Modulating film and design method and manufacturing method thereof, solar panel

Abstract

The present application relates to the technical field of battery panel, disclose a kind of modulation film and its design method and manufacturing method, and it is applied to solar cell panel.The modulation film includes structure and coating with different refractive indexes, by being arranged on the side of solar cell piece away from the incident light or the same side of solar cell piece with incident light, the travel route of incident light is changed based on the different refractive index distribution of modulation film, to increase the total amount of incident light incident to solar cell piece, to increase the utilization efficiency of solar cell piece to incident light, to improve the photoelectric conversion efficiency of photovoltaic module, improve power generation.

Description

TECHNICAL FIELD

[0001] The embodiment of the present application relates to the technical field of battery panel, in particular to a modulation film and a design method and a manufacturing method thereof, and a solar battery panel. BACKGROUND

[0002] The existing solar battery panel is connected by multiple solar cell pieces for the need of assembly and disassembly, but the stability of welding and connection must be considered when the multiple solar cell pieces are connected, so a certain distance gap must be set between the two solar cell pieces to reserve a certain deformation space, and the existence of the gap causes the incident light in the area to be unable to be converted, and the ratio of the occupied area to the converted electric energy is smaller with the larger area of the overall solar panel. SUMMARY

[0003] In view of the above problems, the present application provides a design method of a modulation film, which is used to solve the technical problem of the conversion rate of the overall solar panel affected by the connected solar cell pieces in the prior art.

[0004] According to one aspect of the embodiment of the present application, a modulation film is provided, which is applied to a solar assembly, and the modulation film comprises an adhesive, a substrate, a first structure and a first coating layer which are sequentially stacked; incident light is emitted after sequentially passing through the first structure and the first coating layer;

[0005] The solar assembly comprises at least two solar cell pieces which are spaced apart; the modulation film is arranged on the side opposite to the incident light surface of the solar cell piece or on the same side as the incident light of the solar cell piece;

[0006] The first structure is used to reflect the incident light to the solar cell piece or increase the radiation intensity transmitted to each solar cell piece;

[0007] The first coating layer is used to adhere to the first structure with a uniform thickness, and the refractive index of the first coating layer is different from the refractive index of the first structure.

[0008] In an optional manner, the modulation film further comprises a second substrate arranged on the first structure;

[0009] The second substrate is attached to the first structure through a first adhesive layer, and an air cavity is formed between the first adhesive layer and the first structure;

[0010] The air cavity is used to replace the refractive index difference of the coating structure, increase the deflection angle of the transmitted / reflected light of the modulation film, thereby increasing the travel length of the incident light in the battery assembly, so as to further increase the radiation intensity of the incident light transmitted / reflected to each solar cell piece.

[0011] In an alternative way, the modulation film further comprises a second structure and a second coating layer arranged on the first coating layer in sequence.

[0012] The second structure is used to further increase the angle of the transmitted / reflected light of the light emitted by the first structure.

[0013] The second coating layer is used to be attached to the second structure with a uniform thickness, and the refractive index of the second coating layer is different from that of the second structure.

[0014] In an alternative way, the first structure and the second structure each comprise a plurality of types of microstructures, and the microstructures are composed of one or more structures of a rectangle, a triangle, a semicircle, a trapezoid, a semicircle, a cone, a pyramid (a quadrangular pyramid), a triangular pyramid, and a semi-ellipsoid.

[0015] In an alternative way, when the microstructure is a rectangle, the structure period of the first structure or the second structure is 5um-80um, the width d is 3um-80um, and the height h is 3um-80um.

[0016] When the microstructure is a triangle, the triangle can be any one of an isosceles triangle or an unequal isosceles triangle, the structure period of the first structure or the second structure is 5um-100um, the structure width d1 is 5um-100um, and the height h1 is 5um-80um.

[0017] When the microstructure is a semicircle, the structure period of the first structure or the second structure is 3um-80um, and the radius R is 3um-80um.

[0018] When the microstructure is a trapezoid, the structure period of the first structure or the second structure is 5um-100um, the structure top width a is 1um-40um, the bottom width b is 5um-80um, and the height h2 is 3um-80um.

[0019] When the microstructure is a semicircle, the structure period of the first structure or the second structure is 3um-80um, and the radius R is 3um-80um.

[0020] When the microstructure is a cone, the structure period is 100nm-2000nm, the width d3 is 50-2000nm, and the height h4 is 100-500nm.

[0021] When the microstructure is a triangular pyramid, the structure period is 200nm-80um, the structure width d4 of the first structure 30 or the second structure 50 is 100nm-80um, and the height h5 is 100nm-70um.

[0022] When the microstructure is a quadrangular pyramid, the structure period of the first structure 30 or the second structure 50 is 3nm-80nm, the structure width d5 is 100-6000nm, and the height h6 is 100-500nm.

[0023] When the microstructure is a semi-ellipsoidal, the structure period of the first structure 30 or the second structure 50 is 100nm-2000um, the structure width d6 is 50nm-2000nm, and the height h7 is 100nm-500nm.

[0024] In an alternative way, the thickness of the first coating and the thickness of the second coating are both in the range of 50nm-200nm.

[0025] According to the second aspect of the embodiments of the present application, a method for manufacturing a modulation film is further provided, comprising:

[0026] obtaining the use environment of the target modulation film;

[0027] matching the corresponding manufacturing scheme from the target manufacturing scheme according to the use environment of the target modulation film; the manufacturing scheme includes hot embossing, UV embossing, and double-curing embossing, and the target manufacturing scheme includes manufacturing schemes corresponding to multiple environment parameters;

[0028] determining the corresponding production machine and production steps according to the manufacturing scheme.

[0029] In an alternative way, the step of matching the corresponding manufacturing scheme from the target manufacturing scheme according to the use environment of the target modulation film comprises:

[0030] when the use environment is the outer surface of the solar module surface glass, the manufacturing scheme is hot embossing or double-curing embossing;

[0031] when the use environment is the inner surface of the solar module surface glass, the manufacturing scheme is any one of hot embossing, UV embossing, and double-curing embossing.

[0032] In an alternative way, the step of obtaining the use environment of the target modulation film further comprises:

[0033] When the use environment of the target modulation film is the light-incident side of the solar cell installed in the solar module, the first structure is configured as a structure for increasing the radiation intensity transmitted to each solar cell;

[0034] When the use environment of the target modulation film is the back light side / light-out side of the solar cell installed in the solar module, the first structure is configured as a structure for increasing the radiation intensity reflected to each solar cell.

[0035] According to the second aspect of the embodiment of the present application, a design method of a modulation film is also provided for designing the modulation film, and the design method of the modulation film comprises:

[0036] Obtaining the function of the modulation film;

[0037] Determining the corresponding modulation type and modulation parameter according to the function of the modulation film;

[0038] Manufacturing the modulation film according to the determined modulation type and modulation parameter to obtain a customized modulation film adapted to the function of the modulation film.

[0039] In an optional mode, when the function of the modulation film is to increase the light transmission amount, the modulation film is entirely covered on the outer surface of the front glass;

[0040] When the function of the modulation film is to change the light refraction angle and change the light reflection angle, the modulation film is only covered at the cell gap and the edge gap, and the width d of the modulation film is: (1) the width dc of the inter-string modulation film: x≤dc≤x+4mm; (2) the width dp of the inter-sheet modulation film: y≤dp≤y+4mm, and (3) the width dz of the edge modulation film: z≤dz≤z+4mm.

[0041] The present application discloses a modulation film and a solar cell panel. The modulation film is provided with a first structure and a first coating layer, and is arranged on the same side as the incident light of the solar cell sheet. The modulation film changes the travel route of the incident light by changing the refractive index distribution, thereby increasing the total amount of incident light to the solar cell sheet, increasing the utilization efficiency of the incident light by the solar cell sheet, improving the photoelectric conversion efficiency of the photovoltaic module, and improving the power generation capacity.

[0042] The above description is only a summary of the technical solutions of the embodiments of the present application. In order to more clearly understand the technical means of the embodiments of the present application, the embodiments of the present application can be implemented according to the content of the specification, and in order to make the above and other purposes, features and advantages of the embodiments of the present application more obvious and easy to understand, the specific embodiments of the present application are described below. BRIEF DESCRIPTION OF DRAWINGS

[0043] The accompanying drawings are included to provide a further understanding of the application and are incorporated in and constitute a part of this specification. In the drawings:

[0044] Figure 1 A structural diagram of an embodiment of the modulation film provided by the present application is shown;

[0045] Figure 2 A structural diagram of another embodiment of the modulation film provided by the present application is shown;

[0046] Figure 3 A structural diagram of the microstructure of the first structure and the second structure of the modulation film provided by the present application is shown;

[0047] Figure 4 A light path diagram of an embodiment of the modulation film provided by the present application is shown;

[0048] Figure 5 A light path diagram of another embodiment of the modulation film provided by the present application is shown;

[0049] Figure 6 A structural diagram of another embodiment of the modulation film provided by the present application is shown;

[0050] Figure 7 A light path diagram of another embodiment of the modulation film provided by the present application is shown;

[0051] Figure 8 A light path diagram of another embodiment of the modulation film provided by the present application is shown;

[0052] Figure 9 A light path diagram of another embodiment of the modulation film provided by the present application is shown;

[0053] Figure 10 A light path diagram of another embodiment of the modulation film provided by the present application is shown;

[0054] Figure 11 A light path diagram of another embodiment of the modulation film provided by the present application is shown;

[0055] Figure 12 A structural diagram of another embodiment of the microstructure of the modulation film provided by the present application is shown;

[0056] Figure 13 A structural diagram of an embodiment of the solar cell panel provided by the present application is shown;

[0057] Figure 14 A structural diagram of another embodiment of the solar cell panel provided by the present application is shown;

[0058] Figure 15Fig. 2 shows a structural schematic diagram of another embodiment of the solar cell panel provided by the present application;

[0059] Figure 16 Fig. 3 shows a structural schematic diagram of still another embodiment of the solar cell panel provided by the present application;

[0060] Figure 17 Fig. 4 shows a schematic diagram of the light path in the solar cell panel provided by the present application;

[0061] Figure 18 Fig. 5 shows a schematic diagram of the specific parameter identification of the modulation film in the solar cell panel provided by the present application. DETAILED DESCRIPTION

[0062] Exemplary embodiments of the present application will be described in detail with reference to the drawings. Although exemplary embodiments of the present application are shown in the drawings, it is understood that the present application can be implemented in various forms and should not be limited by the embodiments set forth herein.

[0063] The present application provides a modulation film to solve the technical problem that the splicing of solar cell panels affects the conversion rate of the whole solar panel in the prior art.

[0064] In an optional embodiment, referring to Figs. 1 to 5, the present application provides a modulation film to solve the technical problem that the splicing of solar cell panels affects the conversion rate of the whole solar panel in the prior art. Figure 1 and Figure 2 The present application provides a modulation film to solve the technical problem that the splicing of solar cell panels affects the conversion rate of the whole solar panel in the prior art.

[0065] In an optional embodiment, the modulation film applied to the solar assembly includes an adhesive 10, a substrate 20, a first structure 30, and a first coating layer 40 arranged in sequence. The adhesive 10 is adhered to the glass of the solar assembly. The incident light is emitted after sequentially passing through the first structure 30 and the first coating layer 40. The solar assembly includes at least two solar cell panels arranged at intervals. Referring to Figs. 1 to 5, the modulation film is arranged on the side opposite to the incident light side of the solar cell panel or on the same side as the incident light side of the solar cell panel. Figure 1 , Figure 4 and Figure 5 The modulation film is arranged on the side opposite to the incident light side of the solar cell panel or on the same side as the incident light side of the solar cell panel.

[0066] The first coating layer 40 is attached to the first structure 30 with a uniform thickness. The first structure 30 reflects the incident light to the solar cell panel or increases the radiation intensity transmitted to each solar cell panel. The first coating layer 40 is attached to the first structure 30 with a uniform thickness, and the refractive index of the first coating layer 40 is different from the refractive index of the first structure 30.

[0067] The above scheme sets the first structure 30 and the first coating layer 40, and places the modulation film on the side away from the incident light surface of the solar cell or on the same side as the incident light of the solar cell, so that the leaked incident light between the two solar cells can be reflected to the solar cell again or the number of incident light lines transmitted to the solar cell is increased, thereby increasing the number of incident light lines of the solar cell and improving the utilization rate of sunlight of the photovoltaic module. Thus, the technical problem of affecting the conversion rate of the overall solar panel in the prior art by splicing solar cells is solved.

[0068] Referring to Figure 1 The modulation film applied to the solar module includes an adhesive 10, a base material 20, a first structure 30, and a first coating layer 40 arranged in sequence. Light exits after passing through the first coating layer 40, the first structure 30, and the first coating layer 40 in sequence. The solar module includes at least two solar cells arranged at intervals. Referring to Figure 4 and Figure 5 The modulation film is arranged on the side away from the incident light surface of the solar cell.

[0069] The first coating layer 40 is attached to the first structure 30 with a uniform thickness. The first structure 30 adjusts the reflection angle of light so that the incident light is reflected to the solar cell at a large angle from the first coating layer 40. The refractive index of the first coating layer 40 is different from that of the first structure 30.

[0070] The above scheme sets the first structure 30 and the first coating layer 40, and places the modulation film on the side away from the incident light surface of the solar cell, so that the leaked incident light between the two solar cells can be reflected to the solar cell again, thereby increasing the number of incident light lines of the solar cell and improving the utilization rate of sunlight of the photovoltaic module.

[0071] It should be noted that the first coating layer 40 is used to construct the difference in refractive index between different materials and avoid the structure from being filled and losing effectiveness. The first coating layer 40 can be processed by vacuum coating, spraying, coating, etc. In particular, the first coating layer 40 can also increase the bonding strength of the first structure 30 and the subsequent second structure. In addition, the adhesive 10 is provided to facilitate the bonding of the modulation film and other materials. The film without the adhesive 10 can also be produced separately, and the adhesive 10 can be applied during use.

[0072] During the processing of the first structure 30, the first structure 30 can be formed on the substrate 20 through three methods: hot pressing, UV pressing, and double curing pressing, by the mutual matching of materials. Among them, the hot pressing method requires the materials to have a relatively low processing temperature, such as 60-200℃. If the processing temperature is too high, the requirements for the heat resistance of other materials and the processing equipment will be higher.

[0073] In an alternative embodiment, refer to Figure 7 As shown, the modulation film applied to a solar module includes an adhesive 10, a substrate 20, a first structure 30, and a first coating 40 stacked sequentially; incident light passes through the adhesive 10, substrate 20, first structure 30, and first coating 40 sequentially before exiting. The solar module includes at least two spaced-apart solar cells; the modulation film is disposed on the same side as the incident light of the solar cells.

[0074] The first structure 30 increases the radiation intensity transmitted to each of the solar cells, the first coating 40 is attached to the first structure with a uniform thickness, and the refractive index of the first coating 40 is different from that of the first structure 30.

[0075] The above solution, by setting the first structure 30 and the first coating 40, and placing the modulation film on the same side as the incident light of the solar cell, allows the incident light that is missed between the two solar cells to be redirected by the modulation film and transmitted to the solar cell. By changing the path of the incident light through the different refractive index distribution of the modulation film, the total amount of incident light on the solar cell is increased, thereby improving the utilization efficiency of the photovoltaic module for sunlight, further increasing the radiation intensity of the solar cell with the same area, thereby improving the photoelectric conversion efficiency of the photovoltaic module and increasing the power generation.

[0076] In an alternative embodiment, refer to Figure 6 As shown, the modulation film also includes a second substrate 70 disposed on the first structure 30; the second substrate 70 is bonded to the first structure 30 through a first adhesive layer 80, and an air cavity 90 is formed between the first adhesive layer 80 and the first structure 30.

[0077] The air cavity 90 is formed because the fine structure of the first structure 30, such as rectangular, triangular, semi-circular, trapezoidal, or semi-elliptical, allows the smoothly extending first adhesive layer 80 to adhere to the first structure 30, creating an air cavity between the first adhesive layer 80 and the first structure 30. This air cavity can replace the refractive index difference in the coating structure, increasing the deflection angle of the transmitted / reflected light of the modulation film, thereby increasing the travel length of the incident light in the solar cell / module, and further increasing the radiation intensity of the incident light transmitted / reflected to each solar cell.

[0078] In an optional embodiment, referring to Figure 2 The modulation film further comprises a second structure 50 and a second coating layer 60 sequentially arranged on the first coating layer 40.

[0079] The second structure 50 is used to further increase the angle of the reflected light modulated by the first structure 30.

[0080] The second coating layer 60 is used to adhere to the second structure 50 with a uniform thickness, and the refractive index of the second coating layer 60 is different from that of the second structure 50.

[0081] The second structure 50 is the main optical modulation structure of the optical modulation film, which is used to open the light at a large enough angle so that the light will not leak out of the gap again, and the light passing through the battery gap is reflected back to the battery as much as possible.

[0082] In addition, the second structure 50 can be processed in the following way: through the matching between materials, it can be formed on the substrate 20 by three forms of hot stamping, UV stamping and double curing stamping. Among them, the hot stamping requires a lower processing temperature of the material, such as 60-200℃, and a higher processing temperature requirement for the heat resistance of other materials and the processing equipment.

[0083] Optionally, the first structure 30 and the second structure 50 each comprise a plurality of microstructures, which are composed of one or more of rectangular, triangular, semicircular, trapezoidal and semi-elliptical structures. It can also be realized by random pattern combination.

[0084] Optionally, referring to Figure 3 As shown in Figure 3 Fig. 1 shows a structure schematic diagram of the microstructure of the modulation film provided by the present application, which is a rectangular structure. Figure 3 Fig. 2 shows a structure schematic diagram of the microstructure of the modulation film provided by the present application, which is a triangular structure. Figure 3 Fig. 3 shows a structure schematic diagram of the microstructure of the modulation film provided by the present application, which is a semicircular structure. Figure 3 Fig. 4 shows a structure schematic diagram of the microstructure of the modulation film provided by the present application, which is a trapezoidal structure. Figure 3 Fig. 5 shows a structure schematic diagram of the microstructure of the modulation film provided by the present application, which is a semi-elliptical structure. When the microstructure is rectangular, the structure period of the first structure 30 or the second structure 50 is 5um-80um, the width d is 3um-80um, and the height h is 3um-80um.

[0085] Optionally, referring to Figure 3As shown in the middle 2, when the microstructure is a triangle, the structure period of the first structure 30 or the second structure 50 is 5um-80um, the structure width d1 is 5um-80um, and the height h1 is 5um-80um. The triangle can be any one of an isosceles triangle or an unequal isosceles triangle.

[0086] Optionally, referring to Figure 3 As shown in the middle 2, when the microstructure is a triangle, the structure period of the first structure 30 or the second structure 50 is 5um-100um, the structure width d1 is 5um-100um, and the height h1 is 5um-80um.

[0087] Optionally, referring to Figure 3-3 As shown in the middle 2, when the microstructure is a triangle, the structure period of the first structure 30 or the second structure 50 is 5um-100um, the structure width d1 is 5um-100um, and the height h1 is 5um-80um.

[0088] Optionally, referring to Figure 3-3 As shown in the middle 2, when the microstructure is a triangle, the structure period of the first structure 30 or the second structure 50 is 5um-100um, the structure width d1 is 5um-100um, and the height h1 is 5um-80um.

[0089] Optionally, referring to Figure 3-4 As shown in the middle 2, when the microstructure is a triangle, the structure period of the first structure 30 or the second structure 50 is 5um-100um, the structure width d1 is 5um-100um, and the height h1 is 5um-80um.

[0090] Optionally, referring to Figure 3-5 As shown in the middle 2, when the microstructure is a triangle, the structure period of the first structure 30 or the second structure 50 is 5um-100um, the structure width d1 is 5um-100um, and the height h1 is 5um-80um.

[0091] Optionally, the thickness of the first coating 40 and the thickness of the second coating 60 are both 50-200nm.

[0092] Optionally, the material of the first coating 40 and the material of the second coating 60 are any one of Al, Ag, Ni, Cu, stainless steel, ZnS, ZnO, CaF2, TiO2.

[0093] Optionally, the material of the first structure 30 and the material of the second structure 50 are any one of a thermal compression type, a UV type, and a double curing type.

[0094] The thermal compression type material includes polypropylene (PP), polyethylene terephthalate (PET), high-density polyethylene (HDPE), polycarbonate (PC), polymethyl methacrylate (PMMA), etc.

[0095] The UV type material includes acrylate, pre-polymer of methacrylate group, epoxy, and allyl, etc.

[0096] The double curing type material includes polyurethane acrylate, epoxy resin, bisphenol A epoxy resin, bisphenol F epoxy resin, glycidyl amine special epoxy resin, etc.

[0097] The application also provides a solar panel, referring to Figure 4 , the solar panel includes a solar assembly and the above modulation film, the solar assembly includes at least two solar cell pieces arranged at intervals; the modulation film is arranged on the side opposite to the incident light surface of the solar cell piece.

[0098] Since the solar panel of the application contains all the schemes of the modulation film, the solar panel of the application also has all the beneficial effects of the modulation film, which will not be repeated here.

[0099] Optionally, the solar panel further includes a back plate, EVA, and transparent glass, the transparent glass, EVA, and solar cell piece are sequentially stacked.

[0100] Optionally, referring to Figure 13 , 14 , 15, 16, the modulation film is arranged between the back plate and the solar cell piece.

[0101] At this time, the function of the modulation film is to increase the transmittance. The leaked incident light between the two solar cell pieces can be changed in direction by the modulation film and transmitted to the solar cell piece, the travel route of the incident light is changed by the different refractive index distribution of the modulation film, so as to increase the total amount of incident light of the solar cell piece, thereby improving the utilization efficiency of the photovoltaic assembly to sunlight, further increasing the radiation intensity of the solar cell piece under the same area, thereby improving the photoelectric conversion efficiency of the photovoltaic assembly and increasing the power generation.

[0102] Among them, the EVA also fills the gap between the two solar cell pieces and is attached to the modulation film, so as to ensure that the light path is not deviated.

[0103] Optionally, referring to Figure 4 , 5 , the modulation film is arranged opposite to the gap position between the two solar cell pieces.

[0104] At this time, the leaked incident light between the two solar cell pieces can be reflected by the modulation film to the solar cell piece again, so as to increase the number of incident light lines of the solar cell piece, thereby improving the utilization rate of sunlight of the photovoltaic module. In addition, the actual use area of the modulation film can be reduced according to the use requirement, and the modulation film can be arranged only in the area covered by the light transmission gap, thereby saving the use cost.

[0105] The application provides a modulation film, which is used to solve the technical problem of the influence of spliced solar cell pieces on the conversion rate of the whole solar panel in the prior art.

[0106] In an optional embodiment, as shown in Figure 1 The modulation film applied to the solar module includes an adhesive 10, a base material 20, a first structure 30 and a first coating layer 40 arranged in sequence; and incident light is emitted after sequentially passing through the first structure 30 and the first coating layer 40. The solar module includes at least two solar cell pieces arranged at intervals; and the modulation film is arranged on the side opposite to the incident light surface of the solar cell piece or on the same side as the incident light surface of the solar cell piece.

[0107] The first coating layer 40 is attached to the first structure 30 with a uniform thickness, the first structure 30 transmits / reflects the incident light to the solar cell piece, and the refractive index of the first coating layer 40 is different from that of the first structure 30.

[0108] The above scheme places the first structure 30 and the first coating layer 40, and places the modulation film capable of transmitting on the same side as the incident light surface of the solar cell piece, as shown in Figure 14 The leaked incident light between the two solar cell pieces can be changed in direction by the modulation film and transmitted to the solar cell piece, the travel route of the incident light is changed by the different refractive index distribution of the modulation film, so as to increase the total amount of incident light lines of the solar cell piece, thereby improving the utilization efficiency of sunlight of the photovoltaic module, further increasing the radiation intensity of the solar cell piece under the same area, thereby improving the photoelectric conversion efficiency of the photovoltaic module and the power generation capacity. Or the modulation film with the reflection function is placed on the side opposite to the incident light surface of the solar cell piece, so that the leaked incident light between the two solar cell pieces can be reflected by the modulation film to the solar cell piece again, so as to increase the number of incident light lines of the solar cell piece, thereby improving the utilization rate of sunlight of the photovoltaic module.

[0109] It should be noted that the first coating 40 is used to construct the difference between the refractive index of different materials, in order to avoid the structure being filled and losing the effect, the processing can be carried out by vacuum coating, spraying, coating and the like. In particular, the first coating 40 can also increase the bonding strength of the first structure 30 and the subsequent second structure. In addition, the adhesive 10 is provided to facilitate the bonding of the film and other materials. In fact, the film without adhesive 10 can also be produced separately, and the adhesive 10 is coated when used.

[0110] In the process of processing the first structure 30, the first structure 30 is formed on the substrate 20 by matching the materials with each other, which can be formed by three forms of hot stamping, UV stamping and double curing stamping. Among them, the hot stamping requires that the material has a lower processing temperature, such as 60-200℃, and the processing temperature is too high for the requirement of heat resistance of other materials and processing equipment.

[0111] In an optional embodiment, referring to Figure 8 , the modulation film further comprises a second substrate 70 arranged on the first structure 30; the second substrate 70 is bonded to the first structure 30 through a first adhesive layer 80, and an air cavity 90 is formed between the first adhesive layer 80 and the first structure 30.

[0112] Among them, the air cavity 90 is formed based on the first structure, so that when the first adhesive layer 80 arranged in a smooth and extended manner is bonded to the first structure 30, the air cavity can be formed between the first adhesive layer 80 and the first structure 30. At this time, the air cavity can prevent the first structure 30 from being filled and losing the effect, thereby increasing the travel length of the incident light in the solar energy assembly, increasing the number of incident light lines of the solar cell sheet, and further increasing the radiation intensity of the incident light transmitted or reflected to each of the solar cell sheets.

[0113] In an optional embodiment, referring to Figure 2 , the modulation film further comprises a second structure 50 and a second coating 60 arranged on the first coating 40 in sequence;

[0114] The second structure 50 is used to further increase the transmission or reflection angle of the first structure 30;

[0115] The second coating 60 is used to adhere to the second structure 50 with a uniform thickness, and the refractive index of the second coating 60 is different from that of the second structure 50.

[0116] Among them, referring to Figure 4- Figure 7 , the second structure 50 is the main optical modulation structure of the optical modulation film, which is used to transmit or reflect as much light as possible through the cell gap to the cell. Not only to form a good transmission or reflection effect, but also to open the light line to a large enough angle, so that it will not leak out of the gap again.

[0117] Furthermore, the second structure 50 can be processed in the following ways: through the mutual matching of materials, it can be formed on the substrate 20 by three methods: hot pressing, UV pressing, and double curing pressing. Among them, hot pressing requires the material to have a relatively low processing temperature, such as 60-200℃. If the processing temperature is too high, the requirements for the heat resistance of other materials and the processing equipment will be higher.

[0118] Optionally, both the first structure 30 and the second structure 50 include multiple microstructures, which are composed of one or more structures selected from rectangles, triangles, semicircles, trapezoids, and semi-ellipses. They can also be implemented through random graphic combinations.

[0119] Optionally, refer to Figure 3 As shown in Figure 1, when the microstructure is rectangular, the structural period of the first structure 30 or the second structure 50 is 5um-80um, the width d is 3um-80um, and the height h is 3um-80um.

[0120] Optionally, refer to Figure 3 As shown in Figure 2, when the microstructure is triangular, the structural period of the first structure 30 or the second structure 50 is 5um-100um, the structural width d1 is 5um-100um, and the height h1 is 5um-80um.

[0121] Optionally, refer to Figure 3 As shown in Figure 3, when the microstructure is semi-circular, the structural period of the first structure 30 or the second structure 50 is 3um-80um, and the radius is 3um-40um.

[0122] Optionally, refer to Figure 3 As shown in Figure 4, when the microstructure is trapezoidal, the structural period of the first structure 30 or the second structure 50 is 5um-100um, the top width a is 1um-40um, the bottom width b is 5um-50um, and the height h2 is 3um-80um.

[0123] Optionally, refer to Figure 3 As shown in Figure 5, when the microstructure is semi-elliptical, the structural period of the first structure 30 or the second structure 50 is 5um-80um, the structural width d2 is 5um-80um, and the height h3 is 5um-80um.

[0124] Optionally, refer to Figure 9 As shown, the microstructure can also be an independent individual type, such as a cone, pyramid (square pyramid), triangular pyramid, semi-ellipsoid, etc. Among them, Figure 9 (1) shows a schematic diagram of the rectangular microstructure of the modulation film provided by the present invention.Figure 9 (2) shows a schematic diagram of the triangular microstructure of the modulation film provided by the present invention. Figure 9 (3) shows a schematic diagram of the semi-circular microstructure of the modulation film provided by the present invention. Figure 9 (4) shows a schematic diagram of the trapezoidal microstructure of the modulation film provided by the present invention.

[0125] Optionally, refer to Figure 9 As shown in (1), when the microstructure is a cone, the structural period is 100nm-2000nm, the width d3 is 50-2000nm, and the height h4 is 100-500nm.

[0126] Optionally, refer to Figure 9 As shown in (2), when the microstructure is a triangular pyramid, the structural period is 200nm-80um, the structural width d4 of the first structure 30 or the second structure 50 is 100nm-80um, and the height h5 is 100nm-70um.

[0127] Optionally, refer to Figure 9 As shown in (3), when the microstructure is a square pyramid, the structural period of the first structure 30 or the second structure 50 is 3nm-80nm, the structural width d5 ​​is 100-6000nm, and the height h6 is 100-500nm.

[0128] Optionally, refer to Figure 9 As shown in (4), when the microstructure is semi-elliptical, the structural period of the first structure 30 or the second structure 50 is 100nm-2000um, the structural width d6 is 50nm-2000nm, and the height h7 is 100nm-500nm.

[0129] Optionally, the thickness range of the first coating 40 and the thickness range of the second coating 60 are both 50 to 200 nm.

[0130] Optionally, the materials of the first coating 40 and the second coating 60 are any one of Al, Ag, Ni, Cu, stainless steel, ZnS, ZnO, CaF2, CoO, ZrO2, and TiO2.

[0131] Optionally, the materials of the first structure 30 and the second structure 50 are any one of hot-pressing, UV-curing, and photothermal dual-curing types.

[0132] Among them, hot-pressed materials include polypropylene (PP), polyethylene terephthalate (PET), high-density polyethylene (HDPE), polycarbonate (PC), polymethyl methacrylate (PMMA), etc.

[0133] The UV type material includes prepolymers of acrylate, methacrylate groups, epoxy, and allyl, etc.

[0134] The dual-curing type material includes polyurethane acrylate, epoxy resin, bisphenol A epoxy resin, bisphenol F epoxy resin, glycidyl amine special epoxy resin, etc.

[0135] The application also provides a solar panel, referring to Figure 13-16 The solar panel includes a solar assembly and the modulation film as above, the solar assembly includes at least two solar cells arranged at intervals; the modulation film is arranged on the same side of the incident light of the solar cells.

[0136] Since the solar panel of the application contains all the schemes of the modulation film, the solar panel of the application also has all the beneficial effects of the modulation film, which will not be repeated here.

[0137] Optionally, the solar assembly further includes glass, back plate and EVA, the glass, the cell and the back plate are sequentially stacked.

[0138] When the modulation film is arranged between the glass and the cell, referring to Figure 13-16 The modulation film is a film for further increasing the transmission angle of transmission. At this time, the EVA fills the gap between the modulation film and the cell.

[0139] When the modulation film is arranged between the glass and the cell, referring to Figure 4-5 The modulation film is a film for further increasing the transmission angle of reflection. At this time, the EVA fills the gap between the modulation film and the cell.

[0140] The application also provides a manufacturing method of the modulation film, comprising:

[0141] Obtaining the use environment of the target modulation film;

[0142] The use environment includes the outer surface of the surface glass of the solar assembly and the inner surface of the surface glass of the solar assembly.

[0143] According to the use environment of the target modulation film, the corresponding manufacturing scheme is matched from the target manufacturing scheme; the manufacturing scheme includes hot stamping, UV stamping, and dual-curing stamping, and the target manufacturing scheme includes manufacturing schemes corresponding to various environmental parameters;

[0144] According to the manufacturing scheme, the corresponding production machine and production steps are determined.

[0145] The step of matching the corresponding manufacturing scheme from the target manufacturing scheme according to the use environment of the target modulation film includes:

[0146] When the use environment is the outer surface of the solar module surface glass, the manufacturing scheme is hot embossing or double-curing embossing;

[0147] When the use environment is the inner surface of the solar module surface glass, the manufacturing scheme is any one of hot embossing, UV embossing, and double-curing embossing.

[0148] The following will introduce the above three manufacturing schemes in detail:

[0149] Specific contents of different manufacturing schemes:

[0150] (1) Hot embossing:

[0151] a. The hot embossing generally adopts a hard mold, such as a texture mold engraved from a metal material such as a stainless steel roller or a copper roller.

[0152] b. The mold needs to be treated for anti-sticking before use, which is to make the demolding easy and not easy to cause structural loss, and to increase the service life of the mold. The demolding agent can include fluororesin paint (PTFE, FEP, PFA).

[0153] c. The mold is heated to 60-200°C, and the base material and the structure material are hot-pressed together, wherein the processing speed is 0.5-5 m / s, and the pressure can be located at 0.05-1.5T according to the material type, the structure depth, and the film material thickness.

[0154] d. After hot pressing, a certain interval (3-20 m) needs to be reserved for the film material to cool down to prevent serious bending or deformation. Air cooling or water cooling can be used. For air cooling, a fan can be added in the cooling area, and for water cooling, a water cooling roller needs to be designed according to the equipment to cool the base material (the structure surface cannot be in contact to avoid damage to the structure). The advantage of air cooling is that the cost is cheap, but the cooling distance is longer. The cost of water cooling is relatively high, and whether the equipment supports it needs to be considered comprehensively, but the advantage of water cooling is that it can greatly shorten the space needed for cooling.

[0155] (2) UV type:

[0156] a. The UV type can adopt a hard mold or a soft mold. The hard mold also includes a texture mold engraved from a metal material such as a stainless steel roller or a copper roller. The soft mold can be a UV formed or hot-pressed soft mold, which can be attached to the structure processing roller for use.

[0157] b. In order to increase the service life of the mold, the mold needs to be treated for anti-sticking before use. The demolding agent can include fluororesin paint (PTFE, FEP, PFA). Although such demolding liquid has a high cost, it can increase the service life of the mold by several times.

[0158] c. The dispensing method is used, and the dispensing speed needs to be determined according to the film thickness, film width and processing speed. Generally, it can be 5-40 g / m, the processing speed is 1-20 m / s, the pressure is 0.05-1T, and the glue curing energy is determined according to the type of glue, generally 100-1200 mJ / cm2.

[0159] d. After embossing, a certain interval (3-10 m) needs to be reserved to cool and wind the processed film material, but the cooling condition is much smaller than hot pressing, so normal temperature cooling, air cooling or water cooling can be used.

[0160] (3) Dual-curing type:

[0161] a. In theory, the dual-curing system material can obtain two different properties in the first and second curing stages, respectively. By controlling the composition, structure and performance of the intermediate state material, the later forming process, use mode and the performance, function and morphology of the final state material can be effectively controlled.

[0162] b. Hard mold or soft mold can be used, such as texture mold engraved from metal materials such as stainless steel roller or copper roller. The hard mold also includes texture mold engraved from metal materials such as stainless steel roller or copper roller; the soft mold can be a soft mold formed by UV forming or hot pressing, which can be used by being attached and covered on the structure processing roller.

[0163] c. The mold needs to be treated before use to prevent sticking, one is to make demolding easy and not easy to cause structure loss, and the other is to increase the service life of the mold. The release agent can include fluororesin paint (PTFE, FEP, PFA).

[0164] d. The first structure is pre-formed by using UV curing, and the curing energy is 100-1200 mJ / cm2.

[0165] e. The pre-cured structure is heated to 60-200°C and baked for 0.1-2h to completely form and remove the remaining solvent.

[0166] d. After hot pressing, a certain interval (3-20 m) needs to be reserved to cool the processed film material to prevent serious bending or deformation. Air cooling or water cooling can be used. Air cooling can be achieved by adding a fan in the cooling area, and water cooling needs to be designed according to the equipment to cool the roller from the base material surface (the structure surface cannot be in contact to avoid damage to the structure).

[0167] If a dual-curing material is used for forming, there is a special case that the second structure of the optical modulation film is directly combined with the laminated material of the photovoltaic module, and the structure is directly prepared on the glass by the dual-curing method.

[0168] Among them, the hot-pressing manufacturing method is mainly used for the preparation of modulation films made of polypropylene (PP), polyethylene terephthalate (PET), high-density polyethylene (HDPE), polycarbonate (PC), polymethyl methacrylate (PMMA) and the like. The UV manufacturing method is mainly used for the preparation of modulation films made of acrylate, methacrylate group prepolymers, and epoxy or allyl materials. The dual-curing manufacturing method is mainly used for the preparation of modulation films made of polyurethane acrylate, epoxy resin, and common bisphenol A epoxy resin, bisphenol F epoxy resin, glycidyl amine special epoxy resin and the like.

[0169] Optionally, the step of acquiring the use environment of the target modulation film comprises:

[0170] When the use environment of the target modulation film is the light-incident side of the cell piece installed in the solar module, the first structure is set to a structure that increases the radiation intensity transmitted to each solar cell piece;

[0171] When the use environment of the target modulation film is the back light side / light exit side of the cell piece installed in the solar module, the first structure is set to a structure that increases the radiation intensity reflected to each solar cell piece.

[0172] Optionally, when the use environment of the target modulation film is the light-incident side of the cell piece installed in the solar module, the second structure is set to a structure that increases the radiation intensity transmitted to each solar cell piece;

[0173] When the use environment of the target modulation film is the back light side / light exit side of the cell piece installed in the solar module, the second structure is set to a structure that increases the radiation intensity reflected to each solar cell piece.

[0174] The present application also proposes a design method of a modulation film, which is used for designing the above-mentioned modulation film, and the design method of the modulation film comprises:

[0175] Acquiring the function of the modulation film;

[0176] Among them, the function of the modulation film is determined by the shape and size of the structure, and according to different embodiments, it can be divided into three cases of increasing light transmission, changing light refraction angle and changing light reflection angle.

[0177] According to the function of the modulation film, the corresponding modulation type and modulation parameters are determined;

[0178] The light refraction angle and the light reflection angle mainly include rectangle, triangle, semicircle, trapezoid, and semi-ellipse; the structure for increasing transmission includes cone, pyramid (four-pyramid), three-pyramid, semi-ellipsoid and the like.

[0179] According to the determined modulation type and modulation parameters, the modulation film is manufactured to obtain a customized modulation film that is adapted to the function of the modulation film.

[0180] In this way, the specific first structure type and function of each region can be customized according to the different relative position relationship between the lipid modulation film and each battery piece, the installed battery piece is personalized optimized, and the overall photoelectric conversion rate is higher.

[0181] Optionally, as shown in Figure 18 When the function of the modulation film is to increase the light transmittance, the modulation film covers the entire outer surface of the front glass;

[0182] When the function of the modulation film is to change the light refraction angle and change the light reflection angle, the modulation film only covers the battery gap and the edge gap, and at this time the width d of the modulation film is: (1) the inter-string modulation film width dc: x≤dc≤x+4mm; (2) the inter-piece modulation film width dp: y≤dp≤y+4mm, (3) the edge interval modulation film width dz: z≤dz≤z+4mm.

[0183] Through the above embodiment, the scheme of the modulation film can be determined according to the function, so that the design is started from the actual scheme, so that the modulation film of the present application can be applied to various specifications and various different parameter use environments.

[0184] In the specification provided herein, a large number of specific details are described. However, it can be understood that the embodiments of the present application can be practiced without these specific details. Similarly, in order to simplify the present application and help understand one or more of the various inventive aspects, in the above description of the exemplary embodiments of the present application, various features of the embodiments of the present application are sometimes grouped together into a single embodiment, figure, or description thereof. Among them, the claims following the detailed description are hereby expressly incorporated into the detailed description, wherein each claim itself is a separate embodiment of the present application.

[0185] Those skilled in the art can understand that the modules in the device in the embodiments can be adaptively changed and arranged in one or more devices different from the embodiments. The modules or units or components in the embodiments can be combined into one module or unit or component, and in addition, they can be divided into multiple sub-modules or sub-units or sub-components. Except that at least some of such features and / or processes or units are mutually exclusive.

[0186] It should be noted that the above-mentioned embodiments illustrate rather than limit the application, and that those skilled in the art will be able to design many alternative embodiments without departing from the scope of the appended claims. In the claims, any reference signs placed between parentheses shall not be construed as limiting the claim. The word 'comprising' does not exclude the presence of elements or steps other than those listed in a claim. The word 'a' or 'an' preceding an element does not exclude the presence of a plurality of such elements. The application can be implemented by means of hardware comprising several distinct elements, and by means of a suitably programmed computer. In a unitary claim, several devices, apparatuses or means can be listed, comprising means for performing a certain function. The use of the term'means' in a claim is intended to cover one or more elements comprising the means for performing the function. The use of the terms first, second and third, etc. does not imply any ordering, but rather are used for naming purposes only. The steps of any of the methods disclosed herein do not have to be performed in the exact order disclosed, unless a step is explicitly described as following or preceding another step and / or where it is implicit that expressed or potential conflict between two steps exists.

Claims

1. A modulation film, characterized in that, Applied to solar modules, the modulation film comprises an adhesive, a substrate, a first structure, and a first coating stacked sequentially; incident light passes through the first structure and the first coating sequentially before exiting. The solar module includes at least two solar cells spaced apart. The modulation film is disposed on a side opposite to the incident light surface of the solar cell or on the same side as the incident light surface of the solar cell. The first structure is used to reflect the incident light to the solar cell or increase the radiation intensity transmitted to each of the solar cells; The first coating is used to adhere to the first structure with a uniform thickness, and the refractive index of the first coating is different from the refractive index of the first structure. The modulation film also includes a second substrate disposed on the first structure. The second substrate is bonded to the first structure through a first adhesive layer, and an air cavity is formed between the first adhesive layer and the first structure; The air cavity is used to increase the deflection angle of the transmitted / reflected light of the first structure, thereby increasing the travel length of the incident light in the battery assembly, so as to further increase the radiation intensity of the incident light transmitted / reflected to each of the solar cells. The material of the first coating is any one of Al, Ag, Ni, Cu, stainless steel, ZnS, ZnO, CaF2, and TiO2; The thickness of the first coating ranges from 50 nm to 200 nm.

2. The modulation film as described in claim 1, characterized in that, The modulation film further includes a second structure and a second coating sequentially disposed on the first coating; The second structure is used to further increase the transmission / reflection angle of the light emitted from the first structure; The second coating is used to adhere to the second structure with a uniform thickness, and the refractive index of the second coating is different from that of the second structure.

3. The modulation film as described in claim 2, characterized in that, Both the first structure and the second structure include multiple types of microstructures, which are composed of one or more of the following: rectangular, triangular, semi-circular, trapezoidal, semi-elliptical, conical, square pyramidal, triangular pyramidal, and semi-elliptical body structures.

4. The modulation film as described in claim 3, characterized in that, When the microstructure is rectangular, the structural period of the first structure or the second structure is 5μm-80μm, the width d is 3μm-80μm, and the height h is 3μm-80μm; When the microstructure is a triangle, the triangle is either an isosceles triangle or an isosceles triangle, the structural period of the first structure or the second structure is 5μm-100μm, the structural width d1 is 5μm-100μm, and the height h1 is 5μm-80μm. When the microstructure is semi-circular, the structural period of the first structure or the second structure is 3μm-80μm and the radius R is 3μm-80μm. When the microstructure is trapezoidal, the structural period of the first structure or the second structure is 5μm-100μm, the top width a is 1μm-40μm, the bottom width b is 5μm-80μm, and the height h2 is 3μm-80μm; When the microstructure is semi-elliptical, the structural period of the first structure or the second structure is 5μm-80μm, the structural width d2 is 5μm-80μm, and the height h3 is 5μm-80μm; When the microstructure is a cone, the structural period is 100nm-2000nm, the width d3 is 50-2000nm, and the height h4 is 100-500nm; when the microstructure is a triangular pyramid, the structural period is 200nm-80μm, the structural width d4 of the first structure (30) or the second structure (50) is 100nm-80μm, and the height h5 is 100nm-70μm. When the microstructure is a square pyramid, the structural period of the first structure (30) or the second structure (50) is 3nm-80nm, the structural width d5 ​​is 100-6000nm, and the height h6 is 100-500nm. When the microstructure is semi-ellipsoidal, the structural period of the first structure (30) or the second structure (50) is 100nm-2000μm, the structural width d6 is 50nm-2000nm, and the height h7 is 100nm-500nm.

5. The modulation film as described in claim 2, characterized in that, The thickness of the second coating ranges from 50 nm to 200 nm.

6. A method for manufacturing the modulation film as described in claim 1, characterized in that, include: Obtain the application environment of the target modulation film; Based on the usage environment of the target modulation film, a corresponding manufacturing scheme is matched from the target manufacturing schemes; the manufacturing schemes include hot embossing, UV embossing, and dual curing embossing, and the target manufacturing scheme includes manufacturing schemes corresponding to various environmental parameters; The corresponding production machinery and production steps are determined based on the aforementioned production plan.

7. The method for manufacturing the modulation film as described in claim 6, characterized in that, The step of matching a corresponding manufacturing scheme from the target manufacturing scheme based on the usage environment of the target modulation film includes: When the application environment is the outer surface of the glass of a solar module, the manufacturing method is hot stamping or double curing stamping; When the application environment is the inner surface of the glass of a solar module, the manufacturing method is any one of hot stamping, UV stamping, or double curing stamping. When the target modulation film is used in an environment where it is installed on the light-incident side of the solar cell of the solar module, the corresponding first structure is configured to increase the radiation intensity transmitted to each of the solar cells. When the target modulation film is used in an environment where it is installed on the backlight side / light-emitting side of the solar cell, the first structure is configured to increase the intensity of radiation reflected to each of the solar cells.

8. A method for designing a modulation film, characterized in that, A method for designing the modulation film according to any one of claims 1-5, the method comprising: The function of obtaining the modulation film; The corresponding modulation type and modulation parameters are determined based on the function of the modulation film. A modulation film is fabricated based on the determined modulation type and modulation parameters to obtain a customized modulation film that is functionally compatible with the modulation film.

9. The method for designing a modulation film as described in claim 8, characterized in that, search When the function of the modulation film is to increase light transmittance, the modulation film covers the entire outer surface of the front glass. When the function of the modulation film is to change the angle of light refraction and the angle of light reflection, the modulation film only covers the gaps in the battery and the edge gaps. At this time, the parameters of the modulation film width are: (1) string spacing modulation film width dc: x≤dc≤x+4mm; (2) sheet spacing modulation film width dp: y≤dp≤y+4mm; (3) edge spacing modulation film width dz: z≤dz≤z+4mm.

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