CN106653906A - 一种高效光伏组件及其层压工艺 - Google Patents
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Abstract
本发明涉及一种高效光伏组件及其层压工艺，该组件由面板、正面粘结层、电池片、背面粘结层和背板依次层压而成，正面粘结层为硅酮胶，背面粘结层为掺入或喷涂反光粒子的硅酮胶，相邻的电池片通过汇流条连接，层压时，先放置背板，涂上掺入反光粒子的硅酮胶，或者涂上硅酮胶，将反光粒子喷在硅酮胶表面，硅酮胶固化后，放置电池片，在涂正面高透光的硅酮胶前，在电池片边缘施加一圈支撑框，然后放置面板，本发明的有益效果是：电池片受光面的硅酮胶透明，可多利用紫外光；背面的硅酮胶中的反光粒子，可以将电池间隙的光包括紫外光反射至电池表面，提升了组件的效率，保护背板的作用，在电池片边缘施加一圈玻璃纤维框后，可以承受玻璃重量，防止溢胶。
Description
技术领域
本发明涉及太阳能电池的技术领域，特别是涉及一种高效光伏组件及其层压工艺。
背景技术
常规的化石燃料日益消耗殆尽，在所有的可持续能源中，太阳能无疑是一种最清洁、最普遍和最有潜力的替代能源。光伏发电是最具可持续发展理想特征的发电技术之一。目前，在所有的太阳能电池中，硅太阳能电池是得到大范围商业推广的太阳能电池之一，这是由于硅材料在地壳中有着极为丰富的储量，同时硅太阳能电池相比其他类型的太阳能电池，有着优异的电学性能和机械性能。在未来光伏技术的发展中，随着硅太阳能电池光电性能的进一步提高，硅材料价格的进一步降低，硅太阳能电池将在光伏领域占据重要的地位。
传统晶硅电池封装组件依次采用：玻璃，EVA（或PVB），太阳电池，EVA（或 PVB），背板或者玻璃来封装；由于太阳光中的紫外光会穿过EVA，直接导致背板的老化；为解决该问题，晶硅组件采用的EVA是添加了紫外吸收剂；另外，由于EVA由于化学变化会有老化，也成为改进的目标。
汇流条是用在太阳能电池组件上的集电装置，主要起到连接导电的作用。目前行业内常用的汇流条都是呈长条形，主要有2种，一是横截面为长方形的汇流条，二是横截面为圆形的汇流条。对于横截面为长方形的汇流条而言，该汇流条遮光严重，影响了组件功率。对于横截面为圆形的汇流条而言，虽然圆形汇流条可以将大部分照射到其上的光线反射回电池片表面，从而避免其遮光影响；但是圆形汇流条有两个缺点：（1）为了达到降低电阻的目的，圆形汇流条的直径需要设置的比较大，这就导致焊接时汇流条的高度比较高，这就必须增加组件中EVA的厚度，导致成本上升；（2）圆形汇流条同电池片的接触面太小，从而造成焊接可靠性较差。
发明内容
本发明的目的是克服上述现有技术的不足，提供一种高效光伏组件及其层压工艺，通过对光的二次利用，进一步提升太阳能组件效率。
为实现上述目的，本发明提出的一种高效光伏组件，由面板、正面粘结层、电池片、背面粘结层和背板依次层压而成，所述的正面粘结层为硅酮胶，所述的背面粘结层为表面喷涂反光粒子的硅酮胶，或者所述的背面粘结层为掺入反光粒子的硅酮胶，相邻的电池片通过汇流条连接，所述汇流条包括金属铝线本体，所述金属铝线本体的直径为300~500微米，所述金属铝线本体的横截面为圆弧形，且其面积大于等于相应圆面积的75%。其中，所述金属铝线本体的横截面为圆弧形，且其面积大于等于相应圆面积的75%，即其横截面为大于等于75%个圆形，相当于在原来圆形的基础上切掉了一部分。其切面是用来与光伏电池形成电连接的。
作为优选，在所述的电池片的边缘施加一圈支撑框，支撑框位于正面粘结层和背面粘结层之间，所述的支撑框为玻璃纤维框。
作为优选，所述的反光粒子为纳米二氧化钛颗粒。
作为优选，所述金属铝线本体的弦切面处设有切面涂层，切面涂层的作用是用来和电池片电连接的，当然也可以采用导电胶代替，所述切面涂层为低熔点金属层或低熔点金属合金层；所述低熔点金属层选自Bi、In、Sn或Pb层，所述低熔点金属合金层选自Bi、In、Sn、Pb中的任意两种或两种以上合金层。在层压的过程中，低熔点的金属或合金层会熔融并与光伏电池的金属电极实现电连接。当然，切面涂层也可以采用常规的粘结材料，通过粘结方式实现与金属电极的电连接。
作为优选，所述金属线本体的横截面中，其弦所对应的角度为45~75度。
作为优选，所述金属铝线本体的弧面处设有金属反射层。金属反射层可以采用高反射材料，其目的是将大部分照射到其上的光线反射回电池片表面，进一步提高光的利用率。
作为优选，切面涂层和金属反射层可以采用同种材料。
上文中，所述金属反射层为低熔点金属层或低熔点金属合金层；所述低熔点金属层选自Bi、In、Sn或Pb层，所述低熔点金属合金层选自Bi、In、Sn、Pb中的任意两种或两种以上合金层。金属合金层的选择是为了节约贵金属的耗量，比如In。
作为优选，切面涂层和反射层可以采用不同材料，这样可以进一步减少贵金属的耗量，降低成本。
作为优选，所述金属反射层的厚度为5~15微米。
本发明还提出一种高效光伏组件的层压工艺，先放置背板，涂上掺入反光粒子的硅酮胶，固化后，放置电池片，相邻的电池片通过汇流条连接，在涂正面高透光的硅酮胶前，在电池片边缘施加一圈支撑框，然后放置面板；或者先放置背板，涂上硅酮胶，将反光粒子喷在硅酮胶表面，固化后， 放置电池片，在涂正面高透光的硅酮胶前，在电池片边缘施加一圈支撑框，然后放置面板。
本发明的有益效果是：电池片受光面的硅酮胶透明，且不含紫外吸收剂，较传统EVA可多利用紫外光；电池片背面的硅酮胶掺入或喷涂反光粒子，可以 将电池间隙的光包括紫外光反射至电池表面，提升了太阳能电池组件的转换效率和输出功率，同时紫外光不会到达背板，可起到保护背板的作用。对于背面硅胶含高反光粒子，在层压时，由于重力作用，反光粒子会在层 压过程时泛至正面硅酮胶中，且泛至电池片表面而遮挡发电面积，且影响外观。在电池片边缘施加一圈玻璃纤维框后，可以承受玻璃重量；可以控制胶的厚度，防止溢胶；且玻璃纤维容易被硅胶填满，绝缘性能不受影响，保证组件的可靠性。同时通过在圆形汇流条的基础上设置一个切面，在不影响遮光损失、不明显增加电阻的前提下，不仅能减少汇流条高度，而且还能增加焊接的可靠性，具有积极的现实意义；本发明设计的汇流条还可以和高反射材料相结合来使用，可以进一步提高光的利用率，提高组件的输出功率；本发明在汇流条弧面和切面上分别设置不同的涂层，并对涂层的成分进行优化，能够节省贵金属涂层的耗量，降低成本，同时还能提高后续工艺的兼容性，能够更好的与不同的电连接方式相匹配；本发明的结构简单，易于制备，成本较低，适于推广应用。
附图说明
图1是本发明的一种高效光伏组件的结构示意图；图2是本发明的一种高效光伏组件的汇流条的结构示意图。
具体实施方式
下面结合附图及实施例对本发明作进一步描述：如图1和2所示，一种高效太阳能电池组件，由面板1、正面粘结层2、电池片 3、背面粘结层4和背板5依次层压而成，在电池片3的边缘施加一圈支撑框6， 支撑框6位于正面粘结层2和背面粘结层3之间。正面粘结层2为硅酮胶，硅酮胶透明，且不含紫外吸收剂，背面粘结层4为表面喷涂反光粒子41的硅酮胶，或者背面粘结层4为掺入反光粒子的硅酮胶，反光粒子为纳米二氧化钛颗粒将电池间隙的光反射至电池表面，实现光的二次利用，相邻的电池片3通过汇流条7连接，所述汇流条7包括金属铝线本体71，所述金属铝线本体71的直径为450微米，所述金属铝线本体71的横截面为圆弧形，且其面积大于相应圆面积的75%，所述金属铝线本体71的弦切面处设有切面涂层72，所述切面涂层72为In/Pb合金，所述金属铝线本体71的横截面中，其弦所对应的角度为60度，所述金属铝线本体71的弧所在的外表面处设有金属反射层73。所述金属反射层73为铝层。即本实施例中切面涂层和反射层可以采用不同种材料，所述金属反射层73的厚度为15微米。
本发明相比常规的光伏组件，电池片3前表面采用不含紫外吸收剂的硅酮胶可多利用紫外光，提升转换效率；背面硅酮胶上掺入或喷涂的反光粒 子，可将电池间隙的光反射至电池片3表面，提升了太阳能电池组件的转换效 率和输出功率；另外，由于背面反光粒子的反射作用，可以使包括紫外光发生 反射，紫外光不会到达背板，可起到保护背板的作用。
由于面板1通常为玻璃，重量较重，在层压时容易产生溢胶，导致反光粒 子泛至正面硅酮胶中，甚至泛至电池片3表面而遮挡发电面积。本发明提出一种新的高效光伏组件层压工艺，先放置背板5，涂上掺入反光粒子的硅酮 胶，固化后，放置电池片3，相邻的电池片3通过汇流条7连接，在涂正面高透光的硅酮胶前，在电池片3边缘施加一圈支撑框6，然后放置面板1；或者先放置背板5，涂上硅酮胶，将反光粒子 喷在硅酮胶表面，固化后，放置电池片3，在涂正面高透光的硅酮胶前，在电池 片3边缘施加一圈支撑框6，然后放置面板1。支撑框6为玻璃纤维框。
该层压工艺的优势为：放置的玻璃纤维框可承受玻璃重量；控制胶的厚度，防止溢胶；且玻璃纤维容易被硅酮胶填满，绝缘性能不受影响，保证组件的可靠性。
以上所述是本发明的优选实施方式，应当指出，对于本技术领域的普通技术人员来说，在不脱离本发明原理的前提下，还可以做出若干改进和润饰，这些改进和润饰也视为本发明的保护范围。
Claims (8)
1.一种高效光伏组件，由面板、正面粘结层、电池片、 背面粘结层和背板依次层压而成，其特征是：所述的正面粘结层为硅酮胶，所述的背面粘结层为表面喷涂反光粒子的硅酮胶，或者所述的背面粘结层为掺入反光粒子的硅酮胶，相邻的电池片通过汇流条连接，所述汇流条包括金属铝线本体，所述金属铝线本体的直径为300~500微米，所述金属铝线本体的横截面为圆弧形，且其面积大于等于相应圆面积的75%。
2.根据权利要求1所述的一种高效光伏组件，其特征是：在所述的电池片的边缘施加一圈支撑框，支撑框位于正面粘结层和背面粘结层之间，所述的支撑框为玻璃纤维框。
3.根据权利要求1所述的一种高效光伏组件，其特征是：所述的反光粒子为纳米二氧化钛颗粒。
4.根据权利要求1所述的一种高效光伏组件，其特征是：所述金属铝线本体的弦切面处设有切面涂层，所述切面涂层为低熔点金属层或低熔点金属合金层；所述低熔点金属层选自Bi、In、Sn或Pb层，所述低熔点金属合金层选自Bi、In、Sn、Pb中的任意两种或两种以上合金层。
5.根据权利要求1所述的一种高效光伏组件，其特征是：所述金属线本体的横截面中，其弦所对应的角度为45~75度。
6.根据权利要求1所述的一种高效光伏组件，其特征是：所述金属铝线本体的弧面处设有金属反射层。
7.根据权利要求5所述的一种高效光伏组件，其特征是：所述金属反射层的厚度为5~15微米。
8.一种如权利要求1-8任一项所述的一种高效光伏组件的层压工艺，其特征是：先放置背板，涂上掺入反光粒子的硅酮胶，固化后，放置电池片，相邻的电池片通过汇流条连接，在涂正面高透光的硅酮胶前，在电池片边缘施加一圈支撑框，然后放置面板；或者先放置背板，涂上硅酮胶，将反光粒子喷在硅酮胶表面，固化后， 放置电池片，在涂正面高透光的硅酮胶前，在电池片边缘施加一圈支撑框，然后放置面板。
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