CN116504874A

CN116504874A - Photovoltaic module, preparation method thereof and series welding equipment

Info

Publication number: CN116504874A
Application number: CN202310443292.5A
Authority: CN
Inventors: 郭志球; 张池; 石家乐; 陈振东; 陶武松; 吴宇豪; 郝国晖; 黄世亮
Original assignee: Zhejiang Jinko Solar Co Ltd; Jinko Solar Co Ltd
Current assignee: Zhejiang Jinko Solar Co Ltd; Jinko Solar Co Ltd
Priority date: 2023-04-23
Filing date: 2023-04-23
Publication date: 2023-07-28

Abstract

Disclosed are a photovoltaic module, a preparation method thereof and series welding equipment, wherein the preparation method comprises the following steps: providing a plurality of battery pieces, wherein each battery piece comprises a plurality of grid line structures, and each battery piece comprises a first battery piece and a second battery piece; connecting parts are arranged on the surfaces of the first battery piece and the second battery piece and are intersected with the grid line structure; performing a welding process for alloy-contacting a portion of an intersecting region, the intersecting region being a region where one of the connection members intersects one of the plurality of gate line structures; setting at least one positioning point, wherein each positioning point is positioned on one side of the connecting part far away from the grid line structure and on the surface of the battery piece corresponding to the connecting part; the packaging layer covers the surface of the blocking film connecting component, the surface of at least one positioning point and the surfaces of the plurality of battery pieces, and the cover plate is positioned on one side of the packaging layer away from the plurality of battery pieces; lamination is performed to encapsulate the plurality of battery pieces, and the connection member is electrically connected to the plurality of grid line structures.

Description

Photovoltaic module, preparation method thereof and series welding equipment

Technical Field

The embodiment of the application relates to the field of photovoltaic modules, in particular to a photovoltaic module, a preparation method thereof and series welding equipment.

Background

Solar cells are devices that directly convert light energy into electrical energy through a photoelectric effect or a photochemical effect. The single solar cell cannot be directly used for power generation. Several single batteries must be connected in series and parallel by welding strips and tightly packaged into a module for use. Solar cell modules (also called solar panels) are the core part of and the most important part of a solar power generation system. The solar cell module is used for converting solar energy into electric energy, or sending the electric energy to a storage battery for storage, or pushing a load to work.

The battery piece is very fragile, and the upper and lower surfaces of the battery assembly are generally required to be provided with adhesive films and cover plates for protecting the battery piece. The cover plate is generally made of photovoltaic glass, the photovoltaic glass cannot be directly attached to the battery piece, and the adhesive film is required to be adhered in the middle. The connection between the battery cells typically requires a solder strip for collecting current, and conventional solder strips require alloying between the solder strip and the fine grid by welding during soldering. However, the melting point of the solder in the solder strip is generally high, and in the actual soldering process, the soldering temperature is 20 ℃ higher than the melting point of the solder. The battery piece is large in buckling deformation in the welding process, so that the hidden cracking risk after welding is large, and the breaking rate is high. In the above background, low temperature solder strips and no main grid technology have been developed in order to improve the quality of the solder. There are many factors that affect the yield of the assembly, such as the effect of the solder between the solder strip and the fine grid, the yield of the solder, and the like.

Disclosure of Invention

The embodiment of the application provides a photovoltaic module, a preparation method thereof and series welding equipment, which are at least beneficial to improving the yield of the photovoltaic module.

According to some embodiments of the present application, an aspect of embodiments of the present application provides a method for preparing a photovoltaic module, including: providing a plurality of battery pieces, wherein each battery piece of the plurality of battery pieces comprises a plurality of grid line structures which are arranged at intervals along a first direction, and the plurality of battery pieces comprise a first battery piece and a second battery piece; arranging connecting components on the surfaces of the first battery piece and the second battery piece, wherein the connecting components are intersected with at least one grid line structure of the grid line structures; performing a welding process for alloy-contacting a part of an intersecting region, the intersecting region being a region where one of the connection members intersects one of the plurality of gate line structures; setting at least one positioning point, wherein each positioning point of the at least one positioning point is positioned on one side of the connecting component far away from the grid line structure and the surface of the battery piece corresponding to the connecting component; each positioning point is positioned on two sides of the connecting component along the second direction; the packaging layer covers the surface of the connecting part, the surface of the at least one positioning point and the surfaces of the plurality of battery pieces, and the cover plate is positioned on one side, far away from the plurality of battery pieces, of the packaging layer; and carrying out lamination treatment to encapsulate the plurality of battery pieces and electrically connecting the connecting component with the plurality of grid line structures.

In some embodiments, the process step of setting at least one anchor point comprises: the step of forming the preset glue sites is carried out, and comprises the following steps: setting preset glue points on the surface of the connecting part, and curing the preset glue points; repeating the step of forming the preset glue points until the number of times of forming the preset glue points is equal to the number of the at least one positioning point, wherein the preset glue points after solidification are used as the at least one positioning point.

In some embodiments, after setting the at least one anchor point and before setting the encapsulation layer and the cover plate, further comprising: a blocking film is arranged, the blocking film is positioned on one side, far away from the grid line structure, of the connecting component, the blocking film at least covers the intersecting region and the periphery of the surface of the battery piece opposite to the intersecting region, and the battery piece is the first battery piece or the second battery piece corresponding to the intersecting region; the packaging layer covers the surface of the barrier film; the blocking film has a melting point higher than that of the encapsulation layer.

In some embodiments, the barrier film comprises a laminate film layer or a single layer film layer.

In some embodiments, one of the connection members intersects the plurality of gate line structures and constitutes a plurality of intersection regions arranged at intervals along the first direction; the disposing at least one barrier film includes: providing a plurality of barrier films arranged at intervals along the first direction, wherein each barrier film of the plurality of barrier films is opposite to each intersection region of the plurality of intersection regions; or, a barrier film extending along the first direction is provided, and the barrier film is positioned on the plurality of grid line structures and at least one positioning point.

In some embodiments, before the connecting member is provided, further comprising: glue points are arranged on the surfaces of the first battery piece or the second battery piece, and along the first direction, the glue points are positioned between two adjacent grid line structures of the grid line structures; in the process of setting the connecting component, the connecting component is embedded into the glue point.

In some embodiments, after disposing the connection member and before performing the welding process, includes: and setting a glue film, wherein the glue film at least covers the intersecting area and the periphery of the surface of the battery piece opposite to the intersecting area.

In some embodiments, disposing the glue film comprises: setting a glue film, wherein the glue film is positioned on the grid line structures; along the first direction, the length of the adhesive layer is longer than the lengths of the battery pieces corresponding to the grid line structures; or a plurality of adhesive films are arranged at intervals along the first direction, and each adhesive film of the plurality of adhesive films is opposite to each intersection area.

In some embodiments, the welding process is less than the lamination process.

According to some embodiments of the present application, there is also provided a photovoltaic module according to another aspect of the embodiments of the present application, including: a plurality of battery pieces, each of the plurality of battery pieces including a plurality of grid line structures arranged at intervals along a first direction, the plurality of battery pieces including a first battery piece and a second battery piece; the connecting component is positioned on the surfaces of the first battery piece and the second battery piece and is electrically contacted with at least one grid line structure of the grid line structures; each positioning point of the at least one positioning point is positioned at one side of the connecting component far away from the grid line structure and the surface of the battery piece corresponding to the connecting component; each positioning point is positioned on two sides of the connecting component along the second direction; the packaging layer covers the surface of the connecting part, the surface of the at least one locating point and the surfaces of the plurality of battery pieces, and the cover plate is positioned on one side, far away from the plurality of battery pieces, of the packaging layer.

In some embodiments, comprising: the blocking film is positioned on one side, far away from the grid line structure, of the connecting component, and at least covers an intersecting region and the periphery of the surface of the battery piece opposite to the intersecting region, wherein the battery piece is the first battery piece or the second battery piece corresponding to the intersecting region; the packaging layer covers the surface of the barrier film; wherein the intersecting region is a region where one of the connection members intersects one of the plurality of gate line structures.

In some embodiments, comprising: a plurality of intersecting regions arranged at intervals along the first direction; and a plurality of barrier films arranged at intervals along the first direction, wherein each barrier film of the plurality of barrier films is opposite to each intersection area.

In some embodiments, the barrier film is located on the plurality of gate line structures and the at least one anchor point.

In some embodiments, further comprising: the adhesive films are arranged at intervals along the first direction, each adhesive film of the adhesive films is located between the connecting component and each blocking film of the blocking films, and each adhesive film of the adhesive films is opposite to each intersecting area.

Accordingly, still another aspect of the embodiments of the present application provides a series welding apparatus, where the series welding apparatus is used for performing a welding process on a battery slice, and the series welding apparatus includes: a substrate having magnetic properties, the magnetic properties of the substrate being either a first polarity or a second polarity; the mounting seat is fixed on one side of the substrate along the second direction; the presser is arranged on the mounting seat and comprises a plurality of pressing needles which are sequentially arranged along a second direction, the pressing needles have magnetism, and the magnetism of the pressing needles is of a first polarity or a second polarity.

The technical scheme provided by the embodiment of the application has at least the following advantages:

in the method for manufacturing the photovoltaic module, the welding treatment is used for enabling the connecting component to be in alloy contact with the intersecting area of the grid line structure, so that the relative position of the connecting component and the grid line structure can be positioned, but the connecting component and the grid line structure are not completely alloyed, the long-time welding treatment of complete alloying and the duration of a high-temperature environment are reduced, and the damage of the long-time welding treatment to the battery piece is reduced. At least one positioning point is arranged after the welding treatment, each positioning point is positioned on one side of the connecting component far away from the grid line structure, and the corresponding battery piece surface of the connecting component can fix and position the position between the connecting component and the grid line structure again so as to prevent the offset and the separation of the connecting component. The connecting component is fixed after welding treatment or the connecting component is fixed by positioning points, so that the pushing influence of the molten packaging layer on the connecting component can be reduced, and the problem of poor contact performance caused by separation of the connecting component and immersion of the packaging layer into an intersecting area can be avoided to a certain extent.

Drawings

One or more embodiments are illustrated by way of example and not limitation in the figures of the accompanying drawings, which are not to be construed as limiting the embodiments unless specifically indicated otherwise; in order to more clearly illustrate the embodiments of the present application or the technical solutions in the conventional technology, the drawings that are required to be used in the embodiments will be briefly described below, and it is apparent that the drawings in the following description are only some embodiments of the present application, and other drawings may be obtained according to these drawings without inventive effort for a person of ordinary skill in the art.

Fig. 1 is a first process flow diagram of a method for manufacturing a photovoltaic module according to an embodiment of the present disclosure;

fig. 2 is a second process flow diagram of a method for manufacturing a photovoltaic module according to an embodiment of the present disclosure;

fig. 3 to 33 are schematic structural diagrams of a photovoltaic module corresponding to each step of a method for manufacturing a photovoltaic module according to an embodiment of the present disclosure;

fig. 34 is a schematic structural diagram of a series welding apparatus according to an embodiment of the present disclosure;

fig. 35 is a schematic structural diagram of a welding station of the series welding apparatus according to an embodiment of the present disclosure;

FIG. 36 is a schematic cross-sectional view of FIG. 34 taken along the line A1-A2;

FIG. 37 is a schematic cross-sectional view of FIG. 34 along the line B1-B2.

Detailed Description

As known from the background art, the yield of the current photovoltaic module is poor.

Analysis has found that one of the reasons for poor yield of photovoltaic modules is that conventionally alloying of the solder strip with the grid line is usually accomplished by radiating heat from the top of the solder strip towards the battery cells at a temperature 20 c higher than the solder strip temperature, so that a high melting temperature of the solder strip requires a higher reflow temperature during soldering, which can make the battery cells susceptible to thermal warpage. Thermal warping of the battery plate may compromise the integrity of the formed solder joints, thereby affecting its performance. Thermal warpage of the battery cells may also cause various solder defects such as breakage of the battery cells, pillow effect, and cold joint.

In addition, when the connection member employs a low melting point metal as a solder, and a lamination process is employed to achieve alloying of the gate line structure with the connection member. For example, in a component lamination process, the pressure and temperature of the laminator helps the low melting point metal bond with the gate line structure. However, the melting point of the adhesive film is lower than that of the solder in the solder strip, so that in the process of welding the low-melting-point metal and the grid line structure, the solder strip is usually offset or the adhesive film overflows between the solder strip and the fine grid to cause the situation of battery piece fragmentation or cold joint and the like, thereby influencing the battery performance and causing poor contact effect between the grid line structure and the connecting part.

According to the preparation method of the photovoltaic module, firstly, welding treatment is conducted on the photovoltaic module provided with the connecting component, so that the connecting component is in alloy contact with the intersecting area of the grid line structure part, the relative position of the connecting component and the grid line structure can be positioned, but the connecting component and the grid line structure are not completely alloyed, the long-time welding treatment of complete alloying and the duration of a high-temperature environment are reduced, and the damage of the long-time welding treatment to a battery piece is reduced. At least one blocking film is arranged after the welding treatment, and the blocking film is used for fixing the relative position between the connecting component and the battery piece and preventing the connecting component from deviating and separating; secondly, be used for blockking between the battery piece and the packaging layer flow of molten state when lamination processing, and then prevent to cause the electric connection problem between battery piece and the connecting piece, and improve the subassembly weldability, the tensile of welding the area direction has been improved, the subassembly welding quality has been improved, reduce the subassembly rosin joint scheduling problem, the subassembly product quality has been improved, reduce the abnormality such as repair in the subassembly processing, the productivity anchor point of subassembly has been improved greatly, every location point is located the connecting piece and is kept away from one side of grid line structure and the battery piece surface that the connecting piece corresponds, can fix and fix again the position between connecting piece and the grid line structure, in order to prevent the skew and the break away from of connecting piece. The connecting component is fixed after welding treatment or the connecting component is fixed by positioning points, so that the pushing influence of the molten packaging layer on the connecting component can be reduced, and the problem of poor contact performance caused by separation of the connecting component and immersion of the packaging layer into an intersecting area can be avoided to a certain extent.

Embodiments of the present application will be described in detail below with reference to the accompanying drawings. However, as will be appreciated by those of ordinary skill in the art, in the various embodiments of the present application, numerous technical details have been set forth in order to provide a better understanding of the present application. However, the technical solutions claimed in the present application can be implemented without these technical details and with various changes and modifications based on the following embodiments.

Fig. 1 is a process flow diagram of a method for manufacturing a photovoltaic module according to an embodiment of the present disclosure; fig. 2 is a second process flow diagram of a method for manufacturing a photovoltaic module according to an embodiment of the present disclosure; fig. 3 to 33 are schematic structural diagrams of a photovoltaic module corresponding to each step of the method for manufacturing a photovoltaic module according to an embodiment of the present application.

Wherein fig. 5 and 6 are sectional views of the axis of the connecting member of fig. 4 along a first direction. FIG. 7 is a cross-sectional view of the connecting member of FIG. 4 along an axis of the connecting member in a second direction; FIG. 8 is a cross-sectional view of a photovoltaic module after a soldering process; fig. 9 is a partial enlarged view of the intersection region. FIG. 11 is a cross-sectional view of the connecting member of FIG. 10 along an axis of the connecting member in a second direction; fig. 12 to 14 are sectional views of a first preparation method (at least one anchor point is provided in fig. 10) along a second direction; FIGS. 20 to 21 are sectional views along a first direction of a first production method; fig. 16 to 19 are sectional views of a second manufacturing method (a plurality of barrier films spaced apart in fig. 15) along a second direction; fig. 20 to 24 are sectional views along a first direction of a second production method. Fig. 26 to 28 are sectional views of a third preparation method (a plurality of continuous barrier films in fig. 25) along the second direction. Fig. 29 to 31 are schematic structural diagrams of photovoltaic modules prepared by a fourth preparation method corresponding to the set glue sites. Fig. 32 and 33 are schematic structural diagrams of photovoltaic modules prepared by a fifth preparation method corresponding to the setting of the adhesive film.

Note that the areas surrounded by the broken lines in fig. 7 to 9, 20 to 23, 26, and 27 are intersecting areas.

Referring to fig. 1 and 3, the preparation method includes: a plurality of battery cells are provided, each of the plurality of battery cells including a plurality of gate line structures 101 arranged at intervals along the first direction X, the plurality of battery cells including a first battery cell 11 and a second battery cell 12.

In some embodiments, the battery pieces include, but are not limited to, any of PERC cells (Passivated Emitter and Rear Cell, emitter and back side passivated cells), PERT cells (Passivated Emitter and Rear Totally-diffused cells, passivated emitter back side fully diffused cells), TOPCon cells (Tunnel Oxide Passivated Contact, tunnel oxide passivation contact cells), HIT/HJT cells (Heterojunction Technology, heterojunction cells). In some embodiments, the cell sheet may be a monocrystalline silicon solar cell, a polycrystalline silicon solar cell, an amorphous silicon solar cell, or a multi-compound solar cell, which may be specifically a cadmium sulfide solar cell, a gallium arsenide solar cell, a copper indium selenium solar cell, or a perovskite solar cell.

In some embodiments, the battery piece is a full back electrode contact crystalline silicon solar cell (Interdigitated back contact, IBC), where the IBC battery refers to a back junction back contact solar cell structure in which positive and negative metal electrodes are arranged on the back surface of the battery in an interdigital manner, and the PN junction and the electrodes thereof are located on the back surface of the battery, that is, the electrodes of the emitter region and the base region of the IBC battery are all located on the back surface, and the front surface is free of grid line shielding, so that the photoelectric conversion performance of the battery can be improved.

The battery piece is a whole battery or a slice battery. A sliced cell refers to a cell sheet formed by cutting a complete whole cell. The cutting process comprises the following steps: laser grooving and cutting processes and thermal stress battery separation processes. In some embodiments, the sliced cells are half-cells, which may also be understood as half-sliced cells or half-cells. The half-cell assembly functions to increase the generated power by reducing the resistance loss. From ohm's law, solar cell interconnect electrical losses are proportional to the square of the current magnitude. After the battery is cut into two halves, the current is reduced by half, and the electric loss is reduced to one quarter of the full-size battery loss. The increase in the number of cells also correspondingly increases the number of cell gaps that help to boost the short circuit current through reflection from the back plate of the assembly. In addition, cutting the half cell assembly can optimize the width of the cell solder strip, which conventionally requires an optimized balance between increasing the solder strip width to reduce electrical losses and decreasing the solder strip width to reduce shading losses. And the half-cut battery assembly reduces battery loss, so that the width of the welding strip can be set thinner to reduce shading loss, and the battery efficiency and the power generation power consumption are improved. In some embodiments, the sliced cell may be a three-slice cell, a 4-slice cell, an 8-slice cell, or the like.

In some embodiments, the grid line structure 101 is used to collect photo-generated current within the solar cell body and lead to the outside of the cell. The battery piece comprises a main grid line and an auxiliary grid line, the auxiliary grid line is intersected with the extending direction of the main grid line, the auxiliary grid line is used for collecting the current of the substrate, and the main grid line is used for summarizing the current of the auxiliary grid line and transmitting the current to the welding strip. In some embodiments, the grid line structure 101 is an auxiliary grid line, which may also be called an auxiliary grid line, and the auxiliary grid line is used for guiding current, and the cell is designed without a main grid, so that a carrier transport path is shortened, a series resistance is reduced, a front light receiving area is increased, a component power is increased, and a short circuit current is improved, so that the usage amount of printing silver paste of the grid line is reduced to reduce the production cost.

In some embodiments, the gate line structure 101 includes a first electrode and a second electrode. The first surface of the battery piece is provided with a first electrode, and one side opposite to the first surface, namely the second surface is provided with a second electrode, wherein the first electrode is one of a positive electrode and a negative electrode, and the second electrode is the other of the positive electrode and the negative electrode.

Referring to fig. 4 to 7 and 20, the preparation method includes: the connection member 110 is provided on the surfaces of the first and second battery pieces 11 and 12, and the connection member 110 intersects at least one of the plurality of grid line structures 101. The intersection region 102 is a region where one connection member 110 intersects one gate line structure 101 of the plurality of gate line structures.

In some embodiments, the first battery cells 11 and the second battery cells 12 are connected in series or parallel by the connection member 110 to form a battery string, and the adjacent battery cells 10 have a battery gap therebetween to achieve electrical insulation between the different battery cells 10. Specifically, the connection member 110 connects the first electrode of the first battery cell 11 and the second electrode of the adjacent second battery cell 12, or the connection member 110 connects the second electrode of the first battery cell 11 and the first electrode of the adjacent second battery cell 12.

In some embodiments, referring to fig. 5, the first surfaces of the first battery plate 11 and the second battery plate 12 are all facing the same side, and the second surfaces of the first battery plate 11 and the second battery plate 12 are all facing the same side, or the first electrodes of all battery plates are facing the same side, and the second electrodes of all battery plates are facing the same side, the connection member 110 needs to extend from the first surface of the battery plate to the second surface of the adjacent battery plate, so that the connection member 110 connects the first electrodes and the second electrodes of the adjacent battery plates.

In some embodiments, referring to fig. 6, the first and second battery plates 11 and 12 are sequentially arranged in the order of the first surface, the second surface, the first surface, and the second surface, the connection member 110 is not bent, and the connection member 110 directly connects the first electrode of the first battery plate 11 and the second electrode of the second battery plate adjacent thereto.

In some embodiments, the connection members 110 are solder strips that are used for interconnection between the battery cells 10 and to concentrate current transmission to elements external to the photovoltaic module. The solder strips include a bus solder strip for connecting the string of photovoltaic cells and the junction box, and an interconnect solder strip for connecting between the first cell 11 and the second cell 12.

In some embodiments, the connection member 110 is a core-in-package structure, and the connection member 110 includes a conductive layer 111 and a solder layer 112 covering a surface of the conductive layer. The conductive layer 111 is a main conductive transport layer of the connection part 110, and thus, the lower the resistivity of the conductive layer 111 is, the smaller the electrical loss of the connection part 110 is, and the better the battery efficiency and the generated power are. The material of the conductive layer 111 is a conductive material with good conductivity such as copper, nickel, gold, silver, or an alloy material with low resistivity.

In some embodiments, the solder layer 112 may be plated on the surface of the conductive layer 111 or coated on the surface of the conductive layer 111, and specifically, the source material of the solder layer 112 may be uniformly coated around the conductive layer 111 according to a certain component ratio and thickness by using a special process such as electroplating, vacuum deposition, spraying or hot dip coating. The solder layer 112 is mainly used for enabling the connection member 110 to meet the weldability, and firmly welding the connection member 110 on the grid line structure 101 of the battery chip 10 to perform a good current guiding function.

In some embodiments, the material of the solder layer 112 is a metal material or an alloy material having a lower melting point than the conductive layer 111, such as a tin alloy, which may include a tin-zinc alloy, a tin-bismuth alloy, or a tin-indium alloy. And the tin is used for welding a welding material, has a low melting point, has good affinity with metals such as copper and the like, and has good welding fastness. The lead in the tin-lead alloy can reduce the melting point of the welding strip, and the tin and the lead can form a eutectic point with the melting point of 183 ℃, so that the tin-lead alloy has good welding performance and usability. The embodiment of the application can reduce the melting point temperature and the surface tension by replacing lead with other metal elements or adding other elements, such as bismuth element, to the tin-lead alloy. The melting point of the tin-bismuth alloy can be reduced to 139 ℃ to meet the requirement of low-temperature welding.

In some embodiments, the solder layer 112 has a flux therein, which refers to a chemical substance that aids and facilitates the soldering process while protecting against oxidation reactions during the soldering process. The flux includes an inorganic flux, an organic flux, and a resin flux. It is understood that the flux has a melting point lower than that of the solder layer 112 and increases fluidity of the solder layer 112 in a molten state to form a good alloying of the solder layer 112 with the gate line structure 101.

In some embodiments, the cross-section along the second direction Y of the connection member 110 is circular in cross-sectional shape, and the circular solder strip is free from orientation problems and alignment problems, which is easier to mass produce. In some embodiments, the cross-sectional shape of the connection member 110 may be triangular or any other shape to increase the contact area of the solder strip with the gate line structure and to improve the alignment offset problem of the connection member 110 with the gate line structure 101.

In some embodiments, the surface of the connection member 110 remote from the battery cell 10 has a light reflective layer on the outer side of the solder layer 112 remote from the conductive layer 111 and the battery cell 10. The light reflecting layer serves to improve electrical loss due to the shielding area of the connection member 110 to the battery cell 10. In some embodiments, the outer surface of the solder layer 112 has reflective grooves, which are concave grooves or channels facing the conductive layer 111 from the solder layer 112, and sunlight is reflected onto the battery cells 10 through the sidewalls of the reflective grooves, thereby improving the utilization rate of sunlight.

Referring to fig. 1, 8 to 9 and 21, the preparation method includes: a welding process is performed for alloy contacting the part of the intersection region 102 to form an alloy layer 113. Since the metal element in the gate line structure 101 migrates into the connection member and the metal element in the connection member migrates into the gate line structure 101, the region between the connection member and the gate line structure containing both metal elements constitutes the alloy layer 113.

In some embodiments, the duration of the soldering process is shorter and the temperature of the soldering process is lower, so that the alloy layer 113 is formed in the partially intersected region to locate the relative position of the connection member 110 and the grid line structure 101, and to reduce the damage to the battery cell caused by the long-time soldering process.

It will be appreciated that the duration of the welding process has a positive correlation with the duty cycle of the alloy layer 113 at the intersection region 102. When the duration of the soldering process is long, the area ratio of the formed alloy layer 113 will correspondingly increase, so that the contact performance between the connection member 110 and the grid line structure 101 will also be better, and the yield of the photovoltaic module will correspondingly increase. On the contrary, when the duration of the welding process is short, the area ratio of the formed alloy layer 113 is correspondingly reduced, so that the thermal damage to the battery piece is less, and the breakage rate of the photovoltaic module is also reduced. Similarly, the temperature of the welding process has a positive correlation with the duty cycle of the alloy layer 113 at the intersection region 102.

In some embodiments, the temperature of the soldering process may be greater than the melting point of the solder layer 112 in the connection member 110. The soldering process may include an infrared process or an electric soldering iron heat process.

Referring to fig. 1, 10 and 11, the preparation method includes: at least one positioning point is arranged, and each positioning point 103 of the at least one positioning point is positioned on one side of the connecting part 110 away from the grid line structure 101 and on the surface of the battery piece corresponding to the connecting part 110. The position between the connection member and the gate line structure may be fixed and positioned again to prevent the connection member from being shifted and detached. The connecting component is fixed after welding treatment or the connecting component is fixed by positioning points, so that the pushing influence of the molten packaging layer on the connecting component can be reduced, and the problem of poor contact performance caused by separation of the connecting component and immersion of the packaging layer into an intersecting area can be avoided to a certain extent.

In some embodiments, each of the positioning points 103 is located on both sides of the connection member 110 in the second direction Y. By positioning the connection member 110 with the positioning points 103 on opposite sides, a relative force can be applied to the connection member 110, preventing movement and displacement of the connection member.

In some embodiments, the process step of setting at least one anchor point comprises: the step of forming the preset glue sites is carried out, and comprises the following steps: setting preset glue points on the surface of the connecting part, and curing the preset glue points; repeating the step of forming the preset glue points until the number of times of forming the preset glue points is equal to the number of at least one positioning point, wherein the cured preset glue points are used as at least one positioning point. The curing treatment includes an ultraviolet curing treatment and a heat curing treatment.

In some embodiments, the material of the preset glue sites may include any glue having a viscosity and a fluidity, so that the glue may not be located at the top end of the connection member and may exhaust air located at the gap between the connection member and the battery cell.

In some embodiments, the relationship between the height S of the vertex of the anchor point 103 from the battery piece and the maximum height L of the connecting member 110 along the direction perpendicular to the surface of the battery piece satisfies 0.2 L.ltoreq.S.ltoreq.1.2L, for example, L is greater than S as shown in FIG. 11.

In some embodiments, the shielding area and the contact performance can be regulated by regulating the relation between S and L, for example, if S is larger, the contact performance is better, and the shielding of the positioning point 103 on the battery piece and the thickness of the photovoltaic module are correspondingly increased.

Referring to fig. 1 and 12, the preparation method includes: an encapsulation layer 13 and a cover plate 14 are provided, the encapsulation layer 13 covers the surface of the connecting part 110, at least one positioning point 103 and the surfaces of the plurality of battery pieces 10, and the cover plate 14 is positioned on one side of the encapsulation layer 13 away from the plurality of battery pieces 10.

In some embodiments, the melting point of the encapsulation layer 13 is less than the lamination temperature during the lamination process, and the encapsulation layer 13 is a film layer formed by the macromolecules in a cross-linked state formed by the micromolecules in the adhesive film by combining with each other due to the initiator in the encapsulation layer 13 after the adhesive film is in a molten state at the temperature of the laminating machine. The material of the encapsulating layer 13 includes an organic encapsulating film such as an ethylene-vinyl acetate copolymer (EVA) film, a Polyethylene Octene Elastomer (POE) film, or a polyvinyl butyral (PVB) film.

In some embodiments, the melting point of the encapsulation layer 13 and the melting point of the connection component 110 may be set according to practical requirements. When the melting point of the encapsulation layer 13 is greater than that of the connection part 110, the connection part 110 can be alloyed before the encapsulation layer 13 is in a molten state, so that the molten adhesive film can be effectively prevented from being immersed into the grid line structure 101 and the connection part 110 and pushing the connection part 110 to deviate. When the melting point of the encapsulation layer 13 is smaller than that of the connection part 110, the lamination temperature can be set to be lower, so that the thermal stress of the battery piece is improved, and the yield of the photovoltaic module is improved.

In some embodiments, the cover 14 may be a glass cover, a plastic cover, or the like having a light-transmitting function. Specifically, the surface of the cover plate 14 facing the encapsulation layer 13 may be a concave-convex surface, thereby increasing the utilization rate of incident light. The cover 14 includes a first cover plate opposite to the first surface of the battery cell 10 and a second cover plate opposite to the second surface of the battery cell 10.

Referring to fig. 1, 13 and 14, the preparation method includes: lamination is performed to encapsulate the plurality of battery cells 10, and the connection member 110 is electrically connected to the plurality of grid line structures 101.

In some embodiments, a welding process is used to make a portion of the intersection region 102 into the alloy layer 113 and a lamination process is used to make a majority of the intersection region 102 into the alloy layer 113. The duration of the welding process is shorter than that of the lamination process, so that thermal damage to the surface of the battery piece 10 during the welding process can be reduced, the lamination process has a packaging layer and a cover plate in the middle as a protective layer, the duration of the lamination process can ensure that most of the intersection areas 102 form the alloy layer 113, and the thermal damage to the battery piece is also smaller.

According to the preparation method of the photovoltaic module, firstly, welding treatment is conducted on the photovoltaic module provided with the connecting component, so that the connecting component is in alloy contact with the intersecting area of the grid line structure part, the relative position of the connecting component and the grid line structure can be positioned, but the connecting component and the grid line structure are not completely alloyed, the long-time welding treatment of complete alloying and the duration of a high-temperature environment are reduced, and the damage of the long-time welding treatment to a battery piece is reduced. At least one positioning point is arranged after the welding treatment, each positioning point is positioned on one side of the connecting component far away from the grid line structure, and the corresponding battery piece surface of the connecting component can fix and position the position between the connecting component and the grid line structure again so as to prevent the offset and the separation of the connecting component. The connecting component is fixed after welding treatment or the connecting component is fixed by positioning points, so that the pushing influence of the molten packaging layer on the connecting component can be reduced, and the problem of poor contact performance caused by separation of the connecting component and immersion of the packaging layer into an intersecting area can be avoided to a certain extent.

Correspondingly, referring to fig. 2, the second embodiment and the third embodiment of the present application also provide a method for preparing a photovoltaic module, which is the same as the implementation steps of the previous embodiment, and is different in that: after setting at least one anchor point and before setting the encapsulation layer and the cover plate, further comprising: a barrier film is provided. The same steps as those of the above embodiment will not be repeated here.

In some embodiments, the method of making comprises: a plurality of battery cells 10 are provided, each battery cell 10 of the plurality of battery cells including a plurality of grid line structures 101 arranged at intervals along the first direction X, the plurality of battery cells including a first battery cell 11 and a second battery cell 12. The preparation method comprises the following steps: the connection member 110 is provided on the surfaces of the first and second battery pieces 11 and 12, and the connection member 110 intersects at least one of the plurality of grid line structures 101. The preparation method comprises the following steps: a welding process is performed for alloy contacting the part of the intersection region 102 to form an alloy layer 113.

Referring to fig. 2, 15, 16 and 22, the preparation method includes: the barrier film 120 is disposed, the barrier film 120 is located on one side of the connection part 110 away from the grid line structure 101, the barrier film 120 covers at least the intersection region 102 and the periphery of the surface of the battery cell 10 opposite to the intersection region 102, and the battery cell may refer to the first battery cell 11 or the second battery cell 12 corresponding to the intersection region 102. In this way, the barrier film 120 completely encapsulates the contact interface between the connection member 110 and the grid line structure 101, so as to prevent the molten encapsulation layer from penetrating into the contact interface between the grid line structure 101 and the connection member 110 during the lamination process, thereby affecting the contact performance between the connection member 110 and the grid line structure 101 and further affecting the yield of the photovoltaic module.

In some embodiments, adjacent barrier films 120 do not contact each other along the second direction Y, so that, on one hand, the blocking area of the non-transparent barrier film 120 on the battery sheet 10 can be reduced to reduce optical loss; on the other hand, the softness and permeability of the barrier films 120 may not be the same as those of the encapsulation layer, so that adjacent barrier films 120 are not contacted, and defects (gaps or air intervals) in the photovoltaic module are reduced as much as possible, so that air is discharged as much as possible, and the situation that the encapsulation layer or the barrier films 120 are separated from the surface of the cell 10 due to heating of the air, and then the cell 10 is corroded by moisture is avoided.

In some embodiments, the barrier film 120 may also be used as a compensation part of the encapsulation layer after the lamination process, which is beneficial to reduce the risk of the adhesive film on the surface of the connection component 110 being thinner and the connection component 110 penetrating through the encapsulation layer, and since the barrier film 120 is used as a part of the encapsulation layer, the thickness of the encapsulation layer may be correspondingly reduced, thereby reducing the manufacturing cost of the encapsulation layer. The thickness of the packaging layer is reduced, so that the absorption of the packaging layer to light is reduced, sunlight received by the battery piece 10 is increased, and the photoelectric conversion efficiency of the battery piece 10 is improved. The barrier film 120 may also be used to insulate moisture to improve the performance of the gate line structure 101.

In some embodiments, the barrier film 120 comprises a laminate film layer or a single layer film layer. When the barrier film 120 is a single film layer, the barrier film 120 is a barrier film. When the barrier film 120 is a laminate film layer, the barrier film 120 includes an adhesive film and a release film.

In some embodiments, the adhesive film refers to a film layer composed of a material having tackiness for fixing the connection member 110 to the battery cell 10, preventing the connection member 110 from being deviated in a step before the lamination process; and, preventing the pushing of the molten encapsulation layer against the connection member 110 during the lamination process from causing the connection member 110 to be deviated.

In some embodiments, the adhesive film material includes EVA (ethylene vinyl acetate), acrylates, PE (polyethylene), or the like. When the adhesive film is made of EVA, the adhesive film has certain water resistance and corrosion resistance while ensuring certain adhesiveness so that the connection member 110 is fixed on the battery sheet 10, and can be used as a barrier layer for preventing penetration of the molten encapsulation layer into the connection member 110 and the grid line structure 101 and a protective layer for preventing moisture. The cost of EVA production is low, and the cost of composite membrane 104 production is correspondingly reduced.

When the material of the adhesive film is acrylic esters, the acrylic esters have certain transparency, so that the optical loss of the battery piece 10 is reduced; the acrylic ester can be directly cured in an environment with low temperature, the curing speed is high, the thermal stress on the battery piece 10 is reduced, the risk of breakage of the battery piece 10 is reduced, and the yield of the photovoltaic module is improved; the acrylic acid ester has good water resistance and can be used for preventing the connection part 110 from being damaged by water vapor.

In some embodiments, the thickness of the adhesive film ranges from 10 μm to 150 μm. The thickness of the adhesive film may range from 10 μm to 130 μm, from 10 μm to 109 μm, from 10 μm to 85 μm, from 10 μm to 139 μm, from 30 μm to 150 μm, from 68 μm to 150 μm, from 102 μm to 150 μm, or from 49 μm to 104 μm. The thickness of the adhesive film may be in particular 15 μm, 29 μm, 65 μm, 89 μm, 106 μm, 134 μm or 150 μm. When the thickness of the adhesive film is within the above range, the adhesive film has a sufficient thickness for fixing the connection member 110 on the surface of the battery sheet 10 without being deviated in the subsequent step, and the adhesive film does not occupy more thickness of the photovoltaic module, so as to reduce the thickness of the photovoltaic module to a certain extent, thereby achieving high integration of the photovoltaic module.

In some embodiments, the glass transition temperature of the adhesive film ranges from-55 ℃ to 0 ℃, and the glass transition temperature of the adhesive film is in a high-elasticity state in the normal temperature process, so that the adhesive film can have a certain viscosity for fixing the connecting component 110 and preventing the connecting component 110 from being deviated by the composite film 104, and also for preventing moisture and a molten encapsulation layer from invading from a contact interface between the battery piece 10 and the composite film 104; secondly, some modifier with higher glass transition temperature can be added into the pure polymer material with viscosity in the adhesive film, so that the glass transition temperature of the adhesive film is larger than that of the packaging layer, when the packaging layer is in a molten state, the adhesive film is not molten and is in a glass state, and the molten packaging layer cannot be immersed between the connecting part 110 and the grid line structure 101 through the adhesive film. The glass transition temperature of the adhesive film ranges from-53 ℃ to-1 ℃, from-48 ℃ to-14 ℃, from-31 ℃ to-1 ℃ or from-38 ℃ to-15 ℃.

The glass transition temperature (Tg) refers to a temperature corresponding to the transition from a glass state to a highly elastic state (rubbery state). At lower temperature, the material is in a rigid solid state, similar to glass, and can only generate very small deformation under the action of external force, and the state is a glass state: when the temperature continues to rise to a certain range, the deformation of the material is obviously increased, and the deformation is relatively stable in a certain subsequent temperature interval, wherein the state is a high-elasticity state, the deformation amount is gradually increased when the temperature continues to rise, the material gradually becomes viscous fluid, and the deformation cannot be recovered at the moment, and the state is a viscous state. The glass transition temperature can be measured by a DSC (Differential scanning calorimetry, differential scanning calorimeter) instrument.

In some embodiments, the isolation film refers to a film layer having a certain isolation property for preventing the encapsulation layer in a molten state from penetrating between the connection part 110 and the gate line structure 101 and isolating moisture. The material of the release film includes PET (polyethylene terephthalate), POE (polyolefin), liquid silicone, or PVB (polyvinyl butyral). POE is a nonpolar material, has excellent water vapor barrier capability and ion barrier capability, and the water vapor transmittance is only about 1/8 of that of the EVA adhesive film; because the molecular chain structure is stable, acidic substances are not generated by decomposition in the aging process, and the aging resistance is excellent; PVB has good water resistance, resistance and oil resistance, PVB resin has good optical definition, the refractive index of the PVB resin is similar to that of glass, an image picked up by laminated glass cannot generate optical distortion and double phases, and the loss of incident light contacted with the surface of a photovoltaic module can be reduced. PVB can remain undeformed over a wide temperature range; has the combination of rigidity and flexibility and excellent shock resistance; has excellent adhesion efficiency with various glass surfaces. The liquid silica gel has excellent tearing resistance, rebound resilience, yellowing resistance, heat stability, heat resistance, ageing resistance and the like, and meanwhile, the liquid silica gel has moderate viscosity, convenient operation and high transparency.

In some embodiments, the thickness of the release film ranges from 20 μm to 50 μm. The thickness of the separator may range from 20 μm to 45 μm, from 20 μm to 38 μm, from 20 μm to 31 μm, from 25 μm to 50 μm, from 36 μm to 50 μm, from 23 μm to 48 μm, from 31 μm to 42 μm, or from 30 μm to 40 μm. The thickness of the separator may be in particular 23 μm, 26 μm, 31 μm, 36 μm, 39 μm, 45 μm or 50 μm. When the thickness of the isolation film is within the above range, the isolation film has enough thickness for preventing moisture and the packaging layer in a molten state, and the isolation film does not occupy more thickness of the photovoltaic module, so that the thickness of the photovoltaic module is reduced to a certain extent, and the high integration level of the photovoltaic module is realized. In addition, the isolation film has less light absorption, so that the photoelectric conversion efficiency of the battery piece is improved.

In some embodiments, the ratio of the thickness of the adhesive film to the thickness of the release film is 1/5 to 75. The ratio of the thickness of the adhesive film to the thickness of the release film may be 1/5 to 50, 1/5 to 35, 1/5 to 10, 1 to 75, 18 to 75, 35 to 75, 25 to 51, or 39 to 73. The ratio of the thickness of the adhesive film to the thickness of the release film may be, in particular, 1.3, 10.2, 19.8, 28, 37, 52, 58, 67.5 or 75. The thickness of the adhesive film and the thickness of the isolating film are in the above range, if the thickness of the adhesive film is larger, the proportion of the isolating film is smaller, the softness of the adhesive film is greater than that of the isolating film, if the proportion of the adhesive film is more, the composite film 104 is more easily close to the connecting part 110, and the gap between the composite film 104 and the connecting part 110 is smaller; the thickness of the separation film is large, so that the separation effect is good, and moisture and the like are prevented from being immersed in the battery piece 10. Wherein, the softness degree refers to the flexibility of the film layer or the fitting degree between the film layer and the connecting member.

In some embodiments, at the same preset temperature, the viscosity of the adhesive film is greater than that of the separator, so that the adhesive film may have sufficient viscosity to ensure the adhesion performance between the connection part 110 and the battery piece 10, so that the space formed by the composite film 104 and the battery piece 10 has a certain compactness for preventing the intrusion of the encapsulation layer 13.

In some embodiments, the adhesive film prior to lamination curing has a viscosity number in the range 8000-20000 mPa-s. The adhesive film has a certain fluidity and poor compactness before solidification, and can be discharged to prevent the adhesive film from being ejected by heat in the follow-up air so as to enable the molten adhesive film to flow between the connecting part and the grid line structure. The adhesive film may have a viscosity increased to 10000-30000mPa s after lamination and curing, so that there is sufficient connection force between the connection member 110 and the surface of the battery sheet 10, and the connection member 110 is protected from infiltration of the encapsulation layer 13 during lamination and erosion of moisture in long-term use of the assembly.

In some embodiments, the material of the release film is different from the material of the adhesive film; the water permeability of the material of the isolating film is 2-4 g/m2. The water permeability of the isolating film ranges from 2 to 3.3g/m2, from 2 to 2.8g/m2, from 2 to 2.64g/m2, from 2.35 to 3.89g/m2, from 2.8 to 3.96g/m2 or from 2.6 to 3.35g/m2, and the water permeability of the isolating film can be specifically 2.05g/m2, 2.45g/m2, 2.98g/m2, 3.17g/m2, 3.56g/m2 or 4g/m2. The above-mentioned range of the isolating film shows that the isolating film has good isolating performance, i.e. the isolating performance is the isolating performance of the isolating film to the liquid, the water vapor and other penetrating matters. The barrier property is better, and the molten encapsulation layer cannot pass through the isolation film, and small molecules, moisture and the like of the permeated encapsulation layer cannot pass through, so that better protection of the connecting component 110 is realized.

The water vapor permeability (water vapor permeability) includes both the water vapor permeability and the water vapor permeability coefficient, and the water vapor permeability indicates the weight of the water vapor permeable material under a certain temperature and humidity condition for a certain period of time. The water vapor permeability means the amount of water vapor transmitted through a unit thickness and a unit area of a sample per unit time under a unit water vapor pressure difference in a predetermined temperature and relative humidity environment.

In some embodiments, the glass transition temperature of the separator ranges from 100 to 200 ℃, the glass transition temperature of the separator ranges from 130 to 200 ℃, 153 to 200 ℃, 189 to 200 ℃, or 150 to 184 ℃. The glass transition temperature range of the isolation film is used to ensure that the glass transition temperature of the isolation film is greater than the glass transition temperature of the encapsulation layer 13, and when the encapsulation layer is in a molten state, the isolation film is not molten yet and is in a glass state, and the encapsulation layer in the molten state cannot be immersed between the connection member 110 and the gate line structure 101 through the isolation film.

In some embodiments, the barrier properties of the barrier film may be increased by adding a plasticizer within the barrier film. According to the embodiment of the application, the connecting effect between the isolating film and the battery piece can be improved by adding some small molecules with viscosity into the isolating film, and the offset of the connecting part and the invasion of the packaging layer are avoided. The embodiment of the application can further increase the glass transition temperature of the isolating film by adding some small molecules with high glass transition temperature into the isolating film.

In some embodiments, the release film surrounds a portion of the adhesive film, and then the release film encapsulates the adhesive film, with a greater proportion of the release film being used to prevent ingress of molten encapsulation and moisture for the contact interface between the battery sheet 10 and the barrier film 120.

In some embodiments, the adhesive film surrounds a portion of the separator, and the separator is not in contact with the battery piece 10, so that the more contact surfaces between the adhesive film and the battery piece 10, the better the adhesion effect between the barrier film 120 and the battery piece 10, and the lower the probability of misalignment between the battery piece 10 and the connection member 110. In addition, the compactness of the adhesive film is worse than that of the isolating film, so that air between the adhesive film, the battery piece 10 and the connecting part 110 can be discharged through the adhesive film, and the situation that air exists in a space under the wrapping of the barrier film 120 and pushes the barrier film 120 open, and even the barrier film 120 is separated from the battery piece 10 in the subsequent lamination treatment or any heat treatment process is prevented.

In some embodiments, the side of the blocking film 120 away from the battery cell 10 has a reflective layer or a light emitting groove to increase the solar light utilization and improve the photoelectric conversion efficiency of the battery cell.

In some embodiments, referring to fig. 15, one connection part 110 intersects the plurality of gate line structures 101 and constitutes a plurality of intersecting regions spaced apart along the first direction X; providing at least one barrier film 120 includes: a plurality of barrier films 120 are disposed to be spaced apart along the first direction X, and each barrier film 120 of the plurality of barrier films is opposite to each of the plurality of intersecting regions. In this way, the barrier film 120 covers the area where the gate line structure 101 and the connection member 110 intersect, thereby providing good protection and effectively preventing the encapsulation layer from being immersed during the lamination process. The barrier films 120 are discontinuous at intervals, so that the manufacturing cost of the photovoltaic module can be reduced, the shielding area of the barrier films 120 can be reduced, and the gas discharge is facilitated.

In some embodiments, referring to fig. 25 and 26, one barrier film 120 extending in the first direction X is provided, and the barrier film 12 is located on the plurality of gate line structures 101 and the at least one anchor point 103. By providing the continuous and extended barrier film 120, the number of steps required to align the plurality of barrier films 120 with the intersection area is reduced, and the difficulty in manufacturing the photovoltaic module is reduced. The barrier film 120 is not only located in the intersecting region, but also located in the region between the adjacent gate line structures 101, so that the barrier film 120 can prevent the package layer from being immersed from the contact position between the connection member 110 and the battery cell in the non-intersecting region, and effectively avoid the contact performance between the battery cell and the connection member 110 from being affected by the package layer.

Referring to fig. 2, 17, 23 and 27, the preparation method includes: an encapsulation layer 13 and a cover plate 14 are provided, the encapsulation layer 13 covers the surface of the blocking film 120, the surface of the connecting part 110, at least one positioning point 103 and the surfaces of the plurality of battery pieces 10, and the cover plate 14 is positioned on one side of the encapsulation layer 13 away from the plurality of battery pieces 10.

In some embodiments, the melting point of the encapsulation layer 13 is less than the lamination temperature at the lamination process. The melting point of the encapsulation layer 13 and the melting point of the connection member 110 can be set according to practical requirements.

In some embodiments, the melting point of the barrier film 120 is higher than the melting point of the encapsulation layer 13. When the encapsulation layer 13 is in a molten state, the barrier film 120 still maintains a good morphology, so that the molten adhesive film is effectively prevented from being immersed into the gate line structure 101 and the connection part 110 and pushing the connection part 110 to deviate. For example, at least one of the adhesive film and the release film may have a melting point greater than that of the encapsulation layer.

In some embodiments, the cover 14 may be a glass cover, a plastic cover, or the like having a light-transmitting function. The cover 14 includes a first cover plate opposite to the first surface of the battery cell 10 and a second cover plate opposite to the second surface of the battery cell 10.

Referring to fig. 2, 18, 24 and 28, the preparation method includes: lamination is performed to encapsulate the plurality of battery cells 10, and the connection member 110 is electrically connected to the plurality of grid line structures 101.

Referring to fig. 19, the barrier film is used as a part of the encapsulation layer 13, that is, the film layer of the barrier film is not formed in the photovoltaic module formed after the lamination process, the materials of the barrier film and the encapsulation layer 13 may be the same material, and the original film layer constituting the barrier film is subjected to pretreatment to form the film layer having a higher degree of crosslinking, that is, the barrier film. Due to the increase of the crosslinking degree, the melting point of the barrier film is larger than that of the packaging layer 13, and the viscosity of the barrier film is larger than that of the packaging layer 13, on one hand, the barrier film can assist the mutual fixation between the connecting component 110 and the battery piece 10, and prevent the connecting component 110 from shifting and separating from the surface of the battery piece 10 in the lamination process; on the other hand, during the lamination process, the encapsulation layer 13 is in a molten state, but the barrier film is in a more compact solid state, so that the molten adhesive film can be prevented from flowing between the gate line structure 101 and the connection member 110.

In the method for manufacturing the photovoltaic module provided by the embodiment of the present application, the welding process is used to make the connection member 110 and the grid line structure 102 partially intersect the region 102 in alloy contact, so that the relative position of the connection member 110 and the grid line structure 101 can be positioned, and the damage of the long-time welding process to the battery piece 10 is reduced. After the welding process, at least one blocking film 120 is arranged, wherein the blocking film 120 is used for fixing the relative position between the connecting part 110 and the battery piece 10 and preventing the connecting part 110 from deviating and separating; secondly, the packaging layer 13 in a molten state flows between the connecting part 110 and the battery piece 10 during the barrier lamination treatment, so that the problem of electric connection between the battery piece 10 and the connecting part 110 is caused, the weldability of the component is improved, the tensile force in the welding strip direction is improved, the welding quality of the component is improved, the problems of false welding of the component and the like are reduced, the product quality of the component is improved, the abnormality such as repair in the component manufacturing process is reduced, and the productivity of the component is greatly improved.

Correspondingly, referring to fig. 29 to 31, the fourth embodiment of the present application also provides a method for manufacturing a photovoltaic module, which is the same as the implementation steps of the previous embodiment, and is different in that: before the connection part 110 is provided, it further includes: glue points 104 are arranged on the surfaces of the first battery piece 11 or the second battery piece 12, and the glue points 104 are positioned between two adjacent grid line structures 101 of the grid line structures along the second direction Y; in the process of setting the connection part 110, the connection part 110 is embedded into the glue sites 104. The same steps as those of the above embodiment will not be repeated here.

In some embodiments, the method of making comprises: a plurality of battery cells 10 are provided, each battery cell 10 of the plurality of battery cells including a plurality of grid line structures 101 arranged at intervals along the first direction X, the plurality of battery cells including a first battery cell 11 and a second battery cell 12.

Referring to fig. 29, the preparation method includes: glue sites 104 are arranged on the surfaces of the first battery piece 11 or the second battery piece 12, and the glue sites 104 are located between two adjacent grid line structures 101 of the grid line structures along the second direction Y.

In some embodiments, the glue material used to make the glue dots 104 is preferably transparent glue, so as to ensure the area of the surface of the solar cell capable of absorbing light as much as possible, and avoid the decrease of the area of the surface of the solar cell 10 capable of absorbing light due to the arrangement of the glue dots 104, thereby affecting the efficiency of the solar cell.

Referring to fig. 30 and 31, the preparation method includes: the connection member 110 is provided on the surfaces of the first and second battery pieces 11 and 12, and the connection member 110 intersects at least one of the plurality of grid line structures 101. The connection member 110 is embedded in the glue sites 104.

In some embodiments, the number of glue sites 104 is 2 to 20 for one connecting member 110. The spacing between adjacent glue sites 104 is 5mm to 100mm. The number or the interval of the glue points 104 ensures that the fixing effect of the connecting part 110 and the battery piece 10 is better on one hand, so that the connecting part 110 cannot deviate before and during the lamination process; on the other hand, the number of glue sites 104 also gives optical loss to the battery cell 10 to obtain more electrical performance.

In some embodiments, in the second direction Y, the glue sites 104 are located on both sides of the connecting member 110. In this way, the glue sites 104 can fix the connecting member 110 by two sides of the connecting member 110, and increase the force applied by two opposite sides of the connecting member 110, so as to prevent the connecting member 110 from being deviated. The glue sites 104 are located at two sides of the connecting component 110, which is equivalent to fixing the connecting component 110 by the glue sites 104, so that the contact area between the connecting component 110 and the glue sites 104 is increased, and the risk that the connecting component 110 falls off from the surface of the battery piece 10 is prevented.

In some embodiments, along the second direction Y, on the same connecting member 110, the plurality of glue sites 104 are located on the same side of the connecting member 110; or, along the second direction Y, the same connecting member 110 has a plurality of glue sites 104 alternately arranged on both sides of the connecting member 110.

In some embodiments, the distance H from the top of the glue sites 104 to the surface of the battery sheet 10 in the direction Z perpendicular to the surface of the battery sheet 10 is less than or equal to L. In this way, the contact area between the glue point 104 and the connecting component 110 can ensure the mutual fixation between the battery piece 10 and the connecting component 110, and the glue point 104 is not located on the top surface of the connecting component 110 far away from the battery piece 10, so that the heat can be transferred to the connecting component 110 through the equal medium (packaging layer) in the subsequent lamination treatment, so that good alloy contact is formed between the welding layer 112 of the connecting component 110 and the grid line structure 101, thereby being beneficial to improving the yield and the safety rate of the photovoltaic module. In addition, H is smaller than L, which is advantageous in providing an isolation structure between the connection member 110, and the isolation structure is more compliant with the connection member 110, and the isolation structure has fewer gaps and defects with the connection member 110, thereby preventing the welding performance between the battery cell 10 and the connection member 110 from being affected by the adhesive film in a molten state through the isolation structure.

In some embodiments, the method of preparation: performing a welding process for alloy-contacting a part of the intersection region 102, the intersection region 102 being a region where one connection member 110 intersects one gate line structure 101 of the plurality of gate line structures; at least one blocking film 120 is arranged, the blocking film 120 is positioned on one side of the connecting part 110 far away from the grid line structure 101, the blocking film 120 at least covers the intersecting region 102 and the periphery of the surface of the cell 10 opposite to the intersecting region, and the cell 10 is a first cell 11 or a second cell 12 corresponding to the intersecting region; providing a packaging layer 13 and a cover plate 14, wherein the packaging layer 12 covers the surface of the barrier film 120 and the surfaces of the plurality of battery pieces 10, and the cover plate 14 is positioned on one side of the packaging layer 13 away from the plurality of battery pieces 10; lamination is performed to encapsulate the plurality of battery cells 10, and the connection member 110 is electrically connected to the plurality of grid line structures 101.

Accordingly, referring to fig. 32 and 33, a fifth embodiment provided in the present embodiment is the same as the first embodiment/second embodiment/third embodiment/fourth embodiment, except that: after the connection member 110 is provided and before the welding process is performed, it includes: and a glue film 105 is arranged, and the glue film 105 at least covers the intersecting area and the periphery of the surface of the battery piece 10 opposite to the intersecting area.

In some embodiments, the method of making comprises: a plurality of battery cells 10 are provided, each battery cell 10 of the plurality of battery cells including a plurality of grid line structures 101 arranged at intervals along the first direction X, the plurality of battery cells including a first battery cell 11 and a second battery cell 12. The connection member 110 is provided on the surfaces of the first and second battery pieces 11 and 12, and the connection member 110 intersects at least one of the plurality of grid line structures 101. The connection member 110 is embedded in the glue sites 104.

In some embodiments, the adhesive film 105 is disposed, and the adhesive film 105 covers at least the intersection region and the periphery of the surface of the battery sheet 10 opposite to the intersection region.

In some embodiments, disposing the glue film comprises: setting a glue film 105, wherein the glue film 105 is positioned on the grid line structures 101; along the first direction X, the length of the adhesive layer 105 is greater than the lengths of the battery pieces 10 corresponding to the plurality of grid line structures; or, a plurality of adhesive films 105 are arranged at intervals along the first direction X, and each adhesive film 105 of the plurality of adhesive films is opposite to each intersection area.

In some embodiments, the adhesive film 105 refers to a film layer composed of a material having adhesiveness for fixing the connection member 110 to the battery cell 10, preventing the connection member 110 from being deviated in steps before the lamination process and the welding process; and, preventing the pushing of the molten encapsulation layer against the connection member 110 during the lamination process from causing the connection member 110 to be deviated.

In some embodiments, the material of the adhesive film 105 includes EVA (ethylene vinyl acetate), acrylic esters, PE (polyethylene), or the like. When the material of the adhesive film 105 is EVA, the adhesive film 105 has a certain water resistance and corrosion resistance while ensuring a certain viscosity to fix the connection part 110 on the battery cell 10, and can be used as a barrier layer for preventing the molten encapsulation layer 13 from penetrating into the connection part 110 and the grid line structure 101 and a protection layer for preventing moisture.

When the material of the adhesive film 105 is acrylic esters, the acrylic esters have certain transparency, so that the optical loss of the battery piece 10 is reduced; the acrylic ester can be directly cured in an environment with low temperature, the curing speed is high, the thermal stress on the battery piece 10 is reduced, the risk of breakage of the battery piece 10 is reduced, and the yield of the photovoltaic module is improved; the acrylic acid ester has good water resistance and can be used for preventing the connection part 110 from being damaged by water vapor.

In some embodiments, the thickness of the adhesive film 105 ranges from 10 μm to 150 μm. The thickness of the adhesive film 105 may range from 10 μm to 130 μm, from 10 μm to 109 μm, from 10 μm to 85 μm, from 10 μm to 139 μm, from 30 μm to 150 μm, from 68 μm to 150 μm, from 102 μm to 150 μm, or from 49 μm to 104 μm. The thickness of the glue film 105 may in particular be 15 μm, 29 μm, 65 μm, 89 μm, 106 μm, 134 μm or 150 μm. When the thickness of the adhesive film 105 is within the above range, the adhesive film 105 has a sufficient thickness for fixing the connection part 110 on the surface of the battery piece 10 and will not deviate in the subsequent steps, and the adhesive film 105 will not occupy more thickness of the photovoltaic module, so as to reduce the thickness of the photovoltaic module to a certain extent, and achieve high integration of the photovoltaic module.

In some embodiments, the method of making comprises: performing a welding process for alloy-contacting a part of the intersection region 102, the intersection region 102 being a region where one connection member 110 intersects one gate line structure 101 of the plurality of gate line structures; at least one blocking film 120 is arranged, the blocking film 120 is positioned on one side of the connecting part 110 far away from the grid line structure 101, the blocking film 120 at least covers the intersecting region 102 and the periphery of the surface of the cell 10 opposite to the intersecting region, and the cell 10 is a first cell 11 or a second cell 12 corresponding to the intersecting region; providing a packaging layer 13 and a cover plate 14, wherein the packaging layer 12 covers the surface of the barrier film 120 and the surfaces of the plurality of battery pieces 10, and the cover plate 14 is positioned on one side of the packaging layer 13 away from the plurality of battery pieces 10; referring to fig. 27, a lamination process is performed to package the plurality of battery cells 10 and electrically connect the connection member 110 with the plurality of gate line structures 101.

Correspondingly, according to some embodiments of the present application, another aspect of the embodiments of the present application further provides a photovoltaic module, where the photovoltaic module is prepared by the preparation method of the photovoltaic module provided by the foregoing embodiments. The same elements as those of the above embodiment will not be described in detail herein.

Referring to fig. 4 and 13, the photovoltaic module includes: the plurality of battery cells 10, each battery cell 10 of the plurality of battery cells includes a plurality of grid line structures 101 arranged at intervals along the first direction X, and the plurality of battery cells 10 includes a first battery cell 11 and a second battery cell 12.

In some embodiments, a photovoltaic module includes: and a connection member 110, wherein the connection member 110 is positioned on the surfaces of the first battery piece 11 and the second battery piece 12, and the connection member 110 is in electrical contact with at least one grid line structure 101 of the plurality of grid line structures.

In some embodiments, a photovoltaic module includes: each positioning point 103 of the at least one positioning point is positioned on one side of the connecting component 110 far away from the grid line structure 101 and the surface of the battery piece corresponding to the connecting component; in the second direction Y, each positioning point 103 is located on both sides of the connection member 110.

In some embodiments, referring to fig. 19, a photovoltaic module includes: the blocking film 120, the blocking film 120 is located at one side of the connecting component 110 away from the grid line structure 101, the blocking film 120 at least covers the intersecting region and the periphery of the surface of the battery piece 10 opposite to the intersecting region, and the battery piece is a first battery piece or a second battery piece corresponding to the intersecting region.

Referring to fig. 15, the photovoltaic module includes: a plurality of intersecting regions arranged at intervals along the first direction X; a plurality of barrier films 120 arranged at intervals along the first direction X, each barrier film 120 of the plurality of barrier films being opposite to each intersection region; the intersection region is a region where one connection part 110 intersects one gate line structure 101 of the plurality of gate line structures.

In some embodiments, referring to fig. 25, a barrier film 120 is located on the plurality of gate line structures 101 and the at least one anchor point 103.

In some embodiments, a photovoltaic module includes: the packaging layer 13 and the cover plate 14, the packaging layer 13 covers the surface of the connecting part 110, the surface of the at least one positioning point 103 and the surfaces of the plurality of battery pieces 10, and the cover plate 14 is positioned on one side of the packaging layer 13 away from the plurality of battery pieces 10.

In some embodiments, referring to fig. 32 and 33, the photovoltaic module further comprises: the plurality of adhesive films 105 are arranged at intervals along the first direction X, each adhesive film 105 of the plurality of adhesive films is located between the connecting component 110 and each blocking film 120 of the plurality of blocking films, and each adhesive film 105 of the plurality of adhesive films is opposite to each intersection area.

Fig. 34 is a schematic structural diagram of a series welding apparatus according to an embodiment of the present disclosure; fig. 35 is a schematic structural diagram of a welding station of the series welding apparatus according to an embodiment of the present disclosure; FIG. 36 is a schematic cross-sectional view of FIG. 34 taken along the line A1-A2; FIG. 37 is a schematic cross-sectional view of FIG. 34 along the line B1-B2.

Accordingly, another aspect of the embodiments of the present application provides a series welding device, which is used for performing a welding process on a battery piece. Referring to fig. 34 to 37, the series welding apparatus includes: a substrate 30, the substrate 30 having magnetic properties, the magnetic properties of the substrate 30 being either a first polarity or a second polarity; a soldering station 31 and a dispensing station 32, the soldering station 31 and the dispensing station 32 being located on the substrate 30.

The welding station 31 comprises: a mounting seat 311, along a first direction X, the mounting seat 311 being fixed at one side of the substrate 30; the presser 320, the presser 320 is mounted on the mounting seat 311, the presser 320 includes a plurality of pressing pins 322 sequentially arranged along the first direction X, the pressing pins 322 have magnetism, and the magnetism of the pressing pins 322 is of a first polarity or a second polarity. Through setting up base plate 30 and having magnetism, press needle 322 has magnetism, before the welding process, makes the magnetism of base plate 30 different with the magnetism of press needle 322, based on the principle that opposite magnetism attracts mutually, increases the pressure between connecting component and the battery piece to increase welding area and reinforcing welding pressure, avoid because the problem of the rosin joint or the skew that welding area is less and welding pressure is less to lead to. Wherein at least one of the substrate 30 or the presser pins 322 has a circuit device for making the magnetic property of the substrate 30 be the first polarity or the second polarity and/or the magnetic property of the presser pins 322 be the first polarity or the second polarity. In this way, whether the magnetism of the substrate and the magnetism of the pressing needle are the same before and after the welding treatment can be adjusted, for example, after the welding treatment, the magnetism of the substrate and the magnetism of the pressing needle can be the same based on the circuit device, and the automatic separation of the substrate and the pressing needle can be realized, so that the welding setting efficiency is improved.

In some embodiments, the substrate 30 may include a first plate located at a region opposite to the bonding pins, the first plate having magnetism for cooperating with the bonding pins before the soldering process to increase a contact area between the connection part and the gate line structure and a contact pressure.

In some embodiments, the substrate is used for carrying the battery piece and the connecting component, and a space is arranged between the substrate and the pressing tool, and the space is used for placing the battery piece and the welding strip. The connecting part is positioned on one side of the battery piece far away from the substrate and faces the direction of the press tool.

In some embodiments, the presser 320 includes a presser plate 321, and a side of the presser plate 321 facing the substrate 30 has a plurality of presser pins 322. The pressing needle is used for fixing the part of the connecting part except the intersecting area, so that the distance between the part of the connecting part and the battery piece is reduced as much as possible, the overlapping area of the connecting part and the grid line structure in the welding area is large, the welding stability is ensured, the problems of unstable cold joint deflection and the like of welding strip welding are solved, and the tool replacement cost is reduced.

In some embodiments, the welding apparatus further includes a welding pin that is energized to the corresponding intersection region to heat the welding pin and heat the connection member to effect welding between the connection member and the grid line structure.

It will be understood by those of ordinary skill in the art that the foregoing embodiments are specific examples of implementing the present application and that various changes in form and details may be made therein without departing from the spirit and scope of the present application. Various changes and modifications may be made by one skilled in the art without departing from the spirit and scope of the invention, and the scope of the invention shall be defined by the appended claims.

Claims

1. A method of manufacturing a photovoltaic module, comprising:

providing a plurality of battery pieces, wherein each battery piece of the plurality of battery pieces comprises a plurality of grid line structures which are arranged at intervals along a first direction, and the plurality of battery pieces comprise a first battery piece and a second battery piece;

arranging connecting components on the surfaces of the first battery piece and the second battery piece, wherein the connecting components are intersected with at least one grid line structure of the grid line structures;

performing a welding process for alloy-contacting a part of an intersecting region, the intersecting region being a region where one of the connection members intersects one of the plurality of gate line structures;

setting at least one positioning point, wherein each positioning point of the at least one positioning point is positioned on one side of the connecting component far away from the grid line structure and the surface of the battery piece corresponding to the connecting component; each positioning point is positioned on two sides of the connecting component along the second direction;

The packaging layer covers the surface of the connecting part, the surface of the at least one positioning point and the surfaces of the plurality of battery pieces, and the cover plate is positioned on one side, far away from the plurality of battery pieces, of the packaging layer;

and carrying out lamination treatment to encapsulate the plurality of battery pieces and electrically connecting the connecting component with the plurality of grid line structures.

2. The method of manufacturing a photovoltaic module according to claim 1, wherein the process step of providing at least one anchor point comprises: the step of forming the preset glue sites is carried out, and comprises the following steps: setting preset glue points on the surface of the connecting part, and curing the preset glue points;

repeating the step of forming the preset glue points until the number of times of forming the preset glue points is equal to the number of the at least one positioning point, wherein the preset glue points after solidification are used as the at least one positioning point.

3. The method of manufacturing a photovoltaic module according to claim 1, further comprising, after the disposing of the at least one anchor point and before the disposing of the encapsulation layer and the cover plate: a blocking film is arranged, the blocking film is positioned on one side, far away from the grid line structure, of the connecting component, the blocking film at least covers the intersecting region and the periphery of the surface of the battery piece opposite to the intersecting region, and the battery piece is the first battery piece or the second battery piece corresponding to the intersecting region;

The packaging layer covers the surface of the barrier film; the blocking film has a melting point higher than that of the encapsulation layer.

4. The method of claim 3, wherein the barrier film comprises a laminate film layer or a single film layer.

5. The method of manufacturing a photovoltaic module according to claim 3, wherein one of the connection members intersects the plurality of grid line structures and constitutes a plurality of intersecting regions arranged at intervals along a first direction; the disposing at least one barrier film includes: providing a plurality of barrier films arranged at intervals along the first direction, wherein each barrier film of the plurality of barrier films is opposite to each intersection region of the plurality of intersection regions; or, a barrier film extending along the first direction is provided, and the barrier film is located on the plurality of grid line structures and the at least one positioning point.

6. The method of manufacturing a photovoltaic module according to claim 1, further comprising, prior to disposing the connecting member: glue points are arranged on the surfaces of the first battery piece or the second battery piece, and along the first direction, the glue points are positioned between two adjacent grid line structures of the grid line structures; in the process of setting the connecting component, the connecting component is embedded into the glue point.

7. The method of manufacturing a photovoltaic module according to claim 1, characterized by comprising, after the disposing of the connection member and before the performing of the welding process: and setting a glue film, wherein the glue film at least covers the intersecting area and the periphery of the surface of the battery piece opposite to the intersecting area.

8. The method of claim 7, wherein disposing the adhesive film comprises: setting a glue film, wherein the glue film is positioned on the grid line structures; along the first direction, the length of the adhesive layer is longer than the lengths of the battery pieces corresponding to the grid line structures; or a plurality of adhesive films are arranged at intervals along the first direction, and each adhesive film of the plurality of adhesive films is opposite to each intersection area.

9. The method of manufacturing a photovoltaic module according to claim 1, wherein the welding process is performed for a time less than the laminating process.

10. A photovoltaic module, comprising:

a plurality of battery pieces, each of the plurality of battery pieces including a plurality of grid line structures arranged at intervals along a first direction, the plurality of battery pieces including a first battery piece and a second battery piece;

The connecting component is positioned on the surfaces of the first battery piece and the second battery piece and is electrically contacted with at least one grid line structure of the grid line structures;

each positioning point of the at least one positioning point is positioned at one side of the connecting component far away from the grid line structure and the surface of the battery piece corresponding to the connecting component; each positioning point is positioned on two sides of the connecting component along the second direction;

the packaging layer covers the surface of the connecting part, the surface of the at least one locating point and the surfaces of the plurality of battery pieces, and the cover plate is positioned on one side, far away from the plurality of battery pieces, of the packaging layer.

11. The photovoltaic module of claim 10, comprising: the blocking film is positioned on one side, far away from the grid line structure, of the connecting component, and at least covers an intersecting region and the periphery of the surface of the battery piece opposite to the intersecting region, wherein the battery piece is the first battery piece or the second battery piece corresponding to the intersecting region; the encapsulation layer covers the surface of the barrier film, wherein the intersection region is a region where one of the connection members intersects one of the plurality of gate line structures.

12. The photovoltaic module of claim 11, comprising: a plurality of intersecting regions arranged at intervals along the first direction; and a plurality of barrier films arranged at intervals along the first direction, wherein each barrier film of the plurality of barrier films is opposite to each intersection area.

13. The photovoltaic assembly of claim 11, wherein the barrier film is located on the plurality of grid line structures and the at least one anchor point.

14. The photovoltaic module of claim 13, further comprising: the adhesive films are arranged at intervals along the first direction, each adhesive film of the adhesive films is located between the connecting component and each blocking film of the blocking films, and each adhesive film of the adhesive films is opposite to each intersecting area.

15. A series welding apparatus for performing a welding process of battery cells, comprising:

a substrate having magnetic properties, the magnetic properties of the substrate being either a first polarity or a second polarity;

the mounting seat is fixed on one side of the substrate along the second direction;

the presser is arranged on the mounting seat and comprises a plurality of pressing needles which are sequentially arranged along a second direction, the pressing needles have magnetism, and the magnetism of the pressing needles is of a first polarity or a second polarity.