CN111763481B - Structured packaging material, production method thereof, photovoltaic module and preparation method thereof - Google Patents

Structured packaging material, production method thereof, photovoltaic module and preparation method thereof Download PDF

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Publication number
CN111763481B
CN111763481B CN202010514420.7A CN202010514420A CN111763481B CN 111763481 B CN111763481 B CN 111763481B CN 202010514420 A CN202010514420 A CN 202010514420A CN 111763481 B CN111763481 B CN 111763481B
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substrate
protruding
structured
packaging material
material layer
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CN111763481A (en
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李华
刘继宇
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Taizhou Longi Solar Technology Co Ltd
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Taizhou Longi Solar Technology Co Ltd
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    • C—CHEMISTRY; METALLURGY
    • C09—DYES; PAINTS; POLISHES; NATURAL RESINS; ADHESIVES; COMPOSITIONS NOT OTHERWISE PROVIDED FOR; APPLICATIONS OF MATERIALS NOT OTHERWISE PROVIDED FOR
    • C09J—ADHESIVES; NON-MECHANICAL ASPECTS OF ADHESIVE PROCESSES IN GENERAL; ADHESIVE PROCESSES NOT PROVIDED FOR ELSEWHERE; USE OF MATERIALS AS ADHESIVES
    • C09J7/00—Adhesives in the form of films or foils
    • C09J7/20—Adhesives in the form of films or foils characterised by their carriers
    • C09J7/22—Plastics; Metallised plastics
    • C—CHEMISTRY; METALLURGY
    • C09—DYES; PAINTS; POLISHES; NATURAL RESINS; ADHESIVES; COMPOSITIONS NOT OTHERWISE PROVIDED FOR; APPLICATIONS OF MATERIALS NOT OTHERWISE PROVIDED FOR
    • C09J—ADHESIVES; NON-MECHANICAL ASPECTS OF ADHESIVE PROCESSES IN GENERAL; ADHESIVE PROCESSES NOT PROVIDED FOR ELSEWHERE; USE OF MATERIALS AS ADHESIVES
    • C09J7/00—Adhesives in the form of films or foils
    • C09J7/20—Adhesives in the form of films or foils characterised by their carriers
    • C—CHEMISTRY; METALLURGY
    • C09—DYES; PAINTS; POLISHES; NATURAL RESINS; ADHESIVES; COMPOSITIONS NOT OTHERWISE PROVIDED FOR; APPLICATIONS OF MATERIALS NOT OTHERWISE PROVIDED FOR
    • C09J—ADHESIVES; NON-MECHANICAL ASPECTS OF ADHESIVE PROCESSES IN GENERAL; ADHESIVE PROCESSES NOT PROVIDED FOR ELSEWHERE; USE OF MATERIALS AS ADHESIVES
    • C09J7/00—Adhesives in the form of films or foils
    • C09J7/30—Adhesives in the form of films or foils characterised by the adhesive composition
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01L—SEMICONDUCTOR DEVICES NOT COVERED BY CLASS H10
    • H01L31/00—Semiconductor devices sensitive to infrared radiation, light, electromagnetic radiation of shorter wavelength or corpuscular radiation and specially adapted either for the conversion of the energy of such radiation into electrical energy or for the control of electrical energy by such radiation; Processes or apparatus specially adapted for the manufacture or treatment thereof or of parts thereof; Details thereof
    • H01L31/04—Semiconductor devices sensitive to infrared radiation, light, electromagnetic radiation of shorter wavelength or corpuscular radiation and specially adapted either for the conversion of the energy of such radiation into electrical energy or for the control of electrical energy by such radiation; Processes or apparatus specially adapted for the manufacture or treatment thereof or of parts thereof; Details thereof adapted as photovoltaic [PV] conversion devices
    • H01L31/042—PV modules or arrays of single PV cells
    • H01L31/048—Encapsulation of modules
    • H01L31/0481—Encapsulation of modules characterised by the composition of the encapsulation material
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01L—SEMICONDUCTOR DEVICES NOT COVERED BY CLASS H10
    • H01L31/00—Semiconductor devices sensitive to infrared radiation, light, electromagnetic radiation of shorter wavelength or corpuscular radiation and specially adapted either for the conversion of the energy of such radiation into electrical energy or for the control of electrical energy by such radiation; Processes or apparatus specially adapted for the manufacture or treatment thereof or of parts thereof; Details thereof
    • H01L31/18—Processes or apparatus specially adapted for the manufacture or treatment of these devices or of parts thereof
    • H01L31/1876—Particular processes or apparatus for batch treatment of the devices
    • C—CHEMISTRY; METALLURGY
    • C09—DYES; PAINTS; POLISHES; NATURAL RESINS; ADHESIVES; COMPOSITIONS NOT OTHERWISE PROVIDED FOR; APPLICATIONS OF MATERIALS NOT OTHERWISE PROVIDED FOR
    • C09J—ADHESIVES; NON-MECHANICAL ASPECTS OF ADHESIVE PROCESSES IN GENERAL; ADHESIVE PROCESSES NOT PROVIDED FOR ELSEWHERE; USE OF MATERIALS AS ADHESIVES
    • C09J2203/00—Applications of adhesives in processes or use of adhesives in the form of films or foils
    • C09J2203/322—Applications of adhesives in processes or use of adhesives in the form of films or foils for the production of solar panels
    • C—CHEMISTRY; METALLURGY
    • C09—DYES; PAINTS; POLISHES; NATURAL RESINS; ADHESIVES; COMPOSITIONS NOT OTHERWISE PROVIDED FOR; APPLICATIONS OF MATERIALS NOT OTHERWISE PROVIDED FOR
    • C09J—ADHESIVES; NON-MECHANICAL ASPECTS OF ADHESIVE PROCESSES IN GENERAL; ADHESIVE PROCESSES NOT PROVIDED FOR ELSEWHERE; USE OF MATERIALS AS ADHESIVES
    • C09J2400/00—Presence of inorganic and organic materials
    • C09J2400/10—Presence of inorganic materials
    • C09J2400/14—Glass
    • C09J2400/143—Glass in the substrate
    • C—CHEMISTRY; METALLURGY
    • C09—DYES; PAINTS; POLISHES; NATURAL RESINS; ADHESIVES; COMPOSITIONS NOT OTHERWISE PROVIDED FOR; APPLICATIONS OF MATERIALS NOT OTHERWISE PROVIDED FOR
    • C09J—ADHESIVES; NON-MECHANICAL ASPECTS OF ADHESIVE PROCESSES IN GENERAL; ADHESIVE PROCESSES NOT PROVIDED FOR ELSEWHERE; USE OF MATERIALS AS ADHESIVES
    • C09J2400/00—Presence of inorganic and organic materials
    • C09J2400/20—Presence of organic materials
    • C09J2400/22—Presence of unspecified polymer
    • C09J2400/226—Presence of unspecified polymer in the substrate
    • C—CHEMISTRY; METALLURGY
    • C09—DYES; PAINTS; POLISHES; NATURAL RESINS; ADHESIVES; COMPOSITIONS NOT OTHERWISE PROVIDED FOR; APPLICATIONS OF MATERIALS NOT OTHERWISE PROVIDED FOR
    • C09J—ADHESIVES; NON-MECHANICAL ASPECTS OF ADHESIVE PROCESSES IN GENERAL; ADHESIVE PROCESSES NOT PROVIDED FOR ELSEWHERE; USE OF MATERIALS AS ADHESIVES
    • C09J2423/00—Presence of polyolefin
    • C09J2423/04—Presence of homo or copolymers of ethene
    • C—CHEMISTRY; METALLURGY
    • C09—DYES; PAINTS; POLISHES; NATURAL RESINS; ADHESIVES; COMPOSITIONS NOT OTHERWISE PROVIDED FOR; APPLICATIONS OF MATERIALS NOT OTHERWISE PROVIDED FOR
    • C09J—ADHESIVES; NON-MECHANICAL ASPECTS OF ADHESIVE PROCESSES IN GENERAL; ADHESIVE PROCESSES NOT PROVIDED FOR ELSEWHERE; USE OF MATERIALS AS ADHESIVES
    • C09J2429/00—Presence of polyvinyl alcohol
    • C—CHEMISTRY; METALLURGY
    • C09—DYES; PAINTS; POLISHES; NATURAL RESINS; ADHESIVES; COMPOSITIONS NOT OTHERWISE PROVIDED FOR; APPLICATIONS OF MATERIALS NOT OTHERWISE PROVIDED FOR
    • C09J—ADHESIVES; NON-MECHANICAL ASPECTS OF ADHESIVE PROCESSES IN GENERAL; ADHESIVE PROCESSES NOT PROVIDED FOR ELSEWHERE; USE OF MATERIALS AS ADHESIVES
    • C09J2433/00—Presence of (meth)acrylic polymer
    • C—CHEMISTRY; METALLURGY
    • C09—DYES; PAINTS; POLISHES; NATURAL RESINS; ADHESIVES; COMPOSITIONS NOT OTHERWISE PROVIDED FOR; APPLICATIONS OF MATERIALS NOT OTHERWISE PROVIDED FOR
    • C09J—ADHESIVES; NON-MECHANICAL ASPECTS OF ADHESIVE PROCESSES IN GENERAL; ADHESIVE PROCESSES NOT PROVIDED FOR ELSEWHERE; USE OF MATERIALS AS ADHESIVES
    • C09J2463/00—Presence of epoxy resin
    • C—CHEMISTRY; METALLURGY
    • C09—DYES; PAINTS; POLISHES; NATURAL RESINS; ADHESIVES; COMPOSITIONS NOT OTHERWISE PROVIDED FOR; APPLICATIONS OF MATERIALS NOT OTHERWISE PROVIDED FOR
    • C09J—ADHESIVES; NON-MECHANICAL ASPECTS OF ADHESIVE PROCESSES IN GENERAL; ADHESIVE PROCESSES NOT PROVIDED FOR ELSEWHERE; USE OF MATERIALS AS ADHESIVES
    • C09J2475/00—Presence of polyurethane
    • C—CHEMISTRY; METALLURGY
    • C09—DYES; PAINTS; POLISHES; NATURAL RESINS; ADHESIVES; COMPOSITIONS NOT OTHERWISE PROVIDED FOR; APPLICATIONS OF MATERIALS NOT OTHERWISE PROVIDED FOR
    • C09J—ADHESIVES; NON-MECHANICAL ASPECTS OF ADHESIVE PROCESSES IN GENERAL; ADHESIVE PROCESSES NOT PROVIDED FOR ELSEWHERE; USE OF MATERIALS AS ADHESIVES
    • C09J2483/00—Presence of polysiloxane
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
    • Y02E—REDUCTION OF GREENHOUSE GAS [GHG] EMISSIONS, RELATED TO ENERGY GENERATION, TRANSMISSION OR DISTRIBUTION
    • Y02E10/00—Energy generation through renewable energy sources
    • Y02E10/50—Photovoltaic [PV] energy
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
    • Y02P—CLIMATE CHANGE MITIGATION TECHNOLOGIES IN THE PRODUCTION OR PROCESSING OF GOODS
    • Y02P70/00—Climate change mitigation technologies in the production process for final industrial or consumer products
    • Y02P70/50—Manufacturing or production processes characterised by the final manufactured product

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  • Chemical & Material Sciences (AREA)
  • Organic Chemistry (AREA)
  • Engineering & Computer Science (AREA)
  • Condensed Matter Physics & Semiconductors (AREA)
  • Electromagnetism (AREA)
  • General Physics & Mathematics (AREA)
  • Physics & Mathematics (AREA)
  • Computer Hardware Design (AREA)
  • Microelectronics & Electronic Packaging (AREA)
  • Power Engineering (AREA)
  • Manufacturing & Machinery (AREA)
  • Laminated Bodies (AREA)
  • Photovoltaic Devices (AREA)

Abstract

The application provides a structured packaging material, a production method thereof, a photovoltaic module and a preparation method thereof, and relates to the technical field of photovoltaics. The structured encapsulating material comprises: a substrate, a packaging material layer, wherein the substrate and/or the packaging material layer comprises a plurality of rows of protruding parts protruding from a substrate of the substrate and/or the packaging material layer; the protruding direction of the protruding portion faces the battery string. The convex part has a certain positioning function, is convenient for the laying and alignment of the battery strings, and improves the production efficiency. In the subsequent lamination process, the convex parts of the packaging material layer are melted and/or the convex parts of the substrate squeeze the melted packaging material and are filled in the gaps in the battery strings or the components, so that the pressure born by the solar cells in the lamination process can be reduced, hidden cracks or cracking can be reduced even if gaps among the cells are reduced, the production yield is improved, and the reliability of the components is improved.

Description

Structured packaging material, production method thereof, photovoltaic module and preparation method thereof
Technical Field
The application relates to the technical field of photovoltaics, in particular to a structured packaging material, a production method, a photovoltaic module and a preparation method.
Background
The battery assembly can be provided with more solar cells in a limited space, can increase short-circuit current and provide power output, and therefore, the battery assembly is widely applied.
In the battery assembly, gaps among the batteries in the assembly are reduced, the power output of the battery assembly can be improved, and the appearance is more attractive.
However, in the battery assembly, the gaps between the individual cells are reduced, which is likely to cause cracking or hidden cracking, affecting the reliability of the assembly.
Disclosure of Invention
The application provides a structured packaging material, a production method, a photovoltaic module and a preparation method, and aims to solve the problems that in a battery module, gaps among batteries are reduced, cracking or hidden cracking is easy to cause, and the reliability of the module is affected.
According to a first aspect of the present application there is provided a structured encapsulating material comprising a substrate, an encapsulating material layer, the substrate and/or encapsulating material layer comprising a plurality of columns of protruding portions protruding from a base of the substrate and/or encapsulating material layer;
the protruding direction of the protruding portion faces the battery string.
The structured packaging material comprises a substrate and a packaging material layer, wherein the substrate and/or the packaging material layer comprises a plurality of rows of protruding parts protruding out of a matrix of the substrate and/or the packaging material layer; the protruding direction of bulge is towards the battery cluster, and above-mentioned bulge has certain locate function, and the laying and the counterpoint of battery cluster of being convenient for have improved production efficiency. In the subsequent lamination process, the convex parts of the packaging material layer are melted and/or the convex parts of the substrate squeeze the melted packaging material and are filled in the gaps in the battery strings or the components, so that the pressure born by the solar cells in the lamination process can be reduced, hidden cracks or cracking can be reduced even if gaps among the cells are reduced, the production yield is improved, and the reliability of the components is improved.
According to a second aspect of the present application, there is provided a method of producing a structured encapsulating material comprising a substrate, an encapsulating material layer, the substrate and/or encapsulating material layer comprising a plurality of rows of protruding portions protruding from a base of the substrate and/or encapsulating material layer, the protruding portions being formed by one of the following steps:
hot-pressing the protruding portion on the base;
bonding the substrate and the protruding portion with an adhesive;
extruding a localized area of a substrate to form a convex portion that protrudes from the substrate;
integrally molding the structured packaging material by adopting a pouring mold with a convex part;
the protruding portions are printed on the substrate.
According to a third aspect of the present application there is provided a photovoltaic module comprising at least one cell string laminated encapsulated with a structured encapsulating material as claimed in any preceding claim; in the packaging process, the structured packaging material is arranged on the light-facing surface and/or the backlight surface of the battery string, the protruding direction of the protruding part faces the battery string, and the single solar battery is arranged in the groove formed by the protruding part.
According to a fourth aspect of the present application, there is provided a photovoltaic module manufacturing method comprising the steps of:
providing a structured encapsulating material as claimed in any preceding claim;
providing a battery string; the battery string includes a plurality of solar cells;
providing the structured packaging material on the light-facing surface and/or the backlight surface of the battery string to obtain a component precursor; in the assembly precursor, the protruding direction of the protruding portion faces the battery string;
laminating a laminate comprising the assembly precursor.
The above-mentioned method for producing the structured packaging material, the photovoltaic module, and the method for preparing the photovoltaic module have the same or similar beneficial effects as the foregoing structured packaging material, and in order to avoid repetition, the description is omitted here.
Drawings
In order to more clearly illustrate the technical solutions of the embodiments of the present application, the drawings that are needed in the description of the embodiments of the present application will be briefly described below, it being obvious that the drawings in the following description are only some embodiments of the present application, and that other drawings may be obtained according to these drawings without inventive effort for a person skilled in the art.
FIG. 1 shows a schematic structural diagram of a first structured encapsulating material in an embodiment of the application;
FIG. 2 shows a schematic structural diagram of a second structured encapsulating material in an embodiment of the application;
FIG. 3 shows a schematic structural view of a first photovoltaic laminate in an embodiment of the present application;
FIG. 4 shows a schematic structural diagram of a third structured encapsulating material in an embodiment of the application;
FIG. 5 shows a schematic structural view of a second photovoltaic laminate in an embodiment of the present application;
FIG. 6 shows a schematic structural diagram of a fourth structured encapsulating material in an embodiment of the application;
FIG. 7 shows a schematic structural diagram of a fifth structured encapsulating material in an embodiment of the application;
FIG. 8 is a schematic view showing the structure of a first extrusion die in the embodiment of the present application;
FIG. 9 is a schematic view showing the structure of a second extrusion die in the embodiment of the present application;
fig. 10 shows a schematic structural view of a third photovoltaic laminate in an embodiment of the present application.
Description of the drawings:
1-packaging material layer, 2-convex part, 3-base plate, 4-solar cell, 5-cover plate and 6-back plate.
Detailed Description
The following description of the embodiments of the present application will be made clearly and fully with reference to the accompanying drawings, in which it is evident that the embodiments described are some, but not all embodiments of the present application. All other embodiments, based on the embodiments of the application, which are apparent to those of ordinary skill in the art without inventive faculty, are intended to be within the scope of the application.
In an embodiment of the present application, referring to fig. 1, fig. 1 shows a schematic structural diagram of a first structured encapsulating material in an embodiment of the present application. The structured encapsulating material comprises: the packaging material layer 1, the substrate 3 and/or the packaging material layer 1 comprise a plurality of rows of protruding portions 2 protruding from the substrate 3 and/or the base body of the packaging material layer 1. That is, it may be a convex portion having a convex base only on the base of the encapsulating material layer, or it may be a convex portion having a convex base only on the base of the substrate. Alternatively, the package material layer may have a convex portion protruding from the base on the base of the substrate.
For example, referring to fig. 1, in the structured encapsulating material, the flat area of the encapsulating material layer 1 may be a base body, and the protruding portion 2 protruding from the base body may be a protruding portion 2. There is no protruding portion on the base of the substrate 3 in fig. 1.
The protruding direction of the protruding portion 2 faces the battery string. The convex part has a certain positioning function, is convenient for the laying and alignment of the battery strings, and improves the production efficiency. The protruding parts in the structured packaging material are melted in the subsequent lamination process, and/or the protruding parts of the substrate are extruded to be melted packaging material and filled in the gaps in the battery strings or components, so that the pressure born by the solar cells in the lamination process can be reduced, hidden cracks can be reduced even if gaps between the cells are reduced, and the production yield is improved.
Optionally, under the condition that the structured packaging material is located on the light-facing surface of the battery string, the overall light transmittance of the structured packaging material is greater than or equal to 90%, so that the light utilization rate can be improved.
The number of the convex portions 2 on the base is not particularly limited.
Alternatively, the material of the protruding portion may be the same as or different from the material of the substrate, so that the production process of the structured encapsulating material is more selective. The protruding portion and the base may be integrally formed or stepwise formed. In the embodiment of the present application, this is not particularly limited. If the molding is performed step by step, the protruding part 2 can be the leftover material of the substrate, and the cost can be reduced. In the embodiment of the present application, this is not particularly limited.
For example, referring to fig. 1, the material of the protruding portion 2 in fig. 1 may be the same as that of the base of the encapsulation material layer 1. For another example, referring to fig. 2, fig. 2 shows a schematic structural diagram of a second structured encapsulating material in an embodiment of the application. The material of the protruding portion 2 in fig. 2 may be different from the material of the base of the encapsulation material layer 1.
Alternatively, the protruding part and the substrate can be formed by hot pressing, bonding, extruding and printing, and the forming mode is various and the process is simple.
In the case where the encapsulation material layer includes a convex portion protruding from the base of the encapsulation material layer in the structured encapsulation material, the concave space formed by the base of the encapsulation material layer and the convex portion is used to obliquely dispose each solar cell in the cell string, and the encapsulation material layer may be a front encapsulation material layer and/or a rear encapsulation material layer. That is, the above-mentioned encapsulation material layer is provided only on the light-facing surface of the cell string, and each solar cell in the cell string is disposed obliquely in the concave space formed by the base body of the front encapsulation material layer and the convex portion of the front encapsulation material layer, the convex surface of the convex portion being opposite to the light-facing surface of the solar cell. Alternatively, the above-mentioned packaging material layer is disposed only on the backlight surface of the cell string, and each solar cell in the cell string is disposed obliquely in the concave space formed by the base body of the rear packaging material layer and the convex portion, and the convex surface of the convex portion is opposite to the backlight surface of the solar cell. Or the light-facing surface and the backlight surface of the battery string are respectively provided with the packaging material layer, each solar battery in the battery string is obliquely arranged in a concave space formed by the substrate and the convex parts of the packaging material layers at the two sides, the convex surface of the convex part of the packaging material layer positioned on the light-facing surface of the battery string is opposite to the light-facing surface of the solar battery, and the convex surface of the convex part of the packaging material layer positioned on the backlight surface of the battery string is opposite to the backlight surface of the solar battery. In the embodiment of the present application, this is not particularly limited.
Each solar cell in the cell string is obliquely arranged in a concave space formed by the substrate of the packaging material layer and the convex part, and the concave space can reduce the pressure born by the solar cell in the lamination process, reduce hidden cracks and improve the production yield. Moreover, the inclined arrangement is beneficial to reducing gaps among the solar cells so as to improve the power output of the battery assembly. Meanwhile, the concave space has a certain positioning function, so that the battery strings can be paved and aligned conveniently, and the production efficiency is improved. The convex parts of the packaging material layer in the structured packaging material are melted and filled in the gaps in the solar cells, the cell strings or the components in the subsequent lamination process, so that the pressure born by the solar cells in the lamination process can be reduced, hidden cracks can be reduced, and the production yield can be improved.
Referring to fig. 3, fig. 3 shows a schematic structural view of a first photovoltaic laminate in an embodiment of the present application. As shown in fig. 3, the encapsulation material layers 1 are provided on both the light-facing surface and the backlight surface of the battery string, and the encapsulation material layers 1 each include a convex portion 2 protruding from the base body. In fig. 3, each solar cell 4 in the cell string is obliquely disposed in a concave space formed by the substrate of the encapsulation material layer 1 and the convex portion 2 at both sides, the convex surface of the convex portion 2 of the encapsulation material layer 1 located on the light-facing surface of the cell string is opposite to the light-facing surface of the solar cell 4, and the convex surface of the convex portion 2 of the encapsulation material layer 1 located on the backlight surface of the cell string is opposite to the backlight surface of the solar cell 4.
It should be noted that, the above-mentioned packaging material layers are disposed on the light-facing surface and the backlight surface of the battery string, and the above-mentioned packaging materials each include a protruding portion protruding from the substrate, so that, compared with the case where the above-mentioned packaging material layer containing the protruding portion is disposed only on the light-facing surface or the backlight surface of the battery string, the solar cell is better protected during lamination, and the pressure born by the solar cell during lamination is smaller, so that the hidden crack can be further reduced, and the production yield is improved. The convex parts in the packaging material layer are melted and fully filled in the gaps in the solar cells, the cell strings or the components in the subsequent lamination process, so that the pressure born by the solar cells in the lamination process can be further reduced, hidden cracks can be reduced, and the production yield is improved.
Referring to fig. 3, in the case that the front encapsulant layer includes the protruding portion 2 on the side facing the battery string and the rear encapsulant layer includes the protruding portion 2 on the side facing the battery string, the protruding portions 2 on two sides of the same solar cell 4 are staggered, so that the protruding portions 2 on two sides form a large concave space, and the battery string is conveniently laid.
In the case that the encapsulation material layer in the structured encapsulation material comprises a protruding portion protruding from the base body of the substrate, the protruding portion 2 is located on the side of the encapsulation material layer away from the substrate, and the concave space formed by the base body and the protruding portion in the encapsulation material layer is used for obliquely arranging each solar cell in the cell string; the convex surface of the convex portion is opposite to the light-facing surface and/or the backlight surface of the solar cell. That is, the protruding portion is located at a side of the encapsulation material layer close to the battery string. The encapsulation material layer may be a front encapsulation material layer or a rear encapsulation material layer. In the case where the encapsulation material layer is a front encapsulation material layer, the substrate may be a cover plate. In the case where the encapsulation material layer is a rear encapsulation material layer, the substrate may be a back plate. The material of the cover plate or the back plate is not particularly limited.
For example, referring to fig. 3, the front encapsulant layer and cover plate 5 together comprise a structured encapsulant. The rear encapsulant layer and the back sheet 6 together comprise a structured encapsulant. The protruding part 2 is positioned on one side of the packaging material layer away from the substrate, and the concave space formed by the substrate of the packaging material layer and the protruding part is used for obliquely arranging each solar cell in the cell string.
In the case where the substrate in the structured encapsulating material comprises a protruding portion protruding from the base of the substrate, the protruding portion is located on the side of the substrate close to the layer of encapsulating material. The substrate may be a cover plate or a back plate. The material of the substrate may be glass or a polymer. In the lamination process, the bulge part on one side of the substrate, which is close to the packaging material layer, can extrude the adjacent melted packaging material layer, so that the melted packaging material layer extruded by the bulge part is filled in the gaps of the battery strings or the battery components, the pressure born by the solar battery in the lamination process can be reduced, the hidden cracks can be reduced, and the production yield is improved.
In the structured packaging material, the front packaging material layer comprises a convex part protruding out of the substrate of the front packaging material layer, the rear packaging material layer comprises a convex part protruding out of the substrate of the rear packaging material layer, the cover plate comprises a convex part protruding out of the substrate of the cover plate, and the back plate comprises a convex part protruding out of the substrate of the back plate, which can be at least one of the four, or any permutation and combination. This is not particularly limited in the embodiments of the present application.
For example, referring to fig. 4, fig. 4 shows a schematic structural diagram of a third structured encapsulating material in an embodiment of the application. In the structured encapsulating material shown in fig. 4, the front encapsulating material layer comprises a protruding portion 2 on the side facing away from the cover plate 5, while the cover plate 5 also comprises a protruding portion 2 on the side facing towards the encapsulating material layer.
Referring to fig. 5, fig. 5 shows a schematic structural view of a second photovoltaic laminate in an embodiment of the present application. The front encapsulation material layer and the rear encapsulation material layer each include: protruding from the protruding portion 2 of the base. Each solar cell 4 in the cell string is obliquely arranged in a concave space formed by the substrate of the packaging material layers on two sides and the convex part 2, the convex surface of the convex part 2 of the front packaging material layer positioned on the light-facing surface of the cell string is opposite to the light-facing surface of the solar cell 4, and the convex surface of the convex part 2 of the rear packaging material layer positioned on the backlight surface of the cell string is opposite to the backlight surface of the solar cell 4. Meanwhile, in fig. 5, the cover plate 5 has a convex portion 2 at a side close to the encapsulation material layer.
In fig. 5, the concave space can reduce the pressure born by the solar cell in the lamination process, so as to reduce hidden cracks and improve the production yield. Moreover, the inclined arrangement is beneficial to reducing gaps among the solar cells so as to improve the power output of the battery assembly. Meanwhile, the concave space has a certain positioning function, so that the battery strings can be paved and aligned conveniently, and the production efficiency is improved. The protruding parts of the front packaging material layer and the rear packaging material layer are melted and filled in the gaps in the battery strings or components in the subsequent lamination process, so that the pressure born by the solar battery in the lamination process can be reduced, hidden cracks can be reduced, and the production yield is improved. Meanwhile, the convex part 2 positioned on one side of the cover plate 5 close to the front packaging material layer can extrude the fused front packaging material layer in the lamination process, and is filled in the gaps of the battery strings or the battery components, so that the pressure born by the solar cells in the lamination process can be further reduced, hidden cracks can be reduced, and the production yield is improved.
Alternatively, the projections of the protruding portions on the packaging material layer and the projections of the protruding portions on the substrate may overlap or not overlap on the same side of the battery string. In the embodiment of the present application, this is not particularly limited. For example, referring to fig. 5, the projection of the convex portion on the front encapsulant layer, which is located on the light-facing surface of the battery string, overlaps the projection of the convex portion 2 on the cover plate 5.
The solar cell may be a back contact solar cell, or the solar cell may be a solar cell having an electrode on a light-facing surface, and the like, and in the embodiment of the present application, the method is not particularly limited.
The inclination angle of the solar cell 4 is determined specifically according to the height of the protruding portion, the length of the solar cell, and the like, and is not particularly limited in the embodiment of the present application.
Alternatively, the protruding portions are periodically distributed on the substrate, the process is simple, and in general, the sizes of the solar cells in the cell strings are approximately equal, so that the laying of the cell strings is facilitated. For example, referring to fig. 1, the projections 2 are periodically distributed on the base of the encapsulating material layer 1.
Alternatively, referring to fig. 3, the distance between the centers of the adjacent two rows of convex portions 2 is about the width of a single solar cell, thereby facilitating the oblique placement of the solar cells 4.
Optionally, the distance between the centers of two adjacent rows of protruding portions is smaller than or equal to the width of a single solar cell, so as to facilitate the oblique placement of the solar cells 4.
Optionally, the protruding portions of each row are continuously distributed, that is, the protruding portions are strip-shaped protrusions, the height of the substrate can be 100-800um, the height of the protruding portions protruding the substrate is 20-200um, the width of the protruding portions is 5-100mm along the direction of the battery string, the structured packaging material with the size can stably and obliquely place the solar battery, and the inclination angle is enabled to be favorable for further reducing hidden cracks in the lamination process. Furthermore, further reduction of hidden cracks during lamination is facilitated. In addition, the convex part with the thickness range can be fully filled in gaps between adjacent solar cells or in the assembly after being melted or extruded in the subsequent lamination process, so that hidden cracks in the lamination process can be reduced, gaps between the solar cells can be reduced, and the power output of the cell assembly can be improved.
As shown with reference to fig. 1 or 2, the protruding portions of each row are continuously distributed, the height d1 of the base body of the packaging material layer 1 is 100-800um, the height d2 of the protruding portion 2 protruding the base body is 20-200um, and the width w1 of the protruding portion 2 is 5-100mm along the cell string direction.
Alternatively, each of the column projecting portions is composed of a plurality of sub-projecting portions intermittently extending, and the width of the sub-projecting portions is 1-10mm in the direction of the battery string. The spacing between adjacent sub-projections is 3-20mm. That is, each column of the convex portions is formed by intermittently extending the dot-shaped sub-convex portions, so that the material of the convex portions can be saved, and the cost can be saved. Moreover, the structured packaging material with the size can be used for placing the solar cell in a stable inclined manner, and the inclination angle is also used for further reducing hidden cracks in the lamination process. Furthermore, further reduction of hidden cracks during lamination is facilitated. In addition, the convex part with the thickness range can be fully filled in the gaps in the battery strings or components after being melted or extruded in the subsequent lamination process, so that hidden cracks in the lamination process can be reduced, gaps between the battery strings or components can be reduced, and the power output of the battery components can be improved. Optionally, the shape of the sub-protruding portion includes: one of spherical body, cylinder, polyhedral cylinder, round platform and prismatic platform. And the form of the sub-convex part is varied.
Optionally, the shape of the protruding portion may also include: one of spherical body, cylinder, polyhedral cylinder, round platform and prismatic platform. And the protruding portion is varied in form. For example, referring to fig. 1 or 2, the protruding portion 2 has a triangular prism shape. For another example, referring to fig. 6, fig. 6 shows a schematic structural diagram of a fourth structured encapsulating material in an embodiment of the application. The material of the protruding part 2 in fig. 6 may be the same as the material of the base body. In fig. 6, the protruding portion 2 has a rectangular parallelepiped shape. For another example, referring to fig. 7, fig. 7 shows a schematic structural diagram of a fifth structured encapsulating material in an embodiment of the application. The material of the protruding part 2 in fig. 7 may be different from the material of the base body. In fig. 7, the protruding portion 2 has a rectangular parallelepiped shape.
Optionally, the material of the matrix of the encapsulating material layer is selected from: at least one of epoxy resin, acrylic resin, polyurethane, cyanoacrylate, polyvinyl alcohol, polydimethylsiloxane, ethylene-vinyl acetate copolymer (EVA), ethylene-octene copolymer (POE), polyvinyl butyral (PVB) or silica gel, and the packaging material layer has good protection performance on battery strings.
Optionally, a release layer may be disposed on one or both sides of the substrate and/or the protruding portion, which is not particularly limited in the embodiment of the present application, for convenience in transportation and operation.
The application also provides a method for producing the structured packaging material, the structured packaging material comprises a substrate and a packaging material layer, and the substrate and/or the packaging material layer comprises a plurality of rows of protruding parts protruding from a substrate of the substrate and/or the packaging material layer. Reference may be made to the foregoing description for the structured encapsulating material, and in order to avoid repetition, no further description is given here. The protruding portion may be formed specifically by one of the following steps S1 to S5:
step S1, hot-pressing the convex part on the substrate.
Specifically, the protruding portion is heat-pressed on the base, and the material of the protruding portion may be the same as or different from that of the base. The material of the protruding portion may be selected from: at least one of ethylene vinyl acetate copolymer (EVA), ethylene octene copolymer (POE), polyvinyl butyral (PVB), or silica gel. For example, the protruding portion may be a rim of the base.
Optionally, in the process of hot-pressing the protruding portion on the substrate, the hot-pressing temperature may be 50-150 ℃, the pressure may be 0.1-0.5MPa, the hot-pressing time may be 1-60s, and the above hot-pressing parameters may uniformly attach the protruding portion on the substrate. For example, the hot pressing temperature is 80 ℃, the pressure is 0.1MPa, and the hot pressing time can be 5s.
And S2, bonding the substrate and the convex part by using an adhesive.
Specifically, the material of the protruding portion may be referred to the foregoing description, and in order to avoid repetition, a description thereof will be omitted. The adhesive may be applied to the substrate or the adhesive may be applied to the convex portion, which is not particularly limited in the embodiment of the present application.
Alternatively, the binder may be a synthetic polymeric binder. The binder material may be selected from: at least one of polyvinyl acetate, polyvinyl acetal, acrylate, polystyrene, epoxy resin, acrylic resin, polyurethane resin, unsaturated polyester, butyl rubber, nitrile rubber, phenolic-polyvinyl acetal, or epoxy-polyamide. The adhesive may be a liquid adhesive or an adhesive film at room temperature. And release layers are arranged on one side or two sides of the adhesive film, so that the operation is convenient.
And S3, extruding a local area of the matrix to form a convex part protruding the matrix.
Specifically, the substrate may be laid on a table, and an extrusion die with a convex portion extrudes the substrate to form the convex portion as described above. As shown in reference to fig. 8, fig. 8 shows a schematic structural view of a first extrusion die in an embodiment of the present application. The shape of the convex portion formed by the extrusion die shown in fig. 8 may be a triangular prism. For another example, referring to fig. 9, fig. 9 shows a schematic structural view of a second extrusion die in an embodiment of the present application. The shape of the convex portion formed by the extrusion die shown in fig. 9 may be a rectangular parallelepiped.
Alternatively, the substrate may be heated prior to pressing the localized area of the substrate. And/or heating the substrate during pressing of the localized area of the substrate. The heating temperature may be 100 ℃ or less. Since the substrate may be elastic, the extruded projections may shrink to such an extent that the height of the extruded projections may be less than the integral extruded or bonded projections. By heating the substrate, the degree of shrinkage can be reduced, so that the extruded convex portion is relatively accurate in size, and the substrate is not affected in the above heating temperature range.
And S4, integrally forming the structured packaging material by adopting a pouring mold with a convex part.
Specifically, the matrix precursor solution may be charged into a casting mold with a bulge, and cooled to form the structured encapsulating material described above.
Step S5, printing a convex part on the substrate.
Specifically, the protruding portions may be printed on the substrate by screen printing. For example, UV ink material or sintered glass color glaze printing material is adopted for screen printing on the surface of the glass cover plate. Then the printing ink can be solidified by UV light irradiation or put into a heating furnace to be sintered for 1-5 minutes at the temperature of about 600 ℃ to form the convex part.
The production method of the structured packaging material provided by the embodiment of the application has the same or similar beneficial effects as the structured packaging material, and in order to avoid repetition, the description is omitted here.
The embodiment of the application also provides a photovoltaic module, such as the photovoltaic laminated pieces shown in fig. 3 and 5, and the photovoltaic laminated pieces are laminated to form the photovoltaic module. The photovoltaic module comprises at least one battery string, the battery string is laminated and packaged by any one of the structural packaging materials to form the photovoltaic module, the structural packaging materials are arranged on the light facing surface and/or the backlight surface of the battery string, the battery string can comprise a plurality of solar batteries, and the protruding direction of the protruding part faces the battery string. The individual solar cells are placed in the recesses formed by the protruding portions.
For another example, referring to fig. 10, fig. 10 shows a schematic structural view of a third photovoltaic laminate in an embodiment of the present application. The photovoltaic laminate is laminated to form a photovoltaic module.
Optionally, in the packaging process, the front packaging material layer includes the bulge towards one side of the battery string, and the rear packaging material layer includes the bulge towards one side of the battery string, and under the condition that the bulge that is located the same solar cell both sides staggers and distributes, and then the bulge of both sides forms the indent space great, is convenient for lay of battery string. As shown in fig. 3, 5 and 10, the front and rear sealing material layers on both sides of the first battery piece from left to right are provided with the protruding portions 2, and the projections of the protruding portions 2 on both sides of the first battery piece are not overlapped, i.e., are staggered.
Optionally, the protruding portion of the structured encapsulation material above the solar cell has a size that is larger than the protruding portion of the structured encapsulation material below the solar cell; wherein the structured encapsulant over the solar cells is remote from the lamination stage. That is, the size of the protruding portion of the structured encapsulating material distal to the lamination stage is greater than the size of the protruding portion of the structured encapsulating material proximal to the lamination stage. In the lamination process, due to the action of gravity, the flow effect of the protruding part of the structured packaging material far away from the lamination platform or the flow effect caused by extrusion is good, and the size of the protruding part of the structured packaging material far away from the lamination platform is larger than that of the protruding part of the structured packaging material near the lamination platform, so that the protruding part of the packaging material layer is melted and/or the protruding part of the substrate extrudes the melted packaging material, and the protruding part is filled in a gap in a battery string or a component more sufficiently, and hidden cracks are further reduced.
Optionally, in the lamination process, the melted encapsulation material is melted by the outlet part of the encapsulation material layer and/or extruded by the outlet part of the substrate, and flows to the gap of the solar cells to form an adhesive layer, and the adhesive layer can strengthen the connection reliability between the solar cells on one hand and can fill in the gaps in the cell strings or components on the other hand, so as to reduce hidden cracks.
The above-mentioned photovoltaic laminate and the photovoltaic module after lamination can be referred to the above description, and in order to avoid repetition, the description is omitted here.
Each part in the photovoltaic module refers to the related description, and can achieve similar beneficial effects, and in order to avoid repetition, the description is omitted here.
The embodiment of the application also provides a preparation method of the photovoltaic module, which comprises the following steps:
step SA1, providing any of the structured packaging materials as before.
Step SA2, providing a battery string; the battery string includes a plurality of solar cells.
Step SA3, arranging the structured packaging material on the light-facing surface and/or the backlight surface of the battery string to obtain a component precursor; in the module precursor, the protruding direction of the protruding portion faces the battery string.
Step SA4, laminating a laminate comprising the assembly precursor.
It should be noted that: the laminate may include: the battery comprises a cover plate, a front packaging material layer, a battery string, a rear packaging material layer and a back plate which are sequentially stacked. For example, in the case where the assembly precursor includes a cover sheet, a front encapsulant layer, a battery string, a rear encapsulant layer, and a back sheet, the assembly precursor is a laminate. Each part in the photovoltaic module refers to the related description, and can achieve similar beneficial effects, and in order to avoid repetition, the description is omitted here.
Optionally, the step SA4 may include: primary laminating a laminate comprising the assembly precursor; the primary lamination temperature is: 80-125 ℃; re-laminating the laminate comprising the assembly precursor; the temperature of the re-lamination is: 120-160 ℃. By subjecting the laminate to a lower temperature primary lamination, the encapsulation material, or the raised portions of the encapsulation material layers, of the structured encapsulation material of the laminate, may be sufficiently melted and uniformly and stably flowed to the interconnections prior to the cross-linking reaction, thereby generating uniform static pressure. And then, the preheated laminated piece is laminated again at a higher temperature, so that the laminated piece can be filled and solidified into gaps of the battery strings or components under the condition of uniform static pressure, gapless connection can be realized, and hidden cracks or cracking can be further reduced.
In the method for producing the module, the laying order of the battery strings and the structured packaging material is not limited.
The embodiments of the present application have been described above with reference to the accompanying drawings, but the present application is not limited to the above-described embodiments, which are merely illustrative and not restrictive, and many forms may be made by those having ordinary skill in the art without departing from the spirit of the present application and the scope of the claims, which are all within the protection of the present application.

Claims (21)

1. A structured packaging material, comprising a substrate and a packaging material layer, wherein the substrate comprises a plurality of rows of protruding parts protruding from a matrix of the substrate, and the packaging material layer comprises a plurality of rows of protruding parts protruding from the matrix of the packaging material layer;
the protruding direction of the protruding part faces the battery string;
the protruding part on the substrate is positioned on one side of the substrate close to the packaging material layer;
the projection of the protruding portion on the encapsulation material layer overlaps the projection of the protruding portion on the substrate.
2. The structured packaging material of claim 1, wherein the distance between centers of adjacent columns of said projections is the width of a single solar cell.
3. The structured packaging material of claim 1, wherein a distance between centers of adjacent two columns of the projections is less than or equal to a width of a single solar cell.
4. The structured packing material of claim 1, wherein the protruding portions are periodically distributed on the substrate.
5. The structured packing material of claim 1, wherein the rows of projections are continuously distributed, the projections have a width of 5-100mm and a height of 20-200mm, and the width is a dimension along the string direction.
6. The structured packing material of claim 1, wherein each column of projections is comprised of a plurality of sub-projections extending intermittently; the width of the sub-convex parts is 1-10mm, the interval between the adjacent sub-convex parts is 3-20mm, and the width is the dimension along the direction of the battery string.
7. The structured packing material of claim 6, wherein the shape of the sub-convex portion comprises: one of spherical body, cylinder, polyhedral cylinder, round platform and prismatic platform.
8. The structured packing material of any one of claims 1 to 7, wherein the material of the protruding portion and the material of the base are the same or different.
9. The structured packing material of any one of claims 1 to 7, wherein the material of the matrix of the layer of packing material is selected from the group consisting of: at least one of epoxy, acrylic, polyurethane, cyanoacrylate, polyvinyl alcohol, polydimethylsiloxane, ethylene-vinyl acetate copolymer, ethylene-octene copolymer, polyvinyl butyral, or silica gel.
10. The structured packing material of any one of claims 1 to 7, wherein the protrusions are formed by means of integral molding, hot pressing, bonding, extrusion or printing with the substrate.
11. The structured packaging material of claim 1, wherein the structured packaging material has an overall light transmittance of greater than or equal to 90% with the structured packaging material positioned on the light-facing side of the battery string.
12. A method for producing a structured encapsulating material, wherein the structured encapsulating material comprises a substrate and an encapsulating material layer, the substrate comprises a plurality of rows of protruding parts protruding from a base body of the substrate, and the encapsulating material layer comprises a plurality of rows of protruding parts protruding from the base body of the encapsulating material layer; the protruding direction of the protruding part faces the battery string; the protruding part on the substrate is positioned on one side of the substrate close to the packaging material layer; the projection of the convex part on the packaging material layer is overlapped with the projection of the convex part on the substrate; the protruding portion is formed by one of the following steps:
hot-pressing the protruding portion on the base;
bonding the substrate and the protruding portion with an adhesive;
extruding a localized area of a substrate to form a convex portion that protrudes from the substrate;
integrally molding the structured packaging material by adopting a pouring mold with a convex part;
the protruding portions are printed on the substrate.
13. The method of claim 12, wherein the hot pressing is performed at a temperature of 50-150 ℃, a pressure of 0.1-0.5MPa, and a time of 1-60s.
14. The method of claim 12, wherein the adhesive material is selected from the group consisting of: at least one of polyvinyl acetate, polyvinyl acetal, acrylate, polystyrene, epoxy resin, acrylic resin, polyurethane resin, unsaturated polyester, butyl rubber, nitrile rubber, phenolic-polyvinyl acetal, or epoxy-polyamide.
15. The method of producing structured packing material according to claim 12, wherein the substrate is heated before pressing the localized area of the substrate;
and/or heating the substrate during pressing of the localized area of the substrate;
the heating temperature is less than or equal to 100 ℃.
16. A photovoltaic module comprising at least one string of cells laminated encapsulated with the structured encapsulating material of any one of claims 1-11; in the packaging process, the structured packaging material is arranged on the light-facing surface and/or the backlight surface of the battery string, the protruding direction of the protruding part faces the battery string, and the single solar battery is arranged in the groove formed by the protruding part.
17. The photovoltaic module of claim 16, wherein the protruding portions on both sides of the same solar cell are staggered when the front encapsulant layer includes protruding portions on a side facing the cell string and the rear encapsulant layer includes protruding portions on a side facing the cell string during encapsulation.
18. The photovoltaic module of claim 16 or 17, wherein the protruding portion of the structured encapsulant over the solar cell has a size that is greater than the protruding portion of the structured encapsulant under the solar cell; wherein the structured encapsulant over the solar cells is remote from the lamination stage.
19. The photovoltaic module of claim 16 or 17, wherein the adhesive layer is formed by the molten encapsulant material being flowed to the solar cell gap during lamination by the molten protrusions of the encapsulant material layer and the extruded substrate protrusions.
20. The preparation method of the photovoltaic module is characterized by comprising the following steps of:
providing a structured encapsulating material as claimed in any of claims 1 to 11;
providing a battery string; the battery string includes a plurality of solar cells;
providing the structured packaging material on the light-facing surface and/or the backlight surface of the battery string to obtain a component precursor; in the assembly precursor, the protruding direction of the protruding portion faces the battery string;
laminating a laminate comprising the assembly precursor.
21. The method of claim 20, wherein laminating the laminate comprising the module precursor comprises:
primary laminating a laminate comprising the assembly precursor; the primary lamination temperature is: 80-125 ℃;
re-laminating the laminate comprising the assembly precursor; the temperature of the re-lamination is: 120-160 ℃.
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