CN113948585A - Solar cell unit, preparation method thereof and solar cell module comprising same - Google Patents

Solar cell unit, preparation method thereof and solar cell module comprising same Download PDF

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Publication number
CN113948585A
CN113948585A CN202011578144.7A CN202011578144A CN113948585A CN 113948585 A CN113948585 A CN 113948585A CN 202011578144 A CN202011578144 A CN 202011578144A CN 113948585 A CN113948585 A CN 113948585A
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solar cell
adhesive film
film layer
layer
cell unit
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林于庭
林彦志
陈令佳
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Zhongke South Holding Co ltd
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Zhongke South Holding Co ltd
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    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01L—SEMICONDUCTOR DEVICES NOT COVERED BY CLASS H10
    • H01L31/00—Semiconductor devices sensitive to infrared radiation, light, electromagnetic radiation of shorter wavelength or corpuscular radiation and specially adapted either for the conversion of the energy of such radiation into electrical energy or for the control of electrical energy by such radiation; Processes or apparatus specially adapted for the manufacture or treatment thereof or of parts thereof; Details thereof
    • H01L31/02—Details
    • H01L31/0216—Coatings
    • H01L31/02161—Coatings for devices characterised by at least one potential jump barrier or surface barrier
    • H01L31/02167—Coatings for devices characterised by at least one potential jump barrier or surface barrier for solar cells
    • 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
    • H01L31/04—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
    • H01L31/05—Electrical interconnection means between PV cells inside the PV module, e.g. series connection of PV cells
    • H01L31/0504—Electrical interconnection means between PV cells inside the PV module, e.g. series connection of PV cells specially adapted for series or parallel connection of solar cells in a module
    • H01L31/0512—Electrical interconnection means between PV cells inside the PV module, e.g. series connection of PV cells specially adapted for series or parallel connection of solar cells in a module made of a particular material or composition of materials
    • 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
    • H01L31/054—Optical elements directly associated or integrated with the PV cell, e.g. light-reflecting means or light-concentrating means
    • H01L31/0543—Optical elements directly associated or integrated with the PV cell, e.g. light-reflecting means or light-concentrating means comprising light concentrating means of the refractive type, e.g. lenses
    • 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
    • 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
    • Y02E10/52—PV systems with concentrators
    • 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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  • Engineering & Computer Science (AREA)
  • Computer Hardware Design (AREA)
  • Physics & Mathematics (AREA)
  • Condensed Matter Physics & Semiconductors (AREA)
  • Electromagnetism (AREA)
  • General Physics & Mathematics (AREA)
  • Microelectronics & Electronic Packaging (AREA)
  • Power Engineering (AREA)
  • Life Sciences & Earth Sciences (AREA)
  • Sustainable Development (AREA)
  • Manufacturing & Machinery (AREA)
  • Sustainable Energy (AREA)
  • Photovoltaic Devices (AREA)

Abstract

The invention relates to a solar cell unit, a preparation method thereof and a solar cell module comprising the same, wherein the solar cell unit comprises a cell piece and a first layer positioned on one side of the cell piece, wherein the first layer comprises a first adhesive film layer and a substrate positioned on one side of the first adhesive film layer. The cell sheet in the solar cell unit according to the invention has less hidden cracks compared with the conventional cell sheet packaged into a solar cell module.

Description

Solar cell unit, preparation method thereof and solar cell module comprising same
Technical Field
The invention relates to a solar cell unit, which comprises a cell and a first layer positioned on one side of the cell, wherein the first layer comprises a first adhesive film layer and a substrate positioned on one side of the first adhesive film layer. The solar cell unit can prevent the subfissure of the cell, thereby reducing the probability of the subfissure of the cell in the solar cell module, slowing down the decline of the power generation efficiency of the solar cell module and prolonging the power generation service life of the solar cell module.
Background
The solar cell converts sunlight into electric energy through a photovoltaic effect, and mainly comprises a PN junction.
Common solar cell sheet materials include, but are not limited to, crystalline and amorphous silicon, CdTe, CdAs, CuInSe, CuInGaSe, dye-sensitized, and polymer thin film, among which the development of crystalline silicon (including single crystal silicon and polycrystalline silicon) based solar cells is the most mature.
The production process of the cell in the crystalline silicon solar cell mainly comprises the steps of purifying a silicon material, pulling or casting a crystal, slicing, cleaning and roughening, diffusing to form a PN junction, cleaning for the second time, preparing an anti-reflection film, printing an electrode and sintering.
In the slicing step, the silicon single crystal rod or the silicon polycrystalline ingot tends to be thinner due to cost. In addition, in the process of manufacturing a silicon chip into a battery piece, the silicon chip is subjected to high temperature, etching, film coating and the like, so that thermal stress or mechanical stress is easily remained in the silicon chip. The thin thickness and residual internal stress of the cell sheet make it easy to generate fine cracks, i.e. hidden cracks, which are not easy to be observed by naked eyes in the subsequent process. In addition to the above factors, crystal defects of the silicon chip itself are also one of the main factors causing the subfissure.
In addition, a single solar cell cannot be directly used as a power supply due to low working voltage; therefore, a plurality of solar cells are connected in series or parallel and packaged to obtain a solar cell module that can be used as an independent power source.
The manufacturing process of the solar cell module mainly comprises the steps of laying a light-permeable front cover plate, laying a first layer of light-permeable packaging adhesive film, connecting a plurality of single solar cells in series, welding the single solar cells into a serial, positioning the serial and welding the serial, laying a second layer of packaging adhesive film, laying a back plate, laminating, cutting edges, sealing edges and framing, installing a junction box and the like. The series welding machine, the laminating machine and the framing machine used in the steps directly apply acting force on the solar cell; therefore, if the processing parameters are not properly set (for example, but not limited to, the welding temperature is too high, the hardness of the welding strip is too high, and the mechanical force of pressing down the probe of the series welding machine is too large), the battery piece is difficult to resist the external stress and cause the hidden crack due to the thinning of the thickness, the residual stress in the battery piece and the like.
Specifically, for example, but not limited to, the local position of the cell is welded by heating in the series welding step, so that the temperature difference and the expansion degree between the position and the surroundings are different, and the difference mutually pulls in the same plane to cause the in-plane stress. The thinned cell has poor capability of bearing in-plane stress, and is easy to cause subfissure due to temperature difference caused by welding, and the subfissure caused by the subfissure mainly occurs near a main grid line (busbar), particularly at the head and the tail of the cell because the position has stress concentration effect. In addition, if the welding temperature is too high or the welding time is too long, the over-welding is caused, so that the subfissure and the subfissure of the main grid lines and the thin grid lines (fingers) on the front surface of the battery piece are disconnected.
The influence of the subfissure can be more or less, and the emphasis is on the shape of the crack. According to the shape of the hidden crack of the cell, the shape of the hidden crack can be divided into tree-shaped cracks, comprehensive cracks, oblique cracks, cracks parallel to the main grid lines, cracks vertical to the grid lines and cracks penetrating through the whole cell, wherein the cracks parallel to the main grid lines most easily influence the fine grid lines. If the thin grid lines are broken, the collected current cannot be transmitted to the main grid lines, so that the partial or even all of the battery piece is failed, and the efficiency of the battery piece is greatly reduced.
Therefore, a solar cell capable of preventing the cell from being hidden and cracked, and a thin, light and frameless solar module are desired in the technical field, thereby increasing the applicability of the solar module. There is also a desire in the art for a solar module that can reduce in-plane stresses, such as, but not limited to, the use of solder.
Disclosure of Invention
The invention aims to provide a solar cell unit capable of preventing a solar cell from subfissure, which additionally combines the solar cell with a subfissure-preventing film layer to improve the resistance of the solar cell to mechanical stress and thermal stress, so that the probability of subfissure of the solar cell in a solar cell module is reduced, the decline of the power generation efficiency of the solar cell module is relieved, and the power generation service life of the solar cell module is prolonged.
Another object of the present invention is to provide a method of manufacturing the above solar cell unit.
It is still another object of the present invention to provide a solar cell module including the above solar cell unit, wherein the bonding between the solder ribbon and the electrode wire is partially or completely replaced by a non-soldering method, such as but not limited to a thermal bonding or an adhesive bonding.
Additional aspects and advantages of the embodiments will be set forth in part in the description which follows, and in part will be obvious from the description, or may be learned by practice of the embodiments.
Drawings
The drawings necessary for describing the embodiments of the present application or the prior art will be briefly described below. The drawings are only some of the embodiments in the present application. Other embodiments can be made based on the structures illustrated in the drawings without undue experimentation by those skilled in the art.
FIG. 1: the solar cell unit comprises a first anti-subfissure glue film layer and an anti-subfissure substrate.
FIG. 2: the solar cell unit shown in fig. 1, wherein the first adhesive film layer covers the solder strip.
FIG. 3: the solar cell unit of fig. 1 further comprises a second adhesive film layer.
FIG. 4: the solar cell unit shown in fig. 3, wherein the adhesive film layer covers the solder strip.
FIG. 5: the solar cell unit shown in fig. 3, wherein the second adhesive film layer is covered with an optical film.
FIG. 6: in the prior art, the welding strip and the battery plate are directly connected through welding.
FIG. 7: according to a specific aspect of the method for manufacturing a battery cell of the present invention, the solder strip is aligned with the electrode wire on the battery piece, and then the subfissure prevention thin film layer is bonded to the battery piece, wherein the aligned solder strip and the electrode wire are bonded to each other by bonding the subfissure prevention thin film layer to the battery piece.
FIG. 8: according to another embodiment of the method for manufacturing a battery unit of the present invention, the solder strip is aligned with the anti-subfissure film layer according to the size and the spacing of the electrode wires on the battery piece, and then the solder strip is bonded to the battery piece and the anti-subfissure film layer, wherein the solder strip and the electrode wires are bonded due to the bonding of the anti-subfissure film layer to the battery piece.
FIG. 9: according to another embodiment of the method for manufacturing a battery unit of the present invention, the anti-subfissure film layer is bonded to the battery piece first, wherein the anti-subfissure film layer has a plurality of openings, and the positions of the openings are configured to coincide with the positions of the electrode wires on the battery piece so as to bond the solder strips to the electrode wires through the openings.
FIG. 10: a string of cells comprising prior art solar cells.
FIG. 11: a solar cell module comprising the string of cells of fig. 10.
FIG. 12: a string of cells comprising the solar cell unit of fig. 2 of the present invention.
FIG. 13: a string of cells comprising the solar cell unit of fig. 4 of the present invention.
FIG. 14: a solar cell module comprising the string of solar cells of fig. 12.
FIG. 15: a solar cell module comprising the string of solar cells of fig. 13.
FIG. 16: the EL images of the solar cell according to the prior art before and after the impact test are shown, wherein the left image is the EL image before the impact test and the right image is the EL image after the impact test.
FIG. 17: the solar cell unit according to the present invention is subjected to EL images before and after the impact test, wherein the left image is the EL image before the impact test and the right image is the EL image after the impact test.
FIG. 18: another solar cell unit according to the present invention is EL images before and after the impact test, wherein the left image is the EL image before the impact test and the right image is the EL image after the impact test.
Detailed Description
To facilitate understanding of the disclosure set forth herein, several terms are defined below.
In the present disclosure, the term "about" means an acceptable error in the value determined by one of ordinary skill in the art, which in part depends on how the value is measured or determined.
In the present invention, the term "cell" means a solar cell that converts sunlight into electrical energy through the photovoltaic effect, such as, but not limited to, a crystalline silicon solar cell.
In the present invention, the term "solar cell" corresponds to a combination of a cell and a subfissure-preventing film layer, and can be regarded as a cell in a packaging process of a solar cell module.
Solar cell unit
Compared with the prior art, the solar cell unit according to the invention further comprises a first anti-hidden cracking film layer (hereinafter referred to as a first layer (6)) in addition to the cell sheet (1) as shown in fig. 1, wherein the first anti-hidden cracking film layer comprises a first anti-hidden cracking adhesive film layer (hereinafter referred to as a first adhesive film layer (7)) and an anti-hidden cracking substrate (hereinafter referred to as a substrate (8)), and the first layer is preferably positioned on the back surface of the cell sheet.
Compared with the prior art cell, the solar cell unit has stronger mechanical stress resistance. Therefore, after the battery cell is packaged into a module, the mechanical load capacity of the module is also improved, and the probability of hidden cracking of the battery cell can be reduced.
Battery piece (1)
The cell material used in the solar cell unit according to the present invention is not particularly limited, and can be easily selected by those skilled in the art, such as but not limited to crystalline silicon solar cells, amorphous silicon, CdTe, CdAs, CuInSe, CuInGaSe, dye-sensitized and polymer thin film cells, and the like. The solar cell according to the invention is particularly suitable for crystalline silicon solar cells, which may be monocrystalline silicon or polycrystalline silicon solar cells.
The thickness of the cell sheet used for the solar cell unit according to the present invention is not particularly limited. The solar cell unit according to the invention is particularly suitable for use in a cell sheet having a thickness of not more than about 180 micrometers, more preferably not more than about 150 micrometers, even more preferably not more than about 120 micrometers.
First film layer (7)
The material of the first adhesive film used in the solar cell unit according to the present invention is not particularly limited, and can be easily selected by those skilled in the art, such as but not limited to EVA (ethylene vinyl acetate copolymer resin), POE (polyolefin elastomer resin), PVB (polyvinyl butyral resin), silicone adhesive resin, epoxy resin adhesive, acrylic adhesive, and the like. The first adhesive film layer material used in the invention can be the same as or different from the packaging material used by the subsequent solar cell module.
The first adhesive film layer according to the present invention may have no or open pores; if openings are provided, the positions of the openings are preferably arranged to coincide with the positions of the electrode lines on the cell plates.
According to one embodiment of the present invention, the first adhesive film layer may have more than two openings per square centimeter (such as, but not limited to, a honeycomb structure).
The thickness of the first adhesive film used in the solar cell unit according to the present invention is not particularly limited, and is preferably about 50 to 1000 micrometers, more preferably about 150 to 500 micrometers, and even more preferably about 250 to 400 micrometers.
Base plate (8)
The solar cell unit comprises a substrate, so that at least one layer of material which is different from the first adhesive film layer and is different from the packaging adhesive film exists between the first adhesive film layer and the packaging adhesive film laid in the subsequent packaging process of the solar cell module.
The substrate material used in the solar cell unit according to the present invention is different from the first glue film material, but can be easily selected by those skilled in the art, such as but not limited to metals (such as but not limited to gold, silver, copper, iron, tin, stainless steel or alloys of aluminum, magnesium or titanium, etc.), ceramics (such as but not limited to aluminum oxide, aluminum nitride, boron nitride or zirconium oxide, etc.), organic plastics (such as but not limited to PET, PC, PE, PVC or PP, etc.), glass fiber reinforced thermosetting plastics, carbon fiber reinforced thermosetting plastics, glass cloth, glass or other composite materials. The substrate material used in the solar cell unit according to the present invention is preferably a material with excellent thermal conductivity and/or air tightness, such as, but not limited to, metal or ceramic.
The thickness of the substrate used in the solar cell unit according to the present invention is not particularly limited, and is preferably about 10 to 1000 micrometers, more preferably about 20 to 100 micrometers, and still more preferably about 30 to 50 micrometers.
The substrate according to the invention may have no or openings; if openings are provided, the positions of the openings are preferably arranged to coincide with the positions of the electrode lines on the cell plates.
According to one embodiment of the present invention, the substrate may have more than two openings per square centimeter (e.g., without limitation, a honeycomb structure).
In an embodiment of the invention, the substrate used in the solar cell unit according to the invention has a rough design with uneven microstructure on the surface contacting with the first adhesive film layer, and the rough design can improve the combination of the substrate and the first adhesive film layer.
In one embodiment of the present invention, as shown in fig. 2, the first adhesive film layer covers the solder ribbon (for example, but not limited to 9).
In an embodiment of the invention, the first adhesive film layer covers the solder strip and the solder strip contacts the substrate.
The material of the solder strip covered by the first adhesive film layer in the solar cell unit according to the present invention is not particularly limited, and can be easily selected by those skilled in the art, such as but not limited to copper, tin, silver, lead, bismuth or their combination.
The welding strip coated by the first adhesive film layer in the solar cell unit can be used for connecting main grid lines and main grid lines or connecting cell slices and cell slices.
In one embodiment of the present invention, as shown in fig. 3, the solar cell further includes a second adhesive film layer (10), which is preferably located on the front surface of the cell sheet.
The material of the second adhesive film used in the solar cell unit according to the present invention is not particularly limited, and can be easily selected by those skilled in the art, such as but not limited to EVA (ethylene vinyl acetate copolymer resin), POE (polyolefin elastomer resin), PVB (polyvinyl butyral resin), silicone adhesive resin, epoxy resin adhesive, acrylic adhesive, and the like. The second adhesive film layer material used by the solar cell unit of the invention preferably has high light transmission property, and can improve the quantity of sunlight incident into the cell slice, thereby helping to increase the power generation efficiency of the solar cell module. The material of the second adhesive film layer used in the invention can be the same as or different from the packaging material used by the subsequent solar cell module, and also can be the same as or different from the material of the first adhesive film layer.
The thickness of the second adhesive film used in the solar cell unit according to the present invention is not particularly limited, and is preferably about 50 to 1000 micrometers, more preferably about 150 to 750 micrometers, and even more preferably about 250 to 650 micrometers. The thickness of the second adhesive film layer material used in the invention can be the same as or different from that of the first adhesive film layer.
The second adhesive film layer according to the present invention may have no or open pores; if openings are provided, the positions of the openings are preferably arranged to coincide with the positions of the electrode lines on the cell plates.
According to one embodiment of the present invention, the second adhesive film layer may have more than two openings per square centimeter (such as, but not limited to, a honeycomb structure).
In one embodiment of the present invention, as shown in fig. 4, the second glue film layer covers the solder strip (for example, but not limited to 9).
The solder strip material covered by the second adhesive film layer in the solar cell unit according to the present invention is not particularly limited, and can be easily selected by those skilled in the art, such as but not limited to copper, tin, silver, lead, bismuth or their combination.
The welding strip material coated by the second adhesive film layer in the solar cell unit can be used for connecting main grid lines and main grid lines or connecting cell slices and cell slices.
In one embodiment of the present invention, as shown in fig. 5, the second adhesive film layer is covered with an optical film (11).
The optical thin film material used in the solar cell according to the present invention is not particularly limited, such as but not limited to a PET film material coated with a multi-layer oxide thin film structure to increase the sunlight incident on the solar cell, or a PET film material having a concave-convex structure on its surface to increase the sunlight incident on the solar cell, and the optical thin film preferably forms a light-focusing structure with a front cover plate of a subsequent process, such as but not limited to a fresnel lens structure.
Method for manufacturing solar cell unit
According to the method for manufacturing the solar cell unit, the solar cell unit further comprises the hidden crack prevention thin film layer, so that an additional step is required, the hidden crack prevention thin film layer is mainly jointed with the cell piece, if a welding strip exists, the welding strip in the solar cell unit is accurately aligned with the electrode wire on the cell piece, the jointing of the welding strip and the electrode wire can be completed through the jointing of the hidden crack prevention thin film layer and the cell piece, and the secondary jointing can be locally performed according to the condition, so that the jointing between the welding strip and the electrode wire is improved.
According to the method for manufacturing the solar cell unit, the solder strip and the electrode wire can be jointed without welding, so that the stress remained on the cell can be reduced, and the probability of the cell to generate subfissure in the packaging process or after the packaging process can be reduced.
The preparation method of the solar cell unit comprises the following steps:
the first adhesive film layer and the substrate are jointed into a first anti-subfissure film layer (hereinafter referred to as a first layer); and
at least one selected from the group consisting of:
aligning a solder strip with an electrode wire on a cell, and bonding the first layer obtained in step (a) to the cell, wherein the aligned solder strip and the electrode wire are bonded by the bonding of the first layer to the cell, optionally locally reinforcing the bonding to improve the bonding between the solder strip and the electrode wire, and wherein the first adhesive film layer and the substrate may be perforated or not perforated, preferably not perforated (see fig. 7);
firstly, placing a welding strip on the first layer obtained in the step (A) according to the size and the spacing position of electrode wires on the battery piece, and then jointing the first layer with the battery piece, wherein the welding strip and the electrode wires are jointed due to the jointing of the first layer and the battery piece, and the jointing is locally strengthened according to the situation so as to improve the jointing between the welding strip and the electrode wires, wherein the first adhesive film layer and the substrate can be respectively provided with or without holes, preferably without holes (see fig. 8); and
bonding the first layer obtained in the step (a) to a battery piece, wherein the first adhesive film layer and/or the substrate has a plurality of openings and the positions of the plurality of openings are configured to coincide with the positions of electrode wires on the battery piece so as to bond a solder strip to the electrode wires from the openings (see fig. 9);
wherein in step (a), the first adhesive film layer and the substrate are bonded to each other by, for example, but not limited to, plating (such as, but not limited to, screen printing, spin coating, slot coating, dip coating, extrusion coating) or thermal bonding (such as, but not limited to, roll-to-roll infrared heating, roll-to-roll hot air heating);
wherein in step (B), the bonding of the battery piece to the first layer may be, for example, but not limited to, heat bonding at a temperature of preferably 60 to 250 ℃, more preferably 100 to 150 ℃, or adhesive bonding, and optionally, local secondary bonding by, for example, but not limited to, a heater, to improve the bonding between the solder ribbon and the electrode wire; and
wherein the solder ribbon can be bonded to the electrode wires on the battery plate by, for example, but not limited to, thermal bonding and/or adhesive bonding and/or welding, preferably the solder ribbon is precisely bonded to the electrode wires on the battery plate only by thermal bonding and/or adhesive bonding, more preferably the solder ribbon is precisely bonded to the electrode wires on the battery plate only by thermal bonding, wherein the heating temperature is preferably 60 to 250 ℃, more preferably 100 to 150 ℃.
According to an embodiment of the present invention, the battery plate and the first layer are bonded by heating, wherein when the battery plate and the first layer are pressed by heating, the metal particles in the first layer are crushed, so that the electrode wires on the battery plate and the solder strip are tightly bonded, wherein the heating temperature is preferably 60 to 250 ℃, and more preferably 100 to 150 ℃. By using the method to prepare the solar cell unit, stress effects, such as but not limited to thermal stress and in-plane stress, generated when the welding strip is connected with the electrode on the cell piece in a combined mode can be reduced.
According to an embodiment of the present invention, the method further comprises bonding the second adhesive film layer to the other side of the battery piece, such as but not limited to, by heating, wherein the bonding temperature is preferably 60 to 250 ℃, more preferably 100 to 150 ℃.
According to an embodiment of the present invention, the second adhesive film layer covers the solder strip.
Solar cell module
The solar cell module according to the present invention can be manufactured by processing a single cell into a solar cell unit by the above-mentioned method for manufacturing a solar cell unit, and then by a conventional solar cell module packaging process. In the conventional solar cell module, the cell and the solder ribbon are connected in series to form a cell string (as shown in fig. 10), and the cell string is soldered and packaged to form the conventional solar cell module (as shown in fig. 11).
The solar cell module according to the present invention comprises a plurality of solar cell strings, wherein the plurality of solar cell strings, as shown in fig. 12 or 13, comprise the solar cell unit according to the present invention.
According to an embodiment of the present invention, the solar cell module further includes a front cover plate (12), a first adhesive packaging film (14), a second adhesive packaging film (14), and a back plate (13).
According to an embodiment of the present invention, the solar cell module sequentially comprises a front cover plate (12), a first packaging adhesive film (14), a solar cell string as shown in fig. 12, a second packaging adhesive film (14) and a back plate (13), and wherein the front cover plate (12) and the first packaging adhesive film (14) further preferably comprise an optical film therebetween, and the optical film preferably forms a light-focusing structure with the front cover plate, such as but not limited to a fresnel lens structure.
Front cover board (12)
The material of the front cover plate used in the solar cell module according to the present invention is not particularly limited, and can be easily selected by those skilled in the art, such as but not limited to high light-transmitting polymer plastic or high light-transmitting tempered glass, preferably high light-transmitting polymer plastic. The solar cell unit of the invention has stronger capability of resisting mechanical stress, so the requirement on the strength of the front cover plate can be reduced, the thickness of the front cover plate can be reduced, and thin plastic film materials can be optionally used, such as but not limited to ETFE film materials, PVDF film materials, PTFE film materials, organic silica gel film materials, PET film materials or composite film materials formed by double-double bonding of the film materials, and the aim of thinning, lightening and frameless solar cell module can be achieved by the protective film of the front cover plate.
Back plate (13)
The material of the back sheet used in the solar cell module according to the present invention is not particularly limited, and can be easily selected by those having ordinary skill in the art, such as but not limited to polymer plastic.
First and second packaging adhesive films (14)
The material of the adhesive film for encapsulation used in the solar cell module of the present invention is not particularly limited, and can be easily selected by those skilled in the art, such as but not limited to EVA (ethylene vinyl acetate copolymer resin), POE (polyolefin elastomer resin), PVB (polyvinyl butyral resin), silicone resin, epoxy resin adhesive, acrylic adhesive, etc.
Compared with the conventional solar cell module, the solder strip is only covered by the packaging adhesive film (fig. 11), the solder strip of the solar cell module according to the invention is additionally covered by the first adhesive film layer and at least one layer different from the packaging adhesive film material exists between the back plate and the cell as the substrate as shown in fig. 14 or fig. 15.
Examples of the invention
Subfissure is not easily observed by naked eyes. Therefore, Electroluminescence (EL) is often used in the art to detect internal defects of a solar cell or a module. The EL utilizes the electroluminescence principle of crystalline silicon, obtains a near-infrared image through a high-resolution infrared camera shooting assembly, and can simply and effectively detect the subfissure from the image. The black non-luminous region in the EL image is called the "dead region". The dead zone can not generate electricity, so the current generated by the cell with the dead zone is relatively small, and the generated power of the whole module is reduced. When the dead area of the cell is too large, not only the power of the cell is reduced, but also the loss is amplified after the cell is connected in series. The dead zone not only can reduce the power generation, but also can cause overheating and burn out the module if the area is too large.
Test experiments: falling ball impact test
Steel ball for experiment: the weight was 227 grams and the sphere diameter was 3.8 cm.
Falling ball impact test height: 50 cm.
Sample one (comparative example): transparent plastic front cover plate (300 microns)/POE film (500 microns)/crystalline silicon solar cell piece (150 microns)/POE film (500 microns)/plastic photovoltaic back plate (350 microns).
Sample two (inventive example): transparent plastic front cover plate (300 microns)/POE film (500 microns)/battery unit A (480 microns)/POE film (500 microns)/plastic photovoltaic back plate (350 microns), wherein the structure of the battery unit A is crystalline silicon solar battery piece (150 microns)/first adhesive film layer-POE (300 microns)/stainless steel film substrate (30 microns).
Sample three (inventive example): transparent plastic front cover plate (300 microns)/POE film (500 microns)/battery unit B (500 microns)/POE film (500 microns)/plastic photovoltaic back plate (350 microns), wherein the structure of the battery unit B is crystalline silicon solar battery piece (150 microns)/first adhesive film layer-POE (300 microns)/stainless steel film substrate (50 microns).
Summary of test results to table 1 below:
Figure BDA0002865041930000101
the first sample (comparative example) has a weak ability to withstand falling ball gravity impact, so that the crystalline silicon cell forms a relatively large-area subfissure region due to external stress, wherein the occupation area of the black dead region is large.
In the case of the second and third samples (inventive examples), which are the battery cells according to the present invention (i.e., the battery cells are combined with the first adhesive film layer and the substrate (30 μm/50 μm stainless steel sheet material)), it can be found through the falling ball gravity impact test that the crystalline silicon battery cells in the battery cells according to the present invention form a relatively small-area subfissure region after being subjected to external stress, and the specific area of the black dead region is also small.
From the above results, it can be seen that the cell unit according to the present invention can bear stronger external stress than that of a single crystalline silicon cell, and reduce the occurrence probability of subfissure of the crystalline silicon cell and the area of black dead zone. The solar cell module using the cell unit can reduce the probability of subfissure caused by external stress, thereby reducing power attenuation and prolonging service life.
From the above results, the battery unit according to the present invention improves the stress resistance of the single battery cell through the first adhesive film layer and the substrate, and the thickness of the substrate also has the stress resistance, and the effect of improving the thickness is more obvious.
Assembly of the drawings
1: battery piece
2, the front surface of the battery piece
3, back surface of battery piece
4: upper electrode wire
5 lower electrode wire
6 the first layer (first anti-crazing film layer)
7 the first adhesive film layer (first anti-hidden crack adhesive film layer)
8 base plate (anti-hidden crack base plate)
9: solder strip
10 the second adhesive film layer (second anti-hidden crack adhesive film layer)
11 optical film
12 front cover plate
13 back plate
14 packaging adhesive film
15, a hole opening position

Claims (12)

1. A solar cell unit comprises a cell piece and a first layer positioned on one side of the cell piece, wherein the first layer comprises a first adhesive film layer and a substrate positioned on one side of the first adhesive film layer.
2. The solar cell unit of claim 1, wherein the first adhesive film layer covers the solder ribbon.
3. The solar cell unit of claim 2, wherein the solder ribbon is in contact with the substrate.
4. The solar cell unit according to any one of claims 1 to 3, wherein the substrate is made of a material different from that of the first adhesive film layer.
5. The solar cell unit according to any one of claims 1 to 3, wherein a surface of the substrate in contact with the first adhesive film layer has a concavo-convex microstructure.
6. The solar cell unit of any one of claims 1-3, further comprising a second adhesive film layer on the other side of the cell sheet.
7. The solar cell unit of claim 6, wherein the second adhesive film layer covers the solder ribbon.
8. The solar cell unit of claim 6, wherein one side of the second adhesive film layer is covered with an optical film.
9. The solar cell unit of claim 8, wherein the optical film is a light-concentrating film.
10. A method of making the solar cell unit of any one of claims 1-9, comprising the steps of:
bonding the first adhesive film layer and the substrate into a first layer; and
at least one selected from the group consisting of:
aligning a solder strip with an electrode wire on a cell, and then bonding the first layer obtained in the step (A) with the cell, wherein the aligned solder strip and the electrode wire are bonded because the first layer is bonded with the cell, and the bonding is locally strengthened according to the situation so as to improve the bonding between the solder strip and the electrode wire, and the first adhesive film layer and the substrate can be respectively perforated or not perforated;
firstly, placing a welding strip on the first layer obtained in the step (A) according to the size and the spacing position of electrode wires on the battery piece, and then jointing the first layer with the battery piece, wherein the welding strip and the electrode wires are jointed due to the jointing of the first layer and the battery piece, and the jointing is locally strengthened according to the situation so as to improve the jointing between the welding strip and the electrode wires, wherein the first adhesive film layer and the substrate can be respectively provided with holes or not provided with holes; and
and (b) bonding the first layer obtained in the step (a) with a battery piece, wherein the first adhesive film layer and/or the substrate is provided with a plurality of openings, and the positions of the plurality of openings are configured to coincide with the positions of electrode wires on the battery piece so as to bond a welding strip with the electrode wires from the openings.
11. A solar cell module comprising a plurality of strings of solar cells, wherein the plurality of strings of solar cells comprise the solar cell unit according to any one of claims 1-9.
12. The solar cell module of claim 11, further comprising a front cover plate and an optical film, and the front cover plate and the optical film form a light-concentrating structure.
CN202011578144.7A 2020-06-30 2020-12-28 Solar cell unit, preparation method thereof and solar cell module comprising same Pending CN113948585A (en)

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