CN113394307A

CN113394307A - Dark photovoltaic module and manufacturing process thereof

Info

Publication number: CN113394307A
Application number: CN202110658639.9A
Authority: CN
Inventors: 高镭; 黄晓; 刘亚锋
Original assignee: Risen Energy Co Ltd
Current assignee: Risen Energy Co Ltd
Priority date: 2021-06-11
Filing date: 2021-06-11
Publication date: 2021-09-14

Abstract

The embodiment of the application provides a dark color photovoltaic module and a manufacturing process thereof, and relates to the technical field of photovoltaic power generation. At least part of bus bars in the dark photovoltaic assembly are sectional dark bus bars, the front surfaces of the sectional dark bus bars are first alloy layers and first dark coatings which are arranged at intervals, and at least one end of the front surfaces of the partial sectional dark bus bars is a first alloy layer; the rest bus bars are single-side dark bus bars; the first alloy layer on the front side of the sectional type dark bus bar is completely covered by the alloy layers on the back sides of other bus bars and overlapped together, or the end part of the first alloy layer on the front side of the sectional type dark bus bar is bent and led out of the back side until the front side of the bus bar overlapped and overlapped together is dark. The dark photovoltaic module and the manufacturing process thereof realize lap joint passages among the bus bars, and are convenient for realizing automatic welding; meanwhile, testing and electrifying are realized during detection of the assembly, so that the labor is saved; the heat transfer is easier during welding, the welding is firm, and the product reliability is improved.

Description

Dark photovoltaic module and manufacturing process thereof

Technical Field

The application relates to the technical field of photovoltaic power generation, in particular to a dark color photovoltaic module and a manufacturing process thereof.

Background

At present, enterprises in the photovoltaic power generation field continuously strive to reduce cost and improve efficiency, and large silicon wafer component series products with more advantages in power consumption cost are pushed out in a dispute so as to meet the requirements of photovoltaic power generation. The large silicon wafer assembly series products can increase the area of the battery piece, for example, the width of a photovoltaic assembly of six battery strings reaches more than 1.3m, which is not beneficial to distributed photovoltaic power generation. The distributed photovoltaic power generation places are mainly residential roofs in cities and towns and rural areas, and the large silicon wafer component series products can limit flexible installation and utilization of limited space area on the roofs and bring about increase of transportation cost. Therefore, when the large silicon wafer assembly series assembly is used for distributed photovoltaic power generation, the width is often lower than 1.1m, for example, five series of models are adopted, and the structural characteristics are as follows: a long bus bar is arranged in the middle, and three bus bars at the head, the middle and the tail of the bus bar are required to be lapped to realize a passage.

In addition, the front of the product of the all-black photovoltaic module presents a consistent black appearance, so that the all-black photovoltaic module is more popular with customers when being applied to distributed photovoltaic power generation, and the module has higher premium and has more market competitiveness. However, for the all-black photovoltaic module having the above structural features (such as the five-string type), if the conventional black bus bar (the black side of the bus bar faces in one direction) is used, there are the following problems: the welding of the lap joint area between the middle long bus bar and the three bus bars at the head, the middle and the tail is difficult, and effective access cannot be realized.

In order to solve the problem of lap joint passages among black bus bars, some components are made of conventional silvery white bus bars, and black materials (such as black PET or black EVA) are adopted to shield the front surfaces of the conventional silvery white bus bars before lamination to achieve full black appearance of the front surfaces of the components, but manual secondary adjustment and fixing of the positions of the black materials are often needed, automation is not facilitated, and risks of black material offset and overflow after lamination affect the appearance of the front surface consistency. In addition, some black bus bars are formed by plating black paint on one surface and welding on the other surface, and when the black surfaces of two black bus bars face to one direction and need to be welded, the black surfaces cannot be welded and insulated, so that the welding cannot be performed and normal conduction can still be realized. In addition, some materials of the black coating of the black bus bar are adjusted to simultaneously have black appearance, weldability and conductivity, but the cost is high, and the requirements of cost reduction and efficiency improvement are not met.

Disclosure of Invention

One of the objectives of the embodiment of the present application is to provide a dark photovoltaic module and a manufacturing process thereof, which uses a sectional type dark bus bar or matches with a single-side dark bus bar to realize a lap joint path between the bus bars, thereby facilitating the realization of automatic welding.

One of the purposes of the embodiment of the application is to provide a dark color photovoltaic module and a manufacturing process thereof, a sectional type dark color bus bar is adopted or is matched with a single-side dark color bus bar for use, the bus bar where an outgoing line is located adopts a sectional type black bus bar, testing electrification during detection in the module is realized, and manpower is saved.

One of the purposes of the embodiment of the application is to provide a dark photovoltaic module and a manufacturing process thereof, a sectional type dark bus bar is adopted or is matched with a single-side dark bus bar for use, the bus bar where an outgoing line is located adopts a sectional type black bus bar, heat is transferred more easily when the outgoing line is welded with a junction box, welding is firm, and product reliability is improved.

In a first aspect, embodiments of the present application provide a dark photovoltaic module, which includes a cell layer formed by arranging a plurality of strings of cells, and a plurality of bus bars disposed on a front surface of the cell layer and used for connecting the strings of cells to form a passage, where all the bus bars are segmented dark bus bars or segmented dark bus bars and single-sided dark bus bars; the front side of the sectional type dark color bus bar is provided with a first alloy layer and a first dark color coating which are arranged at intervals, and the back side of the sectional type dark color bus bar is provided with an alloy layer; the front side of the single-side deep-color bus bar is provided with a second deep-color coating, and the back side of the single-side deep-color bus bar is provided with an alloy layer; the first alloy layer on the front surface of the sectional type dark bus bar is completely covered by the alloy layers on the back surfaces of other bus bars and overlapped and lapped together until the front surfaces of the overlapped and lapped bus bars are dark.

In the implementation process, the sectional type deep-color bus bar is adopted or is matched with a single-side deep-color bus bar for use, so that a lap joint passage between the bus bars is realized, the front side is guaranteed to be deep color, and the automatic welding is convenient to realize. Specifically, the length of a segmented area can be controlled to meet the design requirement by a mode of accurately spraying or printing a deep color coating to form a first deep color coating, so that the segmented deep color bus bar is obtained, manual secondary adjustment and deep color material position fixing are not needed, automation is facilitated, risks of deep color material offset and overflow are avoided after lamination, and the front consistent appearance is not influenced; through dark busbar of sectional type and other busbar collocation use, realize overlapping lap welding and dark coating orientation same direction (as openly up) between two busbars, solved because unable welding problem of spray painting face (dark coating), can directly realize through equipment that automatic weld satisfies volume production busbar automatic weld's production requirement, be convenient for realize dark photovoltaic module production automation.

The sectional type dark color bus bar with the dark color coating can be formed by using the conventional dark color coating, so that the cost is greatly saved compared with a non-sectional bus bar with other weldable conductive metal coating (such as nickel-cobalt alloy), and the requirements of cost reduction and efficiency improvement in the photovoltaic industry are met.

In a possible implementation manner, at least one end of the front surface of at least one sectional type dark bus bar is a first alloy layer, and the front surface of the sectional type dark bus bar is formed by bending and leading out the end part of the first alloy layer to the outside of the back surface.

In the implementation process, in the assembly manufacturing process, an EL (electroluminescence) test is required before lamination, a dark color coating of a bus bar outgoing line influences the conduction, a conductive terminal tool needs to be manually placed, and production automation is not facilitated; after lamination, the junction box is welded, the dark color coating of the bus bar outgoing line influences heat transfer, the welding effect is poor, and the reliability of the product is not facilitated. The bus bar at the lead-out wire place also takes the dark bus bar of sectional type, and EL test circular telegram when detecting before realizing the subassembly lamination has saved the manpower, avoids increasing the manpower because of dark coating non-conductive and puts and retrieve manpower and the production beat waste that electrically conductive frock brought, is convenient for realize the automation, has saved the manpower, has promoted the production beat. When the outgoing line is welded with the junction box after the assembly is laminated, the outgoing line (the bus bar with the first alloy layer at the end part of the front side) is a double-layer alloy layer, so that heat transfer is easier during welding, welding is firm, the problems that the outgoing line of the bus bar is poor in heat transfer and welding effect due to the influence of a dark color coating, and cold welding is easy are solved, and meanwhile, the reliability of a product is improved.

In a possible implementation manner, the first bus bar, the second bus bar, the third bus bar and the fourth bus bar are included, the first bus bar, the second bus bar and the third bus bar are respectively overlapped with the head portion, the middle portion and the tail portion of the fourth bus bar, the overlapping surface of the overlapping portion located above is an alloy layer, and the overlapping surface located below is a first alloy layer.

In the implementation process, for the case that the fourth bus bar is arranged and three positions (usually, the head part, the middle part and the tail part) of the bus bar need to be overlapped with other bus bars to meet the requirements of the module model design and the dark appearance of the front surface, the requirements can be achieved by overlapping the sectional type first alloy layer on the front surface of the sectional type dark bus bar with the alloy layer on the back surface of other bus bars (which can be sectional type dark bus bars or single-side dark bus bars).

In a possible implementation manner, the first bus bar and the third bus bar are single-side dark bus bars, the second bus bar is a sectional dark bus bar, the end part of the front side of the second bus bar is a first alloy layer, the end part is bent and led out of the back side of the second bus bar, the fourth bus bar is a sectional dark bus bar, the head part, the middle part and the tail part of the front side of the fourth bus bar are first alloy layers, the rest areas are first dark coating layers, and the alloy layers on the back sides of the first bus bar, the second bus bar and the third bus bar are respectively overlapped with the first alloy layers on the head part, the middle part and the tail part of the front side of the fourth bus bar correspondingly.

In the implementation process, the first bus bar and the third bus bar adopt conventional single-side dark bus bars, the second bus bar and the fourth bus bar adopt correspondingly designed sectional dark bus bars, and then three lap joints between the first bus bar and the fourth bus bar can realize a passage and a dark appearance on the front side according to a mode of overlapping and lapping a back alloy layer and a front first alloy layer. And the second bus bar's design can not only realize with the overlap joint between the fourth bus bar, and the tip of its two-sided alloy-layer wears to the subassembly back outside moreover, realizes that the subassembly is in the process of examining the circular telegram, promotes the reliability of product.

In a possible implementation manner, the first bus bar, the second bus bar, the third bus bar and the fourth bus bar are all sectional dark bus bars, the front end portions of the first bus bar, the second bus bar and the third bus bar are first alloy layers, the front middle portion of the fourth bus bar is a first alloy layer, an alloy layer at the head of the back of the fourth bus bar is overlapped with the first alloy layer at the front end portion of the first bus bar, an alloy layer at the tail of the back of the fourth bus bar is overlapped with the first alloy layer at the front end portion of the third bus bar, an alloy layer at the back of the second bus bar is overlapped with the first alloy layer at the front middle portion of the first alloy layer, and the end portion of the first alloy layer of the second bus bar is bent and led out of the back of the second bus bar.

In the implementation process, the first bus bar, the second bus bar, the third bus bar and the fourth bus bar adopt correspondingly designed sectional dark color bus bars, and then three lap joints among the first bus bar, the second bus bar, the third bus bar and the fourth bus bar can realize a passage and a dark appearance on the front side according to a mode that a back alloy layer and a front first alloy layer are overlapped. And the second bus bar's design can not only realize with the overlap joint between the fourth bus bar, and the tip of its two-sided alloy-layer wears to the subassembly back outside moreover, realizes that the subassembly is in the process of examining the circular telegram, promotes the reliability of product.

In a possible implementation manner, the sectional type dark bus bar comprises a first substrate layer, wherein a front surface and a back surface of the first substrate layer are respectively provided with a first alloy layer, and a sectional type first dark coating layer is further arranged on the first alloy layer on the front surface of the first substrate layer; the single-side deep-color bus bar comprises a second base material layer, wherein a second alloy layer is respectively arranged on the front side and the back side of the second base material layer, and a continuous second deep-color coating layer is further arranged on the second alloy layer on the front side of the second base material layer.

In a possible implementation manner, the first substrate layer and/or the second substrate layer is a copper strip, an aluminum strip or a copper-clad aluminum strip; the thickness of the first base material layer and/or the second base material layer is 0.20-0.30 mm;

the first alloy layer and/or the second alloy layer are/is made of tin soldering alloy;

the thickness of the first alloy layer and/or the second alloy layer on the front surface of the first base material layer and/or the second base material layer is 20-30 μm, the thickness of the first alloy layer and/or the second alloy layer on the back surface of the first base material layer and/or the second base material layer is 5-10 μm, and the thickness of the first alloy layer between the sectional first dark-color coatings is 0-25 μm.

In a possible realization mode, the material of the first dark color coating layer and/or the second dark color coating layer is UV paint, and the thickness is 15-25 μm.

In a second aspect, an embodiment of the present application further provides a manufacturing process of the dark photovoltaic module provided in the first aspect, which includes the following steps:

arranging the battery string on the front glass coated with the front packaging adhesive film to form a battery layer;

automatically cutting single sectional type dark color bus bars with certain specifications on the continuous sectional type dark color bus bars, and connecting the batteries together through a plurality of single sectional type dark color bus bars or at least one single sectional type dark color bus bar and a single-side dark color bus bar to realize a passage;

and laying a back packaging adhesive film and a back plate on the battery layer.

In the implementation process, the single-side dark bus bar is automatically cut according to the design, and then the corresponding bus bar is automatically welded on the arranged battery string, so that the production automation of the dark photovoltaic module is conveniently realized.

In one possible implementation, an automatic cutting machine is used to automatically cut a continuous sectional dark bus bar into a single sectional dark bus bar, the automatic cutting machine includes an optical image lens and a light-emitting plate which are arranged oppositely, and paired cutting knives, and the cutting method is:

pulling out one end of a continuous sectional type dark bus bar, carrying out deviation rectification identification through an optical image lens, controlling the length of a first alloy layer on the front side of the sectional type dark bus bar to be cut not to be larger than the shielding distance of an alloy layer on the back side of the corresponding bus bar, rectifying when the length exceeds the range, cutting off redundant parts by using a cutting knife until the cut single sectional type dark bus bar meets the use requirement.

In the implementation process, the bus bar welding machine (stitch welding machine) realizes automatic welding, the matched automatic cutting machine is additionally provided with the optical image recognition mechanism, the length of the segmentation region (the front first alloy layer) is automatically corrected and calibrated, the segmentation region exceeding the length requirement is cut, the error risk between the bus bar incoming material and the stitch welding machine is avoided, the length of the segmentation region is ensured to realize lap welding, the segmentation region does not exceed the front, and the completely black appearance consistency of the front surface of the assembly is realized.

Drawings

In order to more clearly illustrate the technical solutions of the embodiments of the present application, the drawings that are required to be used in the embodiments of the present application will be briefly described below, it should be understood that the following drawings only illustrate some embodiments of the present application and therefore should not be considered as limiting the scope, and that those skilled in the art can also obtain other related drawings based on the drawings without inventive efforts.

FIG. 1 is a schematic diagram of a five-string layout;

fig. 2 is a schematic structural diagram of a dark photovoltaic module according to a first embodiment of the present disclosure;

FIG. 3 is an exploded view of FIG. 2;

fig. 4 is a schematic view illustrating an overlap joint of bus bars in a dark photovoltaic module according to a first embodiment of the present disclosure;

fig. 5 is a schematic diagram illustrating a trimming process of a fourth bus bar in a dark photovoltaic module according to a first embodiment of the present disclosure;

fig. 6 is a schematic diagram illustrating the cutting of a second bus bar in a dark photovoltaic module according to a first embodiment of the present disclosure;

fig. 7 is a schematic view illustrating a second bus bar bending in a dark photovoltaic module according to a first embodiment of the present disclosure;

fig. 8 is a schematic view of a lap joint at a position a in a dark photovoltaic module according to a first embodiment of the present application;

fig. 9 is a schematic view of a lap joint at B in a dark photovoltaic module according to a first embodiment of the present application;

FIG. 10 is a schematic view of a segmented dark bus bar construction;

fig. 11 is a schematic structural view of an automatic cutting machine;

fig. 12 is a schematic view illustrating an overlap joint of bus bars in a dark photovoltaic module according to a second embodiment of the present application;

fig. 13 is a schematic view illustrating an overlap joint of bus bars in a dark photovoltaic module according to a third embodiment of the present application.

Icon: 01-a battery piece; 02-long bus bar; 100-dark photovoltaic modules; 110-a battery string; 121-a first busbar; 122-a second bus bar; 123-a third bus bar; 124-fourth bus bar; 125-a first substrate layer; 126-a first alloy layer; 127-a first dark coating; 128-a second dark coating; 130-front glass; 140-front side packaging adhesive film; 150-back packaging adhesive film; 160-a back plate; 171-a reel; 172-optical image lens; 173-a light-emitting panel; 174-cutting knife.

Detailed Description

The applicant found that: referring to fig. 1, the five-string format includes 5 long strings of battery strings formed by arranging a plurality of battery pieces 01 and a long bus bar 02, and compared with the conventional six-string format, the five-string format has the difference that one long string of battery strings in the six long strings of battery strings is replaced by the long bus bar 02, the long bus bar 02 mainly plays a role in connection to realize the conduction of positive and negative electrode currents, the long bus bar 02 can replace any long string of battery strings in the original six-string format, and a diode is further arranged on the bus bar at a specific position to ensure that each string of battery strings bypasses one diode. The access demand of current volume production single face black busbar for satisfying five cluster version type photovoltaic module, when two black busbar overlap welds and black face orientation one direction (as openly up), because the unable welding of black paint spray face and insulating, can have following problem: firstly, the circuit cannot be lap-welded and normally conducts electricity; secondly, when EL (electro-luminescence) power-on inspection is carried out before lamination of the assembly, as the black surface of the bus bar at the outgoing line is upward, a pressing pin of a testing instrument cannot be powered up, and a conductive tool needs to be manually placed, so that automation is not facilitated; when the assembly is connected with the junction box, the black surface of the bus bar at the leading-out wire is upward, the black coating surface influences heat transfer, the welding effect of the leading-out wire and the junction box is poor, and the reliability of the product is not facilitated.

In order to solve the above problems, the applicant has searched for a scheme of using a sectional type dark bus bar in combination with a sectional type dark bus bar or a single-side dark bus bar, and has designed the specification of the sectional type dark bus bar accordingly.

In the present application, "front" refers to a surface that receives solar light, and "back" refers to a surface opposite to the "front". "several" in this application means at least two in number.

The technical solutions in the embodiments of the present application will be described below with reference to the drawings in the embodiments of the present application.

In order to make the objects, technical solutions and advantages of the embodiments of the present application clearer, the technical solutions in the embodiments of the present application will be clearly and completely described below with reference to the drawings in the embodiments of the present application, and it is obvious that the described embodiments are some embodiments of the present application, but not all embodiments. The components of the embodiments of the present application, generally described and illustrated in the figures herein, can be arranged and designed in a wide variety of different configurations.

Thus, the following detailed description of the embodiments of the present application, as presented in the figures, is not intended to limit the scope of the claimed application, but is merely representative of selected embodiments of the application. All other embodiments, which can be derived by a person skilled in the art from the embodiments given herein without making any creative effort, shall fall within the protection scope of the present application.

It should be noted that: like reference numbers and letters refer to like items in the following figures, and thus, once an item is defined in one figure, it need not be further defined and explained in subsequent figures.

In the description of the present application, it should be noted that the terms "upper", "lower", "inner", "outer", and the like indicate orientations or positional relationships based on orientations or positional relationships shown in the drawings or orientations or positional relationships conventionally found in use of products of the application, and are used only for convenience in describing the present application and for simplification of description, but do not indicate or imply that the referred devices or elements must have a specific orientation, be constructed in a specific orientation, and be operated, and thus should not be construed as limiting the present application. Furthermore, the terms "first," "second," "third," and the like are used solely to distinguish one from another and are not to be construed as indicating or implying relative importance.

In the description of the present application, it is also to be noted that, unless otherwise explicitly specified or limited, the terms "disposed" and "connected" are to be interpreted broadly, e.g., as being either fixedly connected, detachably connected, or integrally connected; can be mechanically or electrically connected; they may be connected directly or indirectly through intervening media, or they may be interconnected between two elements. The specific meaning of the above terms in the present application can be understood in a specific case by those of ordinary skill in the art.

First embodiment

Referring to fig. 2, fig. 3, fig. 8, and fig. 9, the dark photovoltaic module 100 of the present embodiment includes a cell layer formed by arranging a plurality of cell strings 110, and a plurality of bus bars disposed on the front surface of the cell layer and used for connecting the cell strings 110 to form a passage, wherein all the bus bars are segmented dark bus bars or segmented dark bus bars and single-sided dark bus bars; the front surface of the sectional type dark color bus bar is provided with a first alloy layer 126 and a first dark color coating 127 which are arranged at intervals, the back surface of the sectional type dark color bus bar is provided with an alloy layer, and at least one end of the front surface of a part of the sectional type dark color bus bar is provided with the first alloy layer 126; the front side of the single-side dark bus bar is provided with a second dark coating 128, and the back side of the single-side dark bus bar is provided with an alloy layer; the first alloy layer 126 on the front side of the sectional dark bus bar is completely covered by the alloy layers on the back sides of other bus bars and overlapped together, or the front side of the sectional dark bus bar is that the end part of the first alloy layer 126 is bent and led out to the outside of the back side until the front sides of the bus bars overlapped and overlapped together are dark, that is, the dark coatings of all the bus bars are front sides and the front sides are upward.

Since the photovoltaic module is mainly divided into a single-glass module and a dual-glass module, the basic structure is front glass 130 (such as front coated glass) + front encapsulation film 140 (such as transparent film) + the interconnection structure formed by the cell strings 110 and the bus bars + back encapsulation film 150 (such as transparent film) + back plate 160 (such as back glass); lead-out wire of busbar welds terminal box, and the frame is installed in order to increase mechanical properties after the subassembly lamination, is convenient for install. It should be noted that the "dark color" in the present application is not limited to pure black, but may be other non-white and non-transparent colors. "lap joint" in the embodiments of the present application refers to a contact connection, such as lap welding.

As an embodiment, after the battery cells, which are constituent units in the battery string 110, are subjected to a film coating process, the colors are generally black or blue, and may be generally black, dark blue, blue and light blue, or other relatively dark colors, the front surface of the bus bar is sprayed with a coating material to have an appearance close to the color of the battery cells, and accordingly, the colors of the back plate 160 and the frame in this application may also be matched and combined to maintain the consistency of the appearance of the assembly. The following list of possible structures for the dark photovoltaic module 100 of the embodiments of the present application:

(1) single glass assembly:

the front surface of the module is coated with film glass, the transparent adhesive film, the battery piece and the blue bus bar form an interconnection structure, the transparent adhesive film, the blue back plate and the blue frame, and the appearance of the front surface of the module is blue;

the front surface of the module is displayed to be blue in appearance.

(2) Double-glass assembly:

the front surface of the module is coated with film glass, a transparent adhesive film, an interconnection structure formed by the battery piece and the blue bus bar, the transparent adhesive film, the blue glaze-plated grid glass and the blue frame, and the appearance of the front surface of the module is blue;

the front surface of the module is coated with the film glass, the transparent adhesive film, the battery piece and the blue bus bar form an interconnection structure, the blue composite adhesive film, the transparent glass and the blue frame, and the appearance of the front surface of the module is blue.

Referring to fig. 2, the dark color photovoltaic module 100 in this embodiment is a five-string type, which includes five long strings 110 arranged at least side by side at the bottom right, each long string 110 is divided into two parallel battery packs by the middle, and the positive electrode or the negative electrode of each battery pack is identified, the battery packs are connected by bus bars, the front surfaces of all the bus bars face upward, and the current generated by the battery pieces in each battery pack is left by the positive electrode and flows to the next battery pack.

In other embodiments, the dark color photovoltaic module 100 may also adopt other types, and for the positions where different bus bars need to be lapped, the design of the embodiment of the present application may be adopted, that is, the lapping surface of the bus bar located above the lapping position is the alloy layer, and the lapping surface of the bus bar located below is the first alloy layer 126.

Referring to fig. 2 and 4, fig. 8 and 9, the bus bars include a first bus bar 121 and a second bus bar 122, a third bus bar 123 and a fourth bus bar 124, and the fourth bus bar 124 is the long bus bar 02 of fig. 1. The first bus bar 121, the second bus bar 122, and the third bus bar 123 overlap and join with the head, the middle, and the tail of the fourth bus bar 124, respectively, at A, B, C, respectively, and require a solder path. In order to realize that all the dark coatings face upwards and the lap welding is easy to realize, the lap joint surface of the bus bar (which can be a sectional dark bus bar or a single-side dark bus bar) positioned above the lap joint part is an alloy layer, the bus bar positioned below is a sectional dark bus bar, and the lap joint surface is a first alloy layer 126. That is, the faying surfaces between the head portion of the fourth bus bar 124 and the first bus bar 121 are the first alloy layer 126 and the alloy layer, respectively, the faying surfaces between the middle portion of the fourth bus bar 124 and the second bus bar 122 are the first alloy layer 126 and the alloy layer, respectively, and the faying surfaces between the tail portion of the fourth bus bar 124 and the third bus bar 123 are the first alloy layer 126 and the alloy layer, respectively.

Referring to fig. 4, the first bus bar 121 and the third bus bar 123 are single-sided dark bus bars, the second bus bar 122 is a sectional dark bus bar, the front end portion of the second bus bar is a first alloy layer 126, the front end portion is bent and led out of the back surface, the fourth bus bar 124 is a sectional dark bus bar, the front head portion, the middle portion and the tail portion of the fourth bus bar are first alloy layers 126, the rest regions are first dark coatings 127, and the alloy layers on the back surfaces of the first bus bar 121, the second bus bar 122 and the third bus bar 123 are respectively overlapped with the first alloy layers 126 on the front head portion, the middle portion and the tail portion of the fourth bus bar 124. The first bus bar 121, the second bus bar 122, the third bus bar 123, and the fourth bus bar 124 in the embodiment of the present application may also adopt other combination manners, and it is only necessary to satisfy that the overlapping surface of the bus bar located above the overlapping position is an alloy layer, the bus bar located below is a dark-color sectional bus bar, and the overlapping surface is the first alloy layer 126.

Referring to FIG. 5, the fourth bus bar 124 is a continuous sectional type dark bus bar (a reel 171) cut in a length direction, and as one embodiment, the front surface of the corresponding continuous sectional type dark bus bar is disposed along the length direction of the reel 171 (a first alloy layer 126a + a first dark coating layer 127c + a first alloy layer 126b + a first dark coating layer 127c)_nCirculating in sequence; after cutting by an automatic bus bar welding machine, a single fourth bus bar 124 is obtained, and the front surface of the fourth bus bar is arranged in the length direction to be the first alloy layer 1261/2 a + the first dark color coating 127c + the first alloy layer 126b + the first dark color coating 127c + the first alloy layer 1261/2 a, wherein 1/2a is the width of the first bus bar 121 and the third bus bar 123, b is the width of the second bus bar 122, and c is the length of the single battery string 110; a. b, c can set up according to the version is nimble to divide segment length, and d is long busbar width, sets for according to the version, does not have the relation with segmentation region length, needs satisfy the welding demand of overlap joint, and the subassembly openly does not reveal white, keeps dark outward appearance.

Referring to fig. 6, the second bus bar 122 is a continuous sectional type dark bus bar (a roll 171) cut in a length direction, and as one embodiment, the front surface of the corresponding continuous sectional type dark bus bar is disposed along the length direction of the roll 171 (a first dark coating layer 127e + a first alloy layer 126h + a first dark coating layer 127f + a first alloy layer 126h + a first dark coating layer 127g + a first alloy layer 126h)_nCirculating in sequence; after being cut by the automatic bus bar welding machine, 4 second bus bars 122 are obtained, which are: first dark color coating 127e + first alloy layer 1261/2h, second first alloy layer 1261/2h + first dark colorThe lead-out wire comprises a color coating 127f, a first alloy layer 1261/2h, a first alloy layer 1261/2h, a first dark color coating 127g, a first alloy layer 1261/2h and a first alloy layer 1261/2h and a first dark color coating 127e, wherein the length of the lead-out wire 1/2h is about-2 mm in height (the lead-out wire is a bus bar exposed after the assembly is laminated and packaged, and has a positive electrode and a negative electrode, and the lead-out wire is conveniently connected with a cable after the junction box is installed); the lengths e, f and g of the segments are determined by the 110-type length of the battery string and are independent of other lengths; i is the width of the long bus bar, and is set according to the format and has no relation with the length of the segmentation area; the sectional view is identical to the fourth bus bar 124. As shown in the upper part of fig. 7, the end of the second bus bar 122 is bent to form a lead wire having a height j, and the lead wire is further bent after passing through the back surface, as shown in the lower part of fig. 7.

Referring to fig. 8, the lap joint A, C is a lap joint region of the first bus bar 121, the third bus bar 123 and the fourth bus bar 124, and the segment region of the fourth bus bar 124 is a length 1/2a of the first alloy layer 126, which coincides with the width of the first bus bar 121 and the third bus bar 123; for example, the total length of the 1/2a + C + b + C +1/2a long solder strip can be kept unchanged, the length of the blackened area can meet the tolerance of-0/+ 1mm, and the corresponding width of 1/2a is within the tolerance of-0.5/+ 0mm, so that the risk of appearance whitening is lower, and the conductive performance is not influenced.

Referring to fig. 9, the lap joint B is a lap joint region of the second bus bar 122 and the fourth bus bar 124, and a segment region of the fourth bus bar 124 is a length B of the first alloy layer 126, which coincides with widths of the first bus bar 121 and the third bus bar 123; for example, the total length of the 1/2a + C + b + C +1/2a long solder strip can be kept unchanged, the length of the blackened area can meet the tolerance of-0/+ 1mm, and the corresponding b width is the tolerance of-0.5/+ 0, so that the risk of appearance whitening is lower, and the conductive performance is not influenced.

Referring to fig. 10, the sectional type dark bus bar in the embodiment of the present application includes a first substrate layer 125, a first alloy layer 126 is disposed on each of front and back surfaces of the first substrate layer 125, and a first dark coating layer 127 is further disposed on the first alloy layer 126 on the front surface of the first substrate layer 125 in a sectional manner; the single-side dark bus bar comprises a second base material layer, wherein a second alloy layer is respectively arranged on the front surface and the back surface of the second base material layer, and a second dark coating 128 is continuously arranged on the second alloy layer on the front surface of the second base material layer.

The first substrate layer 125 and the second substrate layer are respectively a copper strip, an aluminum strip or a copper-clad aluminum strip; the thicknesses of the first substrate layer 125 and the second substrate layer are 0.20 to 0.30mm, respectively.

The first alloy layer 126 and the second alloy layer are made of tin soldering alloy and comprise (by weight parts) lead-containing tin-coated copper strips, and the common components are as follows: 63% Sn, 37% Pb, 60% Sn, 40% Pb, 62% Sn, 36% Pb, 2% Ag, etc.; the lead-free tin-copper strip comprises the following common components: 96.5% Sn, 3.0% Ag, 0.5% Cu, 96.5% Sn, 3.5% Ag.

The thicknesses of the first alloy layer 126 on the front surface of the first substrate layer 125 and the second alloy layer on the front surface of the second substrate layer are respectively 20 to 30 μm, the thicknesses of the first alloy layer 126 on the back surface of the first substrate layer 125 and the second alloy layer on the back surface of the second substrate layer are respectively 5 to 10 μm, and the thickness of the first alloy layer 126 between the sectionally arranged first dark color coatings 127 is 0 to 25 μm.

The first deep color coating 127 and the second deep color coating 128 are respectively made of UV coating, and also can be made of organosilicon material, fluorocarbon material and inorganic ceramic film coating, and the thicknesses are respectively 15-25 μm.

As an embodiment, the sectional type bus bar is prepared by: after the first alloy layer 126 is formed by coating both sides of the first substrate layer 125 (copper strip base) with a tin solder alloy, the front side surface is coated with a dark colored material to form a first dark colored coating 127 and the tin solder alloy is coated with a second alloy layer. Copper strip substrates in the industry are generally oxygen-free copper, with a grade greater than oxygen-free copper grade II (TU2) and a copper content greater than 99.95%; the tin solder alloy is generally tin-lead alloy Sn 63% Pb 37%; the first dark color coating 127 is typically a UV coating, such as epoxy acrylate or urethane acrylate, which is sprayed on the surface of the tin-lead alloy and then cured by UV light. During production, after tin soft soldering alloy is coated on two sides of a copper strip, a finished product is obtained by coating a dark color coating on the two sides of the copper strip accurately, then spraying the dark color coating, curing and tearing the film, or the length of the dark color coating is accurately controlled by adopting a printing mode.

Referring to fig. 2 and 3, the present embodiment further provides a manufacturing process of the dark photovoltaic module 100, which includes the following steps:

and S1, arranging the battery string 110 on the front glass 130 coated with the front packaging adhesive film 140 to form a battery layer, specifically, slicing and welding battery sheets into the battery string 110, and automatically arranging the battery string on the front glass 130 coated with the front packaging adhesive film 140 by using a string arranging machine.

And S2, automatically cutting a single sectional type dark bus bar with a specific specification on the continuous sectional type dark bus bar, and automatically welding the battery strings 110 together and realizing the passage by a bus bar automatic welding machine (stitch welding machine) through a plurality of single sectional type dark bus bars or at least one single sectional type dark bus bar and a single-sided dark bus bar (the first bus bar 121 and the third bus bar 123 at the head and the tail of the assembly adopt the conventional single-sided dark bus bar, and the middle second bus bar 122 and the fourth bus bar 124 of the long bus bar adopt the sectional type dark bus bars).

S3, laying back-side packaging adhesive film 150 and back sheet 160 on the battery layer.

S4, the assembly is moved to the middle inspection area, and the second bus bar 122 is bent and inserted into the lead-out wire at the back, so that the EL test can be easily performed. And after the detection is finished, laminating the qualified modules to obtain the dark-color photovoltaic module 100.

In addition, the subsequent steps of the middle inspection are consistent with the conventional assembly production process, namely laminating, edging, appearance inspection, framing, fixing, testing, final inspection and packaging. When the lead wire is welded with the junction box in the framing procedure, the soldering iron is contacted with the double-sided tin coating, so that heat transfer and welding are easier.

Referring to fig. 11, an automatic guillotine, which includes an optical imaging lens 172 and a light panel 173 disposed opposite to each other, and a pair of guillotine blades 174, is used to automatically sever a single segmented dark bus bar from a continuous segmented dark bus bar, as follows:

the bus bar automatic welding machine (stitch welding machine) pulls out one end of the continuous sectional type dark color bus bar scroll 171, firstly, deviation correction identification is carried out through the optical image lens 172 (the light reflection rates of the dark color coating and the alloy layers are obviously different, namely, the sectional area can be accurately identified), the length of the first alloy layer 126 on the front side of the sectional type dark color bus bar to be cut is controlled, the length is controlled not to be larger than the shielding distance of the alloy layer on the back side of the corresponding bus bar, deviation correction is carried out when the length exceeds the range, the redundant part is cut off by using the cutting knife 174, and the obtained sectional type single dark color bus bar meets the use requirement until the cut.

In other embodiments, the following alternatives may also be employed: firstly, an image recognition system is not added in an automatic bus bar welding machine (stitch welding machine), and a bus bar manufacturer supplies a single cut bus bar to use sheet material loading to replace a scroll 171 for loading; punching is carried out on the outgoing line, namely the second bus bar 122 segmented bus bar area, a cylinder punching mechanism is generally added in an automatic bus bar welding machine (stitch welding machine) to obtain a single punched bus bar, punching is not carried out in the bus bar manufacturing process, and the situation that the stretching capacity is reduced and the bus bar is broken in operation is avoided; the center of the punch is positioned on the central line of the length direction of the bus bar, the shape of the punch can be circular, rhombic or irregular, and the side length range of the size is generally half of the width of the bus bar; because the tin layer of bottom terminal box metal face regional thickening during the welding terminal box, the tin layer melts the accessible lead-out wire trompil and spills over during the welding, forms a firm rivet structure, and the operating personnel of being convenient for patrol the visual inspection, promotes subassembly welding reliability, and subassembly product reliability also obtains promoting promptly.

Second embodiment

Referring to fig. 12, the present embodiment provides a dark photovoltaic module, which has substantially the same structure as the first embodiment except that:

the first bus bar 121, the second bus bar 122, the third bus bar 123 and the fourth bus bar 124 are all sectional dark bus bars, the front end portions of the first bus bar 121, the second bus bar 122 and the third bus bar 123 are first alloy layers 126, the front middle portion of the fourth bus bar 124 is a first alloy layer 126, an alloy layer at the head of the back of the fourth bus bar 124 is overlapped with the first alloy layer 126 at the front end portion of the first bus bar 121, an alloy layer at the tail of the back of the fourth bus bar 124 is overlapped with the first alloy layer 126 at the front end portion of the third bus bar 123, an alloy layer at the back of the second bus bar 122 is overlapped with the first alloy layer 126 at the front middle portion of the first alloy layer 126, and the end portion of the first bus bar 126 is bent and led out of the back of the second bus bar 122.

Third embodiment

Referring to fig. 13, the present embodiment provides a dark photovoltaic module, which has substantially the same structure as the first embodiment except that:

the first bus bar 121, the second bus bar 122 and the third bus bar 123 are sectional dark bus bars, the fourth bus bar 124 is a single-sided dark bus bar, an alloy layer at the head of the back of the fourth bus bar 124 is overlapped with a first alloy layer 126 at the end of the front of the first bus bar 121, an alloy layer at the middle of the back of the fourth bus bar 124 is overlapped with a first alloy layer 126 at the end of the front of the second bus bar 122, an alloy layer at the tail of the back of the fourth bus bar 124 is overlapped with a first alloy layer 126 at the end of the front of the third bus bar 123, and the second bus bar 122 is formed by bending and leading out the end of the first alloy layer 126 to the outside of the back.

In summary, the deep color photovoltaic module and the manufacturing process thereof in the embodiment of the application adopt the sectional type deep color bus bar or are matched with the single-side deep color bus bar for use, so that the lap joint passage between the bus bars is realized, and the automatic welding is convenient to realize; meanwhile, the bus bar where the outgoing line is located is also a sectional type dark bus bar, so that testing and electrifying during detection of the component are realized, and labor is saved; the heat transfer is easier during welding, the welding is firm, and the product reliability is improved.

The above description is only an example of the present application and is not intended to limit the scope of the present application, and various modifications and changes may be made by those skilled in the art. Any modification, equivalent replacement, improvement and the like made within the spirit and principle of the present application shall be included in the protection scope of the present application.

Claims

1. A dark photovoltaic component is characterized by comprising a cell layer formed by arranging a plurality of strings of cells, and a plurality of bus bars which are arranged on the front side of the cell layer and are used for connecting the cell strings to form a passage, wherein all the bus bars are sectional dark bus bars or sectional dark bus bars and single-side dark bus bars; the front side of the sectional type dark color bus bar is provided with a first alloy layer and a first dark color coating which are arranged at intervals, and the back side of the sectional type dark color bus bar is provided with an alloy layer; the front side of the single-side dark bus bar is provided with a second dark coating, and the back side of the single-side dark bus bar is provided with an alloy layer; the first alloy layer on the front side of the sectional type dark bus bar is completely covered by the alloy layers on the back sides of other bus bars and overlapped and lapped together until the front sides of the bus bars overlapped and lapped together are dark.

2. The dark photovoltaic module of claim 1, wherein at least one end of the front side of the at least one segmented dark bus bar is a first alloy layer, and the front side of the segmented dark bus bar is formed by bending an end of the first alloy layer out of the back side.

3. The dark photovoltaic module of claim 1, comprising a first bus bar, a second bus bar, a third bus bar and a fourth bus bar, wherein the first bus bar, the second bus bar and the third bus bar overlap the head, the middle and the tail of the fourth bus bar respectively, the overlapping surface of the overlapping part located above is an alloy layer, and the overlapping surface located below is a first alloy layer.

4. The dark photovoltaic module according to claim 3, wherein the first bus bar and the third bus bar are single-sided dark bus bars, the second bus bar is a sectional dark bus bar, the front end of the second bus bar is a first alloy layer, the front end of the second bus bar is bent and led out of the back surface, the fourth bus bar is a sectional dark bus bar, the front head, the middle and the tail of the fourth bus bar are first alloy layers, the rest areas are first dark coatings, and the first alloy layers on the back surfaces of the first bus bar, the second bus bar and the third bus bar are respectively overlapped with the first alloy layers on the front head, the middle and the tail of the fourth bus bar.

5. The dark photovoltaic module according to claim 3, wherein the first, second, third and fourth busbars are segmented dark busbars, the front ends of the first, second and third busbars are first alloy layers, the front middle portion of the fourth busbar is a first alloy layer, the alloy layer at the head of the back of the fourth busbar overlaps the first alloy layer at the front end of the first busbar, the alloy layer at the tail of the back of the fourth busbar overlaps the first alloy layer at the front end of the third busbar, the alloy layer at the back of the second busbar overlaps the first alloy layer at the front middle portion of the first alloy layer, and the end of the first alloy layer of the second busbar is bent and led out of the back.

6. The dark photovoltaic module of claim 1, wherein the segmented dark bus bar comprises a first substrate layer having a first alloy layer disposed on each of a front side and a back side of the first substrate layer, the first alloy layer on the front side of the first substrate layer further having a segmented first dark coating disposed thereon; the single-side deep-color bus bar comprises a second base material layer, wherein a second alloy layer is respectively arranged on the front surface and the back surface of the second base material layer, and a continuous second deep-color coating layer is further arranged on the second alloy layer on the front surface of the second base material layer.

7. The dark photovoltaic module of claim 6, wherein the first and/or second substrate layers are copper, aluminum, or copper-clad aluminum tapes; the thickness of the first base material layer and/or the second base material layer is 0.20-0.30 mm;

the thickness of the first alloy layer and/or the second alloy layer on the front surface of the first base material layer and/or the second base material layer is 20-30 μm, the thickness of the first alloy layer and/or the second alloy layer on the back surface of the first base material layer and/or the second base material layer is 5-10 μm, and the thickness of the first alloy layer between the segmented first dark-color coatings is 0-25 μm.

8. The dark photovoltaic module of claim 1 or 6, characterized in that the material of the first dark coating layer and/or the second dark coating layer is UV paint with a thickness of 15-25 μm.

9. A process for making a dark photovoltaic module according to claim 1, comprising the steps of:

10. The deep color photovoltaic module manufacturing process according to claim 9, wherein an automatic cutting machine is used to automatically cut a continuous sectional deep color bus bar into a single sectional deep color bus bar, the automatic cutting machine comprises an optical image lens and a light emitting plate which are arranged oppositely, and paired cutting knives, and the cutting method is as follows: