Curved surface photovoltaic module and preparation method thereof

Abstract

The embodiment of the invention relates to the technical field of photovoltaic, and provides a curved-surface photovoltaic module and a preparation method thereof. The preparation method of the curved surface photovoltaic module comprises the following steps: lamination treatment: front plate curved surface glass, a first bonding layer, a crystalline silicon cell layer, a second bonding layer, a flexible back plate and a jig are laminated in sequence to obtain a laminated layer, and the shape of the surface, facing the back plate, of the jig is consistent with the shape of the front plate curved surface glass; and step-by-step lamination treatment: carrying out shaping treatment on the lamination layer to enable the first bonding layer, the crystalline silicon cell layer, the second bonding layer and the back plate to follow the shape between the jig and the front plate curved glass, and then carrying out pressure treatment on the lamination layer to obtain the crystalline silicon cell. And the front plate curved glass, the first bonding layer, the crystalline silicon cell layer, the second bonding layer and the back plate are bonded and shaped. The preparation method of the curved-surface photovoltaic module is high in qualified rate and low in cost.

Description

Technical Field

[0001] This application relates to the technical field of photovoltaics. Specifically, it relates to a curved photovoltaic module and a preparation method thereof. Background Art

[0002] With the increasing shortage of global energy, the utilization of solar energy has received more and more attention. The popularization of building-integrated photovoltaics has made the application scenarios of photovoltaic products more diverse. Curved photovoltaic modules can better integrate with buildings, thus realizing more functions. Due to the excellent flexibility of thin-film batteries, most current curved photovoltaic modules are flexible thin-film batteries. However, thin-film batteries have low efficiency, high cost, and are difficult to be popularized on a large scale. While crystalline silicon batteries with higher efficiency, more mature industrial chains, and wider applications are difficult to be curvedly encapsulated due to their brittle characteristics. Therefore, current photovoltaic modules of crystalline silicon batteries are mostly in planar form. Summary of the Invention

[0003] The first aspect of this application provides a preparation method of a curved photovoltaic module. The preparation method of the curved photovoltaic module includes:

[0004] Lamination treatment: laminating a front plate curved glass, a first adhesive layer, a crystalline silicon cell layer, a second adhesive layer, a flexible back plate, and a jig in sequence to obtain a laminate, wherein the shape of the surface of the jig facing the back plate is the same as that of the front plate curved glass; and

[0005] Step-by-step lamination treatment: performing a shaping treatment on the laminate to make the first adhesive layer, the crystalline silicon cell layer, the second adhesive layer, and the back plate conform to the shape between the jig and the front plate curved glass, and then performing a pressing treatment on the laminate to bond and shape the front plate curved glass, the first adhesive layer, the crystalline silicon cell layer, the second adhesive layer, and the back plate.

[0006] In the preparation method of the curved photovoltaic module in the first aspect of this application, in the step of lamination treatment, the shape of the surface of the jig facing the back plate is the same as that of the front plate curved glass. During the step-by-step lamination treatment, first, the jig and the front plate curved glass are used to perform a shaping treatment on the first adhesive layer, the crystalline silicon cell layer, the second adhesive layer, and the back plate, so that each layer structure in the first adhesive layer, the crystalline silicon cell layer, the second adhesive layer, and the back plate deforms with the front plate curved glass. Then, a pressing treatment is performed. In this way, it is beneficial to reduce the probability of hidden cracks in the cells in the crystalline silicon cell layer, thereby improving the qualification rate of the curved photovoltaic module and reducing the production cost. In addition, compared with the curved photovoltaic module of thin-film batteries, the curved photovoltaic module of crystalline silicon batteries has high power generation efficiency, low cost, and greater potential for wide application.

[0007] The second aspect of the present application provides a curved photovoltaic module, which is obtained by using the preparation method of the curved photovoltaic module described in the first aspect of the present application.

[0008] The curved photovoltaic module of the second aspect of the present application has at least the same advantages as the preparation method of the curved photovoltaic module described in the first aspect of the present application, which will not be elaborated here. Description of the Drawings

[0009] Figure 1 It is a flowchart of the preparation method of the curved photovoltaic module according to an embodiment of the present application.

[0010] Figure 2 It is a schematic exploded view of the laminate obtained after the lamination process in the preparation method of the curved photovoltaic module according to an embodiment of the present application.

[0011] Figure 3 It is a schematic structural view of the vacuum pumping system used in the step-by-step lamination process in the preparation method of the curved photovoltaic module according to an embodiment of the present application.

[0012] Figure 4 It is a schematic exploded view of the laminate obtained after the step-by-step lamination process in the preparation method of the curved photovoltaic module according to an embodiment of the present application.

[0013] Description of the Main Component Symbols:

[0014] Laminates 100, 100a

[0015] Front panel curved glass 10

[0016] Recess 10r

[0017] Protrusion 10p

[0018] First adhesive layer 20, 20a

[0019] Crystalline silicon cell layer 30, 30a

[0020] Light-receiving surface 31

[0021] Backlight surface 32

[0022] Second adhesive layer 40, 40a

[0023] Backplane 50, 50a

[0024] Jig 60

[0025] Rigid layer 61

[0026] Elastic layer 62

[0027] Protrusion 60p

[0028] Recess 60r

[0029] Vacuum pumping system 200

[0030] Vacuum bag 210

[0031] Vacuum pump 220

[0032] Air extraction pipeline 230

[0033] Valve 240

[0034] Controller 250 Specific implementation manners

[0035] Next, the technical solutions in the embodiments of the present application will be clearly and completely described in conjunction with the accompanying drawings in the embodiments of the present application. Obviously, the described embodiments are only a part of the embodiments of the present application, rather than all the embodiments.

[0036] Please refer to Figure 1 , the preparation method of the curved surface photovoltaic module in an embodiment of the present application includes the following steps S10 and step S20. Understandably, according to different requirements, the order of some steps or sub-steps of the preparation method of the curved surface photovoltaic module can be changed, and some steps or sub-steps can be omitted or combined.

[0037] Step S10: Laminating process: Stack the front plate curved glass, the first adhesive layer, the crystalline silicon cell layer, the second adhesive layer, the flexible backplane, and the fixture in sequence to obtain a stack, wherein the orientation of the fixture and the shape of the surface of the backplane are the same as the shape of the front plate curved glass.

[0038] Step S20: Step-by-step lamination process: Perform a shaping process on the stack so that the first adhesive layer, the crystalline silicon cell layer, the second adhesive layer, and the backplane conform to the shape between the fixture and the front plate curved glass, and then perform a pressing process on the stack so that the front plate curved glass, the first adhesive layer, the crystalline silicon cell layer, the second adhesive layer, and the backplane are bonded and shaped.

[0039] In the preparation method of the curved surface photovoltaic module in the embodiment of the present application, in the step of the laminating process, the orientation of the fixture and the surface of the backplane are the same as the shape of the front plate curved glass. During the step-by-step lamination process, first, the fixture and the front plate curved glass are used to perform a shaping process on the first adhesive layer, the crystalline silicon cell layer, the second adhesive layer, and the backplane, so that each layer structure in the first adhesive layer, the crystalline silicon cell layer, the second adhesive layer, and the backplane deforms with the front plate curved glass, and then a pressing process is performed. In this way, it is beneficial to reduce the probability of hidden cracks in the cells in the crystalline silicon cell layer, thereby improving the qualified rate of the curved surface photovoltaic module and reducing the production cost. In addition, compared with the curved surface photovoltaic module of the thin film battery, the curved surface photovoltaic module of the crystalline silicon battery has high power generation efficiency and low cost, and has a greater possibility of wide application.

[0040] It should be noted that in the embodiments of the present application, "conformal" means that the shape of the assembly composed of the first adhesive layer, the crystalline silicon cell layer, the second adhesive layer, and the backplane changes with the shape of the jig and the front plate curved glass.

[0041] The following Figures 2 to 4 specifically describes the preparation method of the above-mentioned curved photovoltaic module.

[0042] Step S10: Lamination process: Stack the front plate curved glass, the first adhesive layer, the crystalline silicon cell layer, the second adhesive layer, the flexible backplane, and the jig in sequence to obtain a stack, where the shape of the surface of the jig facing the backplane is the same as the shape of the front plate curved glass.

[0043] As Figure 2 shown, the stack 100 includes the front plate curved glass 10, the first adhesive layer 20, the crystalline silicon cell layer 30, the second adhesive layer 40, the backplane 50, and the jig 60 stacked in sequence.

[0044] The crystalline silicon cell layer 30 includes an opposite light-receiving surface 31 and a backlight surface 32. The front plate curved glass 10 is located on one side of the light-receiving surface 31 to support and protect the light-receiving surface 31 side of the crystalline silicon cell layer 30. Specifically, the front plate curved glass 10 includes a plurality of convex portions 10p and a plurality of concave portions 10r, and each concave portion 10r connects two adjacent convex portions 10p. In this embodiment, both the convex portion 10p and the concave portion 10r are arc-shaped, and each convex portion 10p and a concave portion 10r are sequentially and alternately connected to form a wave shape.

[0045] The front plate curved glass 10 can be a light-transmitting tempered glass or a light-transmitting semi-tempered glass, but is not limited thereto. The thickness of the front plate curved glass 10 is, for example, 3 mm to 5 mm, but is not limited thereto.

[0046] The first adhesive layer 20 is planar. The first adhesive layer 20 is located between the front plate curved glass 10 and the crystalline silicon cell layer 30 to bond the front plate curved glass 10 and the crystalline silicon cell layer 30. The material of the first adhesive layer 20 can be one of ethylene-vinyl acetate copolymer (EVA) film, polyolefin elastomer (POE) film, polyvinyl butyral (PVB) film, silicone rubber, or EPE film, but is not limited thereto. The EPE film is a composite encapsulation film manufactured by a co-extrusion process of an EVA film, a POE film, and an EVA film.

[0047] The second adhesive layer 40 is planar. The second adhesive layer 40 is located between the crystalline silicon cell layer 30 and the backsheet 50 to bond the crystalline silicon cell layer 30 and the backsheet 50. The material of the second adhesive layer 40 can be one of the above-mentioned EVA film, POE film, EVA film, silicone rubber or EPE film. Hereinafter, the first adhesive layer 20 and the second adhesive layer 40 are also referred to as encapsulation materials.

[0048] The backsheet 50 is planar. The backsheet 50 is located on one side of the backlight surface 32 to support and protect the backlight surface 32 side of the crystalline silicon cell layer 30. The backsheet 50 is selected from materials with insulation, moisture-proof and flexibility. The material of the backsheet 50 can be polyethylene terephthalate (PET) or a PET composite material, but is not limited thereto.

[0049] The overall shape of the fixture 60 is consistent with the shape of the front panel curved glass 10. That is, the fixture 60 is a wavy shape formed by the sequential and alternating connection of the protrusions 60p and the depressions 60r. Each protrusion 60p corresponds to a convex portion 10p of the front panel curved glass 10, and each depression 60r corresponds to a concave portion 10r of the front panel curved glass 10. The curvature of each protrusion 60p is the same as or close to the curvature of the corresponding convex portion 10p, and the curvature of each depression 60r is the same as or close to the curvature of the corresponding concave portion 10r. Specifically, the fixture 60 includes a stacked rigid layer 61 and an elastic layer 62. The surface of the elastic layer 62 away from the rigid layer 61 is used to contact the backsheet 50. The elastic layer 62 is used to avoid rigid contact between the fixture 60 and the backsheet 50 of the laminate 100, so as to reduce the risks of cell crack, bubbles, etc. in the crystalline silicon cell layer 30. The material of the elastic layer 62 can be silicone rubber, but is not limited thereto. The elastic layer 62 can also be other elastic and high-temperature resistant materials. The material of the rigid layer 61 can be any one of glass, glass fiber or bakelite (also called phenolic plastic), but is not limited thereto. The rigid layer 61 can also be other non-metallic materials and has a certain weight, which can press the first adhesive layer 20, the crystalline silicon cell layer 30, the second adhesive layer 40 and the backsheet 50 down to contact the front panel curved glass 10.

[0050] In some embodiments, the method for preparing the above-mentioned curved photovoltaic module further includes the step of preparing the crystalline silicon cell layer before the lamination process. Specifically, preparing the crystalline silicon cell layer includes cutting the crystalline silicon cell into n parts (n is, for example, 2, 3, 4, 5 or 6, etc.) to obtain a plurality of cell wafers, and then welding the plurality of cell wafers into a cell array with interconnection bars to obtain the crystalline silicon cell layer 30. In this way, by cutting the crystalline silicon cell into multiple parts, the size of the cell wafers in the crystalline silicon cell layer 30 becomes smaller, which is beneficial to the conformability of the crystalline silicon cell layer 30. Moreover, according to the curvature size of the curved photovoltaic module to be prepared, the number of cuts and the size of the cell wafers can be specifically adjusted to improve the flexibility of the manufacturing process.

[0051] In some embodiments, the slit crystalline silicon cell is a photovoltaic cell with a single-crystalline silicon material as the substrate. For example, the crystalline silicon cell is any one of a Passivated Emitter Rear Cell (PERC), a Tunnel Oxide Passivated Contact (TOPcon) photovoltaic cell, a Heterojunction with Intrinsic Thin-film (HJT) photovoltaic cell, or various types of X BackContact (XBC) photovoltaic cells, etc.

[0052] In some other embodiments, the crystalline silicon cell can also be a tandem cell formed by a photovoltaic cell with a single-crystalline silicon material as the substrate and a thin-film cell. The thin-film cell is, for example, a perovskite thin-film cell, but is not limited thereto.

[0053] In still some other embodiments, the crystalline silicon cell can also be a photovoltaic cell with a polycrystalline silicon material as the substrate. However, since there are more grain boundaries in the crystal structure of polycrystalline silicon, this will hinder the flow of electrons. The efficiency of polycrystalline silicon cells is generally lower than that of single-crystalline silicon cells. Therefore, in terms of the efficiency of the cells, the crystalline silicon cell is a photovoltaic cell with a single-crystalline silicon material as the substrate or the above-mentioned tandem cell.

[0054] Step S20: Step-by-step lamination process: Perform a shaping process on the stack to make the first adhesive layer, the crystalline silicon cell layer, the second adhesive layer, and the backplane conformable between the jig and the front panel curved glass. Then, perform a pressing process on the stack to bond and shape the front panel curved glass, the first adhesive layer, the crystalline silicon cell layer, the second adhesive layer, and the backplane.

[0055] In some embodiments, in order to avoid the displacement of the cells in the crystalline silicon cell layer 30 during the shaping process, the cells in the crystalline silicon cell layer 30 need to be fixed to the first adhesive layer 20 and the second adhesive layer 40 by spot welding with a soldering iron or a hot air gun.

[0056] In addition, in the step-by-step lamination process in step S20, a relatively high requirement for vacuum pumping is needed to remove air during the lamination process, prevent the formation of bubbles, and ensure that the encapsulation materials (such as the first adhesive layer 20 and the second adhesive layer 40) can be evenly and completely bonded between the crystalline silicon cell layer 30 and other layers.

[0057] Specifically, a vacuum pumping system 200 is used to perform a step-by-step lamination process on the stack 100. As Figure 3As shown, the vacuum system 200 includes a vacuum bag 210 for accommodating the laminate 100, a vacuum pump 220 for evacuating the vacuum bag 210, an air extraction pipeline 230 connecting the vacuum bag 210 and the vacuum pump 220, a valve 240 located on the passage of the air extraction pipeline 230 and used to adjust the gas flow rate through the air extraction pipeline 230, and a controller 250 communicatively connected to the vacuum pump 220 and the valve 240. The controller 250 is used to control the rotation speed of the vacuum pump 220 and the opening degree of the valve 240.

[0058] In some embodiments, the controller 250 is a Programmable Logic Controller (PLC). It stores instructions for performing operations through a programmable memory, can receive signals from various sensors and input devices, and controls output devices according to a preset program to achieve automated management of complex industrial processes.

[0059] In some embodiments, the vacuum bag 210 is transparent to facilitate observing the state of the laminate 100 during the lamination process, but is not limited thereto.

[0060] In some embodiments, step S20 may include the following steps S21 to S23.

[0061] Step S21: Shape the laminate.

[0062] Specifically, place the laminate 100 into the vacuum bag 210 of the vacuum system 200, and control the rotation speed of the vacuum pump 220 and the opening degree of the valve 240 through the controller 250 to adjust the vacuum extraction rate and shaping time during the process of shaping the laminate 100.

[0063] As Figure 3 shown, the vacuum bag 210 contains a plurality of laminates 100 arranged in an array to perform step-by-step lamination processing on multiple laminates 100 at a time, improving the efficiency of the manufacturing process.

[0064] In some embodiments, during the shaping process of the laminate 100, the vacuum pumping rate is from 2 L / min to 5 L / min (such as from 2 L / min to 3 L / min, from 3 L / min to 4 L / min, from 4 L / min to 5 L / min, etc.). If the vacuum pumping rate is less than 2 L / min during the shaping process, it is likely to cause areas of insufficient filling or incomplete bonding between the film layers, resulting in the problem of voids in the glue. This will have a negative impact on the performance and durability of the curved photovoltaic module. For example, voids in the glue may cause moisture and air to penetrate into the interior of the curved photovoltaic module, thereby accelerating the aging of the crystalline silicon cell layer 30 and reducing its efficiency. Moreover, voids in the glue may also affect the mechanical strength of the curved photovoltaic module, increasing the risk of cracking or damage. In addition, if the vacuum pumping rate is greater than 5 L / min during the shaping process, it is likely to cause hidden cracks and fragmentation of the crystalline silicon cell layer 30 in the laminate 100. Therefore, by setting the vacuum pumping rate within the above range during the shaping process, it is beneficial to ensure that the crystalline silicon cell layer 30 can slowly conform to the shape, neither easily producing voids in the glue nor easily causing hidden cracks and fragmentation.

[0065] In some embodiments, during the shaping process of the laminate, the shaping time is from 3 min to 8 min (such as from 3 min to 5 min, from 5 min to 6 min, from 6 min to 8 min). If the shaping time is less than 3 min during the shaping process, it is likely to cause voids in the glue between the film layers. If the shaping time is greater than 8 min during the shaping process, it is likely to cause bubbles between the film layers, which will have various negative impacts on the performance and lifespan of the prepared photovoltaic module. For example, the bubbles will hinder the transmission of light, reducing the light absorption efficiency of the photovoltaic module. As a result, the electrical energy generated by the crystalline silicon cell layer will decrease, reducing the overall energy conversion efficiency. The bubbles may also cause local temperature rise in the photovoltaic module, forming hot spots. These hot spots will not only reduce the battery efficiency but may also cause premature aging of the materials of the photovoltaic module, shortening the service life of the photovoltaic module. The bubbles may become channels for moisture and air penetration. Once these external substances enter the interior of the photovoltaic module, they may cause corrosion or other types of damage, further reducing the performance and lifespan of the photovoltaic module. The presence of bubbles will weaken the overall structural integrity and mechanical strength of the photovoltaic module, making it more vulnerable to damage under physical stress or environmental influences, such as under the load of wind or snow. In some cases, the bubbles may cause obstruction of the electrical path in the solar panel, affecting the electrical performance of the solar panel. Therefore, it is crucial to avoid generating bubbles during the lamination process of the photovoltaic module.

[0066] In some embodiments, the lamination 100 is shaped at a temperature range of 145°C to 160°C. In this way, this temperature range is high enough to ensure that the encapsulation materials (such as the first adhesive layer 20 and the second adhesive layer 40) can flow and bond properly, while not being too high to damage the crystalline silicon cell layer 30 or other film layers.

[0067] Step S22: Apply pressure to the lamination.

[0068] In some embodiments, applying pressure to the lamination 100 includes performing first-stage lamination, second-stage lamination, third-stage lamination, and fourth-stage lamination on the lamination 100 in sequence to achieve the following effects through stepwise pressure application.

[0069] First, improve bubble removal: Through stepwise lamination, bubbles can be removed more effectively at each stage. Applying a lower pressure in the initial stage allows the bubbles to escape from the encapsulation materials rather than being trapped inside the materials.

[0070] Second, better interlayer adhesion: Stepwise pressure application allows for better adhesion between each layer because it provides more precise control over the pressure and temperature in each lamination step.

[0071] Third, optimize material properties: Some encapsulation materials may perform best under different pressures. Stepwise pressure application can be adjusted according to the characteristics of these materials, thereby optimizing the performance of the final photovoltaic module.

[0072] Fourth, reduce the defect rate: By more carefully controlling the lamination process, stepwise lamination can reduce the generation of defects, such as inconsistent performance of the photovoltaic module caused by uneven lamination.

[0073] Fifth, improve production efficiency: Although stepwise pressure application may seem more time-consuming, it can actually improve the overall production efficiency by reducing the need for scrap and rework.

[0074] In some embodiments, during the first-stage lamination, the pressure is from 0.05 kPa to 0.1 kPa, and the duration is from 5 min to 10 min. Among them, if the pressure during the first-stage lamination is less than the lower limit, it is likely to cause the problem of void glue; if the pressure during the first-stage lamination is greater than the upper limit, it is likely to cause fragmentation of the crystalline silicon cell layer 30. If the duration during the first-stage lamination is less than the lower limit, it is likely to cause the problem of void glue; if the duration during the first-stage lamination is greater than the upper limit, it is likely to cause the problem of over-crosslinking of the encapsulation material in the laminate 100. When the crosslinking degree of the encapsulation material exceeds the ideal level, it will cause a decrease in the elasticity of the encapsulation material, making it become more brittle and hard, and may cause the crystalline silicon cell layer 30 to be more likely to crack when dealing with thermal expansion or other mechanical stresses. In addition, the problem of over-crosslinking of the encapsulation material may also lead to a decrease in the optical properties of the encapsulation material, thus affecting the light absorption ability of the photovoltaic module.

[0075] In some embodiments, during the second-stage lamination, the pressure is from 0.2 kPa to 0.3 kPa, and the duration is from 5 min to 10 min. Among them, if the pressure during the second-stage lamination is less than the lower limit, it is likely to cause the problem of void glue; if the pressure during the second-stage lamination is greater than the upper limit, it is likely to cause hidden cracks and fragmentation of the crystalline silicon cell layer 30. If the duration during the second-stage lamination is less than the lower limit, it is likely to cause too low crosslinking degree of the encapsulation material in the laminate 100. If the crosslinking degree of the encapsulation material is insufficient, it may reduce the overall mechanical strength of the photovoltaic module, making the photovoltaic module more vulnerable to physical damage, such as tearing or penetration. In addition, if the crosslinking degree of the encapsulation material is insufficient, its barrier effect on water vapor and oxygen may be insufficient, which may lead to the accumulation of water vapor and oxygen inside the photovoltaic module, thus accelerating the performance degradation of the crystalline silicon cell layer 30. In addition, if the duration during the second-stage lamination is greater than the upper limit, it is likely to cause the problem of over-crosslinking of the encapsulation material in the laminate 100.

[0076] In some embodiments, during the third-stage lamination, the pressure is from 0.3 kPa to 0.5 kPa, and the duration is from 10 min to 15 min. Among them, if the pressure during the third-stage lamination is less than the lower limit, it is likely to cause too low crosslinking degree of the encapsulation material in the laminate 100. If the pressure during the third-stage lamination is greater than the upper limit, it is likely to cause hidden cracks in the crystalline silicon cell layer 30. If the duration during the third-stage lamination is less than the lower limit, it is likely to cause too low crosslinking degree of the encapsulation material in the laminate 100. If the crosslinking degree of the encapsulation material is insufficient, it may reduce the overall mechanical strength of the photovoltaic module, making the photovoltaic module more vulnerable to physical damage, such as tearing or penetration. If the duration during the third-stage lamination is greater than the upper limit, it is likely to cause the problem of over-crosslinking of the encapsulation material in the laminate 100.

[0077] In some embodiments, during the fourth-stage lamination, the pressure is from 0.7 kPa to 1 kPa and the duration is from 20 min to 40 min. Among them, if the pressure during the fourth-stage lamination is less than the lower limit or the duration during the fourth-stage lamination is less than the lower limit, it is likely to cause too low a cross-linking degree of the encapsulation material in the laminate 100. If the duration during the fourth-stage lamination is greater than the upper limit, it is likely to cause the problem of over-cross-linking of the encapsulation material in the laminate 100.

[0078] It can be seen that during the process of pressing the laminate, the setting of the pressure and the duration is crucial. After low-pressure shaping and gradually increasing the pressure, through the above-mentioned parameter ranges during the pressing process, the encapsulation material in the laminate 100 obtains an appropriate cross-linking degree, which is also beneficial to reducing the problem of air voids in the laminate 100 and reducing the probability of hidden cracks and fragmentation of the solar cell.

[0079] In some embodiments, the laminate 100 is pressed at a temperature range of 145 °C to 160 °C. In this way, this temperature range is high enough to ensure that the encapsulation materials (such as the first adhesive layer 20 and the second adhesive layer 40) can flow and bond correctly, and at the same time, it is not too high to avoid damaging the crystalline silicon cell layer 30 or other film layers.

[0080] Step S23: Cool down the laminate.

[0081] In some embodiments, step S23 cools down the laminate 100 to room temperature (such as 20 °C to 30 °C), and the time is, for example, 30 min. It should be noted that the above steps need to be carried out strictly in sequence to achieve the best effect.

[0082] As Figure 4 shown, in the laminate 100a obtained after step-by-step lamination, the front plate curved glass 10, the first adhesive layer 20a, the crystalline silicon cell layer 30a, the second adhesive layer 40a, the back plate 50a and the jig 60 are stacked in sequence. In the laminate 100a, the bonding and forming between layers are realized through the first adhesive layer 20a and the second adhesive layer 40a, and the structure composed of the first adhesive layer 20a, the crystalline silicon cell layer 30a, the second adhesive layer 40a and the back plate 50a contacts the front plate curved glass 10 through the jig 60 and has the same shape as the front plate curved glass 10.

[0083] Specifically, after obtaining the Figure 4 shown structure, one step-by-step lamination cycle is completed. In some embodiments, the method for preparing the curved photovoltaic module further includes Figure 4 taking out the Figure 4After removing the fixture 60 from the shown structure, a component is obtained. After subsequent steps such as installing a junction box, curing, and testing, a curved photovoltaic module is obtained.

[0084] In summary, in the above method for preparing a curved photovoltaic module, by cutting a crystalline silicon cell into multiple pieces, the size of the cut cell pieces becomes smaller, which is beneficial for the conformal shaping of the crystalline silicon cell layer. Moreover, according to the curvature of the curved photovoltaic module to be prepared, the number of cuts and the size of the cell pieces can be specifically adjusted, improving the flexibility of the manufacturing process. In addition, during the process of shaping the laminate, the fixture includes an elastic layer that directly contacts the backsheet, which is beneficial for ensuring the effective contact between the first adhesive layer, the crystalline silicon cell layer, the second adhesive layer, the backsheet, and the front plate curved glass, and thus beneficial for ensuring the conformal fit degree of the first adhesive layer, the crystalline silicon cell layer, the second adhesive layer, and the backsheet. Moreover, during the process of applying pressure to the laminate step by step, by setting parameters such as pressure and duration at different stages, it is beneficial to improve the qualified rate of the curved photovoltaic module, which is a special-shaped and fragile product.

[0085] The embodiment of the present application also provides a curved photovoltaic module obtained by using the above method for preparing a curved photovoltaic module. Compared with the curved photovoltaic module of a thin-film battery, the curved photovoltaic module of a crystalline silicon cell in the embodiment of the present application has high power generation efficiency, low cost, and greater potential for wide application.

[0086] The above embodiments are only used to illustrate the technical solutions of the present application and not to limit them. Although the present application has been described in detail with reference to the above preferred embodiments, those of ordinary skill in the art should understand that the technical solutions of the present application can be modified or equivalently replaced without departing from the spirit and scope of the technical solutions of the present application.

Claims

1. A preparation method of a curved photovoltaic module, characterized in that, Including: Laminating process: laminating a front plate curved glass, a first adhesive layer, a crystalline silicon cell layer, a second adhesive layer, a flexible back plate and a jig in sequence to obtain a laminate, wherein the shape of the surface of the jig facing the back plate is the same as that of the front plate curved glass; And Step-by-step lamination process: performing a shaping process on the laminate to make the first adhesive layer, the crystalline silicon cell layer, the second adhesive layer and the back plate conform to the shape between the jig and the front plate curved glass, and then performing a pressing process on the laminate to bond and shape the front plate curved glass, the first adhesive layer, the crystalline silicon cell layer, the second adhesive layer and the back plate.

2. The preparation method of the curved photovoltaic module according to claim 1, wherein During the shaping process of the laminate, the vacuum pumping rate is 2 L / min to 5 L / min, and the shaping time is 3 min to 8 min.

3. The manufacturing method of the curved photovoltaic module according to claim 1, characterized in that, Performing the pressing process on the laminate includes performing first-stage lamination, second-stage lamination, third-stage lamination and fourth-stage lamination on the laminate in sequence; During the first-stage lamination, the pressure is 0.05 kPa to 0.1 kPa, and the duration is 5 min to 10 min; During the second-stage lamination, the pressure is 0.2 kPa to 0.3 kPa, and the duration is 5 min to 10 min; During the third-stage lamination, the pressure is 0.3 kPa to 0.5 kPa, and the duration is 10 min to 15 min; During the fourth-stage lamination, the pressure is 0.7 kPa to 1 kPa, and the duration is 20 min to 40 min.

4. The method for preparing a curved photovoltaic module according to claim 1, wherein Performing the shaping process on the laminate in a temperature range of 145 °C to 160 °C; Performing the pressing process on the laminate in a temperature range of 145 °C to 160 °C.

5. The preparation method of the curved photovoltaic module according to claim 1, characterized in that, The step-by-step lamination process further includes: after performing the pressing process on the laminate, cooling the laminate to 20 °C to 30 °C.

6. The preparation method of the curved photovoltaic module according to claim 1, characterized in that, The jig includes a stacked rigid layer and an elastic layer, the shape of the rigid layer is the same as that of the front plate curved glass, and during the laminating process, the surface of the elastic layer away from the rigid layer contacts the back plate.

7. The preparation method of the curved photovoltaic module according to claim 1, characterized in that, The method for preparing the curved photovoltaic module further includes: before the step-by-step lamination process, spot-welding and fixing the first adhesive layer, the crystalline silicon cell layer and the second adhesive layer.

8. The preparation method of the curved photovoltaic module according to claim 1, characterized in that, Before the laminating process, the method for preparing the curved photovoltaic module further includes: Cutting the crystalline silicon cell to obtain a plurality of cell pieces; and Welding a plurality of the cell pieces with interconnection bars to obtain the crystalline silicon cell layer.

9. The preparation method of the curved photovoltaic module according to any one of claims 1 to 8, characterized in that Performing the step-by-step lamination process on the laminate by using a vacuum pumping system; The vacuum pumping system includes: A vacuum bag for accommodating the laminate; A vacuum pump for pumping vacuum for the vacuum bag; An air extraction pipeline connecting the vacuum bag and the vacuum pump; A valve located on the passage of the air extraction pipeline and used for adjusting the gas flow rate passing through the air extraction pipeline; and A controller, communicatively connected to the vacuum pump and the valve, and configured to control the rotational speed of the vacuum pump and the opening degree of the valve; The step-by-step lamination process of the laminate includes: Placing the laminate into the vacuum bag; Controlling the rotational speed of the vacuum pump and the opening degree of the valve by the controller to adjust the vacuum pumping rate and the shaping time during the shaping process of the laminate; and Controlling the rotational speed of the vacuum pump and the opening degree of the valve by the controller to adjust the pressure and the duration during the pressing process of the laminate.

10. A curved photovoltaic module, characterized in that, Obtained by using the preparation method of the curved photovoltaic module according to any one of claims 1 to 9.

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