Novel photovoltaic module

Abstract

The utility model discloses a novel photovoltaic module, which belongs to the field of photovoltaic technology, abandons a traditional metal electrode design mode, directly constructs a charge extraction electrode at a battery piece end, and collects current by using a metal conductive filament, thereby not only obviously reducing the dependence degree of a crystalline silicon solar battery on precious metal, but also improving the reliability of the photovoltaic module. Compared with the prior art, light shielding is effectively reduced, the remarkable effect of being almost invisible in vision is achieved, the efficiency and the attractiveness of the assembly are synchronously improved, and the obtained photovoltaic assembly is high in efficiency and has the good visual effect and perfectly meets the application requirement of the BIPV.

Description

Technical Field

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

[0002] In the global energy transition, distributed photovoltaic (PV) power generation and building-integrated photovoltaics (BIPV) technology are booming at an unprecedented pace. However, the challenge of integrating PV modules with modern architectural aesthetics remains a key obstacle to their widespread application in high-end buildings. While traditional PV modules feature silver or highly reflective metal grids and conductive wires that exhibit excellent electrical performance, their reflectivity easily leads to a series of light pollution problems, negatively impacting the harmony of urban landscapes and the quality of life for residents. Furthermore, the traditional metal electrode design of crystalline silicon solar cells relies heavily on precious metals, and the metal electrode design increases light shading, reducing the conversion efficiency of the PV module. Summary of the Invention

[0003] This invention provides a novel photovoltaic module that not only significantly reduces the dependence of crystalline silicon solar cells on precious metals and effectively reduces light shading, achieving an excellent visual effect that is almost "invisible," but also simultaneously improves the efficiency and aesthetics of the module.

[0004] To achieve the above objectives, the present invention adopts the following technical solution:

[0005] A novel photovoltaic module comprises, from top to bottom, an encapsulation material, a polymer film, a crystalline silicon solar cell, a polymer film, and an encapsulation material. The crystalline silicon solar cell includes a charge extraction electrode, an adhesive layer, and a metal conductive filament. The charge extraction electrode is arranged parallel to the long side of the solar cell and mounted on the crystalline silicon solar cell. The adhesive layer is laid above the charge extraction electrode, and the metal conductive filament is located on the adhesive layer. The adhesive layer tightly bonds the metal conductive filament to the charge extraction electrode.

[0006] The charge extraction electrodes have a width of 10-30 μm, preferably 8 μm, a number of 50-300, and an electrode spacing of 6.9 mm-41 mm.

[0007] The metal conductive filaments are semi-circular in microscopic shape; the spacing between the metal conductive filaments is the same as that of the charge extraction electrode, and the diameter is 1-20 μm larger than the electrode to completely cover the electrode; the metal conductive filaments can be laid on the adhesive layer or laid on the organic encapsulation material first and then covered on the battery cell.

[0008] An anti-reflection layer is deposited on the crystalline silicon solar cell before the charge extraction electrodes are arranged. The charge extraction electrodes can be prepared on the crystalline silicon solar cell by printing, electroplating or spraying.

[0009] Beneficial effects: This utility model provides a novel photovoltaic module, which has the following advantages compared with the prior art:

[0010] 1. It abandons the traditional metal electrode design mode and directly builds charge extraction electrodes at the end of the cell. It uses metal conductive filaments to collect current, which significantly reduces the dependence of crystalline silicon solar cells on precious metals. It eliminates the metal electrode design, reduces the use of traditional metal electrode reflective materials, reduces light reflection and light pollution, and improves the visual effect of the environment.

[0011] 2. The conductive metal filaments are alloyed with the charge extraction electrode, achieving an overall visual invisibility effect without affecting current collection, effectively reducing light shading and improving the power of the component;

[0012] 3. The design of the metal conductive filaments and charge extraction electrodes allows the current to flow vertically inside the cell, eliminating the need for lateral transmission, reducing the current transmission distance, reducing the demand for silver grid lines, and lowering costs.

[0013] 4. Design the metal conductive filament as a semi-circle to optimize stress distribution and reduce stress concentration;

[0014] 5. The rearrangement of charge extraction electrodes on the solar cell enables more uniform current collection, reducing thermal and mechanical stress caused by local current concentration, thereby reducing the possibility of microcracks.

[0015] 6. An adhesive layer is used to connect the charge extraction electrode and the metal conductive wire, eliminating the need for traditional high-temperature welding processes. This helps reduce thermal stress damage to the cells during welding, effectively inhibits the formation of microcracks, and enhances the overall stability and durability of the module.

[0016] 7. The photovoltaic modules are encapsulated as a whole, which is both highly efficient and visually appealing, enhancing their integration with buildings and perfectly meeting the application requirements of BIPV, effectively promoting building-integrated photovoltaics (BIPV). Attached Figure Description

[0017] Figure 1 This is a schematic diagram of the photovoltaic module structure in an embodiment of this utility model;

[0018] Figure 2 This is a schematic diagram of the structure of the crystalline silicon solar cell in an embodiment of the present invention;

[0019] Figure 3 This is a schematic diagram showing the connection between the crystalline silicon solar cell and the metal conductive filament in an embodiment of this utility model;

[0020] Figure 4This is a schematic diagram showing the arrangement of the charge extraction electrodes on the battery cell in an embodiment of this utility model;

[0021] Figure 5 This is a schematic diagram of the metal conductive filaments laid on the adhesive layer in an embodiment of this utility model.

[0022] Figure 6 This is a schematic diagram of an embodiment of the present invention, in which conductive metal filaments are first laid on an organic encapsulation material and then covered onto a battery cell.

[0023] In the figure, 1-front panel encapsulation material, 2-polymer film, 3-crystalline silicon solar cell, 4-back panel encapsulation material, 5-metal conductive filament, 6-adhesive layer, 7-charge extraction electrode. Detailed Implementation

[0024] The present invention will now be described in detail with reference to the accompanying drawings and specific embodiments:

[0025] like Figure 1 As shown, a novel photovoltaic module comprises, from top to bottom, a front panel encapsulation material 1, a polymer film 2, a crystalline silicon solar cell 3, a polymer film 2, and a back panel encapsulation material 4. Figure 2 As shown, the crystalline silicon solar cell 3 includes a metal conductive filament 5, an adhesive layer 6, and a charge extraction electrode 7, as... Figure 4 As shown, the charge extraction electrodes 7 are arranged parallel to each other along the long side of the solar cell 3 and mounted on the crystalline silicon solar cell 3. The adhesive layer 6 is laid on top of the charge extraction electrodes 7, as shown. Figures 5-6 As shown, the conductive metal filaments 5 are laid on the adhesive layer 6 or first laid on the organic encapsulation material and then covered on the battery cell. The adhesive layer 6 tightly bonds the conductive metal filaments 5 with the charge extraction electrode 7. The conductive metal filaments 5 are semi-circular. To completely cover the electrode, the width of the charge extraction electrode 7 is 10-30μm. Taking a 210 half-cell as an example, the number of electrodes is between 50 and 300. Example

[0026] Preparation of pure black components

[0027] The photovoltaic module is manufactured using materials of the same color scheme, including a black frame, a black composite back panel, a transparent encapsulating film, a high-transparency front glass panel, and black conductive metal wires, through the following steps:

[0028] 1. Design and fabrication steps of charge extraction electrode:

[0029] a. Design: Computer-aided design (CAD) tools are used to optimize the electrode layout to ensure high compatibility between the electrode design and the solar cell;

[0030] b. Material selection: Use copper-silver metal composite material with a high proportion of copper and a low proportion of silver, with metallic silver encapsulating metallic copper.

[0031] c. Fabrication: Charge extraction electrodes are fabricated on the heterojunction solar cell after the deposition of the transparent conductive layer (the electrodes are parallel to the short side of the solar cell, with a width of 20 μm, a height of 6 μm, a length of 104 mm, a spacing of 2.565 mm, a number of electrodes of 80, and a solar cell size of 210*105 mm). The traditional metal electrode design is eliminated, which reduces the use of materials and light shading, and improves the aesthetics and efficiency of the module.

[0032] 2. Preparation and optimization of the adhesive layer (the adhesive layer can be a conductive or non-conductive material):

[0033] a. Material selection: Select a light-curing adhesive with strong adhesion, good thermal stability, and compatibility with metal conductive wires;

[0034] b. Automated laying: Automated equipment is used to precisely lay the adhesive layer on the charge extraction electrode to ensure product reliability and consistency and improve production efficiency.

[0035] 3. Laying of metal conductive wires and stringing of batteries:

[0036] a. Selection of metal conductive wire: Based on current density, mechanical strength, and component design requirements, determine the diameter, spacing, and color of the metal conductive wire. The diameter should be approximately 10 μm larger than the electrode and should completely cover the electrode. Use semi-circular black metal conductive wires.

[0037] b. Automated laying: Automated equipment guided by a machine vision system precisely lays the metal conductive wires on the adhesive layer to ensure full contact between them and the adhesive layer. Then, light curing is performed to ensure a tight bond. After being strung together, they are connected to the black busbar.

[0038] 4. Lamination process and parameter optimization steps:

[0039] a. Preparations before lamination

[0040] The following layers were laid sequentially: black composite backplate, transparent encapsulation film, battery string, transparent encapsulation film, and high-transparency front panel encapsulation material.

[0041] A primer is applied to the contact surfaces between the front and rear panel encapsulation materials and the encapsulation film to enhance the adhesion strength between the front and rear panel encapsulation materials and the encapsulation film.

[0042] During the installation process, ensure the accurate relative positions of each material in the battery string and adjust the distance between the batteries to prepare for lamination.

[0043] b. Lamination

[0044] The laid components are placed into a laminator, and the air inside the components is extracted by vacuuming.

[0045] Parameter optimization: Precisely set lamination temperature, pressure and time, and use an online monitoring system to monitor in real time to ensure that the materials of each layer are tightly bonded, the UV-cured adhesive is fully melted, and the charge extraction electrode and the metal conductive filament are alloyed to have good electrical contact (when the adhesive layer is a conductive material, the charge extraction electrode and the metal conductive filament are connected through the adhesive conductive layer).

[0046] After cooling, remove the laminated components.

[0047] 5. Remove rough edges

[0048] The laminated components are deburred and cleaned to remove excess material and impurities from the edges, ensuring that the component surface is clean and tidy.

[0049] 6. Install the frame

[0050] Apply sealant to the edges of the components and install corner keys;

[0051] Perform punching and framing operations to ensure the black border is securely fixed to the component.

[0052] Finally, wipe away any excess adhesive to protect the edges and corners of the outer encapsulation material and the laminated components, facilitating subsequent installation and use.

[0053] 7. Quality Control: During the lamination process, non-destructive testing techniques are used to ensure that the components are free of internal defects. Example

[0054] pure red components

[0055] The photovoltaic module is manufactured using a red frame, red back transparent glass, red conductive metal wires, red high-transparency encapsulating film, and high-transparency front glass; the process involves the following steps:

[0056] 1. Design and fabrication steps of charge extraction electrode:

[0057] a. Design: Computer-aided design (CAD) tools are used to optimize the electrode layout to ensure high compatibility between the electrode design and the solar cell;

[0058] b. Material selection: Use copper composite material;

[0059] c. Fabrication: Charge extraction electrodes are fabricated on the heterojunction solar cell after the deposition of the transparent conductive layer (the electrodes are parallel to the short side of the solar cell, with a width of 12 μm, a height of 5.6 μm, a length of 104 mm, a spacing of 1.704 mm, a number of electrodes of 120, and a solar cell size of 210*105 mm). The traditional metal electrode design is eliminated, which reduces the use of materials and light shading, and improves the aesthetics and efficiency of the module.

[0060] 2. Preparation and optimization steps of the adhesive layer:

[0061] a. Material selection: Select conductive adhesive materials with strong bonding, good thermal stability and compatibility with metal conductive wires;

[0062] b. Automated laying: Automated equipment is used to precisely lay the adhesive layer, ensuring product reliability and consistency and improving production efficiency.

[0063] 3. Laying and optimization steps of metal conductive wires:

[0064] a. Selection of metal conductive wires: Based on current density, mechanical strength, and component design requirements, determine the diameter, spacing, and other parameters of the metal conductive wires. The diameter should be approximately 20 μm larger than the electrode and should completely cover the electrode. Use semi-circular metal conductive wires with a red surface.

[0065] b. Automated laying: Automated equipment guided by a machine vision system precisely lays the metal conductive wires on the adhesive layer to ensure full contact between them and the adhesive layer.

[0066] 4. Lamination process and parameter optimization steps:

[0067] a. Preparations before lamination

[0068] The following layers were laid out sequentially: red back translucent glass, transparent encapsulating film, battery string, red high-transparency encapsulating film, and high-transparency front glass.

[0069] A primer is applied to the contact surfaces between the front and rear panel encapsulation materials and the encapsulation film to enhance the adhesion strength between the front and rear panel encapsulation materials and the encapsulation film.

[0070] During the installation process, ensure the accurate relative positions of each material in the battery string and adjust the distance between the batteries to prepare for lamination.

[0071] b. Lamination

[0072] The laid components are placed into a laminator, and the air inside the components is extracted by vacuuming.

[0073] Parameter optimization: Precisely set lamination temperature, pressure, and time, and use an online monitoring system to monitor in real time to ensure that each layer of material is tightly bonded.

[0074] After cooling, remove the laminated components.

[0075] 5. Remove rough edges

[0076] The laminated components are deburred and cleaned to remove excess material and impurities from the edges, ensuring that the component surface is clean and tidy.

[0077] 6. Install the frame

[0078] Apply sealant to the edges of the components and install corner keys;

[0079] Perform punching and framing operations to ensure the red border is securely attached to the component.

[0080] Finally, wipe away any excess adhesive to protect the edges and corners of the outer encapsulation material and the laminated components, facilitating subsequent installation and use.

[0081] 7. Quality Control: During the lamination process, non-destructive testing techniques are used to ensure that the components are free of internal defects. Example

[0082] Custom-patterned photovoltaic modules are manufactured through the following steps:

[0083] 1. Design and fabrication steps of charge extraction electrode:

[0084] a. Design: Optimize electrode layout to ensure high compatibility between electrode design and solar cell;

[0085] b. Material selection: Use metallic silver composite material;

[0086] c. Fabrication: Charge extraction electrodes were fabricated on the heterojunction solar cell after the deposition of the transparent conductive layer (the electrodes are parallel to the short side of the solar cell, with a width of 10 μm, a height of 5 μm, a length of 89 mm, a spacing of 1.844 mm, a number of electrodes of 96, and a solar cell size of 182*91 mm).

[0087] 2. Preparation and optimization of the adhesive layer:

[0088] a. Material selection: Select curing adhesives with strong adhesion, good thermal stability, and compatibility with metal conductive wires;

[0089] b. Automated laying: Automated equipment is used to precisely lay the adhesive layer, ensuring product reliability and consistency and improving production efficiency.

[0090] 3. Laying and optimization steps of metal conductive wires:

[0091] a. Selection of metal conductive wire: Select a semi-circular metal conductive wire that matches the color scheme of the component;

[0092] b. Preparation of the metal conductive filament film: A thermoplastic encapsulation film layer is prepared on a high-temperature resistant rigid encapsulation material (such as PET) with a size of 182*91mm. Then, semi-circular metal conductive filaments are laid on the film layer with the arc side facing down. The arrangement is the same as that of the charge extraction electrode. There are a total of 96 metal conductive filaments with a spacing of 1.83mm. The part of the conductive filaments that extends out of the rigid encapsulation material is flattened to facilitate subsequent welding.

[0093] 4. Laying of conductive wire mesh film and stringing of batteries

[0094] a. Precisely lay the conductive wires of the conductive mesh film onto the adhesive layer, ensuring full contact between them. Then, connect the positive and negative conductive wires of adjacent cells together using laser welding. Next, perform thermosetting to ensure a tight bond between the conductive wires and the adhesive layer. After stringing, connect them to the busbars of the same color as the module.

[0095] 5. Lamination process and parameter optimization steps:

[0096] a. Preparations before lamination

[0097] The desired pattern is pre-printed on the high-transparency front panel encapsulation material. The colors of other materials are selected according to the actual situation. The rear panel encapsulation material, transparent encapsulation film, battery string, transparent encapsulation film, and patterned high-transparency front panel encapsulation material are then laid out in sequence.

[0098] A primer is applied to the contact surfaces between the front and rear panel encapsulation materials and the encapsulation film to enhance the adhesion strength between the front and rear panel encapsulation materials and the encapsulation film.

[0099] During the installation process, ensure the accurate relative positions of each material in the battery string and adjust the distance between the batteries to prepare for lamination.

[0100] b. Lamination

[0101] The laid components are placed into a laminator, and the air inside the components is extracted by vacuuming.

[0102] Parameter optimization: Precisely set lamination temperature, pressure, and time, and use an online monitoring system to monitor in real time to ensure that the materials of each layer are tightly bonded, the adhesive layer is fully melted (when the adhesive layer can be a non-conductive material), and the charge extraction electrode and the metal conductive filament form good electrical contact (when the adhesive layer can be a conductive material, the charge extraction electrode and the metal conductive filament are connected through the adhesive conductive layer).

[0103] After cooling, remove the laminated components.

[0104] 6. Remove rough edges

[0105] The laminated components are deburred and cleaned to remove excess material and impurities from the edges, ensuring that the component surface is clean and tidy.

[0106] 7. Install the frame

[0107] Apply sealant to the edges of the components and install corner keys;

[0108] Perform punching and framing operations to ensure the frame is securely fixed to the component.

[0109] Finally, wipe away any excess adhesive to protect the edges and corners of the outer encapsulation material and the laminated components, facilitating subsequent installation and use.

[0110] 8. Quality control: Non-destructive testing techniques are used during the lamination process to ensure that the components are free of internal defects.

[0111] The above are merely preferred embodiments of this utility model. The protection scope of this utility model is not limited to the above embodiments. All technical solutions falling within the scope of this utility model's concept are within its protection scope. It should be noted that for those skilled in the art, any improvements and modifications made without departing from the principle of this utility model should be considered within its protection scope.

Claims

1. A novel photovoltaic module, characterized in that, From top to bottom, the components are encapsulation material, polymer film, crystalline silicon solar cell, polymer film, and encapsulation material. The crystalline silicon solar cell features a design without traditional metal electrodes. It incorporates a charge extraction electrode and utilizes conductive metal filaments to collect current. The crystalline silicon solar cell includes a charge extraction electrode, an adhesive layer, and conductive metal filaments. The charge extraction electrode is arranged parallel to the long side of the solar cell and mounted on it. The adhesive layer is laid above the charge extraction electrode, and the conductive metal filaments are placed on top of the adhesive layer. The adhesive layer tightly bonds the conductive metal filaments to the charge extraction electrode, ensuring the filaments completely cover it. The conductive metal filaments and charge extraction electrode are alloyed, achieving overall visual invisibility. The design of the conductive metal filaments and charge extraction electrode allows current to flow vertically within the solar cell.

2. The novel photovoltaic module according to claim 1, characterized in that, The conductive metal filaments are laid on the adhesive layer or first laid on the organic encapsulation material and then covered onto the battery cell.

3. The novel photovoltaic module according to claim 1, characterized in that, The metal conductive filament is microscopically semi-circular.

4. The novel photovoltaic module according to claim 1, characterized in that, The spacing between the metal conductive filaments is the same as that of the charge extraction electrode, and the diameter is 1-20 μm larger than the width of the charge extraction electrode, ensuring that the metal conductive filaments completely cover the charge extraction electrode.

5. The novel photovoltaic module according to claim 4, characterized in that, The width of the charge extraction electrode is 10-30 μm.

6. The novel photovoltaic module according to claim 1, characterized in that, The number of charge extraction electrodes is 50-300.

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