CN111763481A - Structured packaging material and production method thereof, photovoltaic module and preparation method thereof - Google Patents

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

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Publication number
CN111763481A
CN111763481A CN202010514420.7A CN202010514420A CN111763481A CN 111763481 A CN111763481 A CN 111763481A CN 202010514420 A CN202010514420 A CN 202010514420A CN 111763481 A CN111763481 A CN 111763481A
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packaging material
substrate
protruding
structured
material layer
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CN111763481B (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 Lerri 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
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    • 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
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    • C09—DYES; PAINTS; POLISHES; NATURAL RESINS; ADHESIVES; COMPOSITIONS NOT OTHERWISE PROVIDED FOR; APPLICATIONS OF MATERIALS NOT OTHERWISE PROVIDED FOR
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    • C09J2433/00—Presence of (meth)acrylic polymer
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    • C09J2463/00—Presence of epoxy resin
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    • C09—DYES; PAINTS; POLISHES; NATURAL RESINS; ADHESIVES; COMPOSITIONS NOT OTHERWISE PROVIDED FOR; APPLICATIONS OF MATERIALS NOT OTHERWISE PROVIDED FOR
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    • 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)
  • Microelectronics & Electronic Packaging (AREA)
  • Physics & Mathematics (AREA)
  • Condensed Matter Physics & Semiconductors (AREA)
  • Electromagnetism (AREA)
  • General Physics & Mathematics (AREA)
  • Computer Hardware Design (AREA)
  • Power Engineering (AREA)
  • Manufacturing & Machinery (AREA)
  • Photovoltaic Devices (AREA)
  • Laminated Bodies (AREA)

Abstract

The invention provides a structured packaging material and a production method thereof, a photovoltaic module and a preparation method thereof, and relates to the technical field of photovoltaics. The structured packing material comprises: the packaging structure comprises a substrate and a packaging material layer, wherein the substrate and/or the packaging material layer comprise a plurality of rows of protruding parts protruding out of a base body of the substrate and/or the packaging material layer; the protruding direction of the protruding portion is toward the battery string. The protruding part has a certain positioning function, so that the battery string can be conveniently laid and aligned, and the production efficiency is improved. In the subsequent lamination process, the protruding part of the packaging material layer is melted and/or the protruding part of the substrate extrudes the melted packaging material and is filled in the gaps in the cell strings or the assemblies, so that the pressure born by the solar cells in the lamination process can be reduced, hidden cracks or cracked can be reduced even if the gaps among the cells are reduced, the production yield is improved, and the reliability of the assemblies is improved.

Description

Structured packaging material and production method thereof, photovoltaic module and preparation method thereof
Technical Field
The invention relates to the technical field of photovoltaics, in particular to a structured packaging material and a production method thereof, a photovoltaic module and a preparation method thereof.
Background
The cell module can be provided with more solar cells in a limited space, can increase short-circuit current and provide power output, and therefore, the application is wide.
In the battery pack, the gaps among the batteries in the pack are reduced, so that the power output of the battery pack can be improved, and the appearance is more attractive.
However, in the battery module, the gaps between the cells are reduced, which easily causes cracks or hidden cracks, and affects the reliability of the module.
Disclosure of Invention
The invention provides a structured packaging material and a production method thereof, a photovoltaic module and a preparation method thereof, and aims to solve the problem that in a battery module, gaps among all batteries are reduced, so that cracking or hidden cracking is easily caused, and the reliability of the module is influenced.
According to a first aspect of the present invention, a structured packaging material is provided, which includes a substrate and a packaging material layer, wherein the substrate and/or the packaging material layer includes a plurality of columns of protruding portions protruding from a base of the substrate and/or the packaging material layer;
the protruding direction of the protruding portion is toward 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 base body 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, is convenient for lay and counterpoint of battery cluster, has improved production efficiency. In the subsequent lamination process, the protruding part of the packaging material layer is melted and/or the protruding part of the substrate extrudes the melted packaging material and is filled in the gaps in the cell strings or the assemblies, so that the pressure born by the solar cells in the lamination process can be reduced, hidden cracks or cracked can be reduced even if the gaps among the cells are reduced, the production yield is improved, and the reliability of the assemblies is improved.
According to a second aspect of the present invention, there is provided a method for producing a structured packaging material, the structured packaging material comprising a substrate and a packaging material layer, the substrate and/or the packaging material layer comprising a plurality of rows of protruding portions protruding from a base of the substrate and/or the packaging material layer, the protruding portions being formed by one of the following steps:
hot-pressing the protruding portion on the base;
bonding the base body and the protruding part by using an adhesive;
extruding a local area of a substrate to form a protruding portion protruding out of the substrate;
integrally molding the structured packaging material by adopting a pouring mold with a convex part;
the projections are printed on the substrate.
According to a third aspect of the present invention, there is provided a photovoltaic module comprising at least one string of cells laminated and encapsulated with a structured encapsulant as claimed in any one of the preceding claims; 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 portion faces the battery string, and the single solar battery is arranged in the groove formed by the protruding portion.
According to a fourth aspect of the present invention, there is provided a photovoltaic module manufacturing method, comprising the steps of:
providing a structured packaging material as described in any of the preceding;
providing a battery string; the cell string comprises a plurality of solar cells;
arranging the structured packaging material on a light facing surface and/or a backlight surface of the battery string to obtain a component precursor; in the assembly precursor, a protruding direction of the protruding portion is toward the cell string;
laminating the laminate comprising the assembly precursor.
The production method of the structured packaging material, the photovoltaic module and the preparation method of the photovoltaic module have the same or similar beneficial effects as the structured packaging material, and the details are not repeated herein in order to avoid repetition.
Drawings
In order to more clearly illustrate the technical solutions of the embodiments of the present invention, the drawings used in the description of the embodiments of the present invention will be briefly introduced below, and it is obvious that the drawings in the following description are only some embodiments of the present invention, and it is obvious for those skilled in the art that other drawings can be obtained based on these drawings without inventive exercise.
FIG. 1 shows a schematic structural diagram of a first structured packing material in an embodiment of the present invention;
FIG. 2 is a schematic structural diagram of a second structured packing material in an embodiment of the present invention;
FIG. 3 shows a schematic structural view of a first photovoltaic stack in an embodiment of the present invention;
FIG. 4 shows a schematic structural diagram of a third structured packing material in an embodiment of the present invention;
FIG. 5 shows a schematic structural view of a second photovoltaic stack in an embodiment of the present invention;
FIG. 6 shows a schematic structural diagram of a fourth structured packing material in an embodiment of the present invention;
FIG. 7 is a schematic structural diagram of a fifth structured packing material in an embodiment of the present invention;
FIG. 8 is a schematic view showing the structure of a first extrusion die according to the embodiment of the present invention;
FIG. 9 is a schematic view showing the structure of a second extrusion die according to the embodiment of the present invention;
figure 10 shows a schematic structural view of a third photovoltaic stack in an embodiment of the present invention.
Description of the figure numbering:
1-packaging material layer, 2-projecting part, 3-substrate, 4-solar cell, 5-cover plate and 6-back plate.
Detailed Description
The technical solutions in the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings in the embodiments of the present invention, and it is apparent that the described embodiments are some, but not all embodiments of the present invention. All other embodiments, which can be obtained by a person skilled in the art without any inventive step based on the embodiments of the present invention, are within the scope of the present invention.
In the embodiment of the present invention, referring to fig. 1, fig. 1 shows a schematic structural diagram of a first structured packaging material in the embodiment of the present invention. The structured packing material comprises: the packaging material layer 1, the substrate 3 and/or the packaging material layer 1 comprise a plurality of rows of protruding parts 2 protruding from the substrate 3 and/or the base body of the packaging material layer 1. That is, the protruding portion having the protruding base only on the base of the encapsulating material layer may be provided, or the protruding portion having the protruding base only on the base of the substrate may be provided. Alternatively, the substrate may have a protruding portion protruding from the base on both the base of the encapsulating material layer and the base of the substrate.
For example, referring to fig. 1, in the structured packaging material, the flat region of the packaging material layer 1 may be a substrate, and the protruding portion 2 protrudes from the substrate. The base of the substrate 3 in fig. 1 has no projections.
The convex direction of the convex portion 2 is toward the battery string. The protruding part has a certain positioning function, so that the battery string can be conveniently laid and aligned, and the production efficiency is improved. In the subsequent lamination process of the protruding part in the structured packaging material, the protruding part of the packaging material layer melts and/or the protruding part of the substrate extrudes the molten packaging material and fills the gap in the cell string or the cell assembly, so that the pressure born by the solar cell in the lamination process can be reduced, hidden cracks can be reduced even if the gap between the cells is 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%, and the utilization rate of light can be improved.
The number of the projections 2 on the base is not particularly limited.
Optionally, 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 packaging material is more selective. The projections and the base may be integrally formed or may be formed in steps. In the embodiment of the present invention, this is not particularly limited. If the step-by-step molding is adopted, the convex part 2 can be leftover materials of the substrate and the like, so that the cost can be reduced. In the embodiment of the present invention, 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 the material of the base of the encapsulating material layer 1. For another example, referring to fig. 2, fig. 2 shows a schematic structural diagram of a second structured packaging material in an embodiment of the present invention. The material of the protruding part 2 in fig. 2 may be different from the material of the base of the packaging material layer 1.
Optionally, the protruding portion and the base body can be formed in a hot pressing mode, an adhering mode, an extruding mode and a printing mode, the forming mode is various, and the process is simple.
In the case that the encapsulation material layer in the structured encapsulation material includes a protruding portion protruding from the base of the encapsulation material layer, the base of the encapsulation material layer and the protruding portion form a concave space for obliquely arranging the individual solar cells 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 encapsulating material layer is provided only on the light-facing surface of the string, and each solar cell in the string is obliquely provided in the concave space formed by the base body and the convex portion of the front encapsulating material layer, and the convex surface of the convex portion is opposite to the light-facing surface of the solar cell. Or, the packaging material layer is only arranged on the backlight surface of the battery string, each solar battery in the battery string is obliquely arranged in the concave space formed by the base body of the rear packaging material layer and the convex part, and the convex surface of the convex part is opposite to the backlight surface of the solar battery. Or the packaging material layers are arranged on the light facing surface and the backlight surface of the battery string, each solar battery in the battery string is obliquely arranged in the concave space formed by the base body and the convex part of the packaging material layers on 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 invention, this is not particularly limited.
Each solar cell in the cell string is obliquely arranged in an inwards concave space formed by the base body of the packaging material layer and the protruding part, and the inwards concave space can reduce the pressure born by the solar cell in the laminating process, reduce the hidden crack and improve the production yield. And the inclined arrangement is favorable for reducing gaps among the solar cells so as to improve the power output of the cell module. Meanwhile, the concave space has a certain positioning function, so that the laying and alignment of the battery strings are facilitated, and the production efficiency is improved. The protruding part of the packaging material layer in the structured packaging material is melted and filled in gaps in the solar cells, the cell strings or the assemblies in the subsequent laminating process, so that the pressure born by the solar cells in the laminating process can be reduced, the subfissure 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 stack according to an embodiment of the present invention. Referring to fig. 3, the packaging material layer 1 is disposed on both the light-facing surface and the backlight surface of the battery string, and the packaging material layer 1 includes a convex portion 2 protruding from the base body. In fig. 3, each solar cell 4 in the string is obliquely arranged in the concave space formed by the base body of the packaging material layer 1 and the convex part 2 at two sides, the convex surface of the convex part 2 of the packaging material layer 1 positioned on the light facing surface of the string is opposite to the light facing surface of the solar cell 4, and the convex surface of the convex part 2 of the packaging material layer 1 positioned on the backlight surface of the string is opposite to the backlight surface of the solar cell 4.
It should be noted that, the encapsulating material layers are arranged on both the light-facing surface and the backlight surface of the battery string, and each encapsulating material includes a protruding portion protruding out of the base body, and compared with the encapsulating material layer including the protruding portion only arranged on the light-facing surface or the backlight surface of the battery string, the solar battery is better protected in the laminating process, and the pressure borne by the solar battery is smaller in the laminating process, so that the subfissure can be further reduced, and the production yield can be improved. The protruding part in the packaging material layer is melted and fully filled in the gap in the solar cell, the cell string or the assembly in the subsequent lamination process, so that the pressure born by the solar cell in the lamination process can be further reduced, the subfissure can be reduced, and the production yield can be improved.
Referring to fig. 3, under the condition that the front packaging material layer includes the protruding portion 2 on one side facing the battery string and the rear packaging material layer includes the protruding portion 2 on one side facing the battery string, the protruding portions 2 on two sides of the same solar battery 4 are distributed in a staggered manner, and then the protruding portions 2 on two sides form a larger concave space, which is convenient for laying the battery string.
In the case that the packaging material layer in the structured packaging material comprises a protruding portion protruding from the base of the substrate, the protruding portion 2 is located on a side of the packaging material layer away from the substrate, and a concave space formed by the base and the protruding portion in the packaging 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 on the side of the packaging material layer close to the battery string. The layer of encapsulation material may be a front layer of encapsulation material or a back layer of encapsulation material. In case the layer of encapsulation material is a front layer of encapsulation material, the substrate may be a cover plate. In case the layer of encapsulation material is a back layer of encapsulation material, the substrate may be a backplane. The material of the cover plate or the back plate is not particularly limited.
For example, referring to fig. 3, the front encapsulation material layer and the cover plate 5 together constitute a structured encapsulation material. The back encapsulant layer and the back sheet 6 together constitute a structured encapsulant. The convex part 2 is positioned on one side of the packaging material layer far away from the substrate, and the concave space formed by the base body of the packaging material layer and the convex part is used for obliquely arranging each solar cell in the cell string.
In the case where the substrate in the structured packing material comprises a protruding portion protruding from the base of the substrate, said protruding portion is located on the side of the substrate close to the layer of packing material. The substrate may be a cover plate or a back plate. The material of the substrate may be glass or polymer. In the laminating process, the protruding part of the substrate close to one side of the packaging material layer can extrude the adjacent fused packaging material layer, so that the fused packaging material layer extruded by the protruding part is filled in the gap of the battery string or the battery assembly, the pressure born by the solar battery in the laminating process can be reduced, the subfissure can be reduced, and the production yield can be improved.
In the structured packaging material, the front packaging material layer comprises a protruding part protruding out of the base body of the front packaging material layer, the rear packaging material layer comprises a protruding part protruding out of the base body of the rear packaging material layer, the cover plate comprises a protruding part protruding out of the base body of the cover plate, and the back plate comprises a protruding part protruding out of the base body of the back plate, wherein the protruding part can be at least one of the four or any arrangement combination of the four. This is not particularly limited in the embodiments of the present invention.
For example, referring to fig. 4, fig. 4 shows a schematic structural diagram of a third structured packaging material in an embodiment of the present invention. In the structured encapsulating material shown in fig. 4, the side of the front encapsulating material layer facing away from the cover plate 5 comprises protruding portions 2, while the side of the cover plate 5 facing away from the encapsulating material layer also comprises protruding portions 2.
Referring to fig. 5, fig. 5 shows a schematic structural view of a second photovoltaic stack in an embodiment of the present invention. The front packaging material layer and the back packaging material layer both comprise: protruding the protruding part 2 of the base body. Each solar cell 4 in the cell string is obliquely arranged in an inner concave space formed by the base body of the packaging material layers on the 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 side of the cover plate 5 close to the packaging material layer also has a protruding portion 2.
In fig. 5, the concave space can reduce the pressure applied to the solar cell during the lamination process, thereby reducing the subfissure and improving the production yield. And the inclined arrangement is favorable for reducing gaps among the solar cells so as to improve the power output of the cell module. Meanwhile, the concave space has a certain positioning function, so that the laying and alignment of the battery strings are facilitated, 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 gaps in the cell strings or the assemblies in the subsequent laminating process, so that the pressure born by the solar cells in the laminating process can be reduced, the subfissure can be reduced, and the production yield can be improved. Meanwhile, the protruding part 2 on one side of the cover plate 5 close to the front packaging material layer can extrude the fused front packaging material layer to be filled in the gaps of the battery strings or the battery assemblies in the laminating process, so that the pressure born by the solar batteries in the laminating process can be further reduced, the subfissure can be reduced, and the production yield can be improved.
Alternatively, the projection of the protruding portion on the packaging material layer and the projection of the protruding portion on the substrate on the same side of the battery string may overlap or not overlap. In the embodiment of the present invention, this is not particularly limited. For example, referring to fig. 5, the projection of the convex portion on the front encapsulant layer overlaps the projection of the convex portion 2 on the cover 5 at the light-facing side of the battery string.
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, which is not particularly limited in the embodiment of the present invention.
The solar cell 4 is obliquely disposed in the concave space, and the oblique angle is specifically determined according to the height of the convex portion, the length of the solar cell, and the like, which is not specifically limited in the embodiment of the present invention.
Optionally, the protruding parts are periodically distributed on the substrate, the process is simple, and in general, the sizes of the solar cells in the cell string are approximately equal, so that the cell string is favorably paved. For example, referring to fig. 1, the projections 2 are periodically distributed on the base of the layer of encapsulating material 1.
Alternatively, as shown in fig. 3, the distance between the centers of two adjacent rows of projections 2 is about the width of a single solar cell, thereby facilitating the inclined 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, thereby facilitating the inclined 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 base body can be 800um, the height of the protruding portions protruding out of the base body is 20-200um, the width of the protruding portions is 5-100mm along the cell string direction, the structured packaging material with the size can stably place the solar cell in an inclined mode, and the inclination angle is enabled to be beneficial to further reducing hidden cracks in the laminating process. Moreover, the method is favorable for further reducing the hidden crack in the lamination process. In addition, the protruding part in the thickness range can be fully filled in gaps between adjacent solar cells or in the assembly after melting or extrusion in the subsequent lamination process, so that hidden cracks in the lamination process can be reduced, the gaps among the solar cells can be reduced, and the power output of the cell assembly can be improved.
For example, referring to fig. 1 or fig. 2, the rows of protrusions are distributed continuously, the height d1 of the substrate of the packaging material layer 1 is 100-800um, the height d2 of the protrusion 2 protruding the substrate is 20-200um, and the width w1 of the protrusion 2 along the cell string direction is 5-100 mm.
Alternatively, each row of the projections is composed of a plurality of sub-projections extending intermittently, and the width of the sub-projections is 1 to 10mm in the cell string direction. The spacing between adjacent sub-projecting portions is 3-20 mm. That is, the projection portions of each row are formed by intermittently extending the sub-projection portions in a dot shape, so that the material of the projection portions can be saved and the cost can be saved. Moreover, the structured packaging material with the size can also stably place the solar cell in an inclined mode, and moreover, the inclination angle is enabled to be beneficial to further reducing hidden cracks in the laminating process. Moreover, the method is favorable for further reducing the hidden crack in the lamination process. And the convex part with the thickness range can be fully filled in the gap in the battery string or the assembly after melting or extrusion in the subsequent lamination process, so that the hidden crack in the lamination process can be reduced, and the gap between the battery strings or the assemblies can be reduced, so that the power output of the battery assembly is improved. Optionally, the shape of the sub-protrusion part includes: one of a spherical body, a cylinder, a multi-face cylinder, a round table and a prismatic table. And the form of the sub-projection is various.
Optionally, the shape of the protruding portion may also include: one of a spherical body, a cylinder, a multi-face cylinder, a round table and a prismatic table. And the form of the projection is varied. For example, referring to fig. 1 or 2, the shape of the convex portion 2 is a triangular prism. For another example, referring to fig. 6, fig. 6 shows a schematic structural diagram of a fourth structured packaging material in an embodiment of the present invention. 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 shape of the convex portion 2 is a rectangular parallelepiped. For another example, referring to fig. 7, fig. 7 shows a schematic structural diagram of a fifth structured packaging material in an embodiment of the present invention. The material of the protruding part 2 in fig. 7 may be different from the material of the substrate. In fig. 7, the shape of the convex portion 2 is a rectangular parallelepiped.
Optionally, the material of the substrate of the encapsulation 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 the battery string.
Optionally, one or both sides of the base and/or the protruding portion may be provided with a release layer for facilitating transportation, operation, and the like, which is not particularly limited in the embodiment of the present invention.
The application also provides a production method of 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 comprise a plurality of rows of protruding parts protruding out of a base body of the substrate and/or the packaging material layer. For the structured packaging material, reference may be made to the above description, and further description is omitted here to avoid redundancy. The convex portion may be formed specifically by one of the following steps S1 to S5:
step S1, hot pressing the protruding portion on the base.
Specifically, the protruding portion is hot-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 projections may be matrix offcuts.
Optionally, in the process of hot-pressing the protruding part 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 protruding part can be uniformly attached to the substrate by the hot-pressing parameters. For example, the hot pressing temperature is 80 ℃, the pressure is 0.1MPa, and the hot pressing time may be 5 s.
Step S2, bonding the base and the projection with an adhesive.
Specifically, the material of the protruding portion can refer to the above-mentioned description, and is not repeated herein for the sake of avoiding redundancy. The adhesive may be applied to the base or to the protruding portion, and in the embodiment of the present invention, this is not particularly limited.
Alternatively, the binder may be a synthetic polymer-based binder. The material of the binder may be selected from: at least one of polyvinyl acetate, polyvinyl acetal, acrylate, polystyrene, epoxy resin, acrylic resin, urethane 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 the release layer is arranged on one side or two sides of the adhesive film, so that the operation is convenient.
In step S3, a local area of the base is pressed to form a protruding portion protruding from the base.
Specifically, the base body may be laid on a table, and an extrusion die with a projection extrudes the base body to form the aforementioned projection. As shown in fig. 8, fig. 8 is a schematic structural view of a first extrusion die according to an embodiment of the present invention. 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 is a schematic structural view of a second extrusion die according to an embodiment of the present invention. 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 extruding the localized region of the substrate. And/or heating the substrate during pressing of a localized area of the substrate. The heating temperature may be 100 ℃ or less. Because the base may be resilient, the extruded projections may contract to some extent, such that the height of the extruded projections may be less than the height of the integrally extruded or bonded projections. By heating the substrate, the degree of shrinkage can be reduced, so that the size of the extruded bulge is relatively accurate, and the substrate is not affected within the heating temperature range.
And step S4, integrally molding the structural packaging material by adopting a pouring mold with a convex part.
Specifically, the matrix precursor solution can be filled into a casting mold with a convex part, and the structured packaging material can be formed after cooling.
Step S5, printing the protruding portion on the substrate.
Specifically, the projection may be printed on the base by screen printing. For example, UV ink material or sintering type glass glaze printing material is adopted to screen print on the surface of the glass cover plate. And then the ink can be cured by UV light irradiation or placed in a heating furnace to be sintered for 1-5 minutes at the temperature of about 600 ℃ to form a convex part.
The production method of the structured packaging material provided by the embodiment of the invention has the same or similar beneficial effects as the structured packaging material, and the repeated description is omitted here to avoid repetition.
Embodiments of the present invention further provide a photovoltaic module, such as the photovoltaic laminate shown in fig. 3 and 5, which is laminated to form a 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 single solar cell is placed in the groove formed by the protruding portion.
For another example, referring to fig. 10, fig. 10 shows a schematic structural view of a third photovoltaic stack in an embodiment of the present invention. The photovoltaic laminate is laminated to form a photovoltaic module.
Optionally, in the packaging process, the front packaging material layer includes a protruding portion on one side facing the battery string, and the rear packaging material layer includes a protruding portion on one side facing the battery string, the protruding portions on two sides of the same solar battery are distributed in a staggered manner, so that the protruding portions on two sides form a larger concave space, and the battery string is convenient to lay. As shown in fig. 3, 5 and 10, the front encapsulant layer and the rear encapsulant layer 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 distributed in a staggered manner.
Optionally, the size of the protruding portion of the structured packaging material above the solar cell is larger than the size of the protruding portion of the structured packaging material below the solar cell; wherein the structured encapsulant over the solar cell is remote from the lamination stage. That is, the size of the protruding portion of the structured encapsulation material that is distal from the lamination stage is greater than the size of the protruding portion of the structured encapsulation material that is proximal to the lamination stage. In the laminating process, due to the action of gravity, the size of the protruding part of the structured packaging material far away from the laminating platform has a better flowing effect or a flowing effect caused by extrusion, and the size of the protruding part of the structured packaging material far away from the laminating platform is larger than that of the protruding part of the structured packaging material close to the laminating platform, so that the protruding part of the packaging material layer is melted and/or the substrate protruding part extrudes the melted packaging material, and the melted packaging material is filled in gaps in the battery string or the battery pack more fully, and the hidden crack is further reduced.
Optionally, during the lamination process, the molten encapsulant is partially melted by the encapsulant layer and/or partially extruded by the substrate, and flows to the gap of the solar cells to form an adhesive layer, which can enhance the connection reliability between the solar cells on one hand, and can fill in the gap in the cell string or module on the other hand, so as to reduce the subfissure.
For the photovoltaic laminate and the laminated photovoltaic module, reference may be made to the above description, and details thereof are not repeated herein in order to avoid redundancy.
Each part of the photovoltaic module refers to the related description, and similar beneficial effects can be achieved, and details are not repeated herein to avoid repetition.
The embodiment of the invention also provides a preparation method of the photovoltaic module, which comprises the following steps:
step SA1, providing a structured packaging material as described in any of the preceding.
Step SA2, providing a battery string; the cell string includes a plurality of solar cells.
Step SA3, disposing the structured packaging material on a light-facing surface and/or a backlight surface of the battery string to obtain a component precursor; in the assembly precursor, the protruding direction of the protruding portion is toward the cell string.
Step SA4, laminating the laminate including the assembly precursor.
It should be noted that: the stack may include: the battery pack 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 a cover sheet, a front encapsulant layer, a battery string, a rear encapsulant layer, a back sheet are included in the assembly precursor, the assembly precursor is a laminate. Each part of the photovoltaic module refers to the related description, and similar beneficial effects can be achieved, and details are not repeated herein to avoid repetition.
Optionally, the step SA4 may include: first laminating the laminate including the assembly precursor; the temperature of the primary lamination is as follows: 80-125 ℃; re-laminating the stack including the assembly precursor; the temperature of the re-lamination was: 120 ℃ and 160 ℃. By subjecting the laminate to a lower temperature primary lamination, the encapsulating material extruded from the protruding portions of the substrate in the structured encapsulating material in the laminate, or the protruding portions of the layer of encapsulating material, can be sufficiently melted and uniformly and stably flowed to the interconnections before the crosslinking reaction, thereby generating a uniform static pressure. And then, the preheated laminated member is laminated again at a higher temperature, and can be filled and cured into gaps of a battery string or assembly under the condition of uniform static pressure, so that gapless connection can be realized, and hidden cracks or cracks can be further reduced.
The method for producing the module, the order of laying the battery string and the structured packing material are not limited.
While the present invention has been described with reference to the embodiments shown in the drawings, the present invention is not limited to the embodiments, which are illustrative rather than restrictive, and it will be apparent to those skilled in the art that many more modifications and variations can be made without departing from the spirit of the invention and the scope of the appended claims.

Claims (21)

1. The structured packaging material is characterized by comprising 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 base body of the substrate and/or the packaging material layer;
the protruding direction of the protruding portion is toward the battery string.
2. The structured packing material of claim 1, wherein the distance between the centers of two adjacent columns of the protruding portions is about the width of a single solar cell.
3. The structured packing material of claim 2, wherein the distance between the centers of the protruding portions of two adjacent columns is less than or equal to the 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 protrusions are continuously distributed, and the protrusions have a width of 5-100mm and a height of 20-200mm, the width being a dimension along the cell string.
6. The structured packing material of claim 1, wherein said columns of projections are comprised of a plurality of sub-projections extending intermittently; the width of the sub-projecting parts is 1-10mm, the distance between adjacent sub-projecting 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-projection comprises: one of a spherical body, a cylinder, a multi-face cylinder, a round table and a prismatic table.
8. The structured packing material of any 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 matrix of the layer of packing material is selected from the group consisting of: at least one of epoxy resin, acrylic resin, polyurethane, cyanoacrylate, polyvinyl alcohol, polydimethylsiloxane, ethylene-vinyl acetate copolymer, ethylene-octene copolymer, polyvinyl butyral, or silicone gel.
10. The structured packing material of any of claims 1 to 7, wherein the protrusions are formed by integral molding, heat pressing, bonding, pressing, printing with the substrate.
11. The structured packing material of claim 1, wherein the structured packing material has an overall light transmittance of greater than or equal to 90% with the structured packing material on a light facing side of the string of cells.
12. A method for producing a structured packaging material, wherein the structured packaging material comprises a substrate and a packaging material layer, the substrate and/or the packaging material layer comprises a plurality of rows of protruding parts protruding from a base body of the substrate and/or the packaging material layer, and the protruding parts are formed by one of the following steps:
hot-pressing the protruding portion on the base;
bonding the base body and the protruding part by using an adhesive;
extruding a local area of a substrate to form a protruding portion protruding out of the substrate;
integrally molding the structured packaging material by adopting a pouring mold with a convex part;
the projections are printed on the substrate.
13. The method for producing a structured packing material according to claim 12, wherein the temperature of the hot pressing is 50 to 150 ℃, the pressure is 0.1 to 0.5MPa, and the time of the hot pressing is 1 to 60 s.
14. The method of claim 12, wherein the adhesive is selected from the group consisting of: at least one of polyvinyl acetate, polyvinyl acetal, acrylate, polystyrene, epoxy resin, acrylic resin, urethane resin, unsaturated polyester, butyl rubber, nitrile rubber, phenolic-polyvinyl acetal, or epoxy-polyamide.
15. The method of claim 12, wherein the substrate is heated prior to extruding the localized region of the substrate;
and/or heating the substrate during pressing of a 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 and encapsulated with the structured encapsulant of any 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 portion faces the battery string, and the single solar battery is arranged in the groove formed by the protruding portion.
17. The assembly of claim 16, wherein the protrusions on both sides of the same solar cell are staggered in the encapsulation process where the side of the front encapsulant layer facing the cell string includes protrusions and the side of the back encapsulant layer facing the cell string includes protrusions.
18. The photovoltaic module of claim 16 or 17, wherein the size of the protruding portion of the structured encapsulant above the solar cell is larger than the size of the protruding portion of the structured encapsulant below the solar cell; wherein the structured encapsulant over the solar cell is remote from the lamination stage.
19. The assembly according to claim 16 or 17, wherein during the lamination process, the molten encapsulant is melted by the protruding portion of the encapsulant layer and/or extruded by the protruding portion of the substrate, and flows to the solar cell gap to form the adhesive layer.
20. A preparation method of a photovoltaic module is characterized by comprising the following steps:
providing a structured packing material according to any one of claims 1 to 11;
providing a battery string; the cell string comprises a plurality of solar cells;
arranging the structured packaging material on a light facing surface and/or a backlight surface of the battery string to obtain a component precursor; in the assembly precursor, a protruding direction of the protruding portion is toward the cell string;
laminating the laminate comprising the assembly precursor.
21. The method of making a photovoltaic module of claim 20, wherein laminating the laminate comprising the module precursor comprises:
first laminating the laminate including the assembly precursor; the temperature of the primary lamination is as follows: 80-125 ℃;
re-laminating the stack including the assembly precursor; the temperature of the re-lamination was: 120 ℃ and 160 ℃.
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