Patent Application
20240395949
The present application claims the benefit of priority under the Paris Convention to Chinese Patent Application No. 202310587109.9 filed on May 23, 2023, which is incorporated herein by reference in its entirety.
Embodiments of the present application relate to the technical field of photovoltaics, and in particular to a solar cell, a photovoltaic module, and a method for preparing a photovoltaic module.
A solar cell is a device that directly convert light energy into electrical energy through photoelectric effect or photochemical effect. A single solar cell cannot be directly used for power generation. Several solar cells must be connected in series, parallel, and tightly encapsulated into components through welding strips before use. A photovoltaic module (i.e., solar cell panel) is the core and most important part of a solar power generation system. The photovoltaic module is configured to convert solar energy into electrical energy, send the electrical energy to an accumulator for storage, or drive a load to operate.
A cell sheet is very fragile, and it is generally necessary to set adhesive films and cover plates on an upper surface and a lower surface of the photovoltaic module to protect the solar cells. The cover plate is generally made of photovoltaic glass, which cannot be directly attached to the solar cell, and the adhesive film needs to play a bonding role in the middle. The connection between the solar cells generally requires a welding strip for collecting current, and conventional welding strips require alloying between the welding strips and fingers during welding. However, the melting point of the solder in the welding strip is generally high, and in the actual welding process, the welding temperature should be higher than the melting point of the solder by more than 20 degrees Celsius. Due to significant warping and deformation during the welding process, there is a high risk of hidden cracks and a high rate of fragmentation after welding. In order to improve welding quality, low-welding temperature welding strips and busbar free technology have emerged. But there are still many factors that affect the yield of the photovoltaic module, such as the welding effect between the welding strips and the fingers, and the welding yield.
The embodiments of the present application provide a solar cell, a photovoltaic module, and a method for preparing the photovoltaic module, which are at least advantageous in improving the yield of the photovoltaic module.
According to some embodiments of the present application, in a first aspect, a solar cell is provided according to the present application, and the solar cell includes a substrate having a first surface and a second surface opposite to the first surface, and multiple first busbars arranged at intervals on the first surface of the substrate, each of the multiple first busbars extends along a first direction. At least one of the multiple first busbars near at least one of two opposite edges of the substrate along the first direction includes at least one first widened portion. The solar cell further includes multiple second busbars arranged at intervals on the second surface of the substrate, each of the multiple second busbars extends along the first direction. At least one of the multiple second busbars near at least one of the two opposite edges of the substrate along the first direction includes at least one second widened portion, and the at least one second widened portion is larger than each of the at least one first widened portion.
In some embodiments, each of the multiple first busbars includes two first electrodes near at least one of the two opposite edges of the substrate along the first direction and multiple second electrodes arranged between the two first electrodes, and each of the two first electrodes includes the at least one first widened portion; each of the multiple second electrodes includes at least one third widened portion arranged opposite to each of the at least one first widened portion along the first direction, and each of the at least one third widened portion is smaller than each of the at least one first widened portion.
In some embodiments, each of the multiple second busbars includes multiple third electrodes arranged at intervals along the first direction and multiple fourth electrodes arranged between every two third electrodes of the multiple third electrodes, and each of the multiple third electrodes includes the at least one second widened portion; each of the multiple fourth electrodes includes at least one fourth widened portion arranged opposite to each of the at least one second widened portion along the first direction, and each of the at least one fourth widened portion is smaller than each of the at least one second widened portion.
In some embodiments, each of the at least one fourth widened portion is smaller than each of the at least one first widened portion.
In some embodiments, there are 2 to 20 third electrodes on the second surface.
In some embodiments, each of the at least one second widened portion has a width of 0.2 mm to 1.0 mm along the first direction.
In some embodiments, the solar cell further includes: a passivation layer, where the passivation layer is arranged on the first surface of the substrate, and each of the at least one first widened portion and/or each of the at least one second widened portion are arranged on a surface of the passivation layer away from the substrate without penetrating through the passivation layer; each of the multiple first busbars further includes two first fingers arranged on two sides of each of the at least one first widened portion, respectively, and the each of the two first fingers penetrates through the passivation layer and protrudes from the passivation layer in a direction away from the substrate.
In some embodiments, each of the multiple first busbars is integrally formed, and each of the multiple second busbars is integrally formed.
According to some embodiments of the present application, in a second aspect, a photovoltaic module is further provided according to the present application, the photovoltaic module includes: at least one cell string, where the cell string is formed by electrically connecting multiple solar cells with each other by multiple welding strips, each of the multiple welding strips is electrically connected to a respective first busbar in the multiple first busbars and/or a respective second busbar in the multiple second busbars, and any of the multiple welding strips is in electrical contact with at least one first widened portion or at least one second widened portion; at least one encapsulation layer configured to cover the at least one cell string; at least one cover plate is configured to cover the at least one encapsulation layer.
In some embodiments, there are M first overlapping regions between each of the multiple welding strips and the multiple first busbars; there are N adhesive points on each of the multiple welding strips, each of the N adhesive points is configured to cover a respective first overlapping region of the M first overlapping regions at least including a part of the M first overlapping regions defined on at least one each of the at least one first widened portion, and N is less than M and greater than or equal to a number of the at least one first widened portion; the at least one encapsulation layer is arranged to cover the N adhesive points.
In some embodiments, N is less than or equal to the number of the at least one second widened portion.
In some embodiments, 2≤N≤20.
In some embodiments, the at least one encapsulation layer is arranged on a surface of each of the multiple second busbars, a part of the multiple welding strips arranged on the second surface is in direct contact with the at least one encapsulation layer, and there is no adhesive point on the second surface.
According to some embodiments of the present application, in a third aspect, a method for preparing a photovoltaic module is further provided according to the present application, the method includes providing multiple solar cells and multiple welding strips, welding each of the multiple welding strips and a corresponding solar cell of the multiple solar cells together to form an alloy layer between each of the multiple welding strips and each of multiple first busbars, and between each of the multiple welding strips and each of multiple second busbars, where the multiple solar cells form at least one cell string by the multiple welding strips after welding treatment. The method further includes providing at least one encapsulation layer and at least one cover plate, where the at least one encapsulation layer is configured to cover the at least one cell string, and the at least one cover plate is configured to cover the at least one encapsulation layer. The method further includes laminating the at least one cell string, the at least one encapsulation layer, and the at least one cover plate.
In some embodiments, there are M first overlapping regions between each of the multiple welding strips and the multiple first busbars. After the welding treatment, the method further includes: dispensing adhesive on a part of first overlapping regions on each of the multiple solar cells to form N adhesive points on the first surface of the substrate, where each of the N adhesive points is configured to cover a respective first overlapping region of the M first overlapping regions at least including a part of the M first overlapping regions defined on at least one each of the at least one first widened portion, and N is less than M and greater than or equal to a number of the at least one first widened portion.
One or more embodiments are described as examples with reference to the corresponding figures in the accompanying drawings, and the exemplary description does not constitute a limitation to the embodiments. The figures in the accompanying drawings do not constitute a proportion limitation unless otherwise stated. For more clearly illustrating embodiments of the present disclosure or the technical solutions in the conventional technology, drawings referred to for describing the embodiments or the conventional technology will be briefly described hereinafter. Apparently, drawings in the following description are only examples of the present disclosure, and for the person skilled in the art, other drawings may be acquired based on the provided drawings without any creative efforts.
It can be seen from the background technology that the yield of photovoltaic modules is currently poor.
In the solar cell provided according to the embodiments of the present application, the substrate has the first surface and the second surface opposite to the first surface, each of the multiple first busbars arranged on the first surface has a first widened portion, and each of the multiple second busbars arranged on the second surface has a second widened portion. Each of the at least one first widened portion and each of the at least one second widened portion can increase the welding tension between the multiple first busbars and the multiple welding strips, as well as the welding tension between the multiple second busbars and the multiple welding strips, thus improving the welding effect between the multiple first busbars and the multiple welding strips, as well as the welding effect between the multiple second busbars and the multiple welding strips. Each of the at least one first widened portion is larger than each of the at least one second widened portion. By setting the size of each of the at least one first widened portion on the first surface and the size of each of the at least one second widened portion on the second surface, it is ensured that the size of each of the at least one first widened portion on the first surface is smaller, resulting in a smaller covering area on the first surface and improving the efficiency of the solar cell. Each of the at least one second widened portion of the second surface is at least near at least one of the two opposite edges of the substrate, that is, the number of each of the at least one second widened portions is greater than or equal to the number of each of the at least one first widened portions, thereby increasing the welding area of the second surface by increasing the number of each of the at least one second widened portions, thereby improving the welding tension between the solar cell and the multiple welding strips.
The embodiments of the present application will be described in detail below with reference to the accompanying drawings. However, those of ordinary skill in the art can understand that, in various embodiment of the present application, many technical details are set forth in order to provide the reader with a better understanding of the present application. However, the technical solutions claimed in the present application may be realized even without these technical details and various changes and modifications based on the following embodiments.
It can be understood that the cross-sectional view between each of the at least one second widened portion of the second surface and the second busbar may refer to the positional relationship between each of the at least one first widened portion and the first busbars in
Referring to
The solar cell may be any of a conventional tunnel oxide passivated contact (TOPCON) cell, a passivated emitter and real cell (PERC) cell, and a heterojunction cell. In some embodiments, the solar cell may also be a compound cell, and the compound includes but is not limited to silicon germanide, silicon carbide, gallium arsenide, indium gallide, perovskite, cadmium telluride, copper indium diselenide and other materials.
The solar cell includes a substrate that is sequentially stacked and a passivation layer. The material of the substrate 100 may be an elemental semiconductor material. Specifically, the elemental semiconductor material is composed of a single element, such as silicon. Among them, the element semiconductor material may be in a single crystal state, a polycrystalline state, an amorphous state, or a microcrystalline state (with both single crystal and amorphous states, referred to as microcrystalline state), for example, silicon can be at least one of monocrystalline silicon, polycrystalline silicon, amorphous silicon, or microcrystalline silicon.
In some embodiments, the material of the substrate 100 may also be a compound semiconductor material. Common compound semiconductor materials include but are not limited to silicon germanide, silicon carbide, gallium arsenide, indium gallide, perovskite, cadmium telluride, copper indium diselenide. The substrate 100 may also be a sapphire substrate, a silicon substrate on an insulator, or a germanium substrate on an insulator.
In some embodiments, the substrate 100 may be an N-type semiconductor substrate or a P-type semiconductor substrate. The N-type semiconductor substrate is doped with N-type doping elements, which can be any of the V group elements such as phosphorus (P), bismuth (Bi), antimony (Sb), or arsenic (As). The P-type semiconductor substrate is doped with P-type elements, which can be any of the III group elements such as boron (B), aluminum (Al), gallium (Ga), or gallium (In).
In some embodiments, the solar cell further includes a passivation layer 101, which is arranged on the first surface of the substrate 100. The materials of the passivation layer 101 include any one or more of materials such as silicon oxide, silicon nitride, silicon nitride, carbon nitrogen oxide, titanium oxide, hafnium oxide, or aluminum oxide.
The solar cell includes an emitter and a first passivation layer arranged on the first surface 11 of the substrate 100, a second passivation layer arranged on the second surface 12 of the substrate 100. Each of the multiple first busbar 21 penetrates through the first passivation layer to be in electrical contact with the emitter, and each of the multiple second busbars 22 penetrates through the second passivation layer to be in electrical contact with the second surface 12. The passivation layer 101 includes a first passivation layer and a second passivation layer.
In some embodiments, in response to the solar cell being a TOPCON cell, the solar cell further includes a tunneling dielectric layer and a doped conductive layer stacked together. The tunneling dielectric layer is arranged on the second surface 12 of the substrate 100, and the multiple second busbars 22 penetrate through the second passivation layer to be in electrical contact with the doped conductive layer.
In some embodiments, the multiple first busbars 21 and the multiple second busbars 22 are fingers of the solar cell, and the fingers can be sintered from the burn-through slurry. The multiple first busbars 21 and the multiple second busbars 22 are formed by a screen-printing process to print metal slurry on the surface of a part of the passivation layer. Metal slurry includes at least one of silver, copper, tin, gold, lead, or nickel. The sintering process is carried out on the metal slurry. In some embodiments, the metal slurry contains materials with high corrosive components such as glass. Therefore, during the sintering process, the corrosive components will corrode the passivation layer, which causes the metal slurry to penetrate into the passivation layer 101 to be in electrical contact with the substrate 100.
In some embodiments, each of the multiple first busbars 21 includes two first electrodes 110 near at least one of the two opposite edges of the substrate 100 along the first direction Y and multiple second electrodes 120 arranged between the two first electrodes 110. Each of the two first electrodes 110 includes at least one first widened portion 111, and two first fingers 112 arranged on two sides of each of the at least one first widened portion 111, respectively. Each of the two first fingers 112 penetrates through the passivation layer 101 and protrudes from the passivation layer 101.
In some embodiments, referring to
In some embodiments, each of the at least one first widened portion 111 has a first length L1 of 0.5 mm to 1.5 mm along the second direction X. The first length L1 may be from 0.5 mm to 0.8 mm, 0.58 mm to 1.39 mm, 0.6 mm to 1.5 mm, 0.9 mm to 1.48 mm, 0.5 mm to 1 mm, 0.6 mm to 1.3 mm, or 0.69 mm to 0.8 mm. The first length L1 may be 0.53 mm, 0.58 mm, 0.77 mm, 0.98 mm, 1.19 mm, 1.28 mm, 1.33 mm, 1.42 mm, or 1.5 mm.
In some embodiments, each of the at least one first widened portion 111 has a first width W1 of 0.1 mm to 0.5 mm along the first direction Y. The first width W1 may be from 0.1 mm to 0.16 mm, 0.16 mm to 0.28 mm, 0.28 mm to 0.41 mm, 0.41 mm to 0.5 mm, 0.14 mm to 0.45 mm, 0.16 mm to 0.28 mm, or 0.19 mm to 0.036 mm. The first width W1 may be 0.12 mm, 0.18 mm, 0.21 mm, 0.33 mm, 0.35 mm, 0.42 mm, 0.46 mm, or 0.5 mm.
In some embodiments, the first finger 102 has a fifth width W5 of 10 μm to 45 μm along the first direction Y. The fifth width W5 may be from 11 μm to 15 μm, 15 μm to 20 μm, 20 μm to 38 μm, 38 μm to 45 μm, 10 μm to 25 μm, 18 μm to 32 μm, or 14 μm to 37 μm. The fifth width W5 may be 10.3 μm, 16.8 μm, 21.7 μm, 33.6 μm, 35.8 μm, 41.1 μm, 42.3 μm, or 45 μm.
In some embodiments, referring to
In some embodiments, each of the multiple second busbars 22 includes multiple third electrodes 210 arranged at intervals along the first direction Y and multiple fourth electrodes 220 arranged between every two third electrodes 210 of the multiple third electrodes 210. Each of the multiple third electrodes 210 includes the at least one second widened portion 211, and two second fingers 212 arranged at two sides of each of the at least one second widened portion 211, respectively. Each of the two second fingers 212 penetrates through the passivation layer 101 and protrudes from the passivation layer 101.
In some embodiments, the number of third electrodes 210 within the second surface 12 is 2 to 20. The number of the third electrode 210 is the number of each of the at least one second widened portion 211, which is greater than or equal to the number of each of the at least one first widened portion 111. In this way, the shielding area of the first surface 11 can be reduced, thereby improving the efficiency of the solar cell. By increasing the number of each of the at least one second widened portion 211 to increase the welding area of the second surface, thereby improving the welding tension between the solar cell and the welding strip.
In some embodiments, each of the at least one second widened portion 211 has a second width W2 of 0.2 mm to 1.0 mm along the first direction Y. The second width W2 may be from 0.21 mm to 0.8 mm, 0.2 mm to 0.8 mm, 0.38 mm to 0.78 mm, 0.25 mm to 0.94 mm, 0.29 mm to 0.99 mm, 0.5 mm to 0.82 mm, 0.86 mm to 1.0 mm, or 0.19 mm to 0.69 mm. The second width W2 may be 0.21 mm, 0.38 mm, 0.41 mm, 0.53 mm, 0.65 mm, 0.78 mm, 0.89 mm, or 0.98 mm.
In some embodiments, each of the at least one second widened portion 211 has a second length L2 of 0.5 mm to 1.5 mm along the second direction X. The second length L2 may be from 0.5 mm to 0.8 mm, 0.54 mm to 1.39 mm, 0.6 mm to 1.5 mm, 0.9 mm to 1.48 mm, 0.5 mm to 1 mm, 0.6 mm to 1.3 mm, or 0.56 mm to 0.8 mm. The second length L2 may be 0.53 mm, 0.58 mm, 0.77 mm, 0.98 mm, 1.19 mm, 1.28 mm, 1.33 mm, 1.42 mm, or 1.5 mm.
In some embodiments, each of the at least one second widened portion 211 is arranged on the surface of the passivation layer 101 and does not penetrate through the passivation layer 101, so that the material composition of each of the at least one second widened portion 211 is not the same as that of the second finger 212. For example, each of the at least one second widened portion 211 is prepared from the printing slurry of the busbar, and the second finger 212 is prepared from the printing slurry of the finger.
In some embodiments, the second busbar 22 is integrally formed, that is, each of the at least one second widened portion 211 and the second finger 212 of the third electrode 210 are also integrally formed. Each of the at least one second widened portion 211 and the second finger 212 can be prepared by the same printing slurry in the same preparation process, and both each of the at least one second widened portion 211 and the second finger 212 penetrate through the passivation layer 101. In this way, the width of the second busbar 22 near at least one of the two opposite edges of the solar cell is relatively large, which can alleviate the welding stress of the third electrode 210 and form good contact between the welding strip and the solar cell. In addition, each of the at least one second widened portion 211 can enhance the carrier transmission capacity, thereby allowing the solar cell to have a larger transmission area for collecting current.
In some embodiments, the second finger 212 has a sixth width W6 of 14 μm to 60 μm. The sixth width W6 may be from 15 μm to 20 μm, 20 μm to 28 μm, 28 μm to 35 μm, 35 μm to μ49 μm, 49 μm to 52 μm, 52 μm to 60 μm, or 18 μm to 39 μm. The sixth width W6 may be 14.3 μm, 24.8 μm, 35.7 μm, 41.8 μm, 47.8 μm, 52.1 μm, 59.6 μm, or 60 μm.
Referring to
In some embodiments, each of the at least one third widened portion 121 is arranged on the surface of the passivation layer 101 and does not penetrate through the passivation layer 101, so that the material composition of each of the at least one third widened portion 121 is not the same as that of the third finger 122. For example, each of the at least one third widened portion 121 is prepared from the printing slurry of the busbar, and the third finger 122 is prepared from the printing slurry of the finger.
In some embodiments, referring to
In some embodiments, each of the at least one third widened portion 121 has a third width W3 of 0.02 mm to 0.2 mm along the first direction Y. The third width W3 may be from 0.02 mm to 0.1 mm, 0.18 mm to 0.18 mm, 0.2 mm to 0.14 mm, 0.09 mm to 0.19 mm, 0.05 mm to 0.12 mm, 0.16 mm to 0.2 mm, or 0.09 mm to 0.19 mm. The third width W3 may be 0.02 mm, 0.08 mm, 0.11 mm, 0.13 mm, 0.15 mm, 0.18 mm, 0.19 mm, or 0.2 mm.
In some embodiments, the third finger 122 has a seventh width W7 of 10 μm to 45 μm along the first direction Y. The seventh width W7 may be from 11 μm to 15 μm, 15 μm to 20 μm, 20 μm to 38 μm, 38 μm to 45 μm, 10 μm to 25 μm, 18 μm to 32 μm, or 14 μm to 37 μm. The seventh width W7 may be 10.3 μm, 16.8 μm, 21.7 μm, 33.6 μm, 35.8 μm, 41.1 μm, 42.3 μm, or 45 μm.
In some embodiments, the first busbar 21 is integrally formed, that is, each of the at least one third widened portion 121 and the third finger 122 of the third electrode 120 are also integrally formed. Each of the at least one third widened portion 121 and the third finger 122 can be prepared by the same printing slurry in the same preparation process, and both each of the at least one third widened portion 121 and the third finger 122 penetrate through the passivation layer 101. Each of the at least one third widened portion 121 and the third busbar 122 can enhance the carrier transmission capacity, thereby allowing the solar cell to have a larger transmission area for collecting current.
In some embodiments, referring to
In some embodiments, each of the at least one fourth widened portion 221 is smaller than each of the at least one first widened portion 111. The fourth electrode 220 further includes two second finger 212 arranged on two sides of each of the at least one fourth widened portion 221, respectively. The second finger 212 penetrates through the passivation layer 101 and protrudes from the passivation layer 101.
In some embodiments, each of the at least one fourth widened portion 221 has a fourth width W4 of 0.02 mm to 0.2 mm along the first direction Y. The fourth width W4 may be from 0.02 mm to 0.1 mm, 0.18 mm to 0.18 mm, 0.2 mm to 0.14 mm, 0.09 mm to 0.19 mm, 0.05 mm to 0.12 mm, 0.16 mm to 0.2 mm, or 0.09 mm to 0.19 mm. The fourth width W4 may be 0.02 mm, 0.08 mm, 0.11 mm, 0.13 mm, 0.15 mm, 0.18 mm, 0.19 mm, or 0.2 mm.
In some embodiments, each of the at least one fourth widened portion 221 has a fourth length L4 of 0.5 mm to 1.5 mm along the second direction X. The fourth length L4 may be from 0.5 mm to 0.8 mm, 0.54 mm to 1.39 mm, 0.6 mm to 1.5 mm, 0.9 mm to 1.48 mm, 0.5 mm to 1 mm, 0.6 mm to 1.3 mm, or 0.56 mm to 0.8 mm. The fourth length L4 may be 0.53 mm, 0.58 mm, 0.77 mm, 0.98 mm, 1.19 mm, 1.28 mm, 1.33 mm, 1.42 mm, or 1.5 mm.
In some embodiments, each of the at least one fourth widened portion 221 is arranged on the surface of the passivation layer 101 and does not penetrate through the passivation layer 101, so that that the material composition of each of the at least one fourth widened portion 221 is not the same as that of the fourth finger 222. For example, each of the at least one fourth widened portion 221 is prepared from the printing slurry of the busbar, and the fourth finger is prepared from the printing slurry of the finger.
In some embodiments, the second busbar 22 is integrally formed, that is, each of the at least one fourth widened portion 221 and the fourth finger 222 of the fourth electrode 220 are also integrally formed. Each of the at least one fourth widened portion 221 and the fourth finger 222 can be prepared by the same printing slurry in the same preparation process, and both each of the at least one fourth widened portion 221 and the fourth finger 222 penetrate through the passivation layer 101. In this way, the width of the second busbar 22 near at least one of the two opposite edges of the solar cell is relatively large, which can alleviate the welding stress of the third electrode 220 and form good contact between the welding strip and the solar cell. In addition, each of the at least one fourth widened portion 221 can enhance the carrier transmission capacity, allowing the solar cell to have a larger transmission area for collecting current.
In some embodiments, the solar cell is a sliced cell. In some embodiments, the sliced cell is a half-cell, and the half-cell may also be understood as a cell cut in half or a ½ cell. In other embodiments, the sliced cell may be a ⅓ cell, a ¼ cell, or a ⅛ cell, etc.
Embodiment 0: each of the at least one first widened portion and second widened portion are not provided, that is, each busbar is a complete and uniform busbar.
Embodiment 1: the number of each of the at least one first widened portion is equal to the number of each of the at least one second widened portions, and there is no adhesive point on the first surface. Each of the at least one second widened portion is larger than each of the at least one first widened portion. The first width W1 of each of the at least one first widened portion is 0.3 mm, the first length L1 of each of the at least one first widened portion is 0.8 mm, the second width W2 of each of the at least one second widened portion is 0.3 mm, and the second length L2 of each of the at least one second widened portion is 1.0 mm. The number of first widened portions is 2, and the number of second widened portions is 2.
Embodiment 2: the number of first widened portions is smaller than the number of second widened portions, there are no adhesive points on the first surface, and each of the at least one second widened portion is larger than each of the at least one first widened portion. The first width W1 of each of the at least one first widened portion is 0.3 mm, the first length L1 of each of the at least one first widened portion is 0.8 mm, the second width W2 of each of the at least one second widened portion is 0.3 mm, and the second length L2 of each of the at least one second widened portion is 1.0 mm. The number of first widened portions is 2, and the number of second widened portions is 4.
Embodiment 3: the number of each of the at least one first widened portion is smaller than the number of each of the at least one second widened portion, there are adhesive points on the first surface, and each of the at least one second widened portion is larger than each of the at least one first widened portion. The first width W1 of each of the at least one first widened portion is 0.3 mm, the first length L1 of each of the at least one first widened portion is 0.8 mm, the second width W2 of each of the at least one second widened portion is 0.3 mm, and the second length L2 of each of the at least one second widened portion is 1.0 mm. The number of adhesive points is 4, the number of each of the at least one first widened portion is 2, and the number of second widened portions is 4.
Embodiment 4: the number of first widened portions is equal to the number of second widened portions. The first surface has adhesive points, and each of the at least one second widened portion is larger than each of the at least one first widened portion. The first width W1 of each of the at least one first widened portion is 0.3 mm, the first length L1 of each of the at least one first widened portion is 0.8 mm, the second width W2 of each of the at least one second widened portion is 0.3 mm, and the second length L2 of each of the at least one second widened portion is 1.0 mm. The number of first widened portions is 2, the number of second widened portions is 2, and the number of adhesive points is 4. The first surface has each of the at least one third widened portions, and the second surface have each of the at least one fourth widened portions.
According to Table 1, the number and size of each of the at least one second widened portions are set to increase the welding tension between the welding strip and the solar cell. Among them, the ratio of welding tension between each embodiment and embodiment 0 can indicate that in response to adhesive points being arranged between the welding strip and the solar cell on the first surface, the welding tension is better.
In the solar cell provided according to the embodiments of the present application, the substrate has the first surface and the second surface opposite to the first surface, each of the multiple first busbars arranged on the first surface has a first widened portion, and each of the multiple second busbars arranged on the second surface has a second widened portion. Each of the at least one first widened portion and each of the at least one second widened portion can increase the welding tension between the multiple first busbars and the multiple welding strips, as well as the welding tension between the multiple second busbars and the multiple welding strips, thus improving the welding effect between the multiple first busbars and the multiple welding strips, as well as the welding effect between the multiple second busbars and the multiple welding strips. Each of the at least one first widened portion is larger than each of the at least one second widened portion. By setting the size of each of the at least one first widened portion on the first surface and the size of each of the at least one second widened portion on the second surface, it is ensured that the size of each of the at least one first widened portion on the first surface is smaller, resulting in a smaller covering area on the first surface and improving the efficiency of the solar cell. Each of the at least one second widened portion of the second surface is at least near at least one of the two opposite edges of the substrate, that is, the number of each of the at least one second widened portions is greater than or equal to the number of each of the at least one first widened portions, thereby increasing the welding area of the second surface by increasing the number of each of the at least one second widened portions, thereby improving the welding tension between the solar cell and the multiple welding strips.
According to some embodiments of the present application, in a second aspect, a photovoltaic module is further provided according to the present application, the photovoltaic module includes: at least one cell string, where the cell string is formed by electrically connecting multiple solar cells 50 with each other by multiple welding strips 40. Each of the multiple welding strips 40 is electrically connected to a respective first busbar 21 in the multiple first busbars 21 and/or a respective second busbar 22 in the multiple second busbars 22, and any of the multiple welding strips 40 is in electrical contact with at least one first widened portion 111 or at least one second widened portion 211. The photovoltaic module further includes at least one encapsulation layer 51 configured to cover the at least one cell string and at least one cover plate 52 is configured to cover the at least one encapsulation layer 51.
Specifically, in some embodiments, multiple cell strings 40 can be electrically connected through multiple welding strips 40.
In some embodiments, there is no interval set between the solar cells 50, that is, the solar cells 50 overlap with each other.
In some embodiments, the cross-sectional shape of the welding strip 40 may be circular as shown in
In some embodiments, the welding strip 40 has a width of 160 μm to 300 μm, and the number of welding strips is 12 to 30 per solar cell. The width of the welding strip 40 may be from 160 μm to 180 μm, 180 μm to 200 μm, 200 μm to 220 μm, 220 μm to 240 μm, 240 μm to 280 μm, and 280 μm to 300 μm.
In some embodiments, there are M first overlapping regions between each of the multiple welding strips 40 and the multiple first busbars 21. There are N adhesive points 102 on each of the multiple welding strips 40, each of the N adhesive points 102 is configured to cover a respective first overlapping region of the M first overlapping regions at least including a part of the M first overlapping regions defined on at least one each of the at least one first widened portion 21, and N is less than M and greater than or equal to a number of the at least one first widened portion 21. The at least one encapsulation layer is arranged to cover the N adhesive points. In this way, the welding strip 40 is accurately positioned through the adhesive points 102, and the positional relationship between the welding strip 40 and the first busbar 21 is accurately arranged. Subsequent welding or lamination treatment ensures good contact between the welding strip 40 and the solar cell, which improves welding tension, and maximizes the efficiency of the solar cell.
In some embodiments, each of the N adhesive points 102 is configured to completely cover the first overlapping region, and the area of each of the N adhesive points 102 is greater than or equal to 1.5 times the area of each of the M first overlapping region, thereby firmly positioning the welding strip on the surface of the solar cell and improving the welding tension between the solar cell and the welding strip. The adhesive point can also prevent problems such as deviation of the welding strip during subsequent lamination processing.
In some embodiments, N is less than or equal to the number of second widened portions 211, or 2≤N≤20.
In some embodiments, the at least one encapsulation layer 51 is arranged on a surface of each of the multiple second busbars 22, a part of the multiple welding strips 40 arranged on the second surface 12 is in direct contact with the at least one encapsulation layer 51, and there is no adhesive point on the second surface 12. By not setting adhesive points on the second surface 12, the number and size of each of the at least one second widened portion are increased to increase the welding tension between the solar cell and the welding strip. In this way, the operation of dispensing adhesive can be avoided, thereby reducing the process difficulty.
In some embodiments, the encapsulation layer 51 includes a first encapsulation layer and a second encapsulation layer. The first encapsulation layer is configured to cover one of the front surface or the rear surface of the solar cell 50, and the second encapsulation layer is configured to cover the other of the front surface or the rear surface of the solar cell 50. Specifically, at least one of the first encapsulation layer or the second encapsulation layer is an organic encapsulation film such as a polyvinyl butyral (PVB) adhesive film, an ethylene vinyl acetate copolymer (EVA) film, a polyethylene octene co-elastomer (POE) film, or a polyethylene terephthalate (PET) film, or at least one of the first encapsulation layer or the second encapsulation layer may also be a co-extruded film of one layer of EVA, one layer of POE, and one layer of EVA (EPE) or a co-extruded film of one layer of EVA and one layer of POE (EP).
It can be understood that there is a boundary between the first encapsulation layer and the second encapsulation layer before lamination, and the concept of the first encapsulation layer and the second encapsulation layer will no longer exist when forming the photovoltaic modules after lamination. The first encapsulation layer and the second encapsulation layer have already integrally formed the encapsulation layer 51.
In some embodiments, the cover plate 52 may be a glass cover plate, a plastic cover plate, or other cover plates with light transmission function. Specifically, the surface of the cover plate 52 towards the encapsulation layer 51 can be a surface with protrusions and recesses, thereby increasing the utilization of incident light. The cover plate 52 includes a first cover plate and a second cover plate. The first cover plate faces towards the first encapsulation layer, and the second cover plate faces towards the second encapsulation layer.
According to some embodiments of the present application, in a third aspect, a method for preparing a photovoltaic module is further provided according to the present application, the method includes providing multiple solar cells and multiple welding strips, welding each of the multiple welding strips and a corresponding solar cell of the multiple solar cells together to form an alloy layer between each of the multiple welding strips and each of multiple first busbars, and between each of the multiple welding strips and each of multiple second busbars, where the multiple solar cells form at least one cell string by the multiple welding strips after welding treatment. The method further includes providing at least one encapsulation layer and at least one cover plate, where the at least one encapsulation layer is configured to cover the at least one cell string, and the at least one cover plate is configured to cover the at least one encapsulation layer. The method further includes laminating the at least one cell string, the at least one encapsulation layer, and the at least one cover plate.
In some embodiments, there are M first overlapping regions between each of the multiple welding strips and the multiple first busbars. After the welding treatment, the method further includes: dispensing adhesive on a part of first overlapping regions on each of the multiple solar cells to form N adhesive points on the first surface of the substrate, where each of the N adhesive points is configured to cover a respective first overlapping region of the M first overlapping regions at least including a part of the M first overlapping regions defined on at least one each of the at least one first widened portion, and N is less than M and greater than or equal to a number of the at least one first widened portion.
The terminology used in the description of the various described embodiments herein is for the purpose of describing particular embodiments only and is not intended to be limiting. As used in the description of the various described embodiments and the appended claims, the singular forms “a”, “an” and “the” are intended to include the plural forms as well, unless the context clearly indicates otherwise. It will also be understood that the term “and/or” as used herein refers to and encompasses any and all possible combinations of one or more of the associated listed items. It will be further understood that the terms “includes,” “including,” “has,” “having,” “comprises,” and/or “comprising,” when used in this specification, specify the presence of stated features, integers, steps, operations, elements, and/or components, but do not preclude the presence or addition of one or more other features, integers, steps, operations, elements, components, and/or groups thereof.
In addition, when parts such as a layer, a film, a region, or a plate is referred to as being “on” another part, it may be “directly on” another part or may have another part present therebetween. In addition, when a part of a layer, film, region, plate, etc., is “directly on” another part, it means that no other part is positioned therebetween.
Although the present application is disclosed above with preferred embodiments, it is not used to limit the claims. Any person skilled in the art may make some possible changes and modifications without departing from the concept of the present application. The scope of protection shall be subject to the scope defined by the claims of the present application. In addition, the embodiments and the accompanying drawings in the specification of the present application are only illustrative examples, which will not limit the scope protected by the claims of the present application.
Those of ordinary skill in the art can understand that the above embodiments are specific examples for realizing the present application, and in actual disclosures, various changes may be made in shape and details without departing from the spirit and range of the present application. Any person skilled in the art can make their own changes and modifications without departing from the spirit and scope of the present application. Therefore, the protection scope of the present application should be subject to the scope defined by the claims.
| Number | Date | Country | Kind |
|---|---|---|---|
| 202310587109.9 | May 2023 | CN | national |
