Surface-mounted photovoltaic power generation device and preparation method thereof

Abstract

The invention discloses a patch type photovoltaic power generation device and a preparation method thereof, and relates to the technical field of photovoltaic power generation devices.The patch type photovoltaic power generation device comprises a light-transmitting protection layer, a light-transmitting sealing layer, a unit power generation layer and a current transmission composite layer which are sequentially stacked from top to bottom and connected in a press fit mode, and the unit power generation layer is used for converting light energy into electric energy; the side, close to the current transmission composite layer, of each unit power generation layer is provided with an insulating coating and a plurality of electrode points, each electrode point does not coincide with the insulating coating, and the side, close to the unit power generation layer, of the current transmission composite layer is provided with a conductive circuit corresponding to the corresponding current transmission direction of the electrode points. The electrode points are electrically connected with a conductive circuit of the current transmission composite layer, and the current transmission composite layer is used for leading out current generated by the unit power generation layer. According to the invention, the reliability and the performance stability of the photovoltaic power generation component can be improved.

Description

Technical Field

[0001] The present invention relates to the technical field of photovoltaic power generation devices, and in particular to a patch-type photovoltaic power generation device and a preparation method thereof. Background Art

[0002] For more than 20 years since the commercialization of photovoltaic modules, the product design structure of photovoltaic modules has basically maintained the traditional 5-layer product structure, namely backplane (or glass) / encapsulation film / cell / encapsulation film / tempered glass. In this structure, the cells are connected in series inside the module by welding ribbons from the front of one cell to the back of another cell. However, this traditional series connection method has some disadvantages, such as shading, high-temperature welding stress, etc., and welding stress is not conducive to the promotion of ultra-thin silicon wafers. Summary of the invention

[0003] The purpose of the present invention is to provide a patch type photovoltaic power generation device and a preparation method thereof, so as to solve the problems existing in the above-mentioned prior art and improve the reliability and performance stability of photovoltaic power generation components.

[0004] To achieve the above object, the present invention provides the following solutions: The present invention provides a patch-type photovoltaic power generation device, comprising a light-transmitting protective layer, a light-transmitting sealing layer, a unit power generation layer and a current transmission composite layer which are stacked and pressed together in sequence from top to bottom, wherein the unit power generation layer is used to convert light energy into electrical energy, and the unit power generation layer is provided with an insulating coating and a plurality of electrode points on a side close to the current transmission composite layer, and each of the electrode points does not overlap with the insulating coating, and the current transmission composite layer is provided with a conductive circuit corresponding to the current transmission direction of the electrode point on a side close to the unit power generation layer, the electrode point is electrically connected to the conductive circuit of the current transmission composite layer, and the current transmission composite layer is used to conduct the current generated by the unit power generation layer.

[0005] Preferably, the light-transmitting protective layer is made of a light-transmitting and weather-resistant material.

[0006] Preferably, the unit power generation layer is a unit power generation component.

[0007] Preferably, the plurality of electrode points are arranged in an array on one side of the unit power generation layer close to the current transport composite layer.

[0008] Preferably, a circle of non-insulating coating is provided around each electrode point, the non-insulating coating is used to electrically connect the conductive line of the current transmission composite layer, and the insulating coating is arranged to avoid the non-insulating coating and each electrode point.

[0009] Preferably, the non-insulating coating is located 1.5 mm to 3 mm away from the center of the electrode point.

[0010] Preferably, the non-insulating coating is formed of conductive glue.

[0011] Preferably, the current transmission composite layer includes a metal foil layer, a packaging film layer and a weather-resistant material layer which are stacked and pressed together from top to bottom, the metal foil layer is used to connect the unit power generation layer, and the metal foil layer is engraved with the conductive circuit and positioning marks according to the positions of the electrode points, and the metal foil layer is connected to the weather-resistant material layer through the packaging film layer.

[0012] Preferably, the metal foil layer is copper foil, aluminum foil or copper-aluminum foil.

[0013] The present invention also provides a method for preparing a patch-type photovoltaic power generation device, which is used to prepare the patch-type photovoltaic power generation device described in any one of the above technical solutions, comprising the following steps: S1. Laying each unit layer of the current transfer composite layer on the carrier in sequence to prepare the current transfer composite layer, and fixing the carrier and the current transfer composite material with a high temperature resistant tape, the heat resistant temperature of the carrier is 130°C-300°C, and the current transfer composite layer is engraved with a positioning mark; S2. Printing a conductive glue on the periphery of each electrode point on the unit power generation layer to form a non-insulating coating, and printing an insulating coating on the unit power generation layer at a position other than the electrode point and the non-insulating coating near the current transfer composite layer on one side; S3. Grab the unit power generation layer by a robotic arm, the robotic arm is integrated with a camera, and the camera locates and lays the unit power generation layer by identifying the positioning mark on the current transmission composite layer; S4. Lay the light-transmitting sealing layer and the light-transmitting protective layer in sequence, and then carry out pressing, edge cutting, junction box installation, curing, inspection and testing to realize the production of patch-type photovoltaic power generation devices.

[0014] Compared with the prior art, the present invention has achieved the following technical effects: The patch-type photovoltaic power generation device and the preparation method thereof provided by the present invention include a light-transmitting protective layer, a light-transmitting sealing layer, a unit power generation layer and a current transmission composite layer which are sequentially stacked and pressed from top to bottom and connected. The light-transmitting protective layer can play a light-transmitting and protective role. The light-transmitting sealing layer can realize a sealed connection with the unit power generation layer while transmitting light. The unit power generation layer is used to convert light energy into electrical energy to realize power generation. The unit power generation layer is provided with an insulating coating and a plurality of electrode points on a side close to the current transmission composite layer, and each electrode point does not overlap with the insulating coating. The current transmission composite layer is provided with a conductive line corresponding to the current transmission direction of the electrode point on a side close to the unit power generation layer, and the electrode point is connected to the current transmission composite layer. The conductive lines of the current transmission composite layer are electrically connected, and the circuit diagram of the conductive lines realizes the interconnection and parallel connection of each unit power generation layer. When the unit power generation layer is electrically connected to the current transmission composite layer, the unit power generation layer is directly attached to the current transmission composite layer through automated laser positioning, without the need for additional series connection and welding. The connection between the unit power generation layer and the current transmission composite layer and the final low-temperature pressing and curing can be carried out simultaneously to form a stable patch-type photovoltaic power generation device. At the same time, the process steps are simple, which reduces costs and energy consumption and improves preparation efficiency. The current transmission composite layer is used to conduct the current generated by the unit power generation layer, and can also protect the unit power generation layer to prevent its reliability from being affected by the environment. BRIEF DESCRIPTION OF THE DRAWINGS

[0015] In order to more clearly illustrate the embodiments of the present invention or the technical solutions in the prior art, the drawings required for use in the embodiments will be briefly introduced below. Obviously, the drawings described below are only some embodiments of the present invention. For ordinary technicians in this field, other drawings can be obtained based on these drawings without paying creative work.

[0016] Figure 1 This is a structural exploded view of the patch-type photovoltaic power generation device in Example 1; Figure 2 It is a cross-sectional view of the connection between the unit power generation layer and the current transmission composite layer in Example 1; Figure 3 It is a partial schematic diagram of one side of the unit power generation layer in Example 1; Figure 4 It is a partial schematic diagram of the other side of the unit power generation layer in the first embodiment; Figure 5 It is a cross-sectional view of the current transmission composite layer in Example 1; Figure 6 It is a schematic diagram of the arrangement of the conductive circuit in the first embodiment; In the figure: 1-light-transmitting protective layer, 2-light-transmitting sealing layer, 3-unit power generation layer, 4-current transmission composite layer, 5-conductive adhesive, 6-insulating coating, 7-negative pole, 8-positive pole, 9-weather-resistant material layer, 10-packaging film layer, 11-metal foil layer, 12-conductive circuit. DETAILED DESCRIPTION

[0017] The following will be combined with the drawings in the embodiments of the present invention to clearly and completely describe the technical solutions in the embodiments of the present invention. Obviously, the described embodiments are only part of the embodiments of the present invention, not all of the embodiments. Based on the embodiments of the present invention, all other embodiments obtained by ordinary technicians in this field without creative work are within the scope of protection of the present invention.

[0018] The purpose of the present invention is to provide a patch type photovoltaic power generation device and a preparation method thereof, so as to solve the problems existing in the prior art and improve the reliability and performance stability of photovoltaic power generation components.

[0019] In order to make the above-mentioned objects, features and advantages of the present invention more obvious and easy to understand, the present invention is further described in detail below with reference to the accompanying drawings and specific embodiments.

[0020] Embodiment 1 like Figure 1-Figure 6As shown, this embodiment provides a patch-type photovoltaic power generation device, which combines semiconductor technology and photovoltaic technology and is particularly suitable for the production and manufacturing of solar photovoltaic modules. The patch-type photovoltaic power generation device includes a light-transmitting protective layer 1, a light-transmitting sealing layer 2, a unit power generation layer 3 and a current transmission composite layer 4, which are stacked and pressed together from top to bottom. The light-transmitting protective layer 1 can play a light-transmitting and protective role. The light-transmitting sealing layer 2 can achieve a sealed connection with the unit power generation layer 3 while transmitting light. The unit power generation layer 3 is used to convert light energy into electrical energy to achieve power generation. The unit power generation layer 3 is provided with an insulating coating 6 and a plurality of electrode points on a side close to the current transmission composite layer 4, and each electrode point does not overlap with the insulating coating 6. The current transmission composite layer 4 is provided with a conductive line 12 corresponding to the current transmission direction of the electrode point on a side close to the unit power generation layer 3, and the electrode point and the electrode are connected to each other. The conductive circuit 12 of the current transmission composite layer 4 is electrically connected, and the circuit diagram of the conductive circuit 12 realizes the interconnection and parallel connection of each unit power generation layer 3. When the unit power generation layer 3 is electrically connected to the current transmission composite layer 4, the unit power generation layer 3 is directly attached to the current transmission composite layer 4 through the automation of laser positioning, without the need for additional series connection and welding. The connection between the unit power generation layer 3 and the current transmission composite layer 4 and the final low-temperature pressing and curing can be carried out simultaneously to form a stable patch-type photovoltaic power generation device. At the same time, the process steps are simple, which reduces costs and energy consumption and improves preparation efficiency. The current transmission composite layer 4 is used to conduct the current generated by the unit power generation layer 3, and can also protect the unit power generation layer 3 to prevent its reliability from being affected by the environment, thereby improving the performance stability of the patch-type photovoltaic power generation device and providing the possibility for the promotion of ultra-thin silicon wafers.

[0021] The light-transmitting protective layer 1 is made of a light-transmitting weather-resistant material, such as polymethyl methacrylate (PMMA), polycarbonate (PC), etc. Those skilled in the art can also make adaptive adjustments to the specific material selection according to actual needs.

[0022] The unit power generation layer 3 is a unit power generation component, such as a battery cell.

[0023] A plurality of electrode points are arranged in an array on one side of the unit power generation layer 3 close to the current transmission composite layer 4 , specifically including a plurality of columns of positive electrode points 8 and a plurality of columns of negative electrode points 7 .

[0024] A circle of non-insulating coating is provided around each electrode point, and the non-insulating coating is used to electrically connect the conductive line 12 of the current transmission composite layer 4 to realize current conduction. The insulating coating 6 is arranged to avoid the non-insulating coating and each electrode point, that is, the insulating coating 6 is located on the periphery of the non-insulating coating and does not overlap with the non-insulating coating and the electrode point.

[0025] The non-insulating coating is located 1.5mm-3mm away from the center of the electrode point, and the insulating coating 6 is located 3mm away from the center of the electrode point. That is, on one side of the unit power generation layer 3 close to the current transmission composite layer 4, except for the electrode point that mainly conducts current and the non-insulating coating position around it, other areas are covered with the insulating coating 6.

[0026] The non-insulating coating is formed by the conductive glue 5 , which can realize the connection and conduction between the electrode points and the conductive circuit 12 .

[0027] The current transmission composite layer 4 includes a metal foil layer 11, a packaging film layer 10 and a weather-resistant material layer 9 which are stacked and pressed together from top to bottom. The metal foil layer 11 is used to connect the unit power generation layer 3, and the metal foil layer 11 is engraved with a conductive line 12 and a positioning mark according to the position of the electrode point. The metal foil layer 11 is connected to the weather-resistant material layer 9 through the packaging film layer 10. Among them, the weather-resistant material layer 9 is specifically a weather-resistant insulating polymer sheet, the packaging film layer 10 is an adhesive polymer film, and the metal foil layer 11 is a conductive foil, so that the current transmission composite layer 4 combines the characteristics of weather resistance and conductivity.

[0028] The metal foil layer 11 is copper foil, aluminum foil or copper-aluminum foil. Those skilled in the art can adaptively change the specific material of the metal foil layer 11 according to actual needs.

[0029] Embodiment 2 This embodiment provides a method for preparing a patch-type photovoltaic power generation device, which is used to prepare the patch-type photovoltaic power generation device in Example 1, comprising the following steps: S1. Lay each unit layer in the current transmission composite layer 4 on the carrier in sequence to prepare the current transmission composite layer 4, and use a high-temperature resistant tape to fix the carrier and the current transmission composite material. Use the high-temperature resistant tape to replace the original high-cost vacuum adsorption method to reduce costs. The heat-resistant temperature of the carrier is 130°C-300°C, and the current transmission composite layer 4 is engraved with a positioning mark; Among them, rigid materials such as tempered glass / metal aluminum plate / epoxy resin plate are used to replace the high-cost professional vacuum adsorption carrier as a carrier of the production line to reduce costs and energy consumption; S2. Printing conductive glue 5 on the periphery of each electrode point on the unit power generation layer 3 to form a non-insulating coating. The printing of the conductive glue 5 can be completed offline, so that the unit power generation layer 3 no longer requires the online steel plate printing process of the production line. At the same time, since the conductive glue 5 is directly printed on the unit power generation layer 3, it is no longer necessary to use a large stencil to print the conductive glue 5 on the metal foil as in the traditional technology, thereby saving production costs; and printing the insulating coating 6 on the side of the unit power generation layer 3 close to the current transmission composite layer 4 except for the electrode points and the non-insulating coating. This method can achieve insulation between the unit power generation layer 3 and the metal foil, and no longer requires the separate laying of insulating adhesive layer materials as in the traditional technology. Therefore, the laying process of the insulating adhesive layer is no longer required, further simplifying the component production process; S3. The unit power generation layer 3 is grasped by a robot arm, and a camera is integrated on the robot arm. The camera positions and lays the unit power generation layer 3 by identifying the positioning mark on the current transmission composite layer 4. This automated operation ensures the accurate position of the unit power generation layer 3, further improving the manufacturing accuracy and efficiency of the patch-type photovoltaic power generation device; S4. Lay the light-transmitting sealing layer 2 and the light-transmitting protective layer 1 in sequence, and then carry out conventional processes such as lamination, edge cutting, junction box installation, curing, inspection and testing on the four layers of materials to realize the production of the patch type photovoltaic power generation device. These processes ensure the stability, reliability and product quality of the patch type photovoltaic power generation device, and ensure the performance and life of the final product.

[0030] This embodiment has the following advantages through the above-mentioned steps: (1) Improved yield: The process is modular, and the process steps are simple and controllable, making it suitable for commercial promotion; (2) Simplify the process flow: unmanned and dark-light factories can be realized in the future. As the scale expands, the cost is expected to be significantly reduced; (3) Energy saving: process simplification and material conservation reduce energy consumption and are more environmentally friendly; (4) Environmental pollution control: Due to the reduction of material use and energy consumption, the risk of waste generation and environmental pollution is reduced.

[0031] The present invention uses specific examples to illustrate the principles and implementation methods of the present invention. The above examples are only used to help understand the method and core ideas of the present invention. At the same time, for those skilled in the art, according to the ideas of the present invention, there will be changes in the specific implementation methods and application scopes. In summary, the content of this specification should not be understood as limiting the present invention.

Claims

1. A patch type photovoltaic power generation device, characterized in that: It includes a light-transmitting protective layer, a light-transmitting sealing layer, a unit power generation layer and a current transmission composite layer which are stacked and pressed together from top to bottom. The unit power generation layer is used to convert light energy into electrical energy, and the unit power generation layer is provided with an insulating coating and a plurality of electrode points on a side close to the current transmission composite layer, and each of the electrode points does not overlap with the insulating coating. The current transmission composite layer is provided with a conductive circuit corresponding to the current transmission direction of the electrode point on a side close to the unit power generation layer, the electrode point is electrically connected to the conductive circuit of the current transmission composite layer, and the current transmission composite layer is used to conduct the current generated by the unit power generation layer.

2. The patch type photovoltaic power generation device according to claim 1, characterized in that: The light-transmitting protective layer is made of light-transmitting and weather-resistant material.

3. The patch type photovoltaic power generation device according to claim 1, characterized in that: The unit power generation layer is a unit power generation component.

4. The patch type photovoltaic power generation device according to claim 1, characterized in that: The plurality of electrode points are arranged in an array on one side of the unit power generation layer close to the current transport composite layer.

5. The patch type photovoltaic power generation device according to claim 1, characterized in that: A circle of non-insulating coating is provided around each electrode point, and the non-insulating coating is used to electrically connect the conductive line of the current transmission composite layer. The insulating coating is arranged to avoid the non-insulating coating and each electrode point.

6. The patch type photovoltaic power generation device according to claim 5, characterized in that: The non-insulating coating is located 1.5 mm to 3 mm away from the center of the electrode point.

7. The patch type photovoltaic power generation device according to claim 5, characterized in that: The non-insulating coating is formed by conductive glue.

8. The patch type photovoltaic power generation device according to claim 1, characterized in that: The current transmission composite layer includes a metal foil layer, a packaging film layer and a weather-resistant material layer which are stacked and pressed together in sequence from top to bottom. The metal foil layer is used to connect the unit power generation layer, and the metal foil layer is engraved with the conductive circuit and positioning marks according to the positions of the electrode points. The metal foil layer is connected to the weather-resistant material layer through the packaging film layer.

9. The patch type photovoltaic power generation device according to claim 8, characterized in that: The metal foil layer is copper foil, aluminum foil or copper-aluminum foil.

10. A method for preparing a patch-type photovoltaic power generation device, characterized in that: The method for preparing a patch-type photovoltaic power generation device according to any one of claims 1 to 9 comprises the following steps: S1. Laying each unit layer of the current transfer composite layer on the carrier in sequence to prepare the current transfer composite layer, and fixing the carrier and the current transfer composite material with a high temperature resistant tape, the heat resistant temperature of the carrier is 130°C-300°C, and the current transfer composite layer is engraved with a positioning mark; S2. Printing a conductive glue on the periphery of each electrode point on the unit power generation layer to form a non-insulating coating, and printing an insulating coating on the unit power generation layer at a position other than the electrode point and the non-insulating coating near the current transfer composite layer on one side; S3. Grab the unit power generation layer by a robotic arm, the robotic arm is integrated with a camera, and the camera locates and lays the unit power generation layer by identifying the positioning mark on the current transmission composite layer; S4. Lay the light-transmitting sealing layer and the light-transmitting protective layer in sequence, and then carry out pressing, edge cutting, junction box installation, curing, inspection and testing to realize the production of patch-type photovoltaic power generation devices.

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