells place higher demands on humid and hot environments, the stability of the encapsulation film, and the corrosion resistance of the grid lines. A reliability impact analysis report released by Chint New Energy shows that moisture penetration accounts for 25% of Top-con module failures, encapsulation film degradation for 20%, grid line corrosion for 40%, and rework issues for 15%, demonstrating the crucial importance of encapsulation material selection for module reliability.

[0003] Therefore, developing a packaging structure with high water resistance, excellent resistance to damp heat, good mechanical strength and lightweight properties has become the key to solving the reliability problem of Top-con components and improving their application adaptability. Summary of the Invention

[0004] The technical problem to be solved by this utility model is to provide a high-efficiency Top-con lightweight component with high water resistance, high heat resistance and corrosion resistance.

[0005] To solve the above-mentioned technical problems, the present invention provides a high-efficiency Top-con lightweight component, comprising a top composite front panel layer, a bottom aluminum-containing metal backplate, and a Top-con battery layer between the composite front panel layer and the aluminum-containing metal backplate. The top surface of the Top-con battery layer is bonded to the CPC material barrier front panel layer through a second adhesive film layer. The top surface of the CPC material barrier front panel layer is bonded to the composite front panel layer through a first adhesive film layer. The bottom surface of the Top-con battery layer is bonded to the top surface of the glass fiber reinforcement layer through a third adhesive film layer. The bottom surface of the glass fiber reinforcement layer is bonded to the aluminum-containing metal backplate through a fourth adhesive film layer.

[0006] The composite front panel is formed by bonding a fluorinated polyvinylidene fluoride film and a KPF polymer substrate with an adhesive.

[0007] The fiberglass reinforcement layer includes a fiberglass material layer, a fluorinated air coating on the top surface of the fiberglass material layer, and a fluorinated EVA coating on the bottom surface of the fiberglass material layer.

[0008] The aluminum-containing metal backing plate is made of an upper fluorinated coating with a thickness of 8um to 12um, an aluminum foil with a thickness of 25um to 35um, a polyurethane adhesive with a thickness of 6um to 10um, a PET with a thickness of 220um to 260um, and a lower fluorinated coating with a thickness of 8um to 12um, which are laid in layers from top to bottom.

[0009] The layers are stacked sequentially to form the main body of the high-efficiency Top-con lightweight component. The outer edge of the main body of the high-efficiency Top-con lightweight component is provided with a frame. The frame is made of polyurethane and fiberglass resin composite molding material. The frame has two long sides and two short sides. The long sides and short sides are connected by corner brackets. The corner brackets are fixed and limited by several anti-slip protrusions. The inner side of the frame is provided with a U-shaped groove to accommodate the main body of the high-efficiency Top-con lightweight component.

[0010] The first film layer is a high-transparency POE film with a thickness of 0.3mm~0.6mm and a basis weight of 360g / m³. 2 ~460g / m 2 .

[0011] The CPC material barrier front layer is a fluorine-coated CPC with a thickness of 0.2mm to 0.5mm.

[0012] The second film layer is a high water-resistant pure POE film with a thickness of 0.3mm to 0.5mm.

[0013] The third adhesive film layer is a high-cutoff POE film with a thickness of 0.3mm-0.6mm and a basis weight of 360g / m³. 2 ~460g / m 2 .

[0014] The fourth film layer is a co-extruded EPE film with a thickness of 0.25mm-0.4mm.

[0015] Advantages of this utility model:

[0016] (1) Through the multi-layer structure design of composite front panel layer, flexible film layer and barrier front panel layer, the flexible film layer provides good buffering effect and can effectively absorb external impact force, while the composite front panel layer provides necessary mechanical reinforcement protection, so that the module maintains a stable structure under complex curved surfaces and dynamic loads. At the same time, this design significantly improves the flexibility and impact resistance of the module, and can adapt to complex curved surfaces and special installation environments.

[0017] (2) A combination design of high water-resistant pure POE film, fluorine-coated CPC barrier layer and composite front panel layer is adopted to form a highly efficient water vapor barrier system, which effectively reduces the penetration of moisture through the encapsulation layer into the battery layer and prevents grid line corrosion and electrical performance degradation caused by moisture penetration. In addition, the high water resistance and humid heat stability significantly improve the long-term reliability of the module under harsh climatic conditions such as high temperature and high humidity, delay material aging, and ensure the encapsulation stability of Top-con cells.

[0018] (3) By selecting a lightweight composite front panel, a glass fiber reinforcement layer, and an aluminum-containing metal back panel, significant weight reduction of the component structure is achieved. On this basis, combined with a lightweight frame made of polyurethane and glass fiber resin composite material and an optimized design of the sealant, the overall structure significantly reduces weight while ensuring strength, meeting the needs of weight-sensitive installation scenarios.

[0019] (4) Through the multi-layer composite design of high-performance materials such as fluorine-containing coating, glass fiber reinforcement layer and metal backsheet, the module has excellent weather resistance and mechanical strength, which can effectively resist the influence of extreme external environment. In addition, the fluorine-containing coating provides excellent UV aging resistance and corrosion resistance, further extending the service life of the module and ensuring stable power output and structural integrity in long-term outdoor applications.

[0020] (5) By selecting high-performance POE film, CPC barrier front panel layer and glass fiber reinforcement layer and other functional encapsulation materials, each material has a specific function, such as water vapor barrier, mechanical reinforcement, corrosion resistance and heat resistance stability. The scientific combination of multi-layer materials solves the problems of water vapor permeation, film degradation and grid line corrosion that are easy to occur in traditional encapsulation materials, comprehensively improves the encapsulation reliability of Top-con lightweight modules, and ensures that the modules have excellent electrical performance stability and safety in use during long-term operation. Attached Figure Description

[0021] Figure 1 This is a schematic diagram of the structure of the high-efficiency Top-con lightweight component of this utility model;

[0022] Figure 2 This is a schematic diagram of the glass fiber reinforced layer structure of the high-efficiency Top-con lightweight component of this utility model;

[0023] Figure 3 This is a schematic diagram of the aluminum-containing metal backplate structure of the high-efficiency Top-con lightweight component of this utility model;

[0024] Figure 4 This is a schematic diagram of the frame structure of the high-efficiency Top-con lightweight component of this utility model;

[0025] Figure 5 This is a side view of the frame of the high-efficiency Top-con lightweight component of this utility model. Detailed Implementation

[0026] The high-efficiency Top-con lightweight component of this utility model will be further described in detail below with reference to the accompanying drawings and specific embodiments. Example

[0027] like Figure 1 , 2 As shown in Figure 3, the high-efficiency Top-con lightweight module includes a top composite front panel layer 1, a bottom aluminum-containing metal backsheet 9, and a Top-con cell layer 5 between the composite front panel layer 1 and the aluminum-containing metal backsheet 9. The moisture and heat resistance is further improved through paste improvement and laser-assisted sintering processes, while also exhibiting high cell efficiency. The original cell size of the Top-con cell layer 5 can be 210mm*210mm, 182mm*182mm, 166mm*166mm, or 210mm*182mm. Top-con battery cells can be cut into any suitable small size and then connected in series and parallel. Top-con battery cells can be connected by series welding, ranging from 5 to 16 bars, or by gridless connection. Top-con battery cells can also be connected by silver paste bonding. The top surface of the Top-con battery layer 5 is bonded to the CPC material barrier front panel layer 3 via a second adhesive film layer 4. The top surface of the CPC material barrier front panel layer 3 is bonded to the composite front panel layer 1 via a first adhesive film layer 2. The bottom surface of the battery layer 5 is bonded to the top surface of the glass fiber reinforced layer 7 via a third adhesive film layer 6, and the bottom surface of the glass fiber reinforced layer 7 is bonded to the aluminum-containing metal backplate 9 via a fourth adhesive film layer 8; the composite front panel layer 1 is formed by bonding a fluorinated polyvinylidene fluoride film and a KPF polymer substrate with an adhesive, and the surface of the composite front panel is embossed to form a uniform uneven surface. This structure has a good projection effect on visible light and excellent UV resistance and weather resistance; the glass fiber reinforced layer 7 includes a glass fiber material layer 11 and a fluorinated air-filled layer coated on the top surface of the glass fiber material layer 11. The bottom surface of the air-coated layer 10 and the glass fiber material layer 11 is coated with a fluorinated EVA surface coating 12, which can be white or black. The thickness of the glass fiber reinforcement layer 7 is 0.5 mm. The aluminum metal backing plate 9 is made of an upper fluorinated coating 13 with a thickness of 8 μm to 12 μm, an aluminum foil 14 with a thickness of 25 μm to 35 μm, a polyurethane adhesive 15 with a thickness of 6 μm to 10 μm, a PET 16 with a thickness of 220 μm to 260 μm, and a lower fluorinated coating 17 with a thickness of 8 μm to 12 μm, which are laid down from top to bottom. Figure 4 , 5As shown, the various layers are stacked sequentially to form the main body of the high-efficiency Top-con lightweight module. A frame 18 is provided around the outer edge of the main body. The frame 18 is made of a polyurethane and fiberglass resin composite material. The frame 18 has two long sides and two short sides, connected by corner brackets 21. The corner brackets 21 are fixed and limited by several anti-slip protrusions 19. A U-shaped groove is provided on the inner side of the frame 18 to accommodate the main body of the high-efficiency Top-con lightweight module. The first film layer 2 is a high-transparency POE film with a thickness of 0.3mm~0.6mm and a basis weight of 360g / m³. 2 ~460g / m 2 The first layer (3) is a fluorine-coated CPC material with a thickness of 0.2mm~0.5mm. It has excellent water vapor barrier properties and light transmittance. Its good rigidity and toughness also make the lightweight module resistant to hail impact and anti-aging performance. The second encapsulation layer (4) is a high water-blocking pure POE film with a thickness of 0.3mm~0.5mm. It has very good adsorption properties for free charges, which can effectively prevent Na+ from accumulating on the cell surface, reduce the generation of PID effect, and extend the corrosion resistance and anti-PID capability of the Top-con module by several times. It can effectively delay the intrusion of water vapor on the cell surface and inhibit the corrosion of the front grid lines of the Top-con cell by organic acids, protecting the long-term stability of the Top-con cell under single-glass structure encapsulation. The third encapsulation layer (6) is a high cutoff POE film with a thickness of 0.3mm~0.6mm and a basis weight of 360g / m³. 2 ~460g / m 2 It has the function of effectively protecting the back sheet from UV damage by low UV transmittance and extending the service life of the module; the fourth film layer 8 is a co-extruded EPE film with a thickness of 0.25mm~0.4mm.

[0028] Assembly Process: In the high-efficiency Top-con lightweight module, a composite front panel layer 1 with UV resistance and weather resistance is formed by combining a polymer film with a polymer substrate. A first encapsulating film layer 2 provides excellent visible light transmittance. A barrier front panel layer 3, made of polymer material, possesses both rigidity and toughness to meet the requirements of lightweight modules. A second encapsulating film layer 4 extends the corrosion resistance and PID resistance of the Top-con module several times over. The Top-con cell 5 further improves its resistance to damp heat through slurry improvement and laser-assisted sintering processes, while maintaining high cell efficiency. A third encapsulating film layer 6 provides low UV transmittance, effectively protecting the back panel from UV damage and extending the module's lifespan. A glass fiber reinforcement layer 7, coated with a fluorine-containing coating, serves as the back reinforcement structure of the lightweight module. A fourth encapsulating film layer 8 bonds the glass fiber reinforcement layer to the metal barrier layer 9, further blocking moisture. The metal barrier layer 9 has low moisture transmittance, and the metal material also provides excellent fire resistance for the lightweight module. After the above materials are laid in sequence, the assembly to be laminated is formed. The assembly to be laminated is then sent to the laminator for high-temperature vacuum lamination to form the laminated assembly. Finally, the junction box is installed and cured, the lightweight frame is installed, and the testing and cleaning processes are carried out.

Claims

1. A high efficiency Top-con light weight module characterized by: The composite front plate layer (1) including a top layer, the aluminum-containing metal back plate (9) of a bottom layer, and the Top-con battery layer (5) between the composite front plate layer (1) and the aluminum-containing metal back plate (9), the top surface of the Top-con battery layer (5) is bonded with the CPC material barrier front plate layer (3) through the second adhesive film layer (4), the top surface of the CPC material barrier front plate layer (3) is bonded with the composite front plate layer (1) through the first adhesive film layer (2), the bottom surface of the Top-con battery layer (5) is bonded with the top surface of the glass fiber reinforced layer (7) through the third adhesive film layer (6), and the bottom surface of the glass fiber reinforced layer (7) is bonded with the aluminum-containing metal back plate (9) through the fourth adhesive film layer (8).

2. The high-efficiency Top-con light-weight assembly of claim 1, wherein: The glass fiber reinforced layer (7) includes a glass fiber material layer (11), a fluorine-containing air coating layer (10) coated on the top surface of the glass fiber material layer (11), and a fluorine-containing EVA coating layer (12) coated on the bottom surface of the glass fiber material layer (11).

3. The high-efficiency Top-con light-weight assembly of claim 2, wherein: The aluminum-containing metal back plate (9) is stacked from top to bottom with the upper fluorine-containing coating (13) with a thickness of 8um-12um, the aluminum foil (14) with a thickness of 25um-35um, the polyurethane glue (15) with a thickness of 6um-10um, the PET (16) with a thickness of 220um-260um, and the lower fluorine-containing coating (17) with a thickness of 8um-12um.

4. The high-efficiency Top-con light-weight assembly of claim 1, wherein: The composite front plate layer (1), the first adhesive film layer (2), the CPC material barrier front plate layer (3), the second adhesive film layer (4), the Top-con battery layer (5), the third adhesive film layer (6), the glass fiber reinforced layer (7), the fourth adhesive film layer (8), and the aluminum-containing metal back plate (9) are sequentially stacked to form a high-efficiency Top-con lightweight assembly main body, the periphery of the high-efficiency Top-con lightweight assembly main body is provided with a frame (18), the frame (18) has two long sides and two short sides, the long sides and the short sides are connected through corner codes (21), the corner codes (21) are fixed and limited through a plurality of anti-skid protrusions (19), and the inner side of the frame (18) is provided with a U-shaped groove for accommodating the high-efficiency Top-con lightweight assembly main body.

5. The high-efficiency Top-con light-weight assembly of claim 1, wherein: The first adhesive film layer (2) is a high-transmittance POE adhesive film, with a thickness of 0.3mm~0.6mm and a grammage of 360g / m 2 ~460g / m 2 .

6. The high-efficiency Top-con light-weight assembly of claim 1, wherein: The CPC material barrier front plate layer (3) is a fluorine-coated CPC with a thickness of 0.2mm-0.5mm.

7. The high-efficiency Top-con light-weight assembly of claim 1, wherein: The second adhesive film layer (4) is a high-water-resistance pure POE adhesive film with a thickness of 0.3mm-0.5mm.

8. The high-efficiency Top-con light-weight assembly of claim 1, wherein: The third adhesive film layer (6) is high cut-off POE adhesive film, thickness is 0.3mm-0.6mm, and gram weight is 360g / m 2 460g / m 2 .

9. The high-efficiency Top-con light-weight assembly of claim 1, wherein: The fourth adhesive film layer (8) is a co-extrusion type EPE adhesive film with a thickness of 0.25mm-0.4mm.

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