Manufacturing method of solar luminous card

Abstract

The invention discloses a manufacturing method of a solar luminous card. The manufacturing method comprises the following steps: step 1, manufacturing a solar power generation material into a power generation body; 2, spraying a pre-designed pattern on the transparent film; 3, a light-emitting unit and a control circuit are welded to the front face or the back face of the power generation body; and 4, laminating the transparent film with the pattern on the power generation body. According to the invention, the application of the solar material in a miniature scene, especially a gift card, can be realized, and the production cost of the solar material in the miniature scene is reduced.

Description

Technical Field

[0001] The invention relates to the field of new energy, and in particular to a method for manufacturing a solar luminous card. Background Art

[0002] Existing gift cards are generally made of materials such as cardboard, plastic or metal. They are popular with the public by designing exquisite patterns on the cards and cutting them into suitable shapes and sizes. In order to improve the aesthetic effect of the cards, some cards are also designed with light-emitting units, which use the changes in light and colors to express beauty. However, cards using light-emitting units in the prior art generally need to use batteries as power supply units, while the existing battery components are relatively bloated, and an independent battery component fixing structure needs to be set at the appropriate position of the card, which greatly affects the thinness, beauty, and portability of the card. In order to avoid the battery components being exposed, additional design methods are usually required to cover them, which greatly limits the freedom of card design and increases the difficulty of design. In addition, the battery has a certain service life. When the power is exhausted, the battery needs to be replaced, which causes inconvenience to use.

[0003] With the development of solar power generation material technology, applying solar cells to cards may solve the above problems. However, in the prior art, the mainstream application of solar power generation materials is in industrial scenes under larger environments, using solar power generation to power various large equipment, such as solar power plants, or installing them on roofs and walls to generate electricity, or powering field equipment such as street lights. At present, there are few cases where solar cells are applied to the personal consumer market, let alone solar cells are applied to gift cards. When applying solar cells to industrial scenes under larger environments, since the size of solar panels is generally larger than the smaller size required for application in micro environments, if the solar cell processing technology in the large scene is applied to the micro scene, additional cutting is required, which increases the difficulty of production, increases the defective rate, and leads to extremely high production costs. High cost and high selling price make it difficult to realize the market application of solar cells in micro scenes. The micro scene here refers to the use of solar cells in personal consumer products, and these personal consumer products are generally small, thin, portable and movable card products.

[0004] Therefore, technicians in this field are committed to developing a method for making solar luminous cards, which can apply solar power generation materials in micro-scenes, especially in luminous cards, to reduce production complexity and scrap rate, thereby reducing production costs and achieving marketization. Summary of the invention

[0005] To achieve the above object, the present invention provides a method for making a solar luminous card, comprising:

[0006] Step 1: Make the solar power generation material into a power generation body;

[0007] Step 2: Spray the pre-designed pattern on the transparent film;

[0008] Step 3: welding the light-emitting unit and the control circuit on the power generation body;

[0009] Step 4: Laminating the transparent film with the pattern on the power generation body.

[0010] Furthermore, the step 1 comprises:

[0011] Select the solar power generation material; this material needs to be easy to cut, easy to customize, shatterproof, and soft flexible thin film solar material

[0012] Calculating the voltage and current data of the solar power generation material and cutting them;

[0013] welding and connecting the cut solar power generation materials in series;

[0014] A water-blocking film is formed outside the solar power generation materials after being connected in series through a lamination process.

[0015] Furthermore, when cutting the solar energy material, cutting with a minimum area is achieved while satisfying the same voltage output.

[0016] Furthermore, the cut solar power generation materials are connected by heat welding, and a bus bar is arranged on the back of the solar power generation materials after heat welding, so as to connect the solar power generation materials in series.

[0017] Furthermore, the water-blocking film is a flexible, colorable waterproof film: EVA film, POE film or EPE film.

[0018] Furthermore, in the step 2, the pattern is sprayed on the inner surface or outer surface of the transparent film according to color requirements.

[0019] Furthermore, the position of the light-emitting unit on the power generation body is determined according to the light-emitting points obtained according to the pattern.

[0020] Furthermore, the pattern and the light-emitting unit are respectively located on different surfaces of the light-emitting body.

[0021] Furthermore, in step 4, a packaging layer is provided outside the transparent film. If the image and the power generation components are on the front of the power generation body, there are two layers of film in total, a water-blocking film for encapsulating the solar chip, and a waterproof packaging film with a color pattern, and a back plate is required on the back. If the image and the power generation components are on the back of the power generation body, the back includes a back plate, light-emitting components, and a packaging film printed with an image for packaging.

[0022] Furthermore, the method also includes step five: testing the solar luminous card.

[0023] The method for making solar luminous cards provided by the present invention can expand the application of solar energy materials in micro-scenes, especially in gift cards and bookmarks, breaking through the situation that traditional gift cards use traditional materials such as paper, plastic and metal as substrates, so that the luminous body and the support body of the card are the same part, greatly expanding the freedom of design. In addition, the present invention can reduce a large number of work steps in the technical process of applying solar energy materials in large scenes; after the work steps are reduced, the corresponding working hours are reduced in the same proportion; and after the complexity of the production process is greatly reduced, the defect rate is greatly reduced, and the production cost is reduced.

[0024] According to this production process, the generator body and busbar are packaged separately as an independent generator body, and other equipment and added components are packaged separately from the generator body, which can greatly reduce the packaging difficulty and reduce the defective rate. The double packaging is more solid and has a better waterproof effect than the previous single packaging.

[0025] The concept, specific structure and technical effects of the present invention will be further described below in conjunction with the accompanying drawings to fully understand the purpose, characteristics and effects of the present invention. BRIEF DESCRIPTION OF THE DRAWINGS

[0026] Figure 1 It is a flow chart of a manufacturing method of a preferred embodiment of the present invention;

[0027] Figure 2 It is a flow chart of making solar power generation materials into a power generation body in the present invention. DETAILED DESCRIPTION

[0028] The following describes several preferred embodiments of the present invention with reference to the drawings in the specification, so that the technical content is clearer and easier to understand. The present invention can be embodied in many different forms of embodiments, and the protection scope of the present invention is not limited to the embodiments mentioned in the text.

[0029] In the drawings, components with the same structure are indicated by the same numerical reference numerals, and components with similar structures or functions are indicated by similar numerical reference numerals. The size and thickness of each component shown in the drawings are arbitrarily shown, and the present invention does not limit the size and thickness of each component. In order to make the illustration clearer, the thickness of the components is appropriately exaggerated in some places in the drawings.

[0030] The present invention provides a method for making a solar luminous card, such as Figure 1 As shown, the following steps are included:

[0031] Step 1: Make the solar power generation material into a power generation body. For the specific steps, see Figure 2 .

[0032] 1. Select solar power generation materials. There are many different types of solar power generation materials in the prior art, such as monocrystalline silicon solar panels, polycrystalline solar panels, thin-film solar panels, compound solar cells, dye-sensitized cells and other types. In large-scale scenarios, the main thing is to do a good job of splicing solar power generation materials. You only need to splice pieces of materials into the required large size. However, in a micro environment, because the acceptable size is very small, most of them are smaller than the size of the smallest unit of solar materials. Therefore, in order to meet the requirements of small size and voltage and current at the same time, it is necessary to cut the smallest unit material and then splice it in series to achieve a current and voltage higher than the smallest unit. This process requires manual work, and the fine requirements become larger, which leads to complexity and low yield.

[0033] Different types of solar power generation materials have different base materials. In addition to the difference in conversion efficiency, they also have different mechanical properties. Different materials have different properties such as hardness and flexibility. In solar luminous cards, solar power generation materials not only serve as power supply components, but also constitute the carrier of the card (that is, light-emitting units, patterns and other components are set on the solar power generation materials. In other words, the power generation body made of solar power generation materials replaces the traditional paper, plastic, metal and other substrates used for cards). Cards not only have appearance color and aesthetic requirements, but also need to be passed around and played with frequently. Therefore, when selecting solar power generation materials, they need to have the characteristics of easy cutting, easy customization, anti-shattering, and soft flexible thin film solar materials. At the same time, it is also necessary to select suitable solar materials according to the designed cards, combined with the display effect of the card pattern and the application scenario of the card. It is necessary to consider the conversion efficiency, power parameters, hardness, flexibility, density and other factors of the solar luminescent materials, so that the final formed card has the characteristics of lightness, wear resistance and the like, and can also be well combined with the characteristics of the pattern to display the pattern.

[0034] 2. Calculate the voltage and current data of the solar energy material, and make the smallest and largest unit cuts. According to the voltage and current requirements of the designed card, combined with the power parameters of the selected solar energy material, the calculation is performed. The calculation principle is: to achieve the smallest area cut while meeting the same voltage output. At the same time, while meeting the same area requirements, the original size solar energy materials are reasonably laid out to minimize the cutting of raw materials, avoid material waste, and increase in additional labor costs due to excessive cutting. In addition, in the card provided by the present invention, power generation is not through any energy storage device, that is, solar energy is directly powered, so it is necessary to ensure that the current transmission is stable during cutting.

[0035] 3. Weld and connect the cut solar power generation materials in series. Connect the cut solar power generation materials by heat welding. The cut solar power generation materials are treated as a separate power generation unit and connected by heat welding. Preferably, for the strip-shaped power generation units, ensure that multiple power generation units are aligned. The welded multiple power generation units are treated as a whole, and a bus bar is set on the back of the welded multiple power generation units. The bus bar connects the separate power generation units in series in the form of positive and negative poles in series.

[0036] 4. Wrap the solar power generation material after welding and series connection with a water-blocking film, and then use the lamination process to finally form the power generation body. The water-blocking film can be a known adhesive film in the prior art, such as EVA film, POE film and EPE film. It should be understood that the specific material of the film does not constitute a limitation to this application, and even new materials that appear in the future technological development can be used in this application. Wrap the film around the power generation material, and according to the different temperature resistance conditions of the water-blocking film, laminate the power generation body and the busbar for 30 minutes at a temperature of 100 degrees to 160 degrees to form the power generation body.

[0037] The power generation body produced by the above steps realizes the modularization of the power generation body and has strong versatility, that is, luminous cards with different patterns, if they have the same shape and size, can all be applied to the power generation body produced by the above steps. For scenarios with high requirements for product flexibility and personalization, batch production of the power generation body can be achieved, thereby reducing production costs.

[0038] Step 2: Spray the pre-designed pattern on the transparent film. Preferably, spray it on the inner surface of the transparent film, that is, the side of the transparent film facing the power generation body when the transparent film is set on the power generation body, so as to prevent the pattern from being damaged by wear. The transparent film can be made of a thermoplastic elastomer layer or plastic. Generally speaking, the power generation body is in the form of a sheet, so the pattern of the transparent film can be located on the back or front of the power generation body (that is, the two surfaces with the largest area on the power generation body).

[0039] Step three: Weld the light-emitting unit and the control circuit on the power generation body. The position of the light-emitting unit on the power generation body needs to be determined according to the designed pattern. Specifically, the light-emitting points of the pattern can be obtained according to the designed pattern. These light-emitting points help to improve the overall aesthetics of the pattern, so that the pattern can obtain the most optimized display effect. Then connect the light-emitting unit to the position corresponding to the light-emitting point on the power generation body. The light-emitting unit can use an LED light source, preferably, a patch micro LED light source, and the light source voltage is 2V or 3V. Of course, according to the display effect of the pattern, other shapes of light sources can also be selected, so as to present a three-dimensional display effect. Preferably, the positive and negative poles of the LED light source can be welded to the positive and negative bus bars of the power generation body.

[0040] Preferably, the pattern and the light-emitting unit are located on different sides of the power generation body (i.e., a faceted solution). The faceted design can avoid the problem of high-definition pattern color and power generation efficiency affecting each other, and can maintain the original color of the pattern without affecting the power generation efficiency. The faceted design can also reduce material and labor costs. The lamination requirements for the cut power generation material itself are relatively high, such as 140-160 degree temperature, specific lamination time and special lamination film. The high requirements are mainly to ensure that the power generation material is well isolated from air moisture, etc., to ensure its longer and more stable service life, while avoiding the influence of image color on power generation power. If you choose the front side, that is, the side used for power generation, then different graphic colors need to be separately tested for their impact on power.

[0041] Step 4: Use a lamination process to laminate a transparent film with a pattern on the power generation body, thereby laminating the light-emitting unit, the power generation body, and the transparent film together. It should be understood that an encapsulation layer can also be provided outside the transparent film to further improve the wear resistance and corrosion resistance of the card, thereby increasing the service life. The encapsulation layer can be provided on the back and front of the power generation body after laminating the transparent film, or it can completely wrap the power generation body. The encapsulation layer can be made of glass, plastic and other materials. It should be noted that as long as the encapsulation layer is transparent and has wear resistance and corrosion resistance, its specific material is not specifically limited.

[0042] Step 5: Test the product formed in step 4. Step 5 is not a necessary step for this application, but is a corresponding test to improve product quality. The test content can be set according to actual needs, including but not limited to waterproof, moisture-proof, drop-proof, folding life, luminous detection and other test contents.

[0043] The preferred specific embodiments of the present invention are described in detail above. It should be understood that ordinary technicians in the field can make many modifications and changes based on the concept of the present invention without creative work. Therefore, all technical solutions that can be obtained by technicians in the technical field based on the concept of the present invention through logical analysis, reasoning or limited experiments on the basis of the prior art should be within the scope of protection determined by the claims.

Claims

1. A method for making a solar luminous card, characterized in that: include: Step 1: Make the solar power generation material into a power generation body; Step 2: Spray the pre-designed pattern on the transparent film; Step 3: welding the light-emitting unit and the control circuit on the power generation body; Step 4: Laminating the transparent film with the pattern on the power generation body.

2. The method according to claim 1, characterized in that: The step one comprises: Selecting the solar power generation material; Calculating the voltage and current data of the solar power generation material and cutting them; welding and connecting the cut solar power generation materials in series; A water-blocking film is formed outside the solar power generation materials after being connected in series through a lamination process.

3. The method according to claim 2, characterized in that: When cutting the solar energy material, cutting with a minimum area is achieved while satisfying the same voltage output.

4. The method according to claim 2, characterized in that: The cut solar power generation materials are connected by heat welding, and a bus bar is arranged on the back of the solar power generation materials after heat welding, so as to connect the solar power generation materials in series.

5. The method according to claim 2, characterized in that: The water-blocking film is selected from EVA film, POE film or EPE film.

6. The method according to claim 1, characterized in that: In the step 2, the pattern is sprayed on the inner surface of the transparent film.

7. The method according to claim 1, characterized in that: The position of the light-emitting unit on the power generation body is determined according to the light-emitting points obtained according to the pattern.

8. The method according to claim 1, characterized in that: The pattern and the light-emitting unit are respectively located on different surfaces of the light-emitting body.

9. The method according to claim 1, characterized in that: In the step 4, a packaging layer is provided outside the transparent film.

10. The method according to claim 1, characterized in that: The method also includes step five: testing the solar luminous card.

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