CN103746021A - Light transmission film solar energy assembly containing color artistic pattern, and manufacturing method thereof - Google Patents

Abstract

The invention discloses a light-transmitting thin-film solar module containing colorful artistic patterns and a manufacturing method thereof, which is characterized in that it is composed of ultra-white front glass, power generation film layer, packaging film, color laminated materials, back glass or organic back glass Board composition, its main process is: coating on glass, laser scribing coating front plate glass, attaching confluence material, laying the first layer of transparent encapsulation film, laying color laminated material, laying the second layer of transparent encapsulation film and back plate Glass, laminated components, installation of junction boxes, and production of hollow components with sound insulation and heat insulation properties; the artistic pattern of the present invention is directly formed on the film layer of the thin film battery without destroying the continuity between all sub-cells, laser marking The engraved scheme is simple and easy to program, and does not change with the change of the artistic pattern, does not add any substances and materials inside the module, and does not chemically treat the battery film layer, so as to maintain the film layer function to the maximum extent.

Description

A light-transmitting thin-film solar module containing colorful artistic patterns and its manufacturing method

Technical field:

The invention relates to a novel thin-film solar assembly processing method, which can be used for processing light-transmitting thin-film solar assemblies with colorful artistic patterns, in particular to a light-transmissive thin-film solar assembly with colored artistic patterns and a manufacturing method thereof.

Background technique:

The application of solar modules combined with buildings (Building Integrated Photovoltaics, BIPV) is becoming more and more widespread. It can only replace traditional building curtain walls and windows, and can also be used as a non-polluting renewable energy source. Another big market demand. The application of solar modules on building curtain walls and windows must not only provide electricity to partially meet the needs of industrial and office activities in the building, but also must have a certain light transmission effect. In this regard, thin-film solar modules can achieve uniform and adjustable light transmission effects better than crystalline silicon modules, so they have become a hot spot in the development of BIPV. The basic structure of thin-film solar modules from outdoor to indoor is the high light transmittance front glass, the battery film layer coated on the front glass [transparent front electrode conductive film + Si-based/CIGS/CdTe power generation film + back electrode conductive film], organic films such as PVB/organic silicon film/polyolefin (TPO) film, float glass or organic backplane materials.

At present, there are two main ways to make light-transmitting thin-film solar modules in the market. The first method is to adjust the thickness and structure of thin-film solar cells to realize a semi-transparent power generation film layer. The entire assembly achieves a uniform and continuous light transmission effect; the other is to use laser scribing to remove the power generation film layer and back electrode material in some areas on the thin film battery, leaving only the transparent front electrode conductive film, so that the assembly can realize Striped light transmission effect. These two methods can not damage the power generation performance of the components, but they are monotonous in appearance, lack artistic and beautifying functions, and cannot meet the appearance requirements required for architectural decoration. At present, there are few cases at home and abroad that combine the processing method of architectural decorative glass with photovoltaic power generation technology. This patent also fills this gap, and is conducive to promoting the further combination of building technology and photovoltaic technology, and promoting the development of photovoltaic building integration. Rapid development.

Invention content:

In order to realize the function of improving the artistic decoration and appearance beautification of the thin film module while ensuring the power generation and light transmission of the thin film module, the present invention provides a light-transmitting thin film solar module with colorful artistic patterns and a manufacturing method thereof.

The present invention adopts the following technical solutions to achieve the purpose of the invention: a light-transmitting thin-film solar module containing colorful artistic patterns and a manufacturing method thereof, which consists of an ultra-clear front glass 1, a power generation film layer 2, an encapsulating film 3, and a color sandwich material 4. Backplane glass or organic backplane 5, the main process is: coating on glass 23, laser marking coating front glass 24, attaching confluence material 25, laying the first layer of transparent packaging film 26, laying color clips Adhesive material 27, laying the second layer of transparent packaging film and back glass 28, laminating components, installing junction box 29, preparing hollow components 30 with sound insulation and heat insulation properties;

Coating 23 on glass: First, adopt the common method in the industry to sequentially coat the transparent front electrode conductive film (chemical vapor deposition method, sputtering), Si-based/CIGS/CdTe power generation film layer (PECVD, co-evaporation method and sublimation method) and the conductive film of the back electrode (chemical vapor deposition, sputtering) are plated on the ultra-clear front glass 1 . At present, the front electrode material is transparent conductive metal oxide (TCO), and the back electrode is a metal film layer (such as metal molybdenum Mo) or also a TCO film layer;

Laser scribing the coated front glass 24: place the coated front glass in the laser scribing chamber, with the non-coated side facing the laser head. The laser is incident from the non-coated surface of the front plate glass, focuses on the power generation film layer 2 with a certain spot size, and scratches off the power generation film layer 2 and the conductive film of the back electrode along the direction perpendicular to the dead zone of the thin film battery. The material is sucked away with a vacuum pump. In the direction perpendicular to the dead zone of the thin-film battery and parallel to the edge of the module, the laser scribes a line at a certain distance, and repeats the cycle to create the light transmittance of the coated front glass. Multiple laser heads can be used to work simultaneously to improve processing efficiency; the applicable laser wavelength is 530-540nm green light, and the spot size is 0.05-0.4mm. The type is related to the thickness, and the range is 0.5W-5W; if the coated front glass already has a certain light transmittance, the above steps can be skipped. For example, amorphous silicon thin-film battery can achieve different light transmission effects by controlling the thickness of the amorphous silicon battery layer;

Attach confluence material 25: On the coated front glass with a certain light transmittance, attach the confluence material of the positive and negative batteries, such as silver glue + conductive tape, or conductive tape, and then use the conductive tape to lead out the positive and negative electrodes ;

Lay the first layer of transparent encapsulation film 26: such as organic films such as transparent PVB/organic silicon/polyolefin (TPO)/EVA, if transparent EVA is used, edge sealant should be used to improve its water resistance; The board can only be made of transparent glass;

Lay colored laminated materials 27: Lay colored laminated materials 4 that present colorful artistic patterns, can withstand a certain high temperature (>200 degrees Celsius), and are insoluble in packaging film 3 and backplane materials, including but not limited to silk cloth and colorful embroidery cloth , inkjet cloth, inkjet gum, photo paper. In order to ensure the adhesion between the two layers of packaging films 3, or between the packaging film 3 and the organic material of the backplane, the length and width of the color laminated material 4 must be smaller than the length and width of the film, and it must be cut into a certain degree of hollowness. pattern, the hollow ratio is not less than 30%;

Lay the second layer of transparent encapsulation film and backplane glass 28: in order to enrich the color and enhance the artistic effect, a colored encapsulation film 3 or backplane glass or organic backplane 5 with certain light transmittance can be used; It has a thicker tempered back glass, the thickness range is 3-10mm, and further, a layer of ultra-clear glass and a layer of high light-transmitting packaging film 3 can be added outside the coated front glass, or on the back glass Then add a layer of packaging film and a layer of back glass to make a three-glass laminated assembly. If the thickness difference between two adjacent layers of glass is large, the thickness of the middle layer of packaging film should be increased to compensate for the partial gap between the two layers. The difference in curvature (waveform), the thickness range is 0.3-2mm; in applications where the mechanical strength is not high, the second layer of transparent packaging film and backplane glass can be replaced with a layer of organic backplane material, such as TPT, TPE, PET, etc. , different backplane materials have different UV radiation resistance, and the price is different;

Lamination assembly, installation of junction box 29: After laying the modules of each layer of materials, after the lamination process, the positive and negative conductive strips drawn out are connected to the corresponding terminals of the junction box by welding, and prepared into a light-transmitting display with colorful artistic patterns. Thin film solar modules. Different light transmittance of the whole assembly can be achieved by adjusting the distance between the laser scribed lines and the size of the laser spot on the coated front glass, the color depth and area of the colored interlayer material 4, and the light transmittance of the encapsulating film 3 and the back plate material. Effect;

Preparation of hollow components with sound insulation and heat insulation performance 30: In order to obtain better sound insulation and heat insulation performance, on the back of the double-glass laminated component, hollow layers or vacuum layers of different thicknesses such as 9mm or 12mm can be compounded, and then composited Different tempered flat glass or tempered laminated glass are made into hollow components with sound insulation and heat insulation properties.

Due to the adoption of the above technical scheme, the present invention better realizes its purpose of the invention. The method for introducing colorful artistic patterns on the light-transmitting thin-film solar module of the light-transmitting thin-film solar module with colorful artistic patterns is based on the experience of the glass industry. Lay two layers of encapsulation film in the double-glass module, and embed the color laminated material presenting colorful artistic patterns in the two layers of encapsulation film. Among the organic backplanes; its advantage is that the silk laminated process is very mature in the glass industry, the color laminated materials are rich in varieties and forms, the cost is low, the process is easy to realize, and it can achieve a pleasing beautification effect.

Description of the drawings:

Figure 1 is a cross-sectional view of a light-transmitting component with a colorful artistic pattern.

Figure 2 is the main manufacturing steps of the thin film solar module with color artistic image according to the method.

Fig. 3 shows a schematic diagram of the main process flow of the light-transmitting thin-film solar module with colorful artistic patterns.

Detailed ways:

Below in conjunction with accompanying drawing, the inventive method is further described:

Example 1:

It can be seen from the content of the invention that a light-transmitting thin-film solar module with colorful artistic patterns is composed of ultra-clear front glass 1, power generation film layer 2, encapsulating film 3, color laminated material 4, back glass or organic back plate 5 components, the main technological process is: coating on glass 23, laser marking coating front plate glass 24, attaching confluence material 25, laying the first layer of transparent packaging film 26, laying color laminated material 27, laying the second layer of transparent Encapsulating film and back glass 28, laminating components, installing junction box 29, preparing hollow components 30 with sound insulation and heat insulation properties;

Coating 23 on glass: First, adopt the common method in the industry to sequentially coat the transparent front electrode conductive film (chemical vapor deposition method, sputtering), Si-based/CIGS/CdTe power generation film layer (PECVD, co-evaporation method and sublimation method) and the conductive film of the back electrode (chemical vapor deposition, sputtering) are plated on the ultra-clear front glass 1 . At present, the front electrode material is transparent conductive metal oxide (TCO), and the back electrode is a metal film layer (such as metal molybdenum Mo) or also a TCO film layer;

Laser scribing the coated front glass 24: place the coated front glass in the laser scribing chamber, with the non-coated side facing the laser head. The laser is incident from the non-coated surface of the front plate glass, focuses on the power generation film layer 2 with a certain spot size, and scratches off the power generation film layer 2 and the conductive film of the back electrode along the direction perpendicular to the dead zone of the thin film battery. The material is sucked away with a vacuum pump. In the direction perpendicular to the dead zone of the thin-film battery and parallel to the edge of the module, the laser scribes a line at a certain distance, and repeats the cycle to create the light transmittance of the coated front glass. Multiple laser heads can be used to work simultaneously to improve processing efficiency; the applicable laser wavelength is 530-540nm green light, and the spot size is 0.05-0.4mm. The type is related to the thickness, and the range is 0.5W-5W; if the coated front glass already has a certain light transmittance, the above steps can be skipped. For example, amorphous silicon thin-film battery can achieve different light transmission effects by controlling the thickness of the amorphous silicon battery layer;

Attach confluence material 25: On the coated front glass with a certain light transmittance, attach the confluence material of the positive and negative batteries, such as silver glue + conductive tape, or conductive tape, and then use the conductive tape to lead out the positive and negative electrodes ;

Lay the first layer of transparent encapsulation film 26: such as organic films such as transparent PVB/organic silicon/polyolefin (TPO)/EVA, if transparent EVA is used, edge sealant should be used to improve its water resistance; The board can only be made of transparent glass;

Lay colored laminated materials 27: Lay colored laminated materials 4 that present colorful artistic patterns, can withstand a certain high temperature (>200 degrees Celsius), and are insoluble in packaging film 3 and backplane materials, including but not limited to silk cloth and colorful embroidery cloth , inkjet cloth, inkjet gum, photo paper. In order to ensure the adhesion between the two layers of packaging films 3, or between the packaging film 3 and the organic material of the backplane, the length and width of the color laminated material 4 must be smaller than the length and width of the film, and it must be cut into a certain degree of hollowness. pattern, the hollow ratio is not less than 30%;

Lay the second layer of transparent encapsulation film and backplane glass 28: in order to enrich the color and enhance the artistic effect, a colored encapsulation film 3 or backplane glass or organic backplane 5 with certain light transmittance can be used; It has a thicker tempered back glass, the thickness range is 3-10mm, and further, a layer of ultra-clear glass and a layer of high light-transmitting packaging film 3 can be added outside the coated front glass, or on the back glass Then add a layer of packaging film and a layer of back glass to make a three-glass laminated assembly. If the thickness difference between two adjacent layers of glass is large, the thickness of the middle layer of packaging film should be increased to compensate for the partial gap between the two layers. The difference in curvature (waveform), the thickness range is 0.3-2mm; in applications where the mechanical strength is not high, the second layer of transparent packaging film and backplane glass can be replaced with a layer of organic backplane material, such as TPT, TPE, PET, etc. , different backplane materials have different UV radiation resistance, and the price is different;

Lamination assembly, installation of junction box 29: After laying the modules of each layer of materials, after the lamination process, the positive and negative conductive strips drawn out are connected to the corresponding terminals of the junction box by welding, and prepared into a light-transmitting display with colorful artistic patterns. Thin film solar modules. Different light transmittance of the whole assembly can be achieved by adjusting the distance between the laser scribed lines and the size of the laser spot on the coated front glass, the color depth and area of the colored interlayer material 4, and the light transmittance of the encapsulating film 3 and the back plate material. Effect;

Preparation of hollow components with sound insulation and heat insulation performance 30: In order to obtain better sound insulation and heat insulation performance, on the back of the double-glass laminated component, hollow layers or vacuum layers of different thicknesses such as 9mm or 12mm can be compounded, and then composited Different tempered flat glass or tempered laminated glass are made into hollow components with sound insulation and heat insulation properties.

Example 2:

Now based on the cadmium telluride CdTe thin film battery technology, examples are given for further description.

Inspection and cleaning 7: prepare 1200*600*3.2mm ultra-clear flat glass 6, the light transmittance requirement is ≥90%, pass through the cleaning system (washing with water or organic alkali), dry and set aside;

Deposition battery film layer 9: Coating CdTe thin film battery on ultra-clear flat glass substrate, battery film layer material 8: transparent front electrode conductive film, Si-based CIGS/CdTe power generation film layer and back electrode conductive film, the main steps are as follows:

① Use chemical vapor deposition or sputtering to deposit a transparent conductive film (ITO, AZO, BZO or FTO) as the front electrode;

② Use a laser scribing machine to photolithographically divide the transparent conductive film into blocks to form an isolation trench P1 that is insulated from each other between the front electrode blocks;

③ The CdS film is deposited by chemical water bath method with a film thickness of 0.2-3 microns. As an n-type semiconductor, it forms a p/n junction with p-type CdTe. The chemical reaction mechanism can be expressed as:

Cd(NH ₃ ) ₄ ²⁺ + S=C(NH ₂ ) ₂ + 2OH ^- CdS + CH ₂ N ₂ + 4NH ₃ + 2H ₂ O

④ Deposit a CdTe thin film on the CdS layer by the near-space sublimation method with a film thickness of 1-5 microns. As a p-type semiconductor, the temperature of the substrate glass can be controlled between 450 and 600 °C;

⑤ The CdTe-plated glass is chlorinated at about 400 ° C in an atmosphere containing CdCl ₂ , resulting in secondary crystallization and grain growth of the CdTe film, reducing grain boundary defects, and improving the carrier life of the absorbing layer;

⑥ Use a laser scribing machine to scribe the CdS/CdTe film layer in blocks to form a groove P2 that separates the battery layer blocks from each other. P2 and P1 are parallel to each other but do not overlap;

⑦ Prepare ZnTe/ZnTe:Cu composite back contact layer on CdTe film by co-evaporation method, reduce the contact barrier between CdTe and metal back electrode, and improve module conversion efficiency;

⑧ Deposit a metal back electrode, such as nickel Ni, on the composite back contact layer by sputtering;

⑨ Use a laser to scratch off all the film layers except the front electrode at a certain distance on the glass substrate to form an isolation trench P3 that is parallel to but not overlapping with P1 and P2. P2 is in the middle of P1 and P3, and P3 Separate the battery cells one by one, and each battery cell is connected in series with each other through the overlap of the back battery and the front battery to make a series battery assembly;

Laser scribing a certain transmittance 10: Send the glass coated with battery film into the laser scribing machine, with the glass surface facing the laser head, so that the laser head is along the direction perpendicular to P1, P2 and P3. Scribe all the film layers except the front electrode. The applicable laser wavelength is 530-540nm green light, and the spot size is 0.05-0.4mm. The energy of a single laser is related to the spot size, the type and thickness of the power generation film layer/composite back release layer/back electrode material, and the range is 0.5W -5W. For example, 530nm green light, spot 0.25mm, energy of single laser is 2 W, centerline distance of scribing line is 1mm, at this time the light transmission ratio of the light transmission area is 25%;

Laser edge cleaning or mechanical edge cleaning 11: The coated glass leaves the laser scribing machine, and performs laser edge cleaning on it, or uses a sandblasting machine to clean the edge, removes the conductive substances around the glass, and ensures that the components do not leak to the outside;

Convergence, conduction tape lead out 13: Attach confluence conductive material 12 on the positive and negative electrodes of the battery membrane surface, such as silver glue + conduction tape, or conductive tape, and then use the conduction tape to lead out the positive and negative electrodes;

Laying the first layer of transparent film 15: laying the first layer of transparent polyolefin (PO) film transparent PVB/organic silicon/polyolefin (TPO) film/EVA14 on the coated glass surface, with a thickness of 0.3-1.2mm;

Laying the silk and silk material 17: laying the colored silk and silk material 16, the pattern is a strip of auspicious clouds;

Lay the second layer of transparent film + glass or backplane organic material 19: then lay the second layer of transparent PO film transparency film + glass or backplane organic material 18, the thickness is 0.3-1.2 mm; then lay the transparent backplane tempered glass, the thickness 2.0-8mm;

Lamination under vacuum or high pressure conditions 20: Laminate the above-mentioned stacked templates. There are many lamination methods, and the following vacuum pre-pressing process can be used:

a) Vacuum, the degree of vacuum should be at least -0.9 to -1bar,

b) Keep the vacuum, heat the glass, set the lamination temperature to 150°C, and the lamination time to 15 minutes, then cool down;

Install the junction box 22: paste the sealing tape around the junction box 21, weld the leading ends of the positive and negative electrodes to the junction box 21, fill the box with sealing glue; test the electrical parameters, and stick labels.

What is described above is based on preferred embodiments of the present invention, and is not intended to limit the scope of the present invention. Various changes can also be made to the above-mentioned embodiments of the present invention. That is, all simple and equivalent changes and modifications made according to the claims and description of the application of the present invention fall within the protection scope of the claims of the present invention. the

Claims (1)

1. A light-transmitting thin-film solar module containing colorful artistic patterns and its manufacturing method, characterized in that it consists of ultra-clear front glass (1), power generation film layer (2), encapsulating film (3), and colored laminated materials (4), backplane glass or organic backplane (5), the main process is: coating on glass (23), laser scribing coating front glass (24), attaching confluence material (25), laying the second One layer of transparent encapsulation film (26), laying colored lamination material (27), laying the second layer of transparent encapsulation film and back glass (28), laminating components, installing junction box (29), making a Hollow component (30) for thermal properties; Coating on glass (23): First, adopt the common method in the industry to sequentially coat the transparent front electrode conductive film (chemical vapor deposition method, sputtering), Si-based/CIGS/CdTe power generation film layer (PECVD, co-evaporation method and sublimation into the space) method) and the conductive film of the back electrode (chemical vapor deposition, sputtering) are plated on the ultra-clear front glass (1); at present, the material of the front electrode is transparent conductive metal oxide (TCO), and the back electrode is a metal film layer ( Such as metal molybdenum (Mo) or also TCO film layer; Laser marking the coated front glass (24): place the coated front glass in the laser marking chamber, with the non-coated side facing the laser head, the laser is incident from the non-coated side of the front glass, and focuses on the power generation film with a certain spot size On the layer (2), along the direction perpendicular to the dead zone of the thin film battery, scratch off the power generation film layer (2) and the conductive film of the back electrode, and the scratched material is sucked away by a vacuum pump; In the direction parallel to the edge of the component, the laser scribes a line at a certain distance, and repeats the cycle to create the light transmittance of the coated front glass. Multiple laser heads can be used to work at the same time to improve processing efficiency; the applicable laser The wavelength is 530-540nm green light, and the spot size is 0.05-0.4mm. The energy of a single laser is related to the spot size, the type and thickness of the power generation film layer 2/back electrode material, and the range is 0.5W-5W; If the glass already has a certain light transmittance, the above steps can be skipped; for example, for amorphous silicon thin film batteries, different light transmittance effects can be achieved by controlling the thickness of the amorphous silicon battery layer; Attach confluence material (25): On the coated front glass with a certain light transmittance, attach the confluence material of the positive and negative batteries, such as silver glue + conductive tape, or conductive tape, and then connect the positive and negative electrodes with the conductive tape. lead out; Lay the first layer of transparent packaging film (26): such as transparent PVB/organic silicon/polyolefin (TPO)/EVA and other organic films. If transparent EVA is used, edge sealant is required to improve its waterproofness; if transparent PVB is used , the back panel can only use transparent glass; Laying colored laminated materials (27): laying colored laminated materials (4) that present colorful artistic patterns, can withstand a certain high temperature (>200 degrees Celsius), and are insoluble in packaging film (3) and backboard materials (4), including but not limited to silk Silk cloth, colorful embroidered cloth, inkjet cloth, inkjet adhesive, photo paper; in order to ensure the adhesion between two layers of packaging film (3), or between the packaging film (3) and the organic material of the back plate, color clips The length and width of the adhesive material (4) must be smaller than the length and width of the film, and it must be cut into a pattern with a certain degree of hollowing out, and the hollowing out ratio should not be less than 30%; Lay the second layer of transparent encapsulation film and backplane glass (28): In order to enrich the color and enhance the artistic effect, a colored encapsulation film (3) or backplane glass or organic backplane (5) can be used with a certain light transmittance; In order to improve the strength, a thicker tempered back glass can be used, the thickness range is 3-10mm, and a layer of ultra-clear glass and a layer of high light-transmitting packaging film can be added outside the coated front glass ( 3), or add a layer of packaging film and a layer of back glass behind the back glass to make a three-glass sandwich assembly. If the thickness difference between two adjacent layers of glass is large, the thickness of the middle layer of packaging film should be increased , to make up for the difference in local curvature (waveform) between the two, the thickness range is 0.3-2mm; in applications where the mechanical strength is not high, the second layer of transparent packaging film and back glass can be replaced by a layer of organic back material , such as TPT, TPE, PET, etc. Different backplane materials have different UV resistance and different prices; Lamination assembly, installation of junction box (29): After laying the modules of each layer of materials, after the lamination process, the positive and negative electrode strips drawn out are connected to the corresponding terminals of the junction box by welding, and prepared into a colorful art pattern. Light-transmitting thin-film solar modules; by adjusting the spacing of laser scribed lines and the size of laser spots on the coated front glass, the color depth and area of the color laminated material (4), the light transmission of the encapsulating film (3) and the back plate material The rate can achieve different light transmission effects of the whole component; Preparation of hollow components (30) with sound insulation and heat insulation performance: In order to obtain better sound insulation and heat insulation performance, on the back of the double glass laminated component, hollow layers or vacuum layers of different thicknesses such as 9mm or 12mm can be compounded, Then compound different tempered flat glass or tempered laminated glass to make a hollow component with sound insulation and heat insulation performance.

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