A photovoltaic glass and photovoltaic module

Abstract

This utility model discloses a photovoltaic glass and a photovoltaic module. The photovoltaic glass may include: a first region and a second region extending outward from the first region, wherein the first region corresponds at least to the cell layer of the photovoltaic module, and the edge of the second region is provided with a groove structure opening towards the side. The width of a first shoulder located on one side of the groove structure in the thickness direction of the photovoltaic glass is equal to or less than the width of a second shoulder located on the opposite side of the groove structure in the thickness direction of the photovoltaic glass, and the width of the second shoulder is less than or equal to the width of the second region. This structural optimization of the photovoltaic glass increases the structural stability of the photovoltaic module, effectively solves the problems of edge delamination and springback of the module, and improves the sealing effect and reliability of the photovoltaic module.

Description

Technical Field

[0001] This utility model relates to a photovoltaic glass and a photovoltaic module. Background Technology

[0002] Currently, most double-glass photovoltaic (PV) modules are manufactured using either encapsulation with a sealant film or liquid encapsulation. During the lamination process, the glass edges of double-glass modules are subjected to excessive pressure. This excessive pressure reduces the thickness of the sealant film at the module edges compared to the sealant film in the center. The sealant film at the edges decomposes and ages upon contact with moisture, leading to problems such as edge springback, warping, and delamination, thus affecting the sealing performance and reliability of the PV module. For liquid-encapsulated PV modules, a sealant film is used only around the perimeter, with the encapsulating liquid in the center. During outdoor installation, the weight of the encapsulating liquid can cause the sealant film at the bottom of the module to detach, resulting in edge springback, delamination, and leakage, again affecting the sealing performance and reliability of the PV module. Utility Model Content

[0003] In view of this, the present invention provides a photovoltaic glass and a photovoltaic module, which can increase the structural stability of the photovoltaic module, solve problems such as edge springback, warping, delamination, and leakage, and improve the sealing effect and reliability of the photovoltaic module.

[0004] To solve the above-mentioned technical problems, this utility model provides the following technical solution:

[0005] In a first aspect, embodiments of the present invention provide a photovoltaic glass comprising a first region and a second region extending outward from the first region, wherein the first region corresponds at least to the cell layer of a photovoltaic module.

[0006] The edge of the second region is provided with a groove structure that opens to the side. The width of the first shoulder of the groove structure on one side of the photovoltaic glass thickness direction is equal to or less than the width of the second shoulder of the groove structure on the opposite side of the photovoltaic glass thickness direction, and the width of the second shoulder is less than or equal to the width of the second region.

[0007] Secondly, this utility model provides a photovoltaic module, including a cover plate, a back sheet, an encapsulation layer, and a cell layer, wherein the encapsulation layer is used to encapsulate the cell layer between the cover plate and the back sheet, wherein...

[0008] The cover plate and the back plate are photovoltaic glass according to the first aspect embodiment described above. The first region and the second region included in the cover plate correspond to the first region and the second region included in the back plate, respectively. The first shoulder of the cover plate and the first shoulder of the back plate are close to the cell layer of the photovoltaic module, and the second shoulder of the cover plate and the second shoulder of the back plate are far away from the cell layer of the photovoltaic module.

[0009] The encapsulation layer includes a first encapsulation layer located in the first region corresponding to the cover plate and the back plate, and a second encapsulation layer located in the second region corresponding to the cover plate and the back plate.

[0010] The second encapsulation layer extends between the first shoulder of the cover plate and the first shoulder of the back plate, within the groove structure of the cover plate and the groove structure of the back plate.

[0011] The first aspect of the above-mentioned utility model has the following advantages or beneficial effects:

[0012] The photovoltaic module provided in this embodiment optimizes the structure of the photovoltaic glass by setting a groove structure with side openings around the perimeter of the photovoltaic glass. This groove structure can increase the sealing performance of the module edge, thereby increasing the structural stability of the photovoltaic module and solving problems such as edge rebound, warping, delamination, and leakage, thus improving the sealing effect and reliability of the photovoltaic module.

[0013] The further effects of the aforementioned unconventional alternative methods will be explained below in conjunction with specific implementation methods. Attached Figure Description

[0014] Figure 1 This is a schematic diagram of the overall structure of the photovoltaic glass according to the first embodiment of the present invention;

[0015] Figure 2 This is a cross-sectional view of the photovoltaic glass according to the first embodiment of this utility model;

[0016] Figure 3 This is a schematic diagram of the overall structure of the photovoltaic glass according to the second embodiment of the present invention;

[0017] Figure 4 This is a cross-sectional view of the photovoltaic glass according to the first embodiment of this utility model;

[0018] Figure 5 This is a cross-sectional view of the photovoltaic glass according to the third embodiment of the present invention, showing a portion of the first region and the second region;

[0019] Figure 6This is a cross-sectional view of the photovoltaic glass according to the fourth embodiment of the present invention, showing a portion of the first region and the second region;

[0020] Figure 7 This is a top view of the photovoltaic glass of this utility model embodiment after removing the first shoulder;

[0021] Figure 8 This is an embodiment of the present invention. Figure 1 and Figure 2 The schematic diagram of the cross-sectional structure of the photovoltaic module formed by the photovoltaic glass shown illustrates a portion of the first region and the second region of the backsheet and cover plate.

[0022] Figure 9 This is an embodiment of the present invention. Figure 3 and Figure 4 The schematic diagram of the cross-sectional structure of the photovoltaic module formed by the photovoltaic glass shown illustrates a portion of the first region and the second region of the backsheet and cover plate.

[0023] Figure 10 This is an embodiment of the present invention. Figure 5 The schematic diagram of the cross-sectional structure of the photovoltaic module formed by the photovoltaic glass shown illustrates a portion of the first region and the second region of the backsheet and cover plate.

[0024] Figure 11 This is an embodiment of the present invention. Figure 6 The schematic diagram of the cross-sectional structure of the photovoltaic module formed by the photovoltaic glass shown illustrates a portion of the first region and the second region of the backsheet and cover plate.

[0025] Figure 12 This is a cross-sectional structural schematic diagram of a first photovoltaic module according to another embodiment of the present invention, showing a portion of a first region and a second region of a backsheet and a cover plate;

[0026] Figure 13 It corresponds to Figure 12 A schematic diagram of the battery support structure;

[0027] Figure 14 It corresponds to Figure 12 A top view of the battery support structure and the battery array mounting structure;

[0028] Figure 15 This is a cross-sectional structural schematic diagram of a second photovoltaic module according to another embodiment of the present invention, showing a portion of the first region and the second region of the back sheet and cover plate;

[0029] Figure 16 It corresponds to Figure 15 A schematic diagram of the cell structure of the battery array;

[0030] Figure 17 This is a schematic diagram of the main steps in the preparation method of a photovoltaic module according to another embodiment of the present invention.

[0031] The attached figures are labeled as follows:

[0032] 1-Cover plate; 2-Encapsulation layer; 3-Battery layer; 4-Back plate; 10-First region; 20-Second region; 30-Flush portion; 40-Protrusion portion; 21-First encapsulation layer; 22-Second encapsulation layer; 8-Groove structure; 81-First shoulder; 82-Second shoulder; 9-Inset groove; 5-Battery support structure; 51-Separator layer; 52-Main support layer; 53-Bottom adhesive layer; 31-Transparent conductive layer; 32-Hole transport layer; 33-Perovskite photoelectric conversion layer; 34-Electron transport layer; 35-Back electrode. Detailed Implementation

[0033] The photovoltaic module involved in this embodiment can be any type of double-glass photovoltaic module. The cell array used in the photovoltaic module can be any type of solar cell, such as silicon-based solar cells, perovskite solar cells, etc. Specifically, the silicon-based solar cells can be of the finger-crossing type, back-contact type, or type with electrodes on both sides, etc.

[0034] To address the technical problems existing in the prior art, this utility model provides a photovoltaic glass, a photovoltaic module made using the photovoltaic glass, and a method for making the photovoltaic module. By optimizing the structure of the photovoltaic glass, a groove structure with side openings is provided around the photovoltaic glass. This groove structure can increase the sealing performance of the module edge, solving problems such as edge rebound, warping, delamination, and leakage, and improving the sealing effect and reliability of the photovoltaic module.

[0035] It should be noted that, in this technical solution, "inner" and "outer" refer to directional terms within the plane containing the glass or component. Specifically, "inner" means that the central area is located "inner" relative to the edge area within the plane containing the glass or component; correspondingly, "inward" refers to the direction from the edge area to the central area within the plane containing the glass or component. "Outer" means that the edge area is located "outer" relative to the central area within the plane containing the glass or component; correspondingly, "outward" refers to the direction from the central area to the edge area within the plane containing the glass or component.

[0036] It should be noted that "thickness" refers to the dimension in the direction perpendicular to the plane containing the glass or component. "Width" refers to the distance between two opposing sides within the plane containing the glass or component. For example, "width of the first shoulder" refers to the distance between the outer edge of the first shoulder at the edge of the groove structure and the inner edge at the bottom of the groove structure within the plane containing the glass. Similarly, "width of the second shoulder" refers to the distance between the outer edge of the second shoulder at the edge of the groove structure and the inner edge at the bottom of the groove structure within the plane containing the glass. "Width of the second region" refers to the distance between the outer and inner edges within the plane containing the glass.

[0037] It should be noted that the height of the groove structure refers to the dimension along the thickness direction of the photovoltaic glass, and the depth of the embedded groove refers to the dimension along the thickness direction of the photovoltaic glass.

[0038] The specific implementation process of this utility model's technical solution is described below with reference to the accompanying drawings.

[0039] First, refer to Figure 1 and Figure 2 , Figure 1 This is a schematic diagram of the overall structure of the photovoltaic glass according to the first embodiment of the present invention; Figure 2 This is a cross-sectional view of the photovoltaic glass according to the first embodiment of this utility model. Wherein, Figure 2 It is along Figure 1 The diagram shows a cross-section obtained after the photovoltaic glass is cut by the cutting line shown.

[0040] This utility model embodiment provides a photovoltaic glass, such as Figure 1 and Figure 2 As shown, the photovoltaic glass includes a first region 10 and a second region 20 extending outward from the first region 10. When applied to a photovoltaic module, the first region 10 corresponds at least to the cell layer of the photovoltaic module. The second region 20 is a ring-shaped structure disposed at the edge of the first region 10, and the outlines of the first region 10 and the second region 20 have the same shape as the outline of the photovoltaic glass. For example, if the photovoltaic glass is formed into a rectangle to adapt to the shape of the photovoltaic module, correspondingly, the first region 10 is formed into a rectangle, and the second region 20 is formed into a rectangular ring.

[0041] The edge of the second region 20 is provided with a groove structure 8 that opens to the side. The width of the first shoulder 81 located on one side of the groove structure 8 in the photovoltaic glass thickness direction is less than or equal to the width of the second shoulder 82 located on the opposite side of the groove structure 8 in the photovoltaic glass thickness direction, and the width of the second shoulder 82 is less than or equal to the width of the second region 20.

[0042] According to the embodiments, photovoltaic glass undergoes shaping, grooving, and edge grinding in the raw glass stage, and is then tempered before being formed and used. The tempering method can be physical tempering or chemical tempering. The surface stress range of physically tempered glass can be 40-150 MPa, while the surface stress range of chemically tempered glass can be 300-800 MPa.

[0043] Photovoltaic glass can be tempered or semi-tempered. During the tempering process, stress is generated. When applied to photovoltaic modules, the lamination process can apply excessive pressure to the edges. This excessive pressure can reduce the thickness of the sealant film at the module edges compared to the sealant film in the center of the module. The sealant film at the edges is prone to decomposition and aging, leading to problems such as edge rebound, warping, and delamination, affecting the sealing effect and reliability of the photovoltaic module. For liquid-encapsulated photovoltaic modules, the encapsulating liquid is used in the center. Due to the weight of the encapsulating liquid, the sealant film at the bottom of the module may detach, causing edge rebound, delamination, and leakage, affecting the sealing effect and reliability of the photovoltaic module. Therefore, according to the embodiments of this application, the photovoltaic glass has a groove structure at the edge of the second region. This groove structure can enhance the peel force and sealing performance of the photovoltaic module edges, improving the performance of the photovoltaic module.

[0044] The width of the second shoulder 82 is less than or equal to the width of the second region 20. That is to say, the groove structure 8 can extend to the boundary of the first region 10 and the second region 20, or the groove structure 8 can not extend to the boundary of the first region 10 and the second region 20. It should be understood that the groove structure 8 can enhance the sealing and peeling force of the photovoltaic glass edge, but if the groove structure 8 is too wide, it will correspondingly reduce the strength of the photovoltaic glass edge. Therefore, the width of the second shoulder 82 is less than or equal to the width of the second region 20, which can balance the sealing and strength of the photovoltaic glass edge. For example, conventional photovoltaic glass uses conventional adhesive films, such as EVA plastic (Ethylene Vinyl Acetate Copolymer), POE plastic, EPE (Pearlcotton), and PVB (Polyvinyl Butyral), at the same width as the photovoltaic glass in the second region 20 of this application embodiment. After lamination, the peel force tested is 30-50N. However, the photovoltaic glass according to the application embodiment uses the same adhesive film in the second region 20 and is then laminated. After lamination, the peel force tested is 150-320N. Therefore, by providing a groove structure 8 at the edge of the second region 20, the photovoltaic glass according to the application embodiment can improve the peel force at the edge of the photovoltaic module, thereby improving the performance of the photovoltaic module.

[0045] In specific implementation, the width of the first shoulder 81 can be equal to or less than the width of the second shoulder 82. Optionally, if the width of the first shoulder 81 is less than the width of the second shoulder 82, it facilitates the extrusion layer 2 inside the photovoltaic module to be pressed into the groove structure 8 from the outside of the first shoulder 81 when the photovoltaic glass is applied to the photovoltaic module for lamination, thereby forming an adhesive force between the first shoulder 81 and the second shoulder 82. In specific implementation, the first shoulder 81 or both the first shoulder 81 and the second shoulder 82 can be cut or ground from the inside out and simultaneously from the first shoulder 81 to the second shoulder 82 at an angle, so that the outer edge of the first shoulder 81 is cut off or ground away, thereby making the width of the first shoulder 81 less than the width of the second shoulder 82. The first shoulder 81 and the second shoulder 82 are chamfered at their outer edges by cutting or grinding.

[0046] In one embodiment, the width W of the second region 20 is 2mm to 15mm. The width W2 of the second shoulder 82 is less than or equal to the width W of the second region 20, and the width W2 of the second shoulder 82 can be 1-10mm, for example, 1mm, 2mm, 3mm, 4mm, 5mm, 6mm, 7mm, 8mm, 9mm, or 10mm. The width W1 of the first shoulder 81 can be 1-10mm, for example, 1mm, 2mm, 3mm, 4mm, 5mm, 6mm, 7mm, 8mm, 9mm, or 10mm.

[0047] In this embodiment of the invention, after the photovoltaic glass has a groove structure 8 opened on the side of the edge sealing area, the edge photovoltaic glass is divided into two thinned layers by the groove structure 8 (i.e., a first shoulder 81 and a second shoulder 82 located on opposite sides of the groove structure 8 in the thickness direction). The encapsulation material / sealing material is filled into the groove structure 8 after lamination. On the one hand, the rebound force of the thinned first shoulder 81 and second shoulder 82 is reduced compared to the photovoltaic glass of the whole thickness, making it easier to maintain the structural stability of the photovoltaic module under the action of the encapsulation material / sealing material. On the other hand, the encapsulation material / sealing material between the glass cover plate 1 and the glass back plate 4 of the photovoltaic module can hold the first shoulder 81 of each other, and the encapsulation material / sealing material in the middle of the groove structure 8 can hold the contacting second shoulder 82, so that the encapsulation material / sealing material can better hold the photovoltaic glass cover plate 1 and the back plate 4 as a whole, thereby solving the problems of edge rebound, delamination and poor sealing effect of conventional double-glass photovoltaic modules.

[0048] In one embodiment, the thickness of the second shoulder 82 is greater than the thickness of the first shoulder 81. When photovoltaic glass is applied to a photovoltaic module, the first shoulder 81 is close to the cell array, and the second shoulder 82 is far from the cell array. As a protective layer for the photovoltaic module to withstand stress, setting the thickness of the second shoulder 82 to be greater than the thickness of the first shoulder 81 can enhance the strength of the second shoulder 82, thereby improving the stress-bearing capacity of the photovoltaic module.

[0049] In one embodiment, the thickness d1 of the first shoulder 81 is 20%-25% of the total thickness of the second region 20 (the total thickness of the second region 20 is the sum of the thickness d1 of the first shoulder 81, the thickness d2 of the second shoulder 82, and the height h of the groove structure 8), for example, 20%, 21%, 22%, 23%, 24%, 25%; the height h of the groove structure 8 is 20%-25% of the total thickness of the second region 20, for example, 20%, 21%, 22%, 23%, 24%, 25%; and the thickness d2 of the second shoulder 82 is 50%-60% of the total thickness of the second region 20, for example, 50%, 51%, 52%, 53%, 54%, 55%, 56%, 57%, 58%, 59%, 60%.

[0050] In one embodiment, such as Figure 3 and Figure 4 As shown, the thickness of the second region 20 is greater than or equal to the thickness of the first region 10. As mentioned above, the groove structure 8 reduces the edge strength of the photovoltaic glass. By increasing the thickness of the second region 20 with the groove structure, the reduction in strength of the second region 20 due to the groove structure 8 at the edge can be compensated, thereby improving the edge strength of the photovoltaic glass. Specifically, the portion of the second region 20 higher than the first region 10 is located on one side in the thickness direction of the photovoltaic glass, such that the second region 20 has a flush portion 30 flush with the first region 10 and a protruding portion 40 protruding from the first region on one side in the thickness direction of the photovoltaic glass. The groove structure 8 is provided on the protruding portion 40. The thickness of the second shoulder 82 located on the other side of the groove structure 8 can be greater than or equal to the thickness of the first region 10, so that even if the groove structure 8 is provided, the strength of the second region 20 can be at least equal to or greater than the strength of the first region 10.

[0051] According to one embodiment of the present invention, the thickness difference d between the thickness of the second region 20 and the thickness of the first region 10 can be 50%-100% of the thickness of the first region 10, for example, 50%, 60%, 70%, 80%, 90%, or 100%.

[0052] In one embodiment, the thickness of the second shoulder 82 is greater than the thickness of the first shoulder 81. When photovoltaic glass is applied to a photovoltaic module, the first shoulder 81 is close to the cell array, and the second shoulder 82 is far from the cell array. As a protective layer for the photovoltaic module to withstand stress, setting the thickness of the second shoulder 82 to be greater than the thickness of the first shoulder 81 can enhance the strength of the second shoulder 82, thereby improving the stress-bearing capacity of the photovoltaic module.

[0053] In one embodiment, the thickness of the first shoulder 81 is 20%-25% of the total thickness of the second region 20, for example, 20%, 21%, 22%, 23%, 24%, 25%; the thickness of the groove structure 8 is 20%-25% of the total thickness of the second region 20, for example, 20%, 21%, 22%, 23%, 24%, 25%; and the thickness of the second shoulder 82 is 50%-60% of the total thickness of the second region 20, for example, 50%, 51%, 52%, 53%, 54%, 55%, 56%, 57%, 58%, 59%, 60%.

[0054] In one embodiment, such as Figure 5 and Figure 6 The second shoulder 82 has an inset groove 9 recessed in a direction away from the groove structure 8 on the inner wall facing the groove structure 8. In one embodiment, there may be multiple inset grooves 9, which are spaced apart from each other along the width direction of the second shoulder 82. Specifically, each inset groove 9 has the same profile as the second region 20. Figure 7 The view shown is a top view after removing the first shoulder 81, see reference. Figure 7 The recessed groove 9 has the same outline as the second region 20 and the first region 10, for example, it can be rectangular. It is understood that when the photovoltaic module is of other shapes, the first region 10 and the second region 20 can have the same outline shape as the photovoltaic module, and correspondingly, the recessed groove 9 can also have the same outline shape.

[0055] like Figure 5 As shown, the cross-section of the embedded groove 9 is a parallelogram; as Figure 6 As shown, the cross-section of the embedded groove 9 is an isosceles trapezoid. In other embodiments of this utility model, the cross-section of the embedded groove 9 can also be other shapes, such as one or more combinations of rectangles, squares, arcs, and triangles. By opening the embedded groove 9 in the inner wall of the second shoulder 82, the contact area between the groove structure 8 and the encapsulation / sealing material can be further increased, thereby further improving the adhesion and enhancing the structural stability and sealing effect of the photovoltaic module.

[0056] In the specific implementation process, in order to ensure the process yield of photovoltaic modules, the depth d3 of the embedded groove 9 can be set to be 15%-30% of the thickness d2 of the second shoulder 82, for example, 15%, 16%, 18%, 20%, 22%, 24%, 26%, 28%, 29%, 30%.

[0057] An embodiment of this utility model also provides a photovoltaic module, including a cover plate 1, a back plate 4, an encapsulation layer 2, and a battery layer 3. The encapsulation layer 2 is used to encapsulate the battery layer 3 between the cover plate 1 and the back plate 4. The cover plate 1 and the back plate 4 are photovoltaic glass as described above. The first region 10 and the second region 20 included in the cover plate 1 correspond to the first region 10 and the second region 20 included in the back plate 4, respectively. The first shoulder 81 of the cover plate 1 and the first shoulder 81 of the back plate 4 are close to the battery layer 3 of the photovoltaic module, and the second shoulder 82 of the cover plate 1 and the second shoulder 82 of the back plate 4 are far away from the battery layer 3 of the photovoltaic module. The encapsulation layer 2 includes a first encapsulation layer 21 located in the first region corresponding to the cover plate 1 and the back plate 4 and a second encapsulation layer 22 located in the second region corresponding to the cover plate 1 and the back plate 4. The second encapsulation layer 22 extends between the first shoulder 81 of the cover plate 1 and the first shoulder 81 of the back plate 4, and into the groove structure 8 of the cover plate 1 and the groove structure 8 of the back plate 4.

[0058] The first region 10 of the cover plate 1 and the back plate 4 corresponds to the battery layer 3 at least completely. That is, the area of ​​the first region 10 is equal to the area of ​​the battery layer 3 so that it can just cover the battery layer 3, or the area of ​​the first region 10 is greater than the area of ​​the battery layer 3 so that the edge connecting the first region 10 and the edge 20 of the second region does not cover the battery layer 3, thus protecting the battery layer 3.

[0059] The third layer of the battery can be a silicon-based battery, a heterojunction battery, a perovskite battery, etc.

[0060] Figure 8 To utilize Figure 1 and Figure 2 The photovoltaic module formed by the photovoltaic glass shown is Figure 9 To utilize Figure 3 and Figure 4 The photovoltaic module formed by the photovoltaic glass shown. Figure 10 To utilize Figure 5 The photovoltaic module formed by the photovoltaic glass shown. Figure 11 To utilize Figure 6 The photovoltaic module shown is formed from photovoltaic glass. It should be noted that... Figures 8-11 The photovoltaic module shown is illustrated only by way of example, showing the structure of one edge. It should be understood that the same structure exists on the corresponding other edge.

[0061] According to the embodiments of this application, after the photovoltaic module undergoes the DH3000h aging test, there is no water vapor intrusion at the edge of the module, no delamination at the edge, and the EL (electroluminescent tester) of the edge cells is normal; after the TC600 aging test, there is no delamination at the edge, the EL of the edge cells is normal, and the average change in edge thickness before and after aging is within 0.05mm.

[0062] The DH3000 component test is a specific durability test used to evaluate the component's performance under specific environmental conditions. The specific process is as follows:

[0063] The modules were exposed to 85±2℃ and 85±5% relative humidity for 3000 hours. They were then allowed to recover in 2-4 hours at 23±5℃ and relative humidity not exceeding 75%.

[0064] The TC600 test is a thermal cycling test for photovoltaic modules, and the specific process is as follows:

[0065] The components were placed in an environmental chamber, and the temperature inside the chamber was controlled to cycle between 85°C and -40°C 600 times.

[0066] Conventional photovoltaic glass uses conventional encapsulant films, such as EVA (Ethylene Vinyl Acetate Copolymer), POE (Polyolefin Elastomer), EPE (Pearl Cotton), and PVB (Polyvinyl Butyral), at the same width as the photovoltaic glass in the embodiment of this application. After lamination, the peel force tested is 30-50N. However, the photovoltaic glass according to the embodiment of this application uses the same encapsulant film in the second region 20. After lamination, the peel force tested is 150-320N. Therefore, the peel force at the edge of the photovoltaic module according to the embodiment of this application is improved.

[0067] In one embodiment, the first encapsulation layer 21 and the second encapsulation layer 22 are made of the same material. Specifically, the first encapsulation layer 21 is one or more of EVA film, POE film, PVB film, and EPE film, and / or the second encapsulation layer 22 is one or more of EVA film, POE film, PVB film, and EPE film.

[0068] The photovoltaic modules described above can be fabricated using a lamination method, for example, including the following steps:

[0069] S1. A pre-sealing film is laid on the cover plate 1. The pre-sealing film covers the first region 10 and the second region 20. The pre-sealing film is one or more of EVA film, POE film, PVB film and EPE film.

[0070] S2. A battery layer 3 is laid on the front encapsulation film. The battery layer 3 corresponds to the first region 10. The battery layer 3 can be a battery array formed by silicon-based battery cells connected in series and / or parallel.

[0071] S3. Lay out the encapsulating film, which covers the first region 10 and the second region 20. The encapsulating film is one or more of EVA film, POE film, PVB film, and EPE film.

[0072] S4, Lay the back panel 4;

[0073] S5. After lamination, a laminate is formed, and the front encapsulation film and the rear encapsulation film form the encapsulation layer 2.

[0074] S6. The laminated components are framed and fitted with junction boxes to obtain the photovoltaic module of this application embodiment.

[0075] The cover plate 1 and the back plate 4 are the aforementioned photovoltaic glass. The lamination process is the same as that in the prior art and can be performed using the lamination parameters in the prior art.

[0076] In one embodiment, the first encapsulation layer 21 and the second encapsulation layer 22 are made of different materials. The first encapsulation layer 21 is a liquid encapsulation oil, and / or the second material is one or more of butyl rubber, silicone, and epoxy resin. The liquid encapsulation oil can be one or more of natural ester insulating oil, synthetic ester transformer oil, and low-viscosity bio-based transformer oil.

[0077] The photovoltaic modules described above can be manufactured using the photovoltaic module manufacturing method according to the embodiments of this application. Please refer to... Figure 17 The method for preparing a photovoltaic module according to an embodiment of this application includes:

[0078] Step 1: Lay one of the cover plate 1 or the back plate 4, where the cover plate 1 and the back plate 4 are the photovoltaic glass described above, with the first shoulder 81 of the cover plate 1 or the back plate 4 facing upwards.

[0079] Step 2: Lay the battery layer 3 in the first area 10 of the cover plate 1 or back plate 4.

[0080] Step 3: Lay the second encapsulation layer 22 on the second area 20 of the cover plate 1 or back plate 4;

[0081] Step 4: Lay the backing plate 4 or the cover plate 1 and perform pre-lamination to seal the second region 20 of the cover plate 1 and the second region 20 of the backing plate 4. The pre-lamination temperature is 70-90℃.

[0082] Step 5: Inject liquid encapsulation oil into the space enclosed by the first region 10 of the cover plate 1 and the first region 10 of the back plate 4 to form the first encapsulation layer 21, and finally form a photovoltaic module.

[0083] In step 1, a cover plate 1 can be laid, and in step 4, a back plate 4 can be laid; alternatively, in step 1, a back plate 4 can be laid, and in step 4, a cover plate 1 can be laid.

[0084] The battery layer 3 mentioned in step 2 can be a battery array formed by connecting silicon-based battery cells in series or parallel, or it can be a perovskite battery. If the battery layer 3 is a perovskite battery, a transparent conductive layer 31, a hole transport layer 32, a perovskite photoelectric conversion layer 33, an electron transport layer 34, and a back electrode 35 can be sequentially laid.

[0085] According to the photovoltaic module of the present application embodiment, the groove structure 8 of the second region 20 of the photovoltaic glass can enhance the sealing and peel force of the photovoltaic module edge, so that the first region 10 of the photovoltaic module can be encapsulated with liquid encapsulation oil. Compared with the conventional process of forming the encapsulation layer 2 by high temperature lamination, the preparation temperature can be reduced, and the heat damage caused by high temperature can be reduced.

[0086] The encapsulation liquid used in the first encapsulation layer 21 is, for example, liquid encapsulation oil, which has the characteristics of high light transmittance, recyclability, and high thermal conductivity. At the same time, since water and oil are immiscible, even if water vapor intrudes due to particularly harsh extreme environments or damage to the encapsulation film, it will only form droplets that accumulate at the edge area of ​​the photovoltaic module and will not come into contact with the battery layer 3, thus solving the problem of existing photovoltaic modules being susceptible to moisture.

[0087] like Figure 12 As shown, the first photovoltaic module of this utility model, prepared according to the above-described method using liquid encapsulation oil, has a battery layer 3 formed by a series / parallel connection of silicon-based battery cells in the photovoltaic module. The photovoltaic module also includes a battery support structure 5, which is located within the cavity formed by the first region 10 of the cover plate 1 and the first region 10 of the back plate 4, and is surrounded by the encapsulation layer 2. The battery support structure 5 is embedded in the encapsulation layer 2 and abuts against the cover plate 1 and the back plate 4. The battery support structure 5 fixes and supports the battery layer 3. Specifically, in this embodiment, the battery support structure 5 is surrounded by and embedded in the first encapsulation layer 21.

[0088] In one embodiment of this utility model, the battery support structure 5 includes a partition layer 51 and a stacked main support layer 52 and a bottom adhesive layer 53; the bottom adhesive layer 53 is disposed between the main support layer 52 and the back plate 4, and is used to fix the main support layer 52 to the back plate 4; the partition layer 51 divides the plane of the main support layer 52 into two or four isolation areas and abuts against the cover plate 1; each isolation area is used to support one corner of a battery string in the battery layer 3. Figure 13 As shown, the main support layer 52 and the bottom adhesive layer 53 of the battery support structure 5 are cylindrical. The bottom adhesive layer 53 is fixed to the back plate 4 by its own adhesiveness, and the separator layer 51 abuts against the cover plate 1. The separator layer 51 of the battery support structure 5 divides the plane of the main support layer 52 into four isolation areas by the four edges. Each isolation area supports one corner of a battery string in the battery layer 3, thereby achieving the fixation of the battery layer 3. In specific implementations, the bottom adhesive layer 53 can be a pressure-sensitive adhesive or a heat-adhesive film.

[0089] Figure 15 A second photovoltaic module according to the above-described embodiment of the present invention, prepared using liquid encapsulation oil, is shown. Its cell layer 3 is a perovskite solar cell. Accordingly, during the encapsulation of the photovoltaic module, a second encapsulation layer 21 is used to pre-encapsulate the second region 20 of the cover plate 1 and the back plate 4, forming a sealed cavity between the first region 10 of the cover plate 1 and the first region 10 of the back plate 4. After the cell layer 3 is laid in this region, liquid encapsulation oil is used for encapsulation. That is, the encapsulation layer 2 of the second photovoltaic module includes a first encapsulation layer 21 located in the first region 10 and a second encapsulation layer 22 located in the second region 20. The sealing material used in the second encapsulation layer 22 is, for example, one or a combination of the following materials: high water-resistant butyl rubber, silicone adhesives, epoxy or other polymeric adhesives, and inorganic adhesives, possessing characteristics such as recyclability, resistance to moisture, and good heat dissipation. The encapsulation liquid used in the first encapsulation layer 21 is a liquid encapsulation oil, such as one or more of natural ester insulating oil, synthetic ester transformer oil, and low-viscosity bio-based transformer oil.

[0090] like Figure 16 As shown, the third type of photovoltaic module uses a perovskite solar cell as its cell layer 3, comprising a transparent conductive layer 31, a hole transport layer 32, a perovskite photoelectric conversion layer 33, an electron transport layer 34, and a back electrode 35 stacked sequentially. The transparent conductive layer 31 of the perovskite solar cell is in contact with the cover plate 1. The pre-lamination process uses a low-temperature lamination process of 70~90℃, which significantly improves the thermal damage during the perovskite photovoltaic module manufacturing process. The CTM (temperature coefficient module of a photovoltaic module, used to describe the performance of a photovoltaic module under different temperature conditions) is 1% higher than that of conventional perovskite solar cell photovoltaic modules encapsulated with encapsulants.

[0091] The photovoltaic module of this utility model and its preparation process are described in detail below with reference to specific embodiments.

[0092] Example 1:

[0093] A photovoltaic module, such as a double-glass module of PERC (Passivated Emitter and Rear Cell), TOPCon (Tunnel Oxide Passivated Contact), HJT (Heterojunction with Intrinsic Thin-layer), BC (Back Contact), and their tandem cells, uses... Figure 1 and Figure 3 The photovoltaic glass shown is used to make photovoltaic modules. A schematic diagram of the photovoltaic module structure is shown below. Figure 8 and Figure 9 As shown. Among them, Figure 9 The thickness difference between the second region 20 of the cover plate 1 and the first region 10, and the thickness difference between the second region 20 of the back plate 4 and the first region 10, are both 0.4 mm. The width of the second region 20 of the cover plate 1 and the second region 20 of the back plate 4 is 12 mm. A groove structure 8 is provided on its side, with a height of 0.2 mm. The width of the first shoulder 81 is 6 mm, and the width difference between the second shoulder 82 and the width of the first shoulder 81 of the groove structure 8 is 3 mm. The width of the second shoulder 82 is 9 mm. The conventional encapsulation film used in this photovoltaic module is, for example, 460 g EVA plastic. After lamination, the thickness of the first encapsulation layer 21 in the cavity formed by the first region 10 of the cover plate 1 and the first region 10 of the back plate 4 is 1.1 mm. The thickness of the second encapsulation layer 22 at the thickened position between the second region 20 of the cover plate 1 and the second region 20 of the back plate 4 is between 0.1 mm and 0.25 mm. The photovoltaic module has a normal appearance. Figure 8The photovoltaic glass edges are not thickened; only a groove structure 8 is formed on its side. The height of the groove structure 8 is 0.2 mm, the width of the first shoulder 81 is 6 mm, the width difference between the second shoulder 82 and the width of the first shoulder 81 is 3 mm, and the width of the second shoulder 82 is 9 mm. The conventional encapsulating film used in this photovoltaic module is, for example, 460-gram EVA plastic. After lamination, the thickness of the first encapsulation layer 21 in the cavity formed by the first region 10 of the cover plate 1 and the first region 10 of the back plate 4 is 1.08 mm, and the thickness of the second encapsulation layer 22 at the thickened position between the second region 20 of the cover plate 1 and the second region 20 of the back plate 4 is between 0.78 mm and 1.0 mm. The photovoltaic module appears normal. Figure 8 and Figure 9 After the photovoltaic modules underwent the DH3000h aging test, there was no water vapor intrusion at the edge of the modules, no delamination at the edge, and the EL (electroluminescent) of the edge cells was normal. After the TC600 aging test, there was no delamination at the edge of the modules, the EL of the edge cells was normal, and the average change in edge thickness before and after aging was within 0.05mm.

[0094] The specific manufacturing method of the photovoltaic module mentioned above mainly includes the following steps:

[0095] S1. Prepare a cover plate 1 and a back plate 4 with groove structures 8 on their sides;

[0096] S2. Lay a sealing film on the cover plate 1;

[0097] S3. Lay a battery layer 3 consisting of several battery strings on the upper encapsulation film;

[0098] S4. Lay the lower encapsulation film on the upper layer of battery layer 3;

[0099] S5. Lay backing plate 4 on the upper layer of the lower encapsulating film to form a laminated structure;

[0100] S6. The above-mentioned laminated structure is laminated to obtain a laminated part. At this time, the upper and lower encapsulating films are squeezed to form the encapsulation layer 2.

[0101] S7. Perform framing and junction box installation to obtain photovoltaic modules.

[0102] In the manufacturing process of the photovoltaic module in this embodiment, for Figure 8 The photovoltaic module shown can have its encapsulating film applied to the entire area of ​​the cover plate 1 and the back sheet 4; for Figure 9The photovoltaic module shown can be encapsulated only in the cavity formed by the first region 10 of the cover plate 1 and the first region 10 of the back plate 4. After lamination, the encapsulated film is squeezed and covers the space between the second region 20 of the cover plate 1 and the second region 20 of the back plate 4 and the groove structure 8.

[0103] Example 2:

[0104] The first type of photovoltaic module is a liquid-encapsulated photovoltaic module, which can be a double-glass module of PERC, TOPCon, HJT, BC and their tandem cells. A schematic diagram of the structure of this photovoltaic module is shown below. Figure 12 As shown. Among them, Figure 12 The thickness difference between the second region 20 of the cover plate 1 and the first region 10, and the thickness difference between the second region 20 of the back plate 4 and the first region 10, are both 0.5 mm. The width of the second region 20 of the cover plate 1 and the second region 20 of the back plate 4 are both 15 mm. A groove structure 8 is provided on its side, and the height of the groove structure 8 is 0.3 mm. The width of the first shoulder 81 is 6 mm. The width difference between the width of the second shoulder 82 and the width of the first shoulder 81 of the groove structure 8 is 4 mm. The width of the second shoulder 82 is 10 mm. When the photovoltaic module is encapsulated, the encapsulation layer 2 includes a first encapsulation layer 21 located within the cavity formed by the first region 10 of the cover plate 1 and the first region 10 of the back plate 4, and a second encapsulation layer 22 located between the second region 20 of the cover plate 1 and the second region 20 of the back plate 4 and at the edge of the cavity. The first encapsulation layer 21 is encapsulated using an encapsulation liquid, which is a liquid encapsulation oil, such as an insulating and pressure-resistant oil. The second encapsulation layer 22 uses a 1.5mm thick encapsulation film as a sealing material. In this embodiment, the sealing material is a high-strength structural adhesive and butyl rubber.

[0105] Inside the photovoltaic module, a battery support structure 5 is installed within the cavity formed by the first region 10 of the cover plate 1 and the first region 10 of the backplate 4. The battery support structure 5 includes a separator layer 51, a stacked main support layer 52, and a bottom adhesive layer 53. The bottom adhesive layer 53 and the main support layer 52 are cylindrical. The bottom adhesive layer 53 of the battery support structure 5 is fixed to the backplate 4 by its own adhesiveness to secure the battery support structure 5. The main support layer 52 supports the four corners of the battery string (e.g.,...). Figure 14 (as shown); the top of the separator 51 abuts against the inside of the cover plate 1, and the four edges of the separator 51 can achieve the effect of fixing the battery string.

[0106] This photovoltaic module uses a low-temperature sealing process, which reduces thermal damage during module manufacturing. The liquid encapsulation oil used has characteristics such as high light transmittance, recyclability, and high thermal conductivity. Furthermore, because water and oil are immiscible, even in particularly harsh extreme environments or if the second encapsulation layer 22 is damaged, leading to moisture intrusion, it will only form droplets that accumulate at the edge of the photovoltaic module and will not contact the cell layer 3, thus solving the problem of existing photovoltaic modules being susceptible to moisture intrusion.

[0107] The specific manufacturing method of the photovoltaic module mentioned above mainly includes the following steps:

[0108] S1. Prepare a cover plate 1 and a back plate 4 with groove structures 8 on their sides;

[0109] S2. Install the battery support structure 5 in the first area 10 of the backplate 4;

[0110] S3. Lay out battery layer 3 based on battery support structure 5;

[0111] S4. A sealing material, namely butyl rubber, is laid in the second region 20 of the cover plate 1.

[0112] S5. Cover the back plate 4 with the edge-heated cover plate 1, and perform pre-lamination processes such as pressing, integration, and flipping to obtain the laminated part.

[0113] S6. Inject liquid sealing oil into the cavity enclosed by the first region 10 of the back plate 4 and the cover plate 1, and plug the oil injection hole.

[0114] S7. Perform framing and junction box installation to obtain photovoltaic modules.

[0115] After undergoing the DH3000h aging test, the photovoltaic module showed no moisture intrusion at the edges, no delamination at the edges, and normal edge cell thickness (EL). After undergoing the TC600 aging test, there was no delamination at the edges, the edge cell thickness (EL) was normal, and the average change in edge thickness before and after aging was within 0.05mm.

[0116] Example 3:

[0117] A second type of photovoltaic module, formed by liquid encapsulation, is a double-glass module consisting of perovskite and its tandem cells. A schematic diagram of the photovoltaic module's structure is shown below. Figure 15 As shown. Among them, Figure 15The thickness difference between the second region 20 of the cover plate 1 and the first region 10, and the thickness difference between the second region 20 of the back plate 4 and the first region 10, are both 0.25 mm. The width of the second region 20 of the cover plate 1 and the second region 20 of the back plate 4 are both 8 mm. A groove structure 8 is provided on its side, the height of the groove structure 8 is 0.4 mm, the width of the first shoulder 81 is 4 mm, the width difference between the second shoulder 82 and the width of the first shoulder 81 of the groove structure 8 is 2 mm, and the width of the second shoulder 82 is 6 mm. When the photovoltaic module is encapsulated, the encapsulation layer 2 includes a first encapsulation layer 21 located in the cavity formed by the first region 10 of the cover plate 1 and the first region 10 of the back plate 4, and a second encapsulation layer 22 located between the second region 20 of the cover plate 1 and the second region 20 of the back plate 4 and at the edge of the cavity. The first encapsulation layer 21 is encapsulated using an encapsulation liquid, which is a liquid encapsulation oil, such as an insulating and pressure-resistant oil. The second encapsulation layer 22 uses an encapsulation film with a width of 15 mm and a thickness of 1 mm as a sealing material. In this embodiment, the sealing material is butyl rubber.

[0118] The specific manufacturing method of the photovoltaic module mentioned above mainly includes the following steps:

[0119] S1. Prepare a cover plate 1 and a back plate 4 with groove structures 8 on their sides;

[0120] S2. Install a cell layer 3 composed of perovskite solar cells on the cover plate 1. The cell structure of the perovskite solar cell includes: a transparent conductive layer 31, a hole transport layer 32, a perovskite photoelectric conversion layer 33, an electron transport layer 34, and a back electrode 35 (e.g., Figure 16 (as shown)

[0121] S3. Apply 15mm wide and 1mm thick butyl rubber to the second region 20 of the cover plate 1;

[0122] S4. Cover with back plate 4, integrate and laminate to obtain laminated part;

[0123] S5. Inject liquid sealing oil and plug the oil injection hole;

[0124] S6. Perform framing and junction box installation to obtain photovoltaic modules.

[0125] In the photovoltaic module manufacturing process of this embodiment, a low-temperature lamination process of 70-90℃ is used to manufacture the module, which significantly improves the thermal damage during the module manufacturing process, and the CTM is improved by 1% compared with conventional encapsulated laminated modules. In addition, an encapsulating film can be used to seal the oil injection hole.

[0126] The above steps are provided only to help understand the method, structure, and core idea of ​​this utility model. For those skilled in the art, various improvements and modifications can be made to this utility model without departing from its principles, and these improvements and modifications also fall within the scope of protection of the claims of this utility model.

Claims

1. A photovoltaic glass, characterized in that, The system includes a first region (10) and a second region (20) extending outward from the first region (10), wherein the first region (10) corresponds at least to the cell layer of the photovoltaic module. The edge of the second region (20) is provided with a groove structure (8) that opens to the side. The width of the first shoulder (81) on one side of the groove structure (8) in the thickness direction of the photovoltaic glass is equal to or less than the width of the second shoulder (82) on the opposite side of the groove structure (8) in the thickness direction of the photovoltaic glass, and the width of the second shoulder (82) is less than or equal to the width of the second region (20).

2. Photovoltaic glass according to claim 1, characterized in that The thickness of the second region (20) is greater than or equal to the thickness of the first region (10), such that the second region (20) has a flush portion (30) that is flush with the first region (10) and a protrusion (40) that protrudes from the first region (10) on one side in the thickness direction of the photovoltaic glass, and the groove structure (8) is provided on the protrusion (40).

3. Photovoltaic glass according to claim 1, characterized in that The thickness of the second shoulder (82) is greater than the thickness of the first shoulder (81).

4. The photovoltaic glass according to claim 1, characterized in that, The second shoulder (82) has an inset groove (9) that is recessed in a direction away from the groove structure (8) on the inner wall facing the groove structure (8).

5. The photovoltaic glass according to claim 1, characterized in that, The width of the first shoulder (81) is 1mm-10mm, and the width of the second shoulder (82) is 1mm-10mm; And / or, The width of the second region (20) is 2mm-15mm.

6. The photovoltaic glass according to claim 1 or 2, characterized in that, The thickness of the first shoulder (81) is 20%-25% of the total thickness of the second region (20); The thickness of the groove structure (8) is 20%-25% of the total thickness of the second region (20); The thickness of the second shoulder (82) is 50%-60% of the total thickness of the second region (20).

7. The photovoltaic glass according to claim 4, characterized in that, The depth of the inset groove (9) is 15%-30% of the thickness of the second shoulder (82).

8. A photovoltaic module, characterized by, The system includes a cover plate (1), a back plate (4), an encapsulation layer (2), and a battery layer (3). The encapsulation layer (2) is used to encapsulate the battery layer (3) between the cover plate (1) and the back plate (4). The cover plate (1) and the back plate (4) are photovoltaic glass according to any one of claims 1-7. The first region (10) and the second region (20) included in the cover plate (1) correspond to the first region (10) and the second region (20) included in the back plate (4), respectively. The first shoulder (81) of the cover plate (1) and the first shoulder (81) of the back plate (4) are close to the battery layer (3) of the photovoltaic module, and the second shoulder (82) of the cover plate (1) and the second shoulder (82) of the back plate (4) are far away from the battery layer (3) of the photovoltaic module. The encapsulation layer (2) includes a first encapsulation layer (21) located in the first region (10) corresponding to the cover plate (1) and the back plate (4) and a second encapsulation layer (22) located in the second region (20) corresponding to the cover plate (1) and the back plate (4). The second encapsulation layer (22) extends between the first shoulder (81) of the cover plate (1) and the first shoulder (81) of the back plate (4), the groove structure (8) of the cover plate (1), and the groove structure (8) of the back plate (4).

Images