A novel photovoltaic module

Abstract

The application discloses a novel photovoltaic module. The novel photovoltaic module comprises a photovoltaic cell laminate and a steel back plate, wherein the surface of the steel back plate is covered with a glaze layer, and the outer peripheral dimension is larger than that of the photovoltaic cell laminate, thereby providing better protection and support. The upper and lower surfaces of the photovoltaic cell are both encapsulated with an encapsulating material, thereby improving the protection performance. The front cover glass is arranged on the light-receiving side of the photovoltaic cell, and the steel back plate is arranged on the back light side. The design of the application not only improves the structural stability and durability of the module, but also enhances the heat dissipation effect, thereby improving the power generation efficiency and service life, and reducing the requirement for an additional frame, thereby reducing the cost and installation complexity.

Description

Technical Field

[0001] This application relates to the field of semiconductor technology, specifically to a novel photovoltaic module. Background Technology

[0002] Traditional photovoltaic (PV) modules typically use glass backsheets, requiring an additional frame for fixation and support. However, this design presents several problems: First, glass backsheets are fragile and difficult to recycle, often requiring shredding for disposal, leading to significant resource waste. Second, traditional modules have poor heat dissipation; the heat generated during operation is difficult to dissipate in time, causing the module temperature to rise and affecting power generation efficiency and lifespan. Furthermore, traditional module frames require additional installation, increasing cost and installation complexity. In summary, these factors have constrained the development and application of new PV modules. Utility Model Content

[0003] To address the aforementioned issues, this application provides a novel photovoltaic module with a novel photovoltaic module backsheet material that is not easily broken, is easy to recycle, and has excellent heat dissipation performance, thereby reducing installation costs and complexity, and improving power generation efficiency and service life.

[0004] The embodiments of this application disclose the following technical solutions:

[0005] A novel photovoltaic module includes: a photovoltaic cell laminate and a steel backsheet; the photovoltaic cell laminate includes a front cover glass and a photovoltaic cell; the surface of the steel backsheet is covered with a glaze layer; the outer perimeter of the steel backsheet is larger than the outer perimeter of the photovoltaic cell laminate; both the upper and lower surfaces of the photovoltaic cell are encapsulated with encapsulation material; the front cover glass is disposed on the light-receiving side of the photovoltaic cell, and the steel backsheet is disposed on the backlighting side of the photovoltaic cell.

[0006] In one possible implementation, the thickness of the glaze layer is 0.1-0.5 mm, and the material of the glaze layer is a high-temperature resistant ceramic glaze.

[0007] In one possible implementation, the steel backing plate has a thickness of 1-3 mm.

[0008] In one possible implementation, the steel back plate has a mounting hole extending through the thickness direction, the inner diameter of the mounting hole is 8-12 mm, and the inner wall of the mounting hole is provided with a threaded structure, the mounting hole being used to connect a support component.

[0009] In one possible implementation, the encapsulation material is an adhesive film with a thickness of 0.5-0.8 mm; the steel backplate and the photovoltaic cell are bonded and fixed together by the adhesive film.

[0010] In one possible implementation, the outer perimeter of the steel backplate is at least 3 cm larger than the outer perimeter of the photovoltaic cell laminate.

[0011] In one possible implementation, the glaze layer is prepared by a spraying process and then sintered at a high temperature of 600 degrees Celsius.

[0012] In one possible implementation, a waterproof strip is provided between the periphery of the photovoltaic cell laminate and the steel back plate. The waterproof strip has a rectangular cross-section and forms a sealed connection with the steel back plate and the periphery of the photovoltaic cell laminate.

[0013] In one possible implementation, the surface of the steel back plate and the inner wall of the mounting hole are covered with an anti-rust coating, the thickness of which is 5-15 micrometers.

[0014] In one possible implementation, the glaze surface of the steel back plate is provided with a heat dissipation coating, the thickness of which is 20-50 micrometers.

[0015] Compared with the prior art, this application has the following beneficial effects:

[0016] This application provides a novel photovoltaic module. Specifically, the novel photovoltaic module includes a photovoltaic cell laminate and a steel backsheet. The photovoltaic cell laminate includes a front cover glass and photovoltaic cells, ensuring the module's light-receiving performance. The steel backsheet is covered with a glaze layer, which not only improves the backsheet's corrosion resistance and aesthetics but also enhances its mechanical strength and durability. The outer perimeter of the backsheet is larger than that of the photovoltaic cell laminate, which facilitates stable structural support, allowing the module to be fixed without an additional frame. Simultaneously, both the upper and lower surfaces of the photovoltaic cells are encapsulated with encapsulation material, effectively protecting the cells from environmental influences and improving the module's sealing and durability. In the overall structure, the front cover glass is located on the light-receiving side, ensuring light transmittance, while the steel backsheet is positioned on the backlight side, providing robust rear support for the module, achieving a novel photovoltaic module design that is efficient, reliable, and structurally simple. This application's novel photovoltaic module, by employing a steel backsheet with a glaze layer, significantly improves structural strength and durability, reducing the risk of damage during transportation and installation. Meanwhile, the excellent heat dissipation performance of the steel backsheet helps accelerate heat release, reduce module temperature, and thus improve power generation efficiency and extend service life. Furthermore, the steel backsheet is larger than the photovoltaic cell laminate, achieving stable support without the need for an additional frame, simplifying structural design and reducing manufacturing and installation costs. The optimized configuration of the top and bottom encapsulated materials and the front cover glass further ensures the module's sealing and protective performance. These improvements effectively overcome the shortcomings of traditional designs, such as fragility, poor heat dissipation, and complex installation, promoting the improvement of photovoltaic module performance and the development of its applications. Attached Figure Description

[0017] To more clearly illustrate the technical solutions in this embodiment or the prior art, the drawings used in the description of the embodiment or the prior art will be briefly introduced below. Obviously, the drawings described below are only some embodiments of this application. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.

[0018] Figure 1 This is a schematic diagram of the structure of a conventional photovoltaic module provided in an embodiment of this application;

[0019] Figure 2 This is a schematic diagram of the structure of a novel photovoltaic module provided in an embodiment of this application. Detailed Implementation

[0020] To facilitate understanding of the technical solutions provided in the embodiments of this application, the background technology involved in the embodiments of this application will be described below.

[0021] Traditional photovoltaic modules consist of multiple parts, such as Figure 1 As shown, a photovoltaic module includes a frame, front cover glass, encapsulation materials, solar cells, backsheet, and junction box, with the backsheet typically made of glass. To ensure the stability and safety of the module, this type of backsheet requires an additional frame for fixation and support. However, this design has several significant drawbacks. First, the glass backsheet itself is relatively fragile and easily broken during transportation and installation, leading to an increased product scrap rate. Simultaneously, glass faces significant challenges in recycling; conventional processing often involves crushing, preventing the effective reuse of a large amount of usable resources and resulting in serious resource waste. Second, the overall structure of traditional photovoltaic modules restricts effective heat dissipation. The heat generated during normal operation is difficult to release quickly, causing the module surface temperature to rise, which not only reduces power generation efficiency but also shortens its lifespan. Furthermore, the external frame required to fix the glass backsheet increases production costs and installation complexity, affecting construction efficiency. In summary, the fragility and difficulty in recycling of glass backsheets, insufficient heat dissipation performance, and the cost and installation challenges brought by additional frames are all key bottlenecks restricting the performance improvement and market promotion of traditional photovoltaic modules.

[0022] To address this issue, this application provides a novel photovoltaic module, comprising a photovoltaic cell laminate and a steel backsheet. The photovoltaic cell laminate includes photovoltaic cells with encapsulation material on both upper and lower surfaces, and a front cover glass disposed on the light-receiving side of the photovoltaic cells. The steel backsheet is disposed on the back-lighting side of the photovoltaic cells, and its outer perimeter is larger than that of the photovoltaic cell laminate. The steel backsheet is also covered with a glaze layer. This novel photovoltaic module, by employing a steel backsheet with a glaze layer, significantly improves the mechanical strength and durability of the backsheet, reducing the risk of breakage during transportation and installation. Furthermore, the excellent heat dissipation performance of steel effectively promotes the timely release of heat from the module, reducing operating temperature and thus improving power generation efficiency and extending service life. Simultaneously, because the outer perimeter of the steel backsheet is larger than that of the photovoltaic cell laminate, the module can be stably supported without an additional frame, simplifying structural design and significantly reducing manufacturing and installation costs. In addition, with encapsulation material on both upper and lower surfaces of the photovoltaic cells and the front cover glass strategically positioned on the light-receiving side, the overall encapsulation system enhances the module's sealing and protective performance. In summary, this new photovoltaic module overcomes many shortcomings of traditional designs, such as fragile glass backsheets, poor heat dissipation, and complex installation, and significantly optimizes the module's performance and application potential.

[0023] The technical solutions of the present invention will be clearly and completely described below with reference to the accompanying drawings of the embodiments. Obviously, the described embodiments are only some embodiments of this application, and not all embodiments. Based on the embodiments of this application, all other embodiments obtained by those of ordinary skill in the art without creative effort are within the scope of protection of this application.

[0024] See Figure 2 , Figure 2 This is a schematic diagram of the structure of a novel photovoltaic module provided in an embodiment of this application, as shown below. Figure 2 As shown, the component mainly consists of photovoltaic cell laminates and a steel backsheet.

[0025] The photovoltaic cell laminate includes a front cover glass on the light-receiving side and the photovoltaic cell immediately behind it. The front cover glass is responsible for ensuring sufficient sunlight transmission to the cell, improving power generation efficiency. Both the upper and lower surfaces of the photovoltaic cell are covered with encapsulation material. This double-sided encapsulation effectively protects the cell from external environmental factors such as moisture, dust, and mechanical impact, enhancing the durability and reliability of the module.

[0026] The steel backsheet is coated with a glaze, which not only enhances its corrosion resistance and aesthetics but also strengthens its mechanical properties, making it more stable and durable over long-term use. Notably, the outer circumference of the steel backsheet is larger than that of the photovoltaic cell laminate. This design allows the backsheet to completely enclose and support the photovoltaic cell laminate without relying on additional frames for fixation, thus simplifying the module structure and reducing manufacturing and installation costs. Furthermore, located on the back side of the photovoltaic cells, the steel backsheet serves both as structural support and helps dissipate heat generated during module operation, effectively improving heat dissipation performance and ensuring the module's power generation efficiency and lifespan.

[0027] Overall, this new photovoltaic module achieves an organic combination of high strength, high protection, and excellent heat dissipation through reasonable material selection and structural design, providing strong support for improving the performance and application promotion of photovoltaic modules.

[0028] In one possible implementation, the glaze covering the surface of the steel backing plate has specific design parameters to ensure its performance and durability. Specifically:

[0029] Glaze thickness: The glaze thickness is designed to be 0.1 to 0.5 mm. This range of thickness provides sufficient protection while maintaining reasonable material costs and manufacturing process requirements. Thinner glazes (e.g., 0.1 mm) help control the overall weight of the component, while thicker glazes (e.g., 0.5 mm) provide better abrasion and corrosion resistance.

[0030] Glaze Material: The glaze layer uses high-temperature resistant ceramic glaze. This material not only has excellent high-temperature resistance, remaining stable at the high temperatures generated during photovoltaic module operation, but also exhibits excellent chemical stability and corrosion resistance. The high-temperature resistant ceramic glaze can resist the effects of environmental factors such as ultraviolet radiation, acids, and alkalis, extending the service life of the steel backsheet.

[0031] In summary, by designing the glaze thickness within the range of 0.1 to 0.5 mm and using high-temperature resistant ceramic glaze as the material, the protective performance and durability of the steel backsheet can be effectively improved, ensuring the long-term stable operation of the new photovoltaic modules under various environmental conditions.

[0032] In one possible implementation, the steel backing plate is designed to be 1 to 3 millimeters thick. This thickness range offers several advantages:

[0033] Mechanical strength: The steel backsheet with a thickness between 1 and 3 mm has sufficient mechanical strength to effectively support the photovoltaic cell laminate and resist external impacts and environmental stresses, ensuring the structural stability and durability of the module.

[0034] Heat dissipation performance: Steel has good thermal conductivity, and an appropriate thickness can ensure that heat is efficiently conducted from the photovoltaic cells to the atmosphere, thereby improving power generation efficiency. Thinner steel (e.g., 1 mm) helps dissipate heat faster, while slightly thicker steel (e.g., 3 mm) provides better structural support.

[0035] Cost-effectiveness: Choosing a thickness of 1 to 3 millimeters strikes a balance between material cost and performance. Thinner steel reduces material costs while maintaining the necessary protective and support functions.

[0036] Ease of installation: The appropriate thickness makes the steel backplate easy to process and install, reducing the complexity of the manufacturing and installation process and improving production efficiency.

[0037] In summary, designing the thickness of the steel backsheet within the range of 1 to 3 millimeters can simplify the manufacturing and installation process while ensuring structural stability, heat dissipation, and cost-effectiveness, thereby improving the overall performance and reliability of the new photovoltaic modules.

[0038] In one possible implementation, the steel backplate is designed with mounting holes that extend through the thickness direction. These mounting holes have specific dimensions and structures to ensure effective connection with the support components.

[0039] Mounting hole dimensions: The inner diameter of the mounting hole is designed to be 8 to 12 mm. This range of sizes can accommodate different types of fasteners, such as bolts or screws, providing sufficient strength and flexibility. Smaller inner diameters (e.g., 8 mm) can reduce material costs, while larger inner diameters (e.g., 12 mm) can provide stronger connection force.

[0040] Threaded structure: The inner wall of the mounting hole is threaded. This design allows for direct connection using fasteners with external threads, eliminating the need for additional nuts or washers and simplifying the installation process.

[0041] The threaded structure improves the tightness and reliability of the connection, ensuring a tight connection between the support components and the steel backing plate, and enhancing the overall stability of the components.

[0042] Function: These mounting holes are primarily used to connect support components. Through these holes, photovoltaic modules can be secured to brackets or other support structures, ensuring their stability and safety during installation.

[0043] In summary, the mounting holes on the steel backplate are designed with an inner diameter of 8 to 12 millimeters and have a threaded structure on the inner wall. This not only facilitates the installation process but also improves the reliability of the connection and the overall stability, ensuring that the photovoltaic modules can be safely and securely installed on various support structures.

[0044] In one possible implementation, the encapsulation material is an adhesive film with a thickness set between 0.5 and 0.8 mm, specifically 0.65 mm, to achieve a balance between good protection and material economy. This film not only possesses excellent light transmittance and electrical insulation properties but also effectively prevents moisture, dust, and mechanical impact from damaging the photovoltaic cells, thereby improving the module's durability and stability. Simultaneously, the steel backsheet is firmly bonded to the photovoltaic cells through this adhesive film, achieving a tight bond between the two. As an adhesive medium, the film not only ensures structural stability and prevents loosening or detachment but also provides a certain buffering function, helping to mitigate external stress transmission and protect the photovoltaic cells from damage. This design simplifies the module manufacturing process, improves assembly efficiency, and ensures the overall performance and long-term reliability of the photovoltaic module.

[0045] In one possible implementation, the outer perimeter of the steel backsheet is at least 3 cm larger than the outer perimeter of the photovoltaic cell laminate. This design allows the steel backsheet to fully cover and support the entire photovoltaic cell laminate, providing a wider edge area to enhance the structural stability and resistance to mechanical stress of the module. The larger backsheet size not only facilitates frameless mounting and reduces reliance on additional frames, but also provides sufficient space for mounting holes and other connecting components, facilitating module installation and maintenance. Furthermore, the enlarged backsheet edges help improve the module's sealing performance, reducing environmental damage to the photovoltaic cells and further extending the module's lifespan. Overall, the design of the backsheet exceeding the laminate by at least 3 cm effectively improves the overall reliability and practicality of the photovoltaic module.

[0046] In one possible implementation, the glaze layer is uniformly applied to the surface of the steel backing plate via a spraying process, ensuring complete coverage and uniform thickness distribution. Subsequently, it undergoes high-temperature sintering, with the sintering temperature controlled at approximately 600 degrees Celsius. This temperature is sufficient to fully melt the vitreous and ceramic components in the glaze and firmly bond them to the steel substrate, forming a dense and hard protective layer. This sintering process not only significantly improves the adhesion and wear resistance of the glaze layer but also enhances its corrosion resistance and weather resistance, ensuring long-term stable use of the steel backing plate in complex outdoor environments. Simultaneously, the sintering temperature of 600 degrees Celsius balances material performance and energy efficiency, making it an effective process parameter for achieving high-quality glaze layer preparation.

[0047] In one possible implementation, a waterproof strip is provided between the periphery of the photovoltaic cell laminate and the steel backsheet. This waterproof strip has a rectangular cross-section, facilitating a tight fit and stable installation. The rectangular cross-section of the waterproof strip provides a large contact area, enabling it to form a reliable seal with the steel backsheet and the periphery of the photovoltaic cell laminate, effectively preventing moisture, dust, and other environmental factors from entering the module. This sealing structure not only enhances the module's waterproof and dustproof performance but also improves its overall weather resistance and service life, ensuring the safe operation of the photovoltaic cells under various harsh climatic conditions. Furthermore, the application of the waterproof strip simplifies the sealing process, improves the efficiency and quality stability of module assembly, and plays a crucial role in the long-term reliability of the module.

[0048] In one possible implementation, the surface of the steel backsheet and the inner wall of its through-hole are coated with an anti-rust coating, the thickness of which is controlled within the range of 5 to 15 micrometers. This coating effectively isolates the steel from moisture and oxygen corrosion, significantly improving the corrosion resistance of the backsheet and mounting hole area, preventing rust and material degradation. By simultaneously protecting the backsheet surface and the inner wall of the mounting hole, the structural integrity and long-term stability of critical connection points are ensured, thereby improving the overall service life of the module. Furthermore, a reasonable coating thickness ensures both protective effectiveness and avoids dimensional deviations or installation difficulties caused by excessive coating thickness, meeting manufacturing precision and process requirements and promoting the reliable application of photovoltaic modules.

[0049] In one possible implementation, a heat-dissipating coating is further provided on the glaze surface of the steel backsheet, with the thickness of the coating controlled between 20 and 50 micrometers. This heat-dissipating coating possesses excellent thermal radiation and thermal conductivity, which helps to accelerate the conduction and dissipation of heat generated during module operation to the external environment, thereby effectively reducing the operating temperature of the photovoltaic cells, improving power generation efficiency, and extending service life. A moderate coating thickness ensures effective heat dissipation while avoiding weakened adhesion or mechanical damage due to excessive coating thickness, without significantly increasing the weight of the module. By adding a heat-dissipating coating to the glaze surface, the thermal management capability of the photovoltaic module is enhanced, achieving efficient and stable operation.

[0050] The above provides a detailed description of a novel photovoltaic module provided in this application. The various embodiments in the specification are described in a progressive manner, with each embodiment focusing on its differences from other embodiments. Similar or identical parts between embodiments can be referred to interchangeably. For the apparatus disclosed in the embodiments, since it corresponds to the method disclosed in the embodiments, the description is relatively simple; relevant parts can be referred to in the method section. It should be noted that those skilled in the art can make several improvements and modifications to this application without departing from the principles of this application, and these improvements and modifications also fall within the protection scope of the claims of this application.

[0051] It should be understood that in this application, "at least one (item)" means one or more, and "more than" means two or more. "And / or" is used to describe the relationship between related objects, indicating that three relationships can exist. For example, "A and / or B" can represent three cases: only A exists, only B exists, and both A and B exist simultaneously, where A and B can be singular or plural. The character " / " generally indicates that the preceding and following related objects are in an "or" relationship. "At least one (item) of the following" or similar expressions refer to any combination of these items, including any combination of single or plural items. For example, at least one (item) of a, b, or c can represent: a, b, c, "a and b", "a and c", "b and c", or "a and b and c", where a, b, and c can be single or multiple.

Claims

1. A novel photovoltaic module characterized in that, The novel photovoltaic module includes: a photovoltaic cell laminate and a steel backplate; the photovoltaic cell laminate includes a front cover glass and a photovoltaic cell; the surface of the steel backplate is covered with a glaze layer; the outer perimeter of the steel backplate is larger than the outer perimeter of the photovoltaic cell laminate; both the upper and lower surfaces of the photovoltaic cell are encapsulated with encapsulation material; the front cover glass is disposed on the light-receiving side of the photovoltaic cell, and the steel backplate is disposed on the backlighting side of the photovoltaic cell.

2. The novel photovoltaic module according to claim 1, characterized in that, The thickness of the glaze layer is 0.1-0.5 mm, and the material of the glaze layer is a high-temperature resistant ceramic glaze.

3. The novel photovoltaic module according to claim 1, characterized in that, The thickness of the steel backing plate is 1-3 mm.

4. The novel photovoltaic module of claim 1, wherein, The steel back plate has mounting holes that extend through the thickness direction. The inner diameter of the mounting holes is 8-12 mm, and the inner wall of the mounting holes is provided with a threaded structure. The mounting holes are used to connect support components.

5. The novel photovoltaic module according to claim 1, characterized in that, The encapsulation material is an adhesive film with a thickness of 0.5-0.8 mm; the steel backplate and the photovoltaic cell are bonded and fixed together by the adhesive film.

6. The novel photovoltaic module of claim 1, wherein, The outer circumferential dimension of the steel back plate is at least 3 cm larger than the outer circumferential dimension of the photovoltaic cell laminate.

7. The novel photovoltaic module of claim 1, wherein, A waterproof strip is provided between the periphery of the photovoltaic cell laminate and the steel back plate. The waterproof strip has a rectangular cross-section and forms a sealed connection with the steel back plate and the periphery of the photovoltaic cell laminate.

8. The novel photovoltaic module of claim 1, wherein, The surface of the steel back plate and the inner wall of the mounting hole are covered with an anti-rust coating, the thickness of which is 5-15 micrometers.

9. The novel photovoltaic module of claim 1, wherein, The steel back plate has a heat dissipation coating on its glaze surface, and the thickness of the heat dissipation coating is 20-50 micrometers.

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