CN105576060A - Modularized photovoltaic plate and method of manufacturing same - Google Patents

Abstract

The invention relates to an ultra-thin and ultra-light modular photovoltaic panel with high conversion efficiency, high durability and portability and a manufacturing method thereof. Technical defects, it mainly includes five parts: glass plate, silicon wafer, wire, magnetic sheet, and contact. Solar cell modules are small and portable. A magnetic piece is fixed on the side of a single solar cell module, and the positive and negative contacts of the built-in wire are fixed on the magnetic piece, which facilitates the connection of multiple components. Small and portable photovoltaic panels that can be assembled infinitely provide the possibility for long-term and uninterrupted use of instruments and equipment in outdoor exploration, scientific research and monitoring environments, while also avoiding environmental pollution.

Description

A kind of modular photovoltaic panel and its manufacturing method

technical field

The invention belongs to the technical field of new energy, and in particular relates to an ultra-thin, ultra-light and portable modular photovoltaic panel and a manufacturing method thereof.

Background technique

As a new type of energy with huge reserves, clean and pollution-free, solar energy plays an important role in life, production, and even in important fields such as military and aerospace. At present, due to the limitation of glass components, the double-glass modules used in traditional solar cells use thicker glass components, such as 3.2+3.2mm, 3.2+2.0mm, or 2.0+2.0mm components (the above are the thickness of the glass) , coupled with the silicon wafer and the adhesive layer, lead to an increase in the thickness and weight of the existing solar panel, and the conversion efficiency is low, so it is not easy to carry. Most of the small portable solar cell modules on the market are made of flexible plastic. Although the flexible module can be twisted and folded at a certain angle, its plastic surface is very easy to be damaged. In addition, the plastic surface is easily aged and yellowed under the irradiation of ultraviolet rays and used in the field environment, thus becoming brittle and cracked, and the durability and conversion efficiency are deteriorated.

Contents of the invention

The invention belongs to the field of new energy technologies, and relates to a modular photovoltaic panel that is ultra-thin, ultra-light, high in conversion efficiency, strong in durability and easy to carry. Thinner, lighter, small and portable; multiple components can realize magnetic wireless connection, which provides the possibility for long-term and uninterrupted use of different instruments and equipment in outdoor exploration, scientific research and monitoring environments.

Specifically, the present invention adopts the following technical solutions:

A modular photovoltaic panel, characterized in that the modular photovoltaic panel comprises the following parts:

Back panel, the back panel is cut from ultra-thin tempered glass with a thickness of less than 1mm, and the size is 20-30cm long*20-30cm wide;

lower bonding layer;

A plurality of silicon wafers, the plurality of silicon wafers are tiled on the back plate, bonded to the back plate through the lower adhesive layer, and the plurality of silicon wafers are connected in series by a welding piece through a serial welding process, wherein the length of the welding piece is sufficient After lamination, it is exposed outside the backplane, and the exposed length is 0.1-0.2mm;

upper bonding layer;

The panel, which is also cut from ultra-thin tempered glass with a thickness of less than 1 mm, has the same size as the back panel, and is bonded to the silicon wafer through the upper adhesive layer, thereby encapsulating the silicon wafer between the back panel and the panel;

Magnetic contacts, including magnetic sheets and conductive contacts, the magnetic sheet is embedded on the side of the battery, the surface of the magnetic sheet is flush with the edge of the battery board and has two small holes, which correspond to the positive and negative poles respectively, and the conductive contacts are welded on the magnetic sheet In the two small holes and slightly exposed on the surface of the magnetic sheet, the conductive contact is conductively welded with the exposed solder sheet.

In a preferred embodiment, there is a frame around the battery module, wherein the magnetic sheet is embedded in the frame, and the surface of the magnetic sheet is flush with the surface of the frame.

As a preferred solution, an anti-reflection film layer is also laid on the surface of the panel.

Preferably, the bonding layer is a POE adhesive film used.

The invention also discloses a method for manufacturing a modular photovoltaic panel, which is characterized in that the method includes the following steps:

1) Cut the ultra-thin tempered glass with a thickness of less than 1mm into a glass block with a size of 20-30cm in length*20-30cm in width, place it flat on the workbench, spread multiple silicon wafers on the above-mentioned glass block, and use solder pads For string welding, the interception length of the solder piece should be such that after the lamination is completed, the solder piece can expose the exposed end of 0.1-0.2mm outside the backplane;

2) Cover the pretreated film on the silicon wafer, and then cover it with a panel cut from ultra-thin tempered glass with a thickness of less than 1mm; form a semi-finished product A;

3) Transport the above-mentioned semi-finished product A to a laminator for heating and lamination, wherein the upper and lower pressure of lamination is 43.5-55.5Pa, the temperature is 155-165°C, and the lamination time is 18-20 minutes to form a semi-finished product B;

4) Spread the laminated semi-finished product B on the workbench, and cover and weld the exposed end of the solder piece that is still exposed after lamination with a magnetic contact. The magnetic contact includes a magnetic sheet and a conductive contact. There are two small holes corresponding to the positive and negative poles of the battery in the magnetic sheet, and the conductive contacts are welded in the two small holes, and the conductive contacts are electrically conductively welded to the exposed ends of the welding sheets.

Furthermore, the method of the present invention also includes the step of laying an anti-reflection film layer on the panel, so as to arrange the anti-reflection film on the panel to increase the transmittance.

As a preferred embodiment, the adhesive film used is POE adhesive film.

Due to the use of ultra-thin glass as the packaging material for silicon wafers, the film material is changed from traditional EVA to POE. Compared with EVA materials, the molecular structure of POE is similar to that of EPDM, so POE will also have Excellent properties such as aging resistance, ozone resistance, and chemical medium resistance, the high temperature resistance of POE materials are improved, the permanent deformation is reduced, and the main mechanical properties such as tensile strength and tear strength are greatly improved. Multi-purpose POE performance exceeds PVC, EVA, SBR, EMA, EPDM. At the same time, the temperature of vacuum lamination has also been increased from 140°C to about 165°C, the pressure of upper and lower lamination (negative pressure) has been changed from 39.3-49.5Pa to 43.5-53.9Pa, and the lamination time has been changed from 28min to 28min. Reduced to 20 minutes, the overall reduction in manufacturing energy consumption.

By adopting the scheme of the present invention, the following beneficial effects are achieved:

1. The processing object has been changed, and the processing object has been reduced from an industrial 165.2*98.6cm size panel to a smaller size, making the product application surface more flexible;

2. Because it is a small-sized panel, the size of the required POE film is reduced, the requirements for the surface cleanliness of the POE film are improved, and the cost of raw materials and pretreatment costs are effectively reduced;

3. Because it is a small-sized panel, the pressure and heating conditions in the heating lamination process have been adjusted in a targeted manner. The upper limit of the processing pressure is higher than that of the large-area panel, the upper limit of the temperature is also higher, and the processing time is shorter. Lamination The number of panels that can be processed increases at one time, and the total processing area of one lamination does not have much loss, thereby effectively reducing the processing cost;

4. The application of ultra-thin tempered glass greatly reduces the volume and weight of the panel per unit effective area, significantly improves the portability of the product, reduces the cost of carrying for users, and improves the market competitiveness of the product;

5. Modular design makes it very easy to change the output power output current and output voltage according to the quantity and connection mode of the product, which makes the application of the product wider and improves the market competitiveness of the product. The present invention aims at fast joint, and the connection mode between each component module is changed from the traditional male-female socket connection to the magnetic adsorption connection, which avoids the risk of the traditional interface being easy to wear and break, thereby realizing the rapid joint between the modules separate functions.

Due to the limitation of its thickness, ultra-thin glass itself is very fragile and easy to break. Before the glass is strengthened, it cannot withstand the later processing, mainly the lamination process. With ordinary strengthening process, such as physical tempering, ultra-thin glass cannot withstand the high temperature of tempering furnace, which will cause ultra-thin glass to curl, break or directly melt. Therefore, the processing of ultra-thin glass can only be processed by chemical strengthening, that is, ion exchange process.

Solution: During the chemical strengthening process, the glass needs to enter the molten potassium nitrate for ion exchange. Due to the extremely thin thickness, during the cooling process after the reaction, due to the different shrinkage ratios of different materials, the glass and the fixture The contact point of the glass is very easy to break. To solve this problem, we use refractory fiber cloth to contact the glass to avoid the problem of direct contact between glass and stainless steel materials.

Description of drawings

Fig. 1 is an exploded view of a modularized photovoltaic panel of the present invention;

Fig. 2 is a structural schematic diagram of the junction box part of the modularized photovoltaic panel of the present invention.

detailed description

The invention provides an ultra-thin and ultra-light modular photovoltaic panel. The component is made of high-permeability tempered glass. The thickness of a single piece of glass is less than 1mm (about 0.85mm). At less than 3mm, the weight is only half or less than the old-style components. At the same time, due to its ultra-thin and ultra-light features, the battery assembly can be designed as a portable assembly of various sizes, foldable, and various adaptation forms, which is easy to carry and is suitable for outdoor exploration, scientific research, and monitoring environments. Long-term, uninterrupted use of equipment provides the possibility.

The glass used in battery components has been strengthened by special means, has excellent physical properties, is durable, not easy to be scratched, and can withstand the impact of hail and small falling rocks and soil clods, with strong durability. By miniaturizing the module, when the module is damaged due to external reasons, the replacement cost will also be reduced. In addition, the miniaturized module has enhanced impact resistance and reduced damage probability in terms of external impact.

In addition, the new type of high-transparency glass has been deeply processed to have higher light transmittance, and coating technology is used in post-processing to add a special film layer to reduce the reflection of sunlight on the glass surface, thereby greatly improving the conversion efficiency of solar energy.

The photovoltaic panel is standardized and modularized according to different needs, and multiple components can be connected wirelessly through the magnetic sheet fixed on the side to provide the required voltage for different instruments and equipment, and provide a wide range of applications for outdoor exploration, scientific research and monitoring environments. Long-term, uninterrupted use of different instruments and equipment provides the possibility.

The photovoltaic module of the present invention is an ultra-thin and ultra-light modular photovoltaic panel with high conversion efficiency, strong durability and portability. It mainly includes five parts: glass plate, silicon wafer, wire, magnetic sheet and contact. Long-term and uninterrupted use of equipment in outdoor exploration, scientific research and monitoring environments. This kind of module uses a kind of ultra-thin and ultra-light glass, and the thickness of a single piece of glass is less than 1mm (about 0.85mm).

For fabrication, multiple silicon wafers are laid out on a backplane, coated with an adhesive material, and covered with a faceplate. Several silicon wafers are connected in series into one group, and then several silicon wafer groups are connected in parallel in several rows, and connected with each other by wires. Then, a magnetic sheet is fixed on the side of a single solar cell module, and the positive and negative pole contacts are fixed on the magnetic sheet, corresponding to the positive and negative poles of the built-in wires, to form the modularized photovoltaic panel of the present invention.

In order to overcome the drawbacks of existing solar cell components, such as large thickness and weight, low conversion efficiency, poor durability, and inconvenient portability, the present invention provides an ultra-thin and ultra-light modular photovoltaic panel. It uses an ultra-thin and ultra-light glass plate. Due to its advantages of thinner and lighter, high strength and high light transmission, it not only reduces the thickness and weight of traditional solar cell components, but also improves the conversion efficiency and increases its durability. It makes solar cell modules smaller and more portable, and provides the possibility for long-term and uninterrupted use of instruments and equipment in outdoor exploration, scientific research and monitoring environments.

The technical solution adopted in the present invention is: use ultra-thin and ultra-light new glass components to replace traditional glass components to realize high efficiency, light weight, durability and portability of solar cells; ultra-thin and ultra-light modular photovoltaic panels are mainly composed of five parts: glass There are five parts: board, silicon chip, wire, magnetic sheet, and contact; the built-in wire of a single component is connected to the contact on the magnetic sheet, and the magnetic sheet is embedded in the side of the battery. The surface of the magnetic sheet is flush with the edge of the battery board. The wires are connected and welded to two small holes on the magnetic sheet. The surface of the contact is slightly higher than the surface of the magnetic sheet, which corresponds to the positive and negative poles of the battery. Multiple components can be connected wirelessly through the magnetic sheet.

This new type of ultra-thin glass is made by physical and chemical means under normal pressure conditions. The glass plate is made into the panel and back plate required by the solar cell module through different treatment processes, and a special film layer is added to the panel to reduce the reflection of sunlight on the glass surface.

Cut the ultra-thin tempered glass to meet the processing requirements (length*width: 20-30*20-30cm) [variable size], and place it flat on the workbench. Spread a certain number of optoelectronic silicon wafers on the above glass according to the required size and parameters, and use aluminum foil for serial welding. Cover the wafer with the POE solid adhesive film that has been pretreated to meet the size and cleanliness requirements of the panel and cover glass, and spread another piece of processed ultra-thin tempered glass on the adhesive film as a cover plate. Transport the above processed semi-finished product A to a vacuum laminator for heating and lamination (up and down pressure: 43.5-55.5Pa, temperature 155-165 degrees Celsius), and the lamination time is 18-20min.

Spread the laminated semi-finished product B on the workbench, and cover and weld the exposed aluminum foil (width*height: 5mm*0.15mm) at both ends of B with a contact interface with magnetic adsorption function, so that The product has modular connection capabilities. After washing and drying, the production is complete.

The exploded view and external view of the present invention are shown in Fig. 1, Fig. 2, are made up of five parts of glass plate, silicon wafer, wire, magnetic sheet, contact, and glass plate has adopted a kind of ultra-thin ultra-light glass; Silicon wafer according to Lay flat on the backplane as shown in Figure 1, connect with wires, apply adhesive material, and cover with the panel. As shown in Figure 2, the built-in wires are connected to the external contacts and fixed to the magnetic sheet, which is fixed to the side of the board. The positive and negative poles of multiple boards can be connected through magnetic sheets to meet the voltage requirements of different devices.

Regarding the magnetic connection technology of ultra-thin components, considering that this project is different from industrial solar power plants, the individual components need to be connected frequently, that is to say, the sockets between them need to be plugged frequently. Therefore, the traditional male-female sockets It is very easy to loosen due to frequent use, resulting in poor contact, and also wear and tear. In view of this situation, the interface form between the components of the present invention is changed to a contact type, and the contact point is a copper flat contact, and a strong magnetic sheet is provided at both ends of the interface, and the adsorption force of the strong magnetic sheet is used to make multiple Unit components are connected together to achieve the purpose of topology.

The difficulty in the application of this connection technology on photovoltaic panels is mainly to reduce its volume. The traditional photovoltaic panel junction box is made of plastic and placed on the back of the module. The volume is about 6cm*6cm*3cm, which is not suitable for ultra- Thin components, but the junction box of the present invention changes the material, is made of metal, can be aluminum alloy, while ensuring the strength, it also greatly reduces the volume. Its shape is a metal groove with a length of about 5cm±5mm, and the thickness is about 3mm. , just enough to snap on the edge of the ultra-thin component and integrate with the frame of the module to create a magnetic contact for module splicing. In other words, the installation position of this new junction box is moved from the traditional back to the edge of the module, which can not only reduce the size of the junction box, but also meet the overall ultra-thin characteristics of ultra-thin modules. At the same time, positive and negative copper contacts are integrated on the side of the module, as well as strong magnetic sheets at both ends. Each copper contact is surrounded by a plastic insulating layer to avoid contact with the metal junction box to form a short circuit. Both the strong magnetic sheet and the copper contacts are on the same plane, which ensures that the copper contacts are also connected together after the magnetic connection without poor contact.

Example 1

As shown in Figures 1 and 2, this battery module uses ultra-thin, ultra-light, high-transparency glass. The overall thickness of the completed double-glass module is less than 3mm, and the weight is only half or less than that of the old glass module, and the volume is smaller.

As shown in Figure 1, the battery assembly of the present invention includes a backplane glass, a POE film, a single crystal silicon glass sheet, a POE film and a panel glass. Then use welding tabs for serial welding, then coat the adhesive film, cover the cut panel glass on it, and laminate it to obtain the battery module. Then further cover the frame according to the method of the present invention, cover and weld the exposed soldering piece, connect the magnetic piece, and install the junction box.

Fig. 2 further shows the structure of the junction box. The junction box includes a metal box body embedded in the frame, and a small hole is left on the box body. The magnetic piece and the positive and negative contacts that have been welded and exposed are installed in the small hole of the box body and positioned to form a Magnetically connected modules.

Example 2

The conversion efficiency of old-style solar panels is generally 8%-15%. The photovoltaic panel of the present invention adopts high-strength tempered glass, which is high-alumina glass. Compared with ordinary glass, it has higher light transmission (transmission The light rate is 91%, and the light transmittance of ordinary glass is about 85%), coupled with the thinning of the glass thickness, the light transmittance increases after the glass thickness is reduced, and the coating technology is applied to add a layer of anti-reflection on the glass surface The film reduces the reflection of light on the glass surface and further increases the amount of light transmitted. After testing, the conversion efficiency reaches 20%-30%.

The embodiments of the present invention have been described in detail above in conjunction with the accompanying drawings and specific examples, but the present invention is not limited to the above embodiments, within the scope of knowledge possessed by those of ordinary skill in the art, it can also be implemented without departing from the gist of the present invention. Various changes are made.

Claims (7)

1. a Modular photovoltaic plate, is characterized in that, described Modular photovoltaic plate comprises from bottom to top in turn with lower part:

Backboard, this backboard is formed by the ultra-thin toughened glass cutting of thickness less than 1mm, is of a size of the wide 20-30cm of long 20-30cm*;

Lower tack coat;

Multiple silicon wafer, the plurality of silicon wafer is laid on backboard, is bondd by lower tack coat and backboard, and the plurality of silicon wafer is connected in series by series welding technique weld tabs, and wherein the length of weld tabs is enough to expose outward at backboard after laminating, and length of exposure is 0.1-0.2mm;

Upper tack coat;

Panel, this panel is also formed by the ultra-thin toughened glass cutting of thickness less than 1mm, and size is identical with backboard, is bonded in silicon wafer by upper tack coat, thus is packaged between backboard and panel by silicon wafer;

Magnetic contact, comprise magnetic sheet and conductive contact, magnetic sheet is embedded in battery side, magnetic sheet surface is concordant with cell panel edge and have two apertures, corresponding both positive and negative polarity respectively, in conductive contact and two apertures being welded on magnetic sheet and in the exposure a little of magnetic sheet surface, the weld tabs conductivity of conductive contact and exposure welds together.

2. Modular photovoltaic plate as claimed in claim 1, it is characterized in that having frame around battery module, wherein magnetic sheet is embedded in frame, and magnetic sheet surface is concordant with jamb surface.

3. Modular photovoltaic plate as claimed in claim 1, is characterized in that, be also laid with antireflection rete at panel surface.

4. Modular photovoltaic plate as claimed in claim 1, is characterized in that, tack coat is the POE glued membrane adopted.

5. a method for manufacturing module photovoltaic panel, is characterized in that, said method comprising the steps of:

1) thickness is cut into less than the ultra-thin toughened glass of 1mm the glass blocks being of a size of the wide 20-30cm of long 20-30cm*, be flat on workbench, multiple silicon wafer is laid on above-mentioned glass blocks, use weld tabs to carry out series welding, the intercepted length of weld tabs should make weld tabs after lamination completes can expose the exposure end of 0.1-0.2mm outward at backboard;

2) will cover on silicon through pretreated glued membrane, then the panel that cuts into less than the ultra-thin toughened glass of 1mm of cladding thickness thereon; Form semi-finished product A;

3) above-mentioned semi-finished product A is delivered to heated lamination in laminating machine, wherein the two-way pressure of lamination is 43.5-55.5Pa, and temperature is 155-165 DEG C, and lamination times is 18-20 minute, forms semi-finished product B;

4) the semi-finished product B completed by lamination tiles on workbench, still clad welded is carried out in the weld tabs exposure end magnetic contact exposed after completing lamination, wherein magnetic contact comprises magnetic sheet and conductive contact, the aperture of two corresponding battery plus-negative plates is had in magnetic sheet, conductive contact is welded in these two apertures, and conductive contact welds with weld tabs exposure end conductivity.

6. the method for manufacturing module photovoltaic panel as claimed in claim 5, is characterized in that, be also included in the step of panel laying antireflection rete.

7. the method for manufacturing module photovoltaic panel as claimed in claim 5, it is characterized in that, glued membrane used is POE glued membrane.