CN115763583A - High-efficiency photovoltaic module and manufacturing method thereof - Google Patents
High-efficiency photovoltaic module and manufacturing method thereof Download PDFInfo
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- 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
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Abstract
The invention discloses a high-efficiency photovoltaic module and a manufacturing method thereof, belonging to the technical field of photovoltaic modules, wherein the high-efficiency photovoltaic module comprises a solar cell module, the upper side and the lower side of the solar cell module are respectively provided with a front plate and a back plate, the solar cell module comprises a solar cell piece, a main grid welding strip, a bus line and a bypass diode, the solar cell piece is provided with a series welding non-staggered edge and a series welding staggered edge along the series welding direction, the series welding non-staggered edge is provided with a plurality of first fork structures corresponding to the main grids one by one, and the series welding staggered edge is provided with a plurality of second fork structures and gaps corresponding to the main grids one by one.
Description
Technical Field
The invention mainly relates to the technical field of photovoltaic modules, in particular to a high-efficiency photovoltaic module and a manufacturing method thereof.
Background
The single solar cell can not be directly used as a power supply, a plurality of single cells are required to be connected in series, in parallel and tightly packaged into a module as the power supply, a photovoltaic module, also called as a solar cell panel, is a core part in a solar power generation system and is also the most important part in the solar power generation system, and the photovoltaic module has the function of converting solar energy into electric energy and transmitting the electric energy to a storage battery for storage or pushing a load to work.
The photovoltaic module is formed by combining solar cells or solar cells of different specifications cut by a laser cutting machine or a steel wire cutting machine, and because the current and the voltage of single solar cells are very small, the single solar cells are firstly connected in series to obtain high voltage, then connected in parallel to obtain high current, packaged in a front plate and a back plate, then framed and provided with a junction box.
And (3) component manufacturing flow: the method comprises the steps of battery piece sorting, single welding, series welding, splicing (namely, the series-welded battery pieces are positioned and spliced together), intermediate testing (the intermediate testing comprises near infrared ray (EL) testing and appearance inspection), laminating, edging, appearance after layering, infrared after layering, framing (generally an aluminum frame), wiring box assembling, cleaning, testing (the step also comprises infrared ray testing and appearance inspection, and the grade of the assembly is judged), and packaging.
The defects of the prior art are as follows:
1. the conventional series welding technology of the existing photovoltaic module ensures that a gap of 2-3 mm is required between each battery piece on the battery string, so that the effective area is wasted, and the conversion efficiency of the photovoltaic module is reduced.
2. The stitch welding technology directly overlaps the serial connection positions of the battery pieces, and although the main grid welding belts at the overlapped positions are subjected to flat processing, unbalanced height differences occur after the battery pieces are stacked, so that unbalanced pressure stress is generated in the laminating process, the risk of cracking or hidden cracking is increased, and the product quality and the production yield are influenced.
3. The assembly efficiency of the shingle technique is high, but the corresponding cost is relatively high.
Disclosure of Invention
The technical scheme of the invention aims at the technical problem that the prior art is too single, provides a solution which is obviously different from the prior art, and particularly mainly provides a high-efficiency photovoltaic module and a manufacturing method thereof, which are used for solving the technical problem of series welding gaps of solar cells in the background technology.
The technical scheme adopted by the invention for solving the technical problems is as follows:
a high-efficiency photovoltaic module comprises a solar cell module, wherein a front plate and a back plate are respectively arranged on the upper side and the lower side of the solar cell module, a first adhesive layer is arranged between the solar cell module and the front plate, a second adhesive layer is arranged between the solar cell module and the back plate, and the solar cell module comprises solar cells, a main grid welding strip, a bus bar and a bypass diode;
the solar cell is provided with a plurality of main grids and fine grids gathered around the main grids along the series welding direction, a plurality of main grid welding spots are linearly distributed on each main grid at equal intervals, and the main grid welding spots are electrically connected with main grid welding strips;
the series welding non-staggered edges are provided with a plurality of first fork structures corresponding to the main grids one by one, one end of each first fork structure extends to the edge of the solar cell, the other end of each first fork structure corresponds to one main grid welding strip, and the two fork edges of each first fork structure are a first fork edge and a second fork edge;
the crisscross edge of series welding has second bifurcation structure and the breach of a plurality of one-to-one main bars, every second bifurcation structure one end has and extends to solar wafer border, and the other end corresponds a main bar and welds the area, every two bifurcation limits of second bifurcation structure are third limit and fourth limit, and the breach is located between third limit and the fourth limit.
Preferably, the main grid and the fine grid are vertically distributed.
Preferably, no fine grid is arranged between two branched edges of the first branched structure and the second branched structure.
Preferably, three cutting surfaces are arranged at the position of the notch of the solar cell, an insulating coating is arranged on each cutting surface, and the width of the notch is 0.2mm-5mm.
Preferably, the height difference d1 between the upper end and the lower end of the main grid welding strip is the sum of the thickness of the solar cell and the thickness of the main grid welding strip.
A manufacturing method of a high-efficiency photovoltaic module specifically comprises the following steps:
s1, picking up a solar cell, and cutting a notch at a position corresponding to each second bifurcation structure on a series welding staggered edge of the solar cell by using laser;
s2, spraying insulating coatings on the cutting surfaces of all the notches;
s3, performing infrared drying of 5s to 30s on the position of the cutting notch;
s4, feeding the first solar cell after notch drying into a stringer, welding a pre-picked main grid welding strip on the back of the first solar cell, then picking up the next main grid welding strip, sequentially welding the upper end of the main grid welding strip to the main grid welding points close to the series welding staggered sides of the first solar cell from the main grid welding points close to the series welding non-staggered sides of the first solar cell, and then prefabricating the welding position of the back of the next solar cell through the notch;
s5, dragging the first welded solar cell piece in a series welding machine to displace by the width and length of one solar cell piece, and ensuring that the series welding non-staggered edge of one solar cell piece in two adjacent solar cell pieces is abutted against the series welding staggered edge of the other solar cell piece;
s6, picking up a second solar cell, placing the second solar cell on a position where a main grid welding strip with a bottom welded part is prefabricated, and welding the main grid welding strip on the back;
s7, picking up a third main grid welding strip, sequentially welding the upper end of the third main grid welding strip to the main grid welding points close to the series welding staggered side from the main grid welding points close to the series welding non-staggered side of the second solar cell, and then penetrating through the notch to reach the welding position of the back electrode of the next solar cell to complete the manufacturing of a single solar cell string;
s8, repeating the steps, and manufacturing a plurality of solar cell strings according to the requirements;
s9, welding and connecting a plurality of solar cell strings together in series by using a bus bar, leading out a component electrode, and reserving a welding leading-out terminal of a bypass diode;
s10, manufacturing the solar cell module;
s11, stacking the prepared layer structures in sequence according to a required sequence: the solar cell module comprises a front plate, a first adhesive layer, a solar cell module, a second adhesive layer and a back plate;
s12, conveying the prefabricated laminated piece which is laminated into a laminating machine to finish component lamination;
and S13, carrying out subsequent related detection and assembly on the laminated assembly.
Compared with the prior art, the invention has the following beneficial effects:
(1) According to the invention, the notch is cut by using the laser at the design position of the series welding of the solar cell, so that the notch structure of the solar cell is realized at the cross end of the series welding, the operation is simple and rapid, the existing solar cell is not required to be greatly changed, and the practicability and universality are strong;
(2) According to the invention, the gap structure of the solar cell is subjected to insulation treatment, so that the short circuit of the main grid welding strip and the back of the solar cell in series welding is prevented, and the main grid welding strip penetrates through the U-shaped gap at the staggered end to realize series welding with the next component, so that the conventional series welding equipment is not changed;
(3) The invention realizes that the cell gap of the conventional series welding can be effectively replaced and the series welding gap is cancelled by the U-shaped structure gap designed at the series welding staggered end of the cell, thereby achieving the purpose of carrying out zero-spacing or even negative-spacing series welding on the solar cell with the specific cutting gap,
and the interconnection strips are used for connecting the cell strings in series and parallel to form a solar cell module, so that the area loss of assembly packaging is reduced, and the conversion efficiency and the packaging efficiency of the photovoltaic assembly are improved.
The present invention will be explained in detail below with reference to the drawings and specific embodiments.
Drawings
FIG. 1 is a schematic view of a layer structure of the device of the present invention;
FIG. 2 is a schematic structural diagram of a solar cell module according to the present invention;
FIG. 3 is a schematic view of a solar cell of the present invention;
FIG. 4 is a schematic view of a series welded non-staggered edge structure according to the present invention;
FIG. 5 is a schematic view of a series welding staggered edge structure according to the present invention;
FIG. 6 is a schematic view of the main grid solder strip structure of the present invention;
FIG. 7 is a schematic view of the series welding of the present invention.
Description of the drawings: 101. a solar cell module; 100. a solar cell sheet; 103. a main grid solder strip; 102. a bus line; 104. a bypass diode; 110. series welding non-staggered edges; 111. a first bifurcating structure; 1111. a first edge separation; 1112. a second edge division; 120. series welding staggered edges; 121. a second bifurcating structure; 1211. a third edge division; 1212. a fourth edge; 122. a notch; 1221. cutting the surface; 130. a main grid; 140. a main grid welding spot; 150. fine grids; 201. a front plate; 301. a first adhesive layer; 302. a second adhesive layer; 401. a back plate.
Detailed Description
In order to facilitate an understanding of the invention, the invention will now be described more fully hereinafter with reference to the accompanying drawings, in which several embodiments of the invention are shown, but which may be embodied in different forms and not limited to the embodiments described herein, but which are provided so as to provide a more thorough and complete disclosure of the invention.
It will be understood that when an element is referred to as being "secured to" another element, it can be directly on the other element or intervening elements may be present, and when an element is referred to as being "connected" to another element, it can be directly connected to the other element or intervening elements may also be present, as the terms "vertical", "horizontal", "left", "right" and the like are used herein for descriptive purposes only.
Unless defined otherwise, all technical and scientific terms used herein have the same meaning as commonly understood by one of ordinary skill in the art to which this invention belongs, and the use of such term knowledge in the specification of the invention is for the purpose of describing particular embodiments and is not intended to be limiting of the invention, and the use of the term "and/or" herein includes any and all combinations of one or more of the associated listed items.
In a first embodiment, please refer to fig. 1 to 7, a high efficiency photovoltaic module includes a solar cell module 101, a front plate 201 and a back plate 401 are respectively disposed on an upper side and a lower side of the solar cell module 101, a first adhesive layer 301 is disposed between the solar cell module 101 and the front plate 201, a second adhesive layer 302 is disposed between the solar cell module 101 and the back plate 401, and the solar cell module 101 includes a solar cell 100, a main grid solder strip 103, a bus bar 102, and a bypass diode 104; the solar cell piece 100 is provided with a series welding non-staggered edge 110 and a series welding staggered edge 120 along the series welding direction, the solar cell piece 100 is provided with a plurality of main grids 130 and fine grids 150 gathered around the main grids 130 along the series welding direction, a plurality of main grid welding spots 140 are linearly distributed on each main grid 130 at equal intervals, and the main grid welding spots 140 are electrically connected with the main grid welding strips 103; the series welding non-staggered edge 110 is provided with a plurality of first branch structures 111 corresponding to the main grids 130 one by one, one end of each first branch structure 111 extends to the edge of the solar cell 100, the other end of each first branch structure 111 corresponds to one main grid welding strip 103, and two branch edges of each first branch structure 111 are a first branch edge 1111 and a second branch edge 1112; the series welding staggered edge 120 is provided with a plurality of second branched structures 121 and notches 122 which correspond to the main grids 130 one by one, one end of each second branched structure 121 extends to the edge of the solar cell 100, the other end of each second branched structure corresponds to one main grid welding strip 103, two branched edges of each second branched structure 121 are a third branched edge 1211 and a fourth branched edge 1212, and the notch 122 is located between the third branched edge 1211 and the fourth branched edge 1212;
the front plate 201 is a rigid high-light-transmission panel, such as ultra-white toughened glass, or a material with high water vapor barrier property and excellent weather resistance, such as a flexible polymer composite film, such as tetrafluoroethylene, or a polymer flexible film material, such as ethylene chlorotrifluoroethylene copolymer;
the first adhesive layer 301 and the second adhesive layer 302 are made of high weather-resistant polymer materials, and are used for bonding the front plate 201, the solar cell module 101 and the back plate 401, and filling the gap between the two layers to form a reliable internal structure, and ethylene-vinyl acetate copolymer, polyolefin elastomer, polyvinyl butyral or 2,4, 6-trimethylbenzoyl-diphenyl phosphine oxide can be used, wherein the polyolefin elastomer is preferably high polymer of ethylene and butylene or high polymer of ethylene and octene;
the solar cell piece 100 may be a conventional standard solar cell piece 100, or may be obtained by slicing the conventional standard solar cell piece 100 into equal parts, or may be a half slice, a third slice, or the like, and the type of the solar cell piece 100 may be a single crystal silicon solar cell piece 100, a polycrystalline silicon solar cell piece 100, an amorphous silicon heterojunction solar cell piece 100, or other stacked solar cell pieces 100, or may be a thin film solar cell piece 100 (amorphous silicon, copper indium gallium selenide, gallium arsenide, cadmium telluride, perovskite, or the like) or a solar cell piece 100 of other technologies;
the back plate 401 is an outermost layer structure on the back, can be reinforced float glass, can also be a glass fiber organic composite material, a polymer material such as PC, PMMA, PVC and the like, has good weather resistance, and effectively ensures the service life of the component.
According to the structure, the notches 122 are cut at the serial welding staggered positions of the solar cells 100, the serial welding gaps of the solar cells 100 are eliminated, the power density of assembly packaging is improved, the area loss of the assembly packaging is reduced, the packaging efficiency is improved, and the cost is reduced;
specifically, the method comprises the steps of picking up a solar cell 100, cutting a notch 122 at a position corresponding to each second branch structure 121 on a series welding staggered edge 120 of the solar cell by using laser, optionally using diamond wires or other cutting processes, spraying an insulating coating on cutting surfaces 1221 of all notches 122, performing infrared drying for 5s to 30s on the position of the cut notch 122, feeding a first solar cell 100 which is subjected to drying of the notch 122 into a series welding machine, welding a pre-picked main grid welding strip 103 on the back surface of the first solar cell 100, picking up a next main grid welding strip 103, sequentially welding the upper end of the first solar cell 100 from the main grid welding strip 140 on the side close to the series welding staggered edge 110 to the main grid welding strip 140 on the side close to the series welding staggered edge 120, pre-manufacturing the next main grid welding strip 103 through the notch 122, dragging the first welded solar cell 100 in the series welding machine to a width of the main grid welding strip 100, moving the width of the first solar cell 100 to the main grid welding strip 140 on the side close to the series welding staggered edge 120, placing the adjacent solar cell 100 in series welding position, sequentially, pulling the second solar cell 100 close to the second solar cell 100, and placing the main grid welding strip 100 on the main grid welding strip, sequentially, and placing the main grid welding strip 100 on the back side of the second solar cell 100, and repeating steps of the main grid 100, then, a plurality of solar cell strings are welded and connected in series by using a bus bar 102, a component electrode is led out, a welding leading-out terminal of a bypass diode 104 is reserved, the solar cell module 101 is manufactured, and then, the prepared structures are sequentially stacked according to the required sequence: the front panel 201, the first adhesive layer 301, the solar cell module 101, the second adhesive layer 302 and the back panel 401, the laminated prefabricated laminate is fed into a laminating machine to complete the assembly lamination, and then the laminated assembly is subjected to subsequent related detection and assembly.
In the second embodiment, please refer to fig. 4, 5, and 6 again, the main grids 130 and the fine grids 150 are vertically distributed, the fine grids 150 are also called as auxiliary grids, and are used for collecting photo-generated current, no fine grid 150 is arranged between two branched edges of the first branched structure 111 and the second branched structure 121, three cutting surfaces 1221 are arranged at the position of the notch 122 of the solar cell 100, an insulating coating is arranged on the cutting surfaces 1221, the width of the notch 122 is 0.2mm to 5mm, preferably 0.4mm to 1.5mm, the insulating coating is used for preventing the main grid solder strip 103 from being in contact with and short-circuited with the back surface of the solar cell 100 during series welding, the height difference d1 between the upper end and the lower end of the main grid solder strip 103 is the sum of the thickness of the solar cell 100 and the thickness of the main grid solder strip 103, the upper end of the main grid solder strip 103 is sequentially welded to the main grid solder point 140 near the side of the series welding staggered edge 120, and then passes through the notch 122 to reach the back of the next solar cell 100, and the solar cell 100 is electrically connected to the lower end of the solar cell 100.
The invention is described above with reference to the accompanying drawings, it is obvious that the invention is not limited to the above embodiments, and it is within the scope of the invention to adopt such insubstantial modifications of the inventive method concept and solution, or to apply the inventive concept and solution directly to other applications without such modifications.
Claims (6)
1. A high-efficiency photovoltaic module comprises a solar cell module (101), wherein a front plate (201) and a back plate (401) are respectively arranged on the upper side and the lower side of the solar cell module (101), a first adhesive layer (301) is arranged between the solar cell module (101) and the front plate (201), and a second adhesive layer (302) is arranged between the solar cell module (101) and the back plate (401), and is characterized in that the solar cell module (101) comprises a solar cell piece (100), a main grid welding strip (103), a bus bar (102) and a bypass diode (104);
the solar cell piece (100) is provided with series welding non-staggered edges (110) and series welding staggered edges (120) along the series welding direction, a plurality of main grids (130) and fine grids (150) gathered around the main grids (130) are arranged on the solar cell piece (100) along the series welding direction, a plurality of main grid welding spots (140) are linearly distributed on each main grid (130) at equal intervals, and the main grid welding spots (140) are electrically connected with main grid welding strips (103);
a plurality of first forked structures (111) corresponding to the main grids (130) one by one are arranged on the series welding non-staggered edges (110), one end of each first forked structure (111) extends to the edge of the solar cell (100), the other end of each first forked structure corresponds to one main grid welding strip (103), and two forked edges of each first forked structure (111) are a first forked edge (1111) and a second forked edge (1112);
there are second bifurcation structure (121) and breach (122) of a plurality of one-to-one correspondence main grid (130) on series welding staggered edge (120), every second bifurcation structure (121) one end has and extends to solar wafer (100) border, and the other end corresponds a main grid and welds area (103), every two bifurcate limits of second bifurcation structure (121) are third limit (1211) and fourth limit (1212), and breach (122) are located between third limit (1211) and fourth limit (1212).
2. A high efficiency photovoltaic module as claimed in claim 1, wherein the primary grid (130) and the fine grid (150) are vertically spaced.
3. A high efficiency photovoltaic module according to claim 1, wherein there is no fine grid (150) between the two diverging edges of the first and second diverging structures (111, 121).
4. The high-efficiency photovoltaic module according to claim 1, wherein three cutting surfaces (1221) are formed in the notch (122) of the solar cell piece (100), an insulating coating is formed on each cutting surface (1221), and the width of the notch (122) is 0.2mm to 5mm.
5. The high-efficiency photovoltaic module according to claim 1, wherein the height difference d1 between the upper end and the lower end of the main grid solder strip (103) is the sum of the thickness of the solar cell (100) and the thickness of the main grid solder strip (103).
6. A manufacturing method of a high-efficiency photovoltaic module, which is characterized by being manufactured by using the high-efficiency photovoltaic module as claimed in any one of claims 1 to 5, and the manufacturing method specifically comprises the following steps:
s1, picking up a solar cell (100), and cutting a notch (122) at a position corresponding to each second bifurcation structure (121) on a series welding staggered edge (120) by using laser;
s2, spraying an insulating coating on the cutting surfaces (1221) of all the notches (122);
s3, performing infrared drying at the position of the cutting gap (122) for 5s to 30s;
s4, sending the first solar cell (100) with the dried notch (122) into a series welding machine, welding a pre-picked main grid welding strip (103) on the back of the first solar cell, then picking up the next main grid welding strip (103), sequentially welding the upper end of the first solar cell to a main grid welding point (140) close to the series welding staggered edge (120) side from a main grid welding point (140) close to the series welding non-staggered edge (110) side of the first solar cell (100), and then penetrating through the notch (122) to be prefabricated at the back welding position of the next solar cell (100);
s5, dragging the first welded solar cell (100) in a series welding machine to displace the width and the length of one solar cell (100), and ensuring that the series welding non-staggered edge (110) of one solar cell (100) in two adjacent solar cells (100) is tightly abutted to the series welding staggered edge (120) of the other solar cell (100);
s6, picking up a second solar cell (100), placing the second solar cell at the position where a main grid welding strip (103) with a bottom welding is prefabricated, and welding the main grid welding strip (103) on the back surface;
s7, picking up a third main grid welding strip (103), sequentially welding the upper end of the third main grid welding strip to the main grid welding points (140) close to the side of the series welding staggered edge (120) of the second solar cell piece (100) from the main grid welding points (140) close to the side of the series welding non-staggered edge (110), and then penetrating through the notch (122) to reach the welding position of the back electrode of the next solar cell piece (100) to finish the manufacture of a single solar cell string;
s8, repeating the steps, and manufacturing a plurality of solar cell strings according to the requirements;
s9, welding and connecting a plurality of solar cell strings together in series by using a bus bar (102), leading out a component electrode, and reserving a welding leading-out terminal of a bypass diode (104);
s10, manufacturing the solar cell module (101);
s11, stacking the prepared layer structures in sequence according to a required sequence: a front plate (201), a first adhesive layer (301), a solar cell module (101), a second adhesive layer (302), and a back sheet (401);
s12, feeding the prefabricated laminated piece which is laminated into a laminating machine to complete component lamination;
and S13, carrying out subsequent related detection and assembly on the laminated assembly.
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