High-strength photovoltaic module structure and preparation method thereof

Abstract

The invention discloses a high-strength photovoltaic module structure and a preparation method thereof.The high-strength photovoltaic module structure comprises a core structure used for improving the elasticity modulus, fiber reinforcing layers are arranged on the end faces of the two sides of the core structure, the fiber reinforcing layers arranged on the end faces of the two sides are connected at the side edge parts, and fiber winding surrounding parts are formed on the side edges of the core structure; all the side faces of the periphery of the core structure form full-connection type fiber binding reinforced fixing. Fiber winding is carried out on the side edge of the honeycomb structure photovoltaic module, fibers in a lower panel of the photovoltaic module are connected with fibers in an upper panel of the photovoltaic module, the bending rigidity of the photovoltaic module can be further enhanced, and the fibers in the lower panel of the photovoltaic module and the fibers in the upper panel of the photovoltaic module are connected in the mode that the fibers are wound on the side edge. The bending rigidity of the photovoltaic module is effectively enhanced, and the problem that the improvement of the bending rigidity is limited due to weak side edges of the module in the prior art is solved.

Description

Technical Field

[0001] The present invention relates to the field of new energy technology, and in particular to a high-strength photovoltaic module structure and a preparation method thereof. Background Art

[0002] In recent years, the expansion of photovoltaic power generation applications and the continuous increase in the size of photovoltaic modules have placed increasingly higher demands on the bending resistance of photovoltaic modules. To this end, researchers have conducted research on high-rigidity photovoltaic modules based on reinforced structures such as honeycomb structure backsheets and corrugated structure backsheets. For these high-rigidity module structures, their bending stiffness mainly depends on the structural design and the elastic modulus of the upper and lower panels. To achieve higher bending stiffness, fiber-reinforced high-elastic modulus panels such as glass fiber and carbon fiber are often used. In this case, on the one hand, improving the elastic modulus of the panel requires the use of high-density fibers or fibers with high elastic modulus, which is costly, and there are upper limits to the fiber weaving density and elastic modulus. On the other hand, when the upper and lower surfaces of the reinforced structure are covered with high-strength panels, the side of the module becomes a weak link in the module's bending ability, and further improvement of the bending stiffness of new photovoltaic modules is limited.

[0003] In view of the above, it is necessary to propose a high-strength photovoltaic module structure and a preparation method thereof to solve the above problems. Summary of the Invention

[0004] The purpose of the present invention is to overcome the defects in the prior art and provide a high-strength photovoltaic module structure and a preparation method thereof.

[0005] To achieve the above-mentioned purpose, the technical solution of the present invention is as follows: a high-strength photovoltaic module structure, including a core structure for improving the elastic modulus, fiber reinforcement layers are arranged on both side end faces of the core structure, and the fiber reinforcement layers arranged on both side end faces are connected at the side edges, so that the side edges of the core structure form a fiber winding surrounding portion, so that the outer peripheral side surfaces of the core structure form a fully connected fiber bundling reinforcement fixation.

[0006] Furthermore, the core structure is a honeycomb core or a corrugated core structure; the honeycomb core includes a honeycomb structure plate with at least one layer, and the honeycomb structure plate is provided with an array of densely distributed honeycomb holes; or the corrugated structure is formed by interlacing and stacking multiple layers of corrugated plates and flat plates.

[0007] Furthermore, the core structure is encapsulated in an inner edge strip structure, and the inner edge strip controls the peripheral outer shape of the core structure.

[0008] Furthermore, the fiber winding surrounding portion includes a fiber extension line pre-formed at the edge of the fiber reinforcement layer on either side end face, and the end of the fiber extension line is connected at a fixed point on the fiber reinforcement layer on the other side end face; the arrangement form between the fiber extension lines includes parallel arrangement, cross arrangement or winding arrangement.

[0009] A method for preparing a high-strength photovoltaic module structure includes the above-mentioned high-strength photovoltaic module structure, and its processing includes the following steps: S1: Honeycomb core side shaping: Cut the core structure and inner edge strips according to the target size, use adhesive to bond the core structure and inner edge strips, and use edge sealing tooling to press and fix them. After the adhesive is cured, remove the edge sealing tooling to complete the side shaping of the honeycomb core; S2: Preparation for side winding of honeycomb core: The fiber reinforcement layer includes an upper fiber layer and a lower fiber layer. The fiber reinforcement layer and the core structure are stacked in order from top to bottom as an upper fiber layer, a shaped honeycomb core, and a lower fiber layer; the fiber reinforcement layer on one side with a pre-set fiber extension line is connected to the other side; the fiber extension line is wound around the fiber reinforcement layer on the other side through the outside of the core structure according to a preset winding method, and the fiber extension line and the fiber reinforcement layer on the other side are connected and fixed at a fixed point to complete the side winding preparation of the core structure to form a wound reinforced core.

[0010] Furthermore, the method further includes the following steps: S3: Photovoltaic module lamination: The lamination order is: encapsulation layer, solar cell array, upper panel layer, winding reinforcement core and lower panel layer. Adhesive layers are set between adjacent layers, and the laminated intermediate product is prepared in a laminator; S4: Edge sealing: Setting an outer edge banding strip on the outer side of the laminated intermediate product to achieve edge sealing to form a photovoltaic module; S5: Junction box installation: Install the junction box on the back of the photovoltaic module or inside the honeycomb core, weld the busbars leading from the solar cell array to the junction box, and perform potting treatment; S6: Surface cleaning and performance testing.

[0011] Furthermore, the fiber extension line is formed on the lower layer of fibers, and the distance a between the fixed point and the edge of the core structure is ≥1 cm. Within the spacing a, the fiber extension line should be woven with the upper layer of fibers to enhance the bonding force.

[0012] Furthermore, the encapsulation layer comprises any one or more composites of photovoltaic glass, transparent polymer ethylene-tetrafluoroethylene copolymer, and transparent polymer polyvinylidene fluoride.

[0013] Furthermore, the raw material of the adhesive layer includes any one or more of EVA, POE, and PVB.

[0014] Furthermore, in the photovoltaic module lamination step, the packaging layer faces the heating surface in the laminator, and a vacuum environment is established for lamination. The lamination is pressurized according to a gradient increasing pressure. The last pressure applied to the photovoltaic module is 20kPa~80kPa. The last pressurization process is maintained for 10min~60min. The lamination temperature is 140℃~180℃. After the lamination is completed, it is taken out and trimmed to remove the overflowed residual glue.

[0015] The advantages and beneficial effects of the present invention are: 1. Enhanced bending stiffness: By winding fibers on the sides of honeycomb-structured photovoltaic modules, the fibers in the lower panel and the upper panel of the photovoltaic module are connected, effectively enhancing the bending stiffness of the photovoltaic module and solving the problem of limited improvement in bending stiffness due to weak sides of the modules in the existing technology.

[0016] 2. Little impact on weight and process: While enhancing bending stiffness, it has little impact on the weight and preparation process of photovoltaic modules, ensuring the lightweight of the modules and the feasibility of the preparation process.

[0017] 3. Adaptability to extreme environments: The ultra-high rigidity photovoltaic modules prepared by the method of the present invention have stronger mechanical properties and can be used in extreme environments such as high wind loads and high snow loads, thus expanding the application range of photovoltaic modules. BRIEF DESCRIPTION OF THE DRAWINGS

[0018] Figure 1 This is a schematic diagram of the top view of the side-shaped honeycomb core of the present invention; Figure 2 Schematic diagram of the side view of the side-wound honeycomb core of the present invention; Figure 3 This is a schematic diagram of the top view of the structure of the side-wound honeycomb core after being surrounded by fiber winding in the present invention; Figure 4 It is a structural schematic diagram of the longitudinal section of the high-strength photovoltaic module of the present invention.

[0019] In the figure: 1. Core structure; 2. Fiber reinforcement layer; 3. Fiber winding surrounding part; 4. Honeycomb core; 5. Inner edge strip; 6. Fiber extension line; 7. Fixing point; 8. Adhesive; 9. Edge sealing tool; 10. Upper fiber layer; 11. Lower fiber layer; 12. Winding reinforcement core; 13. Encapsulation layer; 14. Solar cell array; 15. Upper panel layer; 16. Adhesive layer; 17. Outer edge strip; 18. Junction box; 19. Lower panel layer. DETAILED DESCRIPTION

[0020] The following embodiments are further described in conjunction with the accompanying drawings and examples. The following embodiments are only used to more clearly illustrate the technical solutions of the present invention and are not intended to limit the scope of protection of the present invention.

[0021] A high-strength photovoltaic module structure includes a core structure 1 for improving the elastic modulus, a fiber reinforcement layer 2 is arranged on both side end faces of the core structure 1, and the fiber reinforcement layers 2 arranged on the both side end faces are connected at the side portions, so that the side edges of the core structure 1 form a fiber winding surrounding portion 3, so that the outer peripheral side surfaces of the core structure 1 form a fully connected fiber bundling reinforcement fixation.

[0022] As an embodiment, a fiber reinforcement layer corresponding to the side surface can be separately provided, and the side fiber reinforcement layer can be connected to the fiber reinforcement layers on the upper and lower end surfaces respectively. The fiber reinforcement layers arranged on the two side end surfaces are connected at the side edges through special side fiber reinforcement layers, that is, the upper and lower plane fiber reinforcement layers 2 are respectively provided on the upper and lower surfaces of the core structure, and the corresponding side fiber reinforcement layers are also provided on the side surrounding the corresponding core structure 1. During packaging, the fiber extension lines on both sides of the side fiber reinforcement layer are respectively connected to the upper and lower plane fiber reinforcement layers 2.

[0023] As another embodiment, as shown in the following embodiment, preferably, a fiber extension line is pre-set on the edge of the fiber reinforcement layer on one side, and then it is passed around the side of the core structure to connect with the fiber reinforcement layer 2 on the other side.

[0024] The core structure 1 is a key part for improving the elastic modulus of the component and provides basic mechanical support for the component. Fiber reinforcement layers 2 are set on both side faces, and the high strength characteristics of the fiber material are used to enhance the overall mechanical properties of the component. The fiber reinforcement layers 2 on both sides are connected at the side to form a fiber winding surrounding part 3 and a fully connected fiber bundling reinforced fixed structure. This design can effectively disperse the stress of the component when it is under stress and significantly improve the bending stiffness of the component. This structural design addresses the problem of weak sides of existing photovoltaic components. Through the connection of fibers, the mechanical properties of the upper and lower panels are integrated, so that when the component is subjected to bending force, the various parts are forced in coordination, avoiding the sides from becoming stress concentration points, thereby improving the overall bending resistance.

[0025] Furthermore, the core structure 1 is a honeycomb core 4 or a corrugated core structure; the honeycomb core 4 includes a honeycomb structure plate having at least one layer, and the honeycomb structure plate is provided with an array of densely distributed honeycomb holes; or the corrugated structure is formed by interlacing and laminating multiple layers of corrugated plates and flat plates.

[0026] Specifically, the honeycomb core 4 structure is lightweight, high-strength, and has good compressive resistance. The array distribution design of its honeycomb holes reduces the weight of the component while ensuring a certain strength, and can effectively disperse stress. The stacking of multiple layers of honeycomb structure panels can further enhance its mechanical properties. The corrugated core structure forms a unique buffer and support structure by interlacing and laminating multiple layers of corrugated sheets and flat sheets, providing a stable mechanical foundation for the component. Both core structures 1 are relatively common in actual applications, and each has unique mechanical advantages that can meet the requirements for the mechanical performance of photovoltaic modules in different scenarios. At the same time, they also cooperate with the fiber reinforcement layer 2 and the side connection structure to enhance the overall performance of the module.

[0027] Furthermore, the core structure 1 is encapsulated in the inner edge strip 5 structure, and the inner edge strip 5 controls the peripheral shape of the core structure 1. The inner edge strip 5 structure plays an important role in many aspects. It encapsulates the core structure 1 and protects the core structure 1, preventing it from being eroded by the external environment and mechanically damaged. At the same time, by precisely controlling the peripheral shape of the core structure 1, the shape stability of the core structure 1 is ensured, which helps to better cooperate with other components in subsequent processes. In addition, the inner edge strip 5 can also enhance the connection stability between the core structure 1 and the fiber reinforcement layer 2, making the structure of the entire component more stable. During the preparation process, the bonding quality of the inner edge strip 5 and the core structure 1 directly affects the overall performance of the component. Suitable materials and bonding processes for the inner edge strip 5 can ensure that the inner edge strip 5 effectively performs its function.

[0028] Furthermore, the fiber winding surrounding portion 3 includes a fiber extension line 6 pre-formed at the edge of the fiber reinforcement layer 2 on either side end face, and the end of the fiber extension line 6 is connected at a fixed point 7 on the fiber reinforcement layer 2 on the other side end face; the arrangement form between the fiber extension lines 6 includes parallel arrangement, cross arrangement or winding arrangement.

[0029] Specifically, the fiber extension cord 6 is a key component in connecting the two fiber-reinforced layers 2. The fiber extension cord 6 is pre-installed on one end face and connected to a fixed point 7 on the other end face, thereby forming the fiber-wound enclosure 3. Different arrangements of the fiber extension cords 6 (parallel, cross, or wound) have different effects on the mechanical properties of the component. A parallel arrangement facilitates concentrated reinforcement of the component's mechanical properties in a specific direction; a cross arrangement achieves more uniform stress distribution, improving the component's mechanical properties in multiple directions; and a wound arrangement further increases friction and connection strength between the fibers, making the fiber-wound enclosure 3 more structurally stable. By selecting the appropriate arrangement of the fiber extension cords 6, the component's bending stiffness, tensile strength, and other properties can be optimized according to the requirements of the actual application scenario. Furthermore, the fiber extension cords 6 are formed on the lower layer of fibers 11, and the distance a between the fixed point 7 and the edge of the core structure 1 is ≥1 cm. Within this spacing a, the fiber extension cords 6 should be woven with the upper layer of fibers 10 to enhance bonding.

[0030] Example 1: High-strength photovoltaic module based on honeycomb core 4 The core structure 1 utilizes a honeycomb core 4, comprised of three layers of honeycomb panels. The honeycomb cells in each layer are regular hexagonal, with a 5mm diameter and a 0.3mm wall thickness. The cells are densely distributed in an array, with a 6mm center-to-center spacing between adjacent cells. This design effectively reduces component weight while ensuring adequate strength. Fiber reinforcement layers 2 are placed on both sides of the honeycomb core 4, using high-strength carbon fibers as the fiber material. Continuous carbon fiber extension cords 6 with a diameter of 0.2mm are pre-placed along the edge of the fiber reinforcement layer 2 on one side. The fiber extension cords 6 are wrapped around the side edge of the honeycomb core 4 and onto the fiber reinforcement layer 2 on the other side, where they are braided and secured at fixing points 7. The distance between the fixing points 7 and the edge of the honeycomb core 4 is set at 1.5cm. Within this spacing, the fiber extension cords 6 are tightly braided with the fiber reinforcement layer 2 on the other side, enhancing the bond. This creates a fiber-wrapped surround 3 around the side edges of the honeycomb core 4, achieving fully connected fiber-binding reinforcement on all peripheral sides. The honeycomb core 4 is encapsulated in the inner edge strip 5 structure. The inner edge strip 5 is made of aluminum alloy with a thickness of 2 mm. Its shape is adapted to the outer shape of the honeycomb core 4, which can accurately control the peripheral external structure of the honeycomb core 4 and provide additional protection and support for the honeycomb core 4.

[0031] By winding the side fibers, the module's resistance to bending can be effectively enhanced. Taking a photovoltaic module measuring 1m x 0.2m in length and width as an example, the upper and lower panels are made of glass fiber, with a combined thickness of 0.7mm for the fiber and panel, and a thickness of 15mm for the aluminum honeycomb core. A comparative test of bending performance was conducted: without side fiber winding, the maximum deformation of the photovoltaic module under a pressure of 2400Pa was 3mm. In contrast, with the side fiber winding of this embodiment, under the same experimental conditions, the maximum deformation of the photovoltaic module under a pressure of 2400Pa was reduced to 0.3mm, achieving an order of magnitude improvement in the module's resistance to bending.

[0032] Example 2: High-strength photovoltaic module based on corrugated core A corrugated core is selected as the core structure 1. The corrugated core is made of two layers of corrugated board and three layers of flat board interlaced, stacked and bonded. The peak height of the corrugated board is 8mm, the wave pitch is 12mm, and the thickness of the flat board is 1mm. This structural design gives the corrugated core good cushioning and supporting properties. Fiber reinforcement layers 2 are set on both side end faces of the corrugated core. A fiber material mixed with glass fiber and carbon fiber is used, wherein the mass ratio of glass fiber to carbon fiber is 3:2. A fiber extension line 6 is pre-set on the edge of the fiber reinforcement layer 2 on one end face. The fiber extension line 6 is interwoven with glass fiber and carbon fiber and has a diameter of 0.3mm. The fiber extension line 6 is wrapped around the side edge of the corrugated core to the fiber reinforcement layer 2 on the other end face and fixed at the fixed point 7 by bonding. The distance between the fixed point 7 and the edge of the corrugated core is 2cm. Within this spacing, some fiber extensions 6 intersect with the fiber reinforcement layer 2 on the other end face, while others are arranged parallel to enhance the stability of the connection. This creates a fiber-wrapped enclosure 3 around the side edges of the corrugated core, achieving fully connected fiber-binding reinforcement and fixation on all peripheral sides. The corrugated core is encapsulated within an inner edge band 5, which is made of 3mm-thick polyurethane and shaped to match the outer shape of the corrugated core. A special surface treatment is applied to the inner edge band 5 to enhance adhesion to the corrugated core and the fiber reinforcement layer 2, effectively controlling the peripheral shape of the corrugated core.

[0033] A method for preparing a high-strength photovoltaic module structure includes the above-mentioned high-strength photovoltaic module structure, and its processing includes the following steps: S1: shaping the side of the honeycomb core 4: cutting the core structure 1 and the inner edge strip 5 according to the target size, bonding the core structure 1 and the inner edge strip 5 with an adhesive 8, and pressing and fixing them with an edge sealing tool 9. After the adhesive 8 is cured, the edge sealing tool 9 is removed, and the side shaping of the honeycomb core 4 is completed; S2: Preparation for side winding of the honeycomb core 4: The fiber reinforcement layer 2 includes an upper fiber layer 10 and a lower fiber layer 11. The fiber reinforcement layer 2 and the core structure 1 are stacked and placed in order from top to bottom as an upper fiber layer 10, a shaped honeycomb core 4, and a lower fiber layer 11; the fiber reinforcement layer 2 on one side pre-installed with a fiber extension line 6 is connected to the other side; the fiber extension line 6 is wound around the outside of the core structure 1 to the fiber reinforcement layer 2 on the other side according to a preset winding method, and the fiber extension line 6 is connected and fixed to the fiber reinforcement layer 2 on the other side at a fixed point 7 to complete the side winding preparation of the core structure 1 to form a wound reinforced core 12.

[0034] S3: Photovoltaic Module Lamination: The lamination sequence is: encapsulation layer 13, solar cell array 14, upper panel layer 15, wound reinforcement core 12, and lower panel layer 19. Adhesive layers 16 are provided between adjacent layers, and a laminated intermediate is produced in a laminator. Furthermore, the encapsulation layer 13 comprises a composite of one or more of photovoltaic glass, a transparent polymer ethylene-tetrafluoroethylene copolymer, and a transparent polymer polyvinylidene fluoride. Furthermore, the adhesive layer 16 is made of one or more of EVA, POE, and PVB.

[0035] In the photovoltaic module lamination step, the encapsulation layer 13 faces the heating surface in the laminator, and a vacuum environment is established for lamination. The lamination is pressurized according to a gradient increase in pressure. The last pressure applied to the photovoltaic module is 20kPa~80kPa. The last pressurization process is maintained for 10min~60min. The lamination temperature is 140℃~180℃. After lamination is completed, it is taken out and trimmed to remove excess glue.

[0036] S4: Edge sealing: An outer edge band 17 is bonded to the outer side of the laminated intermediate product to achieve edge sealing to form a photovoltaic module; S5: Installation of the junction box 18: Install the junction box 18 on the back of the photovoltaic module or inside the honeycomb core 4, weld the busbars leading from the solar cell array 14 to the junction box 18, and perform potting treatment; S6: Surface cleaning and performance testing.

[0037] Example 3: Take honeycomb core 4 as an example: S1. Preparation of side-shaped honeycomb core 4: Cut the honeycomb core 4 and the inner edge strip 5 according to the target size, and use adhesive 8 to bond the honeycomb core 4 and the inner edge strip 5. The adhesive 8 can be epoxy resin, polyurethane, silicone rubber or other adhesives 8, and use edge sealing tool 9 to press and fix them. After the adhesive 8 is cured, remove the edge sealing tool 9 to complete the preparation of the side-shaped honeycomb core 4.

[0038] S2. Preparation of the side-wound honeycomb core 4: Arrange the upper fiber layer 10, the side-shaped honeycomb core 4, and the lower fiber layer 11 in order from top to bottom. The lower fiber layer 11 contains fiber extensions 6. The lower fiber layer 11 and the fiber extensions 6 can be continuous fibers or two fibers connected by braiding, bonding, or other means. The fiber extensions 6 are wound around the outer side of the side-shaped honeycomb core 4 onto the upper fiber layer 10 and fixed to the upper fiber layer 10 at the fixing point 7 by braiding, bonding, or other means to form the side-wound honeycomb core 4. The distance a between the fixing point 7 and the edge of the side-shaped honeycomb core 4 should be no less than 1 cm. Within the distance a, the fiber extensions 6 should be braided with the upper fiber layer 10 to enhance the bonding strength.

[0039] S3. Photovoltaic module lamination: stack the encapsulation layer 13, adhesive layer 16, solar cell array 14, adhesive layer 16, upper panel layer 15, adhesive layer 16, side-wrapped honeycomb core 4, adhesive layer 16 and lower panel layer 19 in this order and place them into a laminator. The encapsulation layer 13 is generally made of photovoltaic glass, and transparent polymer materials such as ethylene-tetrafluoroethylene copolymer, polyvinylidene fluoride, or their laminated composite structures can also be used; the bonding layer 16 can be made of EVA, POE, PVB, and other adhesive films; the solar cell array 14 can use various types of batteries such as silicon cells, cadmium telluride cells, copper indium gallium selenide cells, perovskite cells, perovskite / silicon laminated cells, etc.; the upper panel layer 15 is mainly used to ensure the insulation between the solar cells and the honeycomb core 4 below, and can also play a role in shaping and reducing lamination stress points. Engineering plastics such as polyvinyl chloride, polyethylene terephthalate, polytetrafluoroethylene, and aramid can be used; the main purpose of the lower panel layer 19 is to protect the honeycomb core 4 and the fibers from direct contact with the outside world. Metal materials such as aluminum and steel can be used, and fiber materials such as glass fiber, carbon fiber, and basalt fiber can also be used. Engineering plastics such as polyvinyl chloride, polyethylene terephthalate, polytetrafluoroethylene, and aramid can also be used. The encapsulation layer 13 faces the heating surface in the laminator, the vacuuming time is 300s~900s, and the pressure is increased in a gradient. The relative pressure of the last pressurization is set to -80kPa~-20kPa, that is, the pressure applied to the photovoltaic module is 20kPa~80kPa. The holding time of the last pressurization process is 10min~60min, and the lamination temperature is 140℃~180℃. After lamination is completed, it is taken out and trimmed to remove the overflowed residual glue.

[0040] S4. Edge sealing: Use silicone rubber, epoxy resin or polyurethane glue to bond the outer edge strip 17 to the side of the laminated photovoltaic module to achieve edge sealing.

[0041] S5. Installation of the junction box 18: Use silicone rubber, epoxy resin or polyurethane glue to install the junction box 18 on the back of the photovoltaic module or inside the honeycomb core 4, use soldering to weld the busbars leading out of the solar cell array 14 to the junction box 18, and use silicone rubber, epoxy resin or polyurethane glue for potting.

[0042] S6. Surface cleaning and performance testing: Clean the surface of photovoltaic modules, remove dirt from the preparation process, and conduct appearance inspection, photoluminescence test, insulation withstand voltage test, and electrical performance test.

[0043] Example 4: The difference between this embodiment and the previous one is that in step S2, in the previous embodiment, the lower fiber layer 11 and the lower panel layer 19 are separated and finally bonded during lamination, while in this embodiment, the lower panel layer 19 and the lower fiber layer 11 are integrated in advance to form an integrated lower fiber 11 board. Specifically, in the preparation of the side-wound honeycomb core 4, the lower layer of fiber 11 board can be directly used for preparation below the honeycomb core 4, that is, the lower fiber 11 and the lower panel layer 19 are integrated in advance to form a lower fiber 11 board. At this time, the fiber extension line 6 is the extension line of the lower fiber 11 board, and an adhesive layer 16 should be placed between the honeycomb core 4 and the lower fiber 11 board, that is: the order of materials from top to bottom of the side-wound honeycomb core 4 is: upper fiber 10, side-shaped honeycomb core 4, adhesive layer 16, lower fiber 11 board. After the side-wrapped honeycomb core 4 is prepared in this order, lamination is performed in the order of the packaging layer 13, the adhesive layer 16, the solar cell array 14, the adhesive layer 16, the upper panel layer 15, the adhesive layer 16, and the side-wrapped honeycomb core 4. The lower panel layer 19 is no longer required during lamination, and the subsequent process is consistent with the aforementioned embodiment.

[0044] Embodiment 5: This embodiment differs from the lamination sequence described in Embodiment 3 in that the honeycomb panel is prepared first and then the photovoltaic module is prepared, including the following steps: S21, preparation of the side-shaped honeycomb core 4: This process is the same as S1.

[0045] S22, preparation of the side-wound honeycomb core 4: This process is the same as S2.

[0046] S23. Preparation of side-reinforced honeycomb panels: Adhesive layers 16 are applied to the surfaces of the upper panel layer 15 and the lower panel layer 19 using processes such as glue spraying and rolling. The adhesive layer 16 is typically made of a liquid adhesive such as polyurethane adhesive, epoxy resin, or silicone rubber. The upper panel layer 15, adhesive layer 16, side-wrapped honeycomb core 4, adhesive layer 16, and lower panel layer 19 are stacked in this order and formed using a press to complete the preparation of the side-reinforced honeycomb panel. Alternatively, adhesive films such as EVA, POE, and PVB may be used for the adhesive layer 16 and hot-pressed.

[0047] S24, photovoltaic module lamination: stack the encapsulation layer 13, adhesive layer 16, solar cell array 14, adhesive layer 16, upper panel layer 15, adhesive layer 16, and side reinforcement honeycomb panel in this order, and place them in a laminator for lamination. The lamination process is the same as S3. S25, edge banding: same as S4 process.

[0048] S26, Junction box 18 installation: same as S5 process.

[0049] S27, surface cleaning and performance testing: same as S6 process.

[0050] This method first completes the preparation of side-reinforced honeycomb panels, and then proceeds to the photovoltaic module preparation. During honeycomb panel preparation, the press can simultaneously press dozens of honeycomb panels, increasing production efficiency. Furthermore, the use of liquid adhesives such as polyurethane adhesive, epoxy resin, and silicone rubber as the adhesive layer 16 reduces costs.

[0051] The high-rigidity photovoltaic module can be provided with mounting holes on the four sides or four corners for subsequent installation and fixation, or the mounting structural parts can be embedded in the honeycomb core in a pre-embedded manner for subsequent installation and fixation.

[0052] The advantages of the present invention over the prior art are: in order to achieve higher bending stiffness, fiber-reinforced high elastic modulus panels such as glass fiber and carbon fiber are often used. In this case, on the one hand, the improvement of the elastic modulus of the panel requires the use of high-density fibers or fibers with high elastic modulus, which is relatively expensive, and there is an upper limit to the fiber weaving density and elastic modulus; on the other hand, when the upper and lower surfaces of the reinforced structure are covered with high-strength panels, the side of the component becomes a weak link in the bending ability of the component, and further improvement of the bending stiffness of the new photovoltaic component is limited. The present invention provides a high-strength photovoltaic component structure and a preparation method thereof. By performing fiber winding on the side of a honeycomb structure photovoltaic component and connecting the fibers in the lower panel of the photovoltaic component with the fibers in the upper panel of the photovoltaic component, the bending stiffness of the photovoltaic component can be further enhanced, and the weight and preparation process of the photovoltaic component are basically unaffected.

[0053] The above is only a preferred embodiment of the present invention. It should be pointed out that for ordinary technicians in this technical field, several improvements and modifications can be made without departing from the technical principles of the present invention. These improvements and modifications should also be regarded as within the scope of protection of the present invention.

Claims

1. A high-strength photovoltaic module structure, characterized in that: It includes a core structure for improving the elastic modulus, fiber reinforcement layers are arranged on both side end faces of the core structure, and the fiber reinforcement layers arranged on both side end faces are connected at the side edges, so that the side edges of the core structure form a fiber winding surrounding portion, so that the peripheral side faces of the core structure form a fully connected fiber bundling reinforcement fixation.

2. A high-strength photovoltaic module structure according to claim 1, characterized in that: The core structure is a honeycomb core or a corrugated core structure; the honeycomb core includes a honeycomb structure plate with at least one layer, and the honeycomb structure plate is provided with an array of densely distributed honeycomb holes; or the corrugated structure is formed by interlacing and stacking multiple layers of corrugated plates and flat plates.

3. A high-strength photovoltaic module structure according to claim 1, characterized in that: The core structure is encapsulated in an inner edge strip structure, and the inner edge strip controls the peripheral outer shape of the core structure.

4. The high-strength photovoltaic module structure according to claim 1, characterized in that: The fiber winding surrounding portion includes a fiber extension line pre-formed at the edge of the fiber reinforcement layer on either side end face, and the end of the fiber extension line is connected at a fixed point on the fiber reinforcement layer on the other side end face; the arrangement form between the fiber extension lines includes parallel arrangement, cross arrangement or winding arrangement.

5. A method for preparing a high-strength photovoltaic module structure, characterized in that: The high-strength photovoltaic module structure according to any one of claims 1 to 4 is processed by: S1: Honeycomb core side shaping: Cut the core structure and inner edge strips according to the target size, use adhesive to bond the core structure and inner edge strips, and use edge sealing tooling to press and fix them. After the adhesive is cured, remove the edge sealing tooling to complete the side shaping of the honeycomb core; S2: Preparation for side winding of honeycomb core: The fiber reinforcement layer includes an upper fiber layer and a lower fiber layer. The fiber reinforcement layer and the core structure are stacked in order from top to bottom as an upper fiber layer, a shaped honeycomb core, and a lower fiber layer; the fiber reinforcement layer on one side with a pre-set fiber extension line is connected to the other side; the fiber extension line is wound around the fiber reinforcement layer on the other side through the outside of the core structure according to a preset winding method, and the fiber extension line and the fiber reinforcement layer on the other side are connected and fixed at a fixed point to complete the side winding preparation of the core structure to form a wound reinforced core.

6. The method for preparing a high-strength photovoltaic module structure according to claim 5, characterized in that: The following steps are also included: S3: Photovoltaic module lamination: The lamination order is: encapsulation layer, solar cell array, upper panel layer, winding reinforcement core and lower panel layer. Adhesive layers are set between adjacent layers, and the laminated intermediate product is prepared in a laminator; S4: Edge sealing: Setting an outer edge banding strip on the outer side of the laminated intermediate product to achieve edge sealing to form a photovoltaic module; S5: Junction box installation: Install the junction box on the back of the photovoltaic module or inside the honeycomb core, weld the busbars leading from the solar cell array to the junction box, and perform potting treatment; S6: Surface cleaning and performance testing.

7. The method for preparing a high-strength photovoltaic module structure according to claim 5, characterized in that: The fiber extension line is formed on the lower layer of fibers, and the distance a between the fixed point and the edge of the core structure is ≥1 cm. Within the spacing a, the fiber extension line should be woven with the upper layer of fibers to enhance the bonding force.

8. The method for preparing a high-strength photovoltaic module structure according to claim 6, characterized in that: The encapsulation layer comprises any one or more of photovoltaic glass, transparent polymer ethylene-tetrafluoroethylene copolymer, and transparent polymer polyvinylidene fluoride.

9. The method for preparing a high-strength photovoltaic module structure according to claim 6, characterized in that: The material of the adhesive layer includes any one or more of EVA, POE, and PVB.

10. The method for preparing a high-strength photovoltaic module structure according to claim 6, characterized in that: In the photovoltaic module lamination step, the packaging layer faces the heating surface in the laminator, and a vacuum environment is established for lamination. The lamination is pressurized according to a gradient increasing pressure. The last pressure applied to the photovoltaic module is 20kPa~80kPa. The last pressurization process is maintained for 10min~60min. The lamination temperature is 140℃~180℃. After the lamination is completed, it is taken out and trimmed to remove the overflowed residual glue.

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