CN110600569A - Flexible solar cell module and preparation method thereof - Google Patents

Abstract

The present application provides a method for preparing a flexible solar cell module, the method comprising pre-laminating at least one functional film and at least one adhesive film to form an overall transparent laminate. Through pre-lamination, the method of the present application can reduce the number of stacked layers of the component, and make at least a part of the translucent or opaque adhesive film transparent, so that the operator can more easily perform visual inspection of each layer of material. Between the positioning, in order to improve product yield and production efficiency.

Description

A kind of flexible solar cell module and preparation method thereof

technical field

The invention relates to the packaging technology of solar cell chips.

Background technique

Due to the nature of cells in flexible solar modules, many layers of encapsulation material are required.

At present, ultra-thin film materials with various functions are used to package flexible solar cell chips, which can better reflect the light, thin and flexible characteristics of thin-film solar cells.

The components of flexible solar products have complex structures and many layers. Taking power generation paper as an example, its packaging material has as many as 9 layers.

Due to the large number of laminated layers and the different sizes of the membrane materials, and the translucent or opaque film materials, the operator cannot accurately align the position visually, and the laminated arrangement of the membrane materials cannot Accurately, manual positioning is difficult. At the same time, there are only a few points of bonding and fixing between the materials of each layer, and the bonding is not reliable. During the subsequent transfer and lamination operations, misalignment and film material falling off are prone to occur.

Therefore, there is a demand in the art for more accurately and reliably packaging solar cell chips to improve the yield of products.

Contents of the invention

In order to solve the above-mentioned problem that the lamination arrangement cannot be performed accurately due to the large number of layers of the packaging film material and the inability of each film material to be accurately aligned visually, the application provides an accurate and reliable process for solar cell chips. The method for encapsulating to improve the yield of products is simple and easy to operate.

In order to achieve the purpose of this application, this application provides a method for preparing a flexible solar cell module, said method comprising: pre-laminating at least one functional film and at least one adhesive film to form an overall transparent, functional film and a laminated body made of an adhesive film; the upper surface and the lower surface of the solar cell chip are laminated and laid with the film material comprising the laminated body.

In this application, the thin-film material is used for encapsulating solar cell chips. Moreover, the film-like materials include functional films, adhesive films and fabric thin layers without pre-lamination, as well as pre-laminated laminates made of functional films and adhesive films and pre-laminated laminates made of Laminates made of film and fabric thin layers.

In this application, the adhesive film may be opaque or translucent.

In the present application, the solar cell chip may be a thin film solar cell chip.

In this application, the term "flexible solar cell module" refers to a flexible, foldable, rollable module made of thin film materials and thin film solar cell chips.

The term "encapsulation" refers to the use of specific materials to protect solar cells to ensure that they are free from physical and chemical erosion during their effective life cycle, so that they can provide stable and reliable output.

The term "lamination" refers to a molding process that combines multiple layers of the same or different materials into a whole under heat and pressure.

The term "lamination laying" refers to the operation process of positioning and fixing multiple layers of thin film materials and the solar cell chip in a sandwich manner with the solar cell chip as the center.

The term "functional film" refers to a film that imparts certain functional properties to the coated product, where the functional film may include, but is not limited to, an anti-adhesive film, a protective film, an anti-corrosion film, a barrier film, a decorative film, etc.

The term "adhesive film" refers to a film material with an adhesive effect.

The present application forms an overall transparent laminate by pre-laminating the at least one functional film and the at least one adhesive film, so that the method of the present application can reduce the number of stacked components and make at least a part of it translucent or opaque The adhesive film becomes transparent, making it easier for operators to visually locate between layers of materials to improve product yield and production efficiency. Moreover, pre-lamination of some functional films and adhesive films not only reduces the number of stacked components, but also makes the stacking arrangement easier and reduces the ability requirements for personnel.

In the above or other embodiments, the at least one adhesive film may include a non-cross-linked adhesive film, a cross-linked adhesive film or a combination thereof. Among them, the non-crosslinked type is suitable for repeated heating, and the crosslinked type is suitable for one-time heating.

In the above or other embodiments, the non-crosslinked adhesive film may include non-crosslinked polyolefin (POE), non-crosslinked ethylene-vinyl acetate copolymer (EVA), polyvinyl butyral (PVB) etc.; the cross-linked film may include cross-linked EVA, cross-linked POE and the like. The non-cross-linked adhesive film used in this application and the cross-linked adhesive film are commercially available products.

In the above or other embodiments, the pre-lamination temperature can be reasonably selected by those skilled in the art according to the desired technical effect of obtaining "a laminate that is transparent as a whole and does not produce isolation in subsequent operations" of.

In the above or other embodiments, the thickness of the at least one functional film may be less than 50 microns, especially less than 25 microns. Among them, the method of the present application is particularly advantageous for ultra-thin functional films such as thicknesses below 50 microns, because functional films below 50 microns will be thermally deformed during high-temperature lamination, resulting in poor product appearance, while in the present application During the pre-lamination process, the pre-lamination temperature does not reach the thermal deformation temperature of the functional film. At this time, the adhesive film is heated and melted, and it will be initially bonded with the functional film, thereby having a preliminary fixing effect on the ultra-thin functional film. In subsequent high-temperature lamination, it plays an important role in reducing poor appearance.

In the above or other embodiments, a functional film may be pre-laminated with an adhesive film to form an overall transparent laminate. Through pre-lamination, the method of the present application only needs simple adhesion to complete stack arrangement or stack laying. And, because after the pre-lamination, the part of the material to be pre-laminated changes from the original point contact to the surface contact, so compared with the bonding through the fixed bonding points between the layers in the prior art , Pre-lamination enhances the bonding firmness between the laminated material layers.

In the above or other embodiments, the combination for pre-lamination can also be two adhesive films+one functional film, two functional films+one adhesive film or multiple functional films+multiple adhesive films, etc. Such a combination can be routinely selected by those skilled in the art according to actual needs and technical effects that are intended to be realized.

In the above or other embodiments, the method may further comprise pre-laminating the thin layer of fabric and the at least one adhesive film to form a laminate of fabric and adhesive film for lay-up.

In the above or other embodiments, the thin fabric layer may be cloth. Thin layers of fabrics such as cloth will be deformed during cutting and have poor appearance. This application uses pre-lamination to compound the film and cloth, which increases the elasticity and thickness of the cloth and reduces the need for subsequent operations. Various bad in. The "defective" here means that the cutting size and angle may be incorrect due to the deformation and undulation of the cloth during operation when cutting the cloth.

In the above or other embodiments, after the laminate is formed, the laminate made of the functional film and the adhesive film, the laminate of the fabric and the adhesive film, or a combination thereof may be cut to size. Wherein, cutting according to size may be cutting according to the structural size of the solar cell chip to be packaged or cutting according to a specific size requirement of the package. Such size requirements can be reasonably selected by those skilled in the art according to actual conditions. Among them, cutting after the formation of the laminate in the present application can provide the accuracy of cutting, especially for ultra-thin functional materials or cloth, and can provide the accuracy of positioning; Compared with the technology of cutting materials, pre-lamination and then cutting can save material.

In the above or other embodiments, the method may further include packaging the stacked solar cell chips.

In the above or other embodiments, the package may be thermocompression packaging or laminated packaging, wherein thermocompression packaging does not require vacuuming, and laminated packaging requires vacuuming.

Described thermocompression encapsulation or laminated encapsulation can adopt conventional technical means in this field, such as this method is applicable to various lamination or thermocompression processes:

1. Lamination:

1. Constant temperature lamination (The temperature is determined according to the film process parameters, and the lamination temperature of different manufacturers' products is different, but generally 135°C-160°C.

2. Variable temperature lamination (the lamination temperature rises from low temperature to high temperature and then drops to low temperature. The temperature selection is selected by the product manufacturing process)

3. Pressure: less than or equal to 1 standard atmospheric pressure (selected according to the manufacturing process of the product).

2. Hot pressing:

1. The temperature is determined by the film process parameters (for example: 140°C)

2. Pressure: (for example: 2.8-4bar).

In the above or other embodiments, the temperature, pressure and time of the pre-lamination can be reasonably selected by those skilled in the art according to the specific functional film and adhesive film, such as pre-pressing the EVA adhesive film and the barrier film, The temperature of pre-lamination is 85°C, the pressure of pre-lamination is 1 standard atmosphere, and the duration is 2-5 minutes. The effect of pre-lamination is that the EVA changes from translucent to transparent, and the material under it can be seen visually , EVA and the barrier film are flat and will not separate during movement.

On the other hand, the present application provides a flexible solar cell module obtained by the above method.

In yet another aspect, the present application provides a flexible solar device, which includes the flexible solar cell assembly obtained by the above method.

Additional features and advantages of the invention will be set forth in the description which follows, and in part will be apparent from the description, or may be learned by practice of the invention. The objectives and other advantages of the invention will be realized and attained by the structure particularly pointed out in the written description and claims.

Detailed ways

In order to make the purpose, technical solutions and advantages of the present invention clearer, the embodiments of the present invention will be described in detail below. It should be noted that, in the case of no conflict, the embodiments in the present application and the features in the embodiments can be combined arbitrarily with each other.

Example 1

Materials for preparing flexible solar cell modules are as follows:

1. Protective film (thickness is 25 microns, transparent, purchased from Yihe), 2. Cross-linked EVA film (non-transparent, purchased from Foster), 3. Thin-film solar cell chip (purchased from Hanergy).

The method of preparing a flexible solar cell module is as follows:

1. Pre-laminate materials 1 and 2 to form a laminate A that is transparent as a whole and does not produce isolation in subsequent operations;

2. Cut the laminate A according to the size requirements, and then use the solar cell chip as the center to laminate the upper and lower surfaces of the battery chip with the laminate A, that is, the laminated laying method of A+chip+A, and then Lamination encapsulation was performed with a laminator (the lamination temperature was 160° C., the lamination pressure was 1 standard atmospheric pressure, and the lamination time was 5 minutes), so as to obtain a solar cell module.

The operating parameters of the above-mentioned pre-lamination step 1 are: the pre-lamination temperature is 85°C, the pre-lamination pressure is 1 standard atmosphere, and the duration is 3 minutes.

After pre-lamination, the part of the pre-laminated material changes from the original point contact to the surface contact, so compared with the bonding through the fixed bonding points between the layers in the prior art, the pre-lamination Lamination enhances the bond strength between the layers of material being laminated.

Through the pre-lamination process, the number of layers of materials to be laminated is reduced. At the same time, by pre-laminating the opaque film material and the protective film to form a transparent laminate, the operator can visually align the laminated materials, which greatly improves the accuracy of material alignment. Thereby significantly improving the excellent rate of the product.

Example 2

Materials for preparing flexible solar cell modules are as follows:

1. Barrier film (100 microns thick, transparent, purchased from 3M), 2. Non-crosslinked POE film (non-transparent, purchased from Foster), 3. Thin film solar cell chip (purchased from Hanergy).

The method of preparing a flexible solar cell module is as follows:

1. Pre-laminate materials 1 and 2 to form a laminate B that is transparent as a whole and does not produce isolation in subsequent operations;

2. Cut the laminate B according to the size requirements, and then use the solar cell chip as the center to laminate the upper and lower surfaces of the battery chip with the laminate A, that is, use the laminated laying method of B+chip+B, and then Lamination encapsulation was performed with a laminator (the lamination temperature was 160° C., the lamination pressure was 1 standard atmospheric pressure, and the lamination time was 5 minutes), so as to obtain a solar cell module.

The operating parameters of the above-mentioned pre-lamination step 1 are: the pre-lamination temperature is 85°C, the pre-lamination pressure is 1 standard atmosphere, and the duration is 3 minutes.

Through the pre-lamination process, the part of the pre-laminated material is changed from the original point contact to the surface contact. Therefore, compared with the bonding through the fixed bonding points between the layers in the prior art, Pre-lamination enhances the bond strength between the layers of material being laminated while reducing the number of layers of material to be laminated. Moreover, by pre-laminating the opaque film material and the protective film to form a transparent laminate, the operator can visually align the laminated materials, which greatly improves the accuracy of material alignment. Thereby significantly improving the excellent rate of the product.

Example 3

Materials for preparing flexible solar cell modules are as follows:

1. Protective film (thickness is 25 microns, transparent, purchased from Yihe), 2. Cross-linked EVA film (non-transparent, purchased from Foster), 3. Barrier film (thickness is 100 microns, transparent, purchased from from 3M), 4. non-crosslinked POE film (non-transparent, purchased from Foster), 5. thin-film solar cell chip (purchased from Hanergy), 6. non-crosslinked POE film (non-transparent, purchased from Foster), 7. barrier film (100 μm thick, transparent, purchased from 3M), 8. cross-linked EVA film (non-transparent, purchased from Foster), 9. protective film (thickness of 150 microns, non-transparent, purchased from before the exhibition)

The method of preparing a flexible solar cell module is as follows:

1. Pre-laminate materials 1 and 2 to form a laminate A that is transparent as a whole and does not produce isolation in subsequent operations;

2. Pre-laminate materials 3 and 4 to form a laminate B that is transparent as a whole and does not produce isolation in subsequent operations;

3. Pre-laminate materials 6 and 7 to form a laminate C that is transparent as a whole and does not produce isolation in subsequent operations;

4. Pre-laminate materials 8 and 9 to form a laminate D that is transparent as a whole and does not produce isolation in subsequent operations;

5. Cut the laminates A to D according to the size requirements, and then use the solar cell chip as the center to lay the laminated layers in a sandwich style, that is, to lay the layers in the A+B+chip+C+D way, and then use the laminated machine for lamination and encapsulation (the lamination temperature is 160° C., the lamination pressure is 1 standard atmospheric pressure, and the lamination time is 5 minutes), so as to obtain a solar cell module.

Wherein the operating parameters of the above-mentioned pre-lamination steps 1-4 are: a pre-lamination temperature of 85° C., a pre-lamination pressure of 1 standard atmosphere, and a duration of 3 minutes.

After pre-lamination, the part of the pre-laminated material changes from the original point contact to the surface contact, so compared with the bonding through the fixed bonding points between the layers in the prior art, the pre-lamination Lamination enhances the bond strength between the layers of material being laminated.

Since the laminate with a certain thickness and hardness is cut after pre-lamination, the cutting accuracy is significantly improved, especially for ultra-thin functional materials such as the above-mentioned material 1 with a thickness of 25 microns. Under the condition that the accuracy of cutting is improved, the method of the present application can significantly reduce the waste of materials and the generation of defective products due to the incorrect size or angle of cutting.

Moreover, since the pre-lamination can make the opaque or translucent adhesive film material and the functional material integrally formed into a transparent pre-lamination body, it is easier for the operator to visually locate the layers of materials to Improve product yield and production efficiency. Moreover, pre-lamination of some functional films and adhesive films not only reduces the number of stacked components, but also makes the stacking arrangement easier and reduces the ability requirements for personnel.

In contrast, if materials 1-9 are not pre-laminated, materials 1-9 are cut separately, and then laminated, due to the small thickness of each material, especially for 25 micron thick materials , The cutting process may cause deformation, undulation, etc. of the material, so the cutting size cannot be exactly the same every time cutting, resulting in increased material waste due to inappropriate cutting size and increased difficulty in stacking. Moreover, since pre-lamination has a preliminary fixing effect on ultra-thin functional films (such as materials with a thickness of 25 microns), it plays an important role in reducing poor appearance during subsequent high-temperature lamination.

Example 4

Except that the protective film of material 9 was replaced with cloth (0.1-2mm), the same materials and methods as in Example 1 were used to prepare a flexible solar cell module.

In this example, the cloth and EVA are pre-laminated to make the cloth and EVA a whole. The molten EVA enters between the fibers of the cloth and plays a role in fixing the warp and weft of the cloth. Moreover, due to the characteristics of EVA, the elasticity of the cloth is increased. During the subsequent movement or cutting operation, this elasticity can be used to conveniently carry out accurate cutting and laying of layers, and the pre-lamination reduces the possibility of cloth being in the middle of the cutting process. Deformation and undulation caused by operation, resulting in unfavorable situations such as incorrect cutting size and angle.

Although the embodiments disclosed in the present invention are as above, the described content is only an embodiment adopted for understanding the present invention, and is not intended to limit the present invention. Anyone skilled in the field of the present invention can make any modifications and changes in the form and details of the implementation without departing from the spirit and scope disclosed by the present invention, but the patent protection scope of the present invention must still be The scope defined by the appended claims shall prevail.

Claims (11)

1. A method for preparing a flexible solar cell module, said method comprising: pre-laminating at least one functional film and at least one adhesive film to form an overall transparent laminate made of the functional film and the adhesive film ; Laminate the upper surface and the lower surface of the solar cell chip with the thin film material including the laminate. 2. The method of claim 1, wherein the at least one adhesive film comprises a non-crosslinked adhesive film, a crosslinked adhesive film, or a combination thereof. 3. The method of claim 1, wherein the at least one functional film has a thickness of 50 microns or less. 4. The method of claim 1, wherein the at least one functional film has a thickness of 25 microns or less. 5. The method of claim 1, wherein a functional film is pre-laminated with an adhesive film to form an overall transparent laminate. 6. The method of claim 1, further comprising pre-laminating a thin layer of fabric and said at least one adhesive film to form a laminate of fabric and adhesive film for lay-up . 7. The method according to any one of claims 1-6, wherein after forming the laminate, the laminate made of functional film and adhesive film, the layer made of fabric and adhesive film are cut to size Compression body or combination thereof. 8 . The method according to claim 7 , further comprising packaging the solar cell chips after stacking. 9. The method according to claim 8, wherein the package is heat-pressed package or laminated package, wherein the heat-pressed package does not require vacuuming, and the laminated package requires vacuuming. 10. A flexible solar cell module obtained by the method according to any one of claims 1-9. 11. A flexible solar device comprising a flexible solar cell module obtained by the method of any one of claims 1-9.