Composite backboard, manufacturing method thereof and photovoltaic module manufactured by using composite backboard

Abstract

The invention discloses a composite backboard, a manufacturing method thereof and a photovoltaic module manufactured by using the composite backboard, and the glass fiber composite backboard comprises a weather-proof layer, a first adhesive layer, longitudinal glass fiber cloth, a polyethylene glycol terephthalate layer, transverse glass fiber cloth, a second adhesive layer and a heat sealing layer which are sequentially stacked from top to bottom, the placement directions of the longitudinal glass fiber cloth and the transverse glass fiber cloth on the two sides of the polyethylene glycol terephthalate layer are different. The manufacturing method comprises the following steps: pre-soaking in an anti-ultraviolet soaking solution, and bonding and co-extruding the glass fiber cloth to form the plate. The supporting performance and the flexibility of the glass fiber composite backboard can be adjusted through materials, and the glass fiber composite backboard has the advantages of being good in weather resistance, low in water vapor permeability and the like and can be applied to flexible assemblies and light assemblies.

Description

Technical Field

[0001] The invention relates to the manufacturing field of flexible components and lightweight components, and in particular to a composite backboard and a manufacturing method thereof, and a photovoltaic component manufactured using the composite backboard. Background Art

[0002] Lightweight components and flexible components can be combined with buildings, carports, vehicles, etc. They are not only beautiful, but also can effectively utilize solar energy resources to provide clean and renewable electricity for humans. Due to the particularity of the application scenarios, lightweight components and flexible components have significant features such as "light", "thin" and "bendable", which are favored by the market, and the installation volume increases year by year. The concept of "photovoltaic +" such as green buildings and green transportation has gradually become a choice for people to pursue green life.

[0003] N-type batteries have the advantages of high conversion rate, low temperature coefficient, high bifaciality, etc. As the cost decreases, they are rapidly seizing the silicon wafer power generation market. In 2024, the market share will exceed 50%. However, the combination of lightweight, flexible components and N-type cells has encountered great problems. Common solar cell modules mainly include backplanes, solar cell circuits, packaging films and front panels. Among them, the photovoltaic backplane is located on the back of the solar panel, which protects and supports the cells. It needs to have reliable insulation, water resistance, and aging resistance. It is an important packaging structure in photovoltaic modules. However, the lightweight and flexible components made of existing conventional backplanes are too flexible and have no support during the production, transportation, and installation of the components. It is easy to cause the internal cells to break and crack, reduce the power generation efficiency, and bring safety hazards. Conventional materials or flexible front panel materials have poor ability to prevent water vapor from passing through, resulting in water vapor corrosion to the battery and reducing the overall life of the components. In the process of manufacturing lightweight and flexible components, the production process is different from that of conventional components. It requires substrate transfer and additional manpower. The production efficiency is low and the yield rate is also low, which greatly increases the production cost and the sales price of the components, creating resistance to the promotion of components.

[0004] Patent No. CN202210477268 discloses a photovoltaic module with high light transmittance and water vapor resistance, and its preparation method and application, including a flexible light-transmitting front panel, a battery cell and a flexible back panel laminated as one, and a back panel water-blocking vapor deposition film is provided on the outer surface of the flexible back panel, which overcomes the difficulty of flexible packaging faced by photovoltaic modules with high sensitivity to water vapor. However, the problem of weak support of flexible modules is not solved.

[0005] The Chinese invention patent with publication number CN 112420864 A discloses a lightweight shingled photovoltaic module based on glass fiber prepreg process and its manufacturing method. The key points of its technical solution are that the shingled battery string is welded with punching welding strips at the head and tail, and connected in series and parallel through busbars, and introduced into the photovoltaic junction box through positive and negative electrodes. The outer side of the shingled battery string is provided with high-transmittance glass fiber prepreg, and the upper and lower ends of the high-transmittance glass fiber prepreg are respectively provided with high-transmittance EVA film, and a transparent flexible front film is provided at the top of its outermost layer. The inner side of the shingled battery string is provided with a rear layer of glass fiber prepreg, and the upper and lower ends of the rear layer of glass fiber prepreg are respectively provided with high-cut-off EVA film, and the outermost layer of the bottom high-cut-off EVA film is provided with a photovoltaic backboard, and a photovoltaic junction box is provided on the outer side of the photovoltaic backboard. The processing steps and processing technology of the glass fiber prepreg in this solution are complicated, and the production cost is high.

[0006] In view of this, the present application aims to develop a backplane material for lightweight components and flexible components, to provide the components with better supporting performance, weather resistance, waterproof permeability and other properties, to improve the component production yield, to reduce the number of operating workers, to increase the degree of automation, to increase production output, to reduce production costs, etc., thereby reducing the cost of lightweight and flexible components. Summary of the invention

[0007] The problem to be solved by the present invention is that the lightweight and flexible components made of existing conventional backplanes are too flexible and have no support during the component manufacturing, transportation, and installation process, which can easily cause the internal battery cells to break and crack, reduce power generation efficiency, and bring safety hazards. Conventional materials or flexible front panel materials have poor ability to prevent water vapor from passing through, which causes water vapor to corrode the battery and reduce the overall life of the component. In the process of manufacturing lightweight and flexible components, the production process is different from that of conventional components, and substrate transportation and additional manpower are required. The production efficiency is low and the yield rate is also low, which greatly increases the production cost and the sales price of the components, bringing resistance to the promotion of components.

[0008] In order to solve the above-mentioned technical problems, the present application provides a composite backboard on the one hand, characterized in that it includes a weather-resistant layer, a first adhesive layer, a longitudinal glass fiber cloth, a polyethylene terephthalate layer, a transverse glass fiber cloth, a second adhesive layer and a heat-sealing layer stacked in sequence from top to bottom, and the longitudinal glass fiber cloth and the transverse glass fiber cloth are placed in different directions on both sides of the polyethylene terephthalate layer.

[0009] According to an embodiment of the present application, the weather-resistant layer is a single-layer structure of any one of a polyvinylidene fluoride film and an ethylene-tetrafluoroethylene film, and the thickness of the weather-resistant layer is 10 μm-500 μm, including end points.

[0010] According to an embodiment of the present application, the adhesive includes one or more of a polyurethane adhesive, an acrylate adhesive, an epoxy resin adhesive, a polyvinyl acetate adhesive or a urea-formaldehyde resin adhesive.

[0011] According to an embodiment of the present application, the longitudinal glass fiber cloth and the transverse glass fiber cloth are dipped in an anti-ultraviolet impregnation liquid.

[0012] According to an embodiment of the present application, the longitudinal glass fiber cloth is a gingham cloth made by weaving a single warp cloth, the single line diameter of the glass fiber on the warp of the longitudinal glass fiber cloth is 100μm-2000μm, and the single line diameter of the glass fiber on the weft is 30μm-500μm.

[0013] According to an embodiment of the present application, the transverse glass fiber cloth is a lattice cloth woven into a single weft cloth, the single line diameter of the glass fiber on the weft of the transverse glass fiber cloth is 100μm-2000μm, and the single line diameter of the glass fiber on the warp is 30μm-500μm.

[0014] According to an embodiment of the present application, the bending radius of the longitudinal glass fiber cloth and the transverse glass fiber cloth is 0.1-1m.

[0015] Another aspect of the present application discloses a photovoltaic module, which includes, from top to bottom: an upper layer component, including a transparent layer and a high-resistance water-resistant adhesive film; a middle layer component, including a P-type or N-type battery cell; a lower layer component, including the adhesive film of the lower layer of the middle layer component and a glass fiber composite backplane; wherein the glass fiber composite backplane is the glass fiber composite backplane described above.

[0016] According to an embodiment of the present application, the transparent layer is glass, ultra-thin glass or a transparent front plate.

[0017] Another aspect of the present application discloses a method for manufacturing a composite backplane as described above, comprising the following steps in sequence:

[0018] Pre-impregnation of anti-ultraviolet impregnation liquid: The flattened glass fiber cloth is dipped in liquid anti-ultraviolet impregnation liquid to make the anti-ultraviolet impregnation liquid and the glass fiber cloth fully contact, so that the surface of the glass fiber cloth is evenly stained with a layer of anti-ultraviolet impregnation liquid, and the fiber fabric that has been dipped is dried; the dipping time is 5s-120s, the drying temperature is 60℃-150℃, and the drying time is 2min-30min;

[0019] Specifically, the anti-ultraviolet impregnation liquid is a mixed solution of zinc titanate, zinc oxide, maleic anhydride grafted polypropylene, polypropylene resin, etc. In the embodiment of the present application, the preparation process of the anti-ultraviolet impregnation liquid is as follows: 100 parts of polypropylene resin, 3 parts of maleic anhydride grafted polypropylene, 2 parts of zinc titanate, and 0.5 parts of zinc oxide are uniformly mixed in a blender, and then heated to 50-100°C, and melted to form a resin melt, which is placed in a container and dip-coated on the surface of the glass fiber.

[0020] Shearing: Shearing the semi-finished product obtained above according to size requirements to obtain longitudinal glass fiber cloth and transverse glass fiber cloth;

[0021] Bonding of glass fiber cloth: Apply adhesive to both sides of the polyethylene terephthalate layer, and co-extrude the longitudinal glass fiber cloth and the transverse glass fiber cloth in different directions and stick them on both sides of the polyethylene terephthalate layer to form a glass fiber functional support layer; wherein the co-extrusion temperature is 10℃-100℃, and the co-extrusion pressure is 50Pa-1000Pa;

[0022] Co-extrusion to form a board: The weather-resistant layer, the first adhesive layer, the glass fiber functional support layer, the second adhesive layer and the heat-sealing layer are stacked in order from top to bottom, and the stacked pre-pressed parts are co-extruded to form a target board.

[0023] The principle of using the glass fiber backboard to adjust the bending performance: by placing the upper longitudinal glass fiber cloth and the lower transverse glass fiber cloth in different directions, the overall support of the backboard is greatly improved. At the same time, the bending performance of the glass fiber backboard can be adjusted by the thickness of the fiber cloth and the placement angle of the longitudinal and transverse fiber cloth. For example, when the warp of the longitudinal glass fiber cloth and the weft of the transverse glass fiber cloth are 90°, the bending performance of the glass fiber composite backboard is the worst; conversely, when the warp of the longitudinal glass fiber cloth and the weft of the transverse glass fiber cloth are 180°, the bending performance of the glass fiber board is the softest. Within the above range of 90°-180°, the bending performance of the glass fiber composite backboard can be achieved by appropriately adjusting the angles between the warp of the longitudinal glass fiber cloth and the weft of the transverse glass fiber cloth as needed.

[0024] The beneficial effects of the technical solution of the present invention compared with the prior art are:

[0025] 1. The present invention adopts an upper and lower insulating layer, respectively fixed with longitudinal glass fiber cloth and transverse glass fiber cloth. The longitudinal glass fiber cloth is made according to a single warp cloth, and its strength is mainly in the warp direction of the fabric; the transverse glass fiber cloth is made according to a single weft cloth, and its strength is mainly in the weft direction of the fabric. By placing the upper and lower glass fiber cloths of the insulating layer in different directions, the overall support of the backboard is greatly improved. At the same time, the bending performance of the functionalized glass fiber backboard can be adjusted by the thickness of the glass fiber cloth and the placement direction angles of the longitudinal and transverse glass fiber cloths, thereby avoiding the problem of poor support of the lightweight and flexible component backboard using conventional backboard materials.

[0026] 2. The functionalized glass fiber backplane material used in the present invention can be used as a backplane material for flexible and lightweight components. Combined with a high-resistance water-repellent film, it can effectively protect P-type and N-type battery cells from corrosion caused by water vapor intrusion, and make the components have good support properties, thereby protecting the battery cells during the transportation and installation of the components.

[0027] 3. The glass fiber backboard material of the present invention can be used as the bottom plate support material for producing flexible components and lightweight components on the transport line. Compared with the traditional components and lightweight components production lines, which require the front glass of the components as the substrate, and the flexible components require another thick glass as the substrate, and the back of the components on the assembly line is upward, the improved process uses a functionalized glass fiber composite material backboard as the substrate, and the front of the components on the assembly line is upward. After the battery string is welded, a flip device is added at the end of the string welding machine to make the battery string face upward, so that the production of lightweight or flexible components is basically similar to that of conventional components, without increasing the number of workers and workload, and improving the overall yield rate. The overall production capacity reaches more than 95% of conventional components, greatly reducing the production cost. The improved new flexible component and lightweight component production process has the advantages of high production efficiency, high yield rate, less labor, and a significant decline in production costs. BRIEF DESCRIPTION OF THE DRAWINGS

[0028] Figure 1 A schematic diagram of the structure of a composite backplane according to an example of the present invention;

[0029] Figure 2 This is a schematic diagram of the structure of a photovoltaic module in an example of the present invention;

[0030] Figure 3 It is a structural schematic diagram of the glass fiber cloth structure diagram in an example of the present invention;

[0031] Figure 4 is a weft-direction cross-sectional view of a longitudinal glass fiber cloth in an example of the present invention;

[0032] Figure 5 is a weft-direction cross-sectional view of a transverse glass fiber cloth in an example of the present invention;

[0033] Figure 6 This is a production process roadmap for a flexible component or a lightweight component in an example of the present invention.

[0034] The following are the descriptions of the reference numerals:

[0035] 10. Glass fiber composite back sheet, 11. Weather resistant layer, 12. First adhesive layer, 13. Longitudinal glass fiber cloth, 14. Polyethylene terephthalate layer, 15. Transverse glass fiber cloth, 16. Second adhesive layer, 17. Heat sealing layer, 21. Transparent layer, 22. High resistance water-gel film, 23. P-type or N-type battery cell, 31. Warp, 32. Weft. DETAILED DESCRIPTION

[0036] The present invention will be further described below in conjunction with the accompanying drawings and specific embodiments. The following embodiments are used to illustrate the present invention but are not intended to limit the scope of the present invention.

[0037] See also Figure 1 , Figure 3 , Figure 4 , Figure 5 As shown, a composite backplane is shown, which includes, from top to bottom, a weather-resistant layer 11, a first adhesive layer 12, a longitudinal glass fiber cloth 13, a polyethylene terephthalate layer 14, a transverse glass fiber cloth 15, a second adhesive layer 16 and a heat-sealing layer 17. In view of the problems of hidden cracks and fragmentation of battery cells caused by being too soft during transportation and installation in the prior art, the glass fiber composite material of the present application can adjust the curvature of the plate according to the thickness of the backplane, so that flexible and lightweight components can be made in combination with a high-resistance water-resistant film 22. The present application is used as a substrate to improve the production process of flexible components and lightweight components. Without increasing the weight and thickness of the components, the components are provided with better supporting performance, weather resistance, waterproof permeability and other properties. Combined with the high-resistance water-resistant film 22, the manufactured components can better protect P-type or N-type batteries, reduce fragments and hidden cracks during production, transportation and installation; during operation, water vapor is blocked to prevent corrosion that affects the life of the components.

[0038] In this embodiment, Figure 1 As shown, a composite backboard is a composite material including a weather-resistant layer 11, a first adhesive layer 12, a longitudinal glass fiber cloth 13, a polyethylene terephthalate layer 14, a transverse glass fiber cloth 15, a second adhesive layer 16 and a heat-sealing layer 17 stacked in sequence from top to bottom, and the longitudinal glass fiber cloth 13 and the transverse glass fiber cloth 15 are placed in different directions on both sides of the polyethylene terephthalate layer 14.

[0039] Specifically, Figures 3 to 5As shown, the longitudinal glass fiber cloth 13 and the transverse glass fiber cloth 15 are both glass fiber woven cloth, and the glass fiber woven cloth is a plain woven fabric with untwisted coarse yarn. The woven cloth is made by weaving a single warp cloth, and its strength is mainly in the direction of the warp 31 of the fabric. The single diameter of the glass fiber on the warp 31 is 100μm-2000μm, and the single diameter of the glass fiber on the weft 32 is 30μm-500μm. This kind of glass fiber woven cloth is the longitudinal glass fiber cloth 13; the woven cloth is made by weaving a single weft cloth, and its strength is mainly in the direction of the weft 32 of the fabric. The single diameter of the glass fiber on the weft 32 is 100μm-2000μm, and the single diameter of the glass fiber on the warp 31 is 30μm-500μm. This kind of glass fiber woven cloth is the transverse glass fiber cloth 15. The fiber fabric woven by the fiber warp threads 31 and weft threads 32 of the above specifications can improve the overall strength and load-bearing effect of the functional fiber fabric layer, thereby making the surface density of the fiber woven fabric meet the design requirements of the flexible composite material.

[0040] The principle of adjusting the bending performance of the glass fiber backboard is as follows: by placing the upper longitudinal glass fiber cloth 13 and the lower transverse glass fiber cloth 15 in different directions, the overall support of the backboard is greatly improved. At the same time, the bending performance of the glass fiber backboard can be adjusted by the thickness of the fiber cloth and the placement angle of the longitudinal and transverse fiber cloth. For example, when the warp of the longitudinal glass fiber cloth and the weft of the transverse glass fiber cloth are 90°, the bending performance of the glass fiber composite backboard is the worst; conversely, when the warp of the longitudinal glass fiber cloth and the weft of the transverse glass fiber cloth are 180°, the bending performance of the glass fiber board is the softest. Within the above range of 90°-180°, the bending performance of the glass fiber composite backboard can be achieved by appropriately adjusting the angles between the warp of the longitudinal glass fiber cloth and the weft of the transverse glass fiber cloth as needed.

[0041] Specifically, the bending radius of the longitudinal glass fiber cloth 13 and the transverse glass fiber cloth 15 is 0.1-1 m.

[0042] Specifically, the longitudinal glass fiber cloth 13 and the transverse glass fiber cloth 15 are dipped in anti-ultraviolet impregnation liquid, and the longitudinal glass fiber cloth 13 and the transverse glass fiber cloth 15 are dipped in the anti-ultraviolet impregnation liquid, and the dipped fiber fabric is dried, thereby obtaining a fiber fabric containing a surface modified substance, thereby improving the flexibility and weather resistance of the glass fiber cloth.

[0043] Specifically, the weather-resistant layer 11 is a single-layer structure of any one of polyvinylidene fluoride film and ethylene-tetrafluoroethylene film, and the thickness of the weather-resistant layer 11 is 10-500 μm, including the end value. The use of a thinner fluorine film weather-resistant layer reduces the use of fluorine film materials and reduces production costs, while ensuring that the back sheet has a lower water vapor permeability and the waterproof performance of the back sheet.

[0044] In this embodiment, the polyethylene terephthalate layer 14 is an insulating layer. The use of the insulating layer ensures that the backboard has good insulation and can improve the arc breakdown resistance of the backboard. The longitudinal glass fiber cloth 13 and the transverse glass fiber cloth 15 are respectively fixed to the upper and lower sides of the polyethylene terephthalate layer 14 by adhesive to form a glass fiber functional support layer. The glass fiber functional support layer can not only increase the impact resistance of the component, but also increase the strength of the component, so that the overall support of the backboard is greatly improved.

[0045] Specifically, a backplane with a glass fiber functional support layer and a high water-resistance film is used, so that the backplane has good waterproof ability and low water vapor permeability, which can protect the battery from water vapor corrosion and increase the service life of the backplane and components.

[0046] Specifically, the adhesive layer can firmly bond the layers of the flexible composite material together, so that the lightweight and flexible material will not slip between layers after multiple flexing, and the weather resistance, tensile strength and shear strength are good. For example, the adhesive layer can make the longitudinal glass fiber cloth 13 and the transverse glass fiber cloth stably fixed at a certain angle on both sides of the polyethylene terephthalate layer 14. At the same time, the materials of the first adhesive layer 12 and the second adhesive layer 16 are not particularly limited. For example, the materials of the first adhesive layer 12 and the second adhesive layer 16 can independently include one or more of polyurethane adhesive, acrylate adhesive, epoxy resin adhesive, polyvinyl acetate adhesive or urea-formaldehyde resin adhesive. When the materials of the first adhesive layer 12 and the second adhesive layer 16 are the aforementioned materials, the first adhesive layer 12 can effectively bond the weather-resistant layer 11 and the longitudinal glass fiber cloth 13, and the second adhesive layer 16 can effectively bond the transverse glass fiber cloth 15 and the heat-sealing layer 17. The first adhesive layer 12 and the second adhesive layer 16 can improve the structural stability of the glass fiber functional support layer.

[0047] Specifically, the heat sealing layer 17 is a protective layer, which is arranged on the outermost layer of the flexible composite material. The material of the heat sealing layer 17 is not particularly limited. For example, the heat sealing layer 17 may include at least one of polyester polyurethane elastomer, polyether polyurethane elastomer, polycaprolactone polyurethane elastomer, polyolefin elastomer, polystyrene elastomer, polyether ester elastomer and polyamide elastomer. When the heat sealing layer 17 is made of the aforementioned material, on the one hand, hydrogen bonds exist inside the aforementioned thermoplastic elastomer. Under the action of hydrogen bonds, the heat sealing layer 17 and the functionalized fiber fabric layer have good interface compatibility. On the other hand, the thermoplastic elastomer has a certain adhesion, which can make the surface of the capsule material anti-fouling and wear-resistant, and improve the rubbing resistance of the capsule material.

[0048] Another aspect of the present application discloses a photovoltaic module, which comprises, from top to bottom:

[0049] The upper layer assembly includes a transparent layer 21 and a high-resistance water-resistant adhesive film 22;

[0050] A middle layer component, including a P-type or N-type cell 23;

[0051] A lower layer assembly, including an adhesive film and a glass fiber composite back sheet 10;

[0052] The glass fiber composite backboard 10 is the glass fiber composite backboard as described above.

[0053] In this embodiment, the glass fiber composite back panel 10 of the present invention can be applied to flexible components and lightweight components, such as Figure 2 As shown, a photovoltaic module structure is as follows from top to bottom: the top transparent layer 21 is made of glass, ultra-thin glass or transparent front plate; the lower layer is a high-resistance water-gel film 22, which can be preferably made of EPE, POE and other materials, which can provide good protection for P-type and N-type cells from water vapor intrusion and corrosion of the cells; the middle layer is a P-type or N-type cell 23; the lower layer is a glue film; the bottom layer is the above-mentioned glass fiber composite backplane 10 layers, which mainly has the functions of UV protection, weather resistance, providing support for the module, and preventing water vapor from entering. The modules made according to this structure can pass the IEC test requirements for flexible modules and conventional modules, and the modules can be widely used in distributed or special architectural curved surfaces.

[0054] Specifically, the functionalized glass fiber composite backboard 10 of the present invention has good supporting and shock absorbing effects, and can optimize the process potential in the production of flexible components or lightweight components, overcoming the problems of complex production of general flexible or lightweight components, low yield, increased labor and increased costs. We have optimized the process route, such as Figure 6As shown, specifically: dicing - welding - battery string flipping - glass fiber composite backplane 10 loading - adhesive film loading - battery laying (battery string swinging) - battery string stack welding (welding strip on the bus bar) - EL detection - high resistance water adhesive film 22 loading (POE adhesive film glass laying) - glass or flexible front plate loading - lamination - edge cutting - component framing (frameless components omit this step) - component installation junction box - component curing - EL detection - IV detection - cleaning - large packaging box. On the production line of traditional components and lightweight components, the front glass of the components is used as the substrate, and the flexible components need another thick glass as the substrate. On the production line, the back of the components faces up. In the above improved process, the functionalized glass fiber composite backplane is used as the substrate, and the front of the components faces up on the production line; after the battery string is welded, a flipping device is added at the end of the string welding machine to make the battery string face up, so that the production of lightweight or flexible components is basically similar to that of conventional components, without increasing the number of workers and workload, improving the overall yield rate, and the overall production capacity reaches more than 95% of conventional components, greatly reducing the production cost.

[0055] In another aspect of the present application, a method for manufacturing the composite backplane is disclosed, which specifically comprises the following steps in sequence:

[0056] Pre-impregnation of anti-ultraviolet impregnation liquid: The flattened glass fiber cloth is dipped in liquid anti-ultraviolet impregnation liquid to make the anti-ultraviolet impregnation liquid and the glass fiber cloth fully contact, so that the surface of the glass fiber cloth is evenly stained with a layer of anti-ultraviolet impregnation liquid, and the fiber fabric that has been dipped is dried; the dipping time is 5s-120s, the drying temperature is 60℃-150℃, and the drying time is 2min-30min;

[0057] Specifically, the anti-ultraviolet impregnation liquid is a mixed solution of zinc titanate, zinc oxide, maleic anhydride grafted polypropylene, polypropylene resin, etc. In the embodiment of the present application, the preparation process of the anti-ultraviolet impregnation liquid is as follows: 100 parts of polypropylene resin, 3 parts of maleic anhydride grafted polypropylene, 2 parts of zinc titanate, and 0.5 parts of zinc oxide are uniformly mixed in a blender, and then heated to 50-100°C, and melted to form a resin melt, which is placed in a container and dip-coated on the surface of the glass fiber.

[0058] Shearing: Shearing the semi-finished product obtained above according to size requirements to obtain longitudinal glass fiber cloth 13 and transverse glass fiber cloth 15;

[0059] Bonding of glass fiber cloth: Apply adhesive to both sides of the polyethylene terephthalate layer 14, and co-extrude the longitudinal glass fiber cloth 13 and the transverse glass fiber cloth 15 in different directions and bond them to both sides of the polyethylene terephthalate layer 14 to form a glass fiber functional support layer; wherein the co-extrusion temperature is 10°C-100°C, and the co-extrusion pressure is 50Pa-1000Pa;

[0060] Co-extrusion to form a sheet: The weather-resistant layer 11, the first adhesive layer 12, the glass fiber functional support layer, the second adhesive layer 16 and the heat-sealing layer 17 are stacked in order from top to bottom, and the stacked pre-pressed parts are co-extruded to form a target sheet. The weather-resistant film is made of weather-resistant materials such as PVDF and ETFE, with a thickness of 10-500μm.

[0061] The above-mentioned production method is simple, can be implemented on conventional equipment, is convenient for industrial mass production, and has good application prospects and potential economic benefits.

[0062] In summary, the technical solution of this application has the following beneficial effects:

[0063] 1. The present invention adopts an upper and lower insulating layer, respectively fixed with longitudinal glass fiber cloth and transverse glass fiber cloth. The longitudinal glass fiber cloth is made according to a single warp cloth, and its strength is mainly in the warp direction of the fabric; the transverse glass fiber cloth is made according to a single weft cloth, and its strength is mainly in the weft direction of the fabric. By placing the upper and lower glass fiber cloths of the insulating layer in different directions, the overall support of the backboard is greatly improved. At the same time, the bending performance of the functionalized glass fiber backboard can be adjusted by the thickness of the glass fiber cloth and the placement direction angles of the longitudinal and transverse glass fiber cloths, thereby avoiding the problem of poor support of the lightweight and flexible component backboard using conventional backboard materials.

[0064] 2. The functionalized glass fiber backplane material used in the present invention can be used as a backplane material for flexible and lightweight components. Combined with a high-resistance water-repellent film, it can effectively protect P-type and N-type battery cells from corrosion caused by water vapor intrusion, and make the components have good support properties, thereby protecting the battery cells during the transportation and installation of the components.

[0065] 3. The glass fiber backboard material of the present invention can be used as the bottom plate support material for producing flexible components and lightweight components on the transport line. Compared with the traditional components and lightweight components production lines, which require the front glass of the components as the substrate, and the flexible components require another thick glass as the substrate, and the back of the components on the assembly line is upward, the improved process uses a functionalized glass fiber composite material backboard as the substrate, and the front of the components on the assembly line is upward. After the battery string is welded, a flip device is added at the end of the string welding machine to make the battery string face upward, so that the production of lightweight or flexible components is basically similar to that of conventional components, without increasing the number of workers and workload, and improving the overall yield rate. The overall production capacity reaches more than 95% of conventional components, greatly reducing the production cost. The improved new flexible component and lightweight component production process has the advantages of high production efficiency, high yield rate, less labor, and a significant decline in production costs.

[0066] The above are only preferred embodiments of the present invention, and are not intended to limit the implementation methods and protection scope of the present invention. Those skilled in the art should be aware that all solutions obtained by equivalent substitutions and obvious changes made using the description and illustrations of the present invention should be included in the protection scope of the present invention.

Claims

1. A composite backplane, characterized in that: The invention comprises a weather-resistant layer, a first adhesive layer, a longitudinal glass fiber cloth, a polyethylene terephthalate layer, a transverse glass fiber cloth, a second adhesive layer and a heat-sealing layer which are stacked in sequence from top to bottom, wherein the longitudinal glass fiber cloth and the transverse glass fiber cloth are placed in different directions on both sides of the polyethylene terephthalate layer, that is, the warp of the longitudinal glass fiber cloth and the weft of the transverse glass fiber cloth form a certain angle.

2. A composite backboard according to claim 1, characterized in that: The weather-resistant layer is a single-layer structure of any one of a polyvinylidene fluoride film and an ethylene-tetrafluoroethylene film, and the thickness of the weather-resistant layer is 10 μm-500 μm, including end values.

3. The composite backboard according to claim 1, characterized in that: The adhesive includes one or more of polyurethane adhesive, acrylate adhesive, epoxy resin adhesive, polyvinyl acetate adhesive or urea-formaldehyde resin adhesive.

4. The composite backboard according to claim 1, characterized in that: The longitudinal glass fiber cloth and the transverse glass fiber cloth are dipped in an anti-ultraviolet impregnation liquid.

5. The composite backboard according to claim 1, characterized in that: The longitudinal glass fiber cloth is a lattice cloth made by weaving a single warp cloth. The single line diameter of the glass fiber on the warp of the longitudinal glass fiber cloth is 100 μm-2000 μm, and the single line diameter of the glass fiber on the weft is 30 μm-500 μm.

6. The composite backboard according to claim 1, characterized in that: The transverse glass fiber cloth is a lattice cloth made by weaving a single weft cloth. The single line diameter of the glass fiber on the weft of the transverse glass fiber cloth is 100 μm-2000 μm, and the single line diameter of the glass fiber on the warp is 30 μm-500 μm.

7. The composite backboard according to claim 1, characterized in that: The bending radius of the longitudinal glass fiber cloth and the transverse glass fiber cloth is 0.1-1m.

8. A photovoltaic module, characterized in that: From top to bottom, they include: The upper component includes a transparent layer and a high-resistance water-resistant adhesive film; Middle-layer components, including P-type or N-type cells; A lower layer component, comprising an adhesive film and a glass fiber composite back panel at the lower layer of the middle layer component; Wherein, the glass fiber composite backboard is the composite backboard described in any one of claims 1-7.

9. A photovoltaic module according to claim 8, characterized in that: The transparent layer is glass, ultra-thin glass or a transparent front plate.

10. A method for manufacturing a composite backplane as claimed in any one of claims 1 to 7, characterized in that: The following steps are included in sequence: Pre-impregnation with anti-ultraviolet impregnation liquid: the flattened glass fiber cloth is dipped in liquid anti-ultraviolet impregnation liquid, so that the anti-ultraviolet impregnation liquid and the glass fiber cloth are fully in contact, so that the surface of the glass fiber cloth is evenly stained with a layer of anti-ultraviolet impregnation liquid, and the fiber fabric after the dip-coating treatment is dried; The dipping treatment time is 5s-120s, the drying treatment temperature is 60°C-150°C, and the drying treatment time is 2min-30min; Shearing: Shearing the semi-finished product obtained above according to size requirements to obtain longitudinal glass fiber cloth and transverse glass fiber cloth; Bonding of glass fiber cloth: Apply adhesive to both sides of the polyethylene terephthalate layer, and co-extrude the longitudinal glass fiber cloth and the transverse glass fiber cloth in different directions and stick them on both sides of the polyethylene terephthalate layer to form a glass fiber functional support layer; wherein the co-extrusion temperature is 10℃-100℃, and the co-extrusion pressure is 50Pa-1000Pa; Co-extrusion to form a board: The weather-resistant layer, the first adhesive layer, the glass fiber functional support layer, the second adhesive layer and the heat-sealing layer are stacked in order from top to bottom, and the stacked pre-pressed parts are co-extruded to form a target board.

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