Photovoltaic module with pattern and preparation method thereof

Abstract

The present invention relates to a photovoltaic module with a pattern and a preparation method thereof. The photovoltaic module with a pattern has a graphic gap space inside the photovoltaic module for forming a low refractive index area. The refractive index difference between the graphic gap space and the physical medium inside the photovoltaic module forms a pattern on the surface of the photovoltaic module. The preparation method is to first prepare the photovoltaic cell layer and each structural layer of the packaging structure, and then lay out and laminate them into a photovoltaic module. The beneficial effect is: compared with the prior art, the scheme of the present invention changes the direction of light through optical refraction, thereby forming color and light and dark contrast. After the light changes direction through refraction, it can still contribute to the power generation of the module, so the optical loss is lower, and the manufacturing is simpler, the cost is lower, and the performance is better, so that it is possible to produce artistic patterns on the surface of the photovoltaic module with high efficiency and low cost.

Description

[0001] This invention patent application is a divisional application. The application number of the original application is 2022106321138. The application date is June 6, 2022. The name of the invention is: Patterned photovoltaic module and preparation method thereof. Technical Field

[0002] The invention relates to the field of photovoltaic technology, in particular to a photovoltaic component with a pattern and a preparation method thereof. Background Art

[0003] Since 2020, photovoltaics have become increasingly close to people's lives. In addition to the original large-scale ground power stations and water power stations, photovoltaic technology is increasingly used in different scenarios such as household roofs, building walls, and roofs of electric vehicles. In addition to the demand for the practicality of photovoltaic products, people are also beginning to pursue the beauty and artistry of photovoltaic products.

[0004] Tesla in the United States has launched colored photovoltaic tiles to replace ordinary roofs, ECN in the Netherlands has launched colored building photovoltaic modules, and domestic companies such as Hanergy Photovoltaic, Changzhou Trina Solar, and Baoding Jiasheng Optoelectronics under Yingli Group have made a lot of pioneering explorations in the colorization of building photovoltaics. In recent years, companies such as Xi'an Longi and Jinko have also launched colored photovoltaic module products to tap into the building photovoltaic market.

[0005] In general, the above-mentioned colored photovoltaic module solutions will sacrifice the power generation efficiency of photovoltaic modules, increasing the power generation cost to a level that the mainstream market cannot accept. Therefore, these products mostly exist in the niche market as demonstration projects and cannot become mainstream.

[0006] Existing color photovoltaic module solutions all use printing color coatings or sputtering coating to form color patterns to enhance the aesthetics of the module. For example, China's invention patent document CN113087406A high-temperature tempered color photovoltaic glass panel and its production method, color solar photovoltaic module, China's invention patent CN109463011A colored photovoltaic module, and Energy Procedia 122 (2017) 175-180 published architectural color photovoltaic facade technology. Such a component colorization solution will cause light blocking and greater energy loss, with power loss ranging from 15% to 25%. Summary of the invention

[0007] The technical problem to be solved by the present invention is to provide a photovoltaic module with a pattern and a preparation method thereof, so as to reduce the influence of the patterning of the photovoltaic module on the power generation efficiency of the module.

[0008] The technical solution adopted by the present invention to solve its technical problem is: a patterned photovoltaic module, which has a patterned gap space inside the photovoltaic module for forming a low refractive index area, and the refractive index difference between the patterned gap space and the physical medium inside the photovoltaic module forms a pattern on the surface of the photovoltaic module.

[0009] It is further defined that the transparent encapsulation structure includes a photovoltaic cell layer and an encapsulation structure for encapsulating the photovoltaic cell layer, and the patterned gap space is located inside the transparent encapsulation structure.

[0010] It is further defined that the transparent packaging structure includes at least one patterned film layer, and the patterned film layer has patterned through holes, grooves or cavities for forming a patterned gap space.

[0011] It is further defined that the side surface of the patterned gap space has an optical microstructure for enhancing the pattern effect of the surface of the photovoltaic module.

[0012] It is further defined that the transparent packaging structure includes at least one patterned film layer, which is a patterned adhesive film layer, which is an adhesive medium layer under lamination process conditions, and the patterned adhesive film layer has patterned through holes, grooves or cavitations for forming a patterned gap space, and the physical dielectric layers of the photovoltaic components on both sides of the patterned adhesive film layer are non-fluid or low-fluidity dielectric layers under lamination process conditions.

[0013] It is further defined that the physical dielectric layer of the photovoltaic module on the light incident side of the patterned adhesive film layer is a non-fluid dielectric layer, and an optical microstructure is provided on the side of the non-fluid dielectric layer facing the patterned adhesive film layer, and the optical microstructure is distributed on the entire surface or a local surface of the non-fluid dielectric layer, and the local surface is the surface area corresponding to the patterned gap space.

[0014] It is further defined that the thickness of the patterned adhesive film layer is 5 to 200 um.

[0015] It is further defined that one side of the patterned adhesive film layer is a photovoltaic cell layer, and the other side of the patterned adhesive film layer is a transparent film layer.

[0016] It is further defined that the specific structure of the patterned photovoltaic component is: from top to bottom, it includes a front cover plate, a packaging adhesive layer, a transparent film layer, a patterned adhesive film layer, a photovoltaic cell layer, a patterned adhesive film layer, a transparent film layer, a packaging adhesive layer and a back cover plate; or, the specific structure is: from top to bottom, it includes a front cover plate, a packaging adhesive layer, a transparent film layer, a patterned adhesive film layer, a photovoltaic cell layer, a packaging adhesive layer and a back cover plate; or, the specific structure is: from top to bottom, it includes a front cover plate, a patterned adhesive film layer, a photovoltaic cell layer, a patterned adhesive film layer and a back cover plate; or, the specific structure is: from top to bottom, it includes a front cover plate, a patterned adhesive film layer, a photovoltaic cell layer, a packaging adhesive layer and a back cover plate.

[0017] It is further defined that the patterned photovoltaic module includes a photovoltaic cell layer and a transparent packaging structure that encapsulates the photovoltaic cell layer, the transparent packaging structure includes at least one patterned film layer, the patterned film layer is a patterned adhesive film layer, the patterned adhesive film layer is an adhesive medium layer under lamination process conditions, the patterned adhesive film layer has a patterned non-adhesive surface under lamination process conditions, and is used to form a patterned gap space, and the photovoltaic module physical medium layer on one side of the patterned non-adhesive surface of the patterned adhesive film layer is a non-adhesive medium layer under lamination process conditions.

[0018] It is further defined that the transparent packaging structure includes at least one patterned film layer, the patterned film layer is a patterned transparent film layer, the patterned transparent film layer is a non-fluid or low-fluidity dielectric layer under lamination process conditions, the patterned transparent film layer has a patterned groove for forming a patterned gap space, and the physical dielectric layer of the photovoltaic module on the grooved side of the patterned transparent film layer is a low-fluidity adhesive dielectric layer under lamination process conditions.

[0019] It is further defined that the patterned transparent film layer is specifically a front cover plate or a rear cover plate.

[0020] It is further defined that the optical microstructure is a groove, a convex-concave texture or a point-type polyhedron.

[0021] It is further defined that the graphic of the graphical gap space is a sketch graphic, preferably a linear sketch graphic or a pen-drawn graphic.

[0022] It is further defined that the patterned photovoltaic module includes a photovoltaic cell layer and a transparent packaging structure for encapsulating the photovoltaic cell layer, the transparent packaging structure includes at least one layer of patterned non-adhesive film layer, the patterned non-adhesive film layer is a non-adhesive medium layer under lamination process conditions, the photovoltaic module physical medium layer on one side of the patterned non-adhesive film layer is a packaging adhesive layer, the photovoltaic module physical medium layer on the other side of the patterned non-adhesive film layer is a non-adhesive medium layer under lamination process conditions, and a patterned gap space is formed between the patterned non-adhesive film layer and the non-adhesive medium layer.

[0023] It is further defined that the non-adhesive medium layer is a photovoltaic cell layer.

[0024] It is further defined that the patterned non-adhesive film layer comprises at least one non-adhesive film unit, and the non-adhesive film units are regularly arranged and combined to form a pattern.

[0025] A method for preparing the above-mentioned patterned photovoltaic module comprises first preparing the photovoltaic cell layer and each structural layer of the packaging structure, and then arranging and laminating them into a photovoltaic module.

[0026] It is further defined that the packaging structure includes a transparent packaging structure for incident light, the transparent packaging structure includes at least one patterned film layer, the patterned film layer is a patterned adhesive film layer, the patterned adhesive film layer is an adhesive medium layer under lamination process conditions, the patterned adhesive film layer has patterned cavitations for forming a patterned gap space, the photovoltaic component physical medium layers on both sides of the patterned adhesive film layer are non-fluid or low-fluidity medium layers under lamination process conditions, and the cavitations on the patterned adhesive film layer are formed by foaming or blowing methods.

[0027] The beneficial effects of the present invention are as follows: the principle on which the scheme of the present invention is based is mainly to use optical refraction to change the direction of light, thereby forming color and light-dark contrast. After the light changes direction through refraction, it can still contribute to the power generation of the component, so the power loss is smaller. Through reasonable product design, such as reducing the pattern area to less than 10% through sketch graphic design, the power loss can be reduced to less than 2%, or even lower.

[0028] In order to form a strong refraction phenomenon and ensure that a clear pattern can be observed on the surface of the photovoltaic module, the refractive index difference between the patterned area in the module and the refractive index of other packaging structures is preferably greater than 0.5. Common dispersion prisms or ultra-thin optical glasses use a method of doping heavy atoms / molecules with large atomic weights to increase the refractive index of polymers, but referring to the definition of the nature of refractive index in "Feynman Lectures on Physics Volume 1", this solution will increase light absorption. The present invention adopts a subtractive solution, that is, a method of creating a gap space in the packaging structure of the component to produce a low refractive index area, the refractive index can be less than or equal to 1, and the low refractive index area absorbs less light. The refractive index of commonly used transparent packaging materials such as PET, EVA or glass is 1.5-1.6, and the refractive index of silicon wafers and SiNx, SiOx, ITO and other materials on the surface of silicon wafers is 2-3.5, which makes the refractive index difference between the gap space and the transparent packaging material or photovoltaic cell greater than 0.5. The larger refractive index difference triggers or enhances the phenomenon of interface optical change direction, causing differences in visual perception and forming a clear pattern on the surface of the photovoltaic module.

[0029] The solution of the present invention can produce graphic space gaps through mechanical or laser processing. The manufacturing method is simple and the added cost is extremely low. Artistic and cultural patterns (such as the Han tile patterns of the Chinese nation) are combined with photovoltaic modules to form a good decorative effect.

[0030] In summary, compared with the prior art, the solution of the present invention has lower optical loss, simpler manufacturing, lower cost, and better performance, thereby making it possible to produce artistic patterns on the surface of photovoltaic modules with high efficiency and low cost. BRIEF DESCRIPTION OF THE DRAWINGS

[0031] The present invention is further described below in conjunction with the accompanying drawings and embodiments;

[0032] Figure 1 is a schematic structural diagram of a photovoltaic module according to Embodiment 1 of the present invention;

[0033] Figure 2 is a schematic diagram of a patterned adhesive film layer with a zigzag pattern according to Example 1 of the present invention;

[0034] Figure 3 It is a pattern of classical pattern a;

[0035] Figure 4 It is a pattern of classical pattern b;

[0036] Figure 5 It is a pattern of classical pattern c;

[0037] Figure 6 It is a Han Dynasty stone relief pattern;

[0038] Figure 7 is a flowchart of the preparation process of the graphic composite layer of Example 1 of the present invention;

[0039] Figure 8 is a schematic structural diagram of a transparent film layer with an optical microstructure according to Example 2 of the present invention;

[0040] Fig. 9 is a schematic structural diagram of a photovoltaic module according to Embodiment 3 of the present invention;

[0041] Fig.10 is a flow chart of the layout of the photovoltaic module of the embodiment 1 of the present invention;

[0042] Fig.11 is a flow chart of the layout of the photovoltaic module of the third embodiment of the present invention;

[0043] Fig.12 is a flow chart of the layout of the photovoltaic module of the fourth embodiment of the present invention;

[0044] Fig.13 is a schematic structural diagram of a photovoltaic module according to embodiment 11 of the present invention;

[0045] Fig.14 is a structural schematic diagram of laying a non-adhesive film unit on a packaging adhesive layer according to embodiment 11 of the present invention;

[0046] In the figure, 1. front cover, 2. packaging adhesive layer, 3-1. transparent film layer, 3-2. patterned adhesive film layer, 4. photovoltaic cell layer, 5. back cover, 6. patterned gap space, 7. optical microstructure, 8. through hole, 9. patterned non-adhesive film layer, 9-1. non-adhesive film unit. DETAILED DESCRIPTION

[0047] Embodiment 1, as Figure 1 , 2 , 3, 4, 5, 6, 7 and 10, a patterned photovoltaic module includes a photovoltaic cell layer 4 and a transparent packaging structure that encapsulates the photovoltaic cell layer 4. The packaging structure that encapsulates the photovoltaic cell layer 4 in this embodiment 1 is a transparent packaging structure, and it is not ruled out that the packaging structure of the photovoltaic cell layer 4 has a non-transparent packaging structure, especially the packaging structure on the back of the photovoltaic cell layer 4, such as a non-transparent back cover 5. A patterned gap space 6 is provided inside the transparent packaging structure, and the refractive index of the patterned gap space 6 is lower than that of the transparent packaging structure, so that a low refractive index area is formed inside the photovoltaic module, and the refractive index difference between the patterned gap space 6 and the physical medium inside the photovoltaic module forms a pattern on the surface of the photovoltaic module.

[0048] The transparent packaging structure includes at least one patterned film layer, which is a patterned adhesive film layer 3-2. The patterned adhesive film layer 3-2 is an adhesive medium layer under the lamination temperature conditions. The patterned adhesive film layer 3-2 has a patterned through hole 8 for forming a patterned gap space 6; the photovoltaic component physical medium layer on both sides of the patterned adhesive film layer 3-2 is a non-flowable medium layer under the lamination temperature.

[0049] Specifically, the low refractive index region formed by the gap space of the patterned photovoltaic module of Example 1 is generated near the surface of the photovoltaic cell layer 4. The non-flowable medium layer on one side of the patterned adhesive film layer 3-2 is the photovoltaic cell layer 4, and the non-flowable medium layer on the other side of the patterned adhesive film layer 3-2 is the transparent film layer 3-1, which has no flowability at a lamination temperature of 150 to 200°C.

[0050] The patterned adhesive film layer 3-2 is extremely thin, with a thickness of 5 to 200 um. Since the patterned adhesive film layer 3-2 is an extremely thin layer of adhesive film, although the patterned adhesive film layer 3-2 can flow and cross-link during lamination, it is not enough to fill the patterned through holes 8 on the patterned adhesive film layer 3-2. Therefore, after lamination, the through holes 8 form a patterned gap space 6 with a low refractive index, which provides the possibility for the incident light to refract and change the propagation path.

[0051] The graphic of the graphical gap space 6 is a sketch graphic, preferably a linear sketch graphic, or a pen-drawn graphic. Figure 2 A schematic example is given. In this figure, the through holes 8 on the surface of the patterned adhesive film layer 3-2 depict a "Hui-shaped pattern" in traditional Chinese patterns.

[0052] Figure 2 The artistic pattern in is just one example. In fact, totems and patterns are often closely related to the development of national culture. Qin bricks and Han tiles decorated with patterns are an important cultural heritage of Chinese civilization. For example, selected from the Complete Collection of Chinese Patterns compiled by Mr. Wu Shan (Shandong Fine Arts Publishing House, 2009) Figures 3 to 5 Several typical classical patterns, and Figure 6 Han Dynasty stone relief patterns. Figure 2 Like the circular patterns, these patterns can be easily mass-produced by the method disclosed in the present invention. Typical patterns of other ethnic groups, such as Egyptian patterns, are also well preserved in museums around the world, such as the Louvre in France, and can also be mass-produced by the scheme disclosed in the present invention.

[0053] like Figure 1 As shown, the specific structure of the patterned photovoltaic module includes, from top to bottom, a front cover plate 1, a packaging adhesive layer 2, a transparent film layer 3-1, a patterned adhesive film layer 3-2, a photovoltaic cell layer 4, a patterned adhesive film layer 3-2, a transparent film layer 3-1, a packaging adhesive layer 2 and a rear cover plate 5. To simplify the figure, the welding strips connecting the photovoltaic cells in the photovoltaic cell layer 4 are not drawn in the figure.

[0054] The front cover plate 1 is glass, the rear cover plate 5 is glass, the encapsulation adhesive layer 2 is EVA or POE, the transparent film layer 3-1 is PET that does not have fluidity at a lamination temperature of 150-200°C, and the patterned adhesive film layer 3-2 is EVA. The photovoltaic cells are electrically and mechanically connected to form a photovoltaic cell layer 4.

[0055] More specifically, the front cover 1 and the rear cover 5 are 2.0 mm tempered glass, the encapsulation adhesive layer 2 is 560 g POE, the transparent film layer 3-1 is 25 um PET, the patterned adhesive film layer 3-2 is 50 um EVA, and the photovoltaic cell layer 4 is a heterojunction cell layer.

[0056] The method for preparing the patterned photovoltaic module is as follows: firstly, the photovoltaic cell layer 4 and various structural layers of the packaging structure are prepared, and then layout and laminate them into a photovoltaic module.

[0057] The specific steps are as follows:

[0058] First, the photovoltaic cells are electrically and mechanically connected to form a photovoltaic cell layer 4, and the transparent film layer 3-1 and the patterned adhesive film layer 3-2 are compounded into a two-layer patterned composite layer, wherein the patterned adhesive film layer 3-2 is a layer of adhesive film, which is prepared by a casting method, and then through holes 8 are made on the surface of the adhesive film by mechanical punching, mechanical cutting or laser processing. The through holes 8 are dots or lines, thereby forming an artistic pattern on the adhesive film, realizing the patterning of the adhesive film, and obtaining the patterned adhesive film layer 3-2, such as Figure 7 As shown;

[0059] Then, if Fig.10 As shown, the front cover plate 1, the encapsulation adhesive layer 2, the patterned composite layer, the photovoltaic cell layer 4, the patterned composite layer, the encapsulation adhesive layer 2, and the rear cover plate 5 are laid in sequence to complete the layout of the photovoltaic module;

[0060] Finally, the photovoltaic module that has completed layout enters a laminator for lamination to obtain the photovoltaic module with pattern of this embodiment 1.

[0061] Embodiment 2, in order to enhance the change of the light path by the patterned gap space 6 in embodiment 1, on the basis of embodiment 1, as Figure 8 As shown, an optical microstructure 7 is formed on the light incident side of the patterned gap space 6 to enhance the pattern effect on the surface of the photovoltaic module. Specifically, the optical microstructure 7 is manufactured on the side of the transparent film layer 3-1 facing the patterned adhesive film layer 3-2. The optical microstructure 7 is a linear groove, a convex-concave texture or a point-type polyhedron, etc. The point-type polyhedron is specifically a pyramid point, a regular hexagonal prism, etc. The linear groove is specifically a groove of an inverted regular triangular prism, etc. The optical microstructure 7 is distributed on the entire surface or a local surface of the transparent film layer 3-1, and the local surface is the surface area corresponding to the patterned gap space 6.

[0062] The first method for manufacturing the optical microstructure 7 on the transparent film layer 3-1 is to mechanically engrave the surface of the transparent film layer 3-1 close to the patterned adhesive film layer 3-2 to form linear grooves, convex and concave textures or point polyhedrons of specific angles and sizes on the surface.

[0063] The second method for manufacturing the optical microstructure 7 on the transparent film layer 3-1 is: coating a layer of polymer film on the surface of the transparent film layer 3-1 close to the patterned adhesive film layer 3-2, and then forming the optical microstructure 7 by embossing or rolling, forming linear grooves, convex and concave textures or point polyhedrons of specific angles and sizes on the surface; then, shaping it by thermal curing, photocuring or other energy curing methods.

[0064] Embodiment 3, as Fig. 9 and 11 As shown, compared with Example 1, the low refractive index area formed by the gap space of the patterned photovoltaic module of Example 3 is generated near the surface of the front cover plate 1.

[0065] like Fig. 9 As shown, the specific structure of the patterned photovoltaic module is: from top to bottom, it includes a front cover plate 1, a patterned adhesive film layer 3-2, a photovoltaic cell layer 4, a packaging adhesive layer 2 and a rear cover plate 5.

[0066] Compared with the conventional packaging adhesive layer 2, the fluidity of the patterned adhesive film layer 3-2 at the lamination temperature is worse. The patterned adhesive film layer 3-2 is generally a pre-crosslinked polymer film, a low-fat-soluble polymer film or a fiber-reinforced polymer reinforced film. The patterned adhesive film layer 3-2 can also be patterned by making through holes 8 on its surface by mechanical punching, mechanical cutting or laser processing.

[0067] More specifically, the front cover 1 is 3.2 mm tempered glass, the patterned adhesive film layer 3-2 is 560 grams of low-fat EVA, the photovoltaic cell layer 4 is a PERC cell layer, the encapsulation adhesive layer 2 is 560 grams of conventional EVA, and the rear cover 5 is a TPT backplane.

[0068] The specific steps of the method for preparing the patterned photovoltaic module are as follows:

[0069] First, the photovoltaic cell layer 4 and each structural layer of the encapsulation structure are prepared;

[0070] Then, if Fig.11 As shown, the front cover plate 1, the patterned adhesive film layer 3-2, the photovoltaic cell layer 4, the encapsulation adhesive layer 2, and the rear cover plate 5 are laid in sequence to complete the layout of the photovoltaic module;

[0071] Finally, the photovoltaic module that has completed layout enters a laminator for lamination to obtain the photovoltaic module with pattern of this embodiment 3.

[0072] Embodiment 4, compared with Embodiment 3, manufactures an optical microstructure 7 on the lower surface of the front cover plate 1 of the glass material on the basis of Embodiment 3. The optical microstructure 7 can be simply formed in the process of glass rolling and embossing.

[0073] Embodiment 5 is a second solution of forming a low refractive index region through a gap space near the surface of the front cover plate 1. Compared with Embodiment 1, it is basically the same, except that the specific structure of the patterned photovoltaic module includes, from top to bottom, the front cover plate 1, the patterned adhesive film layer 3-2, the transparent film layer 3-1, the encapsulation adhesive layer 2, the photovoltaic cell layer 4, the patterned adhesive film layer 3-2, the transparent film layer 3-1, the encapsulation adhesive layer 2 and the rear cover plate 5.

[0074] The front cover plate 1 is 3.2 mm tempered glass, the patterned adhesive film layer 3-2 is 50 um EVA, the transparent film layer 3-1 is 25 um PET, the encapsulation adhesive layer 2 is 560 g POE, and the photovoltaic cell layer 4 is a TOPCON cell layer.

[0075] The patterned adhesive film layer 3 - 2 , the transparent film layer 3 - 1 , and the encapsulation adhesive layer 2 are compounded into a three-layer patterned composite layer for layout and lamination.

[0076] like Fig.12 As shown, the layout steps are: laying the front cover 1, the patterned composite layer, the photovoltaic cell layer 4, the patterned composite layer, and the rear cover 5 in sequence to complete the layout of the photovoltaic module.

[0077] Embodiment 6 is basically the same as Embodiment 1, except that the rear cover plate 5 is a TPT back plate.

[0078] The layout steps are as follows: 2.0 mm tempered glass, 560 g POE, a graphic composite layer of two layers of EVA and PET in Example 1, a heterojunction photovoltaic cell layer 4, a graphic composite layer of two layers of EVA and PET in Example 1, 560 g POE, and a TPT backplane are laid in sequence to complete the layout of the photovoltaic module.

[0079] Example 7 is basically the same as Example 1, except that the patterned film layer is a patterned transparent film layer 3-1, the patterned transparent film layer 3-1 is a non-fluid or low-fluidity dielectric layer at the lamination temperature, the patterned transparent film layer 3-1 has a patterned groove for forming a patterned gap space 6, and the physical dielectric layer of the photovoltaic module on the grooved side of the patterned transparent film layer 3-1 is a low-fluidity adhesive dielectric layer at the lamination temperature.

[0080] Specifically, the patterned transparent film layer 3 - 1 is the front cover plate 1 in the packaging structure, and patterned grooves are made on the lower surface of the front cover plate 1 facing the photovoltaic cell layer 4 .

[0081] The specific structure of the patterned photovoltaic module includes, from top to bottom, a patterned front cover plate 1, a packaging adhesive layer 2, a photovoltaic cell layer 4, a packaging adhesive layer 2 and a rear cover plate 5.

[0082] The encapsulation adhesive layer 2 is a pre-crosslinked polymer film, a low-fat-soluble polymer film or a fiber-reinforced polymer reinforced film, which is a low-fluidity adhesive medium layer with poor fluidity. During the lamination process, the encapsulation adhesive layer 2 will not fill in the patterned grooves on the patterned adhesive film layer 3-2.

[0083] Embodiment 8 is basically the same as Embodiment 1, and the packaging structure includes a transparent packaging structure for incident light, and the transparent packaging structure includes a patterned film layer, and the patterned film layer is a patterned adhesive film layer 3-2. The difference is that the patterned adhesive film layer 3-2 has patterned cavitations for forming a patterned gap space 6, and the physical dielectric layers of the photovoltaic components on both sides of the patterned adhesive film layer 3-2 are non-fluid or low-fluidity dielectric layers at the lamination temperature, and the cavitations on the patterned adhesive film layer 3-2 are formed by foaming or blowing methods.

[0084] The specific structure of the patterned photovoltaic module includes, from top to bottom, a front cover plate 1, a patterned adhesive film layer 3-2, a photovoltaic cell layer 4, a packaging adhesive layer 2 and a rear cover plate 5.

[0085] The patterned adhesive film layer 3-2 is selected from packaging adhesive materials with low fluidity, such as pre-crosslinked film, low soluble film, or fiber reinforced film, etc. During the casting or coating process, cavitation is formed in the patterned adhesive film layer 3-2 by cavitation doping to achieve patterning. The cavitation doping method includes foaming, blowing and other cavitation doping methods. At the same time, plasma, heat, light, electromagnetic wave and other methods are selected or combined to uniformly or non-uniformly solidify the patterned adhesive film layer 3-2, so that the cavitation is retained. The photovoltaic module physical dielectric layer on both sides of the patterned adhesive film layer 3-2 is a non-fluid or low-fluid dielectric layer at the lamination temperature. These two methods ensure that the patterned adhesive film layer 3-2 will not be filled and disappeared by other dielectric layer materials during the lamination process.

[0086] The specific method of cavitation doping by foaming is: in the process of casting or coating manufacturing, a foaming agent is selectively added to different areas of the material of the patterned adhesive film layer 3-2, and the concentration of the foaming agent is controlled according to the graphic requirements. The higher the concentration of the foaming agent, the more foaming is, and the more graphic gap spaces 6 are formed. The lower the concentration of the foaming agent, the less foaming is, and the less graphic gap spaces 6 are formed. According to the sketching principle, a sketch pattern will be formed on the surface of the photovoltaic module.

[0087] The specific steps of a method for preparing a patterned photovoltaic module of Example 8 are as follows:

[0088] First, the photovoltaic cells are electrically and mechanically connected to form a photovoltaic cell layer 4, and the adhesive film material of the patterned adhesive film layer 3-2 is selectively mixed with a foaming agent in different areas during its casting or coating manufacturing process;

[0089] Then, the front cover plate 1, the adhesive film material mixed with the foaming agent, the photovoltaic cell layer 4, the encapsulation adhesive layer 2, and the rear cover plate 5 are laid in sequence to complete the layout of the photovoltaic module;

[0090] Finally, the photovoltaic modules that have completed typesetting enter the laminator for lamination. The foaming agent foams at the lamination temperature to pattern the adhesive film material mixed with the foaming agent. The adhesive film material mixed with the foaming agent forms a patterned adhesive film layer 3-2, thereby obtaining the patterned photovoltaic module of this embodiment 8.

[0091] Example 9 is basically the same as Example 1, except that the transparent packaging structure includes at least one patterned film layer, which is a patterned adhesive film layer 3-2, and the patterned adhesive film layer 3-2 has a patterned non-bonding surface under lamination temperature conditions, which is used to form a patterned gap space 6, and the physical dielectric layer of the photovoltaic component on the side of the patterned non-bonding surface of the patterned adhesive film layer 3-2 is a non-bonding dielectric layer under lamination temperature conditions.

[0092] The specific structure of the patterned photovoltaic module includes, from top to bottom, a front cover plate 1, a patterned adhesive film layer 3-2, a photovoltaic cell layer 4, a packaging adhesive layer 2 and a rear cover plate 5.

[0093] The patterned adhesive film layer 3-2 is non-uniformly cured by plasma, heat, light, electromagnetic waves and other methods to achieve the patterning of the patterned adhesive film layer 3-2. Specifically, laser is preferably used as the patterning processing workpiece. The adhesive film material of the patterned adhesive film layer 3-2 will undergo non-uniform curing under the action of laser to form a non-bonding surface. A patterned gap space 6 will be formed between the non-bonding surface and the front cover plate 1 after typesetting and lamination.

[0094] By adjusting the laser parameters, the curing degree of the adhesive film material of the patterned adhesive film layer 3-2 can be adjusted. Different fixing degrees have different adhesive properties. Laser grooving and hole opening can also be achieved by laser.

[0095] Example 10 is basically the same as Example 1, except that in Example 1, the transparent film layer 3-1 and the patterned adhesive film layer 3-2 are directly hot-pressed and composited, while in Example 10, the transparent film layer 3-1 and the patterned adhesive film layer 3-2 are bonded and composited into a patterned composite layer by an adhesive.

[0096] Embodiment 11, as Fig.13 and 14As shown, a patterned photovoltaic component includes a photovoltaic cell layer 4 and a transparent packaging structure that encapsulates the photovoltaic cell layer 4, the transparent packaging structure includes at least one layer of patterned non-adhesive film layer 9, the patterned non-adhesive film layer 9 is a non-adhesive medium layer at the lamination temperature, the photovoltaic component physical medium layer on one side of the patterned non-adhesive film layer 9 is a packaging adhesive layer 2, the photovoltaic component physical medium layer on the other side of the patterned non-adhesive film layer 9 is a non-adhesive medium layer at the lamination temperature, and a patterned gap space 6 is formed between the patterned non-adhesive film layer 9 and the non-adhesive medium layer.

[0097] The principle of forming a patterned gap space 6 between the patterned non-adhesive film layer 9 and the non-adhesive medium layer is as follows: the material surface of the patterned non-adhesive film layer 9 and the material surface of the non-adhesive medium layer are not absolutely flat. As long as they are not absolutely flat, a patterned gap space 6 will still be formed between the two after they are laminated together. The patterned gap space 6 forms a low refractive index area inside the photovoltaic module, and the refractive index difference between the patterned gap space 6 and the physical medium inside the photovoltaic module forms a pattern on the surface of the photovoltaic module.

[0098] In order to ensure the effect of forming a pattern on the surface of the photovoltaic module, a patterned non-adhesive film layer 9 and / or a non-adhesive dielectric layer with a certain surface roughness may be selected or manufactured.

[0099] In this embodiment 11, preferably, the non-adhesive medium layer is the photovoltaic cell layer 4. The surface of the photovoltaic cell of the photovoltaic cell layer 4 has a velvet surface formed by velveting, and after lamination, the patterned non-adhesive film layer 9 and the photovoltaic cell layer 4 are not completely attached, thereby forming a patterned gap space 6 between the two.

[0100] The patterned non-adhesive film layer 9 includes at least one non-adhesive film unit 9 - 1 , and the non-adhesive film units 9 - 1 are regularly arranged and combined to form a pattern.

[0101] The following describes the method for preparing the patterned photovoltaic module of this embodiment 11 by taking the packaging adhesive layer 2 as EVA and the non-adhesive medium layer as the photovoltaic cell layer 4 as an example.

[0102] A method for preparing a patterned photovoltaic module comprises the following steps:

[0103] (1) processing a plurality of non-bonded film units 9-1;

[0104] (2) During the component layout process, a plurality of non-adhesive film units 9-1 are laid between the photovoltaic cell layer 4 and the EVA to form a patterned non-adhesive film layer 9, and the non-adhesive film units 9-1 are regularly arranged and combined to form a desired pattern;

[0105] (3) The photovoltaic module after layout is put into a laminator for lamination to obtain the photovoltaic module with pattern of this embodiment 11.

[0106] Step (1) specifically includes the following steps:

[0107] (1.1) Select PET film or PE film and plan the shape of the non-adhesive film unit 9-1;

[0108] (1.2) PET film or PE film is cut in batches by machine tool or laser to obtain batches of non-adhesive film units 9-1. The shape and size of the non-adhesive film units 9-1 can be adjusted and controlled by the size of the components. The processing is simple, the operation is convenient, and the yield rate is high.

[0109] Step (2) specifically includes the following steps:

[0110] (2.1) Prepare the front cover 1, EVA, photovoltaic cells, and rear cover 5, where the front cover 1 is made of glass;

[0111] (2.2) First, lay the glass on the laminating table, then lay the EVA, and then regularly spread the non-adhesive film units 9-1 on the EVA to form various patterns. The non-adhesive film units 9-1 do not overlap, such as Fig.14 As shown, the non-adhesive film unit 9-1 is circular, and a plurality of circular non-adhesive film units 9-1 in the upper region of the encapsulation adhesive layer 2 form a circular pattern, and a plurality of circular non-adhesive film units 9-1 in the lower region of the encapsulation adhesive layer 2 form the capitalized English word CAN;

[0112] (2.3) Lay photovoltaic cells on the EVA of the non-adhesive film unit 9-1 according to the template, and then lay EVA and the rear cover plate 5 in sequence.

[0113] After lamination, the pattern effect on the surface of the photovoltaic module is observed, and it can be found that the non-adhesive film unit 9-1 presents a bright light blue color that is obviously different from the color of the contact part between the EVA and the photovoltaic cell.

[0114] The patterned photovoltaic module of this embodiment 11 forms the required pattern by regularly arranging and combining the non-adhesive film units 9-1, and has simple materials, simple processes, and high flexibility and success rate.

Claims

1. A photovoltaic module with a pattern, characterized by: A patterned gap space (6) is provided inside the photovoltaic module for forming a low refractive index region, and a refractive index difference between the patterned gap space (6) and the physical medium inside the photovoltaic module forms a pattern on the surface of the photovoltaic module; A transparent packaging structure comprising a photovoltaic cell layer (4) and the photovoltaic cell layer (4) being packaged; The transparent packaging structure comprises at least one patterned film layer, which is a patterned adhesive film layer (3-2). The patterned adhesive film layer (3-2) is an adhesive medium layer under lamination process conditions. The patterned adhesive film layer (3-2) has patterned through holes (8), grooves or cavities for forming a patterned gap space (6). The photovoltaic component physical medium layers on both sides of the patterned adhesive film layer (3-2) are non-fluid or low-fluidity medium layers under lamination process conditions.

2. The patterned photovoltaic module according to claim 1, characterized in that: The physical medium inside the photovoltaic assembly on one side of the patterned gap space (6) is a photovoltaic cell.

3. The patterned photovoltaic module according to claim 1, characterized in that: The internal physical medium of the photovoltaic module on one side of the patterned gap space (6) is a photovoltaic cell with a velvet surface formed by velveting.

4. The patterned photovoltaic module according to claim 1, characterized in that: The side surface of the patterned gap space (6) has an optical microstructure (7) for enhancing the pattern effect on the surface of the photovoltaic module.

5. The patterned photovoltaic module according to claim 1, characterized in that: The photovoltaic module physical medium layer on the light incident side of the patterned adhesive film layer (3-2) is a non-fluid medium layer, and an optical microstructure (7) is provided on the side of the non-fluid medium layer facing the patterned adhesive film layer (3-2). The optical microstructure (7) is distributed on the entire surface or a local surface of the non-fluid medium layer, and the local surface is a surface area corresponding to the patterned gap space (6).

6. The patterned photovoltaic module according to claim 1 or 5, characterized in that: The thickness of the patterned adhesive film layer (3-2) is 5 to 200 μm.

7. The patterned photovoltaic module according to claim 1 or 5, characterized in that: One side of the patterned adhesive film layer (3-2) is a photovoltaic cell layer (4), and the other side of the patterned adhesive film layer (3-2) is a transparent film layer (3-1).

8. The patterned photovoltaic module according to claim 1 or 5, characterized in that: The specific structure is as follows: from top to bottom, it includes a front cover plate (1), a packaging adhesive layer (2), a transparent film layer (3-1), a patterned adhesive film layer (3-2), a photovoltaic cell layer (4), a patterned adhesive film layer (3-2), a transparent film layer (3-1), a packaging adhesive layer (2) and a rear cover plate (5); Alternatively, the specific structure is: from top to bottom, it includes a front cover plate (1), a packaging adhesive layer (2), a transparent film layer (3-1), a patterned adhesive film layer (3-2), a photovoltaic cell layer (4), a packaging adhesive layer (2) and a rear cover plate (5); Alternatively, the specific structure is: from top to bottom, it includes a front cover plate (1), a patterned adhesive film layer (3-2), a photovoltaic cell layer (4), a patterned adhesive film layer (3-2) and a rear cover plate (5); Alternatively, the specific structure is: from top to bottom, it includes a front cover plate (1), a patterned adhesive film layer (3-2), a photovoltaic cell layer (4), a packaging adhesive layer (2) and a rear cover plate (5).

9. The patterned photovoltaic module according to claim 4, characterized in that: The optical microstructure (7) is a groove, a convex-concave texture or a point-type polyhedron.

10. The patterned photovoltaic module according to claim 1, characterized in that: The graphic of the graphical gap space (6) is a sketch graphic.

11. A photovoltaic module with a pattern, characterized by: A patterned gap space (6) is provided inside the photovoltaic module for forming a low refractive index region, and a refractive index difference between the patterned gap space (6) and the physical medium inside the photovoltaic module forms a pattern on the surface of the photovoltaic module; The transparent packaging structure comprises a photovoltaic cell layer (4) and a packaging photovoltaic cell layer (4), wherein the transparent packaging structure comprises at least one patterned film layer, wherein the patterned film layer is a patterned adhesive film layer (3-2), wherein the patterned adhesive film layer (3-2) is an adhesive medium layer under lamination process conditions, wherein the patterned adhesive film layer (3-2) has a patterned non-adhesive surface under lamination process conditions and is used to form a patterned gap space (6), and wherein the photovoltaic component physical medium layer on the side of the patterned adhesive film layer (3-2) having the patterned non-adhesive surface is a non-adhesive medium layer under lamination process conditions.

12. The patterned photovoltaic module according to claim 11, characterized in that: The physical medium inside the photovoltaic assembly on one side of the patterned gap space (6) is a photovoltaic cell.

13. The patterned photovoltaic module according to claim 11, characterized in that: The internal physical medium of the photovoltaic module on one side of the patterned gap space (6) is a photovoltaic cell with a velvet surface formed by velveting.

14. The patterned photovoltaic module according to claim 11, characterized in that: The side surface of the patterned gap space (6) has an optical microstructure (7) for enhancing the pattern effect on the surface of the photovoltaic module.

15. The patterned photovoltaic module according to claim 14, characterized in that: The optical microstructure (7) is a groove, a convex-concave texture or a point-type polyhedron.

16. The patterned photovoltaic module according to claim 11, characterized in that: The graphic of the graphical gap space (6) is a sketch graphic.

17. A photovoltaic module with a pattern, characterized by: A patterned gap space (6) is provided inside the photovoltaic module for forming a low refractive index region, and a refractive index difference between the patterned gap space (6) and the physical medium inside the photovoltaic module forms a pattern on the surface of the photovoltaic module; A transparent packaging structure comprising a photovoltaic cell layer (4) and the photovoltaic cell layer (4) being packaged; The transparent packaging structure comprises at least one patterned film layer, the patterned film layer is a patterned transparent film layer (3-1), the patterned transparent film layer (3-1) is a non-fluid or low-fluidity medium layer under lamination process conditions, the patterned transparent film layer (3-1) has a patterned groove for forming a patterned gap space (6), and the photovoltaic component physical medium layer on the groove side of the patterned transparent film layer (3-1) is a low-fluidity bonding medium layer under lamination process conditions.

18. The patterned photovoltaic module according to claim 17, characterized in that: The side surface of the patterned gap space (6) has an optical microstructure (7) for enhancing the pattern effect on the surface of the photovoltaic module.

19. The patterned photovoltaic module according to claim 17, characterized in that: The graphic transparent film layer (3-1) is specifically a front cover plate (1) or a rear cover plate (5).

20. The patterned photovoltaic module according to claim 18, characterized in that: The optical microstructure (7) is a groove, a convex-concave texture or a point-type polyhedron.

21. The patterned photovoltaic module according to claim 17, characterized in that: The graphic of the graphical gap space (6) is a sketch graphic.

22. A photovoltaic module with a pattern, characterized by: A patterned gap space (6) is provided inside the photovoltaic module for forming a low refractive index region, and a refractive index difference between the patterned gap space (6) and the physical medium inside the photovoltaic module forms a pattern on the surface of the photovoltaic module; A transparent packaging structure comprising a photovoltaic cell layer (4) and a packaging photovoltaic cell layer (4), wherein the transparent packaging structure comprises at least one patterned non-adhesive film layer (9), wherein the patterned non-adhesive film layer (9) is a non-adhesive medium layer under lamination process conditions, wherein the photovoltaic module physical medium layer on one side of the patterned non-adhesive film layer (9) is a packaging adhesive layer (2), wherein the photovoltaic module physical medium layer on the other side of the patterned non-adhesive film layer (9) is a non-adhesive medium layer under lamination process conditions, and wherein a patterned gap space (6) is formed between the patterned non-adhesive film layer (9) and the non-adhesive medium layer. The non-adhesive medium layer is a photovoltaic cell layer (4), and the surface of the photovoltaic cells of the photovoltaic cell layer (4) has a velvet surface formed by velveting.

23. The patterned photovoltaic module according to claim 22, characterized in that: The side surface of the patterned gap space (6) has an optical microstructure (7) for enhancing the pattern effect on the surface of the photovoltaic module.

24. The patterned photovoltaic module according to claim 23, characterized in that: The optical microstructure (7) is a groove, a convex-concave texture or a point-type polyhedron.

25. The patterned photovoltaic module according to claim 22, characterized in that: The graphic of the graphical gap space (6) is a sketch graphic.

26. A method for preparing a patterned photovoltaic module according to claim 1 or 11 or 17 or 22, characterized in that: Firstly, a photovoltaic cell layer (4) and various structural layers of a packaging structure for packaging the photovoltaic cell layer (4) are prepared, and then they are laid out and laminated into a photovoltaic module.

27. A method for preparing a patterned photovoltaic module, characterized in that: The patterned photovoltaic module has a patterned gap space (6) inside the photovoltaic module for forming a low refractive index region, and the refractive index difference between the patterned gap space (6) and the physical medium inside the photovoltaic module forms a pattern on the surface of the photovoltaic module; Firstly, a photovoltaic cell layer (4) and various structural layers of a packaging structure for packaging the photovoltaic cell layer (4) are prepared, and then they are laid out and laminated into a photovoltaic module; The packaging structure comprises a transparent packaging structure for incident light, the transparent packaging structure comprises at least one patterned film layer, the patterned film layer is a patterned adhesive film layer (3-2), the patterned adhesive film layer (3-2) is an adhesive medium layer under lamination process conditions, the patterned adhesive film layer (3-2) has patterned cavitations for forming a patterned gap space (6), the photovoltaic component physical medium layers on both sides of the patterned adhesive film layer (3-2) are non-fluid or low-fluidity medium layers under lamination process conditions, and the cavitations on the patterned adhesive film layer (3-2) are formed by foaming or blowing methods.

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