CN115472710A - 一种柔性可卷曲的背接触太阳电池模组及其制备方法 - Google Patents

一种柔性可卷曲的背接触太阳电池模组及其制备方法 Download PDF

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CN115472710A
CN115472710A CN202110705336.8A CN202110705336A CN115472710A CN 115472710 A CN115472710 A CN 115472710A CN 202110705336 A CN202110705336 A CN 202110705336A CN 115472710 A CN115472710 A CN 115472710A
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邱新旺
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Golden Solar Quanzhou New Energy Technology Co Ltd
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Abstract

本发明提供了一种柔性可卷曲的背接触太阳电池模组，其长度可无限延长，由多个大电池块串联或并联组成；大电池块由多个小电池串串联或并联组成；小电池串由多个小方块电池片串联或并联组成；大电池块、小电池串、小方块电池片相互之间的串联或并联连接采用水平或垂直方向的柔性互连条焊接。小方块电池片的电极都在背面，由背接触太阳电池切割而成，且受光面表面用胶层贴合保护层。同时制备时采用先对太阳电池和保护层进行预切割后贴合，再进行碎片处理。实现了背接触太阳电池模组可根据实际应用需求对大电池块进行串联、并联、串并联自由结合，且电极不遮挡受光面，使得设计更灵活、加工更方便、光利用率更高。

Description

一种柔性可卷曲的背接触太阳电池模组及其制备方法
技术领域
本发明涉及太阳能电池制备领域，尤其涉及一种柔性可卷曲的IBC或HBC背接触太阳电池模组及其制备方法。
背景技术
前一代柔性太阳电池模组，通过对太阳电池芯片切割成很多小电池片后再在小电池片表面贴合保护，因为小电池片尺寸小，贴合保护层要求精度高，造成较多不良。再者，组成柔性太阳能板的小电池片的正负极在电池不同的面，生产时要将小电池的正负极串焊，串焊时需要在焊完正极或负极面后，翻转后焊接另一面，或者小电池的两面都铺设互连条后同时串焊，由于组成柔性组件的小电池尺寸小，要求的工艺非常精密，加工难度比较大，且小电池焊接时采用统一水平方向焊接，使得柔性电池组件的设计受到一定的局限性。再者，再此外，由于电池的受光面和背面两面都有电极，串焊后的互连条会对发电面产生一定的遮光作用，降低了发电效率。
背接触太阳电池(IBC、HBC)最显著的特点是PN结和金属接触都处于太阳电池的背部，前表面彻底避免了金属栅线电极和焊接电极的互连条的遮挡，能够最大限度地利用入射光，减少光学损失，具有更高的短路电流。同时，电池的正负极都在电池的背面，也可以进一步提高焊接小电池片操作中的工艺效率。这种前面无遮挡的太阳电池不仅转换效率高，而且具有外形美观等优势。
发明内容
为解决现有技术存在的缺陷，本发明提供了一种柔性可卷曲的背接触太阳电池模组，其特征在于，所述背接触太阳电池模组长度可无限延长，由多个大电池块串联或并联组成；所述大电池块由多个小电池串串联或并联组成；所述小电池串由多个小方块电池片串联或并联组成；所述大电池块、小电池串、小方块电池片相互之间的串联或并联连接采用水平或垂直方向的柔性互连条焊接。所述小方块电池片的电极都在背面，由背接触太阳电池切割而成，且受光面表面用胶层贴合保护层。
为获得所述背接触太阳电池模组，本发明采用如下技术：
对背接触太阳电池和保护层进行预切割，形成多块未完全断开的小方块电池和小方块保护层；
用胶层将背接触太阳电池受光面和保护层贴合在一起；
进行碎片处理，形成多块受光面贴合有保护层的小方块电池片；
利用芯片自动裂片排片设备将多块小方块电池片排列好，并用高温胶带贴在背面的中间以固定小方块电池片的位置，再通过柔性互连条串联或并联焊接形成小电池串；
将多串小电池串排列好，再通过柔性互连条串联或并联焊接形成大电池块；
根据设计需求将多块大电池块通过柔性互连条串联或并联焊接形成背接触太阳电池模组。
优选的，所述无限延长的背接触太阳电池模组还可以根据设计需求在合适的位置切断，重新形成多个大电池，再经柔性互连条重新串并联连接，形成满足新设计要求的太阳电池模组。
优选的，所述背接触太阳电池模组由大电池块串联连接形成时，采用水平方向的柔性互连条将大电池块的正负极进行连接。
优选的，所述背接触太阳电池模组由大电池块并联连接形成时，采用垂直方向的柔性互连条将大电池块的正极与正极、负极与负极进行连接。
优选的，所述小方块电池片长度为1-100mm，宽度为1-100mm，小方块电池片相互之间保持一定的间距。
优选的，所述柔性互连条为0.1-20mm的FCCL软性焊带或FPCB或柔性镀锡铜带，通过柔性互连条连接后的小电池串之间间隙为0.1-5mm。
优选的，所述保护层为硬质材料层，其可以为玻璃、PC、PMMA、PP、PET或透明氟材料层，其厚度为0.2-2mm。
优选的，所述小方块电池片与保护层的贴合胶层为硅胶、EVA胶、POE胶、双面胶等，采用UV光固化或高温固化。
优选的，所述背接触太阳电池为交叉指式背接触(IBC)太阳电池或交叉指式背接触异质结(HBC)太阳电池的一种。
由上述对本发明的描述可知，和现有技术相比，本发明具有如下优点：
本发明提供的背接触太阳电池模组可以无限延长，并根据实际应用需求同时利用水平方向和垂直方向的柔性互连条对组成背接触太阳电池模组的大电池块进行串联、并联、串并联自由结合；且通过对背接触太阳电池和保护层进行预切割，并在胶层贴合后再进行碎片处理，使得太阳能电池组件的设计更灵活、加工更方便。再者，背接触太阳电池模组的电极都在背面，既方便柔性互连条的焊接，又不会遮挡受光面，有效提高光利用率。此外，因为本发明提供的背接触太阳电池模组可以无限延长，因此，本发明提供的背接触太阳电池模组还可以在任意宽度尺寸上实现不同电流、电压需求的太阳能电池组件的设计。
附图说明
构成本申请的一部分的附图用来提供对本发明的进一步理解，本发明的示意性实施例及其说明用于解释本发明，并不构成对本发明的不当限定。在附图中：
图1为本发明提供的背接触太阳电池模组的剖视结构示意图；
图2本发明提供的提供的实施例背接触太阳电池模组的正面结构示意图；
图3为本发明提供的背接触太阳电池切割成小方块电池片示意图；
图4为本本发明提供的背接触太阳电池贴合硬质材料玻璃后再划线成小方块电池片的结构示意图；
图5为本本发明提供的小方块电池片排列成小电池串后背面贴高温胶带的结构示意图；
图6为本本发明提供的小电池串两串并列排放的结构示意图；
图7为本本发明提供的在两串小电池串间背面焊柔性互连条后的结构示意图；
图8为本本发明提供的两串小电池串通过柔性互连条串联连接后的剖视结构示意图；
图9为本发明提供的大电池块的结构示意图；
图10为本发明提供的两块大电池块通过柔性互连条焊接连接的结构示意图；
图11为本发明提供的可无限延长的背接触太阳电池模组根据设计需求在合适的位置切断的结构示意图。
具体实施方式
为了使本发的目的、技术方案及优点更加清楚明白，以下结合附图及实施例，对本发明进行进一步详细说明。应当理解，此处所描述的具体实施例仅仅用以解释本发明，并不用于限定本发明。
图1和2所示，本发明提供了一种柔性可卷曲的背接触太阳电池模组，所述背接触太阳电池模组长度可无限延长，由多个大电池块10串联或并联组成；所述大电池块10由多个小电池串7串联或并联组成；所述小电池串7由多个小方块电池片2串联或并联组成；所述大电池块10、小电池串7、小方块电池片2相互之间的串联或并联连接采用水平或垂直方向的柔性互连条8焊接。所述小方块电池片2的电极都在背面，由背接触太阳电池1切割而成，且受光面表面用胶层3贴合保护层4。
所述背接触太阳电池模组制备过程如下：
首先，对背接触太阳电池1和保护层4进行预切割，形成多块未完全断开的小方块电池2和小方块保护层4；图3所示，所述背接触太阳电池1为交叉指式背接触异质结(HBC)太阳电池，切割后的小方块电池片2长度为12.0mm，宽度为8.0mm，且小方块电池片的正负极都在电池的背面。
其次，用胶层3将背接触太阳电池1受光面和保护层4贴合在一起；其中，所述胶层3为光学硅胶，采用温度高温固化；所述保护层4为硬质材料透明玻璃，厚度为0.4mm；
接着，对贴合后的背接触太阳电池1进行碎片处理，形成多块受光面贴合有保护层的小方块电池片2；
图4和5所示，利用芯片自动裂片排片设备将每串20小方块电池片2，相互间隔0.4mm排列好，并用高温胶带6贴在背面的中间以固定小方块电池片2的位置，再通过柔性互连条8串联或并联焊接形成小电池串7；
图9所示，将13串小电池串7排列好，再通过柔性互连条8串联焊接形成大电池块10，并在在最外边小电池串7的正极和负极再焊上柔性互连条8，用与其它大电池块之间的串并联连接。其中，小电池串7相互之间隔0.2mm(图6所示)，两串小电池串7正负极间用柔性互连条8串联焊接(图7和8所示)。
图10所示，根据设计需求将两块大电池块10通过柔性互连条8并联焊接形成背接触太阳电池模组。
图11所示，多个大电池块10串并联形成背接触太阳电池模组后，还可以根据设计需求，在需要的位置切断并经柔性互连条重新串联或并联焊接重新组成背接触太阳电池模组。
本发明提供的背接触太阳电池模组可以无限延长，并根据实际应用需求同时利用水平方向和垂直方向的柔性互连条对组成背接触太阳电池模组的大电池块进行串联、并联、串并联自由结合，且通过对背接触太阳电池和保护层进行预切割，并在胶层贴合后再进行碎片处理，使得太阳能电池组件的设计更灵活、加工更方便。再者，背接触太阳电池模组的电极都在背面，既方便柔性互连条的焊接，又不会遮挡受光面，有效提高光利用率。此外，因为本发明提供的背接触太阳电池模组可以无限延长，因此，本发明提供的背接触太阳电池模组还可以在任意宽度尺寸上实现不同电流、电压需求的太阳能电池组件的设计。
以上所述仅为本发明的较佳实施例而已，并不用以限制本发明，凡在本发明的精神和原则之内所作的任何修改、等同替换和改进等，均应包含在本发明的保护范围之内。

Claims (9)

1.一种柔性可卷曲的背接触太阳电池模组，其特征在于：所述背接触太阳电池模组长度可无限延长，由多个大电池块串联或并联组成；所述大电池块由多个小电池串串联或并联组成；所述小电池串由多个小方块电池片串联或并联组成；所述大电池块、小电池串、小方块电池片相互之间的串联或并联连接采用水平或垂直方向的柔性互连条焊接。所述小方块电池片的电极都在背面，由背接触太阳电池切割而成，且受光面表面用胶层贴合保护层。所述背接触太阳电池模组，采用如下技术：
对背接触太阳电池和保护层进行预切割，形成多块未完全断开的小方块电池和小方块保护层；
用胶层将背接触太阳电池受光面和保护层贴合在一起；
进行碎片处理，形成多块受光面贴合有保护层的小方块电池片；
利用芯片自动裂片排片设备将多块小方块电池片排列好，并用高温胶带贴在背面的中间以固定小方块电池片的位置，再通过柔性互连条串联或并联焊接形成小电池串；
将多串小电池串排列好，再通过柔性互连条串联或并联焊接形成大电池块；
根据设计需求将多块大电池块通过柔性互连条串联或并联焊接形成背接触太阳电池模组。
2.根据权利要求1所述背接触太阳电池模组，其特征还在于：所述背接触太阳电池模组还可以根据设计需求在合适的位置切断，重新形成多个大电池，再经柔性互连条重新串并联连接，形成满足新设计要求的太阳电池模组。
3.根据权利要求1或2所述的背接触太阳电池模组，其特征在于：所述的背接触太阳电池模组由大电池块串联连接形成时，采用水平方向的柔性互连条将大电池块的正负极进行连接。
4.根据权利要求1或2所述的背接触太阳电池模组，其特征在于：所述的背接触太阳电池模组由大电池块关联连接形成时，采用垂直方向的柔性互连条将大电池块的正极与正极、负极与负极进行连接。
5.根据权利要求1或2所述的背接触太阳电池模组，其特征在于：所述小方块电池片长度为1-100mm，宽度为1-100mm，小方块电池片相互之间保持一定的间距。
6.根据权利要求1或2所述的背接触太阳电池模组，其特征在于：所述柔性互连条为0.1-20mm的FCCL软性焊带或FPCB或柔性镀锡铜带，通过柔性互连条连接后的小电池串之间间隙为0.1-5mm，所述小电池串由2片以上小方块电池组成。
7.根据权利要求1或2所述的背接触太阳电池模组，其特征在于：所述保护层为硬质材料层，其可以为玻璃、PC、PMMA、PP、PET或透明氟材料层，其厚度为0.2-2mm。
8.根据权利要求1或2所述的背接触太阳电池模组，其特征在于：小方块电池片与保护层的贴合胶层为硅胶、EVA胶、POE胶、双面胶等，采用UV光固化或高温固化。
9.根据权利要求1或2所述的背接触太阳电池模组，其特征在于：所述背接触太阳电池为交叉指式背接触(IBC)太阳电池或交叉指式背接触异质结(HBC)太阳电池的一种。
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