CN110491961B - Light photovoltaic module formed by continuous composite molding and continuous composite molding equipment thereof - Google Patents
Light photovoltaic module formed by continuous composite molding and continuous composite molding equipment thereof Download PDFInfo
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- CN110491961B CN110491961B CN201910689090.2A CN201910689090A CN110491961B CN 110491961 B CN110491961 B CN 110491961B CN 201910689090 A CN201910689090 A CN 201910689090A CN 110491961 B CN110491961 B CN 110491961B
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- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01L—SEMICONDUCTOR DEVICES NOT COVERED BY CLASS H10
- H01L31/00—Semiconductor devices sensitive to infrared radiation, light, electromagnetic radiation of shorter wavelength or corpuscular radiation and specially adapted either for the conversion of the energy of such radiation into electrical energy or for the control of electrical energy by such radiation; Processes or apparatus specially adapted for the manufacture or treatment thereof or of parts thereof; Details thereof
- H01L31/04—Semiconductor devices sensitive to infrared radiation, light, electromagnetic radiation of shorter wavelength or corpuscular radiation and specially adapted either for the conversion of the energy of such radiation into electrical energy or for the control of electrical energy by such radiation; Processes or apparatus specially adapted for the manufacture or treatment thereof or of parts thereof; Details thereof adapted as photovoltaic [PV] conversion devices
- H01L31/042—PV modules or arrays of single PV cells
- H01L31/048—Encapsulation of modules
- H01L31/0481—Encapsulation of modules characterised by the composition of the encapsulation material
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- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01L—SEMICONDUCTOR DEVICES NOT COVERED BY CLASS H10
- H01L31/00—Semiconductor devices sensitive to infrared radiation, light, electromagnetic radiation of shorter wavelength or corpuscular radiation and specially adapted either for the conversion of the energy of such radiation into electrical energy or for the control of electrical energy by such radiation; Processes or apparatus specially adapted for the manufacture or treatment thereof or of parts thereof; Details thereof
- H01L31/04—Semiconductor devices sensitive to infrared radiation, light, electromagnetic radiation of shorter wavelength or corpuscular radiation and specially adapted either for the conversion of the energy of such radiation into electrical energy or for the control of electrical energy by such radiation; Processes or apparatus specially adapted for the manufacture or treatment thereof or of parts thereof; Details thereof adapted as photovoltaic [PV] conversion devices
- H01L31/042—PV modules or arrays of single PV cells
- H01L31/048—Encapsulation of modules
- H01L31/049—Protective back sheets
-
- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01L—SEMICONDUCTOR DEVICES NOT COVERED BY CLASS H10
- H01L31/00—Semiconductor devices sensitive to infrared radiation, light, electromagnetic radiation of shorter wavelength or corpuscular radiation and specially adapted either for the conversion of the energy of such radiation into electrical energy or for the control of electrical energy by such radiation; Processes or apparatus specially adapted for the manufacture or treatment thereof or of parts thereof; Details thereof
- H01L31/18—Processes or apparatus specially adapted for the manufacture or treatment of these devices or of parts thereof
- H01L31/1876—Particular processes or apparatus for batch treatment of the devices
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- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
- Y02E—REDUCTION OF GREENHOUSE GAS [GHG] EMISSIONS, RELATED TO ENERGY GENERATION, TRANSMISSION OR DISTRIBUTION
- Y02E10/00—Energy generation through renewable energy sources
- Y02E10/50—Photovoltaic [PV] energy
-
- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
- Y02P—CLIMATE CHANGE MITIGATION TECHNOLOGIES IN THE PRODUCTION OR PROCESSING OF GOODS
- Y02P70/00—Climate change mitigation technologies in the production process for final industrial or consumer products
- Y02P70/50—Manufacturing or production processes characterised by the final manufactured product
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- Electromagnetism (AREA)
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- Computer Hardware Design (AREA)
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Abstract
The invention discloses a light photovoltaic module formed by continuous composite forming, which comprises a photovoltaic laminating part and a light photovoltaic back plate, wherein the photovoltaic laminating part comprises a front flexible packaging layer, a battery sheet layer and a back flexible packaging layer which are laminated and packaged into a whole; the invention also discloses continuous composite molding equipment; the invention has the advantages of light weight, safety, reliability, no frame design, difficult dust accumulation, no grounding, flexible and variable plate types, avoids the high burst problem of the traditional double-glass assembly, does not have the problems of bubbling, degumming, deformation, creeping and the like under the scheme of the light photovoltaic back panel using the adhesive film layer structure, is not limited by the thickness of the light photovoltaic back panel, completely meets the requirement of photovoltaic standards, and can realize real-scale popularization and application.
Description
Technical Field
The invention belongs to the photovoltaic packaging technology, and particularly relates to a continuously composite molded light photovoltaic module.
Background
Reliability, safety and low cost are requirements that any energy product must meet at the same time. In the past decades, the photovoltaic industry has been reducing the cost of photovoltaic products by as much as 300 times over the past 40 years by continuing and focusing on research and development to improve the efficiency of photoelectric conversion, the supply chain, and the home-made and automated means of production facilities. Of course, these last decades have been very significant and effective in reducing the cost of photovoltaic cells almost to the utmost, and bottlenecks are about to be encountered both at the limit of conversion efficiency and in production scale effects, and therefore, more technological innovation is required for photovoltaic module products.
The applicant notices that in the photovoltaic module before twenty years, the price of the photovoltaic cell is far higher than that of the packaging structure, and the initial photovoltaic module product has to use the packaging structures such as heavy glass and thick aluminum frames to carefully care the golden photovoltaic cell and exert the power generation function of the cell to the maximum extent. However, with the achievement of extreme cost through technical innovation in recent decades on photovoltaic cells, the structural distribution of the cost of the cells and the packaging material in the photovoltaic module product is reversed, the cost of the packaging material begins to exceed the cost of the cells, that is, the cells are relatively cheap, so that new photovoltaic module cell structure technologies such as double-sided, half-sheet and laminated tile are available at present, and the maximum utilization rate of the packaging material is strived for through the structure. People have changed from "caring for batteries" to "protecting packaging materials with pitfalls".
Furthermore, in the packaging structure of the conventional photovoltaic module product, the glass for light receiving surface packaging and the aluminum frame mounted on the back occupy most of the packaging structure cost, and the additional labor cost and the construction difficulty of carrying, packaging, transporting, constructing, grounding requirements and the like caused by the use of the glass and the metal aluminum frame are not negligible. In addition, the photovoltaic module product which is packaged by adopting the glass and the metal aluminum frame can further cause safety problems due to heavy weight.
For this reason, in the last five years, the applicant has been dedicated to focus on high-quality technical innovation of the photovoltaic module packaging structure and packaging material, and has proposed more packaging schemes of photovoltaic module products with flexible mounting effect; with the research and development of the applicant in the field of photovoltaic packaging and the continuous and deep research and development of the applicant in the photovoltaic industry for twenty years based on the applicant inventor, and the introduction of the photovoltaic industry to scale cost reduction and the promotion of the development of technical innovation in China, the discovery that the development of the light photovoltaic module can be the next step of innovative development direction for breaking through the packaging technology of the photovoltaic product.
In this direction, the applicant proposes a technical solution of a lightweight photovoltaic module, and before the application is proposed, a systematic and comprehensive investigation, search and analysis are performed on the light photovoltaic module packaging technology which has been proposed so far, and the following comparison documents are listed:
comparison document 1: the chinese patent publication No. CN109390422A discloses a lightweight photovoltaic module, which is proposed to adopt a structure of a first substrate layer, a honeycomb core layer, and a second substrate layer stacked in sequence as a back sheet layer, so that the thickness is reduced, and a metal aluminum frame design can be eliminated to achieve a lightweight effect, wherein the first substrate layer and the second substrate layer can adopt epoxy resin insulating layers or metal layers, the honeycomb core layer, the first substrate layer and the second substrate layer are bonded and compounded into a whole by adhesives, and in order to prevent the honeycomb core composite back sheet from bubbling and degumming during the lamination process, an exhaust hole is provided in the core layer and penetrates through the substrate layers, and the structure inevitably causes severe reduction of the strength of the structure and barrier water vapor permeability, and is difficult to be really applied.
Comparison document 2: the invention patent of CN109192801A discloses a lightweight photovoltaic module and a preparation method thereof, the lightweight photovoltaic module includes a transparent front film, a reinforcing plate, a first adhesive film layer, a solar cell, a second adhesive film layer, a first substrate layer, a third adhesive film layer, a honeycomb core layer, a fourth adhesive film layer and a second substrate layer, which are sequentially stacked.
Comparison document 3: PCT publication No. WO 2018/013618 Al discloses a photovoltaic module laminated structure for replacing an aluminum frame mounting structure, and proposes to use a polyethylene foam layer, and to bond composite polypropylene glass fiber material layers on upper and lower surfaces of the polyethylene foam layer through adhesive layers, for replacing the aluminum frame mounting structure.
Although these documents propose a structure using a substrate layer and a honeycomb core layer to directly replace a back panel and an aluminum frame, these technologies all use an adhesive layer or a glue film layer to realize the connection and combination between the substrate layer and the honeycomb core layer, however, as mentioned in reference 1, the composite structure applied to a photovoltaic back panel can cause the problems of bubbling, degumming, deformation and creep during subsequent lamination, which leads to a serious influence on the effect of the final photovoltaic module product, and the conventional idea of the photovoltaic packaging technology is that the glue film layer is used to perform the connection and combination between the functional material layers and the glue is used to perform the connection and combination, which is also the conventional molding and combination process of a conventional honeycomb panel or a conventional foam panel, which also leads to the light photovoltaic module solutions in the above-mentioned references 1-3 to realize the combination by the conventional glue film or glue after the substrate layer and the honeycomb core layer are respectively subjected to technical development, after the applicant searches intensively, the applicant finds that in order to solve the problems of the composite structures, either the vent structure is arranged or the composite effect is directly sacrificed. Therefore, the application of the technologies is basically at the laboratory certification or small test level, and the large-scale popularization and application cannot be really implemented.
Based on the current situation, the market urgently needs to find a lightweight photovoltaic module solution which can be popularized and applied in a large scale.
Disclosure of Invention
In view of the above, an object of the present invention is to provide a continuously composite-molded light photovoltaic module, which has the advantages of light weight, safety, reliability, no frame, less dust accumulation, no grounding, and flexible and variable plate types, and avoids the problem of high burst of the conventional dual-glass module.
The invention also aims to provide continuous composite molding equipment for the light photovoltaic module, which is rapid in composite molding and adjustable in thickness and is very suitable for implementing the continuous composite molding process of the light photovoltaic module.
The technical scheme adopted by the invention is as follows:
the light photovoltaic assembly comprises a photovoltaic laminated part and a light photovoltaic back plate, wherein the photovoltaic laminated part comprises a front flexible packaging layer, a battery sheet layer and a back flexible packaging layer which are laminated and packaged into a whole, the light photovoltaic back plate at least comprises a honeycomb-shaped or porous foaming-shaped thermoplastic core layer and a first thermoplastic substrate layer, and the photovoltaic laminated part and the light photovoltaic back plate are compounded into a whole through a continuous composite molding process.
Preferably, the operation steps of the continuous composite molding process include:
s10), sequentially laminating the photovoltaic laminated piece and the light photovoltaic back plate and then placing the laminated piece and the light photovoltaic back plate into continuous flat plate type composite equipment;
s20), heating and pressurizing the laminated laying member by the continuous flat plate type composite equipment to obtain the photovoltaic module;
s30), edge cutting is carried out on the photovoltaic module, and the light photovoltaic module is obtained.
Preferably, in the step S20), the heating range is 130-200 ℃, the pressurizing range is 0.5-250 Kpa, and the heating and pressurizing time range is 10-150S.
Preferably, in step S30), after the edge cutting is completed, the method further includes performing protective edge sealing on the edge of the photovoltaic module by using an edge sealing device, and obtaining the light photovoltaic module after the edge sealing is completed.
Preferably, the base material of the thermoplastic core layer is a core layer thermoplastic polymer, the base material of the first thermoplastic substrate layer is a substrate layer thermoplastic polymer, and the core layer thermoplastic polymer is the same as or different from the substrate layer thermoplastic polymer.
Preferably, the thermoplastic polymer of the core layer or the thermoplastic polymer of the substrate layer is any one or a mixture of thermoplastic polypropylene, PET, PA, PC and PE.
Preferably, the thermoplastic substrate layer is a composite of continuous fibers reinforcing a thermoplastic polymer of the substrate layer, the continuous fibers being in a dispersed phase and the thermoplastic polymer of the substrate layer being in a continuous phase.
Preferably, the other side of the thermoplastic core layer is compounded with a second thermoplastic substrate layer, and the second thermoplastic substrate layer is directly contacted and connected with the photovoltaic laminate.
Preferably, a hot melt adhesive film layer is arranged between the photovoltaic laminated piece and the light photovoltaic back plate, or a hot melt adhesive film layer is arranged between the thermoplastic core layer and the first thermoplastic substrate layer.
Preferably, the continuous composite molding equipment for the light photovoltaic module is used for continuously carrying out composite molding to obtain the light photovoltaic module, and comprises an upper belt type pressure device and a lower belt type pressure device which are distributed in the vertical direction and driven by pressure roller wheels, wherein a heating area and a cooling area which are symmetrically distributed in the vertical direction are respectively arranged in the upper belt type pressure device and the lower belt type pressure device, the distance between the upper belt type pressure device and the lower belt type pressure device is adjustable, a conveyor belt for conveying laminated laying materials is arranged, the inlet of the conveyor belt is close to the heating area, and the outlet of the conveyor belt is close to the cooling area; and the outlet of the conveying belt is connected with a cutting device.
Preferably, the outlet of the conveying belt is further connected with an automatic edge sealing or semi-automatic edge sealing device, and the automatic edge sealing or semi-automatic edge sealing device is located at the next station of the cutting device.
It should be noted that the thermoplastic core layer in the honeycomb shape or the porous foamed shape according to the present invention can be obtained by direct procurement from composite material enterprises in the market at present; the composite materials have the characteristics of sound insulation and light weight, and are widely applied to the fields of high-speed rails, aerospace, automobiles, building materials, packaging and the like to realize the sound insulation function, the specific preparation and forming process is not particularly limited, and the typical preparation process can be selected as follows: the honeycomb-shaped thermoplastic core layer is formed by adopting a hot-melt extrusion process; the thermoplastic core layer in the form of a cellular foam is formed by a foaming process, which is common knowledge in the field of composite materials, and therefore the invention is not described one by one.
It should be further noted that, the continuous composite molding process is applied in a large amount in the existing composite film materials, the present invention does not have any particular necessary limitation to the continuous composite molding process, but changes the technical thinking limitation that the conventional technicians adopt the lamination process for the photovoltaic module preparation process, and applies the continuous composite molding process to the photovoltaic module preparation for the first time, which brings a great breakthrough to the photovoltaic module preparation process, and solves the core technical bottleneck that the light photovoltaic back panel structure is applied to the photovoltaic module:
the method combines the profound research and development background and theoretical knowledge level of the inventor in different fields, creatively adopts the steps of preparing the cell laminate in advance through long-time exploration test of the process, and then continuously and compositely molding the cell laminate and the light photovoltaic back panel, thereby surprisingly bringing the following positive technical effects:
1. according to the continuous composite molding, long-time heating and pressurization are not needed, so that the problems of bubbling, degumming, deformation and creeping and the like can be avoided even if the scheme of the adhesive film layer (the adhesive film layer comprises an adhesive scheme) in a comparison document is adopted, the lamination quality of the light photovoltaic module is effectively ensured, the yield is high, and the performance test can verify that the continuous composite molding completely meets the photovoltaic standard requirement, so that the real-scale popularization and application can be realized;
2. because the continuous composite molding process is usually used for preparing composite film materials, when the composite film materials are applied to preparing photovoltaic modules, the appearance of the photovoltaic module products can be more smooth and beautiful, and the actual construction operation is more facilitated; meanwhile, in order to ensure the rigidity and the lightweight property of the back plate, the thickness of the thermoplastic core layer in a honeycomb shape or a porous foaming shape is usually thicker (8-25mm), and due to the characteristics of the lamination process, the maximum lamination thickness of the applied lamination equipment generally does not exceed 10mm (even 8mm) of the photovoltaic module product, the excessively thick photovoltaic module product is easy to damage the lamination equipment, and the lamination thickness suitable for a single lamination equipment is fixed and nonadjustable, but the continuous composite molding process is not limited by the thickness of the lightweight photovoltaic module at all, and can completely meet the molding requirement of the lightweight photovoltaic module;
3. compared with the traditional photovoltaic module backboard structure, the light photovoltaic backboard for the photovoltaic module has the positive technical effects of light weight, safety, reliability, no frame, difficult dust accumulation, no grounding, flexible and changeable version, avoidance of the high-burst problem of the traditional double-glass module and the like, and is a powerful technical solution for breaking through the next step of innovative development direction of the photovoltaic product packaging technology;
the invention further preferably provides that the thermoplastic polypropylene is used as the base materials of the thermoplastic core layer and the thermoplastic substrate layer, the applicant finds that the thermoplastic polypropylene has excellent performance of blocking water vapor transmission and good weather resistance, and the performance of the light photovoltaic backboard for the photovoltaic module can be further effectively improved by combining and applying the thermoplastic polypropylene to the light photovoltaic backboard structure;
the invention also preferably provides a preparation method of the thermoplastic substrate layer by adopting the composite material of the thermoplastic polymer of the continuous fiber reinforced substrate layer, wherein the continuous fiber is in a dispersed phase, the thermoplastic polymer of the substrate layer is in a continuous phase, and particularly after the thermoplastic polymer of the substrate layer is subjected to multi-layer compounding in different directions, the tensile strength of the thermoplastic substrate layer can be further enhanced, and the compressive strength of the whole photovoltaic module during installation is improved;
the invention further preferably provides continuous composite molding equipment for the light photovoltaic module, the composite molding is rapid and adjustable in thickness, and the continuous composite molding equipment is very suitable for implementing the continuous composite molding process of the light photovoltaic module.
Drawings
Fig. 1 is a schematic structural view of a lightweight photovoltaic backsheet 100a in example 1 of the present invention;
FIG. 2 is a schematic diagram of the exploded layer structure of FIG. 1;
fig. 3 is a schematic view of the layer structure of the lightweight photovoltaic module 10 in example 1 of the present invention;
fig. 4 is a schematic structural view of a lightweight photovoltaic backsheet 100b according to example 4 of the present invention;
FIG. 5 is a schematic view of the exploded layer structure of FIG. 4;
fig. 6 is a schematic structural view of a lightweight photovoltaic backsheet 100c in example 5 of the present invention;
FIG. 7 is a schematic view of the exploded layer structure of FIG. 6;
fig. 8 is a schematic view of the layer structure of a light photovoltaic backsheet 100d in example 14 of the present invention;
fig. 9 is a schematic structural view of a continuous composite molding apparatus 20 according to an embodiment of the present invention.
Detailed Description
The embodiment of the invention discloses a light photovoltaic assembly formed by continuous composite forming, the light photovoltaic assembly comprises a photovoltaic laminating part and a light photovoltaic back plate, the photovoltaic laminating part comprises a front flexible packaging layer, a battery sheet layer and a back flexible packaging layer which are laminated and packaged into a whole, the light photovoltaic back plate at least comprises a honeycomb-shaped or porous foaming-shaped thermoplastic core layer and a first thermoplastic substrate layer, and the photovoltaic laminating part and the light photovoltaic back plate are compounded into a whole through a continuous composite forming process.
The embodiment of the invention also discloses continuous composite forming equipment for the light photovoltaic module, which is used for obtaining the light photovoltaic module by continuous composite forming, the continuous composite forming equipment comprises an upper belt type pressure device and a lower belt type pressure device which are distributed in the vertical direction and driven by a pressure roller wheel, a heating area and a cooling area which are symmetrically distributed in the vertical direction are respectively arranged in the upper belt type pressure device and the lower belt type pressure device, the distance between the upper belt type pressure device and the lower belt type pressure device is adjustable, a conveying belt for conveying laminated laying materials is arranged, the inlet of the conveying belt is close to the heating area, and the outlet of the conveying belt is close to the cooling area; the outlet of the conveying belt is connected with a cutting device.
In order to make those skilled in the art better understand the technical solution of the present invention, the technical solution in the embodiment of the present invention will be clearly and completely described below with reference to the drawings in the embodiment of the present invention, and it is obvious that the described embodiment is only a part of the embodiment of the present invention, and not all embodiments. All other embodiments, which can be derived by a person skilled in the art from the embodiments given herein without making any creative effort, shall fall within the protection scope of the present invention.
Example 1: referring to fig. 3, a light photovoltaic module 10 formed by continuous composite molding includes a photovoltaic laminate 200 and a light photovoltaic back panel 100a, a hot melt adhesive film layer 300 is disposed between the photovoltaic laminate 200 and the light photovoltaic back panel 100a, the photovoltaic laminate 200 includes a front flexible packaging layer 210, a battery sheet layer 220, and a back flexible packaging layer 230, which are integrally packaged by lamination, specifically, in this embodiment, the front flexible packaging layer includes a front composite layer and a front adhesive film layer, which are prepared by using a flexible composite material, the composite layer specifically uses an acrylic thermosetting powder coating composite fiber cloth, and a specific technical solution thereof can be directly referred to CN 201610685536.0; the back flexible packaging layer 230 includes an EVA film layer and a PET, and other back packaging structures may also be adopted, which may be selected according to actual application requirements, and the embodiment is not particularly limited to the front flexible packaging layer 210 and the back flexible packaging layer 230; the photovoltaic laminate of the embodiment can be performed by adopting the existing conventional laminating process, and the embodiment is not specifically explained;
the lightweight photovoltaic backsheet 100a includes a thermoplastic core layer in a honeycomb shape or a porous foamed shape and a first thermoplastic substrate layer; preferably, in this embodiment, please refer to a light photovoltaic back sheet 100a for a light photovoltaic module shown in fig. 1 and fig. 2, the light photovoltaic back sheet 100a includes a thermoplastic core layer 110 and a first thermoplastic substrate layer 120 which are integrated by hot melting and pressing, the thermoplastic core layer 110 is directly connected to a back adhesive film layer of the photovoltaic module in a contact manner; wherein, the base material of the thermoplastic core layer 110 is a core layer thermoplastic polymer, the base material of the first thermoplastic substrate layer 120 is a substrate layer thermoplastic polymer, and the core layer thermoplastic polymer is the same as the substrate layer thermoplastic polymer; in the present embodiment, the thermoplastic core layer 110 is in a polygonal honeycomb shape, the thickness range is 5-25mm, and the thermoplastic core layer is formed by a hot-melt extrusion process or other known forming processes in composite materials, which is not specifically limited in the specific implementation of the present invention; the thickness of the first thermoplastic substrate layer 120 ranges from 0.05mm to 5 mm; preferably, in this embodiment, thermoplastic polypropylene is used for both the core layer thermoplastic polymer and the substrate layer thermoplastic polymer, the thickness of the thermoplastic core layer 110 is 8mm, and the thickness of the first thermoplastic substrate layer 120 is in the range of 1 mm; in other embodiments, other thicknesses of the thermoplastic core layer 110 may be selected, such as 2mm, 3mm, 5mm, 10mm, 12mm, 14mm, 15mm, 20mm, 25 mm; other thicknesses of the first thermoplastic substrate layer 120 may also be selected, such as 0.05mm, 0.1mm, 0.2mm, 0.3mm, 0.3mm, 0.4mm, 0.6mm, 0.8mm, 1.5mm, 2mm, 2.5mm, 3mm, 3.5mm, 4mm, 4.5mm, 5 mm; the thickness of the thermoplastic core layer 110 is greater than that of the first thermoplastic substrate layer 120 in general, and otherwise the advantage of light weight is relatively insignificant;
preferably, in the present embodiment, the weight per unit area of the lightweight photovoltaic backsheet 100a ranges from 60 to 2500g/m2More preferably, in the present embodiment, the weight per unit area of the lightweight back sheet 100a ranges from 60 to 500g/m2(ii) a Specifically, in the present embodiment, the weight per unit area of the lightweight photovoltaic backsheet 100a is 100g/m2The light photovoltaic back panel 100a of the present embodiment can replace a metal frame as a lining structure of a photovoltaic module;
in the embodiment, the photovoltaic laminated part and the light photovoltaic back plate are compounded into a whole through a continuous composite molding process; preferably, in the present embodiment, the operation steps of the continuous composite molding process include:
s10), sequentially laminating the photovoltaic laminate 200, the hot melt adhesive film layer 300 and the light photovoltaic back panel 100a, and placing the laminated layers in continuous flat plate type composite equipment;
s20), heating and pressurizing the laminated laying member by the continuous flat plate type composite equipment to obtain the photovoltaic module;
s30), edge cutting is carried out on the photovoltaic component, edge sealing equipment is adopted to carry out protective edge sealing on the edge of the photovoltaic component, and the light photovoltaic component 10 is obtained after edge sealing is finished.
Preferably, in the step S20), the heating range is 130-200 ℃, the pressurizing range is 0.5-250 Kpa, and the heating and pressurizing time range is 10-150S; specifically, in the present embodiment, the heating temperature is 140 ℃, the pressurizing pressure is 1Kpa, and the heating and pressurizing time is 100 s; in other embodiments, the skilled person can select the heating temperature, the pressurizing pressure and the time within the preferable range, and the embodiment is not illustrated;
preferably, referring to fig. 9, the present embodiment further provides a continuous composite molding apparatus 20 for a lightweight photovoltaic module, which is used for continuously composite molding to obtain the lightweight photovoltaic module 10 as described above, the continuous composite molding apparatus 20 includes an upper belt pressure device 22 and a lower belt pressure device 23 which are distributed in the up-down direction and driven by a pressure roller 21, the upper belt pressure device 22 and the lower belt pressure device 23 are respectively provided with a heating zone 24 and a cooling zone 25 which are distributed symmetrically up and down, a conveyor belt (not shown) for conveying a laminated material is arranged between the upper belt pressure device 22 and the lower belt pressure device 23, an inlet of the conveyor belt is close to the heating zone 24, and an outlet of the conveyor belt is close to the cooling zone 25; the outlet of the conveyor belt is connected with a cutting device 26; preferably, in the present embodiment, the outlet of the conveyor belt is further connected with an automatic edge sealing or semi-automatic edge sealing device 27, and the automatic edge sealing or semi-automatic edge sealing device 27 is located at the next station of the cutting device 26; particularly preferably, the conveyor belts of the upper belt type pressure device 22 and the lower belt type pressure device 23 are teflon conveyor belts; the cutting device 26, the automatic edge banding or semi-automatic edge banding device 27 can be directly applied to the prior art.
Example 2: the rest of the technical solutions of this embodiment 2 are the same as those of embodiment 1, except that: in this example 2, the light photovoltaic backsheet of the comparison document 2 was used as the light photovoltaic backsheet.
Example 3: the rest of the technical solutions of this embodiment 2 are the same as those of embodiment 1, except that: in this example 3, the light photovoltaic backsheet of reference 3 was used as the light photovoltaic backsheet.
Example 4: the rest of the technical solutions of this embodiment 4 are the same as those of embodiment 1, except that: referring to fig. 4 and 5, in this embodiment 4, a lightweight photovoltaic back sheet 100b is provided, and a thermoplastic core layer 110b of the lightweight photovoltaic back sheet 100b is in a porous foamed shape and is formed by a foaming process.
Example 5: the rest of the technical scheme of the embodiment 5 is the same as the embodiment 1, and the difference is only that: referring to fig. 6 and 7, in this embodiment 5, a light-weight photovoltaic back sheet 100c is provided, a second thermoplastic substrate layer 130 is further compounded on the other side of the thermoplastic core layer 110 of the light-weight photovoltaic back sheet 100c, and the second thermoplastic substrate layer 130 is directly connected to the back adhesive film layer 13 of the photovoltaic module 10c in a contact manner.
Example 6: the rest of the technical solutions of this embodiment 6 are the same as those of embodiment 1, except that: in this embodiment 6, the thermoplastic substrate layer 120 is made of a composite material of thermoplastic polymers of a continuous fiber reinforced substrate layer, the continuous fiber is in a dispersed phase, and the thermoplastic polymer of the substrate layer is in a continuous phase; specifically, in the present embodiment, the continuous fiber is a continuous glass fiber, and in other embodiments, a prior art continuous fiber having a similar effect to the continuous glass fiber, such as a continuous carbon fiber or a continuous aramid fiber, may also be used; in this embodiment, the thermoplastic substrate layer 120 is a single unidirectional tape, wherein the single unidirectional tape is prepared by the following steps:
A10) heating and melting a thermoplastic polymer raw material of the substrate layer in advance, and impregnating the thermoplastic polymer of the substrate layer in a molten state with continuous fibers;
A20) and extruding the continuous fibers impregnated with the thermoplastic polymer of the substrate layer into a unidirectional tape.
Example 7: the rest of the technical solutions of this embodiment 7 are the same as those of embodiment 6, except that: in this example 7, the thermoplastic substrate layer 120 employs a multi-layer unidirectional tape laminate structure, wherein the process for preparing the multi-layer unidirectional tape laminate employs the following steps:
A10) heating and melting a thermoplastic polymer raw material of the substrate layer in advance, and impregnating the thermoplastic polymer of the substrate layer in a molten state with continuous fibers;
A20) extruding the continuous fiber impregnated with the thermoplastic polymer of the substrate layer into a unidirectional tape;
A30) the unidirectional tapes are laminated for multiple times in a manner of 90 degrees or 45 degrees, and by heating and pressurizing, thermoplastic polymers of substrate layers of the unidirectional tapes of different layers are melted, soaked mutually, and simultaneously fully wrap continuous fibers to obtain a multilayer unidirectional tape lamination, specifically, in the embodiment 7, the multilayer unidirectional tape lamination adopts a 4-layer unidirectional tape lamination.
Example 8: the rest of the technical solutions of this embodiment 8 are the same as those of embodiment 1, except that: in this example 8, PET (abbreviation for Polyethylene terephthalate) was used for both the core layer thermoplastic polymer and the substrate layer thermoplastic polymer.
Example 9: the rest of the technical solutions of this embodiment 9 are the same as those of embodiment 1, except that: in this example 9, PA (abbreviation for Polyamide, meaning Polyamide) was used for both the core layer thermoplastic polymer and the substrate layer thermoplastic polymer.
Example 10: the rest of the technical solutions of this embodiment 10 are the same as those of embodiment 1, except that: in this example 10, PC (abbreviation for Polycarbonate) was used for both the core layer thermoplastic polymer and the substrate layer thermoplastic polymer.
Example 11: the rest of the technical solutions of this embodiment 11 are the same as those of embodiment 1, except that: in this example 11, PE (Polyethylene, abbreviation) was used for both the core layer thermoplastic polymer and the substrate layer thermoplastic polymer.
Example 12: the rest of the technical solutions of this embodiment 12 are the same as those of embodiment 7, except that: in this example 12, both the core layer thermoplastic polymer and the substrate layer thermoplastic polymer are PET in example 8 or PA in example 9 or PC in example 10 or PE in example 11 or a mixture of these materials.
Example 13: the rest of the technical solutions of this embodiment 13 are the same as those of embodiment 1, except that: in this example 13, the core layer thermoplastic polymer is thermoplastic polypropylene and the substrate layer thermoplastic polymer is PET in example 8 or PA in example 9 or PC in example 10 or PE in example 11 or a mixture of these materials.
Example 14: the rest of the technical solutions of this embodiment 14 are the same as those of embodiment 1, except that: referring further to fig. 8, in this embodiment 14, a light-weight photovoltaic backsheet 100d is provided, and a hot melt adhesive film layer 140 is disposed between the thermoplastic core layer 110 and the first thermoplastic substrate layer 120.
Comparative example 1: the lightweight photovoltaic module proposed in reference 1 was used.
Comparative example 2: the lightweight photovoltaic module proposed in reference 2 was used.
Comparative example 3: the lightweight photovoltaic module proposed in reference 3 was used.
Comparative example 4: photovoltaic modules employing prior art conventional transparent back sheet applications.
Comparative example 5: adopt prior art's dual-glass photovoltaic module.
In the present application, the photovoltaic modules are applied, installed and implemented in the above embodiments and comparative examples, and the implementation effect is compared, and the main comparison results refer to table 1 below:
TABLE 1 comparison of the effects of the examples of the invention with those of the comparative examples
The test standard basis of the water vapor permeability resistance is GB/T26253-.
As can be seen from table 1 above, in this example, after the existing conventional composite material is subjected to targeted screening and applied, a photovoltaic module lightweight photovoltaic backsheet solution can be obtained with versatile positive technical effects, also, by the technical effects of example 7 and example 12 of the present application, it has been surprisingly found that a multilayer unidirectional tape laminate structure made of a thermoplastic polymer of a continuous fiber-reinforced substrate layer is used as a substrate layer structure, the applicant finds that the composite material is superior to continuous fibers in a dispersed phase and a substrate layer thermoplastic polymer in a continuous phase, and can realize a very good and unique cladding fusion structure after the two are subjected to multilayer compounding in different directions, so that the performances of the tensile strength and the water vapor barrier property are obvious. Since the material cost of example 12 is significantly higher than that of example 5, example 7 is the most preferable example of the present application;
it is found through a large number of applications that the thermoplastic core layer 110 can be compounded with the double-sided thermoplastic substrate layer according to the technical scheme described in embodiment 5, or can be directly compounded with the back adhesive film layer 13 of the photovoltaic module, which has little difference in technical effects, and can effectively save one thermoplastic substrate layer, reduce material cost, simplify the compounding process, and belong to the preferred embodiment.
This application further verifies by example 13 that backsheets made of different materials but heat-fusible composite are found to be less effective in lamination than backsheets made of the same materials.
It will be evident to those skilled in the art that the invention is not limited to the details of the foregoing illustrative embodiments, and that the present invention may be embodied in other specific forms without departing from the spirit or essential attributes thereof. The present embodiments are therefore to be considered in all respects as illustrative and not restrictive, the scope of the invention being indicated by the appended claims rather than by the foregoing description, and all changes which come within the meaning and range of equivalency of the claims are therefore intended to be embraced therein. Any reference sign in a claim should not be construed as limiting the claim concerned.
Furthermore, it should be understood that although the present description refers to embodiments, not every embodiment may contain only a single embodiment, and such description is for clarity only, and those skilled in the art should integrate the description, and the embodiments may be combined as appropriate to form other embodiments understood by those skilled in the art.
Claims (9)
1. A continuously composite molded light photovoltaic module is characterized by comprising a photovoltaic laminated part and a light photovoltaic back plate, wherein the photovoltaic laminated part comprises a front flexible packaging layer, a cell sheet layer and a back flexible packaging layer which are laminated and packaged into a whole, the light photovoltaic back plate at least comprises a honeycomb-shaped or porous foaming-shaped thermoplastic core layer and a first thermoplastic substrate layer, and the photovoltaic laminated part and the light photovoltaic back plate are compounded into a whole through a continuous composite molding process; the continuous composite molding process comprises the following operation steps:
s10), sequentially laminating the photovoltaic laminated piece and the light photovoltaic back plate and then placing the laminated piece and the light photovoltaic back plate into continuous flat plate type composite equipment;
s20), heating and pressurizing the laminated laying member by the continuous flat plate type composite equipment to obtain the photovoltaic module; in the step S20), the heating range is 130-200 ℃, the pressurizing range is 0.5-250 Kpa, and the heating and pressurizing time range is 10-150S;
s30), edge cutting is carried out on the photovoltaic module, and the light photovoltaic module is obtained.
2. The continuously composite molded light weight photovoltaic module as claimed in claim 1, wherein in step S30), after the edge cutting, the method further comprises performing protective edge sealing on the edge of the photovoltaic module by using an edge sealing device, and obtaining the light weight photovoltaic module after the edge sealing is completed.
3. The continuous composite molded lightweight photovoltaic module of claim 1, wherein the base material of the thermoplastic core layer is a core layer thermoplastic polymer, the base material of the first thermoplastic substrate layer is a substrate layer thermoplastic polymer, and the core layer thermoplastic polymer is the same or different than the substrate layer thermoplastic polymer.
4. The continuous composite molded lightweight photovoltaic module of claim 1, wherein said core layer thermoplastic polymer or said substrate layer thermoplastic polymer is any one or a mixture of thermoplastic polypropylene, PET, PA, PC and PE.
5. The continuous composite molded lightweight photovoltaic module of claim 1, wherein said thermoplastic substrate layer is a composite of a continuous fiber reinforced substrate layer thermoplastic polymer, said continuous fibers being in a dispersed phase and said substrate layer thermoplastic polymer being in a continuous phase.
6. The continuous composite molded lightweight photovoltaic module of claim 1, wherein said thermoplastic core layer is further compounded on the other side with a second thermoplastic substrate layer, and said second thermoplastic substrate layer is joined in direct contact with the photovoltaic laminate.
7. The continuous composite molded light weight photovoltaic module of claim 1, wherein a hot melt adhesive film layer is disposed between the photovoltaic laminate and the light weight photovoltaic backsheet, or a hot melt adhesive film layer is disposed between the thermoplastic core layer and the first thermoplastic substrate layer.
8. The continuous composite molding light weight photovoltaic module according to claim 1, wherein the continuous flat plate type composite equipment comprises an upper belt type pressure device and a lower belt type pressure device which are distributed in the up-down direction and driven by pressure roller wheels, a heating area and a cooling area which are distributed in the upper belt type pressure device and the lower belt type pressure device respectively are arranged in the upper belt type pressure device and the lower belt type pressure device, the distance between the upper belt type pressure device and the lower belt type pressure device is adjustable, a conveyor belt for conveying laminated paving materials is arranged, the inlet of the conveyor belt is close to the heating area, and the outlet of the conveyor belt is close to the cooling area; and the outlet of the conveying belt is connected with a cutting device.
9. The continuous composite molded light weight photovoltaic module of claim 8, wherein the outlet of the conveyor belt is further connected with an automatic edge sealing or semi-automatic edge sealing device, and the automatic edge sealing or semi-automatic edge sealing device is located at the next station of the cutting device.
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| CN114068745B (en) * | 2022-01-17 | 2022-05-17 | 深圳市华宝新能源股份有限公司 | Light solar power generation panel and preparation method thereof |
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