Thin photovoltaic module and power generation system and packaging structure thereof

Abstract

The utility model relates to a thin photovoltaic assembly and a power generation system and a packaging structure thereof. The thin photovoltaic module comprises a packaging structure, a photovoltaic cell string and an outlet cable, one end of the outlet cable is connected with the photovoltaic cell string in the packaging structure, and the outlet cable is led out from the side face of the packaging structure. The power generation system comprises at least two thin photovoltaic modules, and the thin photovoltaic modules are electrically connected through exposed metal wires at the ends of the outgoing cables and are sleeved with heat shrink tubes for protection. The packaging structure comprises a packaging container and a plurality of thin photovoltaic modules stacked in the packaging container, and the photovoltaic modules stacked together are arranged in a staggered mode in a reciprocating staggered mode with at least two photovoltaic modules as a group. The photovoltaic module has the advantages that the photovoltaic module does not need a junction box any more, the thickness inside and outside the photovoltaic module can be uniform, the thickness can be 1-10 mm, the thickness can be reduced by 90%, more photovoltaic modules can be contained in the packaging space, and the transportation cost is greatly reduced.

Description

Technical Field

[0001] This utility model relates to the field of photovoltaic module technology, and in particular to a thin photovoltaic module, its power generation system and packaging structure. Background Technology

[0002] Power outages are frequent in Africa, making electricity access difficult. Photovoltaic modules can meet the electricity needs of users in Africa. However, shipping costs to Africa are high, and African users are price-sensitive to photovoltaic modules. Therefore, how to provide affordable photovoltaic module products to users in Africa has become an urgent technical problem to be solved.

[0003] Existing photovoltaic (PV) modules have junction boxes on the front or back. The current from the PV cell strings within the module is introduced into the junction box via a busbar, and then discharged through the outgoing cables on the junction box. The junction box's thickness accounts for at least 90% of the PV module's thickness, and PV modules with junction boxes are typically around 35mm thick. The thicker the PV module, the larger the packaging space it occupies, resulting in higher shipping costs per module. Utility Model Content

[0004] The technical problem to be solved by this utility model is to provide a thin photovoltaic module, its power generation system and packaging structure, which reduces the thickness of the module and reduces transportation costs.

[0005] The technical solution adopted by this utility model to solve its technical problem is: a thin photovoltaic module, including an encapsulation structure, a photovoltaic cell string and an output cable. The photovoltaic cell string is encapsulated in the encapsulation structure, and one end of the output cable is connected to the photovoltaic cell string in the encapsulation structure. The output cable exits from the side of the encapsulation structure to conduct the power generation current of the photovoltaic cell string.

[0006] In some embodiments, optionally, the side of the encapsulation structure constitutes the side of the thin photovoltaic module; or, the side of the encapsulation structure is sealed with edge-sealing adhesive or edge-sealing tape, and the sealed side of the encapsulation structure constitutes the side of the thin photovoltaic module; the outgoing cables in the encapsulation structure are located on the same layer as the photovoltaic cell string within the encapsulation structure.

[0007] In some embodiments, optionally, the outgoing cable is a completely flat outgoing cable, the flat direction of the outgoing cable is the same as the flat direction of the encapsulation structure; or, the outgoing cable is a partially flat outgoing cable, at least the outgoing cable located within the encapsulation structure is a flat structure, and the flat direction is the same as the flat direction of the encapsulation structure.

[0008] In some embodiments, optionally, the photovoltaic cell string has a diode bypass protection circuit, which is located within the package structure, and the diodes in the diode bypass protection circuit are surface mount diodes.

[0009] In some embodiments, the encapsulation structure may optionally include a panel on the light-receiving side and a backplate on the backlight side, with the edge of the backplate extending beyond the edge of the panel.

[0010] In some embodiments, optionally, the back panel has perforations on the edge extending beyond the panel for driving in nails to secure the thin photovoltaic module.

[0011] In some embodiments, the outgoing cables are optionally divided into positive outgoing cables and negative outgoing cables, and the outgoing positions of the positive outgoing cables and negative outgoing cables are located on opposite sides of the encapsulation structure.

[0012] In some embodiments, the outlet positions of the positive and negative terminal cables are optionally located at the middle position on the side of the package structure.

[0013] A power generation system for the aforementioned thin photovoltaic module includes at least two thin photovoltaic modules, which are electrically connected to each other via exposed metal wires at the ends of outgoing cables, and heat shrink tubing is used to protect the electrical connection points between the outgoing cables.

[0014] A packaging structure for the aforementioned thin photovoltaic module includes a packaging container and multiple thin photovoltaic modules stacked from top to bottom within the packaging container. The output cables are divided into positive output cables and negative output cables. The output positions of the positive and negative output cables are located at the same positions on opposite sides of the packaging structure. Taking the two sides of the thin photovoltaic module with output cables as the front and back sides, the vertically adjacent thin photovoltaic modules are aligned in the front and back side direction and staggered in the left and right side direction to make the vertically adjacent output cables staggered in the left and right directions. The stacked thin photovoltaic modules are arranged in a staggered manner in groups of at least two thin photovoltaic modules.

[0015] The beneficial effects of this utility model are: this photovoltaic module no longer needs a junction box, and the thickness of the photovoltaic module can be uniform inside and out. The thickness of this photovoltaic module can be 1mm to 10mm. Compared with traditional photovoltaic modules with junction boxes, the thickness is reduced by up to 90%, which allows more photovoltaic modules to be packed in the same volume of packaging space, greatly reducing transportation costs.

[0016] The design of the flat outgoing cable can further reduce the thickness of the photovoltaic module while ensuring the reliability of the packaging;

[0017] The design of the back panel extending beyond the edge of the panel can protect the edge of the panel, especially when the panel is a glass panel. In addition, the edge of the back panel extending beyond the edge of the panel can also serve as a mounting structure for fixing photovoltaic modules.

[0018] Compared to the existing solution that uses a dedicated photovoltaic plug for plug-and-play connection, the design that uses exposed metal wires at the ends of the outgoing cables for electrical connection and protects the electrical connection points between the outgoing cables with heat shrink tubing is more cost-effective while still ensuring reliable electrical connection.

[0019] Outgoing cables inevitably have a certain thickness. If the outgoing cables cause the photovoltaic modules to be slightly thicker at the outgoing cable location, packaging the photovoltaic modules using a staggered stacking method can reduce the stacking height. Even if the outgoing cables are flat enough, it will not affect the thickness of the photovoltaic modules at the outgoing cable location. Packaging the photovoltaic modules using a staggered stacking method can also prevent the outgoing cables from being too concentrated in the same location, which would affect the stacking of the photovoltaic modules. If the outgoing cables are too concentrated in the same location, it will also require more packaging space in the area where the outgoing cables are concentrated. Attached Figure Description

[0020] The present invention will be further described below with reference to the accompanying drawings and embodiments;

[0021] Figure 1 This is a schematic diagram of the power generation system of the thin photovoltaic module according to Embodiment 1 of this utility model;

[0022] Figure 2 This is a schematic diagram of the packaging structure of the thin photovoltaic module according to Embodiment 1 of this utility model;

[0023] Figure 3 This is a structural schematic diagram of Embodiment 2 of this utility model;

[0024] In the diagram, 1. Packaging structure, 1-1. Panel, 1-2. Backplane, 2. Photovoltaic cell string, 3. Outgoing cable, 4. Diode bypass protection circuit, 5. Heat shrink tubing, 6. Outgoing cable position, 7. Thin photovoltaic module, 8. Perforation, 9. Packaging container, 10. Foam board. Detailed Implementation

[0025] Example 1, such as Figure 1 As shown, a thin photovoltaic module includes an encapsulation structure 1, a photovoltaic cell string 2, and an output cable 3. The photovoltaic cell string 2 is encapsulated within the encapsulation structure 1. One end of the output cable 3 is connected to the photovoltaic cell string 2 within the encapsulation structure 1. The output cable 3 exits from the side of the encapsulation structure 1 to conduct the power generation current of the photovoltaic cell string 2.

[0026] The side of the encapsulation structure 1 does not have the frame of a traditional photovoltaic module, and the side of the encapsulation structure 1 constitutes the side of the thin photovoltaic module 7. This thin photovoltaic module 7 also eliminates the need for a junction box, as there is no junction box on either the front or back of the module, thus exhibiting uniform thickness both inside and out. Its typical thickness is approximately 3mm, which is about 90% less than the 35mm thickness of a traditional photovoltaic module.

[0027] Of course, it is also possible that the sides of the encapsulation structure 1 are sealed with edge-sealing adhesive or edge-sealing tape, and the sealed sides of the encapsulation structure 1 constitute the sides of this thin photovoltaic module 7.

[0028] Outgoing cable 3 is a completely flat outgoing cable, and the flattening direction of outgoing cable 3 is the same as that of encapsulation structure 1. Alternatively, outgoing cable 3 is a partially flat outgoing cable, where at least the outgoing cable 3 within encapsulation structure 1 is flat, and its flattening direction is the same as that of encapsulation structure 1. Flat outgoing cables can further reduce the thickness of photovoltaic modules while ensuring encapsulation reliability. The metal conductors within the flat outgoing cable are either metal strip conductors or multi-strand metal conductors.

[0029] The photovoltaic cell string 2 has a diode bypass protection circuit 4, which is located within the package structure 1. The diodes in the diode bypass protection circuit 4 are surface-mount diodes. Of course, the diode bypass protection circuit 4 can also be omitted. Surface-mount diodes have a flat structure, and their thickness is significantly reduced compared to ordinary diodes.

[0030] The encapsulation structure 1 includes a panel 1-1 on the light-receiving side and a backplate 1-2 on the backlight side, as well as front and rear encapsulation adhesive materials for bonding. The panel 1-1 and backplate 1-2 can be made of PET. Of course, the panel 1-1 and backplate 1-2 can also be made of other commonly used materials for panel 1-1 and backplate 1-2 in traditional photovoltaic modules.

[0031] The outgoing cable 3 within the encapsulation structure is located on the same layer as the photovoltaic cell string 2 within the encapsulation structure.

[0032] The thin photovoltaic module 7 is typically rectangular in shape. The output cables 3 are divided into positive and negative output cables, and the output positions 6 of the positive and negative output cables are located on opposite sides of the encapsulation structure 1. The output positions 6 of the positive and negative output cables are located in the middle of the side of the encapsulation structure 1.

[0033] like Figure 1As shown, a power generation system for the above-mentioned thin photovoltaic module includes at least two thin photovoltaic modules 7. The thin photovoltaic modules 7 are electrically connected to each other through exposed metal wires at the ends of the outgoing cables 3, and heat shrink tubing 5 is used to protect the electrical connection between the outgoing cables 3.

[0034] The thin photovoltaic module 7 can be fixed to the mounting base using structural adhesive on the back of the module, or it can be directly fixed to the mounting base (such as asbestos tile) using nails. The nails are nailed to the sides of the thin photovoltaic module 7, and the nail heads are pressed against the light-receiving surface of the panel 1-1 of the thin photovoltaic module 7.

[0035] like Figure 2 As shown, a packaging structure for a thin photovoltaic module includes a packaging container 9 and multiple thin photovoltaic modules 7 stacked from top to bottom within the packaging container 9. The outlet positions 6 of the positive and negative electrode cables are located at the same positions on opposite sides of the packaging structure 1, i.e., the middle positions of the sides. The stacked thin photovoltaic modules 7 have four directions: front, back, left, and right. The two sides of the thin photovoltaic modules 7 with outlet cables 3 are the front and back sides. The vertically adjacent thin photovoltaic modules 7 are aligned in the front and back directions and staggered in the left and right directions to stagger the vertically adjacent outlet cables 3. The stacked thin photovoltaic modules 7 are arranged in a staggered manner in groups of at least two thin photovoltaic modules 7.

[0036] More specifically, in Figure 2 In the middle, the stacked thin photovoltaic modules 7 are arranged in groups of 5 in a staggered manner. From top to bottom, the top 5 thin photovoltaic modules 7 are first staggered to the right, and the next 5 thin photovoltaic modules 7 are reversed and staggered to the left.

[0037] Foam board 10 is filled between the packaging container 9 and the stacked thin photovoltaic modules 7.

[0038] The thin photovoltaic module 7 is packaged using the aforementioned stacking method, which significantly reduces transportation costs. Based on estimated freight rates in Africa, the packaging structure of this thin photovoltaic module 7 can achieve a freight cost of 0.3 yuan per watt.

[0039] Example 2, a thin photovoltaic module, its power generation system, and packaging structure, is basically the same as Example 1, except that: Figure 3 As shown, in this embodiment 2, the thin photovoltaic module 7 has a glass panel 1-1 and a PET backsheet 1-2. The edge of the backsheet 1-2 extends beyond the edge of the panel 1-1, thereby providing protection for the edge of the panel 1-1.

[0040] A through hole 8 is provided on the edge of the back plate 1-2 that extends beyond the panel 1-1 for driving in nails. The nail passes through the through hole 8 of the back plate 1-2 and is driven into the mounting base to fix the thin photovoltaic module 7 in place.

Claims

1. A thin photovoltaic module, characterized in that: It includes an encapsulation structure (1), a photovoltaic cell string (2), and an output cable (3). The photovoltaic cell string (2) is encapsulated in the encapsulation structure (1). One end of the output cable (3) is connected to the photovoltaic cell string (2) inside the encapsulation structure (1). The output cable (3) exits from the side of the encapsulation structure (1) to output the power generation current of the photovoltaic cell string (2).

2. The thin photovoltaic module according to claim 1, characterized in that: The side of the encapsulation structure (1) constitutes the side of the thin photovoltaic module (7); or, the side of the encapsulation structure (1) is sealed with edge sealing glue or edge sealing tape, and the side of the sealed encapsulation structure (1) constitutes the side of the thin photovoltaic module (7). The outgoing cable (3) within the encapsulation structure is located on the same layer as the photovoltaic cell string (2) within the encapsulation structure.

3. The thin photovoltaic module according to claim 1, characterized in that: The outgoing cable (3) is a completely flat outgoing cable, and the flat direction of the outgoing cable (3) is the same as the flat direction of the encapsulation structure (1). Alternatively, the outgoing cable (3) is a partially flat outgoing cable, at least the outgoing cable (3) located in the encapsulation structure (1) is a flat structure, and the flat direction is the same as the flat direction of the encapsulation structure (1).

4. The thin photovoltaic module according to claim 1, characterized in that: The photovoltaic cell string (2) has a diode bypass protection circuit (4), which is located inside the package structure (1). The diodes in the diode bypass protection circuit (4) are surface mount diodes.

5. The thin photovoltaic module according to claim 1, characterized in that: The encapsulation structure (1) includes a panel (1-1) on the light-receiving surface and a back plate (1-2) on the back-light-receiving surface, with the edge of the back plate (1-2) extending beyond the edge of the panel (1-1).

6. The thin photovoltaic module according to claim 5, characterized in that: The back plate (1-2) has a through hole (8) on the edge of the panel (1-1) for driving in nails to fix the thin photovoltaic module (7) with nails.

7. The thin photovoltaic module according to claim 1, characterized in that: The outgoing cable (3) is divided into a positive outgoing cable and a negative outgoing cable. The outgoing positions (6) of the positive outgoing cable and the negative outgoing cable are located on opposite sides of the encapsulation structure (1).

8. The thin photovoltaic module according to claim 7, characterized in that: The outlet positions (6) of the positive and negative outlet cables are located in the middle of the side of the encapsulation structure (1).

9. A power generation system for a thin photovoltaic module as described in claim 1, characterized in that: It includes at least two thin photovoltaic modules (7), which are electrically connected to each other through exposed metal wires at the ends of the outgoing cables (3), and heat shrink tubing (5) is used to protect the electrical connection between the outgoing cables (3).

10. A packaging structure for a thin photovoltaic module as described in claim 1, characterized in that: Including packaging The container (9) and multiple thin photovoltaic modules (7) stacked from top to bottom in the packaging container (9) have outgoing cables (3) divided into positive outgoing cables and negative outgoing cables. The outgoing positions (6) of the positive outgoing cables and negative outgoing cables are located at the same positions on opposite sides of the encapsulation structure (1). The two sides of the thin photovoltaic module (7) with outgoing cables (3) are the front and back sides. The thin photovoltaic modules (7) that are adjacent to each other are aligned in the front and back side direction and staggered in the left and right side direction to make the outgoing cables (3) of the upper and lower sides staggered in the left and right direction. The stacked thin photovoltaic modules (7) are arranged in a staggered manner with at least 2 thin photovoltaic modules (7) as a group.

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