CN114695586A - 一种bipv光伏组件及其制备方法 - Google Patents
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Abstract
本发明公开了一种BIPV光伏组件，包括依次层叠设置的透明有机高分子氟膜、封装胶膜、电池串、绝缘胶膜和安装面板，所述透明有机高分子氟膜、所述封装胶膜、所述电池串、所述绝缘胶膜和所述安装面板一体成型。本申请用彩涂钢板或防水卷材直接作为背板进行组件封装，最终形成一种彩钢瓦一体BIPV柔性轻质组件或防水卷材一体BIPV柔性轻质组件，以解决现有装置安装复杂、成本高、重量大、适应性差等缺点，可根据项目需要快速加工，直接安装。
Description
技术领域
本发明涉及一种BIPV光伏组件及其制备方法，属于光伏组件加工技术领域。
背景技术
随着“碳达峰、碳中和”的目标提出和分布式光伏发电兴起，轻质柔性光伏组件被广泛使用在彩钢瓦屋顶等载荷较低的项目上，现有的解决方案是将轻质柔性光伏组件用胶直接粘贴安装在彩钢瓦上，工艺复杂、成本高，而且此光伏组件一般机械强度不足，在安装和使用过程中容易导致组件中电池片碎裂等，从而影响产品使用寿命和发电量。
另外，光伏建筑一体化(主要包括有光伏建筑屋顶)是光伏发电应用的重要领域，也是光伏发电技术应用的重点发展方向。防水卷材是建筑上常用防水产品，在现有技术的光伏建筑屋顶的安装施工过程中，其光伏组件需要在屋顶上通过支架固定，因此在施工过程中需要破坏屋顶的防水层从而造成防水隐患，而且安装操作复杂，工程造价较高。
发明内容
发明目的：针对现有技术中存在的问题与不足，本发明提供一种结构简单、制造容易且成本较低的BIPV光伏组件。
技术方案：一种BIPV光伏组件，包括依次层叠设置的透明有机高分子氟膜、封装胶膜、电池串、绝缘胶膜和安装面板，所述透明有机高分子氟膜、所述封装胶膜、所述电池串、所述绝缘胶膜和所述安装面板一体成型。
进一步的，所述透明有机高分子氟膜厚度为250-400μm，外表面设有疏水涂层。
进一步的，所述封装胶膜采用EVA或POE或PVB。
进一步的，所述绝缘胶膜为EPE结构，厚度为0.1-1.0mm。
进一步的，所述安装面板为彩涂钢板，所述彩涂钢板的厚度为0.15mm-1.5mm。
进一步的，所述安装面板为防水卷材，所述防水卷材的厚度为1-5 mm。
本申请还提供了一种BIPV光伏组件制备方法，包括以下步骤：
（1）在载物台上铺设安装面板和绝缘胶膜，绝缘胶膜和安装面板经粘接热压工艺形成整体；
（2）在铺设绝缘胶膜的安装面板上放置电池串，保证电池串处于加工位置；
（3）继续铺设封装胶膜和透明有机高分子氟膜，经过层压后形成整体；
（4）层压生产出的BIPV柔性轻质组件，直接平铺在屋顶屋面上，边缘通过热风焊接。
进一步的，当所述步骤（1）中的安装面板为彩涂钢板时，按照上述步骤（1）至步骤（3）进行加工，完成后在组件边缘空隙处加工成彩涂钢板的角驰和锁边搭接结构。
进一步的，当所述步骤（1）中的安装面板为防水卷材时，将防水卷材分割成多个含有独立电池串的单元组件，再按照上述步骤（1）至步骤（4）进行加工。
有益效果：本申请用彩涂钢板或防水卷材直接作为背板进行组件封装，最终形成一种彩钢瓦一体BIPV柔性轻质组件或防水卷材一体BIPV柔性轻质组件，以解决现有装置安装复杂、成本高、重量大、适应性差等缺点，可根据项目需要快速加工，直接安装。
附图说明
图1为本申请BIPV光伏组件一种实施例结构示意图；
图2为图1中电池串结构示意图；
图3为彩涂钢板一体BIPV柔性轻质组件安装示意图；
图4为防水卷材一体BIPV柔性轻质组件安装示意图。
图中标记： 1、透明有机高分子氟膜，2、封装胶膜，3、电池串，4、绝缘胶膜，5、安装面板，6、彩涂钢板，7、防水卷材。
具体实施方式
下面结合附图和具体实施例，进一步阐明本发明。
实施例1
如图1-3所示，本实施例提供了一种BIPV光伏组件，包括依次层叠设置的透明有机高分子氟膜1、封装胶膜2、电池串3、绝缘胶膜4和安装面板5，其中安装面板5采用彩涂钢板6。
具体而言，透明有机高分子氟膜1为含氟薄膜，厚度为250-400μm，透光率大于85%，外表面设有疏水涂层。
具体而言，封装胶膜2选用EVA（乙烯与醋酸乙烯共聚物）、POE（聚烯烃）、PVB（聚乙烯醇缩丁醛酯）中的一种，胶膜克重大于400g/m²，通过层压机加热抽真空将所述透明有机高分子氟膜1与电池串3、绝缘胶膜4以及彩涂钢板6层压一体化成型。
优选的，电池串3选用单晶硅电池，每个单晶硅电池通过涂锡铜带焊接串联或者通过导电箔串联，电池片厚度为100-200μm。
具体而言，绝缘胶膜4选用EPE（EVA/PET /EVA），POE/PET/POE、PVB/PET/PVB中的一种复合胶膜，优选的，选用EPE，厚度为0.1-1mm，复合绝缘胶膜不同层材料经粘接热压等工艺形成整体。
具体而言，彩涂钢板4，厚度0.15mm-1.5mm，采用的基板为冷轧基板或热镀锌基板或电镀锌基板，基板上的涂层种类可分为聚酯、硅改性聚酯，偏聚二氟乙烯和塑料溶胶；彩钢瓦一体BIPV柔性轻质组件具有多个发电单元，发电单元一般位于彩钢瓦波谷中，宽度为200-2000mm，根据实际需求按规格尺寸在组件边缘处辊压冷弯成角驰、锁边等搭接结构。
本实施例还提供了彩涂钢板一体BIPV光伏组件制备方法，包括以下步骤：在载物台上铺设彩涂钢板和绝缘胶膜，这些不同层材料经粘接热压工艺形成整体；然后在彩涂钢板上精确放置电池串，保证电池串处于加工位置；继续铺设封装胶膜和透明有机高分子氟膜，经过层压、削边、安装接线盒和测试分档后，在组件边缘空隙处加工成彩钢瓦的角驰、锁边等搭接结构；层压生产出的大面积彩钢瓦一体BIPV柔性轻质组件，在组件边缘空隙处加工成彩钢瓦的角驰、锁边等搭接结构。
实施例2
如图1、2和4所示，本实施例提供了一种BIPV光伏组件，包括依次层叠设置的透明有机高分子氟膜1、封装胶膜2、电池串3、绝缘胶膜4和安装面板5，其中，安装面板5采用防水卷材7。
具体而言，透明有机高分子氟膜1为含氟薄膜，厚度为250-400μm，透光率大于85%，外表面设有疏水涂层。
具体而言，封装胶膜2选用EVA（乙烯与醋酸乙烯共聚物）、POE（聚烯烃）、PVB（聚乙烯醇缩丁醛酯）中的一种，胶膜克重大于400g/m²，通过层压机加热抽真空将所述透明有机高分子氟膜1与电池串3、绝缘胶膜4以及彩涂钢板6层压一体化成型。
优选的，电池串3选用单晶硅电池，每个单晶硅电池通过涂锡铜带焊接串联或者通过导电箔串联，电池片厚度为100-200μm。
具体而言，绝缘胶膜4选用EPE（EVA/PET /EVA），POE/PET/POE、PVB/PET/PVB中的一种复合胶膜，优选的，选用EPE，厚度为0.1-1mm，复合绝缘胶膜不同层材料经粘接热压等工艺形成整体。
具体而言，防水卷材5厚度1mm-5mm，其材质选用TPO（热塑性聚烯烃）、PVC（聚氯乙烯）、EPDM(乙烯-丙烯-环戊二烯三元共聚物)中的一种防水卷材，各组件通过层压机抽真空并加压，将各组成部分粘接在一起，从而形成彩钢瓦一体BIPV柔性轻质组件，防水卷材一体BIPV柔性轻质组件具有多个发电单元，发电单元一般位于防水卷材中部位置。
本实施例还提供了一种防水卷材一体BIPV光伏组件制备方法，包括以下步骤：在载物台上铺设防水卷材和绝缘胶膜，这些不同层材料经粘接热压等工艺形成整体；然后在防水卷材上精确放置电池串，保证电池串处于加工位置；继续铺设封装胶膜和透明有机高分子氟膜，经过层压后得到大面积基于防水卷材的层压件，在层压件上面进行接线盒安装和测试包装，必要时也可分割成多个含有独立电池串的单元组件；层压生产出的防水卷材一体BIPV柔性轻质组件，直接平铺在屋顶屋面上，边缘通过热风焊接。
以上所述仅是本发明的优选实施方式，应当指出，对于本技术领域的普通技术人员来说，在不脱离本发明原理的前提下，还可以作出若干改进，这些改进也应视为本发明的保护范围。
Claims (9)
1.一种BIPV光伏组件，其特征在于：包括依次层叠设置的透明有机高分子氟膜、封装胶膜、电池串、绝缘胶膜和安装面板，所述透明有机高分子氟膜、所述封装胶膜、所述电池串、所述绝缘胶膜和所述安装面板一体成型。
2.根据权利要求1所述的一种BIPV光伏组件，其特征在于：所述透明有机高分子氟膜厚度为250-400μm，外表面设有疏水涂层。
3.根据权利要求1所述的一种BIPV光伏组件，其特征在于：所述封装胶膜采用EVA或POE或PVB。
4.根据权利要求1所述的一种BIPV光伏组件，其特征在于：所述绝缘胶膜为EPE结构，厚度为0.1-1.0mm。
5.根据权利要求1所述的一种BIPV光伏组件，其特征在于：所述安装面板为彩涂钢板，所述彩涂钢板的厚度为0.15mm-1.5mm。
6. 根据权利要求1所述的一种BIPV光伏组件，其特征在于：所述安装面板为防水卷材，所述防水卷材的厚度为1-5 mm。
7.一种BIPV光伏组件制备方法，其特征在于，包括以下步骤：
（1）在载物台上铺设安装面板和绝缘胶膜，绝缘胶膜和安装面板经粘接热压工艺形成整体；
（2）在铺设绝缘胶膜的安装面板上放置电池串，保证电池串处于加工位置；
（3）继续铺设封装胶膜和透明有机高分子氟膜，经过层压后形成整体；
（4）层压生产出的BIPV柔性轻质组件，直接平铺在屋顶屋面上，边缘通过热风焊接。
8.根据权利要求7所述的一种BIPV光伏组件制备方法，其特征在于：当所述步骤（1）中的安装面板为彩涂钢板时，按照上述步骤（1）至步骤（3）进行加工，完成后在组件边缘空隙处加工成彩涂钢板的角驰和锁边搭接结构。
9.根据权利要求7所述的一种BIPV光伏组件制备方法，其特征在于：当所述步骤（1）中的安装面板为防水卷材时，将防水卷材分割成多个含有独立电池串的单元组件，再按照上述步骤（1）至步骤（4）进行加工。
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