Photovoltaic module and manufacturing method therefor

Abstract

The present application relates to a photovoltaic module and a manufacturing method therefor. The photovoltaic module (10) comprises a plurality of cell strings (100) which are arranged at intervals in a first direction and / or a second direction, and a plurality of bypass units (200) which are connected by means of at least one of a series connection and a parallel connection, wherein the plurality of cell strings (100) are connected by means of at least one of a series connection and a parallel connection, and each cell string (100) comprises a plurality of cell units (110) which are connected in series and arranged at intervals in the second direction; each bypass unit (200) is arranged on a first surface side of a cell unit (110) or a group of cell units in the cell string (100), and is coupled to the cell unit (110) or the group of cell units; and each bypass unit (200) comprises a bypass element (210), a first electrically conductive member (220) connected to the bypass element (210), a second electrically conductive member (230) connected to the first electrically conductive member (220) and the cell unit (110), and a first insulating layer (240) arranged between the first electrically conductive member (220) and the cell unit (110). The photovoltaic module may reduce the impact of shading on the overall output power of the module and reduce the "hotspot effect".

Description

Photovoltaic modules and their manufacturing methods Technical Field

[0001] This application relates to the field of solar cell technology, and in particular to a photovoltaic module and a method for manufacturing the same. Background Technology

[0002] Photovoltaic modules are the core component of solar power generation systems. Within these modules, solar cells are easily affected by localized shading from surrounding buildings and other structures, leading to a decrease in the module's conversion efficiency. Furthermore, shaded solar cells may experience localized overheating, resulting in a "hot spot effect." This not only accelerates the aging process of the solar cells and shortens the lifespan of the photovoltaic module, but in severe cases, it can also burn out the solar cells, compromising the module's safety.

[0003] To mitigate the negative impact of localized shading on the conversion efficiency and safety of photovoltaic (PV) modules, the most common approach is to install bypass diodes in the junction box of the PV module. Each bypass diode is connected in reverse parallel with one or more cell strings. When several cells in a cell string are shaded, the bypass diodes are turned on to maintain the current conduction path for the other cell strings. This not only prevents shaded cells from lowering the overall conversion efficiency of the PV module, but also prevents shaded cells from overheating and being damaged.

[0004] However, existing bypass diode configurations still have many disadvantages. In specific application scenarios, especially for low-power photovoltaic modules or portable photovoltaic modules, the improvement in module efficiency is limited and still cannot meet the actual needs of users. Summary of the Invention

[0005] Therefore, it is necessary to provide a photovoltaic module and its manufacturing method to address the aforementioned technical problems, so as to further improve the conversion efficiency and excellent hot spot durability of the photovoltaic module.

[0006] Therefore, one aspect of this application provides a photovoltaic module, comprising:

[0007] A plurality of battery strings spaced apart along a first direction and / or a second direction, the plurality of battery strings being connected by at least one of series and parallel connection to provide an output voltage, wherein each of the battery strings includes a plurality of battery cells connected in series and spaced apart along the second direction, the first direction being perpendicular to the second direction;

[0008] Multiple bypass units are connected in at least one manner, either in series or in parallel. Each bypass unit is disposed on the first surface side of a battery cell or a group of battery cells in the battery string and coupled to the battery cell or group of battery cells, wherein the battery cell group comprises multiple battery cells connected in series. The bypass unit includes:

[0009] Bypass components;

[0010] A first conductive member connected to the bypass element, wherein the first conductive member extends along the second direction;

[0011] A second conductive member connected to the first conductive member, the second conductive member being disposed on the first surface side of one of the plurality of battery cells or a group of battery cells and connected to the battery cell;

[0012] A first insulating layer is disposed between the first conductive component and the battery cell;

[0013] The thickness of the bypass unit is less than or equal to 2.3 mm.

[0014] Alternatively, in conjunction with any of the above aspects, in another implementation of this aspect, the thickness of the bypass unit is less than or equal to 1.2 mm.

[0015] Alternatively, in conjunction with any of the above aspects, in another implementation of this aspect, the bypass element includes a bypass diode and a conductive pin, the bypass diode being connected to the first conductive member via the conductive pin.

[0016] Optionally, in combination with any of the above aspects, another implementation of this aspect further includes: a plurality of busbars respectively disposed at opposite first and second ends of the battery strings, the plurality of battery strings being connected in series through the busbars.

[0017] Alternatively, in conjunction with any of the above aspects, in another implementation of this aspect, each of the busbars is connected to a first conductive member of one of the bypass units.

[0018] Alternatively, in conjunction with any of the above aspects, in another implementation of this aspect, the bypass diode is a thin-film diode, or the thickness of the bypass diode is less than or equal to 1 mm.

[0019] Alternatively, in conjunction with any of the above aspects, in another implementation of this aspect, in the vertical direction of the plane where the insulating layer is located, the height of the bypass diode is greater than the height of the connection between the conductive pin and the first conductive member, and the height of the connection between the conductive pin and the first conductive member is greater than the height of the first conductive member.

[0020] Alternatively, in conjunction with any of the above aspects, in another implementation of this aspect, the first conductive member and / or the second conductive member are made of metal foil.

[0021] Optionally, in conjunction with any of the above aspects, in another implementation of this aspect, the thickness of the first conductive member is less than the thickness of the second conductive member, and / or the width of the first conductive member is greater than the thickness of the second conductive member.

[0022] Alternatively, in conjunction with any of the above aspects, in another implementation of this aspect, the width of the conductive pin is less than or equal to the width of the first conductive member.

[0023] Alternatively, in conjunction with any of the above aspects, in another implementation of this aspect, the projection of each of the bypass elements or the bypass diodes onto the plane where the plurality of battery strings are located is completely covered by the projection of one of the battery cells onto the plane where the plurality of battery strings are located.

[0024] Alternatively, in combination with any of the above aspects, in another implementation of this aspect, two adjacent battery cells in each battery string are connected in series through a plurality of grid lines;

[0025] The second conductive member is connected to all the grid lines on the first surface side of the battery cell that are not covered by the insulating layer.

[0026] Optionally, in conjunction with any of the above aspects, in another implementation of this aspect, the plurality of busbars includes a first positive busbar and a first negative busbar, the first positive busbar and the first negative busbar being connected to a junction box.

[0027] Alternatively, in conjunction with any of the above aspects, in another implementation of this aspect, the bypass element is not provided in the junction box.

[0028] Optionally, in combination with any of the above aspects, another implementation of this aspect further includes a jumper unit, comprising:

[0029] A third conductive member is disposed on the first surface side of one of the plurality of battery cells or a group of battery cells, wherein the third conductive member is connected to the first negative electrode busbar and the junction box;

[0030] A second insulating layer is disposed between the third conductive member and the battery cell.

[0031] Alternatively, in combination with any of the above aspects, in another implementation of this aspect, the jumper unit and the bypass unit are arranged at intervals along the first direction.

[0032] Optionally, in combination with any of the above aspects, another implementation of this aspect further includes at least two encapsulation units, in which the plurality of battery strings and the plurality of bypass units are encapsulated between the at least two encapsulation units.

[0033] As another aspect of this application, a method for manufacturing a photovoltaic module is provided, comprising:

[0034] The step of forming a battery circuit includes a plurality of battery strings spaced apart along a first direction and / or a second direction, the plurality of battery strings being connected by at least one of series and parallel connection to provide an output voltage, each of the battery strings including a plurality of battery cells connected in series and spaced apart along the second direction, the first direction being perpendicular to the second direction;

[0035] The step of forming a bypass circuit includes a plurality of bypass units connected by at least one of series and parallel connections, each bypass unit corresponding to a battery cell or a group of battery cells, the battery cell group including a plurality of battery cells connected in series; wherein, the bypass unit includes: a bypass element, a first conductive member connected to the bypass element, a second conductive member connected to the first conductive member, and a first insulating layer disposed between the first conductive member and the battery cell; wherein, the thickness of the bypass unit is less than or equal to 2.3 mm;

[0036] The step of electrically connecting the second conductive member to the battery cell.

[0037] As another aspect of this application, a method for manufacturing a photovoltaic module is provided, comprising:

[0038] The step of forming a battery circuit includes a plurality of battery strings spaced apart along a first direction and / or a second direction, the plurality of battery strings being connected by at least one of series and parallel connection to provide an output voltage, each of the battery strings including a plurality of battery cells connected in series and spaced apart along the second direction, the first direction being perpendicular to the second direction;

[0039] The step of forming a first bypass circuit includes a first insulating layer and a plurality of second conductive members. The second conductive members are disposed on the first surface side of one of the plurality of battery cells or a group of battery cells and connected to the battery cell. The battery cell group includes a plurality of battery cells connected in series. The first insulating layer is disposed between the second conductive members and the battery cells.

[0040] The step of forming a second bypass circuit, the second bypass circuit including a bypass element and a first conductive member connected to the bypass element;

[0041] The method includes the step of electrically connecting the first conductive member and the second conductive member to form a bypass circuit, the bypass circuit comprising a plurality of bypass units connected by at least one of series and parallel connection, each bypass unit corresponding to a battery cell or a group of battery cells; wherein the bypass unit comprises: the bypass element, a first conductive member connected to the bypass element, a second conductive member connected to the first conductive member, and a first insulating layer disposed between the first conductive member and the battery cell; wherein the thickness of the bypass unit is less than or equal to 2.3 mm.

[0042] As described above, the photovoltaic module and its manufacturing method, by coupling each bypass unit to a cell cell or a cell cell group, allows for short-circuiting of the cell cell or the cell cell group containing the cell cell when a cell cell is shaded, rather than short-circuiting the entire cell string containing the cell cell. Only the shaded cell cell or the cell cell group containing the cell cell stops working, while other cell cells and other cell strings in the cell string containing the cell cell can operate normally. This reduces the impact of shading on the overall output power of the module and provides superior hot spot durability. Furthermore, by placing the bypass unit on the first surface side of the cell cell, this application improves the rationality of the circuit layout, eliminating the need to increase the gap between two adjacent cell strings to accommodate the bypass unit. This also avoids excessive stress on the cell cell, which could cause damage, increasing the unit power generation area of ​​the photovoltaic module while maintaining excellent reliability.

[0043] The foregoing application provides a simplified overview of some concepts, which will be further described in detail in the following specific embodiments. The foregoing application is not intended to identify key or essential features of the claimed subject matter, nor is it intended to help determine the scope of the claimed subject matter. The subject matter claimed in this application is not limited to embodiments that address any or all the shortcomings pointed out in the background art. Attached Figure Description

[0044] The accompanying drawings, incorporated in and forming part of this specification, illustrate embodiments consistent with this application and, together with the description, serve to explain the principles of this application. To more clearly illustrate the technical solutions of the embodiments of this application, the drawings used in the description of the embodiments will be briefly introduced below. Obviously, those skilled in the art can obtain other drawings based on these drawings without any creative effort. These drawings and textual descriptions are not intended to limit the scope of the concept of this application in any way, but rather to illustrate the concepts of this application to those skilled in the art by referring to specific embodiments.

[0045] Figure 1 is a schematic diagram of the structure of a photovoltaic module provided in an embodiment of this application, viewed from the front.

[0046] Figure 2 is a schematic diagram of the structure of a photovoltaic module provided in an embodiment of this application, viewed from the back.

[0047] Figure 3 is a schematic diagram of the structure of a photovoltaic module from the front view according to another embodiment of this application.

[0048] Figure 4 is a structural schematic diagram of a photovoltaic module provided in another embodiment of this application, viewed from the back.

[0049] Figure 5 is a schematic diagram of the connection between two adjacent battery cells in the same battery string according to an embodiment of this application.

[0050] Figure 6 is a schematic diagram of the current flow direction in the photovoltaic module provided in Figure 1.

[0051] Figure 7 is a schematic diagram of the current flow direction in the photovoltaic module provided in Figure 3.

[0052] Figure 8 is a magnified view of part B in Figure 4.

[0053] Figure 9 is a magnified view of part A in Figure 2.

[0054] Figure 10 is a cross-sectional view of the bypass unit of the photovoltaic module provided in Figure 2 or Figure 4.

[0055] Figure 11 is an exploded view of a photovoltaic module provided in another embodiment of this application. Detailed Implementation

[0056] To make the above-mentioned objectives, features, and advantages of this application more apparent and understandable, the specific embodiments of this application are described in detail below with reference to the accompanying drawings. Many specific details are set forth in the following description to provide a thorough understanding of this application. However, this application can be implemented in many other ways different from those described herein, and those skilled in the art can make similar modifications without departing from the spirit of this application. Therefore, this application is not limited to the specific embodiments disclosed below.

[0057] In the description of this application, it should be understood that if terms such as "center", "longitudinal", "lateral", "length", "width", "thickness", "upper", "lower", "front", "rear", "left", "right", "vertical", "horizontal", "top", "bottom", "inner", "outer", "clockwise", "counterclockwise", "axial", "radial", "circumferential" appear, these terms indicate the orientation or positional relationship based on the orientation or positional relationship shown in the accompanying drawings, and are only for the convenience of describing this application and simplifying the description, and do not indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation, and therefore should not be construed as a limitation of this application.

[0058] Furthermore, where the terms "first" and "second" appear, these terms are for descriptive purposes only and should not be construed as indicating or implying relative importance or implicitly specifying the number of technical features indicated. Thus, a feature defined with "first" or "second" may explicitly or implicitly include at least one of that feature. In the description of this application, where the term "multiple" appears, "multiple" means at least two, such as two, three, etc., unless otherwise explicitly specified.

[0059] In this application, unless otherwise expressly specified and limited, the terms "installation," "connection," "joining," and "fixing," etc., should be interpreted broadly. For example, they can refer to a fixed connection, a detachable connection, or an integral part; they can refer to a mechanical connection or an electrical connection; they can refer to a direct connection or an indirect connection through an intermediate medium; they can refer to the internal communication of two components or the interaction between two components, unless otherwise expressly limited. Those skilled in the art can understand the specific meaning of the above terms in this application based on the specific circumstances.

[0060] In this application, unless otherwise expressly specified and limited, the use of descriptions such as "above" or "below" the second feature indicates that the first and second features are in direct contact or indirect contact via an intermediate medium. Furthermore, "above," "on top of," and "over" the second feature can mean that the first feature is directly above or diagonally above the second feature, or simply that the first feature is at a higher horizontal level than the second feature. Similarly, "below," "below," and "under" the second feature can mean that the first feature is directly below or diagonally below the second feature, or simply that the first feature is at a lower horizontal level than the second feature.

[0061] It should be noted that if an element is referred to as being "fixed to" or "set on" another element, it can be directly on the other element or there may be an intervening element. If an element is considered to be "connected to" another element, it can be directly connected to the other element or there may be an intervening element. If so, the terms "vertical," "horizontal," "upper," "lower," "left," "right," and similar expressions used in this application are for illustrative purposes only and do not represent the only possible implementation.

[0062] Photovoltaic modules, as the core component of a solar power generation system, are typically composed of multiple cell strings connected in series and parallel. Each cell string includes multiple cell units connected in series. However, photovoltaic modules are susceptible to localized shading from surrounding buildings, vegetation, clouds, etc., which can lead to a decrease in the conversion efficiency of the photovoltaic modules. Furthermore, solar cells affected by shading may experience localized overheating, resulting in a "hot spot effect." This accelerates the aging process of the solar cells, shortens the lifespan of the photovoltaic modules, and in severe cases, can burn out the solar cells, compromising the safety of the photovoltaic system.

[0063] To mitigate the negative impact of localized shading on the conversion efficiency and safety of photovoltaic (PV) modules, the most common approach is to connect a bypass diode in reverse parallel to each cell string within the PV module. When sunlight is unobstructed, the bypass diode is reverse-biased, and each cell in the string generates electricity. When a cell is shaded, it stops generating electricity, becoming a high-resistance resistor. Simultaneously, the other cells reverse-bias it, causing the bypass diode connected to the cell to conduct. The current that would have flowed through the shaded cell is now diverted by the bypass diode.

[0064] However, even if only one battery cell is damaged or shaded, the power generation of the other battery cells connected in series with that cell in the battery string will be affected. This impact may be negligible for high-power applications such as photovoltaic power plants, but it is a huge loss for low-power or portable photovoltaic modules. Therefore, there is still a need to further improve the conversion efficiency and hot spot durability of photovoltaic modules.

[0065] As shown in Figures 1 and 2, one embodiment of this application provides a photovoltaic module 10, which includes multiple battery strings 100 and multiple bypass units 200. The multiple battery strings 100 are arranged at intervals along a first direction and / or a second direction and connected by at least one of series and parallel connections to provide an output voltage. The first direction is perpendicular to the second direction. Throughout this text, "first direction" refers to the direction of the "X-axis" shown in Figure 1, and "second direction" refers to the direction of the "Y-axis" shown in Figure 1. All battery strings 100 can be arranged at intervals along the first direction (see Figure 1) or along the second direction, depending on requirements; alternatively, a portion of the battery strings 100 can be arranged at intervals along the first direction, while the remaining battery strings 100 can be arranged at intervals along the second direction. Each battery string 100 includes multiple battery cells 110 connected in series and arranged at intervals along the second direction.

[0066] The output voltage of the photovoltaic module 10 is mainly related to the connection method and number of the battery strings 100 and the number of battery cells 110 set in each battery string 100. The multiple battery strings 100 can be connected in series, in parallel, or in a mixed series-parallel connection. The number of battery strings 100 can be set to 2, 3, 4, 5 or more. The number of battery cells 110 in each battery string 100 can be set to 2, 3, 4, 5, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, 15, 16, 17 or more. For example, the photovoltaic module 10 shown in Figures 1 and 2 has four battery strings 100 connected in series, and each battery string 100 has 13 battery cells 110. The photovoltaic module 10 has a power generation of 200W. For example again, the photovoltaic module 10 shown in Figures 3 and 4 has three battery strings 100 connected in series, and each battery string 100 has 16 battery cells 110. The photovoltaic module 10 has a power generation of 120W.

[0067] The battery cell 110, as the smallest power generation unit of the photovoltaic module 10, can be an IBC cell (Interdigitated Back Contact), a TOPCON (Tunnel Oxide Passivated Contact) cell, a PERC cell (Passivated emitter and real cell), or a heterojunction cell. This application does not impose specific restrictions on the type of battery cell 110.

[0068] As shown in Figure 5, adjacent battery cells 110 in each battery string 100 are connected in series via multiple grid lines 120. Each battery cell 110 has a first surface 111 and a second surface 112 facing each other. The first surface 111 is the negative electrode of the battery cell 110, and the second surface 112 is the positive electrode of the battery cell 110; alternatively, the first surface 111 is the positive electrode of the battery cell 110, and the second surface 112 is the negative electrode of the battery cell 110. The first surface 111 of one battery cell 110 is connected in series with the second surface 112 of the next battery cell 110 via grid lines 120, or vice versa. When sunlight shines on the surface of the battery cell 110, the battery cell 110 absorbs the light and generates a current. Photogenerated charge carriers are separated under the influence of a built-in electric field, and electrons are collected by the grid lines 120 on the battery cell 110.

[0069] Optionally, a plurality of grid lines 120 on the first surface 111 and / or the second surface 112 of the battery cell 110 are spaced apart along a first direction.

[0070] The photovoltaic module 10 also includes busbars respectively disposed at the first and second ends of the cell strings 100, and multiple cell strings 100 are connected through the busbars. The busbars facilitate the series, parallel, or mixed series-parallel connection of multiple cell strings 100. Among them, the first surface 111 or the second surface 112 of the outermost cell unit 110 in the cell string 100 is connected to the busbar through the grid line 120.

[0071] Optionally, the busbar can be a foil strip made of a highly conductive metal such as copper, aluminum, silver, molybdenum, tin-plated copper, or silver-plated molybdenum.

[0072] The number of busbars is mainly related to the number and connection method of the battery strings 100. For example, when the photovoltaic module 10 has 3 battery strings 100 connected in series, there are 2 busbars at the first end of the battery strings 100 and 2 busbars at the second end of the battery strings 100. For example again, when the photovoltaic module 10 has 4 battery strings 100 connected in series, there are 3 busbars at the first end of the battery strings 100 and 2 busbars spaced apart at the second end of the battery strings 100.

[0073] In one embodiment, as shown in Figures 2 and 4, the photovoltaic module 10 provided in this embodiment further includes a junction box (not shown in the figures); multiple busbars include a first positive busbar 310 and a first negative busbar 320, which are connected to the junction box. This arrangement facilitates the connection of the power generated by the photovoltaic module 10 to external lines. It should be noted that the first positive busbar 310 shown in Figure 4 is pulled to the opening of the back panel via a jumper wire to connect to the junction box on the back of the back panel.

[0074] When the number of battery strings 100 is even, the current transmission path through the busbars in the multiple battery strings 100 is shown in Figure 6. As can be seen from Figure 6, the current inflow and outflow ends are located at the same end of the multiple battery strings 100. At this time, the first positive busbar 310 and the first negative busbar 320 are located at the same end of the multiple battery strings 100. The dashed arrows in Figure 6 represent the direction of current flow.

[0075] When the number of battery strings 100 is odd, the current transmission path through the busbars in the multiple battery strings 100 is shown in Figure 7. As can be seen from Figure 7, the current inflow and outflow ends are located at different ends of the multiple battery strings 100. In this case, the first positive busbar 310 and the first negative busbar 320 are located at different ends of the multiple battery strings 100. To facilitate the connection of the first positive busbar 310 and the first negative busbar 320 to the junction box, as shown in Figure 4, the photovoltaic module 10 may also include a jumper unit 400, which is connected to the first negative busbar 320 and the junction box. The jumper unit 400 allows the negative and positive terminals of the photovoltaic module 10 to be pulled to the same side, facilitating the connection of the positive and negative terminals of the photovoltaic module 10 to the junction box. The dashed arrows in Figure 7 represent the direction of current flow.

[0076] In one embodiment, as shown in FIG8, the jumper unit 400 includes a third conductive member 410 and a second insulating layer 420. The third conductive member 410 is disposed on the first surface 111 side of one of the battery cells 110 or a group of battery cells 110. The third conductive member 410 is connected to the first negative busbar 320 and the junction box. The battery cell group includes a plurality of battery cells 110 connected in series. The second insulating layer 420 is disposed between the third conductive member 410 and the battery cell 110. By disposing the third conductive member 410 on the first surface 111 side of one of the battery cells 110 or a group of battery cells 110, rather than on the side, the frame width of the photovoltaic module 10 does not need to be increased, which can increase the unit power generation area of ​​the photovoltaic module 10 and improve the energy density of the photovoltaic module 10. In addition, the second insulating layer 420 disposed between the battery cell 110 and the third conductive member 410 can separate the third conductive member 410 from the battery cell 110 and avoid short circuits. It should be noted that the "width direction" in the entire text is the same as the "first direction" mentioned above.

[0077] Optionally, the third conductive component 410 is made of metal foil. If the thickness of the third conductive component 410 is too large, it will increase the thickness non-uniformity of the entire photovoltaic module 10. During hot lamination, the third conductive component 410 is prone to crushing the cell unit 110, and the reliability of the module product during use will also decrease. Therefore, the third conductive component 410 is made of metal foil, and its thickness needs to be precisely designed. It should be noted that the "thickness direction" in this text refers to the direction of the "Z-axis" shown in Figure 1, which is perpendicular to the first and second directions.

[0078] Optionally, the third conductive component 410 is a metal foil strip structure. Considering that a smaller thickness of the third conductive component 410 would lead to an increase in its resistivity, in this embodiment, the third conductive component 410 is made into a strip structure, which increases its width and thus its cross-sectional area, thereby reducing its resistivity and improving the efficiency of the photovoltaic module 10. The third conductive component 410 can be a metal foil strip made of materials such as copper, aluminum, silver, molybdenum, tin-plated copper, or silver-plated molybdenum.

[0079] Optionally, as shown in Figure 4, the bypass unit 200 and the jumper unit 400 are arranged at intervals along the first direction. This arrangement prevents the bypass unit 200 and the jumper unit 400 from being connected together, thus avoiding short circuits.

[0080] Multiple bypass units 200 are connected in at least one manner, either in series or in parallel. Each bypass unit 200 is disposed on the first surface 111 side of a battery cell 110 or a battery cell group in the corresponding battery string 100 and is coupled to that battery cell 110 or battery cell group. It should be noted that since each bypass unit 200 is coupled to a corresponding battery cell 110 or battery cell group, and not to the entire battery string 100, the connection method of the multiple bypass units 200 described here is not the same as the connection method of the multiple battery strings 100. Instead, the series and parallel connection design of the circuit should be carried out according to the actual situation.

[0081] When sunlight shines on the surface of battery cell 110, battery cell 110 absorbs photons and generates current. Photogenerated charge carriers are separated under the action of the built-in electric field. Electrons are collected by the grid lines 120 on battery cell 110, while holes flow out through the metal electrodes of battery cell 110, and the corresponding bypass unit 200 is in a reverse bias state. When a battery cell 110 or a battery cell group is shaded, the power generation efficiency of the shaded battery cell 110 is significantly reduced. At this time, the corresponding bypass unit 200 is turned on, and current flows through the corresponding bypass unit 200, short-circuiting the battery cell 110 or the battery cell group including the battery cell 110, to prevent the battery cell 110 from being broken down or overheated and damaged.

[0082] Each bypass unit 200 can be coupled to one battery unit 110 or multiple battery units 110 connected in series (i.e., the "battery unit group" mentioned above). Optionally, each bypass unit 200 is coupled to two to four battery units 110 connected in series, that is, two to four battery units 110 connected in series are connected in reverse parallel with one bypass unit 200. With this configuration, it is not necessary for each battery unit 110 to be connected in reverse parallel with a bypass unit 200, which can reduce the manufacturing cost of the photovoltaic module 10 and also reduce the impact of shading on the overall output power of the photovoltaic module 10.

[0083] Optionally, the thickness of the bypass unit 200 is less than or equal to 2.3 mm, such as 2.3 mm, 2.2 mm, 2.1 mm, 2.0 mm, 1.9 mm, 1.8 mm, 1.7 mm, 1.6 mm, 1.5 mm, 1.4 mm, 1.3 mm, 1.2 mm, 1.1 mm, 1.0 mm, 0.9 mm, 0.8 mm, 0.7 mm, 0.6 mm, 0.5 mm, etc. Because the battery unit 110 is made of crystalline silicon and its thickness is only 0.1–0.3 mm, the battery unit 110 is relatively brittle and prone to microcracks. Therefore, when the bypass unit 200 is disposed on the first surface 111 side of the battery cell 110 or battery cell group, the thickness of the bypass unit 200 must not be too thick. Otherwise, it will increase the unevenness of the component thickness. During component thermal lamination or use, the stress generated by the bypass unit 200 will compress the battery cell 110, causing microcracks or breakage, leading to an increased product defect rate. To address this, this application embodiment optimizes the thickness of the bypass unit 200 through reasonable circuit design and material selection, thus ensuring the product pass rate. It should be noted that the thickness of the bypass unit 200 refers to the thickness of the thickest part of the bypass unit 200, which typically refers to the location of the bypass element 211.

[0084] This application couples each bypass unit 200 to a battery cell 110 or a battery cell group. When a battery cell 110 is blocked, the battery cell 110 or the battery cell group including the battery cell 110 can be short-circuited, rather than the entire battery string 100 including the battery cell 110. Only the blocked battery cell 110 or the battery cell group including the battery cell 110 stops working, while other battery cells 110 and other battery strings 100 including the battery cell 110 can work normally. That is, the embodiments of this application realize a cell-level bypass design, reduce the impact of blocking on the overall output power of the module, and can provide better hot spot durability performance. In addition, by optimizing the circuit design and material selection of the first bypass unit 200, this application places the first bypass unit 200 on the first surface 111 side of the battery cell 110, rather than on the side. This eliminates the need to increase the gap between two adjacent battery strings 100 to accommodate the first bypass unit 200, thus improving the rationality of the circuit layout. At the same time, it avoids excessive stress on the battery cell, which could cause damage to the battery cell. This increases the unit power generation area of ​​the photovoltaic module while maintaining excellent reliability.

[0085] In some embodiments of this application, as shown in Figures 8 and 9, the bypass unit 200 includes a bypass element 210, a first conductive member 220, a second conductive member 230, and a first insulating layer 240. The first conductive member 220 is connected to the bypass element 210 and extends along a second direction. The second conductive member 230 is connected to the first conductive member 220 and is disposed on the first surface 111 side of one of the battery cells 110 or a group of battery cells and connected to the battery cell 110. The first insulating layer 240 is disposed between the first conductive member 220 and the battery cell 110. The bypass element 210 is connected in reverse parallel to a battery cell 110 or a group of battery cells through the first conductive member 220 and the second conductive member 230, so as to provide a bypass path for the battery cell 110 or the group of battery cells coupled to the bypass unit 200.

[0086] In one embodiment, the first conductive member 220 is made of metal foil (e.g., copper foil strip, aluminum foil strip, tin-plated copper foil strip, silver-plated molybdenum foil strip, etc.). The metal foil not only has good conductivity, but also has a very small thickness, which can be as thin as 0.2 mm. This reduces the thickness of the first conductive member 220, making the thickness of the bypass unit 200 less than or equal to 2.3 mm.

[0087] Similarly, the second conductive component 230 may also be made of metal foil (e.g., copper foil strip, aluminum foil strip, tin-plated copper foil strip, silver-plated molybdenum foil strip, etc.).

[0088] Since the first conductive member 220 spans multiple battery cells 110, it is more prone to crushing the battery cells 110 during module lamination than the second conductive member 230. Furthermore, it is necessary to optimize the thermal performance of the bypass unit 200. In one embodiment, the thickness of the first conductive member 220 is set to be less than the thickness of the second conductive member 230; for example, the thickness of the first conductive member 220 is 0.1 mm, and the thickness of the second conductive member 230 is 0.2 mm. This setting reduces the stress of the first conductive member 220 on the battery cells 110. Since the second conductive member 230 is connected to the grid lines of the battery cells 110, and the carriers move first in the thickness direction and then sequentially in the length direction, the thickness of the second conductive member 230 is set to be larger, which reduces the resistance of the second conductive member 230 and decreases losses and heat generation during the transmission process.

[0089] Considering that a small thickness of the first conductive member 220 would lead to an increase in its resistivity, potentially causing severe overheating of the bypass element 210, this embodiment addresses this by setting the width of the first conductive member 220 to be greater than the width of the second conductive member 230. Increasing the width of the first conductive member 220 increases its cross-sectional area, thereby reducing its resistivity and minimizing losses and heat generation during transmission.

[0090] In one embodiment, the first insulating layer 240 extends along a second direction. The width of the first insulating layer 240 is set to be greater than or equal to the width of the first conductive member 220. The length of the first insulating layer 240 is greater than or equal to the length of the battery string 100.

[0091] For reference, the following lists the temperature test data for the photovoltaic module 10. The photovoltaic module 10 provided in the embodiment of Figure 1 of this application was selected as the test object. After being exposed to simulated sunlight with an irradiance of 1000 W / m² for 14 hours, the temperature of the bypass diodes corresponding to the four battery cells 110 (A, B, C, and D) was tested respectively. Battery cell 110 was 30% shaded, battery cell 110 was 50% shaded, battery cell 110 was 70% shaded, and battery cell 110 was 100% shaded (all represent percentages of shaded area). The temperature test data are shown in the table below:

[0092] The temperature data shows that although the battery cell 110 is blocked to varying degrees, the temperature of its corresponding bypass element 210 does not exceed 70°C. In other words, the design of the bypass unit 200 can significantly improve the temperature reliability of the bypass element 210. This is mainly due to the reasonable material selection and circuit design of the first conductive component 220, the second conductive component 230, and the bypass element 210.

[0093] In one embodiment, each busbar is connected to a first conductive member 220 of a bypass unit 200. Thus, in the bypass unit 200 connected to the busbar, the bypass element 210 does not need to use two second conductive members 230 to couple with the corresponding battery cell 110 or battery cell group. Reusing the busbar as the second conductive member of the bypass unit 200 simplifies the structure of the bypass unit 200, thereby reducing the manufacturing difficulty and cost of the photovoltaic module 10.

[0094] In each battery string 100, all bypass units 200 can share a single solder strip to form a first conductive member 220. Specifically, the solder strip extends from the busbar at the first end of the battery string 100 to the busbar at the second end of the battery string 100 and is divided into multiple sub-strips. A bypass element 210 is provided between two adjacent sub-strips, and the second conductive member 230 of each bypass unit 200 is vertically disposed on the corresponding sub-strip. The sub-strips located between two adjacent second conductive members 230 constitute the first conductive member 220 of the corresponding bypass unit 200.

[0095] The number of battery cells 110 connected in parallel to each bypass unit 200 can be determined using the photovoltaic module 10 shown in Figure 2 as an example: Referring to Figure 2, for the first bypass unit 200a, the two battery cells 110 (i.e., the first battery cell 110a and the second battery cell 110b) between the upper busbar and the second conductive member 230 are connected in parallel with the first bypass unit 200a; for the second bypass unit 200a, the two battery cells 110 (i.e., the third battery cell 110c and the fourth battery cell 110d) between the bypass element 210 and the second conductive member 230 are connected in parallel with the second bypass unit 200b; for the third bypass unit 200c, the two battery cells 110 (i.e., the fifth battery cell 110e and the sixth battery cell 110f) between the bypass element 210 and the second conductive member 230 are connected in parallel with the third bypass unit 200c; for the fourth bypass unit... For the fourth bypass unit 200d, the two battery units 110 (i.e., the seventh battery unit 110g and the eighth battery unit 110h) between the bypass element 210 and the second conductive member 230 are connected in parallel with the fourth bypass unit 200d; for the fifth bypass unit 200e, the two battery units 110 (i.e., the ninth battery unit 110i and the tenth battery unit 110j) between the bypass element 210 and the second conductive member 230 are connected in parallel with the fifth bypass unit 200e; for the sixth bypass unit 200f, the two battery units 110 (i.e., the eleventh battery unit 110k and the twelfth battery unit 110m) between the bypass element 210 and the second conductive member 230 are connected in parallel with the sixth bypass unit 200f; for the seventh bypass unit 200g, the one battery unit 110 (i.e., the thirteenth battery unit 110n) between the lower busbar and the second conductive member 230 is connected in parallel with the seventh bypass unit 200g.

[0096] In one embodiment, the second conductive member 230 is connected to all the grid lines 120 on the first surface 111 side of the battery cell 110 that are not covered by the first insulating layer 240. This arrangement allows the second conductive member 230 to fully collect the charge carriers generated by the battery cell 110, thereby improving the conversion efficiency of the assembly. For example, the first surface 111 of the battery cell 110 has 16 grid lines 120, of which 2 grid lines 120 are covered by the first insulating layer 240, and the remaining 14 grid lines 120 are connected to the second conductive member 230. Optionally, at the location where the first insulating layer 240 overlaps with the grid lines 120 and the second conductive member 230, an opening can be provided in the first insulating layer 240, through which the second conductive member 230 can connect to the grid lines 120, thereby further enhancing the charge carrier collection capability.

[0097] In the entire bypass unit 200, the bypass element 210 has the largest thickness, meaning its thickness determines the maximum thickness of the bypass unit 200. Therefore, during module manufacturing or use, the stress on the battery cell 110 will primarily originate from the bypass element 210, necessitating a carefully designed thickness. In one embodiment, as an example, the bypass element 210 is designed to have a thickness of 0.7 mm, while the thicknesses of the first conductive member 220 and the second conductive member 230 are 0.1 mm and 0.2 mm respectively, and the thickness of the first insulating layer 240 is 0.2 mm. Thus, the total thickness of the bypass unit 200 (at its maximum thickness) is 1.2 mm. In other words, setting the thickness of the bypass unit 200 to be less than or equal to 1.2 mm facilitates the manufacturing of the bypass element 210 and further reduces the defect rate of the module products, improving the reliability of the module during use.

[0098] In one embodiment, the bypass elements 210 of all bypass units 200 are disposed on the first surface 111 side of the corresponding battery string 100. That is, there is no need to provide bypass elements 210 in the junction box, nor is there a need to provide additional heat dissipation structure to dissipate heat for the bypass elements 210. This simplifies the internal structure of the junction box and facilitates the improvement of the conversion efficiency of the photovoltaic module while reducing the manufacturing cost of the photovoltaic module 10.

[0099] In one embodiment, as shown in Figures 8 and 9, the bypass element 210 includes a bypass diode 211 and a conductive pin 212. The bypass diode 211 is connected to the first conductive member 220 via the conductive pin 212. The conductive pin 212 facilitates the connection between the bypass diode 211 and the first conductive member 220.

[0100] The diode is a two-sided diode, which may include a PN junction and p-electrodes and n-electrodes respectively disposed on two opposite surfaces of the PN junction. The p-electrodes and n-electrodes are respectively connected to the first conductive member 220. Optionally, the bypass diode 211 is a thin-film diode. The thin-film diode is very thin, ensuring that the thickness of the bypass element 210 is less than 1 mm. Of course, in some other embodiments, the thickness of the bypass diode 211 may also be less than 1 mm, for example, it may be 0.9 mm, 0.8 mm, 0.7 mm, 0.6 mm, 0.5 mm, etc.

[0101] Optionally, the projection of each bypass element 210 or bypass diode 211 onto the plane containing the multiple battery strings 100 is completely covered by the projection of a battery cell 110 onto the plane containing the multiple battery strings 100. That is, the bypass element 210 or bypass diode 211 is completely disposed on the first surface 111 side of the battery cell 110, rather than partially or entirely disposed between two consecutively connected battery cells 110. Therefore, the battery cell 110 can cover the light-receiving surface of the photovoltaic module 10 as much as possible, thereby increasing the power generation area and the overall energy density of the module.

[0102] Optionally, as shown in Figure 10, in the vertical direction of the plane containing the first insulating layer 240, the height H1 of the bypass diode 211 is greater than the height H2 at the connection between the conductive pin 212 and the first conductive member 220, and the height H2 at the connection between the conductive pin 212 and the first conductive member 220 is greater than the height H3 of the first conductive member 220. It should be noted that the "height direction" throughout this text is the same as the "thickness direction" mentioned above. This configuration causes the heights of the bypass diode 211, the connection between the conductive pin 212 and the first conductive member 220, and the first conductive member 220 to decrease in a stepped manner, which can gradually alleviate the stress of the bypass diode 211 on the battery cell 110, making it less likely for the bypass diode 211 to crush the battery cell 110. As an example, the heights of the bypass diode 211, the connection between the conductive pin 212 and the first conductive member 220, and the first conductive member 220 are set to 0.7 mm, 0.4 mm, and 0.1 mm, respectively. Optionally, the conductive pin 212 may be made of metal foil (e.g., copper foil, aluminum foil, tin-plated copper foil, etc.).

[0103] Optionally, the width of the conductive pin 212 is less than or equal to the width of the first conductive member 220. Optionally, the conductive pin 212 can also be configured in a trapezoidal shape in the second direction, with the long side of the trapezoid connected to the first conductive member 220 and the short side connected to the bypass diode 211. This configuration increases the cross-sectional area of ​​the conductive pin 212, thereby reducing its resistance and losses and improving the efficiency of the photovoltaic module.

[0104] In some embodiments of this application, the photovoltaic module 10 further includes at least two encapsulation units, encapsulating multiple battery strings 100 and multiple bypass units 200 between the at least two encapsulation units. After the multiple battery strings 100 and multiple bypass units 200 are placed between the at least two encapsulation units, hot pressing is performed. The adhesive layer on the encapsulation unit melts and remains transparent, wrapping the battery strings 100 and bypass units 200 and bonding each encapsulation unit into a whole. During the lamination process, the parts with height differences between the bypass units 200 and the battery strings 100 are also filled with molten adhesive, which can protect the battery units 110 and make the photovoltaic module 10 more reliable.

[0105] Optionally, the adhesive layer on the encapsulation unit is made of EVA (Ethylene Vinyl Acetate Copolymer) or POE (Polyethylene and Octene Polymer).

[0106] Optionally, as shown in FIG11, the photovoltaic module 10 is provided with a first encapsulation unit 510 and a second encapsulation unit 520, wherein the first encapsulation unit 510 and the second encapsulation unit 520 may be glass plates, and a first adhesive layer 530 is provided on the side of the first encapsulation unit 510 facing the second encapsulation unit 520, and a second adhesive layer 540 is provided on the side of the second encapsulation unit 520 facing the first encapsulation unit 510.

[0107] Secondly, one embodiment of this application provides a method for manufacturing a photovoltaic module 10, the method comprising:

[0108] In step S100 of forming a battery circuit, the battery circuit includes a plurality of battery strings 100 spaced apart along a first direction and / or a second direction. The plurality of battery strings 100 are connected by at least one of series and parallel connection to provide an output voltage. Each battery string 100 includes a plurality of battery cells 110 connected in series and spaced apart along the second direction. The first direction is perpendicular to the second direction.

[0109] Step S200 of forming a bypass circuit includes a plurality of bypass units 200 connected by at least one of series and parallel connections. Each bypass unit 200 corresponds to a battery cell 110 or a battery cell group. The battery cell group includes a plurality of battery cells 110 connected in series. The bypass unit 200 includes: a bypass element 210, a first conductive member 220 connected to the bypass element 210, a second conductive member 230 connected to the first conductive member 220, and a first insulating layer 240 disposed between the first conductive member 220 and the battery cell 110. The thickness of the bypass unit 200 is less than or equal to 2.3 mm.

[0110] And step S300, which electrically connects the second conductive member 230 to the battery cell 110.

[0111] The photovoltaic module 10 obtained by this manufacturing method, by coupling each bypass unit 200 to a battery cell 110 or a battery cell group, can short-circuit the battery cell 110 or the battery cell group including the battery cell 110 when a battery cell 110 is shaded, instead of short-circuiting the entire battery string 100 including the battery cell 110. Only the shaded battery cell 110 or the battery cell group including the battery cell 110 stops working, while other battery cells 110 and other battery strings 100 including the battery cell 110 can work normally. This reduces the impact of shading on the overall output power of the module and can provide better hot spot durability performance. In addition, by optimizing the thickness of the first bypass unit 200, this application improves the rationality of the circuit layout, eliminating the need to increase the gap between two adjacent battery strings 100 to accommodate the bypass unit 200, while avoiding excessive stress on the battery cell 110 that could cause damage to the battery cell 110. This increases the unit power generation area of ​​the photovoltaic module while maintaining excellent reliability.

[0112] For step S100, multiple battery strings 100 can be connected in series or in parallel by combining grid lines 120 with bus bars to form a battery circuit.

[0113] The order of steps S200 and S100 can be interchanged.

[0114] Prior to step S300, the manufacturing method further includes a first stacking step S400. Specifically, the first stacking step S400 includes: providing a first encapsulation unit 510, coating a first adhesive layer 530 on the surface of the first encapsulation unit 510, and then laying the battery circuitry on the first adhesive layer 530.

[0115] After step S300, the manufacturing method further includes a second stacking step S500. Specifically, the first stacking step S500 includes: coating a second adhesive layer 540 on the battery circuit and bypass circuit, and then laying a second encapsulation unit 520 on the second adhesive layer 540 to form a stacked component.

[0116] Following step S500, the manufacturing method further includes a lamination step S600. Specifically, the lamination step S600 includes: feeding the laminated components into a high-temperature vacuum laminator for thermal lamination. The first adhesive film layer and the second adhesive film layer melt and fuse together, remaining transparent, to encapsulate the battery string 100 and the bypass unit 200, and to bond the first encapsulation unit 510 and the second encapsulation unit 520 into a whole.

[0117] As an optional implementation, another embodiment of this application provides a method for manufacturing a photovoltaic module 10, the method comprising:

[0118] In step S100 of forming a battery circuit, the battery circuit includes a plurality of battery strings 100 spaced apart along a first direction and / or a second direction. The plurality of battery strings 100 are connected by at least one of series and parallel connection to provide an output voltage. Each battery string 100 includes a plurality of battery cells 110 connected in series and spaced apart along the second direction. The first direction is perpendicular to the second direction.

[0119] In step S200, the first bypass circuit includes a first insulating layer 240 and a plurality of second conductive members 230. The second conductive members 230 are disposed on the first surface 111 side of one of the battery cells 110 or a group of battery cells 110 in the battery circuit formed in step S100 and are connected to the battery cell 110. The battery cell group includes a plurality of battery cells 110 connected in series. The first insulating layer 240 is disposed between the second conductive members 230 and the battery cell 110.

[0120] Step S300: Forming a second bypass circuit, the second bypass circuit includes a bypass element 210 and a first conductive member 220 connected to the bypass element 210.

[0121] The process includes step S400, which involves electrically connecting the first conductive member 220 and the second conductive member 230 to form a bypass circuit. The bypass circuit includes a plurality of bypass units 200 connected in at least one manner, either in series or in parallel. Each bypass unit 200 corresponds to a battery cell 110 or a group of battery cells formed in step S100. The bypass unit 200 includes a bypass element 210, a first conductive member 220 connected to the bypass element 210, a second conductive member 230 connected to the first conductive member 220, and a first insulating layer 240 disposed between the first conductive member 220 and the battery cell 110. The thickness of the bypass unit 200 is less than or equal to 2.3 mm.

[0122] Compared to the previous embodiment, this embodiment optimizes the sequence of process steps by connecting the second conductive component 230 in the bypass unit 200 to the battery unit 110 in advance. This step S200 can be completed on the same automated production line as step S100. In step S300, only the connection process between the bypass element 210 and the first conductive component 220 needs to be performed. Since the second conductive component 230 is connected to the back of the battery unit 110 in advance, the second bypass circuit can be more easily laid flat on the back of the battery circuit in step S400, which is advantageous for completing this step using manual soldering.

[0123] It should be noted that in this application, the same or similar terms, concepts, technical solutions and / or application scenario descriptions are generally described in detail only when they appear for the first time. When they appear again later, they are generally not repeated for the sake of brevity. When understanding the technical solutions and other contents of this application, the same or similar terms, concepts, technical solutions and / or application scenario descriptions that are not described in detail later can be referred to their previous relevant detailed descriptions.

[0124] The technical features of the above embodiments can be combined in any way. For the sake of brevity, not all possible combinations of the technical features in the above embodiments are described. However, as long as there is no contradiction in the combination of these technical features, they should be considered to be within the scope of this specification.

[0125] The embodiments described above are merely illustrative of several implementation methods of this application, and while the descriptions are relatively specific and detailed, they should not be construed as limiting the scope of the patent application. It should be noted that those skilled in the art can make various modifications and improvements without departing from the concept of this application, and these all fall within the protection scope of this application. Therefore, the protection scope of this patent application should be determined by the appended claims.

[0126] The embodiments described above are merely illustrative of several implementation methods of this application, and while the descriptions are relatively specific and detailed, they should not be construed as limiting the scope of the patent application. It should be noted that those skilled in the art can make various modifications and improvements without departing from the concept of this application, and these all fall within the protection scope of this application. Therefore, the protection scope of this patent application should be determined by the appended claims.

Claims

1. A photovoltaic module, characterized in that, include: A plurality of battery strings spaced apart along a first direction and / or a second direction, the plurality of battery strings being connected by at least one of series and parallel connection to provide an output voltage, wherein each of the battery strings includes a plurality of battery cells connected in series and spaced apart along the second direction, the first direction being perpendicular to the second direction; Multiple bypass units are connected in at least one manner, either in series or in parallel. Each bypass unit is disposed on the first surface side of a battery cell or a group of battery cells in the battery string and coupled to the battery cell or group of battery cells, wherein the battery cell group comprises multiple battery cells connected in series. The bypass unit includes: Bypass components; A first conductive member connected to the bypass element, wherein the first conductive member extends along the second direction; A second conductive member connected to the first conductive member, the second conductive member being disposed on the first surface side of one of the plurality of battery cells or a group of battery cells and connected to the battery cell; A first insulating layer is disposed between the first conductive component and the battery cell; The thickness of the bypass unit is less than or equal to 2.3 mm.

2. The photovoltaic module as described in claim 1, characterized in that, The thickness of the bypass unit is less than or equal to 1.2 mm.

3. The photovoltaic module as described in claim 2, characterized in that, The bypass element includes a bypass diode and a conductive pin, and the bypass diode is connected to the first conductive member through the conductive pin.

4. The photovoltaic module as described in claim 3, characterized in that, Also includes: Multiple busbars are respectively disposed at opposite first and second ends of the battery strings, and the multiple battery strings are connected in series through the busbars.

5. The photovoltaic module as described in claim 4, characterized in that, Each of the busbars is connected to a first conductive member of one of the bypass units.

6. The photovoltaic module as described in claim 3, characterized in that, The bypass diode is a thin-film diode, or the thickness of the bypass diode is less than or equal to 1 mm.

7. The photovoltaic module as described in claim 3, characterized in that, In the vertical direction of the plane containing the insulating layer, the height of the bypass diode is greater than the height of the connection between the conductive pin and the first conductive member, and the height of the connection between the conductive pin and the first conductive member is greater than the height of the first conductive member.

8. The photovoltaic module as described in claim 1, characterized in that, The first conductive component and / or the second conductive component are made of metal foil.

9. The photovoltaic module as described in claim 1, characterized in that, The thickness of the first conductive member is less than the thickness of the second conductive member, and / or the width of the first conductive member is greater than the thickness of the second conductive member.

10. The photovoltaic module as described in claim 3, characterized in that, The width of the conductive pin is less than or equal to the width of the first conductive member.

11. The photovoltaic module as described in claim 3, characterized in that, The projection of each bypass element or bypass diode onto the plane containing the plurality of battery strings is completely covered by the projection of one battery cell onto the plane containing the plurality of battery strings.

12. The photovoltaic module as described in claim 11, characterized in that, Each of the battery strings consists of two adjacent battery cells connected in series via multiple grid lines; The second conductive member is connected to all the grid lines on the first surface side of the battery cell that are not covered by the insulating layer.

13. The photovoltaic module as described in claim 4, characterized in that, The plurality of busbars includes a first positive busbar and a first negative busbar, which are connected to a junction box.

14. The photovoltaic module as described in claim 13, characterized in that, The bypass element is not installed in the junction box.

15. The photovoltaic module as described in claim 13, characterized in that, It also includes jumper units, including: A third conductive member is disposed on the first surface side of one of the plurality of battery cells or a group of battery cells, wherein the third conductive member is connected to the first negative electrode busbar and the junction box; A second insulating layer is disposed between the third conductive member and the battery cell.

16. The photovoltaic module as described in claim 15, characterized in that, The jumper unit and the bypass unit are arranged at intervals along the first direction.

17. The photovoltaic module as described in claim 1, characterized in that, It also includes at least two layers of encapsulation units, which encapsulate the plurality of battery strings and the plurality of bypass units in the middle of the at least two layers of encapsulation units.

18. A method for manufacturing a photovoltaic module, characterized in that, include: The step of forming a battery circuit includes a plurality of battery strings spaced apart along a first direction and / or a second direction, the plurality of battery strings being connected by at least one of series and parallel connection to provide an output voltage, each of the battery strings including a plurality of battery cells connected in series and spaced apart along the second direction, the first direction being perpendicular to the second direction; The step of forming a bypass circuit includes a plurality of bypass units connected by at least one of series and parallel connections, each bypass unit corresponding to a battery cell or a group of battery cells, the battery cell group including a plurality of battery cells connected in series; wherein, the bypass unit includes: a bypass element, a first conductive member connected to the bypass element, a second conductive member connected to the first conductive member, and a first insulating layer disposed between the first conductive member and the battery cell; wherein, the thickness of the bypass unit is less than or equal to 2.3 mm; The step of electrically connecting the second conductive member to the battery cell.

19. A method for manufacturing a photovoltaic module, characterized in that, include: The step of forming a battery circuit includes a plurality of battery strings spaced apart along a first direction and / or a second direction, the plurality of battery strings being connected by at least one of series and parallel connection to provide an output voltage, each of the battery strings including a plurality of battery cells connected in series and spaced apart along the second direction, the first direction being perpendicular to the second direction; The step of forming a first bypass circuit includes a first insulating layer and a plurality of second conductive members. The second conductive members are disposed on the first surface side of one of the plurality of battery cells or a group of battery cells and connected to the battery cell. The battery cell group includes a plurality of battery cells connected in series. The first insulating layer is disposed between the second conductive members and the battery cells. The step of forming a second bypass circuit, the second bypass circuit including a bypass element and a first conductive member connected to the bypass element; The method includes the step of electrically connecting the first conductive member and the second conductive member to form a bypass circuit, the bypass circuit comprising a plurality of bypass units connected by at least one of series and parallel connection, each bypass unit corresponding to a battery cell or a group of battery cells; wherein the bypass unit comprises: the bypass element, a first conductive member connected to the bypass element, a second conductive member connected to the first conductive member, and a first insulating layer disposed between the first conductive member and the battery cell; wherein the thickness of the bypass unit is less than or equal to 2.3 mm.

Images