A BIPV photovoltaic module and a preparation method thereof

Abstract

The application discloses a BIPV photovoltaic module and a preparation method thereof. The BIPV photovoltaic module comprises a front glass, a front encapsulation adhesive film, a power generation unit, a back encapsulation adhesive film and a back plate which are sequentially stacked. A high-transmittance color layer is arranged on at least one of the front glass and the front encapsulation adhesive film, and the projection of the high-transmittance color layer covers the power generation unit. A pattern structure is arranged on the light-incident surface of the back plate, and the pattern structure corresponds to the gap of the cell in the power generation unit. A color developing layer is arranged on the light-incident surface of the back plate or the back encapsulation adhesive film, and the color developing layer corresponds to the gap of the cell in the power generation unit. The pattern structure is consistent with the texture structure of the light-receiving surface of the cell. The color developing layer is consistent with the color of the light-receiving surface of the cell. The application can solve the problem that the overall appearance consistency of the existing photovoltaic module is poor, and there is obvious color difference on the surface of the module.

Description

Technical Field

[0001] This invention relates to the field of photovoltaic module technology, specifically to a BIPV photovoltaic module and its preparation method. Background Technology

[0002] BIPV photovoltaic modules can be widely used in building skylights, curtain walls, highway sound barriers, and facility agriculture and animal husbandry. Especially in the future construction of new rural areas, they are an indispensable component of the energy structure of every household.

[0003] Colored BIPV (Building Integrated Photovoltaic) modules can blend well with the surrounding environment and buildings, serving as both building components and power generation functions, making them a popular design element. Currently, existing colored BIPV modules primarily achieve their color appearance by using colored high-transmittance front glass or colored high-transmittance front encapsulation films. However, upon closer inspection, significant differences in appearance can be observed between the individual cells. This is because the high light transmittance of the front side of existing colored BIPV modules relies mainly on the underlying color for color rendering. Since the colors and patterns between the cells and the color rendering layers differ, the resulting variations in appearance lead to noticeable color differences and poor overall consistency in the module's appearance. Summary of the Invention

[0004] The purpose of this invention is to address the problems of obvious color differences on the surface and poor overall appearance consistency of existing BIPV photovoltaic modules, and to design and provide a BIPV photovoltaic module and a simple preparation method for the BIPV photovoltaic module.

[0005] This invention is achieved through the following technical solution:

[0006] A BIPV photovoltaic module, characterized in that the BIPV photovoltaic module comprises: a front glass, a front encapsulating film, a power generation unit, a back encapsulating film, and a back sheet, which are stacked sequentially.

[0007] Wherein: at least one layer of the front glass or the front encapsulating film is provided with a high light transmittance color layer, and the projection of the high light transmittance color layer covers the power generation unit;

[0008] The backplate has a patterned structure on its light-incident surface, and the patterned structure corresponds to the spacing between the battery cells in the power generation unit.

[0009] A color-developing layer is provided on the light-incident surface of the backplate or on the back sealing film, and the color-developing layer is provided corresponding to the gap between the battery cells in the power generation unit.

[0010] The pattern structure is consistent with the texture structure of the light-receiving surface of the battery cell;

[0011] The color rendering layer is set to match the color of the light-receiving surface of the solar cell.

[0012] Specifically, the back panel can be a glass back panel or a polymer material back panel.

[0013] Specifically, the BIPV photovoltaic module designed in this invention is a BIPV photovoltaic module with color aesthetics. Its structure from top to bottom is as follows: front glass + front encapsulating film + power generation unit + back encapsulating film + backsheet. Above the power generation unit is a high-transmittance color layer, whose color can be customized according to different needs. In the BIPV photovoltaic module designed in this invention, the final color is displayed through the high-transmittance color layer and the underlying color rendering layer. Therefore, this invention designs the pattern and color (color rendering layer) inside the backsheet (light-receiving surface) to be consistent with the light-receiving surface of the solar cells. The color rendering layer also serves to reflect light, which improves the power generation efficiency of the module on the one hand; on the other hand, this design makes the overall appearance of the module highly consistent, with no obvious color difference on the surface. Even when observing the module closely, there is no obvious difference in appearance between the solar cells in the power generation unit and the gaps between the cells, resulting in a highly consistent overall appearance and no obvious color difference on the surface. At the same time, the combination of the high-transmittance color layer and the color rendering layer gives the BIPV photovoltaic module of this invention excellent aesthetics.

[0014] Furthermore, in a BIPV photovoltaic module, the high-transmittance color layer is formed by coating with high-transmittance color ink;

[0015] The high transmittance colored ink comprises the following components by mass fraction: 45-60 wt% nano-silica, 10-25 wt% water-based ink, 20-25 wt% organic solvent, 1.5-3.5 wt% pigment, and 1.0-5.0 wt% light conversion material; the light conversion material is used to convert near-infrared light into visible light.

[0016] Specifically, pigments can be selected from sources such as aluminum oxide, zirconium oxide, iron oxide, zinc oxide, and zinc oxide.

[0017] Furthermore, a BIPV photovoltaic module: the average particle size of the nano-silica is 20-60 nm.

[0018] Furthermore, in a BIPV photovoltaic module, the light conversion material is selected from rare earth luminescent materials with a particle size of 1.0 to 10.0 μm.

[0019] Specifically, the rare-earth luminescent material can be selected from BaYF5:Nd 3+ ,Yb 3+ Er 3+ AlF3-YbF3:Er 3+ Y2MoO6:Eu 3+ One of them.

[0020] Furthermore, in a BIPV photovoltaic module, the thickness of the high-transmittance color layer is 10–20 μm.

[0021] Furthermore, in a BIPV photovoltaic module, the light transmittance of the high-transmittance color layer is >50%.

[0022] Furthermore, in a BIPV photovoltaic module, the high-transmittance color layer is disposed on the light-emitting surface of the front glass.

[0023] A method for manufacturing a BIPV photovoltaic module, characterized in that the method includes the following steps:

[0024] S1. Connect several battery cells in series to form several battery strings, and connect several of the battery strings in series / parallel to form a power generation unit for later use.

[0025] S2. A pattern structure consistent with the texture of the light-receiving surface of the battery cell is provided on the light-incident surface of the back plate, and the pattern structure corresponds to the gap of the battery cell; a color-developing layer consistent with the color of the light-receiving surface of the battery cell is provided on the pattern structure for later use.

[0026] Alternatively, a patterned structure consistent with the texture of the light-receiving surface of the battery cell can be provided on the light-incident surface of the back plate, and a color-developing layer consistent with the color of the light-receiving surface of the battery cell can be provided on the back encapsulation film. The color-developing layer and the patterned structure correspond to the gaps of the battery cell and are ready for use.

[0027] S3. A high-transmittance colored layer is applied to at least one layer of the front glass or the front encapsulating film, and the layer is set aside after application.

[0028] S4. The back sealing film, the power generation unit, the front sealing film and the front glass are sequentially stacked on the back plate described in step S2, and then the plate is laminated in a laminator to obtain the BIPV photovoltaic module.

[0029] Furthermore, a method for preparing a BIPV photovoltaic module includes: step S3, coating at least one layer of high-transmittance colored ink onto the front glass or the front encapsulation film, and obtaining a high-transmittance colored layer after curing.

[0030] Furthermore, a method for preparing a BIPV photovoltaic module: the curing temperature is 160-180℃, and the curing time is 3-5 minutes.

[0031] The beneficial effects of this invention are:

[0032] (1) The BIPV photovoltaic module structure designed in this invention makes the pattern and color inside the backsheet consistent with the cell, so that the overall appearance of the module is more consistent and there is no obvious color difference on the surface of the module; when the BIPV photovoltaic module structure is used as a building material, it can add beauty to the building aesthetics.

[0033] (2) The high-transmittance color layer in this invention can be customized in color according to different needs; the final color display of the BIPV photovoltaic module of this invention is presented by the combination of the high-transmittance color layer and the underlying color-enhancing layer; for this purpose, the pattern structure and color-enhancing layer on the light-receiving surface of the back panel are designed to be consistent with the pattern and color of the light-receiving surface of the solar cell; at the same time, the color-enhancing layer has a certain light reflection effect, which can reflect the light transmitted from the gaps between the solar cells back onto the solar cells, which is beneficial to improving the power generation efficiency of the photovoltaic module; and the combination design of the high-transmittance color layer and the color-enhancing layer also makes the overall appearance of the module highly consistent. Even when closely observing the module, it is difficult to see obvious differences in the appearance of the solar cells and the gaps between the solar cells in the power generation unit of the module, making the overall appearance of the module highly consistent and the surface of the module without obvious color difference. This invention uses the combination design of the high-transmittance color layer + color-enhancing layer to give the BIPV photovoltaic module a good aesthetic function. When used as a building material, it can form a good aesthetic match with the surrounding environment, adding color to the architectural aesthetics while also having a power generation function, maximizing the promotion and application of photovoltaic modules.

[0034] (3) The patterned structure designed in the BIPV photovoltaic module provided by the present invention is also beneficial to the lamination of the back sheet and the back encapsulation film. The patterned structure can prevent the module from cracking during use.

[0035] (4) The nano-silica used in the high transmittance colored ink of the present invention is beneficial to the formation of a high transmittance colored layer, thereby improving the bonding strength between the high transmittance colored layer and the glass; at the same time, the high transmittance colored ink of the present invention also uses a light conversion material, which converts near-infrared light into visible light, which is beneficial to the improvement of transmittance, so that the transmittance of the formed high transmittance colored layer can be greater than 50%. Attached Figure Description

[0036] To more clearly illustrate the technical solutions of the embodiments of the present invention, the drawings used in the following description of the embodiments will be briefly introduced. Obviously, the drawings described below are only some embodiments of the present invention. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.

[0037] Figure 1 This is a schematic diagram of the structure of the BIPV photovoltaic module provided in Embodiment 1 of the present invention;

[0038] Figure 2 This is a schematic diagram of the structure of the BIPV photovoltaic module provided in Embodiment 2 of the present invention.

[0039] The markings in the diagram are: 1. Front glass, 2. Front encapsulation film, 3. Power generation unit, 4. Back encapsulation film, 5. Backplate, 6. Color layer, 1-1. High transmittance color layer, 3-1. Battery cell, 5-1. Pattern structure. Detailed Implementation

[0040] The technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. The following description of at least one exemplary embodiment is merely illustrative and is in no way intended to limit the present invention or its application or use. All other embodiments obtained by those skilled in the art based on the embodiments of the present invention without creative effort are within the scope of protection of the present invention.

[0041] In the description of this invention, it should be understood that the terms "upper," "lower," "left," "right," "top," and "bottom," etc., indicating orientation or positional relationships, are merely for the convenience of describing the invention and simplifying the description, and do not indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation, and therefore should not be construed as a limitation of the invention. Furthermore, the terms "first" and "second" are used for descriptive purposes only and should not be construed as indicating or implying relative importance or implicitly specifying the number of indicated technical features. Thus, a feature defined with "first" and "second" may explicitly or implicitly include one or more of that feature. Moreover, the terms "first," "second," etc., are used to distinguish similar objects and are not necessarily used to describe a specific order or sequence. It should be understood that such data can be interchanged where appropriate so that the embodiments of the invention described herein can be implemented in orders other than those illustrated or described herein.

[0042] Example 1

[0043] like Figure 1As shown, a BIPV photovoltaic module is provided, characterized in that the BIPV photovoltaic module includes: a front glass 1, a front encapsulant film 2, a power generation unit 3, a back encapsulant film 4, and a back sheet 5, which are stacked in sequence.

[0044] Wherein: a high transmittance color layer 1-1 with a thickness of 15μm (transmittance > 50%) is provided on the light-emitting surface of the front glass 1, and the projection of the high transmittance color layer 1-1 covers the power generation unit 3;

[0045] The backplate 5 has a patterned structure 5-1 on its light-receiving surface, and the patterned structure 5-1 is arranged in relation to the gaps between the battery cells 3-1 in the power generation unit 3; a color-developing layer 6 with the same color as the light-receiving surface of the battery cells 3-1 is provided on the patterned structure 5-1.

[0046] The pattern structure 5-1 is set to be consistent with the texture structure of the light-receiving surface of the battery cell 3-1;

[0047] The high-transmittance color layer is formed by coating with high-transmittance color ink, which comprises the following components by mass fraction: 54wt% nano-silica (average particle size 45nm), 20wt% water-based ink, 20wt% organic solvent (ethanol), 2.5wt% pigment (alumina), and light conversion material (BaYF5:Nd). 3+ ,Yb 3+ Er 3+ 3.5 wt%; the average particle size of the light conversion material is 1.0 μm, and it is used to convert near-infrared light into visible light.

[0048] The method for preparing a BIPV photovoltaic module provided in Embodiment 1 above is characterized by comprising the following steps:

[0049] S1. Connect several battery cells 3-1 in series to form several battery strings, and connect several of the battery strings in series / parallel to form a power generation unit 3 for later use.

[0050] S2. A pattern structure 5-1 with the same texture as the light-receiving surface of the battery cell 3-1 is provided on the light-incident surface of the back plate 5, and the pattern structure 5-1 corresponds to the gap of the battery cell 3-1; a color-developing layer 6 with the same color as the light-receiving surface of the battery cell 3-1 is provided on the pattern structure 5-1 for later use.

[0051] S3. A high-transmittance color layer 1-1 is set on the light-emitting surface of the front glass 1 and is set aside for later use. Specifically, the high-transmittance color ink is coated onto the light-emitting surface of the front glass 1 and cured at 180°C for 3 minutes to obtain the high-transmittance color layer 1-1.

[0052] S4. The back sealing film 4, the power generation unit 3, the front sealing film 2 and the front glass 1 are sequentially stacked on the back sheet 5 obtained in step S2, and then put into a laminator for lamination to obtain the BIPV photovoltaic module.

[0053] Example 2

[0054] like Figure 2 As shown, a BIPV photovoltaic module is provided, characterized in that the BIPV photovoltaic module includes: a front glass 1, a front encapsulant film 2, a power generation unit 3, a back encapsulant film 4, and a back sheet 5, which are stacked in sequence.

[0055] Wherein: a high transmittance color layer 1-1 with a thickness of 10μm (transmittance > 50%) is provided on the light-emitting surface of the front glass 1, and the projection of the high transmittance color layer 1-1 covers the power generation unit 3;

[0056] The backplate 5 has a patterned structure 5-1 on its light-receiving surface, and the patterned structure 5-1 is provided in relation to the gaps between the battery cells 3-1 in the power generation unit 3; a color-developing layer 6 is provided on the back sealing film 4, which is the same color as the light-receiving surface of the battery cells 3-1, and the color-developing layer 6 is provided in relation to the gaps between the battery cells 3-1 in the power generation unit 3.

[0057] The pattern structure 5-1 is set to be consistent with the texture structure of the light-receiving surface of the battery cell 3-1;

[0058] The high-transmittance color layer is formed by coating with high-transmittance color ink, which comprises the following components by mass fraction: 45wt% nano-silica (average particle size 60nm), 25wt% water-based ink, 23.5wt% organic solvent (ethanol), 1.5wt% pigment (iron oxide), and light conversion material (Y2MoO6:Eu). 3+ 5.0 wt%; the average particle size of the light conversion material is 5.0 μm, and it is used to convert near-infrared light into visible light.

[0059] The method for preparing a BIPV photovoltaic module provided in Embodiment 2 above is characterized by comprising the following steps:

[0060] S1. Connect several battery cells 3-1 in series to form several battery strings, and connect several of the battery strings in series / parallel to form a power generation unit 3 for later use.

[0061] S2. A pattern structure consistent with the texture of the light-receiving surface of the battery cell 3-1 is provided on the light-incident surface of the back plate 5. A color-developing layer 6 consistent with the color of the light-receiving surface of the battery cell 3-1 is provided on the back sealing film 4. The color-developing layer 6 and the pattern structure 5-1 correspond to the gap of the battery cell 3-1 and are ready for use.

[0062] S3. A high-transmittance color layer 1-1 is set on the light-emitting surface of the front glass 1 and is set aside for later use. Specifically, the high-transmittance color ink is coated onto the light-emitting surface of the front glass 1 and cured at 160°C for 5 minutes to obtain the high-transmittance color layer 1-1.

[0063] S4. The back sealing film 4, the power generation unit 3, the front sealing film 2 and the front glass 1 are sequentially stacked on the back sheet 5 obtained in step S2, and then put into a laminator for lamination to obtain the BIPV photovoltaic module.

[0064] Example 3

[0065] A BIPV photovoltaic module is provided, characterized in that the BIPV photovoltaic module comprises: a front glass 1, a front encapsulating film 2, a power generation unit 3, a back encapsulating film 4, and a back sheet 5, which are stacked sequentially.

[0066] Wherein: a high transmittance color layer 1-1 with a thickness of 20μm (transmittance > 50%) is provided on the light-emitting surface of the front glass 1, and the projection of the high transmittance color layer 1-1 covers the power generation unit 3;

[0067] The backplate 5 has a patterned structure 5-1 on its light-receiving surface, and the patterned structure 5-1 is arranged in relation to the gaps between the battery cells 3-1 in the power generation unit 3; a color-developing layer 6 with the same color as the light-receiving surface of the battery cells 3-1 is provided on the patterned structure 5-1.

[0068] The pattern structure 5-1 is set to be consistent with the texture structure of the light-receiving surface of the battery cell 3-1;

[0069] The high-transmittance color layer is formed by coating with high-transmittance color ink, which comprises the following components by mass fraction: 60wt% nano-silica (average particle size 20nm), 10.5wt% water-based ink, 25wt% organic solvent (ethanol), 3.5wt% pigment (alumina), and light conversion material (AlF3-YbF3:Er). 3+ 1.0 wt%; the average particle size of the light conversion material is 10.0 μm, and it is used to convert near-infrared light into visible light.

[0070] The method for preparing a BIPV photovoltaic module provided in Embodiment 3 above is characterized by comprising the following steps:

[0071] S1. Connect several battery cells 3-1 in series to form several battery strings, and connect several of the battery strings in series / parallel to form a power generation unit 3 for later use.

[0072] S2. A pattern structure 5-1 with the same texture as the light-receiving surface of the battery cell 3-1 is provided on the light-incident surface of the back plate 5, and the pattern structure 5-1 corresponds to the gap of the battery cell 3-1; a color-developing layer 6 with the same color as the light-receiving surface of the battery cell 3-1 is provided on the pattern structure 5-1 for later use.

[0073] S3. A high-transmittance color layer 1-1 is set on the light-emitting surface of the front glass 1 and set aside for later use; specifically, the above-mentioned high-transmittance color ink is coated on the light-emitting surface of the front glass 1 and cured at 170°C for 4 minutes to obtain the high-transmittance color layer 1-1.

[0074] S4. The back sealing film 4, the power generation unit 3, the front sealing film 2 and the front glass 1 are sequentially stacked on the back sheet 5 obtained in step S2, and then put into a laminator for lamination to obtain the BIPV photovoltaic module.

[0075] The above-described preferred embodiments of the present invention are for illustrative purposes only and are not intended to limit the scope of the invention. Any obvious variations or modifications derived from the technical solutions of the present invention are still within the protection scope of the present invention.

Claims

1. A BIPV photovoltaic module, characterized in that, The BIPV photovoltaic module includes: a front glass, a front encapsulating film, a power generation unit, a back encapsulating film, and a backsheet, which are stacked in sequence. Wherein: at least one layer of the front glass or the front encapsulating film is provided with a high light transmittance color layer, and the projection of the high light transmittance color layer covers the power generation unit; The backplate has a patterned structure on its light-incident surface, and the patterned structure corresponds to the spacing between the battery cells in the power generation unit. A color-developing layer is provided on the light-incident surface of the backplate or on the back sealing film, and the color-developing layer is provided corresponding to the gap between the battery cells in the power generation unit. The pattern structure is consistent with the texture structure of the light-receiving surface of the battery cell; The color rendering layer is set to match the color of the light-receiving surface of the solar cell.

2. A BIPV photovoltaic module according to claim 1, characterized in that, The high-transmittance color layer is formed by coating with high-transmittance color ink; The high transmittance colored ink comprises the following components by mass fraction: 45-60 wt% nano-silica, 10-25 wt% water-based ink, 20-25 wt% organic solvent, 1.5-3.5 wt% pigment, and 1.0-5.0 wt% light conversion material; the light conversion material is used to convert near-infrared light into visible light.

3. A BIPV photovoltaic module according to claim 2, characterized in that, The average particle size of the nano-silica is 20–60 nm.

4. A BIPV photovoltaic module according to claim 2, characterized in that, The light conversion material is selected from rare earth luminescent materials with a particle size of 1.0 to 10.0 μm.

5. A BIPV photovoltaic module according to claim 1, characterized in that, The thickness of the high-transmittance color layer is 10–20 μm.

6. A BIPV photovoltaic module according to claim 1, characterized in that, The light transmittance of the high-transmittance color layer is >50%.

7. A BIPV photovoltaic module according to claim 1, characterized in that, The high-transmittance color layer is disposed on the light-emitting surface of the front glass.

8. A method for preparing a BIPV photovoltaic module according to any one of claims 1 to 7, characterized in that, The method includes the following steps: S1. Connect several battery cells in series to form several battery strings, and connect several of the battery strings in series / parallel to form a power generation unit for later use. S2. A pattern structure consistent with the texture of the light-receiving surface of the battery cell is provided on the light-incident surface of the back plate, and the pattern structure corresponds to the gap of the battery cell; a color-developing layer consistent with the color of the light-receiving surface of the battery cell is provided on the pattern structure for later use. Alternatively, a patterned structure consistent with the texture of the light-receiving surface of the battery cell can be provided on the light-incident surface of the back plate, and a color-developing layer consistent with the color of the light-receiving surface of the battery cell can be provided on the back encapsulation film. The color-developing layer and the patterned structure correspond to the gaps of the battery cell and are ready for use. S3. A high-transmittance colored layer is applied to at least one layer of the front glass or the front encapsulating film, and the layer is set aside after application. S4. The back sealing film, the power generation unit, the front sealing film and the front glass are sequentially stacked on the back plate described in step S2, and then the plate is laminated in a laminator to obtain the BIPV photovoltaic module.

9. A method for preparing a BIPV photovoltaic module according to claim 8, characterized in that, Step S3: Apply high-transmittance colored ink to at least one layer of the front glass or front encapsulation film, and obtain a high-transmittance colored layer after curing.

10. A method for preparing a BIPV photovoltaic module according to claim 9, characterized in that, The curing temperature is 160-180℃, and the curing time is 3-5 minutes.

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