Flexible photovoltaic module and production method thereof

Abstract

The invention discloses a flexible photovoltaic module and a production method thereof. The flexible photovoltaic module comprises a front plate, a first EVA (Ethylene Vinyl Acetate) adhesive film, a battery piece, a second EVA adhesive film and a back plate, the flexible photovoltaic module produced by the production method provided by the invention is good in applicability, can be suitable for various scenes due to the flexible material, and can be attached to the surfaces of objects with various irregular shapes, such as bent roofs, arc-shaped building facades, automobile shells and the like; and the flexible photovoltaic module is light in weight, and the weight of the flexible photovoltaic module is far lower than that of a traditional rigid photovoltaic module, so that the requirement of the flexible photovoltaic module on a supporting structure in the installation process is low, and the installation difficulty and cost are reduced.

Description

Technical Field

[0001] The invention belongs to the field of flexible photovoltaic components, and in particular relates to a flexible photovoltaic component and a production method thereof. Background Art

[0002] Photovoltaic technology uses the photoelectric effect of semiconductor materials to directly convert solar energy into electrical energy. After years of development, it has achieved remarkable results. As the main application form of early photovoltaic technology, rigid photovoltaic modules have occupied an important position in the field of solar power generation. They are usually made of materials such as crystalline silicon or amorphous silicon, and have high conversion efficiency and stability. However, rigid photovoltaic modules also have some obvious limitations. Their hard and heavy characteristics make them subject to certain restrictions in installation and application scenarios. For example, on some curved or irregular surfaces, rigid photovoltaic modules are difficult to achieve close fitting installation, which not only affects the aesthetics, but also may reduce the efficiency of solar energy reception. In addition, rigid photovoltaic modules cannot meet actual needs in some occasions with strict weight requirements, such as portable devices, lightweight building structures, etc. Summary of the invention

[0003] In order to solve the defects in the prior art, the present invention discloses a flexible photovoltaic module, including a front plate, an EVA film, a battery sheet, two EVA films, and a back plate.

[0004] The present invention also discloses a method for producing a flexible photovoltaic module, comprising the following steps: S1-1: Connect the positive and negative electrodes of the battery string to form a series battery cell; S1-2: Lay the glass carrier 6 and the flexible photovoltaic module front plate 1, then lay a layer of EVA film 2, position and flatten it at a manual station, eliminate bubbles between the layers, and then fix them with tape; S2: Laying the series-connected battery sheets on a layer of EVA film 2, and connecting the series-connected battery sheets through bus bars to form a parallel connection; S3: Fixing the battery cell 3; S4: Perform EL testing on the surface of the laminated flexible photovoltaic modules. Good products will continue to the next process, and defective products will be repaired. S5: The qualified products after EL test are laid with two layers of EVA film 4 by a two-layer laying machine, and then covered with a back sheet 5; S6: After the back sheet 5 is laid, manual deviation correction is performed to position and fix the flexible photovoltaic module; S7: Manual laying of cover cloth 7; S8: The flexible photovoltaic module covered with the cover cloth 7 is laminated, and after the lamination is completed, the cover cloth 7 and the glass carrier 6 are recycled; S9: Trim and cut the tailings on the four sides of the flexible photovoltaic module to ensure that the four sides of the flexible photovoltaic module are smooth; S10: grinding the front plate 1 where the two bus bars 32 are located to expose the connection points; S11: placing the flexible photovoltaic module on a carrier plate; S12: Weld the grafting joints at the six connection points exposed by grinding in S10, and apply primer around the grafting joints; S13: Position and install three junction boxes 8, weld the junction boxes 8, and check whether there is a cold solder joint; S14: Filling the junction box 8 with glue; S15: transporting the flexible photovoltaic module to a curing room for curing; S16: After curing is completed, cover the junction box; S17: Carry out the final EL test and RV test, and classify the finished products; S18: Finished products leave the production line and the carrier board is recovered; S19: Finished product packaging.

[0005] Preferably, in S2, the bus bars are divided into three groups, namely one bus bar 31, two bus bars 32, and three bus bars 33. Each group of bus bars contains six small bars. One bus bar 31 and three bus bars 33 are distributed on both sides of the flexible photovoltaic component, and two bus bars 32 are distributed in the middle of the flexible photovoltaic component, and the three groups of bus bars have no bends.

[0006] Preferably, in S2, the battery cells of the second, fourth and sixth rows are laid out first, and then the battery cells of the first, third and fifth rows are laid out to form an AB string.

[0007] Preferably, in S7, the middle portion of the cover cloth 7 is hollowed out.

[0008] Preferably, in S10, the six small bus bars in the two bus bars 32 are grouped in pairs, for a total of three groups, and the front plate 1 at the positions of two adjacent end points of each group is polished to expose six wiring points.

[0009] Preferably, the cover cloth 7, the glass carrier 6 and the carrying plate are all reusable.

[0010] Compared with the prior art, the beneficial effects of the present invention are as follows: the flexible photovoltaic modules produced by the production method provided by the present invention have good applicability. Because of their flexible material, they can be used in a variety of scenarios and can be attached to the surfaces of various irregularly shaped objects, such as curved roofs, curved building facades, car shells, etc.; and the flexible photovoltaic modules are light in weight, and their weight is much lower than that of traditional rigid photovoltaic modules. This feature makes it have lower requirements on the supporting structure during the installation process, reducing the difficulty and cost of installation.

[0011] In the production method provided by the present invention, a cover cloth with a hollow middle portion is laid before lamination to facilitate integrated lamination, and the cover cloth 7 has a hollow middle portion, thereby reducing production costs; The busbar is not bent, which helps maintain low resistance, better ensures close and uniform contact with other components, reduces contact resistance, and ensures that current is stably transmitted from the battery cell to the external circuit. The busbar without bending has better rigidity and integrity, can better resist external forces, protect the battery cells and connection structures inside the photovoltaic module, avoid stress concentration, and reduce damage caused by mechanical stress, thereby extending the service life of the photovoltaic module; The cover cloth, glass carrier and carrier plate used can be recycled and reused, thereby controlling costs. BRIEF DESCRIPTION OF THE DRAWINGS

[0012] Figure 1 It is a schematic diagram of the positions of the various layers, cover cloth and glass carrier of the flexible photovoltaic module of the present invention; Figure 2 is a plan view of the flexible photovoltaic module of the present invention; Figure 3 It is a flow chart of the method for producing flexible photovoltaic modules in the present invention. DETAILED DESCRIPTION

[0013] 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.

[0014] See also Figure 1 The present invention provides a technical solution: a flexible photovoltaic module and a production method thereof, wherein the flexible photovoltaic module comprises a front plate 1, an EVA film 2, a battery cell 3, two EVA films 4, and a back plate 5.

[0015] The present invention also provides a technical solution: a method for producing a flexible photovoltaic module, comprising the following steps: S1-1: Connect the positive and negative electrodes of the battery string by a string welding machine to form a series battery cell; S1-2: Lay the glass carrier 6 and the flexible photovoltaic module front plate 1 through a glass loading machine, and then lay a layer of EVA film 2 through a layer laying machine, and position and flatten it at a manual station, eliminate bubbles between the layers, and then fix them with tape; S2: Lay the series-connected cells on a layer of EVA film 2, first lay the cells in rows 2, 4 and 6, then lay the cells in rows 1, 3 and 5, to form an AB string, which can improve power generation efficiency and component stability; connect the series-connected cells through bus bars through a stack welding machine to form a parallel connection; See also Figure 2 In S2, there are three groups of bus bars, namely one bus bar 31, two bus bars 32, and three bus bars 33. Each group of bus bars contains six small bars. One bus bar 31 and three bus bars 33 are distributed on both sides of the flexible photovoltaic component, and two bus bars 32 are distributed in the middle of the flexible photovoltaic component. There are no bends on the three groups of bus bars, so the surface of the flexible photovoltaic component has no protrusions and is a plane.

[0016] The busbar is not bent, which helps to maintain low resistance, better ensure close and uniform contact with other components, reduce contact resistance, and ensure that current is stably transmitted from the battery cell to the external circuit. The busbar without bending has better rigidity and integrity, can better resist external forces, protect the battery cells and connection structures inside the photovoltaic module, avoid stress concentration, reduce damage caused by mechanical stress, and thus extend the service life of the photovoltaic module. S3: Using a tape machine to stick tape on the battery cell 3 to fix the battery cell 3; S4: Use an EL detector to perform EL testing (Electroluminescence testing) on ​​the surface of the laminated flexible photovoltaic modules. Good products will continue to the next process, and defective products will be returned for repair after recording the defective location and defective information; S5: The qualified products after EL test are laid with two layers of EVA film 4 by a two-layer laying machine, and then covered with a back sheet 5; S6: After the back sheet 5 is laid, manual deviation correction is performed, barcodes are affixed, and the flexible photovoltaic module is positioned and fixed; S7: Manual laying of cover cloth 7; In S7, the cover cloth 7 can facilitate integrated lamination, and the middle part of the cover cloth 7 is hollowed out, thereby reducing production costs.

[0017] S8: The flexible photovoltaic module covered with the cover cloth 7 is laminated by a laminator. After the lamination is completed, the cover cloth 7 and the glass carrier 6 are recycled. The cover cloth 7 and the glass carrier 6 can be reused; S9: Trim and cut the tailings on the four sides of the flexible photovoltaic module to ensure that the four sides of the flexible photovoltaic module are smooth; S10: The six small bus bars in the two bus bars 32 are grouped in pairs, for a total of three groups, and the front plate 1 at the positions of two adjacent end points of each group is polished to expose six wiring points for subsequent installation of the wiring box 8; S11: placing the flexible photovoltaic module on a carrier plate; In S11, due to the material characteristics of the flexible photovoltaic modules, the supporting plate is used to transport the flexible photovoltaic modules to the subsequent process to ensure that the flexible photovoltaic modules are not bent during production. The surface of the supporting plate is made of soft velvet material to protect the flexible photovoltaic modules.

[0018] S12: Manually weld the grafting joints at the six connection points exposed by grinding in S10, and apply primer around the grafting joints by an automatic glue dispenser; S13: manually positioning and installing three junction boxes 8, welding the junction boxes 8 by an automatic welding machine, and then manually checking whether there is a cold solder joint; S14: Filling the junction box 8 with glue using an automatic glue filling machine to encapsulate the device so as to improve the performance of the flexible photovoltaic module; S15: transporting the flexible photovoltaic module to a curing room for curing, the curing time being 4 hours; S16: After curing is completed, cover the junction box; S17: Carry out the final EL test and RV test (Reverse Voltage test) to grade the finished products; S18: Finished products leave the production line, and the carrier plates are recovered. The carrier plates can be reused on the production line; S19: Finished product packaging.

[0019] For a complete flowchart, see Figure 3 .

[0020] The flexible photovoltaic modules produced by this production method have good applicability. Because of their flexible material, they can be used in a variety of scenarios and can be attached to the surfaces of various irregular shapes, such as curved roofs, curved building facades, car shells, etc.

[0021] Flexible photovoltaic modules are also lightweight, weighing much less than traditional rigid photovoltaic modules. This feature reduces the requirements for supporting structures during installation, reducing the difficulty and cost of installation.

[0022] It will be apparent to those skilled in the art that the invention is not limited to the details of the exemplary embodiments described above and that the invention can be implemented in other specific forms without departing from the spirit or essential features of the invention. Therefore, the embodiments should be considered in all respects as exemplary and non-restrictive, and the scope of the invention is defined by the appended claims rather than the foregoing description, and it is intended that all changes within the meaning and range of equivalents of the claims be included in the invention. Any reference numeral in a claim should not be considered as limiting the claim to which it relates.

[0023] Although embodiments of the present invention have been shown and described, it will be appreciated by those skilled in the art that various changes, modifications, substitutions and variations may be made to the embodiments without departing from the principles and spirit of the present invention, and that the scope of the present invention is defined by the appended claims and their equivalents.

Claims

1. A flexible photovoltaic module, characterized in that: It comprises a front plate (1), an EVA adhesive film (2), a battery cell (3), a second EVA adhesive film (4), and a back plate (5).

2. A method for producing a flexible photovoltaic module, characterized in that: The following steps are involved: S1-1: Connect the positive and negative electrodes of the battery string to form a series battery cell; S1-2: Laying the carrier and the flexible photovoltaic module front plate (1), and then laying a layer of EVA film (2), positioning and leveling at a manual workstation, eliminating bubbles between the layers, and fixing with tape; S2: Laying the series-connected battery sheets on a layer of EVA adhesive film (2), and connecting the series-connected battery sheets via bus bars to form a parallel connection, wherein the bus bars are in total three groups, namely, one bus bar (31), two bus bars (32), and three bus bars (33); S3: fixing the battery cell (3); S4: Perform EL testing on the surface of the laminated flexible photovoltaic modules. Good products will continue to the next process, and defective products will be repaired. S5: The qualified products that have passed the EL test are laid with two layers of EVA film (4) by a two-layer laying machine, and then covered with a backing plate (5); S6: After the back sheet (5) is laid, manual deviation correction is performed to position and fix the flexible photovoltaic module; S7: Manual laying of the cover cloth (7); S8: laminating the flexible photovoltaic module covered with the cover cloth (7), and after the lamination is completed, recycling the cover cloth (7) and the glass carrier (6); S9: Trim and cut the tailings on the four sides of the flexible photovoltaic module to ensure that the four sides of the flexible photovoltaic module are smooth; S10: grinding the front plate (1) where the two bus bars (32) are located to expose the connection points; S11: placing the flexible photovoltaic module on a carrier plate; S12: Weld the grafting joints at the six connection points exposed by grinding in S10, and apply primer around the grafting joints; S13: Position and install three junction boxes (8), weld the junction boxes (8), and check whether there is any cold solder joint; S14: Filling the junction box (8) with glue; S15: transporting the flexible photovoltaic module to a curing room for curing; S16: After curing is completed, cover the junction box; S17: Carry out the final EL test and RV test, and classify the finished products; S18: Finished products leave the production line and the carrier board is recovered; S19: Finished product packaging.

3. The method for producing a flexible photovoltaic module according to claim 2, characterized in that: In S1-2, the carrier is a glass carrier (6).

4. The method for producing a flexible photovoltaic module according to claim 2, characterized in that: In S2, each group of bus bars contains six small bars, one bus bar (31) and three bus bars (33) are distributed on both sides of the flexible photovoltaic module, and two bus bars (32) are distributed in the middle of the flexible photovoltaic module, and the three groups of bus bars are not bent.

5. The method for producing a flexible photovoltaic module according to claim 2, characterized in that: In S2, the battery cells in rows 2, 4 and 6 are laid out first, and then the battery cells in rows 1, 3 and 5 are laid out to form an AB string.

6. The method for producing a flexible photovoltaic module according to claim 2, characterized in that: In S7, the middle part of the cover cloth (7) is hollowed out.

7. The method for producing a flexible photovoltaic module according to claim 2, characterized in that: In S10, the six small bus bars in the two bus bars (32) are grouped in pairs, for a total of three groups, and the front plate (1) at the positions of two adjacent end points of each group is polished to expose six connection points.

8. The method for producing a flexible photovoltaic module according to claim 2, characterized in that: The cover cloth (7), the glass carrier (6) and the carrying plate are all reusable.

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