Integrated Structure, System and Installation Method of Flexible Photovoltaic Modules

Abstract

The present invention relates to an integrated structure, system and installation method of a flexible photovoltaic module. The structure includes a flexible photovoltaic module formed by integral lamination, an adhesive layer, and a secondary waterproof coiled material. A hot air welding area is provided on the back surface of the secondary waterproof coiled material. The method includes: laminating and encapsulating each layer of materials of the flexible photovoltaic module and the secondary waterproof coiled material to achieve integration; arranging a primary waterproof coiled material on the roof, and a hot air welding area corresponding to the hot air welding area on the secondary waterproof coiled material is formed on the entire front surface of the primary waterproof coiled material; the hot air welding area on the back surface of the secondary waterproof coiled material is attached to the hot air welding area on the front surface of the primary waterproof coiled material and hot air welding is carried out. The present invention solves the problem of the connection failure of the photovoltaic module or panel by using the adhesive method in the application in the construction field. At the same time, the use of no structural parts greatly reduces the material cost and installation cost of the product. After the wind uplift verification of the roof system with a wind pressure of plus or minus 5000 Pa, the installation structure is safe and reliable.

Description

Technical Field

[0001] The present invention belongs to the field of photovoltaic products, and particularly relates to an integrated structure of a flexible photovoltaic module, a system and an installation method of the system. Background Art

[0002] Due to the limitation of installation conditions, existing photovoltaic modules or panels are installed on the roof by using back glue or sealant and structural adhesive. However, it is extremely difficult for the glue to reach the same service life as that of the photovoltaic, and the increase in temperature during power generation of the photovoltaic product will further reduce the service life of the glue. This makes the structural life of the gluing solution not match the power generation life of the module, resulting in secondary maintenance costs and even batch module detachment and damage. At the same time, this solution cannot meet the long-term waterproof function of the building. Summary of the Invention

[0003] The purpose of the present invention is to provide an integrated structure of a flexible photovoltaic module, which greatly reduces the material cost and installation cost of the product.

[0004] To achieve the above purpose, the technical solution adopted by the present invention is: an integrated structure of a flexible photovoltaic module, which includes a secondary waterproof coiled material, a flexible photovoltaic module integrated on the front surface of the secondary waterproof coiled material, and an adhesive layer provided between the front surface of the secondary waterproof coiled material and the flexible photovoltaic module. A hot air welding area is provided on the back surface of the secondary waterproof coiled material. The flexible photovoltaic module includes a backplane material, and the hot air welding area on the secondary waterproof coiled material is located at or around the corresponding position of the flexible photovoltaic module or a partial area around the corresponding position.

[0005] Preferably, the flexible photovoltaic module includes a flexible panel material, a glue film, a fiber reinforced layer, a glue film, a solar cell, and a glue film.

[0006] Preferably, the secondary waterproof coiled material is in a frame shape, strip shape or block shape. The adhesive layer is provided on the overlapping area when the secondary waterproof coiled material and the flexible photovoltaic module are attached. The adhesive layer is a glue film, and is laminated with the secondary waterproof coiled material into one body synchronously when the flexible photovoltaic module is laminated.

[0007] The present invention also provides an integrated system of a flexible photovoltaic module, which includes a roof structure and an integrated structure of a flexible photovoltaic module fixed on the roof structure by hot air welding. The integrated structure of the flexible photovoltaic module is any one of the above-mentioned integrated structures of a flexible photovoltaic module. The roof structure includes a main waterproof coiled material and a roof substrate below the main waterproof coiled material.

[0008] Preferably, the secondary waterproof coiled material and the main waterproof coiled material are made of the same polymer material with the same main components.

[0009] Optimized, the main components of the secondary waterproofing membrane and the main waterproofing membrane are TPO or PVC.

[0010] Optimized, the main components of the main waterproofing membrane, the secondary waterproofing membrane and the backsheet material are all TPO.

[0011] Optimized, the main components of the secondary waterproofing membrane and the main waterproofing membrane are both PVC, and the main component of the backsheet material is TPO.

[0012] Optimized, the roofing substrate includes a thermal insulation layer, a waterproof and breathable layer below the thermal insulation layer, and a steel plate load-bearing layer below the waterproof and breathable layer.

[0013] The present invention also provides an installation method for the above-mentioned flexible photovoltaic module integrated system, which includes the following steps:

[0014] a. Assemble and lay the secondary waterproofing membrane with each layer of materials of the flexible photovoltaic module;

[0015] b. Laminating, rolling or autoclave sandwiching the secondary waterproofing membrane of the assembled and laid flexible photovoltaic module to form a flexible photovoltaic module integrated structure with the flexible photovoltaic module;

[0016] c. Set the main waterproofing membrane on the roof, and a hot air welding area corresponding to the hot air welding area on the secondary waterproofing membrane is provided on the front of the main waterproofing membrane;

[0017] d. Affix the flexible photovoltaic module integrated structure to the front of the main waterproofing membrane, with the flexible photovoltaic module facing upwards, and the hot air welding area on the back of the secondary waterproofing membrane is affixed and welded to the front hot air welding area of the main waterproofing membrane to complete the installation.

[0018] Optimized, the hot air welding areas on the secondary waterproofing membrane are all frame-shaped areas, or two parallel rectangular areas, or the area on the back of the entire secondary waterproofing membrane.

[0019] The present invention also provides an installation method for the above-mentioned flexible photovoltaic module integrated system, which includes the following steps:

[0020] A. Assemble and lay the secondary waterproofing membrane with each layer of materials of the flexible photovoltaic module;

[0021] B. Laminating, rolling or autoclave sandwiching the secondary waterproofing membrane of the assembled and laid flexible photovoltaic module to form a flexible photovoltaic module integrated structure with the flexible photovoltaic module;

[0022] C. Use blind rivets to fixedly connect the flexible photovoltaic module and the secondary waterproof coiled material, and the blind rivets are distributed on the outer periphery of the solar cells of the flexible photovoltaic module;

[0023] D. Affix the integrated structure of the flexible photovoltaic module onto the front surface of the main waterproof coiled material, with the flexible photovoltaic module facing upwards. The hot air welding area on the back surface of the secondary waterproof coiled material is attached to and welded with the hot air welding area on the front surface of the main waterproof coiled material to complete the installation.

[0024] Due to the application of the above technical solutions, the present invention has the following advantages compared with the prior art: The present invention solves the problem of the failure of the adhesive connection method when photovoltaic modules or panels are applied in the construction field. At the same time, the absence of structural components greatly reduces the material cost and installation cost of the product; the flexible photovoltaic module further reduces the load requirements of the photovoltaic power generation product on the building roof, making the application scope of this solution wider; through the integrated encapsulation of the flexible photovoltaic module and the secondary waterproof coiled material, and reserving the welding area during roof installation, the hot air welding process is used during roof installation. The hot air welding process directly melts and then solidifies two products of the same material to combine them into a complete whole. Therefore, its connection life can be the same as that of photovoltaic power generation. After passing the wind resistance verification of the roof system with a wind pressure of plus or minus 5000 Pa, the installation structure is safe and reliable. BRIEF DESCRIPTION OF THE DRAWINGS

[0025] FIG Figure 1 is an exploded view of the integrated structure of the flexible photovoltaic module;

[0026] FIG Figure 2 is an exploded view of the integrated system of the flexible photovoltaic module;

[0027] FIG Figure 3 is a schematic diagram of the integrated system of the flexible photovoltaic module in Embodiment 1;

[0028] FIG Figure 4 is a schematic diagram after the installation of the integrated system of the flexible photovoltaic module in Embodiment 1;

[0029] FIG Figure 5 is an exploded schematic diagram of the integrated system of the flexible photovoltaic module using a partial bonding method;

[0030] FIG Figure 6 is an exploded schematic diagram of the integrated system of the flexible photovoltaic module using a full bonding method;

[0031] FIG Figure 7 is a schematic diagram of the integrated structure of the flexible photovoltaic module in Embodiment 2;

[0032] FIG Figure 8 is a schematic diagram after the installation of the integrated system of the flexible photovoltaic module in Embodiment 2;

[0033] Appendix Figure 9 Figure for the connection of the auxiliary waterproof coil 11 and the flexible photovoltaic module 12 in Embodiment 2;

[0034] In the above figures: 1. Integrated structure of flexible photovoltaic module; 2. Roof structure; 3. Hot air welding area; 4. Overlap area; 5. Rivet; 6. Screw; 11. Auxiliary waterproof coil; 12. Flexible photovoltaic module; 13. Adhesive layer; 21. Main waterproof coil; 22. Roof substrate;; 23. Sheet waterproof coil; 120. Glue film; 121. Flexible panel material; 122. Fiber reinforced layer; 123. Solar cell; 124. Backsheet material; 221. Thermal insulation layer; 222. Waterproof and breathable layer; 223. Steel plate load-bearing layer. Specific embodiments

[0035] The present invention will be further described below with reference to the embodiments shown in the drawings.

[0036] Embodiment 1

[0037] As Figures 1-4 shown, the integrated system of flexible photovoltaic modules includes a roof structure 2 and an integrated structure 1 of flexible photovoltaic modules fixed to the roof structure 2 by hot air welding, and the integrated structure 1 of flexible photovoltaic modules is the above-mentioned integrated structure 1 of flexible photovoltaic modules.

[0038] The roof structure 2 includes a main waterproof coil 21 and a roof substrate 22 below the main waterproof coil 21. The roof substrate 22 includes a thermal insulation layer 221, a waterproof and breathable layer 222 below the thermal insulation layer 221, and a steel plate load-bearing layer 223 below the waterproof and breathable layer 222.

[0039] Integrated structure of flexible photovoltaic module 1, which includes a secondary waterproof coiled material 11, a flexible photovoltaic module 12 integrated on the front of the secondary waterproof coiled material 11, an adhesive layer 13 provided between the front of the secondary waterproof coiled material 11 and the flexible photovoltaic module 12, and a hot air welding area 3 provided on the back of the secondary waterproof coiled material 11. The hot air welding area 3 is located at the corresponding position of the flexible photovoltaic module 12 or around the corresponding position or a partial area around the corresponding position. The flexible photovoltaic module 12 includes a flexible panel material 121, a glue film 120, a fiber reinforcement layer 122, a glue film 120, a solar cell 123, a glue film 120, and a backplane material 124 which are stacked in sequence. The secondary waterproof coiled material 11 is a polymer roofing coiled material. The secondary waterproof coiled material 11 is a TPO coiled material or a PVC coiled material. In this embodiment, a TPO coiled material is used, and the backplane material 124 is also a TPO coiled material (thermoplastic polyolefin waterproof coiled material). The two can be coiled materials with the same or different models but the main component is TPO, which can form an integral body of the flexible photovoltaic module 12 and the secondary waterproof coiled material 11, and can effectively ensure the connection strength and service life of the two. The secondary waterproof coiled material 11 is in a frame shape or a strip shape or a block shape. In this embodiment, it is in a frame shape. The adhesive layer is provided on the overlapping area 4 when the secondary waterproof coiled material 11 and the flexible photovoltaic module 12 are bonded. The adhesive layer 13 is also a glue film, and is laminated integrally with the secondary waterproof coiled material 11 synchronously when the flexible photovoltaic module 12 is laminated and formed.

[0040] The installation method of the above integrated system of flexible photovoltaic modules includes the following steps:

[0041] a. Assemble and lay the secondary waterproof coiled material 11 and each layer of materials of the flexible photovoltaic module 12;

[0042] b. Laminating, rolling or autoclave sandwich gluing the secondary waterproof coiled material 11 of the assembled and laid flexible photovoltaic module 12 to integrate the secondary waterproof coiled material 11 with the flexible photovoltaic module 12;

[0043] c. Set a main waterproof coiled material 21 on the roof, and the entire front surface of the main waterproof coiled material 21 is a hot air welding area;

[0044] d. Apply the integrated structure 1 of the flexible photovoltaic module on the front of the main waterproof coiled material 21, with the flexible photovoltaic module 12 facing upwards, and the hot air welding area 3 on the back of the secondary waterproof coiled material 11 is bonded and welded to the hot air welding area on the front of the main waterproof coiled material 21 to complete the installation.

[0045] Steps a and b can be completed step by step or synchronously. For example, Figures 5-6As shown in the figure, the front hot air welding area 3 of the main waterproof membrane 21 is the same as the back hot air welding area 3 of the secondary waterproof membrane 11. The hot air welding area 3 is either a frame-shaped area, or two parallel rectangular areas, or the area on the back of the complete secondary waterproof membrane. For example, Figure 5 As shown in the figure, when the roof is inclined and the secondary waterproof membrane 11 is in a frame shape, the hot air welding area 3 on the secondary waterproof membrane 11 is located on the back of the two vertically arranged rectangular sides of the frame, forming a heat dissipation gap between the two sides of the secondary waterproof membrane 11 at the same height and the main waterproof membrane. This can ensure the heat dissipation performance of the flexible photovoltaic module 12 while ensuring the connection strength between the secondary waterproof membrane 11 and the main waterproof membrane 21.

[0046] The integrated flexible photovoltaic module system installed by the above method is tested according to the following test method, and its load performance is as follows:

[0047]

[0048] Test method

[0049] 1. Gas is continuously injected through the pressure vessel until the load reaches the first pressure level, with a deviation range of 0 kPa to +0.1 kPa. The air pressure rising rate is 0.07 kPa / s ± 0.05 kPa / s. When the pressure reaches the graded pressure value, this pressure should be maintained for 60 s. When the test piece is maintained at a certain pressure level, the test piece should be observed to ensure that it meets the conditions for continuing the test;

[0050] 2. After maintaining for 60 s, then unload to the reference zero position. After the load reaches the reference zero position, the interval time between the next load application is 1 min (60 s). During the loading interval time, the state of the test piece of the system should be observed through the observation window or the internal camera device of the box to check whether the test piece is damaged or functionally damaged. Increase the gas to increase the pressure level to the next graded pressure value, and the increase rate and deviation shall be carried out according to the above requirements. When reaching the next pressure level, this pressure level should be maintained for 60 s. When maintaining at a certain pressure level, pay attention to observing the test piece to ensure that it meets the conditions for continuing the test;

[0051] 3. Repeat the above steps until the calibrated load is reached and maintained for 60 s. After the test is completed, remove the test piece and carefully observe and record all phenomena that do not conform to the standard regulations;

[0052] 4. Test result representation: The anti-simulated wind pressure level is the highest wind pressure level that the system can reach and maintain for 60 s and still meets the test requirements.

[0053] It can be seen that the wind uplift resistance verification of the roof system with a wind pressure of 5000 Pa shows that the installation structure is safe and reliable.

[0054] Example Two

[0055] As Figure 1 、 2 As shown in Figures 6, 7, the flexible photovoltaic module integrated system includes a roofing structure 2 and a flexible photovoltaic module integrated structure 1 fixedly attached to the roofing structure 2 by hot air welding. The flexible photovoltaic module integrated structure 1 is the above-mentioned flexible photovoltaic module integrated structure 1.

[0056] The roofing structure 2 includes a main waterproof membrane 21 and a roofing substrate 22 below the main waterproof membrane 21. The roofing substrate 22 includes a thermal insulation layer 221, a waterproof and breathable layer 222 below the thermal insulation layer 221, and a steel plate load-bearing layer 223 below the waterproof and breathable layer 222.

[0057] The flexible photovoltaic module integrated structure 1 includes a secondary waterproof membrane 11, a flexible photovoltaic module 12 integrated on the front surface of the secondary waterproof membrane 11, an adhesive layer 13 provided between the front surface of the secondary waterproof membrane 11 and the flexible photovoltaic module 12, and a hot air welding area 3 provided on the back surface of the secondary waterproof membrane 11 at or around the corresponding position of the flexible photovoltaic module 12. The flexible photovoltaic module 12 includes a flexible panel material 121, a glue film 120, a fiber reinforcement layer 122, a glue film 120, a solar cell 123, a glue film 120, and a backsheet material 124 stacked in sequence. The secondary waterproof membrane 11 is a polymer roofing membrane. The secondary waterproof membrane 11 is a TPO membrane or a PVC membrane. When the main waterproof membrane 21 is a PVC membrane (polyvinyl chloride membrane), the secondary waterproof membrane 11 is also a PVC membrane, but the backsheet material 124 is a TPO membrane. The secondary waterproof membrane 11 is in a frame shape, strip shape, or block shape, and is in a frame shape in this embodiment. The adhesive layer is provided on the overlapping area 4 when the secondary waterproof membrane 11 and the flexible photovoltaic module 12 are attached. The adhesive layer 13 is also a glue film and is laminated integrally with the secondary waterproof membrane 11 during the lamination molding of the flexible photovoltaic module 12.

[0058] The installation method of the above flexible photovoltaic module integrated system includes the following steps:

[0059] A. Assemble and lay the secondary waterproof membrane 11 and the various layers of the flexible photovoltaic module 12;

[0060] B. Laminate, roll, or autoclave the secondary waterproof membrane 11 of the assembled and laid flexible photovoltaic module 12 to form a flexible photovoltaic module integrated structure 1 with the flexible photovoltaic module 12;

[0061] C. The secondary waterproofing membrane 11 is a PVC membrane, and the backplate material 124 is a TPO membrane. The lamination connection strength between the two is not as good as that in Example 1 where the secondary waterproofing membrane 11 is a TPO membrane. Therefore, it is necessary to use blind rivets 5 to fixedly connect the flexible photovoltaic module 12 and the secondary waterproofing membrane 11. The blind rivets 5 are distributed on the outer periphery of the solar cells of the flexible photovoltaic module 12. Fixing the secondary waterproofing membrane at the edge of the flexible photovoltaic module with blind rivets 5 again after being integrally laminated with the photovoltaic module can make the connection between the flexible photovoltaic module and the secondary waterproofing membrane firmer and can reduce the material cost of the secondary waterproofing membrane. As Figure 8 shown, that is, reducing the size of A and reducing the secondary waterproofing membrane originally arranged around the photovoltaic module to be fixed at the upper and lower ends or the left and right ends.

[0062] D. Fix the main waterproofing membrane 21 and the roof substrate 22 with screws 6 and use the hot air welding process to integrate the main waterproofing membrane 21 and the secondary waterproofing membrane 11;

[0063] E. Use the hot air welding process on the main waterproofing membrane 21 at the position where there are screws 6 to secondarily cover the screws 6 on the main waterproofing membrane 21 with the sheet-shaped waterproofing membrane 23 to ensure the waterproof performance of the roof.

[0064] Steps A and B can be completed step by step or synchronously. As Figures 5-6 shown, among them, the hot air welding area 3 on the front of the main waterproofing membrane 21 is the same as the hot air welding area 3 on the back of the secondary waterproofing membrane 11. The hot air welding areas 3 are all frame-shaped areas or two parallel rectangular areas or the area on the back of the complete secondary waterproofing membrane. When the roof is inclined and the secondary waterproofing membrane 11 is frame-shaped, the hot air welding area 3 on the secondary waterproofing membrane 11 is located on the back of the two vertically arranged rectangular sides of the frame, forming a heat dissipation gap between the two sides of the secondary waterproofing membrane 11 at the same height and the main waterproofing membrane. In this way, the heat dissipation performance of the flexible photovoltaic module 12 can be ensured on the premise of ensuring the connection strength between the secondary waterproofing membrane 11 and the main waterproofing membrane 21.

[0065] The above embodiments are only used to illustrate the technical concept and characteristics of the present invention, and their purpose is to enable those familiar with this technology to understand the content of the present invention and implement it accordingly, and should not be used to limit the protection scope of the present invention. All equivalent changes or modifications made according to the spirit and essence of the present invention should be covered within the protection scope of the present invention.

Claims

1. A flexible photovoltaic module integrated system, characterized in that: It includes a roofing structure and an integrated flexible photovoltaic module structure fixed to the roofing structure by hot air welding. The integrated flexible photovoltaic module structure includes a secondary waterproofing membrane, a flexible photovoltaic module integrated on the front surface of the secondary waterproofing membrane, and an adhesive layer provided between the front surface of the secondary waterproofing membrane and the flexible photovoltaic module. A hot air welding area is provided on the back surface of the secondary waterproofing membrane. The flexible photovoltaic module includes a backsheet material. The hot air welding area on the secondary waterproofing membrane is located at or around the corresponding position of the flexible photovoltaic module or a partial area around the corresponding position; the roofing structure includes a primary waterproofing membrane and a roofing substrate below the primary waterproofing membrane; the hot air welding area on the secondary waterproofing membrane is located on the back surfaces of two rectangular sides arranged vertically in a frame shape, and a heat dissipation gap is formed between the two sides of the secondary waterproofing membrane at the same height and the primary waterproofing membrane.

2. The integrated flexible photovoltaic module system according to claim 1, wherein: The flexible photovoltaic module includes a flexible panel material, a glue film, a fiber reinforcement layer, a glue film, a solar cell, and a glue film.

3. The integrated flexible photovoltaic module system according to claim 1, characterized in that: The secondary waterproofing membrane is in a frame shape or a strip shape or a block shape. The adhesive layer is provided on the overlapping area when the secondary waterproofing membrane and the flexible photovoltaic module are adhered. The adhesive layer is a glue film and is laminated and formed into one body with the secondary waterproofing membrane synchronously when the flexible photovoltaic module is laminated.

4. The integrated system of flexible photovoltaic modules according to claim 1, wherein: The secondary waterproofing membrane and the primary waterproofing membrane are made of the same polymer material as the main component.

5. The integrated flexible photovoltaic module system according to claim 4, wherein: The main components of the secondary waterproofing membrane and the primary waterproofing membrane are TPO or PVC.

6. The integrated flexible photovoltaic module system according to claim 5, characterized in that: The main components of the primary waterproofing membrane, the secondary waterproofing membrane, and the backsheet material are all TPO.

7. The integrated flexible photovoltaic module system according to claim 5, characterized in that: The main components of the secondary waterproofing membrane and the primary waterproofing membrane are both PVC, and the main component of the backsheet material is TPO.

8. The integrated flexible photovoltaic module system according to claim 1, wherein: The roofing substrate includes a thermal insulation layer, a waterproof and breathable layer below the thermal insulation layer, and a steel plate load-bearing layer below the waterproof and breathable layer.

9. An installation method for the integrated system of the flexible photovoltaic module described in claim 6, characterized in that, It includes the following steps: a. Assemble and lay the secondary waterproofing membrane and the various layer materials of the flexible photovoltaic module; b. Laminate, roll, or autoclave the secondary waterproofing membrane of the assembled and laid flexible photovoltaic module to form an integrated flexible photovoltaic module structure with the flexible photovoltaic module; c. Set the primary waterproofing membrane on the roof. A hot air welding area corresponding to the hot air welding area on the secondary waterproofing membrane is provided on the front surface of the primary waterproofing membrane; d. Affix the integrated flexible photovoltaic module structure to the front surface of the primary waterproofing membrane with the flexible photovoltaic module facing upward. The hot air welding area on the back surface of the secondary waterproofing membrane is adhered and welded to the hot air welding area on the front surface of the primary waterproofing membrane to complete the installation.

10. The installation method according to claim 9, characterized in that: The hot air welding areas on the secondary waterproofing membrane are all frame-shaped areas or two parallel rectangular areas or the area on the back surface of the complete secondary waterproofing membrane.

11. A method for installing the integrated system of the flexible photovoltaic module described in claim 7, characterized in that, It includes the following steps: A. Assemble and lay the secondary waterproofing membrane and the various layer materials of the flexible photovoltaic module; B. Laminate, roll, or autoclave the secondary waterproofing membrane of the assembled and laid flexible photovoltaic module to form an integrated flexible photovoltaic module structure with the flexible photovoltaic module; C. Fix the flexible photovoltaic module and the secondary waterproof coiled material by using blind rivets, and the blind rivets are distributed on the outer periphery of the solar cells of the flexible photovoltaic module; D. Apply the integrated structure of the flexible photovoltaic module on the front surface of the main waterproof coiled material, with the flexible photovoltaic module facing upward. The hot air welding area on the back surface of the secondary waterproof coiled material is attached to and welded with the hot air welding area on the front surface of the main waterproof coiled material to complete the installation.

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