Photovoltaic module

Abstract

The utility model relates to photovoltaic technical field especially relates to a kind of photovoltaic module.The photovoltaic module includes multiple cell pieces, solder strip and carrier film. Among them, solder strip is connected multiple cell pieces in series, along first direction, solder strip is located between two adjacent cell pieces, and there is overlapping area between two adjacent cell pieces along first direction.In two adjacent cell pieces, carrier film is arranged between one of cell pieces and solder strip, and / or, carrier film is arranged between another cell piece and solder strip;And the carrier film in overlapping area has bending section, and the thickness of bending section is greater than the single-layer thickness of carrier film.The photovoltaic module can reduce the phenomenon that cell piece overlapping area is hidden crack in lamination process, improve the reliability of photovoltaic module.

Description

Technical Field

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

[0002] Coating technology for photovoltaic modules, as a key process for achieving grid-free cell interconnection, has been widely used and extensively studied due to its advantages of low temperature and low stress. Negative-pitch series connection of cells in photovoltaic modules has become an effective means to improve module efficiency. However, negative-pitch series connection of multiple cells increases the risk of microcracks or cell breakage during manufacturing, thus affecting the performance and reliability of the photovoltaic module.

[0003] In existing technologies, a carrier film is typically placed in the overlapping area of ​​the solar cells to buffer the pressure during the lamination process and prevent cell cracking. However, with continuous improvements in carrier film technology, its thickness has been gradually reduced to less than 100μm. Since the overlapping area of ​​the cells contains solder ribbons, the buffer thickness in this area is insufficient during the encapsulation lamination process. This easily leads to microcracks in the solar cells above and below the solder ribbons, becoming a key bottleneck restricting the improvement of photovoltaic module performance and cost control.

[0004] Therefore, there is an urgent need to design a photovoltaic module to solve the above technical problems. Utility Model Content

[0005] The purpose of this invention is to propose a photovoltaic module that reduces the occurrence of microcracks in the overlapping areas of the solar cells during the lamination process, thereby improving the reliability of the photovoltaic module.

[0006] To achieve this objective, the present invention adopts the following technical solution:

[0007] This utility model provides a photovoltaic module, comprising:

[0008] Multiple battery cells;

[0009] A solder strip, wherein the solder strip connects multiple battery cells in series, and the solder strip is located between two adjacent battery cells along a first direction, and there is an overlapping area between two adjacent battery cells along the first direction;

[0010] A carrier film is disposed between one of the adjacent battery cells and the solder ribbon, and / or the carrier film is disposed between the other battery cell and the solder ribbon; and the carrier film located in the overlapping region has a bent section, the thickness of which is greater than the thickness of a single layer of the carrier film.

[0011] As an optional technical solution for photovoltaic modules, the bent section includes at least two stacked layers, and the projection of the stacked layers on the front of the solar cell at least covers the width range of the solder strip within the overlapping area.

[0012] As an optional technical solution for photovoltaic modules, the width of the stacked layer along a second direction perpendicular to the first direction is not less than the width of the overlapping area.

[0013] As an optional technical solution for photovoltaic modules, the two adjacent stacked layers are bonded together.

[0014] As an optional technical solution for photovoltaic modules, the edges of two adjacent stacked layers are flush along the first direction.

[0015] As an optional technical solution for photovoltaic modules, the thickness of a single layer of the carrier film is no greater than 100 μm, and the basis weight corresponding to the thickness of a single layer of the carrier film is no greater than 100 g / m³. 2 .

[0016] As an optional technical solution for photovoltaic modules, the thickness of the bent section is no more than 450μm.

[0017] As an optional technical solution for photovoltaic modules, the carrier film is one of EVA, POE, TPO, or PVB.

[0018] As an optional technical solution for photovoltaic modules, the carrier film is continuously or intermittently distributed between the solar cells and the solder ribbon.

[0019] As an optional technical solution for photovoltaic modules, the photovoltaic module further includes an encapsulation layer, which encapsulates the solar cells, the solder ribbon, and the carrier film. The encapsulation layer is made of glass or a polymer component.

[0020] The beneficial effects of this utility model include at least the following:

[0021] This invention provides a photovoltaic module comprising multiple solar cells, a solder ribbon, and a carrier film. The solder ribbon connects the multiple solar cells in series, and along a first direction, the solder ribbon is located between two adjacent solar cells, with an overlapping area between adjacent solar cells along the first direction. In each pair of adjacent solar cells, the carrier film is disposed between one solar cell and the solder ribbon, and / or, the carrier film is disposed between another solar cell and the solder ribbon; the carrier film located in the overlapping area has a bent section, the thickness of which is greater than the thickness of a single layer of the carrier film.

[0022] In this design, a carrier film is positioned between the solar cell and the solder ribbon. The carrier film in the overlapping area of ​​two adjacent solar cells has a bent section, the thickness of which is greater than the thickness of a single layer of the carrier film. During lamination, when pressure is applied to the solar cell, the increased thickness of the bent section provides a stronger buffering effect, effectively dispersing pressure and reducing localized stress concentration from the solder ribbon. Compared to a single-layer carrier film, this bent structure allows for a degree of pressure absorption and buffering before it is transmitted to the solar cell, thereby reducing the risk of microcracks in the overlapping area and improving the reliability and performance of the photovoltaic module. Attached Figure Description

[0023] To more clearly illustrate the technical solutions in the embodiments of this utility model, the drawings used in the description of the embodiments of this utility model will be briefly introduced below. Obviously, the drawings described below are only some embodiments of this utility model. For those skilled in the art, other drawings can be obtained based on the content of the embodiments of this utility model and these drawings without creative effort.

[0024] Figure 1 This is a cross-sectional view of the photovoltaic module provided in this embodiment of the utility model;

[0025] Figure 2 This is a top view of the photovoltaic module (continuously distributed carrier film) provided in this embodiment of the utility model;

[0026] Figure 3 This is a top view of the photovoltaic module (discontinuously distributed carrier film) provided in this embodiment of the present invention;

[0027] Figure 4 This is a schematic diagram of EL imaging of photovoltaic modules in the prior art;

[0028] Figure 5 This is a schematic diagram of EL imaging of a photovoltaic module provided in an embodiment of this utility model.

[0029] Figure Labels

[0030] 10. Solar cell; 20. Welding strip; 30. Overlapping area; 40. Carrier film; 41. Bending section; 42. Stacked layer. Detailed Implementation

[0031] To make the objectives, technical solutions, and advantages of the embodiments of this utility model clearer, the technical solutions of the embodiments of this utility model will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of this utility model, and not all embodiments. The components of the embodiments of this utility model described and shown in the accompanying drawings can generally be arranged and designed in various different configurations.

[0032] Therefore, the following detailed description of the embodiments of the present invention provided in the accompanying drawings is not intended to limit the scope of the claimed invention, but merely to illustrate selected embodiments of the invention. All other embodiments obtained by those skilled in the art based on the embodiments of the present invention without inventive effort are within the scope of protection of the present invention.

[0033] It should be noted that similar labels and letters in the following figures indicate similar items. Therefore, once an item is defined in one figure, it does not need to be further defined and explained in subsequent figures.

[0034] In the description of this utility model, it should be noted that the terms "upper," "lower," "left," "right," "vertical," "horizontal," "inner," and "outer," etc., indicate the orientation or positional relationship based on the orientation or positional relationship shown in the accompanying drawings, or the orientation or positional relationship commonly used when the product of this utility model is in use. They are used only for the convenience of describing this utility model and for simplifying the description, and do not indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation. Therefore, they should not be construed as limitations on this utility model. Furthermore, the terms "first," "second," and "third," etc., are used only to distinguish descriptions and should not be construed as indicating or implying relative importance. In the description of this utility model, unless otherwise stated, "a plurality of" means two or more.

[0035] In the description of this utility model, it should also be noted that, unless otherwise explicitly specified and limited, the terms "set" and "connection" should be interpreted broadly. For example, they can refer to a fixed connection, a detachable connection, or an integral connection; they can refer to a mechanical connection or an electrical connection. Those skilled in the art can understand the specific meaning of the above terms in this utility model based on the specific circumstances.

[0036] In this invention, unless otherwise explicitly specified and limited, "above" or "below" the second feature can include direct contact between the first and second features, or contact between the first and second features through another feature between them. Furthermore, "above," "over," and "on top" of the second feature includes the first feature directly above or diagonally above the second feature, or simply indicates that the first feature is at a higher horizontal level than the second feature. "Below," "below," and "under" the second feature includes the first feature directly below or diagonally below the second feature, or simply indicates that the first feature is at a lower horizontal level than the second feature.

[0037] The embodiments of this utility model are described in detail below. Examples of these embodiments are shown in the accompanying drawings, wherein the same or similar reference numerals denote the same or similar elements or elements having the same or similar functions throughout. The embodiments described below with reference to the accompanying drawings are exemplary and are only used to explain this utility model, and should not be construed as limiting this utility model.

[0038] This embodiment provides a photovoltaic module that can reduce the occurrence of microcracks in the overlapping areas of the solar cells during the lamination process, thereby improving the reliability of the photovoltaic module.

[0039] like Figures 1-3 As shown, the photovoltaic module mainly includes multiple solar cells 10, solder ribbons 20, and a carrier film 40. The solder ribbons 20 connect the multiple solar cells 10 in series. Along a first direction, the solder ribbons 20 are located between two adjacent solar cells 10, and there is an overlap region 30 between two adjacent solar cells 10 along the first direction. In two adjacent solar cells 10, the carrier film 40 is disposed between one solar cell 10 and the solder ribbon 20, and / or, the carrier film 40 is disposed between another solar cell 10 and the solder ribbon 20; and the carrier film 40 located in the overlap region 30 has a bent section 41, the thickness of which is greater than the thickness of a single layer of the carrier film 40.

[0040] Specifically, along a second direction perpendicular to the first direction, the edges of two adjacent solar cells 10 are stacked on opposite sides to create a negative spacing between them. This ensures high optical efficiency of the photovoltaic module, reduces its size, and increases the conversion efficiency per unit area, thereby improving the module's power output. The first direction is... Figure 1 The Y-axis direction in the middle, the second direction is... Figure 1 The X-axis direction in the diagram.

[0041] In this embodiment, the carrier film 40 is disposed between the solar cell 10 and the solder ribbon 20. The carrier film 40 located in the overlapping region 30 has a bent section 41, the thickness of which is greater than the thickness of a single layer of the carrier film 40. During the lamination process, when pressure is applied to the solar cell 10, the bent section 41, due to its increased thickness, provides a stronger buffering effect, effectively dispersing the pressure and reducing local stress concentration of the solder ribbon 20 on the solar cell 10. Compared to a single-layer carrier film 40, this bent structure carrier film 40 can absorb and buffer the pressure to a certain extent before it is transmitted to the solar cell 10, thereby reducing the risk of microcracks in the solar cell 10 in the overlapping region 30 and improving the reliability and performance of the photovoltaic module.

[0042] Furthermore, the bent section 41 is formed by bending the end of the carrier film 40 itself, rather than by adding additional material. And except for the overlapping region 30, the other regions are single-layer carrier film 40. This increases the thickness of the carrier film 40 in the overlapping region 30 without significantly increasing material costs, thus achieving cost savings. Simultaneously, the continuity of the carrier film 40 improves the adhesion stability of the carrier film 40, reducing loosening caused by shrinkage or environmental changes.

[0043] Furthermore, the carrier film 40 located in the overlapping region 30 has a bent section 41, the thickness of which is greater than the single-layer thickness of the carrier film 40. This can also supplement the amount of filler in the overlapping region 30, reduce or avoid the problem of air bubbles due to insufficient filler, and improve the reliability of the photovoltaic module.

[0044] like Figure 4 and Figure 5 As shown, Figure 4 In conventional photovoltaic modules that do not have the bending segment 41 described in this application within the overlapping area 30, microcracks (i.e.,) are clearly visible on the cells 10 after EL imaging. Figure 4 (The black dot within the dashed box). For example... Figure 5 As shown, by setting a bending segment 41 in the overlapping area 30, no black spots appear on the solar cells after EL imaging of the photovoltaic module, that is, no microcracks occur in the solar cells.

[0045] For example, the position of the bent section 41 can be formed by bending downward or upward along the first direction. The carrier film 40 is fixed to the battery cell 10 and the solder ribbon 20 by low-temperature hot pressing, so that the carrier film 40 is laid on the battery cell 10, ensuring that there is no relative displacement between the solder ribbon 20 and the battery cell 10.

[0046] For example, the monolayer thickness of the carrier membrane 40 is no greater than 100 μm, and the basis weight corresponding to the monolayer thickness of the carrier membrane 40 is no greater than 100 g / m³. 2Reducing the thickness of a single layer of the carrier film 40 can decrease the amount of material used, thereby lowering material costs. Simultaneously, by controlling the basis weight, the balance between material performance and cost is further optimized while ensuring sufficient strength and adhesion of the carrier film 40. For example, a thinner carrier film 40 can reduce production costs and improve the product's market competitiveness while still meeting cushioning and adhesion requirements.

[0047] In practical implementation, the thickness and basis weight of the carrier film 40 can be adjusted according to different application scenarios. For example, for photovoltaic modules used in general ground-mounted power stations, the single-layer thickness of the carrier film 40 can be designed to be 80μm-90μm, and the basis weight to be 70g / m³. 2 -80g / m 2 For distributed photovoltaic modules, considering the installation environment and mechanical load requirements, the thickness of the carrier film 40 single layer can be designed to be 90μm-100μm, with a basis weight of 80g / m³. 2 -100g / m 2 .

[0048] For example, the thickness of the bent segment 41 in this embodiment is no greater than 450 μm. Limiting its thickness to no more than 450 μm, while ensuring sufficient buffering effect, avoids a significant increase in material costs and other potential problems caused by an excessively thick bent segment 41, such as increased overall photovoltaic module thickness and decreased optical performance. Simultaneously, controlling the thickness of the bent segment 41 to no more than 450 μm reduces its impact on light transmittance. A thinner bent segment 41 can minimize light absorption and scattering while maintaining its buffering function, thereby improving the optical performance of the photovoltaic module.

[0049] Optionally, the thickness of the bent section 41 can be set to 300μm, 350μm, 400μm, 450μm, etc.

[0050] For example, the carrier film 40 in this embodiment is one of EVA, POE, TPO or PVB. All of these materials have good insulation, adhesion and elasticity, and are suitable for low temperature coating process.

[0051] Preferably, the carrier membrane 40 is made of POE material, which has strong UV resistance and hydrolysis resistance, and is better suited for outdoor high-temperature environments.

[0052] like Figure 1As shown, the bending section 41 includes at least two stacked layers 42, the projection of which covers the front of the solar cell 10 at least the width of the solder ribbon 20 within the overlapping region 30. The arrangement of at least two stacked layers 42 allows the carrier film 40 to form a relatively stable support system within the overlapping region 30. The stacked layers 42 interact with each other, jointly bearing the pressure during the external lamination process, thus improving the structural stability of the photovoltaic module. Simultaneously, since the projection of the stacked layers 42 on the front of the solar cell 10 covers the width of the solder ribbon 20, it ensures a uniform distribution of buffering effect in the area where the solder ribbon 20 is located, preventing microcracks caused by excessive local stress on the solar cell 10 due to uneven buffering.

[0053] Specifically, the number of stacked layers 42 can be 2, 3 or 4, such as each stacked layer 42 having a thickness of 50μm-70μm, to ensure sufficient buffering and support in the overlapping area 30 of the solar cells 10.

[0054] like Figure 1 As shown, along the second direction perpendicular to the first direction, the width of the stacked layer 42 is not less than the width of the overlapping region 30. This ensures that the entire overlapping region 30 has sufficient buffering, avoiding microcracks at the edges of the battery cell 10 due to insufficient lateral edge buffering. At the same time, the full lateral coverage of the stacked layer 42 reduces stress differences at the edges of the overlapping region 30 during lamination, reducing the loosening of the carrier film 40 caused by excessive local stress.

[0055] For example, if the width of the overlapping area 30 of adjacent battery cells 10 in the second direction is 5 mm, the width of the stacked layer 42 in the second direction can be set to 5 mm (just covering) or 6 mm (slightly exceeding the overlapping area 30).

[0056] In some alternative embodiments, adjacent stacked layers 42 are bonded together, which enhances the bonding strength between the stacked layers 42 and prevents relative displacement or separation between the stacked layers 42 during lamination. This ensures the integrity and stability of the carrier film 40 in the overlapping region 30, allowing it to better perform its buffering function and improve the reliability and performance of the photovoltaic module.

[0057] In practice, special photovoltaic adhesives can be used to bond adjacent stacked layers 42, such as silane-modified polyurethane adhesives, which have good bonding performance and weather resistance.

[0058] like Figure 1As shown, along the first direction, the edges of adjacent stacked layers 42 are flush. This flush edge design makes the processing and assembly of the stacked layers 42 more convenient and precise during production. Each stacked layer 42 can be processed using a uniform mold or cutting tool, ensuring edge consistency and improving production efficiency and product quality. Simultaneously, during assembly, the flush edges also facilitate alignment and positioning between the stacked layers 42, reducing assembly errors. Furthermore, the flush edges of the stacked layers 42 ensure uniform stress distribution in the first direction, avoiding stress concentration.

[0059] like Figures 2-3 As shown, the carrier film 40 is continuously or intermittently distributed between the solar cell 10 and the solder ribbon 20. Specifically, a continuously distributed carrier film 40 (i.e., the carrier film 40 is in block form) ensures that the entire area of ​​the solder ribbon 20 in contact with the solar cell 10 is covered by the carrier film 40. In other words, a whole sheet of carrier film 40 covers the solar cell 10, improving the reliability of the application and reducing local loosening, which is suitable for scenarios with high reliability requirements for photovoltaic modules. An intermittently distributed carrier film 40 consists of multiple strip-shaped carrier films 40 arranged in a row. Each carrier film 40 corresponds one-to-one with the solder ribbon 20 on the solar cell 10, meaning that each carrier film 40 lays the solder ribbon 20 on the solar cell 10. No carrier film 40 is placed between two adjacent solder ribbons 20 to reduce the amount of carrier film 40 used, reduce costs, and at the same time, not affect the buffering effect of the overlapping area 30.

[0060] The photovoltaic module in this embodiment also includes an encapsulation layer, which encapsulates the solar cell 10, the solder ribbon 20, and the carrier film 40. The encapsulation layer is made of glass or a polymer component. The encapsulation layer forms a physical barrier, isolating external moisture, dust, and mechanical impact, and protecting the internal structure of the photovoltaic module.

[0061] The glass encapsulation layer offers high transparency, high hardness, and excellent weather resistance, effectively protecting the solar cells from environmental damage such as ultraviolet radiation and moisture intrusion. The polymer encapsulation layer, on the other hand, provides good flexibility and insulation, offering additional mechanical protection and electrical insulation. Through the encapsulation effect, the mechanical strength and environmental adaptability of the photovoltaic module are improved, extending its lifespan.

[0062] For example, for a single-glass photovoltaic module, the encapsulation layer can be configured as a front glass and a back sheet; for a double-glass photovoltaic module, the encapsulation layer can be configured as a front glass and a back glass.

[0063] Obviously, the above description is merely a preferred embodiment of the present invention and the technical principles employed. Those skilled in the art will understand that the present invention is not limited to the specific embodiments described herein, and various obvious changes, readjustments, and substitutions can be made without departing from the protection scope of the present invention. Therefore, although the present invention has been described in detail through the above embodiments, the present invention is not limited to the above embodiments. Many other equivalent embodiments may be included without departing from the concept of the present invention, and the scope of the present invention is determined by the scope of the appended claims.

[0064] Note that in the description of this specification, the references to terms such as "some embodiments," "other embodiments," etc., indicate that a specific feature, structure, material, or characteristic described in connection with that embodiment or example is included in at least one embodiment or example of this utility model. In this specification, the illustrative expressions of the above terms do not necessarily refer to the same embodiment or example. Furthermore, the specific features, structures, materials, or characteristics described may be combined in any suitable manner in one or more embodiments or examples.

Claims

1. A photovoltaic module, characterized in that, include: Multiple solar cells (10); A solder strip (20) is connected in series with multiple battery cells (10). Along a first direction, the solder strip (20) is located between two adjacent battery cells (10) and there is an overlapping area (30) between two adjacent battery cells (10) along the first direction. A carrier film (40) is disposed between one of the adjacent battery cells (10) and the solder ribbon (20), and / or the carrier film (40) is disposed between the other battery cell (10) and the solder ribbon (20); and the carrier film (40) located in the overlapping region (30) has a bent section (41) with a thickness greater than the single layer thickness of the carrier film (40).

2. The photovoltaic module according to claim 1, characterized in that, The bent section (41) includes at least two stacked layers (42), the stacked layers (42) covering at least the width of the solder strip (20) within the overlapping area (30) in the front projection of the battery cell (10).

3. The photovoltaic module according to claim 2, characterized in that, Along a second direction perpendicular to the first direction, the width of the stacked layer (42) is not less than the width of the overlapping region (30).

4. The photovoltaic module according to claim 2, characterized in that, The two adjacent stacked layers (42) are bonded together.

5. The photovoltaic module according to claim 2, characterized in that, Along the first direction, the edges of two adjacent stacked layers (42) are flush.

6. The photovoltaic module according to claim 1, characterized in that, The thickness of the single layer of the carrier membrane (40) is not greater than 100 μm, and the basis weight corresponding to the thickness of the single layer of the carrier membrane (40) is not greater than 100 g / m³. 2 .

7. The photovoltaic module according to claim 6, characterized in that, The thickness of the bent section (41) is no greater than 450 μm.

8. The photovoltaic module according to claim 1, characterized in that, The carrier membrane (40) is one of EVA, POE, TPO or PVB.

9. The photovoltaic module according to claim 1, characterized in that, The carrier film (40) is continuously or intermittently distributed between the battery cell (10) and the solder strip (20).

10. The photovoltaic module according to any one of claims 1-9, characterized in that, The photovoltaic module further includes an encapsulation layer that encapsulates the solar cell (10), the solder ribbon (20), and the carrier film (40). The encapsulation layer is made of glass or a polymer component.

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