Blackened photovoltaic module

Abstract

The embodiment of the application discloses a blackened photovoltaic module, which comprises a glass layer and a cell piece, the cell piece is suitable for laying along the surface of the glass layer, the light-receiving surface of the cell piece faces the glass layer, the glass layer is provided with a transparent area and a non-transparent area, the distribution of the non-transparent area is adapted to the gap area and / or the non-power generation area of the cell piece; a plurality of grooves are formed on the side of the non-transparent area where the cell piece is laid, and the grooves are suitable for accommodating the solder strip and / or the bus bar, the blackening effect is good, the structure is stable, and the cost is low, and the solder strip and the bus bar are not easy to deviate in the processing process and affect the blackening effect.

Description

Technical Field

[0001] This application relates to the field of photovoltaic module technology, and in particular to a blackened photovoltaic module. Background Technology

[0002] Photovoltaic power generation technology is a power generation technology that uses the photovoltaic effect at the semiconductor interface to directly convert solar energy into electrical energy. It usually uses photovoltaic modules, which typically arrange a number of cells into a cell string. The cells are connected by individual welding and string welding, and the front electrode of the previous cell is connected to the back electrode of the next cell by heating and welding. In this way, the cells are connected in series to form a cell string. Then the welded cell strings are arranged and welded to busbars. The busbar leads are connected in series with bypass diodes in the junction box to bring out the positive and negative terminals. Finally, through a series of module manufacturing processes, a photovoltaic module is formed.

[0003] Traditional photovoltaic modules and building-integrated photovoltaic (BIPV) modules often use transparent glass for their front panels. Since the solder strips and busbars are usually silver-white, the appearance is not aesthetically pleasing and can easily cause light pollution. Therefore, there is an increasing demand for completely black modules in distributed rooftop power station systems.

[0004] However, the inventors believe that the aforementioned technologies have the following drawbacks: using black material to isolate and shield the solder ribbon and busbar can achieve certain effects, but it is prone to film flow displacement and also poses a risk of silver leakage. If all busbars and solder ribbons are used, the cost is relatively high, and the welding effect of black solder ribbon is not good. Using enamel-coated printed grids or black grid films on glass is prone to deformation during high-temperature lamination. The enamel layer decomposes and flakes off, while the black film layer wrinkles and delaminates, causing the light-transmitting area to be misaligned with the solar cell, blocking the light-receiving surface of the solar cell, reducing power generation efficiency. After glass printing, there will also be problems such as reduced impact strength and reduced mechanical load capacity. The battery string is fixed to the busbar and is easily affected by the film during production line operation and lamination, which is more obvious when using a smooth film, and it will also cause the front grid to block the solar cell.

[0005] In addition, the busbar fixing often relies on tape or welding tape connection. After lamination, the material shrinkage can easily cause displacement, resulting in microcracks in the battery cells or failure of circuit connection, which seriously affects the reliability of the module. Summary of the Invention

[0006] This application provides one or more embodiments of a blackened photovoltaic module to solve or at least partially alleviate the problems of poor blackening effect, high cost, and low reliability of photovoltaic modules in related technologies.

[0007] One or more embodiments of this application provide a blackened photovoltaic module, which adopts the following technical solution:

[0008] A blackened photovoltaic module includes a glass layer and solar cells. The solar cells are adapted to be laid along the surface of the glass layer, with the light-receiving surface of the solar cells facing the glass layer. The glass layer has transparent and non-transparent areas. The distribution of the non-transparent areas is adapted to the gap areas and / or non-power-generating areas of the solar cells. Multiple grooves are formed on the side of the non-transparent areas where the solar cells are laid. The grooves are adapted to accommodate solder strips and / or busbars.

[0009] In some embodiments, after the solar cells are laid out, a spacing region between the solar cells and an edge region between the solar cells and the edge of the glass layer are formed. The structure of the solar cell includes a power generation region and a main busbar. The transparent region corresponds to the power generation region of the solar cell, and the non-transparent region corresponds to one or more of the spacing region, the edge region, and the main busbar.

[0010] In some embodiments, the non-transparent area is shaped like a grid; the grooves form an array within the non-transparent area.

[0011] In some embodiments, a first adhesive film layer is provided between the battery cell and the glass layer, and a calendered filling portion is provided on the first adhesive film layer. The calendered filling portion is adapted to be accommodated in the groove and is adapted to support the solder strip.

[0012] In some embodiments, a corner adhesive film pad is provided between the first adhesive film layer and the glass layer, the corner adhesive film pad being adapted to fill the gap side of the solder strip on the busbar.

[0013] In some embodiments, the groove for accommodating the solder strip is a first groove, and the groove for accommodating the busbar is a second groove, wherein the bottom of the second groove is lower than the bottom of the first groove, so that the solder strip and the busbar overlap and contact in the thickness direction.

[0014] In some embodiments, the battery cell is provided with a plurality of main grid line solder strips, the groove spacing along the first direction is consistent with the main grid line solder strip spacing; the width of the groove along the first direction is 0.01mm-0.03mm wider than the width of the solder strips; and the depth of the groove along the first direction is 0.2mm.

[0015] In some embodiments, the width of the groove along the second direction is 0.01mm-0.03mm wider than the width of the busbar; the depth of the groove along the second direction is 0.3mm.

[0016] In some embodiments, the non-transparent area is black and is etched by laser.

[0017] In some embodiments, the non-transparent area covers the surface of the glass layer and the surface of the groove, or the non-transparent area covers the entire length of the glass layer along its thickness direction.

[0018] Compared with related technologies, one or more embodiments of this application include at least one of the following beneficial technical effects:

[0019] (1) The blackened photovoltaic module of this application uses black grid glass for the glass layer of the front panel, and forms a black glaze layer of transparent and non-transparent areas by laser etching. The grid width is matched with the gap of the cell, which ensures that the transparent area accurately covers the gap of the cell, the busbar and the solder strip area after lamination. The production cost is low, and the offset of the cell string during production line operation and lamination is reduced. This is especially noticeable when using a smooth film, which reduces the probability of the non-transparent area blocking the cell and reduces the hot spot problem caused by poor blackening effect and the problem of affecting the power generation efficiency of the photovoltaic module.

[0020] (2) The blackened photovoltaic module of this application sets a groove array on the glass layer surface of the front panel and matches it with the main grid line and busbar size of the cell. Before lamination, the main grid line of the cell is embedded in the corresponding groove and the busbar is pre-embedded in the horizontal groove to achieve positioning, thereby improving the reliability of the module and achieving the technical effect of reducing or even eliminating the misalignment between the transparent area and the cell, and improving the power generation efficiency. Attached Figure Description

[0021] To more clearly illustrate the technical solutions of the embodiments of this application, the accompanying drawings of the embodiments will be briefly introduced below. Obviously, the drawings described below only involve some embodiments of this application and are not intended to limit this application.

[0022] Figure 1 This is a front view of a photovoltaic module with cell grids according to some embodiments of this application.

[0023] Figure 2 This is a longitudinal cross-sectional view of a photovoltaic module with a main grid of cells according to some embodiments of this application.

[0024] Figure 3 According to some embodiments of this application Figure 2 A magnified view of point a in the middle.

[0025] Figure 4 This is a cross-sectional view of a photovoltaic module with a main grid line for solar cells according to some embodiments of this application.

[0026] Figure 5 According to some embodiments of this application Figure 4 A magnified view of point b in the middle.

[0027] Figure 6 This is a front view of a photovoltaic module without main grid lines according to some embodiments of this application.

[0028] Figure 7 This is a longitudinal cross-sectional view of a photovoltaic module without main grid lines according to some embodiments of this application.

[0029] Figure 8 This is a flowchart illustrating the manufacturing process of a photovoltaic module according to some embodiments of this application.

[0030] In the diagram: 1. Glass layer; 11. Transparent area; 12. Non-transparent area; 121. Spacing area; 122. Edge area; 13. First groove; 14. Second groove; 2. First adhesive film layer; 21. Calendered filling part; 3. Battery cell; 31. Power generation area; 32. Main busbar; 4. Second adhesive film layer; 5. Backplate; 6. Junction box; 7. Solder strip; 8. Busbar; 9. Corner adhesive film pad layer. Detailed Implementation

[0031] To make the objectives, technical solutions, and advantages of this application clearer, the technical solutions in the embodiments of this application will be clearly and completely described below with reference to the accompanying drawings showing multiple embodiments according to this application. It should be understood that the described embodiments are only a part of the embodiments of this application, and not all of the embodiments. All other embodiments obtained by those skilled in the art based on the embodiments described in this application without creative effort will fall within the scope of protection of this application.

[0032] Unless otherwise defined, all technical and scientific terms used in this application have the same meaning as commonly understood by one of ordinary skill in the art to which this application pertains; the terminology used in the description of this application is for the purpose of describing specific embodiments only and is not intended to limit this application; the terms "comprising," "including," "having," "containing," etc., in the description, claims, and accompanying drawings of this application are open-ended terms. Therefore, "comprising," "including," or "having" refers to, for example, a method or apparatus having one or more steps or elements, but is not limited to having only these one or more elements. The terms "first," "second," etc., in the description, claims, or accompanying drawings of this application are used to distinguish different objects, not to describe a specific order or hierarchy. Furthermore, the terms "first" and "second" are used for descriptive purposes only and should not be construed as indicating or implying relative importance or implicitly specifying the number of indicated technical features. Thus, a feature defined as "first" or "second" may explicitly or implicitly include one or more of that feature. In the description of this application, unless otherwise stated, "a plurality of" means two or more.

[0033] In the description of this application, it should be understood that the terms "center", "lateral", "length", "width", "upper", "lower", "front", "rear", "left", "right", "vertical", "horizontal", "top", "bottom", "inner", "outer", "axial", "radial", "circumferential", etc., indicate the orientation or positional relationship based on the orientation or positional relationship shown in the accompanying drawings. They are used only for the convenience of describing this application and simplifying the description, and do not indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation. Therefore, they should not be construed as limitations on this application.

[0034] In the description of this application, it should be noted that, unless otherwise expressly specified and limited, the terms "installation," "connection," "linking," and "attachment" should be interpreted broadly. For example, they can refer to a fixed connection, a detachable connection, or an integral connection; they can refer to a direct connection or an indirect connection through an intermediate medium; and they can refer to the internal communication between two components. Those skilled in the art can understand the specific meaning of the above terms in this application according to the specific circumstances.

[0035] In this application, the term "implementation" means that a specific feature, structure, or characteristic described in connection with an implementation can be included in at least one implementation of this application. The appearance of this phrase in various places in the specification does not necessarily refer to the same implementation, nor is it a separate or alternative implementation mutually exclusive with other implementations. Those skilled in the art will understand, explicitly and implicitly, that the implementations described in this application can be combined with other implementations.

[0036] As mentioned above, it should be emphasized that when the term "comprising / including" is used in this specification, it is used to explicitly indicate the presence of the stated feature, integer, step, or component, but does not exclude the presence or addition of one or more other features, integers, steps, components, or groups of features, integers, steps, or components. As used in this application, the singular forms "a," "an," and "the" also include the plural forms, unless the context clearly indicates otherwise.

[0037] One or more embodiments of this application disclose a blackened photovoltaic module, referencing... Figures 1 to 8The system includes a glass layer 1 and solar cells 3. The size of the solar cells 3 (which can be 125mm, 156mm, 158mm, 166mm, 182mm, 210mm, 218mm, etc.) is suitable for being laid along the surface of the glass layer 1. The light-receiving surface of the solar cells 3 faces the glass layer 1, so that the solar cells 3 can generate photovoltaic power after passing through the barrier of the glass layer 1. The glass layer 1 is provided with transparent areas 11 and non-transparent areas 12. The distribution of the non-transparent areas 12 is adapted to the gap areas and / or non-power-generating areas of the solar cells 3, and can be adapted to the laying form and structure of the solar cells 3, so that the non-transparent areas 12 can cover the area outside the light-receiving surface of the solar cells 3, thereby achieving the blackening of the photovoltaic module. Compared with the traditional photovoltaic module blackening through black insulating pads, black bonding tape, black busbars, black solder strips, etc., this application can solve the problems of solar cell misalignment and silver leakage and high cost of the above solutions.

[0038] In addition, multiple grooves are formed on the side where the solar cell 3 is laid in the non-transparent area 12. The grooves are suitable for accommodating the solder strip 7 and / or busbar 8. The grooves can be used to position the solar cell 3 and busbar 8, reduce the probability of the solar cell 3 being offset and the light-receiving surface being blocked, and reduce the shrinkage displacement of the solar cell 3, busbar 8 and solder strip 7 before and after lamination, thereby improving the reliability of the photovoltaic module.

[0039] like Figure 1 and 6 In the embodiment shown, after the battery cells 3 are laid out, a spacing area 121 is formed between the battery cells 3 (including the spacing area 121 between the battery strings composed of battery cells 3, which is mainly determined and matched according to the size of the battery cells 3 and the battery strings. The spacing size of the cells is not limited and can be a negative spacing of -0.5-2mm, a small gap or a large gap. The spacing between strings is not limited and can be 1-4mm, etc.) and an edge area 122 between the battery cells 3 and the edge of the glass layer 1 (the area is mainly determined according to the edge creepage distance and the blank area of ​​the busbar 8). The structure of the battery cell 3 includes a power generation area 31 and a main busbar 32. When the battery cell 3 is laid on the glass layer 1, the transparent area 11 covers the power generation area 31, and the non-transparent area 12 covers one or more of the spacing area 121, the edge area 122 and the main busbar 32.

[0040] like Figure 1 and 6 In the embodiment shown, the non-transparent area 12 has a grid-like shape, which is aesthetically pleasing, neat, and has a good visual effect.

[0041] In some embodiments, the non-transparent area 12 is covered on the surface of the glass layer 1 and the surface of the groove, which is simple and convenient to process.

[0042] like Figure 3In the embodiment shown, the non-transparent area 12 is covered along the thickness direction of the glass layer 1, which is not easily worn and provides a better hiding and masking effect for the solder strip 7 and the busbar 8.

[0043] In some embodiments, the transparent area 11 and the non-transparent area 12 are processed by laser etching, which has high processing efficiency, more precise dimensions, and the non-transparent area 12 is not easily worn.

[0044] In this application, since the main purpose of photovoltaic modules is to blacken them, the non-transparent area 12 is generally chosen to be black. If users have other requirements for the color scheme of photovoltaic modules, the non-transparent area 12 can also be adjusted to other common colors.

[0045] like Figure 1 and 6 In the embodiment shown, the grooves are arranged in an array within the non-transparent area 12 to accommodate multiple solder strips 7 and / or multiple busbars 8.

[0046] In some embodiments, a plurality of main grid line solder strips 7 are provided on the battery cell 3, along a first direction (refer to...). Figure 1 and Figure 6 The groove spacing (in the horizontal direction) is consistent with the spacing of the main grid line solder strip 7 and is suitable for accommodating the main grid line solder strip 7, along the second direction (refer to...). Figure 1 and Figure 6 The groove spacing (in the vertical direction) is set according to the arrangement spacing of the busbar 8 and is suitable for accommodating the busbar 8.

[0047] In some embodiments, the width of the groove along the first direction is 0.01mm-0.03mm wider than the width of the solder strip 7; the depth of the groove along the first direction is 0.2mm, which facilitates the placement of the solder strip 7 in the groove and ensures that the solder strip 7 does not fall out of the groove after being placed.

[0048] In some embodiments, the width of the groove along the second direction is 0.01mm-0.03mm wider than the width of the busbar 8; the depth of the groove along the second direction is 0.3mm, which facilitates the placement of the busbar 8 in the groove and ensures that the busbar 8 does not fall out of the groove after being placed.

[0049] like Figure 5 In the embodiment shown, the groove for accommodating the solder strip 7 (along the first direction) is the first groove 13, and the groove for accommodating the busbar 8 (along the second direction) is the second groove 14. The bottom of the second groove 14 is lower than the bottom of the first groove 13, so that the solder strip 7 and the busbar 8 overlap and contact in the thickness direction, which can improve the connection strength and connection stability between the solder strip 7 and the busbar 8, making the photovoltaic module more stable.

[0050] Specifically, the second groove 14 is slotted downward with the bottom surface of the first groove 13 as the reference surface. The first groove 13 and the second groove 14 are joined together so that the solder strip 7 and the busbar 8 are adapted to overlap and contact in the thickness direction of the glass layer 1.

[0051] like Figure 3 In the embodiment shown, a first adhesive film layer 2 is provided between the battery cell 3 and the glass layer 1. A calendered filling portion 21 is provided on the first adhesive film layer 2. The calendered filling portion 21 is obtained by calendering the first adhesive film layer 2 and protrudes from the first adhesive film layer 2. The calendered filling portion 21 is adapted to fit into the groove and is adapted to support the solder ribbon 7. The first adhesive film layer 2 is positioned by the calendered filling portion 21 fitting into the groove, thereby reducing the sliding displacement phenomenon of the first adhesive film layer 2 during the lamination process and improving the stability of the component.

[0052] In some embodiments, the thickness of the first adhesive film layer 2 plus the first groove 13 is approximately equal to the thickness of the calendered filling portion 21 plus the solder ribbon 7, so that the glass layer 1, the battery cell 3 and the solder ribbon 7 can be bonded more smoothly and tightly, reducing gaps.

[0053] In some embodiments, the first adhesive film layer 2 is initially bonded and fixed to the glass layer 1, the battery cell 3, the solder ribbon 7, and the busbar 8 under conditions of 80-100°C pressure and 5-10MPa pressure for 5 minutes. Then, the bonding is completed under conditions of 140-150°C and 30-50MPa pressure for 12 minutes. Combined with the limiting effect of the groove on the solder ribbon 7 and the busbar 8, the battery string displacement caused by thermal expansion can be effectively suppressed, the probability of microcracks in the battery cell 3 and circuit connection failure can be reduced, and the reliability of the component can be improved.

[0054] like Figure 5 In the embodiment shown, a corner adhesive film pad 9 is provided between the first adhesive film layer 2 and the glass layer 1. The corner adhesive film pad 9 is suitable for filling the gap side of the solder strip 7 on the busbar 8. Since the busbar 8 and the solder strip 7 are staggered, considering that the solder strip 7 is difficult to accurately cover the top of the busbar 8 and is prone to gaps, the corner adhesive film pad 9 is provided to compensate for the gap between the first adhesive film pad and the busbar 8. The corner adhesive film pad 9 can melt and bond with the first adhesive film layer 2 during lamination and fill the gap between the first adhesive film pad and the busbar 8.

[0055] like Figures 6 to 7 In the embodiment shown, if the battery cell 3 (battery string) does not have a main grid line 32, the first groove 13 can be omitted, and only the second groove 14 can be formed.

[0056] The common structure of a photovoltaic module using the solution of this application includes a glass layer 1, a first encapsulant layer 2, a solar cell 3, a second encapsulant layer 4, a backsheet 5, and a junction box 6.

[0057] like Figure 8 As shown, the manufacturing process steps of the photovoltaic module in this application are as follows:

[0058] The first step is to use 2.0-4.0mm patterned glass and, according to the required component screen size, use a CNC laser engraving machine to etch 0.15mm wide grid lines on the glass surface at a wavelength of 1064nm.

[0059] The second step is to weld the solder strip 7 to the busbar 8. A 0.2mm deep groove is processed in the transparent area 11 and the non-transparent area 12 of the grid glass. The spacing of the first groove 13 is consistent with the position of the main grid line 32 of the battery cell 3 (if the battery cell 3 has 16 main grid lines 32, then 16 longitudinal grooves are opened accordingly). The width is 0.01-0.03mm larger than the solder strip 7. The second groove 14 is etched with two 0.3mm deep grooves according to the arrangement spacing of the busbar 8. The width is 0.01-0.03mm larger than the busbar 8.

[0060] The third step is to place the glass layer 1 and then place the rolled first adhesive film layer 2 into the first groove 13 of the glass layer 1.

[0061] The fourth step involves using a vision positioning system to align the main grid line 32 of the battery cell 3 with the longitudinal groove, and then using a robotic arm to place the battery cell 3 with an accuracy of 0.05mm.

[0062] Fifth step: Insert the busbar 8 into the second groove 14 and then weld it to the welding strip 7 for fixation.

[0063] Step 6: Apply the second adhesive film layer 4 and place the backing plate 5. The backing plate 5 can be glass or an organic backing plate material, such as TPT, CPC, KPF and other softer materials.

[0064] It is worth noting that since the glass layer 1 is black grid glass, it can already achieve a shielding effect. Therefore, the back panel 5 can be transparent, black, black grid, white grid, etc. The organic back panel 5 can also be white, transparent, black, or grid. Alternatively, transparent glass and back panel 5 can be combined with black film, etc.

[0065] Step 7: After assembling the glass layer 1, the first adhesive film layer 2, the battery cell 3, the second adhesive film layer 4, and the backplate 5, a segmented lamination method is used. First, a low temperature (preferably 90℃) pressure of 5-10MPa is maintained for 5 minutes for pre-pressing to achieve initial bonding. The first adhesive film layer 2 is melted to fix the battery string and busbar 8, so that the first adhesive film layer 2 cannot flow quickly and detach from the groove, and is completely fixed. Then, a high temperature (preferably 140-145℃) pressure of 30-50MPa is maintained for 12 minutes for lamination to complete cross-linking. The temperature uniformity is monitored throughout the process by infrared thermal imaging.

[0066] Step 8: After lamination, the laminated component is obtained. Junction box 6 is installed, framed, and junction box 6 is installed to complete the all-black finished component.

[0067] The basic principles, main features, and advantages of this application have been described above. Those skilled in the art should understand that this application is not limited to the above embodiments. The embodiments and descriptions in the specification are merely the principles of this application. Various changes and modifications can be made to this application without departing from its spirit and scope, and all such changes and modifications fall within the scope of the claims. The scope of protection claimed by this application is defined by the appended claims and their equivalents.

Claims

1. A blackened photovoltaic module, characterized in that: The device includes a glass layer and a solar cell. The solar cell is adapted to be laid along the surface of the glass layer, with the light-receiving surface of the solar cell facing the glass layer. The glass layer has transparent and non-transparent areas. The distribution of the non-transparent areas is adapted to the gap areas and / or non-power-generating areas of the solar cell. Multiple grooves are formed on the side where the solar cell is laid within the non-transparent areas. The grooves are adapted to accommodate solder strips and / or busbars.

2. The blackened photovoltaic module as described in claim 1, characterized in that: After the solar cells are laid out, a spacing area between the solar cells and an edge area between the solar cells and the glass layer are formed. The structure of the solar cell includes a power generation area and a main busbar. The transparent area corresponds to the power generation area of ​​the solar cell, and the non-transparent area corresponds to one or more of the spacing area, the edge area, and the main busbar.

3. A blackened photovoltaic module as described in claim 2, characterized in that: The non-transparent area is shaped like a grid; the grooves form an array within the non-transparent area.

4. A blackened photovoltaic module as described in claim 1, characterized in that: A first adhesive film layer is disposed between the battery cell and the glass layer. A calendered filling portion is disposed on the first adhesive film layer. The calendered filling portion is adapted to fit into the groove and is adapted to support the solder strip.

5. A blackened photovoltaic module as described in claim 4, characterized in that: An edge adhesive film pad is provided between the first adhesive film layer and the glass layer, and the edge adhesive film pad is adapted to fill the gap side of the solder strip on the busbar.

6. A blackened photovoltaic module as described in claim 1, characterized in that: The groove for accommodating the solder strip is a first groove, and the groove for accommodating the busbar is a second groove. The bottom of the second groove is lower than the bottom of the first groove, so that the solder strip and the busbar overlap and contact each other in the thickness direction.

7. A blackened photovoltaic module as described in claim 1, characterized in that: The battery cell is provided with multiple main grid line solder strips, and the spacing of the grooves along the first direction is the same as the spacing of the main grid line solder strips; the width of the grooves along the first direction is 0.01mm-0.03mm wider than the width of the solder strips; the depth of the grooves along the first direction is 0.2mm.

8. A blackened photovoltaic module as described in claim 1, characterized in that: The width of the groove along the second direction is 0.01mm-0.03mm wider than the width of the busbar; the depth of the groove along the second direction is 0.3mm.

9. A blackened photovoltaic module as described in claim 1, characterized in that: The non-transparent area is black and is etched using a laser.

10. A blackened photovoltaic module as described in any one of claims 1 to 9, characterized in that: The non-transparent area covers the surface of the glass layer and the surface of the groove, or the non-transparent area covers the entire length of the glass layer along its thickness direction.

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