CN111261741A - Method for manufacturing laminated assembly and laminated assembly - Google Patents
Method for manufacturing laminated assembly and laminated assembly Download PDFInfo
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- CN111261741A CN111261741A CN202010076454.2A CN202010076454A CN111261741A CN 111261741 A CN111261741 A CN 111261741A CN 202010076454 A CN202010076454 A CN 202010076454A CN 111261741 A CN111261741 A CN 111261741A
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Classifications
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- 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
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- 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
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- 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
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- 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
Abstract
The present invention relates to a method of manufacturing a stack assembly and a stack assembly. In the manufacturing method, in the lamination step, the solar battery pieces are arranged on the bottom side film in a laminated manner, so that the adjacent solar battery pieces are in conductive connection through the direct contact of the main grid lines; and heating the bottom side film and/or the top side film to enable the bottom side film and/or the top side film to be at least partially in a molten state and to be in contact with the solar cell piece in the molten state, so that the region in the molten state can be fixed with the solar cell piece after being solidified. According to the scheme provided by the invention, the solar cell can be fixed on the bottom side film through the heating melting characteristic of the thermoplastic film without using an additional adhesive. The scheme can combine the typesetting process and the laminating process into a whole, and the battery pieces are directly laminated and typeset on the bottom side packaging material, so that the mode has the advantages of low cost, high efficiency and easy operation.
Description
Technical Field
The invention relates to the field of energy, in particular to a method for manufacturing a laminated assembly and the laminated assembly.
Background
With the increasing consumption of conventional fossil energy such as global coal, oil, natural gas and the like, the ecological environment is continuously deteriorated, and particularly, the sustainable development of the human society is seriously threatened due to the increasingly severe global climate change caused by the emission of greenhouse gases. Various countries in the world make respective energy development strategies to deal with the limitation of conventional fossil energy resources and the environmental problems caused by development and utilization. Solar energy has become one of the most important renewable energy sources by virtue of the characteristics of reliability, safety, universality, long service life, environmental protection and resource sufficiency, and is expected to become a main pillar of global power supply in the future.
In a new energy revolution process, the photovoltaic industry in China has grown into a strategic emerging industry with international competitive advantages. However, the development of the photovoltaic industry still faces many problems and challenges, and the conversion efficiency and reliability are the biggest technical obstacles restricting the development of the photovoltaic industry, while the cost control and the scale-up are economically restricted. The photovoltaic module is taken as a core component of photovoltaic power generation, and the development of high-efficiency modules by improving the conversion efficiency of the photovoltaic module is a necessary trend. Various high efficiency modules, such as shingles, half-sheets, multi-master grids, double-sided modules, etc., are currently emerging on the market. With the application places and application areas of the photovoltaic module becoming more and more extensive, the reliability requirement of the photovoltaic module becomes higher and higher, and particularly, the photovoltaic module with high efficiency and high reliability needs to be adopted in some severe or extreme weather frequent areas.
Under the background of vigorous popularization and use of green solar energy, the shingled assembly utilizes the electrical principle of low current and low loss (the power loss of the photovoltaic assembly is in direct proportion to the square of working current) so as to greatly reduce the power loss of the assembly. And secondly, the inter-cell distance region in the cell module is fully utilized to generate electricity, so that the energy density in unit area is high. In addition, the conventional photovoltaic metal welding strip for the assembly is replaced by the conductive adhesive with the elastomer characteristic at present, the photovoltaic metal welding strip shows higher series resistance in the whole battery, and the stroke of a current loop of the conductive adhesive is far smaller than that of a welding strip, so that the laminated assembly becomes a high-efficiency assembly, and meanwhile, the outdoor application reliability is more excellent than that of the conventional photovoltaic assembly, and the laminated assembly avoids stress damage of the metal welding strip to the interconnection position of the battery and other confluence areas. Especially, under the dynamic (load action of natural world such as wind, snow and the like) environment with alternating high and low temperatures, the failure probability of the conventional assembly which is interconnected and packaged by adopting the metal welding strips is far higher than that of the laminated assembly which is interconnected and cut by adopting the conductive adhesive of the elastomer and packaged by the crystalline silicon battery small pieces.
The mainstream technology of the current tile stack assembly is to use a conductive adhesive to interconnect the cut battery pieces, wherein the conductive adhesive mainly comprises a conductive phase and a bonding phase. The conductive phase mainly comprises precious metals, such as pure silver particles or particles of silver-coated copper, silver-coated nickel, silver-coated glass and the like, and is used for conducting electricity among solar cells, the particle shape and distribution of the conductive phase are based on the requirement of optimal electricity conduction, and at present, more sheet-shaped or sphere-like combined silver powder with D50 being less than 10um is adopted. The adhesive phase is mainly composed of a high molecular resin polymer having weather resistance, and acrylic resin, silicone resin, epoxy resin, polyurethane, and the like are usually selected in accordance with the adhesive strength and weather resistance. In order to enable the conductive adhesive to achieve low contact resistance, low volume resistivity and high adhesion and maintain long-term excellent weather resistance, a conductive adhesive manufacturer can generally complete the design of a conductive phase and an adhesive phase formula, so that the performance stability of the laminated tile assembly under an initial stage environment corrosion test and long-term outdoor practical application is ensured.
And after being packaged, the battery assembly connected by the conductive adhesive is subjected to environmental erosion in outdoor practical use, for example, high and low temperature alternating expansion and contraction with heat generates relative displacement between the conductive adhesives. The most serious reason is that the current is connected in a virtual way or even disconnected, and the main reason is generally that the materials are combined and then are weak in mutual connection capacity. The weak connection capability mainly shows that a process operation window is needed for the operation of the conductive adhesive in the manufacturing process, and the window is relatively narrow in the actual production process and is very easily influenced by environmental factors, such as the temperature and humidity of an operation place, the time for which the conductive adhesive stays in the air after being coated and the like, so that the conductive adhesive loses activity. Meanwhile, the phenomenon of uneven sizing and missing easily occurs under the conditions of glue dispensing, glue spraying or printing process due to the characteristic change of glue, and great hidden danger is caused to the reliability of products. And the conductive adhesive mainly comprises high polymer resin and a large amount of noble metal powder, so that the cost is high, and the ecological environment is damaged to a certain extent (the production and processing of noble metals have great pollution to the environment). Moreover, the conductive adhesive belongs to a paste, has certain fluidity in the process of gluing or laminating, and is very easy to overflow to cause short circuit of the positive electrode and the negative electrode of the laminated interconnected battery string.
That is to say, for most of the laminated assemblies made by adopting the conductive adhesive bonding mode, the characteristics of weak mutual connection strength exist, the requirement of the manufacturing process on the environment is high, the glue overflow and short circuit are easy to occur in the process, the use cost is high, the production efficiency is low, and the like.
It is therefore desirable to provide a method of manufacturing a stack assembly and a stack assembly that addresses the above problems.
Disclosure of Invention
The object of the present invention is to provide a method of manufacturing a stack and a stack. According to the scheme provided by the invention, the solar cell can be fixed on the bottom side film and/or the top side film through the heating melting property of the bottom side film and/or the top side film without additionally using a conductive adhesive and/or an adhesive. The layout process and the lamination process are combined into one, the battery pieces are directly laminated and arranged on the bottom side packaging material, and the mode is low in cost, high in efficiency and easy to operate.
According to one aspect of the present invention, there is provided a method of manufacturing a stack assembly comprising an encapsulation structure and an array of battery cells within the encapsulation structure, and the encapsulation structure comprising a bottom side film on a bottom side of the array of battery cells and in direct contact with the array of battery cells and a top side film on a top side of the array of battery cells and in direct contact with the array of battery cells, the method comprising the steps of laying down the bottom side film, stacking the film on the bottom side film and laying down the top side film on the top side of the array of battery cells, wherein the stack assembly comprises a first and a second stack of battery cells, and wherein the first and second stack of battery cells are stacked on the top side film and the
In the lamination step, solar cells are arranged on the bottom side film in a laminated manner, so that adjacent solar cells are in conductive connection through direct contact of the main grid lines;
heating the bottom-side film and/or the top-side film to make the bottom-side film and/or the top-side film at least partially in a molten state and contact the solar cell sheet in the molten state, so that the region in the molten state can be fixed with the solar cell sheet after being solidified;
and applying other parts of the packaging structure on the combination of the bottom side film, the top side film and the battery piece array, and integrally laminating.
In one embodiment, the method comprises a step of heating the bottom-side film, and the heating step and the step of placing the solar cell sheet on the bottom-side film are performed simultaneously, so that the region of the bottom-side film to receive the solar cell sheet is always kept in a molten state.
In one embodiment, the method comprises: presetting heating parameters of a heating process so that for two solar cells which are sequentially and continuously placed, placing a later one on the bottom side film, wherein the former one of the solar cells is fixed on the bottom side film in the process, and the former one of the solar cells can be used as a reference for placing the later one of the solar cells.
In one embodiment, the step of heating the bottom-side film comprises: applying heat to the bottom side film and/or the top side film by a heating mechanism independent of the shingle assembly.
In one embodiment, the heating parameters of the heating process are matched with the material parameters of the bottom-side film and/or the top-side film, and the heating method is at least one of a direct heating method, an infrared heating method, a microwave heating method and a laser heating method.
In one embodiment, heating is achieved by a combination of infrared and ultraviolet illumination.
In one embodiment, the method includes the step of heating the bottom side film, the step of heating the bottom side film comprising: and placing the solar cell piece with heat on the bottom side film to melt the bottom side film.
In one embodiment, the method further comprises a pre-lamination step prior to placing the solar cell sheet on the bottom-side film, the pre-lamination step comprising: the solar battery pieces are arranged in sequence by an electrostatic or vacuum adsorption method, but the solar battery pieces are not contacted with each other.
In one embodiment, a robot is provided to complete the lamination on the bottom film, and the method further comprises: and setting parameters of the manipulator based on the size of the solar cell piece and the position of the main grid line on the solar cell piece, so that the manipulator can accurately contact the main grid line of the adjacent solar cell piece when in operation.
In one embodiment, multiple sets of robots are provided to operate simultaneously.
In one embodiment, the method comprises the following steps after placing the array of battery pieces on the bottom-side film: and arranging a bus bar on the cell array to lead out the current of the cell array.
In one embodiment, the package structure includes a top plate, the method further comprising the following steps after placing the array of battery pieces on the bottom side film and before laminating: a top plate is placed on the top side membrane.
In one embodiment, the package structure includes a bottom plate on which the bottom side film is laid.
In one embodiment, the method includes the step of manufacturing a solar cell sheet, the step of manufacturing a solar cell sheet including:
arranging a whole solar cell;
laser grooving is carried out on the whole solar cell piece;
and splitting the whole solar cell into a plurality of solar cells.
In one embodiment, the quality of the lamination is detected by a detection mechanism during the process of arranging the solar cells into the cell string, and the detection result is fed back to a monitoring platform in real time.
In one embodiment, the manufacturing system further includes a control device, which is associated with the detection mechanism so as to control the lamination work mechanism based on a detection result of the detection mechanism.
In one embodiment, the lamination to be processed is detected by using EL electroluminescence or PL photoluminescence before the lamination step, and if the detection is unqualified, the defect detection is carried out again after the lamination to be processed is repaired.
In one embodiment, the method does not include the step of applying an adhesive to secure the individual solar cells relative to one another.
According to another aspect of the present invention there is provided a stack of tiles manufactured by the method of any preceding claim, the stack of tiles comprising:
a package structure comprising a bottom side film and a top side film;
the solar cell array comprises a plurality of cell strings arranged along a first direction, each cell string comprises a plurality of solar cells arranged in a shingled manner along a second direction perpendicular to the first direction, main grid lines are arranged on the solar cells, and any two adjacent solar cells in each cell string are in direct contact through the main grid lines to realize conductive connection,
wherein the bottom side film and/or the top side film is a thermoplastic monolithic film structure and is capable of securing the array of battery cells therewith by thermal fusion.
In one embodiment, the solar cell is a crystalline silicon solar cell or a heterojunction solar cell.
In one embodiment, the solar cell sheet is formed in a rectangular shape, and the length thereof is 2 to 10 times the width.
In one embodiment, the bottom-side film and the top-side film are an EVA monolithic film structure, a POE monolithic film structure, or a silicone monolithic film structure.
In one embodiment, the package structure further comprises a top plate and a bottom plate located below the bottom film, the top plate and the bottom plate being rigid or flexible weather-resistant monolithic structures having dimensions larger than the array of battery strings.
In one embodiment, the size of the overlapping portion between the adjacent solar cells of each cell string in the second direction is 0.05mm-5 mm.
In one embodiment, the bus bar is a positive electrode disposed on a top surface of the solar cell sheet and a back electrode disposed on a bottom surface of the solar cell sheet, wherein
The positive electrode is discontinuously arranged in the extending direction of the positive electrode, and the back electrode is continuously arranged in the extending direction of the back electrode; or
The positive electrode is continuously arranged in the extending direction of the positive electrode, and the back electrode is discontinuously arranged in the extending direction of the back electrode; or
The positive electrode is intermittently arranged in the extending direction thereof, the back electrode is intermittently arranged in the extending direction thereof, and the positive electrode and the back electrode are aligned in the second direction.
In one embodiment, the bus bars are a positive electrode disposed on a top surface of the solar cell sheet and a back electrode disposed on a bottom surface of the solar cell sheet, the positive electrode and the back electrode are each formed in a zigzag structure, and when two solar cell sheets are connected in a shingled manner, the positive electrode and the back electrode of the two solar cell sheets are in contact with each other in a rack-and-pinion manner.
In one embodiment, the solar cells within the shingle assembly have multiple specifications.
In one embodiment, no adhesive is provided within the stack for securing the individual solar cells relative to each other.
According to the scheme provided by the invention, the solar cell can be fixed on the bottom side film and the top side film through the heating melting property of the films without using an additional adhesive. The scheme can combine the typesetting process and the laminating process into a whole, and the battery pieces are directly laminated and typeset on the bottom side packaging material, so that the mode has the advantages of low cost, high efficiency and easy operation.
Drawings
For a better understanding of the above and other objects, features, advantages and functions of the present invention, reference should be made to the preferred embodiments illustrated in the accompanying drawings. Like reference numerals in the drawings refer to like parts. It will be appreciated by persons skilled in the art that the drawings are intended to illustrate preferred embodiments of the invention without any limiting effect on the scope of the invention, and that the various components in the drawings are not drawn to scale.
FIG. 1 is a flow chart of a method of manufacturing a stack assembly according to a preferred embodiment of the present invention;
FIG. 2 is a schematic view of a stack assembly during a lamination process according to a preferred embodiment of the present invention;
figure 3 is a schematic view of the shingle assembly of figure 2 after lamination has been completed.
Detailed Description
Reference will now be made in detail to the embodiments of the present invention, examples of which are illustrated in the accompanying drawings. What has been described herein is merely a preferred embodiment in accordance with the present invention and other ways of practicing the invention will occur to those skilled in the art and are within the scope of the invention.
The present invention provides a method of manufacturing a laminated assembly and a laminated assembly, a preferred embodiment of which is shown in figures 1 to 3.
In a preferred embodiment, a stack assembly includes an encapsulation structure and an array of battery cells within the encapsulation structure. The package structure may further include a top plate, a top side film, a bottom plate, and a bottom side film, wherein the top side film is located on the top surface of the array of battery pieces and directly contacts the array of battery pieces, the top plate covers the top side film, the bottom side film is located on the bottom surface of the array of battery pieces and directly contacts the bottom surface of the array of battery pieces, and the bottom plate is located below the bottom side film. In the present invention, the bottom-side film is a thermoplastic bottom-side film. The top and bottom sheets may be, for example, rigid sheets such as tempered glass, and the top and thermoplastic bottom films may be flexible film structures made of EVA, POE, or silicone.
A preferred embodiment of a method of manufacturing the stack of tiles is generally shown in figure 1, and as can be seen the method generally comprises steps S1 to S6. It should be noted that S1 and S6 are not necessarily strictly chronological, and for example, step S2, step S3 and step S4 may be simultaneous at the same time.
Step S1 is a step of laying a thermoplastic bottom-side film. Specifically, step S1 may also include providing a base sheet and laying down the thermoplastic bottom-side film onto the base sheet.
Step S2 is a step of heating a region of the thermoplastic bottom-side film to receive the solar cell sheet (simply referred to as a region to be received). Specifically, in this step, the thermoplastic bottom-side film is heated to bring its area to be received into a molten state. Preferably, the heating is accomplished by applying heat to the thermoplastic bottom-side film by a heating mechanism that is independent of the stack assembly. More preferably, the heating parameters (such as heating temperature, heating time, etc.) of the heating process are matched with the material parameters of the thermoplastic bottom-side film, so as to ensure that the area to be received of the thermoplastic bottom-side film is in a controllable molten state. The heating method can be a direct heating method, an infrared heating method, a microwave heating method or a laser heating method, or the heating can be realized by an infrared and ultraviolet combined illumination mode. More preferably, the heating process may be local heating or global heating of the thermoplastic bottom side film.
Step S3 is a step of placing a solar cell sheet in the melted region of the thermoplastic bottom-side film. Specifically, each solar cell piece is accurately placed on the molten region of the thermoplastic bottom-side film, and the individual solar cell pieces are arranged in a shingled manner into a cell string. In each cell string, any two adjacent solar cells are in conductive connection through direct contact of the main grid lines. Because the main grid lines of the solar cells are in direct contact with each other, the conductive connection is realized, and therefore, no conductive adhesive needs to be arranged on the cell array.
Preferably, a manipulator can be arranged to complete the step, and parameters of the manipulator can be set based on the size of the solar cell and the position of the main grid line on the solar cell, so that the manipulator can accurately contact the main grid line of the adjacent solar cell when in operation. More preferably, a plurality of groups of mechanical hands can be arranged to work simultaneously and arrange the sheets simultaneously. More preferably, the quality of the lamination is detected by a detection mechanism in the process of arranging the solar cells into the cell string, and the detection result is fed back to the monitoring platform in real time. The manufacturing system further includes a control device that is associated with the detection mechanism so as to control the lamination work mechanism based on a detection result of the detection mechanism.
Step S4 is a step of cooling the region where the solar cell sheet is placed and fixing the solar cell sheet. It will be appreciated that the thermoplastic bottom-side film is capable of securing the solar cell sheet thereto after melting and solidifying. Since the solar cell is already fixed on the thermoplastic bottom film by this method, no additional adhesive material such as an adhesive is required.
Step S5 is to set other package structures. For example, bus bars are provided, a top side film is applied on the top surface of the array of battery cells and a top plate is covered on the top side film.
Step S6 is an integral lamination step. And (3) before the laminating step, performing defect detection on the lamination piece by adopting EL electroluminescence or PL photoluminescence, and if the detection is unqualified, performing defect detection again after the lamination piece is repaired. The color of the monolithic body obtained after lamination may be a color with distinct appearance characteristics, such as black or white.
It is again emphasized that the individual steps described above are merely schematic and that their chronological order does not necessarily follow the order described above.
For example, the heating step and the step of placing the solar cell sheet on the thermoplastic bottom-side film are performed simultaneously so that the region of the thermoplastic bottom-side film to receive the solar cell sheet is always kept in a molten state. More preferably, the heating parameters of the heating process may be preset such that for two solar cells placed successively in sequence, the former solar cell is fixed on the thermoplastic bottom-side film during the process of placing the latter solar cell on the thermoplastic bottom-side film, and the former solar cell can be used as a reference for placing the latter solar cell. The arrangement can enable the melting state of the thermoplastic bottom film to be relatively controllable, and can avoid damage to the thermoplastic bottom film or the solar cell piece caused by overhigh overall heating temperature.
For another example, the simultaneous implementation of the steps of heating and melting the region to be received of the thermoplastic bottom-side film and placing the solar cell sheet in the region to be received may be: the self-heating solar cell sheet is placed on the thermoplastic bottom-side film to melt the thermoplastic bottom-side film. Specifically, the solar cell sheet is heated before being placed, and when the solar cell sheet is placed on the thermoplastic bottom-side film, the bottom area of the solar cell sheet can be heated and melted, and after the area is melted and cooled, the solar cell sheet can be fixed on the thermoplastic bottom-side film.
Preferably, the method provided by the present invention may further comprise some steps not shown in fig. 1. For example, the method further comprises a pre-lamination step prior to placing the solar cell pieces on the thermoplastic bottom-side film, the pre-lamination step comprising: the solar battery pieces are arranged in sequence by an electrostatic or vacuum adsorption method, but the solar battery pieces are not contacted with each other. For another example, the method includes the following steps after placing the array of battery pieces on the thermoplastic bottom-side film: and arranging a bus bar on the cell array to lead the current of the cell array outwards. For another example, the top and bottom panels can be made of multiple layers of weatherable materials such as TPT, KPK, KPM, KPC, APE, and the like.
Preferably, the method provided by the invention further comprises the step of manufacturing the solar cell. The manufacturing method of the solar cell piece comprises the following steps: arranging a whole solar cell; laser grooving is carried out on the whole solar cell piece; and splitting the whole solar cell into a plurality of solar cells.
The above steps may also have further optimized settings. For example, the whole solar cell is subjected to visual detection and position positioning, and the detection platform is provided with high-precision CCD cameras above and below to capture special patterns (such as mark points, main and auxiliary grids and the like) on the front and back surfaces of the solar cell and PL (photoluminescence laser detector) so as to realize that the printing error of the solar cell exceeds a certain range, and the appearance defect or the internal crack is automatically identified and removed to an NG material box. It should be noted that, after the stack tile battery is subjected to precise color, efficiency and high-low open-voltage sorting, the loaded battery is a battery with basically consistent attributes (capable of matching with the small-piece sorting function). Meanwhile, the equipment feeding platform is suitable for feeding small pieces and is provided with a special material box and a processing mechanism.
And then, the qualified whole solar cell is accurately transmitted to a laser cutting platform, the transmission mode can adopt servo transportation or a transmission belt with adsorption, the laser cutting track carries out position compensation according to the visual positioning of the solar cell, and finally, the whole solar cell is accurately cut and split into 2-N solar cells along the cell cutting position by laser.
And carrying out high-precision visual inspection on the heat affected zone, the cutting depth, the cutting line width and the like of the cut solar cell. The NG slices which are detected to be unqualified on line are placed at an NG station, a laser cutting process comprises the use of lasers with different wavelengths (such as picoseconds or femtosecond level lasers matched with lower wave bands of green light, purple light and the like on the basis of red nanosecond), and the method can be suitable for splitting slices in a local thermal stress low-loss or nondestructive mode.
Furthermore, the split solar cell or the solar cell which is separately processed completely outside the line is automatically rejected on line due to poor appearance through CCD visual inspection screening, and meanwhile, relative position coordinates are output to a transmission robot or a motion module to realize loading lamination processing. The module comprises a multi-head carrying mechanical device, and can realize the carrying and lamination laying actions of a plurality of groups of multi-sheet or single-sheet laminated batteries. Wherein the processing link integrates the functions of mechanical correction and visual positioning deviation correction and realizes the module of lamination laying angle and paster stress control, each mechanical and electrical system can be automatically controlled, and the precision can reach +/-0.05 mm
And then, the bottom plate is output to a thermoplastic bottom side film laying unit, the thermoplastic bottom side film which is pre-cut or synchronously cut after being subjected to righting and positioning is transplanted to the surface of the bottom plate by a carrying hand, and the transplanting comprises negative pressure adsorption, traction and other implementation modes. After the laying is finished, the center coincidence of the bottom plate and the thermoplastic bottom side film is met, and the poor manufacturing process caused by laying deflection is avoided.
When the gluing end lead process is adopted, the mechanical arm preferentially lays a pre-coating conductive lead, and then a solar cell and another lead are sequentially laid until a battery string with effective connection output is provided. The conductive top plate packaging mode is adopted, the packaging mode comprises a battery piece array, a main grid line and a back surface contain a confluence or bypass welding plate, namely, the battery piece position of the laminated assembly comprises batteries with various specifications, and a solar battery piece with the welding plate specification can be laid at the lamination designated position according to the bypass design.
After the laying is finished, the whole body is conveyed to the next station for confluence treatment, a metal confluence belt is adopted to finish confluence connection by precoating a conductive adhesive or heating a laser designated area, and the plate type bypass protection device is treated in the same way. After the confluence and bypass protection connection processing is completed, the rear glue film, the rear cover plate and the outgoing line are laid for processing, conductive media such as conductive glue, tin paste and the like are pre-coated on the circuit pad connecting point of the rear cover plate on the newly-added independent station for the stacking and arranging integrated conductive top plate, and the coating mode comprises glue spraying and printing. Realize laminating through equipment is automatic to be connected and switch on, need lay the top side membrane and the completion is punched a hole to the region in cutting or synchronous tensile cutting to the top side membrane assigned position in advance to the battery cluster surface before the laminating action takes place to conductive medium can effectively connect battery piece and roof circuit pad.
The lamination part with the conductive connection function is detected to be qualified through EL (electroluminescence) and VI (visual appearance), and then enters a lamination process, wherein the lamination process comprises three-cavity lamination. The lamination process is combined with a new interconnection structure, the vacuum pumping, heating and pressurizing are carried out in a closed cavity, so that the thermoplastic bottom side film is completely thermally cured, the laminated tile assembly is tightly attached, and finally, a complete structural member is laminated, and the positive and negative electrodes of the front and rear solar cells in the structural member form good physical contact so as to realize electric conduction. And then, after the laminating process is finished, the laminated part is subjected to framing, junction box curing, cleaning, safety test, power test, EL test, finished product inspection and other procedures to finish the machining of the final finished laminated assembly.
In another embodiment, the top-side film may be provided in a thermoplastic film structure, and the top-side film may be heated to a thermally fused state to contact the array of battery cells, and the array of battery cells may be fixed relative to the top-side film after the thermally fused region is cooled. For example, the heat of the solar cell from the previous process can be used, and if the lamination speed is fast enough, the solar cell can be covered with the top-side film when the solar cell is not cooled, and the heat of the solar cell can automatically melt the area on the top of the solar cell; alternatively, the top-side film that has been heated to a hot-melt state may be overlaid on the array of battery cells after lamination is completed. Preferably, both the top-side film and the bottom-side film having thermal fusion properties may be used, and after both of them are cooled, the top-side film, the bottom-side film, and the cell array are fixed together.
Figures 2 and 3 show a schematic view during lamination and a schematic view after lamination completion of a stack assembly manufactured by the above method. Fig. 2 and 3 only show the cell array 3, the base plate 1 and the thermoplastic bottom-side film 2 of the stack assembly and part of the bus bar structure, other components not being shown in fig. 2 and 3.
Specifically, the stack assembly includes an encapsulation structure and a solar cell array 3. The packaging structure further comprises a top plate, a top side film positioned between the top plate and the battery piece array 3 and a bottom plate 1 positioned below the thermoplastic bottom side film 2, wherein the top plate and the bottom plate 1 are rigid or flexible weather-resistant integral plate structures with sizes larger than that of the battery string array. The cell array 3 is located on the top surface of the thermoplastic bottom-side film 2, the cell array 3 comprises a plurality of cell strings arranged along a first direction, each cell string comprises a plurality of solar cells arranged in a shingled manner along a second direction perpendicular to the first direction, main grid lines are arranged on the solar cells, and any two adjacent solar cells in each cell string are in direct contact through the main grid lines to realize conductive connection. Wherein the thermoplastic bottom-side film 2 fixes the cell array 3 thereon by thermal fusion.
Various preferred embodiments of the above-described individual components are possible. For example, the solar cell is a crystalline silicon solar cell or a heterojunction solar cell; the solar cell sheet is formed into a rectangle, and the length of the solar cell sheet is 2-10 times of the width; the thermoplastic bottom-side film 2 and the thermoplastic top-side film can be of an EVA integral film structure, a POE integral film structure or a silica gel integral film structure; the size of the overlapping part between the adjacent solar cell pieces of each cell string in the second direction is 0.05mm-5 mm.
The bus bars of the solar cell sheet, which may be in direct contact with each other, may also have various structures. The main grid line is a positive electrode disposed on the top surface of the solar cell sheet and a back electrode disposed on the bottom surface of the solar cell sheet. Wherein the positive electrode is discontinuously arranged in the extending direction of the positive electrode, and the back electrode is continuously arranged in the extending direction of the back electrode; or the positive electrode is continuously arranged in the extending direction of the positive electrode, and the back electrode is discontinuously arranged in the extending direction of the back electrode; or the positive electrode is intermittently arranged in the extending direction thereof, the back electrode is intermittently arranged in the extending direction thereof, and the positive electrode and the back electrode are aligned in the second direction. Preferably, the bus bar is a positive electrode disposed on a top surface of the solar cell and a back electrode disposed on a bottom surface of the solar cell, the positive electrode and the back electrode are both formed in a zigzag structure, and when two solar cells are connected in a shingled manner, the positive electrode and the back electrode of the two solar cells are in contact with each other in a rack-and-pinion manner.
Referring to fig. 3, a main bus bar 41 and a bypass bus bar 42 may be further disposed on the cell array for drawing current outward.
It can be understood that since the solar cells are electrically connected by the direct contact of the main grid lines, the conductive adhesive is not required to be arranged. Since the solar cells are fixed by thermal melting of the thermoplastic bottom side film, no adhesive is required for fixing the individual solar cells relative to one another.
Alternatively or additionally to the above, the top side film of the top surface of the array of cells may also be made of a thermoplastic material, the top side film being capable of fixing the array of cells relative thereto by thermal fusion.
The scheme provided by the invention can fix the solar cell on the bottom side film through the heating melting characteristic of the thermoplastic bottom side film without using an additional adhesive. The scheme can combine the typesetting process and the laminating process into a whole, and the battery pieces are directly laminated and typeset on the bottom side packaging material, so that the mode has the advantages of low cost, high efficiency and easy operation.
The foregoing description of various embodiments of the invention is provided for the purpose of illustration to one of ordinary skill in the relevant art. It is not intended that the invention be limited to a single disclosed embodiment. As mentioned above, many alternatives and modifications of the present invention will be apparent to those skilled in the art of the above teachings. Thus, while some alternative embodiments are specifically described, other embodiments will be apparent to, or relatively easily developed by, those of ordinary skill in the art. The present invention is intended to embrace all such alternatives, modifications and variances of the present invention described herein, as well as other embodiments that fall within the spirit and scope of the present invention as described above.
Reference numerals:
Thermoplastic bottom film 2
Bypassing the bus bar 42.
Claims (28)
1. A method of manufacturing a stack assembly comprising an encapsulation structure and an array of battery cells within the encapsulation structure, and the encapsulation structure comprising a bottom side film on a bottom side of the array of battery cells and in direct contact with the array of battery cells and a top side film on a top side of the array of battery cells and in direct contact with the array of battery cells, the method comprising the steps of laying down the bottom side film, stacking the bottom side film and laying down the top side film on the top side of the array of battery cells, characterized in that,
placing the solar battery pieces on the bottom side film in a tiling mode, and enabling adjacent solar battery pieces to be in conductive connection through direct contact of the main grid lines;
heating the bottom-side film and/or the top-side film to make the bottom-side film and/or the top-side film at least partially in a molten state and contact the solar cell sheet in the molten state, so that the region in the molten state can be fixed with the solar cell sheet after being solidified;
and applying other parts of the packaging structure on the combination of the bottom side film, the top side film and the battery piece array, and integrally laminating.
2. The method according to claim 1, wherein the method comprises a step of heating the bottom-side film, and the heating step and the step of placing the solar cell sheet on the bottom-side film are performed simultaneously, so that the region of the bottom-side film to receive the solar cell sheet is always kept in a molten state.
3. The method of claim 2, wherein the method comprises: presetting heating parameters of a heating process so that for two solar cells which are sequentially and continuously placed, placing a later one on the bottom side film, wherein the former one of the solar cells is fixed on the bottom side film in the process, and the former one of the solar cells can be used as a reference for placing the later one of the solar cells.
4. The method of claim 1, wherein the step of heating the bottom side film comprises: applying heat to the bottom side film and/or the top side film by a heating mechanism independent of the shingle assembly.
5. The method of claim 4, wherein the heating parameters of the heating process are matched with the material parameters of the bottom-side film and/or the top-side film, and the heating method is at least one of a direct heating method, an infrared heating method, a microwave heating method and a laser heating method.
6. The method of claim 4, wherein heating is achieved by a combination of infrared and ultraviolet illumination.
7. The method of claim 1, comprising the step of heating the bottom side film, the step of heating the bottom side film comprising: and placing the solar cell piece with heat on the bottom side film to melt the bottom side film.
8. The method of claim 1, further comprising a pre-lamination step prior to placing the solar cell sheet on the bottom-side film, the pre-lamination step comprising: the solar battery pieces are arranged in sequence by an electrostatic or vacuum adsorption method, but the solar battery pieces are not contacted with each other.
9. The method of claim 1, wherein a robot is provided to complete the lamination on the bottom film, and further comprising: and setting parameters of the manipulator based on the size of the solar cell piece and the position of the main grid line on the solar cell piece, so that the manipulator can accurately contact the main grid line of the adjacent solar cell piece when in operation.
10. The method of claim 9, wherein a plurality of sets of robots are provided for simultaneous operation.
11. The method of claim 1, comprising the following steps after placing an array of battery pieces on the bottom-side membrane: and arranging a bus bar on the cell array to lead out the current of the cell array.
12. The method of claim 1, wherein the package structure comprises a top plate, the method further comprising the following steps after placing the array of battery pieces on the bottom side film and before laminating: and placing a top side film and a top plate on the cell array.
13. The method of claim 1, wherein the encapsulation structure comprises a bottom plate, and wherein the bottom-side film is laid on the bottom plate.
14. The method of claim 1, comprising the step of fabricating a solar cell sheet, the step of fabricating a solar cell sheet comprising:
arranging a whole solar cell;
laser grooving is carried out on the whole solar cell piece;
and splitting the whole solar cell into a plurality of solar cells.
15. The method of claim 1, wherein the quality of the laminate is detected by a detection mechanism during the arrangement of the solar cells into the string, and the detection result is fed back to the monitoring platform in real time.
16. The method of claim 15, further comprising a control device associated with the detection mechanism to enable control of the lamination work mechanism based on a detection result of the detection mechanism.
17. The method of claim 1, wherein the laminate is inspected for defects using EL electroluminescence or PL photoluminescence prior to the laminating step, and if the inspection fails, the inspection is performed again after the repair of the laminate is completed.
18. The method of any one of claims 1-16, wherein the method does not include the step of applying an adhesive to secure the individual solar cells relative to each other.
19. A stack of tiles manufactured by the method according to any one of claims 1 to 18, comprising:
a package structure comprising a bottom side film and a top side film;
the solar cell array comprises a plurality of cell strings arranged along a first direction, each cell string comprises a plurality of solar cells arranged in a shingled manner along a second direction perpendicular to the first direction, main grid lines are arranged on the solar cells, and any two adjacent solar cells in each cell string are in direct contact through the main grid lines to realize conductive connection,
wherein the bottom side film and/or the top side film is a thermoplastic monolithic film structure and is capable of being secured together with the array of battery cells by thermal fusion.
20. The shingle assembly of claim 19, wherein the solar cell is a crystalline silicon solar cell or a heterojunction solar cell.
21. The shingle assembly of claim 19, wherein the solar cell sheet is formed in a rectangular shape and has a length that is 2-10 times the width.
22. The stack assembly of claim 19, wherein the bottom-side membrane and the top-side membrane are EVA monolithic membrane structures, POE monolithic membrane structures, or silicone monolithic membrane structures.
23. The stack assembly of claim 19, wherein the packaging structure further comprises a top plate and a bottom plate underlying the bottom side film, the top plate and the bottom plate being of rigid or flexible weatherable monolithic plate structure having dimensions larger than the array of battery strings.
24. The shingle assembly of claim 19, wherein the overlap between adjacent solar cells of each of the cell strings has a dimension in the second direction of 0.05mm to 5 mm.
25. The stack assembly of claim 19, wherein the bus bars are a positive electrode disposed on a top surface of the solar cell sheet and a back electrode disposed on a bottom surface of the solar cell sheet, wherein
The positive electrode is discontinuously arranged in the extending direction of the positive electrode, and the back electrode is continuously arranged in the extending direction of the back electrode; or
The positive electrode is continuously arranged in the extending direction of the positive electrode, and the back electrode is discontinuously arranged in the extending direction of the back electrode; or
The positive electrode is intermittently arranged in the extending direction thereof, the back electrode is intermittently arranged in the extending direction thereof, and the positive electrode and the back electrode are aligned in the second direction.
26. The stack assembly of claim 19, wherein the bus bars are a positive electrode disposed on a top surface of the solar cell sheet and a back electrode disposed on a bottom surface of the solar cell sheet, the positive electrode and the back electrode are each formed in a zigzag structure, and when two solar cell sheets are connected in a stack, the positive electrode and the back electrode of the two solar cell sheets are in contact with each other in a rack-and-pinion manner.
27. The stack assembly of claim 19, wherein the solar cells within the stack assembly have multiple gauges.
28. The stack of any of claims 19-27, wherein no adhesive is provided within the stack for securing the individual solar cells relative to each other.
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| CN202010076454.2A CN111261741A (en) | 2020-01-23 | 2020-01-23 | Method for manufacturing laminated assembly and laminated assembly |
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Cited By (4)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| WO2021008634A1 (en) * | 2020-01-23 | 2021-01-21 | 成都晔凡科技有限公司 | Manufacturing method for shingled assembly and shingled assembly |
| CN114464704A (en) * | 2022-01-29 | 2022-05-10 | 环晟新能源(江苏)有限公司 | Production process of laminated tile assembly |
| CN114530523A (en) * | 2022-01-24 | 2022-05-24 | 江苏日托光伏科技股份有限公司 | Online detection method of back contact photovoltaic cell and production method of photovoltaic module |
| CN114464704B (en) * | 2022-01-29 | 2024-04-26 | 环晟新能源(江苏)有限公司 | Production process of laminated tile assembly |
-
2020
- 2020-01-23 CN CN202010076454.2A patent/CN111261741A/en active Pending
Cited By (4)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| WO2021008634A1 (en) * | 2020-01-23 | 2021-01-21 | 成都晔凡科技有限公司 | Manufacturing method for shingled assembly and shingled assembly |
| CN114530523A (en) * | 2022-01-24 | 2022-05-24 | 江苏日托光伏科技股份有限公司 | Online detection method of back contact photovoltaic cell and production method of photovoltaic module |
| CN114464704A (en) * | 2022-01-29 | 2022-05-10 | 环晟新能源(江苏)有限公司 | Production process of laminated tile assembly |
| CN114464704B (en) * | 2022-01-29 | 2024-04-26 | 环晟新能源(江苏)有限公司 | Production process of laminated tile assembly |
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