CN111969073A

CN111969073A - Semi-flexible solar module and manufacturing method thereof

Info

Publication number: CN111969073A
Application number: CN202010811822.3A
Authority: CN
Inventors: 孙菁; 贺卿
Original assignee: Suzhou Safray Energy Technology Co ltd
Current assignee: Suzhou Bowens New Material Technology Co.,Ltd.
Priority date: 2020-08-13
Filing date: 2020-08-13
Publication date: 2020-11-20

Abstract

The invention discloses a semi-flexible solar module and a manufacturing method thereof, and in a first aspect, the invention provides a photovoltaic module scheme, a front layer of ultraviolet reflecting material; one or more impact cushioning layers; a crystalline silicon substrate, a multi-component compound thin film material, a polymer modified electrode type, and a solar cell layer of a sensitized nanocrystalline or organic compound solar cell; a support layer of semi-flexible material supporting the solar cell layer; a back layer; none of the layers is composed of glass. The solar module has certain flexibility and wider application than the traditional rigid solar module; and is lighter than conventional solar modules, has low transportation costs, and is easily bent, facilitating assembly to conform to the curvature of the installation site.

Description

Semi-flexible solar module and manufacturing method thereof

Technical Field

The present invention relates to a solar module, and more particularly, to a semi-flexible solar module using a crystalline solar cell and a method for manufacturing the same.

Background

Solar cells or photovoltaic cells are electrical devices that convert light energy directly into electrical energy. In general, a plurality of solar cells are integrated in a solar module, which is called a solar panel. In general, a solar module includes a metal frame, a crystalline solar cell, and a glass cover plate. Since the crystalline solar cells are fragile, the metal frame and the glass cover plate serve to protect the crystalline solar cells and generally maintain the solar module in a predetermined shape.

Recently, flexible solar modules using thin film solar cells, which are not as fragile as crystalline solar cells and can be rolled up, have been developed. Thin film solar modules tend to be smaller and more portable. Thin film solar cells are less efficient at converting light into electrical energy than crystalline and other solar cells.

Therefore, there is a need for a semi-flexible solar module that can use crystalline and other solar cells with a wide range of applications.

Disclosure of Invention

The invention aims to overcome the problems in the prior art and provides a semi-flexible solar module which can use a crystalline silicon substrate, a multi-compound thin film material, a polymer modified electrode type, a sensitized nano-crystal or organic compound solar cell. The invention also relates to an electrical connection device for a semi-flexible solar module and a surface pattern for a semi-flexible solar module. Due to certain flexibility, the solar module has wider application than a rigid solar module. Such semi-flexible solar modules are also lighter than conventional solar modules. The semi-compliant assembly is easily bent to conform to the curvature of the installation site; the weight is light, so that the transportation cost is lower, and the assembly is convenient; the surface of the component is self-cleaning allowing because it is a non-stick material and its texture minimizes its surface tension; the assembly may be secured with adhesive or screws.

In order to achieve the technical purpose and achieve the technical effect, the invention is realized by the following technical scheme:

a semi-flexible solar module, comprising:

a front layer of ultraviolet reflective material;

one or more impact cushioning layers;

a crystalline silicon substrate, a multi-component compound thin film material, a polymer modified electrode type, and a solar cell layer of a sensitized nanocrystalline or organic compound solar cell;

a support layer of semi-flexible material supporting the solar cell layer;

a back layer;

none of the layers consists of glass.

Preferably, the support layer is provided as a transparent support layer, which is located between the front layer and the solar cell layer.

Preferably, the impact buffer layer is provided as an adhesive layer; one or more of the impact-cushioning layers thereof also serves as an adhesive layer.

Preferably, a second impact buffer layer is arranged between the solar cell layer and the support layer.

Preferably, one or more adhesive layers are further arranged between the front layer, the solar cell layer, the support layer and the rear layer.

Preferably, a bus bar is disposed on the solar cell layer, and a bypass diode is disposed on the bus bar.

Preferably, the bypass diode is provided in plurality, and the plurality of bypass diodes are respectively arranged on different bus bars on the solar cell layer.

Preferably, the thickness of the solar module does not exceed 7 mm.

A semi-flexible solar module, comprising:

a front layer formed of a fluoroplastic film;

a plurality of impact buffers formed of a high polymer encapsulation material;

a solar cell layer formed by a crystalline silicon substrate, a multi-component compound thin film material, a polymer modified electrode type and a sensitized nanocrystalline or organic compound solar cell;

a support layer formed of a thermoplastic polyester material;

and a back layer comprised of a photovoltaic backsheet.

The invention has the beneficial effects that:

1. the invention provides a semi-flexible solar component which can use a crystalline silicon substrate, a multi-component compound thin film material, a polymer modified electrode type, a sensitized nano crystal or an organic compound solar cell;

2. the invention also relates to an electrical connection device for a semi-flexible solar module and a surface pattern for a semi-flexible solar module;

3. the solar module has a certain flexibility and has wider application than the traditional rigid solar module; compared with the traditional solar energy component, the solar energy component has light weight, low transportation cost, easy bending and convenient assembly, and is in line with the curvature of the installation position;

4. the present invention employs a non-stick material and its texture to minimize its surface tension, allowing its component surfaces to be self-cleaning; in addition, the assembly may be secured using adhesives or screws.

The foregoing is a summary of the present invention, and in order to provide a clear understanding of the technical means of the present invention and to be implemented in accordance with the present specification, the following is a detailed description of the preferred embodiments of the present invention with reference to the accompanying drawings. The detailed description of the present invention is given in detail by the following examples and the accompanying drawings.

Drawings

The accompanying drawings, which are included to provide a further understanding of the invention and are incorporated in and constitute a part of this application, illustrate embodiment(s) of the invention and together with the description serve to explain the invention without limiting the invention. In the drawings:

FIG. 1 illustrates an example of a semi-flexible solar module;

FIG. 2 illustrates another example of a semi-flexible solar module;

FIG. 3 illustrates yet another example of a semi-flexible solar module;

FIG. 4 is yet another example of a semi-flexible solar module;

FIG. 5 illustrates an example of bus bars and bypass diodes in the semi-flexible solar module with junction box of FIG. 1;

FIG. 6 illustrates an example of a series connector for the semi-flexible solar module of FIG. 1;

FIG. 7 illustrates an example of a parallel connector for the semi-flexible solar module of FIG. 1;

FIG. 8 illustrates an example of a junction box for use with the connector of FIG. 5;

FIG. 9 illustrates a close-up of the bypass diode in the laminated solar module;

FIG. 10 is a top view illustrating a surface pattern applied to a front layer of the semi-flexible solar module of FIG. 1;

FIG. 11 is a side view illustrating a surface pattern applied to the front layer of the semi-flexible solar module of FIG. 1;

FIG. 12 is a flow chart of a method of applying a pattern to a surface of a solar module.

Detailed Description

The invention is further described with reference to the accompanying drawings in which:

fig. 1 illustrates an example of a semi-flexible solar module 100. In this example, the solar module 100 includes a front layer 105, an impact buffer layer 110, a solar cell layer 115, a support layer 120, and a back layer 125.

Fig. 2 illustrates another example of a semi-flexible solar module 200. The example of fig. 2 is similar to that of fig. 1, except that an additional impact buffer layer 110 is provided between the solar cell layer 115 and the support layer 120.

Fig. 3 illustrates a further example of a semi-flexible solar module 300. In this embodiment, the support layer 120 and the solar cell layer 115 in fig. 2 have been switched in position, the support layer 120 now being located above the solar cell layer 115 and between the two impact buffer layers 110. The support layer 120 is disposed on the solar cell layer 115 to reinforce the buffer layer to prevent external severe impact, but it will slightly reduce light transmission.

The front layer 105 is transparent in order to provide some protection for the solar module. In particular, the front layer 105 may provide Ultraviolet (UV) protection to reduce or prevent degradation of the underlying layer due to solar exposure. The front layer 105 may be made of at least one material selected from Ethylene Tetrafluoroethylene (ETFE), ethylene chlorotrifluoroethylene, polyvinyl fluoride film, ethylene propylene copolymer. The thickness of the previous layer may be less than 0.2 mm. The purpose of the previous layer is to provide, depending on the material chosen:

a good adhesion to the underlying layer (possibly by surface treatment);

b good dielectric strength, which helps make the front layer 105 an effective insulator;

c good mechanical strength (tear strength) and dimensional stability;

d, moisture protection;

e low surface energy, the front layer 105 will remain clean and can be easily cleaned.

The impact buffer layer 110 is intended to absorb impact energy, such as solid debris from hail, snow, wind, etc., to prevent damage to the solar cells within the solar cell layer 115. The impact buffer layer 110 may be generally disposed adjacent to the solar cell layer 115. In some cases, impact buffer layers 110 may be provided on both sides of the solar cell layer 115 to provide greater protection. In some cases, the impact buffer layer 110 may also serve as an adhesive between the front layer 105 and the solar cell layer 115 and/or between the solar cell layer 105 and the support layer 120 and/or other layers in the stack. The impact buffer layer 110 may be at least one material selected from ethylene-vinyl acetate (EVA), a silicone sealant, an epoxy resin, a polyolefin, a butyl rubber-based adhesive, or an ethylene-based phenol resin.

The solar cell layer 115 is composed of a crystalline silicon substrate, a multi-component thin film material, a polymer modified electrode type, a sensitized nanocrystal or organic compound solar cell. These cells may be of conventional size, such as 156 mm x156 mm, or may be of other sizes or types mounted on the solar cell layer 115. In the solar panel, the cells can be connected in series by solder strips or the like, each solar cell can be manually or automatically soldered together, and the solar cells can be adhered to the solder strips by conductive adhesive.

The support layer 120 is configured to have sufficient load bearing characteristics to enable the support layer 120 to support the solar cell layer 115 such that the solar cell layer 115 does not crack. Thus, the support layer 120 may be rigid or semi-flexible and made of at least one material selected from the following group of materials: polyethylene terephthalate (PET), polyurethane, polyetherimide, polyethylene-vinyl fluoride, ethylene vinyl acetate, polyester, fiberglass sheet, plastic or stainless steel sheet coated with an insulating layer, carbon fiber reinforced thermoplastic, and glass fiber reinforced thermoplastic. In some examples, if the support layer is placed over the solar cell, the support layer needs to be transparent and not more than 0.8 mm thick. In some cases, the thickness needs to be about 0.5 mm. If the support layer is placed under the solar cell layer, the thickness of the material may be between 0.5mm and 2 mm.

In some cases, the support layer 120 may be transparent and may be placed on top of the solar cell layer 115. The support layer 120 is intended to be placed over the solar cell layer 115, which will provide further protection for the solar cell layer 115 from impacts and the like. As shown in fig. 2 and 3, in some cases, the support layer 120 may be disposed above the solar cell layer 115, while the impact buffer layer 110 may be disposed above and below the support layer 120, as well as below the solar cell layer 115, to provide a softer layer for impact protection, while also including impact protection from the support layer 120.

The backing layer 125 is intended to provide different physical or chemical properties to protect against various environmental factors. These properties include, for example, mechanical strength, uv resistance, dielectric strength, thermal stability, hydrolytic stability, and moisture resistance. The backing layer 125 may be rigid or semi-flexible and may be selected from polyester sheet, kynar film, plastic elastomer, aluminum coated sheet, stainless steel coated sheet, glass fiber, carbon fiber reinforced thermoplastic, glass fiber reinforced thermoplastic. The backing layer 120 may be less than 6 mm thick. It is to be understood that crystalline solar cells are fragile when the film is rolled up. Such semi-flexible solar panels may be bent at least 30 degrees over a 1 meter length with a curve radius greater than 800 millimeters.

In some cases, the backing layer 120 may comprise a plurality of sub-layers, for example a sub-layer of a polyurethane thermoplastic material as an intermediate or upper sub-layer, and at least a second material layer is required for the backing layer 120 in addition to this sub-layer. The second layer of material may be polyvinyl fluoride (polyvinyl formal), or polyvinylidene fluoride, thermoplastic fluoropolymer material (with high water resistance and inherent strength, low moisture permeability, steam, petroleum and available in a wide temperature range, for example-70 ℃ to 110 ℃).

In each of the above examples, one or more adhesive layers 130 may be provided between the layers to maintain adhesion when the layer material itself cannot be used to establish adhesion between the layers. In some cases, adhesive layer 130 may also serve as impact buffer layer 110.

Fig. 4 illustrates another example of a solar module 400. Fig. 4 shows specific materials for the above layers in a solar module 400.

In this particular embodiment, the front layer 405 is a fluorine-based plastic. Such plastics have uv protection and other properties such as high light transmittance (greater than or equal to 92%), high dielectric strength, which helps make the layer an effective insulator, good mechanical strength and moisture permeability. These previous layers may require properties. The front layer 405 may be bonded to the support layer 420 with a first adhesive layer 407 of ethylene-vinyl acetate. In some cases, the first adhesion layer 407 may include two or more sub-layers of ethylene vinyl acetate material. In this embodiment, the first adhesive layer 407 may also serve as the impact buffer layer 410.

The support layer 420 is a polyethylene terephthalate material. In this case, the support layer 420 may also serve as the impact buffer layer 410. The second adhesive layer 413 adheres the support layer 420 to the solar cell layer 415. The third adhesive layer 423 adheres the solar cell layer 415 to the back side layer 425. The second and third

adhesive layers

413, 423 may serve as further impact buffer layers 410 for the solar cell layer 415.

The back layer 425 is formed from a tetrafluoroethane film material having a thickness of about 0.645 millimeters. The layer has high tensile strength, dimensional stability and low water vapour permeability. In this example, the thickness of the fluorine-based plastic layer is 0.1mm, the thickness of the adhesive layer is 0.5mm, the thickness of the thermoplastic support layer is 0.4mm, the thickness of the solar cell layer is 0.20mm, and the thickness of the back layer is 0.4 mm.

Generally, the examples of semi-flexible solar modules described herein are manufactured without the use of glass in order to provide a degree of flexibility to the solar module. In addition, the solar module generally does not require an aluminum frame, which weighs about 40% to 50% of conventional modules. For example, the weight load of a conventional solar module is about 11 kilograms per square meter, while the weight load of a semi-flexible solar module provided herein is about 4 to 5 kilograms per square meter. In some particular cases, the weight is about 4.6 kg/m. The solar module is intended to include a high efficiency, low cost crystalline silicon cell integrated solar module constructed from a lightweight, rigid or semi-flexible substrate structure. In some cases, the semi-compliant structure allows approximately 30 degrees of assembly flexure. The total thickness of the assembly should be less than 8 mm. In some special cases, the thickness of the solar module may be 3 mm.

Fig. 5 illustrates solar cell layer 115 in further detail. As shown in fig. 5, the solar cell layer 115 will include a plurality of solar cells and busbars that extend across both sides of the solar cells to interconnect the solar cells and allow the solar cells to produce and pass electrical current through the solar cells. The bus bars may be assembled into the solar cell layer 115 by conventional methods, such as by conventional manual or automated soldering techniques. In other cases, the bus bars may be adhered to the solar cell layer 115 by a conductive adhesive. In some cases of the present example, the bus bars will be covered during lamination by, for example, the impact buffer layer 110 and the front layer 105. The battery pack comprises a junction box 450, a battery string 455 and a battery piece 460.

Fig. 7 shows the state where the low-state button connectors 550 are connected in parallel. Similar to fig. 6, fig. 7 includes male studs 555 and female sockets 560 on a solar module configured to be connected in parallel to

respective connectors

565 and 570 by press connections. To ensure that there are no holes, the connectors must be filled. In some cases, the filler may be silicone or a similar material. The bus bars may be covered with an insulating tape to prevent contact with other conductive materials that could cause electrical shorts.

Fig. 8 shows a junction box 600 that provides a bus bar 605 on the solar cell layer 105. The bus bar 605 may be connected to the terminal block terminal 610 by welding or the like. If the power of the component does not exceed (include) 100w, the junction box comprises a bypass diode; if the module power exceeds 100w, the junction box does not contain a bypass diode, but the bypass diode is integrated into the module.

Fig. 9 illustrates the provision of one or more diodes on the bus bar. These bypass diodes are used to protect the solar cells from the risk of hot spots when one or more solar cells are shadowed or somehow damaged. There is usually one bypass diode per string of solar cells. In conventional solar modules, bypass diodes are provided in the junction box. However, in some examples, the bypass diode is disposed directly on the bus bar and wrapped in a laminate of layers of the solar module.

Conventional bypass diodes of solar panels may serve as a protection mechanism to enable continued power generation even if one or more strings of cells within the panel are not operational, e.g., shadowed, damaged, or the like. Typically, all of the strings of cells are connected in series, with each cell producing a current proportional to the amount of sunlight it receives. If any one cell begins to operate at a low capacity, e.g., the cell is covered, contaminated, damaged or the like, the overall string current may be limited to the range of currents that the weakest cell can provide. In this case, the solar cell panel cannot be operated at full load.

A typical battery may have a forward voltage of about 0.5 v when at optimal loading. If a cell is shaded and may not produce as much current as other cells in the vicinity, the cell may be forced into a reverse mode of operation where it is subject to a negative voltage. Poorly performing cells can become heating elements creating hot spots on the solar module that can damage the solar module. To prevent these problems, the series units of pv modules are arranged in strings and a bypass diode is connected in parallel to each string.

The purpose of the connector is to use a low profile and compact form for integration into a solar module. In some cases, the connector thickness is about 0.7 millimeters, making the lamination process of the flexible component easier and smoother than conventional processes. The diodes on the bus bars are soldered between the two strings. By integrating diodes it is possible to use more diodes per solar module, which may allow the remaining sub-strings to continue to operate in partial shadow conditions.

In some examples, the solar module may be configured to include a surface pattern 900 on the front layer 405 as shown in fig. 4, as shown in fig. 10, 11. The surface pattern 900 may be mechanically created, for example, by pressure treatment of the front layer 405. The surface pattern 900 is intended to prevent surface wrinkles during the production of the module, reduce solar reflection loss, and improve the output efficiency of the module. In some conventional solar modules, severe surface wrinkles can be observed. Examples of solar modules herein include special pattern templates applied to the surface of the front layer 405 during module processing that are intended to provide consistent surface angle contact through a pre-set outline mold. The preset profile may be one of a pattern including an intaglio pattern, a triangular pattern, a rectangular pattern, a square pattern, and a linear cross-hatched pattern. By printing a cross-hatch pattern on the front layer 405 of the solar module, the solar module is able to maintain a light transmission efficiency of over 90% while reducing or eliminating surface wrinkles of the module. The surface template can be selected from high-temperature template plastics, cross-coated polytetrafluoroethylene fiber templates, deformed glass fiber templates and coating metal templates.

Fig. 12 illustrates a method of applying a template to a solar module. At 1005, the material is placed to fabricate a solar module. At 1010, a template is placed on top of the solar module. At 1015, the solar panel is fed into a laminator. The lamination process may include applying a vacuum for a period of time, with the pressure controlled to be no greater than 90 kilopascals and the temperature at about 175 ℃. At 1020, the solar module is removed from the laminator for cooling. The finished assembly is placed on a discharge conveyor and cooled after lamination. In some cases, a slab or similar object may be placed on top of the pattern for a period of time in order to maintain the shape of the component surface pattern and prevent warping of the component during cooling.

The purpose of the localized surface treatment is to increase the surface energy so that the junction box or other joint has excellent bond strength when it contacts a surface. The local surface may be treated by corona (in the case of o2/n2, n2, n2/co2, etc.), flame treatment, atmospheric plasma activation, atmospheric or low pressure plasma deposition, etc.

In the previous descriptions, for purposes of explanation, corresponding details were set forth in order to provide a thorough understanding of the examples. In other instances, well-known electrical structures and circuits are shown in block diagram form in order not to obscure the understanding of this description. For example, specific details are not provided as to whether the examples described herein are implemented as software routines, hardware circuits, firmware, or a combination thereof.

The above description is only for the specific embodiments of the present invention, but the scope of the present invention is not limited thereto, and any person skilled in the art can easily conceive of the changes or substitutions within the technical scope of the present invention, and all the changes or substitutions should be covered within the scope of the present invention. Therefore, the protection scope of the present invention shall be subject to the protection scope of the claims.

Claims

1. Semi-flexible solar module, characterized in that includes:

a front layer of ultraviolet reflective material;

one or more impact cushioning layers;

a support layer of semi-flexible material supporting the solar cell layer;

a back layer;

none of the layers consists of glass.

2. The semi-flexible solar module of claim 1, wherein: the support layer is provided as a transparent support layer, which is located between the front layer and the solar cell layer.

3. The semi-flexible solar module of claim 1, wherein: the impact buffer layer is arranged as an adhesive layer; one or more of the impact-cushioning layers thereof also serves as an adhesive layer.

4. The semi-flexible solar module of claim 1, wherein: and a second impact buffer layer is arranged between the solar cell layer and the support layer.

5. The semi-flexible solar module of claim 1, wherein: one or more adhesive layers are also disposed between the front layer, the solar cell layer, the support layer and the back layer.

6. The semi-flexible solar module of claim 1, wherein: the solar cell layer is provided with a bus, and the bus is provided with a bypass diode.

7. The semi-flexible solar module of claim 6, wherein: the bypass diode is provided in plurality, and the plurality of bypass diodes are respectively arranged on different bus bars on the solar cell layer.

8. The semi-flexible solar module of claim 1, wherein: the thickness of the solar component is not more than 7 mm.

9. Semi-flexible solar module, characterized in that includes:

a front layer formed of a fluoroplastic film;

a plurality of impact buffers formed of a high polymer encapsulation material;

a support layer formed of a thermoplastic polyester material;

and a back layer comprised of a photovoltaic backsheet.