A solar module

Abstract

The present invention discloses a solar component, which includes a substrate, a photoelectric conversion layer, a packaging layer and a cover plate arranged in sequence. The photoelectric conversion layer is fixed on the substrate, a pattern layer is provided on the photoelectric conversion layer, the packaging layer fixes the cover plate on the photoelectric conversion layer, and the cover plate is made of a transparent material. The solar component provided by the present invention can present various pattern effects after forming a pattern on the photoelectric conversion layer and covering the light-transmitting cover plate, greatly enriching the implementation means of the pattern layer, ensuring that the graphics are clear and controllable; and can increase the selection range of the cover plate, expanding its application in the field of lightweight; and has the characteristics of convenient implementation, simple structure and low cost, and the electrical and aesthetic effects are much better than traditional products.

Description

Technical Field

[0001] The present invention relates to the field of solar cell modules, and particularly to the field of manufacturing 3D and painted patterns on solar power generation film layers. Background Art

[0002] With the progress of technology, the high consumption of energy and the improvement of environmental protection awareness nowadays, the solar energy industry has witnessed great development. From single-crystalline, polycrystalline, thin-film, to biomass power generation, various solar power generation technologies are blooming, with the conversion efficiency constantly reaching new highs. The market demand has shifted from large-scale ground applications to industrial and commercial rooftops and then to residential rooftops. Solar clean energy is flourishing everywhere.

[0003] The existing monotonous appearance of solar modules fails to meet people's aesthetic requirements for buildings, and 3D and painted solar modules have emerged as the times require. Chinese Patent Document CN202021149899.0 discloses a simulated three-dimensional flat power generation tile, and Chinese Patent Document CN201811581408.7 discloses a colored photovoltaic module for photovoltaic tiles. The basic idea of both is to design different patterns and film layers on the cover glass to achieve the required aesthetic and optical effects. The limitation of such solutions is that the cover must be glass, and it is difficult to adjust the product once it is formed.

[0004] In addition, Chinese Patent Documents CN201811114810.4 and CN201910256386.5 obtain this effect by introducing encapsulation materials with different colors and patterns. The products produced by this method have disadvantages such as weak three-dimensional sense, complex film layer structure, and difficulty in controlling the pattern layer after lamination. Summary of the Invention

[0005] The technical problem to be solved by the present invention is to provide a solar module that can not only produce a three-dimensional pattern effect, but also does not limit the cover material and has a simple structure.

[0006] The technical solution adopted by the present invention to solve the above technical problem is to provide a solar module, including a substrate, a photoelectric conversion layer, an encapsulation layer, and a cover plate arranged in sequence. The photoelectric conversion layer is fixed on the substrate, a pattern layer is provided on the photoelectric conversion layer, the encapsulation layer fixes the cover plate on the photoelectric conversion layer, and the cover plate is made of a transparent material.

[0007] Preferably, the substrate is glass, steel, or plastic, and the cover plate is a glass cover plate or a plastic cover plate.

[0008] Preferably, the photoelectric conversion layer is a film layer or a chip having a PN junction semiconductor structure.

[0009] Preferably, the photoelectric conversion layer is an amorphous silicon, single-crystalline silicon, polycrystalline silicon, CIGS, or perovskite solar cell.

[0010] Preferably, the pattern layer is a 3D pattern or a painted pattern formed on the antireflection film.

[0011] Preferably, the pattern layer is fabricated on the photoelectric conversion layer by printing, and the drying temperature during printing is 140 - 180 °C.

[0012] Preferably, the pattern layer is fabricated on the photoelectric conversion layer by spraying, and the thickness of the formed pattern layer is 8 - 20 microns; or, the pattern layer is fabricated on the photoelectric conversion layer by evaporation, and the thickness of the pattern layer is 0.2 - 2 microns.

[0013] Preferably, the pattern layer is fabricated on the photoelectric conversion layer by laser engraving or sticker pasting.

[0014] Preferably, the material of the encapsulation layer is EVA, POE or PVB.

[0015] Preferably, medium - aluminum glass coated with a Mo layer is selected as the substrate; the glass substrate is cleaned, and the back - electrode Mo layer is deposited by DC magnetron sputtering; a CIGS thin film is deposited on the Mo layer, and then the Mo - coated glass deposited with the CIGS thin film is annealed in a hydrogen selenide atmosphere to form a CIGS thin film; a CdS thin film is deposited on the annealed CIGS thin film by a water - bath method, and then a double - layer ZnO thin film is fabricated by CVD; a MgF 2 antireflection film is covered, and the pattern layer is formed on the MgF 2 antireflection film; the cover plate is fixed on the photoelectric conversion layer and the pattern layer by using the encapsulation layer to form a CIGS thin - film solar cell module.

[0016] The present invention has the following beneficial effects compared with the prior art: The solar cell module provided by the present invention can present various pattern effects after forming patterns on the photoelectric conversion layer and covering with a light - transmissive cover plate, greatly enriching the implementation means of the pattern layer, ensuring clear and controllable graphics; it can increase the selection range of the cover plate, expanding its application in the field of lightweight; and it has the characteristics of convenient implementation, simple structure and low cost, and its electrical and aesthetic effects are much better than traditional products. BRIEF DESCRIPTION OF THE DRAWINGS

[0017] Figure 1 It is a schematic structural diagram of a photovoltaic module in an embodiment of the present invention.

[0018] In the figure:

[0019] 1 - substrate, 2 - photoelectric conversion layer, 3 - encapsulation layer, 4 - cover plate. DETAILED DESCRIPTION OF THE EMBODIMENTS

[0020] The present invention will be further described below in conjunction with the accompanying drawings and embodiments.

[0021] Please refer to Figure 1 , the solar module provided in this embodiment includes a substrate 1, a photoelectric conversion layer 2, a packaging layer 3, and a cover plate 4 arranged in sequence. The substrate 1 can be glass, steel, plastic, etc. A photoelectric conversion layer 2 with a pattern layer is fabricated above the substrate 1. The photoelectric conversion layer 2 can be a film layer or chip with a PN junction semiconductor structure such as amorphous silicon, single crystal silicon, polycrystalline silicon, CIGS (copper indium gallium tin), perovskite, etc. Specifically, for thin-film solar cells such as amorphous silicon, CIGS, and perovskite, the photoelectric conversion layer 2 is deposited on the substrate 1; for single crystal silicon and polycrystalline silicon thin-film solar cells, the photoelectric conversion layer is the chip itself. The pattern layer can be a 3D layer or a painted pattern, and the pattern layer can be realized on the photoelectric conversion layer by means such as printing, spraying, evaporation coating, laser engraving, and sticker pasting. The fabrication of the pattern layer will affect the light transmittance, resulting in a slight reduction in power generation efficiency. The balance between the pattern and power generation efficiency can be achieved by selecting materials with high transmittance and optimizing the pattern transmittance matching. The material with high transmittance is preferably MgF 2 antireflection film. In a specific embodiment, the size of the chip sub-cells is adjusted by the light-shielding coefficient of different patterns and the changes in the size and characteristics of the printing, spraying, or evaporation coating materials during the lamination process to ensure the current matching between the sub-cells and avoid the occurrence of hot spot phenomena; for the pattern material selection and film layer matching during printing, spraying, or evaporation coating, and high-temperature resistant inks or evaporation coating materials, corresponding screen plates are designed to fabricate corresponding patterns; for the printing method, special attention should be paid to scratch prevention and drying temperature control during the operation process to obtain a better pattern. Preferably, the drying temperature during printing is 140 - 180 °C; for the spraying or evaporation coating method, special control should be exerted on the film thickness uniformity of the formed film pattern. Preferably, the thickness of the pattern layer formed by the spraying method is 8 - 20 microns, and for the evaporation coating method, the thickness of the pattern layer is 0.2 - 2 microns. For laser engraving and sticker pasting, it is relatively simple, and the corresponding designed patterns can be directly engraved on the chip or an insulating picture film can be pasted. Those skilled in the art can fabricate the solar module into a tile shape for use on the roof according to needs, or fabricate it into a brick shape for use on the wall, or design various colorful patterns, etc.

[0022] A packaging layer 3 is provided on the photoelectric conversion layer 2 with a pattern layer in the embodiment of the present invention. The packaging layer 3 can be a material with an adhesive function such as EVA (ethylene-vinyl acetate copolymer), POE (polyolefin elastomer), PVB (polyvinyl butyral), etc. A cover plate 4 is covered above the packaging layer 3. The cover plate 4 can be a material with a light-transmitting effect such as glass, plastic, etc. After the above four layers are pressed together under a certain pressure and temperature, the solar power generation product with a pattern is completed, and the pattern is clearly visible through the cover plate 4, and the module perfectly integrates the aesthetic and electrical effects.

[0023] Taking the optoelectronic conversion layer 2 as a CIGS solar cell as an example, the formation process of the pattern layer is as follows: Select medium-aluminum glass coated with a Mo (molybdenum) layer as the substrate; Clean the glass substrate, and deposit the back electrode Mo layer by DC magnetron sputtering; Deposit a CIGS thin film on the Mo layer, and then anneal the Mo-coated glass deposited with the CIGS thin film in an atmosphere of hydrogen selenide to form a CIGS thin film; Deposit a CdS (cadmium sulfide) thin film on the annealed CIGS thin film by the water bath method, and then deposit a double-layer ZnO (zinc oxide) thin film by CVD (chemical vapor deposition); Finally, cover a layer of MgF 2 (magnesium fluoride) antireflection film, and form the pattern layer on the MgF 2 antireflection film. By controlling the thickness of the antireflection film, the thickness of the pattern layer can be flexibly determined. Since the pattern layer is on the antireflection film, it hardly affects the light transmission effect of the optoelectronic conversion layer; Use the encapsulation layer to fix the cover plate on the optoelectronic conversion layer and the pattern layer to form a CIGS thin film solar module.

[0024] Compared with the existing solar modules, the solar module provided by the embodiment of the present invention has at least the following advantages:

[0025] 1. The pattern layer is arranged on the optoelectronic conversion layer, and the cover plate is not limited to a glass plate. The cover plate can be a plastic film, which greatly reduces the weight of the solar module product and expands its application in the field of lightweight.

[0026] 2. The graphic scheme can be optimized and adjusted at any time according to requirements, including but not limited to various 3D patterns and various painted patterns, so as to obtain the required aesthetic and electrical effects;

[0027] 3. The painted pattern is realized on the optoelectronic conversion layer by various means such as printing, spraying, evaporation coating, laser engraving, and sticker pasting, and the pattern is clear and controllable;

[0028] 4. The solar products produced by this method are easy to implement, have a simple structure, low cost, and the electrical and aesthetic effects are much better than traditional products.

[0029] Although the present invention has been disclosed above with preferred embodiments, it is not intended to limit the present invention. Any person skilled in the art can make some modifications and improvements without departing from the spirit and scope of the present invention. Therefore, the protection scope of the present invention shall be defined by the claims.

Claims

1. A solar component, characterized in that, it includes a substrate, a photoelectric conversion layer, a packaging layer and a cover plate which are arranged in sequence. The photoelectric conversion layer is fixed on the substrate, a pattern layer is provided on the photoelectric conversion layer, the packaging layer fixes the cover plate on the photoelectric conversion layer, and the cover plate is made of a transparent material; the photoelectric conversion layer is a film layer or a chip with a PN junction semiconductor structure; the photoelectric conversion layer is an amorphous silicon, single crystal silicon, polycrystalline silicon, CIGS or perovskite solar cell; the pattern layer is a 3D pattern or a painted pattern formed on an antireflection film; when the photoelectric conversion layer is a CIGS solar cell, the formation process of the pattern layer is as follows: select a medium aluminum glass coated with a Mo layer as a substrate; clean the glass substrate and deposit a back electrode Mo layer by DC magnetron sputtering; deposit a CIGS thin film on the Mo layer, and then anneal the Mo-coated glass deposited with the CIGS thin film in a hydrogen selenide atmosphere to form a CIGS thin film; deposit a CdS thin film on the annealed CIGS thin film by a water bath method, and then fabricate a double-layer ZnO thin film by CVD; Cover a layer of MgF 2 antireflection film, and form the pattern layer on the MgF 2 antireflection film; use the encapsulation layer to fix the cover plate on the photoelectric conversion layer and the pattern layer to form a CIGS thin-film solar cell module.

2. The solar component according to claim 1, characterized in that, the substrate is glass, steel or plastic, and the cover plate is a glass cover plate or a plastic cover plate.

3. The solar component according to claim 1, characterized in that, the pattern layer is fabricated on the photoelectric conversion layer by printing, and the drying temperature during printing is 140 - 180 °C.

4. The solar component according to claim 1, characterized in that, the pattern layer is fabricated on the photoelectric conversion layer by spraying, and the thickness of the formed pattern layer is 8 - 20 microns, or, the pattern layer is fabricated on the photoelectric conversion layer by evaporation, and the thickness of the pattern layer is 0.2 - 2 microns.

5. The solar component according to claim 1, characterized in that, the pattern layer is fabricated on the photoelectric conversion layer by laser engraving or sticker pasting.

6. The solar component according to claim 1, characterized in that, the material of the packaging layer is EVA, POE or PVB.

Images