A thinning adhesive film and suction cup type laminated corner combined photovoltaic module packaging structure

Abstract

The utility model discloses a kind of thinning adhesive film and chuck type laminated corner combined photovoltaic module packaging structure, including the thinning adhesive film structure and adaptive chuck type laminated corner of cell piece on the laying, the thinning adhesive film structure is composed of basic part adhesive film and convex part adhesive film, the convex part adhesive film is located cell piece solder strip just above, gradually thins to the basic part adhesive film along the center of grid line, the chuck type laminated corner includes chuck, substrate and two side edges with the hollow structure glue discharging hole, the substrate is isosceles right triangle, two side edges are respectively with the two right angle of substrate vertically fixedly connected on the upper surface of substrate and form the space that can accommodate photovoltaic module corner, one or more arc hollow structure glue discharging holes are equipped on two side edges, the chuck is fixedly embedded in the middle of substrate. By thinning adhesive film structure and adaptive chuck type laminated corner both synergies realize that adhesive film greatly reduces, component yield improves, single line capacity increases, reduce production cost.

Description

Technical Field

[0001] This utility model relates to the field of photovoltaic module manufacturing technology, and in particular to a photovoltaic module encapsulation structure combining a thinned adhesive film and a suction cup-type laminated corner protector. Background Technology

[0002] With fossil fuels becoming increasingly scarce, solar energy, as a clean, pollution-free, and inexhaustible new energy source, is gradually becoming a guarantee for human future development. Existing solar cell modules typically consist of a laminated structure, which, in the order of manufacturing process, comprises a transparent substrate, a first encapsulating film, solar cells, a second encapsulating film, and a backsheet. The two encapsulating films provide protection for the solar cell module.

[0003] Lamination corner protectors are installed at the four corners of a photovoltaic module during the lamination process. Their function is to limit the lamination thickness, ensuring that the thickness of the laminated photovoltaic module matches the thickness of the corner protectors. This prevents over-lamination from causing the module to become too thin or under-lamination from causing the module to become too thick. In addition, lamination corner protectors can also limit the amount of encapsulant overflow between the two layers of glass during lamination, thereby achieving the desired thickness. They can also position the photovoltaic module to prevent horizontal displacement of certain parts of the photovoltaic module during lamination, which could lead to poor product quality after lamination.

[0004] As module manufacturers strive to reduce costs and increase efficiency in double-glass modules, one way to reduce costs for encapsulant film, one of the eight auxiliary materials for modules, is to reduce the amount of encapsulant film used. However, simply reducing the basis weight of the encapsulant film will result in insufficient filling of the encapsulant film in the module, thus losing the protective effect of the encapsulant film on the solar cells, and causing defects such as black lines at the grid lines to appear in the EL pattern after lamination. Utility Model Content

[0005] To address the aforementioned issues, this invention provides a photovoltaic module encapsulation structure combining a thinner adhesive film and a suction cup-type laminated corner protector.

[0006] To solve the above-mentioned technical problems, the technical solution adopted by this utility model is: a photovoltaic module encapsulation structure combining a thinned adhesive film and a suction cup-type laminated corner protector, including a thinned adhesive film structure laid on the battery cell and a matching suction cup-type laminated corner protector. The thinned adhesive film structure consists of a base adhesive film and a protruding adhesive film. The protruding adhesive film is located directly above the battery cell solder strip and gradually thins along the center of the grid line to the base adhesive film. The suction cup-type laminated corner protector includes a suction cup, a substrate, and two sides with hollowed-out adhesive discharge holes. The substrate is an isosceles right triangle, and the two sides are respectively perpendicularly fixed to the two right-angled sides of the substrate on the upper surface of the substrate to form a space that can accommodate the corners of the photovoltaic module. One or more arc-shaped hollowed-out adhesive discharge holes are provided on the two sides. The suction cup is fixedly embedded in the middle of the substrate.

[0007] Furthermore, the protruding adhesive film is semi-circular or elliptical in shape, and the width of the protruding adhesive film is greater than that of the battery cell solder strip.

[0008] Furthermore, the protruding adhesive film is at least one-third the weight of the base adhesive film, and the number and position of the protruding adhesive film are set according to the encapsulated battery cell.

[0009] Furthermore, the combination of the base film and the protruding film is either thermoplastic integral or layered.

[0010] Furthermore, the right angle of the substrate can be changed to an arc or a straight line connected to the two isosceles right-angled sides.

[0011] Furthermore, the two sides are either directly thermoplastic integrated or segmented spliced, and the height of the two sides is designed according to the required thickness of the double-glass module.

[0012] As can be seen from the above description of the structure of this utility model, compared with the prior art, this utility model has the following advantages:

[0013] 1. This utility model increases and thickens the grid lines that are most susceptible to stress, and the protrusions precisely cover the grid lines, thereby better protecting the battery cells. At the same time, the remaining areas are thinned normally to maximize the reduction of the amount of adhesive film used.

[0014] 2. This utility model uses suction cups for installation and fixation, eliminating the problem of tape marks after lamination when using tape. The installation method is simple and quick. The suction cup's adsorption force is much greater than that of tape, making it less likely to detach from the lamination and burst the components. In addition, the glue drainage holes on both sides of the corner protectors ensure normal glue drainage at the four corners, providing convenience for subsequent glue removal.

[0015] 3. By using an encapsulant film with a base and protrusion structure, and an appropriate corner protector with a side height that ensures the structural and performance stability of the double-glass module, the two work together to reduce encapsulant film usage by 28-32%, reduce edge cutting and jamming rate by 96%, reduce EL black line defect rate to <0.4%, improve module yield, increase single-line capacity, and reduce production costs. Attached Figure Description

[0016] The accompanying drawings, which form part of this application, are used to provide a further understanding of the present invention. The illustrative embodiments of the present invention and their descriptions are used to explain the present invention and do not constitute an undue limitation of the present invention. In the drawings:

[0017] Figure 1 This is a schematic diagram of the thinned adhesive film structure of this utility model;

[0018] Figure 2 This is a schematic diagram of the suction cup type laminated corner protector structure of this utility model. Detailed Implementation

[0019] To make the objectives, technical solutions, and advantages of this utility model clearer, the present utility model will be further described in detail below with reference to the accompanying drawings and embodiments. It should be understood that the specific embodiments described herein are merely illustrative of the present utility model and are not intended to limit the present utility model.

[0020] Example

[0021] refer to Figure 1 , Figure 2 A photovoltaic module encapsulation structure combining a thinned adhesive film and a suction cup-type laminated corner protector is disclosed. The structure includes a thinned adhesive film structure 10 laid on a solar cell and a matching suction cup-type laminated corner protector 20. The thinned adhesive film structure 10 consists of a base adhesive film 11 and a protruding adhesive film 12. Both the base adhesive film 11 and the protruding adhesive film 12 are thermoplastic integrally molded films. The base adhesive film 11 has a basis weight of 300g, and the protruding adhesive film 12 has a basis weight of 100g. The protruding adhesive film 12 is located directly above the solar cell solder strip and gradually thins along the center of the grid line to the base adhesive film 11. The suction cup-type laminated corner protector 20 includes a suction cup 20, a substrate 22, and a strip. The substrate 22 is an isosceles right triangle with two sides 23 having hollowed-out glue discharge holes 24. The two sides 23 are respectively vertically fixed to the two right-angled sides of the substrate 22 on the upper surface of the substrate to form a space that can accommodate the corners of the photovoltaic module. One or more arc-shaped hollowed-out glue discharge holes 24 are provided on the two sides 23. The two sides 23 are made of Teflon material in one piece. Teflon material has the advantages of high temperature resistance, wear resistance and non-deformation. The two sides 23 are directly thermoplastic integrally molded. The height of the two sides 23 is designed according to the required thickness of the double glass module. The suction cup 21 is fixedly embedded in the middle of the substrate 22. The suction cup 21 is made of high temperature resistant material HT2.

[0022] The protruding adhesive film 12 is semi-circular in shape. The number and position of the protruding adhesive film 12 are set according to the encapsulated battery cell. The width of the protruding adhesive film 12 is greater than that of the battery cell solder strip.

[0023] The specific encapsulation method for the photovoltaic module encapsulation structure is as follows: A flat, high-transparency, thin-film encapsulating material with a basis weight of 200g is laid on the front glass. The BC cells are then arranged symmetrically, with the front side facing the front glass and the back side facing up, based on the short side of the front glass. Next, a high-cutoff encapsulating film with a thin-film structure 10 is laid on the back of the BC cells, where the base encapsulating film 11 and the protruding encapsulating film 12 are in contact with the back of the BC cells on opposite sides. The protruding encapsulating film 12 faces away from the front glass and upwards, with its long side flush with the long side of the front glass, ensuring alignment between the protruding encapsulating film 12 and the cell grid lines. After covering the back glass with its four sides flush with the four sides of the front glass, the front edge of the front glass is sealed with edge-sealing tape. Part of the back glass, a portion of the back edge of the back glass, and the portion between the front glass and the back glass are wrapped and wrapped. Because the silicone sheet is inflated and pressed downwards during lamination, the heated and melted fluid film will overflow to the sides of the module when the film is fully filled, causing waste. Therefore, in this embodiment, suction cup type laminated corner protectors 20 with a height that is compatible with the minimum thickness of the double glass module to ensure the integrity and performance stability of the double glass structure are used. After aligning the two sides 23 of the suction cup type laminated corner protector with the corners of the double glass module, place it on the back glass and press the suction cup 21 with your hand to expel the air and adsorb the back glass, so that the corner protector is fixed on the corner. After lamination is completed, it can be removed by lifting it up from both sides. By combining the suction cup corner protector 20 and the thinning film structure 10, the suction cup corner protector is easy to install before lamination, reducing manpower burden, speeding up the cycle and increasing production capacity. During lamination, the corner protector protects the component from excessive compression, allowing the film to be appropriately reduced in weight while improving film utilization and reducing costs. The 12-gram weight of the protruding film can protect the grid lines and prevent the solder ribbon from being damaged under stress. After lamination, the corner protector can be easily removed by simply lifting the edge to allow air to enter the suction cup. At the same time, the glue discharge hole 24 ensures smooth glue discharge in the corner protector-wrapped area of ​​the component, preventing excessive glue accumulation and manual scraping. When encapsulating conventional cells, a combination of a high-transparency film with a thinning structure and a high-cutoff film with a thinning structure can also be selected.

[0024] This invention increases and thickens the grid lines where they are most susceptible to stress, with the protruding part precisely covering the grid lines to better protect the battery cells. Meanwhile, the remaining areas are thinned normally to maximize the reduction of adhesive film usage. The use of suction cups for installation and fixation eliminates the problem of tape marks after lamination. The installation method is simple and quick, and the suction cup's adsorption force is far greater than that of tape, making it less likely to detach from the laminate and cause component breakage. Furthermore, the adhesive drainage holes on both sides of the corner protectors ensure proper adhesive drainage at all four corners, facilitating subsequent adhesive removal.

[0025] This invention utilizes an adhesive film with a base and protrusion structure, and an adaptive corner protector with a side height that ensures the structural and performance stability of the double-glass module. Together, these two elements reduce adhesive film usage by 28-32%, decrease edge trimming and jamming rate by 96%, reduce EL black line defect rate to <0.4%, improve module yield, increase single-line capacity, and reduce production costs.

[0026] The above description is only a preferred embodiment of the present utility model and is not intended to limit the present utility model. Any modifications, equivalent substitutions and improvements made within the spirit and principles of the present utility model should be included within the protection scope of the present utility model.

Claims

1. A photovoltaic module encapsulation structure combining a thinned adhesive film and suction cup-type laminated corner protectors, characterized in that: The device includes a thinning adhesive film structure laid on the solar cell and a matching suction cup-type laminated corner protector. The thinning adhesive film structure consists of a base adhesive film and a protruding adhesive film, which are integrally formed. The protruding adhesive film is located directly above the solar cell solder strip and gradually thins along the center of the grid line to the base adhesive film. The suction cup-type laminated corner protector includes a suction cup, a substrate, and two sides with perforated adhesive discharge holes. The substrate is an isosceles right triangle, and the two sides are perpendicularly fixed to the two right-angled sides of the substrate on the upper surface of the substrate to form a space that can accommodate the corners of the photovoltaic module. One or more arc-shaped perforated adhesive discharge holes are provided on the two sides. The suction cup is fixedly embedded in the middle of the substrate.

2. The photovoltaic module encapsulation structure combining a thinned adhesive film and a suction cup-type laminated corner protector as described in claim 1, characterized in that: The protruding adhesive film is semi-circular or elliptical in shape, and the width of the protruding adhesive film is greater than that of the battery cell solder strip.

3. The photovoltaic module encapsulation structure combining a thinned adhesive film and a suction cup-type laminated corner protector as described in claim 1, characterized in that: The protruding adhesive film is at least one-third the weight of the base adhesive film, and the number and position of the protruding adhesive film are set according to the encapsulated battery cell.

4. The photovoltaic module encapsulation structure combining a thinned adhesive film and a suction cup-type laminated corner protector as described in claim 1, characterized in that: The combination of the base film and the protruding film can be either thermoplastic integral or layered.

5. The photovoltaic module encapsulation structure combining a thinned adhesive film and a suction cup-type laminated corner protector as described in claim 1, characterized in that: The right angle of the substrate can be changed to an arc or a straight line connected to the two isosceles right-angled sides.

6. The photovoltaic module encapsulation structure combining a thinned adhesive film and a suction cup-type laminated corner protector as described in claim 1, characterized in that: The two sides are either directly thermoplastic integrated or segmented spliced, and the height of the two sides is designed according to the required thickness of the double glass module.

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