WO2019210800A1 - 光伏组件及其制造方法 - Google Patents

光伏组件及其制造方法 Download PDF

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Publication number
WO2019210800A1
WO2019210800A1 PCT/CN2019/084242 CN2019084242W WO2019210800A1 WO 2019210800 A1 WO2019210800 A1 WO 2019210800A1 CN 2019084242 W CN2019084242 W CN 2019084242W WO 2019210800 A1 WO2019210800 A1 WO 2019210800A1
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Prior art keywords
slices
slice
battery
photovoltaic module
rectangular
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PCT/CN2019/084242
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English (en)
French (fr)
Inventor
夏正月
闫新春
徐洁
丁增千
邢国强
Original Assignee
阿特斯阳光电力集团有限公司
常熟阿特斯阳光电力科技有限公司
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Priority claimed from CN201810420032.5A external-priority patent/CN110459634B/zh
Application filed by 阿特斯阳光电力集团有限公司, 常熟阿特斯阳光电力科技有限公司 filed Critical 阿特斯阳光电力集团有限公司
Publication of WO2019210800A1 publication Critical patent/WO2019210800A1/zh

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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
    • H01L31/0248—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 characterised by their semiconductor bodies
    • 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
    • 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
    • H—ELECTRICITY
    • H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
    • H02S—GENERATION OF ELECTRIC POWER BY CONVERSION OF INFRARED RADIATION, VISIBLE LIGHT OR ULTRAVIOLET LIGHT, e.g. USING PHOTOVOLTAIC [PV] MODULES
    • H02S10/00—PV power plants; Combinations of PV energy systems with other systems for the generation of electric power
    • 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
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
    • Y02P—CLIMATE CHANGE MITIGATION TECHNOLOGIES IN THE PRODUCTION OR PROCESSING OF GOODS
    • Y02P70/00—Climate change mitigation technologies in the production process for final industrial or consumer products
    • Y02P70/50—Manufacturing or production processes characterised by the final manufactured product

Definitions

  • the invention relates to the field of photovoltaics, in particular to a photovoltaic module and a manufacturing method thereof.
  • the battery sheets are connected to each other by a solder ribbon, such that one end of the solder ribbon is connected to one electrode of the battery sheet, and the other end is connected to the other surface electrode of the adjacent battery sheet, thereby forming a battery serial connection.
  • traditional photovoltaic modules are limited by some factors (such as ribbon loss, layout and connection methods), making it difficult to generate more power generation efficiency. Increase in range.
  • the industry is gradually developing high-efficiency photovoltaic modules, which requires a large improvement in the traditional photovoltaic components, as much as possible to reduce the internal losses of the components, in order to improve efficiency.
  • the present invention provides a photovoltaic module and a method of manufacturing the same to reduce internal loss and improve power generation efficiency.
  • a photovoltaic module comprising a plurality of battery strings, the battery series comprising a plurality of battery cells connected in series, each battery cell including at least one profile Slices and a rectangular slice, and in the same battery string, the shaped slices in all the cells are placed in the same direction.
  • the profiled slice has a chamfered side edge and a cut side edge that are parallel to each other, and the chamfered side edge is overlapped with the adjacent rectangular slice.
  • the number of the rectangular slices is larger than the number of the shaped slices; in the same battery string, the irregular slices and the rectangular slices are arranged regularly.
  • an adjacent one of the two battery cells is overlapped with a cut side edge by a chamfered side edge.
  • a gap is provided between adjacent two battery strings, and the width of the gap changes regularly.
  • two adjacent battery cells are cut from the same photovoltaic cell, and a single battery cell includes one profiled slice and two rectangular slices that are overlapped with each other.
  • two rectangular slices are arranged at intervals between every two shaped slices.
  • the single battery unit has two profiled slices and a plurality of rectangular slices, and the rectangular slices are located between the two profiled slices.
  • adjacent two battery cells achieve overlapping connections by two profiled slices.
  • the invention also provides a method of manufacturing a photovoltaic module, comprising:
  • the shaped slice and the rectangular slice from the same half piece are connected by edge overlap to form a battery unit, and then several battery cells are overlapped and connected in a straight line to form a battery string, and all the shaped slices in the battery string are placed. The same direction.
  • the “providing a plurality of main gate line electrodes on the surface of the photovoltaic cell sheet” specifically includes: printing a plurality of equally spaced main gate line electrodes on the surface of the photovoltaic cell sheet, wherein the two main gate line electrodes are symmetrically distributed on the battery The sides of the center line of the sheet and the distance between the two are 0.2-1 cm.
  • the method of “dividing the photovoltaic cell into two pieces to obtain two halves” specifically includes: splitting along the center line of the photovoltaic cell to obtain two identical half pieces.
  • a cutting groove is formed on the back side of the photovoltaic cell by using a laser, and the cutting groove is extended along the length direction of the main gate line electrode.
  • performing equal splitting processing on the two halves respectively comprises: placing a single half piece on at least two independently movable adsorption stages, and moving the half piece along the cutting groove position by relative movement between the adsorption stages Breaking, the shaped slice and the rectangular slice are obtained.
  • the adsorption stage generates motion by applying an oblique downward external force.
  • each of the alien slice and the rectangular slice of the same battery cell is optically detected before the profiled slice and the rectangular slice are overlapped and connected.
  • the abnormally shaped slice and the rectangular slice in the battery unit are rejected into the recovery device, and the remaining qualified shaped slices and rectangular slices in the battery unit are respectively stored in different buffer baskets. in.
  • the shaped slice and the rectangular slice in the buffer basket can be reconstructed into one battery unit, the shaped slice and the rectangular slice will be retrieved from the buffer basket again.
  • the invention also provides a method of manufacturing a photovoltaic module, comprising:
  • One of the shaped slices is rotated 180 degrees so that the two shaped slices are placed in the same direction;
  • the shaped slice and the rectangular slice obtained by the same photovoltaic cell lobes are sequentially connected to form a battery unit;
  • a plurality of the battery cells are overlapped and connected in a straight line to form a battery string, and all the shaped slices in the battery string are placed in the same direction.
  • the “providing a plurality of main gate line electrodes on the surface of a single photovoltaic cell” specifically includes:
  • the profiled slice and the rectangular slice are overlapped and connected, the profiled slice and the rectangular slice are optically detected, and the unqualified detection is removed to the recovery device, and then the qualified slice is obtained from the replenishing device. Make up the position.
  • the invention adopts the slice cut by the standard cell sheet, and realizes the electrical connection by overlapping the slices at the edges, thereby eliminating the welding tape in the existing photovoltaic module and avoiding the welding tape.
  • the loss and assembly problems, and the special layout method solves the problem that the profiled slice is difficult to be utilized due to the inconsistent shape, and also improves the overall aesthetics and production efficiency of the photovoltaic module, avoids the waste of the profiled slice or separates it. The trouble of handling.
  • FIG. 1 is a front elevational view showing a battery sheet for manufacturing a photovoltaic module in a first embodiment of the present invention before cutting.
  • Figure 2 is a process of the process of preparing the photovoltaic module of the first embodiment in the cell sheet of Figure 1.
  • Figure 3 is a front elevational view of a photovoltaic module in a first embodiment of the present invention.
  • Figure 4 is a partial enlarged view of the photovoltaic module of the first embodiment shown in Figure 3.
  • Figure 5 is a front elevational view of a cell sheet for fabricating a photovoltaic module in a second embodiment of the present invention prior to cutting.
  • Figure 6 is a process of the battery chip of Figure 5 in the process of preparing the photovoltaic module of the second embodiment.
  • Figure 7 is a front elevational view of a photovoltaic module in a second embodiment of the present invention.
  • Figure 8 is a partial enlarged view of the photovoltaic module of the second embodiment shown in Figure 7.
  • Figure 9 is a schematic illustration of the splitting process in the first embodiment of the present invention.
  • a first embodiment of the present invention provides a photovoltaic module 100 and a manufacturing method thereof.
  • the photovoltaic module 100 includes a plurality of battery strings 10, each of which The battery string 10 includes a plurality of repeatedly arranged battery cells 11 , and a plurality of battery cells 11 of the same series 10 are overlapped with each other, wherein each of the battery cells 11 includes at least two elongated strips
  • the battery is sliced, and the battery slices are overlapped with each other.
  • the battery slice is aliquoted by a standard square single crystal cell sheet 20, since the single crystal cell 20 exists.
  • each of the battery cells 11 includes a profiled slice A and a rectangular slice B, each of which is located on the same side of each of the battery cells 11, thereby forming a regular distribution, and the profiled cut A has a chamfered side edge S1 and a cutting side edge S2 (see FIG.
  • the gap 12 between the two columns of battery strings 10 also exhibits a regular change, on the one hand, the aesthetics of the photovoltaic module 100 is improved, and on the other hand, the area of the gap 12 is increased.
  • the provision of the reflective coating in the gap 12 provides the possibility, and more importantly, in the manufacturing process of the photovoltaic module 100, it is not necessary to specifically remove the profiled slice A for the consistency of the shape of the battery slice, thereby improving the production efficiency and also being excellent. Use the profiled slice A.
  • the present invention further provides a manufacturing method of the photovoltaic module 100.
  • the manufacturing method includes:
  • a plurality of main grid line electrodes and a conductive paste are disposed on the surface of the battery sheet;
  • the two halves are separately subjected to equal splitting processing, so that each half is equally divided into at least two battery slices;
  • the battery chips from the same half are overlapped to each other to form a battery unit 11, and a plurality of battery units 11 are overlapped and connected in a straight line in a string.
  • the "providing a plurality of main gate line electrodes on the surface of the battery sheet” mainly comprises: printing a plurality of equally spaced main gate line electrodes 13 on the surface of the battery sheet, wherein the two main grid line electrodes 13 are symmetrically distributed on the battery sheet The two sides of the center line O, and the distance between the two is 0.2-1 cm, as shown in Figure 1.
  • the “splitting the battery sheet into two pieces to obtain two half sheets” mainly includes: splitting along the center line O of the battery sheet to obtain two identical half sheets H1 and H2.
  • the embodiment further includes: forming a cutting groove on the back side of the photovoltaic cell by using a laser, and making the cutting groove
  • the main gate line electrode extends in the longitudinal direction.
  • the “single one of the half pieces is rotated by 180 degrees” mainly includes: rotating one of the half pieces H2 in the horizontal plane by 180 degrees, so that the two half pieces are placed in the same direction, as shown in FIG. 2, for clarity.
  • the dark color represents the half piece H2 that is rotated.
  • the method of “dividing two halves into equal splitting sheets so that each half is equally divided into at least two battery slices” mainly includes: splitting half pieces H1 and H2 into at least two along the cutting groove.
  • the elongated battery is sliced, and the battery slice includes a profiled slice A and at least one rectangular slice B. Specifically, as shown in FIG.
  • the half sheets H1, H2 are transported to the splitting station, and a plurality of independently movable adsorption stages 30 are disposed below the half sheets H1, H2 for adsorbing different areas of the half sheets H1, H2, And the half pieces H1 and H2 are split by the movement of the adsorption stage 30; after the splitting, the irregular slice A and the rectangular slice B are kept in the same direction, and are transmitted as a whole.
  • the movement of the adsorption stage 30 refers to applying an inclined downward external force F (inclination angle ⁇ ) to the adsorption stage 30 to cause relative movement with the adjacent adsorption stage 30, thereby causing the adjacent two.
  • the half pieces H1, H2 above the adsorption stage 30 are broken at the cutting groove, and preferably, the adsorption stage 30a at the first and last positions is driven first, so that the slice at the edge is first cleaved.
  • the "the battery slices from the same half are overlapped to each other to form a battery unit 11, and the plurality of battery cells 11 are overlapped and connected in a straight line in a series", which mainly includes: cutting the shaped slices from the same half.
  • the rectangular slices B are sequentially overlapped, and the profiled slices A are located at the first position in the battery unit 11 so as to overlap the rectangular slices B at the last position of the adjacent battery cells 11.
  • a second embodiment of the present invention provides another photovoltaic module 200 and a method of fabricating the same.
  • the battery slices in the photovoltaic module 200 in the embodiment are also equally divided by a standard square single crystal cell 20, as shown in FIG. 7 and FIG.
  • the assembly 200 includes a plurality of battery strings 50, and each of the battery strings 50 includes a plurality of battery cells 60.
  • the battery cells 60 are formed by connecting a plurality of the battery slices, and the battery slices are divided into shaped slices A and rectangles.
  • the present invention further provides a manufacturing method of the photovoltaic module 200, as shown in FIG. 5 and FIG. 6, the manufacturing method includes:
  • One of the profiled slices is rotated 180 degrees;
  • a plurality of the battery cells are overlapped and connected in a line in a straight line.
  • providing a plurality of main gate line electrodes on the surface of a single cell sheet mainly comprises: printing a plurality of parallel-extending main gate line electrodes 13 on the surface of the single cell sheet 20, wherein the two rightmost main gate line electrodes 13 are in close proximity to each other And the distance between the two is 0.5-1 cm.
  • the rightmost main gate line electrode and the leftmost main gate line electrode are both parallel to the two side edges of the cell sheet, and the distance L away from the both side edges is at least 15 mm. As shown in Figure 5.
  • the "single one of the profiled slices is rotated by 180 degrees” mainly includes: rotating one of the profiled slices A by 180 degrees in a horizontal plane so that it is placed in the same direction as the other shaped slice A, as shown in FIG. In the figure, for the sake of clarity, the figure shows a deformed slice A that is rotated with a dark color.
  • the manufacturing method in this embodiment also needs to rotate the battery slice 180 degrees to adjust its placement direction, except that in the first embodiment, the entire half piece is rotated. However, in this embodiment, only one of the profiled slices A is rotated.
  • the battery slice needs to be first performed before the battery slices (including the profiled slice A and the rectangular slice B) of the same battery unit are overlapped and connected. Optical detection, and the unqualified battery slices in the battery unit are removed into the recovery device, and the qualified shaped slices and rectangular slices in the battery unit are temporarily stored in different buffer baskets for later use, thereby avoiding Waste, when the shaped slices and rectangular slices in the two buffer baskets can be reconstructed into a battery unit, the shaped slices and rectangular slices will be re-taken from the buffer basket and re-introduced into the assembly line in a predetermined order.
  • the photovoltaic modules 100, 200 in the first embodiment and the second embodiment have the same number of battery strings as the number of slices cut by a single standard cell, that is, if the standard cell is After being divided into six equal parts, the number of battery strings of the entire photovoltaic module is set to six columns.
  • the slice cut by the standard cell sheet is used, and the electrical connection is realized by overlapping the slices at the edges, thereby eliminating the solder ribbon in the existing photovoltaic module, thereby avoiding Loss and assembly problems caused by the ribbon.
  • the present invention adopts a unique manufacturing method to rotate a part of the battery slice, which can not only solve the problem that the profiled slice is inconsistent due to the inconsistent shape. The problem of being utilized, but also improves the overall aesthetics and production efficiency of the photovoltaic module, avoiding the waste of the profiled slice or the trouble of treating it separately.

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Abstract

本发明提供一种光伏组件，包括若干电池串列，所述电池串列内包含有若干相互串接的电池单元，每一电池单元内均包括至少一个异形切片及一个矩形切片，且在同一电池串列中，所有电池单元内的异形切片均朝向相同的方向摆放。本发明采用由标准电池片等分切割得来的切片，通过切片之间在边缘处相互交叠的方式实现电性连接，取消了现有光伏组件中的焊带，避免了焊带所带来的损耗和装配问题，而且利用特殊的布局方式解决了异形切片因外形不一致而难以被利用的问题，也提升了光伏组件的整体美观性和生产效率，避免了异形切片的浪费或对其进行单独处理的麻烦。

Description

光伏组件及其制造方法
相关申请的交叉引用
本专利申请要求于2018年05月04日提交的、申请号为2018104200325、发明名称为“光伏组件及其制造方法”的中国专利申请的优先权，该申请的全文以引用的方式并入本文中。
技术领域
本发明涉及光伏领域，尤其涉及一种光伏组件及其制造方法。
背景技术
传统的光伏组件中，电池片之间通过焊带相互连接，使焊带的一端连接至电池片的一面电极，另一端连接至相邻电池片的另一面电极，从而形成电池串接。然而，随着市场对高功率组件的需求越来越高，传统光伏组件受限于自身的某些因素(如焊带损耗、版型及连接方式等)，使得其发电效率很难有较大幅度的提升。目前，业界逐渐开始研发高效光伏组件，这要求对传统光伏组件进行较大幅度的改善，尽可能的降低组件内部的损耗，以此来提升效率。
发明内容
有鉴于此，本发明提供一种光伏组件及其制造方法，以降低内部损耗、提高发电效率。
具体地，本发明是通过如下技术方案实现的：一种光伏组件，包括若干电池串列，所述电池串列内包含有若干相互串接的电池单元，每一电池单元内均包括至少一个异形切片及一个矩形切片，且在同一电池串列中，所有电池单元内的异形切片均朝向相同的方向摆放。
进一步地，所述异形切片具有相互平行的一倒角侧边缘及一切割侧边缘，所述倒角侧边缘与相邻的矩形切片交叠连接。
进一步地，在同一电池单元内，所述矩形切片的数量大于所述异形切片的数量；在同一电池串列中，所述异形切片和矩形切片呈规律性排布。
进一步地，相邻两个电池单元之间通过一倒角侧边缘与一切割侧边缘实现交叠连接。
进一步地，相邻两个电池串列之间设有间隙，且所述间隙的宽度呈规律性变化。
进一步地，相邻两个电池单元由同一光伏电池片切割而得，且单个电池单元内包括相互交叠连接的一个异形切片及两个矩形切片。
进一步地，在同一电池串列中，每两个异形切片之间间隔设置有两个矩形切片。
进一步地，所述单个电池单元内具有两个异形切片及若干矩形切片，且所述矩形切片位于所述两个异形切片之间。
进一步地，相邻两个电池单元通过两个异形切片实现交叠连接。
本发明还提供一种光伏组件的制造方法，包括：
在光伏电池片表面设置若干主栅线电极；
将所述光伏电池片二等分裂片，得到两个半片；
将其中一个半片在水平面内旋转180度，从而使两个半片的摆放方向相同；
对所述两个半片分别进行等分裂片处理，使每一半片被等分为至少一个异形切片及一个矩形切片；
将来自同一半片的异形切片和矩形切片通过边缘交叠连接形成一电池单元，再将若干电池单元沿直线方向交叠连接形成一电池串列，且该电池串列内的所有异形切片的摆放方向相同。
进一步地，所述“在光伏电池片表面设置若干主栅线电极”，具体包括：在光伏电池片表面印刷若干条等间距分布的主栅线电极，其中两条主栅线电极对称分布于电池片的中心线的两侧且两者之间的距离为0.2-1cm。
进一步地，所述“将所述光伏电池片二等分裂片，得到两个半片”，具体包括：沿光伏电池片中心线进行裂片，得到两个相同的半片。
进一步地，在沿光伏电池片中心线进行裂片之前，先利用激光在光伏电池片背面侧形成切割槽，并使所述切割槽沿主栅线电极长度方向延伸。
进一步地，对所述两个半片分别进行等分裂片处理，包括：将单个半片放置于至少两个可独立运动的吸附台上，通过吸附台之间的相对运动使所述半片沿切割槽位置断裂，得到所述异形切片和矩形切片。
进一步地，所述吸附台通过施加倾斜向下的外力而产生运动。
进一步地，在异形切片和矩形切片交叠连接之前，先对同一电池单元的每一异形切片和矩形切片进行光学检测。
进一步地，光学检测时，将所述电池单元内检测不合格的异形切片和矩形切片剔除至回收装置内，将该电池单元内剩余的检测合格的异形切片和矩形切片分别存放至不同的缓冲篮中。
进一步地，当所述缓冲篮内的异形切片和矩形切片能够重新构成一个电池单元时，所述异形切片和矩形切片将被重新从缓冲篮内取出。
本发明还提供一种光伏组件的制造方法，包括：
在单个光伏电池片表面设置若干主栅线电极及导电胶；
对所述光伏电池片进行等分裂片处理，得到两个异形切片及若干矩形切片；
将其中一个异形切片180度旋转，从而使两个异形切片的摆放方向相同；
将由同一光伏电池片裂片得到的异形切片及矩形切片依次交叠连接，形成一电池单元；
将若干所述电池单元沿直线方向交叠连接形成一电池串列，且该电池串列内的所有异形切片的摆放方向相同。
进一步地，所述“在单个光伏电池片表面设置若干主栅线电极”，具体包括：
在单个光伏电池片表面印刷若干平行延伸的主栅线电极，其中最右侧的两条主栅线电极彼此紧邻且两者之间的距离为0.5-1cm，而且所述若干主栅线电极中，最右侧的主栅线电极和最左侧的主栅线电极均远离与之平行的光伏电池片的两条侧边缘，且与该两侧边缘的距离至少为15mm。
进一步地，在所述异形切片与矩形切片交叠连接之前，先对所述异形切片和矩形切片进行光学检测，并将检测不合格的剔除至回收装置中，然后从补给装置中获取合格的切片进行补位。
本发明采用由标准电池片等分切割得来的切片，通过切片之间在边缘处相互交叠的方式实现电性连接，取消了现有光伏组件中的焊带，避免了焊带所带来的损耗和装配问题，而且利用特殊的布局方式解决了异形切片因外形不一致而难以被利用的问题，也提升了光伏组件的整体美观性和生产效率，避免了异形切片的浪费或对其进行单独处理的 麻烦。
附图说明
图1是用于制造本发明第一实施例中光伏组件的电池片在切割前的正面示意图。
图2是图1所示电池片在制备第一实施例光伏组件过程中的处理过程。
图3是本发明第一实施例中光伏组件的正面视图。
图4是图3所示第一实施例光伏组件的局部放大图。
图5是用于制造本发明第二实施例中光伏组件的电池片在切割前的正面示意图。
图6是图5所示电池片在制备第二实施例光伏组件过程中的处理过程。
图7是本发明第二实施例中光伏组件的正面视图。
图8是图7所示第二实施例中光伏组件的局部放大图。
图9是本发明第一实施例中裂片处理的示意图。
具体实施方式
这里将详细地对示例性实施例进行说明，其示例表示在附图中。下面的描述涉及附图时，除非另有表示，不同附图中的相同数字表示相同或相似的要素。以下示例性实施例中所描述的实施方式并不代表与本发明相一致的所有实施方式。相反，它们仅是与如所附权利要求书中所详述的、本发明的一些方面相一致的装置和方法的例子。
在本发明使用的术语是仅仅出于描述特定实施例的目的，而非旨在限制本发明。在本发明和所附权利要求书中所使用的单数形式的“一种”、“所述”和“该”也旨在包括多数形式，除非上下文清楚地表示其他含义。还应当理解，本文中使用的术语“和/或”是指并包含一个或多个相关联的列出项目的任何或所有可能组合。
如图1至图4所示，为本发明第一实施例，其提供了一种光伏组件100及制造方法，在本实施例中，所述光伏组件100包括若干个电池串列10，每一个电池串列10中包含有若干重复排列的电池单元11，同一串列10中的若干电池单元11之间彼此相互交叠连接，其中，所述每一电池单元11内包括至少两个长条形的电池切片，且电池切片之间彼此相互交叠连接，在本实施例中，所述电池切片是由标准的四方形单晶电池片20经过等分切割而来，由于单晶电池片20存在四个倒角，因而，在等分切割后，会存在两 个边缘处的电池切片的形状与其他电池切片不同，称为异形切片A，所述电池切片经过规律性的排布形成所述电池串列10，且每一电池单元11中均包含有一所述异形切片A及一个矩形切片B，所述异形切片A均位于每一电池单元11的同一侧，从而形成规律性分布，且异形切片A具有相互平行的一倒角侧边缘S1及一切割侧边缘S2(参图4)，所述倒角侧边缘S1由于倒角的存在，因而长度略小于所述切割侧边缘S2，而且所述切割侧边缘S2与同一电池单元11内矩形切片B交叠连接，而所述倒角侧边缘S1则与相邻电池单元11内的矩形切片B交叠连接。
由于异形切片A的存在，使得两列电池串列10之间的间隙12也呈现规律性变化，一方面提高了光伏组件100的美观度，另一方面也使得间隙12的面积有所提升，为间隙12内反光涂层的设置提供可能，更重要的是，在光伏组件100的制造过程中无需为了电池切片形状的一致性而特意将异形切片A剔除，提高了生产效率，也能很好的将异形切片A利用起来。
另外，在第一实施例中，本发明还提供一种光伏组件100的制造方法，如图1、图2所示，该制造方法包括：
在电池片表面设置若干主栅线电极及导电胶；
将电池片二等分裂片，得到两个半片；
将其中一个半片进行180度旋转；
将两个半片分别进行等分裂片处理，使每一半片被等分为至少两个电池切片；
将来自同一半片的所述电池切片相互交叠连接形成一电池单元11，再将若干电池单元11沿直线方向交叠连接成串。
其中，所述“在电池片表面设置若干主栅线电极”，主要包括：在电池片表面印刷若干条等间距分布的主栅线电极13，其中两条主栅线电极13对称分布于电池片的中心线O的两侧，且两者之间的距离为0.2-1cm，如图1所示。
其中，所述“将电池片二等分裂片，得到两个半片”，主要包括：沿电池片中心线O进行裂片，得到两个相同的半片H1、H2。
值得一提的是，在“将电池片二等分裂片，得到两个半片”之前，本实施例中还包括：利用激光在光伏电池片的背面侧形成切割槽，并使所述切割槽沿主栅线电极长度方向延伸。
其中，所述“将其中一个半片进行180度旋转”，主要包括：将其中一个半片H2在水平面内旋转180度，从而使得两个半片的摆放方向相同，如图2所示，为了清楚展示，图中用深色代表发生旋转的半片H2。
其中，所述“将两个半片分别进行等分裂片处理，使每一半片被等分为至少两个电池切片”，主要包括：沿所述切割槽将半片H1、H2掰裂成至少两个长条形电池切片，且所述电池切片中包含有一个异形切片A及至少一个矩形切片B。具体来说，如图9所示，将半片H1、H2运送至裂片工位，在半片H1、H2的下方设置若干可独立运动的吸附台30，用于吸附住半片H1、H2的不同区域，并通过吸附台30的运动将半片H1、H2掰裂；掰裂后保持异形切片A和矩形切片B摆放方向不变，将其作为一个整体进行传送。如图3所示，所述吸附台30的运动是指对吸附台30施加倾斜向下的外力F(倾斜角度θ)，使其与相邻的吸附台30产生相对运动，从而促使相邻两个吸附台30上方的半片H1、H2在所述切割槽处发生断裂，且优选地，先驱动首、末位置上的吸附台30a，使边缘处的切片先被掰裂下来。
其中，所述“将来自同一半片的所述电池切片相互交叠连接形成一电池单元11，再将若干电池单元11沿直线方向交叠连接成串”，主要包括：将来自同一半片的异形切片A、矩形切片B依次交叠连接，且所述异形切片A在电池单元11中均位于首位的位置上，以便与相邻电池单元11末位位置上的矩形切片B交叠连接。
如图5至图8所示，为本发明第二实施例，其提供了另一种光伏组件200及其制造方法。与第一实施例一样，本实施例中所述光伏组件200内的电池切片同样由标准的四方形单晶电池片20经过等分切割而来，参图7、图8所示，所述光伏组件200包括若干电池串列50，且每一电池串列50内包含有若干电池单元60，所述电池单元60由若干所述电池切片连接而成，所述电池切片分为异形切片A及矩形切片B，且同一电池单元内具有两个异形切片A，且该两个异形切片A中的一个异形切片A经180度旋转后与该电池单元内的矩形切片B交叠连接，以使得两个异形切片A可以朝向相同的方向摆放，相比较而言，假如同一电池单元内的一个异形切片A不进行旋转而保持原状的话，会使得该异形切片A的倒角侧边缘与相邻电池单元异形切片A的倒角侧边缘交叠连接，显然，由于倒角侧边缘的长度稍短，对于连接的可靠性和稳定性来说并不是最佳的方式，因而本实施例中将其中一个异形切片A进行180度旋转以改善上述问题。
另外，在第二实施例中，本发明还提供一种光伏组件200的制造方法，如图5、图6所示，该制造方法包括：
在单个光伏电池片表面设置若干主栅线电极及导电胶；
对所述电池片进行等分裂片处理，得到两个异形切片及若干矩形切片；
将其中一个异形切片进行180度旋转；
将所述异形切片及矩形切片依次交叠连接，形成一电池单元；
将若干所述电池单元沿直线方向交叠连接成串。
其中，“在单个电池片表面设置若干主栅线电极”，主要包括：在单个电池片20表面印刷若干平行延伸的主栅线电极13，其中最右侧的两条主栅线电极13彼此紧邻且两者之间的距离为0.5-1cm。所述若干主栅线电极中，最右侧的主栅线电极和最左侧的主栅线电极均与电池片的两个侧边缘平行，且远离该两侧边缘的距离L至少为15mm，如图5所示。
其中，所述“将其中一个异形切片进行180度旋转”，主要包括：将其中一个异形切片A在水平面内旋转180度，使得其与另一个异形切片A的摆放方向相同，如图6所示，为了清楚展示，图中用深色代表发生旋转的异形切片A。
与第一实施例中的制造方法相比，本实施例中所述制造方法同样需要对电池切片进行180度旋转，以调整其摆放方向，只不过在第一实施例中旋转的是整个半片，而本实施例中旋转的只是其中的一个异形切片A。
值得一提的是，无论是第一实施例还是第二实施例，在将同一电池单元的电池切片(包括异形切片A及矩形切片B)交叠连接之前，都需要先对所述电池切片进行光学检测，并将该电池单元内的检测不合格的电池切片剔除至回收装置中，将该电池单元内检测合格的异形切片和矩形切片分别暂存在不同的缓冲篮内，以备后用，避免浪费，当两个缓冲篮内的异形切片和矩形切片的能够重新构成一个电池单元时，所述异形切片和矩形切片将被重新从缓冲篮内取出，被按预设的顺序重新流入流水线上。当然，除此方式外，也可采用从补给装置中直接获取合格的电池切片实现补位的方式完成。另外，所述第一实施例和第二实施例中，所述单个电池片最终经六等分裂片后，均可得到四个矩形切片B及两个异形切片A，所述异形切片A由于存在两个缺角，因而其表面积略小于所述矩形切片B。
除此之外，所述第一实施例和第二实施例中的光伏组件100、200，其电池串列的数量与单个标准电池片等分切割得到的切片的数量相同，即若标准电池片被六等分，那么整个光伏组件的电池串列数量则设为六列。
本发明所述光伏组件内采用由标准电池片等分切割得来的切片，通过切片之间在边缘处相互交叠的方式实现电性连接，取消了现有光伏组件中的焊带，避免了焊带所带来的损耗和装配问题。不仅如此，为了更好地实现可持续性生产，尤其是对于标准的单晶电池片来说，本发明采用独特的制造方法，将部分电池切片进行旋转，不仅可以解决异形切片因外形不一致而难以被利用的问题，而且还提升了光伏组件的整体美观性和生产效率，避免了异形切片的浪费或对其进行单独处理的麻烦。
以上所述仅为本发明的较佳实施例而已，并不用以限制本发明，凡在本发明的精神和原则之内，所做的任何修改、等同替换、改进等，均应包含在本发明保护的范围之内。

Claims (21)

  1. 一种光伏组件，包括若干电池串列，所述电池串列内包含有若干相互串接的电池单元，其特征在于，每一电池单元内均包括至少一个异形切片及一个矩形切片，且在同一电池串列中，所有电池单元内的异形切片均朝向相同的方向摆放。
  2. 如权利要求1所述的光伏组件，其特征在于，所述异形切片具有相互平行的一倒角侧边缘及一切割侧边缘，所述倒角侧边缘与相邻的矩形切片交叠连接。
  3. 如权利要求2所述的光伏组件，其特征在于，在同一电池单元内，所述矩形切片的数量大于所述异形切片的数量；在同一电池串列中，所述异形切片和矩形切片呈规律性排布。
  4. 如权利要求3所述的光伏组件，其特征在于，相邻两个电池单元之间通过一倒角侧边缘与一切割侧边缘实现交叠连接。
  5. 如权利要求4所述的光伏组件，其特征在于，相邻两个电池串列之间设有间隙，且所述间隙的宽度呈规律性变化。
  6. 如权利要求5所述的光伏组件，其特征在于，相邻两个电池单元由同一光伏电池片切割而得，且单个电池单元内包括相互交叠连接的一个异形切片及两个矩形切片。
  7. 如权利要求6所述的光伏组件，其特征在于，在同一电池串列中，每两个异形切片之间间隔设置有两个矩形切片。
  8. 如权利要求5所述的光伏组件，其特征在于，所述单个电池单元内具有两个异形切片及若干矩形切片，且所述矩形切片位于所述两个异形切片之间。
  9. 如权利要求8所述的光伏组件，其特征在于，相邻两个电池单元通过两个异形切片实现交叠连接。
  10. 一种光伏组件的制造方法，其特征在于，包括：
    在光伏电池片表面设置若干主栅线电极；
    将所述光伏电池片二等分裂片，得到两个半片；
    将其中一个半片在水平面内旋转180度，从而使两个半片的摆放方向相同；
    对所述两个半片分别进行等分裂片处理，使每一半片被等分为至少一个异形切片及一个矩形切片；
    将来自同一半片的异形切片和矩形切片通过边缘交叠连接形成一电池单元，再将若干电池单元沿直线方向交叠连接形成一电池串列，且该电池串列内的所有异形切片的摆放方向相同。
  11. 如权利要求10所述的光伏组件的制造方法，其特征在于，所述“在光伏电池片表面设置若干主栅线电极”，具体包括：在光伏电池片表面印刷若干条等间距分布的主栅线电极，其中两条主栅线电极对称分布于电池片的中心线的两侧且两者之间的距离为0.2-1cm。
  12. 如权利要求11所述的光伏组件的制造方法，其特征在于，所述“将所述光伏电池片二等分裂片，得到两个半片”，具体包括：沿光伏电池片中心线进行裂片，得到两个相同的半片。
  13. 如权利要求12所述的光伏组件的制造方法，其特征在于，在沿光伏电池片中心线进行裂片之前，先利用激光在光伏电池片背面侧形成切割槽，并使所述切割槽沿主栅线电极长度方向延伸。
  14. 如权利要求13所述的光伏组件的制造方法，其特征在于，对所述两个半片分别进行等分裂片处理，包括：将单个半片放置于至少两个可独立运动的吸附台上，通过吸附台之间的相对运动使所述半片沿切割槽位置断裂，得到所述异形切片和矩形切片。
  15. 如权利要求14所述的光伏组件的制造方法，其特征在于，所述吸附台通过施加倾斜向下的外力而产生运动。
  16. 如权利要求15所述的光伏组件的制造方法，其特征在于，在异形切片和矩形切片交叠连接之前，先对同一电池单元的每一异形切片和矩形切片进行光学检测。
  17. 如权利要求16所述的光伏组件的制造方法，其特征在于，光学检测时，将所 述电池单元内检测不合格的异形切片和矩形切片剔除至回收装置内，将该电池单元内剩余的检测合格的异形切片和矩形切片分别存放至不同的缓冲篮中。
  18. 如权利要求17所述的光伏组件的制造方法，其特征在于，当所述缓冲篮内的异形切片和矩形切片能够重新构成一个电池单元时，所述异形切片和矩形切片将被重新从缓冲篮内取出。
  19. 一种光伏组件的制造方法，其特征在于，包括：
    在单个光伏电池片表面设置若干主栅线电极及导电胶；
    对所述光伏电池片进行等分裂片处理，得到两个异形切片及若干矩形切片；
    将其中一个异形切片180度旋转，从而使两个异形切片的摆放方向相同；
    将由同一光伏电池片裂片得到的异形切片及矩形切片依次交叠连接，形成一电池单元；
    将若干所述电池单元沿直线方向交叠连接形成一电池串列，且该电池串列内的所有异形切片的摆放方向相同。
  20. 如权利要求19所述的光伏组件的制造方法，其特征在于，所述“在单个光伏电池片表面设置若干主栅线电极”，具体包括：
    在单个光伏电池片表面印刷若干平行延伸的主栅线电极，其中最右侧的两条主栅线电极彼此紧邻且两者之间的距离为0.5-1cm，而且所述若干主栅线电极中，最右侧的主栅线电极和最左侧的主栅线电极均远离与之平行的光伏电池片的两条侧边缘，且与该两侧边缘的距离至少为15mm。
  21. 如权利要求20所述的光伏组件的制造方法，其特征在于，在所述异形切片与矩形切片交叠连接之前，先对所述异形切片和矩形切片进行光学检测，并将检测不合格的剔除至回收装置中，然后从补给装置中获取合格的切片进行补位。
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