CN217933809U

CN217933809U - Photovoltaic module

Info

Publication number: CN217933809U
Application number: CN202221217198.5U
Authority: CN
Inventors: 施正荣; 王伟力; 徐征阳
Original assignee: Shangmai Zhenjiang New Energy Technology Co ltd; Sunman Shanghai Co ltd
Current assignee: Shangmai Zhenjiang New Energy Technology Co ltd; Sunman Shanghai Co ltd
Priority date: 2022-05-18
Filing date: 2022-05-18
Publication date: 2022-11-29
Anticipated expiration: 2032-05-18

Abstract

The utility model discloses a photovoltaic module, include positive encapsulation unit, photovoltaic cell unit, the back encapsulation unit that lamination process encapsulation is as an organic whole, positive encapsulation unit includes thermoplasticity printing opacity encapsulation rete at least, back encapsulation unit includes thermoplastic fiber reinforced substrate at least, thermoplastic fiber reinforced substrate adopts continuous fiber reinforcement thermoplastic polymer unilateralism area single layer structure or multilayer laminated structure; the thermoplastic light-transmitting packaging film layer is made of a light-transmitting thermoplastic high polymer material; the utility model discloses demonstrate excellent light transmissivity, flexibility, water vapour resistance permeability and good mechanical installation performance simultaneously, it is high to promote application prospect.

Description

Photovoltaic module

Technical Field

The utility model belongs to the photovoltaic power generation field, concretely relates to photovoltaic module.

Background

Reliability, safety, and low cost are requirements that any energy product must meet at the same time. In the last decades, the photovoltaic industry has been reducing the cost of photovoltaic products by as much as 300 times over the last 40 years by continuing and high-quality focus on developing major means to improve the efficiency of photoelectric conversion, localization and automation of supply chains and 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 shingle are available at present, and the maximum packaging material utilization rate is strived for through the structure. People have become a pity of packaging materials from "caring for batteries".

Furthermore, the performance of the photovoltaic module back plate as a back packaging material of the photovoltaic module directly determines the packaging effect performance of the photovoltaic module. The traditional photovoltaic module back plate mostly adopts PET (polyethylene terephthalate) base materials, however, because PET belongs to thermoplastic engineering plastics, the defects of low strength, easiness in hydrolysis, high water blocking rate and high heat shrinkage rate exist.

The applicant proposes a photovoltaic module with an authorization publication number of CN211555907U, mainly proposes to use a single-layer structure or a multi-layer laminated structure based on a continuous fiber reinforced thermoplastic polymer unidirectional tape as a photovoltaic module back panel, and in practical application, CN211555907U further proposes to use transparent glass or a flexible composite material layer as a front encapsulation layer to achieve an encapsulation effect on the photovoltaic module.

Since the package weight of the transparent glass is heavy and fragile, the flexible composite material layer is preferable as the front side package layer. With the deep popularization and application of the applicant, it is found that when a flexible composite material layer is used as a front side packaging layer and a single-layer structure or a multi-layer laminated structure based on a continuous fiber reinforced thermoplastic polymer unidirectional tape is used as a photovoltaic module back plate, the overall performance of the photovoltaic module on light transmittance and water vapor permeability resistance is still to be improved.

For this reason, the applicant decides to seek an innovative scheme to further optimize and improve the technology based on CN211555907U as a technical foundation.

Disclosure of Invention

In view of this, the utility model aims at providing a photovoltaic module demonstrates excellent light transmissivity, flexibility, water vapour resistance permeability and good mechanical installation performance simultaneously, and popularization and application prospect is high.

The utility model adopts the technical scheme as follows:

a photovoltaic module comprises a front packaging unit, a photovoltaic cell unit and a back packaging unit which are packaged into a whole through a laminating process, wherein the front packaging unit at least comprises a thermoplastic light-transmitting packaging film layer, the back packaging unit at least comprises a thermoplastic fiber reinforced substrate, and the thermoplastic fiber reinforced substrate adopts a continuous fiber reinforced thermoplastic polymer unidirectional belt single-layer structure or a multilayer laminated structure; the thermoplastic light-transmitting packaging film layer is made of a light-transmitting thermoplastic high polymer material.

Preferably, the light-transmitting thermoplastic polymer material is any one of PET, TPO and PC.

Preferably, the thermoplastic light-transmitting packaging film layer is formed by an injection molding process or an extrusion process or a blow molding process.

Preferably, the thermoplastic polymer is any one of PP, PET, PA, PC and PE.

Preferably, the continuous fiber is any one of continuous glass fiber, natural fiber, basalt fiber, carbon fiber and aramid fiber.

Preferably, the thickness of the thermoplastic light-transmitting encapsulation film layer ranges from 0.05 mm to 6mm.

Preferably, the thickness of the thermoplastic fiber reinforced substrate is in the range of 0.05 to 5mm.

Preferably, at least a front side packaging adhesive film layer is arranged between the thermoplastic light-transmitting packaging film layer and the photovoltaic cell unit, and/or at least a back side packaging adhesive film layer is arranged between the thermoplastic fiber reinforced substrate and the photovoltaic cell unit.

Preferably, the outer surface of the thermoplastic light-transmitting packaging film layer is provided with a front weather-proof protective layer, and/or the outer surface of the thermoplastic fiber reinforced substrate is provided with a back weather-proof protective layer.

Preferably, the photovoltaic cell unit comprises a crystalline silicon cell and/or an amorphous silicon cell and/or a thin film cell.

Further preferably, in order to improve the service life and ensure the water vapor permeability resistance, the thermoplastic fiber reinforced substrate related to the present application may adopt the technical solution of the patent application previously proposed by the present applicant (CN 2022104233132):

the continuous fiber reinforced thermoplastic polymer unidirectional belt in the thermoplastic fiber reinforced substrate is obtained by compounding a thermoplastic polymer and continuous fibers subjected to surface treatment by a coupling agent through melting and impregnation; wherein the thermoplastic polymer comprises PP and polar grafts of PP, and intermolecular force is generated between the coupling agent and the polar grafts of PP in the process of melt impregnation compounding.

Preferably, the monomer of the polar graft is selected from one or a mixture of any more of acrylic acid, acrylate, acrylonitrile or maleic anhydride; the coupling agent includes a silane coupling agent and/or a non-silane coupling agent.

Preferably, the silane coupling agent is selected from one or a mixture of any of aminosilane coupling agent, epoxy silane coupling agent, acryloxy silane coupling agent, alkyl silane coupling agent and vinyl silane coupling agent.

Preferably, before the melt impregnation compounding, the continuous fiber is melted to form a melt drawn wire, and the surface of the melt drawn wire is subjected to infiltration modification treatment by using an impregnating compound, wherein the impregnating compound comprises not less than 0.1wt% of a coupling agent, so that the continuous fiber subjected to the surface treatment by the coupling agent is obtained.

Preferably, the impregnating compound accounts for 0.5-5wt% of the continuous fiber; the impregnating compound also comprises a film forming agent and/or a lubricant and/or an antistatic agent.

Preferably, the PP represents not less than 85% by weight of the thermoplastic polymer and the polar grafts of PP represent in the range 0.2-15% by weight of the PP.

Preferably, the weight part ratio of the thermoplastic polymer to the continuous fibers is 20 to 80wt%:80-20wt%.

Preferably, the thermoplastic polymer further comprises an antioxidant and/or a light stabilizer; the antioxidant comprises a main antioxidant and an auxiliary antioxidant which are matched in a synergistic manner, wherein the main antioxidant comprises hindered phenols and/or secondary arylamines, and the auxiliary antioxidant comprises phosphites and/or sulfites; the light stabilizer comprises a light shielding agent and/or an ultraviolet absorber and/or a quenching agent and/or a free radical trapping agent.

Preferably, a method for preparing a thermoplastic fiber reinforced substrate as described above comprises the following operating steps:

s10), respectively preparing a thermoplastic polymer and continuous fibers subjected to surface treatment by a coupling agent;

s20), forming a resin melt by melt extrusion of a thermoplastic polymer, then injecting the resin melt into an impregnation mould, and impregnating and compounding the resin melt with continuous fibers spread by traction;

s30), cooling to obtain a unidirectional prepreg tape, namely a continuous fiber reinforced thermoplastic polymer unidirectional tape;

s40) carrying out multilayer lamination compounding on the unidirectional prepreg tape to obtain the thermoplastic fiber reinforced substrate.

It should be noted that the PET referred to throughout this application includes PET materials and modified PET materials modified based on PET materials, where PET refers to the abbreviation of "Polyethylene terephthalate" and means: polyethylene terephthalate, which is usually prepared by the exchange of dimethyl terephthalate and ethylene glycol or the esterification of terephthalic acid and ethylene glycol to synthesize dihydroxy ethyl terephthalate, and then carrying out polycondensation reaction; TPO as referred to throughout this application refers to thermoplastic polyolefin-based materials; PP referred to throughout this application is an abbreviation for Polypropylene, meaning: polypropylene; PA is an abbreviation for Polyamide, referred to throughout the application, meaning: a polyamide; PC referred to throughout the application is an abbreviation for Polycarbonate, meaning: a polycarbonate; PE referred to throughout this application is an abbreviation for Polyethylene, meaning: polyethylene.

The PET, TPO, PP, PA, PC and PE mentioned in the present application are commercially available directly, and various known additives such as antioxidants, light stabilizers and softeners are generally added to these thermoplastic polymers, which are well known to those skilled in the art, and will not be further described herein.

The water vapor transmission rate data related to the application is obtained by testing according to the GB/T31034-2014 standard; the light transmittance data is obtained by testing according to ISO9050-2003 standard; the bending resistance data is obtained according to internal enterprise standard tests formulated by the applicant.

After the applicant is deeply developed and applied, the applicant surprisingly discovers that when the front side packaging unit comprising the thermoplastic light-transmitting packaging film layer and the thermoplastic fiber reinforced substrate comprising the continuous fiber reinforced thermoplastic polymer unidirectional tape single-layer structure or the multilayer laminated structure are used as the back side packaging unit, excellent light transmittance, flexibility, water vapor permeability resistance and good mechanical installation performance can be simultaneously shown, and the thermoplastic light-transmitting packaging film layer, the continuous fiber reinforced thermoplastic polymer unidirectional tape single-layer structure or the multilayer laminated structure are all known materials which can be massively produced, the recyclable effect is realized, and the popularization and application prospect is high.

Drawings

Fig. 1 is a schematic view of a layer structure of a photovoltaic module in embodiment 1 of the present invention;

fig. 2 is a schematic structural diagram of a photovoltaic module layer in embodiment 2 of the present invention;

fig. 3 is a schematic view of a layer structure of a photovoltaic module in embodiment 3 of the present invention;

fig. 4 is a schematic view of a photovoltaic module layer structure in embodiment 4 of the present invention.

Detailed Description

The embodiment of the utility model discloses a photovoltaic module, including positive encapsulation unit, photovoltaic cell unit, the back encapsulation unit that lamination process encapsulation is as an organic whole, positive encapsulation unit includes thermoplasticity printing opacity encapsulation rete at least, and back encapsulation unit includes thermoplastic fiber reinforcing base plate at least, and thermoplastic fiber reinforcing base plate adopts continuous fiber reinforcing thermoplasticity polymer unilateralism area single layer structure or multilayer laminated structure; wherein, the thermoplastic light-transmitting packaging film layer is made of a light-transmitting thermoplastic high polymer material.

Preferably, in order to ensure light transmission and waterproof vapor transmission, in the present embodiment, the light-transmitting thermoplastic polymer material accounts for not less than 85wt%, more preferably not less than 90wt%, further preferably 92 to 99wt%, and still further preferably 94 to 98wt% of the thermoplastic light-transmitting encapsulation film layer; in the specific implementation, an antioxidant and/or a light stabilizer and/or a softener and/or other known additives (which may also include fibers) and the like can be added into the light-transmitting thermoplastic polymer material according to the actual needs;

preferably, in the present embodiment, the thermoplastic light-transmitting encapsulating film layer is formed by an injection molding process, an extrusion process or a blow molding process, but may be formed by other known processes; preferably, in order to facilitate the packaging effect on the photovoltaic battery cell, in the present embodiment, the thickness of the thermoplastic light-transmitting packaging film layer ranges from 0.05 mm to 6mm, more preferably from 0.1 mm to 2mm, and still more preferably from 0.2 mm to 1mm;

preferably, in the present embodiment, the light-transmitting thermoplastic polymer material includes PET and/or TPO and/or PC, wherein the light-transmitting thermoplastic sheet made of PET or TPO and/or PC can be directly purchased from the market, wherein the light-transmitting thermoplastic sheet made of PET generally includes not less than 93wt% by weight of PET material, and some well-known additives are usually added; light-transmitting thermoplastic sheets made of TPO generally comprise not less than 93% by weight of TPO material, usually with the addition of known auxiliaries; the light-transmitting thermoplastic plate made of PC usually comprises not less than 93wt% by weight of PC material, and usually some known additives are added; of course, a mixture of any two or three of PET, TPO, and PC (if necessary, a known additive may be added) may be used as the light-transmitting thermoplastic polymer material.

Preferably, in the present embodiment, the continuous fiber reinforced thermoplastic polymer unidirectional tape is obtained by compounding the thermoplastic polymer and the continuous fiber surface-treated with the coupling agent by melt impregnation; the thermoplastic polymer comprises PP and polar grafts of PP, and intermolecular force is generated between the coupling agent and the polar grafts of PP in the process of melt impregnation compounding.

Preferably, in this embodiment, the weight ratio of thermoplastic polymer to continuous fibers is 20 to 80wt%:80-20wt%; more preferably from 25 to 60wt%:75 to 40wt%, more preferably 28 to 50wt%:50-72wt%; preferably, in this embodiment, the thermoplastic polymer comprises PP and/or PET and/or PA and/or PC and/or PE.

Further preferably, in this embodiment, the thermoplastic polymer comprises PP, wherein PP comprises not less than 85wt%, more preferably 90 to 99wt%, of the thermoplastic polymer by weight; and the proportion of the polar graft of PP in parts by weight of PP is in the range of 0.2 to 15wt%, more preferably 0.5 to 10wt%, and still more preferably 1 to 5wt%; further preferably, in the present embodiment, the PP may be of isotactic or syndiotactic stereoconfiguration, a homopolymeric resin may be selected; as a less preferred embodiment, a copolymer resin of propylene monomer and ethylene monomer can be selected, the copolymerization structure of the copolymer resin adopts a block-type and/or crystallizable copolymerization system, and a physical blend resin of polyethylene and polypropylene can be selected, wherein when the physical blend resin of polyethylene and polypropylene is adopted, the weight part of polypropylene polymer in PP is not less than 70wt%, otherwise the encapsulation performance of PP is obviously influenced.

In order to facilitate the good impregnation of the PP with the continuous fiber during the melt impregnation compounding process, preferably, in the present embodiment, it is recommended to use a PP with a higher fluidity, and particularly preferably, a PP with a melt index of MFI =30-120g/10min at 230 ℃ and under a load of 2.16Kg, where the melt index is measured at 230 ℃ and under a load of 2.16Kg according to ASTM D1238-2010 in the present embodiment.

Preferably, in the present embodiment, the continuous fibers may include glass fibers and/or natural fibers (e.g., hemp fibers, bamboo fibers, etc.) and/or basalt fibers and/or carbon fibers and/or aramid fibers, and more preferably, the continuous fibers are glass fibers; the glass fiber is a more preferable selection, and further preferably, the glass fiber is alkali-free E glass fiber, the strength of the glass fiber is obviously higher than that of other types of alkali glass fiber or low-alkali glass fiber, and the glass fiber has the performance of higher resistivity; preferably, in this embodiment, the diameter of the continuous fibers is 3 to 30 micrometers, more preferably 8 to 30 micrometers, and still more preferably 15 to 25 micrometers.

Preferably, in the embodiment, the monomer of the polar graft is selected from one or a mixture of any of acrylic acid, acrylate, acrylonitrile and maleic anhydride, and the polar graft of PP can be directly obtained from external sources; the coupling agent comprises a silane coupling agent and/or a non-silane coupling agent, wherein the silane coupling agent is a more preferable choice; further preferably, in the present embodiment, the silane coupling agent is selected from one or a mixture of any more of an aminosilane coupling agent (represented by the model number KH 550), an epoxy silane coupling agent (represented by the model number KH 560), an acryloxy silane coupling agent (represented by the model number KH 570), an alkyl silane coupling agent, and a vinyl silane coupling agent, and the aminosilane coupling agent is taken as a more preferred example; the non-silane coupling agent may be selected from other known coupling agents, and this example is not intended to limit the present invention.

Preferably, in this embodiment, before performing melt impregnation compounding, the continuous fibers are melted to form melt-drawn fibers, and an impregnating agent is used to perform an infiltration modification treatment on the surface of the melt-drawn fibers, and particularly, in the specific implementation, the continuous fibers are melted and melted to form melt-drawn fibers by a crucible method or a tank furnace method, and then are bundled into precursor fibers by an infiltration tank containing the impregnating agent, so that the continuous fibers subjected to the surface treatment by the coupling agent are obtained; further preferably, in the present embodiment, the proportion of the size in parts by weight of the continuous fiber is in the range of 0.5 to 5wt%, more preferably 0.8 to 2wt%; wherein, the wetting agent preferably comprises not less than 0.1wt% of the coupling agent, more preferably 0.5-10wt%, and further preferably 1-5wt%; further preferably, in the embodiment, the solid content of the impregnating agent ranges from 6 to 30wt%; in order to achieve the effect of protecting or modifying the continuous fibers, preferably, in the present embodiment, the size may further include a film forming agent and/or a lubricant and/or an antistatic agent, and the film forming agent, the lubricant and the antistatic agent may be selected according to common knowledge, which is not limited in particular innovation in this embodiment.

Preferably, in the present embodiment, the light-transmitting thermoplastic polymer material and the thermoplastic polymer may further include an antioxidant and/or a light stabilizer; wherein the weight proportion range of the antioxidant is 0.1-5wt%, and more preferably 0.5-2wt%; the proportion by weight of light stabilizer ranges from 0.01 to 2%, more preferably from 0.1 to 0.8% by weight;

preferably, in this embodiment, other known processing aids may be further added to the light-transmitting thermoplastic polymer material and the thermoplastic polymer, respectively, and the weight ratio of the processing aids may be selected from 0.1 to 5wt%; the processing aid can be specifically: plasticizers and/or nucleating agents and/or lubricants and/or mold release agents, which are conventional technical choices that may be made in the practice of the present application, are not the only limitations of the present application.

The embodiment of the utility model also discloses a preparation method of as above thermoplastic fiber reinforced substrate, including following operating procedure:

s10), respectively preparing a thermoplastic polymer and continuous fibers subjected to surface treatment by a coupling agent; when preparing the thermoplastic polymer, weighing the raw material components according to a predetermined weight part ratio, and blending by using a mixing device;

s20), forming a resin melt by melt extrusion of a thermoplastic polymer, then injecting the resin melt into an impregnation die, and impregnating and compounding the resin melt and continuous fibers spread by traction;

s40), carrying out multilayer lamination compounding on the unidirectional prepreg tape to obtain a thermoplastic fiber reinforced substrate; preferably, in the specific implementation, the unidirectional prepreg tapes of adjacent layers can be compounded by adopting a lamination angle of 0 °/90 °/0 ° or 0 °/45 °/90 °/45 °/0 ° or other modes, so as to ensure that the thermoplastic fiber reinforced substrate has excellent mechanical bearing performance in all directions; in the case of multi-layer lamination, the lamination at a specific lamination angle can also be performed in steps: for example, the lamination angle compounding of the unidirectional prepreg tape at 0 °/90 ° is completed first, and then the lamination angle compounding is performed with the unidirectional prepreg tape at 0 °, or the required number of laminated layers of the unidirectional prepreg tape may be selected according to the actual application requirements, which are all the implementation ranges that can be changed according to the actual requirements of the application, and the embodiment is not limited to the only one.

Preferably, in this embodiment, the grammage of the single-layer unidirectional prepreg tape is 200-600g/m ² (ii) a The device for realizing the multi-layer lamination can be a belt laminating machine or a steel belt laminating machine, and the laminating temperature can be selected to be 180-280 ℃.

Preferably, in this embodiment, the thermoplastic fiber reinforced substrate has a thickness in the range of 0.05 to 5mm, preferably 0.1 to 4mm, and more preferably 0.3 to 3mm.

Preferably, in the embodiment, the photovoltaic module is packaged into a whole through a lamination process, and particularly, the lamination process can be implemented by using a known lamination composite device, the lamination temperature in the lamination process can be set to 130-160 ℃, the lamination time can be set to 1-5 minutes, and of course, other lamination processes can also be used to implement the present application, which is not particularly limited in the present application;

preferably, in order to further facilitate flexible protection of the photovoltaic cell unit, in this embodiment, at least a front side packaging adhesive film layer is arranged between the thermoplastic light-transmitting packaging film layer and the photovoltaic cell unit, and/or at least a back side packaging adhesive film layer is arranged between the thermoplastic fiber reinforced substrate and the photovoltaic cell unit, and/or a front side weather-resistant protective layer is arranged on the outer surface of the thermoplastic light-transmitting packaging film layer, and/or a back side weather-resistant protective layer is arranged on the outer surface of the thermoplastic fiber reinforced substrate; further preferably, the front side encapsulation adhesive film layer and the back side encapsulation adhesive film layer may be made of any known adhesive film material, for example, EVA adhesive film, POE adhesive film, or the like may be specifically used; any known weather-resistant layer may be used for the front weather-resistant protective layer and the rear weather-resistant protective layer, and for example, a fluorine film, a fluorine-containing paint cured coating, or the like may be used.

It should be noted that, when implementing the present application, a person skilled in the art may further provide other well-known functional layer structures in the photovoltaic module according to actual needs, which are not specifically limited to the present application.

Preferably, in the present embodiment, the photovoltaic cell unit may include a crystalline silicon cell, may also be an amorphous silicon cell, and may also be any type of thin film cell, which is not particularly limited in the present application; among them, the present application suggests a crystalline silicon cell as a more preferable embodiment.

In order to make the technical solutions in the present invention better understood, the technical solutions in the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings in the embodiments of the present invention, and it is obvious that the described embodiments are only some embodiments of the present invention, but not all embodiments. Based on the embodiments of the present invention, all other embodiments obtained by a person skilled in the art without creative efforts shall fall within the protection scope of the present invention.

Example 1: on the basis of the above implementation content, the present application specifically proposes embodiment 1, please refer to fig. 1, where embodiment 1 proposes a photovoltaic module 1, which includes a thermoplastic transparent encapsulating film layer 10 encapsulated as a whole by a lamination process, a photovoltaic cell unit 20 made of crystalline silicon cell (other embodiments may also use amorphous silicon or amorphous silicon), a backside EVA encapsulating film layer 30, and a thermoplastic fiber reinforced substrate 40; the thermoplastic light-transmitting packaging film layer 10 is a PET layer with a thickness of 2.5mm, and the thermoplastic fiber-reinforced substrate 40 is specifically a glass fiber-reinforced PP unidirectional tape multilayer laminated structure (prepared by referring to the embodiment of CN 211555907U), and has a thickness of 0.9mm.

Example 2: the technical solution of this embodiment 2 is the same as that of embodiment 1, except that, referring to fig. 2, in this embodiment 2, a front EVA encapsulant film layer 50 is disposed between the thermoplastic light-transmitting encapsulant film layer 10 and the photovoltaic cell unit 20.

Example 3: the technical solution of this embodiment 3 is the same as that of embodiment 2, with reference to fig. 3, in this embodiment 3, a fluorine film 60 serving as a front weather-resistant protective layer is disposed on an outer surface of a thermoplastic light-transmitting encapsulation film layer 10, and in order to facilitate a composite molding effect during actual manufacturing, an adhesive film layer 80 (specifically, an EVA material) is further disposed, and the fluorine film 60 and the adhesive film layer 80 are integrally combined with the photovoltaic module 1 through a lamination process; in another embodiment, a cured coating of a fluorine-containing paint may be provided on the outer surface of the thermoplastic light-transmitting envelope film layer 10, as described in example 4 below.

Example 4: the technical solution of this embodiment 4 is different from that of embodiment 3 in that, referring to fig. 4, in this embodiment 4, a fluorine-containing coating 70 serving as a rear weather-resistant protective layer is disposed on an outer surface of the thermoplastic fiber reinforced substrate 40; considering that the thermoplastic fiber reinforced substrate 40 has structural rigidity and the dyne value of the substrate surface is low, when actually manufacturing the fluorine-containing

coating

70, 1 surface of the thermoplastic fiber reinforced substrate 40 is subjected to corona treatment (other known surface pretreatment methods can also be adopted), so that the dyne value of the thermoplastic fiber reinforced substrate 40 on the surface is more than 48dyn/cm; then, a screen printing process (in other embodiments, a gravure printing process, a spraying process, a curtain coating process, or other coating processes with similar effects may also be used) is used to uniformly coat the liquid fluorine-containing paint on the surface of the thermoplastic fiber reinforced substrate 40 subjected to the corona treatment, and after a curing process for 48 hours, the fluorine-containing paint is cured to form the fluorine-containing coating 70.

Example 5: the technical solution of this example 5 is the same as that of example 1, except that in this example 5, a TPO layer with a thickness of 1.5mm is used as the thermoplastic light-transmitting encapsulating film layer.

Example 6: the technical solution of this embodiment 6 is the same as that of embodiment 1, except that in this embodiment 6, a PC layer with a thickness of 1.5mm is used as the thermoplastic light-transmitting encapsulating film layer.

Example 7: the technical solution of this example 7 is different from that of example 1 in that in this example 7, a glass fiber reinforced PET unidirectional tape multilayer laminated structure is specifically adopted for the thermoplastic fiber reinforced substrate.

Example 8: the technical solution of this embodiment 8 is different from that of embodiment 1 in that in this embodiment 8, a carbon fiber reinforced PC unidirectional tape multilayer laminated structure is specifically adopted for the thermoplastic fiber reinforced substrate.

Example 9: the technical solution of this embodiment 9 is different from that of embodiment 1 in that in this embodiment 9, a glass fiber reinforced PE unidirectional tape multilayer lamination structure is specifically adopted for the thermoplastic fiber reinforced substrate.

Example 10: the technical solution of this example 10 is different from that of example 1 in that, in this example 10, the thickness of the PET layer is 0.7mm.

Example 11: the technical means of this example 11 is different from that of example 5 in that the thickness of the TPO layer in this example 11 is 0.6mm.

Example 12: the technical solution of this example 12 is the same as that of example 6, except that in this example 12, the thickness of the PC layer is 1.5mm.

Example 13: the technical solution of this example 13 is the same as that of example 1, except that in this example 13, the thickness of the thermoplastic fiber reinforced substrate is 1.5mm.

Example 14: the technical solution of this example 14 is the same as that of example 1, except that in this example 14, the thickness of the thermoplastic fiber reinforced substrate is 3mm.

Example 15: the technical solution of this example 15 is the same as that of example 1, except that in this example 15, the thickness of the thermoplastic fiber reinforced substrate is 4.5mm.

Example 16: the technical solution of this example 16 is the same as that of example 1, except that in this example 16, the thermoplastic fiber reinforced substrate is prepared by the following raw materials in parts by weight:

100 parts of polypropylene resin (from BX 3920/Korea SK, melt index MFI =100g/10 min);

240 parts of continuous alkali-free E glass fiber (from 362C/boulder group, 2400tex, the fiber diameter of 17 mu m), wherein the 240 parts of continuous E glass fiber is subjected to soaking modification treatment by a crucible method, wherein the solid content of the soaking agent is 10%, and the soaking agent specifically comprises 1wt% of KH550 coupling agent;

2 parts of PP-g-MAH (as polar graft of polypropylene, light from GPM 200B/Nile energy, MFI =50g/10min, functional group content 0.7%);

1010 parts of main antioxidant (from Henan Ruilong chemical);

168 parts of auxiliary antioxidant (from Henan Ruilong chemical engineering);

0.5 part of light stabilizer UV-531 (from Henan Ruilong chemical engineering);

0.5 part of light stabilizer UV-770 (Henan Rui chemical).

Adding the polypropylene resin, the maleic anhydride grafted polypropylene PP-g-MAH, the main antioxidant 1010, the auxiliary antioxidant 168, the light stabilizer UV-531 and the light stabilizer UV-770 into the mixtureUniformly mixing in a stirrer, melt-extruding by a double-screw extruder to form a resin melt, injecting the resin melt into an impregnation die, fully melting, impregnating and compounding with continuous alkali-free E glass fiber spread by traction, and cooling to obtain the glass fiber with the gram weight of about 250g/m ² The unidirectional prepreg tape of (a);

and compounding 5 unidirectional prepreg tapes by a steel tape compounding machine according to a lamination angle of 0 degree/90 degrees/0 degrees, cooling and rolling to obtain the thermoplastic fiber reinforced substrate with the thickness of 0.75mm.

Example 17: the technical solution of this example 17 is the same as that of example 16, except that in this example 17, the weight part of the continuous alkali-free E glass fiber is reduced to 200 parts.

Example 18: the technical solution of this example 18 is the same as that of example 16, except that in this example 18, the weight part of the continuous alkali-free E glass fiber is reduced to 100 parts.

Example 19: the technical solution of this example 19 is the same as that of example 16, except that in this example 19, the continuous alkali-free E glass fibers were replaced with basalt fibers, and the fiber diameter was 20 μm.

Example 20: the remaining technical solution of this example 20 is the same as that of example 16, except that in this example 20, the impregnating compound specifically includes 1.5wt% of KH560 coupling agent.

Example 21: the other technical solutions of this example 21 are the same as those of example 16, except that in this example 21, the impregnating compound specifically includes 5wt% of the KH550 coupling agent.

Example 22: the remaining technical solution of this example 22 is the same as that of example 16, except that in this example 22, the impregnating compound specifically includes 0.5wt% of KH550 coupling agent.

Example 23: the remaining technical solution of this example 23 is the same as that of example 16, except that in this example 23, the weight part of the maleic anhydride-grafted polypropylene was increased to 5 parts.

Example 24: the remaining technical solution of this example 24 is the same as that of example 16, except that in this example 24, the weight part of the maleic anhydride-grafted polypropylene is increased to 8 parts.

Example 25: the remaining technical solution of this example 25 is the same as that of example 16, except that in this example 25, the weight part of the maleic anhydride-grafted polypropylene is reduced to 1 part.

Example 26: the remaining technical solution of this example 26 is the same as that of example 16, except that in this example 26, the weight part of the maleic anhydride-grafted polypropylene is reduced to 0.2 part.

Example 27: the remaining technical solution of this example 27 is the same as that of example 16, except that in this example 27, 1 surface of the thermoplastic fiber reinforced substrate obtained in example 15 is subjected to corona treatment, so that the dyne value of the substrate is greater than 48dyn/cm on the surface; and then uniformly coating the liquid fluorine-containing paint on the thermoplastic fiber reinforced surface subjected to corona treatment by adopting a screen printing process, and curing the fluorine-containing paint by a curing process for 48 hours to finally obtain the thermoplastic fiber reinforced substrate provided with the back weather-proof protective layer.

Example 28: the remaining technical solutions of this embodiment 28 are the same as those of embodiment 2, and the difference is that in this embodiment 1, a front surface fluorine film layer serving as a front surface weather-resistant protection layer is disposed on an outer surface of the thermoplastic light-transmitting encapsulation film layer, and a back surface fluorine film layer serving as a back surface weather-resistant protection layer is disposed on an outer surface of the thermoplastic fiber-reinforced substrate, where an adhesive film layer is disposed between the front surface fluorine film layer and the thermoplastic light-transmitting encapsulation film layer, and an adhesive film layer is disposed between the thermoplastic fiber-reinforced substrate and the back surface fluorine film layer, and the thermoplastic fiber-reinforced substrate and the back surface fluorine film layer are directly integrated through a lamination process.

Comparative example 1: the other technical scheme of the comparative example 1 is the same as that of the example 1, except that in the comparative example 1, the acrylic thermosetting powder coating composite fiber cloth with the thickness of 0.6mm is adopted to replace the thermoplastic light-transmitting packaging film layer.

Comparative example 2: the remaining technical solutions of comparative example 2 are the same as those of example 1, except that in comparative example 2, a conventional tempered glass is used instead of the thermoplastic light-transmitting encapsulating film layer.

Comparative example 3: the remaining technical solution of comparative example 3 is the same as that of example 1, except that in comparative example 3, a glass fiber reinforced PP unidirectional tape multilayer laminated structure with a thickness of 2.5mm is used instead of the thermoplastic light-transmitting encapsulation film layer.

Comparative example 4: the other technical solutions of the comparative example 4 are the same as those of the example 1, except that in the comparative example 4, an EVA adhesive film layer with a thickness of 2.5mm is used instead of the thermoplastic light-transmitting encapsulation film layer.

Comparative example 5: the remaining technical solution of comparative example 5 is the same as example 1 except that in comparative example 5, a PET layer having a thickness of 2.5mm is used instead of the thermoplastic fiber-reinforced substrate.

Comparative example 6: the remaining technical solution of comparative example 6 is the same as example 1 except that in comparative example 6, a PP sheet having a thickness of 1.5mm is used instead of the thermoplastic fiber-reinforced substrate.

Comparative example 7: the remaining technical solution of comparative example 7 is the same as example 1 except that in comparative example 7, a PC board having a thickness of 1.5mm is used instead of the thermoplastic fiber-reinforced substrate.

Comparative example 8: the other technical solutions of the comparative example 8 are the same as those of the example 1, except that in the comparative example 8, the thermoplastic fiber reinforced substrate is replaced by the commercially available KPK double-sided fluorocarbon PET base material back sheet (thickness of 0.3 mm).

Comparative example 9: the other technical solutions of the comparative example 9 are the same as those in the example 1, except that in the comparative example 9, chopped glass fiber reinforced PP (which is directly purchased in the market and is usually obtained by blending and extruding chopped glass fibers and PP) with the thickness of 1.2mm is used to replace a thermoplastic fiber reinforced substrate.

Comparative example 10: the other technical solutions of the comparative example 10 are the same as those of the example 1, except that in the comparative example 10, chopped glass fiber reinforced PC (obtained by direct purchase in the market, and generally obtained by blending and extruding chopped glass fiber and PC) with a thickness of 1.2mm is used to replace a thermoplastic fiber reinforced substrate.

Comparative example 11: the remaining technical solution of comparative example 11 is the same as example 1 except that the thermoplastic fiber-reinforced substrate is replaced with an acrylic thermosetting powder coating composite fiber cloth having a thickness of 0.6mm.

In order to verify the technical effect of the present application, the present application performs the relevant performance detection on the photovoltaic modules provided in the foregoing embodiments 1 to 28, respectively, and the overall detection results of the embodiments 1 to 28 are as follows:

the packaging weight is less than or equal to 2.5Kg/m ² ；

The light transmittance (aiming at a front encapsulation layer of the photovoltaic module) in the wavelength range of 380-1100nm is more than or equal to 90 percent;

water vapor transmission (for the back side encapsulation layer of the photovoltaic module): less than or equal to 0.25g/m ² ·24h；

The bending resistance frequency is more than or equal to 10 ten thousand (the bending resistance means that after the photovoltaic module is bent for 10 ten thousand by adopting bending resistance equipment, the photovoltaic module is not obviously hidden and cracked);

and the main material of the packaging layer structure of the photovoltaic module adopts thermoplastic material, so that the photovoltaic module can be recycled.

In order to further verify the technical effect of the present application, the present application further performs the correlation performance detection on the whole photovoltaic modules provided in the above embodiments 1 to 28 according to GB/T31034 to 2014, respectively, and the correlation detection results are as follows:

the heat shrinkage rate is 0%;

after DH1500 hours, the color difference delta b is less than or equal to 5; wherein DH is Damp Heat resistance test;

UV250kWh/m ² then, the photovoltaic module has no layering and pulverization problems, and delta b is less than or equal to 5;

it should be noted that the weather-resistant and aging-resistant performance of example 27 is the most excellent, the weather-resistant and aging-resistant performance of examples 16 to 25 is also significantly better than that of examples 1 to 15 and example 26, and the photovoltaic module examples provided with the weather-resistant protective layer of examples 1 to 15 and example 28 also have relatively more excellent weather-resistant and aging-resistant performance.

Referring also to the test standards of the above examples, the corresponding tests of comparative examples 1 to 11 of the present application are shown in the following table 1:

TABLE 1 comparison of test results data for comparative examples 1-11

It should be noted that, the above comparative examples 1 and 11 of the present application have the problems of non-recyclability and high material cost, which are not suitable for large-scale popularization and application.

It is obvious to a person skilled in the art that the invention is not restricted to details of the above-described exemplary embodiments, but that it can be implemented in other specific forms without departing from the spirit or essential characteristics of the invention. 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

1. A photovoltaic module comprises a front packaging unit, a photovoltaic cell unit and a back packaging unit which are packaged into a whole by a laminating process, and is characterized in that the front packaging unit at least comprises a thermoplastic light-transmitting packaging film layer, the back packaging unit at least comprises a thermoplastic fiber reinforced substrate, and the thermoplastic fiber reinforced substrate adopts a continuous fiber reinforced thermoplastic polymer unidirectional tape single-layer structure or a multilayer laminated structure; the thermoplastic light-transmitting packaging film layer is made of a light-transmitting thermoplastic high polymer material.

2. The photovoltaic module according to claim 1, wherein the light-transmitting thermoplastic polymer material is any one of PET, TPO and PC.

3. The photovoltaic module of claim 1, wherein the thermoplastic light transmissive encapsulant film layer is formed using an injection molding process or an extrusion process or a blow molding process.

4. The photovoltaic module of claim 1, wherein the thermoplastic polymer is any one of PP, PET, PA, PC, PE.

5. The photovoltaic module of claim 1, wherein the continuous fiber is any one of continuous glass fiber, natural fiber, basalt fiber, carbon fiber and aramid fiber.

6. The photovoltaic module of claim 1 wherein the thermoplastic light transmissive encapsulant film layer has a thickness in the range of 0.05-6mm.

7. The photovoltaic module of claim 1, wherein the thermoplastic fiber reinforced substrate has a thickness in the range of 0.05-5mm.

8. The photovoltaic module of claim 1, wherein at least a front encapsulant layer is disposed between the thermoplastic light transmissive encapsulant layer and the photovoltaic cell unit, and/or at least a back encapsulant layer is disposed between the thermoplastic fiber-reinforced substrate and the photovoltaic cell unit.

9. The photovoltaic module of claim 1, wherein the outer surface of the thermoplastic light transmissive encapsulant film layer is provided with a front weatherproof protective layer and/or the outer surface of the thermoplastic fiber reinforced substrate is provided with a back weatherproof protective layer.

10. The photovoltaic module according to claim 1, wherein the photovoltaic cell unit comprises a crystalline silicon cell sheet and/or an amorphous silicon cell sheet and/or a thin film cell sheet.