CN114843370A - Packaging method of solar cell module - Google Patents
Packaging method of solar cell module Download PDFInfo
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- CN114843370A CN114843370A CN202210478071.7A CN202210478071A CN114843370A CN 114843370 A CN114843370 A CN 114843370A CN 202210478071 A CN202210478071 A CN 202210478071A CN 114843370 A CN114843370 A CN 114843370A
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- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01L—SEMICONDUCTOR DEVICES NOT COVERED BY CLASS H10
- H01L31/00—Semiconductor devices sensitive to infrared radiation, light, electromagnetic radiation of shorter wavelength or corpuscular radiation and specially adapted either for the conversion of the energy of such radiation into electrical energy or for the control of electrical energy by such radiation; Processes or apparatus specially adapted for the manufacture or treatment thereof or of parts thereof; Details thereof
- H01L31/18—Processes or apparatus specially adapted for the manufacture or treatment of these devices or of parts thereof
-
- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01L—SEMICONDUCTOR DEVICES NOT COVERED BY CLASS H10
- H01L21/00—Processes or apparatus adapted for the manufacture or treatment of semiconductor or solid state devices or of parts thereof
- H01L21/67—Apparatus specially adapted for handling semiconductor or electric solid state devices during manufacture or treatment thereof; Apparatus specially adapted for handling wafers during manufacture or treatment of semiconductor or electric solid state devices or components ; Apparatus not specifically provided for elsewhere
- H01L21/67005—Apparatus not specifically provided for elsewhere
- H01L21/67242—Apparatus for monitoring, sorting or marking
- H01L21/67271—Sorting devices
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- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01L—SEMICONDUCTOR DEVICES NOT COVERED BY CLASS H10
- H01L31/00—Semiconductor devices sensitive to infrared radiation, light, electromagnetic radiation of shorter wavelength or corpuscular radiation and specially adapted either for the conversion of the energy of such radiation into electrical energy or for the control of electrical energy by such radiation; Processes or apparatus specially adapted for the manufacture or treatment thereof or of parts thereof; Details thereof
- H01L31/04—Semiconductor devices sensitive to infrared radiation, light, electromagnetic radiation of shorter wavelength or corpuscular radiation and specially adapted either for the conversion of the energy of such radiation into electrical energy or for the control of electrical energy by such radiation; Processes or apparatus specially adapted for the manufacture or treatment thereof or of parts thereof; Details thereof adapted as photovoltaic [PV] conversion devices
- H01L31/042—PV modules or arrays of single PV cells
- H01L31/048—Encapsulation of modules
- H01L31/0488—Double glass encapsulation, e.g. photovoltaic cells arranged between front and rear glass sheets
-
- 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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- Condensed Matter Physics & Semiconductors (AREA)
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- Power Engineering (AREA)
- Electromagnetism (AREA)
- Manufacturing & Machinery (AREA)
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Abstract
The invention relates to the technical field of solar cell manufacturing, and particularly provides a packaging method of a solar cell module, which comprises the following steps: forming an initial stacked assembly; performing defect inspection on the initial laminated assembly to screen out a defective initial laminated assembly and a qualified initial laminated assembly; forming a sealant layer surrounding the first encapsulant layer, the solar cell set and the second encapsulant layer at an edge region between the first encapsulant layer and the second encapsulant layer of the qualified initial stacked assembly; after the sealant layer is formed, the initial stacked assembly is laminated. The packaging method of the solar cell module is high in packaging efficiency and yield.
Description
Technical Field
The invention relates to the technical field of solar cell manufacturing, in particular to a packaging method of a solar cell module.
Background
The solar cell is a mode for realizing solar power generation by utilizing a photovoltaic power generation principle, and is an environment-friendly energy mode. Generally, after a solar cell is manufactured, a solar cell assembly is formed through the process steps of forming a solar cell group through an inter-sheet interconnection process, forming a to-be-packaged laminated member through a lamination process, heating and curing each packaged laminated member through a lamination process, and the like, and is packaged with the solar cell into a whole. In a solar power station, the unit for generating electricity is a solar cell module. In order to obtain better solar illumination, solar power stations are generally arranged outdoors and are subjected to various weathers such as wind, frost, rain, snow and the like.
In order to prevent the solar cell from being influenced by water vapor to reduce the photoelectric conversion efficiency and prolong the service life of the solar cell, sealant is added to protect the solar cell during packaging of the solar cell module in the prior art. In general, in the lamination process, a sealant is coated on the edge of a glass plate, and then a structure such as a glue film, a solar cell set, and a glue film is sequentially placed on the front surface. In the solar cell module after the lamination process, glue films, sealant and the like in the laminated member are integrated with the glass and the solar cell set, and a sealing glue layer is formed on the periphery of the laminated member. On one hand, the packaging performance of the solar cell module is usually tested after the lamination is completed, and once the solar cell module with defects is required to be repaired after the solar cell module is unqualified, the unqualified packaging structure needs to be removed so as to take out the solar cell module for re-packaging. However, due to the hot melting of the adhesive film and the sealant, the structures of the laminated member are firmly bonded together, so that the possibility of solar cell cracking during separation is increased, and the difficulty of removing the sealant due to adhesion is increased, so that the packaging efficiency and yield of the solar cell module are greatly reduced. On the other hand, the sealant is heated, melted and cooled in the lamination process to achieve the packaging effect, and in the time period from the completion of sealant application to the start of lamination, the sealant is easily affected by the environment, the timeliness is poor, and the sealing effect is affected.
Therefore, the packaging method of the solar cell module in the prior art needs to be improved.
Disclosure of Invention
Therefore, the technical problem to be solved by the present invention is to overcome the problem of low packaging efficiency and yield of the solar cell module in the prior art.
In order to solve the above technical problem, the present invention provides a method for encapsulating a solar cell module, including: forming an initial stacked assembly, the step of forming the initial stacked assembly comprising: the solar cell module comprises a first packaging layer, a first packaging adhesive layer, a solar cell array, a second packaging adhesive layer and a second packaging layer which are sequentially arranged from bottom to top, wherein the side walls of the first packaging adhesive layer, the solar cell array and the second packaging adhesive layer are recessed relative to the side wall of the first packaging layer and the side wall of the second packaging layer; performing defect inspection on the initial laminated assembly to screen out a defective initial laminated assembly and a qualified initial laminated assembly; forming a sealant layer surrounding the first encapsulant layer, the solar cell set and the second encapsulant layer at an edge region between the first encapsulant layer and the second encapsulant layer of the qualified initial stacked assembly; after the sealant layer is formed, the initial stacked assembly is laminated.
Optionally, the step of forming a sealant layer surrounding the first encapsulant layer, the solar cell array, and the second encapsulant layer in an edge region between the first encapsulant layer and the second encapsulant layer of the qualified initial stacked assembly includes: providing a sealant material; heating the sealant material to melt the sealant material; the sealant material after melting is applied laterally to the edge region between the first and second encapsulant layers of the initial laminate assembly.
Optionally, the sealant material is coated by a gluing device; the gluing device comprises a pneumatic glue gun.
Optionally, in the step of heating the sealant material, the temperature of the sealant material is 110 to 140 ℃.
Optionally, the width of the sealant layer is set to 3mm to 6mm before the initial laminated assembly is laminated.
Optionally, the sealant layer is set to a thickness of 0.5mm to 3.5mm before the initial laminated assembly is laminated.
Optionally, before laminating the initial stacked assembly, a distance between an inner side wall of the sealant layer and a side wall of the first encapsulation adhesive layer is set to be 3mm to 5 mm.
Optionally, before laminating the initial stacked assembly, setting a distance between an edge of the first encapsulation glue layer and an edge of the first encapsulation layer to be 8 mm-10 mm.
Optionally, the performing defect inspection on the initial laminated assembly includes: and any one or more of appearance detection, hidden crack detection and cold solder joint detection.
Optionally, the sealant layer includes at least a butyl sealant layer.
Optionally, the first packaging layer is placed in sequence from bottom to top, the first packaging adhesive layer, the solar battery pack, the second packaging adhesive layer and the second packaging layer are arranged in sequence, and the second packaging adhesive layer further extends to cover the side wall surface of the solar battery pack.
The technical scheme of the invention has the following advantages:
according to the packaging method of the solar cell module, the initial laminated module is subjected to defect inspection so as to screen out the defective initial laminated module and the qualified initial laminated module; and forming a sealing adhesive layer surrounding the first packaging adhesive layer, the solar cell array and the second packaging adhesive layer in the edge area between the first packaging layer and the second packaging layer of the qualified initial laminated assembly, wherein the sealing adhesive layer is formed in the qualified initial laminated assembly, so that when the defective initial laminated assembly is repaired, because the sealing adhesive layer is not arranged between the first packaging layer and the second packaging layer, the difficulty of separating the first packaging layer from the second packaging layer during the repair is reduced, and the probability of the solar cell array from being hidden and broken due to excessive force applied during the separation is also reduced, therefore, the packaging efficiency and the yield of the packaging method of the solar cell assembly are high.
Drawings
In order to more clearly illustrate the embodiments of the present invention or the technical solutions in the prior art, the drawings used in the embodiments or the prior art descriptions will be briefly described below, and it is obvious that the drawings in the following description are some embodiments of the present invention, and other drawings can be obtained by those skilled in the art without creative efforts.
Fig. 1 is a flowchart illustrating a method for packaging a solar cell module according to an embodiment of the present invention;
FIG. 2 is a schematic structural diagram of an initial stacked assembly according to an embodiment of the present invention;
FIG. 3 is a schematic diagram illustrating a sealant layer forming method in the prior art;
FIG. 4 is a schematic diagram illustrating a sealant layer forming method according to an embodiment of the present invention;
FIG. 5 is a schematic structural diagram of an initial laminated assembly after forming a sealant layer according to an embodiment of the present invention;
fig. 6 is a schematic structural diagram of a solar cell module according to an embodiment of the invention.
Description of reference numerals:
101-a first encapsulation layer; 102-a second encapsulation layer; 103-a first packaging adhesive layer; 104-a second packaging adhesive layer; 105-a solar cell set; 200-sealing adhesive layer; j-a gluing device; w-width; t-thickness; l1-distance; l2-distance.
Detailed Description
The technical solutions of the present invention will be described clearly and completely with reference to the accompanying drawings, and it should be understood that the described embodiments are some, but not all embodiments of the present invention. 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 invention.
In the description of the present invention, it should be noted that the terms "center", "upper", "lower", "left", "right", "vertical", "horizontal", "inner", "outer", etc., indicate orientations or positional relationships based on the orientations or positional relationships shown in the drawings, and are only for convenience of description and simplicity of description, but do not indicate or imply that the device or element being referred to must have a particular orientation, be constructed and operated in a particular orientation, and thus, should not be construed as limiting the present invention. Furthermore, the terms "first," "second," and "third" are used for descriptive purposes only and are not to be construed as indicating or implying relative importance.
In the description of the present invention, it should be noted that, unless otherwise explicitly specified or limited, the terms "mounted," "connected," and "connected" are to be construed broadly, e.g., as meaning either a fixed connection, a removable connection, or an integral connection; 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 meanings of the above terms in the present invention can be understood in specific cases to those skilled in the art.
In addition, the technical features involved in the different embodiments of the present invention described below may be combined with each other as long as they do not conflict with each other.
The invention provides a solar cell module, which comprises the following steps with reference to fig. 1:
step S1: forming an initial stacked assembly, the step of forming the initial stacked assembly comprising: the solar cell module comprises a first packaging layer, a first packaging adhesive layer, a solar cell array, a second packaging adhesive layer and a second packaging layer which are sequentially arranged from bottom to top, wherein the side walls of the first packaging adhesive layer, the solar cell array and the second packaging adhesive layer are recessed relative to the side wall of the first packaging layer and the side wall of the second packaging layer;
step S2: performing defect inspection on the initial laminated assembly to screen out a defective initial laminated assembly and a qualified initial laminated assembly;
step S3: forming a sealing adhesive layer surrounding the first packaging adhesive layer, the solar cell set and the second packaging adhesive layer in the edge area between the first packaging layer and the second packaging layer of the qualified initial laminated assembly;
step S4: after the sealant layer is formed, the initial stacked assembly is laminated.
In the existing packaging method of the solar cell module, the formation of the sealing adhesive layer is to adopt a mode of sticking a sealing adhesive tape around glass, and then put in an adhesive film, a solar cell module and back panel glass to form an initial laminated module, the defects of the method are mainly focused on the problem of repairing the defective solar cell module after the defect detection of the initial laminated module, because once the laminated solar cell module needs to be repaired, the solar cell piece needs to be separated from the solar cell module, at the moment, the glass and the back panel glass in the laminated solar cell module are adhered by the sealing adhesive tape, the separation difficulty is increased, if the force is not proper in the separation process, the solar cell piece in the solar cell module can be deviated or hidden and cracked, meanwhile, the sealing adhesive tape remains on the separated glass and the back panel glass, the cleaning of the residual adhesive sealing tape can seriously reduce the production progress of the solar cell module.
The method for packaging a solar cell module provided in this embodiment detects the structure and the qualification of each laminate set in the lamination process, and repairs the package in time if a problem is found, instead of detecting and repairing the package after the lamination process is completed. Therefore, the detection is carried out before the sealant is not formed (the lamination process is not started certainly), once a problem is found, the defective initial laminated assembly is repaired, and because the sealant layer is not arranged between the first packaging layer and the second packaging layer, the difficulty of separating the first packaging layer from the second packaging layer during the repair is reduced, and the probability of the solar battery pack from being hidden and broken due to the fact that excessive force is applied during the separation is reduced, so that the packaging efficiency and the yield of the packaging method of the solar battery pack are high.
In step S1, specifically, referring to fig. 2, the step of forming the initial stacked assembly includes: providing a first packaging layer 101, a second packaging layer 102, a first packaging adhesive layer 103, a second packaging adhesive layer 104 and a solar cell set 105; place on first encapsulation layer 101 first encapsulation glue film 103 is in the back of the face of one side of first encapsulation layer 101 is placed solar cell set 105 is in the back of the face of one side of first encapsulation layer 101 is placed to solar cell set 105 second encapsulation glue film 104 is in the back of the face of one side of first encapsulation layer 101 is placed second encapsulation layer 102, first encapsulation glue film 103, solar cell set 105 and the lateral wall of second encapsulation glue film 104 for the lateral wall of first encapsulation layer 101 and the lateral wall recess of second encapsulation layer 102.
In one embodiment, with continued reference to fig. 2, the first encapsulant layer 103 is shown having a size larger than the size of the solar cell array 105.
In an embodiment, with reference to fig. 2, the first encapsulant layer 103, the solar cell array 105, the second encapsulant layer 104, and the second encapsulant layer 102 are sequentially disposed from bottom to top of the first encapsulant layer 101, the second encapsulant layer 104 further extends to cover the sidewall surface of the solar cell array 105, and the second encapsulant layer 104 protects the solar cell array 105. In other embodiments, the first encapsulant layer 103, the solar cell array 105, the second encapsulant layer 104, and the second encapsulant layer 102 are sequentially disposed from bottom to top of the first encapsulant layer 101, and the second encapsulant layer 104 may not extend to cover the sidewall surface of the solar cell array 105.
In one embodiment, with continued reference to fig. 2, the distance L1 between the edge of the first encapsulating glue layer 103 and the edge of the first encapsulating layer 101 before laminating the initial laminated assembly is 8 mm-10 mm, such as 9 mm; if the distance L1 between the edge of the first encapsulation adhesive layer 103 and the edge of the first encapsulation layer 101 is less than 8mm, the space left by the encapsulation adhesive layer is too small; if the distance L1 between the edge of the first encapsulant layer 103 and the edge of the first encapsulant layer 101 is greater than 10mm, the space left by the encapsulant layer is too large, and more encapsulant layers need to be filled in the sealed solar cell module, which results in resource waste.
In this embodiment, the first encapsulation layer 101 has a single-layer structure, and the material of the first encapsulation layer 101 includes glass. In other embodiments, the first encapsulation layer is a multilayer structure, the first encapsulation layer includes a protection layer, an insulation layer, and an adhesive layer that are stacked, the insulation layer is located between the adhesive layer and the protection layer, the adhesive layer is bonded to the first encapsulation adhesive layer, the material of the protection layer includes polyvinylidene fluoride, the material of the insulation layer includes polyethylene terephthalate, and the material of the adhesive layer includes polyolefin. The first packaging layer has protection and support functions on the solar battery pack.
In one embodiment, the material of the first encapsulant layer 103 includes ethylene and vinyl acetate copolymer. In other embodiments, the material of the first encapsulant layer may also include other materials with adhesive property and optical transparency.
In one embodiment, the material of the second encapsulant layer 104 includes ethylene and vinyl acetate copolymer. In other embodiments, the material of the second encapsulant layer may also include other materials with adhesive property and optical transparency.
In one embodiment, the material of the second encapsulation layer 102 includes glass. In other embodiments, the material of the second encapsulation layer may also include other transparent materials.
In step S2, the performing defect inspection on the initial laminated assembly specifically includes: one or more of appearance detection, hidden crack detection and cold solder joint detection, wherein: the appearance and appearance detection means that whether the initial laminated assembly is damaged or not is detected from an appearance angle, the subfissure detection means that whether solar cells in the solar cell set are cracked or not is detected, and the cold joint detection means that whether cold joints exist between the solar cells in the solar cell set and a solder strip or not is detected.
When the defect inspection is carried out on the initial laminated assembly, the second packaging layer plays a role in protecting the solar battery pack, so that the solar battery in the non-laminated initial laminated assembly can be prevented from being damaged due to external factors in the transmission process, and the probability of the solar battery pack from being hidden and broken can be reduced.
In one embodiment, the defective initial laminated assembly needs to be reworked until qualified.
In one embodiment, specifically, when the appearance and appearance of the initial stacked assembly are detected to be damaged, for example, when the first package layer or the second package layer is damaged, the defective initial stacked assembly needs to be repaired; the repair includes: separating the first packaging layer, the second packaging layer, the first packaging adhesive layer, the second packaging adhesive layer and the solar battery pack in the initial laminated assembly, and if the first packaging layer is damaged, replacing the first packaging layer with a new one; if the second packaging layer is damaged, replacing a new second packaging layer; and forming an initial laminated assembly by the first packaging layer, the second packaging layer, the first packaging adhesive layer, the second packaging adhesive layer and the solar battery pack until the initial laminated assembly is inspected to be qualified.
In another embodiment, when the subfissure detection is performed on the initial stacked assembly, and it is detected that a solar cell in the initial stacked assembly has a split, the initial stacked assembly having the split needs to be repaired, where the repairing includes: separating the first packaging layer, the second packaging layer, the first packaging adhesive layer, the second packaging adhesive layer and the solar battery pack in the initial laminated assembly, and replacing the solar battery with splinters; and then, forming an initial laminated assembly by the previous first packaging layer, the second packaging layer, the first packaging adhesive layer, the second packaging adhesive layer and the new solar battery pack until the initial laminated assembly is qualified through inspection.
In another embodiment, when the cold joint detection is performed on the initial laminated assembly, and a cold joint is detected to exist between the solar cell and the solder strip in the initial laminated assembly, the repair of the initial laminated assembly with the cold joint needs to be performed, and the repair includes: separating the first packaging layer, the second packaging layer, the first packaging adhesive layer, the second packaging adhesive layer and the solar battery pack in the initial laminated assembly; then, re-welding the position where the cold joint exists between the solar cell and the welding strip; and then forming an initial laminated assembly by the first packaging layer, the second packaging layer, the first packaging adhesive layer, the second packaging adhesive layer and the new solar battery pack until the initial laminated assembly is inspected to be qualified.
In step S3, specifically, referring to fig. 4, the step of forming the sealant layer 200 surrounding the first encapsulant layer 103, the solar cell array 105 and the second encapsulant layer 104 in the edge region between the first encapsulant layer 101 and the second encapsulant layer 102 of the qualified initial stacked assembly includes: providing a sealant material; heating the sealant material to melt the sealant material; the sealant material after melting is applied laterally to the edge region between the first and second encapsulant layers of the initial laminate assembly.
In one embodiment, the sealant material is applied by a glue applicator J, specifically, the sealant material is applied laterally to the edge region between the first encapsulant layer 101 and the second encapsulant layer 102 of the initial laminate assembly using the glue applicator J.
Referring to fig. 3, fig. 3 is a schematic diagram of a sealing adhesive layer forming manner in the prior art, which is different from the gluing manner of the present application, before the second encapsulation layer 102 is not placed, gluing is performed from the front side of the first encapsulation layer 101 to apply a sealing adhesive layer, and then a second encapsulation layer is placed on a side surface of the second encapsulation layer opposite to the first encapsulation layer to form an initial laminated assembly. Therefore, even if detection is carried out at the moment, on one hand, the laminated structure moves to cause the alignment problem, and on the other hand, if the detection is carried out and repair is needed, the first packaging layer and the second packaging layer have residual sealing glue layers, and the production progress of the solar cell module can be seriously reduced by cleaning the residual sealing glue layers; even if the repair is not needed, the sealant is particularly sensitive to the environment, so that the sealant can be failed once being attached or being affected by hair, air and other tiny particles in the detection process, and the sealing effect is affected.
After the initial laminated assembly is formed, referring to fig. 4, specifically, after the edge region between the first encapsulating layer 101 and the second encapsulating layer 102 of the initial laminated assembly is coated with the sealant layer by the glue coating device J, the sealant layer is coated on the side surface of the edge region between the first encapsulating layer 101 and the second encapsulating layer 102 of the initial laminated assembly, and then the initial laminated assembly is laminated to form the solar cell assembly. The mode has good water vapor blocking effect and good sealing effect; but is easily affected by the stack waiting time before the lamination process, and has certain influence on the timeliness of the butyl rubber.
In another embodiment, the application of the sealant layer may also be performed after the initial stacked assembly is laminated, specifically, after the edge region between the first encapsulating layer 101 and the second encapsulating layer 102 after the lamination is performed is subjected to side gluing and the sealant layer is applied by using the gluing device J, and after the sealant layer is laterally applied to the edge region between the first encapsulating layer 101 and the second encapsulating layer 102 of the initial stacked assembly, the solar cell assembly is formed. Compared with the former mode, the mode has a slightly inferior water vapor blocking effect, and the sealing effect is slightly reduced; but the solar cell module finished product is obtained after the butyl rubber is coated at high temperature after lamination and cooled, and the aging effect of the butyl rubber is avoided.
In conclusion, the packaging mode of gluing from the side surface has various advantages and disadvantages, but the beneficial effects are better than the packaging effect of gluing from the front surface in the prior art and the timeliness is more timely from the view of final cost and production efficiency. In the actual production process, the time for coating the rubber from the side surface can be flexibly selected according to the field production man-hour arrangement and the working condition of the laminating machine, and the balance between the butyl rubber aging and the sealing effect is obtained, which is not limited here.
In one embodiment, the glue application device comprises a pneumatic glue gun; in other embodiments, the glue applying device may further include other glue applying devices capable of controlling the flow rate and monitoring the flow rate by changing the air pressure.
The sealant layer may be formed, for example, using a butyl sealant. In general, butyl rubber is solid at 25 ℃ and has a certain fluidity when heated to at least 80 ℃ or higher.
The existing solar cell module is packaged by adopting a packaging process of sealing tape pasting, in order to reduce the cost of the solar cell module, a mode of reducing the thickness of a first packaging layer and a second packaging layer can be adopted, and under the condition that the distance between the inner side wall of the sealing tape and the side wall of the first packaging adhesive layer is not changed, bubbles may exist in the laminated solar cell module; when the distance between the inner side wall of the sealing tape and the side wall of the first packaging adhesive layer is shortened, in order to ensure the sealing performance of the solar cell module, the width of the sealing tape needs to be increased, and the width of the sealing tape is constant, which increases the process difficulty.
And adopt the mode of formation sealant layer that this embodiment provided, one of them advantage lies in can changing the inside wall of sealant layer wantonly to as required the distance between the first encapsulation glue film lateral wall, the mode of change only need through the play gluey volume of changing sealed glue and the play gluey speed of sealed glue just can realize, and the formation of sealant layer can not influence the position of each structure in the initial laminated assembly, therefore the mode of formation sealant layer that this embodiment provided easy operation. That is, in order to prevent the sealant from affecting other laminate positions during the coating process, a distance L2 may be reserved, and after lamination, the molten adhesive film and sealant may be partially or completely covered by pressing the adhesive film and sealant to a distance L2. The distance L2 can be controlled by changing the glue discharging amount and the glue applying speed to obtain a proper size.
In one embodiment, with continued reference to fig. 4, the distance L2 between the inner side wall of the sealant layer 200 and the side wall of the first encapsulant layer 103 is 3 mm-5 mm, such as 4mm, before the initial laminate assembly is laminated; if the distance L2 between the inner sidewall of the sealant layer 200 and the sidewall of the first encapsulant layer 103 is less than 3mm, the sealant layer may overflow onto the first encapsulant layer during the lamination process; if the distance L2 between the inner sidewall of the sealant layer 200 and the sidewall of the first encapsulant layer 103 is greater than 5mm, a gap may exist between the sealant layer and the first encapsulant layer in the finally formed solar cell module, resulting in an unstable structure of the solar cell module.
In one embodiment, the step of heating the sealant material is performed at a temperature of 110-140 degrees celsius, such as 130 degrees celsius; if the temperature of the sealant material is lower than 110 ℃, the flowability of the sealant material is poor; the temperature of the sealant material can be changed from a solid state to a liquid state at 110-140 ℃, and if the temperature of the sealant material is higher than 140 ℃, the temperature of the sealant material is too high, the pneumatic glue gun can be difficult to bear, and heat waste can be caused.
In one embodiment, with continued reference to fig. 4, the sealant layer 200 has a width W of 3mm to 6mm, such as 5mm, prior to lamination of the initial laminate assembly; the width W of the sealing adhesive layer is less than 3mm, so that the sealing adhesive layer has a weak effect of preventing water vapor and dust in the environment from penetrating through the sealing adhesive layer and permeating into the solar battery pack; if the width W of the sealant layer is greater than 6mm, the width of the sealant layer is too large, which may cause the sealant layer to overflow to the sidewalls of the first and second encapsulation layers during lamination, resulting in waste.
The width W of the sealant layer 200 is parallel to the first and second encapsulant layers 101 and 102.
The width W of the sealant layer 200 is determined according to the water-blocking strength of butyl rubber molecules in practical application, and the width is determined according to the water-blocking standard. Before the initial stacked assembly is laminated, the width W of the sealant layer 200 may be adjusted according to the distance between the first and second encapsulation layers, the thickness of the first encapsulation layer, the thickness of the second encapsulation layer, and the thickness of the solar cell.
In one embodiment, with continued reference to fig. 4, prior to laminating the initial laminate assembly, the sealant layer 200 has a thickness T of 0.5mm to 3.5mm, such as 3 mm; the thickness T of the sealant layer 200 is less than 0.5mm, and it may be difficult to make the solar cell module in a completely closed environment if the thickness of the sealant layer is too small; if the thickness T of the sealant layer 200 is greater than 3.5mm, the thickness of the sealant layer is too large, and the sealant is easily overflowed during the lamination process, thereby causing resource waste.
The thickness T of the sealant layer 200 is perpendicular to the first and second encapsulant layers 101 and 102.
The thickness of the sealant layer 200 is determined according to the actual distance between the first and second package layers of the assembly, and the factors influencing the thickness include: the thickness between the first packaging adhesive layer and the second packaging adhesive layer, the thick bottom of the solar battery pack, the diameter of the solder strip and the like. Before the initial stacked assembly is laminated, the thickness T of the sealant layer 200 may be adjusted according to the distance between the first and second encapsulation layers, the thickness of the first encapsulation adhesive layer, the thickness of the second encapsulation adhesive layer, and the thickness of the solar cell.
In one embodiment, the sealant layer comprises a butyl sealant layer. In other embodiments, the sealant layer may also include other materials with water resistance.
In one embodiment, the solar cell set 105 comprises a number of parallel-connected solar cell strings comprising a number of series-connected solar cells; the adjacent solar cells are sequentially connected in series through the interconnection bars to form the solar cell string; the solar cell group is formed by connecting the adjacent solar cell strings in parallel through bus bars, and the solar cells include but are not limited to heterojunction solar cells. In the existing solar cell types, water vapor has little influence on the PERC cell and has great influence on the heterojunction solar cell; moreover, the application of the butyl rubber in the photovoltaic field is still in development and attempt at present, so that the butyl rubber product is single in model, and particularly in the initial butyl rubber market, only butyl adhesive tapes can be provided, so that only a pasting mode but not a coating mode can be adopted when the peripheral sealant is formed.
In step S4, referring to fig. 6, the sealant layer 200 is in close contact with the two encapsulant layers 104 in the solar cell module formed after the initial stacked module is laminated, and the distance L2 from the inner sidewall of the sealant layer 200 to the sidewall of the first encapsulant layer 103 in fig. 5 is almost zero.
In the prior art, the reason why the detection is performed after the lamination is completed is the protective effect of the back glass on the solar battery pack: on one hand, the solar cell pieces in the solar cell group which are subjected to the lamination process but not laminated can be ensured not to cause the position deviation of the solar cell string due to external factors such as inertia or external force in the conveying process; secondly, the solar cell can be ensured not to be subjected to irregular point pressure when the metal pressing pin is pressed on the bus bar of the solar cell array, namely when the metal pressing pin is pressed on the bus bar of the solar cell array, the solar cell and even the whole solar cell array are easily damaged if the pressing pin is directly contacted with the solar cell array instead of the bus bar. Therefore, the prior art intends to perform EL detection on the pre-lamination assembly, which is limited by process reasons, always covers the backplane glass in advance, and ensures that the bus bar is led out through the opening of the backplane glass, and finally the current guiding bar is contacted with the press pin.
It should be understood that the above examples are only for clarity of illustration and are not intended to limit the embodiments. Other variations and modifications will be apparent to persons skilled in the art in light of the above description. This need not be, nor should it be exhaustive of all embodiments. And obvious variations or modifications therefrom are within the scope of the invention.
Claims (10)
1. A method for encapsulating a solar cell module, comprising:
forming an initial stacked assembly, the step of forming the initial stacked assembly comprising: the solar cell module comprises a first packaging layer, a first packaging adhesive layer, a solar cell array, a second packaging adhesive layer and a second packaging layer which are sequentially arranged from bottom to top, wherein the side walls of the first packaging adhesive layer, the solar cell array and the second packaging adhesive layer are recessed relative to the side wall of the first packaging layer and the side wall of the second packaging layer;
performing defect inspection on the initial laminated assembly to screen out a defective initial laminated assembly and a qualified initial laminated assembly;
forming a sealant layer surrounding the first encapsulant layer, the solar cell set and the second encapsulant layer at an edge region between the first encapsulant layer and the second encapsulant layer of the qualified initial stacked assembly;
after the sealant layer is formed, the initial stacked assembly is laminated.
2. The method of claim 1, wherein the step of forming an encapsulant layer around the first encapsulant layer, the solar cell array and the second encapsulant layer in the edge region between the first encapsulant layer and the second encapsulant layer of the qualified initial stacked assembly comprises:
providing a sealant material;
heating the sealant material to melt the sealant material;
applying the sealant material after melting from the side to an edge region between the first and second encapsulation layers of the initial laminated assembly;
preferably, the sealant material is coated by a gluing device; the gluing device comprises a pneumatic glue gun.
3. The method of claim 2, wherein the step of heating the sealant material is performed at a temperature of 110-140 ℃.
4. The method for encapsulating a solar cell module according to any one of claims 1 to 3, wherein the width of the sealant layer is set to 3mm to 6mm before the initial laminated assembly is laminated.
5. The method for encapsulating a solar cell module according to any one of claims 1 to 3, wherein the sealant layer is provided to have a thickness of 0.5mm to 3.5mm before the initial laminated assembly is laminated.
6. The method for encapsulating a solar cell module according to any one of claims 1 to 3, wherein a distance between an inner side wall of the sealant layer and a side wall of the first encapsulant layer is set to 3mm to 5mm before the initial laminated module is laminated.
7. The method of any of claims 1-3, wherein a distance between an edge of the first encapsulant layer and an edge of the first encapsulant layer is set to be 8 mm-10 mm before the initial laminate assembly is laminated.
8. The method of encapsulating a solar module according to any of claims 1-3, wherein performing a defect inspection on the initial stacked module comprises: and any one or more of appearance detection, hidden crack detection and cold solder joint detection.
9. The method of any one of claims 1-3, wherein the sealant layer comprises at least a butyl sealant layer.
10. The method for encapsulating a solar cell module according to any one of claims 1 to 3, wherein the first encapsulating adhesive layer, the solar cell module, the second encapsulating adhesive layer and the second encapsulating layer are sequentially disposed from bottom to top of the first encapsulating layer, and the second encapsulating adhesive layer further extends to cover the surface of the sidewall of the solar cell module.
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