Curved surface solar panel and preparation method thereof

Abstract

The embodiment of the invention relates to the field of photovoltaic technology, and provides a curved-surface solar panel and a preparation method thereof. The preparation method of the curved-surface solar panel comprises the following steps: hot-bending preforming treatment: putting a planar solar cell layer into a hot-press forming mold for hot-bending preforming to obtain a curved-surface solar cell layer; and carrying out molding treatment after laminating, namely sequentially laminating front plate curved glass, a first bonding layer, the curved-surface-shaped solar cell layer, a second bonding layer and a flexible back plate, and then putting the laminated front plate curved glass, the first bonding layer, the curved-surface-shaped solar cell layer, the second bonding layer and the flexible back plate into a laminating furnace to carry out secondary hot-pressing packaging so as to obtain the curved-surface solar panel. According to the preparation method of the curved-surface solar panel, the solar cell is prevented from being broken and displaced, and the reliability of the curved-surface solar panel is further improved.

Description

Technical Field

[0001] This application relates to the field of photovoltaic technology, and more particularly, to a curved solar panel and a method for manufacturing the same. Background Art

[0002] In the existing method for manufacturing a curved solar panel, the solar cells that make up the curved solar panel are usually bent rigidly at room temperature, which results in the problem that the solar cells are prone to breakage. In addition, in the existing method for manufacturing a curved solar panel, there is also the problem that the solar cells in the curved solar panel are prone to shift, which affects the appearance and reliability of the curved solar panel. Summary of the Invention

[0003] A first aspect of this application provides a method for manufacturing a curved solar panel. The method for manufacturing the curved solar panel includes:

[0004] Hot bending preforming treatment: placing a planar solar cell layer into a hot pressing forming mold for hot bending preforming to obtain a curved solar cell layer; and

[0005] Post-lamination molding treatment: sequentially laminating a front panel curved glass, a first adhesive layer, the curved solar cell layer, a second adhesive layer, and a flexible back panel, and then placing the laminated structure into a laminating furnace for secondary hot pressing encapsulation to obtain a curved solar panel.

[0006] The method for manufacturing a curved solar panel according to the first aspect of this application can effectively reduce the problem of rigid breakage caused by rigidly bending solar cells at room temperature in the existing method for manufacturing a curved solar panel by hot bending preforming a planar solar cell layer into a curved solar cell layer. Moreover, through the hot bending preforming treatment, the solar cell layer subjected to the post-lamination molding treatment is in a curved shape, which is conducive to better fitting of the solar cell layer with the front panel curved glass in the post-lamination molding treatment step, thereby reducing the force for shaping the solar cell layer during the post-lamination molding treatment, preventing appearance problems such as fragmentation and displacement, and facilitating ensuring the reliability of the obtained curved solar panel.

[0007] A second aspect of this application provides a curved solar panel. The curved solar panel includes a front panel curved glass, a first adhesive layer, a curved solar cell layer, a second adhesive layer, and a flexible back panel that are sequentially laminated. In the direction from the front panel curved glass to the back panel, the curved solar cell layer includes a first support layer, a first pre-encapsulation adhesive layer, a solar cell, a second pre-encapsulation adhesive layer, and a second support layer that are sequentially laminated.

[0008] In the curved surface solar panel according to the second aspect of the present application, one side of the solar cell layer is protected by a front panel curved glass, a first adhesive layer, a first support layer, and a first pre-packaging adhesive layer, and the other side is protected by a second pre-packaging adhesive layer, a second support layer, a second adhesive layer, and a flexible backplane, with strong reliability. Description of the Drawings

[0009] Figure 1 It is a flowchart of the preparation method of the curved surface solar panel according to an embodiment of the present application.

[0010] Figure 2 It is a schematic exploded view of the first stack in the preparation method of the curved surface solar panel according to an embodiment of the present application.

[0011] Figure 3 It is a schematic structural view of the planar solar cell layer in the preparation method of the curved surface solar panel according to an embodiment of the present application.

[0012] Figure 4 It is a schematic structural view of the thermoforming pre-treatment in the preparation method of the curved surface solar panel according to an embodiment of the present application.

[0013] Figure 5 It is a schematic structural view of the curved surface solar cell layer obtained in the preparation method of the curved surface solar panel according to an embodiment of the present application.

[0014] Figure 6 It is a schematic diagram showing the change of the strength of the crystal grains and the strength of the grain boundaries in the solar cell layer with temperature in the preparation method of the curved surface solar panel according to an embodiment of the present application.

[0015] Figure 7A It is a schematic structural view of the front panel curved glass in the preparation method of the curved surface solar panel according to an embodiment of the present application.

[0016] Figure 7B It is a schematic structural view of the second mold in the preparation method of the curved surface solar panel according to an embodiment of the present application.

[0017] Figure 8 It is a schematic exploded view of the second stack in the preparation method of the curved surface solar panel according to an embodiment of the present application.

[0018] Main Element Symbol Description:

[0019] First Stack 10a

[0020] Solar Cell 11

[0021] First Protective Layer 12

[0022] First Support Layer 12a

[0023] First Pre-Packaging Adhesive Layer 12b

[0024] Second protective layer 13

[0025] Second support layer 13a

[0026] Second pre - encapsulation adhesive layer 13b

[0027] Planar solar cell layer 10b

[0028] Hot - press forming die 200

[0029] First die 210

[0030] First forming surface 210a

[0031] Second die 220

[0032] Second forming surface 220a

[0033] Second concave surface 220r

[0034] Second convex surface 220p

[0035] Second laminate 100

[0036] Curved - surface solar cell layer 10

[0037] Light - receiving surface 10a

[0038] Back - light surface 10b

[0039] Concave surface 10r

[0040] Convex surface 10p

[0041] Front - plate curved glass 20

[0042] First concave surface 20r

[0043] First convex surface 20p

[0044] First adhesive layer 30

[0045] Second adhesive layer 40

[0046] Backplane 50

[0047] First tangent turning angle θ1

[0048] Second tangent turning angle θ2 Detailed implementation manners

[0049] Next, the technical solutions in the embodiments of the present application will be clearly and completely described in conjunction with the accompanying drawings in the embodiments of the present application. Obviously, the described embodiments are only a part of the embodiments of the present application, rather than all the embodiments.

[0050] Please refer to Figure 1 , the preparation method of the curved surface solar panel according to an embodiment of the present application includes the following steps S10 and S20. According to different requirements, the order of some steps or sub-steps of the preparation method of the curved surface solar panel can be changed, and some steps or sub-steps can be omitted or combined.

[0051] Step S10: Thermoforming preforming treatment: Place the planar solar cell layer into a hot pressing and forming mold for thermoforming preforming to obtain a curved surface solar cell layer.

[0052] Step S20: Laminating post-forming treatment: Stack the front panel curved glass, the first adhesive layer, the curved surface solar cell layer, the second adhesive layer, and the flexible backplane in sequence, and then place them into a laminating furnace for secondary hot pressing and encapsulation to obtain a curved surface solar panel.

[0053] The preparation method of the curved surface solar panel according to the embodiment of the present application can effectively reduce the problem of rigid fragmentation caused by hard bending of the solar cell at room temperature in the existing preparation method of the curved surface solar panel by thermoforming the planar solar cell layer into a curved surface solar cell layer. Moreover, through the thermoforming preforming treatment, the solar cell layer for the laminating post-forming treatment is in a curved surface shape, which is beneficial for the solar cell layer to better fit with the front panel curved glass in the laminating post-forming treatment step, thereby reducing the force for shaping the solar cell layer during the laminating post-forming treatment process, preventing appearance problems such as fragmentation and displacement, and being beneficial for ensuring the reliability of the obtained curved surface solar panel.

[0054] The following is a specific description of Figures 2 to 8 the above preparation method of the curved surface solar panel.

[0055] Step S10: Thermoforming preforming treatment: Place the planar solar cell layer into a hot pressing and forming mold for thermoforming preforming to obtain a curved surface solar cell layer.

[0056] In some embodiments, before the thermoforming preforming treatment, the preparation method of the above curved surface solar panel further includes a pre-encapsulation treatment to prepare a planar solar cell layer. Specifically, the pre-encapsulation treatment includes the following steps S01 and S02.

[0057] Step S01: Stack the first support layer, the first pre-encapsulation adhesive layer, the solar cell, the second pre-encapsulation adhesive layer, and the second support layer in sequence to obtain a first stack.

[0058] Such as Figure 2As shown, in the first stack 10a, on opposite sides of the solar cell 11 are a first protective layer 12 and a second protective layer 13 respectively. The first protective layer 12 includes a first support layer 12a and a first pre-packaging adhesive layer 12b. The first pre-packaging adhesive layer 12b is located between the first protective layer 12 and the solar cell 11 to bond the first support layer 12a and the solar cell 11. The second protective layer 13 includes a second support layer 13a and a second pre-packaging adhesive layer 13b to bond the second support layer 13a and the solar cell 11.

[0059] In some embodiments, the solar cell 11 is a photovoltaic cell with a single-crystalline silicon material as the substrate. For example, the crystalline silicon cell is any one of a Passivated Emitter Rear Cell (PERC), a Tunnel Oxide Passivated Contact (TOPcon) photovoltaic cell, a Heterojunction with Intrinsic Thin-film (HJT) photovoltaic cell, or various types of X BackContact (XBC) photovoltaic cells, etc.

[0060] In some other embodiments, the solar cell 11 is a stacked cell formed by a photovoltaic cell with a single-crystalline silicon material as the substrate and a thin-film cell. The thin-film cell is, for example, a perovskite thin-film cell, but is not limited thereto.

[0061] In still some other embodiments, the solar cell 11 is a photovoltaic cell with a polycrystalline silicon material as the substrate. However, due to the presence of more grain boundaries in the crystal structure of polycrystalline silicon, this will hinder electron flow. The efficiency of polycrystalline silicon cells is generally lower than that of single-crystalline silicon cells. Therefore, in terms of the efficiency of the cell, the solar cell 11 is a photovoltaic cell with a single-crystalline silicon material as the substrate or the above-mentioned stacked cell.

[0062] In some embodiments, the materials of the first support layer 12a and the second support layer 13a are, for example, Polyethylene terephthalate (PET) or a PET composite material. Since the first support layer 12a will be retained in the curved solar panel and is located on the light-receiving surface side of the solar cell layer, in order to avoid its influence on the light reception of the solar cell layer, the first support layer 12a is light-transmissive. The second support layer 13a will be retained in the curved solar panel and is located on the backlight surface side of the solar cell layer. Therefore, the second support layer 13a can be light-opaque.

[0063] In some embodiments, the first pre - encapsulation adhesive layer 12b and the second pre - encapsulation adhesive layer 13b are thermosetting or thermoplastic adhesive films, which are cured to bond the adjacent film layers. Specifically, the materials of the first pre - encapsulation adhesive layer 12b and the second pre - encapsulation adhesive layer 13b can be one of ethylene - vinyl acetate copolymer (EVA) adhesive film, polyolefin elastomer (POE) adhesive film, polyvinyl butyral (PVB) adhesive film or EPE adhesive film, but not limited thereto. The EPE adhesive film is a composite encapsulation adhesive film manufactured by co - extrusion process of EVA adhesive film, POE adhesive film and EVA adhesive film.

[0064] Step S02: Place the first stack into a laminator for preliminary hot - press encapsulation to obtain a planar solar cell layer.

[0065] In some embodiments, the laminator is a single - chamber laminator. During the preliminary hot - press encapsulation, the temperature is 130°C to 150°C (for example, 130°C to 135°C, 135°C to 140°C or 140°C to 150°C), and the vacuum pumping time is 260 s to 600 s (for example, 260 s to 400 s, 400 s to 500 s or 500 s to 600 s). In this way, the temperature range during the preliminary hot - press encapsulation is high enough to ensure that the encapsulation materials (such as the first pre - encapsulation adhesive layer 12b and the second pre - encapsulation adhesive layer 13b) can flow and bond correctly, while not being too high to avoid damaging the solar cell 11 or other film layers. In addition, if the vacuum pumping time during the preliminary hot - press encapsulation exceeds the above upper limit, some film layers in the first stack 10a may be over - dried or thermally damaged, which will also cause unnecessary energy waste, extend the production cycle and increase the production cost. If the vacuum pumping time during the preliminary hot - press encapsulation is less than the above lower limit, it may lead to ineffective removal of air between each film layer due to insufficient vacuum pumping time, resulting in the formation of bubbles in the planar solar cell layer. The bubbles will affect the photoelectric conversion efficiency and durability of the subsequent curved solar panel, and may also cause local overheating, that is, hot - spot effect, thereby damaging the battery or reducing the battery life.

[0066] In some other embodiments, the laminator is a double-chamber laminator. During the preliminary hot-press encapsulation process, the temperature in one chamber of the double-chamber laminator is 130°C to 140°C (such as 130°C to 135°C or 135°C to 140°C), and the vacuum pumping time is 260 s to 600 s (such as 260 s to 400 s, 400 s to 500 s, or 500 s to 600 s). The temperature in the second chamber of the double-chamber laminator is 140°C to 150°C (such as 140°C to 145°C, or 145°C to 150°C), and the vacuum pumping time is 100 s to 300 s (such as 100 s to 150 s, 150 s to 200 s, or 200 s to 300 s).

[0067] Compared with the preliminary hot-press encapsulation using a single-chamber laminator, the double-chamber laminator can process two batches of the first stack 10a simultaneously, so as to improve the production throughput and efficiency, and reduce the waiting time and production cycle. Moreover, compared with two single-chamber laminators, one double-chamber laminator generally occupies less space, which is an advantage for factory layout and space utilization. In addition, the double-chamber laminator allows the production line to continue production in one chamber while the other chamber is under maintenance or adjustment, which can reduce the downtime and improve the production flexibility.

[0068] In some embodiments, the preliminary hot-press encapsulation process includes performing first-stage lamination, second-stage lamination, and third-stage lamination on the first stack in sequence. In this way, by laminating the first stack in stages, it is allowed to gradually remove air bubbles at different lamination stages, and it helps to achieve a more uniform encapsulation pressure distribution, so as to prevent the breakage or damage of the solar cell 11, and improve the uniformity of the encapsulation of each part of the solar cell 11 in the first stack 10a. Furthermore, it helps to improve the long-term reliability and weather resistance of the obtained curved solar panel. The first-stage lamination, second-stage lamination, and third-stage lamination can all be performed in a single-chamber laminator, or all be performed in a double-chamber laminator.

[0069] In some embodiments, during the first-stage lamination, the pressure is from -80 kPa to -40 kPa (such as from -80 kPa to -60 kPa, from -60 kPa to -50 kPa, or from -50 kPa to -40 kPa), and the duration is from 30 s to 100 s (such as from 30 s to 50 s, from 50 s to 70 s, from 70 s to 80 s, or from 80 s to 100 s). Among them, if the pressure during the first-stage lamination is less than the lower limit, it is likely to cause the problem of void glue; if the pressure during the first-stage lamination is greater than the upper limit, it is likely to cause fragmentation of the solar cell 11. If the duration during the first-stage lamination is less than the lower limit, it is likely to cause the problem of void glue; if the duration during the first-stage lamination is greater than the upper limit, it is likely to cause the problem of over-crosslinking of the encapsulation material in the first stack 10a. When the crosslinking degree of the encapsulation material exceeds the ideal level, it will cause the elasticity of the encapsulation material to decrease, become more brittle and hard, and then may cause the solar cell 11 to be more likely to crack when dealing with thermal expansion or other mechanical stresses. In addition, the problem of over-crosslinking of the encapsulation material may also lead to a decrease in the optical properties of the encapsulation material, thereby affecting the light absorption ability of the obtained curved solar panel.

[0070] In some embodiments, during the second-stage lamination, the pressure is from -60 kPa to -10 kPa (such as from -60 kPa to -40 kPa, from -40 kPa to -30 kPa, or from -30 kPa to -10 kPa), and the duration is from 30 s to 100 s (such as from 30 s to 50 s, from 50 s to 70 s, from 70 s to 80 s, or from 80 s to 100 s). If the pressure during the second-stage lamination is less than the lower limit, it is likely to cause the problem of void glue; if the pressure during the second-stage lamination is greater than the upper limit, it is likely to cause the problem of hidden cracks and fragmentation of the solar cell 11. If the duration during the second-stage lamination is less than the lower limit, it is likely to cause too low crosslinking degree of the encapsulation material in the first stack 10a. If the crosslinking degree of the encapsulation material is insufficient, it may reduce the overall mechanical strength of the obtained curved solar panel, resulting in the obtained curved solar panel being more vulnerable to physical damage, such as tearing or penetration. In addition, if the crosslinking degree of the encapsulation material is insufficient, its barrier effect on water vapor and oxygen may be insufficient, which may lead to the accumulation of water vapor and oxygen inside the obtained curved solar panel, thereby accelerating the performance degradation of the solar cell 11. In addition, if the duration during the second-stage lamination is greater than the upper limit, it is likely to cause the problem of over-crosslinking of the encapsulation material in the first stack 10a.

[0071] In some embodiments, during the third-stage lamination, the pressure is from -20 kPa to 0 (such as from -20 kPa to -15 kPa, from -15 kPa to -10 kPa, or from -10 kPa to 0), and the duration is from 600 s to 1200 s (such as from 600 s to 800 s, from 800 s to 1000 s, from 1000 s to 1100 s, or from 1100 s to 1200 s). If the pressure during the third-stage lamination is less than the lower limit or the duration during the third-stage lamination is less than the lower limit, it is likely to result in too low a crosslinking degree of the encapsulation material in the first stack 10a. If the pressure during the third-stage lamination is greater than the upper limit or the duration is greater than the upper limit, it is likely to cause the problem of over-crosslinking of the encapsulation material in the first stack 10a.

[0072] It can be seen that during the lamination process of the first stack, the setting of the pressure and the duration is crucial. Through the above various parameter ranges during the lamination process, the encapsulation material in the first stack 10a obtains an appropriate crosslinking degree, which is conducive to reducing the problem of air voids in the first stack 10a and the probability of fragmentation of the solar cells.

[0073] In some embodiments, after the first stack 10a undergoes step S02, a planar solar cell layer 10b as shown in Figure 3 is obtained. It should be noted that during the above preliminary hot-press encapsulation process, by performing plastic encapsulation on the first stack 10 at high temperature and high pressure, the crosslinking degree of the encapsulation material (such as the first pre-encapsulation adhesive layer 12b and the second pre-encapsulation adhesive layer 13b) is ensured to be between 50% and 80%, so that the obtained planar solar cell layer 10b has a certain tensile strength and elongation at break and can be bent to a certain extent. In addition, in the planar solar cell layer 10b, the relative two sides of the solar cell 11 are respectively covered by the first protective layer 12 and the second protective layer 13. Since the first protective layer 12 and the second protective layer 13 have a certain structural strength, it is conducive to increasing the impact resistance and mechanical strength of the planar solar cell layer 10b, and thus conducive to the thermal bending and shaping of the planar solar cell layer 10b during the subsequent hot bending and preforming process.

[0074] Specifically, as shown in Figure 4As shown, in the steps of hot bending preforming, the hot pressing mold 200 includes opposite first mold 210 and second mold 220. The first mold 210 includes a curved first forming surface 210a, and the second mold 220 includes a curved second forming surface 220a. The hot bending preforming process includes placing the planar solar cell layer 10b on the first forming surface 210a and between the first forming surface 210a and the second forming surface 220a. Then, pressure is applied to the planar solar cell layer 10b from the first mold 210 to the second mold 220, causing the planar solar cell layer 10b to conform to the second forming surface 220a. Wait for 10 min to 20 min to complete the hot bending preforming process, and then obtain a Figure 5 curved solar cell layer 10 as shown.

[0075] In some embodiments, the temperature of the planar solar cell layer 10b placed in the hot pressing mold 200 in step S10 is greater than 100 °C. More specifically, in step S02, the temperature of the planar solar cell layer 10b taken from the laminator is greater than 120 °C. The planar solar cell layer 10b processed by high temperature and high pressure has a very high temperature within 3 to 5 minutes, and it is placed in the hot pressing mold 200 at this temperature. Specifically, an increase in temperature will cause an increase in the dislocation density of the material, and the lattice and grain boundary structures become looser, as Figure 6 shown, the increase in temperature reduces the yield strength of the material. Therefore, compared with directly and rigidly bending the planar solar cell layer at room temperature, in the above steps of hot bending preforming, it is beneficial to reduce the yield strength of each material in the planar solar cell layer, and thus beneficial to reduce the probability of the solar cell breaking during the bending process.

[0076] Please refer to Figure 5 again. The curved solar cell layer 10 includes opposite light-receiving surface 10a and backlight surface 10b. The light-receiving surface 10a is curved and includes a wavy surface formed by sequentially connecting a concave surface 10r and a convex surface 10p. The backlight surface 10b is also curved and includes a wavy surface. Specifically, in the steps of the hot bending preforming process, the hot pressing mold 200 is arranged as Figure 7AThe shape and size of the front plate curved glass 20 shown are bent and deformed. Both the first forming surface 210a and the second forming surface 220a match the overall shape of the front plate curved glass 20. The front plate curved glass 20 includes a pressing surface 20a for bonding with the light-receiving surface 10a. The pressing surface 20 includes a wavy surface formed by sequentially connecting a first concave surface 20r and a first convex surface 20p. In the step of post-lamination forming treatment, the first concave surface 20r of the front plate curved glass 20 is used to bond with a corresponding convex surface 10p of the curved solar cell layer 10, and the first convex surface 20p is used to bond with a corresponding concave surface 10r of the curved solar cell layer 10. The second forming surface 220a of the second mold 220 is used to form the curved light-receiving surface 10a. As Figure 7B shown, the second forming surface 220a includes a wavy surface formed by sequentially connecting a second concave surface 220r and a second convex surface 220p.

[0077] Please refer to Figure 5 , Figure 7A and Figure 7B . In the second mold 220, each second concave surface 220r corresponds to a first concave surface 20r in the front plate curved glass 20 to form a corresponding convex surface 10p in the curved solar cell layer 10, and each second convex surface 220p in the second mold 220 corresponds to a first convex surface 20p in the front plate curved glass 20 to form a corresponding concave surface 10r in the light-receiving surface 10a of the curved solar cell layer 10.

[0078] In some embodiments, to make the curved solar cell layer 10 fit better with the front plate curved glass 20 in the subsequent post-lamination forming treatment step, the average curvature of the second forming surface 220a of the second mold 220 is made greater than the average curvature of the pressing surface 20a of the front plate curved glass 20, or in other words, the bending degree of the second forming surface 220a of the second mold 220 is made greater than the bending degree of the pressing surface 20a. Specifically, the curvature of each second concave surface 220r is greater than the curvature of a corresponding first concave surface 20r so that the obtained light-receiving surface 10a of the curved solar cell layer 10 fits better with the pressing surface 20a of the front plate curved glass 20.

[0079] More specifically, the first concave surface 20r, the first convex surface 20p, the second concave surface 220r, and the second convex surface 220p are all arc surfaces. Define the angle between the tangent line between the adjacent first concave surface 20r and the first convex surface 20p and the tangent plane passing through the vertex of the first concave surface 20r as the first tangent rotation angle θ1. Figure 7AThe first tangent angle θ1 in [description] is the angle between the first dashed line M1 passing through the vertex of the first concave surface 20r and the first dashed line M2 at the tangent point of the first concave surface 20r and the first convex surface 20p. The angle between the tangent line between the adjacent second concave surface 220r and the second convex surface 220p and the tangent plane passing through the vertex of the second concave surface 220r is defined as the second tangent angle θ2. Figure 7B The second tangent angle θ2 in [description] is the angle between the third dashed line M3 passing through the vertex of the second concave surface 220r and the fourth dashed line M4 at the tangent point of the second concave surface 220r and the second convex surface 220p.

[0080] In some embodiments, the first tangent angle θ1 and the second tangent angle θ2 satisfy: 0 < θ2 - θ1 < 10°. If θ2 - θ1 < 0, during the hot bending pre - forming process, the bending degree of the curved solar cell layer 10 is too large, resulting in the need for reverse bending during the subsequent lamination post - forming process for correction. If the bending directions of the solar cell layer in the two steps of the hot bending pre - forming process and the lamination post - forming process are inconsistent, it will lead to a decrease in the adhesion force between layers in the solar cell layer, increasing the risk of interlayer delamination. Moreover, bending in different directions may cause stress concentration in some areas of the solar cell layer, where the stress level is much higher than other parts, resulting in the formation and expansion of micro - cracks, thereby affecting the electrical performance of the obtained curved solar panel and making the output of the curved solar panel unstable. If θ2 - θ1 > 10°, it is not conducive to the close fitting between the curved solar cell layer 10 and the front - plate curved glass 20 during the lamination post - forming process, and there are local stress problems caused by interference in the curved solar cell layer 10. Therefore, 0 < θ2 - θ1 < 10° is conducive to the better fitting between the curved solar cell layer 10 and the front - plate curved glass 20, and reduces the shaping force during the lamination post - forming process, preventing appearance problems such as fragmentation and displacement of the solar cells.

[0081] Step S20: Lamination post - forming process: Stack the front - plate curved glass, the first adhesive layer, the curved solar cell layer, the second adhesive layer, and the flexible back - plate in sequence and then put them into a lamination furnace for secondary hot - press encapsulation to obtain a curved solar panel.

[0082] Specifically, as Figure 8As shown, the front plate curved glass 20, the first adhesive layer 30, the curved solar cell layer 10, the second adhesive layer, and the back plate 50 are laminated in sequence to obtain the second laminate 100. In the second laminate 100, both the front plate curved glass 20 and the first adhesive layer 30 are located on one side of the light-receiving surface 10a of the curved solar cell layer 10. The first adhesive layer 30 is located between the pressing surface 20a of the front plate curved glass 20 and the light-receiving surface 10a of the curved solar cell layer 10 to bond the two. Both the second adhesive layer 40 and the back plate 50 are located on one side of the backlight surface 10b of the curved solar cell layer 10. The second adhesive layer 40 is located between the back plate 50 and the backlight surface 10b of the curved solar cell layer 10 to bond the two.

[0083] In some embodiments, the front plate curved glass 20 can be tempered glass or semi-tempered glass that is light-transmissive, but is not limited thereto.

[0084] In some embodiments, both the first adhesive layer 30 and the second adhesive layer 40 can be one of an EVA film, a POE film, an EVA film, or an EPE film, but are not limited thereto.

[0085] In some embodiments, the back plate 50 is selected from materials having insulation, moisture-proof, and flexibility. The material of the back plate 50 can be polyethylene terephthalate (PET) or a PET composite material, but is not limited thereto.

[0086] In some embodiments, the second laminate 100 is placed in a laminating furnace for secondary hot pressing and encapsulation, and a segmented process control can be used for processing. Specifically, the segmented process includes, for example, a pre-pressing stage, a main pressing stage, and a cooling stage. The pre-pressing stage includes placing the stacked solar panels in the laminating furnace and first performing preheating and slight pre-pressing. This step is mainly to soften the first adhesive layer 30 and the second adhesive layer 40 so as to better fit the curved solar cell layer 10 and the front plate curved glass 20. In addition, the pre-pressing stage helps to expel the air between the layers and prevent the formation of bubbles. The main pressing stage includes gradually increasing the pressure and temperature to a set value. The purpose of this stage is to completely melt the first adhesive layer 30 and the second adhesive layer 40 and make them tightly bond with the adjacent layer materials through pressure. The cooling stage includes gradually reducing the temperature while maintaining the pressure. This step is to prevent the material from generating internal stress or deformation due to too rapid temperature change during the cooling process. The post-laminating forming process also includes taking out the second laminate after secondary hot pressing and encapsulation, as well as performing steps such as visual inspection and electrical performance testing, so as to obtain a curved solar panel with the encapsulation quality meeting the standards.

[0087] In summary, in the method for preparing a curved solar panel according to an embodiment of the present application, by thermally bending and preforming a planar solar cell layer into a curved solar cell layer, the problem of rigid fragmentation caused by hard bending of the solar cell at room temperature in the existing method for preparing a curved solar panel can be effectively reduced. Moreover, through the thermally bending and preforming treatment, the formed solar cell layer after lamination is curved, which is conducive to better fitting of the solar cell layer with the front panel curved glass in the post-lamination forming treatment step, thereby reducing the force for shaping the solar cell layer in the post-lamination forming treatment process, preventing appearance problems such as fragmentation and displacement, and being conducive to ensuring the reliability of the obtained curved solar panel.

[0088] An embodiment of the present application further provides a curved solar panel obtained by using the above method for preparing a curved solar panel. The curved solar panel includes a front panel curved glass, a first adhesive layer, a curved solar cell layer, a second adhesive layer, and a flexible backplane stacked in sequence. In the direction from the front panel curved glass to the backplane, the curved solar cell layer includes a first support layer, a first pre-encapsulation adhesive layer, a solar cell, a second pre-encapsulation adhesive layer, and a second support layer stacked in sequence. This curved solar panel has at least the same advantages as the above method for preparing a curved solar panel, and will not be elaborated herein.

[0089] The above embodiments are only used to illustrate the technical solutions of the present application rather than to limit them. Although the present application has been described in detail with reference to the above preferred embodiments, those of ordinary skill in the art should understand that the technical solutions of the present application can be modified or equivalently replaced without departing from the spirit and scope of the technical solutions of the present application.

Claims

1. A preparation method of a curved surface solar panel, characterized in that, Including: Hot bending preforming process: putting the planar solar cell layer into a hot pressing forming die for hot bending preforming to obtain a curved solar cell layer; And Laminating post-forming process: laminating the front plate curved glass, the first adhesive layer, the curved solar cell layer, the second adhesive layer, and the flexible back plate in sequence and then putting them into a laminating furnace for secondary hot pressing encapsulation to obtain a curved solar panel.

2. The preparation method of the curved surface solar panel according to claim 1, characterized in that, The hot pressing forming die includes opposite first and second dies. The first die includes a first forming surface matching the shape of the front plate curved glass, and the second die includes a second forming surface matching the shape of the front plate curved glass; The hot bending preforming process includes: placing the planar solar cell layer between the second forming surface and the first forming surface, applying pressure to the planar solar cell layer through the first die to make the planar solar cell layer fit the second forming surface to obtain the curved solar cell layer.

3. The preparation method of the curved surface solar panel according to claim 2, wherein The curved solar cell layer includes opposite curved light-receiving surface and curved backlight surface. The second forming surface is used to form the curved light-receiving surface. The front plate curved glass includes a pressing surface for bonding with the curved light-receiving surface. The average curvature of the second forming surface is greater than that of the pressing surface.

4. The preparation method of the curved surface solar panel according to claim 3, characterized in that, The pressing surface includes a wavy surface formed by sequentially connecting a first concave surface and a first convex surface. The second forming surface includes a wavy surface formed by sequentially connecting a second concave surface and a second convex surface. The curvature of each second concave surface is greater than that of a corresponding first concave surface.

5. The preparation method of the curved surface solar panel according to claim 4, characterized in that, The first concave surface, the first convex surface, the second concave surface, and the second convex surface are all arc surfaces. Define the included angle between the tangent line between adjacent first concave surface and first convex surface and the tangent plane passing through the vertex of the first concave surface as the first tangent rotation angle θ1, and define the included angle between the tangent line between adjacent second concave surface and second convex surface and the tangent plane passing through the vertex of the second concave surface as the second tangent rotation angle θ2. The first tangent rotation angle θ1 and the second tangent rotation angle θ2 satisfy: 0 < θ2 - θ1 < 10°.

6. The preparation method of the curved surface solar panel according to any one of claims 1 to 5, characterized in that, Before the hot bending preforming process, it further includes: Pre-encapsulation process: laminating the first support layer, the first pre-encapsulation adhesive layer, the solar cell, the second pre-encapsulation adhesive layer, and the second support layer in sequence and then putting them into a laminator for preliminary hot pressing encapsulation to obtain the planar solar cell layer.

7. The manufacturing method of the curved surface solar panel according to claim 6, characterized in that, The temperature of the planar solar cell layer taken from the laminator is greater than 120 °C, and the temperature of the planar solar cell layer put into the hot pressing forming die is greater than 100 °C.

8. The manufacturing method of the curved surface solar panel as described in claim 6, characterized in that, During the preliminary hot pressing encapsulation process, the temperature is 130 °C to 150 °C, and the vacuum pumping time is 260 s to 600 s.

9. The manufacturing method of the curved surface solar panel according to claim 6, characterized in that The preliminary hot pressing encapsulation process includes performing first-stage lamination, second-stage lamination, and third-stage lamination on the first stack in sequence; During the first-stage lamination process, the pressure is -80 kPa to -40 kPa, and the duration is 30 s to 100 s; During the second-stage lamination, the pressure ranges from -60 kPa to -10 kPa, and the duration ranges from 30 s to 100 s; During the third-stage lamination, the pressure ranges from -20 kPa to 0, and the duration ranges from 600 s to 1200 s.

10. A curved solar panel, characterized in that, It includes a front panel curved glass, a first adhesive layer, a curved solar cell layer, a second adhesive layer, and a flexible backplane stacked in sequence. In the direction from the front panel curved glass to the backplane, the curved solar cell layer includes a first support layer, a first pre-packaging adhesive layer, a solar cell, a second pre-packaging adhesive layer, and a second support layer stacked in sequence.

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