A curved surface solar glass, manufacturing method and vehicle comprising the same

Abstract

The present invention discloses a curved solar glass, a manufacturing method thereof, and a vehicle including the same. The curved solar glass includes an outer curved glass, an outer film, a solar cell, an inner film, and an inner curved glass which are sequentially stacked; the solar cell includes a plurality of solar cell chips connected by solder tapes; adjacent two solar cell chips are connected by the solder tape, and the solder tape includes three consecutive segments: a first segment solder tape, a second segment solder tape, and a third segment solder tape; the lower surface of the first segment solder tape is connected to the upper surface of one solar cell chip; the upper surface of the third segment solder tape is connected to the lower surface of another solar cell chip, and the second segment solder tape separates adjacent two solar cell chips; both the first segment solder tape and the third segment solder tape exceed the edge of the solar cell chip at one end where they are connected to the second segment solder tape.

Description

Technical Field

[0001] The present invention relates to the field of glass, and particularly to a curved solar glass, a manufacturing method thereof, and a vehicle including the same. Background Art

[0002] Patent application CN1794472A discloses a solar car sunroof and a manufacturing method thereof, including: a car sunroof glass, a solar cell, a back seal material layer, an adhesive layer, an extraction electrode, an electrode covering layer, and a sealing edge material. It also includes using the car sunroof glass as a substrate, on which a solar cell complementary to the arc surface of the sunroof glass is supported. It further includes: a photovoltaic module with an integrated arc structure laminated by a dedicated module, adopting an arc lamination process to form an integrated arc structure by connecting the solar cells arranged in series / parallel on the arc surface of the car sunroof glass, and having a power generation function. It can be mass-produced, significantly improving the solar cell. However, the module of the arc lamination equipment is a hexahedron, and at least one surface is processed into a curved surface that coincides with the arc surface of the car sunroof glass; obviously, this is an arc lamination tooling. After placing the semi-finished product before lamination on this tooling, the lamination and encapsulation process is then carried out. The car sunroof has a development trend towards fixed sunroofs. Fixed sunroofs have a relatively large area, and the required arc lamination tooling is a very large tooling. Then there are two ways. One is to make the area of the lamination equipment very large, which is very demanding on the equipment. The other is to use the existing lamination equipment with a relatively limited cavity area, and the number of sunroofs that can be laminated at one time is very small, which will inevitably limit the rhythm / output. In addition, when the lamination equipment is in a vacuum state, heating the solar car sunroof to a specified temperature takes a long time, and the temperature of the sunroof glass is uneven. Therefore, this method is not suitable for mass production. Moreover, installing the sealing edge material around the laminated solar car sunroof will make the appearance of the car sunroof relatively ugly, not meeting the aesthetic requirements of the car. The lamination process parameters in this patent application are applicable to EVA film encapsulation, and it is difficult to achieve effective bonding between the PVB film and the glass according to this lamination process, and defects such as bubbles or delamination are likely to occur. Not to mention that after aging experiments, defects such as bubbles or delamination are even more serious. Generally, PVB needs to be processed with an autoclave or a process combining roll pressing and high pressure or initial pressing and high pressure. Then, due to the force during roll pressing or initial pressing and air extraction, the battery chips in the curved glass are likely to have cracks or hidden cracks.

[0003] Patent application CN108365041A discloses a method for preparing a photovoltaic module. First, a preset section in the solder ribbon is thinned, so that the solder ribbon is divided into a first solder ribbon section, a second solder ribbon section, and a third solder ribbon section, wherein the thickness of the third solder ribbon section is lower than the thicknesses of the first solder ribbon section and the second solder ribbon section, that is, the original solder ribbon is made into a solder ribbon with uneven thickness; when using the solder ribbon to connect solar cells, the thinned third solder ribbon section serves as the bent part between two adjacent solar cells. Since the solder ribbon section between the solar cells is relatively thin, thinning the third solder ribbon section will increase the width of the third solder ribbon section at the same time. When laminating to form a photovoltaic module, a certain space for elastic deformation can be left between adjacent solar cells, and at the same time, the pressure and pressure of the solder ribbon on the solar cells can be reduced, thereby reducing the risk of hidden cracks in the solar cells. This technical solution is used to solve the problem that when laminating a planar photovoltaic module, if the thickness of the solder ribbon is made too large, when laminating the planar photovoltaic module, due to the force being concentrated at the edge position of the cell, thinning the solder ribbon between the two cells can solve the problem of hidden cracks in the cells of the planar photovoltaic module. However, during room-temperature vacuum pumping of a curved photovoltaic module, due to the air pressure difference inside and outside the laminated glass, a direct pressure is formed on the solder ribbon, so the risk of hidden cracks will increase at all positions of the solder ribbon on the cell. Therefore, thinning only the third section of the solder ribbon cannot completely solve the problem of hidden cracks in the curved photovoltaic glass.

[0004] Patent document CN107369732B discloses a preparation method of a solar double-glass module. Its process mainly includes processes such as string welding, cutting, lamination, pressing, and assembly. Among them, the pressing process is the core process, and parameters such as temperature and pressure need to be precisely controlled. Before pressing, the double-glass module needs to be fixed with a pressing plate. At least one rectangular hollow part is provided in the pressing plate for placing the double-glass module. The shape of the rectangular hollow part matches the shape of the double-glass module. The thickness of the pressing plate is less than the thickness of the double-glass module before lamination and greater than the thickness after lamination. And a heat-insulating cloth is wrapped on the outer surface of the pressing plate. After the double-glass module is fixed, the relative sliding of the upper and lower glass plates can be prevented, thereby reducing the generation of bubbles. After the heat-insulating cloth is set at the end of lamination, it is convenient for the next operation, preventing the operator from being scalded by the high-temperature pressing plate, and reducing the direct contact of the overflowing POE glue with the metal, which is convenient for replacement and cleaning. The specific pressing process is: control the temperature at 148°C to 152°C, evacuate for 360 to 480 s, and keep the vacuum degree at -99 to 105 kPa; after the evacuation is completed, apply a pressure of -60 kPa for 4 to 6 s, continue to apply a pressure of -40 kPa for 4 to 6 s, and then continue to apply a pressure of -15 kPa for 1000 to 1100 s. Obviously, the pressing plate or the limiting frame is used to frame the planar photovoltaic module. The temperature of the pressing chamber is 148°C to 152°C, and the vacuum is -99 to 105 kPa. The planar double-glass photovoltaic module is placed in the pressing chamber under this condition, and the inside and outside of the glass of the double-glass module are simultaneously at a vacuum degree without air pressure difference. In a high-temperature and vacuum chamber, after POE melts within 360 to 480 s, different pressures and times are applied to the photovoltaic module through the silica gel plate to complete the pressing process. Summary of the Invention

[0005] The purpose of the present invention is to provide a curved solar glass, a manufacturing method and a vehicle including the same. The curved solar glass and its manufacturing method can solve the problem of hidden cracks in the battery chips in the curved solar laminated glass.

[0006] In order to achieve the above purposes, the present invention adopts the following technical solutions:

[0007] On the one hand, the present invention provides a curved solar glass, which includes an outer curved glass, an outer film adhesive, a solar cell, an inner film adhesive and an inner curved glass stacked in sequence;

[0008] The solar cell includes a plurality of solar cell chips connected by welding tapes;

[0009] Two adjacent solar cells are connected by the welding ribbon, and the welding ribbon includes three sections in sequence: a first welding ribbon section, a second welding ribbon section and a third welding ribbon section; the lower surface of the first welding ribbon section is connected to the upper surface of one solar cell; the upper surface of the third welding ribbon section is connected to the lower surface of another solar cell, and the second welding ribbon section separates the two adjacent solar cells;

[0010] The first section of the welding ribbon and the third section of the welding ribbon both extend beyond the edge of the solar cell at one end connected to the second section of the welding ribbon.

[0011] In the curved solar glass of the present invention, the solar cell is connected by bending the middle of the welding strip, and the second section of the welding strip is the bending part. Hidden cracks or visible cracks in the solar cell are mainly caused by stress concentration when the welding strip is pressed on the solar cell, so it is required that the bending position cannot directly contact the cell, otherwise cracks will easily occur. Therefore, the present invention preferably has a certain distance between the bending part and the edge of the cell, that is, the first section of the welding strip and the third section of the welding strip both extend beyond the edge of the solar cell at the end connected to the second section of the welding strip, and the distances on both sides can be equal or unequal.

[0012] According to the curved solar glass of the present invention, preferably, the thickness of the first welding strip and the third welding strip is ≤0.2 mm.

[0013] Thinning the first and third sections of the welding strip helps to reduce the yield strength in the thickness direction, helps to reduce the pressure on the position of the welding strip on the solar cell when evacuating during the preparation process, and reduces the risk of hidden cracks in the solar cell at the welding strip; the present invention limits the thickness of the first and third sections of the welding strip to ≤ 0.2 mm. The thickness of the bending part of the welding strip (i.e., the second section of the welding strip) can be the same or different from that of the first and third sections of the welding strip. If the thickness is the same, the processing difficulty is reduced, which is convenient for mass production and improves the work efficiency. In addition, the specific bending shape can be an S-shaped bend, or a Z-shaped bend of 90° or other angles (such as an obtuse angle).

[0014] According to the curved solar glass of the present invention, preferably, the distances of the first section of the welding strip and the third section of the welding strip beyond the edge of the solar cell are both greater than or equal to 10% of the distance between two adjacent solar cells, for example, 25%, but not limited thereto. The distances of the ends of the thinned first section of the welding strip and the third section of the welding strip beyond the edge of the solar cell can be specifically adjusted according to the distance between the two solar cells. The distance of the first section of the welding strip beyond the edge of the solar cell can be equal to or different from the distance of the third section of the welding strip beyond the edge of the solar cell.

[0015] For the curved solar glass according to the present invention, preferably, the portions of the first section of solder tape and the third section of solder tape that extend beyond the edges of the solar cell do not fall within the thickness range of the solar cell, that is, these extended portions will not droop and fall between two solar cells.

[0016] For the curved solar glass according to the present invention, preferably, the second section of solder tape includes a first branch connected to the first section of solder tape, a third branch connected to the third section of solder tape, and a second branch connecting the first branch and the third branch; the first branch and the third branch do not fall within the thickness range of the solar cell. In this case, the connections between the first branch, the second branch, and the third branch are bent at a certain angle or with a transition arc, that is, the bending points of the solder tape are located at the connections between the first branch and the second branch, and between the second branch and the third branch. In addition, the second section of solder tape may also have only the second branch, directly connecting to the first section of solder tape and the third section of solder tape at both ends, that is, the bending points of the solder tape are located at the connections between the first section of solder tape and the second branch, and between the second branch and the third section of solder tape.

[0017] For the curved solar glass according to the present invention, preferably, the outer sheet curved glass is a hyperbolic glass made of ultra-clear glass or white glass.

[0018] For the curved solar glass according to the present invention, preferably, the materials of the outer sheet adhesive film and the inner sheet adhesive film are EVA, POE, EPE, or PVB.

[0019] For the curved solar glass according to the present invention, preferably, the solar cells are selected from solar cells with silicon as the substrate, such as monocrystalline silicon cell, polycrystalline silicon cell, PERC cell, TOPCON cell, heterojunction solar cell, etc.

[0020] For the curved solar glass according to the present invention, preferably, the connection method between multiple solar cells is series connection, parallel connection, or series-parallel connection.

[0021] For the curved solar glass according to the present invention, preferably, the outer sheet glass and the inner sheet glass are printed with ink, the area outside the ink is the light-transmitting area, and the solar cells are located below the light-transmitting area of the outer sheet glass; the bus bars and the wire harnesses are covered by the ink, the wire harnesses include metal terminals and connection terminals, the metal terminals are connected to the bus bars, and the connection terminals are outside the curved solar glass.

[0022] On the other hand, the present invention provides a manufacturing method of a curved solar glass, including the following steps:

[0023] Stack the outer sheet curved glass, the outer sheet adhesive film, the solar cells, the inner sheet adhesive film, and the inner sheet curved glass in sequence to form a laminated structure, and seal the periphery of the laminated structure with a sealing ring or put the laminated structure into a sealed bag;

[0024] The laminated structure is kept horizontally placed and the temperature is maintained at 22°C to 35°C. The sealing ring or sealing bag is evacuated to a vacuum state so that a closed space is formed inside the laminated structure.

[0025] According to the manufacturing method of the present invention, preferably, the evacuation to a vacuum state includes two stages:

[0026] The first stage: The evacuation rate does not exceed 0.25 L / min until the vacuum degree reaches -50 kPa to -85 kPa, and it is maintained at this vacuum degree for at least 10 min;

[0027] The second stage: Continue to evacuate at the same evacuation rate until the vacuum degree reaches -95 kPa to -100 kPa, and it is maintained at this vacuum degree for at least 0.5 h.

[0028] Specifically, the evacuation operation is performed on the air extraction port of the sealing ring or sealing bag. One air extraction port can be provided on any one side, or two air extraction ports can be provided on opposite sides.

[0029] During the evacuation process, the laminated structure is kept horizontally placed and the temperature is maintained at 22°C to 35°C. If the temperature is too low, the diaphragm will become hard; if the temperature is too high, the diaphragms are likely to adhere to each other, and it is not easy to evacuate completely during evacuation.

[0030] During evacuation, due to the formation of an air pressure difference inside and outside the glass, the atmospheric pressure forms a pressure on the laminated structure, and there is a risk of chipping at the solder tape on the solar cell. By appropriately pressing and thinning the solder tape, and maintaining the vacuum degree at -50 kPa to -85 kPa in the first stage of evacuation, the pressure of the solder tape on the cell can be effectively reduced, thereby effectively controlling the hidden crack of the cell.

[0031] According to the manufacturing method of the present invention, preferably, the manufacturing method further includes a step of heating under a vacuum state: maintaining the laminated structure at a vacuum degree of -95 kPa to -100 kPa for heating.

[0032] More preferably, during the heating under a vacuum state:

[0033] When the outer sheet adhesive film and the inner sheet adhesive film are cross-linking reaction adhesive films, the heating rate is 1°C / min to 5°C / min, the maximum heating temperature does not exceed 160°C, and it is maintained at the maximum temperature for at least 10 min;

[0034] When the outer sheet film and the inner sheet film are non-crosslinking reaction films, the heating rate is ≤ 3 °C / min, the maximum heating temperature does not exceed 120 °C, and it is maintained at the maximum temperature for at least 30 min; then it is continuously heated to 140 °C - 150 °C, and at the same time, the pressure is increased to 10 bar - 12 bar, and it is maintained at a constant temperature and pressure for at least 30 min.

[0035] The crosslinking reaction films include, for example, EVA, POE, and EPE, and the non-crosslinking reaction films include, for example, PVB.

[0036] According to the manufacturing method of the present invention, preferably, during the process of sequentially stacking the outer curved glass, the outer sheet film, the solar cell, the inner sheet film, and the inner curved glass into a laminated structure, it further includes connecting the solder ribbons, the bus bars, and the wire harnesses.

[0037] On the other hand, the present invention provides a vehicle, including the above-mentioned curved solar glass. Preferably, the curved solar glass is used as a skylight glass. Description of the Drawings

[0038] Figure 1 It is a schematic cross-sectional structure diagram of the curved solar glass provided by the present invention.

[0039] Figure 2 One of the schematic diagrams of the connection method of the solar cell wafers in the curved solar glass of the present invention.

[0040] Figure 3 Another schematic diagram of the connection method of the solar cell wafers in the curved solar glass of the present invention.

[0041] Figure 4 Another schematic diagram of the connection method of the solar cell wafers in the curved solar glass of the present invention.

[0042] Figure 5 Another schematic diagram of the connection method of the solar cell wafers in the curved solar glass of the present invention.

[0043] Figure 6 It is a schematic plan view of the curved solar glass provided by the present invention.

[0044] Figure 7 It is a process curve diagram of evacuating to a vacuum state in the manufacturing method of the curved solar glass of the present invention.

[0045] Figure 8 It is a process curve diagram of the heating stage of the crosslinking reaction film in the manufacturing method of the curved solar glass of the present invention.

[0046] Figure 9 It is a process curve diagram of the heating stage of the non-crosslinking reaction film in the manufacturing method of the curved solar glass of the present invention.

[0047] Description of Reference Numerals

[0048] 100. Curved solar glass;

[0049] 1. External curved glass;

[0050] 2. Outer film;

[0051] 3. Solar cell, 31. Solar cell sheet, 32. Welding strip, 32-1. First section of welding strip, 32-2. Second section of welding strip, 32-2-1. First branch, 32-2-2. Second branch, 32-2-3. Third branch, 32-3. Third section of welding strip, 3-1. Outer boundary of solar cell;

[0052] 4. Inner film;

[0053] 5. Inner curved glass;

[0054] 6. Ink area, 6-1. Inner boundary of the ink area;

[0055] 7. Busbar;

[0056] 8. wiring harness, 81. metal terminal, 82. connecting terminal;

[0057] d1, the distance that the first section of the welding ribbon exceeds the edge of the solar cell, d2, the distance that the third section of the welding ribbon exceeds the edge of the solar cell, d3, the distance between two adjacent solar cells, d4, the length of the first branch, d5, the length of the third branch. DETAILED DESCRIPTION

[0058] In order to explain the present invention more clearly, the present invention is further described below in conjunction with preferred embodiments. It should be understood by those skilled in the art that the following specific description is illustrative rather than restrictive, and should not be used to limit the scope of protection of the present invention.

[0059] The curved solar glass provided by the present invention is as follows Figure 1 As shown, it comprises an outer curved glass 1, an outer adhesive film 2, a solar cell 3, an inner adhesive film 4 and an inner curved glass 5 which are stacked in sequence;

[0060] The solar cell 3 includes a plurality of solar cells 31 connected by welding ribbons 32;

[0061] like Figure 2As shown, two adjacent solar cells 31 are connected by a bent welding strip 32, and the welding strip 32 includes three sections in sequence: a first welding strip 32-1, a second welding strip 32-2, and a third welding strip 32-3; the lower surface of the first welding strip 32-1 is connected to the upper surface of one solar cell 31; the upper surface of the third welding strip is connected to the lower surface of another solar cell 31, and the second welding strip 32-2 is the bent portion of the welding strip 32, which separates the two adjacent solar cells 31; the first welding strip 32-1 and the third welding strip 32-3 are both beyond the edge of the solar cell 31 at one end connected to the second welding strip 32-2 (i.e., the junction with the bent part), and the beyond distances are d1 and d2 respectively, and d1 and d2 are equal or different. Preferably, the portions of the first welding strip 32-1 and the third welding strip 32-3 beyond the edge of the solar cell do not fall within the thickness range of the solar cell 31.

[0062] The present invention connects the solar cell 31 through a welding strip 32 bent in the middle, and the second section of the welding strip 32-2 is the bending point. Hidden cracks or visible cracks in the solar cell are mainly caused by stress concentration when the welding strip is pressed on the solar cell. Therefore, it is required that the bending position should not directly contact the cell, otherwise cracks will easily occur. Therefore, the bending point is limited to a certain distance from the edge of the solar cell, that is, the first section of the welding strip and the third section of the welding strip are both beyond the edge of the solar cell at the end connected to the second section of the welding strip, and the distances d1 and d2 on both sides can be equal or different.

[0063] Preferably, the thickness of the first section of the welding strip 32-1 and the third section of the welding strip 32-3 is thinned to ≤0.2mm, which helps to reduce the yield strength in the thickness direction, helps to reduce the pressure on the position of the welding strip on the battery cell when evacuating air during the preparation process, and reduces the risk of hidden cracks in the battery cell at the welding strip.

[0064] The thickness of the second section 32-2 (i.e., the bend) of the welding strip can be the same as or different from that of the first section 32-1 and the third section 32-3. There is no requirement for this. When the thickness is the same, the processing difficulty is reduced, batch production is convenient, and operation efficiency is improved. In addition, there is no specific requirement for the specific bending shape. It can be an S-shaped bend or a Z-shaped bend of 90° or other angles.

[0065] Preferably, the distances d1 and d2 of the first section of the welding strip 32-1 and the third section of the welding strip 32-3 beyond the edge of the solar cell are both greater than or equal to 10% of the distance d3 between two adjacent solar cells, that is, d1 / d3≥10%, d2 / d3≥10%. For example, when d3=2mm, d1=d2=0.5mm; when d3=1mm, d1 and d2 are 0.2-0.3mm, which are equal or different.

[0066] The overhanging distances d1 and d2 at the ends of the first section of the thinned solder tape 32-1 and the third section of the solder tape 32-3 can be specifically adjusted according to the distance between two solar cells 31.

[0067] As Figure 3 shown, preferably, the second section of the solder tape 32-2 includes a first branch 32-2-1 connected to the first section of the solder tape 32-1, a third branch 32-2-3 connected to the third section of the solder tape 32-3, and a second branch 32-2-2 connecting the first branch 32-2-1 and the third branch 32-2-3; the lengths of the first branch 32-2-1 and the third branch 32-2-3 are d4 and d5 respectively, which may be equal or unequal; the first branch 32-2-1 and the third branch 32-2-3 do not fall within the thickness range of the solar cell 31. In this case, the connections between the first branch 32-2-1, the second branch 32-2-2, and the third branch 32-2-3 are bent at a certain angle (such as Figure 2 and Figure 3 the 90° in Figure 4 or the obtuse angle in Figure 2 and Figure 3 ), or by a transition arc bend, that is, the bending points of the solder tape are located at the connections between the first branch 32-2-1 and the second branch 32-2-2, and between the second branch 32-2-2 and the third branch 32-2-3, Figure 2 and Figure 3 being like this.

[0068] In addition, as Figure 4 and Figure 5 shown, the second section of the solder tape may also have only the second branch 32-2-2. At this time, the lengths d4 = d5 = 0 of the first branch 32-2-1 and the second branch 32-2-2, and the two ends of the second branch 32-2-2 are directly connected to the first section of the solder tape 32-1 and the third section of the solder tape 32-3 respectively, that is, the bending points of the solder tape 32 are located at the connections between the first section of the solder tape 32-1 and the second branch 32-2-2, and between the second branch 32-2-2 and the third section of the solder tape 32-3. Figure 5 The distance between the two solar cells 31 in

[0069] is shorter, which is the sum of d1, d2, and the thickness of the second section of the solder tape.

[0070] Specifically, the outer sheet curved glass 1 can be hyper white glass or double-curved glass of white glass. The outer sheet adhesive film 2 and the inner sheet adhesive film 4 can be adhesive films that undergo cross-linking reactions, and the specific materials are such as EVA, POE, EPE, or they can also be non-cross-linking reaction adhesive films, and the specific materials are such as PVB.

[0071] The connection mode between the solar cells 31 can be series connection, parallel connection or series-parallel connection, and the connection is realized through the welding tape 32.

[0072] As Figure 6 shown, in the curved surface solar glass 100, the outer glass and the inner glass are printed with ink to form an ink area 6, and the area outside the ink area 6 is a light-transmitting area. The solar cell 3 is located below the light-transmitting area of the outer glass. The bus bar 7 and the wire harness 8 are covered by the ink area 6. The wire harness 8 includes a metal terminal 81 and a connection terminal 82. The metal terminal 81 is connected to the bus bar 7, and the connection terminal 82 is outside the curved surface solar glass 100.

[0073] The present invention also provides a manufacturing method for the curved surface solar glass, including the following steps:

[0074] Stack the outer curved surface glass 1, the outer film adhesive 2, the solar cell 3, the inner film adhesive 4 and the inner curved surface glass 5 in sequence to form a laminated structure, and seal the periphery of the laminated structure with a sealing ring or put the laminated structure into a sealed bag. Preferably, the laminated structure is kept horizontally placed and the temperature is kept at 22°C to 35°C. The sealing ring or the sealed bag is evacuated to a vacuum state through an air extraction port, so that a closed space is formed inside the laminated structure; one air extraction port can be provided for the sealing ring or the sealed bag, on any one side, or two, on opposite sides.

[0075] As Figure 7 shown, preferably, the evacuation to the vacuum state includes two stages:

[0076] The first stage: The air extraction rate does not exceed 0.25 L / min until the vacuum degree is -50 kPa to -85 kPa, and it is kept at this vacuum degree for at least 10 min;

[0077] The second stage: Continue to evacuate at the same air extraction rate until the vacuum degree is -95 kPa to -100 kPa, and it is kept at this vacuum degree for at least 0.5 h.

[0078] During the air extraction process, the laminated structure is kept horizontally placed and the temperature is kept at 22°C to 35°C. If the temperature is too low, the film will become hard; if the temperature is too high, the films are likely to adhere to each other and it is not easy to evacuate them completely during air extraction.

[0079] During air extraction, due to the formation of an air pressure difference inside and outside the glass, the atmospheric pressure forms a pressure on the laminated structure, and there is a risk of cracking at the welding tape on the solar cell; by appropriately pressing and thinning the welding tape, and keeping the vacuum degree at -50 kPa to -85 kPa in the first stage of air extraction, the pressure of the welding tape on the cell can be effectively reduced, thereby effectively controlling the hidden crack of the cell.

[0080] Preferably, the manufacturing method further includes a step of heating under a vacuum state: maintaining the laminated structure under a vacuum degree of -95 kPa to -100 kPa for heating.

[0081] More preferably, as Figure 8 shown, when the encapsulation materials (outer sheet film and inner sheet film) are crosslinking reaction films, the heating rate is 1 °C / min to 5 °C / min, the maximum heating temperature does not exceed 160 °C, and it is maintained at the maximum temperature for at least 10 min. The crosslinking reaction films such as EVA, POE, and EPE.

[0082] As Figure 9 shown, when the encapsulation materials (outer sheet film and inner sheet film) are non-crosslinking reaction films, the heating rate ≤ 3 °C / min, the maximum heating temperature does not exceed 120 °C, and it is maintained at the maximum temperature for at least 30 min; then it is continuously heated to 140 °C to 150 °C, while pressurized to 10 bar to 12 bar, and maintained at a constant temperature and pressure for at least 30 min. The non-crosslinking reaction films such as PVB.

[0083] During the process of this manufacturing method, when stacking the outer sheet curved glass, outer sheet film, solar cell, inner sheet film, and inner sheet curved glass in sequence to form a laminated structure, it further includes connecting the solder ribbons, bus bars, and wire harnesses.

[0084] The above curved solar glass can be used as a skylight glass in a vehicle.

[0085] Specific Examples 1 and 2 are provided below to more clearly show the manufacturing process of the curved solar glass of the present invention.

[0086] Example 1:

[0087] Stack 2.1 mm white glass, 0.6 mm EVA, heterojunction solar cell chips, 0.6 mm EVA, and 2.1 mm white glass in sequence Figure 1 to form a laminated structure. Among them, the heterojunction solar cell chips are connected in series or in parallel with 0.16 mm thick solder ribbons, and are connected to the bus bars and wire harnesses as Figure 5 shown.

[0088] While the laminated structure is lying flat at 25 °C all the time, seal it with a sealed bag and evacuate it, with an evacuation flow rate of 0.2 L / min until the vacuum degree reaches -80 kPa. After maintaining at this vacuum degree for 20 min, continue to evacuate until the vacuum degree is -100 kPa, and maintain at this vacuum degree for 0.5 h.

[0089] Keep the laminated structure in a vacuum state of -100 kPa and put it into the heating chamber. Start heating from 25 °C to 150 °C at a rate of 5 °C / min, and keep it at a constant temperature of 150 °C for 15 min.

[0090] Example 2:

[0091] Stack a 2.1 mm white glass, a 0.76 mm PVB, an IBC solar cell, a 0.76 mm PVB, and a 2.1 mm white glass in accordance with Figure 1 to form a laminated structure. Among them, the IBC solar cells are connected in series or parallel with a solder strip having a thickness of 0.12 mm, and are connected to the bus bar and the wire harness in accordance with Figure 5 as shown.

[0092] While the laminated structure is lying flat at 30 °C all the time, seal the periphery with a sealing ring and evacuate the air. The evacuation flow rate is 0.15 L / min until the vacuum degree reaches -60 kPa. After maintaining at this vacuum degree for 30 min, continue to evacuate until the vacuum degree is -100 kPa, and maintain at this vacuum degree for 2 h.

[0093] Place the laminated structure in a heating chamber while maintaining a vacuum state of -100 kPa, heat from 30 °C to 120 °C at a rate of 1 °C / min, and keep the temperature constant at 120 °C for 30 min; continue to heat to 140 °C while pressurizing to 11 bar, and keep the temperature and pressure constant for 40 min.

[0094] Obviously, the above embodiments of the present invention are merely examples for clearly illustrating the present invention, rather than limiting the implementation manners of the present invention. For those of ordinary skill in the art, other different forms of changes or modifications can be made on the basis of the above description. It is impossible to list all the implementation manners here. Any obvious changes or modifications derived from the technical solutions of the present invention still fall within the protection scope of the present invention.

Claims

1. A curved solar glass, characterized in that, The curved surface solar glass includes an outer curved surface glass, an outer film adhesive, a solar cell, an inner film adhesive, and an inner curved surface glass that are stacked in sequence; The solar cell includes a plurality of solar cell chips connected by solder tapes; Adjacent two solar cell chips are connected by the solder tape. The solder tape includes three consecutive segments: a first segment solder tape, a second segment solder tape, and a third segment solder tape. The lower surface of the first segment solder tape is connected to the upper surface of one solar cell chip. The upper surface of the third segment solder tape is connected to the lower surface of another solar cell chip. The second segment solder tape separates adjacent two solar cell chips; One end of the first segment solder tape and the third segment solder tape that connects the second segment solder tape both extends beyond the edge of the solar cell chip. The distances that the first segment solder tape and the third segment solder tape extend beyond the edge of the solar cell chip are both greater than or equal to 10% of the distance between adjacent two solar cell chips. And, the distance that the first segment solder tape extends beyond the edge of the solar cell chip is equal to or not equal to the distance that the third segment solder tape extends beyond the edge of the solar cell chip; The parts of the first segment solder tape and the third segment solder tape that extend beyond the edge of the solar cell chip do not fall within the thickness range of the solar cell chip.

2. The curved surface solar glass according to claim 1, characterized in that, The thickness of the first segment solder tape and the third segment solder tape ≤ 0.2 mm.

3. The curved solar glass according to claim 1, wherein The materials of the outer film adhesive and the inner film adhesive are EVA, POE, EPE, or PVB.

4. The curved solar glass according to claim 1, characterized in that, The solar cell chips are selected from solar cells with silicon as the substrate.

5. The curved solar glass according to claim 1, wherein The connection mode between multiple solar cell chips is series connection, parallel connection, or series-parallel connection.

6. A manufacturing method of the curved surface solar glass according to any one of claims 1-5, characterized in that, This manufacturing method includes the following steps: Stack the outer curved surface glass, the outer film adhesive, the solar cell, the inner film adhesive, and the inner curved surface glass in sequence into a laminated structure, and seal the periphery of the laminated structure with a sealing ring or put the laminated structure into a sealed bag; Keep the laminated structure horizontally placed and the temperature at 22°C to 35°C, evacuate the sealing ring or the sealed bag to a vacuum state, so that a closed space is formed inside the laminated structure.

7. The manufacturing method according to claim 6, characterized in that, The evacuation to the vacuum state includes two stages: The first stage: The evacuation rate does not exceed 0.25 L / min until the vacuum degree is -50 kPa to -85 kPa, and maintain at this vacuum degree for at least 10 min; The second stage: Continue to evacuate at the same evacuation rate until the vacuum degree is -95 kPa to -100 kPa, and maintain at this vacuum degree for at least 0.5 h.

8. The manufacturing method according to claim 6, characterized in that, This manufacturing method further includes the step of heating in a vacuum state: Maintain the laminated structure at a vacuum degree of -95 kPa to -100 kPa for heating.

9. The manufacturing method according to claim 8, characterized in that, During the heating in the vacuum state: When the outer film adhesive and the inner film adhesive are cross-linked reaction films, the heating rate is 1°C / min to 5°C / min, the maximum heating temperature does not exceed 160°C, and maintain at the maximum temperature for at least 10 min; When the outer sheet film and the inner sheet film are non-crosslinking reaction films, the heating rate is ≤ 3 °C / min, the maximum heating temperature does not exceed 120 °C, and it is maintained at the maximum temperature for at least 30 min; then it is continuously heated to 140 °C - 150 °C, and at the same time, the pressure is increased to 10 bar - 12 bar, and the constant temperature and constant pressure are maintained for at least 30 min.

10. The manufacturing method according to claim 6, characterized in that, During the process of stacking the outer sheet curved glass, the outer sheet film, the solar cell, the inner sheet film and the inner sheet curved glass into a laminated structure in sequence, it also includes connecting the solder tape, the bus bar and the wire harness.

11. A vehicle comprising the curved solar glass according to any one of claims 1 - 5.

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