Photovoltaic power generation module manufacturing method and photovoltaic power generation module

Abstract

The present application relates to a method for manufacturing a photovoltaic power generation module and a photovoltaic power generation module. [Solution] A method for manufacturing a photovoltaic module includes the steps of providing a front sealing structure including a cover plate and a sealing layer, a solar cell, and a back sheet, providing an insulating layer and a through hole on at least one surface of the solar cell, and aligning the through hole with the grid line of the solar cell, providing a conductive layer on the back sheet, providing a conductive adhesive in the through hole and / or on the conductive layer, connecting the back sheet to the solar cell, laminating the insulating layer to the conductive layer, and electrically connecting the grid line and the conductive layer through the through hole with the conductive adhesive, providing a sealing layer on the side of the solar cell away from the back sheet, providing a cover plate on the side of the sealing layer away from the solar cell, and laminating the cover plate, the sealing layer, the solar cell, and the back sheet to form a photovoltaic module. The method for manufacturing a photovoltaic module according to the present application can reduce the process complexity of the photovoltaic module and make the process steps simpler.

Description

Detailed Description of the Invention

[0001] This invention claims priority to a Chinese patent application filed with the China Patent Office on September 5, 2022, bearing application number 202211075516.3 and entitled "Method for manufacturing a photovoltaic power generation module and a photovoltaic power generation module," the entire contents of which are incorporated herein by reference. [Technical Field]

[0002] The present application relates to the field of photovoltaic technology, and in particular to a method for manufacturing a photovoltaic module and a photovoltaic module. [Background technology]

[0003] A photovoltaic module typically includes a front sealing structure, a rear sealing structure, solar cells, an insulating layer, and a conductive layer, and the positive and negative grid lines of the solar cells must be connected to the conductive layers to form electrical connection paths. The insulating layer is used to insulate and separate the conductive layers from areas of the solar cells other than those used to connect the positive and negative grid lines.

[0004] The conventional photovoltaic modules have a problem in that the manufacturing process requires high precision, and therefore the process steps are complicated. Summary of the Invention [Problem to be solved by the invention]

[0005] The present application provides a method for manufacturing a photovoltaic power generation module, and a photovoltaic power generation module, which can reduce the complexity of the process for manufacturing the photovoltaic power generation module. [Means for solving the problem]

[0006] A first aspect of the present application provides a method for manufacturing a photovoltaic power generation module, the method comprising: providing a front encapsulation structure including a cover plate and an encapsulation layer, a solar cell, and a backsheet; providing an insulating layer and through holes on at least one surface of the solar cell, and aligning the positions of the through holes with the grid lines of the solar cell; providing a conductive layer on the backsheet; providing a conductive adhesive in the through holes and / or on the conductive layer; connecting the backsheet to the solar cell, bonding the insulating layer to the conductive layer, and electrically connecting the grid lines and the conductive layer through the through holes with the conductive adhesive; providing the encapsulation layer on a side of the solar cell away from the backsheet; providing the cover plate on a side of the encapsulation layer away from the solar cell; and laminating the cover plate, the encapsulation layer, the solar cells, and the backsheet to form the photovoltaic module.

[0007] In one possible design, when an insulating layer and a through hole are provided on at least one surface of the solar cell, the manufacturing method of the solar power module specifically includes printing an insulating adhesive on at least one surface of the solar cell, curing the insulating adhesive to form the insulating layer, and forming the through hole in an area on the surface of the solar cell where the insulating adhesive is not printed.

[0008] In one possible design, the insulating adhesive is a transparent insulating adhesive.

[0009] In one possible design, before printing an insulating adhesive on at least one surface of the solar cell, or after curing the insulating adhesive to form the insulating layer and forming the through holes in areas of the surface of the solar cell where the insulating adhesive is not printed, the method for manufacturing the solar cell further includes performing an electrical performance test on the solar cell, and / or after curing the insulating adhesive to form the insulating layer and forming the through holes in areas of the surface of the solar cell where the insulating adhesive is not printed, the method for manufacturing the solar cell further includes sorting the solar cell based on its color and appearance.

[0010] In one possible design, the thickness of the insulating layer is D1 and the thickness of the conductive adhesive is D2, where 1.2≦D2:D1≦1.5.

[0011] In one possible design, when a conductive layer is provided on the backsheet, the manufacturing method of the photovoltaic module specifically includes the steps of providing a mask plate on the backsheet, depositing a transparent metal oxide on the surface of the backsheet through the openings in the mask plate to form a metal conductive layer, and removing the mask plate to form insulating grooves in the areas of the backsheet where the transparent metal oxide is not deposited.

[0012] In one possible design, after removing the mask plate and forming insulating grooves in the areas of the backsheet where the transparent metal oxide is not deposited, the method for manufacturing the photovoltaic module further includes the step of forming an electrode connection layer on the surface of the metal conductive layer by printing and sintering, and the metal conductive layer and the electrode connection layer jointly constitute the conductive layer.

[0013] In one possible design, the backsheet material is one of glass, polycarbonate, and polyethylene terephthalate.

[0014] In one possible design, the backsheet material is one of polyvinyl fluoride, ethylene-tetrafluoroethylene copolymer, and polyvinylidene fluoride, and before laminating the cover plate, the encapsulant layer, the solar cells, and the backsheet to form the photovoltaic module, the method for manufacturing the photovoltaic module further includes the step of inverting the cover plate, the encapsulant layer, the solar cells, and the backsheet as a whole, with the cover plate facing down and the backsheet facing up.

[0015] A second aspect of the present application provides a photovoltaic module manufactured by the above manufacturing method, the photovoltaic module including, along a thickness direction of the photovoltaic module, a backsheet, a solar cell including grid lines, a conductive adhesive, a sealing layer, and a cover plate; The back sheet is provided with a conductive layer, an insulating layer and through holes are provided on at least one surface of the solar cell, the through holes corresponding to the positions of the grid lines; the conductive adhesive is located in the through-hole, and both ends of the conductive adhesive are connected to the conductive layer and the grid line, respectively; the sealing layer is on a side of the solar cell that is away from the back sheet, The cover plate covers the side of the encapsulation layer that faces away from the solar cell, and the cover plate, together with the back sheet, sandwiches the encapsulation layer and the solar cell.

[0016] In one possible design, the conductive layer includes a metal conductive layer and an electrode connection layer, the electrode connection layer is provided on the surface of the metal conductive layer that is closest to the solar cell, and the conductive adhesive has one end connected to the positive or negative electrode of the solar cell and the other end connected to the electrode connection layer.

[0017] In one possible design, the material of the electrode connection layer is one or more of Au, Ag, Cu, Al, Bi, Sn, and Pb.

[0018] In one possible design, the backsheet has an insulating groove formed therein, and the conductive layer is disposed around the insulating groove; The region where the electrode connection layer is connected to the positive electrode of the solar cell and the region where the electrode connection layer is connected to the negative electrode of the solar cell are located on both sides of the insulating groove. [Effects of the Invention]

[0019] In the method for manufacturing a photovoltaic module according to the present application, by providing an insulating layer directly on the surface of the solar cell, the complexity of the manufacturing process for the photovoltaic module can be reduced, and the accuracy of the positioning of the through-holes can be improved, ensuring that they are positioned corresponding to the grid lines, thereby reducing the risk of poor contact of the conductive adhesive due to misalignment between the through-holes and the grid lines. In the lamination process, the risk of poor contact and short circuits caused by misalignment of the conductive adhesive during lamination of the insulating layer and the solar cell can also be reduced. At the same time, by providing a conductive layer directly on the surface of the backsheet, the risk of poor contact due to misalignment of the conductive adhesive can also be reduced.

[0020] It is to be understood that the foregoing general description and the following detailed description are exemplary only and are not restrictive of the present application. [Brief explanation of the drawings]

[0021] The drawings herein are incorporated in and constitute a part of this specification, illustrate embodiments consistent with the present application, and together with the specification, serve to explain the principles of the present application.

[0022] [Figure 1] 1 is a schematic diagram illustrating the configuration of a photovoltaic power generation module manufactured according to the present invention. [Figure 2] 1 is a flowchart of the manufacturing of a photovoltaic module according to the present application. [Figure 3] FIG. 2 is a schematic diagram illustrating the configuration of one surface of a solar cell. [Figure 4] 1 is a flowchart of the manufacturing of a photovoltaic module according to the present application. [Figure 5] 1 is a flowchart of the manufacturing of a photovoltaic module according to the present application. [Figure 6] 1 is a flowchart of the manufacturing of a photovoltaic module according to the present application. [Figure 7] FIG. 1 is a schematic cross-sectional view of a solar power generation module. [Figure 8] FIG. 1 is a schematic cross-sectional view of a solar cell. [Figure 9] 1 is a flowchart of the manufacturing of a photovoltaic module according to the present application. [Figure 10] 1 is a flowchart of the manufacturing of a photovoltaic module according to the present application. [Figure 11] FIG. 2 is a schematic diagram illustrating the configuration of a back sheet. [Figure 12] 1 is a flowchart of the manufacturing of a photovoltaic module according to the present application. DETAILED DESCRIPTION OF THE INVENTION

[0023] In order to better understand the technical solution of the present application, the embodiments of the present application will be described in detail below with reference to the drawings.

[0024] It should be clear that the described embodiments are only some of the embodiments of the present application, and are not all of the embodiments. Based on the embodiments of the present application, all other embodiments that a person skilled in the art can obtain without creative work shall fall within the scope of protection of the present application.

[0025] The terms used in the examples of this application are used only for the purpose of describing particular examples and are not intended to limit the scope of this application. As used in the examples of this application and the appended claims, the singular forms "a," "the," and "the" are intended to include the plural forms unless the context clearly dictates otherwise.

[0026] The term "and / or" used in this specification is merely a relation describing related objects, and indicates that three relations may exist. For example, it should be understood that A and / or B can indicate three situations: A exists alone, A and B exist simultaneously, and B exists alone. Furthermore, the character " / " in the text generally indicates that the related objects before and after it are in an "or" relationship.

[0027] Note that directional terms such as "upper," "lower," "left," and "right" used in the embodiments of the present application are described in terms of angles shown in the drawings and should not be construed as limiting the embodiments of the present application. Furthermore, when a certain element is referred to as being connected "up" or "down" to another element in the context, it should be understood that the element may not only be directly connected "up" or "down" to the other element, but may also be indirectly connected "up" or "down" to the other element via an intermediate element.

[0028] Conventional methods for manufacturing photovoltaic modules typically involve first installing an insulating layer and a conductive layer separately, and then laminating and assembling solar cells, insulating layers, conductive layers, and a backsheet. This process is complicated and prone to poor contact between the solar cells and the backsheet.

[0029] Therefore, an embodiment of the present application provides a method for manufacturing a photovoltaic module, as shown in FIGS. 1 and 2, including the following steps:

[0030] In step S1, a front encapsulation structure including a cover plate 5 and an encapsulation layer 4, a solar cell 2 and a backsheet 1 are provided.

[0031] As shown in Figure 1, a photovoltaic module is constructed by laminating and sealing a cover plate 5, a sealing layer 4, solar cells 2, and a back sheet 1 to form a photovoltaic module that can be used outdoors for a long period of time. The sealing process ensures that the solar cells 2 have good mechanical strength and can reduce the impact of conditions such as hail damage, wind blows, and mechanical vibrations. The sealing process also improves the sealing of the solar cells 2, improving their erosion resistance and safety.

[0032] In step S2, an insulating layer 21 and through-holes 211 are provided on at least one surface of the solar cell 2, and the positions of the through-holes 211 and the grid lines 20 of the solar cell 2 are aligned.

[0033] As shown in FIG. 3 , the surface of the solar cell 2 is covered with an insulating layer 21, preventing short circuits caused by communication between the positive and negative grid lines of the solar cell 2. A plurality of through-holes 211 are formed in the insulating layer 21 at positions corresponding to the grid lines 20 of the solar cell 2, allowing electrical connection between the solar cell 2 and the backsheet 1. Compared to the prior art, which separately forms the insulating layer 21 and then connects it to the solar cell 2, this embodiment forms the insulating layer 21 directly on the surface of the solar cell 2, thereby reducing the complexity of the solar cell module manufacturing process, eliminating the need for the insulator 21 composition process, simplifying the manufacturing steps, and reducing the manufacturing costs of the solar cell module. In the subsequent lamination process, the risk of poor contact and short circuits due to misalignment of the conductive adhesive 3 during lamination of the insulating layer 21 and the solar cell 2 is also reduced.

[0034] In addition, by providing the insulating layer 21 directly on the surface of the solar cell 2, the adhesion between the insulating layer 21 and the solar cell 2 can be improved, which is advantageous in improving the insulating effect of the insulating layer 21, improving the electrical insulation of the solar power generation module, and further improving the service life and safety of the solar power generation module.

[0035] Specifically, the insulating layer 21 and the through holes 211 may be manufactured synchronously using a screen printing or mask printing method, or the insulating layer 21 may be first applied to the entire surface of the solar cell 2, and then a portion of the insulating layer 21 at a position corresponding to the grid line 20 may be removed to form the through holes 211.

[0036] The solar cell 2 in the present application may be a full cell, or may be configured by connecting a plurality of battery strings in parallel.

[0037] In step S3, a conductive layer 11 is provided on the back sheet 1.

[0038] Compared with the prior art in which the conductive layer 11 is provided separately and then connected to the backsheet 1 and the solar cell 2, in this embodiment, the conductive layer 11 is provided directly on the surface of the backsheet 1, thereby further reducing the complexity of the solar power generation module process.

[0039] In step S4, the conductive adhesive 3 is provided in the through-holes 211 and / or on the conductive layer 11.

[0040] A conductive adhesive 3 is provided in the through-holes 211 and / or on the conductive layer 11, and the conductive adhesive 3 is used to realize electrical connection between the positive and negative grid lines of the solar cell 2 and the conductive layer 11.

[0041] In step S5, the backsheet 1 is connected to the solar cell 2, the insulating layer 21 is attached to the conductive layer 11, and the grid lines 20 and the conductive layer 11 are electrically connected via the through holes 211 with the conductive adhesive 3.

[0042] When the solar cell 2 is connected to the back sheet 1, the conductive adhesive 3 electrically connects the grid line 20 and the conductive layer 11 through the through holes 211, thereby improving the stability of the electrical connection of the solar power generation module and further increasing the yield rate of the solar power generation module.

[0043] In step S6, the sealing layer 4 is provided on the side of the solar cell 2 that is away from the back sheet 1.

[0044] The encapsulating layer 4 is used to protect the side of the solar cell 2 that is away from the backsheet 1, and can also bond the cover plate 5, the solar cell 2, and the backsheet 1 together. The material of the encapsulating layer 4 may be one of materials such as ethylene-vinyl acetate copolymer (EVA), polyolefin elastomer (POE), polyvinyl butyral (PVB), etc., and to meet the sealing requirements of the solar photovoltaic module, the thickness should be greater than 300 μm. Preferably, the thickness of the encapsulating layer 4 is 400-800 μm, which can ensure good mechanical strength of the solar photovoltaic module and contribute to improving the yield rate and reliability of the solar photovoltaic module.

[0045] In step S7, a cover plate 5 is provided on the side of the sealing layer 4 that is remote from the solar cell 2.

[0046] The cover plate 5 is located on the top layer of the photovoltaic module and is used to allow sunlight to pass through and improve the waterproof and moisture-proof capabilities of the photovoltaic module. It seals the photovoltaic cells 2 together with the backsheet 1. The cover plate 5 can be made of a rigid material such as tempered glass, polyethylene terephthalate (PET), or polycarbonate (PC), or a flexible material such as polyvinyl fluoride (PVF), ethylene-tetrafluoroethylene copolymer (ETFE), or polyvinylidene fluoride (PVDF). These materials have high light transmittance, ensuring that more light is irradiated onto the surface of the solar cells 2 and increasing the light absorption of the photovoltaic module.

[0047] In step S8, the cover plate 5, the sealing layer 4, the solar cells 2 and the backsheet 1 are laminated together to form a photovoltaic module.

[0048] The laminate protects the solar cells 2 by bonding and fusing the components of the photovoltaic module together under certain temperature, pressure and vacuum conditions.

[0049] In the method for manufacturing a photovoltaic module according to the present application, by providing the insulating layer 21 directly on the surface of the solar cell 2, the complexity of the process for manufacturing the photovoltaic module can be reduced, the positional accuracy of the through-holes 211 can be improved, and they can be ensured to be opened in positions corresponding to the grid lines 20, thereby reducing the risk of poor contact of the conductive adhesive 3 due to misalignment between the through-holes 211 and the grid lines 20. In the lamination process, the risk of poor contact or short circuits occurring due to misalignment of the insulating layer 21 and the solar cell 2 during lamination, which could cause the position of the conductive adhesive 3 to change, can also be reduced. At the same time, by providing the conductive layer 11 directly on the surface of the backsheet 1, the risk of poor contact due to misalignment of the conductive adhesive 3 can also be reduced.

[0050] The solar cell 2 has opposing surfaces, specifically a light-receiving surface and a light-reverse surface of the solar cell 2. The light-receiving surface refers to the surface of the solar cell 2 that receives direct sunlight toward the light source, and the light-reverse surface refers to the surface of the solar cell 2 that receives sunlight reflected by the ground away from the light source.

[0051] Specifically, in this embodiment, providing the insulating layer 21 and the through-holes 211 on at least one surface of the solar cell 2 refers to providing the insulating layer 21 and the through-holes 211 on the rear optical surface, or providing the insulating layer 21 and the through-holes 211 on both the light-receiving surface and the rear optical surface. Preferably, the solar cell 2 is a back-contact cell. Compared to a typical solar cell, both the positive and negative grid lines are provided on the rear optical surface of the solar cell 2, and no metal grid lines are provided on the light-receiving surface. This reduces shading of sunlight, increases the light-receiving area of ​​the solar cell 2, and improves the photoelectric conversion efficiency of the solar power generation module. Furthermore, when the solar cell 2 is a back-contact cell, it is only necessary to provide the insulating layer 21 and the through-holes 211 on the rear optical surface, thereby reducing the manufacturing cost of the solar power generation module.

[0052] Furthermore, in this embodiment, the shape of the grid lines 20 is not limited, and they may be through-type, segmented grid lines, or point-like electrode points.

[0053] In one specific embodiment, as shown in FIG. 4, for step S2 of providing an insulating layer 21 and a through hole 211 on at least one surface of the solar cell 2, the method for manufacturing a solar power generation module specifically includes the following steps:

[0054] In step A1, an insulating adhesive is printed on at least one surface of the solar cell 2.

[0055] The insulating adhesive can be printed by using a screen printing method, where a patterned template is attached to a screen. Specifically, the solar cell 2 is placed under the screen with the template, and the insulating adhesive is forced through the mesh in the center of the screen by the pressure of a squeegee, and printed onto the surface of the solar cell 2. The template on the screen seals some of the small holes in the screen, preventing the insulating adhesive from passing through, so the insulating adhesive is applied only to positions on the surface of the solar cell 2 that correspond to the image on the screen, and through-holes 211 are formed in the remaining positions. Specifically, some of the small holes in the screen are sealed at positions corresponding to the grid lines 20 on the screen template, ensuring accurate positioning of the through-holes 211. The thickness of the screen is 10 to 200 μm, and the thickness of the insulating adhesive after printing is 15 to 300 μm, ensuring that the final insulating layer 21 has good insulating properties.

[0056] In addition, the insulating adhesive may be printed using a mask plate with a pattern printed thereon, employing a mask printing method. The principles and effects of this method are similar to those of the screen printing method, and therefore, a description thereof will be omitted here.

[0057] In step A2, the insulating adhesive is cured to form the insulating layer 21, and through holes 211 are formed in the areas on the surface of the solar cell 2 where the insulating adhesive is not printed.

[0058] After the insulating adhesive is printed on the solar cell 2, a curing process is carried out to form the insulating layer 21. A high-temperature curing process is generally used, with the curing temperature being 100°C to 200°C. To prevent the insulating adhesive from failing due to excessively high temperatures and to improve the manufacturing efficiency of the solar photovoltaic module, the curing time should be controlled to 10 minutes or less.

[0059] Specifically, the insulating adhesive in this embodiment preferentially covers the entire surface of the solar cell 2 except for the through-holes 211, and during the lamination process, the insulating adhesive can provide a cushioning effect for the solar cell 2 and the backsheet 1 in addition to its insulating effect, thereby reducing the chipping rate of the laminate and improving the yield rate of the solar power generation module.

[0060] Furthermore, the insulating adhesive does not need to be completely cured during the curing process, but maintains a certain viscosity, and when connecting the solar cells 2 and the back sheet 1, the insulating adhesive serves to connect the solar cells 2 and the back sheet 1, achieving a temporary fixation effect, eliminating the need for temporary fixation between the solar cells 2 and the back sheet 1 in subsequent processes, further simplifying the process steps for manufacturing a solar power module. The insulating adhesive is completely cured during the lamination process.

[0061] In one specific embodiment, the insulating adhesive is a transparent insulating adhesive.

[0062] The insulating adhesive may be one or more of organosilicon, acrylic, and epoxy resins, with a viscosity of 0-50 Pa·s before curing and a light transmittance of 75% or more after curing, allowing the rear surface of the solar cell 2 to maintain high light transmittance, thereby allowing the solar power module to receive more light reflected from the ground, which is advantageous for realizing double-sided power generation of the solar power module.

[0063] In one specific embodiment, as shown in FIGS. 5 and 6, the method for manufacturing a photovoltaic module further includes step A0 of performing an electrical performance test on the solar cell 2 before step A1 or after step A2.

[0064] Due to the randomness of battery manufacturing conditions, the performance of manufactured solar cells 2 varies, so in order to effectively combine solar cells 2 with the same or similar performance, they should be classified based on their performance parameters. Testing the solar cells 2 can improve the utilization rate and produce photovoltaic modules with good quality. The electrical performance test mainly tests the basic characteristics of the solar cells 2 to detect the outdoor power generation capacity of the solar cells 2.

[0065] In this embodiment, the electrical performance test may be performed before or after the process of providing the insulating layer 21 and the through hole 211, and during the test process, the position of the test tool presser needle should coincide with the position of the through hole 211 to ensure the accuracy of the test results.

[0066] And / or, the method for manufacturing a photovoltaic module further includes, after step A2, step A3 of sorting the solar cells 2 based on their color and appearance.

[0067] After the process of providing the insulating layer 21 and the through-holes 211, it is necessary to further select the color and appearance of the solar cell 2. The thickness, defects, flatness, etc. of the solar cell 2 are inspected mainly visually, and the color of the solar cell 2 should be maintained uniformly with no obvious color differences.

[0068] 7 and 8, the thickness of the insulating layer 21 is D1, the thickness of the conductive adhesive 3 is D2, and 1.2≦D2:D1≦1.5. Specifically, D2:D1 may be 1.2, 1.3, 1.4, 1.5, etc.

[0069] In this embodiment, the thickness D2 of the conductive adhesive 3 is greater than the thickness D1 of the insulating layer 21, but should not be too large or too small. Specifically, the thickness D2 of the conductive adhesive 3 and the thickness D1 of the insulating layer 21 must satisfy the relationship 1.2≦D2:D1≦1.5. If the ratio D2:D1 is too large (e.g., greater than 1.5), the amount of conductive adhesive 3 used will increase, increasing the manufacturing cost of the photovoltaic module and not significantly improving the conductive effect of the conductive adhesive 3. If the ratio D2:D1 is too small (e.g., less than 1.2), the thickness D2 of the conductive adhesive 3 will be close to the thickness D1 of the insulating layer 21, resulting in an insufficient amount of conductive adhesive 3 used and preventing the through-holes 211 from being fully filled. This will prevent the conductive adhesive 3 from establishing a stable electrical connection between the grid lines 20 and the conductive layer 11.

[0070] As shown in the table below, when the values ​​of D2:D1 are different, the basic situation of the finished photovoltaic module is as shown in the table below.

[0071] [Table 1]

[0072] In addition, the conductive adhesive 3 may be applied directly into the through hole 211 using a dispensing method, or the conductive adhesive 3 may be printed at a position corresponding to the through hole 211 of the conductive layer 11 using a printing method.

[0073] In one specific embodiment, as shown in FIG. 9, for step S3 of providing a conductive layer 11 on the back sheet 1, the method for manufacturing a photovoltaic module specifically includes the following steps:

[0074] In step B1, a mask plate is provided on the back sheet 1.

[0075] A patterned mask plate is laminated to the surface of the backsheet 1 and is used to indicate the areas where the conductive layer 11 needs to be provided. Here, the backsheet 1 can be made of a material with high light transmittance, which can further improve the bifacial power generation capability of the photovoltaic module.

[0076] In step B2, a transparent metal oxide is deposited on the surface of the backsheet 1 through the openings in the mask plate to form a metal conductive layer 111.

[0077] A transparent metal oxide is deposited on the surface of the backsheet 1 by physical and / or chemical methods to form a metal conductive layer 111 having a thickness of 10 to 100 μm. The transparent metal oxide may be one or more of In2O3, SnO2, ZnO, CdO, CdIn2O4, Cd2SnO4, Zn2SnO4, and In2O3-ZnO. The transparent metal conductive layer 111 can ensure that more light reflected from the ground is irradiated onto the backside of the solar cell 2, which is advantageous for achieving bifacial power generation in a solar power module.

[0078] In step B3, the mask plate is removed and insulating grooves 113 are formed in the areas of the backsheet 1 where no transparent metal oxide is deposited.

[0079] As shown in Figure 11, no transparent metal oxide is deposited in the area on the surface of the backsheet 1 that is shielded by the mask plate, so an insulating groove 113 is formed, insulating and isolating the area where the metal conductive layer 111 is connected to the positive electrode of the solar cell 2 from the area where the metal conductive layer 111 is connected to the negative electrode of the solar cell 2, thereby preventing short circuits.

[0080] In one specific embodiment, as shown in FIG. 10 , after step B3, the method for manufacturing a photovoltaic module further includes step B4, in which an electrode connection layer 112 is formed on the surface of the metal conductive layer 111 by printing and sintering, and the metal conductive layer 111 and the electrode connection layer 112 jointly constitute the conductive layer 11.

[0081] The provision of the electrode connection layer 112 can improve the stability of the electrical connection between the metal conductive layer 111 and the grid lines 20 and reduce the risk of poor contact in the photovoltaic module. Specifically, the electrode connection layer 112 is formed by printing and sintering a paste containing a highly conductive material so that the electrode connection layer 112 can be firmly attached to the metal conductive layer 111.

[0082] This embodiment is not limited to a specific structure of the electrode connecting layer 112, and it may be a line, a dot, or other structure.

[0083] In one specific embodiment, as shown in FIG. 12, the material of the back sheet 1 is one of polyvinyl fluoride, ethylene-tetrafluoroethylene copolymer, and polyvinylidene fluoride, and the method for manufacturing a photovoltaic module further includes, before step S7, step C2 of inverting the cover plate 5, the encapsulating layer 4, the solar cells 2, and the back sheet 1 as a whole, with the cover plate 5 facing down and the back sheet 1 facing up.

[0084] The back sheet 1 is made of a flexible material. To prevent the flexible material from coming into contact with the supply table and deforming and breaking during lamination, the cover plate 5, encapsulating layer 4, solar cells 2, and back sheet 1 must be inverted as a whole before the lamination process, with the cover plate 5 facing downward and the back sheet 1 facing upward, and the inverted solar photovoltaic module must then be placed on the supply table of the laminating machine. This prevents the back sheet 1 from being damaged during lamination and improves the yield of solar photovoltaic modules.

[0085] In addition, polyvinyl fluoride (PVF), ethylene-tetrafluoroethylene copolymer (Ethylene-Tetra-Fluoro-Ethylene ETFE), and polyvinylidene fluoride (PVDF) are all transparent materials with high light transmittance and thicknesses of 0.2 mm to 6 mm, which can ensure that more light reflected from the ground is irradiated onto the back surface of the solar cell 2, which is advantageous for realizing bifacial power generation of solar modules.

[0086] In another specific embodiment, the material of the backsheet 1 is one of glass, polycarbonate, and polyethylene terephthalate.

[0087] In this embodiment, the back sheet 1 is made of a rigid material, and when performing the lamination process, there is no need to invert the entire photovoltaic module, but rather it can be placed directly on the supply table of the laminating machine. At this time, the back sheet 1 comes into contact with the supply table, and because of its high hardness, it will not be deformed or damaged during the lamination process. Compared with the back sheet 1 made of a flexible material, the back sheet 1 of this embodiment reduces the process complexity, omits the inversion step before lamination, and reduces the risk of defects in the manufacturing process of the photovoltaic module.

[0088] In addition, glass, polycarbonate (PC), and polyethylene terephthalate (PET) are all transparent materials with high light transmittance and thicknesses of 0.2 mm to 6 mm, which can ensure that more light reflected from the ground is irradiated onto the back surface of the solar cell 2, which is advantageous for realizing bifacial power generation of solar power modules.

[0089] Examples of the present application further provide a photovoltaic module, the photovoltaic module being manufactured by the manufacturing method described in each of the above embodiments, and including, along the thickness direction X of the photovoltaic module, a back sheet 1, solar cells 2, a conductive adhesive 3, a sealing layer 4, and a cover plate 5, as shown in Figures 1, 3, and 7. Here, a conductive layer 11 is provided on the back sheet 1, the solar cells 2 include grid lines 20, an insulating layer 21 and through holes 211 are provided on at least one surface of the solar cells 2, the through holes 211 correspond to the positions of the grid lines 20, the conductive adhesive 3 is located within the through holes 211, and both ends of the conductive adhesive 3 are connected to the conductive layer 11 and the grid lines 20, respectively, the sealing layer 4 covers the side of the solar cells 2 away from the back sheet 1, and the cover plate 5 covers the side of the sealing layer 4 away from the solar cells 2, and the cover plate 5, together with the back sheet 1, sandwich the sealing layer 4 and the solar cells 2.

[0090] In this embodiment, the surface of the solar cell 2 is covered with an insulating layer 21, which insulates the grid lines 20 from the conductive layer 11 and prevents short circuits caused by communication between the positive and negative grid lines of the solar cell 2. A plurality of through holes 211 are formed in the insulating layer 21 at positions corresponding to the grid lines 20 of the solar cell 2, and when the solar cell 2 is connected to the backsheet 1, a conductive adhesive 3 is provided in the through holes 211 and / or on the conductive layer 11 to electrically connect the grid lines 20 to the conductive layer 11 through the through holes 211, thereby improving the stability of the electrical connection of the solar power generation module and further increasing the yield rate of the solar power generation module.

[0091] In this embodiment, the insulating layer 21 is provided directly on the surface of the solar cell 2, and the conductive layer 11 is provided directly on the surface of the backsheet 1. This reduces the complexity of the solar cell module manufacturing process, eliminating the need for the composition process of the insulating layer 21 and the conductive layer 11, and simplifying the manufacturing process. At the same time, the risk of poor contact due to misalignment of the conductive adhesive 3 between the through-holes 211 and the grid lines 20 is also reduced. In the lamination process, the risk of poor contact or short circuits occurring due to misalignment of the insulating layer 21 and the solar cell 2 during lamination can also be reduced.

[0092] Specifically, as shown in FIG. 11, the conductive layer 11 includes a metal conductive layer 111 and an electrode connection layer 112, and the electrode connection layer 112 is provided on the surface of the metal conductive layer 111 that is close to the solar cell 2, and the conductive adhesive 3 has one end connected to the positive or negative electrode of the solar cell 2 and the other end connected to the electrode connection layer 112.

[0093] As shown in FIG. 2 , a plurality of grid lines 20 are provided at intervals on the surface of the solar cell 2. The grid lines 20 include positive and negative grid lines. The through-holes 211 expose a partial region of the positive grid line. The conductive adhesive 3 connects the region to the conductive layer 11 within the through-holes 211, thereby achieving the purpose of electrically connecting the positive electrode of the solar cell 2 to the conductive layer 11. Similarly, the through-holes 211 expose a partial region of the negative grid line. The conductive adhesive 3 connects the region to the conductive layer 11 within the through-holes 211, thereby achieving the purpose of electrically connecting the negative electrode of the solar cell 2 to the conductive layer 11.

[0094] Specifically, the conductive layer 11 includes a metal conductive layer 111 and an electrode connection layer 112, and the electrode connection layer 112 is firmly attached to the metal conductive layer 111 and is used to improve the stability of the electrical connection between the metal conductive layer 111 and the grid line 20 and reduce the risk of poor contact in the solar power generation module.

[0095] In one specific embodiment, the material of the electrode connecting layer 112 is one or more of Au, Ag, Cu, Al, Bi, Sn, and Pb.

[0096] In this embodiment, Au, Ag, Cu, Al, Bi, Sn, and Pb all have strong electrical conductivity. One or more of these materials are selected to be made into a highly conductive paste, which is then printed on the metal conductive layer 111 and sintered to form the electrode connection layer 112. This ensures that the conductive layer 11 has good electrical conductivity and prevents poor contact in the photovoltaic module.

[0097] In one specific embodiment, as shown in FIG. 11 , an insulating groove 113 is formed in the back sheet 1, the conductive layer 11 is arranged surrounding the insulating groove 113, and the region where the electrode connection layer 112 is connected to the positive electrode of the solar cell 2 and the region where the electrode connection layer 112 is connected to the negative electrode of the solar cell 2 are located on both sides of the insulating groove 113.

[0098] In this embodiment, the insulating groove 113 is formed in the conductive layer 11, and can insulate and isolate the area where the metal conductive layer 111 is connected to the positive electrode of the solar cell 2 from the area where the metal conductive layer 111 is connected to the negative electrode of the solar cell 2, thereby preventing a short circuit due to connection between the positive and negative electrodes of the solar cell 2 and improving the reliability and safety of the solar power generation module.

[0099] The above is only a preferred embodiment of the present application, and is not intended to limit the present application, and various modifications and variations are possible for those skilled in the art. Any modifications, equivalent replacements, improvements, etc. made within the spirit and principle of the present application shall be included within the protection scope of the present application. [Explanation of symbols]

[0100] 1-Back seat 11-Conductive layer 111-metal conductive layer 112-Electrode connection layer 113-Insulation Groove 2- Solar Cells 20-Grid Lines 21-Insulating layer 211-Through hole 3-Conductive adhesive 4-Sealing layer 5-Cover Plate

Claims

1. A method for manufacturing a solar power generation module, comprising: providing a front encapsulation structure comprising a cover plate (5) and an encapsulation layer (4), a solar cell (2) and a backsheet (1); providing an insulating layer (21) and a plurality of through holes (211) on at least one surface of the solar cell (2), aligning the positions of the plurality of through holes (211) with the grid lines (20) of the solar cell (2), and providing the plurality of through holes (211) at intervals in the extension direction of the grid lines (20); a step of depositing a transparent metal oxide on the back sheet (1) to form a transparent metal oxide layer, printing and sintering the surface of the transparent metal oxide layer to form an electrode connection layer (112), thereby forming a conductive layer (11), forming an insulating groove (113) in an area on the surface of the back sheet (1) where the transparent metal oxide is not deposited, the conductive layer (11) being provided surrounding the insulating groove (113), and the area where the electrode connection layer (112) is connected to the positive electrode of the solar cell (2) and the area where the electrode connection layer (112) is connected to the negative electrode of the solar cell (2) being located on both sides of the insulating groove (113); providing a conductive adhesive (3) on the conductive layer (11); connecting the backsheet (1) to the solar cell (2), bonding the insulating layer (21) to the conductive layer (11), and electrically connecting the grid lines (20) and the conductive layer (11) via the through holes (211) with the conductive adhesive (3); providing the sealing layer (4) on the side of the solar cell (2) away from the back sheet (1); providing the cover plate (5) on the side of the encapsulation layer (4) that is remote from the solar cell (2); laminating the cover plate (5), the encapsulation layer (4), the solar cells (2) and the backsheet (1) to form the photovoltaic module; When an insulating layer (21) and a through hole (211) are provided on at least one surface of the solar cell (2), the method for manufacturing the solar power generation module specifically includes: a step of printing an insulating adhesive on at least one surface of the solar cell (2); curing the insulating adhesive to form the insulating layer (21), and forming the through holes (211) in areas of the surface of the solar cell (2) where the insulating adhesive is not printed, and the insulating adhesive is not completely cured during the curing process; When laminating the cover plate (5), the sealing layer (4), the solar cell (2), and the back sheet (1), the insulating adhesive is completely cured, A method for manufacturing a solar power generation module, characterized in that the thickness of the insulating layer (21) is D1, the thickness of the conductive adhesive (3) is D2, and 1.2≦D2:D1≦1.

5.

2. The method for manufacturing a photovoltaic module according to claim 1 , wherein the insulating adhesive is a transparent insulating adhesive.

3. The method for manufacturing a photovoltaic module further includes conducting an electrical performance test on the solar cell (2) before printing an insulating adhesive on at least one surface of the solar cell (2) or after curing the insulating adhesive to form the insulating layer (21) and forming the through-hole (211) in an area of ​​the surface of the solar cell (2) where the insulating adhesive is not printed, and / or the method for manufacturing a solar photovoltaic module according to claim 1, further comprising sorting the solar cell (2) based on its color and appearance after curing the insulating adhesive to form the insulating layer (21) and forming the through-hole (211) in an area on the surface of the solar cell (2) where the insulating adhesive is not printed.

4. 2. The method for manufacturing a photovoltaic module according to claim 1, wherein the material of the backsheet (1) is one of glass, polycarbonate, and polyethylene terephthalate.

5. The material of the back sheet (1) is one of polyvinyl fluoride, ethylene-tetrafluoroethylene copolymer, and polyvinylidene fluoride, and before laminating the cover plate (5), the sealing layer (4), the solar cell (2), and the back sheet (1) to form the photovoltaic module, the method for manufacturing the photovoltaic module further includes:

2. The method for manufacturing a photovoltaic module according to claim 1, further comprising the step of inverting the cover plate (5), the encapsulation layer (4), the solar cells (2) and the back sheet (1) as a whole, with the cover plate (5) facing downward and the back sheet (1) facing upward.

6. A photovoltaic module, Along the thickness direction of the photovoltaic module, the photovoltaic module includes a backsheet (1), solar cells (2) including grid lines (20), a conductive adhesive (3), an encapsulation layer (4), and a cover plate (5); The back sheet (1) is provided with a conductive layer (11), an insulating layer (21) and a plurality of through holes (211) are provided on at least one surface of the solar cell (2), the plurality of through holes (211) corresponding to the positions of the grid lines (20), and the plurality of through holes (211) are provided at intervals in the extension direction of the grid lines (20); The conductive adhesive (3) is located in the through-hole (211), and both ends of the conductive adhesive (3) are connected to the conductive layer (11) and the grid line (20), respectively; The sealing layer (4) covers the side of the solar cell (2) that is away from the back sheet (1), the cover plate (5) covers the side of the sealing layer (4) that is away from the solar cell (2), and the cover plate (5) and the back sheet (1) sandwich the sealing layer (4) and the solar cell (2); The thickness of the insulating layer (21) is D1, the thickness of the conductive adhesive (3) is D2, and 1.2≦D2:D1≦1.5; the conductive layer (11) is composed of a transparent metal oxide layer and an electrode connection layer (112), the transparent metal oxide layer is composed of a transparent metal oxide, the electrode connection layer (112) contains a highly conductive material, and the electrode connection layer (112) is provided on a surface of the transparent metal oxide layer that is close to the solar cell (2); One end of the conductive adhesive (3) is connected to the positive electrode or negative electrode of the solar cell (2), and the other end is connected to the electrode connection layer (112), An insulating groove (113) is formed on the surface of the back sheet (1) on which the transparent metal oxide layer is not formed, and the conductive layer (11) is provided surrounding the insulating groove (113); A solar power generation module characterized in that a region where the electrode connection layer (112) is connected to the positive electrode of the solar cell (2) and a region where the electrode connection layer (112) is connected to the negative electrode of the solar cell (2) are located on both sides of the insulating groove (113).

7. 7. The photovoltaic module according to claim 6, wherein the material of the electrode connection layer is one or more of Au, Ag, Cu, Al, Bi, Sn, and Pb.

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