CN116666490A - Manufacturing method of photovoltaic module - Google Patents
Manufacturing method of photovoltaic module Download PDFInfo
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- CN116666490A CN116666490A CN202210835929.0A CN202210835929A CN116666490A CN 116666490 A CN116666490 A CN 116666490A CN 202210835929 A CN202210835929 A CN 202210835929A CN 116666490 A CN116666490 A CN 116666490A
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- 238000004519 manufacturing process Methods 0.000 title claims abstract description 45
- 238000003466 welding Methods 0.000 claims abstract description 241
- 229920006280 packaging film Polymers 0.000 claims abstract description 169
- 239000012785 packaging film Substances 0.000 claims abstract description 169
- 238000009459 flexible packaging Methods 0.000 claims abstract description 159
- 239000002131 composite material Substances 0.000 claims abstract description 39
- 239000011521 glass Substances 0.000 claims abstract description 12
- 229910000679 solder Inorganic materials 0.000 claims description 108
- 238000000034 method Methods 0.000 claims description 63
- 238000010438 heat treatment Methods 0.000 claims description 56
- 230000008569 process Effects 0.000 claims description 22
- 238000003825 pressing Methods 0.000 claims description 19
- 239000003292 glue Substances 0.000 claims description 18
- 238000007599 discharging Methods 0.000 claims description 16
- 238000005520 cutting process Methods 0.000 claims description 11
- 238000005096 rolling process Methods 0.000 claims description 9
- 230000001360 synchronised effect Effects 0.000 claims description 9
- 238000005538 encapsulation Methods 0.000 claims description 8
- 238000004070 electrodeposition Methods 0.000 claims description 6
- 230000009471 action Effects 0.000 claims description 5
- 239000000463 material Substances 0.000 claims description 4
- 238000005336 cracking Methods 0.000 abstract description 8
- 239000007779 soft material Substances 0.000 abstract description 4
- 230000007246 mechanism Effects 0.000 description 33
- 238000010586 diagram Methods 0.000 description 4
- 230000009286 beneficial effect Effects 0.000 description 2
- 230000000694 effects Effects 0.000 description 2
- 238000003475 lamination Methods 0.000 description 2
- 238000004513 sizing Methods 0.000 description 2
- 239000000758 substrate Substances 0.000 description 2
- 230000001680 brushing effect Effects 0.000 description 1
- 238000007731 hot pressing Methods 0.000 description 1
- 238000004093 laser heating Methods 0.000 description 1
- 238000002844 melting Methods 0.000 description 1
- 230000008018 melting Effects 0.000 description 1
- 238000005507 spraying Methods 0.000 description 1
- 238000006467 substitution reaction Methods 0.000 description 1
- 230000007306 turnover Effects 0.000 description 1
Classifications
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- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01L—SEMICONDUCTOR DEVICES NOT COVERED BY CLASS H10
- H01L31/00—Semiconductor devices sensitive to infrared radiation, light, electromagnetic radiation of shorter wavelength or corpuscular radiation and specially adapted either for the conversion of the energy of such radiation into electrical energy or for the control of electrical energy by such radiation; Processes or apparatus specially adapted for the manufacture or treatment thereof or of parts thereof; Details thereof
- H01L31/18—Processes or apparatus specially adapted for the manufacture or treatment of these devices or of parts thereof
-
- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01L—SEMICONDUCTOR DEVICES NOT COVERED BY CLASS H10
- H01L31/00—Semiconductor devices sensitive to infrared radiation, light, electromagnetic radiation of shorter wavelength or corpuscular radiation and specially adapted either for the conversion of the energy of such radiation into electrical energy or for the control of electrical energy by such radiation; Processes or apparatus specially adapted for the manufacture or treatment thereof or of parts thereof; Details thereof
- H01L31/04—Semiconductor devices sensitive to infrared radiation, light, electromagnetic radiation of shorter wavelength or corpuscular radiation and specially adapted either for the conversion of the energy of such radiation into electrical energy or for the control of electrical energy by such radiation; Processes or apparatus specially adapted for the manufacture or treatment thereof or of parts thereof; Details thereof adapted as photovoltaic [PV] conversion devices
- H01L31/042—PV modules or arrays of single PV cells
- H01L31/048—Encapsulation of modules
-
- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01L—SEMICONDUCTOR DEVICES NOT COVERED BY CLASS H10
- H01L31/00—Semiconductor devices sensitive to infrared radiation, light, electromagnetic radiation of shorter wavelength or corpuscular radiation and specially adapted either for the conversion of the energy of such radiation into electrical energy or for the control of electrical energy by such radiation; Processes or apparatus specially adapted for the manufacture or treatment thereof or of parts thereof; Details thereof
- H01L31/04—Semiconductor devices sensitive to infrared radiation, light, electromagnetic radiation of shorter wavelength or corpuscular radiation and specially adapted either for the conversion of the energy of such radiation into electrical energy or for the control of electrical energy by such radiation; Processes or apparatus specially adapted for the manufacture or treatment thereof or of parts thereof; Details thereof adapted as photovoltaic [PV] conversion devices
- H01L31/042—PV modules or arrays of single PV cells
- H01L31/05—Electrical interconnection means between PV cells inside the PV module, e.g. series connection of PV cells
- H01L31/0504—Electrical interconnection means between PV cells inside the PV module, e.g. series connection of PV cells specially adapted for series or parallel connection of solar cells in a module
- H01L31/0512—Electrical interconnection means between PV cells inside the PV module, e.g. series connection of PV cells specially adapted for series or parallel connection of solar cells in a module made of a particular material or composition of materials
-
- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01L—SEMICONDUCTOR DEVICES NOT COVERED BY CLASS H10
- H01L31/00—Semiconductor devices sensitive to infrared radiation, light, electromagnetic radiation of shorter wavelength or corpuscular radiation and specially adapted either for the conversion of the energy of such radiation into electrical energy or for the control of electrical energy by such radiation; Processes or apparatus specially adapted for the manufacture or treatment thereof or of parts thereof; Details thereof
- H01L31/04—Semiconductor devices sensitive to infrared radiation, light, electromagnetic radiation of shorter wavelength or corpuscular radiation and specially adapted either for the conversion of the energy of such radiation into electrical energy or for the control of electrical energy by such radiation; Processes or apparatus specially adapted for the manufacture or treatment thereof or of parts thereof; Details thereof adapted as photovoltaic [PV] conversion devices
- H01L31/042—PV modules or arrays of single PV cells
- H01L31/05—Electrical interconnection means between PV cells inside the PV module, e.g. series connection of PV cells
- H01L31/0504—Electrical interconnection means between PV cells inside the PV module, e.g. series connection of PV cells specially adapted for series or parallel connection of solar cells in a module
- H01L31/0516—Electrical interconnection means between PV cells inside the PV module, e.g. series connection of PV cells specially adapted for series or parallel connection of solar cells in a module specially adapted for interconnection of back-contact solar cells
-
- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01L—SEMICONDUCTOR DEVICES NOT COVERED BY CLASS H10
- H01L31/00—Semiconductor devices sensitive to infrared radiation, light, electromagnetic radiation of shorter wavelength or corpuscular radiation and specially adapted either for the conversion of the energy of such radiation into electrical energy or for the control of electrical energy by such radiation; Processes or apparatus specially adapted for the manufacture or treatment thereof or of parts thereof; Details thereof
- H01L31/18—Processes or apparatus specially adapted for the manufacture or treatment of these devices or of parts thereof
- H01L31/1876—Particular processes or apparatus for batch treatment of the devices
- H01L31/188—Apparatus specially adapted for automatic interconnection of solar cells in a module
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- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
- Y02E—REDUCTION OF GREENHOUSE GAS [GHG] EMISSIONS, RELATED TO ENERGY GENERATION, TRANSMISSION OR DISTRIBUTION
- Y02E10/00—Energy generation through renewable energy sources
- Y02E10/50—Photovoltaic [PV] energy
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- Engineering & Computer Science (AREA)
- Computer Hardware Design (AREA)
- Physics & Mathematics (AREA)
- Condensed Matter Physics & Semiconductors (AREA)
- Electromagnetism (AREA)
- General Physics & Mathematics (AREA)
- Microelectronics & Electronic Packaging (AREA)
- Power Engineering (AREA)
- Life Sciences & Earth Sciences (AREA)
- Sustainable Development (AREA)
- Manufacturing & Machinery (AREA)
- Sustainable Energy (AREA)
- Photovoltaic Devices (AREA)
Abstract
The embodiment of the application provides a manufacturing method of a photovoltaic module, and relates to the technical field of photovoltaic modules. The manufacturing method of the photovoltaic module comprises the following steps: sequentially placing component glass and a second flexible packaging film, and placing a plurality of battery pieces on the second flexible packaging film according to typesetting requirements of the photovoltaic component; embedding a plurality of welding strips into a first flexible packaging film according to typesetting requirements of the photovoltaic module to form a composite welding strip film, and covering the composite welding strip film on the battery piece, wherein the positions of the welding strips correspond to the positions of electrodes of the battery piece; and placing a backboard above the composite welding strip film, and performing laser welding. Because the first flexible packaging film is made of soft materials, the welding strip is embedded or adhered to the first flexible packaging film without damaging the first flexible packaging film, so that the risks of hidden cracking of the battery piece and white leakage of the grid line in assembly manufacturing are reduced.
Description
Technical Field
The application relates to the technical field of photovoltaic modules, in particular to a manufacturing method of a photovoltaic module.
Background
At present, in the back contact battery assembly, a welding strip is fixed on a battery piece through a series welding process to form a combination of the welding strip and the battery piece, which is also called a battery string, and the common welding strip fixing mode in the manufacture of the battery string is as follows: the welding strip is directly pulled or carried on the battery piece to be welded and fixed, and the battery piece is fragile, so that the mode of fixing the welding strip on the battery piece easily causes hidden cracking of the battery piece, and the welding strip is low in efficiency and complex in structure.
In addition, when the welding strip is pulled to the surface of the battery by series welding, the bonding degree and the consistency of the welding strip on the surface of the battery piece are poor, the local heights are inconsistent, uneven stress and overlarge local pressure occur when the assembly is laminated, and the battery piece is prone to hidden cracking.
Disclosure of Invention
In order to solve the above technical problems, an embodiment of the present application may be implemented as follows:
in a first aspect, an embodiment of the present application provides a method for manufacturing a photovoltaic module, including:
sequentially placing component glass and a second flexible packaging film, and placing a plurality of battery pieces on the second flexible packaging film according to typesetting requirements of the photovoltaic component;
embedding a plurality of welding strips into a first flexible packaging film according to typesetting requirements of the photovoltaic module to form a composite welding strip film, and covering the composite welding strip film on the battery piece, wherein the positions of the welding strips correspond to the positions of electrodes of the battery piece;
and placing a backboard above the composite welding strip film, and performing laser welding.
In a second aspect, an embodiment of the present application provides a method for manufacturing a photovoltaic module, including:
sequentially placing a back plate and a first flexible packaging film, and embedding a plurality of welding strips into the first flexible packaging film according to typesetting requirements of the photovoltaic module to form a composite welding strip film;
placing a plurality of battery pieces on the composite welding strip film according to typesetting requirements of the photovoltaic module, wherein the positions of the welding strips correspond to the electrode positions of the battery pieces;
and sequentially placing a second flexible packaging film and component glass above the battery piece, and performing laser welding.
The manufacturing method of the photovoltaic module provided by the embodiment of the application has the beneficial effects that:
1) The plurality of welding strips are embedded into the first flexible packaging film or adhered to the first flexible packaging film to form a composite welding strip film, and then the composite welding strip film is assembled into the photovoltaic module;
2) The welding strip is embedded into the first flexible packaging film, so that the thickness difference between the welding strip and the first flexible packaging film can be reduced, and the occurrence of hidden cracking is further reduced;
3) The welding strip fixing method is simple, has low failure rate, is particularly suitable for being directly used on the production process of the full-page assembly, and can be fixed with the first flexible packaging film of the full-page breadth at one time due to a sufficient number of welding strips when the full-page assembly is arranged, so that the method is very efficient, and the additional EVA packaging film is not needed when the whole photovoltaic assembly is manufactured and packaged, thereby saving the working procedure, improving the manufacturing efficiency and saving the cost.
In an alternative embodiment, each battery piece is provided with a plurality of positive electrodes and negative electrodes which are arranged at intervals on the same surface, and the positive electrodes and the negative electrodes of the adjacent battery pieces are connected through welding strips.
In an alternative embodiment, a method of embedding a plurality of solder strips into a first flexible packaging film includes: heating the welding strip, transmitting heat to the first flexible packaging film through the welding strip, and softening the contact part of the first flexible packaging film and the welding strip so as to embed the welding strip into the first flexible packaging film;
wherein the temperature for heating the welding belt is 50-180 ℃.
In an alternative embodiment, a method of heating a solder strip includes: after the solder strip is at least partially attached to the first flexible packaging film, the solder strip is heated by a heated roller or laser.
Therefore, the heating mode is simple, and the heating temperature is accurately controlled.
In an alternative embodiment, when the solder tape is heated using a heated roller, the position of the heated roller pressing down is controlled so that the solder tape is partially embedded in the first flexible encapsulation film.
In an alternative embodiment, when the solder strip is heated by the heating roller, a plurality of solder strip pressing grooves are formed in the heating roller, and the distance between adjacent solder strip pressing grooves is equal to the distance between adjacent solder strips.
In an alternative embodiment, a method of embedding a plurality of solder strips into a first flexible packaging film includes: outputting and arranging the welding strips on the first flexible packaging film side by side in a mode of driving the rollers or in a mode of driving the clamping jaws by the linear motion module;
and in the process of outputting and arranging the welding strips on the first flexible packaging film side by side, the movement speed of the driving roller or the linear movement module is controlled, so that the movement speed of the welding strips and the movement speed of the first flexible packaging film are the same and synchronous in the movement direction of the first flexible packaging film.
In an alternative embodiment, when the solder strip is heated by means of a heated roller, the heated roller is controlled to be in a rolling state, and the rolling speed of the heated roller is controlled to be synchronous with the moving speed of the first flexible packaging film.
In an alternative embodiment, a method of embedding a plurality of solder strips into a first flexible packaging film includes: after the solder strip is at least partially attached to the first flexible packaging film, a downward force is applied to the solder strip so that the thickness of the solder strip fixed in the first flexible packaging film is consistent.
In an alternative embodiment, a method of embedding a plurality of solder strips into a first flexible packaging film includes: and in the process of embedding the plurality of welding strips into the first flexible packaging film, cutting the plurality of welding strips after the welding strips are conveyed out of the target length.
In an alternative embodiment, the welding strips and the first flexible packaging film are discharged by adopting reels, the discharging speed of the reels and the discharging speed of the first flexible packaging film are controlled simultaneously, a plurality of welding strips are embedded into the first flexible packaging film in the discharging process of the reels and the first flexible packaging film, and when the welding strips and the first flexible packaging film are respectively output to a preset length, cutting actions are respectively carried out.
In a third aspect, an embodiment of the present application provides a method for manufacturing a photovoltaic module, including:
sequentially placing component glass and a second flexible packaging film, and placing a plurality of battery pieces on the second flexible packaging film according to typesetting requirements of the photovoltaic component;
according to typesetting requirements of the photovoltaic module, fixing a plurality of welding strips on a first flexible packaging film through glue to form a composite welding strip film, and then covering the composite welding strip film on the battery piece, wherein the positions of the welding strips correspond to the positions of electrodes of the battery piece;
and placing a backboard above the composite welding strip film, and performing laser welding.
The manufacturing method of the photovoltaic module provided by the embodiment of the application can reduce the risks of hidden cracking of the battery piece and white leakage of the grid line in the manufacturing of the module, save working procedures, improve manufacturing efficiency and save cost.
Drawings
In order to more clearly illustrate the technical solutions of the embodiments of the present application, the drawings that are needed in the embodiments will be briefly described below, it being understood that the following drawings only illustrate some embodiments of the present application and therefore should not be considered as limiting the scope, and other related drawings may be obtained according to these drawings without inventive effort for a person skilled in the art.
Fig. 1 is a flowchart of a method for manufacturing a photovoltaic module according to the present application;
FIG. 2 is a schematic structural view of a photovoltaic module;
fig. 3 is a schematic structural diagram of a fixing manner of a solder strip according to the present embodiment;
FIG. 4 is a schematic illustration of a composite solder strip film;
fig. 5 is a schematic structural diagram of another fixing manner of the solder strip according to the present embodiment;
fig. 6 is a schematic structural diagram of another fixing manner of the solder strip according to the present embodiment;
fig. 7 is a schematic structural diagram of another fixing manner of the solder strip according to the present embodiment;
fig. 8 is a flowchart of another method for manufacturing a photovoltaic module according to the present application.
Icon: 1-a back plate; 2-a first flexible encapsulation film; 3-welding the tape; 4-a composite welding strip film; 5-battery pieces; 6-a second flexible encapsulation film; 7-component glass; 8-welding strip feeding mechanism; 81-diversion trenches; 9-heating rollers; 91-welding a tape pressing groove; 10-a sizing mechanism; 11-a laser; 12-welding a coil; 13-flexible packaging film rolls; 14-a fitting mechanism; 15-welding strip fixing mechanism.
Detailed Description
For the purpose of making the objects, technical solutions and advantages of the embodiments of the present application more apparent, the technical solutions of the embodiments of the present application will be clearly and completely described below with reference to the accompanying drawings in the embodiments of the present application, and it is apparent that the described embodiments are some embodiments of the present application, but not all embodiments of the present application. The components of the embodiments of the present application generally described and illustrated in the figures herein may be arranged and designed in a wide variety of different configurations.
Thus, the following detailed description of the embodiments of the application, as presented in the figures, is not intended to limit the scope of the application, as claimed, but is merely representative of selected embodiments of the application. All other embodiments, which can be made by those skilled in the art based on the embodiments of the application without making any inventive effort, are intended to be within the scope of the application.
It should be noted that: like reference numerals and letters denote like items in the following figures, and thus once an item is defined in one figure, no further definition or explanation thereof is necessary in the following figures.
In the description of the present application, it should be noted that, if the terms "upper", "lower", "inner", "outer", and the like indicate an azimuth or a positional relationship based on the azimuth or the positional relationship shown in the drawings, or the azimuth or the positional relationship in which the inventive product is conventionally put in use, it is merely for convenience of describing the present application and simplifying the description, and it is not indicated or implied that the apparatus or element referred to must have a specific azimuth, be configured and operated in a specific azimuth, and thus it should not be construed as limiting the present application.
Furthermore, the terms "first," "second," and the like, if any, are used merely for distinguishing between descriptions and not for indicating or implying a relative importance.
It should be noted that the features of the embodiments of the present application may be combined with each other without conflict.
As one embodiment, please refer to fig. 1 and 2, the present embodiment provides a method for manufacturing a photovoltaic module, which includes the following steps:
s11: sequentially placing component glass 7 and a second flexible packaging film 6, and placing a plurality of battery pieces 5 on the second flexible packaging film 6 according to typesetting requirements of the photovoltaic components;
s12: embedding a plurality of welding strips 3 into the first flexible packaging film 2 according to typesetting requirements of the photovoltaic module to form a composite welding strip film 4 (please refer to fig. 4), and then covering the composite welding strip film 4 on the battery piece 5, wherein the positions of the welding strips 3 correspond to the electrode positions of the battery piece 5;
s13: and placing the backboard 1 above the composite welding strip film 4 for laser welding.
In addition, after the back plate 1 is placed on the composite solder tape film 4, it may be necessary to turn over the assembly and then perform laser welding in order to facilitate welding.
As another embodiment, please refer to fig. 2 and 8, a method for manufacturing a photovoltaic module is provided, which is similar to the method provided in the above embodiment, and is different in that the assembly order of the layers of the photovoltaic module is different.
The method specifically comprises the following steps:
s21: and sequentially placing the backboard 1 and the first flexible packaging film 2, and embedding a plurality of welding strips 3 into the first flexible packaging film 2 according to typesetting requirements of the photovoltaic module to form a composite welding strip film 4.
S22: and placing a plurality of battery pieces 5 on the composite welding strip film 4 according to typesetting requirements of the photovoltaic module, wherein the positions of the welding strips 3 correspond to the electrode positions of the battery pieces 5.
S23: and a second flexible packaging film 6 and a piece of component glass 7 are sequentially arranged above the battery piece 5 for laser welding.
According to the manufacturing method of the photovoltaic module, the welding strip is embedded into the first flexible packaging film, and is different from the process that the welding strip is carried to the battery piece for welding and fixing in the prior art, and the object of the welding strip fixing is the first flexible packaging film which is made of soft materials, so that the welding strip is fixed and cannot damage the flexible packaging film, hidden cracks of the battery piece are reduced, the manufacturing method is particularly suitable for high-efficiency fixing of the welding strip of the full-page module, and the step that the packaging film is paved during final lamination in the prior art is omitted because the welding strip is directly fixed on the packaging film. The solder strip is fixed in the packaging film, so that the grid line leakage can be reduced, the problems of complex conventional solder strip fixing structure, low solder strip processing efficiency and the like are solved, and a novel photovoltaic module manufacturing process is provided.
It should be noted that the gate line is an electrode, and the electrode is divided into a positive electrode and a negative electrode.
The first flexible packaging film 2 and the second flexible packaging film 6 may be packaging films such as EVA and POE. The assembly typesetting is to arrange the battery pieces and the welding strips on a substrate (generally glass and packaging films), the number of the battery pieces and the welding strips is multiple, the battery pieces and the welding strips are generally in an array form when arranged on the substrate, and the assembly typesetting requirements correspond to multiple types due to the assembly plate types and the battery piece grid line structures with different sizes, so that the assembly typesetting is performed according to actual requirements.
As another embodiment, each of the battery pieces 5 has a plurality of positive electrodes and negative electrodes disposed at intervals on the same surface, and the positive electrodes and the negative electrodes of the adjacent battery pieces 5 are connected by the solder strips 3. The method is particularly suitable for the battery pieces with multiple main grid lines, and the positive electrodes and the negative electrodes of the adjacent battery pieces 5 are connected through the welding strips 3. Specifically, the positive electrode of the previous cell is connected with the negative electrode of the next cell through a welding strip, and the negative electrode of the previous cell is connected with the positive electrode of the next cell through a welding strip.
As another embodiment, the method of embedding the plurality of solder strips 3 into the first flexible packaging film 2 includes: heating the welding strip 3, so that heat is transferred to the first flexible packaging film 2 through the welding strip 3, and the contact part of the first flexible packaging film 2 and the welding strip 3 is softened to embed the welding strip 3 into the first flexible packaging film 2; wherein the temperature for heating the welding belt 3 is 50-180 ℃. The heating makes the welding strip soften and can fix the welding strip 3 through the first flexible packaging film 2, and the temperature of the welding strip 3 is moderate, so that the first flexible packaging film 2 cannot be softened due to too low temperature, the adhesion effect of the first flexible packaging film 2 and the welding strip 3 is reduced, and the first flexible packaging film 2 cannot be melted due to too high temperature.
As another embodiment, referring to fig. 3 and 6, the method for heating the solder tape 3 includes: after the solder tape 3 is at least partially attached to the first flexible packaging film 2, the solder tape 3 is heated by a heating roller 9 or a laser 11. Both heating modes are simple and easy to operate, and the heating temperature is accurately controlled.
When the solder strip 3 is heated by the heating roller 9, the pressing position of the heating roller 9 is controlled, so that the solder strip 3 is partially embedded into the first flexible packaging film 2, the thickness difference between the solder strip 3 and the first flexible packaging film 2 can be reduced, and the risk of hidden cracking is further reduced.
Wherein, when the heating roller 9 is used for heating the welding strip 3, a plurality of welding strip pressing grooves 91 are arranged on the heating roller 9, and the distance between the adjacent welding strip pressing grooves 91 is equal to the distance between the adjacent welding strips 3. In this way, by providing the solder strip pressing groove 91 on the heating roller 9, the solder strip 3 can be accurately controlled to be positioned in the process of being embedded into the first flexible packaging film 2, so that the position of the solder strip 3 fixed in the first flexible packaging film 2 corresponds to the position of the grid line of the battery piece.
As another embodiment, the method of embedding the plurality of solder strips 3 into the first flexible packaging film 2 includes: the solder strips 3 are output and arranged side by side on the first flexible packaging film 2 by adopting a mode of driving rollers or adopting a mode of driving a plurality of clamping jaws by adopting a linear motion module (not shown in the figure). Referring to fig. 3, in this embodiment, a solder strip feeding mechanism 8 with a diversion trench 81 is used to output solder strips 3, and a carrying mechanism (not shown) for carrying a first flexible packaging film 2 is used to drive the first flexible packaging film 2 to move in the sending direction of the solder strips 3. Wherein, the positioning accuracy of a plurality of welding strips 3 is ensured by controlling the position of the welding strip feeding mechanism 8 for outputting the welding strips 3 and the spacing accuracy of the diversion trenches 81. In the process of outputting and arranging the welding strips 3 on the first flexible packaging film 2 side by side, the movement speed of the driving roller or the linear movement module is controlled, and the movement speed of the welding strips 3 and the movement speed of the first flexible packaging film 2 are the same and synchronous in the movement direction of the first flexible packaging film 2. In this way, the plurality of solder strips 3 can be embedded in the first flexible packaging film 2 at a faster rate.
As another example, when the solder tape 3 is heated by means of the heating roller 9, the heating roller 9 is controlled to be in a rolling state, and the rolling speed of the heating roller 9 is controlled to be synchronized with the moving speed of the first flexible packaging film 2. In this way, during the heating of the solder tape 3 by means of the heating roller 9, no relative sliding occurs between the heating roller 9 and the first flexible packaging film 2. Preferably, the rolling speed of the heating roller 9 is controlled to be synchronous with the moving speed of the first flexible packaging film 2, and meanwhile, the moving speed of the welding strips 3 and the moving speed of the first flexible packaging film 2 are controlled to be the same and synchronous, and the welding strips 3 and the moving speed of the first flexible packaging film 2 are synchronous, so that the fixing process of the welding strips 3 and the first flexible packaging film 2 can be better ensured while discharging and transferring the welding strips onto the first flexible packaging film 2.
As another embodiment, the method of embedding the plurality of solder strips 3 into the first flexible packaging film 2 further includes: after the bonding tape 3 is at least partially attached to the first flexible packaging film 2, a downward force is applied to the bonding tape 3 so that the thickness of the bonding tape 3 fixed in the first flexible packaging film 2 is uniform. For example, by arranging a pressing mechanism (such as a roller) and controlling the position and the precision of the pressing mechanism, the consistency of the thickness and the surface of the welding strip fixed in the first flexible packaging film 2 can be controlled, and the depth consistency of the welding strip embedded into the first flexible packaging film 2 can be controlled, so that when the assembly is manufactured and laminated, the stress is more uniform, the hidden cracks of the battery piece in the assembly manufacture are further reduced, and the product quality of the photovoltaic assembly is improved.
More specifically, the process of heating the solder tapes using the heating roller 9 to embed the plurality of solder tapes 3 into the first flexible packaging film 2 is as follows:
the welding strip 3 outputs a plurality of welding strips through a driving roller or a plurality of clamping jaws driven by a linear motion module in a welding strip feeding mechanism 8, in the process of transferring to a first flexible packaging film 2, the welding strip 3 is cut when being output to a required length, wherein the welding strip feeding mechanism 8 continuously feeds out the plurality of welding strips 3 according to the electrode spacing of a battery piece at a certain speed, meanwhile, an EVA film (the first flexible packaging film 2) also moves along the feeding direction of the welding strip 3, the motion parameters of the two are controlled, no relative movement of the head of the welding strip 3 relative to the EVA film is ensured at any time, when the welding strip 3 is fed out from the welding strip feeding mechanism 8 for a certain length (such as 5-10 mm), the head of the welding strip 3 enters under a heating roller 9, the heating roller 9 is pressed down on the upper surface of the welding strip 3, the welding strip 3 enters a welding strip pressing groove 91 of the heating roller 9, and the distance between each welding strip pressing groove 91 on the heating roller 9 is ensured, so that the spacing between the plurality of welding strips 3 in the hot pressing process is accurately positioned, namely, the position of the welding strip 3 is ensured to be fixed in the corresponding to the electrode piece of the battery piece. In addition, the accurate interval location among a plurality of welding strips 3 can be further ensured through controlling the position of the welding strip feeding mechanism 8 for outputting the welding strip and the precision of the diversion trench on the welding strip feeding mechanism 8. The heating roller 9 heats the welding strip, and the heating temperature is controlled to be 50-180 ℃. In addition, the heating roller 9 is always in a rolling state in the pressing process, and the rolling motion parameters are controlled to be consistent with the motion parameters of the welding strip at any time, so that the heating roller and the welding strip are ensured to have no relative sliding and only relatively roll; next, the position where the heating roller 9 is pressed down is controlled so that the solder tape 3 is partially pressed into the EVA film. After the heating roller 9 presses the welding strip into the EVA film, the welding strip 3 and the EVA film continuously and synchronously move, and leave the heating roller 9, and the EVA film is cooled, so that the welding strip 3 and the EVA film are firmly combined. All the solder strips 3 required for component arrangement are sequentially pressed and fused into the EVA film according to the method, so that a composite solder strip film is formed, and the final bonding effect is shown in fig. 4.
Still more particularly, referring to fig. 6, the process of embedding the plurality of solder tapes 3 into the first flexible encapsulation film 2 using the laser 11 to heat the solder tapes is as follows:
the method for transferring the output of the welding strip 3 to the first flexible packaging film 2 and the cutting process of the welding strip according to the required length are the same as the above, a laser 11 is arranged behind the position, which is away from the outlet of the welding strip feeding mechanism 8, of the welding strip 3, when the welding strip 3 is sent out from the welding strip feeding mechanism 8 to the position right below the laser 11, the laser 11 heats each welding strip 3 through laser light, the heating temperature is controlled by controlling the power of the laser 11, the heat is transferred to the first flexible packaging film 2 through the welding strip 3, the contact position of the first flexible packaging film 2 and the welding strip 3 is melted, the heating temperature is controlled to be 50-180 ℃, the welding strip 3 is adhered to the first flexible packaging film 2 under the action of the attaching force, the welding strip 3 is separated from the laser 11, and the first flexible packaging film 2 is cooled, so that the welding strip 3 and the first flexible packaging film 2 are firmly combined. All the welding strips 3 required by the arrangement of the components are sequentially pressed and fused into the EVA film according to the method, so that a composite welding strip film is formed.
The above two specific heating modes can control the speed of the welding strip feeding mechanism 8 and the moving speed of the first flexible packaging film 2, and ensure that the head of the welding strip 3 does not move relatively to the first flexible packaging film 2 at any time, thereby improving the working efficiency.
As another embodiment, the method of embedding the plurality of solder strips 3 into the first flexible packaging film 2 includes: in the process of embedding the plurality of solder strips 3 into the first flexible packaging film 2, after the solder strips 3 are conveyed out of the target length, cutting actions are carried out on the plurality of solder strips 3. In this way, the continuously discharged plurality of welding strips 3 can be cut according to the target length, and the welding strips 3 can be fed according to the length requirement of the grid line of the battery piece and cut according to the target length. The welding strip 3 is mainly used for connecting batteries on adjacent battery pieces, and the target length of the welding strip 3 is set according to the length of a grid line on the battery pieces. The first flexible packaging film 2 is embedded while feeding and cutting, so that the fixed speed of the welding strip is effectively ensured.
As another embodiment, please refer to fig. 7, the solder strips 3 and the first flexible packaging film 2 are both discharged by using a roll, and the discharging speed of the roll of the solder strips 3 and the discharging speed of the first flexible packaging film 2 are simultaneously controlled, a plurality of solder strips 3 are embedded into the first flexible packaging film 2 in the discharging process of the two, and when the solder strips 3 and the first flexible packaging film 2 are respectively output to a preset length, cutting actions are respectively performed. The preset length of the solder strip 3 when cutting is, for example, the length of two battery pieces 5, and the preset length of the first flexible packaging film 2 when cutting is, for example, the length required by a photovoltaic module. By adopting the mode, besides the welding strip 3 can be embedded into the first flexible packaging film 2 while discharging, the first flexible packaging film 2 can be cut while discharging, the working efficiency is further improved, and the time required for discharging the first flexible packaging film 2, cutting and transferring to the lower part of the welding strip in the conventional mode is saved. Wherein a solder strip coil 12 provides a solder strip 3 and a flexible packaging film coil 13 provides a first flexible packaging film 2. The discharging speed of the material roll of the welding strip 3 and the discharging speed of the first flexible packaging film 2 are controlled, the welding strip 3 is attached to the first flexible packaging film 2 by adopting a conventional attaching mechanism 14, and a plurality of welding strips 3 are embedded into the first flexible packaging film 2 through a welding strip fixing mechanism 15 in the discharging process of the welding strip 3 and the first flexible packaging film 2.
In other embodiments, the cut solder tape 3 may be further carried onto the first flexible packaging film 2 and processed to obtain the composite solder tape film 4. Specifically, the solder strip 3 is cut according to the required length, that is, the cut solder strip 3 is obtained when the solder strip 3 is fed, and then the solder strip 3 is fixed on the first flexible packaging film 2 by hot press roll hot melting, glue application or laser heating, so as to form the composite solder strip film 4.
As another embodiment, referring to fig. 2 and 5, the present embodiment provides a method for manufacturing a photovoltaic module, including:
sequentially placing component glass 7 and a second flexible packaging film 6, and placing a plurality of battery pieces 5 on the second flexible packaging film 6 according to typesetting requirements of the photovoltaic components; according to typesetting requirements of a photovoltaic module, fixing a plurality of welding strips 3 on a first flexible packaging film 2 through glue to form a composite welding strip film 4, and then covering the composite welding strip film 4 on a battery piece 5, wherein the positions of the welding strips 3 correspond to the electrode positions of the battery piece 5; and placing a backboard 1 above the composite welding strip film 4 for laser welding.
Specifically, as shown in fig. 5, before or after the solder strip feeding mechanism 8 sends out the solder strip 3, a glue applying mechanism 10 for applying glue on the EVA film (the first flexible packaging film 2) is provided, the glue is applied on the EVA film at the position where the solder strip needs to be fixed by glue, the glue application is not limited to glue application, glue dispensing, glue spraying or glue brushing, and the specific position of glue application is determined according to the electrode of the battery piece, and meanwhile, the position where the solder strip feeding mechanism 8 sends out the solder strip 3 is ensured to be consistent with the position where the glue is applied in advance, and the width of glue application does not exceed the width of the solder strip. Taking the sizing mechanism 10 arranged before the welding strip feeding mechanism 8 as an example, when the EVA film with glue is fed into the welding strip outlet of the welding strip feeding mechanism 8, the welding strip 3 cuts the plurality of welding strips 3 into required lengths through a cutter in the welding strip feeding mechanism 8, meanwhile, the welding strip feeding mechanism 8 sends out the plurality of welding strips 3 at a certain speed, the position and the precision of the welding strip outlet of the welding strip feeding mechanism 8 are controlled to ensure accurate spacing positioning among the plurality of welding strips 3, the matched welding strip 3 sends out motion parameters and the EVA film moving speed, and the head of the welding strip 3 does not move relative to the EVA film. All the solder strips 3 required for the battery assembly are adhered to the EVA film in the above-described manner, thereby forming a composite solder strip film 4 required for the assembly.
According to the manufacturing method of the photovoltaic module, the welding strip 3 is fixed in the first flexible packaging film 2 through glue, so that hidden cracks of battery pieces are reduced, the manufacturing method is particularly suitable for efficient fixation of the welding strip of the full-page module, and the step that the packaging film is paved during final lamination in the prior art is omitted because the welding strip 3 is directly fixed on the packaging film. The solder strip is fixed in the packaging film, so that the grid line leakage can be reduced, the problems of complex conventional solder strip fixing structure, low solder strip processing efficiency and the like are solved, and a novel photovoltaic module manufacturing process is provided.
The manufacturing method of the photovoltaic module provided by the embodiment of the application has the beneficial effects that:
1) The welding strip 3 is fixed on the first flexible packaging film 2, and the welding strip 3 is fixed without damaging the material of the first flexible packaging film 2 because the first flexible packaging film 2 is made of soft materials, so that the risk of hidden cracking of the battery piece 5 in assembly manufacturing is reduced, and a new process method is provided for fixing the welding strip 3 in the assembly; moreover, by pressing the portion of the solder strip 3 into the first flexible packaging film 2, the thickness difference between the solder strip 3 and the first flexible packaging film 2 can be reduced, further reducing the risk of occurrence of hidden cracks;
2) Because the battery piece 5 is too fragile, the whole welding strip 3 cannot be directly pressed by a mechanism in the traditional series welding, so that the consistency of the bonding degree of the welding strip 3 on the surface of the battery piece 5 is poor, and the local height is inconsistent, so that when the assembly is laminated, the stress is uneven, the local pressure is too large, and the battery piece 5 is easy to be hidden and cracked; in the application, as the first flexible packaging film 2 is made of soft material, downward acting force can be applied to the welding strip 3 after the welding strip 3 is at least partially attached to the first flexible packaging film 2, for example, the position and the precision of a pressing mechanism are controlled, so that the thickness and the surface consistency of the welding strip 3 fixed in the first flexible packaging film 2 are controlled, the depth consistency of a plurality of welding strips 3 in the composite welding strip film 4 is ensured, the stress is uniform when the assembly is manufactured and laminated, and the risk of hidden cracking of the battery piece 5 in the assembly manufacture is reduced;
3) The application can control the spacing of a plurality of welding strips 3 by controlling the spacing of the diversion trench of the welding strip feeding mechanism 8 and the welding strip pressing slot 91 of the heating roller 9 to be consistent with the grid line spacing of the battery piece 5, more importantly, the welding strips 3 are sent out and fixed at the same time in the embodiment, the spacing precision of the welding strips 3 of the formed composite welding strip film 4 is high and the consistency is good, and the blank leakage is reduced in the assembly manufacturing process;
4) The welding strip 3 fixing method is simple, has low failure rate, is particularly suitable for being directly used on the production process of the full-page assembly, and when the full-page assembly is arranged in the mode, a sufficient number of welding strips 3 can be fixed with the first flexible packaging film 2 of the full-page breadth at one time, so that the method has the advantages that no additional packaging film is needed when the whole photovoltaic assembly is manufactured and packaged, and the working procedure and the cost are saved;
5) In this embodiment, the fixing manner of the solder strip 3 may be intermittent fixing or continuous feeding fixing, the solder strip feeding 3 adopts a stepping or continuous moving manner, and the first flexible packaging film 2 also moves in a stepping or continuous manner, and in combination with the solder strip fixing mechanism 15, the fixing process of the solder strip 3 on the first flexible packaging film 2 can be completed in the continuous moving process of the solder strip 3 and the first flexible packaging film 2, so that the fixing rate of the solder strip 3 can be greatly improved, and the efficiency can be further improved by synchronizing the speed of the solder strip feeding 3 with the speed of the bearing mechanism.
The above electrodes are only specific embodiments of the present application, but the scope of the present application is not limited thereto, and any changes or substitutions easily conceivable by those skilled in the art within the technical scope of the present application should be covered in the scope of the present application. Therefore, the protection scope of the application is subject to the protection scope of the claims.
Claims (13)
1. The manufacturing method of the photovoltaic module is characterized by comprising the following steps of:
sequentially placing component glass (7) and a second flexible packaging film (6), and placing a plurality of battery pieces (5) on the second flexible packaging film (6) according to typesetting requirements of the photovoltaic components;
embedding a plurality of welding strips (3) into a first flexible packaging film (2) according to typesetting requirements of a photovoltaic module to form a composite welding strip film (4), and then covering the composite welding strip film (4) on the battery piece (5), wherein the positions of the welding strips (3) correspond to the electrode positions of the battery piece (5);
and placing a back plate (1) above the composite welding strip film (4) for laser welding.
2. The manufacturing method of the photovoltaic module is characterized by comprising the following steps of:
sequentially placing a back plate (1) and a first flexible packaging film (2), and embedding a plurality of welding strips (3) into the first flexible packaging film (2) according to typesetting requirements of a photovoltaic module to form a composite welding strip film (4);
placing a plurality of battery pieces (5) on the composite welding strip film (4) according to typesetting requirements of the photovoltaic module, wherein the positions of the welding strips (3) correspond to the electrode positions of the battery pieces (5);
and a second flexible packaging film (6) and component glass (7) are sequentially arranged above the battery piece (5) for laser welding.
3. The method for manufacturing the photovoltaic module according to claim 1 or 2, wherein each cell (5) has a plurality of positive electrodes and negative electrodes arranged at intervals on the same surface, and the positive electrodes and the negative electrodes of adjacent cells (5) are connected through the solder strips (3).
4. The method of manufacturing a photovoltaic module according to claim 1 or 2, characterized in that the method of embedding a plurality of solder strips (3) into a first flexible encapsulation film (2) comprises: heating the welding strip (3) to enable heat to be transferred to the first flexible packaging film (2) through the welding strip (3), and enabling the contact part of the first flexible packaging film (2) and the welding strip (3) to be softened so as to embed the welding strip (3) into the first flexible packaging film (2);
wherein the temperature for heating the welding strip (3) is 50-180 ℃.
5. The method of manufacturing a photovoltaic module according to claim 4, characterized in that said method of heating the solder strip (3) comprises: after the welding strip (3) is at least partially attached to the first flexible packaging film (2), the welding strip (3) is heated by a heating roller (9) or a laser (11).
6. The method of manufacturing a photovoltaic module according to claim 5, characterized in that when the solder ribbon (3) is heated by the heating roller (9), the position of the pressing down of the heating roller (9) is controlled so that the solder ribbon (3) is partially embedded in the first flexible packaging film (2).
7. The method according to claim 5, wherein when the heating roller (9) is used to heat the solder tape (3), a plurality of solder tape pressing grooves (91) are provided on the heating roller (9), and the distance between adjacent solder tape pressing grooves (91) is equal to the distance between adjacent solder tapes (3).
8. The method of manufacturing a photovoltaic module according to claim 5, characterized in that the method of embedding a plurality of solder strips (3) into a first flexible encapsulation film (2) comprises: outputting and arranging the welding strips (3) on the first flexible packaging film (2) side by side in a manner of driving rollers or in a manner of driving a plurality of clamping jaws by adopting a linear motion module;
and in the process of outputting and arranging the welding strips (3) on the first flexible packaging film (2), controlling the movement speed of the driving roller or the linear movement module, so that the movement speed of the welding strips (3) and the movement speed of the first flexible packaging film (2) are the same and synchronous in the movement direction of the first flexible packaging film (2).
9. The method for manufacturing the photovoltaic module according to claim 8, wherein when the solder strip (3) is heated by means of the heating roller (9), the heating roller (9) is controlled to be in a rolling state, and the rolling speed of the heating roller (9) is controlled to be synchronous with the moving speed of the first flexible packaging film (2).
10. The method of manufacturing a photovoltaic module according to claim 1 or 2, characterized in that the method of embedding a plurality of solder strips (3) into a first flexible encapsulation film (2) comprises: after the welding strip (3) is at least partially attached to the first flexible packaging film (2), downward acting force is applied to the welding strip (3), so that the thickness of the welding strip (3) fixed in the first flexible packaging film (2) is consistent.
11. The method of manufacturing a photovoltaic module according to claim 1 or 2, characterized in that the method of embedding a plurality of solder strips (3) into a first flexible encapsulation film (2) comprises: and in the process of embedding the plurality of welding strips (3) into the first flexible packaging film (2), cutting the plurality of welding strips (3) after the welding strips (3) are conveyed out of the target length.
12. The method for manufacturing the photovoltaic module according to claim 1 or 2, wherein the solder strips (3) and the first flexible packaging film (2) are discharged by adopting a material roll, the discharging speed of the material roll of the solder strips (3) and the discharging speed of the first flexible packaging film (2) are controlled simultaneously, a plurality of solder strips (3) are embedded into the first flexible packaging film (2) in the discharging process of the two, and when the solder strips (3) and the first flexible packaging film (2) are respectively output to a preset length, cutting actions are respectively carried out.
13. The manufacturing method of the photovoltaic module is characterized by comprising the following steps of:
sequentially placing component glass (7) and a second flexible packaging film (6), and placing a plurality of battery pieces (5) on the second flexible packaging film (6) according to typesetting requirements of the photovoltaic components;
according to typesetting requirements of a photovoltaic module, fixing a plurality of welding strips (3) on a first flexible packaging film (2) through glue to form a composite welding strip film (4), and then covering the composite welding strip film (4) on a battery piece (5), wherein the positions of the welding strips (3) correspond to the positions of electrodes of the battery piece (5);
and placing a back plate (1) above the composite welding strip film (4) for laser welding.
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