A high water-resistant composite photovoltaic tile

Abstract

This invention discloses a high water-resistant composite photovoltaic tile, comprising a first encapsulation layer, a first encapsulation film layer, a first PET layer, a second encapsulation film layer, a solar cell layer, a third encapsulation film layer, a second PET layer, a fourth encapsulation film layer, and a substrate, stacked sequentially and integrally formed by lamination. The solar cell layer includes multiple solar cell strings. The first encapsulation layer is an FRP board containing acrylic resin. The high water-resistant composite photovoltaic tile provided by this invention has good load-bearing capacity, impact resistance, water-resistant properties, light weight, low cost, rich and varied colors, and excellent resistance to ultraviolet aging.

Description

Technical Field

[0001] This invention belongs to the field of photovoltaic technology, specifically relating to a high water-resistant composite photovoltaic tile. Background Technology

[0002] Since the 1970s, with the development of modern industry, the global energy crisis and air pollution have become increasingly prominent. Traditional fuel energy is dwindling, causing increasing harm to the environment, and approximately 2 billion people worldwide lack access to reliable energy supplies. At this juncture, the world has turned its attention to renewable energy, hoping it can transform humanity's energy structure and sustain long-term sustainable development.

[0003] Solar energy has become a focus of attention due to its unique advantages. Abundant solar radiation is an important energy source—inexhaustible, pollution-free, inexpensive, and freely usable by humankind. Up to 800 megawatt-hours of solar energy reach the Earth's surface every second. If 0.1% of the solar energy on the Earth's surface were converted into electricity at a conversion rate of 5%, the annual power generation would reach 5.6 × 10¹² kilowatt-hours, equivalent to 40 times the world's energy consumption. Precisely because of these unique advantages, since the 1980s, the types of solar cells have continuously increased, their applications have broadened, and the market size has gradually expanded.

[0004] Even though existing photovoltaic tile products are widely used in the BIPV field, many problems still exist:

[0005] 1. Existing photovoltaic tiles differ from traditional glass photovoltaic modules and cannot increase the load-bearing requirements of existing building roofs;

[0006] 2. Existing photovoltaic tiles replace the original roofing metal tile materials. The edges must be frameless. Since solar panels have a multi-layered structure, the edges of frameless photovoltaic tile products are in direct contact with the air, resulting in poor protection. Moisture and oxygen can easily penetrate from between the layers, accelerating the aging and failure of the solar panels, and even causing the solar panels to delaminate.

[0007] 3. As a building-integrated photovoltaic (BIPV) product, existing photovoltaic tiles need to have the excellent processing performance of metal sheets in order to adapt to various complex shapes and designs;

[0008] 4. The substrates of existing photovoltaic tiles are mostly made of aluminum alloy, which is heavy and expensive, and the products also require grounding.

[0009] 5. As a building-integrated photovoltaic (BIPV) product, existing photovoltaic tiles need to have high strength and be able to withstand certain loads. Summary of the Invention

[0010] In view of this, the present invention provides a high water-resistant composite photovoltaic tile with good load-bearing capacity, impact resistance, water-resistant properties, light weight, low cost, rich and colorful colors, and excellent anti-ultraviolet aging properties.

[0011] Specifically as follows:

[0012] A high water-resistant composite photovoltaic tile includes a first encapsulation layer, a first encapsulation film layer, a first PET layer, a second encapsulation film layer, a cell layer, a third encapsulation film layer, a second PET layer, a fourth encapsulation film layer, and a substrate, which are stacked in sequence and laminated together by a laminator; the cell layer includes multiple solar cell strings; the first encapsulation layer is an FRP board containing acrylic resin.

[0013] Furthermore, the acrylic resin comprises the following raw materials in weight percentages: 40%–50% fluorinated acrylic resin, 10%–15% curing agent, 30%–40% diluent, and 3%–5% additives.

[0014] Furthermore, the fluorinated modified acrylic resin comprises one or a mixture of the following materials: fluoroalkyl alcohol acrylic resin, fluorosilicone modified hydroxyl acrylic resin, organofluorine modified acrylic resin, and silicone fluorinated polyurethane acrylic resin.

[0015] Furthermore, the curing agent is one or a mixture of the following materials: isocyanate, amino resin, tetraisopropoxy titanium, and vinyl dimethicone.

[0016] Furthermore, the diluent is one or a mixture of the following materials: styrene, ethyl acetate, ethanol, propylene glycol, and isopropanol.

[0017] Furthermore, the additive is one or a mixture of the following materials: leveling agent, defoamer, color paste, and accelerator.

[0018] Furthermore, the first PET layer is a water-resistant reinforced composite PET, characterized in that it comprises: a reinforcing material and a PET film material for coating.

[0019] Furthermore, the reinforcing material accounts for 30-40% of the weight of the first PET layer and includes one or more of the following materials: nanofibers, whiskers, and carbon fibers.

[0020] The substrate is a multilayer co-extruded composite board containing a special resin film material A and a resin substrate B. The multilayer co-extruded composite board is made by melting and extruding the raw materials of the special resin film material A and the raw materials of the resin substrate B separately through an extruder, and then merging them at the co-extrusion die through their respective flow channels, followed by casting and cooling.

[0021] Furthermore, the special resin membrane material A includes any one of the following materials: PPS, PEI, ASA; the resin membrane material B includes any one of the following materials: PVC, PMMA, PET.

[0022] Beneficial effects:

[0023] 1. FRP sheets impregnated with fluorinated acrylic resin can replace traditional glass and fluorine film for encapsulation, which can reduce the weight of the module, have the UV resistance of fluorine film, and at the same time, the sheet has a load-bearing effect to protect the module.

[0024] 2. Using PET as the core material with reinforcing filler further enhances the product's strength and improves its impact resistance. At the same time, combined with a nano-coating, it has high water resistance and protects the battery components in the photovoltaic tile.

[0025] 3. Using resin-synthetic boards as substrates further reduces product weight and price. These boards utilize co-extrusion technology, giving them excellent resistance to UV aging. They can also be further processed through heated bending processes. Attached Figure Description

[0026] Figure 1 A schematic diagram of a high water-resistant composite photovoltaic tile structure provided in one embodiment of the present invention; Detailed Implementation

[0027] Exemplary embodiments of the present application will now be described in more detail with reference to the accompanying drawings. While exemplary embodiments of the present application are shown in the drawings, it should be understood that the present application may be implemented in various forms and should not be limited to the embodiments set forth herein. Rather, these embodiments are provided so that this application will be thorough and complete, and will fully convey the scope of the present application to those skilled in the art.

[0028] like Figure 1 As shown, a high water-resistant composite photovoltaic tile includes a first encapsulation layer 1, a first encapsulation film layer 2, a first PET layer 3, a second encapsulation film layer 4, a cell layer 5, a third encapsulation film layer 6, a second PET layer 7, a fourth encapsulation film layer 8, and a substrate 9, which are stacked in sequence and integrally formed by lamination. The cell layer includes multiple solar cell strings. The first encapsulation layer is an FRP board containing acrylic resin.

[0029] Preferably, the cell layer can be a single-sided crystalline silicon solar cell, a double-sided crystalline silicon solar cell, an n-IBC cell, a thin-film cell, or a perovskite dye-sensitized cell; when the cell layer is a PERC cell or other crystalline silicon cell, it is interconnected by solder ribbon or shingled interconnect.

[0030] It should be noted that the length and width dimensions of the first encapsulation layer 1, the first encapsulation film layer 2, the fourth encapsulation film layer 8, and the substrate 9 are the same, and are larger than the length and width dimensions of the first PET layer 3, the second encapsulation film layer 4, the battery cell layer 5, the third encapsulation film layer 6, and the second PET layer 7.

[0031] The length and width dimensions of the first PET layer 3, the second encapsulating film layer 4, the battery cell layer 5, the third encapsulating film layer 6, and the second PET layer 7 are also the same.

[0032] The fourth encapsulation film layer and the substrate have the same length and width dimensions, which can ensure that the fourth encapsulation film layer is completely attached to the substrate and has stronger adhesion.

[0033] During lamination, the EVA or POE of the fourth encapsulating film layer flows into the edge area on the back of the photovoltaic panel, thus forming a self-overflowing sealing edge.

[0034] Furthermore, the second PET layer 7 is an insulating PET.

[0035] Furthermore, the first encapsulating film layer, the second encapsulating film layer, the third encapsulating film layer, and the fourth encapsulating film layer are any one of EVA, POE, and PVB.

[0036] Furthermore, the acrylic resin comprises the following raw materials by weight percentage: 40%–50% fluorinated acrylic resin, 10%–15% curing agent, 30%–40% diluent, and 3%–5% additives. It should be noted that the sum of the proportions of the above raw materials is 100%.

[0037] It should be noted that 40% to 50% means [40% to 50%].

[0038] Furthermore, the fluorinated modified acrylic resin comprises one or a mixture of the following materials: fluoroalkyl alcohol acrylic resin, fluorosilicone modified hydroxyl acrylic resin, organofluorine modified acrylic resin, and silicone fluorinated polyurethane acrylic resin.

[0039] Furthermore, the curing agent is one or a mixture of the following materials: isocyanate, amino resin, tetraisopropoxy titanium, and vinyl dimethicone.

[0040] Furthermore, the diluent is one or a mixture of the following materials: styrene, ethyl acetate, ethanol, propylene glycol, and isopropanol.

[0041] Furthermore, the additive is one or a mixture of the following materials: leveling agent, defoamer, color paste, and accelerator.

[0042] Furthermore, the first PET layer is a water-resistant reinforced composite PET, characterized in that it comprises: a reinforcing material and a PET film material for coating.

[0043] Furthermore, the reinforcing material accounts for 30-40% of the weight of the first PET layer and includes one or more of the following materials: nanofibers, whiskers, and carbon fibers.

[0044] The substrate is a multilayer co-extruded composite board containing a special resin film material A and a resin substrate B. The multilayer co-extruded composite board is made by melting and extruding the raw materials of the special resin film material A and the raw materials of the resin substrate B separately through an extruder, and then merging them at the co-extrusion die through their respective flow channels, followed by casting and cooling.

[0045] Furthermore, the special resin film material A includes any one of the following materials: PPS, PEI, ASA; the resin substrate B includes any one of the following materials: PVC, PMMA, PET.

[0046] A first aspect of the present invention provides a method for preparing photovoltaic tiles, comprising the following steps:

[0047] S1 Lamination: The first encapsulation layer, the first encapsulation film layer, the first PET layer, the second encapsulation film layer, the battery cell layer, the third encapsulation film layer, the second PET layer, the fourth encapsulation film layer, and the substrate are laid in sequence, ready for lamination;

[0048] S2 Vacuuming and Dehumidification: The photovoltaic tile installation components stacked in step S1 are conveyed to the vacuum chamber of the laminator via a conveyor belt for vacuuming and dehumidification;

[0049] S3 Lamination: The photovoltaic tile installation parts after vacuuming and dehumidification in step S2 are transported to the lamination chamber of the laminator for lamination;

[0050] S4 Cooling: The photovoltaic tile laminate after step S3 is transported to the cooling chamber of the laminator for cooling treatment;

[0051] S5 Cutting: Laser cutting is performed on the photovoltaic tile laminate after the cooling treatment in step S4;

[0052] S6 Folding: The photovoltaic tile laminate cut in step S5 is transported to a hot bending machine for heating and folding.

[0053] Beneficial effects:

[0054] 1. FRP sheets impregnated with fluorinated acrylic resin can replace traditional glass and fluorine film for encapsulation, which can reduce the weight of the module, have the UV resistance of fluorine film, and at the same time, the sheet has a load-bearing effect to protect the module.

[0055] 2. Using PET as the core material with reinforcing filler further enhances the product's strength and improves its impact resistance. At the same time, combined with a nano-coating, it has high water resistance and protects the battery components in the photovoltaic tile.

[0056] 3. Using resin-synthetic boards as substrates further reduces product weight and price. These boards utilize co-extrusion technology, giving them excellent resistance to UV aging. They can also be further processed through heated bending processes.

[0057] It will be readily understood by those skilled in the art that the above are merely preferred embodiments of the present invention and are not intended to limit the present invention. Any modifications, combinations, substitutions, improvements, etc., made under the spirit and principles of the present invention are included within the protection scope of the present invention.

Claims

1. A high water-resistive composite photovoltaic tile, characterized in that, The first encapsulation layer, the first encapsulation adhesive film layer, the first PET layer, the second encapsulation adhesive film layer, the battery piece layer, the third encapsulation adhesive film layer, the second PET layer, the fourth encapsulation adhesive film layer and the substrate are sequentially stacked and laminated by a laminating machine to form an integrated body; the battery piece layer comprises a plurality of solar cell strings; the first encapsulation layer is an FRP plate containing acrylic resin; The acrylic resin comprises raw materials in the following proportions by weight: 40-50% of fluorine-modified acrylic resin, 10-15% of curing agent, 30-40% of diluent and 3-5% of auxiliary agent; The substrate is a multi-layer co-extrusion composite plate containing special resin film material A and resin base material B; the multi-layer co-extrusion composite plate is formed by melting and extruding the raw materials of the special resin film material A and the raw materials of the resin base material B through an extruder, respectively, converging at a co-extrusion die head through their respective flow channels, and then being cooled after cast sheet forming.

2. The high-water-resistive composite photovoltaic tile according to claim 1, characterized in that, The fluorine-modified acrylic resin comprises one or a mixture of several of the following materials: fluorine alkyl alcohol acrylic resin, fluorine silicon-modified hydroxyl acrylic resin, organic fluorine-modified acrylic resin and silicon fluorinated polyurethane acrylic resin.

3. The high-water-resistive composite photovoltaic tile according to claim 1, wherein, The curing agent is one or a mixture of several of the following materials: isocyanate, amino resin, tetraisopropoxy titanium and vinyl dimethyl acrylate.

4. The high-water-resistive composite photovoltaic tile according to claim 1, wherein, The diluent is one or a mixture of several of the following materials: styrene, ethyl acetate, ethanol, propylene glycol and isopropyl alcohol.

5. The high-water-resistive composite photovoltaic tile according to claim 1, wherein, The auxiliary agent is one or a mixture of several of the following materials: leveling agent, defoaming agent, color paste and accelerator.

6. The high-water-resistive composite photovoltaic tile according to claim 1, wherein, The first PET layer is a water-blocking reinforced composite PET, characterized in that it comprises: reinforcing material and plated PET film material.

7. The high-water-resistive composite photovoltaic tile according to claim 6, characterized in that, The reinforcing material accounts for 30-40% of the weight of the first PET layer and comprises one or a mixture of several of the following materials: nano glass fiber, whisker and carbon fiber.

8. The high-water-resistive composite photovoltaic tile according to claim 1, wherein, The raw materials of the special resin film material A include any one of the following materials: PPS, PEI and ASA; the raw materials of the resin base material B include any one of the following materials: PVC, PMMA and PET.

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