Manufacturing method of vacuum compaction type photovoltaic photo-thermal coupling structure

Abstract

The invention provides a manufacturing method of a vacuum compaction type photovoltaic photo-thermal coupling structure. The manufacturing method comprises the following steps: preparing a semitransparent photovoltaic cell; preparing a photo-thermal reflecting mirror; and the semitransparent photovoltaic cell and the photo-thermal reflecting mirror are coupled and connected in a vacuum compaction mode. Reliable connection between the semitransparent photovoltaic cell and the photo-thermal reflecting mirror is achieved in a vacuum compaction mode, use of mechanical structures and fixing parts can be effectively reduced, the manufacturing cost and the installation difficulty are reduced, light reflection loss of an interface air layer can be eliminated through the vacuum environment, the overall efficiency of a photoelectric and photo-thermal system is improved, and the service life of the photovoltaic and photo-thermal system is prolonged. The manufactured vacuum compaction type photovoltaic photo-thermal coupling structure has a good light transmission effect and durability, is better in structural stability, can be applied to a tower type photo-thermal power station, a groove type photo-thermal power station, a Fresnel type photo-thermal power station, a disc type photo-thermal power station and other photo-thermal power stations, and has wide application prospects. The device is especially suitable for an efficient concentrated photovoltaic photo-thermal integrated system requiring high sealing performance and high stability.

Description

Technical Field

[0001] The present invention relates to the technical field of photovoltaic-thermal coupling structure manufacturing, and in particular to a method for manufacturing a vacuum compaction photovoltaic-thermal coupling structure. Background Art

[0002] Photovoltaic-thermal coupling system has shown great potential in centralized energy utilization, especially in solar thermal power stations, which can organically combine photovoltaic power generation with thermal energy collection to achieve efficient utilization of energy in multiple dimensions. Photovoltaic modules are responsible for absorbing and converting short-wave light energy into electrical energy, while photothermal reflectors focus and convert medium- and long-wave light energy into thermal energy, thereby greatly improving the overall energy efficiency of the entire system. This technology is not only suitable for the centralized utilization of large-scale clean energy, but also provides an important solution to address the challenges of global energy demand growth and carbon emissions.

[0003] However, in centralized applications with high temperature and high pressure, the combination of rigid welding and mechanical fixation may have great limitations. The welding method has high requirements for the thermal expansion matching of the materials, and is prone to interface fatigue and crack propagation problems under long-term high-temperature operation; the mechanical fixation method may cause the infiltration of air, moisture or impurities due to insufficient sealing performance of the contact surface, thereby affecting the performance of photovoltaic modules and reflectors. In addition, these combination methods are usually difficult to maintain long-term stability under complex terrain and dynamic load conditions, limiting their application in large-scale photovoltaic thermal power stations. Summary of the invention

[0004] In view of the above problems, the present invention proposes a method for manufacturing a vacuum compacted photovoltaic thermal coupling structure, which achieves high-strength bonding and perfect sealing performance by forming a vacuum between a semi-transparent photovoltaic cell and a thermal reflector and applying a compaction force. This method effectively avoids the effects of thermal expansion and gas penetration on the interface, ensuring the reliability and durability of the system in a high temperature and high pressure environment. In addition, the vacuum compaction method between the semi-transparent photovoltaic cell and the thermal reflector also reduces heat conduction losses, further improving the thermal energy collection efficiency of the thermal reflector. The vacuum compacted photovoltaic thermal coupling structure is particularly suitable for high-demand scenarios such as concentrated solar power stations and industrial heat supply, providing a strong guarantee for improving the reliability and economy of the energy system.

[0005] The present invention provides a method for manufacturing a vacuum compaction photovoltaic thermal coupling structure, which specifically includes:

[0006] Preparation of semi-transparent photovoltaic cells;

[0007] Preparation of photothermal reflectors;

[0008] The semi-transparent photovoltaic cell is coupled with the photothermal reflector by vacuum compaction to form a vacuum compaction photovoltaic photothermal coupling structure.

[0009] The vacuum compaction photovoltaic-thermal coupling structure can be applied to tower-type solar thermal power stations, trough-type solar thermal power stations, Fresnel-type solar thermal power stations, dish-type solar thermal power stations and other solar thermal power stations. The vacuum compaction photovoltaic-thermal coupling structure is suitable for high-efficiency centralized photovoltaic-thermal integration systems that require high sealing and high stability, and is particularly suitable for applications that require low heat loss.

[0010] According to a method for manufacturing a vacuum compaction photovoltaic thermal coupling structure provided by the present invention, a semi-transparent photovoltaic cell is coupled and connected with a thermal reflector by a fully encapsulated plastic vacuum compaction method, specifically comprising:

[0011] Precisely cut and clean semi-transparent photovoltaic cells and photothermal reflectors to ensure a clean and dust-free surface;

[0012] Placing a semi-transparent photovoltaic cell on the surface of the photothermal reflector and adjusting the semi-transparent photovoltaic cell to be precisely aligned with the photothermal reflector;

[0013] The semi-transparent photovoltaic cells and the photothermal reflectors are completely wrapped with heat-shrinkable plastic film;

[0014] Use an edge banding machine or heating tool to heat seal the edges of the heat shrinkable plastic film to form a completely closed structure;

[0015] A vacuum pump is used to extract the air inside the heat shrinkable plastic film to eliminate the air gap between the semi-transparent photovoltaic cell and the surface of the photothermal reflector;

[0016] The wrapped semi-transparent photovoltaic cell and the photothermal reflector assembly are heated, and the heat shrinkable plastic film is evenly heated by infrared heating or a hot air gun to shrink the heat shrinkable plastic film so that the semi-transparent photovoltaic cell and the photothermal reflector are tightly fitted.

[0017] Wherein, the heat shrinkable plastic film is a polyvinyl butyral film or a polyester heat shrinkable film.

[0018] According to a method for manufacturing a vacuum compaction photovoltaic thermal coupling structure provided by the present invention, a semi-transparent photovoltaic cell is coupled with a thermal reflector by a semi-encapsulated vacuum compaction method, specifically comprising:

[0019] Precisely cut and clean semi-transparent photovoltaic cells and photothermal reflectors to ensure a clean and dust-free surface;

[0020] Placing a semi-transparent photovoltaic cell on the surface of the photothermal reflector and adjusting the semi-transparent photovoltaic cell to be precisely aligned with the photothermal reflector;

[0021] Highly weather-resistant packaging materials are used to seal the outer edges of the components of the semi-transparent photovoltaic cells and the photothermal reflectors to form a closed cavity;

[0022] The closed cavity is evacuated by a vacuum pump to eliminate the air gap between the semi-transparent photovoltaic cell and the surface of the photothermal reflector;

[0023] The semi-transparent photovoltaic cell and the photothermal reflector are subjected to a heat pressing treatment by a constant temperature heat pressing device, so that the semi-transparent photovoltaic cell and the photothermal reflector are closely fitted together;

[0024] The edges of the components of the semi-transparent photovoltaic cells and the photothermal reflectors are then packaged and sealed.

[0025] Wherein, the highly weather-resistant packaging material is a fluorinated polymer film or a polyurethane film.

[0026] According to a method for manufacturing a vacuum compacted photovoltaic-thermal coupling structure provided by the present invention, a semi-transparent photovoltaic cell is coupled to a photothermal reflector by vacuum compaction of a fully-enclosed flexible airbag, specifically comprising:

[0027] A flexible semi-transparent photovoltaic cell and a curved photothermal reflector are used, the flexible semi-transparent photovoltaic cell is placed on the surface of the curved photothermal reflector, and the position is adjusted so that the flexible semi-transparent photovoltaic cell and the curved photothermal reflector are completely fitted together;

[0028] The assembly of the flexible semi-transparent photovoltaic cell and the curved photothermal reflector is placed inside the flexible airbag;

[0029] The inside of the flexible airbag is evacuated by a vacuum pump, so that the flexible airbag shrinks under the internal negative pressure and is tightly wrapped around the outside of the component to eliminate the air gap between the flexible semi-transparent photovoltaic cell and the surface of the curved photothermal reflector, thereby ensuring that the flexible semi-transparent photovoltaic cell and the curved photothermal reflector fit tightly together;

[0030] The vacuum interface of the flexible airbag is sealed.

[0031] Wherein, the flexible airbag is made of polyimide or polyvinyl butyral material.

[0032] According to a method for manufacturing a vacuum compaction photovoltaic-thermal coupling structure provided by the present invention, a semi-transparent photovoltaic cell is coupled and connected with a photothermal reflector by vacuum compaction of a vacuum grid, specifically comprising:

[0033] Laying and bonding a micron-scale vacuum grid layer on the surface of the photothermal reflector, bonding a semi-transparent photovoltaic cell to the micron-scale vacuum grid layer, and precisely aligning the position of the semi-transparent photovoltaic cell with the photothermal reflector;

[0034] The outer edges of the components of the semi-transparent photovoltaic cells and the photothermal reflectors are sealed with nano-encapsulation materials;

[0035] The inside of the micron-scale vacuum grid layer is evacuated by a vacuum pump to create a high negative pressure inside the micron-scale vacuum grid layer, thereby eliminating the air gap between the semi-transparent photovoltaic cell and the surface of the photothermal reflector, and ensuring that the semi-transparent photovoltaic cell and the photothermal reflector are tightly fitted through the micron-scale vacuum grid layer.

[0036] Wherein, the micron-scale vacuum grid is made of nanoporous material, the nanoporous material is a silicon dioxide film or an aluminum oxide film, and the nano packaging material is a fluorinated polymer film or a polyurethane film.

[0037] The manufacturing method of the vacuum compaction type photovoltaic thermal coupling structure provided by the present invention can effectively reduce the use of mechanical structures and fixings, and reduce the manufacturing cost and installation difficulty, because the vacuum compaction method is used to achieve a reliable connection between the semi-transparent photovoltaic cell and the thermal reflector. The adhesive photovoltaic thermal coupling structure made by the manufacturing method provided by the present invention can be applied to tower-type thermal power stations, trough-type thermal power stations, Fresnel-type thermal power stations, dish-type thermal power stations and other thermal power stations. The vacuum compaction type photovoltaic thermal coupling structure is suitable for high-efficiency centralized photovoltaic thermal integration systems that require high sealing and high stability, and is particularly suitable for applications that require low heat loss. BRIEF DESCRIPTION OF THE DRAWINGS

[0038] In order to more clearly illustrate the specific implementation methods of the present invention or the technical solutions in the prior art, the drawings required for use in the specific implementation methods or the description of the prior art will be briefly introduced below. Obviously, the drawings described below are some implementation methods of the present invention. For ordinary technicians in this field, other drawings can be obtained based on these drawings without paying creative work.

[0039] Figure 1 This is a flow chart of the manufacturing method of the vacuum compaction photovoltaic thermal coupling structure of the present invention;

[0040] Figure 2 A schematic diagram of a vacuum compaction photovoltaic thermal coupling structure manufactured using an embodiment of the present invention;

[0041] Figure 3 Another schematic diagram of a vacuum compaction photovoltaic thermal coupling structure manufactured using an embodiment of the present invention.

[0042] Description of reference numerals:

[0043] 1. Semi-transparent photovoltaic cells;

[0044] 2. Photothermal reflector;

[0045] 3. Micron-level vacuum grid layer;

[0046] 4. Packaging materials. DETAILED DESCRIPTION

[0047] The technical solution of the present invention will be clearly and completely described below in conjunction with the embodiments. Obviously, the described embodiments are part of the embodiments of the present invention, rather than 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.

[0048] In the description of the present invention, it should be understood that the terms "center", "longitudinal", "lateral", "length", "width", "thickness", "up", "down", "front", "back", "left", "right", "vertical", "horizontal", "top", "bottom", "inside", "outside", "clockwise", "counterclockwise" and the like indicate orientations or positional relationships based on the orientations or positional relationships shown in the accompanying drawings, and are only for the convenience of describing the present invention and simplifying the description, and do not indicate or imply that the referred device or element must have a specific orientation, be constructed and operated in a specific orientation, and therefore should not be understood as limiting the present invention.

[0049] In addition, the terms "first" and "second" are only used for descriptive purposes and cannot be understood as indicating or implying relative importance or implicitly indicating the number of technical features indicated. Therefore, the features defined as "first" and "second" may explicitly or implicitly include one or more of the features. In the description of the present invention, "multiple" means two or more, unless otherwise clearly and specifically defined. In addition, the terms "installed", "connected" and "connected" should be understood in a broad sense, for example, it can be a fixed connection, a detachable connection, or an integral connection; it can be a mechanical connection or an electrical connection; it can be a direct connection, or it can be indirectly connected through an intermediate medium, or it can be the internal connection of two components. For those of ordinary skill in the art, the specific meanings of the above terms in the present invention can be understood according to specific circumstances.

[0050] like Figures 1 to 3 As shown, the manufacturing method of the vacuum compaction photovoltaic thermal coupling structure of the embodiment of the present invention includes:

[0051] Preparation of semi-transparent photovoltaic cell 1;

[0052] Prepare a photothermal reflector 2;

[0053] The semi-transparent photovoltaic cell 1 is coupled and connected with the photothermal reflector 2 by means of vacuum compaction to form a vacuum compaction photovoltaic photothermal coupling structure.

[0054] The embodiment of the present invention adopts a vacuum compaction method to achieve a reliable connection between the semi-transparent photovoltaic cell 1 and the photothermal reflector 2, which can effectively reduce the use of mechanical structures and fixings, reduce manufacturing costs and installation difficulties, and eliminate light reflection losses in the interface air layer through a vacuum environment, thereby not only improving the overall efficiency of the photovoltaic and photothermal systems, but also the vacuum compaction photovoltaic photothermal coupling structure has good light transmission effects and durability, and better structural stability.

[0055] The vacuum compaction type photovoltaic thermal coupling structure made by the embodiment of the present invention can be applied to tower type photovoltaic power stations, trough type photovoltaic power stations, Fresnel type photovoltaic power stations, dish type photovoltaic power stations and other photovoltaic power stations. The vacuum compaction type photovoltaic thermal coupling structure is suitable for high-efficiency centralized photovoltaic thermal integration systems that require high sealing and high stability, especially for applications that require low heat loss. The vacuum compaction type photovoltaic thermal coupling structure is also suitable for high-temperature working environments, because the material in a vacuum state can effectively resist thermal expansion and has good sealing, which is suitable for long-term stable operation in high-temperature environments, such as centralized photovoltaic power stations. For applications that need to withstand greater mechanical pressure, such as large photovoltaic thermal coupling collectors, the vacuum compaction type photovoltaic thermal coupling structure can provide strong structural strength and sealing performance.

[0056] The preparation of semi-transparent photovoltaic cells, the preparation of photothermal reflectors and the specific method of coupling the two are described in detail below.

[0057] 1. Preparation process of semi-transparent photovoltaic cells

[0058] The semi-transparent photovoltaic cell of this embodiment can be a semi-transparent perovskite solar cell, a semi-transparent quantum dot solar cell, a semi-transparent dye-sensitized solar cell or a semi-transparent organic solar cell. The structure of the semi-transparent photovoltaic cell includes: a substrate, a first transparent electrode, an electron transport layer, a light absorption layer, a hole transport layer, a second transparent electrode and an encapsulation layer. The specific preparation process is as follows:

[0059] 1. Choose glass or flexible polymer materials (such as PET, PI, etc.) to make the substrate, and then use deionized water, ethanol and acetone to ultrasonically clean the substrate in turn to remove surface impurities. Then blow the substrate dry with nitrogen, and treat the substrate surface with UV-Ozone or plasma to improve wettability.

[0060] 2. Use ITO (indium tin oxide), FTO (fluorine-doped tin oxide) and other materials as the deposition material of the first transparent electrode, deposit a thin film on the substrate by magnetron sputtering or thermal evaporation to form the first transparent electrode, and then anneal the first transparent electrode (annealing temperature is controlled at 500°C, annealing time is controlled at 30 minutes) to improve conductivity and light transmittance.

[0061] 3. Prepare the electron transport layer by spin coating or slit coating. The material of the electron transport layer can be titanium dioxide, tin dioxide, C60 and other materials (the spin coating speed can be set to 5000 rpm, and the spin coating time can be controlled within 30 seconds), and then anneal in air (the annealing temperature is controlled at 150°C, and the annealing time is controlled within 30 minutes).

[0062] 4. Prepare a perovskite precursor solution (such as a solution of lead iodide + MAI in DMF / DMSO). Then coat the perovskite layer on the electron transport layer by spin coating. Spin coating can be done by step-by-step spin coating (such as first spin coating at 1000 rpm for 10 seconds, then spin coating at 3000 rpm for 30 seconds). During the spin coating process, drop an anti-solvent (such as chloroform, toluene, etc.) to induce perovskite crystallization. Then place the prepared substrate in a hot plate for heating and annealing (such as the annealing temperature is controlled at 100°C and the annealing time is controlled at 20 minutes) to form a uniform light absorption layer.

[0063] 5. Use materials such as Spiro-OMeTAD and PEDOT:PSS to prepare a hole transport layer on the perovskite light absorption layer by spin coating or slit coating, and then place it in the air to promote doping.

[0064] 6. Deposition of the second transparent electrode:

[0065] The second transparent electrode is deposited on the hole transport layer by magnetron sputtering, electron beam evaporation or the like, wherein the material of the second transparent electrode can be a transparent conductive oxide such as ITO, FTO or the like.

[0066] 7. Use epoxy resin or polymer packaging film to cover and encapsulate the entire device to prevent moisture and oxygen in the environment from corroding the perovskite material. Encapsulate under vacuum and perform UV curing or hot pressing.

[0067] 2. Preparation process of photothermal reflector

[0068] The structure of the photothermal reflector of this embodiment includes: a glass substrate, a metal coating, a spectrum separation layer and a nano anti-reflection coating. The preparation process of the photothermal reflector includes the steps of selecting the material of the reflector, a molding process, setting the spectrum separation layer, and depositing the nano anti-reflection coating. The photothermal reflector achieves more efficient light energy utilization through the multiple settings of the spectrum separation layer and the nano anti-reflection coating. The specific preparation process is as follows:

[0069] 1. Use a high reflectivity metal material (such as aluminum, silver, etc.) to coat the glass substrate to form a reflector body to ensure that the reflectivity is above 90%. The reflector body can be a flat structure or a curved structure according to actual use requirements.

[0070] When the main body of the reflector adopts a curved structure, the glass substrate needs to be processed into a micro-curved or curved surface through hot bending or vacuum forming technology. Alternatively, a flexible polymer substrate material (such as PI film) is used to replace the glass substrate to make the reflector lightweight and impact-resistant.

[0071] 2. Select double-layer or multi-layer dielectric films (such as silicon dioxide, aluminum oxide, etc.) as the spectrum separation layer to control the transmission and reflection of light of different wavelengths.

[0072] Using electron beam evaporation, silicon dioxide and aluminum oxide are alternately deposited on the surface of the reflector. The thickness of each layer of silicon dioxide and aluminum oxide is controlled between 5 and 100 nanometers to ensure high reflectivity of ultraviolet-visible light and allow infrared light to pass through. The thickness and refractive index of the multilayer film are optimized, and the interference principle is used to achieve spectral selective reflection and maximize the light absorption rate of the photovoltaic cell.

[0073] 3. Use the sol-gel method or electron beam evaporation method to deposit a nano anti-reflection coating on the surface of the spectrum separation layer to ensure uniform distribution and improve the light transmission performance of the reflector. Among them, the nano anti-reflection coating selects hydrophobic and high-temperature resistant materials (such as silicon dioxide, fluoride, etc.), and the thickness of the nano anti-reflection coating is controlled at 100 to 200 nanometers to reduce light reflection losses and improve the weather resistance of the reflector. Self-cleaning nanoparticles (such as titanium dioxide) can also be used as additives for the nano anti-reflection coating to give the mirror a self-cleaning function while maintaining high light transmittance.

[0074] 4. Plasma surface treatment is performed on the nano anti-reflection coating to improve its chemical stability in high temperature environments. The prepared photothermal reflector is then placed under simulated high temperature conditions for aging testing to ensure that the reflector maintains efficient optical performance when exposed to high temperature environments for a long time.

[0075] 3. Coupling process of semi-transparent photovoltaic cells and photothermal reflectors

[0076] Coupling semi-transparent photovoltaic cells with photothermal reflectors by vacuum compaction can be achieved in several ways.

[0077] 1. Prepare by all-inclusive plastic sealing and vacuum compaction:

[0078] During the preparation process, the semi-transparent photovoltaic cells and photothermal reflectors need to be precisely cut and cleaned to ensure that their surfaces are dust-free and clean to provide the best contact conditions. Subsequently, a suitable heat-shrinkable plastic film is selected as the packaging material. The plastic must have high mechanical strength, thermal stability and air tightness. Commonly used materials include polyvinyl butyral (PVB) and polyester heat-shrinkable film (PETG). The thickness of the plastic film should take into account the flexibility and protection of the material to ensure that there will be no damage or reduction in sealing performance during processing.

[0079] During the assembly process, the photovoltaic cells are precisely placed on the surface of the photothermal reflector and their positions are adjusted according to the design requirements. After the photovoltaic module and the reflector are aligned, the entire module is wrapped with heat-shrinkable plastic film. When wrapping, it is necessary to reserve appropriate edge margins for subsequent heat sealing operations. To ensure airtightness, the edges of the plastic film are heat-sealed using an edge banding machine or heating tool to form a completely enclosed structure. Then, the air inside the plastic film is extracted using a vacuum pump. The vacuum operation can not only effectively eliminate the air gap between the photovoltaic cell and the reflector surface, thereby improving the optical and thermal transmission efficiency, but also prevent the long-term corrosion of the module by oxidizing substances in the air.

[0080] Finally, the wrapped components are heated, and the plastic film is evenly heated using infrared heating or a hot air gun to cause thermal shrinkage. This thermal shrinkage can further enhance the fit of the plastic film, allowing it to fit tightly to the surface of the photovoltaic cell and the photothermal reflector to form a highly stable structure. At the same time, the heat-sealed plastic film can also provide waterproof, dustproof and certain mechanical protection, significantly improving the service life and environmental adaptability of the components. The key to this process lies in the selection of heat-shrinkable plastics and the precise control of heating parameters, which must ensure the sealing of the components while avoiding thermal damage to the functional layers of the photovoltaic cells or photothermal reflectors. This method can not only effectively improve the coupling efficiency of photovoltaics and photothermal reflectors, but also significantly reduce manufacturing costs, providing technical support for large-scale promotion and application.

[0081] 2. Preparation by vacuum compaction in a semi-enclosed cavity:

[0082] The use of vacuum compaction to achieve reliable coupling connection between semi-transparent photovoltaic cells and photothermal reflectors is an advanced technology that takes into account both efficient optical transmission and environmental stability, and is particularly suitable for the assembly of large photovoltaic modules. The process flow is as follows:

[0083] First, prepare semi-transparent photovoltaic cells and photothermal reflectors to ensure that their surface finish meets industrial standards. Photovoltaic cells need to have high light transmittance and photoelectric conversion efficiency, while photothermal reflectors need to have high reflectivity and thermal stability. In order to optimize the interface optical performance, the back of the photovoltaic cell can be designed as an anti-reflection layer or set with an appropriate anti-reflection film to further reduce scattering and reflection losses.

[0084] During the assembly process, the semi-transparent photovoltaic cells are precisely placed on the photothermal reflectors to ensure that they are aligned and there is no obvious gap. Then, the outer edges of the two are sealed with highly weather-resistant encapsulation materials. Commonly used encapsulation materials include fluorinated polymer films (such as ETFE films) or polyurethane films. These materials not only have excellent mechanical strength and flexibility, but also have the characteristics of UV resistance, moisture resistance, and corrosion resistance, and can work stably for a long time in harsh outdoor environments. The encapsulation material is firmly connected to the edge of the component through hot melt adhesive or UV curing adhesive to form a closed cavity with extremely high airtightness.

[0085] Subsequently, a vacuum pump is used to evacuate the closed cavity through a preset vacuum interface. The vacuum treatment can effectively eliminate the gas interference between the semi-transparent photovoltaic cell and the photothermal reflector, eliminate the interface air gap, and reduce the energy loss caused by light scattering and reflection, thereby improving the optical and thermal coupling efficiency. The degree of vacuuming needs to be precisely controlled according to the application requirements, and the vacuum degree is usually required to be below 1Pa to ensure full fit of the interface.

[0086] After the vacuum treatment is completed, the photovoltaic cells and reflectors are further fixed in place by hot pressing technology. This process can use constant temperature hot pressing equipment to evenly heat the components. The heating temperature is usually controlled between 60-80°C to avoid high temperature damage to the sensitive material layer of the photovoltaic cells. The components after hot pressing not only have high optical performance, but also have excellent mechanical stability.

[0087] Finally, the edge of the module is sealed again with edge sealing materials to enhance the sealing performance and improve the overall resistance to water vapor intrusion. After the above process, the photovoltaic thermal coupling module prepared has excellent performance in photoelectric conversion efficiency, thermal management performance and environmental adaptability, especially the long-term stability in high temperature and strong ultraviolet environment, which provides reliable guarantee for the application of large-scale photovoltaic thermal integration system.

[0088] 3. Preparation by vacuum compaction of all-inclusive flexible airbags:

[0089] The use of flexible airbag vacuum compaction to achieve reliable coupling between semi-transparent photovoltaic cells and photothermal reflectors is an innovative technology that takes into account both efficient optical performance and thermal stress buffering capabilities. It is particularly suitable for the combination of curved photothermal reflectors and flexible semi-transparent photovoltaic cells. The process, materials and implementation steps of this method are as follows:

[0090] First, prepare flexible semi-transparent photovoltaic cells and curved photothermal reflectors. Flexible photovoltaic cells are lightweight in design, and their structure should have high flexibility and transmittance. The surface is usually coated with an anti-reflection film to improve the photoelectric conversion efficiency. Photothermal reflectors use high-reflectivity metal or ceramic coatings and are precisely processed on the curved surface to ensure optical performance.

[0091] Place the flexible semi-transparent photovoltaic cell on the surface of the curved photothermal reflector and make preliminary adjustments to ensure that the two fit perfectly. To reduce the interface gap, a thin film interface material, such as transparent thermally conductive silicone or low-viscosity polymer resin, can be applied to the back of the photovoltaic cell to fill the tiny gaps and further optimize thermal conductivity and optical contact.

[0092] Next, the photovoltaic cell and reflector assembly are placed inside the flexible airbag. The flexible airbag is made of transparent polymer material, and the recommended material is polyimide (PI) or polyvinyl butyral (PVB). Its excellent high temperature resistance and UV resistance can ensure long-term stable operation in harsh outdoor environments. The thickness of the airbag material is usually controlled at 10 to 30 microns to achieve high light transmittance and low light absorption loss, while having sufficient mechanical strength to withstand vacuum negative pressure.

[0093] Connect the vacuum port of the airbag through a vacuum pump and start the vacuuming process. During the vacuuming process, the flexible airbag will gradually shrink under the internal negative pressure and tightly wrap around the outside of the photovoltaic cell and photothermal reflector assembly. This process not only eliminates the air layer between the photovoltaic cell and the reflector, but also ensures the close fit of the assembly at the interface through the uniform pressure distribution of the airbag, thereby reducing optical reflection loss and optimizing energy transfer efficiency.

[0094] The flexible design of the airbag can effectively buffer the stress caused by thermal expansion and contraction, and is particularly suitable for applications with curved structures or complex environments with large temperature differences. To ensure the final coupling effect, low-temperature heating treatment (e.g. 50-70°C) can be combined during the vacuuming process to allow the interface material on the back of the photovoltaic cell to fully flow and solidify, thereby further enhancing the adhesion strength and thermal conductivity of the interface.

[0095] Finally, the vacuum interface of the airbag is sealed by a sealing device to complete the sealing process of the component. This method not only improves the interface stability between the photovoltaic cell and the photothermal reflector, but also provides the system with good environmental adaptability, especially suitable for complex scenes with high temperature, high ultraviolet rays and curved photothermal structures. The overall process is simple and efficient, and the material has excellent optical, mechanical and thermal properties, providing important support for flexible photovoltaic and photothermal integration technology.

[0096] 4. Preparation by vacuum grid vacuum compaction:

[0097] The coupling connection between the semi-transparent photovoltaic cell and the photothermal reflector is realized by using a micron-scale vacuum grid layer, and the process flow is highly accurate and stable. First, a micron-scale vacuum grid layer is laid on the surface of the photothermal reflector. The grid layer is made of high-performance nanoporous materials, such as silicon dioxide film or aluminum oxide film, with a regular microporous structure, a pore size controlled at 0.1 to 5 microns, and a thickness range of 10 to 100 microns. This design not only ensures high transmittance and low thermal conductivity, but also effectively reduces light scattering and heat loss, and improves the overall efficiency of the photovoltaic thermal system. The micron-scale vacuum grid layer is treated with surface treatment techniques such as plasma cleaning or chemical modification to improve its adhesion and durability, while ensuring its close fit with the photovoltaic cell and the reflector.

[0098] Nano packaging materials are used to seal the outer edges of the semi-transparent photovoltaic cells and the photothermal reflectors. The packaging materials are usually fluorinated polymer films or polyurethane films. Such materials have excellent high temperature resistance, UV resistance and moisture resistance, as well as good flexibility and light transmittance, which helps to seal the micron-level vacuum grid layer and prevent the infiltration of external gas or moisture, thereby maintaining the long-term stability of the vacuum environment. After the sealing is completed, the inside of the micron-level vacuum grid layer is evacuated by a vacuum pump, so that the inside of the grid layer reaches a high negative pressure state, which minimizes the air barrier effect between the photovoltaic cell and the photothermal reflector and ensures a close fit between the two.

[0099] In addition, in order to improve the mechanical strength and thermal stability of the entire system, the micron-scale vacuum grid layer is combined with the photovoltaic cells and the photothermal reflector by bonding. The bonding material uses high-temperature curing glue, which can withstand long-term high temperatures and strong ultraviolet radiation, and has excellent bonding strength. The temperature and pressure are strictly controlled throughout the process to avoid deformation or damage to the grid layer. After vacuum extraction and bonding, the structure exhibits excellent optical transmittance and thermal isolation performance, which is suitable for high-efficiency photovoltaic and photothermal coupling systems, especially in outdoor environments that require long-term stability.

[0100] In summary, the vacuum compaction photovoltaic thermal coupling structure made using the embodiment of the present invention has significant weather resistance and long-term stability, and can maintain excellent performance under extreme environmental conditions. By comparison with the existing photovoltaic thermal coupling system, the structure exhibits higher weather resistance and reliability, especially in harsh climate environments. For example, in the ambient temperature range of -20°C to 85°C, after 1000 hours of weather resistance testing, the performance retention rate of the vacuum compaction photovoltaic thermal coupling structure exceeded 95%, which is significantly better than the traditional system. The structure can maintain better temperature stability under high temperature conditions. After 1000 hours of high temperature aging testing, the power attenuation rate of the battery is less than 3%, while the attenuation rate of the traditional system is usually more than 5%.

[0101] In addition, due to the vacuum compaction characteristics of the vacuum compaction photovoltaic thermal coupling structure, it is possible to achieve a close combination between the photovoltaic cell and the thermal reflector, reduce the thermal isolation effect of the air layer, and effectively reduce energy loss. The vacuum state not only improves the photoelectric conversion efficiency, but also plays a positive role in the thermal management of the system, avoiding heat accumulation and damage to the photovoltaic cells caused by excessive temperature, and further improving the overall efficiency and service life of the system. After 500 hours of light stability testing, the photoelectric conversion efficiency of the vacuum compaction structure remained above 98% of the original value, while the conversion efficiency of the traditional structure usually dropped to around 95%. The structure is able to maintain efficient operation for a long time without frequent maintenance, reducing the demand for maintenance resources and reducing operating costs.

[0102] In addition, the sealing and anti-aging capabilities of the vacuum compacted photovoltaic-thermal coupling structure enable it to maintain excellent performance in harsh environmental conditions, such as high temperature, high humidity or high salt fog, reducing the risk of material aging and failure. Compared with the traditional photovoltaic-thermal coupling structure, this structure can effectively extend the service life of photovoltaic modules and thermal reflectors, further promote the integrated application of photovoltaic and thermal technologies, and provide a more reliable solution for the long-term stable operation of large-scale solar power generation systems.

[0103] Finally, it should be noted that the above embodiments are only used to illustrate the technical solutions of the present invention, rather than to limit it. Although the present invention has been described in detail with reference to the aforementioned embodiments, those skilled in the art should understand that they can still modify the technical solutions described in the aforementioned embodiments, or replace some or all of the technical features therein with equivalents. However, these modifications or replacements do not cause the essence of the corresponding technical solutions to deviate from the scope of the technical solutions of the embodiments of the present invention.

Claims

1. A method for manufacturing a vacuum compaction photovoltaic thermal coupling structure, characterized in that: include: Preparation of semi-transparent photovoltaic cells; Preparation of photothermal reflectors; The semi-transparent photovoltaic cell is coupled with the photothermal reflector by vacuum compaction to form a vacuum compaction photovoltaic photothermal coupling structure.

2. The method for manufacturing a vacuum compaction photovoltaic thermal coupling structure according to claim 1, characterized in that: The semi-transparent photovoltaic cell and the photothermal reflector are coupled and connected by a full-encapsulation plastic sealing vacuum compaction method, which specifically includes: Precisely cut and clean semi-transparent photovoltaic cells and photothermal reflectors to ensure a clean and dust-free surface; Placing a semi-transparent photovoltaic cell on the surface of the photothermal reflector and adjusting the semi-transparent photovoltaic cell to be precisely aligned with the photothermal reflector; The semi-transparent photovoltaic cells and the photothermal reflectors are completely wrapped with heat-shrinkable plastic film; Use an edge banding machine or heating tool to heat seal the edges of the heat shrinkable plastic film to form a completely closed structure; A vacuum pump is used to extract the air inside the heat shrinkable plastic film to eliminate the air gap between the semi-transparent photovoltaic cell and the surface of the photothermal reflector; The wrapped semi-transparent photovoltaic cell and the photothermal reflector assembly are heated, and the heat shrinkable plastic film is evenly heated by infrared heating or a hot air gun to shrink the heat shrinkable plastic film so that the semi-transparent photovoltaic cell and the photothermal reflector are tightly fitted.

3. The method for manufacturing a vacuum compaction photovoltaic-thermal coupling structure according to claim 2, characterized in that: The heat shrinkable plastic film is a polyvinyl butyral film or a polyester heat shrinkable film.

4. The method for manufacturing a vacuum compaction photovoltaic-thermal coupling structure according to claim 1, characterized in that: The semi-transparent photovoltaic cell and the photothermal reflector are coupled and connected by a semi-encapsulated plastic vacuum compaction method, which specifically includes: Precisely cut and clean semi-transparent photovoltaic cells and photothermal reflectors to ensure a clean and dust-free surface; Placing a semi-transparent photovoltaic cell on the surface of the photothermal reflector and adjusting the semi-transparent photovoltaic cell to be precisely aligned with the photothermal reflector; Highly weather-resistant packaging materials are used to seal the outer edges of the components of the semi-transparent photovoltaic cells and the photothermal reflectors to form a closed cavity; The closed cavity is evacuated by a vacuum pump to eliminate the air gap between the semi-transparent photovoltaic cell and the surface of the photothermal reflector; The semi-transparent photovoltaic cell and the photothermal reflector are subjected to a heat pressing treatment by a constant temperature heat pressing device, so that the semi-transparent photovoltaic cell and the photothermal reflector are closely fitted together; The edges of the components of the semi-transparent photovoltaic cells and the photothermal reflectors are then packaged and sealed.

5. The method for manufacturing a vacuum compaction photovoltaic-thermal coupling structure according to claim 4, characterized in that: The highly weather-resistant packaging material is a fluorinated polymer film or a polyurethane film.

6. The method for manufacturing a vacuum compaction photovoltaic-thermal coupling structure according to claim 1, characterized in that: The semi-transparent photovoltaic cell and the photothermal reflector are coupled and connected by vacuum compaction of a fully enclosed flexible airbag, specifically including: A flexible semi-transparent photovoltaic cell and a curved photothermal reflector are used, the flexible semi-transparent photovoltaic cell is placed on the surface of the curved photothermal reflector, and the position is adjusted so that the flexible semi-transparent photovoltaic cell and the curved photothermal reflector are completely fitted together; The assembly of the flexible semi-transparent photovoltaic cell and the curved photothermal reflector is placed inside the flexible airbag; The inside of the flexible airbag is evacuated by a vacuum pump, so that the flexible airbag shrinks under the internal negative pressure and is tightly wrapped around the outside of the component to eliminate the air gap between the flexible semi-transparent photovoltaic cell and the surface of the curved photothermal reflector, thereby ensuring that the flexible semi-transparent photovoltaic cell and the curved photothermal reflector fit tightly together; The vacuum interface of the flexible airbag is sealed.

7. The method for manufacturing a vacuum compaction photovoltaic-thermal coupling structure according to claim 6, characterized in that: The flexible airbag is made of polyimide or polyvinyl butyral material.

8. The method for manufacturing a vacuum compaction photovoltaic-thermal coupling structure according to claim 1, characterized in that: The semi-transparent photovoltaic cell and the photothermal reflector are coupled and connected by vacuum grid vacuum compaction, which specifically includes: Laying and bonding a micron-scale vacuum grid layer on the surface of the photothermal reflector, bonding a semi-transparent photovoltaic cell to the micron-scale vacuum grid layer, and precisely aligning the position of the semi-transparent photovoltaic cell with the photothermal reflector; The outer edges of the components of the semi-transparent photovoltaic cells and the photothermal reflectors are sealed with nano-encapsulation materials; The inside of the micron-scale vacuum grid layer is evacuated by a vacuum pump to create a high negative pressure inside the micron-scale vacuum grid layer, thereby eliminating the air gap between the semi-transparent photovoltaic cell and the surface of the photothermal reflector, and ensuring that the semi-transparent photovoltaic cell and the photothermal reflector are tightly fitted through the micron-scale vacuum grid layer.

9. The method for manufacturing a vacuum compaction photovoltaic-thermal coupling structure according to claim 8, characterized in that: The micron-scale vacuum grid is made of nanoporous material, which is a silicon dioxide film or an aluminum oxide film, and the nano-encapsulation material is a fluorinated polymer film or a polyurethane film.

10. The method for manufacturing a vacuum compaction photovoltaic-thermal coupling structure according to any one of claims 1 to 9, characterized in that: The vacuum compaction photovoltaic thermal coupling structure is suitable for a tower-type solar thermal power generation system, a trough-type solar thermal power generation system, a Fresnel-type solar thermal power generation system, and a dish-type solar thermal power generation system.

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