A curved photovoltaic module and a method for manufacturing the same, vehicle

Abstract

The present application relates to a kind of curved surface photovoltaic module and its manufacturing method, vehicle, a kind of curved surface photovoltaic module, including curved surface panel, photovoltaic cell layer, backboard and transition layer, photovoltaic cell layer is located between curved surface panel and backboard, photovoltaic cell layer includes a plurality of spaced apart cell piece, backboard includes a plurality of backboard units, backboard unit head-to-head lap, the lap area of adjacent two backboard units is staggered with the edge of cell piece Setting;Transition layer is laid on backboard, transition layer includes a plurality of sequentially spliced transition units, splicing position is located above cell piece, and is staggered with lap area Setting. By setting backboard into small area backboard unit, and backboard unit head-to-head lap, so that the bending degree of backboard and curved surface panel is adapted, so that backboard can spread open when pressing and not wrinkle;Transition layer can effectively buffer atmospheric pressure, to avoid cell piece crack piece.

Description

Technical Field

[0001] This invention relates to the field of photovoltaic technology, and in particular to a curved photovoltaic module and its manufacturing method, as well as a vehicle. Background Technology

[0002] With the development of new energy technologies, people are becoming increasingly aware of energy conservation and environmental protection. Some car manufacturers have integrated photovoltaic cells into automotive glass to power small-power electrical appliances such as blowers, car refrigerators, and seats. In particular, photovoltaic power generation can supply electricity when the vehicle is parked or stopped, ensuring that the vehicle still has power available even when the engine is off, or to charge small batteries, or even charge the main battery.

[0003] In related technologies, sunroof glass integrating photovoltaic cells is manufactured using a curved lamination process. Specifically, the sunroof glass assembly includes sunroof glass, solar cells, a back sealing material layer, lead-out electrodes, an electrode capping layer, and edge sealing material. During the curved lamination process, the curved sunroof glass serves as a substrate, and solar cells, matching the curvature of the sunroof glass, are supported on it and laminated using specialized modules. In these technologies, the electrode capping layer is composed of multiple small blocks to prevent wrinkling during the curved lamination process.

[0004] However, using the aforementioned curved lamination process has two drawbacks: firstly, the lamination space is limited; secondly, the dedicated modules must match the size of the sunroof. Currently, sunroofs are increasingly trending towards fixed panoramic sunroofs, meaning the corresponding modules must be quite large. This limits the number of modules that can be placed within the limited lamination space, resulting in long cycle times and low production capacity. Furthermore, in related technologies, the back sealing material layer is flat. The curvature of the back sealing material and the sunroof glass are mismatched, and their surface areas are unequal. Even with dedicated curved lamination modules, wrinkles will appear, leading to an unattractive product appearance. Summary of the Invention

[0005] Therefore, it is necessary to address the technical problem of wrinkles easily occurring during the fabrication of sunroof glass integrating photovoltaic cells in existing technologies, and to provide a curved photovoltaic module, its fabrication method, and a vehicle thereof.

[0006] A curved photovoltaic module includes a curved panel, a photovoltaic cell layer, and a backsheet. The photovoltaic cell layer is disposed between the curved panel and the backsheet and includes a plurality of spaced-apart cells. The backsheet includes a plurality of backsheet units, which overlap end to end. The overlap area of ​​two adjacent backsheet units is arranged to avoid the edge of the cells.

[0007] In one embodiment, the overlapping area avoids the gap area between the battery cells.

[0008] In one of the embodiments, the overlapping area is arranged above the interval area between two of the battery pieces.

[0009] In one of the embodiments, the overlapping area has an overlapping degree of ≥10mm.

[0010] In one of the embodiments, the length of the battery piece is defined as L1, the distance between the edge of the overlapping area and the edge of the battery piece is defined as L2, and when the overlapping area is above the battery piece, L2≥L1 / 4.

[0011] In one of the embodiments, the interval distance between two of the battery pieces is defined as D, and the overlapping degree of the overlapping area is defined as W, and D≥3W.

[0012] In one of the embodiments, along the arrangement direction of the backboard units, the leading end of at least one of the backboard units overlaps the trailing end of the backboard unit adjacent thereto.

[0013] And / or, the trailing end of the backboard unit overlaps the leading end of the backboard unit adjacent thereto.

[0014] In one of the embodiments, along the arrangement direction of the backboard units, one end of the backboard is defined as the first end, and the other end is defined as the second end, one end of each of the backboard units close to the first end of the backboard is defined as the leading end of the backboard unit, and one end of each of the backboard units close to the second end of the backboard is defined as the trailing end of the backboard unit.

[0015] In one of the embodiments, the curved photovoltaic module further comprises a first adhesive film layer and a second adhesive film layer, the first adhesive film layer is arranged between the photovoltaic cell layer and the curved panel, the second adhesive film layer is arranged between the photovoltaic cell layer and the backboard, and a third adhesive film layer is arranged between the two backboard units at the overlapping area.

[0016] A preparation method of a curved photovoltaic module, the curved photovoltaic module comprising a curved panel and a photovoltaic cell layer, the preparation method comprising the following steps:

[0017] Step 1, providing the curved panel, and laying a first adhesive film layer on the concave surface of the curved panel;

[0018] Step 2, laying the photovoltaic cell layer on the first adhesive film layer;

[0019] Step 3, laying a second adhesive film layer on the photovoltaic cell layer;

[0020] Step 4, laying a backboard on the second adhesive film layer to form a laminated piece, the backboard comprising a plurality of backboard units, the backboard units being overlapped at the leading end and the trailing end, and the overlapping area being arranged away from the edge of the battery piece;

[0021] Step 5: Lay a transition layer on the side of the laminate facing the back sheet. The transition layer includes multiple sequentially spliced ​​transition units. The splicing position is located above the battery cell and avoids the overlapping area.

[0022] Step 6: After pressing the laminate and the transition layer together, remove the transition layer to form the curved photovoltaic module.

[0023] In one embodiment, in step 5:

[0024] The distance between the opposite edges of the splicing position and the overlapping area is defined as d1, where d1 ≥ 20 mm;

[0025] And / or, the edge of the transition layer is recessed relative to the edge of the back plate, and the recess distance is defined as d2, 3mm≤d2≤5mm.

[0026] A vehicle comprising a curved photovoltaic module as described above.

[0027] The beneficial effects of the present invention include at least the following:

[0028] This invention provides a curved photovoltaic module and its fabrication method, which can be applied to vehicles and other transportation vehicles as an auxiliary power source to provide electricity. Traditional / existing curved photovoltaic modules are fabricated using a curved lamination process, which suffers from low production cycle time and easy wrinkling of the back sealing material when applied to curved sunroof glass. This invention addresses this by setting the back sheet as small-area back sheet units and overlapping the ends of these units, allowing the back sheet to fit more closely to the curved panel, thus preventing wrinkling during lamination. Attached Figure Description

[0029] Figure 1 This is a schematic diagram of the stacked structure of a curved photovoltaic module according to an embodiment of the present invention;

[0030] Figure 2 This is a top view of the backsheet overlap of a curved photovoltaic module according to an embodiment of the present invention;

[0031] Figure 3 for Figure 2 A cross-sectional view of a curved photovoltaic module along section AA;

[0032] Figure 4 for Figure 2 The cross-sectional view along AA after the transition layer is set in the middle;

[0033] Figure 5 This is a schematic diagram of a backplate structure provided in an embodiment of the present invention;

[0034] Figure 6A top view of the back plate lap joint of the curved photovoltaic module according to another embodiment of the present application;

[0035] Figure 7 A cross-sectional view along B-B of the curved photovoltaic module according to another embodiment of the present application; Figure 6

[0036] Figure 8 An enlarged schematic view of A in the curved photovoltaic module according to another embodiment of the present application; Figure 7

[0037] Figure 9 An enlarged schematic view of another structure form at A in the curved photovoltaic module according to another embodiment of the present application; Figure 7

[0038] Figure 10 A cross-sectional view along B-B of the curved photovoltaic module according to another embodiment of the present application after a transition layer is arranged; Figure 6

[0039] A cross-sectional view along B-B of the curved photovoltaic module according to another embodiment of the present application after a third adhesive film layer is arranged between two back plate units; Figure 11 Figure 6 An enlarged schematic view of B in the curved photovoltaic module according to another embodiment of the present application;

[0040] Figure 12 Figure 9 A top view of the transition layer of the curved photovoltaic module according to an embodiment of the present application;

[0041] Figure 13 A kind of exhaust mode of the curved photovoltaic module according to an embodiment of the present application;

[0042] Figure 14 A laminating flow schematic diagram of the curved photovoltaic module according to an embodiment of the present application;

[0043] Figure 15 A schematic diagram of the preparation method of the curved photovoltaic module according to an embodiment of the present application;

[0044] Figure 16 A schematic diagram of the preparation method of the curved photovoltaic module according to an embodiment of the present application when the adhesive film layer adopts thermosetting material;

[0045] Figure 17 A schematic diagram of the preparation method of the curved photovoltaic module according to an embodiment of the present application when the adhesive film layer adopts thermoplastic material;

[0046] Figure 18 A schematic diagram of the preparation method of the curved photovoltaic module according to an embodiment of the present application when the adhesive film layer adopts thermoplastic material;

[0047] Figure 19 A schematic diagram of the preparation method of the curved photovoltaic module according to an embodiment of the present application when the adhesive film layer adopts thermoplastic material;

[0048] Reference signs:

[0049] ​​​​​Curved panel 100; first adhesive film layer 200; photovoltaic cell layer 300; cell 310; second adhesive film layer 400; back panel 500; first end 500a; second end 500b; back panel unit 510; inner layer 511; intermediate layer 512; outer layer 513; head end 514; tail end 515; lap region 520; transition layer 600; transition unit 610; third adhesive film layer 700; vacuum pump 800; air extraction bag 900; arrangement direction X. DETAILED DESCRIPTION

[0050] In order to make the above objectives, features and advantages of the present application more clear and comprehensible, the specific embodiments of the present application will be described in detail below with reference to the accompanying drawings. In the following description, a large number of specific details are set forth in order to provide a thorough understanding of the present application. However, the present application can be implemented in many different ways other than those described herein, and one of ordinary skill in the art can make similar improvements without departing from the scope of the present application, and therefore the present application is not limited to the specific embodiments disclosed below.

[0051] In the description of the present application, it should be understood that the terms "length", "width", "height" and the like indicate the orientation or positional relationship based on the orientation or positional relationship shown in the drawings, and are only for the purpose of facilitating the description of the present application and simplifying the description, and do not indicate or imply that the device or element referred to must have a particular orientation, be constructed and operated in a particular orientation, and therefore cannot be understood as a limitation on the present application.

[0052] In addition, the terms "first", "second" are only for descriptive purposes and cannot be understood as indicating or implying relative importance or implicitly indicating the number of technical features indicated. Therefore, the features defined with "first", "second" can explicitly or implicitly include at least one of the features. In the description of the present application, the meaning of "a plurality of" is at least two, such as two, three, etc., unless otherwise explicitly specified and limited.

[0053] In the present application, unless otherwise explicitly specified and limited, the first feature is "on" or "under" the second feature can be that the first and second features are in direct contact, or the first and second features are indirectly in contact through an intermediate medium. Moreover, the first feature "above", "above" and "above" the second feature can be that the first feature is directly above or obliquely above the second feature, or only indicates that the first feature is higher in horizontal height than the second feature. The first feature "below", "below" and "below" the second feature can be that the first feature is directly below or obliquely below the second feature, or only indicates that the first feature is lower in horizontal height than the second feature.

[0054] An embodiment of the present application provides a vehicle which applies the curved photovoltaic module as described below. The vehicle can be any kind and any model of vehicle. In the present application, the curved photovoltaic module is taken as an example to illustrate the sunroof glass of the vehicle.

[0055] Referring to Figures 1 to 5 An embodiment of the present application provides a curved photovoltaic module, comprising a curved panel 100, a photovoltaic cell layer 300 and a back panel 500, the photovoltaic cell layer 300 is arranged between the curved panel 100 and the back panel 500, the photovoltaic cell layer 300 comprises a plurality of cell pieces 310 arranged at intervals, and the back panel 500 comprises a plurality of back panel units 510, the back panel units 510 are overlapped at the head and tail, and the overlapping area 520 of the two adjacent back panel units 510 is arranged away from the edge of the cell piece 310.

[0056] The embodiment provides a curved photovoltaic module, which can be applied to a vehicle or the like as an auxiliary power supply to provide power for the vehicle or the like. The conventional / existing curved photovoltaic module is prepared by using a curved laminating process, and has problems of low production rhythm and easy wrinkling of back sealing material when applied to a curved sunroof glass. The present application sets the back panel 500 as a small-area back panel unit 510, so that the back panel 500 is more fitted to the curved panel, thereby preventing the back panel 500 from being wrinkled when being pressed, and the back panel unit 510 is overlapped at the head and tail to obtain an effective packaging effect.

[0057] It can be understood that the curved panel 100 can be a curved glass plate or a curved plastic plate capable of transmitting light. In the embodiment, the light transmittance of the curved panel 100 is not limited. The back panel 500 is usually a composite structure of 3 layers or more, comprising an inner layer 511, an intermediate layer 512 and an outer layer 513, wherein one layer facing the photovoltaic cell layer 300 is the inner layer 511, one layer facing the atmosphere is the outer layer 513, and the intermediate layer 512 is sandwiched between the inner layer 511 and the outer layer 513. The inner layer 511 can be a film layer or a non-film layer. When the inner layer 511 is a non-film layer, the adhesive strength between the inner layer 511 and the first film layer 200 is preferably not less than 40 N / cm. The transition layer 600 can be tempered glass with a thickness of not more than 1 mm, or plastic with a softening temperature greater than or equal to 250℃ and a thickness of 1-2 mm. The strength of the transition layer is much higher than that of the back panel, which can effectively bear the pressure formed after pumping, thereby effectively avoiding the cell piece cracking defect.

[0058] As Figure 1 shown, it can be understood that the curved photovoltaic module further comprises a first film layer 200 and a second film layer 400, the first film layer 200 is arranged between the photovoltaic cell layer 300 and the curved panel 100, and the second film layer 400 is arranged between the photovoltaic cell layer 300 and the back panel 500. The first film layer 200 and the second film layer 400 can be any one of transparent EVA (ethylene-vinyl acetate copolymer) film, POE (polyolefin elastomer) film, PVB (polyvinyl butyral) and the like.

[0059] It should be noted that the overlapping area 520 refers to the area between two adjacent backboard units after the end-to-end overlapping, as shown by the area circled by the dashed line in Figure 8 and Figure 9 As shown in Figure 8 , one end of the backboard unit 510 is obliquely overlapped on the other end of the other backboard unit 510 after the second adhesive film layer 400 is attached. Figure 9 As shown in Figure 9 , in another embodiment, one end of the backboard unit 510 is attached to the second adhesive film layer 400 adjacent to the end of the other backboard unit 510 and then folded and overlapped on the other end of the other backboard unit 510.

[0060] The overlapping degree of the overlapping area 520 is W, and preferably W≥10mm. In one embodiment, the overlapping area 520 avoids the spacing area between the battery pieces 310. That is, the overlapping area 520 between the backboard units 510 is arranged above the battery pieces 310, and the edge of the overlapping area 520 should avoid the edge of the battery pieces 310 to prevent the overlapping area 520 between the backboard units 510 from causing stress concentration on the edge of the battery pieces 310, thereby reducing the risk of cracking of the edge of the battery pieces 310 during pressing. Further, as shown in Figure 3 , the length of the battery piece 310 is L1, the distance between the edge of the overlapping area 520 and the edge of the battery piece 310 is L2, and when the overlapping area 520 is above the battery piece 310, preferably L2≥L1 / 4.

[0061] In another embodiment, as shown in Figure 3 , the spacing distance between two battery pieces 310 is defined as D, and when D≥3W, the overlapping area 520 is preferably arranged above the spacing area between the two battery pieces 310. In this way, the overlapping area also avoids the edge of the battery piece.

[0062] The number of backplate units 510 is represented by N. In the embodiments of the present invention, N > 2, and N can be 3, 4, 5, ... or even more. It should be noted that the arrangement direction X of the backplate units 510 is the direction in which the backplate units 510 are arranged side by side. Along the arrangement direction X of the backplate units 510, the backplate units 510 have a head end 514 and a tail end 515. In this embodiment, multiple backplate units 510 are overlapped head to tail along the arrangement direction X of the backplate units 510. There is no limitation on the overlapping method of the backplate units 510. It can be that along the arrangement direction X of the backplate units 510, at least one backplate unit 510's head end 514 overlaps above the tail end 515 of its adjacent backplate unit 510. Along the arrangement direction X of the backplate units 510, one end of the backplate 500 is defined as the first end 500a, and the other end as the second end 500b. The end of each backplate unit 510 closest to the first end 500a is the head end of the backplate unit 510, and the end closest to the second end 500b is the tail end of the backplate unit 510. For example... Figure 7 As shown, the first end 500a of the back plate 500 is the left end in the figure, and the second end 500b of the back plate 500 is the right end in the figure.

[0063] Taking a backplate unit 510 with a quantity N=4 as an example, the first overlapping method of the backplate unit 510 described above will be explained. For ease of understanding, please refer to... Figures 2 to 4 To understand this, the backplate units 510 are numbered 1, 2, 3, and 4 from left to right. This left-to-right arrangement can be interpreted as the X-direction of the backplate units 510, with the left end being the first end 514 and the right end being the last end 515. In the first overlapping method, the first end 514 of backplate unit 2 overlaps above the last end 515 of backplate unit 1, the first end 514 of backplate unit 3 overlaps above the last end 515 of backplate unit 2, and the first end 514 of backplate unit 4 overlaps above the last end 515 of backplate unit 3.

[0064] In another embodiment, along the arrangement direction X of the backplate units 510, the first end of some backplate units 510 overlaps the top of the tail end of their adjacent backplate units 510, and the tail end of some backplate units 510 overlaps the top of the first end of their adjacent backplate units 510. Similarly, the second overlapping method of the backplate units 510 described above will be explained using an example of N=4 backplate units 510. For ease of understanding, refer to... Figure 6 , Figure 7 and Figure 10It is understood that the backboard units 510 are numbered from left to right as 1, 2, 3, 4, and the left-to-right direction can be understood as the arrangement direction X of the backboard units 510, the left end being the head end 514 of the backboard unit 510 and the right end being the tail end 515 of the backboard unit 510. The tail end 515 of the No. 2 backboard unit 510 and the tail end 515 of the No. 3 backboard unit 510 are the boundaries, and the tail end 515 of the No. 1 backboard unit 510 on the left side is overlapped above the head end 514 of the No. 2 backboard unit 510; the head end 514 of the No. 4 backboard unit 510 on the right side is overlapped above the tail end 515 of the No. 3 backboard unit 510. For the overlapping mode of the tail end 515 of the No. 2 backboard unit 510 and the head end 514 of the No. 3 backboard unit 510, the tail end 515 of the No. 2 backboard unit 510 can be overlapped above the head end 514 of the No. 3 backboard unit 510, or the head end 514 of the No. 3 backboard unit 510 can be overlapped above the tail end 515 of the No. 2 backboard unit 510.

[0065] The material of the inner layer 511 of the backboard 500 is different, and the overlapping mode of the backboard unit 510 is different. Specifically, when the inner layer 511 of the backboard 500 is a film, either of the above two overlapping modes can be used. Among them, the inner layer 511 of the backboard unit 510 is preferably selected to be the same type of film as the second film layer 400. When the inner layer 511 of the backboard 500 is not a film, the second overlapping mode is preferably used, that is, the right angle side of the backboard unit is closer to the lowest part of the curved panel.

[0066] When the inner layer 511 of the backboard 500 is not a film material, the second film layer 400 is a thermosetting material, for example, the second film layer 400 is EVA or POE, the second overlapping mode can be directly used. When the second film layer 400 is a thermosetting material, the second film has good fluidity during the pressing process. Considering the combined effect of the weight of the film itself and the air pressure, the molten film can fill the gap in the overlapping area when it is extruded and flow, and overflow to the overlapping area, so that the two backboard units in the overlapping area can also be effectively bonded.

[0067] Referring to Figure 11 and Figure 12It is understood that when the inner layer 511 of the backboard unit 510 is a non-film material, and the second film layer 400 is a thermoplastic material, for example, the second film layer 400 is PVB, during the pressing process, the softened PVB has low flowability, and the softened PVB can fill the gap on one side of the lap joint area to a certain extent, but cannot flow to the lap joint area to fill the lap joint area. Therefore, it is preferred to provide a third film layer 700 between the two backboard units 510 at the lap joint area 520, so that the softened third film layer 700 bonds the two backboard units of the lap joint area together. It should be noted that the thickness of the third film layer 700 is preferably not more than 0.2 mm. It can be understood that when the third film layer 700 is provided between the two backboard units 510 at the lap joint area 520, the edge of the third film layer 700 is preferably not more than the edge of the overlapping part of the two backboard units 510, so as to avoid the adhesion of the transition layer 600 and the backboard 500 caused by the third film layer 700 after pressing, and facilitate the removal of the transition layer 600 after pressing.

[0068] As shown in Figure 15 and Figure 19 An embodiment of the present application also provides a preparation method of a curved photovoltaic module, the curved photovoltaic module comprising a curved panel and a photovoltaic cell layer, the preparation method comprising the following steps:

[0069] S100, providing a curved panel, and laying a first film layer on the concave surface of the curved panel;

[0070] S200, laying a photovoltaic cell layer on the first film layer;

[0071] S300, laying a second film layer on the photovoltaic cell layer;

[0072] S400, laying a backboard on the second film layer to form a laminated piece, the backboard comprising a plurality of backboard units, the backboard units being end-to-end lap jointed, and the lap joint area being arranged away from the edge of the cell sheet;

[0073] S500, laying a transition layer on the side of the laminated piece facing the backboard, the transition layer comprising a plurality of transition units sequentially spliced, the splicing position being above the cell sheet and away from the lap joint area;

[0074] S600, after pressing the laminated piece and the transition layer, removing the transition layer to form a curved photovoltaic module.

[0075] In this embodiment, after preparing the photovoltaic cell layer, the structural layers of the curved photovoltaic module are stacked sequentially. First, a curved panel is laid, then a first encapsulating film layer is laid on the concave surface of the curved panel. Next, the photovoltaic cell layer is laid on the first encapsulating film layer, followed by a second encapsulating film layer. Then, a backsheet is laid on the second encapsulating film layer. The backsheet is divided into multiple backsheet units, with adjacent backsheet units overlapping end-to-end to form the laminate. During installation, care should be taken to ensure that the overlapping area of ​​two backsheet units avoids the edges of the solar cells. Next, a transition layer is laid above the backsheet. In this embodiment, the transition layer is composed of multiple transition units. The joint position of two adjacent transition units should be located above the solar cells, avoiding the overlapping area of ​​the backsheet units and the gap between the two solar cells. Finally, the laminate is pressed together to form the curved photovoltaic module.

[0076] In this embodiment, the transition layer 600 is configured as a plurality of sequentially spliced ​​transition units 610, making the transition layer 600 fit more closely to the backsheet surface. The backsheet 500 is configured as a plurality of overlapping backsheet units 510, ensuring that when the backsheet 500 is laid on the photovoltaic cell layer 300, it fits closely to the curved panel surface, thereby reducing wrinkles after the backsheet 500 is pressed. The overlapping area 520 between the backsheet units 510 is designed to avoid contact with the edge of the solar cell 310 to prevent cracking of the edge of the solar cell 310 during pressing. It is understood that, referring to... Figure 13 It is understandable that, since the curved panel 100 is curved, after the transition unit 610 is laid on the back plate 500, the two ends of the splice of the transition unit 610 remain in contact, and gaps are allowed in the middle area. If the overlapping area 520 falls in the gap between the transition units 610, then the back plate units in the overlapping area cannot make effective contact during the pressing process, and there is a chance of delamination. Therefore, the splice area should be avoided from being set in the same position as too many unit splices, and they should be set apart.

[0077] In one embodiment, such as Figure 4 As shown, in step 5, the distance between the opposite edges of the splicing position and the overlapping area 520 is d1, where d1 ≥ 20 mm. This setting ensures that the splicing position of the transition unit 610 avoids the overlap area 520 of the backplate unit 510, preventing stress concentration on the battery cells. The edge of the transition layer 600 is recessed relative to the edge of the backplate 500 by a recess distance of d2, where 3 mm ≤ d2 ≤ 5 mm. This setting prevents the transition layer 600 from sticking due to excess adhesive during pressing, thus facilitating the removal of the transition layer 600 after pressing.

[0078] Reference Figure 14 and Figure 16 It is understood that, in one embodiment, the laminate and transition layer include:

[0079] S610, placing the laminated piece and the transition layer into the vacuum bag and vacuumizing the vacuum bag to make the vacuum degree between the layers of the laminated piece reach a preset value;

[0080] S620, keeping the vacuum degree within the preset value and heating the laminated piece and the transition layer to a preset temperature range.

[0081] Referring to Figure 14 and Figure 17 It is understood that, in one embodiment, when the material of the first adhesive film layer and the second adhesive film layer is thermosetting material:

[0082] S611, vacuumizing the opposite ends of the vacuum bag at the same time to make the vacuum degree between the layers of the laminated piece reach between -90 and -100 kPa;

[0083] S621, keeping the vacuum degree and heating the laminated piece to between 135 and 180 °C for at least 15 mins.

[0084] Since the thermosetting material has good fluidity, vacuumizing the opposite ends of the vacuum bag at the same time is beneficial to keeping the balance of the flow of the molten adhesive film layer, so that the distribution of the adhesive film in the curved photovoltaic module after pressing is more uniform.

[0085] In one preferred embodiment, the pressing of the laminated piece and the transition layer comprises:

[0086] The vacuum pumps 800 at the opposite ends of the vacuum bag 900 are opened at the same time to vacuumize the inside of the vacuum bag 900 to make the vacuum degree in the vacuum bag 900 reach -100 kPa and keep for at least 5 mins. Under the vacuum degree of -100 kPa, the laminated piece is heated to 150 °C at a heating rate of 0.5 °C / min and kept for at least 15 mins. The pressing method provided in this embodiment is suitable for the first adhesive film layer and the second adhesive film layer which are preferably thermosetting adhesive film materials. Using this manufacturing method, the pressing time is shorter, which is beneficial to optimizing the production rhythm and improving the production efficiency. After the above process is completed, the transition layer is taken out.

[0087] Referring to Figure 14 and Figure 18 It is understood that, in one embodiment, when the material of the first adhesive film layer and the second adhesive film layer is thermosetting material:

[0088] S611 ’ , vacuumizing the vacuum bag 900 to make the vacuum degree between the layers of the laminated piece and the transition layer reach between -90 and -100 kPa and keep for at least 0.5 h;

[0089] S621 ’The vacuum is maintained, and the laminated piece and the transition layer are heated at a temperature of 100-110°C at a heating rate of 0.6°C / min or less.

[0090] S622. The laminated piece and the transition layer are heated at a temperature of 140-160°C at a heating rate of 0.8-1.2 kPa, and then the vacuum is removed, and the temperature and pressure are maintained for at least 40 minutes.

[0091] In another preferred embodiment, the pressing of the laminated piece and the transition layer comprises:

[0092] The inside of the air exhaust bag 900 is vacuumed. In this embodiment, the vacuuming can be performed from one end of the air exhaust bag 900, or from opposite ends of the air exhaust bag 900, so that the vacuum degree in the air exhaust bag 900 is -95 kPa, and is maintained for at least 0.5 h. The laminated piece is heated at a temperature of 110°C at a heating rate of 0.5°C / min under the vacuum degree of -95 kPa. Then, the vacuum degree is removed, and the temperature is accelerated to 150°C, and the pressure is increased to 1.1 kPa, and the temperature and pressure are maintained for at least 40 minutes. The pressing method provided in this embodiment is suitable for the first adhesive film layer and the second adhesive film layer being preferably thermoplastic adhesive film materials. After the above process is completed, the transition layer is removed.

[0093] The technical features of the above embodiments can be combined in any manner. In order to make the description concise, all possible combinations of the technical features in the above embodiments are not described, however, as long as the combinations of the technical features do not contradict, they should be considered as the scope of the present disclosure.

[0094] The above embodiments only express several embodiments of the present application, and the description is relatively specific and detailed, but it should not be understood as a limitation on the scope of the patent. It should be pointed out that for ordinary skilled in the art, without departing from the concept of the present application, a number of modifications and improvements can be made, which are within the scope of the present application. Therefore, the scope of protection of the present application should be subject to the appended claims.

Claims

1. A curved photovoltaic module, characterized in that, The device includes a curved panel, a photovoltaic cell layer, and a back sheet. The photovoltaic cell layer is disposed between the curved panel and the back sheet. The photovoltaic cell layer includes multiple spaced-apart cells. The back sheet includes multiple back sheet units. The back sheet units overlap end to end. The overlap area of ​​two adjacent back sheet units is set to avoid the edge of the cells. The side length of the battery cell is defined as L1, and the distance between the edge of the overlapping area and the edge of the battery cell is defined as L2. When the overlapping area is located above the battery cell, L2 ≥ L1 / 4.

2. The curved photovoltaic module according to claim 1, characterized in that, It also includes a transition layer, which is laid on the side of the back plate away from the curved panel; The transition layer includes multiple sequentially spliced ​​transition units, the splicing position of which is located above the battery cell and is configured to avoid the overlapping area of ​​the backsheet unit.

3. The curved photovoltaic module according to claim 2, characterized in that, The distance between the splicing position of the transition layer and the opposite edges of the overlapping area is d1, and d1 satisfies the condition: d1≥20mm.

4. The curved photovoltaic module according to claim 2, characterized in that, The edge of the transition layer is recessed relative to the edge of the back plate, and the recess distance is defined as d2, wherein d2 satisfies the following condition: 3mm≤d2≤5mm.

5. The curved photovoltaic module according to claim 1, characterized in that, The overlap of the overlapping area is ≥10mm.

6. The curved photovoltaic module according to claim 1, characterized in that, The distance between two of the battery cells is defined as D, and the overlap of the overlapping area is defined as W, wherein D ≥ 3W.

7. The curved photovoltaic module according to claim 1, characterized in that, Along the arrangement direction of the backplate units, the first end of at least one of the backplate units overlaps the upper end of the tail end of the adjacent backplate unit. And / or, the tail end of the backplate unit overlaps the head end of the adjacent backplate unit; Along the arrangement direction of the backplate units, one end of the backplate is defined as the first end and the other end as the second end. The end of each backplate unit closest to the first end of the backplate is the head end of the backplate unit, and the end closest to the second end of the backplate is the tail end of the backplate unit.

8. The curved photovoltaic module according to claim 1, characterized in that, The curved photovoltaic module further includes a first adhesive film layer and a second adhesive film layer. The first adhesive film layer is disposed between the photovoltaic cell layer and the curved panel, the second adhesive film layer is disposed between the photovoltaic cell layer and the back sheet, and a third adhesive film layer is disposed between the two back sheet units at the overlapping area.

9. A method for fabricating a curved photovoltaic module, characterized in that, The curved photovoltaic module includes a curved panel and a photovoltaic cell layer, and the fabrication method includes the following steps: Step 1: Provide the curved panel and lay a first adhesive film layer on the concave surface of the curved panel; Step 2: Lay the photovoltaic cell layer on the first adhesive film layer; Step 3: Lay a second adhesive film layer on the photovoltaic cell layer; Step 4: Lay a backsheet on the second adhesive film layer to form a laminate. The backsheet includes multiple backsheet units, which overlap end to end, and the overlapping area is set to avoid the edge of the battery cell. Step 5: Lay a transition layer on the side of the laminate facing the back sheet. The transition layer includes multiple sequentially spliced ​​transition units. The splicing position is located above the battery cell and avoids the overlapping area. Step 6: After pressing the laminate and the transition layer together, remove the transition layer to form the curved photovoltaic module; In step 5: The distance between the opposite edges of the splicing position and the overlapping area is defined as d1, where d1 ≥ 20 mm; And / or, the edge of the transition layer is recessed relative to the edge of the back plate, and the recess distance is defined as d2, 3mm≤d2≤5mm.

10. A vehicle, characterized in that, The vehicle includes a curved photovoltaic module as described in any one of claims 1-8.

Images