Preparation method for solar battery pack module

Abstract

The present application provides a preparation method for a solar battery pack module, comprising: providing a first packaging layer; forming a water-blocking adhesive layer on one side of the first packaging layer; forming a liquid or semi-liquid semi-solid first light-transmitting adhesive film on a battery pack placement region on one side of the first packaging layer; laying solar battery packs on a surface of the side of the first light-transmitting adhesive film facing away from the first packaging layer; forming a liquid or semi-liquid semi-solid second light-transmitting adhesive film on surfaces of the side of the solar battery packs facing away from the first light-transmitting adhesive film; providing a second packaging layer on the side of the water-blocking adhesive layer and the second light-transmitting adhesive film facing away from the first packaging layer; and laminating the structure comprising the first packaging layer, the first light-transmitting adhesive film, the solar battery packs, the second light-transmitting adhesive film, and the second packaging layer, so that after the laminating, the first light-transmitting adhesive film and the second light-transmitting adhesive film are melted and cured, and both the first light-transmitting adhesive film and the second light-transmitting adhesive film are in contact with the water-blocking adhesive layer. The photoelectric conversion efficiency, power, and reliability of the solar battery pack module formed by the preparation method are improved.

Description

A method for preparing a solar cell module

[0001] CROSS-REFERENCE TO RELATED APPLICATIONS

[0002] This application claims priority to the Chinese patent application filed with the China Patent Office on August 31, 2023, with application number 202311124825.X and invention name “A method for preparing a solar cell module”, the entire contents of which are incorporated herein by reference. Technical Field

[0003] The present application relates to the technical field of solar cell manufacturing, and in particular to a method for preparing a solar cell module. Background Art

[0004] Heterojunction cell technology, a high-efficiency technology that has garnered significant industry attention in recent years, has become recognized by the industry as the ultimate solution for future battery technology due to its high power, high photoelectric conversion efficiency, excellent performance, and significant potential for cost reduction. It was once hailed by the industry as the cutting-edge technology for the next generation of commercial photovoltaic production. However, the efficiency of high-efficiency heterojunction solar cell groups cannot be fully utilized after being encapsulated into solar cell modules. This is due to the fact that the maximum light transmittance of glass is around 94.3%, while the light transmittance of encapsulation film is around 90%. Furthermore, the ITO material used in the transparent conductive layer (TCO) of heterojunction solar cells is very sensitive to moisture. Exposure to moisture can lead to significant electrical performance loss, resulting in a decrease in the power of the solar cell module. Furthermore, solar cell modules are susceptible to mechanical impact during transportation and vibration caused by natural gravity when stored flat, which can increase the risk of cracking the solar cells in the solar cell module.

[0005] Therefore, there is a need to provide a solar cell module with higher photoelectric conversion efficiency and reliability, and accordingly there is a need to improve the preparation method.

[0006] Summary of the Invention

[0007] Therefore, the technical problem to be solved by the present application is to overcome the defects of low photoelectric conversion efficiency and reliability of solar cell modules formed by existing methods for preparing solar cell modules, and further provide a method for preparing solar cell modules.

[0008] The present application provides a method for preparing a solar cell module, comprising: providing a first encapsulation layer, the first encapsulation layer including a battery group placement area and an edge area surrounding the battery group placement area; forming a water-blocking adhesive layer in the edge area on one side of the first encapsulation layer; forming a liquid or semi-liquid and semi-solid first light-transmitting adhesive film in the battery group placement area on one side of the first encapsulation layer, the first light-transmitting adhesive film and the water-blocking adhesive layer being located on the same side of the first encapsulation layer; laying a solar cell group on a surface of the first light-transmitting adhesive film on a side facing away from the first encapsulation layer; forming a liquid adhesive layer on a surface of the solar cell group on a side facing away from the first light-transmitting adhesive film. a second light-transmitting adhesive film in a semi-liquid or semi-solid state; a second encapsulation layer is arranged on the side of the water-blocking adhesive layer and the second light-transmitting adhesive film facing away from the first encapsulation layer, and the thickness of the water-blocking adhesive layer is equal to or greater than the distance from the surface of the second light-transmitting adhesive film facing away from the first encapsulation layer to the first encapsulation layer; a structure including the first encapsulation layer, the first light-transmitting adhesive film, the solar cell group, the second light-transmitting adhesive film and the second encapsulation layer is laminated, and after lamination, the first light-transmitting adhesive film and the second light-transmitting adhesive film are melted and then solidified, and the first light-transmitting adhesive film and the second light-transmitting adhesive film are both in contact with the water-blocking adhesive layer.

[0009] Optionally, in the step of forming a liquid or semi-liquid and semi-solid first light-transmitting adhesive film in the battery pack placement area on one side of the first packaging layer, there is a gap between the first light-transmitting adhesive film and the water-blocking adhesive layer; in the step of laminating the first packaging layer, the first light-transmitting adhesive film, the solar cell group, the second light-transmitting adhesive film and the second packaging layer, the first light-transmitting adhesive film and / or the second light-transmitting adhesive film fills the gap.

[0010] Optionally, the width of the gap is 2 mm to 8 mm.

[0011] Optionally, the thickness of the water-blocking adhesive layer is 0.2 mm to 0.5 mm greater than the distance from the surface of the second light-transmitting adhesive film on the side facing away from the first encapsulation layer to the first encapsulation layer.

[0012] Optionally, the viscosity of the liquid or semi-liquid and semi-solid first light-transmitting adhesive film is 40,000 MPa.s to 60,000 MPa.s; the viscosity of the liquid or semi-liquid and semi-solid second light-transmitting adhesive film is 40,000 MPa.s to 60,000 MPa.s.

[0013] Optionally, the process used to form the liquid or semi-liquid and semi-solid first light-transmitting adhesive film includes a spraying process or a screen printing process; the process used to form the liquid or semi-liquid and semi-solid second light-transmitting adhesive film includes a spraying process or a screen printing process.

[0014] Optionally, the process used to form the first liquid or semi-liquid and semi-solid light-transmitting adhesive film includes a spraying process; in the steps of forming the first liquid or semi-liquid and semi-solid light-transmitting adhesive film: spraying is performed alternately along the first direction and the second direction; the first direction is perpendicular to the second direction; the process used to form the second liquid or semi-liquid and semi-solid light-transmitting adhesive film includes a spraying process; in the steps of forming the second liquid or semi-liquid and semi-solid light-transmitting adhesive film: spraying is performed alternately along the first direction and the second direction; the first direction is perpendicular to the second direction.

[0015] Optionally, the parameters for laminating the first encapsulation layer, the first light-transmitting adhesive film, the solar cell group, the second light-transmitting adhesive film and the second encapsulation layer include: a lamination temperature of 70°C to 120°C; a lamination time of 660s to 700s, and a lamination pressure of 35kPa to 75kPa.

[0016] Optionally, the process of laminating the first encapsulation layer, the first light-transmitting adhesive film, the solar cell group, the second light-transmitting adhesive film and the second encapsulation layer includes: a first lamination, a second lamination and a third lamination performed in sequence, with the pressure of the first lamination, the second lamination and the third lamination decreasing gradually.

[0017] Optionally, the pressure of the first lamination is 65 kPa to 75 kPa; the pressure of the second lamination is 45 kPa to 55 kPa; and the pressure of the third lamination is 35 kPa to 45 kPa.

[0018] Optionally, the first lamination time is 15s to 25s; the second lamination time is 15s to 25s; and the third lamination time is 630s to 650s.

[0019] Optionally, in the step of forming a liquid or semi-liquid and semi-solid first light-transmitting adhesive film in the battery pack placement area on one side of the first encapsulation layer, the thickness of the first light-transmitting adhesive film is 0.3mm~0.8mm; in the step of forming a liquid or semi-liquid and semi-solid second light-transmitting adhesive film on the surface of the solar cell group facing away from the first light-transmitting adhesive film, the thickness of the second light-transmitting adhesive film is 0.3mm~0.8mm.

[0020] Optionally, the material of the first light-transmitting adhesive film includes at least one of liquid silicone, silicone, liquid silicone rubber, liquid glue, gel, organic silicone gel, silicone body glue, silicone rubber, liquid raw material, silicone rubber glue and silicone rubber raw material; the material of the second light-transmitting adhesive film includes at least one of liquid silicone, silicone, liquid silicone rubber, liquid glue, gel, organic silicone gel, silicone body glue, silicone rubber, liquid raw material, silicone rubber glue and silicone rubber raw material.

[0021] Optionally, before laminating the first encapsulation layer, the first light-transmitting adhesive film, the solar cell group, the second light-transmitting adhesive film and the second encapsulation layer, the width of the water-blocking adhesive layer is 2 mm to 15 mm, and the thickness of the water-blocking adhesive layer is 0.5 mm to 3.5 mm.

[0022] Optionally, the material of the water-blocking adhesive layer includes any one of an isobutylene polymer and an isoprene polymer.

[0023] The technical solution of this application has the following advantages:

[0024] The present application provides a method for preparing a solar cell assembly, comprising the following steps: forming a water-blocking adhesive layer at an edge area on one side of a first encapsulation layer; forming a liquid or semi-liquid and semi-solid first light-transmitting adhesive film at a battery pack placement area on one side of the first encapsulation layer, wherein the first light-transmitting adhesive film and the water-blocking adhesive layer are located on the same side of the first encapsulation layer; laying a solar cell group on a surface of the first light-transmitting adhesive film on a side facing away from the first encapsulation layer; forming a liquid or semi-liquid and semi-solid second light-transmitting adhesive film on a surface of the solar cell group facing away from the first light-transmitting adhesive film; arranging a second encapsulation layer on a side of the water-blocking adhesive layer and the second light-transmitting adhesive film facing away from the first encapsulation layer, wherein the thickness of the water-blocking adhesive layer is equal to or greater than the distance from the surface of the second light-transmitting adhesive film on a side facing away from the first encapsulation layer to the first encapsulation layer; and laminating the first encapsulation layer, the first light-transmitting adhesive film, the solar cell group, the second light-transmitting adhesive film, and the second encapsulation layer, wherein after lamination, the first light-transmitting adhesive film and the second light-transmitting adhesive film are melted and then solidified, and the first light-transmitting adhesive film and the second light-transmitting adhesive film are both in contact with the water-blocking adhesive layer. First, the first light-transmitting adhesive film and the second light-transmitting adhesive film have the characteristics of high light transmittance and no yellowing, thus improving the light transmittance, photoelectric conversion efficiency and power of the solar cell module; secondly, the first light-transmitting adhesive film and the second light-transmitting adhesive film have the characteristics of aging resistance, and the first light-transmitting adhesive film, the second light-transmitting adhesive film and the water-blocking adhesive layer form a closed and insulated space, which can effectively prevent external water vapor, dust, etc. from penetrating into the interior of the solar cell module, thereby improving the water vapor resistance and weather resistance of the solar cell module; thirdly, the first light-transmitting adhesive film and the second light-transmitting adhesive film have the characteristics of flexibility. When the solar cell module is subjected to mechanical collision, the first light-transmitting adhesive film and the second light-transmitting adhesive film can play a buffering and protective role for the solar cell group, thus the reliability of the solar cell module is high. In summary, the solar cell module formed by the preparation method of the solar cell module has high photoelectric conversion efficiency, power and reliability. BRIEF DESCRIPTION OF THE DRAWINGS

[0025] In order to more clearly illustrate the specific implementation methods of the present application or the technical solutions in the prior art, the following is a brief introduction to the drawings required for use in the specific implementation methods or the description of the prior art. Obviously, the drawings described below are some implementation methods of the present application. For ordinary technicians in this field, other drawings can be obtained based on these drawings without any creative work.

[0026] FIG1 is a flow chart of a method for preparing a solar cell module according to an embodiment of the present application;

[0027] 2 to 9 are schematic structural diagrams of a solar cell assembly manufacturing process according to an embodiment of the present application;

[0028] FIG10 is a comparison diagram of the spectral response of a solar cell assembly formed by the method for preparing a solar cell assembly provided in this embodiment and a solar cell assembly formed by encapsulating with a conventional high-transmittance adhesive film.

[0029] Explanation of the accompanying symbols: 1-first encapsulation layer; 11-battery pack placement area; 12-edge area; 13-water-blocking adhesive layer; 21-first light-transmitting adhesive film; 3-solar cell group; 22-second light-transmitting adhesive film; 4-second encapsulation layer; L-gap; X-first direction; Y-second direction. DETAILED DESCRIPTION

[0030] The following will clearly and completely describe the technical solution of this application in conjunction with the accompanying drawings. Obviously, the embodiments described are only part of the embodiments of this application, not all of them. Based on the embodiments in this application, all other embodiments obtained by ordinary technicians in this field without making any creative efforts are within the scope of protection of this invention.

[0031] In the description of this application, it should be noted that the terms "center," "upper," "lower," "left," "right," "vertical," "horizontal," "inner," and "outer," etc., indicating orientations or positional relationships, are based on the orientations or positional relationships shown in the accompanying drawings and are intended solely to facilitate the description of this application and simplify the description. They do not indicate or imply that the devices or components referred to must have a specific orientation, be constructed, or operate in a specific orientation. Therefore, they should not be construed as limitations on this application. Furthermore, the terms "first," "second," and "third" are used for descriptive purposes only and should not be construed as indicating or implying relative importance.

[0032] In the description of this application, it should be noted that, unless otherwise expressly specified or limited, the terms "mounted," "connected," and "connected" should be understood in a broad sense. For example, they can refer to fixed connections, detachable connections, or integral connections; mechanical connections or electrical connections; direct connections or indirect connections through an intermediate medium; and internal connections between two components. Those skilled in the art will understand the specific meanings of the above terms in this application based on the specific circumstances.

[0033] In addition, the technical features involved in the different embodiments of the present application described below can be combined with each other as long as they do not conflict with each other.

[0034] This embodiment provides a method for preparing a solar cell module, referring to FIG1 , comprising the following steps:

[0035] Step S1: providing a first packaging layer, wherein the first packaging layer includes a battery pack placement area and an edge area surrounding the battery pack placement area;

[0036] Step S2: forming a water-blocking adhesive layer on an edge area of ​​one side of the first encapsulation layer;

[0037] Step S3: forming a liquid or semi-liquid and semi-solid first light-transmitting adhesive film on the battery pack placement area on one side of the first packaging layer, wherein the first light-transmitting adhesive film and the water-blocking adhesive layer are located on the same side of the first packaging layer;

[0038] Step S4: laying a solar cell group on the surface of the first light-transmitting adhesive film facing away from the first encapsulation layer;

[0039] Step S5: forming a second light-transmitting adhesive film in a liquid or semi-liquid and semi-solid state on a surface of the solar cell group facing away from the first light-transmitting adhesive film;

[0040] Step S6: providing a second encapsulation layer on the side of the water-blocking adhesive layer and the second light-transmitting adhesive film facing away from the first encapsulation layer, wherein the thickness of the water-blocking adhesive layer is equal to or greater than the distance from the surface of the second light-transmitting adhesive film facing away from the first encapsulation layer to the first encapsulation layer;

[0041] Step S7: Laminating the structure including the first encapsulation layer, the first light-transmitting adhesive film, the solar cell group, the second light-transmitting adhesive film and the second encapsulation layer, wherein the first light-transmitting adhesive film and the second light-transmitting adhesive film are melted and then solidified after lamination, and the first light-transmitting adhesive film and the second light-transmitting adhesive film are both in contact with the water-blocking adhesive layer.

[0042] The method for preparing a solar cell module provided by this embodiment, wherein the first light-transmitting adhesive film and the second light-transmitting adhesive film are both in contact with the water-blocking adhesive layer, firstly, the first light-transmitting adhesive film and the second light-transmitting adhesive film have the characteristics of high light transmittance and no yellowing, thus, the light transmittance, photoelectric conversion efficiency and power of the solar cell module can be improved, secondly, the first light-transmitting adhesive film and the second light-transmitting adhesive film have the characteristics of aging resistance, and the first light-transmitting adhesive film, the second light-transmitting adhesive film and the water-blocking adhesive layer form a closed and insulated space, which can effectively prevent external water vapor, dust, etc. from penetrating into the interior of the solar cell module, thereby improving the water vapor resistance and weather resistance of the solar cell module; thirdly, the first light-transmitting adhesive film and the second light-transmitting adhesive film have the characteristics of flexibility, and when the solar cell module is subjected to mechanical collision, the first light-transmitting adhesive film and the second light-transmitting adhesive film can play a buffering and protective role for the solar cell group, thus, the reliability of the solar cell module is high. In summary, the solar cell module formed by the method for preparing the solar cell module has high photoelectric conversion efficiency, power and reliability.

[0043] During the step of laminating the first encapsulation layer, the first light-transmitting adhesive film, the solar cell assembly, the second light-transmitting adhesive film, and the second encapsulation layer, the first light-transmitting adhesive film and / or the second light-transmitting adhesive film fill the gap. The gap is filled with the first light-transmitting adhesive film and the second light-transmitting adhesive film, which have high light transmittance and are non-yellowing. While the solar cell assembly fully utilizes light, the first and second light-transmitting adhesive films on the sides can also improve the utilization of light from the sides, thereby increasing the photoelectric conversion efficiency of the solar cell assembly.

[0044] The method for preparing the solar cell module will be described in detail below with reference to FIG. 2 to FIG. 9 .

[0045] 2 , a first encapsulation layer 1 is provided. The first encapsulation layer 1 includes a battery pack placement area 11 and an edge area 12 surrounding the battery pack placement area 11 .

[0046] In one embodiment, the first encapsulation layer 1 comprises glass, and the glass is photovoltaic glass commonly used in the photovoltaic industry.

[0047] 3 , a water-blocking adhesive layer 13 is formed in an edge region 12 on one side of the first encapsulation layer 1 .

[0048] In one embodiment, the water-blocking adhesive layer 13 is formed by applying adhesive using a barrel or directly applying adhesive tape.

[0049] In one embodiment, the water-blocking adhesive layer 13 includes a transparent water-blocking adhesive layer and a non-transparent water-blocking adhesive layer.

[0050] In one embodiment, the width of the water-blocking adhesive layer 13 is 2 mm to 15 mm, for example, 3 mm, 5 mm, 8 mm, 10 mm, 12 mm or 14 mm; if the width of the water-blocking adhesive layer 13 is less than 2 mm, the water-blocking adhesive layer has a weak effect of preventing water vapor and dust in the environment from passing through the water-blocking adhesive layer and penetrating into the solar cell group; if the width of the water-blocking adhesive layer 13 is greater than 15 mm, the width of the water-blocking adhesive layer is too large, which may cause the water-blocking adhesive layer to overflow during lamination, resulting in waste.

[0051] In one embodiment, the thickness of the water-blocking adhesive layer 13 is 0.5 mm to 3.5 mm, for example, 1 mm, 1.5 mm, 2 mm, 2.5 mm or 3 mm; if the thickness of the water-blocking adhesive layer 13 is less than 0.5 mm, the thickness of the water-blocking adhesive layer is too small, which may cause the solar cell group to be in a less completely enclosed environment and play a lesser role in blocking water vapor; if the thickness of the water-blocking adhesive layer 13 is greater than 3.5 mm, it is easy for the adhesive to overflow during the lamination process, resulting in a waste of resources.

[0052] In one embodiment, the material of the water-blocking adhesive layer 13 includes any one of an isobutylene polymer and an isoprene polymer; in other embodiments, the material of the water-blocking adhesive layer may also include other butyl adhesive materials with high-performance water vapor barrier and anti-aging capabilities.

[0053] 4 , a liquid or semi-liquid and semi-solid first light-transmitting adhesive film 21 is formed in the battery pack placement area 11 on one side of the first packaging layer 1 . The first light-transmitting adhesive film 21 and the water-blocking adhesive layer 13 are located on the same side of the first packaging layer 1 .

[0054] In one embodiment, the material of the first light-transmitting adhesive film 21 includes at least one of liquid silicone, silicone, liquid silicone rubber, liquid glue, gel, organic silicone gel, silicone gel, silicone rubber, liquid raw material, silicone rubber glue and silicone rubber raw material.

[0055] In one embodiment, referring to FIG4 , in the step of forming a liquid or semi-liquid and semi-solid first light-transmitting adhesive film in the battery pack placement area 11 on one side of the first packaging layer 1 , a gap L is provided between the first light-transmitting adhesive film 21 and the water-blocking adhesive layer 13 .

[0056] In one embodiment, the size of the gap L is 2 mm to 8 mm, for example, 2.5 mm, 3 mm, 3.5 mm, 4 mm, 4.5 mm, 5.5 mm or 6.5 mm; if the gap L between the first light-transmitting adhesive film 21 and the water-blocking adhesive layer 13 is less than 2 mm, the water-blocking adhesive layer may overflow onto the first light-transmitting adhesive film during the lamination process; if the gap L between the first light-transmitting adhesive film 21 and the water-blocking adhesive layer 13 is greater than 8 mm, in the final solar cell assembly, there may still be gaps between the water-blocking adhesive layer and the first light-transmitting adhesive film and between the water-blocking adhesive layer and the second light-transmitting adhesive film, which may easily lead to the formation of bubbles, affecting the appearance and weather resistance of the solar cell assembly. In order to avoid the presence of bubbles between the water-blocking adhesive layer and the first light-transmitting adhesive film and between the water-blocking adhesive layer and the second light-transmitting adhesive film after lamination, before a liquid or semi-liquid and semi-solid first light-transmitting adhesive film is formed in the battery pack placement area on one side of the first encapsulation layer, and before a liquid or semi-liquid and semi-solid second light-transmitting adhesive film is formed on the surface of the solar cell group facing away from the first light-transmitting adhesive film, the method also includes: removing bubbles from the material of the first light-transmitting adhesive film and the material of the second light-transmitting adhesive film. The method for removing bubbles includes combining vacuuming and baking, centrifuging, or standing the material of the first light-transmitting adhesive film and the material of the second light-transmitting adhesive film. The resting time is 30 minutes to 2 hours, allowing bubbles in the first and second light-transmitting adhesive films to float to the surface and be discharged. The centrifugal method involves stirring the first and second light-transmitting adhesive films in a clockwise direction for 2 to 3 minutes. After stirring evenly, the first and second light-transmitting adhesive films are allowed to stand for 5 to 20 minutes to automatically degas. This method is only suitable for first and second light-transmitting adhesive films with relatively thin viscosities. If the first and second light-transmitting adhesive films are very thick, trapped bubbles are difficult to rise and discharge. Furthermore, combining vacuuming and baking can also help volatilize impurities in the first and second light-transmitting adhesive films.

[0057] In one embodiment, in the step of forming a liquid or semi-liquid and semi-solid first light-transmitting adhesive film 21 in the battery pack placement area 11 on one side of the first packaging layer 1, the thickness of the first light-transmitting adhesive film 21 is 0.3mm to 0.8mm, for example, 0.35mm, 0.4mm, 0.45mm, 0.5mm, 0.55mm, 0.6mm or 0.65mm; if the thickness of the first light-transmitting adhesive film 21 is less than 0.3mm, then when the solar cell assembly is subjected to mechanical collision, the buffering protection effect of the first light-transmitting adhesive film on the solar cell group is not obvious; if the thickness of the first light-transmitting adhesive film 21 is greater than 0.8mm, then the first light-transmitting adhesive film is easy to overflow during the lamination process, resulting in waste of resources.

[0058] In one embodiment, the process of forming the liquid or semi-liquid and semi-solid first light-transmitting adhesive film includes a spraying process or a screen printing process, and the spraying process includes a barrel glue spraying method or a dispensing glue method.

[0059] In one embodiment, the viscosity of the liquid or semi-liquid / semi-solid first light-transmitting adhesive film is between 40,000 MPa.s and 60,000 MPa.s, for example, 45,000 MPa.s, 50,000 MPa.s, or 55,000 MPa.s. If the viscosity of the liquid or semi-liquid / semi-solid first light-transmitting adhesive film is less than 40,000 MPa.s, the viscosity of the first light-transmitting adhesive film is too low, resulting in a long curing time. If the viscosity of the liquid or semi-liquid / semi-solid first light-transmitting adhesive film is greater than 60,000 MPa.s, the viscosity of the first light-transmitting adhesive film is too high, resulting in poor fluidity, a short curing time, and ineffective automatic filling of gaps between solar cells. Therefore, selecting a viscosity of the first light-transmitting adhesive film between 40,000 MPa.s and 60,000 MPa.s achieves both a short curing time and a good effect of filling gaps between adjacent solar cells in a solar cell array.

[0060] In one embodiment, with reference to Figures 4 and 5, the process used to form the liquid or semi-liquid and semi-solid first light-transmitting adhesive film includes a spraying process; in the step of forming the liquid or semi-liquid and semi-solid first light-transmitting adhesive film: spraying is performed alternately along a first direction X and a second direction Y; the first direction X is perpendicular to the second direction Y; and the first direction X is parallel to the side of the first encapsulation layer.

[0061] Referring to Figure 6 , a solar cell group 3 is placed on the surface of the first light-transmitting adhesive film 21 facing away from the first encapsulation layer 1. During the placement of the solar cell group 3 on the surface of the first light-transmitting adhesive film 21 facing away from the first encapsulation layer 1, the first encapsulation layer and the first light-transmitting adhesive film are kept horizontal. A suction cup is used to absorb the solar cell group, and after precise positioning, the solar cell group is placed on the surface of the first light-transmitting adhesive film 21 facing away from the first encapsulation layer 1, within the battery group placement area 11.

[0062] In one embodiment, the steps for forming the solar cell group 3 include: arranging the solar cells cut by laser in sequence through a string welding machine, wherein the solar cells include half-cell cells, and then welding the solar cells in series in sequence through interconnecting strips; after welding, a plurality of solar cell strings in series are formed; then, the plurality of solar cell strings in series are arranged in sequence according to the electrode sequence through a typesetting machine to complete the laying of multiple solar cell strings, and then the solar cell strings are connected in parallel with bus bars through a stack welding machine, and leads are left for installation with the junction box in the subsequent process. After the bus welding is completed, a solar cell string array is formed; and then the solar cell string array is positioned by tape to position the solar cell string array to form a solar cell group.

[0063] In one embodiment, the solar cell comprises a double-sided heterojunction solar cell without busbar printing, and a transparent conductive film (TCO) is provided on the surface of the solar cell, which is an ITO film or an AZO film; the busbar is a common welding ribbon in the photovoltaic industry.

[0064] In one embodiment, after laying the solar cell group 3 on the surface of the first light-transmitting adhesive film 21 facing away from the first packaging layer 1, it also includes: performing defect detection on the solar cell group 3 and repairing the defective solar cell group. Compared with performing defect detection after the solar cell assembly is formed, such operation is beneficial to avoid causing a large amount of repeated rework workload, reduce labor costs, improve production line utilization and production efficiency, and reduce repair costs.

[0065] Defect detection of the solar cell group includes: one or more of appearance morphology detection, hidden crack detection and cold solder joint detection. Appearance morphology detection is to detect whether the solar cell group is damaged. Hidden crack detection is to detect whether the solar cells in the solar cell group have cracks. Cold solder joint detection is to detect whether there are cold solder joints between the solar cells and the soldering ribbons in the solar cell group.

[0066] In one embodiment, when performing the hidden crack detection on the solar cell group, if cracks are detected in solar cells in the solar cell group, the solar cell group with the cracks needs to be repaired until the solar cell group passes the inspection.

[0067] In another embodiment, when the cold solder joint detection is performed on the solar cell group, if a cold solder joint is detected between the solar cell and the soldering ribbon in the solar cell group, the cold solder joint position between the solar cell and the soldering ribbon with the cold solder joint needs to be re-soldered until the solar cell group passes the inspection.

[0068] 7 , a second light-transmitting adhesive film 22 in a liquid or semi-liquid and semi-solid state is formed on a surface of the solar cell group 3 facing away from the first light-transmitting adhesive film 21 .

[0069] In one embodiment, the material of the second light-transmitting adhesive film 22 includes at least one of liquid silicone, silicone, liquid silicone rubber, liquid glue, gel, organic silicone gel, silicone gel, silicone rubber, liquid raw material, silicone rubber glue and silicone rubber raw material.

[0070] In one embodiment, in the step of forming a liquid or semi-liquid and semi-solid second light-transmitting adhesive film 22 on the surface of the solar cell group 3 facing away from the first light-transmitting adhesive film 21, the thickness of the second light-transmitting adhesive film 22 is 0.3 mm to 0.8 mm, for example, 0.35 mm, 0.4 mm, 0.45 mm, 0.5 mm, 0.55 mm, 0.6 mm or 0.65 mm; if the thickness of the second light-transmitting adhesive film 22 is less than 0.3 mm, when the solar cell assembly is subjected to a mechanical collision, the buffering protection effect of the second light-transmitting adhesive film on the solar cell group is not obvious; if the thickness of the second light-transmitting adhesive film 22 is greater than 0.8 mm, the second light-transmitting adhesive film is likely to overflow during the lamination process, resulting in a waste of resources.

[0071] In one embodiment, the thickness of the water-blocking adhesive layer is 0.2 mm to 0.5 mm greater than the distance from the surface of the second light-transmitting adhesive film on the side facing away from the first encapsulation layer to the first encapsulation layer, for example, 0.3 mm. This is conducive to the first light-transmitting adhesive film, the second light-transmitting adhesive film and the water-blocking adhesive layer forming a closed and insulating space, which can effectively prevent external water vapor, dust, etc. from penetrating into the interior of the solar cell module, thereby improving the water vapor barrier performance and weather resistance of the solar cell module.

[0072] In one embodiment, the process of forming the liquid or semi-liquid and semi-solid second light-transmitting adhesive film 22 includes a spraying process or a screen printing process, and the spraying process includes a barrel glue spraying method or a dispensing glue method.

[0073] In one embodiment, the viscosity of the liquid or semi-liquid / semi-solid second light-transmitting adhesive film is 40,000 MPa.s to 60,000 MPa.s, such as 45,000 MPa.s, 50,000 MPa.s, or 55,000 MPa.s. If the viscosity of the liquid or semi-liquid / semi-solid second light-transmitting adhesive film is less than 40,000 MPa.s, the viscosity of the second light-transmitting adhesive film is too low, resulting in a long curing time. If the viscosity of the liquid or semi-liquid / semi-solid second light-transmitting adhesive film is greater than 60,000 MPa.s, the viscosity of the second light-transmitting adhesive film is too high, resulting in poor fluidity, a short curing time, and ineffective automatic filling of the gaps between the cells. In this embodiment, the viscosity of the second light-transmitting adhesive film is selected to be 40,000 MPa.s to 60,000 MPa.s, which achieves a good balance between a short curing time and a good effect of filling the gaps between the cells.

[0074] In one embodiment, the process used to form the second liquid or semi-liquid and semi-solid light-transmitting adhesive film includes a spraying process; in the steps of forming the liquid or semi-liquid and semi-solid second light-transmitting adhesive film: spraying is performed alternately along a first direction and a second direction; the first direction is perpendicular to the second direction and the first direction is parallel to the side of the first encapsulation layer.

[0075] Referring to Figure 8 , a second encapsulation layer 4 is disposed on the side of the water-blocking adhesive layer 13 and the second light-transmitting adhesive film 22 facing away from the first encapsulation layer 1. Specifically, a glass laminating machine or a laying machine is used to dispose the second encapsulation layer 4 on the side of the water-blocking adhesive layer 13 and the second light-transmitting adhesive film 22 facing away from the first encapsulation layer 1. The first encapsulation layer, the first light-transmitting adhesive film, the solar cell group, the second light-transmitting adhesive film, and the second encapsulation layer constitute a solar cell module stack.

[0076] In one embodiment, the second encapsulation layer 4 comprises glass, which is photovoltaic glass commonly used in the photovoltaic industry.

[0077] Refer to Figure 9, which is a schematic diagram of the first encapsulation layer, the first light-transmitting adhesive film, the solar cell group, the second light-transmitting adhesive film and the second encapsulation layer in Figure 8 after lamination. After lamination, the first light-transmitting adhesive film, the second light-transmitting adhesive film and the water-blocking adhesive layer form a sealed package for the solar cell group. The first encapsulation layer, the first light-transmitting adhesive film, the solar cell group, the second light-transmitting adhesive film and the second encapsulation layer are laminated. During the lamination, the first light-transmitting adhesive film and the second light-transmitting adhesive film are melted and solidified, and the first light-transmitting adhesive film and the second light-transmitting adhesive film are both in contact with the water-blocking adhesive layer.

[0078] In one embodiment, after the second encapsulation layer 4 is set on the side of the water-blocking adhesive layer 13 and the second light-transmitting adhesive film 22 facing away from the first encapsulation layer 1, before laminating the first encapsulation layer, the first light-transmitting adhesive film, the solar cell group, the second light-transmitting adhesive film and the second encapsulation layer, the method further includes: defect detection of the solar cell module stack. If problems are found, the unqualified solar cell module stack is placed on a repair station for timely repair. The defects before lamination of the first encapsulation layer, the first light-transmitting adhesive film, the solar cell group, the second light-transmitting adhesive film and the second encapsulation layer are first eliminated. Lamination is performed after completion, and the entire solar cell module after lamination is inspected and repaired to strictly ensure product quality. In this way, the difficulty of separating the first encapsulation layer and the second encapsulation layer during repair is reduced, and the probability of the solar cell group causing hidden cracks and fragments due to excessive force during separation is also reduced. Therefore, the encapsulation efficiency and yield of the preparation method of the solar cell module are high. The solar cell module needs to be inspected before lamination to ensure that defective products can be repaired. After lamination, the laminated parts cannot be repaired and the quality level can only be confirmed by inspection and identification of solar cell components.

[0079] In one embodiment, before laminating the first packaging layer, the first light-transmitting adhesive film, the solar cell group, the second light-transmitting adhesive film and the second packaging layer, the method further includes: vacuuming the cavity of the laminator, and the vacuuming time is 280s to 320s, for example, 290s, 300s or 310s. If the vacuuming time of the cavity of the laminator is less than 280s, the gas in the battery component stack is not extracted thoroughly, which may easily lead to the presence of bubbles between the first light-transmitting adhesive film and the solar cell group, between the second light-transmitting adhesive film and the solar cell group, between the first packaging layer and the first light-transmitting adhesive film, and between the second packaging layer and the second light-transmitting adhesive film, thereby affecting the appearance and weather resistance of the solar cell component.

[0080] In one embodiment, the parameters for laminating the first encapsulation layer 1, the first light-transmitting adhesive film 21, the solar cell group 3, the second light-transmitting adhesive film 22 and the second encapsulation layer 4 include: the lamination temperature is: 70°C to 120°C, for example, 100°C; the lamination time is: 660s to 700s, for example, 690s; the lamination pressure is 35kPa to 75kPa, for example, 70kPa.

[0081] In one embodiment, the process of laminating the first encapsulation layer 1, the first light-transmitting adhesive film 21, the solar cell group 3, the second light-transmitting adhesive film 22, and the second encapsulation layer 4 includes: a first lamination, a second lamination, and a third lamination performed sequentially, with the pressures of the first, second, and third laminations decreasing. The first lamination time is 15s to 25s, for example, 20s; the first lamination pressure is 65kPa to 75kPa, for example, 70kPa; the second lamination time is 15s to 25s, for example, 20s; the second lamination pressure is 45kPa to 55kPa, for example, 50kPa; the third lamination time is 630s to 650s, for example, 640s; and the third lamination pressure is 35kPa to 45kPa, for example, 40kPa. The lamination of the first encapsulation layer 1 , the first light-transmitting adhesive film 21 , the solar cell group 3 , the second light-transmitting adhesive film 22 and the second encapsulation layer 4 is divided into three laminations, which is conducive to complete curing of the first light-transmitting adhesive film 21 and the second light-transmitting adhesive film 22 .

[0082] In one embodiment, after laminating the first encapsulation layer 1, the first light-transmitting adhesive film 21, the solar cell group 3, the second light-transmitting adhesive film 22 and the second encapsulation layer 4, the method further includes: performing appearance inspection and trimming on the laminated battery assembly stack.

[0083] In one embodiment, the first light-transmitting adhesive film and the second light-transmitting adhesive film are both mixed adhesives of type A and type B, with a mixing ratio of 1:1. Single type A or type B adhesive does not cure. After mixing, the curing time required at room temperature of 25 degrees Celsius is greater than 6 hours. When the lamination temperature is greater than 70 degrees Celsius, the liquid silicone rubber has a light transmittance of more than 94%, a yellowing index and a haze of less than 0.2%, and a volume shrinkage of less than 0.1%.

[0084] In one embodiment, the method for preparing the solar cell assembly further includes: providing a packaging frame (not shown in the drawings), the packaging frame having a accommodating cavity, and forming a frame glue on the inner wall surface of the accommodating cavity; thereafter, inserting the edge area of ​​the laminated battery assembly into the accommodating cavity.

[0085] In one embodiment, before the second encapsulation layer 4 is provided on the side of the water-blocking adhesive layer 13 and the second light-transmitting adhesive film 22 facing away from the first encapsulation layer 1, the method further includes: forming lead holes, wherein three lead holes are arranged at intervals, and the diameter of each lead hole is 9 mm to 13 mm. The surface of the second encapsulation layer facing away from the first encapsulation layer is covered with centrifugal paper, which covers the lead holes and has channels for allowing busbars to pass through. The centrifugal paper is made of a high-temperature resistant material and does not shrink or melt under high temperature conditions, such as 150 degrees Celsius. The lead holes also penetrate the second encapsulation layer and the second light-transmitting adhesive film in a direction perpendicular to the first encapsulation layer 1. During the process of providing the second encapsulation layer 4 on the side of the water-blocking adhesive layer 13 and the second light-transmitting adhesive film 22 facing away from the first encapsulation layer 1, the busbar is passed through the lead holes. Thereafter, a sealing filler is formed in the lead holes, and the sealing filler is then cured. In one embodiment, the method for preparing the solar cell module further includes power testing and final inspection steps.

[0086] The first and second light-transmitting adhesive films formed after the liquid silicone is cured can convert light in the ultraviolet band into visible light. They have the characteristics of high light transmittance, aging resistance, no yellowing, and softness. The first and second light-transmitting adhesive films formed after the liquid silicone is cured can achieve a light transmittance of about 94% of the glass, which can fully utilize the light.

[0087] Referring to Table 1, the method for preparing a solar cell module provided in this embodiment can effectively improve the water resistance and optical gain of the solar cell module, as well as the reliability and power of the solar cell module. Simulation tests have shown that the service life of the solar cell module can be extended to over 40 years. Table 1 shows the different test parameters obtained by performing different tests on two groups of solar cell modules provided in this embodiment. Among them, "initial" refers to the test of electrical performance parameters of solar cell modules without any treatment; "DH1000h" refers to the test of electrical performance parameters after 1000 hours of damp heat aging test on solar cell modules; "DH1000h" decay refers to the change of electrical performance parameters after 1000 hours of damp heat aging test on solar cell modules compared with the change of electrical performance parameters after no treatment on solar cell modules; "TC200" refers to the test of electrical performance parameters after 200 cycles of temperature cycling on solar cell modules; "TC200 decay" refers to the change of electrical performance parameters after 200 cycles of temperature cycling on solar cell modules compared with the change of electrical performance parameters after no treatment on solar cell modules; "PID288h" refers to the test of electrical performance parameters after 288 hours of temperature cycling on solar cell modules. The electrical performance parameters are tested after potential induced decay (PID288h decay), and the electrical performance parameters are measured after 288 hours of potential induced decay and without any treatment. The electrical performance parameters are tested after UV120 irradiation of the solar cell module at a power of 120kWh and without any treatment. Among the test parameters, Isc refers to the short-circuit current, Voc refers to the open-circuit voltage, Imp refers to the current at the maximum power point, Vmp refers to the voltage at the maximum power point, Pmax refers to the maximum power temperature coefficient, and FF refers to the fill factor.

[0088] Table 1

[0089] The test data in Table 1 are environmental aging experiments conducted in accordance with IEC test standards. From the parameters of "DH1000h attenuation", "TC200 attenuation", "PID288h attenuation", and "UV120 attenuation", it can be seen that the solar cell module formed by the preparation method of the solar cell module provided in this embodiment has a power attenuation that is far less than the IEC test requirements. Therefore, it can be seen that the solar cell module formed by the preparation method of the solar cell module has excellent anti-aging performance and can significantly increase the reliability of the solar cell module.

[0090] Referring to Table 2, which shows the short-circuit current parameters of a solar cell module formed using the method for preparing a solar cell module provided by this embodiment and the current integrated density of the spectral response of a solar cell module formed using conventional high-transmittance film encapsulation, it can be seen that compared with the solar cell module formed using the method for preparing a solar cell module provided by this embodiment, the solar cell module formed using the method for preparing a solar cell module provided by this embodiment has a 1.4% increase in photoelectric conversion efficiency within the 300nm-1200nm spectrum, a 2.5% increase in photoelectric conversion efficiency within the 300nm-380nm spectrum, a 1.3% increase in photoelectric conversion efficiency within the 380nm-780nm spectrum, and a 1.5% increase in photoelectric conversion efficiency within the 780nm-1200nm spectrum. This improves the overall power of the module.

[0091] Table 2

[0092] Referring to Figure 10, Figure 10 is a comparison of the spectral responses of a solar cell assembly formed using the method for preparing a solar cell assembly provided by this embodiment and a solar cell assembly formed using conventional high-transmittance film encapsulation. In Figure 10, the horizontal axis represents wavelength, and the vertical axis represents spectral response. Spectral response indicates the ability of a solar cell to convert incident light energy of different wavelengths into electrical energy, and its unit is amperes per watt (Amp / Watt). As can be seen from Figure 10, in the ultraviolet band of 400nm to 1080nm, the internal quantum efficiency of the solar cell assembly formed using the method for preparing a solar cell assembly provided by this embodiment is significantly better than that of the solar cell assembly formed using conventional high-transmittance film encapsulation, more intuitively reflecting that the solar cell assembly formed using the method for preparing a solar cell assembly provided by this embodiment has a better photoelectric conversion efficiency than the solar cell assembly formed using conventional high-transmittance film encapsulation.

[0093] Obviously, the above embodiments are merely examples for clarity of explanation and are not intended to limit the implementation methods. Those skilled in the art will readily appreciate that other variations or modifications based on the above descriptions are possible. It is not necessary and impossible to enumerate all implementation methods here. Obvious variations or modifications arising therefrom remain within the scope of protection of the present invention.

Claims

1. A method for preparing a solar cell module, characterized in that: include: Providing a first packaging layer, the first packaging layer comprising a battery pack placement area and an edge area surrounding the battery pack placement area; forming a water-blocking adhesive layer at an edge region of one side of the first encapsulation layer; A first light-transmitting adhesive film in a liquid or semi-liquid and semi-solid state is formed in a battery pack placement area on one side of the first packaging layer, wherein the first light-transmitting adhesive film and the water-blocking adhesive layer are located on the same side of the first packaging layer; Laying a solar cell group on the surface of the first light-transmitting adhesive film on a side away from the first encapsulation layer; Forming a second light-transmitting adhesive film in a liquid or semi-liquid and semi-solid state on a surface of the solar cell group on a side away from the first light-transmitting adhesive film; A second encapsulation layer is provided on the side of the water-blocking adhesive layer and the second light-transmitting adhesive film away from the first encapsulation layer, and the thickness of the water-blocking adhesive layer is equal to or greater than the distance from the surface of the second light-transmitting adhesive film away from the first encapsulation layer to the first encapsulation layer; The structure including the first encapsulation layer, the first light-transmitting adhesive film, the solar cell group, the second light-transmitting adhesive film and the second encapsulation layer is laminated, and after lamination, the first light-transmitting adhesive film and the second light-transmitting adhesive film are melted and then solidified, and the first light-transmitting adhesive film and the second light-transmitting adhesive film are both in contact with the water-blocking adhesive layer.

2. The method for preparing a solar cell assembly according to claim 1, characterized in that: In the step of forming a liquid or semi-liquid and semi-solid first light-transmitting adhesive film in the battery pack placement area on one side of the first packaging layer, a gap is provided between the first light-transmitting adhesive film and the water-blocking adhesive layer; In the step of laminating the first encapsulation layer, the first light-transmitting adhesive film, the solar cell group, the second light-transmitting adhesive film and the second encapsulation layer, the first light-transmitting adhesive film and / or the second light-transmitting adhesive film fills the gap; Preferably, the width of the gap is 2 mm to 8 mm; Preferably, the thickness of the water-blocking adhesive layer is 0.2 mm to 0.5 mm greater than the distance from the surface of the second light-transmitting adhesive film on the side away from the first encapsulation layer to the first encapsulation layer.

3. The method for preparing a solar cell assembly according to claim 1, characterized in that: The viscosity of the first light-transmitting adhesive film in liquid or semi-liquid and semi-solid state is 40000mpa.s to 60000mpa.s; the viscosity of the second light-transmitting adhesive film in liquid or semi-liquid and semi-solid state is 40000mpa.s to 60000mpa.s.

4. The method for preparing a solar cell assembly according to claim 1, characterized in that: The process used to form the first light-transmitting adhesive film in liquid or semi-liquid and semi-solid state includes spraying process or screen printing process; the process used to form the second light-transmitting adhesive film in liquid or semi-liquid and semi-solid state includes spraying process or screen printing process.

5. The method for preparing a solar cell assembly according to claim 4, characterized in that: The process for forming the first light-transmitting adhesive film in a liquid or semi-liquid and semi-solid state includes a spraying process; in the step of forming the first light-transmitting adhesive film in a liquid or semi-liquid and semi-solid state: spraying is performed alternately along a first direction and a second direction; the first direction is perpendicular to the second direction; The process used to form the liquid or semi-liquid and semi-solid second light-transmitting adhesive film includes a spraying process; in the step of forming the liquid or semi-liquid and semi-solid second light-transmitting adhesive film: spraying is performed alternately along the first direction and the second direction; the first direction is perpendicular to the second direction.

6. The method for preparing a solar cell assembly according to claim 1, characterized in that: Parameters for laminating the first encapsulation layer, the first light-transmitting adhesive film, the solar cell group, the second light-transmitting adhesive film and the second encapsulation layer include: a lamination temperature of 70° C. to 120° C.; a lamination time of 660 s to 700 s; and a lamination pressure of 35 kPa to 75 kPa; Preferably, the process of laminating the first encapsulation layer, the first light-transmitting adhesive film, the solar cell group, the second light-transmitting adhesive film and the second encapsulation layer comprises: a first lamination, a second lamination and a third lamination performed in sequence, and the pressure of the first lamination, the second lamination and the third lamination decreases gradually; Preferably, the pressure of the first lamination is 65kPa to 75kPa; the pressure of the second lamination is 45kPa to 55kPa; the pressure of the third lamination is 35kPa to 45kPa; Preferably, the first lamination time is 15s to 25s; the second lamination time is 15s to 25s; and the third lamination time is 630s to 650s.

7. The method for preparing a solar cell module according to any one of claims 1 to 6, characterized in that: In the step of forming a liquid or semi-liquid and semi-solid first light-transmitting adhesive film in the battery pack placement area on one side of the first packaging layer, the thickness of the first light-transmitting adhesive film is 0.3 mm to 0.8 mm; In the step of forming a liquid or semi-liquid and semi-solid second light-transmitting adhesive film on a surface of the solar cell group facing away from the first light-transmitting adhesive film, the thickness of the second light-transmitting adhesive film is 0.3 mm to 0.8 mm.

8. The method for preparing a solar cell module according to any one of claims 1 to 6, characterized in that: The material of the first light-transmitting adhesive film includes at least one of liquid silicone, silicone, liquid silicone rubber, liquid glue, gel, organic silicone gel, silicone gel, silicone rubber, liquid raw material, silicone rubber glue and silicone rubber raw material; The material of the second light-transmitting adhesive film includes at least one of liquid silicone, silicone, liquid silicone rubber, liquid glue, gel, organic silicone gel, silicone gel, silicone rubber, liquid raw material, silicone rubber glue and silicone rubber raw material.

9. The method for preparing a solar cell module according to any one of claims 1 to 6, characterized in that: Before laminating the first encapsulation layer, the first light-transmitting adhesive film, the solar cell group, the second light-transmitting adhesive film and the second encapsulation layer, the width of the water-blocking adhesive layer is 2 mm to 15 mm, and the thickness of the water-blocking adhesive layer is 0.5 mm to 3.5 mm.

10. The method for preparing a solar cell module according to any one of claims 1 to 6, characterized in that: The material of the water-blocking adhesive layer includes any one of isobutylene polymers and isoprene polymers.

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